SM-Kobelco SK350-9 Tier 4 Hydraulic Excavator Service Repair Manual (YC12U2400 and Higher - ) [PDF]

Zitiervorschau

SERVICE MANUAL Hydraulic Excavator SK350-9 Tier 4

S5LC0026E03 KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

English Part Number S5LC0026E03 Printed in U.S.A. • Rac

Issued July 2011 1st Edition

APPLICABLE: SK350-9 . . . . . . . . . . . . . YC12U2400 and higher ~

model

SK350-9

INDEX 1 SPECIFICATIONS SECTION 2 MAINTENANCE SECTION

SYSTEM

SHOP MANUAL

MAINTENANCE SPECIFICATIONS

HYDRAULIC EXCAVATOR

5 TROUBLESHOOTING 6 ENGINE SECTION

OPT.

OF INSTALLING 7 PROCEDURE OPTIONS SECTION

E / G TROUBLESHOOTING

4 DISASSEMBLY SECTION

DISASSEMBLING

3 SYSTEM SECTION

Book Code No.S5LC0026E03 0-1

GENERAL SAFETY INFORMATION

3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as follows:

Do not operate or perform any maintenance on this machine until all instructions found in the OPERATOR’S MANUAL and this MANUAL have been thoroughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death. Always keep the manual in storage. If it is missing or damaged, place an order with an authorized Distributor for a replacement. If you have any questions, please consult an authorized Distributor.

(4) It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by the Manufacturer. (5) While operating the machine, be sure to perform the work with great care, to prevent damage to the machine and prevent accidents. (6) Continue studying the manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

(1) Most accidents that occur during operation are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death to personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read and understood by all personnel before starting any work with or on the machine. (2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. (3) Messages of safety appear in the manual and on the machine: All messages of safety are identified by the following signal words “DANGER”, “WARNING” and “CAUTION”. 1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:

0-2

SAFETY PRECAUTIONS Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death.

The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.

(6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.

(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly. (8) Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section “Specifications.” The following is a list of basic precautions that must always be observed. (1) Read and understand all Warning plates and decals on the machine before Operating, Maintaining or Repairing this machine.

(9) To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

(2) Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, and confine long hair and loose clothing before working on this machinery.

(10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely.

(3) Disconnect the battery and hang a “Do Not Operate” tag in the Operators Compartment. Remove ignition keys.

(12)Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

(4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not roll while working on or under the machine. Hang a “Do Not Operate” tag in the Operators Compartment. (5) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly.

(13)Always use the proper tools that are in good condition and are suited for the job at hand. Be sure you

0-3

been damaged or altered should be checked for balance before reusing.

understand how to use them before performing any service work.

(22)Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.

(14)Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary. (15)Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted. (16)Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged or will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. (17)Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work. (19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in the event of a line, tube or seal failure must be installed correctly. (21)Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has

0-4

INDEX

NA

SK350LC-9

SYSTEM

MAINTENANCE SPECIFICATIONS

Book Code No. Distribution Year–Month S5YN0129E01 2010-09 S5LC0226E01 2010-09 S5LC0325E01 2010-09 S5LC1123E01 2010-09 S5LC1226E01 2010-09 S5LC1325E03 2011-05 S5LC2125E03 2011-05 S5LC2226E02 2011-05 S5LC2326E01 2010-09 S5LC2426E01 2010-09 S5LC2525E01 2010-09

Title

Index No.

OUTLINE

1

SPECIFICATIONS

2

ATTACHMENT DIMENSIONS

3

TOOLS

11

STANDARD MAINTENANCE 12 TIME SCHEDULE MAINTENANCE STANDARD 13 AND TEST PROCEDURE MECHATRO CONTROL 21 SYSTEM HYDRAULIC SYSTEM

22

ELECTRIC SYSTEM

23

COMPONENTS SYSTEM

24

AIR-CONDITIONER SYSTEM

25

DISASSEMBLING & ASSEMBLING

31

ATTACHMENT

32

UPPER STRUCTURE

33

TRAVEL SYSTEM

34

BY ERROR CODES

46

BY TROUBLE

47

1 33 25

34 2

3 51 11

12

_

E/G TROUBLESHOOTING

DISASSEMBLING

S5YN3129E01 2010-09 S5LC3226E01 2010-09 S5LC3326E01 2010-09 S5LC3426E01 2010-09 S5LC4625E01 2010-09 S5LC4726E01 2010-09 _ _

S5LC5125E02 2011-05

21 13

46 22

23 47 31

ENGINE

_

51 32 24

_ _

APPLICABLE MACHINES

YC

0-5

NOTE: This Manual is prepared as a technical document where the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specification, Maintenance, System, Disassembly, Troubleshooting, Engine, and Installation Procedures for Optional Attachment.

This Manual may be properly revised due to the improvement of products, modification of specifications, etc. There are cases where the system on an actual machine and a part of the contents of this manual may differ due to the variations of specifications by each country. For the section in which the description is not understood, contact our distributor.

•

The Chapter “Specification” describes the specifications for the entire machine, and are instructive for replacement and repairing attachments.

•

The Chapter “Maintenance” describes the documentation, which is helpful for maintenance service and adjustments for the entire machine.

A number is assigned to every part handled in this Manual on account of the description, but the parts cannot be supplied as service parts. Therefore, a parts order must be placed with respective formal part numbers from the Parts Manual for the applicable machine.

•

The Chapter “System” describes the operating systems: hydraulic system, electric system, components, and so on.

•

The Chapter “Disassembly” describes the removal and installation of the assembly mounted on the upper structure and undercarriage, and the assembly and disassembly of the associated hydraulic equipment.

•

The Chapter “Troubleshooting” describes how to find the equipment fault.

•

The Chapter “Engine” describes the use of the “Maintenance Manual” provided by the engine supplier.

•

The Chapter “Installation Procedures for Optional Attachment” describes the supplements added on request as required.

0-6

1. OUTLINE

1

1. OUTLINE TABLE OF CONTENTS

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ........................................ 1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING ............................................. 1-3 1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................... 1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......... 1-4 1.1.4 ELECTRICAL EQUIPMENT ........................................................................ 1-6 1.1.5 HYDRAULIC PARTS ................................................................................... 1-7 1.1.6 WELD REPAIR ............................................................................................ 1-7 1.1.7 ENVIRONMENTAL ISSUES ....................................................................... 1-7 1.2 INTERNATIONAL UNIT SYSTEM ....................................................................... 1-8

Book Code No. S5YN0129E01 1-1

1. OUTLINE

Issue First edition

Data of Issue

Applicable Machines

Remarks S5YN0129E01 (NA)

September, 2010 SK350-9: YC

1-2

1. OUTLINE

1.1

GENERAL PRECAUTIONS FOR MAKING REPAIRS

1.1.1

PREPARATION BEFORE DISASSEMBLING

Read Operator's Manual before disassembling

(1) Knowledge of operating procedure Read Operator's Manual carefully to understand the operating procedure. (2) Cleaning machines Clean machines of soil, mud, and dust before bringing the machines into the service shop. Bringing a soiled machine into the service shop causes less efficient work and damage to parts. (3) Inspecting machines Confirm the disassembling section before starting the work, determine the disassembly procedure, taking the conditions in work shop into account, and request to procure the necessary parts in advance. (4) Recording Record the following items and keep the documentation to prevent malfunction from reacurring. 1. Inspecting date and place. 2. Model name, serial number and records on the hour meter. 3. Trouble condition, place, and cause. 4. Visible oil leaks, water leaks and damage. 5. Clogging of filters, oil level, oil quality, oil contamination and loose fasteners. 6. Examine the problems on the basis of the monthly operation rate with the last inspection date and records on the hour meter. (5) Arrangement and cleaning in service shop 1. Tools required for repair work. 2. Prepare the places to put the disassembled parts. 3. Prepare oil pans for leaking oil, etc.

1.1.2

SAFETY WHEN DISASSEMBLING AND ASSEMBLING

WARNING

(1) Safety 1. Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. 2. Attach a "Do Not Operate" tag on the control lever, and begin a meeting before starting the work. 3. Stop the engine before starting inspection and maintenance. 4. Confirm the position of the first-aid kit and fire extinguisher, and also where to make contact for emergencies. 5. Choose a hard, level and safe place to park the machine, and always put the attachment on the ground. 6. Use hoist, etc. to remove heavy parts that weight (23kg [50 lb] or more). 7. Use proper tools, and change or repair defective tools. 8. Machine and attachment required to work in the lifting condition should be securely supported with supports or blocks.

1-3

1

1. OUTLINE 1.1.3

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

(1) Removing hydraulic equipment assemblies 1. Before removing tubes and hoses, release the pressure in the hydraulic oil tank, or open the cover on the return side to tank, and take out the filter. 2. Drain the oil in the removed pipes and hoses into a pan to prevent the oil from spilling on the ground. 3. Plug or cap hoses, tubes, and fittings to prevent oil leaking, entry of dust, etc. 4. Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on the work bench. (2) Disassembling hydraulic equipment 1. Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture's side, disassembly, assembly and modification without permission are strictly prohibited. 2. If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. 3. Place matching marks on parts for easier reassembling. 4. Before disassembling, read disassembling Instructions in advance, and determine if the disassembly and assembly are permitted or not. 5. For parts that require the use jigs and tools, always use the specified jigs and tools. 6. For parts which cannot be removed in the specified procedure, never force the removal. Check for the cause first. 7. The removed parts should be put in order and tagged so they can be installed correctly. 8. For common parts, pay attention to the quantity and places. (3) Inspecting parts 1. Check that the disassembled parts are free from adherence, interference and an uneven working face. 2. Measure the wear of parts and clearance, and record the measured values. 3. If an abnormality is detected, repair or replace the parts. (4) Reassembling hydraulic equipment 1. Ventilate the room during parts cleaning. 2. Before assembly, clean parts roughly first, and then completely. 3. Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. 4. Replace the removed O-rings, back-up rings and oil seals with new ones, and apply oil on them before assembling. 5. Remove dirt and water on the surfaces where liquid sealants are applied, and apply liquid sealant on them. 6. Remove rust preventives on new parts before assembling. 7. Use special tools to fit bearings, bushings and oil seals. 8. Assemble parts matching the marks made before disassembly. 9. After completion, check that there is no omission of parts.

1-4

1. OUTLINE (5) Installing hydraulic equipment 1. Confirm the correct hydraulic oil and lubrication oil. 2. Air pressure release is required in the following cases; a. Hydraulic oil change b. Replacement of parts on suction pipe side c. Removing and attaching hydraulic pump d. Removing and attaching swing motor e. Removing and attaching travel motor f. Removing and attaching hydraulic cylinder 3. For air bleed of the hydraulic pump and swing motor, loosen the drain plug on the upper part, start engine, and run at low idle, then bleed air until hydraulic oil comes out. When the hydraulic oil comes out, tighten plug securely. 4. For air bleed of travel motors and hydraulic cylinders, start engine and operate it for 10 minutes or more at noload and low speed. 5. Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions thoroughly. 6. Check hydraulic oil level. Move attachments to the hydraulic oil check position, and check hydraulic oil level in the tank. Refill oil if the oil level is lower than the specified level. How to check oil level in the hydraulic oil tank

Important imformation imformation Important LEVEL GAUGE GAUGE LEVEL

Oil level level of of hydraulic hydraulic oil oil Oil tank. tank. the indicator indicator isis within within IfIf the level marks, marks, the the oil oil quantity quantity level acceptable. isis acceptable.

If hydraulic oil and lubricating oil are not filled and the air bleed is not performed, the hydraulic equipment may be damaged.

For cylinders, don't move cylinders to the stroke end at the beginning.

1-5

1

1. OUTLINE 1.1.4

ELECTRICAL EQUIPMENT

(1) The disassembly of electrical equipment is not allowed. (2) Handle equipment with care so as not to drop it or bump it. (3) Connector should be removed by unlocking while holding the connector. Never stress in tension the caulked section by pulling wire. (4) Check that connector is connected and locked completely. (5) Engine key off before removing and connecting connector. (6) Engine key off before touching terminals of starter and alternator. (7) Remove battery grounding terminal before beginning work close to battery and battery relay with tools. (8) Wash machine with care to prevent splashing water on electrical equipment and connectors. (9) When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting.

Battery fluid is dangerous. The battery fluid is dilute sulfuric acid and causes loss of eyesight when adhering on eyes, and causes scald on skin and clothes. When the fluid has adhered on body parts, take an emergency measure immediately and see a doctor for medical advice. -When it has adhered on skin; wash with soap and water. -When it has splashed in eyes; wash in water for 10 minutes or more immediately. -When it has spilled out in large quantity; Use sodium bicarbonate to neutralize, or wash away with water. -When it has been swallowed; drink milk or water. -When it has adhered on clothes; Wash clothes immediately.

1-6

1. OUTLINE 1.1.5

HYDRAULIC PARTS

1 (1) O-ring • Check that O-ring is free from flaw and has elasticity before fitting. • Even if the size of the O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated. So, choose the proper O-ring. • Fit O-rings without distortion and bend. • Floating seals should be put in pairs. (2) Flexible hose (F hose) • Even if the connector and length of the hose are the same, the parts differ according to the withstanding pressure. Use proper parts. • Tighten it to the specified torque, and check that it is free from twist, over tension, interference, and oil leak.

1.1.6

WELD REPAIR

(1) The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the grounding cable of battery. If the grounding cable is not disconnected, the electrical equipment may be damaged. (2) Remove parts which may cause fire due to the entry of spark beforehand. (3) Repair attachments that are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don't fail to cover the section with flame-proof covers.

1.1.7

ENVIRONMENTAL ISSUES

(1) Engine should be started and operated in the place where air can be sufficiently ventilated. (2) Waste disposal The following parts follow the regulation. Waste oil, waste container and battery (3) Precautions for handling hydraulic oil Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes when handling oil. -When oil gets in your eyes ; Wash your eyes with water until the stimulus is gone. -When it has been swallowed ; Don't force the individual to vomit, immediately get medical treatment. -When it has adhered on skin ; Wash with soap and water. (4) Others For spare parts, grease and oil, use KOBELCO genuine parts and lubricants.

1-7

1. OUTLINE

1.2

INTERNATIONAL UNIT SYSTEM Base units Table 1-1

Introduction Although this manual uses the SI units system. Outline of SI units system is described here. Given hereinunder are an excerpt of the units that are related to this manual : 1. Etymology of SI Units English : International System of units 2. Construction of SI Unit System

SI unit system

Derived units of base units Table 1-3

Supplemen tary units Table 1-2

SI units

Derived units bearing peculiar designations Table 1-4

Derived units

Prefixes of SI (n-th power of 10, where n is an integer) Table 1- 5

(4) Derived Units bearing Peculiar Designations

(1) Basic Units

Table1-4

Table1-1 QUANTITIES

SIGN

QUANTITY

Meter Kilogram Second Ampere Kelvin

m kg s A K

Frequency

Mol Candela

mol cd

DESIGNATION

Length Mass Time Current Thermodynamic temperature Gram molecule Luminous intensity

SYMBOL

FORMULA

hertz

Hz

1Hz=1/s

newton

N

kg • m/s 2

Pa

N/m2

J

N•m

watt

W

J/s

coulomb

C

A•s

rad sr

Electric potential difference, volt Voltage, and Electromotive force

V

W/A

SIGN

Quantity of static electricity farad and Electric capacitance

F

C/V

Force

Pressure and pascal Stress Energy, Work and Quantity of joule heat Power Quantity of electricity

(2) Supplementary Units Table1-2 QUANTITIES Plain angle Solid angle

DESIGNATION Radian Steradian

SIGN

(3) Derived Units of Basic Units Table1-3 QUANTITIES Area Volume Velocity Acceleration Density

DESIGNATION Square meter Cubic meter Meter per second Meter per second / second Kilogram per cubic meter

m2 m3 m/s m/s2 kg/m3

UNIT

Electric resistance

ohm

celcius Celcius degree or temperature degree Illuminance

1-8

lux

V/A C

(t+273.15)K

lx

l m/m2

°

1. OUTLINE (5) Prefixes of SI

(6) Unit Conversion Table Table1-5

PREFIX

1

Table1-6 QUANTITIES

POWER

JIS

SI

REMARKS

Mass

kg

kg

Force

kgf

N

1kgf=9.807N

DESIGNATION

SIGN

Giga

G

109

Mega

M

10

Torque

kgf•m

N•m

1kgf•m=9.807N•m

Kilo

k

103

Pressure

kgf/cm2

MPa

1kgf/cm2=0.098MPa

Hecto

h

10

Motive power

PS

kW

1PS=0.7355kW

Revolution

r.p.m

min–1

1r.p.m=1min–1

6

2

Deca

da

10

Deci

d

10

Centi

c

10–2

Milli

m

10–3

Micro

μ

10–6

Nano

n

10–9

Pico

p

10–12

–1

1-9

1. OUTLINE

1-10

2. SPECIFICATIONS

2

2. SPECIFICATIONS TABLE OF CONTENTS

2.1 NAME OF COMPONENTS ..................................................................................2-3 2.2 GENERAL DIMENSIONS ....................................................................................2-4 2.2.1 SK350-9 [6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Standard Arm + 1.40m3 (1.83cu-yd) Bucket] ......................................................................2-4 2.3 WEIGHT OF COMPONENTS ..............................................................................2-5 2.4 TRANSPORTATION .............................................................................................2-7 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ...........................2-7 2.4.2 DIMENSIONS OF ATTACHMENT ...............................................................2-8 2.5 SPECIFICATIONS AND PERFORMANCE ..........................................................2-9 2.5.1 SPEED AND CLIMBING CAPABILITY ........................................................2-9 2.5.2 ENGINE .......................................................................................................2-9 2.5.3 HYDRAULIC COMPONENTS .....................................................................2-9 2.5.4 WEIGHT .......................................................................................................2-9 2.6 TYPE OF CRAWLER ...........................................................................................2-10 2.6.1 SK350-9 .......................................................................................................2-10 2.7 COMBINATIONS OF ATTACHMENT ...................................................................2-12 2.8 ENGINE SPECIFICATION ...................................................................................2-13 2.8.1 SPECIFICATIONS .......................................................................................2-13 2.8.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-UV) .............................2-14

Book Code No. S5LC0226E01 2-1

2. SPECIFICATIONS

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC0226E01 NA

September, 2010 SK350-9: YC

2-2

2. SPECIFICATIONS

2.1

NAME OF COMPONENTS

ARM ARM CYLINDER BOOM

2

BOOM CYLINDER

CAB

IDLER LINK

BUCKET CYLINDER

SLEWING BEARING SLEWING MOTOR

BUCKET LINK

FUEL TANK CONTROL VALVE HYDRAULIC TANK HYDRAULIC PUMP

BUCKET GUARD MONITOR PANEL

SHOE

FRONT IDLER

IDLER ADJUST ENGINE UPPER ROLLER AIR CLEANER

COUNTERWEIGHT

LOWER ROLLER RADIATOR AND OIL COOLER BATTERY TRAVEL MOTOR

2-3

2. SPECIFICATIONS

GENERAL DIMENSIONS

2.2.1

SK350-9 [6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Standard Arm + 1.40m3 (1.83cu-yd) Bucket]

50 (2")

2.2

R3

500

(11

'6")

11200 (36'9")

2980 (9'9")

4960 (16'3") 5980 (19'7")

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

2-4

500*

3210 (10'6")

3210 (10'6") 800 (31.5")

(19.7")

1190* 30 (1.18") (3'11")

2750 (9'0")

3420 (11'3")

3500 (11'6")

3390 (11'2")

2. SPECIFICATIONS

2.3

WEIGHT OF COMPONENTS Unit: kg (lb) Item / Model

SK350-9

Machine complete

36,600 (80,700)

1. Upper frame assy (Assembly of following :) 1.1 Upper frame 1.2 Counterweight Counterweight (Semi-weighted) 1.3 Cab 1.4 Engine 1.5 Hydraulic oil tank 1.6 Fuel tank 1.7 Slewing motor (including reduction unit) 1.8 Control valve 1.9 Boom cylinder 1.10 Pin (for mounting boom) 1.11 Pump 1.12 Radiator (including intercooler)

16,100 (35,500) 2,800 (6,170) 8,800 (19,400) 480 (1,060) *705 (1,550) *195 (430) *220 (490) *445 (980) *240 (530) *270 (600) X 2 80 (180) *140 (310) *180 (400)

2. Lower frame assy (Assembly of following :) 2.1 Lower frame 2.2 Slewing bearing 2.3 Travel motor (including reduction unit) 2.4 Upper roller 2.5 Lower roller 2.6 Front idler 2.7 Idler adjuster 2.8 Sprocket 2.9 Swivel joint 2.10 Track guide 2.11 Track link with 800mm (31.5in) shoes assy 2.11.1 Track link assy

13,100 (28,890) 4,200 (9,260) 555 (1,220) 400 (880) X 2 30 (70) X 4 60 (130) X 18 180 (400) X 2 190 (420) X 2 75 (165) X 2 *25 (50) 39 (86) X 2 2,610 (5,760) X 2 900 (1,990) X 2

3. Attachment (Assembly of following / STD :) {6.50m(21ft-4in)Boom + 3.30m(10ft-10in)Arm+1.40m3(1.83cu-yd)Bucket} 3.1 Bucket assy (STD) 3.2 STD Arm assy (Assembly of following :) 3.2.1 STD Arm 3.2.2 Bucket cylinder 3.2.3 Idler link 3.2.4 Bucket link 3.2.5 Pin (2pcs.for mounting bucket cylinder / 2pcs. for mounting bucket) 3.3 Boom assy (Assembly of following :)

6,700 (14,770)

3.3.1 Boom 3.3.2 Arm cylinder 3.3.3 Pin (Mounting arm • Mounting arm cylinder)

2,650 (5,840) *505 (1,110) 70 (150)

2-5

1,075 (2,370) 2,000 (4,410) 1,270 (2,800) *265 (580) 30 (70) X 2 140 (310) 115 (250) 3,600 (7,940)

2

2. SPECIFICATIONS Unit: kg (lb) Item / Model

SK350-9

4. Lubricant and water (Assembly of following :) 4.1 Hydraulic oil 4.2 Engine oil 4.3 Fuel 4.4 Water

755 (1,660) 215 (470) 25 (55) 485 (1,070) 30 (66)

Marks * show dry weight.

2-6

2. SPECIFICATIONS

2.4

TRANSPORTATION

2.4.1

OVERALL DIMENSIONS OF MACHINE ON A TRAILER

(1) 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm+1.40m3 (1.83cu-yd) Bucket Item/Model

SK350-9

Width 800mm (31.5in) shoes

3,390 (11ft-2in)

Weight

2

36,600kg (80,700 lbs)

2090 (6'10")

75 (3.0")

600 1080(3'7") (23.6")

77.5 (4.5")

4095 (13'5")

11200 (36'9")

2-7

2. SPECIFICATIONS 2.4.2

DIMENSIONS OF ATTACHMENT

(1) BOOM Item / Type

6.50m (21ft-4in) Boom

Length X Height X Width L X H X W: m (ft-in)

6.75 X 1.84 X 0.83 (22'2" X 6'0" X 2'9") 3,290 (7,250)

H

Weight: kg (lbs)

L (2) Arm Item / Type

3.30 m (10ft-10in) Arm

Length X Height X Width L X H X W: m (ft-in)

4.48 X 0.97 x 0.62 (14'8" X 3'2" X 2'2") 1,830 (4,040)

H

Weight: kg (lbs)

L

2-8

2. SPECIFICATIONS

2.5

SPECIFICATIONS AND PERFORMANCE

2.5.1

SPEED AND CLIMBING CAPABILITY Item / Area & Model

SK350-9 10.0 min-1 {10.0 rpm}

Swing speed Travel speed (1-speed/2-speed)

3.3 / 5.6 km/h (2.05 / 3.5 mile/h)

Gradeability

2.5.2

70 % (35 degree)

ENGINE

Engine model

HINO J08E-UV Water-cooled, 4-cycle 6 cylinder direct injection type engine with intercooler turbo charger

Type Number of cylinders-BoreXStroke

6 -112 dia. mm X 130 mm(4.41 in X 5.12 in)

Total displacement Rated output / Engine speed Maximum torque / Engine speed

7.684 L (468.9 cu-in) Net 213 kW (289 PS) / 2,100 min-1 (ISO 14396 : Without fan) Net 1,017 N-m (750 lbf-ft)/ 1,600 min-1 (ISO 14396 : Without fan)

Starter

24 V / 5.0kW

Alternator

2.5.3

24 V / 60A

HYDRAULIC COMPONENTS

Hydraulic pump

Variable displacement axial piston pump X 2 + gear pump X 1

Hydraulic motor (swing)

Axial piston motor X 1

Hydraulic motor (travel)

Variable displacement axial piston motor X 2 (with counterbalance valve)

Control valve

8-spool control valve X 1

Cylinder (Boom, Arm, Bucket)

Double action cylinder

Oil cooler

2.5.4

Air-cooled type

WEIGHT Item / Model

SK350-9

Fully equipped weight

36,700 (80,920)

Upper structure

16,100 (35,500)

Lower machinery

13,100 (28,890)

6.50m(21ft-4in) Boom+3.30m(10ft-10in) Arm+1.40m3 (1.83cu-yd) Bucket

6,700 (14,770)

2-9

2

2. SPECIFICATIONS

2.6

TYPE OF CRAWLER

2.6.1

SK350-9 Shape

Grouser shoe

Shoe width mm (in)

Overall width of crawler mm (ft-in)

Ground pressure kPa (psi)

600 (23.6)

3,190 (10'6")

67 (9.72)

700 (27.6)

3,290 (10'10")

58 (8.41)

800 (31.5)

3,390 (11'2")

52 (7.54)

900 (35.4)

3,490 (11'5")

46 (6.67)

48 LINKS

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

2-10

2. SPECIFICATIONS

2.7

COMBINATIONS OF ATTACHMENT

Bucket

Available Arm

Heaped capacity m3 (cu•yd)

Struck m3 (cu•yd)

3.3m (10ft-10in) Arm (STD)

—

—

—

1.40 (1.83) STD

1.00 (1.31)

—

—

—

—

—

—

Breaker

—

—

Nibbler

—

—

Type

Hoe bucket

2

Standard combination General operation : Excavation or loading of sand, gravel, and clay Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel) Prohibited combination : There are problems from the view points of strength and stability. •

Use the attachments recommended by NEW HOLLAND KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibility

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

2-11

2. SPECIFICATIONS

2.8

ENGINE SPECIFICATION

2.8.1

SPECIFICATIONS

Applicable machine

SK350-9

Engine model

HINO J08E-UV Water-cooled, 4 cycle 6 cylinder direct injection type diesel engine with intercooler turbo-charger

Type Number of cylinder-Bore X Stroke

6 X 112mm (4.41 in) X 130mm (5.12 in)

Total displacement

7,684cc (469 cu-in)

Compression ratio

17.0 Net 213 kW (289 PS) at 2,100 min-1 (ISO 14396 : Without fan)

Rated out put

Net 1,017 N-m (750 lbf-ft) at 1,600 min-1 (ISO 14396 : Without fan)

Maximum torque High idling

2,100 min-1

Low idling

1,000 min-1

Injection starting pressure Thermostat action

3.2 MPa (464 psi) Start 350 K (170F degrees)/Full open 363 K (194F degrees)

Firing order

1-4-2-6-3-5

Compression pressure

3.4 MPa (493 psi) to 3.7 MPa (537 psi) at 280 min-1

Fuel injection timing

Valve clearance

Electron type Valve clearance

Open

Close

Intake valve

0.3 mm at cool

14 deg. before top dead point

30 deg. after bottom dead point

Exhaust valve

0.45 mm at cool

54 deg. before top dead point

13 deg. after top dead point

Starter capacity

24 V X 5.0 kW

Generator capacity (Alternator) Cooling fan drive method

24 V X 60 A 850 dia. (33.5 in) X suction type 6 fans, V-belt drive, pulley ratio Crank / Fan= 0.80 Full level 26.0 L (6.87 gal) Low level 20.0 L (5.28 gal) Total 28.5 L (7.53 gal)

Engine oil quantity Dry weight

kg (

Fuel consumption ratio Allowable inclination

210 g / kw-h (154 g / PS-h) Front / Rear and Right / Left : 35 degrees 1,314 mm X 941 mm X 1,112 mm (4 ft 3.73 in X 37.1 in X 3 ft 7.8 in)

Dimension (L X W X H) Rotating direction

lbs)

Counterclockwise seeing from flywheel side

2-12

2. SPECIFICATIONS 2.8.2

ENGINE CHARACTERISTIC CURVE (HINO J08E-UV) Condition to be measured: The net value is indicated, measuring with cooling fan. marks show the rated point

1000 900 (kW) 240

800

SHAFT TORQUE

(N.m)

700

SHAFT OUTPUT

200

160

120

80

40

0

1000

1400

1800

2200

2600

3000

ENGINE SPEED (min-1) Fuel consumption volume Fuel consumption rate X kW X Load factor ( ) 0.835 X 1000 210g/kW.h X 213kW X 0.835 X 1000 53.6

. L/h

2-13

: Standard load factor (0.70~0.80) Fuel consumption in regular operation (load factor 0.70~0.80) 37.5 L/h~42.9 L/h

2

2. SPECIFICATIONS

2-14

3. ATTACHMENT DIMENSIONS

3. ATTACHMENT DIMENSIONS 3

TABLE OF CONTENTS

3.1 BOOM .................................................................................................................. 3-3 3.1.1 BOOM DIMENSIONAL DRAWING .............................................................. 3-3 3.1.2 BOOM MAINTENANCE STANDARD .......................................................... 3-4 3.2 ARM ..................................................................................................................... 3-6 3.2.1 ARM DIMENSIONAL DRAWING ................................................................. 3-6 3.2.2 ARM MAINTENANCE STANDARD ............................................................. 3-7 3.3 BUCKET .............................................................................................................. 3-10 3.3.1 BUCKET DIMENSIONAL DRAWING .......................................................... 3-10 3.3.2 LUG SECTION DIMENSIONAL DRAWING ................................................ 3-10 3.3.3 BOSS SECTION DIMENSIONAL DRAWING .............................................. 3-10

Book Code No. S5LC0325E01 3-1

3. ATTACHMENT DIMENSIONS

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC0325E01 NA

September, 2010 SK350-9: YC

3-2

3. ATTACHMENT DIMENSIONS

3.1

BOOM

3.1.1

BOOM DIMENSIONAL DRAWING d4

J

I K

d3

D C

d1

B

G

H

3

E

F

K

A J

d2

SECTION K-K Boom Dimensional Drawing STD

5.65M (18ft-6in) BOOM No.

LC02B00236F1

NAME

DIMENSIONS: mm (ft-in) 6,500 (21'4") 826 (32.5") 405.8 (16.0") 577 (22.7") 1,115 (3'8")

A B C D E

Boom length Boom foot width Boom end inner width Boom end outer width Height of boom cylinder rod pin

F G H I J

Height of arm cylinder (head side) pin Distance between pins of boss Distance between pins of bracket Arm cylinder (head side) inner width Outer width of bracket on the boom cylinder (rod side) mounting

d1 d2 d3 d4

Boom foot pin dia. Boom cylinder (rod side) pin dia. Pin dia. of boom end. Arm cylinder (head side) pin dia.

1,460.8 (4'9.5") R2,955 (9'8") R3,390.5 (11'1.5") 146 (5.75") 564 (22.2") 125 dia. (4.92") 110 dia. (4.33") 110 dia. (4.33") 110 dia. (4.33")

3-3

3. ATTACHMENT DIMENSIONS 3.1.2

BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section

D

A C

B Clearance Of Pin And Bushing On Boom Section

Unit : mm (in) Standard value Symbol

Item

Pin part No.

A

Boom foot

LC02B01373P1

B

Boom cylinder (Head side)

LC02B01344P1

C

Boom cylinder (Rod side)

LC02B01345P1

D

Arm cylinder (Head side)

LC02B01337P1

Clearance

Bushing i.d. tolerance

Standard value

+ 0.020 + 0.226 ø 110 (+0.0008) (+0.0089) (4.331) - 0.020 + 0.098 (-0.0008) (+0.0039) + 0.222 0 (+0.087) ø 100 - 0.040 + 0.105 (3.937) (-0.0016) (+0.0041)

+ 0.246 (+0.0097) + 0.078 (+0.0031) + 0.262 (0.0103) + 0.0105 (+0.0041)

Pin dia.

Pin dia. tolerance

+ 0.230 + 0.250 (+0.0091) (+0.0098) + 0.085 + 0.020 + 0.105 ø 110 (+0.0008) (+0.0041) (+0.0033) (4.331) - 0.020 + 0.226 + 0.246 (-0.0008) (+0.0089) (+0.0097) + 0.098 + 0.078 (+0.0039) (+0.00031)

3-4

Repaira Service Remedy ble limit level

More than 2.5 (0.10)

3.0 (0.12)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom cylinder installation section

D

D

C C

A L3

L3'

X3

A

B B

3 PL3 X1

L1

SECTION C-C

X4 L4 PL4

PL2

PL2 PL1 SECTION A-A

SECTION D-D X2 L2

L2 X2

SECTION B-B Clearance In Thrust Direction On The Boom Cylinder Installation Section

Unit : mm (in) Basic size Sec.

Item No. Boom

A-A Boom foot

B-B

Boom cylinder (Head side)

Boom cylinder C-C (Rod side)

Arm cylinder D-D (Head side)

L1

Size 826 (32.5)

Upper frame

832 (32.8)

Boom cylinder

130 (5.12)

L2 Upper frame Boom cylinder Boom

L3 L3'

Arm cylinder L4 Boom

136 (5.35) 130 (5.12) 564 (22.2) 140 (5.51) 146 (5.75)

Clearance X adjusted with shim (total of both sides)

Pin length Remedy

Standard value

Repairable level

Service limit

0.5 (0.02) or less

1.0 (0.04)

1.5 (0.06)

PL1

1,026 (3'4.4")

0.6~1.0 (0.02~0.04)

2.0 (0.08)

2.5 (0.10)

PL2

286 (11.26)

0.6~2.0 (0.02~0.08)

3.0 (0.12)

4.0 (0.16)

PL3

877 (34.5)

0.6~1.0 (0.02~0.04)

2.0 (0.08)

2.5 (0.10)

PL4

309 (12.2)

3-5

No. Length

Shim adjust ment

3. ATTACHMENT DIMENSIONS

3.2

ARM

3.2.1

ARM DIMENSIONAL DRAWING

VIEW J SECTION X-X

SECTION Y-Y

SECTION Z-Z

Arm Dimensional Drawing

3.30m (10ft-10in) ARM Code

LC12B00330F1

NAME

Unit : mm (ft-in) DIMENSION

Code

NAME

DIMENSION

C

Arm length

3,300 (10'10")

N

Bracket inner width

146 (5.75")

D

Distance between pins of boss and bracket

R1,010 (3'4")

O

Bracket inner width

136 (5.35")

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")

ø125 (4.92")

R

Height between pins of boss and center

44 (1.73")

D4 I.D of boss E

Distance between pins of boss and bracket

R2,429.5 (7'12")

d1

Pin dia.

ø90 (3.54")

F

Distance between pins of boss and boss

R515 (20.3")

d2

Pin dia.

ø80 (3.15")

G

Height between pins of boss and bracket

735.5 (29.0")

d3

Pin dia.

ø110 (4.33")

H

Height between pins of boss and bracket

280 (11.0")

d4

Pin dia.

ø110 (4.33")

K

Arm top end bushing width

d5

Pin dia.

ø90 (3.54")

L

Arm link section boss width

380 (15.0") 390 (15.4")

M

Boss width

400 (15.75")

3-6

3. ATTACHMENT DIMENSIONS 3.2.2

ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing

E

F

D, D'

B A

3 C

G

Clearance Of Pin And Bushing On Arm Section Unit : mm (in) Standard dimensions No.

A

Item

Pin part No.

Pin dia.

Arm point LC12B01657P2

B

Bucket link (Bucket side)

ø90 (3.5433)

C

Idler link (Connected part LC12B01613P1 of arm)

ø80 (3.1496)

D

Bucket link (Idler link side)

D'

E

Bucket cylinder LC12B01461P1 (Head side)

F

Arm cylinder (Rod side)

G

–0.020 (-0.0008) –0.060 (-0.0024)

0 (0) –0.040 (-0.0016)

LC12B01614P1 Bucket cylinder (Rod side)

Pin dia. tolerance

ø90 (3.5433)

LC02B01337P1

Arm foot (Connected part LC12B01468P2 of boom)

ø110 (4.331)

+0.020 (+0.0008) –0.020 (-0.0008)

3-7

Clearance

Bushing i.d. tolerance

Standard value

+0.272 (+0.0107) +0.095 (+0.0037)

+0.332 (+0.0131) +0.115 (+0.0045)

+0.217 (+0.0085) +0.071 (+0.0028)

+0.277 (+0.0109) +0.091 (+0.0036)

+0.222 (+0.0087) +0.079 (+0.0031)

+0.262 (+0.0103) +0.079 (+0.0031)

+0.219 (+0.0086) +0.034 (+0.0013)

+0.259 (+0.0102) +0.034 (+0.0013)

+0.235 (+0.0093) +0.074 (+0.0029)

+0.275 (+0.0108) +0.074 (+0.0029)

+0.238 (+0.0094) +0.077 (+0.0030)

+0.258 (+0.0102) +0.057 (+0.0022)

+0.226 (+0.0089) +0.098 (+0.0039)

+0.246 (+0.0097) +0.078 (+0.0031)

+0.200 (+0.0079) +0.099 (+0.0039)

+0.220 (+0.0087) +0.079 (+0.0031)

Repairable level

Service limit

2.5 (0.10)

3.0 (0.01)

Remedy

Replace bushing or pin

3. ATTACHMENT DIMENSIONS (2) Clearance of arm and cylinder installing sections in thrust direction

E D, D'

B

A

C

B A

D, D'

F G

C X1

G

L3

X3

L1

F

E

X5 L5 PL5

PL1

X2

L2

L6

SECTION E-E

PL3

SECTION A-A

X6

SECTION C-C L4

X4

PL6

SECTION F-F PL2

SECTION B-B

X4'

X7

L4' PL4

L7 PL7

SECTION D-D,D'-D'

SECTION G-G

Clearance Of Arm And Cylinder Installing Sections In Thrust Direction

3-8

3. ATTACHMENT DIMENSIONS

Unit : mm (in) Basic size Sec.

Item No. Arm

A-A Arm point

L1 Bucket Link side

B-B Bucket link

C-C

Idler link (Arm connection)

Bucket link D-D (Idler link connection) D’-D’

Bucket link (Rod side)

Bucket cylinder E-E (Head side)

F-F

Arm cylinder (Rod side)

L2

Size

380 (14.96) 382 (15.04)

Arm

390 (15.35)

Link side

—

Rod side Link side

L4’

390 (15.35) 130 (5.12)

Link side

136 (5.35)

Head side

130 (5.12)

L5 Arm

136 (5.35)

Rod side

140 (5.51)

L6 Arm

146 (5.75)

Arm

400 (15.75)

L7 Boom

—

2.0 (0.08)

Remedy

PL1 576 (22.7)

—

PL2

3 With in 0.5 (0.02)

1.0 (0.04)

2.5 (0.10)

PL3

— L4

Rod side

G-G Arm foot

Pin length

Standard Repairable Service limit No. Length level value

380 (14.96) 1.0 (0.04) or less 381 (15.10)

Bucket L3

Clearance X adjusted with shim (total of both sides)

405.8 (15.98)

0.6~1.0 (0.024~0.04)

0.6~2.0 (0.024~0.08)

With in 0.5 (0.02)

3-9

505 (19.9)

2.0 (0.08)

3.0 (0.12)

1.0 (0.04)

PL4

PL5

299 (11.8)

PL6

309 (12.2)

PL7

577 (22.7)

4.0 (0.16)

2.5 (0.10)

Shim adjust -ment

3. ATTACHMENT DIMENSIONS

3-10

11. TOOLS

11. TOOLS 11

TABLE OF CONTENTS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS .............................. 11-3 11.2 SCREW SIZE ..................................................................................................... 11-5 11.2.1 CAPSCREW (BOLT) ................................................................................. 11-5 11.2.2 CAPSCREW (SOCKET BOLT) .................................................................. 11-5 11.2.3 SOCKET SET SCREW ............................................................................. 11-5 11.3 TIGHTENING TORQUE FOR HOSE AND FITTING ......................................... 11-6 11.3.1 JOINT (O-RING TYPE) ............................................................................. 11-6 11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ........................................... 11-6 11.3.3 JOINT (ORS TYPE) ................................................................................... 11-6 11.3.4 SPLIT FLANGE ......................................................................................... 11-6 11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES ..................................... 11-7 11.5 PLUGS ............................................................................................................... 11-8 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................... 11-8 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................... 11-9 11.6 SPECIAL SPANNER FOR TUBE ...................................................................... 11-11 11.7 SPECIAL TOOLS ............................................................................................... 11-12 11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND .... 11-14 11.9 SUCTION STOPPER ......................................................................................... 11-15 11.9.1 COMPONENTS ......................................................................................... 11-15 11.9.2 DIMENSION .............................................................................................. 11-15 11.9.3 APPLICABLE MODEL ............................................................................... 11-15 11.10 UPPER FRAME LIFTING JIG ............................................................................ 11-16 11.11 ENGINE MOUNTING PEDESTAL ..................................................................... 11-17

Book Code No. S5LC1123E01 11-1

11. TOOLS

Issue

Data of Issue

First Edition

March, 2009

E385B: LC11-08501~ E385BLC: YC11-04501~

S5LC1123E01 NHK-RUS (HS Engine)

↑

↑

E385B: LC11-08501~ E385BLC: YC11-04501~

↑ NHK-Mid.East & Afr. (HS Engine)

↑ ↑

Applicable Machines

September, 2010 E385CLC: YC ↑

Remarks

(NHK)

SK350-9: YC

NA

11-2

↑ ↑

11. TOOLS

11.1

TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Table "Metric coarse thread (Not plated)" and Table "Metric fine thread (Not plated)" indicate tightening torques applicable to cases where no special note is given. Overtightening of bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.

Unit : 1‡POEf‡ft) COassification NoPLQDO size

4.8T

7T

10.9T

No OXEULFDWLRn OLO OXEUication No OXEULcation 2LO OXEULcation No OXEULFDWLRn OLO OXEULFDWLRn

M6

P=1

4.4±0.5 3.2±0.4)

3.7±0.4 2.7±0.3)

9.6±1.0 7.1±0.7)

8.1±0.8 6.0±0.6)

17.4±1.8 12.8±1.3)

14.7±1.5 0.8±1.1)

M8

P=1.25

10.7±1.1 .9±0.8)

9.0±0.9 6.6±0.7)

23.5±2.0 7.3±1.5)

19.6±2.0 14.5±1.5)

42.2±3.9 31.1±2.9)

35.3±3.9 6.0±2.9)

M10

P=1.5

21.6±2.0 15.9±1.4)

17.9±1.8 13.2±1.3)

46.1±4.9 34.0±3.6)

39.2±3.9 28.9±2.9)

83.4±8.8 61.5±6.5)

70.6±6.9 52.1±5.1)

M12

P=1.75

36.3±3.9 26.8±2.9)

31.4±2.9 23.2±2.1)

79.4±7.8 58.6±5.8)

66.7±6.9 49.2±5.1)

143±15 105±11)

121±12 89.2±8.9)

M14

P=2

57.9±5.9 42.7±4.4)

49.0±4.9 36.1±3.6)

126±13 92.9±9.6)

106±10 78.2±7.4)

226±20 167±15)

191±19 141±14)

M16

P=2

88.3±8.8 65.1±6.5)

74.5±6.9 55.0±5.1)

191±20 141±15)

161±16 119±12)

343±39 253±29)

284±29 209±21)

M18

P=2.5

122±12 90.0±8.9)

103±10 75.8±7.2)

265±29 195±21)

226±20 167±15)

481±49 355±36)

402±39 297±29)

M20

P=2.5

172±17 27±13)

144±14 106±10)

373±39 275±29)

314±29 232±21)

667±69 492±51)

559±59 412±44)

M22

P=2.5

226±20 67±15)

192±20 142±15)

500±49 369±36)

422±39 311±29)

902±88 665±65)

755±78 557±58)

M24

P=3

294±29 217±21)

235±29 173±21)

637±69 470±51)

520±49 83±36)

1160±118 856±87)

941±98 694±72)

M27

P=3

431±39 318±29)

353±39 260±29)

941±98 694±72)

765±78 64±58)

1700±167 1250±123)

1370±137 1010±101)

M30

P=3.5

588±59 34±44)

490±49 361±36)

1285±127 948±94)

1079±108 96±80)

2300±235 700±173)

1940±196 1430±145)

M33

P=3.5

794±78 586±58)

667±69 492±51)

1726±177 1270±131)

1451±147 1070±108)

3110±314 2290±232)

2610±265 1930±195)

M36

P=4

1030±98 60±72)

863±88 637±65)

2226±226 1640±167)

1863±186 1370±137)

4010±402 2960±297)

3360±333 2480±246)

Tightening Torque For Metric Coarse Threads (Not Plated)

11-3

11

11. TOOLS

Torque value Unit : 1‡POEf‡ft) Classification NoPLQDO size

4.8T

7T

10.9T

No OXEULFDWLRn Oil OXErication No OXEULcation Oil OXEULcation No OXEULFDWLRn Oil OXEULFDWLRn

M8

P=1.0

11.3±1.1 “)

9.5±1.0 7.0±0.7)

24.5±2.0 18.1±1.5)

20.6±2.0 15.2±1.5)

44.1±3.9 32.5±2.9)

37.3±3.9 7.5±2.9)

M10

P=1.25

22.6±2.0 16.7±1.5)

18.7±1.9 13.8±1.4)

48.1±4.9 5.5±3.6)

41.2±3.9 30.3±2.9)

87.3±8.8 64.4±6.5)

73.5±6.9 4.2±5.1)

M12

P=1.25

39.2±3.9 28.9±2.9)

33.3±2.9 24.6±2.1)

85.3±8.8 2.9±6.5)

71.6±6.9 52.8±5.1)

154±16 114±12)

129±13 5.2±9.6)

M16

P=1.5

92.2±8.8 68.0±6.5)

77.5±7.8 57.2±5.8)

196±20 145±15)

169±17 125±13)

363±39 268±29)

304±29 224±21)

M20

P=1.5

186±19 137±14)

155±16 114±12)

402±39 297±29)

333±29 46±21)

726±69 535±51)

608±59 448±44)

M24

P=2

314±29 232±21)

265±29 195±21)

686±69 506±51)

569±59 420±44)

1240±118 915±87)

1030±98 760±72)

M30

P=2

637±59 470±44)

530±49 391±36)

1390±137 1030±101)

1157±118 853±87)

2500±255 1840±188)

2080±206 1530±152)

M33

P=2

853±88 629±65)

706±70 521±52)

1860±186 1370±137)

1550±155 1140±114)

3350±334 2470±246)

2790±275 2060±203)

M36

P=3

1070±108 789±80)

892±88 658±65)

2330±226 1720±167)

1940±196 1430±145)

4200±422 3100±311)

3500±353 2580±260)

Tightening Torques For Metric Fine Threads (Not Plated)

11-4

11. TOOLS

11.2

SCREW SIZE

11.2.1 CAPSCREW (BOLT) Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm Tool size

M6

10

M36

55

M8

13

M42

65

M10

17

M45

70

M12

19

M48

75

(M14)

22

M56

85

M16

24

(M60)

90

(M18)

27

M64

95

M20

30

(M68)

100

(M22)

32

M72

105

M24

36

M76

110

(M27)

41

M80

115

M30

46

d

B

11

11.2.2 CAPSCREW (SOCKET BOLT) Nominal screw size (d) M6

B mm Tool size 10

Nominal screw size (d) M36

B mm Tool size 55

M8

13

M42

65

M10

17

M45

70

M12

19

M48

75

(M14)

22

M56

85

M16

24

(M60)

90

(M18)

27

M64

95

M20

30

(M68)

100

(M22)

32

M72

105

M24

36

M76

110

(M27)

41

M80

115

d

B

11.2.3 SOCKET SET SCREW Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm

d

Tool size

M2.5

1.27

M8

4

M3

1.5

M10

5

M4

2

M12

6

M5

2.5

M16

8

M6

3

M20

10

B

11-5

11. TOOLS

11.3

TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE) Size (PF)

Wrench (mm)

Tightening torque 1‡P (lbf‡ft)

1/8

14

17±2 (13±1.5)

1/4

19

36±2 (27±1.5)

3/8

22

74±5 (55±4)

1/2

27

108±9.8 (80.0±7)

3/4

36

162±9.8 (119±7)

1

41

255±9.8 (188±7)

11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) Size (PF)

Wrench(mm)

Tightening torque 1‡P (lbf‡ft)

1/8

17

15±2.0 (11±1.5)

1/4

19

29±4.9 (21±3.6)

3/8

22

49±4.9 (36±3.6)

1/2

27

78±4.9 (58±3.6)

3/4

36

118±9.8 (87±7.2)

1

41

137±15 (101±11)

UNION NUT

11.3.3 JOINT (ORS TYPE) Tightening Torque 1‡P (lbf‡ft)

Unified screw size

Opposing flats

1-14 UNS

30, 32

137±14 (101±10)

36

177±18 (131±13)

1 3 / 16-12 UN 1 7/ 16-12 UN

41

206±21 (152±15)

41

206±21 (152±15)

46

206±21 (152±15)

11.3.4 SPLIT FLANGE Tightening torque N‡m (lbf‡ft) Standard pressure series 20.6 MPa

Bolt size

3/4

33.9±5.6 (25±4)

M10

39.5±5.6 (29±4)

M10

1

42.4±5.6 (31±4)

M10

62.2±5.6 (46±4)

M12

Size

Hi pressure series 41.2 MPa

Bolt size

11/4

55.1±7.1 (41±5)

M10

93.3±8.4 (69±6)

M14

11/2

70.6±8.4 (52±6)

M12

169±11 (125±8)

M16

2

81.9±8.4 (60±6)

M12

282±11 (208±8)

M20

11-6

CONNECTOR

O-RING

NUT

FITTING

11. TOOLS

11.4

TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table below indicates standard tightening torques applicable to cases where no particular note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections. Always tighten nuts and sleeves to proper torques.

Manufacturer's name

Nippon A.M.C.

Ihara Koatu

Working pressure MPa (psi)

Tube size OD × thickness mm (in)

29.4 (4270)

29.4 (4270)

Opposing flats (HEX) mm

Tightening torque N‡m (lbf‡ft)

ø10×1.5 (0.394×0.059)

19

49.0±9.8 (36±7.2)

ø15×2.0 (0.591×0.079)

27

118±12 (87±8.7)

ø18×2.5 (0.709×0.098)

32

147±15 (110±11)

ø22×3.0 (0.866×0.118)

36

216±22 (160±16)

ø28×4.0 (1.10×0.157)

41

275±27 (200±20)

ø35×5.0 (1.38×0.197)

55

441±44 (330±33)

SLEEVE

11

NUT B

d

d

Tube size ød

Ihara Koatu

Nippon A.M.C.

Tube size ød

6

ZF93S06000

—

6

Parts No.

Opposing flats (HEX) mm 14

Parts No. Nippon A.M.C. Ihara Koatu ZF93N06000

—

8

ZF93S08000

—

8

17

ZF93N08000

—

10

ZF93S10000

ZA93S10000

10

19

ZF93N10000

ZA93N10000

12

ZF93S12000

—

12

22

ZF93N12000

—

15

ZF93S15000

ZA93S15000

15

27

ZF93N15000

ZA93N15000

18

ZF93S18000

ZA93S18000

18

32

ZF93N18000

ZA93N18000

22

ZF93S22000

ZA93S22000

22

36

ZF93N22000

ZA93N22000

28

ZF93S28000

ZA93S28000

28

41

ZF93N28000

ZA93N28000

32

ZF93S32000

—

32

50

ZF93N32000

—

35

ZF93S35000

ZA93S35000

35

55

ZF93N35000

ZA93N35000

38

ZF93S38000

—

38

60

ZF93N38000

—

11-7

11. TOOLS

11.5

PLUGS

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

A

Applicable tube O. D : A 6 8 10 12 15 18 22 28

H1

T screw

H

Cap nut parts No.

T screw

ZF83H06000 ZF83H08000 ZF83H10000 ZF83H12000 ZF83H15000 ZF83H18000 ZF83H22000 ZF83H28000

M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5

Opposing flats

H1 14 17 17 19 24 27 32 38

H 14 17 19 22 27 32 36 41

A

(2) Plug (Tube plug)

Sleeve Type joint body

Nut

Applicable tube O. D : A

Plug parts No.

6 8 10 12 15 18 22

ZF83P06000 ZF83P08000 ZF83P10000 ZF83P12000 ZF83P15000 ZF83P18000 ZF83P22000

d screw

A

(3) Nut

Applicable tube O. D : A 6 8 10 12 15 18 22 28 32 35 38

11-8

Nut parts No.

d screw

Opposing flats

ZF93N06000 ZF93N08000 ZF93N10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000

M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5 M42 X 1.5 M45 X 1.5 M48 X 1.5

14 17 19 22 27 32 36 41 50 55 60

11. TOOLS

11.5.2 PLUG FOR HYDRAULIC EQUIPMENT (1) PF screw

O-ring

B PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring 19 PF1/4 ZE72X04000 ZD12P01100 1B P11 22 PF3/8 ZE72X06000 ZD12P01400 1B P14 27 PF1/2 ZE72X08000 ZD12P01800 1B P18 36 PF3/4 ZE72X12000 ZD12P02400 1B P24 41 PF1 ZE72X16000 ZD12P02900 1B P29

PF screw (2) PT screw

11

PT screw

B PT screw Plug parts No. ZE82T02000 PT1/8 ZE82T04000 PT1/4 ZE82T06000 PT3/8 ZE82T08000 PT1/2 ZE82T12000 PT3/4 ZE82T16000 PT1 ZE82T20000 PT1 1/4 ZE82T24000 PT1 1/2

B mm 5 6 8 10 14 17 22 22

(3) Plug for(F)flare hose

PF screw

60

PF screw Plug parts No. 2444Z2728D1 PF1/4 2444Z2728D2 PF3/8 2444Z2728D3 PF1/2 2444Z2728D4 PF3/4 2444Z2728D5 PF1

60

Opposing flats B

PF screw PF1/4 PF3/8 PF1/2 PF3/4 PF1 PF1 1/4

PF screw

Opposing flats F

Opposing flats E

11-9

Plug parts No. 2444Z2729D1 2444Z2729D2 2444Z2729D3 2444Z2729D4 2444Z2729D5 2444Z2729D6

E mm 14 17 23 27 36 40

B mm 14 17 22 27 36

F mm 19 22 27 36 41 50

11. TOOLS (4) Plug for ORS joints Male

Female

(5) Plug for half clamp 4-oH

For standard pressure : 20.6 MPa (2990 psi) Size

Plug part No.

C mm D mm

1/2 ZE12Q08000 38.10

C

3/4 ZE12Q12000 47.63 1 D

ZE12Q16000 52.37

1 1/4 ZE12Q20000 58.72

G mm

25.53~ 25.40 31.88~ 22.23 31.75 39.75~ 26.19 39.62 44.58~ 30.18 44.45 17.48

H mm

O-ring part No.

9

45Z91D2

11

ZD12P02600

11

ZD12P03400

11

ZD12P03800

H mm

O-ring part No.

9

2445Z831D1

11

ZD12P02600

13

ZD12P03400

15

ZD12P03800

For high pressure : 41.2 MPa (5970 psi) G

Size

Plug part No.

C mm D mm

1/2 ZE13Q08000 40.49 3/4 ZE13Q12000 50.80 1

ZE13Q16000 57.15

1 1/4 ZE13Q20000 66.68

11-10

G mm

25.53~ 25.40 31.88~ 23.80 31.75 39.75~ 27.76 39.62 44.58~ 31.75 44.45 18.24

11. TOOLS

11.6

SPECIAL SPANNER FOR TUBE

Applicable tube diameter mm (in)

Part No.

HEX (mm)

Drawing of a special spanner mm (in)

70(2.76)

15 (0.591)

2421T160

16 (0.630)

27

22 (0.866)

(0.315)

12.7

40(1.57)

(0.500

)

70(2.76) 42(1.65)

18 (0.709)

2421T138

22 (0.866)

19 (0.748)

32

22(0.866)

48(1.89)

22 (0.866)

2421T130

12.7

22 (0.866)

12.7

60(2.36)

28 (1.10)

2421T115

2421T231

46

32 (1.26)

2421T232

50

35 (1.38)

2421T314

55

11-11

)

22 (0.866)

12.7

28 (1.10)

(0.500

109(4.29) 14.5(0.571)

29 (1.142)

41

)

70(2.76) 11.5(0.453)

23 (0.906)

36

(0.500

(0.500

)

11

11. TOOLS

11.7

No. 1

SPECIAL TOOLS

Tools name Spanner or socket Nominal B: 17

Tools No.

Shape

Applicable Pump install

ZT22A17000 General tools CUT

2

Spanner Nominal S: 36

ZT12A36000

Swing motor A,B port Commercial tool outer width (D) - cut length = Required length

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

3

Plug PF1

Additional M10 X 22 threading for M10 eye bolt

ZE72X16000

PF1

For slinging the swing motor (M port)

O-ring M12 Eye bolt

ZS91C01200 or commercial equivalent

For slinging the swing motor & Flare hose 22

4

Eye bolt M12×22

M12

M8 Eye bolt

5

Plug (Nominal tube dia. 22) Reference Eye bolt Nut

ZF83P22000 Reference nut

ZS91C00800 ZF93N22000

M8 X 18 Addtional threading for M8 Eye bolt

11-12

Flare hose

11. TOOLS

M8 Eye bolt

6

Plug Nominal 1-14UNS

YN01H01001P1

Eye bolt

ZS91C00800

M8 X 18 Additional threading HEX 27

Flare hose

1-14UNS

M8 Eye bolt

Plug 7

YN01H01002P1

M8 X 18 Additional threading

11

Nominal 1 3/16-12UN Eye bolt

HEX 36

ZS91C00800

Flare hose

1 3/16-12UN

M12 Eye nut

8

Plug PF1/2

ZE25F08000 Weld

Coupling half

For slinging the swivel joint

Coupling half PF 1/2

9

TORX driver (with tamper proof) T30 (For M6)

5.49

—

Point shape

11-13

For instrument panel cover (RH)

11. TOOLS

11.8

APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND

(1) For general use Manufacturer

Service

Features

Loctite

Three-Bond

#242

1360K

Low strength

#262

1374

Middle strength

#271

1305

High strength

#515

1215

Sealing

Screw locking compound Sealing compound

(2) For specific location No. Use

1

Manufacturer

Name

Equivalent

Applicable

Three-Bond

# 1901 # 1215 gray # 1211 white # 1303B

(Manufacturer ; Loctite) Anti-seizure # 5699 # 5301J # 211

Cylinder Swing motor Swing motor Main pump

Sealing Loctite compound & adhesive Loctite Sumitomo Chemical Co., Ltd. Shell petroleum

# 222 # 277

(Manufacturer ; Three-Bond) # 1344N Main pump # 1307N Pilot valve

Parmatex 98D

(Manufacturer ; Three-Bond) # 1121 Hydraulic oil tank :

Cyano Bond PO-1

Hose

Shell Alvania EP2 New Molyknock Grease 2

Swing bearing grease bath

11-14

11. TOOLS

11.9

SUCTION STOPPER

11.9.1 COMPONENTS No.

NAME

PARTS No.

Q'TY

SUCTION STOPPER ASSY 24100P978F2

1

ROD

2420T4660D1

1

2

NUT

ZN16C08007

1

3

COVER

2414T2123D2

1

4

O-RING

45Z91D6

1

1 Rod

2 Nut 3 Cover 4 O-ring Components Of Suction Stopper

11.9.2 DIMENSION 50 (1.97")

R (1 8 .3 1

O113 (4.45")

5"

M8 NUT

O8 (1.315")

600 (23.6")

)

O100 +0.5 0 (3.94 +0.0197 ) 0

(0.787") 20

M8

O108 (4.25") COVER

ROD Dimension Of Suction Stopper

Applicable model Part No. 24100P978F2

٤ E385B

11.9.3 APPLICABLE MODEL

11-15

2 (0.08")

11

11. TOOLS

11.10 UPPER FRAME LIFTING JIG

No.

NAME

Q'TY

TYPE

1 MASTER LINK L

1

KITO HL050

2 HIGH COUPLING HC

9

KITO HC020

3 CHAIN

1

8 4.4m(14' 5")

4 CHAIN

2

8 1.5m(4' 11")

5 GRAB HOOK H

1

KITO HH020

6 HOOK

2

KITO HJ050

Upper Frame Lifting Jig

11-16

11. TOOLS

11.11 ENGINE MOUNTING PEDESTAL Material : Wood Unit : mm(inch) 5 1

6 3

2

11 6

6

4 6

6

1X1 set 5X1 set

4X1 set

2X1 set

3X1 set 6X5 sets

Engine Stand

11-17

11. TOOLS

11-18

12. STANDARD MAINTENANCE TIME TABLE

12. STANDARD MAINTENANCE TIME TABLE TABLE OF CONTENTS

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ... 12-4 12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST ........................... 12-16 12.2.1 MEASURING METHOD ............................................................................ 12-16 12.2.2 WORKING CONDITION ............................................................................ 12-16 12.2.3 STANDARD TIME CONSTITUENT ........................................................... 12-17 12.2.4 MEANING OF WORDS IN USE ................................................................ 12-18

Book Code No. S5LC1226E01 12-1

12

12. STANDARD MAINTENANCE TIME TABLE

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC1226E01 NA

September, 2010 SK350-9: YC

12-2

12. STANDARD MAINTENANCE TIME TABLE PREFACE (1) Working Conditions 1. Workers: More than one worker shall be 1st class service technician (having five years or more of field experience and having received training in operation). 2. Equipment: Jigs, tools, apparatuses and testers used in field service work will be available commercially. The maintenance plant will be equipped with a service shop, a crane and inspection apparatuses necessary for specific self inspection activities. 3. Place: A flat land where work may be performed and a service car or a truck crane is accessible. (2) Range of standard maintenance time 1. Standard maintenance time=Direct maintenance time X Preparation time 2. Direct maintenance time: Net time actually spent for maintenance 3. Spare time: Time needed to move machines for service, prepare safety operations, discuss work, and process the needs of the team. (3) Extra time (not included in the standard service time) 1. Repair time: Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting. 2. Items excluded from service time because of uncertainty in time: Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults, diagnosis, and inspection. 3. Indirect time: Time for: field work, preparation of necessary parts before leaving for work, return for field work, waiting time because of user's convenience in the field, paper work after returning to shop, and preparation of bills. 4. Special time: Working in the early morning, at midnight and on holidays are to be calculated separately. 5. Separate calculation: The operating time for service cars, trucks with a crane and crane trucks. (4) Applicable machine for estimation of standard maintenance time 1. Standard machine 2. A well maintained and controlled machine with a standard combination of attachments that is used in a general environment.

12-3

12

12. STANDARD MAINTENANCE TIME TABLE

12.1

STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR

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

: Air conditioner

C/V

: Control valve

O/H

: Over haul

ASSY

: Assembly

Cyl

: Cylinder

SOL

: Solenoid

ATT

: Attachment

E/G

: Engine

SW

: Switch

BRG

: Bearing

F hose

: Flexible hose

V

: Valve

(2) Classification of work code No.

GROUP

REMARKS

01 02 03 04

Attachment Cab & Guard Swing frame Travel system

Indicates installing, removing, replacement and overhaul.

06

Electric equipments

Indicates the installing, removing and replacement of single items.

09

E/G relation

Indicates overhaul of the single engine. (Materials prepared by manufacturer)

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

12-4

12. STANDARD MAINTENANCE TIME TABLE 01 Attachment Group

Location

00

Bucket relation

01 02 03 04 05 06

Bucket ASSY -Bucket attaching and detaching position -Bucket attaching pin -Bucket drive pin -Bucket sling and movement Bucket (single)

07 08 09

-Tooth -Side cutter -Bushing

10

Arm relation

11 12 13 14 15 16 17 18

Arm ASSY -Bucket cylinder attaching and detaching position and piping -Bucket cylinder rod pin -Bucket cylinder head pin -Bucket cylinder assy -Arm cylinder rod pin -Boom top pin -Arm sling and movement

30

Boom portion

31 32 33 34 35 36 37 38 39 40 41 42 43 50 51 52 53 60 61 70 71 80 81

Boom ASSY -Boom attaching and detaching position -Boom cylinder temporary slinging -Boom cylinder rod pin -Boom cylinder piping -Arm & bucket piping -Boom assy temporary slinging -Boom foot pin -Boom assy slinging Arm cylinder attaching and detaching -Arm cylinder piping -Arm cylinder head pin -Arm cylinder slinging Boom cylinder attaching and detaching -Boom cylinder piping -Boom cylinder head pin -Boom cylinder slinging Bucket cylinder -Pin bushing Arm cylinder -Pin bushing Boom cylinder -Pin bushing

Work to be done

Unit

Remarks

Unit: Hour

See 32.1.2 Detach/attach Preparation

1 pc. 1 pc.

Include adjustment

0.9 0.1

Detach/attach Detach/attach Preparation O/H

1 1 1 pc. 1 pc.

Include stopper pin.

0.2 0.2 0.3 3.6

Replace Replace Replace

1 pc. 1 pc. 1 pc.

Not include attaching and detaching

0.9 1.8 0.9

See 32.1.3 Detach/attach Preparation

1 pc. 1 pc.

Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

1.9 0.6 Include stopper pin. Include stopper pin. Include stopper pin. Include wire stop pin

0.2 0.2 0.2 0.2 0.2 0.3

See 32.1.4 Detach/attach Preparation Preparation Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach O/H Replace O/H Replace O/H Replace

12-5

1 pc. 1 pc. 2 pcs. 2 2 pc. 1 pc. 1 pc. 1 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 2 pcs. 2 2 pcs. 2 1 1 1 1 set 2 1 set

Include two stopper pins.

Include stopper pin.

Include stopper pin.

Include seal. Include seal. Include seal.

2.1 0.1 0.3 0.3 0.3 0.3 0.1 0.3 0.2 0.7 0.3 0.2 0.2 1.0 0.4 0.3 0.3 4.0 1.5 4.0 1.5 8.0 1.5

12

12. STANDARD MAINTENANCE TIME TABLE 02 Cab & Guard (1/2) Group

Location

10

Cab relation

11 12 13 14 15 16 17 18

Cab ASSY -Front lower glass, floor mat -Seat rear cover top, bottom -Right side panel (include A/C duct) -Cable and harness (electric) -Controller (KPSS) -Cab mounting bolt -Cab slinging

20

Guard relation

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Bonnet assy (F1) Bonnet assy (F2) Guard (C1) Guard (A23) Guard (A24) Guard (A17) Guard (A18) Guard (D1) Cover (H4) Stay (G1) Stay (E1) Panel assy (B1) Panel assy (B2) Panel assy (B3) Panel assy (A31) Guard (A25) Guard (A26) Guard (A27) Guard (D2) Beam (A7) Beam (A12) Pillar (A5) Bracket assy (A13) Guard (A14) Cover assy (C5) Guard assy (C2) Guard assy (C3) Cover (C4) Plate (A28) Guard assy (A22) Cover assy (H1)

Work to be done

Unit

Remarks

Unit: Hour

See 33.1.2 1.6 0.1 0.3 0.3 0.2 0.2 0.2 0.3

1 pc. Detach/attach Detach/attach 1 pc. each Detach/attach 1 pc. each 3 Detach/attach 6 Detach/attach 1 pc. Detach/attach 8 pcs. Detach/attach Detach/attach 3 places See 33.1.4 Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

Note: The numbers in the parenthesis like guard (26) match the guard numbers on the upper structure.

12-6

0.3 0.3 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

12. STANDARD MAINTENANCE TIME TABLE 02 Cab & Guard (2/2) Group

Location

50

Under cover relation

51 52 53 54 55 56 57 58 59

Cover (1) Cover (2) Cover (3) Cover (4) Cover (5) Cover (6) Cover (7) Cover (10) Cover (11)

70

Counterweight relation

71 72 73 74

Counterweight ASSY -Counterweight temporary slinging -Counterweight mounting bolt -Counterweight slinging

Work to be done

Unit

Remarks

Unit: Hour

See 33.1.5 Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach

0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. See 33.1.11

Detach/attach Preparation Detach/attach Detach/attach

1 pc. 1 pc. 1 pc. 1 pc.

0.9 0.3 0.3 0.2

Note: The numbers in the parenthesis like cover (2) match the cover numbers on the upper structure.

12

12-7

12. STANDARD MAINTENANCE TIME TABLE 03 Swing frame (1/3) Group

Location

10

Intake relation

11 12 13 14

Air cleaner ASSY -Hose (3) -Air cleaner mounting bolt -Element

20

Exhaust relation

21 22 23 24 25

Filter ASSY -Harness connector -Hose -Bracket -Rubber mount

30

Radiator relation

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

Radiator ASSY -Coolant (LLC) --Concentration of coolant -A/C condenser -Fuel cooler -Stay -Bracket -Sub tank hose -Fan guard -Water hose (radiator ~ E/G) -Radiator mounting bolts removing -Under cover -Hydraulic oil tank suction stopper -Hydraulic oil piping -Inter cooler hose & tube (E/G to inter cooler) -Radiator lifting or hoisting -Radiator inter cooler core & oil cooler

50

Fuel relation

51 52 53 54 55 56

Fuel tank ASSY -Fuel -Hose (water separator side) -Tube (tank side) -Fuel tank installing bolts -Tank slinging Other necessary works

60

Hydraulic oil tank relation

61 65 66 68 69 70 71 72 73

Hydraulic oil tank ASSY -Cover -Hydraulic oil -Pilot drain hose -Pump suction hose -Mounting bolt -Hydraulic oil tank slinging -Return filter -Suction filter

Work to be done

Unit

Remarks

Unit: Hour

See 33.1.9 Detach/attach Detach/attach Detach/attach Replace

0.4 0.1 0.2 0.1

1 pc. 1 1 set 1 See 33.1.10

Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach

0.5 0.1 0.1 0.3 0.3

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. See 33.1.12

Detach/attach Replace Measuring Moving Moving Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 1 pc. 3 pc. 2 1 set 1 pc. 1 pc. 1 pc. 2 pcs.

5.0 0.3 0.2 0.3 0.3 0.1 0.3 0.1 0.4 0.6 0.2 0.1 0.2 0.6 0.5

Detach/attach Cleaning

1 pc. 1 pc.

0.2 1.0 See 33.1.6

Detach/attach Replace Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach

1 pc. 1 pc. 2 1 1 pc. 1 pc. 1 pc.

Removing and installing guard

1.8 0.4 0.1 0.1 0.3 0.3 0.4

See 33.1.7 Detach/attach Detach/attach Replace Detach/attach Detach/attach Detach/attach Detach/attach Replace Cleaning

12-8

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 1

3.0 0.2 0.6 0.2 0.5 0.2 0.3 0.2 0.2

12. STANDARD MAINTENANCE TIME TABLE 03 Swing frame (2/3) Group

Location

Work to be done

Unit

80

Pump relation

81 82 83 84 85 86 87 88 89

Pump ASSY -Hydraulic oil tank cover -Strainer & stopper -Piping -Guard -Pump slinging -Cleaning -Vent air Pump ASSY

90

Swing motor unit relation

91 92 93 94 95 96 97

Swing motor ASSY -Piping -Mounting bolt -Unit slinging -Cleaning and sealant Swing motor Swing reduction gear

100

Swivel joint relation

101 102 103 104 105 106 107 108 109

Swivel joint ASSY -Piping (Top part only) -Whirl stop bolt -Cover -Joint & elbow -Mounting bolt -Swivel joint slinging -Cleaning Swivel joint

Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Cleaning O/H

1 1 set 1 1 1 set 1 set 1 1 set 1 set

Other necessary works

Detach/attach

1 set

120

Main control valve

121 122 123 124 125 126

Main control valve ASSY -Attach tag to port name of pipe -Piping -Bracket mounting bolt -Valve slinging Main control valve ASSY Other necessary works

Remarks

Unit: Hour

See 33.1.8 Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Cleaning Adjust O/H

3.2 0.3 0.3 1.0 1.0 0.5 0.1 0.1 4.0

1 pc. 1 pc. 1 pc. 1 set 5 pcs. 1 pc. 1 pc. 1 pc. 1 pc. See 33.1.18

Detach/attach Detach/attach Detach/attach Detach/attach Cleaning O/H O/H

2.4 1.0 0.7 0.5 0.2 4.0 5.0

1 pc. 1 set 1 pc. 1 pc. 1 set 1 pc. 1 pc. See 33.1.19

Removing and installing guard Lower piping

2.6 0.5 0.2 0.4 0.4 0.4 0.4 0.3 3.6 0.6

See 33.1.15 Detach/attach Preparation Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach

12-9

1 pc. 1 pc. 1 set 1 pc. 1 pc. 1 set 1 set

Guard

2.5 0.6 1.7 0.1 0.1 6.0 0.4

12

12. STANDARD MAINTENANCE TIME TABLE 03 Swing frame (3/3) Group

Location

Work to be done

Unit

Detach/attach Preparation Detach/attach Detach/attach

1 1 1 set 1

130

Valve relation

131 132 133 134

Solenoid valve ASSY -Attach tag to port name of pipe -Piping -Mounting bolt

140

Engine (E/G) mounting relation

141

Engine ASSY

Detach/attach

1 pc.

142

-Harness connector & grounding & cable connection -Fuel hose -Others -Mounting bolt -Engine slinging -Cleaning Engine

Detach/attach

1 pc.

Detach/attach Detach/attach Detach/attach Detach/attach Cleaning O/H

1 pc. 1 set 1 pc. 1 set 1 pc. 1 set

Other necessary works

Detach/attach

1 set

Detach/attach

1 set

Detach/attach

1 set

Detach/attach

1 set

Detach/attach

1 set

Detach/attach

1 set

143 144 145 146 147 148

150

Upper frame

151 152 153 154 155

Upper frame ASSY -Mounting bolt -Upper frame slinging -Cleaning -Sealant Other necessary works

Remarks

Unit: Hour 1.0 0.2 0.5 0.3

See 33.1.13 After removing pump & radiator

Reference for engine (Chapter 51) Removing and installing guard Removing and installing Counterweight Removing and installing pump Removing and installing air cleaner Removing and installing muffler Removing and installing radiator

2.0 0.3 0.1 0.5 0.5 0.3 0.5 0.6 0.9 3.2 0.4 0.4 4.0

See 33.1.20 Detach/attach Detach/attach Detach/attach Cleaning Apply Detach/attach Detach/attach Detach/attach Detach/attach

12-10

1 pc. 1 set 1 pc. 1 pc. 1 pc. 1 set 1 set 1 set 1 set

After removing swivel joint

Cab Guard Counterweight Boom

1.3 0.4 0.4 0.3 0.2 1.4 0.4 0.9 2.1

12. STANDARD MAINTENANCE TIME TABLE 04 Travel system Group

Location

00

Travel relation

01

Track link ASSY

02 03 04 05

-Track link attaching and detaching position -Master pin -Track link extending and winding Shoe plate

10

Upper roller relation

11 12

Lower roller ASSY Lower roller

20

Lower roller relation

21 22

Lower roller ASSY Lower roller

30

Front idler relation

31 32 33 34

Front idler ASSY Front idler ASSY slinging Front idler ASSY Idler ASSY

40

Sprocket

41

Sprocket

50

Travel motor relation

51 52 53 54 55 56 57 58

Travel motor ASSY -Motor cover -Hydraulic piping -Motor mounting bolt -Motor slinging Motor cleaning Travel motor Travel reduction gear

60

Swivel joint relation

61

Pipe on swivel joint travel side

62

Swivel joint

70

Swing bearing

71 72 73

Swing bearing ASSY Swing bearing mounting bolt Swing bearing slinging

Work to be done

Unit

Remarks

Unit: Hour

See 34.1.2 Detach/attach

One side

Preparation

One side

Detach/attach Detach/attach Replace

One side One side 1 pc.

Include adjustment of tension

2.0 0.1 0.7 0.7 0.4

See 34.1.3 Detach/attach O/H

1 1

After removing track link

0.3 1.0

See 34.1.4 Detach/attach O/H

1 1

0.3 1.5 See 34.1.5

Detach/attach Detach/attach Detaching O/H

One side One side One side One side

After removing track link

0.8 0.3 0.5 1.5

See 34.1.6 Replace

One side

After removing track link

0.9

See 34.1.7 Detach/attach Detach/attach Detach/attach Detach/attach Detach/attach Cleaning O/H O/H

One side One side One side One side One side One side One side One side

After removing track link

2.4 0.1 1.3 0.6 0.2 0.2 4.0 4.0

Detach/attach

1 pc.

0.6

O/H

1 pc.

Include bonnet assy removing and installing. See 33.2.6

3.6

See 34.1.8 Detach/attach Detach/attach Detach/attach

12-11

1 pc. 1 pc. 1 pc.

After removing upper frame

0.8 0.6 0.4

12

12. STANDARD MAINTENANCE TIME TABLE 06 Electric equipments (1/4) Group

Location

Work to be done

Unit

Replace Replace Replace Replace Replace

1 1 1 1 1

0.5 1.0 2.0 1.0 1.0

Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 1 0.3 0.3 0.3 0.3 0.3 0.3 1 1

Remarks

Unit: Hour

Controller C-1 C-2 C-4 C-5 C-8

Controller (KPSS) Gauge cluster Air conditioner Amplifier Engine coolant level controller Engine controller Diode

D-4 D-5 D-6 D-9 D-10 D-12 D-13 D-14 D-15 D-16 D-17 D-18 D-19 D-20 D-21 D-22 D-23 D-25 D-66 D-67

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Electric equipments

E-1 E-2 E-3 E-5 E-6 E-7 E-8 E-9 E-10 E-11

Fuse & relay box Alternator Hour meter Horn (High) Horn (Low) Tuner AM & FM (OPT) Speaker left Speaker right Receiver dryer Air compressor

Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace

1 1 1 1 1 1 1 1 1 1

E-12 E-22 E-23 E-27 E-46 E-49 E-63 E-65

Battery DC-DC conveter 12V socket Accel emergency mode volume Rear camera DC-DC converter (proportional) DC-DC converter (for camera) 24V socket

Replace Replace Replace Replace Replace Replace Replace Replace

2 1 1 1 1 1 1 1

12-12

Include gas sealing. Include Counterweight removing and installing.

0.4 0.3 0.3 0.5 0.3 0.3 0.3 0.3

12. STANDARD MAINTENANCE TIME TABLE 06 Electric equipments (2/4) Group

Location

Work to be done

Unit

Replace Replace Replace Replace Replace

1 1 1 1 1

Bulb

0.2 0.2 0.2 0.2 0.2

Include Counterweight removing and installing.

1.2

Remarks

Unit: Hour

Light L-1 L-2 L-5 L-7 L-8

Boom work light left Frame working light right Room light Cab working light front 1 Cab working light front 2 Motor

M-1

Starter motor

Replace

1

M-3 M-4

Wiper motor Washer motor

Replace Replace

1 1

0.5 0.5

Proportional valve PSV-A PSV-B

Arm 2 speed inverse proportional valve P2 unload proportional valve

Replace Replace

1 1

PSV-C PSV-D PSV-R PSV-P1 PSV-P2

Travel straight proportional valve P1 unload proportional valve Controll proportional valve P1 pump proportional valve P2 pump proportional valve

Replace Replace Replace Replace Replace

1 1 1 1 1

Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Include proportional valve block removing and installing.

0.5 0.5 0.5 0.5 0.5 0.5 0.5

Relay R-1 R-2 R-3 R-4 R-5 R-6 R-9 R-11 R-23 R-24 R-25 R-26 R-28 R-29 R-30 R-31 R-32 R-94

Battery relay Starter relay Glow relay Safety relay Horn relay Work light relay Cab working light relay 1 Cab working light relay 2 Auto idle stop relay 1 Auto idle stop relay 2 E/G emergency stop relay Safety lock lever relay Alternator relay Wiper motor relay (Normal rotation) Wiper motor relay (Reverse rotation) Wiper motor relay arc prevention relay Washer motor relay Neutral stop relay

12-13

0.3 0.3 0.3 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

12

12. STANDARD MAINTENANCE TIME TABLE 06 Electric equipments (3/4) Group

Location

Work to be done

Unit

Remarks

Unit: Hour

Sensor SE-1 SE-2 SE-3 SE-4 SE-5 SE-7 SE-8 SE-9

Pressure sensor: Bucket digging Pressure sensor: Bucket dump Pressure sensor: Boom up Pressure sensor: Boom down Pressure sensor: Swing Pressure sensor: Arm in Pressure sensor: Arm out Pressure sensor: Travel right

Replace Replace Replace Replace Replace Replace Replace Replace

1 1 1 1 1 1 1 1

SE-10

Pressure sensor: Travel left

Replace

1

SE-11

Pressure sensor: P2 side OPT.

Replace

1

SE-13

Engine speed sensor

Replace

1

SE-15

Fuel sensor

Replace

1

SE-16 SE-20

Accel potentiometer Pressure sensor: P1 side : P1 side (OPT.) Pressure sensor: P1 pump Pressure sensor: P2 pump

Replace Replace

1 1

Replace Replace

1 1

SE-22 SE-23

Include under cover removing and installing Include under cover removing and installing Include under cover removing and installing Include under cover removing and installing Include guard removing and installing Include under cover removing and installing

0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Solenoid SV-1

Swing parking SOL

Replace

1

SV-2

Attachment boost pressure SOL

Replace

1

SV-3

2-speed travel SOL

Replace

1

SV-4

Safety lever lock SOL

Replace

1

12-14

Include proportional valve block removing and installing. Include proportional valve block removing and installing. Include proportional valve block removing and installing. Include proportional valve block removing and installing.

0.5 0.5 0.5 0.5

12. STANDARD MAINTENANCE TIME TABLE 06 Electric equipments (4/4) Group

Location

Work to be done

Unit

Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks

Unit: Hour

Switch SW-1 SW-4 SW-5 SW-7 SW-8 SW-10 SW-11 SW-15 SW-17 SW-19 SW-20 SW-21 SW-27 SW-55 SW-56

Key switch Swing parking release switch Hron switch (right) Engine oil pressure switch Clogged air filter switch Horn switch (left) Safety lever lock switch Conflut/single select switch (OPT.) Roof wiper switch Wiper interlock switch Attachment power boost switch (right) Attachment power boost switch (left) Engine cooling coolant level switch Boom work light switch Fuel supply auto stop switch

0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

12

12-15

12. STANDARD MAINTENANCE TIME TABLE

12.2

ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

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

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

12.2.2 WORKING CONDITION 12.2.2.1 TOOLS, INSTRUMENT (1) Hand tool: Tools which are commercially available and each workman usually carries. (2) Common tool: Tools which are commercially available and each workman does not usually carry but the storing place is specified. (3) Special tool: Tools especially prepared by HINO Motor's Ltd. and the storing place is specified. (4) Machine tool: When measuring equipment and instruments are used, the time required to move parts to the specified place is included, but the time waiting for tools is not included as a general rule.

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

12.2.2.3 STANDARD WORKMAN QUALIFICATION Workmen shall basically acquire 2 to 3 years of maintenance experience on HINO.

12-16

12. STANDARD MAINTENANCE TIME TABLE 12.2.3 STANDARD TIME CONSTITUENT 12.2.3.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD ALLOWANCE TIME (1) Net working time The time a workman actually works and the time required for measurement, cleaning, and so on is included, but the time required for troubleshooting is not included. (2) Standard time Time required for preparation to the beginning of work, preparation of a special tool, measuring equipment, parts and so on, and for the work site clean-up. (3) Standard allowance time Calculate the allowance time directly required for workmen from the following equation. Net standard time X HINO allowance rate Allowance rate varies within the range of 0.15 to 0.75 according to the work difficulty, contents, working position and so on.

12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME 12.2.3.2.1 HINO allowance rate (0.15 to 0.75) (1) Basic rate: 0.10 (2) Working posture allowance (Fatigue coefficient): Take any one of the followings according to the work contents. Standing work: 0.05 Work in bent posture: 0.10 Work while lying: 0.15 (3) Difficult work allowance: 0.30 (4) Seized rusted section (For new vehicle): 0.50 Take any one of above (3) and (4). Min. allowance rate = Basic allowance + standing work allowance = 0.1 + 0.05 = 0.15 Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75 12.2.3.2.2 STANDARD WORKING TIME (1) Working standard time: 3 minutes (One time for a set of works) (2) Special tool standard time: 3 minutes (One time for a set of works) (3) Standard time of non-portable machine: 3 minutes (For single work) (4) Part standard time: 6 minutes (up to 10 items), 10 minutes (10 items or more) (One time for a set of works) (5) est:15 minutes (One time for a set of works) (6) Preparation time for chain block, measuring instrument, piston, heater and so on: 3 minutes (One time for a set of works) (7) General cleaning: 2 minutes (One time for a set of works) (8) Safety treatment like wheel stopper, and so on: 3 minutes (9) Visual checks: 2 minutes The preparation time is classified as described above, and only items required for the work are selected, calculated, and counted as preparation time for the work.

12-17

12

12. STANDARD MAINTENANCE TIME TABLE 12.2.4 MEANING OF WORDS IN USE •

•

•

•

• •

• • •

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

12-18

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

1

00101

Engine adjustment A set

Completed machine

Timing adjustment Valve clearance adjustment

2.5

2

00103

Engine adjustment B set

Completed machine

A set and nozzle adjustment

-

Include: Engine warm-up, valve clearance adjustment, removing air cleaner element and battery specific gravity measurement

4.3

3

00111

Compression measuring

Completed machine

8

99012

Replacing cylinder, block, piston, ring and liner simultaneously

Single unit

From engine is removed condition

31.6

9

99013

Replacing crank shaft, piston, ring and liner simultaneously

Single unit

From engine is removed condition

25.8

Replacing cylinder block

Single unit

From engine is removed condition Include: Valve clearance adjustment Exclude: Installing expansion plug knock pin

30

Adding hour by 1 each

12

11

00126

Replacing crank shaft

Single unit

From engine is removed condition

22.8

12

00127

Replacing crank shaft main bearing

Single unit

From engine is removed condition

22.8

From engine is removed condition Include: Adjustment of water pump, oil pump, valve clearance, valve lapping and measurement/cleaning Exclude: Replacing of injection pump, electrical equipment, water pressure test, clutch overhaul and valve guide

44.3

15

00151

Engine overhaul

Single unit

16

00152

Compression measuring

Single unit

17

00153

Replacing piston

Single unit

From piston & connecting rod are removed conditions

0.5

0.5

18

00154

Replacing piston ring

Single unit

From piston & connecting rod are removed conditions

0.2

0.2

19

00155

Replacing cylinder liner

Single unit

From piston & connecting rod are removed conditions

0.4

0.4

3.1

12-19

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

20

00157

Replacing connecting rod

Single unit

21

00158

Replacing piston pin bushing

Single unit

26

00165

Replacing expansion plug

41

00302

Valve clearance adjustment

42

00305

43

Work unit

Q'ty

Works 1

Adding hour by 1 each

From piston & connecting rod are removed conditions

0.3

0.3

From connecting rod is a single unit condition Include: Reaming

0.4

0.4

Single unit

0.4

0.4

Completed machine

2

Replacing rocker chamber cover upper

One set

1.4

00306

Replacing rocker chamber cover lower

One set

44

00304

Replacing rocker chamber cover gasket

One set

1.4

45

00312

Removal and installing rocker arm and support

Completed machine

3.3

46

00313

Replacing rocker arm

Completed machine

3.4

47

00314

Replacing rocker arm support

Completed machine

3.4

48

00315

Replacing rocker arm shaft

Completed machine

3.4

50

00322

Removal and installing cylinder head

Completed machine

Excluding: Removal and installing of nozzle holder or injector and injector sub harness

10.4

51

00323

Replacing cylinder head

Completed machine

Include: Valve lapping Exclude: Replacing of valve guide

16.9

Include: Valve lapping Exclude: Replacing of valve guide, water pressure test and replacing valve seat

18.8

Include: Removal and installing upper

4.3

52

00324

Overhaul of cylinder head

Completed machine

53

00325

Replacing cylinder head gasket

Completed machine

54

00326

Replacing valve

Completed machine

Include: Valve lapping

15.6

55

00327

Replacing valve spring

Completed machine

Exclude: Removal and installing of cylinder head

8.8

57

00328

Replacing valve stem seal

Completed machine

Exclude: Removal and installing of cylinder head

9.4

10.4

12-20

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

61

00376

Removal and installing camshaft housing plug

62

00377

Removal and installing camshaft (with camshaft gear)

63

00352

Replacing cylinder head (one piece and one set require same hour)

66

00355

Replacing valve guide

72

00361

Replacing expansion plug

Work unit

Q'ty

Works 1

Adding hour by 1 each

One set

1.6

0.2

Completed machine

3.4

Single unit

With manifold and nozzle holder Include: Valve lapping Excluding: Removal and installing of cylinder head, replacing valve guide, water pressure test and replacing valve seat

6.5

Unit of 1 cylinder

1

0.8

Single unit

0.4

0.4

00371

Replacing rocker arm (one piece and one set require same hour)

Unit of 1 cylinder

0.1

74

00372

Replacing rocker arm support (one piece and one set require same hour)

Unit of 1 cylinder

0.1

75

00373

Replacing rocker arm bushing

Unit of 1 cylinder

0.3

0.1

76

00374

Replacing valve

Unit of 1 cylinder

From cylinder head is removed condition Include: Valve lapping

0.5

0.5

77

00375

Replacing valve spring

Unit of 1 cylinder

From cylinder head is removed condition

0.2

0.2

78

00330

Replacing valve stem seal

Unit of 1 cylinder

From cylinder head is removed condition

0.3

0.3

81

00406

Removal and installing supply pump

One set

Include: Function check

2.3

84

00411

Tightening oil pan

Single unit

From engine is removed condition

0.5

85

00412

Removal and installing oil pan

Single unit

From engine is removed condition

0.5

86

00413

Replacing oil pan

Single unit

From engine is removed condition

0.7

73

12-21

12

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

Adding hour by 1 each

87

00414

Replacing oil pan gasket

Single unit

From engine is removed condition

0.7

88

00421

Replacing oil pan drain cock

Single unit

From engine is removed condition

0.5

0.8

89

00422

Replacing oil pan drain cock gasket

Single unit

From engine is removed condition

0.5

0.4

92

00443

Replacing breather hose

Single unit

From engine is removed condition

0.2

0.3

93

00444

Replacing oil level gauge

Single unit

From engine is removed condition

0.1

94

00445

Replacing oil level gauge guide

Single unit

From engine is removed condition

0.2

0.1

95

00446

Replacing oil level gauge bracket

Single unit

From engine is removed condition

0.2

0.5

102

00512

Replacing fly wheel housing

Single unit

From engine is removed condition

3.4

0.2

103

00541

Replacing fly wheel housing gasket

Single unit

From engine is removed condition

5.4

0.3

104

00542

Replacing rear end plate

Single unit

From engine is removed condition

5.4

105

00543

Replacing rear end plate gasket

Single unit

From engine is removed condition

5.4

106

00515

Replacing crank shaft rear oil seal

Single unit

From engine is removed condition

5.4

119

00552

Replacing crank shaft rear oil seal

Single unit

From fly wheel is removed condition

0.2

131

00613

Replacing intake manifold

One set

Include: Applying liquid gasket

2.3

132

00614

Replacing intake manifold gasket

One set

Include: Applying liquid gasket

2.3

133

00636

Removal and installing intake pipe (manifold side)

One set

1.6

134

00637

Replacing intake pipe (manifold side)

One set

1.6

135

00622

Replacing air intake hose

One set

0.4

0.2

136

00623

Replacing air intake pipe

One set

0.4

0.2

137

00626

Replacing air intake pipe

One set

Turbo charger to inter cooler

0.4

138

00627

Replacing air intake pipe

One set

Air cleaner to turbo charger

0.4

12-22

0.2

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

Adding hour by 1 each 0.2

139

00675

Replacing silencer body

Completed machine

0.3

142

00641

Tightening exhaust manifold

Completed machine

1.3

143

00643

Removal and installing exhaust manifold

Completed machine

With insulator and stud bolt

3.2

144

00644

Replacing exhaust manifold

Completed machine

Include: Replacing stud bolt with new one and insulator (TI system)

3.4

145

00645

Replacing exhaust manifold gasket

Completed machine

146

00646

Replacing exhaust heat insulator

One side of completed machine

147

00651

Replacing exhaust pipe

One set

0.8

148

00653

Replacing exhaust pipe gasket

One set

0.6

164

00686

Removal and installing turbo charger

One set

2.5

165

00687

Replacing turbo charger

One set

Include: Replacing stud bolt

2.5

167

00689

Replacing turbo charger oil return pipe

One set

Include: Removal and installing of lower insulator

0.9

174

00624

Replacing air intake pipe upper (cooler to manifold)

One set

188

00701

Removal and installing engine and timing gear cover (fly wheel housing)

Single unit

From engine is removed condition Include: Removal and installing of cylinder head

5.4

189

00711

Replacing timing gear cover (fly wheel housing)

Single unit

From engine is removed condition Include: Removal and installing of cylinder head

5.4

190

00712

Replacing timing gear cover gasket (fly wheel housing)

Single unit

From timing gear cover is removed condition

0.7

191

00713

Replacing timing gear cover plate (rear end plate)

Single unit

From timing gear cover is removed condition

1.0

3.2 Removal and installing of turbo charger

2.6

0.4

12-23

12

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

Adding hour by 1 each

192

00714

Replacing timing gear cover plate gasket (rear end plate gasket)

Single unit

From timing gear cover is removed condition

1.0

193

00725

Replacing idler gear (main)

Single unit

From timing gear cover is removed condition

0.2

0.2

194

00736

Replacing idler gear (sub)

Single unit

From timing gear cover is removed condition

0.1

0.2

195

00726

Replacing idler gear shaft (main)

Single unit

From timing gear cover is removed condition

0.2

196

00737

Replacing idler gear shaft (sub)

Single unit

From timing gear cover is removed condition

0.1

197

00724

Replacing crank shaft gear rear

Single unit

201

00738

Replacing cam idle gear

Single unit

From timing gear cover is removed condition

0.4

202

00739

Replacing cam idle gear shaft

Single unit

From timing gear cover is removed condition

0.4

203

00731

Replacing camshaft

Single unit

From timing gear cover is removed condition

0.8

204

00732

Replacing camshaft gear

Single unit

From timing gear cover is removed condition

0.8

205

00751

Replacing crank pulley

One set

1.9

206

00754

Replacing crank dumper

One set

2.8

207

00755

Replacing crank shaft front oil seal

One set

2.2

208

00757

Replacing crank shaft front oil seal retainer

One set

2.8

209

00758

Replacing crank shaft front oil seal retainer gasket

One set

2.8

211

00801

Checking injection timing

Completed machine

0.3

226

00834

Replacing priming pump

One set

0.4

227

00835

Cleaning fuel feed pump strainer

One set

0.4

228

00836

Replacing through feed valve

One set

0.4

230

00838

Replacing fuel injection pipe

One set

2.5

0.4

12-24

0.1

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

Adding hour by 1 each 0.2

236

00851

Replacing fuel filter assembly

One set

0.5

237

00857

Replacing fuel filter cartridge

One set

0.3

253

00875

Replacing fuel hose

One set

0.8

254

00876

Replacing fuel leakage pipe

One set

0.8

276

00912

Replacing oil filter cartridge

One set

0.4

277

00907

Replacing oil filter relief valve (oil filter regulator valve)

One set

0.3

278

00908

Replacing oil filter relief valve spring (oil filter regulator valve)

One set

0.3

279

00909

Replacing oil filter safety valve

One set

0.3

280

00910

Replacing oil filter safety valve spring

One set

0.3

294

00961 Removal and installing fly (timing wheel housing gear (timing gear cover) cover)

Single unit

From engine is removed condition

6.1

295

00942

Replacing oil pump

Single unit

From engine is removed condition

6.3

296

00944

Replacing oil pump gear

Single unit

From engine is removed condition

6.5

297

00943

Overhaul of oil pump

Single unit

From engine is removed condition

6.5

298

00946

Replacing suction strainer

One set

0.1

299

00947

Replacing suction strainer O-ring

One set

0.1

301

00951

Replacing oil pipe

One set

0.4

0.4

302

00954

Replacing oil hose

One set

0.4

0.4

303

00971

Replacing cooling oil jet

1

0.2

0.2

327

01028

Removal and installing water pump

One set

Include: Filling engine coolant up

4.0

328

01029

Replacing water pump

One set

Include: Filling engine coolant up

4.0

12-25

12

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

Adding hour by 1 each

329

01030

Overhaul of water pump

Single unit

0.8

330

01031

Replacing water pump pulley

Single unit

0.6

331

01032

Replacing water pump casing gasket

One set

332

01036

Replacing cooling fan

One set

0.9

333

01037

Replacing fluid fan coupling

One set

0.9

334

01044

Replacing thermostat casing

One set

Include: Filling engine coolant up

1.3

336

01046

Replacing thermostat casing cover

One set

Include: Filling engine coolant up

1.0

337

01047

Replacing thermostat casing cover gasket

One set

Include: Filling engine coolant up

1.0

338

01048

Replacing thermostat

One set

Include: Checking for temperature at valve start opening

1.0

339

01049

Checking thermostat

One set

Include: Checking for temperature at valve start opening

1.0

341

01053

Replacing coolant hose

One set

0.3

0.2

342

01054

Replacing radiator hose

One set

0.3

0.2

343

01071

Replacing fluid fan coupling

1

0.3

344

01072

Replacing cooling fan

1

0.3

345

01073

Replacing water pump

1

346

01074

Overhaul of water pump

1

0.8

402

01401

Removal and installing alternator

One set

0.8

403

01402

Replacing alternator

One set

0.9

404

01406

Replacing alternator support bracket

One set

1.0

405

01408

Replacing V-belt

One set

0.3

438

01801

Removal and installing supply pump

One set

Include: Function check

3.0

439

01802

Replacing supply pump

One set

Include: Function check

3.0

Liquid gasket

From cooling fan is removed condition

12-26

4.0

1.7

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

Adding hour by 1 each

440

01830

Removal and installing common rail assembly (with pressure sensor, pressure limiter)

441

01804

Replacing common rail assembly (with pressure sensor, pressure limiter)

442

01805

Removal and installing injector assembly

Completed machine

Include: Function check

3.5

443

01806

Replacing injector assembly

Completed machine

Include: Function check and reprogramming

4.0

444

01807

Removal and installing injector assembly

One set

Include: Function check

1.9

0.2

445

01808

Replacing injector assembly

One set

Include: Function check and reprogramming

2.4

0.2

446

01809

Removal and installing injector sub harness assembly

One set

Include: Function check

1.9

447

01810

Replace injector sub harness assembly

One set

Include: Function check

1.9

448

01811

Removal and installing flow dumper

One set

Include: Function check

1.2

0.3

449

01812

Replacing flow dumper

One set

Include: Function check

1.2

0.3

450

01813

Removal and installing pressure limiter

One set

Include: Function check

1.2

451

01814

Replacing pressure limiter

One set

Include: Function check

1.2

452

01815

Replacing common rail pressure sensor

One set

Include: Function check

1.2

453

01816

Replacing main engine speed sensor

One set

Include: Function check

1.2

454

01817

Replacing sub engine speed sensor

One set

Include: Function check

1.2

455

01818

Replacing coolant temperature sensor

One set

Include: Function check

1.2

456

01819

Replacing fuel temperature sensor

One set

Include: Function check

1.2

One set

Include: Function check

3.8

One set

Include: Function check

3.8

12-27

12

12. STANDARD MAINTENANCE TIME TABLE

SK350-9 Work No.

Work

Work unit

Q'ty

Works 1

Adding hour by 1 each

457

01820

Replacing accel sensor

One set

Include: Function check

1.5

460

01823

Removal and installing pressure sensor

1

Include: Function check

0.3

461

01824

Removal and installing pressure limiter

1

Include: Function check

0.3

463

01826

Replacing injection pipe

One set

Include: Function check

1.2

0.1

464

01827

Replacing fuel pipe (common rail to supply pump)

One set

Include: Function check

1.2

0.1

465

01828

Replacing fuel leakage pipe

One set

Include: Function check

1.7

469

01840

Checking leakage of pressurized fuel

One set

Include: Function check

1.2

471

01901

Replacing main engine speed sensor

One set

Include: Function check

1.2

472

01902

Replacing sub engine speed sensor

One set

Include: Function check

1.2

473

01903

Replacing coolant temperature sensor

One set

Include: Function check

1.2

474

01904

Replacing accel sensor

One set

Include: Function check

1.5

475

01908

Removal and installing EGR valve

One set

Include: Function check

2.5

476

01909

Replacing EGR valve

One set

Include: Function check

2.5

479

01916

Removal and installing EGR cooler

One set

1.8

480

01917

Replacing EGR cooler

One set

1.8

481

01918

Removal and installing closed ventilator

One set

0.3

482

01919

Replacing closed ventilator

One set

0.3

12-28

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13. MAINTENANCE STANDARD AND TEST PROCEDURE TABLE OF CONTENTS 13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS ........................... 13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE .................................................... 13-4 13.3 MEASUREMENT OF ENGINE SPEED .......................................................................... 13-6 13.3.1 MEASUREMENT OF ENGINE SPEED ................................................................. 13-6 13.4 MEASUREMENT OF HYDRAULIC PRESSURE ........................................................... 13-7 13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE ...................................... 13-7 13.4.2 PLACE TO INSTALL PRESSURE GAUGE ........................................................... 13-7 13.4.3 PRESSURE ADJUSTMENT POSITION ............................................................... 13-8 13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE ................................................ 13-10 13.5 MEASURING TRAVEL PERFORMANCES .................................................................... 13-12 13.5.1 TRAVEL SPEED .................................................................................................... 13-12 13.5.2 DEVIATION OF TRAVEL ....................................................................................... 13-12 13.5.3 PERFORMANCES OF PARKING BRAKE ............................................................ 13-13 13.5.4 DRAIN RATE OF TRAVEL MOTOR ...................................................................... 13-14 13.6 MEASURING SWING PERFORMANCES ..................................................................... 13-15 13.6.1 SWING SPEED ..................................................................................................... 13-15 13.6.2 PERFORMANCE OF SWING BRAKE .................................................................. 13-15 13.6.3 PERFORMANCE OF SWING PARKING BRAKE ................................................. 13-16 13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................ 13-17 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES .................................... 13-18 13.7.1 OPERATING TIME OF CYLINDERS .................................................................... 13-18 13.7.2 OIL TIGHTNESS OF CYLINDERS ........................................................................ 13-19 13.8 MEASURING PERFORMANCES OF SWING BEARING .............................................. 13-20 13.9 MECHATRO CONTROLLER .......................................................................................... 13-22 13.9.1 ENGINE CONTROL INPUT / OUTPUT ................................................................. 13-22 13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) ......................................................................................... 13-22 13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER ................................................................................. 13-29 13.10 EXHAUST GAS POST-CLEANING DEVICE (DPF (DIESEL PARTICULATE FILTER)) ........................................................................ 13-30 13.10.1 HANDLING OF EXHAUST GAS POST-CLEANING DEVICE ............................... 13-30 13.10.2 INSPECTION ......................................................................................................... 13-31 13.10.3 MAINTENANCE STANDARD ................................................................................ 13-31 13.10.4 DPF (DIESEL PARTICULATE FILTER) ................................................................. 13-32

Book Code No. S5LC1325E03 13-1

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC1325E01 (NA)

September, 2010 SK350-9: YC

Revision

February, 2011

SK350-9: YC

S5LC1325E02 (NA)

Revision

May, 2011

SK350-9: YC

S5LC1325E03 (NA)

13-2

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1

HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

(1) Application 1. When the machine is new: Confirm the performances are in accordance with standard specifications as compared to the performance standards. 2. At specific self inspection: (Rule by country) Use the data for the criterion, for the purpose of correction, adjustment and replacement. 3. When performances are deteriorated: Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations. 4. When main components are replaced: For example, use data to restore performances of pumps and other components. (2) Terminology 1. Standard values: Values to be used to service or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standard shoes). 2. Reference values for remedy: Values where readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the machine over the specified values. 3. Service limit: This is the limit value where reconditioning is impossible without replacement of parts. If the value is expected to exceed the service limit before the next inspection and correction are performed; replace the parts immediately. The operation over the specified values causes damage to increase and requires the down time of the machine, and also causes safety problems.

13 (3) Cautions to be Exercised at Judgment 1. Evaluation of measured data: Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values. 2. Determining correction, adjustment or replacement: Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels. (4) Other Cautions to be Exercised 1. Parts liable to degrade: Rubber products, such as, hydraulic hoses: O-rings and oil seals deteriorate with time; replace them at regular intervals or at overhauls. 2. Parts requiring regular replacement: For critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly. 3. Inspection and replacement of oil and grease: In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.

13-3

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2

PERFORMANCE INSPECTION STANDARD TABLE

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

Port

Tolerance

Standard value NAS 8 or less

Unit

Hi

Lo

—

— - 5 (23)

°

Adjusting Point

Measuring condition

—

Sampling

C

—

Atmospheric temp

- 15 (5) (°F)

—

50°C~-10°C (122°F~14°F)

Tank surface

50 (122)

+ 5 (41)

Radiator surface

75 (167)

+ 15 (59)

1000

+ 30

- 30

2100

+ 30

- 30

1050

+ 30

- 30 min-1

1850

+ 30

- 30

1700

+ 30

- 30

5.0 (725)

+ 0.5 (+73)

0

34.3 (4970) + 0.7 (+100)

- 0.5 (-73)

MR1 Boom up

0

MR1 Boom up

H mode Lo idle H mode Hi idle H mode Decel S mode Hi idle E mode Hi idle

ATT Boost

Arm Bucket Swing

Travel

Over load relief valve pressure

Boom

RH LH

G pump

a4

P1

a1

P2

a2

P1

a1

P2

a2

R

a1

H R H R H RH LH FW RV FW RV

Main pump

valve pressure

Main relief

Measure the engine speed at multi display on the gauge cluster.

PF1/4

a2 a1 a2

37.8 (5480)

+ 0.5 (+73)

Adjustment not required

Hydraulic oil temperature Water temperature

Pilot primary pressure circuit

High pressure circuit

Size

Cleanliness of hydraulic oil Hydraulic oil in tank

Engine speed

Standard Measuring condition

Position

Class

Measuring Position

Inspection Item

PR1

LOW throttle Full throttle (HI idle)

Perform all measurement with the air-conditioner "OFF". HI idle

37.8 (5480)

0 - 4.0 (-580)

OR4

Boom down

39.7 (5760)

0 - 5.9 (-855)

OR3

Boom up

39.7 (5760)

0 - 5.9 (-855)

OR8

Arm out

37.8 (5480)

0 - 4.0 (-580) MPa

OR7

Arm in

37.8 (5480)

0 - 4.0 (-580) (psi)

OR2

Bucket dump

39.7 (5760)

0 - 5.9 (-855)

OR1

Bucket digging

29.0 (4205) + 6.0 (+870)

0

OR6

Swing RH

29.0 (4205) + 6.0 (+870)

0

OR5

Swing LH

a1

35.8 (5190)

0 - 2.0 (-290)

a2

35.8 (5190)

0 - 2.0 (-290)

13-4

— — — —

Simultaneous operation of travel RH and LH

13. MAINTENANCE STANDARD AND TEST PROCEDURE

Standard value

Inspection item Track link revolution (RH,LH) (H mode)

1st speed 34.3 ~ 30.7

LC

2nd speed 20.4 ~ 18.0

Up

3.0 ~ 3.7

Down

2.5 ~ 3.2

In

3.6 ~ 4.2

Out

3.3 ~ 3.9

Digging

2.9~ 3.6

Dumping

2.1 ~ 2.7

Operating speed

Boom Operating time of cylinder (At no load)

Bucket Swing speed Travel speed Amount of travel deviation

Performance

Arm

RH LH

Unit sec / 3 rev

sec

17.9 ~ 20.0 sec / 3 rev

1st speed

Iron shoe 21.0 ~ 26.5

2nd speed

Iron shoe 13.0 ~ 15.2

sec / 20 m

2nd speed

0 ~ 240

mm / 20 m

Parking brake drift

15 degree gradient

0

mm / 5 min

Performance of Swing brake

Neutral position after 180° full speed swing

72 ~ 112

degree

Performance of Swing parking brake

15 degree gradient

0

mm

Tip of the bucket tooth

120

Boom cylinder

4.2

Arm cylinder

6

ATT amount of drift

Amount of horizontal play at the bucket tooth

(At no load)

27 ~ 53

mm / 5min (At no load) mm

The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in advance. (1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down (5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out

13-5

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3

MEASUREMENT OF ENGINE SPEED

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

RED WHITE

BLUE (2) Engine speed measured value through service diagnosis (See below Fig.) 1. Turn "ON" the starter switch with the buzzer stop switch pressed. 2. A program No. and an actual engine revolution are displayed as the No.2 Item. 3. The screen advances to No.2, No.3....each time the "Up Arrow Switch" on the gauge cluster is pushed. 4. The screen returns to No.45, No.44....each time the "Down Arrow Switch" is pushed. 5. The display does not disappear unless the starter switch is turned to"OFF".

BUZZER STOP SWITCH

NO.2 ENG G-3 SPEED SET MEAS 1 MEAS 2 G-5 ENG OIL PRS. WATER TEMP. F MODE ATT MODE H-1 ACCEL. VOLT. POS ECU OUTPUT

UP ARROW SWITCH

2205 2201 2201 LIVE 100 OFF HM BRK 4.2V 100% 0.5V

Service Diagnosis for E/G Speed Measuring (Example)

DOWN ARROW SWITCH Switch for E/G Speed Indication

13-6

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4

MEASUREMENT OF HYDRAULIC PRESSURE

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

a5

A3

A2 (A1)

PSV2 (PSV1)

Dr3 B3 B1 a1

a2

Gauge Port On Main Pump

After releasing air in the hydraulic oil tank, open the cover and take a sample of oil from the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter and change the hydraulic oil.

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

13-7

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.3 PRESSURE ADJUSTMENT POSITION (1) Main control valve

OR8 : ARM (R)

PLUG FOR OPTIONAL RELIEF

MACHINE FRONT

MR1 : MAIN RELIEF (ATT & TRAVEL)

OR3 : BOOM (H)

OR2 : BUCKET (R)

VIEW FROM THE TOP OF THE MACHINE

OR4 : BOOM (R)

OR1 : BUCKET (H)

MACHINE FRONT

OR7 : ARM (H)

PLUG FOR OPTIONAL RELIEF

VIEW FROM THE BOTTOM OF THE MACHINE Relief Valve Position On Main Control Valve

13-8

13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pilot relief valve The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

A3

a5

Dr3 B3

PR1 ADJUST SCREW FOR PILOT RELIEF

Pilot Relief Valve Position (3) Swing over load relief The swing motor is equipped with plugs PA and PB for pressure measurement, but the measurement is carried out using gauge ports (a1) and (a2). (See the "Gauge Port On Main Pump" Fig.) PLUGS FOR PRESSURE MEASUREMENT 2-PT1/4 A

B

PA

PB

13 DB

OR5 SWING LEFT OVERLOAD RELIEF

OR6 SWING RIGHT OVERLOAD RELIEF

Swing Over Load Relief Position

13-9

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE (1) Pilot relief valve Adjust it with adjust screw (311). Tools: Spanner: 24 mm, Tightening torque : 29.4 N-m (22 lbf-ft) Tools: Allen wrench: 6 mm

No. of turns of adjust screw Pressure change MPa (psi) 1 turn

Approx. 2.1 (305)

311

LOCK NUT HEX24

Pilot Relief Valve (2) 2-stage main relief valve (Commom for travel and ATT sections) Start from the boosting side first. Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustment on the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment. Tools: Spanner: 32 mm, Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft) Tools: Spanner: 22 mm, Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft) Tools: Spanner: 19 mm, Adjust screw Tools: Allen wrench: 6 mm HEX32 HEX19 1 2

No. of turns of adjust screw Pressure change MPa (psi) Boosting side 1 turn STD side 1 turn

Approx. 17.6 (2560) Approx. 17.6 (2560)

4

3 HEX22

Main Relief Valve (Travel Section, Att Common Section)

13-10

13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Over load relief valve (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw (2). Tools: Spanner: 22 mm, Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft) Tools: Allen wrench: 6 mm

No. of turns of adjust screw Pressure change MPa (psi) 1 turn

Approx. 17.7 (2560)

2

1 HEX22

Over Load Relief Valve (Boom, Bucket, Arm Sections) (4) Over load relief valve (Swing) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap (2). Tools: Spanner: 30, 38 mm, Tightening torque: 118 N-m (87 lbf-ft) Tools: Allen wrench: 12 mm HEX38 1

No. of turns of adjust screw Pressure change MPa (psi) 1 turn

HEX30 2

Approx. 10 (1450)

13 3

R

Swing Over Load Relief Valve (5) Travel over load relief valve This valve was adjusted by valve maker. Do not replace any inner parts except for O-rings.

Travel Over Load Relief Valve

13-11

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5

MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED (1) Purposes Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system. (2) Conditions Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) Crawler on the right and left sides are tensioned evenly.

One Side Lifted Position (3) Preparation Attach the reflection panel shoe plate. Swing the swing frame 90° as shown in above Fig. and raise one side of the tracks off the ground using the attachment.

REFLECTION PANEL

Adhering Position Of Reflection Panel (4) Measurement Engine revolution: High idle 2-speed travel switch: 1st-speed and 2nd-speed Measuring points : Right and left Method, example Measure the revolutions visually.

Unit : sec / 3 rev.

Track link revolution Measurement item LC

H mode 1st speed H mode 2nd speed

Standard value

Reference value for remedy

Service limit

33.2~36.4 19.7~21.7

42.5~46.6 25.2~27.8

57.2~ 31.1~

13.5.2 DEVIATION OF TRAVEL (1) Purpose Measure the amount of deviation at 20 (66 t) travel, and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system. (2) Condition Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution: High idle

13-12

BOOM FOOT PIN

ARM TOP PIN

Travel position

13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Preparation 1. Straight course more than 30 m (108 ft) 2. Travel position in which the bottom of the bucket is lifted by about 30 cm (1 ft). A 20m (66ft)

Measuring Method (4) Measurement 1. Measure the max. deviation distance of the circular arc in the 20 m (66 ft) length, excluding the preliminary run of 3 to 5 m (10 to 16 ft). 2. Operate the travel lever at the same time.

Travel deviation

Unit : mm (in) / 20m (66ft)

Measuring position

Standard value

A

240 (9.45) or less

Reference value Service limit for remedy

480 (18.9)

720 (28.4)

13.5.3 PERFORMANCES OF PARKING BRAKE (1) Purpose Confirm that the parking brake holds a stopped condition of the machine in a no-load travel position and on a 15 degree slope. (2) Condition A slope with approximately a 15° gradient and a stopped condition in a no-load travel position. (3) Preparation Place an angle meter on the shoe plate and confirm that it makes an angle more than 15°. Hang a perpendicular in parallel with the guide frame rib on the track frame and put a mark (matching mark) on the shoe plate.

BOOM FOOT PIN

ARM TOP PIN

13

15 degree slope

Parking Brake Operating Position

(4) Measurement Five minutes after the engine stops, measure the movement distance of the matching mark.

C

GUIDE FRAME

ANGLE METER

Method of Measurement Parking brake Measuring position

C

13-13

Unit : mm(in)/5min Reference value Standard value Service limit for remedy

0

1 (0.04)

2 (0.08)

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5.4 DRAIN RATE OF TRAVEL MOTOR (1) Purpose To measure the drain rate of the travel motor and to confirm the performances of the travel motor. (2) Conditions Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) Engine revolution: Hi idle

90 o 10 (3.54") (0.394")

FORWARD

o 22 PIPE (0.866") RIB "A"

40 (1.57") 150 (5.91")

STOPPER "B"

ROTARY DIRECTION

o 90 (3.54")

Location Of Stopper Applied To Travel Sprocket (3) Preparation 1. Place a stopper under the RH and LH travel sprockets. 2. Stop the engine and release pressure from the hydraulic circuit. 3. Connect a hose to the drain port on the travel motor and drain oil into a container.

Method Of Measuring The Drain Rate Of Travel Motor (4) Measurement : at Travel Lock 1. Start the engine and relieve pressure at the full stroke of the travel lever. 2. Measure the drain rate for 30 seconds of relieving.

Travel deviation

Unit : L(gal)/30sec

Measuring position

Standard value

Drain rate

7.0 (1.8)

Reference value Service limit for remedy

14.0 (3.7)

21.0 (5.5)

Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. (See Upper right Fig.)

13-14

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6

MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED (1) Purpose Measure the swing time and confirm the performances between the hydraulic pump and the swing motor. (2) Conditions Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) Firm, level ground Engine revolution: High idle (3) Preparation With the bucket empty and extend the boom, arm and bucket cylinder fully. Swing Speed Measuring Position (at the min. reach) (4) Measurement Swing the machine by bringing the swing lever to its full stroke. Measure the time required to make two turns after one turn of a preliminary run and calculate the time required for one turn.

13.6.2 PERFORMANCE OF SWING BRAKE (1) Purpose Confirm the braking torque performances by the swing relief valve. (2) Conditions Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) Firm, level ground Engine revolution: High idle

Swing speed

(3) Preparation 1. With the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. Move the boom so the arm top pin is positioned at the same height as the boom foot pin. 2. Put a matching mark on the outer circumference of the swing bearing on the upper frame side and on the track frame side. Place two poles (flags) on the front and back of the extended line on the matching mark.

13-15

Measuring position

Right Left

ARM TOP PIN

Unit : sec/3 rev Reference value Standard value Service limit for remedy

17.9~20.0 17.9~20.0

21.9~24.4 21.9~24.4

27.2~ 27.2~

BOOM FOOT PIN

Swing Brake Performance Measuring Position

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Measurement 1. When operating in regular swing speed, by shifting the lever to the neutral position at the pole position, the swing operation stops. 2. Calculate the swing drift angle by the following equation, after the upper swing body stops, use the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race:

MEASURING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE

MATCHING MARKS ON INNER RACE

Amount of deflection of Swing drift matching marks [m (ft-in)] X 360 angle ( ) = Circumferential length of swing race [m (ft-in)]

Swing brake performance Measuring position

Swing 180

Unit : degree

Reference value Standard value Service limit for remedy

112 or less

123

134

13.6.3 PERFORMANCE OF SWING PARKING BRAKE (1) Purpose To confirm the mechanical performances of the swing parking brake that is fitted to the inside of the swing motor. (2) Conditions On a slope of a 15° incline. Stop the machine at right angles with the slope. With the bucket empty, retract the arm cylinder fully and extend the bucket cylinder fully. Move the boom so the arm top pin is positioned at the same height as the boom foot pin. Swing Parking Brake Performance Measuring Position (3) Preparation Place the angle meter on the shoe plate and make sure that the angle is more than 15°. Put a matching mark on the outer race side and on the inner race side.

MEASUREING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE

MATCHING MARKS ON INNER RACE

Measuring Position Of Swing Parking Brake Performances (4) Measurement When five minutes has passed after the engine is shut off, measure the length of the movement of the matching marks.

13-16

Performance of swing parking brake Measuring position

C

Unit : mm(in)/5min

Reference value Standard value Service limit for remedy

0

1 (0.04)

2 (0.08)

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.6.4 DRAIN RATE OF SWING MOTOR (1) Purpose Measure the drain rate of the swing motor and confirm the performance of the swing motor. (2) Conditions Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) Firm, level ground Engine revolution: High idle (3) Preparation 1. Stop the engine. 2. Release pressure from inside the hydraulic circuit. 3. Disconnect the swing motor drain hose from its end returning to the hydraulic oil tank and take oil in a container. 4. Put a plug to the tank side.

(4) Measurement: at Swing Lock 1. Start the engine and put the side faces of the bucket against the inside of the right or left shoe plates. 2. Relieve the swing motor at full stroke of the swing motion. 3. Collect the amount of drained oil in a container for 30 seconds.

13-17

Travel deviation Measuring position

Drain rate

Unit : L(gal)/30sec

Reference value Standard value Service limit for remedy

2.1 (0.55)

5.2 (1.4)

6.2 (1.6)

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7

MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS (1) Purpose Measure the operating time of the boom, arm and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system. 30cm (1ft)

Measuring Position For Bucket Digging And Dump (2) Condition Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) Engine revolution: High idle Operating time excluding the cushion stroke.

Condition : Arm cylinder most retracted Bucket cylinder most extended

Measuring Position For Boom Up And Down Motions (3) Preparation Firm level ground with the bucket empty (4) Measurement 1: Boom up and down With the boom operating lever at full stroke, measure the required operating time of the bucket between the ground surface and its highest position.

30cm (1ft)

Measuring Position For Arm In And Out Motions Measurement 2: Arm in and out, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30 cm (1ft) above ground, measure the full stroke operating time required with the arm and bucket operating levers at full stroke.

Cylinder Operating time Measuring position

Unit : sec

Reference value Standard value Service limit for remedy

2.9~3.6

3.7~4.5

4.8~

2.1~2.7

2.7~3.5

3.6~

3.0~3.7

3.8~4.6

5.0~

2.5~3.2

3.2~4.0

4.2~

3.6~4.2

4.5~5.2

5.7~

3.3~3.9

4.1~4.9

5.3~

When lowering the boom, lower the bucket onto soft ground or cushioning such as rubber tires. Never put the bucket against concrete or other solid material.

13-18

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.7.2 OIL TIGHTNESS OF CYLINDERS (1) Purpose Confirm that the cylinder oil is tight by checking the moving length of the cylinder rods. (2) Condition Hydraulic oil temperature: 45 to 55C degrees (113 to 131F degrees) Firm, level ground. After cylinders are replaced, bleed out air from the cylinders before checking for oil tightness. Retract the arm cylinder rod 50 mm (2 in) from stroke end so the piston does not match the same range of the cushioning mechanism. (3) Preparation With the bucket empty. Retract the arm cylinder rod 50mm (2in) from the most retracted position. And extend the bucket cylinders fully. Then hold the boom so the arm top pin is positioned at same height as the boom foot pin. (4) Measurement Measure the items five minutes after the engine is turned off. B BOOM FOOT PIN

C A ARM TOP PIN

D

Oil tightness of cylinder Measuring position

Unit : mm/5min

Reference value Standard value Service limit for remedy

A

4 (0.16 in)

5 (0.2 in)

7 (0.28 in)

B

6 (0.24 in)

7.5 (0.3 in)

10 (0.4 in)

C

-

-

-

D

120 (4.7 in)

150 (5.9 in)

200 (7.9 in)

13

13-19

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.8

MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing. (2) Condition Firm, level ground. The swing bearing mounting bolts are not loosened. The swing bearing is lubricated well and not making abnormal sounds during swinging.

LOCATION OF BEARING MOUNTING BOLTS

SWING BEARING A

DIAL INDICATOR LOWER FLAME

How To Measure The Axial Play Of Swing Bearing (3) Preparation 1. Install a dial indicator to the magnetic base and attach it to the lower frame. 2. Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero.

90 ~100

30cm (1ft)

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

BOOM FOOT PIN

ARM TOP PIN

Measuring Position 2

Axial play of swing bearing Measuring position

A

13-20

Unit : mm (in)

Reference value Standard value Service limit for remedy

0.8~1.8 (0.03~0.07)

2.3~3.3 (0.09~0.13)

3.6~ (0.14)

13. MAINTENANCE STANDARD AND TEST PROCEDURE (5) Measurement 2 (Measuring position 3) 1. Retract the arm cylinder fully and extend the bucket cylinder fully. Move the boom so the arm top pin is positioned at the same height as the boom foot pin. Then swing the bucket right and left by man power. In this case, the gap of the attachment is included.

BOOM FOOT PIN

ARM TOP PIN

Measuring Position 2 Right and left movement of the tip of bucket Measuring position

Bucket

Unit : mm (in)

Reference value Standard value Service limit for remedy

50 (1.97)

100 (3.94)

120 (4.72)

13

13-21

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9

MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

C-8: ENGINE CONTROLLER

C-2: GAUGE CLUSTER

E-27: EMERGENCY ACCEL INJECTOR E-1: FUSE&RELAY BOX

ENGINE SPEED SENSOR

STARTER SWITCH

C-1: MECHATRO CONTROLLER

ACCEL POTENTIO METER

ENGINE

PUMP PROPORTIONAL VALVE

Input / Output

13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) 13.9.2.1 PURPOSE OF THE ADJUSTMENT There are 2 kinds of adjustment of mechatro controller as shown below: every adjustment is an essential function to ensure performance of the machine. (1) Adjustment of pump ("B" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with the engine rated output. (2) Adjustment of unloading valve ("C" adjustment) This adjustment is performed to correct the open variation of the unloading valve to improve the operability further.

13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED: When the following parts are replaced or repaired, carry out the adjustment without fail. (1) Mechatro controller (2) Engine or engine controller. (3) Hydraulic pump or hydraulic pump proportional valve. (4) Unloading proportional valve, spool of the unloading valve.

13-22

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.3 PREPARATION (1) Raise the oil temperature to about 50C degrees (122F degrees) to warm up the engine. (2) Turn the air conditioner OFF. (3) Turn the starter key switch OFF to stop the engine. When the mechatro controller is 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 the Error Code List.

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

13

13-23

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.4 ADJUSTING PROCEDURE

MULTI DISPLAY

WORK MODE SELECT SWITCH

UP ARROW SWITCH MENU SWITCH

BUZZER STOP SWITCH DOWN ARROW SWITCH Gauge Cluster (1) Adjustment of pump ("B" adjustment) Procedure 1. Turn the starter key switch ON, keep the work mode selector switch on the gauge cluster pressed, and hold it for 5 to 10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

MULTI DISPLAY (EXAMPLE) S

12:15

E

2. Keep the buzzer stop switch on the gauge cluster pressed for 5 seconds and release it, and the screen for selecting the adjustment is displayed. When adjustment data is not entered in mechatro controller; "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations.

3. Press the menu switch on the gauge cluster to display "START ENGINE". "Engine SPEED", P1 and P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.

13-24

F

ADJUST OUTPUT

FIN

ADJUST UNLOAD

FIN

ADJUST CRANE

---

ADJUST 0 CRANE

---

ADJUST LMN

---

ADJ INTERFE PREV

---

ADJUST INITIAL

---

START ENGINE ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

13. MAINTENANCE STANDARD AND TEST PROCEDURE 4. After engine starting, press the menu switch on the gauge cluster, and "MEMORY PUMP" is displayed. And the adjustment shifts to pump adjustment automatically. Then 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 the pump is increased. The "ENGINE SPEED", P1 and P2 "PUMP PRESSURE", and P1 and P2 pump "PROPOVALVE" current (command value) are indicated. 5. After detection of the engine rated speed, the adjustment of the pump is automatically completed. And "FINISH PUMP" is displayed. (Press the buzzer stop switch on the gauge cluster while this display appears and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.)

MEMORY PUMP ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

FINISH PUMP ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

(2) Adjustment of unloading valve ("C" adjustment) Procedure 1. The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is displayed. The "ENGINE SPEED", P1 and P2 "PUMP PRESSURE", and P1 and P2 "PROPO-VALVE" voltage (command value) are indicated.

2. When the unloading valve operates to the specified value, the adjustment of the unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to the acceleration potentiometer. The adjusting current value is indicated on the display of the current of P1 and P2 unloading proportional valves. The adjusting range is usually 520 to 635 mA. Stop the engine. (The automatically stored.)

adjusted

data

is

13-25

13 MEMORY UNLOAD ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

FINISH UNLOAD ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Corrective actions taken when the adjustment cannot be performed: 1. In cases where the adjustment of the pump cannot be performed: And "ERROR PUMP" is displayed. Judging Condition 1: P1 and P2 average pump pressure at the time when the adjustment is completed is 25MPa or less. Judging Condition 2: The adjustment does not complete although the pump proportional valve current reaches the specified value.

ERROR PUMP ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

The P1 and P2 pump pressures usually increase to 33~38MPa. 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 pressure leaks. -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. 2. In cases where the unloading valve cannot be performed: And "ERROR UNLOAD" is displayed. Judging Condition 1: The pump pressure does not increase up to the pressure in the range of the specified adjustment. Or the increased pressure is held as it is. Judging Condition 2: Pressure sensor of either the P1 pump or P2 pump has failed. Normally the pump pressures of the P1 and P2 pumps gradually increase to 10 to 25 MPa. (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 pressure leaks. -Check that the pressure sensor functions normally. And so on.

13-26

ERROR UNLOAD ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Other precautions: 1. In the event of a failure, there is case where the adjustment may not be performed normally. First service the machine, and perform the adjustment work. 2. In the condition where a large load is constantly applied to engine, the adjustment cannot be performed normally.

For machines equipped with a lifting magnet, turn the generator OFF. (5) When the adjustment of the unloading valve only is performed: ("C" adjustment) In the event where only the unloading valve and unloading proportional valve are replaced, perform the adjustment of the unloading valve only. Procedure 1. Turn the starter switch ON, keep the work mode selector switch on the gauge cluster pressed, and hold it for 5 to 10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

MULTI DISPLAY (EXAMPLE) S

12:15

E

2. Keep the buzzer stop switch on the gauge cluster pressed for 5 seconds and release it, and the screen for selection of the adjustment type is displayed. And "ADJUST" is displayed. When adjustment data is not entered in the mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations. 3. Change the adjusting items with the up arrow switch (UP) and down arrow switch (DOWN), and select "ADJUST UNLOAD". (See Fig. "Gauge cluster") Like the output adjustment, when adjustment data is not entered in the mechatro controller, "READY" is indicated. If the adjustment operation has been performed, "FIN" is indicated.

13-27

F

ADJUST OUTPUT

FIN

ADJUST UNLOAD

FIN

ADJUST CRANE

---

ADJUST 0 CRANE

---

ADJUST LMN

---

ADJ INTERFE PREV

---

ADJUST INITIAL

---

ADJUST OUTPUT

FIN

ADJUST UNLOAD

FIN

ADJUST CRANE

---

ADJUST 0 CRANE

---

ADJUST LMN

---

ADJ INTERFE PREV

---

ADJUST INITIAL

---

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE 4. Press the menu switch on the gauge cluster to display "START ENG". "ENGINE SPEED", P1 and P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.

5. After starting engine, press the menu switch on the gauge cluster and "MEMORY UNLOAD" is indicated, the engine speed is automatically increased and the adjustment of the unloading valve is performed. "ENGINE SPEED", P1 and P2 "PUMP PRESSURE" and "PROPO-VALVE" (acceleration command current) are indicated.

6. When the unloading proportional valve operates to the specified value, the adjustment of the unloading proportional valve automatically completes. "FINISH UNLOAD" is indicated. The speed is shifted to the speed corresponding to the acceleration potentiometer. The value of the adjusting current is indicated on the display of the current for the P1 and P2 unloading proportional valves. The adjusting range is usually 520 to 635 mA. Stop the engine. (The automatically stored.)

adjusted

data

is

13-28

START ENGINE ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

MEMORY UNLOAD ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

FINISH UNLOAD ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER (1) Engine emergency mode When the trouble occurs and the control of the engine is impossible, the engine speed can be controlled by operating the emergency acceleration (E-27) provided on the rear side of the seat. Operating procedure: 1. Set the emergency acceleration to the NORMAL position. 2. Start engine. 3. Turn the emergency acceleration to High side and control the engine speed. 4. When stopping the engine, set the emergency acceleration to the NORMAL position before stopping. Never increase the engine speed immediately after starting engine. It is dangerous. To avoid this danger, repeat the above procedure, or the engine speed will not increase. When the machine does not operate, set the emergency acceleration to the NORMAL position. (2) Pump emergency mode In the event where a failure of the P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on the multi display provided on the gauge cluster, the full power control of the pump and positive control through the mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to emergency mode, making the operation with the power shift control of the pump and the constant power control by means of self-pressure possible. But be careful, in emergency mode, the accuracy of inching becomes poor and the frequency of engine down is increased, and the engine stalls in the LOW speed condition.

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

13-29

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.10 EXHAUST GAS POST-CLEANING PARTICULATE FILTER))

DEVICE

(DPF

(DIESEL

13.10.1 HANDLING OF EXHAUST GAS POST-CLEANING DEVICE After about 10 hours of operating time, some quantity of soot is trapped by filter. And the soot is deposited in the exhaust gas post-cleaning device. The exhaust gas post-cleaning device is changed to regeneration mode automatically. This regeneration system uses soot combustion to generate. To avoid malfunction of the exhaust gas post-cleaning device, observe the following points. (According to working conditions, this deposition time varies.) During automatic soot combustion for regeneration, the exhaust sound changes, but this change of sound does not show any malfunction of system.

When some quantity of soot is trapped by the filter and deposits in the exhaust gas post-cleaning device, this device starts combustion treatment (Regeneration) automatically. This function prevents abnormal deposits of soot, and keeps the purification capacity in good condition at all times. We make soot combustion during working possible by use of a high-performance catalyst and common rail fuel injection system.

A. Do not use unspecified fuel.

Use the low-sulfur diesel fuel (S50: Sulfur content 50 ppm or lower). In cold areas, use appropriate low-sulfur diesel fuel. If you use unspecified fuel, it adversely affects the engine and the exhaust gas post-cleaning device, and it causes white smoke and malfunction.

B. Use recommended brand engine oil.

To maintain the function of the exhaust gas post-cleaning device for long periods, use the recommended brand of engine oil.

C. Do not modify the tail-pipe.

To avoid adverse effect, do not modify the tail-pipe. If the tail-pipe direction or length is modified, it causes an adverse effect to the exhaust gas post-cleaning device.

13-30

13. MAINTENANCE STANDARD AND TEST PROCEDURE D. The exhaust gas post-cleaning device burns trapped soot automatically. (Regeneration)

Immediately after the machine is operated and during regeneration, the temperature of the exhaust pipe, muffler and exhaust gas are very high. It causes fire: remove all flammable materials from these hot parts. And also, you can get burned by hot exhaust gas.

Depending on the condition of operation, the combustion of trapped soot (regeneration) may not be completed. When the demand of regeneration operation is displayed on the gauge cluster (monitor), push the regeneration switch and start the combustion of soot (regeneration).

When the regeneration operation is performing, the engine speed is set to a constant speed and the pump relief may not function. But this is not a malfunction. This raises the temperature of the exhaust gas and the purpose of purification of the exhaust gas.

13.10.2 INSPECTION 1. Check for damage of the sensor wiring/hoses that are located on the main unit of the exhaust gas post-cleaning device.

13 To avoid burns, immediately after the machine operation, do not check of wirings and hoses of the sensor. 2. If damage (Cracks etc.) is found on the surface of the hose for the sensor, replace the hose immediately.

Replace the hoses for the sensor with a new one about every two years. Replace the mounts for the sensor with new oneed about every two years.

13.10.3 MAINTENANCE STANDARD 1. Check the DPF backpressure every 4,500 hours and determine whether maintenance is required or not.

When other than HINO genuine oil and irregular fuel are used, it is not warrantable at the maintenance interval. See the 10-14 page in chapter 51 engine.

13-31

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.10.4 DPF (DIESEL PARTICULATE FILTER) 1. Routine inspection items (1) Confirm that there is no abnormal increase of the engine oil in the oil pan.

If the engine oil quantity has increased abnormally, it is possible that there is a malfunction in the injection system or that unburned fuel has leaked through the gap between the piston rings and the cylinder liner into the engine oil pan. See the 10-14 page in chapter 51 engine.

13-32

21. MECHATRO CONTROLLER

21. MECHATRO CONTROLLER TABLE OF CONTENTS

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM ........................................... 21-4 21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..................................... 21-4 21.1.2 UNLOAD VALVE CONTROL ..................................................................... 21-6 21.1.3 POSITIVE CONTROL & P-Q CONTROL .................................................. 21-8 21.1.4 BOOM UP CONFLUX CONTROL ............................................................. 21-10 21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL ................................ 21-12 21.1.6 ARM-IN ANTI-CAVITATION CONTROL .................................................... 21-14 21.1.7 ARM-OUT CONFLUX CONTROL ............................................................. 21-16 21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL ................................. 21-18 21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL .................................. 21-20 21.1.10 SWING PRIORITY CONTROL .................................................................. 21-22 21.1.11 TRAVEL STRAIGHT CONTROL ............................................................... 21-24 21.1.12 PRESSURE RELEASE CONTROL ........................................................... 21-26 21.1.13 N&B SWITCH CONTROL (OPTION) ........................................................ 21-28 21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................... 21-30 21.2 MECHATRO CONTROLLER ............................................................................. 21-33 21.2.1 SUMMARY OF MULTI DISPLAY ............................................................... 21-33 21.2.2 SELF DIAGNOSIS DISPLAY ..................................................................... 21-46 21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................... 21-48 21.2.4 TROUBLE HISTORY DIAGNOSIS ............................................................ 21-59 21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE .............................. 21-60 21.2.6 ADJUSTING PROCEDURE OF DISPLAY ................................................ 21-62 21.2.7 MECHATRO CONTROL EQUIPMENT ..................................................... 21-65

Book Code No. S5LC2125E03 21-1

21

21. MECHATRO CONTROLLER

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC2125E01 (NA)

September, 2010 SK350-9: YC

Revision

February, 2011

SK350-9: YC

S5LC2125E02 (NA)

Revision

May, 2011

SK350-9: YC

S5LC2125E03 (NA)

21-2

21. MECHATRO CONTROLLER PREFACE This manual explains machines with the electro hydraulic conversion only with the mechatro control. This manual summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system.

21

21-3

21. MECHATRO CONTROLLER

21.1

SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ELECTRIC CONTROLLER INPUT SIGNAL HYDRAULIC PILOT SECONDARY PRESSURE

VOLTAGE OUTPUT L1

SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT

LH

RH

LH

RH

OPTION PILOT VALVE PILOT VALVE FOR TRAVEL

PILOT VALVE FOR ATT

SE-9 SE-10

MULTI CONTROL VALVE OR SENSOR BLOCK

COOLANT TEMP. GAUGE

LOWER SW. SCREEN CHANGE BUZZER STOP MODE WASHER WIPER TRAVEL DIGGING MODE NIBBLER MODE BREAKER MODE DECEL

(4)

SE-3

(2)

SE-1 SE-8 SE-7

L2 L3

(3)

SE-2

(1)

(8) (7)

L4

(6) SE-5

(5)

ATTACHMENT MODE SELECT SW CAN COMMUNICATION

SE-16

SE-4

OUTPUT VOLTAGE

GAUGE CLUSTER LCD DISPLAY FOR SELECTION FUEL GAUGE

ACCEL DIAL

SE-11 LOW PRESSURE SENSOR

SW-111

SE-23 HIGH PRESSURE SENSOR

C-1

SE-22

MECHATRO CONTROLLER

A1

L5 A2

ENGINE

A3

INJECTOR SPEED SENSOR SE-13

PSV -P1 P1 PUMP PROPORTIONAL VALVE

: HIGH PRESSURE SENSOR (FOR P1,P2 : 2pcs)

PSV -P2 P2 PUMP PROPORTIONAL VALVE

: INJECTOR : E/G SPEED SENSOR : LOW PRESSURE SENSOR (ATT : 7pcs, TRAVEL : 2pcs)

CAN COMMUNICATION ENGINE SPEED COMMAND CURRENT

L6

C-8 ENGINE CONTROLLER

: ACCEL DIAL POTENTIOMETER

L7 VOLTAGE 24V PROPORTIONAL COMMAND CURRENT

E-27 EMERGENCY MODE ACCEL DIAL

21-4

21. MECHATRO CONTROLLER

L1

MAIN CONTROL VALVE SE-29

DIGGING

UP

REVERSE

REVERSE

L2 L3

(7)

N&B SELECTOR VALVE

(5)

SV-13

OPTION

(8)

BOOM UP CONFLUX P2 UNLOAD

TRAVEL LEFT

P1 P2

(6)

ARM 1 SPEED

(3)

PL1 ATTACHMENT BOOST

(3)

BOOM LOW SPEED

(1)

LEFT ARM OUT

FORWARD

(4)

SWING

DOWN FORWARD

BUCKET

ARM 2 SPEED

(2)

TRAVEL P1 UNLOAD STRAIGHT

DUMP

(8)

TRAVEL RIGHT

ARM OUT

SOL

RIGHT ARM IN

SOLENOID VALVE

L4 SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

PSV -A

PSV PSV PSV -D -C -B

SV -2

SV -3

SV -1

SAFETY LOCK LEVER

SWING PARKING BRAKE

TRAVEL 1,2 SPEED

ATTACHMENT BOOST

P2 UNLOAD

TRAVEL STRAIGHT

P1 UNLOAD

L5

ARM IN 2 SPEED

BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX

SV -4

ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX

(7) ARM IN

L6

BUCKET CYLINDER DIGGING / DUMP CONFLUX

L7 PROPORTIONAL VALVE SOLENOID VALVE

21-5

) BLOCK

21

21. MECHATRO CONTROLLER

P2

(LEFT)

(RIGHT)

OPTIONAL PILOT VALVE

PILOT VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.2 UNLOAD VALVE CONTROL

P1

PILOT VALVE

PILOT VALVE FOR TRAVEL

SE-11 SE-10

SE-9

LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4

SE-5,7,8

pi

PILOT SIGNAL PROCESS

PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

MECHATRO PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE

(1) On starting any one of the operations, the control pilot secondary pressure switches spools and enters in respective low pressure sensors. (2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes pilot signals and output commands according to the input voltage to each unload pressure proportional valve. (3) Each unload pressure proportional valve outputs pilot secondary pressure according to the command output by the mechatro controller and switches each of the unload spools. (4) With this operation, the bleed opening according to the lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each of the actuators is delivered and makes each actuator start operating.

21-6

21. MECHATRO CONTROLLER

This page is blank for editing convenience.

21

21-7

21. MECHATRO CONTROLLER

P2

SE-23

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

OPTIONAL PILOT VALVE

P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.3 POSITIVE CONTROL & P-Q CONTROL

P1

SE-22

SE-11

(LEFT)

(RIGHT)

PILOT VALVE

PILOT VALVE

PILOT VALVE FOR TRAVEL

SE-10

SE-9

LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4

SE-5,7,8

pi PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE COMMAND

P2 PUMP PROPORTIONAL VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi

pi

PILOT SIGNAL PROCESS PILOT SECONDARY PRESSURE

P1 PUMP PROPORTIONAL VALVE COMMAND

P1 PUMP PROPORTIONAL VALVE PSV-P1

MECHATRO pi : PROPORTIONAL VALVE CONTROLLER

SECONDARY PRESSURE

21-8

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

P-Q CONTROL

PILOT SIGNAL PROCESS

PUMP PROPORTIONAL SECONDARY PRESSURE

PUMP PROPORTIONAL SECONDARY PRESSURE

POSITIVE CONTROL

PILOT PRESSURE

PILOT SIGNAL PROCESS

21

PUMP DELIVERY PRESSURE

21-9

21. MECHATRO CONTROLLER

P2

PILOT VALVE

P1

LOW PRESSURE SENSOR SE-3

pi PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS MECHATRO CONTROLLER BOOM UP PILOT SECONDARY PRESSURE

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P2 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

21-10

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.4 BOOM UP CONFLUX CONTROL

21. MECHATRO CONTROLLER (1) On starting boom up operation, the boom up operating pilot pressure switches the boom spool and boom up conflux spool and is input to the low pressure sensor. (2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and output commands 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 the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload pressure control valve. (4) With the original hydraulic pressure command, the boom main spool and boom up conflux spool are switched, and also with the mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on the P1 pump side confluxes delivery oil on the P2 pump side during boom up operation.

21

21-11

21. MECHATRO CONTROLLER

P2

LOW PRESSURE SENSOR SE-1~6

P1

LOW PRESSURE SENSOR SE-7

CONTROL PROCESS FOR 2 SPEED

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE P1 PUMP PROPORTIONAL VALVE PSV-P1

PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi PILOT SECONDARY PRESSURE

pi REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

ARM PILOT SECONDARY PRESSURE

P2 PUMP PRESSURE

MECHATRO CONTROLLER

21-12

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

P2 UNLOAD

SWING

SOLENOID

OPTION

N&B SELECTOR VALVE

ARM 1 SPEED

21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL

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

21-13

21

21. MECHATRO CONTROLLER

P2

LOW PRESSURE SENSOR SE-7

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.6 ARM-IN ANTI-CAVITATION CONTROL

P1

ACCEL POTENTIO

pi PILOT SIGNAL PROCESS

ARM IN PILOT SECONDARY PRESSURE pi

PILOT SIGNAL PROCESS

pi P2 PUMP PROPORTIONAL VALVE PSV-P2

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

ARM IN PILOT SECONDARY PRESSURE

pi REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND

ENGINE SPEED (COMMAND VALUE)

MECHATRO CONTROLLER

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

pi

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

(1) On starting the arm-in operation, the arm-in operating pilot secondary pressure switches the arm 1 spool and is input to the low pressure sensor. (2) The engine speed command output by the accel potentiometer is input to the mechatro controller. (3) The low pressure sensor output voltage is input to the mechatro controller, and the mechatro controller processes pilot signal processing and outputs commands according to the input voltage to the P2 pump proportional valve and the P2 unload proportional valve. (4) And also outputs commands according to input pressure output by the potentiometer to the reverse proportional valve for arm 2 spool. (5) Each proportional valve outputs pilot secondary pressure according to each command output by the mechatro controller, and consequently since the reverse proportional valve for the arm 2 spool is controlled to the spool stroke according to engine speed and changes in the recirculation rate to prevent the cavitation from occurring even if the pump delivery rate is low due to low engine speed.

21-14

21. MECHATRO CONTROLLER

This page is blank for editing convenience.

21

21-15

21. MECHATRO CONTROLLER

P2

PILOT VALVE

P1

LOW PRESSURE SENSOR SE-8

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

ARM OUT PILOT SECONDARY PRESSURE pi P1 PUMP PROPORTIONAL VALVE PSV-P1

ARM OUT PILOT SECONDARY PRESSURE

pi P2 UNLOAD PROPORTIONAL VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE pi

MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE

P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

21-16

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.7 ARM-OUT CONFLUX CONTROL

21. MECHATRO CONTROLLER (1) On starting arm-out operation, the arm-out operating pilot pressure switches the arm 1 spool and arm 2 spool and is input to the low pressure sensor. (2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and output commands according to the input voltage to the P1 and P2 proportional valves and the P1 and P2 unload proportional valves. (3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload pressure control valves. (4) With the original hydraulic pressure command, the arm 1 spool and arm 2 spool are switched and with the command output by the mechatro controller, the P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on the P2 pump side confluxes delivery oil on the P1 pump side during armout operation.

21

21-17

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR SE-1(2) pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P1 PUMP PROPORTIONAL VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P1 UNLOAD PROPORTIONAL VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

TRAVELSTRAIGHT PROPORTIONAL VALVE PSV-C

MECHATRO BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE

SECONDARY PRESSURE

21-18

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

PILOT VALVE

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL

21. MECHATRO CONTROLLER (1) On starting the bucket digging (dump) operation, the bucket digging (dump) operating pilot pressure switches the bucket spool and is input to the low pressure sensor. (2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and output commands according to the input voltage to the P1 and P2 pump proportional valves, the P1 and P2 unload proportional valves and the travel straight proportional valve. (3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload valves and the travel straight valve of the control valve. (4) The tandem passage is connected to the P2 port because of the travel straight valve being switched and the P1 pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve being switched.

21

21-19

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR SE-1 (2)

pi

PILOT SIGNAL PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS ACCEL POTENTIO

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P1 UNLOAD PROPORTIONAL VALVE PSV-D

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS BUCKET ANTI-CAVITATION PROCESS

ATT BOOST SOLENOID VALVE SV-2

ENGINE SPEED (COMMAND VALUE)

MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE

P1 PUMP PRESSURE

21-20

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

PILOT VALVE

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL

21. MECHATRO CONTROLLER (1) On starting the bucket digging (dump) operation, the bucket digging operating pilot pressure switches the bucket spool and is input to the low pressure sensor. (2) The engine speed command output by the accel potentiometer is input to the mechatro controller. (3) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and output commands according to the input voltage to the P1 and P2 pump proportional valves, the P1 and P2 unload proportional valves and the travel straight proportional valve. (4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload valves and the travel straight valve of the control valve. (5) The tandem passage is connected to the P2 port because of the travel straight valve being switched and the P1 pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve being switched. (6) The ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary pressure, and the actuate stroke limiter and then controls the stroke of the bucket spool. The control of the spool stroke makes the prevention of cavitation possible even if the engine speed is low and the pump delivery rate is low. (7) When the P1 pump pressure was raised at the 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 the bucket spool.

21

21-21

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR pi

PILOT SIGNAL PROCESS

ARM IN PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D

ARM IN PILOT SECONDARY PRESSURE

pi

SWING PILOT SECONDARY PRESSURE

pi

SWING PILOT SECONDARY PRESSURE

TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND

TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C

REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

MECHATRO CONTROLLER

21-22

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

PILOT VALVE

OPTION

21.1.10 SWING PRIORITY CONTROL

21. MECHATRO CONTROLLER (1) During the arm-in operation, the arm operating pilot secondary pressure switches the arm spool and is input to the low pressure sensor on starting of the swing operation (or arm-in operation during swing operation), and the swing operation pilot secondary pressure switches the swing spool and is input to the low pressure sensor. (2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and output commands according to the input voltage to the P1 and P2 proportional valves, the P1 and P2 unload pressure proportional valves, the travel straight valve and the reverse proportional valve for the arm 2 spool. (3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload spool, travel straight spool, and arm 2 spool. (4) With the original hydraulic pressure command, the arm 1 spool and swing spool are switched and also with the command by the mechatro controller, the P1 and P2 unload spools, the travel straight spool, and the arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil on the arm cylinder rod side is recirculated into the arm cylinder head side. (5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and the pump delivery rate is used for the swing operation by priority, and operated by the recirculated oil, making operation with the minimum speed drop possible.

21

21-23

21. MECHATRO CONTROLLER

(RIGHT)

PILOT VALVE

P2

P1

PILOT VALVE FOR TRAVEL

SE-11 SE-10

SE-9

LOW PRESSURE SENSOR

TRAVEL STRAIGHT SIGNAL

pi PILOT SIGNAL PROCESS

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P1 PUMP PROPORTIONAL VALVE PSV-P1

PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

PILOT SECONDARY PRESSURE pi

PILOT SIGNAL PROCESS

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

PILOT SECONDARY PRESSURE

21-24

P1 UNLOAD PROPORTIONAL VALVE PSV-D

MECHATRO CONTROLLER

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

TRAVEL STRAIGHT

(LEFT)

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

OPTIONAL PILOT VALVE

OPTION

21.1.11 TRAVEL STRAIGHT CONTROL

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

21

21-25

21. MECHATRO CONTROLLER

P2

P1

SE-23

ENGINE

PRESSURE RELEASE CONTROL

ENGINE SPEED CONTROL

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

pi

PILOT SIGNAL PROCESS

pi

pi

PILOT SIGNAL PROCESS

PILOT SIGNAL PROCESS MECHATRO CONTROLLER

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

21-26

SE-22

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX PILOT VALVE

P2 UNLOAD

GAUGE CLUSTER

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.12 PRESSURE RELEASE CONTROL

21. MECHATRO CONTROLLER (1) Change the mechatro controller to "PRESSURE DRAINING MODE" by operating the switch on the gauge cluster. For details of changing the mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1. (2) Once the mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot, accel potentiometer, etc.) of the mechatro controller; 1. Outputs minimum tilt angle command to the P1 and P2 pump proportional valves and fixes the P1 and P2 pumps to a minimum tilt angle. 2. Output commands of pressure release and output commands of pressure release control to the ECU and fixes the engine speed to the pressure release control speed. 3. Outputs maximum command to the P1 and P2 unload valves and each pilot secondary pressure fixes the P1 and P2 unload valves to the maximum opening. (3) The mechatro controller senses the output voltage from the main pump high pressure sensor, and decides the pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on the gauge cluster. (4) Each pump delivery of oil is unloaded to the tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching the spool with the unload valve opened.

21

21-27

21. MECHATRO CONTROLLER

P2

NIBBLER MODE BREAKER MODE ATTACHMENT MODE

pi

BREAKER MODE SWITCH

MECHATRO CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

21-28

P1

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SWING

SOLENOID

OPTION

PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE

ARM 1 SPEED

21.1.13 N and B SWITCH CONTROL (OPTION)

21. MECHATRO CONTROLLER (1) Nibbler circuit 1. Select nibbler mode by pressing the nibbler mode switch located on the gauge cluster. 2. The nibbler display appears on the gauge cluster. 3. The return oil from the nibbler passes through the selector valve and the option spool and is led to the tank line of main the control valve. 4. When selecting the nibbler mode through the select switch, the breaker pressure sensor has no function to output. It is normal when there is no output from the sensor in nibbler mode, and in cases of other than above, an error display is output to the gauge cluster. (2) Breaker circuit 1. Select breaker mode by pressing the breaker mode switch located on the gauge cluster. 2. Breaker display appears on the gauge cluster. 3. The return oil from the breaker passes through the selector valve and directly returns into the hydraulic oil tank. 4. When selecting breaker mode through the select switch, the breaker pressure sensor outputs signal. It is normal when there is an output from the sensor in breaker mode, and in cases of other than above, an error display is output to the gauge cluster.

21

21-29

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR SE-11

pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE

21-30

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

PILOT VALVE

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

21.1.14 OPTION CONFLUX CONTROL (OPTION)

21. MECHATRO CONTROLLER (1) Using the "OPTION SETTING" display located on the "USER MENU" screen, the flow rate is adjusted. At this time, if the setting flow rate is larger than the one pump flow rate, the flow becomes automatically confluent flow. (2) On starting option operation, option operating pilot pressure switches the option spool and is input to the low pressure sensor. (3) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and output commands according to the input voltage to the P1 and P2 pump proportional valves, the P1 and P2 unload pressure proportional valves and the travel straight proportional valve. (4) Each proportional valve output pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload valves and the travel straight valve of the control valve. (5) The parallel passage on the P2 side is connected to the P1 port because of the travel straight valve being switched and the P1 pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve being switched.

21

21-31

21. MECHATRO CONTROLLER

This page is blank for editing convenience.

21-32

21. MECHATRO CONTROLLER

21.2

MECHATRO CONTROLLER

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

SAFETY LOCK LEVER

RIGHT CONTROL LEVER WITH ATT BOOST SW. STARTER SWITCH

FUSE & RELAY BOX

ACCEL DIAL

B DETAIL A EMERGECY ACCEL DIAL

SWING PARKING BRAKE RELEASE SWITCH

21 A

DETAIL B (2) Gauge cluster

18

S

2

12:15

1 E

9

F

11

6

7 13 16 10

8 5 4

17

3

14 15

12

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

21-33

Name Engine coolant temperature gauge Fuel level gauge Screen change switch Buzzer stop switch Work mode select switch Washer switch Wiper switch Travel high speed, low speed select switch Auto accel switch Menu switch Digging mode switch Nibbler mode switich Breaker mode switch Up arrow switch Down arrow switch Next arrow switch Back arrow switch Multi display (LCD)

21. MECHATRO CONTROLLER (3) Screen selection by work mode select switch The mode after the engine starting is always the start from "S" mode. The work mode is switched in order of "S" to "E" to "H" to "S" each time the work mode select switch is pressed. Select the proper work mode shown below according to the work condition and the purpose. For the selected work mode, refer to the upper left corner of the display. • • •

S mode: For standard excavating work ECO mode: For low fuel consumption excavating work H mode: For heavy duty excavating work

S

12:15

E

F

S mode

S

12:15

E

"S mode" is suitable for standard digging and loading works and is saving fuel consumption and is in good balance to the workload.

F

ECO mode

E

12:15

E

"Eco mode" is the mode focusing on better fuel economy, allowing for normal digging operation with lower fuel consumption than S mode.

F

H mode

H

12:15

E

"H mode" is suitable for heavy duty digging work which gives priority to the workload at high speed.

F

21-34

21. MECHATRO CONTROLLER (4) Screen selection by attachment mode switich This switch is used for switching the attachment mode. Attachment mode display Press the Digging mode switch (1) to select Digging mode from the attachment modes. And selected Digging mode is indicated. Press the Nibbler mode switch (2) to select Nibbler mode from the attachment modes. And the selected Nibbler mode is indicated. Press Breaker mode switch (3) to select the Breaker mode from the attachment modes. And selected Breaker mode is indicated. Depending on the attachment employed, select the applicable mode from "Digging", "Nibbler" and "Breaker". Before working, confirm whether the appropriate attachment has been selected.

S

E

F

2

1. Digging mode switch 2. Nibbler mode switch 3. Breaker mode switch

Attachment Mode

12:15

3 1

Switch Position

Displays of Multi-Display S

Selection of Attachment

12:15

Digging Mode

Select in case of digging E

S

21

F

12:15

Select conflux flow when the attachment like a nibbler requires conflux flow circuit

Nibbler Mode E

S

F

12:15

Select single flow when the attachment like a breaker requires single flow circuit

Breaker Mode E

21-35

F

21. MECHATRO CONTROLLER (5) Procedure of setting a flow rate and an option relief pressure at the Nibbler/Breaker mode 1: Buzzer Stop Switch 2: Menu Switch 3: Nibbler Mode Switch 4: Breaker Mode Switch 5: Up Arrow Switch 6: Down Arrow Switch 7: Next Arrow Switch 8: Back Arrow Switch According to some attachments, it is required to change the flow rate and relief pressure for the service circuit. Regarding the adjustment of the flow rate and relief pressure for the Nibbler and Breaker, the settings of 10 patterns are available.

S

12:15

E

F

3

4 7 2

1

8

5

6

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10 180 530 470 410 350 294 270 240 210 Flow rate L/min 588 Nibbler 25 Not set yet Not set yet Not set yet Not set yet Pressure A MPa Not set yet Not set yet Not set yet Not set yet Not set yet (Crusher) 25 Not set yet Not set yet Not set yet Not set yet Pressure B MPa Not set yet Not set yet Not set yet Not set yet Not set yet SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10 Flow rate L/min 294 270 240 210 180 150 120 90 60 30 Breaker 30 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Pressure B MPa Both Nibblers are set in conditions "SET 6" as factory a default in the above table at shipping. Both Breakers are set in conditions "SET 1" as factory a default in the above table at shipping. * The meaning of "Not set yet" shows that 50MPa as pressure is temporary value. Set the flow rate and relief pressure in accordance with next procedure. These setting values in the above adjustment are selectable by using the after-mentioned "Flow Rate and Relief Pressure Selection".

21-36

21. MECHATRO CONTROLLER 1) When using Nibbler

TURN STARTER KEY SWICH ON No.1 + MAIN CONT. P/N XLB22E00026F1 PRIGRAM VERSION 1-VER 00.07 2-VER 00.00 SERVICE DIAG 1 CLUSTER DIAG 1 CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 01.00

(a)

(b)

+

SERVICE MENU

(C) SERVICE ADJUST1-2

(d)

(e) or

NIBBLER SETTING

NIBBLER SETTING

SERVICE DIAGNOSIS

AUTO ACCEL

SET1

472 L/min

25

MPa

25 MPa

SET1

472 L/min

25

MPa

25

TROUBLE HISTORY

START MODE

SET2

443

L/min

50

MPa

50 MPa

SET2

443 L/min

50

MPa

50

LANGUAGE & LOGO SETTING

CANCEL LOW TEMP

SET3

394 L/min

50

MPa

50 MPa

SET3

394 L/min

50

MPa

50

SERVICE ADJUST 1

CANCEL MODE

SET4

344 L/min

50

MPa

50 MPa

SET4

344 L/min

50

MPa

50

SERVICE ADJUST 2

CHECK INJECTOR

SET5

295 L/min

50

MPa

50 MPa

SET5

295 L/min

50

MPa

50

FACTORY PRESET

PRESS DRAIN

SET6

246 L/min

25

MPa

25 MPa

SET6

246 L/min

25

MPa

25

FAULT DIAG MODE

NIBBLER SETTING

SET7

221 L/min

50

MPa

50 MPa

SET7

221 L/min

50

MPa

50

BREAKER SETTING

SET8

197 L/min

50

MPa

50 MPa

SET8

197 L/min

50

MPa

50

CAMERA 1 SETTING

SET9

172 L/min

50

MPa

50

SET9

172 L/min

50

MPa

50

CAMERA 2 SETTING

SET10

148

50

50

SET10

148

50

50

BACK

ON

NEXT

BACK

DOWN

ON

NEXT

DOWN

L/min

MPa

BACK

ON

HOME

DOWN

MPa

MPa

NEXT

L/min

BACK

MPa

ON DOWN

(g) NIBBLER SETTING

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

NEXT RESET

(f) NIBBLER SETTING

SET1

472 L/min

25

MPa

25

SET1

472 L/min

25 MPa

25

SET2

443 L/min

50

MPa

50

SET2

443 L/min

50 MPa

50

SET3

394 L/min

50

MPa

50

SET3

394 L/min

50 MPa

50

SET4

344 L/min

50

MPa

50

SET4

344 L/min

50 MPa

50

SET5

295 L/min

50

MPa

50

SET5

295 L/min

50 MPa

50

SET6

246 L/min

25

MPa

25

SET6

246 L/min

25 MPa

25

SET7

221 L/min

50

MPa

50

SET7

221 L/min

50 MPa

50

SET8

197 L/min

50

MPa

50

SET8

197 L/min

50 MPa

50

SET9

172 L/min

50

MPa

50

SET9

172 L/min

50 MPa

50

SET10

148

50

50

SET10

148

50

50

L/min

BACK

MPa

ON DOWN

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

NEXT RESET

L/min

BACK

MPa

ON DOWN

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

NEXT RESET

1. Turn the starter switch ON. After pressing the Nibbler mode switch (3) to select the Nibbler mode, turn the starter switch OFF. 2. Hold down the buzzer stop switch (1) and turn the starter switch ON. The service diagnosis screen (a) is displayed. 3. Start the engine. 4. Hold down the buzzer stop switch (1) and press the menu switch (2) 3 times. "SERVICE MENU" screen (b) is displayed. 5. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "SERVICE ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST 1-2 (c) is displayed. 6. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to the "NIBBLER SETTING" display (c). Press the menu switch (2), and NIBBLER SETTING (d) is displayed. 7. There are 10 steps from "SET 1" to "SET 10". Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and select the desired set number. To set the desired set number, press "NEXT ARROW SWITCH" (7). 8. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow rate. Then press menu switch (2) and the cursor is pointed to the pressure display (f). 9. During pressing the rear (heel side) of the optional right pedal (P2 pump optional operation), use switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When the value of pressure reaches the desired pressure, press menu switch (2) to set. (If you fail to press rear (heel side) of optional right pedal, 0MPa is displayed.) 10.Then, the cursor is pointed to pressure (see display (g)). Use the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When the value of pressure reaches the desired pressure, press menu switch (2) to set. (If you fail to press front (toe side) of the optional right pedal, 0MPa is displayed.) 11.Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

21-37

21

21. MECHATRO CONTROLLER 2) When using Breaker TURN STARTER KEY SWICH ON No.1 + MAIN CONT. P/N XLB22E00026F1 PRIGRAM VERSION 1-VER 00.07 2-VER 00.00 SERVICE DIAG 1 CLUSTER DIAG 1 CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 01.00

(a)

(b)

+

SERVICE MENU

(C) SERVICE ADJUST1-2

(d)

(e) or

BREAKER SETTING

BREAKER SETTING

SERVICE DIAGNOSIS

AUTO ACCEL

SET1

246 L/min

25

MPa

SET1

246 L/min

25

TROUBLE HISTORY

START MODE

SET2

221 L/min

30

MPa

SET2

221 L/min

30

LANGUAGE & LOGO SETTING

CANCEL LOW TEMP

SET3

197 L/min

30

MPa

SET3

197 L/min

30

SERVICE ADJUST 1

CANCEL MODE

SET4

172 L/min

30

MPa

SET4

172 L/min

30

SERVICE ADJUST 2

CHECK INJECTOR

SET5

148 L/min

30

MPa

SET5

148 L/min

30

FACTORY PRESET

PRESS DRAIN

SET6

123 L/min

30

MPa

SET6

123 L/min

30

FAULT DIAG MODE

NIBBLER SETTING

SET7

98

L/min

30

MPa

SET7

98

L/min

30

BREAKER SETTING

SET8

74

L/min

30

MPa

SET8

74

L/min

30

CAMERA 1 SETTING

SET9

49

L/min

30

SET9

49

L/min

30

CAMERA 2 SETTING

SET10

30

30

SET10

30

30

BACK

ON

NEXT

BACK

DOWN

ON DOWN

NEXT

MPa

L/min

BACK

MPa

ON DOWN

NEXT

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

L/min

BACK

RESET

MPa

ON DOWN

NEXT RESET

(f) BREAKER SETTING SET1

246 L/min

25

SET2

221 L/min

30

SET3

197 L/min

30

SET4

172 L/min

30

SET5

148 L/min

30

SET6

123 L/min

30

SET7

98

L/min

30

SET8

74

L/min

30

SET9

49

L/min

30

SET10

30

30

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

L/min

BACK

MPa

ON DOWN

NEXT RESET

1. Turn starter switch ON. After pressing the Breaker mode switch (4) to select Breaker mode, turn the starter switch OFF. 2. Hold down the buzzer stop switch (1) and turn the starter switch ON. The service diagnosis screen (a) is displayed. 3. Start the engine. 4. Hold down the buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen (b) is displayed. 5. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "SERVICE ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST 1-2 (c) is displayed. 6. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "BREAKER SETTING" display (c). Press "NEXT ARROW SWITCH" (7), and BREAKER SETTING (d) is displayed. 7. There are 10 steps from "SET 1" to "SET 10". Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and select the desired set number. To set the desired set number, press the "NEXT ARROW SWITCH" (7). 8. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow rate. Then press the menu switch (2) and the cursor is pointed to pressure display (f). 9. During pressing the front (toe side) of the optional right pedal (P2 pump optional operation), use switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When you reach the desired pressure, press the menu switch (2) to set. (If you fail to press the front (toe side) of the optional right pedal, 0MPa is displayed.) 10.Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

21-38

21. MECHATRO CONTROLLER (6) Pump flow rate adjustment (Nibbler mode / Breaker mode) (Option)

6

1: Screen Change Switch 2: Buzzer Stop Switch 3: Work Mode Select Switch 4: Washer Switch 5: Wiper Switch 6: Travel Speed Select Switch 7: Auto Accel Switch 8: Menu Switch 9: Attachment Mode Select Switch 10: Arrow Switch

7

4

5 9

3

2

1

10

8

Nibbler mode

S

12:15

E

S

12:15

F

USER MENU

SET1

472 L/min

25 MPa

25 MPa

SWITCH STATUS

SWITCH STATUS

SET2

443 L/min

50 MPa

50 MPa

OPTION SETTING

OPTION SETTING

SET3

394 L/min

50 MPa

50 MPa

CONSUMPTION

CONSUMPTION

SET4

344 L/min

50 MPa

50 MPa

SCREEN SETTING

SCREEN SETTING

SET5

295 L/min

50 MPa

50 MPa

CLOCK SETTING

CLOCK SETTING

SET6

246 L/min

25 MPa

25 MPa

SET7

221 L/min

50 MPa

50 MPa

30

SET8

197 L/min

50 MPa

50 MPa

15

SET9

172 L/min

50 MPa

50 MPa

SET10

148 L/min

50 MPa

PRESSURE A

50 Mpa

PRESSURE B

50 Mpa F

L/min

25

20

15

10

5

0

0.0 L/h

AVERAGE

(a)

NIBBLER SETTING

MAINTENANCE

780 L/min

E

30 MIN

USER MENU

MAINTENANCE

FLOW RATE

or

0

RESET

(b)

BACK

UP

HOME

DOWN

NEXT

(c)

BACK

UP

HOME

DOWN

NEXT

BACK

UP

HOME

DOWN

(d)

50 MPa NEXT

(e)

In breaker mode

S

12:15

E

S

12:15

MAINTENANCE

SET1

246 L/min

30 MPa

SWITCH STATUS

SET2

221 L/min

30 MPa

OPTION SETTING

OPTION SETTING

SET3

197 L/min

30 MPa

CONSUMPTION

CONSUMPTION

SET4

172 L/min

30 MPa

SCREEN SETTING

SCREEN SETTING

SET5

148 L/min

30 MPa

CLOCK SETTING

CLOCK SETTING

SET6

123 L/min

30 MPa

SET7

98 L/min

30 MPa

30

SET8

74 L/min

30 MPa

15

SET9

49 L/min

30 MPa

SET10

30 L/min

50 Mpa

F

L/min

AVERAGE

20

15

10

0.0 L/h

5

0

or

0

RESET

(b)

BREAKER SETTING

SWITCH STATUS

480 L/min

PRESSURE A

E

25

USER MENU

MAINTENANCE

FLOW RATE

F

30 MIN

21 USER MENU

BACK

UP

HOME

DOWN

NEXT

(c)

BACK

UP

HOME

DOWN

NEXT

(d)

30 MPa

BACK

UP

HOME

DOWN

NEXT

(e)

1. After turning the starter key switch ON, the main screen (a) appears. 2. When the display is in main screen (a), change the attachment mode from "DIGGING MODE" to "NIBBLER MODE" or "BREAKER MODE". The flow rate indication screen (b) appears. 3. When the display displays the flow rate indication screen (b), press "Menu Switch" to enter into "USER MENU" display (c). 4. Move the cursor to "OPTION SETTING", and press "NEXT" to enter into the "OPTION SETTING" display (e). 5. When the display displays the "OPTION SETTING" display (e), move the cursor to the desired flow rate. And press the menu switch to set the target flow rate.

If there is no switching operation for 20 seconds, this display returns to main display.

21-39

21. MECHATRO CONTROLLER (7) Maintenance screen displays This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil.

1

2

After turning the starter key switch ON or starting the engine, the display returns to "SERVICE ADJUST 1-2" screen (c). This display shows the recommended replacement time of engine oil, time for next engine oil change and date of previous engine oil change.

S

INTERVAL

12:15

E

USER MENU

ENGINE OIL

MAINTENANCE

FUEL FILTER

SWITCH STATUS

HYD. FILTER

OPTION SETTING

HYD. OIL

CONSUMPTION

F

BACK

UP

HOME

DOWN

NEXT

FUEL FILTER HYD. FILTER

(a)

HYD. OIL

INTERVAL

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

REMAINDER

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

EXCHANGE DAY

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

Replacement interval

500 Hr

Fuel filter

500 Hr

Hydraulic oil filter

1,000 Hr

Hydraulic oil

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 of "INTERVAL, REMAINING TIME, EXCHANGE DAY".

INTERVAL

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

21-40

REMAINDER

500Hr 500Hr 500Hr 500Hr 1000Hr 1000Hr 5000Hr 5000Hr

EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12

REMAINDER

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

INTERVAL

08/12/12

For the initial set value of the recommenced replacement/change time, see the following table.

Engine oil

08/12/12 08/12/12 08/12/12 08/12/12

CLOCK SETTING

INTERVAL

Default

EXCHANGE DAY

SCREEN SETTING

ENGINE OIL

Item

REMAINDER

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

REMAINDER

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12

EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12

21. MECHATRO CONTROLLER INTERVAL

2. Remaining time display to the coming fuel filter replacement This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY".

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

INTERVAL

3. Remaining time display to the coming hydraulic oil filter replacement This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY". 4. Remaining time display to the coming hydraulic oil change This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY".

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

REMAINDER

500Hr 500Hr 500Hr 500Hr 1000Hr 1000Hr 5000Hr 5000Hr REMAINDER

500Hr 500Hr 500Hr 500Hr 1000Hr 1000Hr 5000Hr 5000Hr

EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12 EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12

EXCHANGE INTERVAL REMAINDER DAY

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

500Hr 500Hr 500Hr 500Hr 1000Hr 1000Hr 5000Hr 5000Hr

08/12/12 08/12/12 08/12/12 08/12/12

For the setting procedure of the maintenance time to be performed to the coming oil change in each type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.

21

21-41

21. MECHATRO CONTROLLER (8) Gauge cluster display After the key is switched on and the logo mark display disappears, the screen for operator is displayed on the multi screen. The display functions of the multi display are explained below.

CLOCK DISPLAY

MACHIN CONDITION S

E

SELF DIAGNOSIS / WARNING

F

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 an abnormality is detected on the mechatro system like sensor, proportional valve, etc., this displays the error code. 1.3 Warning display: When the machine was thrown into a dangerous state, or has failed, the warning display displays warning contents with the symbol and a statement.

. Warning CAUTION ATTACHMENT

These descriptions indicate error codes. W009

POWER BOOST ON

WARM FINISH WARM-UP DATA

CPU COMMUNICATION ERROR

LOW ENG OIL PRESS.

W005

PREHEAT

HIGH ENG WATER TEMP.

W006

CHARGE ERROR

LOW ENG WATER W004 LEVEL

LOW FUEL LEVEL

CLOGGED AIR FLTR W008

WARM AUTO WARMING UP

SWING BRAKE DISENGAGED

ENGINE STOP

CHANGE ENG OIL

CHANGE FUEL FLTR

LIFT UP LOCK LEVER BEFORE ENGINE START

ENG PREHEAT

CHANGE HYD. OIL FLTR

CHANGE HYD. OIL

1. LIFT UP LOCK LEVER 2. PUSH REGENERATION SW. REGENERATION 1. LIFT UP LOCK LEVER 2. PUSH REGENERATION SW. EXHAUST GAS AFTER TREATMENT EQUIPMENT WILL BE DAMAGED EXHAUST GAS AFTER TREATMENT EQUIPMENT FAILURE

21-42

W011

21. MECHATRO CONTROLLER

Error codes are stored as trouble history, and displayed on the monitor by the trouble history display function. 1. Machine condition display: Displays machine operating condition. 2.

Display function for maintenance: Displays remaining time up to replacement/change of the following items. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil

3.

Failure history display function: Stores abnormality that has occurred on the mechatro system in the past and displays them in order of recent occurrence.

4.

Mechatro adjustment display: Displays the procedure for the adjustment of the mechatro system, like output adjustment and unload adjustment, etc.

5.

Service diagnosis display: Displays information like the pressure sensor sensed value, proportional valve command, etc. output by the mechatro controller

21

21-43

21. MECHATRO CONTROLLER (9) Rearview camera 1) Setting of display picture of rearview camera 1: Buzzer Stop Switch 2: Menu Switch 3: Up Arrow Switch 4: Down Arrow Switch 5: Next Arrow Switch 6: Back Arrow Switch

5

1

6

TURN STARTER KEY SWICH ON No.1 + MAIN CONT. P/N XLB22E00026F1 PRIGRAM VERSION 1-VER 00.07 2-VER 00.00 SERVICE DIAG 1 CLUSTER DIAG 1 CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 01.00

(a)

(b)

+

SERVICE MENU

4

3

(C) SERVICE ADJUST1-2

2

(d) SERVICE ADJUST1-2

(e) SERVICE ADJUST1-2

SERVICE DIAGNOSIS

AUTO ACCEL

AUTO ACCEL

AUTO ACCEL

TROUBLE HISTORY

START MODE

START MODE

START MODE

LANGUAGE & LOGO SETTING

CANCEL LOW TEMP

CANCEL LOW TEMP

CANCEL LOW TEMP

SERVICE ADJUST 1

CANCEL MODE

CANCEL MODE

CANCEL MODE

SERVICE ADJUST 2

CHECK INJECTOR

CHECK INJECTOR

CHECK INJECTOR

FACTORY PRESET

PRESS DRAIN

PRESS DRAIN

PRESS DRAIN

FAULT DIAG MODE

NIBBLER SETTING

NIBBLER SETTING

NIBBLER SETTING

BREAKER SETTING

BREAKER SETTING

BACK

ON

BREAKER SETTING

CAMERA 1 SETTING

OFF

CAMERA 1 SETTING

OFF

CAMERA 1 SETTING

CAMERA 2 SETTING

OFF

CAMERA 2 SETTING

OFF

CAMERA 2 SETTING

NEXT

BACK

DOWN

ON DOWN

NEXT

BACK

ON OFF

BACK OK

ON OFF ON OFF

OK

1. Hold down the buzzer stop switch (1) and turn the starter switch ON. The service diagnosis screen (a) is displayed. 2. Hold down the buzzer stop switch (1) and press the menu switch (2) 3 times. "SERVICE MENU" screen (b) is displayed. 3. Using the "UP" switch (3) or "DOWN" switch (4), point the cursor to the "SERVICE ADJUST 1" display (b). Press the "NEXT" switch (5), and SERVICE ADJUST 1-2 (c) is displayed. 4. Using the "UP" switch (3) or "DOWN" switch (4), point the cursor to the "CAMERA 1 SETTING" display (c). 5. Press the "NEXT" switch (5), and the cursor is pointed to "OFF" on the display (d). 6. Press the "UP" switch (3), and it points to "ON" of the display (e). 7. Press the menu switch (2), and the rearview camera is set. 8. After that screen returns to "SERVICE ADJUST 1-2" (c). 9. Turn off the starter key switch.

21-44

21. MECHATRO CONTROLLER 2) Troubleshooting 1. The gauge cluster is powered on but the picture does not appear and it shows a blue screen. No.

Parts

Parts/Normal Condition

Corrective Action

1

Power-supply box to Cab harness

Make sure the connector between the power-supply box and cab harness is connected.

Check connections.

2

Cable to Cab harness

Make sure the connector between the cable and cab harness is connected.

Check connections.

3

Cable to Camera cable

Make sure the connector between the cable and camera cable is connected.

Check connections.

4

Fuse & Relay box

Make sure the No. 30 fuse (5A) did not melt down.

Replace fuse.

5

Setting of camera

Make sure the camera (1) of the service adjustment 1 is on, and camera (2) and camera (3) are off.

Check the setting.

2. Gauge cluster is powered on but the picture does not appear and it shows the fuel consumption graph or logo. No. 1

Parts Setting of camera

Parts/Normal Condition Make sure the camera (1) of the service adjustment 1 is on.

Corrective Action Check the setting.

21

21-45

21. MECHATRO CONTROLLER 21.2.2 SELF DIAGNOSIS DISPLAY

CONTROL

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

Proportional valve, Battery relay Selector valve (SOL)

CAN COMMUNICATION Gauge cluster (Buzzer sound)

(3) Self diagnosis display items As displayed clock (Usually main screen). When an error occurs, and specifies the failed section and the failure type with the the aid of an error code. Alphabet: Decide system failure occurred.

S

B 01 3

Last 2nd and 3rd digits: Specifies failed section. Last 1 digit: Specifies failure type.

E

F

B013

A Last 2,3 digits

01 02 03 04 05 06

Controller memory Engine adjust data Torque adjust data Unload adjust data Boom up adjust data Arm in adjust data Arm out adjust data

B

C

D

E

F

G

Proportional Low pressure High pressure Proportional Solenoid valve for valves valve for pumps valve sensor sensor P1 unload P1 pump Boom up P1 pump ATT boost Boom down

P2 pump

P2 unload

Arm out

Boom head

Travel straight

Arm in

Boom rod

Bucket digging Bucket dump Swing

P2 pump

Speed sensor

Swing parking Travel 1,2 speed Option selector

Angle sensor for shovel Angle sensors for shovel & ECU

H

I

K

Potentiometer Communication Battery relay etc Acceleration Battery relay

P

R

Engine ECU

Relay output

Z

Wiper ark Common rail prevention relay press.

Boom angle

Wiper ark forward rotation relay

Arm angle

Wiper ark reverse rotation relay

Washer motor Bucket stroke limit

Arm 2 spool for arm in

07 08 Fuel sensor

Travel right

Refer to next page (Engine)

09 Travel left

10 Selector position detection

11

CAN communication

12 13 14 15 P1 side option

Swing flasher right relay Swing flasher left relay Travel alarm relay AIS relay 2

16 Engine stop relay Safety lock lever relay

P2 side option

17 18 19

24

Adjustment data sector 1 Adjustment data sector 2 Hourmeter sector 1 Hourmeter sector 2

25

Proportional valve adjust data

21 22 23

Safety relay

Larger than Larger than normal range normal range

0 1

-

2

-

3

-

4

-

CAN error

Transistor OFF failure / Grounding short circuit

Transistor Over run Wrong output Wrong output Transistor ON failure ON failure Disconnection Disconnection Disconnection Disconnection Transistor ON Disconnection failure / Disconnection Power source Power source short circuit short circuit

5

21-46

Disconnection Time is over

Power source short circuit

Contact point is melted and adhered

Refer to next page (Engine)

31 Abnormal

Power source short circuit

21. MECHATRO CONTROLLER ERROR CODE OF ENGINE

We left this page blank because we did not receive the manufacturer’s instructions yet.

21

21-47

21. MECHATRO CONTROLLER 21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION The current service diagnosis is displayed on the multi display based on the data received from the mechatro controller. This section explains the operating procedure and examples of each screen. The values in the display change according to the conditions like engine speed, attachment position, etc. (1) Service diagnosis display screen operating procedure 1. Turn the starter switch ON, keeping the buzzer stop switch pressed. Buzzer Stop Switch

2. After logo mark is displayed, the screen changes to service diagnosis mode. The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first. The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1". The screen number each mode can display differs. The screen number displayed by each mode is as follows. • Mode No.1 : Screen No.1 to No.22 • Mode No.2 : Screen No.1, Screen No.23 to No.27 • Mode No.3 : Screen No.1, Screen No.28 to No.32 3. The screen changes each time each switch is pressed from now on. Up Arrow Switch

Screen gains by 1 in order. (No.2-->No.3-->No.4-->...) Down Arrow Switch

Screen loses by 1 in order. (No.24-->No.23-->No.22-->...) Next Arrow 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-->...) Back Arrow 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 the key switch OFF and the display of the service diagnosis mode is closed.

21-48

21. MECHATRO CONTROLLER (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. 1

Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00 SERVICE DIAG 1 CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 02.00

2

4

NO.2 ENG G-3 SPEED SET 2205 MEAS1 2201 MEAS2 2201 G-5 ENG PRS. LIVE WATER TEMP 100 OFF MODE HM ATT MODE BUCKET H-1 ACCEL VOLT. 4.2V POS. 100% ECU OUTPUT 0.5V

NO.3 SOL.VALVE F-1 POWER BOOST COMP. OFF MEAS. OFF SWITCH OFF F-2 SWING-BRAKE COMP. OFF MEAS. OFF RELEASE SW OFF F-3 1/2-TRAVEL COMP. OFF MEAS. OFF SWITCH OFF

Contents

No. 5

P/No. indication

Displays

K-1 AIS RELAY 2 OFF K-2 SAFETY RLY OFF K-3 ENG STOP OFF KEY SWITCH OFF START SWITCH OFF CHARGE LIVE K-4 LOCK LEVER OFF SWITCH OFF

Program version indication MERIT controller program version Service diagnosis mode

Contents

NO.4 RELAY Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch

P/NO. indication Program Version indication

6 No load setting rpm Actual rpm 1 Actual rpm 2 (Engine controller) Engine oil pressure Coolant temperaturre sensor Work mode Attachment mode Potentiometer voltage Voltage % indication Accel output voltage to engine controller

Set value in computer Measured value Switch Set value in computer Measured value Switch

NO.5 PRESS.SENSOR B-1 BOOM RAISE 3.5V 2.6M B-2 BOOM LOWER 3.5V 2.6M B-3 ARM OUT 3.5V 2.6M B-4 ARM IN 3.5V 2.6M B-5 BUCKET DIG 3.5V 2.6M B-6 BUCKET DUMP 3.5V 2.6M B-7 SWING 3.5V 2.6M B-9 TRAVEL(R) 3.5V 2.6M B-10 TRAVEL(L) 3.5V 2.6M B-16 P1 OPT. 3.5V 2.6M B-17 P2 OPT. 3.5V 2.6M

Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value

21

Set value in computer Measured value Switch

21-49

21. MECHATRO CONTROLLER

No. 7

8

9

10

Displays NO.6 P.SENSOR PROPO-V C-1 PUMP 1 3.5V 32.6M C-2 PUMP 2 3.5V 32.6M C-3 BOOM-HEAD 3.5V 32.6M C-4 BOOM-ROD 3.5V 32.6M E-1 P1 PUMP COMP. 600mA 4.5M MEAS. 600mA 4.5M POWER SHIFT 100mA FLOW RATE 100L E-2 P2 PUMP COMP. 600mA 4.5M MEAS. 600mA 4.5M POWER SHIFT 100mA FLOW RATE 100L NO.7 PROPO-VALVE D-1 P1 UN-LOAD(BP-CUT) COMP. 600mA 4.5M MEAS. 600mA 4.5M D-2 P2 UN-LOAD(BP-CUT) COMP. 600mA 4.5M MEAS. 600mA 4.5M D-3 S-TRAVEL COMP. 600mA 4.5M MEAS. 600mA 4.5M D-6 ARM IN-2-SPEED COMP. 600mA 4.5M MEAS. 600mA 4.5M E-3 OPT RELIEF 1 COMP. 600mA 14.5M MEAS. 600mA 14.5M E-4 OPT RELIEF 2 COMP. 600mA 14.5M MEAS. 600mA 14.5M NO.8 SENSOR,SWITCH H-9 FUEL LEVEL 4.5V 90% H-10 HYD.OIL TEMP 4.5V 30 GLOW OFF AIR FILTER LIVE WATER SEPA. LIVE ENG OIL FILTER LIVE FRONT WINDOW OFF DOUBLE FLOW ON KPSS SW OFF HEATER OFF ENG OIL LEVEL LIVE COOLANT LEVEL LOW FUEL DIST 9999 FUEL TEMP -100 NO.9 SOL.VALVE F-4 OPT SELECT COMP. OFF MEAS. OFF SPOOL POS. NIB SELECT SWITCH NIB F-5 FAN PUMP COMP. OFF MEAS. OFF F-6 COMP. OFF MEAS. OFF

Contents

No. 14

Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Set value in computer / Converted value from pressure Measured value / Converted value from pressure

Power shift Flow rate of pump P1 Set value in computer / Converted value from pressure Measured value / Converted value from pressure

Power shift Flow rate of pump P2

Set value in computer / Converted value from pressure Measured value / Converted value from pressure

Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value

Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure

15 Fuel level Hydraulic oil temperature Glow switch Air filter clogging Water separator clogging Engine oil filter clogging Front window open/close switch Conflux/Single flow select switch KPSS switch Command from air heater Engine oil level Coolant level Fuel dist Fuel temperture

Set value in computer Measured value (Feed back value) Spool position Mode of selector valve Set value in computer Measured value

NO.14 DIGITAL INPUT DI1 OFF DI2 OFF DI3 OFF DI4 OFF DI5 OFF DI6 OFF DI7 OFF DI8 OFF DI9 OFF DI10 OFF DI11 OFF DI12 OFF DI13 OFF DI14 OFF DI15 OFF DI16 OFF DI17 OFF DI18 OFF DI19 OFF DI20 OFF DI21 OFF DI22 OFF DI23 OFF DI24 OFF DI25 OFF DI26 OFF

ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication

NO.15 DIGITAL INPUT DI27 OFF DI28 OFF I29 OFF DI30 OFF DI31 OFF DI32 OFF DI33 OFF DI34 OFF DI35 OFF DI36 OFF DI37 OFF DI38 OFF DI39 OFF DI40 OFF DI41 OFF DI42 OFF

ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication

Set value in computer Measured value

16

NO.12 PROPO-VALVE D-11 P1 I-TRAVEL COMP. 600mA 4.5M MEAS. 600mA 4.5M D-12 P2 I-TRAVEL COMP. 600mA 4.5M MEAS. 600mA 4.5M D-14 FAN DRIVE COMP. 600mA 4.5M MEAS. 600mA 4.5M D-15 COMP. 600mA 4.5M MEAS. 600mA 4.5M D-16 COMP. 600mA 4.5M MEAS. 600mA 4.5M

Contents

Set value in computer / Converted value from pressure Measured value / Converted value from pressure

11

13

Displays NO.13 PRESS.SENSOR B-11 3.5V 12.6M B-12 3.5V 12.6M B-13 3.5V 12.6M B-14 3.5V 12.6M B-15 3.5V 12.6M B-18 DOZER 1 3.5V 12.6M B-19 DOZER 2 3.5V 12.6M B-20 3.5V 12.6M C-5 3.5V 12.6M C-6 3.5V 12.6M C-7 3.5V 12.6M C-8 3.5V 12.6M

Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure

21-50

See Mechatro controller connector

21. MECHATRO CONTROLLER

Displays No. 17 NO.16 DIGITAL OUTPUT DO1 COMP. OFF MEAS. OFF DO2 COMP. OFF MEAS. OFF DO3 COMP. OFF MEAS. OFF DO4 COMP. OFF MEAS. OFF DO5 COMP. OFF MEAS. OFF DO6 COMP. OFF MEAS. OFF DO7 COMP. OFF MEAS. OFF DO8 COMP. OFF MEAS. OFF DO9 COMP. OFF MEAS. OFF DO10 COMP. OFF MEAS. OFF DO11 COMP. OFF MEAS. OFF DO12 COMP. OFF MEAS. OFF DO13 COMP. OFF MEAS. OFF

18

19

Contents Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value

Displays No. 20 NO.19 WIPER SYSTEM WIPER SW OFF RISEUP SW OFF REVERSE SW OFF PREVENT ARC OFF CW MOTOR RLY OFF CCW MOTOR RLY OFF WASHER SW OFF MOTOR RELAY OFF

22

Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value

NO.18 DIGITAL OUTPUT DO27 COMP. OFF MEAS. OFF DO28 COMP. OFF MEAS. OFF

Set value in computer Measured value Set value in computer Measured value

Wiper switch Wiper rise-up switch Wiper reverse rotation switch Wiper motor ark prevention relay Wiper normal rotation relay Wiper reverse rotation relay Washer switch Washer motor relay

NO.21 MERIT SYSTEM COMMUNICATION

23

NO.17 DIGITAL OUTPUT DO14 COMP. OFF MEAS. OFF DO15 COMP. OFF MEAS. OFF DO16 COMP. OFF MEAS. OFF DO17 COMP. OFF MEAS. OFF DO18 COMP. OFF MEAS. OFF DO19 COMP. OFF MEAS. OFF DO20 COMP. OFF MEAS. OFF DO21 COMP. OFF MEAS. OFF DO22 COMP. OFF MEAS. OFF DO23 COMP. OFF MEAS. OFF DO24 COMP. OFF MEAS. OFF DO25 COMP. OFF MEAS. OFF DO26 COMP. OFF MEAS. OFF

Contents

OFF

NO.22 ENG CONT. TRANS.COUNT. 100 RECEIVE COUNT. 100 DIAG STATUS 9 NUMBER OF DIAG 100 BOOST PRESS. 100 BOOST TEMP. -100 BAROMETRIC P. 100 FUEL TEMP. -100 FUEL CONS. 200 INTAKE TEMP. -100 ENG PRESS. 300 GLOW OFF ENG STOP OFF TORQUE 1000 BUZZER ON CLOG 10 REGENE NO ON FORCED REGENE ON ENG. RAIL PRESS 1000 UREA LEVEL 100 UREA TEMP. 100

21-51

Status of communication in MERIT controller

Counted number of transmission error Counted number of reception error Diagnosis status Numbers of error Boost pressure Boost temperature Atmospheric pressure Fuel temperature Fuel consumption Intake air temperature Common rail pressure Glow output from ECU Engine stop command from ECU Calculated torque of ECU Clogging Information for Prevention of regeneration Information for regeneratio Engine rail pressure UREA level UREA temperature

21

21. MECHATRO CONTROLLER 2) Service diagnosis mode No.2 No. 1

Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00 SERVICE DIAG 2 CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 02.00

24

25

Contents

No. 26

P/No. indication Program version indication MERIT controller program version Service diagnosis mode

P/NO. indication

Displays

Contents

NO.25 BUCKET C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA B-5 BUCKET DIG 1.9M B-6 BUCKET DUMP 1.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Bucket digging pressure sensor Bucket dump pressure sensor Engine actual speed Power shift current

NO.26 TRAVEL C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA B-9 TRAVEL(R) 13.9M B-10 TRAVEL(L) 13.9M Pi-P1 13.9M Pi-P2 13.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Travel right pressure sensor Travel left pressure sensor Pilot pressure at travel straight (P1 side) Pilot pressure at travel straight (P2 side) Engine actual rpm Power shift current

NO.27 OPT C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA E-3 OPT RELIEF 600mA B-16 P1 OPT 1.9M B-17 P2 OPT 1.9M F-4 OPT SELECT NIB DOUBLE FLOW SW NIB G-3 ENG SPEED 2205 POWER SHIFT 100mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current P1 side option pressure sensor P2 side option pressure sensor Optional selector SOL (Nibbler line) Conflux/ Single selector switch Engine actual rpm Power shift current

Program Version indication

27

NO.23 BOOM C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA B-1 BOOM RAISE 1.9M B-2 BOOM LOWER 1.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Boom up pressure sensor Boom down pressure sensor Engine actual speed Power shift current

NO.24 ARM,SWING C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA D-6 ARM-IN-2 600mA B-3 ARM OUT 13.9M B-4 ARM IN 13.9M B-1 BOOM RAISE 13.9M B-7 SWING 13.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current Arm out pressure sensor Arm in pressure sensor Boom up pressure sensor Swing pressure sensor Engine actual speed Power shift current

28

21-52

21. MECHATRO CONTROLLER 3) Service diagnosis mode No.3 No. 1

Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00 SERVICE DIAG 3 CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 02.00

29

NO.28 ADJUSTMENT 1 ENG HI-IDLE 2205 PUMP ACT I 515mA I 15mA PUMP P 35.0M ESS N 2040 UN-LOAD P1 600mA P2 600mA BOOM 137 137 ARM 137 137 OFFSET 137 137 INTER-B 137 137

31 NO.30 MACHINE-INFORM. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200

Contents

No. 32

P/No. indication Program version indication MERIT controller program version

Displays

Contents

NO.31 MACHINE-INFORM. PUMP PRESS. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%

Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours

WATER TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%

Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours

FUEL TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%

Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours

HYD. OIL TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%

Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours

Service diagnosis mode

P/NO. indication Program Version indication

Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment

Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated high-reach crane operating time

All accumulated starter operating time

21

21-53

21. MECHATRO CONTROLLER (3) Service diagnosis data list Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use this data to decide normal/abnormal status. • The values in the following display are reference values with a standard attachment attached to the machine. • The value of the pressure sensor is calculated taking variations into account. When compared to the performance check reference criteria, measure it with the aid of a calibrated measuring instrument. • The current of the proportional valve is not the measured value, but the command value. The measured value should be confirmed by the value in the displayed value for each proportional valve. • The current value of the pump proportional valve is a reference value because it varies according to the pump pressure and adjusted torque value. • The value in the display during operation shows the value in a steady state, rather than, at start of operation. • Check on the machine after sufficiently warming up the machine. • The value in the display may differ according to the software version. Contact our dealer/distributor. Operation No.1: No operation H mode High idle

Operation No.2: No operation S mode High idle

No.24 ARM, SWING

No.24 ARM, SWING

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

0.2 to 2.0 M 0.2 to 2.0 M 350 mA 350 mA 750 mA 750 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 0.0 M 2070 to 2130 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

0.2 to 2.0 M 0.2 to 2.0 M 350 mA 350 mA 750 mA 750 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 0.0 M 1870 to 1930 0 mA

Operation No.3: Boom up in full lever operation & relief H mode High idle

Operation No.4: Boom up in full lever operation & in operation H mode High idle

No.23 BOOM

No.23 BOOM

C-1 C-2 E-1 E-2 D-1 D-2 B-1 B-2 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) BOOM RAISE BOOM LOWER ENG SPEED POWER SHIFT

33.0 to 35.8 M 33.0 to 35.8 M 470 to 585 mA 470 to 585 mA 360 mA 360 mA 3.0 M 0.0 M 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 B-1 B-2 G-3

21-54

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) BOOM RAISE BOOM LOWER ENG SPEED POWER SHIFT

13.0 to 18.0 M 13.0 to 18.0 M 630 to 770 mA 630 to 725 mA 360 mA 360 mA 3.0 M 0.0 M 2050 to 2200 0 mA

21. MECHATRO CONTROLLER

Operation No.5: Boom down in full lever operation & in operation H mode High idle No.23 BOOM C-1 C-2 E-1 E-2 D-1 D-2 B-1 B-2 G-3

5.0 to 9.0 M 0.2 to 2.0 M 600 to 620 mA 350 mA 427 to 477 mA 750 mA 0.0 M 3.0 M 2050 to 2200 0 mA

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) BOOM RAISE BOOM LOWER ENG SPEED POWER SHIFT

Operation No.6: Arm-in in full lever operation & relief H mode High idle

Operation No.7: Arm-in in full lever operation & in operation H mode High idle

No.24 ARM, SWING

No.24 ARM, SWING

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

33.0 to 35.8 M 33.0 to 35.8 M 470 to 585 mA 470 to 585 mA 360 mA 360 mA 350 mA 200 mA 0.0 M 3.0 M 0.0 M 0.0 M 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

21-55

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

9.0 to 13.0 M 9.0 to 13.0 M 750 to 770 mA 750 to 770 mA 360 mA 360 mA 350 mA 395 mA 0.0 M 3.0 M 0.0 M 0.0 M 2050 to 2200 0 mA

21

21. MECHATRO CONTROLLER

Operation No.8: Arm-out in full lever operation & relief H mode High idle

Operation No.9: Arm-out in full lever operation & in operation H mode High idle

No.24 ARM, SWING

No.24 ARM, SWING

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

33.0 to 35.8 M 33.0 to 35.8 M 470 to 585 mA 470 to 585 mA 360 mA 360 mA 350 mA 750 mA 3.0 M 0.0 M 0.0 M 0.0 M 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

15.0 to 22.0 M 15.0 to 22.0 M 570 to 680 mA 570 to 680 mA 360 mA 360 mA 350 mA 750 mA 3.0 M 0.0 M 0.0 M 0.0 M 2050 to 2200 0 mA

* Measure the values after a lapse of 5 minutes or after release of the low temperature mode Operation No.10: Swing in full lever operation & relief H mode High idle

Operation No.11: Swing in full lever operation & in operation H mode High idle

No.24 ARM, SWING

No.24 ARM, SWING

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

0.2 to 2.0 M 28.0 to 35.8 M 350 mA 615 to 770 mA 750 mA 360 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 3.0 M 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 D-6 B-3 B-4 B-1 B-7 G-3

21-56

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL ARM-IN-2 ARM OUT ARM IN BOOM RAISE SWING ENG SPEED POWER SHIFT

0.2 to 2.0 M 10.0 to 15.0 M 350 mA 770 mA 750 mA 360 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 3.0 M 2050 to 2200 0 mA

21. MECHATRO CONTROLLER

Operation No.12: Bucket digging in full lever operation & relief H mode High idle

Operation No.13: Bucket digging in full lever operation & in operation H mode High idle

No.25 BUCKET

No.25 BUCKET

C-1 C-2 E-1 E-2 D-1 D-2 D-3 B-5 B-6 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL BUCKET DIG BUCKET DUMP ENG SPEED POWER SHIFT

33.0 to 35.8 M 33.0 to 35.8 M 470 to 585 mA 470 to 585 mA 360 mA 360 mA 720 mA 3.0 M 0.0 M 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 B-5 B-6 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL BUCKET DIG BUCKET DUMP ENG SPEED POWER SHIFT

7.0 to 11.0 M 7.0 to 11.0 M 670 to 770 mA 600 to 620 mA 360 mA 360 mA 720 mA 3.0 M 0.0 M 2050 to 2200 0 mA

Operation No.14: Bucket dump in full lever operation & relief H mode High idle

Operation No.15: Bucket dump in full lever operation & in operation H mode High idle

No.25 BUCKET

No.25 BUCKET

C-1 C-2 E-1 E-2 D-1 D-2 D-3 B-5 B-6 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL BUCKET DIG BUCKET DUMP ENG SPEED POWER SHIFT

33.0 to 35.8 M 33.0 to 35.8 M 470 to 585 mA 470 to 585 mA 360 mA 360 mA 720 mA 0.0 M 3.0 M 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 B-5 B-6 G-3

21-57

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL BUCKET DIG BUCKET DUMP ENG SPEED POWER SHIFT

15.0 to 24.0 M 15.0 to 24.0 M 550 to 770 mA 550 to 770 mA 360 mA 360 mA 720 mA 0.0 M 3.0 M 2050 to 2200 0 mA

21

21. MECHATRO CONTROLLER

Operation No.16: P2 side option in full lever operation & relief A mode High idle

Operation No.17: P2 side option in full lever operation & relief B mode High idle

No.27 OPT

No.27 OPT

C-1 C-2 E-1 E-2 D-1 D-2 D-3 E-3 B-16 B-17 F-4 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL OPT RELIEF P1 OPT P2 OPT OPT SELECT DOUBLE FLOW SW. ENG SPEED POWER SHIFT

22.5 to 26.0 M 22.5 to 26.0 M 530 to 665 mA 530 to 665 mA 360 mA 360 mA 720 mA 0 mA 0.0 M 2.0 to 2.6 M NIB ON 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 E-3 B-16 B-17 F-4 G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL OPT RELIEF P1 OPT P2 OPT OPT SELECT DOUBLE FLOW SW. ENG SPEED POWER SHIFT

0.2 to 1.5 M 22.5 to 26.0 M 350 mA 770 mA 750 mA 360 mA 350 mA 0 mA 0.0 M 2.0 to 2.6 M BRK OFF 2050 to 2200 0 mA

* Conflux switch is ON. Relief set pressure is value at shipping. * Conflux switch is OFF. Relief set pressure is value at shipping. Operation No.18: Travel right in full lever operation & travel idling H mode High idle

Operation No.19 : Travel left in full lever operation & travel idling H mode High idle

No.26 TRAVEL

No.26 TRAVEL

C-1 C-2 E-1 E-2 D-1 D-2 D-3 B-9 B-10

G-3

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL TRAVEL(R) TRAVEL(L) Pi-P1 Pi-P2 ENG SPEED POWER SHIFT

7.0 to 13.0 M 0.2 to 2.0 M 770 mA 350 mA 360 mA 750 mA 350 mA 2.0 to 2.5 M 0.0 M 0.0 M 0.0 M 2050 to 2200 0 mA

C-1 C-2 E-1 E-2 D-1 D-2 D-3 B-9 B-10

G-3

21-58

P1-PRES P2-PRES P1-PSV P2-PSV P1-UL(BPC) P2-UL(BPC) S-TRAVEL TRAVEL(R) TRAVEL(L) Pi-P1 Pi-P2 ENG SPEED POWER SHIFT

0.2 to 1.5 M 7.0 to 13.0 M 350 mA 770 mA 750 mA 360 mA 350 mA 0.0 M 2.0 to 2.5 M 0.0 M 0.0 M 2050 to 2200 0 mA

21. MECHATRO CONTROLLER 21.2.4 TROUBLE HISTORY DIAGNOSIS The items of error detected by the mechatro controller self diagnosis function are stored in the mechatro controller as one of history. And the errors are able to be indicated on the multi display. The warning content is recorded partially in the "Travel History Screen". The error code for self diagnosis is stored. (1) How to display 1. Turn starter switch on. 2. While holding down the menu switch, press the buzzer stop switch 3 times. And select "TROUBLE HISTORY" to display the trouble history diagnosis. 3. Transmit trouble history data (One or many) and hour meter to the gauge cluster. -Hour meter and 10 failure data are displayed on the screen. -In case of more than 10 data failures, turn a page to check next data. 4. Paging (Up and down) -Press "UP ARROW SWITCH" to move the item up. -Press "DOWN ARROW SWITCH" to move the item down. 5. Turn the starter switch OFF, and the display disappears.

(Example) No errors

NO ERROR

Error detected in the past

(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 the starter switch off.

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

21-59

21

21. MECHATRO CONTROLLER 21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE Travel speed select switch

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

Wiper switch Washer switch

Buzzer stop switch Screen change switch

Menu switch

Interval of replacement parts is mentioned below. -Engine oil: 500 Hr -Fuel filter: 500 Hr -Hydraulic filter: 1,000 Hr -Hydraulic oil: 5,000 Hr

1. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound. 2. The fuel filter change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound. 3. The hydraulic oil filter change time is displayed on the multi-display by 1000 hours as a warning, but the buzzer does not sound. 4. The hydraulic oil change time is displayed on the multi-display by 5000 hours as a warning, but the buzzer does not sound.

21-60

21. MECHATRO CONTROLLER Procedure

Operating Procedure

Display on Multidisplay After several seconds, display is S changed to clock automatically

1

Turn starter key switch ON.

12:15

E

S

12:15

F

USER MENU MAINTENANCE SWITCH STATUS

2

Press "MENU SWITCH" located on the multi-display, the display changes to "USER MENU" display.

OPTION SETTING E

CONSUMPTION

F

SCREEN SETTING CLOCK SETTING

BACK

UP

HOME

DOWN

INTERVAL

USER MENU

3

Press "NEXT" switch once to enter into "MAINTENANCE". At this time, "INTERVAL" box is indicated in blue.

MAINTENANCE

FUEL FILTER

SWITCH STATUS

HYD. FILTER

OPTION SETTING

HYD. OIL

CONSUMPTION

Press "NEXT" switch once more, and "REMAINING TIME" box is indicated in blue.

5

BACK

UP

HOME

DOWN

ENGINE OIL FUEL FILTER HYD. FILTER

INTERVAL

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

FUEL FILTER HYD. FILTER HYD. OIL

FUEL FILTER HYD. FILTER

7

21-61

HYD. OIL

REMAINDER

REMAINDER

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

REMAINDER

500Hr 455Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

INTERVAL

ENGINE OIL

Press "Screen Change Switch" once, and the display returns to main display (a).

08/12/12 08/12/12 08/12/12

NEXT

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

INTERVAL

Press "NEXT" switch to fix the value.

08/12/12

21

ENGINE OIL

6

EXCHANGE DAY

CLOCK SETTING

HYD. OIL

Using switch "DOWN" or "UP", and get the desired time until the replacement. Press "MENU SWITCH" once to return to default setting time.

REMAINDER

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

SCREEN SETTING

INTERVAL

4

ENGINE OIL

NEXT

REMAINDER

500Hr 450Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

EXCHANGE DAY

INTERVAL

08/12/12

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

EXCHANGE DAY

08/12/12

INTERVAL

or

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

EXCHANGE DAY

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

EXCHANGE DAY

S

REMAINDER

500Hr 455Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

INTERVAL

08/12/12

REMAINDER

500Hr 500Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

REMAINDER

500Hr 455Hr 500Hr -100Hr 1000Hr 500Hr 3000Hr 3000Hr

EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12

EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12

EXCHANGE DAY

08/12/12 08/12/12 08/12/12 08/12/12

12:15

08/12/12 08/12/12 08/12/12 08/12/12 E

F

21. MECHATRO CONTROLLER 21.2.6 ADJUSTING PROCEDURE OF DISPLAY (1) For operator 1) Clock Adjustment Switches

6

1: Screen Change Switch 2: Buzzer Stop Switch 3: Work Mode Select Switch 4: Washer Switch 5: Wiper Switch 6: Travel Speed Select Switch 7: Auto Accel Switch 8: Menu Switch 9: Arrow Switch

7

4

3

2

1

S

12:15

E

F

5

USER MENU

USER MENU

9

CLOCK SETTING

8

CLOCK SETTING

MAINTENANCE

MAINTENANCE

YEAR

10

YEAR

10

SWITCH STATUS

SWITCH STATUS

MONTH

01

MONTH

01

OPTION SETTING

OPTION SETTING

DATE

01

DATE

01

CONSUMPTION

CONSUMPTION

HOUR

13

HOUR

13

SCREEN SETTING

SCREEN SETTING

MINUTE

25

MINUTE

25

CLOCK SETTING

CLOCK SETTING

or

(a)

BACK

UP

HOME

DOWN

(b)

NEXT

BACK

UP

HOME

DOWN

(c)

NEXT

BACK

UP

HOME

DOWN

NEXT

(d)

Selcet Year / Month / Day / Hour / Minute

BACK

UP

HOME

DOWN

NEXT

(e)

Increase / Decrease

1. After turning the starter key switch ON, the main screen (a) appears. Press "MENU SWITCH" to enter into "USER MENU" display (b). 2. Using switch "DOWN" or "UP", move the cursor to "CLOCK SETTING" display. Press "NEXT" to select "CLOCK SETTING" display (d). 3. Using switch "DOWN" or "UP", select "YEAR/MONTH/DAY/HOUR/MINUTE" display. Press "NEXT" to select the desired item. 4. Using switch "DOWN" or "UP" to get the desired value. 5. After adjustment, press "Menu Switch". The adjusted values are stored as memory and the clock setting is completed. Press "Screen Change Switch", and the display returns to the main display (a).

21-62

21. MECHATRO CONTROLLER 2) Contrast Adjustment Switches

6

1: Screen Change Switch 2: Buzzer Stop Switch 3: Work Mode Select Switch 4: Washer Switch 5: Wiper Switch 6: Travel Speed Select Switch 7: Auto Accel Switch 8: Menu Switch 9: Arrow Switch

7

4

3

2

1

S

12:15

E

F

5

USER MENU

USER MENU

9

SCREEN SETTING

8

SCREEN SETTING

MAINTENANCE

MAINTENANCE

CONTRAST

SWITCH STATUS

SWITCH STATUS

Brightness(day)

OPTION SETTING

OPTION SETTING

Brightness(night)

5

CONSUMPTION

CONSUMPTION

SCREEN SETTING

SCREEN SETTING

CLOCK SETTING

CLOCK SETTING

CONTRAST

100

5

Brightness(day)

5

100

Brightness(night)

5

or

(a)

BACK

UP

HOME

DOWN

(b)

NEXT

BACK

UP

HOME

DOWN

(c)

NEXT

BACK

UP

HOME

DOWN

(d)

NEXT

BACK

UP

HOME

DOWN

(e)

Increase / Decrease

1. After turning the starter key switch ON, the main screen (a) appears. Press "Menu Switch" to enter into "USER MENU" display (b). 2. Move the cursor to "SCREEN SETTING" display. Press "NEXT" to select "SCREEN SETTING" display (d). 3. Move the cursor to "CONTRAST" display (d) on the "SCREEN SETTING" display. Press "NEXT" to select desired value. 4. Use cursor, and get the desired values. Step of the adjustable range is from 1 to 10. Example: 1 (Faint) to 10 (Clear) * Default is set to 5. 5. After adjustment, press "Menu Switch" and the adjusted values are stored as memory and the "CONTRAST" setting is completed. Press "Screen Change Switch", and the display returns to the main display (a).

21-63

21

21. MECHATRO CONTROLLER (2) Function for service The following items are provided for adjustment of the 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 attachment

Does left rotation pedal use? (Unload valve does not actuate because P4 pump is equipped in EU.)

Setting of optional equipment

Optional flow rate limitation, relief pressure limitation, combination of return selector adjustment.

Engine speed

ON/OFF of engine rpm display

Auto acceleration

Adjustment the type of the engine speed of auto deceleration runs up abruptly.

Change of starter mode

Change of start mode

Low temperature mode forcible release

Low temperature mode release

Cylinders calibration

Injection adjust mode of engine

Pressure release

For pressure release

21-64

21. MECHATRO CONTROLLER 21.2.7 MECHATRO CONTROL EQUIPMENT (1) C-1 Mechatro controller 1) Outside view 2 1

10

6

2 1

22

18

4 2 1 8

2

1

16 26 34 27 CN101

CN105

CN102

16 12 CN103

28

22

CN104

CN106 CN107 CN108 CN109 21 7 2 16 21 9 21 7 21

9 21

10

31

12

8

16 22

24

17

7 17

28 10 22 13 19 20 15 16

8

2) List of connectors

Connector No.

Pin No.

Port name

CN101

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

GA A1 +5VA +5VA A2 GA GA A3 +5VA +5VA A4 GA GA A5 +5VA +5VA A6 GA TXD1 RXD1 GP SHG1 TXD3 RXD3 DL GP CANH1 CANL1 DO 20 DO 21 DO 22 DO 23 DO 24 DI 36

Function

Input/Output

Boom up

Input

Boom down

Input

Arm in

Input

Arm out

Input

Bucket digging

Input

Bucket dump

Input

Spare

Transmission

Reception

Down load

Transmission

Reception

E/G ECU E/G ECU Spare Safety relay Spare Rotary light (yellow) Rotary light (green) Heavy lift

21-65

Output Output Output Output Output Input

Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V RS232C communication RS232C communication 0V Shield GND RS232C communication RS232C communication EARTH / OPEN(5V) 0V CAN communication CAN communication EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN

21

21. MECHATRO CONTROLLER

Connector No. CN102

Connector No. CN103

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Port name GA A8 +5VA +5VA A9 GA GA A10 +5VA +5VA A13 GA GA A14 +5VA +5VA A27 GA GA A28 +5VA D1 37

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Port name GA A +5VA +5VA A11 GA GA A12 +5VA +5VA A15 GA GA A16 +5VA

Function

Input/Output

Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V

Travel right

Input

Travel left

Input

Accelation

Input

P1 option

Input

P2 option

Input

Spare

Input

Spare

Input

Spare

Input

GND / OPEN

Input/Output

Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V

Function Swing

Input

P1 pump

Input

P2 pump

Input

Boom angle

Input

Arm angle

Input

Reserved

21-66

21. MECHATRO CONTROLLER Connector No. CN104

Connector No. CN105

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Port name GA A17 +5VA +5VA A18 GA GA A19 +5VA +5VA A20 GA A21 GA A22 GP A23 GA GA A24 +5VA +5VA A25 GA GA A26 +5VA DI 1

Pin No. 1 2

Port name +24V +24V

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

+24V DO 7 DO 8 DO 9 DO 11 GND GND D10+ D1+ D1D2+ D2D3+ D3D4+ D4D5+ D5GND D10D6+ D6D7+ D7D8+ D8D9+ D9+24V

Function

Input/Output

Boom head

Input

Boom rod

Input

Extra pressure source

Input

Spare

Input

Spare

Input

Fuel level

Input

Spare

Input

Selector detection

Input

Spare

Input

Spare

Input

Cab slow up and down

Input

Function Battery relay output side Battery relay output side (sensor analog output) Battery relay output side

Input/Output

Output Swing P/B select valve Output Travel 1,2 speed select valve Output Attachment boost select valve Output Battery (-) Battery (-) OPT changeable relief 1 Output P1 unload Output Travel 1,2 speed select valve

P2 unload

Output

Travel straight

Output

Arm in

Output

P1 pump

Output

Battery (-) OPT changeable relief 1 P2 pump

Output Output

Spare

Output

Boom cushion

Output

Arm cushion

Output

Battery direct connection

21-67

Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0.5~4.5V 0V 0.5~4.5V 0V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V GND / OPEN Signal level 20~32V 20~32V 20~32V 24V/OPEN 24V/OPEN 24V/OPEN 24V/OPEN 0V 0V +0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA -0~800mA +0~800mA 20~32V

21

21. MECHATRO CONTROLLER

Connector No. CN106

Connector No. CN107

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Port name +24V SHGF F1+ F1F2+ F2OIL OILG D11+ D11D12+ D12D13+ D13D14+ D14GND D12+ D12E1+ E1SHG3 CANH2 CANL2

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Port name DI 3 DI 8 DI 9 DI 10 DI 11 DI 12 DI 13 DI 14 DI 15 DI 20 DI 28 DI 32 DI 38 DI 39 DI 40 DI 41

Function

Input/Output

Battery relay secondary side

0

Accel motor A phase (spare) Accel motor A phase (spare) Accel motor B phase (spare) Accel motor B phase (spare)

Oil level (spare)

Output Output Output Output 0

OPT changeable relief 2

Output

Spare

Output

Spare

Output

Spare

Output

Battery (-) Spare

Output

E/G speed sensor

Input

Gauge cluster

Function Key switch (GLOW) Spare E/G oil pressure Air filter Stroke end check Spare E/G coolant level Spare Spare ECU main relay Spare Hand control nibbler Quick coupler Extra pressure Spare Spare Reserved

21-68

Input/Output

Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input

Signal level 20~32V Shield GND +24V 1.5A +24V 1.5A +24V 1.5A +24V 1.5A

+0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V +0~800mA -0~800mA XX~XXVp-p 0V Shield GND CAN communication CAN communication Signal level +24V/OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN

21. MECHATRO CONTROLLER

Connector No. CN108

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Connector No. CN109

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Port name DI 2 DI 4 DI 5 DI 6 DI 7 DI 16 DI 17 DI 18 DI 19 DI 21 DI 22 DI 23 DI 24 DI DI DI DI DI

25 26 27 29 30

GP DI 33 DI 34 DI 35 H1+ H2H2+ H2Port name DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 12 DO 13 DO 14 DO 15 DO 16 DO 17 DO 18 DO 19 GP TXD2 RXD2 RTS CTS SHG2 DO 10

Function Key switch (ON) Spare Swing P/B release E/G start High reach(hoisting at fixed position)

Wiper rise up Wiper reverse ATT boost Nibbler open check SW Working light SW Spare Lever lock Hand control rotation / clamp open or close Front window open or close Hand control breaker Manual playback signal Overload select High reach (hoist at travel) Reserved Charge Manual playback switch Spare Reserved Accel signal 1

Input/Output

Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input

Input Input Input Reserved

GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN

~12V / 12V~ +24V / OPEN +24V / OPEN 0~5V 0V 0~5V 0V

Accel signal 2

Function Wiper arc prevention Wiper normal moving Wiper reserve moving Washer motor Bucket move limitation Reserved Rotary light (RH) Swing flasher (RH) Swing flasher (LH) Travel alarm Auto idle stop relay Engine stop Lever lock Extra pressure release Reserved IT controller

Signal level +24V / OPEN +24V / OPEN GND / OPEN +24V / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN +24V / OPEN +24V / OPEN +24V / OPEN

Input/Output

Output Output Output Output Output Output Output Output Output Output Output Output Output Output

Signal level GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN 0V

Transmission RS232C communication

Spare Spare Forced playback signal

21-69

Reception RS232C communication RS232C communication RS232C communication Shield GND 24V/OPEN SV

21

21. MECHATRO CONTROLLER (2) Gauge cluster (symbol C-2) 1) General view NIBBLER MODE SWITCH BREAKER MODE SWITCH

CN-600 MULTI DISPLAY LCD

1 2 3 4 5 6 7 8 HARNESS SIDE AMP 040 (8P) HOUSING : 174044-2 TERMINAL : 173681-2

DIGGING MODE SWIHCH WORK MODE SWIHCH BUZZER STOP SWITCH BACK ARROW SWITCH

NEXT ARROW SWITCH MENU SWITCH DOWN ARROW SWITCH

SCREEN CHANGE SWITCH

UP ARROW SWITCH

CN-601 HARNESS SIDE 1 2 3 4 5 6 AMP 040 (12P) 7 8 9 10 1112 HOUSING : 174045-2 TERMINAL : 173681-2

2) Connector CN-600 (Harness side) No.

Item name

Wire color

No.

Item name

Wire color

1

Reserved

-

5

Source (+24V)

White

2

Reserved

-

6

GND

Black

3

Reserved

-

7

Source (+24V)

White

4

Reserved

-

8

Reserved

Wire color

No.

-

3) Connector CN-601 (Harness side) No.

Item name

Item name

Wire color

1

Reserved

-

7

Reserved

-

2

Reserved

-

8

Reserved

-

3

Reserved

-

9

Reserved

-

4

Rearview camera video signal

White

10

GND

5

Reserved

-

11

Reserved

6

Mechatro-controller --> Gauge cluster (CAN communication)

Red

12

Gauge cluster --> Mechatro-controller (CAN communication)

Black White

4) Function a. It processes signals by communication between the gauge cluster and the mechatro controller, displays them in lamps, displays them in LCDs and actuates the buzzer. b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro controller through the communication port.

21-70

21. MECHATRO CONTROLLER 5) Summary of display and drive item No. 1

Item

Remarks

Monitar display

LCD dot 120X168

2

-

3

-

4

Buzzer

5

Screen change switch

6

Buzzer stop switch

7

Work mode select switch

8

Digging mode switch

9

Nibbler mode switch

10

Breaker mode switch

11

Up arrow switch

12

Down arrow switch

13

Next arrow switch

14

Back arrow switch

15

Back light

Piezo-electricity type

LED

21

21-71

21. MECHATRO CONTROLLER (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

14

1

14

1

12

CN2-1

20

CN2-2

20

CN4-1

17

11

22

1

7

1

10

CN5

15

1

3

13

26

1

13

26

13

20

6

2

6

1

3

1

3

CN4-2 12

CN3-2

CN8

16

8

24

12 2

1 CN9

CN15

CN14 2

6

2

6

1

3

1

6

12

1

3

3 CN12 2

1

3

2

9

1 17 CN3-1

9

1 CN17

CN16

2

1 CN2-3 3

CN13 6

2

6

CN1 1

2 2

4

2

CN10

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX No. CODE IN CIRCUIT

21-72

PARTS NAME

21. MECHATRO CONTROLLER 2) Circuit diagram

21

21-73

21. MECHATRO CONTROLLER

21-74

21. MECHATRO CONTROLLER

21

21-75

21. MECHATRO CONTROLLER (4) High pressure sensor: LS52S00015P1 ECONOSEAL SERIES MARK 3POLES CAP MATING HOUSING174357-2

SPECIFICATION :

(+)>

PRESSURE RANGE : 0

50 MPa (0

7110 psi)

POWER SOURCE VOLTAGE : 5.0+0.5V DC OUTPUT : 1/10Vs-9/10Vs

COMMON

(Vs=5V DC 0.5

OUTPUT (+)

4.5V DC)

INSURANCE RESISTANCE : 100M

POWER SOURCE (+) HOUSING

OR MORE

(BETWEEN CASING AND ALL IN/OUT

TERMINAL

TERMINALS AT 50V DC MEGGER)

CONDENSER

PLASTIC POTTING

COVER

ELECTRIC CONNECTING DIAGRAM

DIE CASING

FLEXIBLE BOARD CIRCUIT

(Ex. Construction of internal controller)

DIAPHRAGM PIPE

O-RING P14 JIS B2401 CLASS1B

THREAD

PF 3/8 Tightening torgue 73.5N.m (54.2lbf.ft)

STRUCTURE

(5) Low pressure sensor: LC52S00019P1

AMP MQS CONNECTOR 3 POLE (B TYPE) OPPOSITE CONNECTOR (FEMALE) HOUSING 2-967642-1 TERMINAL (GOLD PLATED) 965906-5

A

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

VIEW A 19

21.9 HEX

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

SPECIFICATION :

DETAIL OF SENSOR CONNECTOR

PRESSURE RANGE : 0

3.0 MPa (0

448 psi)

RATED VOLTAGE : 5.0+0.5V DC INSURANCE RESISTANCE : 100M

OR MORE

(BETWEEN BODY AND EACH TERMINAL AT 50V DC MEGGER)

21-76

22. HYDRAULIC SYSTEM

22. HYDRAULIC SYSTEM TABLE OF CONTENTS

22.1 SUMMARY ......................................................................................................... 22-3 22.2 HYDRAULIC CIRCUITS AND COMPONENTS ................................................. 22-4 22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS .......................... 22-8 22.4 NEUTRAL CIRCUIT ........................................................................................... 22-8 22.5 TRAVEL CIRCUIT .............................................................................................. 22-10 22.6 BUCKET CIRCUIT ............................................................................................. 22-12 22.7 BOOM CIRCUIT ................................................................................................ 22-14 22.8 SWING CIRCUIT ............................................................................................... 22-18 22.9 ARM CIRCUIT ................................................................................................... 22-20 22.10COMBINED CIRCUIT ........................................................................................ 22-26 22.11 PRESSURE DRAINING ..................................................................................... 22-30

22

Book Code No. S5LC2226E02 22-1

22. HYDRAULIC SYSTEM

Issue First Edition Revision

Date of Issue

Applicable Machines

September, 2010 SK350LC-9 : YC May, 2011

SK350LC-9 : YC

22-2

Remarks S5LC2226E01 NA S5LC2226E02 NA

22. HYDRAULIC SYSTEM

22.1

SUMMARY

22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT 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.

Attachment

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

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,

(simultaneous operation of arm in and swing motions)

swing press digging

Automatic swing parking brake

Swing parking brake when operating at on a slope

Hydraulic pilot control system

Light action with operating lever

Pilot safety lock system

Cut out of pilot circuit by safety lock lever.

Lock valve (boom / arm)

Protect boom and arm from unexpected drop (Natural fall).

Holding valve for boom (Option)

Prevention of boom falling when boom head side piping breaks

Pressurized hydraulic oil tank

To prevent hydraulic oil from entering dust and to

Pump

Suction strainer

Remove dust on suction side.

Line filter ; pilot circuit

To prevent pilot operating circuit from malfunctioning

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 solenoid proportional valve of the variable displacement pump

Positive flow rate control

Flow control by positive pilot control pressure

Hydraulics backup control

Backup control by hydraulic when the electric flow controlled

Attachment

variable displacement pump fails.

Boom up conflux circuit

Speed up of boom up operation

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)

Efficient operation in all work modes

Auto accel

Reduce fuel consumption and noise by lowering engine speed when control lever is in neutral position.

Micro computer

Mass handling capability Low fuel consumption

Function

promote self suction ability of pump

Others

Easy operability and safety

Swing

Travel

Perfor- Device mance

22-3

22

22. HYDRAULIC SYSTEM

22.2

HYDRAULIC CIRCUITS AND COMPONENTS

STD. SCHEMATIC HYD. LINES Item

Component name

LC01Z00092P1 Part No.

Model No.

1

Hyd. pump assy

LC10V00029F2

K5V140DTP (with PTO.)

2

Control valve (main)

LC30V00039F1

KMX15YE

3

Swing motor unit

LC15V00022F2

M5X180-CHB

4

Travel motor unit

LC15V00031F1

GM60VA

5

Boom cylinder (RH & LH)

LC01V00044F1

100 dia. X 140 dia. X 1550

6

Arm cylinder

LC01V00054F1

120 dia. X 170 dia. X 1788 (SE.Asia)

7

Bucket cylinder

LC01V00055F1

100 dia. X 150 dia. X 1193 (SE.Asia)

8

Swivel joint

YN55V00053F1

9

Pilot valve (ATT)

LQ30V00033F1

PV48K2058

10

Pilot valve (travel)

YN30V00105F1

6TH6 NRZ

11

Inline filter

YN50V00020F1

Y-457400

12

Suction strainer

LC50V00006F2

SB281J0A023A

13

Solenoid valve assy

YN35V00047F2

8KWE5A-30

14

Return filter

LC52V01002F1

FZ1F180A001C

15

Air breather

YN57V00005F1

16

Restrictor

YN21V00005F4

07745-00000

The part numbers may be changed due to modification, so use only the numbers for references.

22-4

22. HYDRAULIC SYSTEM 22.2.1 STANDARD SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

MB

P A2 a2

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

REG

MA

MA

A

B1

B3 Dr3

2 MAIN CONTROL VALVE 34.3MPa 37.8MPa

14

PCb

NOTES 1

P2 P1

CMR1

PL PTb

HYD.TANK

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

CT2

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

SWING

CRb

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb

39.7MPa

PSV-B

PSV-C

PSV-D

PSV-A

T2

13

P2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

A8 ARM2

PAs

3

4

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

22

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

2

37.8MPa BUCKET

PAc ATT A4 BOOSTING

1

RH ARM 1

PCc PBc

SE7 SE8 P P

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

PBb

SV-2

B

A3

PAr

SV-3

TRAVEL LEFT

a5

12

SV-1

PA

PB

5.0MPa

15

SV-4

D

8

11

P1

PG

29.0MPa D

a4

M 203kw /2100min-1

SWING

REG

TRAVEL RIGHT

Dr

3 M

1 a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16 LC01Z00092P1 01

22-5

22. HYDRAULIC SYSTEM 22.2.2 N&B SPECIFICATION (OPTION) YN01Z00162P1

N&B specification NO. 50 51 52 53 P2

T1

P1

PART No. MODEL No. YN30V00104F1 VBY-174B 24100P3133F1 YN30V00080F1 16030-00000 YN22V00035F1 KRBP13C

NOTE:

T2

1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT. 2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.

PTb PCb

PARTS SELECTOR VALVE STOP VALVE PILOT VALVE RELIEF VALVE

P1 UNLOAD

TRAVEL PRIORITY

SELECTION CONFLUX / SINGLE FLOW CHANGEOVER SWITCH

M P2 UNLOAD MAIN PUMP

PCa

ELECTROMAGNETIC COMMAND SIGNAL OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-)

COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE (W: , W/O: ) P1 PUMP

P2 PUMP

TRAVEL STRAIGHT

P1 UNLOAD P2 UNLOAD

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

3. WHEN USING NIBBLER, ACCORDING TO SPECIFICATION OF NIBBLER INSTALLED, CHOOSE CONFLUENCE OR SINGLE FLOW BY CONFLUENCE FLOW CHANGEOVER SWITCH. 4. ADJUST OVERLOAD RELIEF VALVE OF OPTIONAL PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.

51 LEFT

53

HYD.TANK

NIBBLER

RIGHT BREAKER

PBo OPTION

PSV E

PSV I

SOL/V BLOCK

52

PAo NIBBLER & BREAKER PILOT VALVE Ao

T P

Bo

B

LEVER A1 LOCK

C1

C2 A P SE-11

T

50 Ps P SE-29

C

SV-13 PL

YN01Z00189P1 02

22-6

22. HYDRAULIC SYSTEM 22.2.3 EXTRA SPECIFICATION (OPTION) LC01Z00086P1

N&B specification

P2

M

P1

T1

NO. 50 51 52 53 54

T2

PARTS GEAR PUMP CONTROL VALVE SOLENOID VALVE SOLENOID VALVE SHUTTLE VALVE

PART No. YN10V00019F1 YN30V00107F1 YN35V00010F2 PW35V00002F1 YB26V00002F1

MODEL No. SGP2A20F1H1-R144 KMC10-1025 16084-00000 2KWE5A-30/G12R-278

50 20.3cc / rev

HYD. TANK

53 54 A C SW SW-98

TO EXTRA SOL / V BLOCK

LEVER A1 LOCK

ATT RIGHT SIDE

ATT LEFT SIDE

B

PSV-8

A2

22

A1 PSV-9

P

T

26.5MPa

B1 A1

26.5MPa

51

Pb1 Pa1

PL

24.5MPa P

Dr

A

52

G P SE-28

P

T

LC01Z00086P1 02

22-7

22. HYDRAULIC SYSTEM

22.3

COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS

Blue Feed, drain circuit

22.4

NEUTRAL CIRCUIT

This section describes the following. (1) Bypass cut valve and unload valve control (2) Safety lock lever and pilot circuit (3) Pump positive flow control (4) Pump P-Q (Pressure-Quantity) curve control

less than 0.44 MPa (64 psi) Green Return, make up circuit, 0.44~0.59 MPa (64~86 psi) Purple Secondary pilot pressure, (including proportional vlave) 0.59~5 MPa (86~725 psi) Red Primary pilot pressure, (including proportional vlave) 5 MPa (725 psi) Orange Main pump drive pressure, 5~34.3 MPa (725~4970 psi) Blue tone At valve operation Red valve When solenoid proportional valve (reducing) is operating

22.4.1 OPERATION OF UNLOADING VALVE AND BY-PASS CUT VALVE HOUSED IN CONTROL VALVE (1) Unloading valve On starting engine, like the by-pass cut valve, the secondary pressures output by P1 and P2 unloading proportional valves (PSV-D and PSV-B) exert on PCb and PCa ports, consequently the P1 and P2 unloading valves are switched to the OPEN side. (2) By-pass cut valve When machine is under normal conditions, by-pass cut valve is closed. If pilot pressure sensor or unloading proportional valve is disconnected or malfunctioned, the unloading valve closes completely. Even if control valve is in neutral position, hydraulic oil is trapped. As a result, the pump relieves due to pressure increase. In such a case, before the machine is repaired, open the bypass cut valve manually. And the machine is operable by draining the excess oil to hydraulic tank.

Red solenoid In active and exciting Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual, refer to the electric circuit diagram.

22-8

22.4.2 SAFETY LOCK LEVER AND PILOT CIRCUIT (1) Purpose: To protect the attachment from unexpected movement for safety. (2) Principle: Cut pressure source of pilot valve for operation. (3) Operation: If the safety lock lever (red) is pushed forward after the engine starts, the limit switch (SW-11) is turned on. The timer relay is actuated one second later which causes the solenoid (SV-4) of the solenoid valve block (13) to be energized and the pilot operating circuit is on stand by.

22.4.3 PUMP POSITIVE FLOW CONTROL (1) Type: Electric flow controlled variable displacement pump. (2) Principle: The current command I to the pump's solenoid proportional valve controls the delivery rate of the pump. (3) Operation: 1. Flow rate rise operation (Eg. P1 pump) By operating any of the control levers, the operating secondary pressure of the pilot valve rises, and the rising pressure is transformed to the rise of output voltage corresponding to the pressure input by the low pressure sensor. The mechatro controller signal-processes this change of voltage, resulting in a rise of command current value I to the pump proportional solenoid valve and consequently the pump flow rate rises. This is called "Positive Control System". As the pump command current value rises, the secondary pressure of the proportional solenoid valve also rises. On the regulator attached on the pump, the spool (652) through piston (643) is pushed leftward, and stops at the position where being in proportion to the force of pilot spring (646). The tank port connected to the large bore of the servo piston (532) opens, and the piston moves leftward by delivery pressure from the P1 of the small bore resulting in the increase of tilt angle (Éø). The servo piston and spool (652) are connected to feedback lever (611). Therefore when the servo piston moves leftward, the spool (652) also moves rightward by means of the feedback lever. With this movement, the opening of the spool sleeve closes gradually, and the servo piston stops at the position the opening closed completely. 2. Flow rate reduction operation As the current value I of the mechtro controller reduces, the secondary pressure of the solenoid proportional valve reduces, and spool (652) is moved rightward by the force of pilot spring (646). With the movement of the spool, the delivery pressure from P1 usually flows into the large bore of the piston through the spool. The delivery pressure from P1 flows in the small bore of the servo piston, but the servo piston moves rightward due to the difference of area, resulting in the reduction of the tilt angle. Similarly, when the servo piston moves rightward, the spool (652) is moved leftward by the feedback lever.

The operation is maintained until the opening of the spool sleeve is closed.

22.4.4 PUMP P-Q OPERATION

CURVE

CONTROL

(1) Type: Electrical flow control type variable pump (2) Principle: Perform an operation of the value from pump high pressure sensor to P-Q curve control value, and send a command to the pump solenoid proportional valve. (3) Operation: The pump high pressure sensor converts the pressure to the output voltage corresponding to the pump delivery pressure. The mechatro controller converts the voltage output by the high pressure sensor to the P-Q curve control value. On the other hand, select the pump positive control command current value from the low pressure sensor in lower order, and the values are output to the respective pump proportional valve as a command current. With this operation, the pump power is controlled so as not to exceed the engine power, therefore the engine does not stall.

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

652

29.0MPa D

MA

MA

646

5.0MPa

M 203kw /2100min-1

B1

B3 Dr3

A3

2 P2 P1

MAIN CONTROL VALVE 34.3MPa 37.8MPa CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-1

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-4

B

A a5

11

P1

PA

PB

8

a4

Dr

D

TRAVEL LEFT

532 a3

PG

REG

TRAVEL RIGHT 643

SWING

M

1

611

3 DB

REG

651

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

(OCEANIA)

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 NEUTRAL CIRCUIT : Positive Control Function At Safety Lock Lever Down (Unlocked Position)

22-9

22. HYDRAULIC SYSTEM

22.5

TRAVEL CIRCUIT

This section describes the following. (1) Travel forward pilot simultaneous operation circuit (2) 2 speed travel solenoid command circuit and auto 1-speed return function (3) Travel main circuit (4) Travel motor function

22.5.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT (1) Purpose: Light operating force and shockless operation (2) Mechatronics: 1. If the travel lever with damping mechanism is operated for travel right, left and forward motions; the secondary pilot proportional pressure comes out of the 3 and 1 ports of P/V (10). The higher of the pressures is selected, and comes out of the 6 and 5 ports and acts upon the low pressure sensors (SE9) (SE-10). 2. The pilot secondary pressure flows to PAr and PAL ports of the control valve (2), moves the travel spool, and switches the main circuit. 3. The low pressure sensor output voltage is input into the mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase of flow rate to the P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2), and at the same time the command current is output to the P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B). 4. The secondary pressures output by the P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exert on the pump regulator, actuating the pump on the delivery flow rate increase side. 5. The secondary pressure delivered in the P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is fed to PBp1, Pcb, PBp2 and PCa ports provided in the control valve (2). The secondary pressure from the proportional valve which has exerted on PBp1 and PBp2 ports holds the by-pass cut spool on the CLOSE side, like the operation in the lever neutral position. The secondary pressure from the proportional valve which has exerted on PCb and PCa ports switches the unloading spool in the CLOSE side.

22-10

22.5.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN FUNCTION (1) Purpose: Change travel motor speed with switch. (2) Principle: If the switch is turned, an electric signal is issued. It energizes the 2-speed travel solenoid which in turn converts the primary pilot pressure and the self pressure to a tilting angle of the variable displacement motor. (3) Operation: If the rabbit marked switch on the gauge cluster is pressed, the solenoid (SV-3) of the proportional valve block (13) is energized and changes the proportional valve. Then the solenoid command pressure is issued from port A3, enters the P port of the travel motor (4), opens the oil passage to the 2nd speed select piston, and causes the motor to run in the 2nd speed tilting mode by its self pressure. However, when the main circuit pressure rises above 28 MPa (4060 psi), the motor's self pressure pushes the 2nd speed select piston back to the 1st speed.

22.5.3 TRAVEL MAIN CIRCUIT (1) Operation: The delivery oil from Pump A1 and A2 ports by changing the travel spool with the operation of the travel pilot flows in each VA port on the left side of the travel motor (4) throughthe C and D ports of the swivel joint (8) from AL and AR ports of the C/V, and rotates the travel motor.

22.5.4 TRAVEL MOTOR FUNCTION (1) Function: 1. Prevents the motor from over running on a slope. 2. Check valve that prevents cavitation of the hydraulic motor. 3. Shockless relief valve and anti cavitation valve when inertia force stops. 4. High/Low 2 step speed change mechanism and auto 1st speed return at high load. 5. Travel parking brake.

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 TRAVEL CIRCUIT : Travel 2nd Speed, RH & LH Simultaneous Operation.

22-11

22. HYDRAULIC SYSTEM

22.6

port provided in the control valve (2) and shifts the travel straight valve.

BUCKET CIRCUIT

This section describes the following. (1) Bucket digging pilot circuit (2) Auto accel operation (3) Flow control in the work mode (4) Bucket digging travel straight main circuit (5) Bucket spool stroke limiter

22.6.1 PILOT CIRCUIT DIGGING

FOR

BUCKET

(1) Mechatronics: 1. When the operation for bucket digging is performed, the pilot proportional secondary pressure is delivered through port 1 of the right pilot V (9), flows to PAc port, and acts on the low pressure sensor (SE-1), and at the same time the bucket spool is switched. 2. The voltage output by the low pressure sensor inputs in the mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase of the pump flow rate to the pump proportional valves (PSV-P1) and (PSV-P2) on the P1 and P2 pump sides; and at the same time the command current is output to the P1 unloading valve (PSV-D), P2 unloading valve (PSV-B) and travel straight proportional valve (PSV-C). In the following pages, the relation of operation of the low pressure sensor to both the increase of the pump flow rate and unloading proportional valve is the same. Therefore the explanation is omitted. 3. The secondary pressure output by the P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exerts on the pump regulator, actuating the pump onto the delivery flow increase side. 4. The secondary pressure delivered in the P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is led to PBp1, PCb, PBp2 and PCa ports provided in the control valve (2). The secondary pressure from the proportional valve which has exerted on PBp1 and PBp2 ports holds the by-pass cut spool on the CLOSE side, like the operation in the lever neutral position. The secondary pressure from the proportional valve which has exerted on PCb and PCa ports switches the unloading spool in the CLOSE side. 5. The secondary pressure delivered in the travel straight proportional valve (PSV-C) is led to PTb

22-12

22.6.2 AUTO OPERATION

ACCELERATION

(1) Principle: Auto acceleration actuates according to signals from the low pressure sensor. (2) Operation:

In the event where the sensor does not receive signal for 4 seconds or more even though the acceleration dial is set to MAX position, the engine speed should rise to 1000 rpm.

When the pressure 0.6 MPa (87 psi) is input to the low pressure sensor in the STD specification (travel, bucket, swing, arm), the proportional voltage from the low pressure sensor inputs in the mechatro controller, and then the engine speed returns to the dial set position corresponding to the lever operation.

22.6.3 STAND-BY CURRENT CONSTANT CONTROL (1) Principle: When the engine speed is at intermediate speed or lower, the command current value to have the pump delivery rate constant is output. (2) Operation: Even if the engine speed specified by the acceleration potentiometer is low speed, as the delivery rate corresponds to the intermediate speed, the actuator moves earlier than the movement equivalent to the control lever angle rate in light load operation.

22.6.4 BUCKET DIGGING AND TRAVEL STRAIGHT CONFLUENCE (CONFLUX) MAIN CIRCUIT (1) Operation: 1. The oil delivered through the A1 port of the P1 pump goes into the P1 port of C/V (2), opens the load check valve LCc through the parallel circuit and enters in the bucket spool. 2. On the other hand, the oil delivered through the P2 port of the P2 pump goes into the P2 port of C/V (2), confluences with oil from the P1 pump through

the travel straight valve, and goes into the bucket spool. (Confluence of oil from 2 pumps)

3. With the function of the pilot circuit, the oil flow is switched from the bucket spool, and is fed into the bucket cylinder head side through the AC port of C/ V (2). On the other hand, the return oil from the cylinder rod (R) side is throttled by the bucket spool and returns to the tank circuit from the BC port of C/ V (2). References: • In bucket dumping operation, the travel straight valve also switches like the digging operation, resulting in confluence with the travel straight. • When the bucket operation and an other operation are simultaneously performed, the travel straight valve does not actuate, resulting in single flow of the bucket circuit.

22.6.5 BUCKET LIMITER

SPOOL

STROKE

(1) Purpose : To secure simultaneous operability of the boom and arm on the boosting up attachment pressure (Pump flow rate decreases) and to prevent cavitations at low engine speed. (2) Operation: On boosting up attachment pressure, the pilot primary pressure exerts on PCc port of C/V(2) through the attachment booster solenoid valve, operates stroke limiter of the bucket spool, and throttle oil path of the spool. As a result, the P1 pump pressure increases, making the simultaneous operation of boom up and bucket digging possible. Even though the engine speed is low, similarly the cavitations can be prevented by actuating the stroke limiter.

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

A8 ARM2

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK B

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

P2

LC01Z00092P1 01

13 BUCKET CIRCUIT : Bucket Digging (Travel Straight Conflux), Auto-Accelation and Standby Flow Rate Constant Control

22-13

22. HYDRAULIC SYSTEM

22.7

BOOM CIRCUIT

(1) Boom up pilot circuit (2) Boom up 2 pumps conflux main circuit in C/V

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

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

22-14

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

SV-3

LEVER A1 LOCK

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH

PAb 39.7MPa

SE7 SE8 P P

2

PB1

LCa

CRb

ARM 1

SOL/V BLOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

(HEAD)Ab

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 BOOM CIRCUIT: Boom Up Operation, Confluence Function

22-15

22. HYDRAULIC SYSTEM This section describes boom lower operation. (1) Boom down pilot circuit (2) Prevention of natural fall by lock valve and actuation at lowering (3) Constant recirculation function of boom down main circuit

22.7.3 BOOM DOWN PILOT CIRCUIT (1) Operation: 1. If the boom down operation is performed, the secondary pilot proportional pressure comes out of port C of the right pilot valve (9) and acts upon the low pressure sensor (SE-4). At the same time, the pressure acts upon the PBb port of C/V (2). 2. The voltage output of the low pressure sensor (SE4) enters the mechatro controller and is processed. 3. Then, the proportional secondary pressure is fed into the C/V (2) PBb port and branches off in two lines and switches the boom spool and releases the boom lock valve.

22.7.4 PREVENTION OF NATURAL FALL BY LOCK VALVE AND ACTUATION AT LOWERING (1) Purpose: Prevention of natural fall when the lever is neutral. (2) Principle: The oil is prevented from returning to the boom spool by the poppet seat of the boom lock valve. (3) Operation: In the boom down action, the selector valve is changed over by the secondary proportional pressure of the PBb port. Then the poppet spring chamber of the lock valve CRb gets through the drain line (Dr) and makes the lock valve poppet open. When the boom lever is in neutral, the drain line on the lock valve CRb poppet spring chamber is closed which causes the poppet to close. The result is the oil returning from the boom cylinder head (H) to the boom spool is held and makes the leak from the boom spool zero. Thus the boom cylinder is prevented from making a natural fall.

22-16

22.7.5 CONSTANT RECIRCULATION FUNCTION OF BOOM DOWN MAIN CIRCUIT (1) Purpose: Prevention of cavitation during boom lowering motion. (2) Principle: The oil returning from the boom cylinder head (H) is recirculated to the rod (R). (3) Operation: When the oil is supplied to the boom cylinder rod (R) side during boom down operation, the boom moves faster than it should in some cases by the weight of the attachment. On this occasion, the circuit pressure on the rod (R) side is on the negative side. The oil supplied to the boom cylinder rod (R) flows into the A1 port of the P1 pump and the P1 port of C/V. The oil then passes through the boom spool and goes out of the Bb port. On this occasion, the oil returning from the head (H) goes through the recirculation path in the boom spool, pushes the check valve in the spool open, is recirculated to the Bb port and is supplied to the rod (R). When the (R) pressure is larger than the head (H) pressure, the check valve in the spool closes. Thereupon, the recirculation is stopped.

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

MB

P A2 a2

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 BOOM CIRCUIT: Boom Down Operation & Prevention Of Natural Boom Falling.

22-17

22. HYDRAULIC SYSTEM

22.8

SWING CIRCUIT

This section describes the following operations. (1) Swing left pilot circuit (2) Swing auto parking brake (3) Swing main circuit (4) Swing motor circuit

22.8.1 PILOT CIRCUIT FOR LEFT SWING (1) Operation: 1. When the left swing operation is performed, the pilot proportional secondary pressure is delivered through port (5) of the left pilot V (9), and the secondary pressure acts on the PBs port of C/V (2), and simultaneously flows out from Pss port of C/V and acts on the low pressure sensor (SE-5). 2. The voltage output by the low pressure sensor is input in the mechatro controller, and is signal processed. 3. Then, the secondary pressure led into the PBs port of C/V (2) switches the swing spool.

22.8.2 SWING AUTO PARKING BRAKE (1) Purpose: Swing lock in neutral position and parking (2) Principle: Release mechanical brake only when required to operate swing and arm in. (3) Operation: 1. The swing parking system energizes the swing parking SOL (SV-1) usually if the key switch is turned on and works by the action of the mechanical brake. 2. The mechanical brake is released if the swing parking solenoid is de-energized only when the secondary operating pressure in the swing and arm in actions acts upon any of the low pressure sensors (SE-5, 7). 3. The swing parking solenoid (SV-1) is energized five seconds after the pressure of the swing low pressure sensors (SE-5) is reduced to zero. In the case of arm in operation, the swing parking solenoid (SV-1) is energized the moment the pressure of the arm in the low pressure sensor (SE7) is reduced to zero. This causes the mechanical brake to operate.

22-18

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

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

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa

A

B1

B3 Dr3

A3

2

14

12

PCb

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb

PCc PBc

39.7MPa

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

3

4

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

22

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

2

37.8MPa

PAc ATT A4 BOOSTING

1

RH ARM 1

XAb

SE7 SE8 P P

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

HYD.TANK

P2 P1

CMR1

PL PTb

SV-1

B

a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

5

OPTION

16

PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 SWING CIRCUIT: Swing Operation (LH)

22-19

22. HYDRAULIC SYSTEM

22.9

ARM CIRCUIT

This section describes the following operations. (1) Arm in, light-load operating pilot circuit (2) Arm in, light-load variable normal recirculation main circuit / internal conflux main circuit

22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT CIRCUIT (1) Purpose: Speed-up and Anticavitation when the arm is at light loaded. (2) Principle: The oil returning from the arm cylinder rod (R) is recirculated variably to the head (H) at the arm 2 spool in C/V. (3) Operation: 1. When the arm in operation is performed, the secondary pilot proportional pressure flows out of port 7 of the left pilot valve (9) and acts upon the low pressure sensor (SE-7). At the same time, the pressure is branched off in two flows, acts upon the Paa1 port and the PLc2 port, changes over the arm spool and the arm lock valve CRar releases. 2. The output voltage by the low pressure sensor is input into the mechatro controller, and is pilot signal processed, and is output to the P1 and P2 pump proportional valves (PSV-P1 and PSV-P2) and the arm 2 inverse proportional valve (PSV-A). 3. The secondary pressure from the pilot proportional valve, which is reduced by the arm 2 inverse proportional valve (PSV-A) switches the arm 2 spool.

22.9.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL RECIRCULATION, INTERNAL CONFLUX MAIN CIRCUIT (1) Operation: 1. The P2 pump delivery oil flows in the travel left section through the P2 port of C/V (2) and is branched off in the by-pass circuit and parallel circuit, but because the arm 1 spool is switched, the delivery oil which goes through the parallel circuit opens the load check valve LCa and flows into the arm 1 spool. 2. On the other hand, the P1 pump delivery oil flows in the P1 port of C/V (2), and flows in the travel straight section and travel right tandem path. Then because the arm 2 spool was switched, the delivery oil opens the load check valve LCAT2, goes through the arm 2 spool, and confluences with the P2 pump delivery oil in the valve section, and then flows into the arm cylinder head (H) side through the Aa port of C/V (2). 3. The return oil from the arm cylinder (R) side flows in the Ba port of C/V (2) and passes through the Ba port because the arm lock valve CRar is open, and flows into the arm 2 spool through the arm 1 spool. 4. Because the arm 2 spool is switched to the normal recirculation position, causing restriction of passage to tank, the return oil from the arm cylinder (R) side flows into arm cylinder (H) side. -Because, at light load, the pressure in the cylinder rod (R) side is higher than that in the head (H) side, it opens the check valve housed-in arm 2 spool and is recirculated in the head (H) side, resulting in the speed up of arm-in operation at light load. 5. Cavitations prevention control in arm-in operation Command current is output to arm 2 solenoid proportional valve by signal processing of E/G speed and arm-in pilot pressure, accordingly the arm 2 spool is switched to the neutral (cavitations prevention) position, resulting in cavitation prevention. Position Of Arm 2 Spool Neutral position (Anticavitation position)

Normal recirculation position Recirculation

From arm out P/V From arm 2 inverse proportional valve

22-20

Reference: In light-load arm-in operation (normal recirculation, conflux), when the attachment to which the circuit in the P1 pump side is applied and operated, the meter-in path of the arm 2 spool is closed, resulting in single flow operation. Spool position at arm in, light load and combined operation (This position is not shown in hydraulic diagram) Neutral position

Arm 2 spool

Meter-in passage (Close)

Normal recirculation opsition

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

A8 ARM2

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

P2

LC01Z00092P1 01

13 ARM CIRCUIT: Arm in (Light Load) Operation, Arm Variable Recirculation & Anti Cavitation Function

22-21

22. HYDRAULIC SYSTEM This section describes the following operations. (6) Arm in, heavy load operating pilot circuit (recirculation cut) (7) Arm in, heavy load operating sequence confluxed main circuit

open, the return oil goes through the arm lock valve CRar and flows in the arm 2 spool. 4. The return oil returns directly into the tank circuit because the arm 2 spool is switched to recirculation cut position. Position of Arm 2 Spool

22.9.3 ARM IN, HEAVY LOAD OPERATING PILOT CIRCUIT (1) Operation: 1. The left pilot valve actuation due to arm-in operation is equivalent to that at light load operation. 2. In arm-in operation, when the heavy loading is applied to the arm and the P2 pump pressure increases to the set pressure, the voltage output by the P2 pump pressure sensor (SE-23) is converted to a signal (signal processing) by the mechatro controller, consequently the current of the arm 2 solenoid proportional valve is controlled according to the load pressure and the arm variable recirculation is cut. When the recirculation is cut, internal confluence is held similarly to that in light load operation.

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

22-22

Neutral position

Recirculation cut position

From arm out P/V From arm 2 inverse proportional valve

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

MB

P A2 a2

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 ARM CIRCUIT: Arm In (Heavy Load) Operation, Arm Confluence & Recirculation Cut Function

22-23

22. HYDRAULIC SYSTEM This section describes the following operations. (5) Arm out pilot circuit (6) Arm out 2 pumps conflux main circuit (7) Natural fall protection with arm lock valve

22.9.5 ARM OUT PILOT CIRCUIT (1) Operation: 1. When the arm out operation is performed, the secondary pilot proportional pressure flows out of port 8 of the left pilot valve (9), and acts upon the low pressure sensor (SE-8). At the same time, the oil is branched off in two flows and acts upon the PBa1 and Pba2 ports of C/V (2). 2. The operating proportional secondary pressure flows in the Pba1 port of C/V (2) and switches the arm 1 spool. 3. Then, the operating secondary pressure flows in the PBa2 port of C/V (2) and switches the arm 2 spool valve.

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

22-24

22.9.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE (1) Purpose: To prevent the arm from falling naturally by the weight of the arm and bucket. (2) Principle: Complete seat of the return circuit against the arm spool of the arm cylinder (R) side circuit. (3) Operation: 1. When the secondary pressure for arm operation disappears and the arm cylinder stops, the pressure on the rod (R) side passes through the selector of the lock valve from the Ba port of C/V, acts the back pressure on the lock valve CRar and seats the lock valve. 2. Since the oil flow into the arm spool from the lock valve is shut off completely; natural fall of the arm due to oil leaks through the arm spool is prevented.

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

D

PA

PB

TRAVEL LEFT

8

a4 5.0MPa

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

B

A a5

B1

B3 Dr3

A3

2

11 P2 P1

MAIN CONTROL VALVE 34.3MPa 37.8MPa CMR1

PL PTb

14

12

PCb

NOTES 1

CT1

CMR2

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

SENSOR BLOCK

T3

LCs

LCb

PBb

SWING

SE1 SE2 SE3 SE4 P P P P 2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

PAs Pss

SE5 P

PBs

As Bs PAa1

37.8MPa (ROD)Bb

SE7 SE8 P P

1

PB1 PCa

CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

BOOST CHECK

CT2 PAr

HYD.TANK

T1

9

CRb LCa

(HEAD)Ab SOL/V BLOCK P1 SV-4

SV-1

SV-3

LEVER A1 LOCK

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

39.7MPa

PSV-B

PSV-C

PSV-D

PSV-A

T2

ATT A4 BOOSTING

BUCKET

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

PBa1

LH

37.8MPa

PAc SV-2

RH ARM 1

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 ARM CIRCUIT: Arm Out Operation, Confluence Function

22-25

22. HYDRAULIC SYSTEM

22.10 COMBINED CIRCUIT This section describes only the difference in combined operation. (1) Boom up / travel, pilot circuit (2) Boom up / travel, main circit

22.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT (1) Operation:

1. The mechatro controller outputs command current to the travel straight solenoid proportional valve after signal processing, and the solenoid valve outputs secondary pressure and acts on the PTb port of C/V (2). 2. Then the pressure of the PTb port switches the travel straight valve.

22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT (1) Purpose: To insure straight travel movement during travel operation even if the attachment is operated. (2) Principle: The travel action and the attachment action are actuated by separate pumps. (3) Operation: 1. The P1 pump delivery oil flows through the P1 port of C/V(2) and branches off in the P1 parallel circuit and travel straight spool. The P2 pump delivery oil flows through the P2 port of C/V(2) and branches off in the P2 tandem circuit and travel straight spool. 2. The delivery oil flows into the P1 parallel circuit of the P1 pump opens the check valve CT1 and LCb and flows in the boom spool, which exerts on the boom up operation. The delivery oil flows into the travel straight spool of the P1 pump opens the check valve CT2 because the travel straight spool is shifted, and flows in the boom conflux spool and exerts on the boom up operation with the internal oil conflux. (In travel straight operation, the P1 pump delivery oil exerts on the swing operation of the attachment.)

22-26

3. The delivery oil flow into the P2 tandem circuit of the P2 pump and flows in the left travel spool to travel leftward. The delivery oil flow into the travel straight spool of the P2 pump flows in the right travel spool because the travel straight spool is shifted and exerts on the right travel operation. (In travel straight operation, P2 pump delivery oil exerts on travel operation.) 4. However, a portion of the flow is led to the travel straight spool notch restriction. The speed of attachments like travel, boom, etc. is adjusted by the circuit of restriction.

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 COMBINED CIRCUIT: Boom Up & Travel Forward 1st Speed Operation, Travel Straight Function

22-27

22. HYDRAULIC SYSTEM In this section, the independent operation is omitted and describes the difference in combined operation.

Position of Arm 2 Spool

(3) Swing / Arm in light load, pilot circuit (4) Swing / Arm in, swing priority main circuit

22.10.3 SWING / ARM IN LIGHT LOAD, PILOT CIRCUIT (1) Operation: 1. When operating swing (left) and arm-in motions simultaneously, the mechatro controller outputs command current to the travel straight solenoid proportional valve (PSV-C) and the arm 2 solenoid inverse proportional valve according to signal processing, and this proportional valve outputs secondary pressure, which acts on the PTb port and PAa2 port of C/V(2). 2. The PTb port pressure switches the travel straight spool 2 steps, and the PAa2 port pressure switches the arm 2 spool to the forced recirculation position.

22.10.4 SWING / ARM IN, SWING PRIORITY MAIN CIRCUIT (1) Purpose: Stable swing speed. (2) Principle: Raise the oil pressure flowing to the arm cylinder, and give a priority of the delivery of the P2 pump to swing operation. (3) Operation: 1. The swing main circuit operates with P2 pump flow. But on the P2 pump circuit side, the flow goes to the swing circuit and arm circuit simultaneously because the swing circuit and arm circuit are parallel. Then since the return oil from the arm cylinder rod (R) side is restricted in the arm 2 spool because the arm 2 spool is switched to forced recirculation position, the pressure of the return oil is raised, causing the rise of the circuit pressure on the arm cylinder head (H) side. 2. At the same time meter-in of arm 2 spool closes and arm-in conflux is therefore cancelled, and delivery oil from P2 pump and P1 pump are combined in the parallel circuit on the P2 pump side because the travel straight spool was switched. The conflux oil of P1 and P2 delivery oil in high pressure flows in the swing side taking priority over all others. This operation is called "Swing Priority Circuit".

22-28

Position of forced recirculation Neutral position From arm out P/V

Meter-in passage (Close) From arm 2 inverse proportional valve

Arm 2 spool

Normal recirculation opsition

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 COMBINED CIRCUIT: Swing / Arm In Operation, Swing Priority Function

22-29

22. HYDRAULIC SYSTEM

22.11 PRESSURE DRAINING This section describes the following operations. (1) Pressure drain (releasing) pilot circuit (2) Pressure drain (releasing) main circuit

22.11.1 PRESSURE RELIEVING PILOT CIRCUIT (1) Purpose: To release the pressure in the main circuit for piping repair works. (2) Principle: After the mode is switched to "Pressure Relief Mode" with the switch on the gauge cluster, the mechatro controller outputs the following commands. 1. Minimum tilting command value to pump proportional valve (PSV-P1 and PSV-P2). 2. Output "Pressure relief control speed command value" at ECU. (Electric system) 3. Stand-by command value to P1 and P2 unloading proportional valves How to switch to "Pressure Release Mode" 1. Select the service diagnosis mode. (Hold down the "BUZZER STOP SWITCH" on the gauge cluster, turn the starter key switch on.) 2. Select the service adjustment mode 1. (Under the condition that "Screen No.1" of "Service Diagnosis Mode 1" is indicated, hold down the "BUZZER STOP SWITCH", press the "MENU SWITCH" 3 times. When "SERVICE MENU" is displayed, using "UP" switch or "DOWN" switch, select "SERVICE ADJUST 1". Press "NEXT" switch, to select "SERVICE ADJUST 1-2".) 3. Using "UP" switch or "DOWN" switch, and select "PRESS DRAIN". Then press "NEXT" switch, and cursor points to "OFF". 4. Press "UP" switch to display "ON", and press "MENU" switch. 5. Screen of gauge cluster changes to ordinary display, and "DRAINING HYD. PRESS." is appears. (3) Operation: 1. Pump proportional valve reduces the pump flow rate to the minimum. 2. The unloading proportional valves (PSV-D and PSV-B) output secondary pressure and the secondary pressure flows in PCb and PCa ports of C/V(2) and switches the P1 and P2 unloading valves to the OPEN position.

22-30

22.11.2 PRESSURE RELEASE MAIN CIRCUIT

When the hydraulic pressure releasing is performed, make sure to place the bucket on the ground. (1) Operation: When the operating lever is shifted to neutral during engine running, "DRAINING HYD. PRESS." is displayed on the gauge cluster while the mode switch is changed to pressure relieving mode. In this time the intermittent buzzer sounds continuously. When the right and left operating levers are operated 4 or 5 times to their full stroke, pressure is relieved. After draining pressure is completed, turn off the starter key and the buzzer sound stops. If the pump pressure is determined to be more than 1 MPa (145 psi) by the output value of the high pressure sensor or the high pressure sensors (SE-22,23) are broken, "FAIL DRAIN HYD. PRESS." is displayed and the buzzer sounds continuously. In that case, also the buzzer is not stopped unless the engine key is turned to OFF. Repeat the pressure releasing procedure once again. (2) Hydraulics: If the travel straight valve is turned to the pressure release position, the oil delivered by each pump is unloaded to the tank passage. If the spools are switched by pilot operation, the remaining pressure from the actuators may be relieved to the tank circuit, i.e. the main circuit pressure may be released.

22. HYDRAULIC SYSTEM

SE22 SE23 MAIN PUMP

PSV1

a1

A1

P

P

PH1

PH2

P A2 a2

MB

MB

PSV-P1

4

PSV-P2

Pcr 35.8~37.8 MPa

VB

VB

VA

VA

Pcr 35.8~37.8 MPa

29.0MPa D

MA

MA

5.0MPa B1

B3 Dr3

A3

2 P2 P1

CMR1

PL PTb

14

12

PCb

HYD.TANK

NOTES 1

T1

T2

PBL TRAVEL PRIORITY

P1UNLOAD

TRAVEL LEFT

BOOM CONFLUX

P2UNLOAD CP1

BR AR

LCs

LCb

PBb

SWING

CRb

SV-3

SWING A2 P/B TRAVEL 1/2 SPEED A3 CHANGEOVER

PAb XAb PCc PBc

SV-2

BUCKET

PSV-B

PSV-C

PSV-D

PSV-A

T2

A5 P2UNLOAD

TRAVEL A6 PRIORITY

A7 P1UNLOAD

PAs

5

6

7

8

1

2

3

4

5

6

7

8

Pss

SE5 P

PBs

9

PBa1

LH

BUCKET CYLINDER

Aa (HEAD)

LCc

37.8MPa

CRar

(ROD)Bc (HEAD)Ac

22

ARM 2

PLc2

7

BOOM & BUCKET

6

ARM CYLINDER

P

T

RH

Ba (ROD)

39.7MPa

PBa2

4

37.8MPa

PAc ATT A4 BOOSTING

3

RH ARM 1

39.7MPa

SE7 SE8 P P

2

PB1

LCa

(HEAD)Ab

LEVER A1 LOCK

T3

SE1 SE2 SE3 SE4 P P P P 1

As Bs PAa1

37.8MPa (ROD)Bb

SOL/V BLOCK

SENSOR BLOCK

PCa CCb

PBr Dr

BOOM UP BOOM DOWN

PAL AL BL

CP2

TRAVEL RIGHT

BOOM

SWING RIGHT SWING LEFT ARM OUT ARM IN BUCKET DUMP BUCKET DIGGING

CT1

CMR2

CT2 PAr

SV-1

B

A a5

MAIN CONTROL VALVE 34.3MPa 37.8MPa

SV-4

PA

PB

8

11

P1

D

TRAVEL LEFT

a4

M

PG

REG

TRAVEL RIGHT

203kw /2100min-1

SWING

M

1

Dr

3 DB

REG

a3

P

PSV2

ARM & SWING

P

P

T

LH

T

39.7MPa LCAT2 LCAP2

LCo

16

5

OPTION PAo

BOOM CYLINDER

Ao Bo

PAa2 MU

RIGHT TRAVEL FORWARD RIGHT TRAVEL REVERSE

3

6

4 P SE9

1

5

2 P SE10

LEFT TRAVEL FORWARD LEFT TRAVEL REVERSE

PBo

(P3)

10

(P4)

16

A8 ARM2

P2

LC01Z00092P1 01

13 PRESSURE DRAIN (RELEASE) CIRCUIT: At Pressure Release Mode

22-31

22. HYDRAULIC SYSTEM

22-32

23. ELECTRICAL SYSTEM

23. ELECTRICAL SYSTEM TABLE OF CONTENTS

23.1 ELECTRIC CIRCUIT DIAGRAM ........................................................................ 23-3 23.2 ELECTRICAL EQUIPMENT LIST ...................................................................... 23-9 23.3 HARNESS .......................................................................................................... 23-11 23.3.1 HARNESS LIST ......................................................................................... 23-11 23.3.2 INSTRUMENT PANEL ASSY .................................................................... 23-12 23.3.3 CONTROLLER INSTALL ........................................................................... 23-13 23.3.4 OPERATORS CONTROLS ....................................................................... 23-14 23.3.5 UPPER ELECTRIC ASSY ......................................................................... 23-16 23.3.6 UPPER HARNESS ASSY ......................................................................... 23-17 23.3.7 UPPER HARNESS ASSY (BHL MULTI) ................................................... 23-37 23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) ............................................. 23-38 23.3.9 CAB HARNESS ASSY .............................................................................. 23-47 23.3.10 BOOM HARNESS ASSY ........................................................................... 23-54 23.3.11 BOOM LIGHT INSTALL ............................................................................. 23-54 23.3.12 UPPER LIGHT INSTALL .......................................................................... 23-55 23.3.13 FLASHER LAMP INSTALL ........................................................................ 23-56 23.3.14 TRAVEL ALARM ASSY ............................................................................. 23-56

23

Book Code No. S5LC2326E01 23-1

23. ELECTRICAL SYSTEM

Issue First Edition

Date of Issue

Applicable Machines

Remarks S5LC2326E01 NA

September, 2010 SK350-9: YC

23-2

23. ELECTRICAL SYSTEM

23.1

ELECTRIC CIRCUIT DIAGRAM

23

(1/8)

LC03Z00046P1 03

23-3

23. ELECTRICAL SYSTEM

(2/8)

LC03Z00046P1 03

23-4

23. ELECTRICAL SYSTEM

23

(3/8)

LC03Z00046P1 03

23-5

23. ELECTRICAL SYSTEM

(4/8)

LC03Z00046P1 03

23-6

23. ELECTRICAL SYSTEM

23

(5/8)

LC03Z00046P1 03

23-7

23. ELECTRICAL SYSTEM

(6/8)

LC03Z00046P1 03

23-8

23. ELECTRICAL SYSTEM

FUSE & RELAY BOX ALTERNATOR HOUR METER HORN HIGH HORN LOW TUNER AM & FM SPEAKER LEFT SPEAKER RIGHT RECEIVER DRIER AIR-CON COMPRESSOR BATTERY TRAVEL ALARM FUSIBLE LINK ONE WAY CALL AMP ONE WAY CALL SPEAKER DC-DC CONVETER 12V SOCKET GPS ANTENNA PDC ANTENNA ACCEL REDUNDANT VOLUME REAR CAMERA DC-DC CONVETER (PROPORTIONAL) DC-DC CONVETER (FOR CAMERA) 24V SOCKET

(C) CONTROLLER

(D) DIODE (E) ELECTRIC FITTINGS

YN02D01001P1 ACCESSORY OF RELAY BOX

YN20D01001P1

YN24E00016F2 ENGINE ACCESSORY LQ58S00002P1 LC53S00001D1 LC53S00001D2 YN54S00044P1 YN54S00006P1 YN54S00041P1 YX91V00001F1 YN72S00010P1 YN53S00004F1 LE73E00001S001 2447R145 LC54S00004P1 YN77S00033P1 YN81S01002P1 YN54S00047P1 YN54S00048P1 YN52S00052P1 EZ55S00023F1 YN77S00033P1 YN77S00040P1 LQ81S01001P1

GROUP

M-1 M-3 M-3 M-4 M-8 M-9 M-11

STARTER MOTOR WIPER MOTOR WIPER MOTOR WASHER MOTOR GREASE MOTOR ROOF WINDOW WIPER MOTOR FUEL SUPPLY PUMP

ENGINE ACCESSORY LQ53C00003S001 YN46S00006P1 YT54C00003F1 LC71V00001P1 YN76S00005P1 YF22P00009P1

PSV-A PSV-B PSV-C PSV-D PSV-E PSV-I PSV-R PSV-P1 PSV-P2 PSV-6 PSV-7 PSV-8 PSV-9

ARM TWO-SPEED INVERSE PROPORTIONAL SOL. P2 UN-LOAD PROPORTIONAL SOL. TRAVEL PRIORITY PROPORTIONAL SOL. P1 UN-LOAD PROPORTIONAL SOL. OPT. RELIEF ADJUSTMENT PROPORTIONAL SOL. 1 OPT. RELIEF ADJUSTMENT PROPORTIONAL SOL. 2 CONTROLL PROPORTIONAL SOL. PUMP P1 PROPORTIONAL SOL. PUMP P2 PROPORTIONAL SOL. NIBBLER OPEN PROPORTIONAL SOL. (RIGHT SLIDE) NIBBLER OPEN PROPORTIONAL SOL. (LEFT SLIDE) EXTRA (A2) PROPORTIONAL SOL. (RIGHT SLIDE) EXTRA (A1) PROPORTIONAL SOL. (LEFT SLIDE)

YN35V00049F1 YN35V00048F1

R-1 R-2 R-3 R-4 R-5 R-6 R-8 R-9 R-10 R-11 R-12 R-13 R-15 R-16 R-17 R-19 R-23 R-24 R-25

BATTERY RELAY STARTER RELAY GLOW RELAY SAFETY RELAY HORN RELAY WORK LIGHT RELAY TRAVEL ALARM RELAY 1 CAB WORKING LIGHT RELAY BACKET CONTROL RELAY TRAVEL ALARM RELAY 2 REVOLUTION RIGHT RELAY REVOLUTION LEFT RELAY NIBBLER OPEN RELAY NIBBLER CLOSE RELAY EXTRA DIS-PRESS. RELAY FLASHER RELAY AUTO IDLE STOP RELAY 1 AUTO IDLE STOP RELAY 2 ENGINE EMERGENCY STOP RELAY

YN24S00008F1 ENGINE ACCESSORY

NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only.

YN22V00035F1 YN35V00052F1

(R) RELAY

E-1 E-2 E-3 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-15 E-16 E-17 E-22 E-23 E-24 E-25 E-27 E-46 E-49 E-63 E-65

C-5

PARTS No. YW80S00001F1 YT80S00002F2 FRAME WORK LIGHT RIGHT SWING FLASHER LEFT & WORKING UNIT YM820S00001F1 SWING FLASHER RIGHT & WORKING UNIT YM80S00001F2 YT80S00001P1 ROOM LIGHT YT80S00002F2 CAB WORKING LIGHT FRONT 1 CAB WORKING LIGHT FRONT 2 2456R457 HIGH REACH ROTARY LIGHT CAB WORKING LIGHT FRONT 3 CAB WORKING LIGHT FRONT 3 HIGH REACH THREE COLORS ROTARY LIGHT EZ53E00013F1 2456R457 ROTARY LIGHT

(SE) SENSOR

DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE

C-2 C-4

NAME

BOOM WORK LIGHT LEFT

YN10V00023F1

NAME LEVER LOCK RELAY ALTERNATOR RELAY WIPER MOTOR RELAY WIPER MOTOR REVERSING RELAY PREVENT SPARK RELAY WINDOW WASHER MOTOR RELAY ROTARY LIGHT RELAY (RED) (OPT RELAY 2) ROTARY LIGHT RELAY (YELLOW) (OPT RELAY 3) ROTARY LIGHT RELAY (GREEN) (OPT RELAY 4) WIPER MOTOR RELAY NEUTRAL STOP RELAY

PARTS No. YN24S00010P1

SE-1 SE-2 SE-3 SE-4 SE-5 SE-7 SE-8 SE-9 SE-10 SE-11 SE-13 SE-15 SE-16 SE-17 SE-19 SE-20 SE-22 SE-23

PRESSURE SENSOR : BUCKET DIGGING PRESSURE SENSOR : BUCKET DUMP PRESSURE SENSOR : BOOM RAISING PRESSURE SENSOR : BOOM LOWRING PRESSURE SENSOR : SWING PRESSURE SENSOR : ARM IN PRESSURE SENSOR : ARM OUT PRESSURE SENSOR : TRAVEL RIGHT PRESSURE SENSOR : TRAVEL LEFT PRESSURE SENSOR : P2 OPT. ENGINE REVOLUTION SENSOR FUEL SENSOR ACCEL POTENTIO. BOOM POTENTIO. ARM POTENTIO. PRESSURE SENSOR : P1 OPT. PRESSURE SENSOR : PUMP P1 PRESSURE SENSOR : PUMP P2 PRESSURE SENSOR : BOOM HEAD (FOR OVER LOAD ALARM) PRESSURE SENSOR : BOOM ROD EXTRA PRESSURE OPT. SELECTOR DETECT SENSOR SUCTION TEMPERATURE SENSOR/ AIR FLOW METER

LC52S00019P1

SWING PARKING BRAKE SOL. POWER BOOST SOL. TWO-SPEED SELECT SOL. OPERATING LEVER LOCK SOL. BUCKET DUMP CUT SOL. REVOLUTION RIGHT SOL. REVOLUTION LEFT SOL. NIBBLER OPEN SOL. NIBBLER CLOSE SOL. EXTRA DIS-PRESSURE SOL. OPT. SELECTOR SOL. QUICK COUPLER OPERATION SOL.

YN52S00048P1 YN35V00051F1 YN35V00050F1

SE-25 SE-28 SE-29 SE-62

YN24S00010P1 YN24S00010P1

YY24S00001P2 YN24S00010P1

CODE R-26 R-28 R-29 R-30 R-31 R-32 R-36 R-37 R-38 R-44 R-94

SE-24

(SV) SOLENOID

D-4 D-5 D-6 D-9 D-10 D-12 D-13 D-14 D-16 D-17 D-18 D-19 D-20 D-21 D-22 D-23 D-25 D-66 D-67

C-1

PARTS No. GROUP CODE YN22E00214F1 L-1 (HARD) L-2 YN59S00028F1 L-3 L-4 AIR CON ACCESSORY L-5 ENGINE ACCESSORY L-7 L-8 LC22E00081P1 L-10 YN22E00238F1 L-15 ENGINE ACCESSORY L-16 L-19 YN02D01001P1 L-20 ACCESSORY OF RELAY BOX

(L) LIGHT

C-6 C-7 C-8

NAME MECHATRO CONTROLLER (TCO-60-2) GAUGE CLUSTER AIR CONDITIONER AMP RADIATOR COOLANT LEVEL CONTROLLER AUTO GREASE CONTROLLER IT CONTROLLER ENGINE CONTROLLER

(M) MOTOR

CODE

(P) PROPORTIONAL SOLENOID VALVE

GROUP

ELECTRICAL EQUIPMENT LIST

(R) RELAY

23.2

SV-1 SV-2 SV-3 SV-4 SV-6 SV-7 SV-9 SV-10 SV-11 SV-13 SV-14

YN24S00012P2

YN24S00010P1 YR24S00002P1 YN24S00010P1

ENGINE ACCESSORY YN52S00045F1 YN52S00032P1 YR52S00016P1 LC52S00019P1 YN52S00048P1

LC52S00019P1 -

23

LE35V00001F2 LC35V00004F3 YN35V000010F2 -

(7/8)

LC03Z00046P1 03

23-9

23. ELECTRICAL SYSTEM

(SW) SWITCH

GROUP

CODE SW-1 SW-4 SW-5 SW-7 SW-8 SW-10 SW-11 SW-12 SW-13 SW-17 SW-19 SW-20 SW-21 SW-26 SW-27 SW-29 SW-30 SW-33 SW-34 SW-35 SW-37 SW-40 SW-41 SW-55 SW-56 SW-64 SW-96 SW-98 SW-99 SW-100 SW-112 SW-131

NAME KEW SWITCH SWING PARKING RELEASE SWITCH HORN SWITCH RIGHT ENGINE OIL PRESS SWITCH AIR FILTER RESTRICTION SWITCH HORN SWITCH LEFT LEVER LOCK SWITCH OVER LOAD ALARM SELECT SWITCH TRAVEL ALARM SWITCH ROOF WIPER SWITCH WIPER INTERLOCK SWITCH POWER BOOST SWITCH RIGHT POWER BOOST SWITCH LEFT CAB WORK LIGHT SWITCH RADIATOR COOLANT LEVEL SWITCH NIBBLER OPEN SWITCH NIBBLER CLOSE SWITCH REVOLUTION RIGHT SWITCH REVOLUTION LEFT SWITCH HEAVY LIFT SWITCH INDEPENDENT TRAVEL SWITCH ROTARY LIGHT SWITCH HIGH REACH CRANE SWITCH BOOM, DECK WORKING SWITCH FUEL SUPPLY AUTO STOP SWITCH QUICK COUPPLER OPERATION SWITCH DRAIN PRESSURE SWITCH PRESS SWITCH (PROPORTIONAL) NIBBLER OPEN-CLOSE SWITCH EXTRA (A1, A2) SWITCH FUEL FILTER RESTRICTION SWITCH MANUAL REPRODUCTION SWITCH

PARTS No. YN50S00029F1 YN50S00047P1 YN50E00017P1 ENGINE ACCESSORY YR11P00008S005 YN50E00017P1 YN50S00055F1 YN50S00040D6 YN50S00040DF YN50S00040D9 YT50S00004P1 YN50E00017P1

GROUP

CODE

NAME

GROUP

CODE

NAME

PARTS No.

YN50S00040D4 ENGINE ACCESSORY LF03M01005F2

YN50S00040D5 YN50S00040DB YN50S00040D2 PY50S00003P2 YN50S00040D1 YF52S00004P1 YN50S00043D5 LV50S00003D5 GB50S00049F2 YY03M01239F1 YY03M01240F2 LV50S00003D9

NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only.

23-10

PARTS No.

(8/8)

LC03Z00046P1 03

23. ELECTRICAL SYSTEM

23.3

HARNESS

23.3.1 HARNESS LIST DIVISION

DRAWING No.

POSITION ITEM

NAME

HARNESS ASSEMBLY No.

3.2

INSTRUMENT PANEL ASSY

YN17M00121F1

3.3

CONTROLLER INSTALL

LC22E00210F1

3.4

OPERATORS CONTROLS

YN03M00318F1

3.5

UPPER ELEC ASSY

LQ03E00014F1

3.6

UPPER HARNESS ASSY

LC13E00099F1

CODE No.

UPPER HARNESS ASSY

REMARKS

DRAWING No.

CABLE

YN17M01072P1

1

HARNESS

LC13E01406P1

UPPER

2

CABLE

LQ13E01248P1

BATTERY TO BATTERY

3

CABLE

LC13E01407P1

BATTERY TO RELAY

4

CABLE

LC13E01408P1

BATTERY TO GROUND

5

CABLE

LC13E01410P1

STARTER

6

CABLE

LC13E01413P1

ENGINE GROUND

7

CABLE

LE13E01006P1

FLOOR GROUND

8

CABLE

LC13E01180P2

GLOW RELAY TO STARTER RELAY

9

HARNESS

LQ13E01209P1

TOOL BOX MODULE

10

HARNESS

LC13E01193P1

AIR FILTER MODULE

11

HARNESS

LC13E01415P1

AIR FOLW

LC13E00100F1

1

HARNESS

LC13E01412P1

LC13E00102F1

1

HARNESS

LC13E01414P1

FLOOR

9

CABLE

LE13E01005P1

CAB SUB

13

HARNESS

LC13E01428P1

FLOOR GROUND

1

HARNESS

LS14E01013P1

CAB

6

HARNESS

YN11E01205P1

HOUR METER

7

HARNESS

YN13E01580P1

POWER SUPPLY SOCKET

1

HARNESS

LC15E01053P1

BOOM LIGHT

UPPER FRAME 3.7

NAME

7-7

(BHL MULTI) 3.8

UPPER HARNESS ASSY

CAB

(FLOOR PLATE) 3.9

LIGHT

BOOM 3.10

CAB HARNESS ASSY

LS14E00007F1

BOOM HARNESS ASSY

LC15E00051F1

3.11

BOOM LIGHT INSTALL

LC80E00004F1

BOOM LIGHT

3.12

UPPER LIGHT INSTALL

LQ80E00014F1

DECK LIGHT

3.13

FLASHER LAMP INSTALL

LC80E00025F1

FLASHER LAMP

TRAVEL ALARM ASSY

LC53E00008F1

ALARM 3.14

23

The parts number may be changed due to the improvement of machine, so use the number for reference only.

23-11

23. ELECTRICAL SYSTEM 23.3.2 INSTRUMENT PANEL ASSY INSTRUMENT PANEL ASSY ITEM 1

YN17M00121F1

PART NAME

PART No.

(01)

(01)

INSTRUMENT PANEL ASSY YN17M00119F1

1-17

GAUGE CLUSTER

YN59S00028F1

1

1-19

KEY SWITCH

YN50S00026F1

1

1-22

POTENTIO METER

LQ52S00025P1

1

1-25

HOUR METER

LQ58S00002P1

1

1-41

SOCKET

YN81S01002P1

1

SWITCH INSTALL

YN50E00061F1

SWITCH

YN50S00040D1

2 2-2

1-17 TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

ADJUST FOR THE CENTER OF THE ROTATOIN OF THO RING NUT SHUTTER TO CENTER THE RANGE OF THIS AREA WITH 0~1 PLAIN WASHERS OF ACCESSORY (t0.8) AND 0~2 WASHERS OF WASHER (t0.3).

REMARKS

Q'TY

CENTER OF ROTATION

1-22

K250 WITH LOGO

SHUTTER

PLAIN WASHER (t0.8)

RING NUT

TIGHTENING TORQUE 4.9 N.m (3.61 lbf.ft)

WAVE WASHER

WASHER

12V (01)

1

1-19

WORKING LIGHT 1-19 SECTION BB

VIEW I

TIGHTENING TORQUE 9.7 N.m (7.15 lbf.ft) INSTALL TO CAB.

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

SEMS-BOLT

TIGHTENING TORQUE 1.0 N.m (0.74 lbf.ft)

HANG IT ON THE CAB.

TAPPING SCREW SEMS-BOLT

INSTALL TO CAB. TIGHTENING TORQUE 23 N.m (16.96 lbf.ft)

TAPPING SCREW

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) 2 PLACES

1-41 FORWARD

SEMS-BOLT

SEMS-BOLT 4 PLACES

SEMS-BOLT

SEMS-BOLT

SEMS-BOLT

BEFORE SIGS ITEM 1-1, 1-6 AND ASSEMBLY

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) INSTALL TO SUPPORT ELEC.

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) INSTALL TO CAB.

INSTALL TO CAB. TIGHTENING TORQUE 9.7 N.m (7.15 lbf.ft)

SECTION AA

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) INSTALL TO CAB.

TIGHTENING TORQUE 1.5 N.m (1.1 lbf.ft)

SEMS-BOLT

HANG IT ON THE CAB.

2-1

1-17

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) INSTALL TO CAB.

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) INSTALL TO CAB.

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) INSTALL TO CAB.

SEMS-BOLT

SEMS-BOLT

SEMS-BOLT

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) INSTALL TO CAB.

FORWARD

SEMS-BOLT

SEMS-BOLT

INSTALL TO CAB. TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

FORWARD

SEMS-BOLT

INSTALL TO CAB. TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

NUT

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

INSTALL TO FLOOR PLATE. TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

1-25 FORWARD

23-12

SEMS-BOLT

INSTALL TO CAB. TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

INSTALL TO FOOT DUCT. TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

INSTALL TO CAB. TIGHTENING TORQUE . 9.7 N m (7.15 lbf.ft)

SEMS-BOLT

INSTALL TO FLOOR PLATE. TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

TAPPING SCREW

TIGHTENING TORQUE 1.0 N.m (0.74 lbf.ft)

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) 2 PLACES

VIEW II

23. ELECTRICAL SYSTEM 23.3.3 CONTROLLER INSTALL ASSEMBLE WITH THE NUT OF THE ACCESSORY. TIGHTENING TORQUE 1.47 N.m (1.081 lbf.ft)

CONTROLLER INSTALL

LC22E00210F1

(01)

ITEM

PART NAME

PART No.

Q'TY

1

CONTROLLER INSTALL

YN22E00423F1

1-4

SWITCH

YN50S00047P1

1

SLEWING PARKING RELEASE

1-6

POTENTIO METER

YN52S00052P1

1

SLEWING PARKING RELEASE TIGHTEN THE SET SCREW

2

CONTROLLER

LC22E00206F1

2-1

CONTROLLER

YN22E00425F1

3

RELAY BOX ASSY

YN24E00031F1

3-1

RELAY BOX ASSY

YN24E00016F3

CONTPOLLER INSTAL

YN22E00424F1

CONTROLLER

ENGINE ACSSESSORY

RELAY ASSY

YN24E00030F1

FLASHER RELAY

YY24S00001P2

6

CONVERTER

YN77S00053F1

6-1

CONVERTER

YN77S00017P1

4 4-1 5 5-1

REMARKS

MECHATRO (01)

SUPPORT

DETAIL aa

1 (01)

4-1

CLIP

TIGHTENING TORQUE 5 N.m (3.67 lbf.ft)

STICK TO SUPPORT

SEMS-BOLT

COOLANT LEVEL (01)

1 (01) 1

CLIP

STICK TO MECHATRONICS CONTROLLER.

INSTALLATION CLIP AND TRIM UPPER HEXAGON NUT

VIEW III TIGHTENING TORQUE 23 N.m (17 lbf.ft) INSTALL TO CAB.

SEMS-BOLT

INSTALL THE CORNER IN THIS DIRECTION.

TOOTHED LOCK WASHER

TIGHTENING TORQUE 5 N.m (3.67 lbf.ft) INSTALL TO CAB.

HORN WASHER

SEMS-BOLT 4 PLACES

VIEW II

TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)

SEMS-BOLT

5-1

ENGAGE AND FIX.

CLIP

LOWER HEXAGON NUT

1-4 TIGHTENING TORQUE 9.7 N.m (7.15 lbf.ft)

SEMS-BOLT

2 ENGAGE AND FIX.

CLIP

1-4

CAPSCREW

VIEW I

STICK TO SUPPORT

CLIP

TIGHTENING TORQUE 23 N.m (17 lbf.ft) TIGHTEN THE BOLT USED BY SUB-ASSY (MARK ) AGAIN.

CAPSCREW

TRIM

TIGHTENING TORQUE 1.7 N.m (1.25 lbf.ft) ASSEMBLE WITH THE NUT OF THE ACCESSORY.

AFTER INSERTING A DIAL IN THE DIRECTION FROM WHICH A SET SCREW IS ON THE PLACE SIDE OF A SHAFT.

(01)

1

STICK TO SUPPORT

1-6

(02)

1

TRIM

SECTION AA 6-1

CLIP

ENGAGE AND FIX.

CLIP

SEMS-BOLT

23

3

SEMS-BOLT

TIGHTENING TORQUE 5 N.m (3.67 lbf.ft) 3 PLACES

SEMS-BOLT

TIGHTENING TORQUE 46.5 N.m (34.3 lbf.ft)

TIGHTENING TORQUE 46.5 N.m (34.3 lbf.ft) FORWARD

SEMS-BOLT

CASE OF INSTAL TO SUB-ASSY (FLOOR)

SEMS-BOLT

FORWARD

CASE OF INSTAL TO CAB

CONNECT WITH CONNECTOR FOR SWING FLASHER RELAY OF CAB HARNESS.

AFTER INSTALL TO CAB TIGHTEN THE BOLT USED BY SUB-ASSY (MARK ) AGAIN. TIGHTENING TORQUE 23 N.m (17 lbf.ft)

SEMS-BOLT

TIGHTENING TORQUE 2.9 N.m (2.14 lbf.ft) 2PLACES

FORWARD

23-13

23. ELECTRICAL SYSTEM 23.3.4 OPERATORS CONTROLS (1/2) OPERATORS CONTROLS ITEM

PART NAME

YN03M00318F1 PART No.

(01)

GRIP ASSY

YN03M02138F1

3-1 GRIP ASSY

YN03M02139F2

1

YN50E00017P1

1

YN03M02139F1

1

YN50E00017P1

1

3

3-1-3 SWITCH ASSY 3-2 GRIP ASSY 3-2-3 SWITCH ASSY 4

SWITCH INSTAL

4-2 SWITCH 7

RADIO INSTAL

3-2

(01)

YN50E00059F1 LV50E00003D5

3-1

REMARKS

Q'TY

R/H POWER BOOST L/H HORN (01)

1

YN54E00033F1

3-1-3

(02)

7-2 RADIO

YN54S00045P2

1

7-7 CABLE

YN17M01072P1

1

GRIP CASE CAPSCREW

TIGHTENING TORQUE 2.7 N.m (2.0 lbf.ft)

3-2-3 GRIP CASE CAPSCREW

TIGHTENING TORQUE 2.7 N.m (2.0 lbf.ft)

DRAIN PRESSURE

4-2

LEVER

LEVER

CAP

TIGHTENING TORQUE 41.2 N.m (30.4 lbf.ft)

NUT

2 PLACES

DETAIL OF GRIP ASSY

HANG TO PROJECTION PART OF CONSOL.

SECTION AA

ADJUST THE CLEARANCE SO AS TO PROVIDE 4.5 0.5mm WHEN THE LIMIT SWITCH IS POSITIONED AT THE STROKE END.

PROCEDURE FOR ADJUSTING THE LIMIT SWITCH

23-14

23. ELECTRICAL SYSTEM 23.3.4 OPERATORS CONTROLS (2/2)

23.3.4.7-7 CABLE : YN17M01072P1

23

.5

12

PLUS SIDE CLICK TYPE

in

)

BURIED CONDENSER 150PF

(0.125 in)

(0

(0.197 in)

(0

.3

78

( in) INN ER

DI

A.

)

23.3.4.7 RADIO INSTALL : YN54E00033F1 (02)

23-15

23. ELECTRICAL SYSTEM 23.3.5 UPPER ELECTRIC ASSY UPPER ELECTRIC ASSY ITEM

LQ03E00014F1

(01)

PART No.

Q'TY

PART NAME

THE RELAY (GLOW & STARTER) TO THE OF BRACKET TIGHTENING TORQUE 23.5 N.m (17.3 lbf.ft)

REMARKS

1

BATTERY RELAY

YN24S00008F1

1

2

HORN

LC53S00001D1

1

HIGH

3

HORN

LC53S00001D2

1

LOW

SEMS-BOLT

GLOW RELAY

BRACKET COVER

SEMS-BOLT

TIGHTENING TORQUE 15.5 N.m (11.4 lbf.ft)

TIGHTENING TORQUE 10.7 N.m (7.9 lbf.ft) 2 PLACES

SEMS-BOLT

E-6 : HORN LOW

NUT COVER

STARTER RELAY

TIGHTENING TORQUE 17.5 N.m (12.9 lbf.ft)

B TERMINAL C TERMINAL

E-5 : HORN HIGH

1

SEMS-BOLT

BATTERY RELAY BOX

TIGHTENING TORQUE 11.7 N.m (8.6 lbf.ft MAX)

SECTION AA (DETAIL OF BATTERY RELAY BOX)

GROUND HORN (HIGH) HORN (LOW)

CONNECT AS SHOWN SO AS TO AVOID SHORT CIRCUIT ON POWER GND SOURCE LINE.

TIGHTENING TORQUE 10.7 N.m (7.9 lbf.ft) TIGHTEN AFTER CHECKING NO PAINT

SEMS-BOLT

TIGHTEN FROM THE FOWARD

GND TERMINAL

CONNECT AS SHOWN SO AS TO AVOID SHORT CIRCUIT ON POWER SOURCE LINE.

BRACKET

SEMS-BOLT

B

B

(BLACK)

(BLACK)

HORN STAY GO

GO

(GREEN ORANGE)

(GREEN ORANGE)

VIEW II

23-16

SET THE GND TERMINAL BETWEEN THE HONE STAY AND THE SEMS-BOLT.

2

VIEW I

3

VIEW III (DETAIL OF COVER FITTING)

23. ELECTRICAL SYSTEM 23.3.6 UPPER HARNESS ASSY (1/7) UPPER HARNESS ASSY LC13E00099F1 ITEM

PART NAME

(05)

PART No.

Q'TY

1

HARNESS

LC13E01406P1

1

UPPER

REMARKS

2

CABLE

LQ13E01248P1

1

BATTERY - BATTERY

3

CABLE

LC13E01407P1

1

BATTERY - RELAY

4

CABLE

LC13E01408P1

1

BATTERY - GROUND

5

CABLE

LC13E01410P1

1

STARTER

6

CABLE

LC13E01413P1

1

ENGINE GROUND

7

CABLE

LE13E01006P1

1

FLOOR GROUND

8

CABLE

LC13E01180P2

1

GROW RELAY - STARTER RELAY

9

CABLE

LQ13E01209P1

1

TOOL BOX MODULE

10

HARNESS

LC13E01193P1

1

AIR FILTER MODULE

11

HARNESS

LC13E01415P1

1

AIR FOLW

FLOOR HARNESS GROUND NEUTRAL STOP RELAY REVOLUTION LEFT SW. HORN SW. LEFT POWER BOOST SW. LEFT SPLICE SPLICE NIBBLER CLOSE SW. 12V / 24V SOCKET DRAIN PRESSURE SW. HORN SW. RIGHT POWER BOOST SW. RIGHT REVOLUTION RIGHT SW. QUICK COUPPLER OPERATION SW. HIGH REACH CRANE SW. (OPT.) TUNER AM & FM

23

23-17

23. ELECTRICAL SYSTEM 23.3.6 UPPER HARNESS ASSY (2/7)

23-18

23. ELECTRICAL SYSTEM 23.3.6 UPPER HARNESS ASSY (3/7)

23

23-19

23. ELECTRICAL SYSTEM 23.3.6 UPPER HARNESS ASSY (4/7)

23-20

23. ELECTRICAL SYSTEM 23.3.6 UPPER HARNESS ASSY (5/7)

23

23-21

23. ELECTRICAL SYSTEM 23.3.6 UPPER HARNESS ASSY (6/7)

23-22

23. ELECTRICAL SYSTEM 23.3.6 UPPER HARNESS ASSY (7/7)

23

23-23

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (1/10) : LC13E01406P1

23-24

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (2/10) : LC13E01406P1

23

23-25

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (3/10) : LC13E01406P1

23-26

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (4/10) : LC13E01406P1

23

23-27

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (5/10) : LC13E01406P1

23-28

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (6/10) : LC13E01406P1

23

E

23-29

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (7/10) : LC13E01406P1

E

23-30

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (8/10) : LC13E01406P1

23

23-31

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (9/10) : LC13E01406P1

23-32

23. ELECTRICAL SYSTEM 23.3.6-1 UPPER HARNESS (10/10) : LC13E01406P1

23

23-33

23. ELECTRICAL SYSTEM 23.3.6-2 BATTERY CABLE : LQ13E01248P1 23.3.6-3 BATTERY RELAY CABLE : LC13E01407P1 23.3.6-4 BATTERY GROUNDING CABLE : LC13E01408P1 23.3.6-5 STARTER CABLE : LC13E01410P1 23.3.6-6 ENGINE GROUNDING CABLE : LC13E01413P1

BATTERY CABLE : LQ13E01248P1

STARTER CABLE : LC13E01410P1 2580 (8'5.6") 70 (2.76")

360 (14.17")

820 (32.28")

220 (8.66")

70 (2.76")

16 (0.63")

8.

FUSE BOX

BATTERY RELAY CABLE : LC13E01407P1 FUSE

640 (25.19")

20 (0.79")

ENGINE GROUNDING CABLE : LC13E01413P1 370 (14.57")

BATTERY GROUNDING CABLE : LC13E01408P1 380 (14.96")

4

22.5 (0.89")

8.

16 (0.63")

23-34

")

33

. (0

")

33

0. 4(

22.5 (0.89")

170 (6.69")

320 (12.6")

23. ELECTRICAL SYSTEM 23.3.6-7 FLOOR GROUNDING CABLE : LE13E01006P1 23.3.6-8 RELAY CABLE : LC13E01180P2 23.3.6-9 TOOL BOX HARNESS : LQ13E01209P1

TOOL BOX HARNESS : LQ13E01209P1

FLOOR GROUNDING CABLE : LE13E01006P1 TOWARO THE END OF TERMINAL

100 (3.94")

LA308

5B

E

E 120 (4.72")

5B

E

1PAM YAZAKI 7122-3010

TOWARO THE CENTER OF THE HOLE OF LA TERMINAL

TAPING

TAPING

WHITE TAPING

WHITE TAPING

WHITE TAPING

BATTERY CABLE : LQ13E01248P1

180 (7.09")

TAPED DOUBLY

CAP TO BE INSTALLED CAP YAZAKI 7034-1280

TERMINAL

HEAT SHRINKAGE TUBE TO BE INSTALLED

TERMINAL

23

23-35

23. ELECTRICAL SYSTEM 23.3.6-10 AIR CLEANER HARNESS : LC13E01193P1 23.3.6-11 AIR FOLW HARNESS : LC13E01415P1

AIR FOLW HARNESS : LC13E01415P1

AIR CLEANER HARNESS : LC13E01193P1

SW-8 : AIR FILTER CLOGGING SWITCH WHITE TAPING

WHITE TAPING

23-36

23. ELECTRICAL SYSTEM 23.3.7 UPPER HARNESS ASSY (BHL MULTI) 23.3.7.1 HARNESS (BHL MULTI) : LC13E01412P1

UPPER HARNESS ASSY(BHL MULTI)

HARNESS (BHL MULTI) : LC13E01412P1

UPPER HARNESS ASSY LC13E00100F1 ITEM 1

PART NAME HARNESS

PART No.

Q'TY

LC13E01412P1

1

REMARKS

SET THE WHITE TAPING PART TO THE WHITE TAPING PART UPP HARNESS AND FIX WITH CLIP CLIP FORWARD WHITE TAPING

SE-4 : PRESS SENSOR : BOOM LOWERING

1 CLIP WASHER TANK

CLIP CLIP WHITE TAPING

VIEW I

SE-8 : PRESS SENSOR : ARM OUT

SE-3 : PRESS SENSOR : BOOM RAISING

FIX A HARNESS WITH WASHER TUBE BY CLIP

SE-7 : PRESS SENSOR : ARM IN

WASHER TUBE

WHITE TAPING

FORWARD

CLIP CLIP WHITE TAPING

WHITE TAPING

VIEW III

CONNECT TO FLOOR HARNESS BOUNDLED TO FLOOR HARNESS CLIP FIX A HARNESS WITH WASHER TUBE BY CLIP FLOOR HARNESS WHITE TAPING

23

VIEW II SE-3 : PRESS SENSOR : BOOM RAISING SE-4 : PRESS SENSOR : BOOM LOWERING SE-7 : PRESS SENSOR : ARM IN SE-8 : PRESS SENSOR : ARM OUT

VIEW IV

23-37

23. ELECTRICAL SYSTEM 23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (1/3) UPPER HARNESS ASSY LC13E00102F1 ITEM

PART NAME

PART No.

Q'TY

SW-40 : ROTARY LIGHT SW. (RED TAPING) SW-96 : DRAIN PRESSURE SW. (YELLOW TAPING)

FIX WITH TILTED LEVER.

(03)

REMARKS

CLIP

1

HARNESS

LC13E01414P1

1

FLOOR

9

CABLE

LE13E01005P1

1

FLOOR HARNESS GROUND

13

HARNESS

LC13E01428P1

1

CAB SUB HARNESS

SW-59 : QUICK COUPPLER OPERATION SW. (BLUE TAPING) (EU)

E-7 : TUNER

SW-1 : KEY SW.

SW-20 : POWER BOOST SW. RIGHT (YELLOW TAPING) SW-33 : REVOLUTION RIGHT SW. (OPT) (RED TAPING) SW-5 : HORN SW. RIGHT (OPT) (BLUE TAPING) SW-29 : NIBBLER OPEN SW. (OPT) (GREEN TAPING)

FIX WHITE TAPING POSITION.

TIGHTENING TORQUE 9.6 N.m (7.08 lbf.ft)

SEMS-BOLT CLIP

FIX A CLIP ON HOLE OF STAND BOAD.

FIX TO THE PILOT HOSE.

SW-96 : DRAIN PRESSURE SW. (YELLOW TAPING)

SW-131 : MANUAL REPRODUCTION SW. (BROWN TAPING)

FIX POSITION TO VINYL TUBE. E-1 : FUSE & RELAY BOX

SW-40 : ROTARY LIGHT SW. (RED TAPING)

FRONT

FRONT

CLIP PLATE

PILOT HOSE FLOOR HARNESS

CLIP

FIX WHITE TAPING POSITION.

VIEW I FIX WITH TILTED LEVER.

CLIP

SW-10 : HORN SW. LEFT (BLUE TAPING) SW-21 : POWER BOOST SW. LEFT (OPT) (YELLOW TAPING) SW-30 : NIBBLER CLOSE SW. (OPT) (GREEN TAPING) SW-34 : REVOLUTION LEFT SW. (OPT) (RED TAPING)

IT BUNDLES AND CLIP FIX WITH TILTED LEVER.

CLIP

SW-11 : LEVER LOCK SW. FIX TO THE PILOT HOSE.

CLIP

FRONT

FLOOR HARNESS

CLIP PILOT HOSE

CLIP

FIX WHITE TAPING POSITION.

VIEW II

23-38

FIX WHITE TAPING POSITION.

CLIP TO LOCK POSITION OF CONNECTOR FIX A CONNECTOR TO THE LEVER LOCK SW.

23. ELECTRICAL SYSTEM 23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (2/3) CLIP TIGHTEN AFTER CHECKING NO PAINT. TIGHTENING TORQUE 10.7 N.m (7.89 lbf.ft) GND

SE-20 : PRESS SENSOR : P1 OPT.

CLIP

CLIP

NUT LOCK WASHER WASHER

TO PRESS. SENSOR.

9 FLOOR HARNESS GROUND NEUTRAL STOP RELAY REVOLUTION LEFT SW. HORN SW. LEFT POWER BOOST SW. LEFT NIBBLER CLOSE SW. 12V / 24V SOCKET DRAIN PRESSURE SW. HORN SW. RIGHT POWER BOOST SW. RIGHT REVOLUTION RIGHT SW. QUICK COUPPLER OPERATION SW. HIGH REACH CRANE SW. (OPT.) TUNER AM & FM

FIX WHITE TAPING POSITION. CONNECT WITH EARTH CABLE OF UPP FRAME. SE-10 : PRESS SENSOR : TRAVEL LEFT. SE-9 : PRESS SENSOR : TRAVEL RIGHT. SE-11 : PRESS SENSOR : P2 OPT.

1

FIX WHITE TAPING POSITION.

TO THE FRONT SIDE OF FLOOR PLATE.

VIEW FROM THE BACK SIDE OF FLOOR PLATE.

CLIP USES TWO CLIPS CASE BY SENSOR TOWER.

SE-3 : PRESS SENSOR : BOOM RAISING.

CLIP

SE-4 : PRESS SENSOR : BOOM LOWERING.

23

SE-1 : PRESS SENSOR : BUCKET DIGGING. SE-2 : PRESS SENSOR : BUCKET DUMP.

SE-1 : PRESS SENSOR : BUCKET DIGGING.

SE-7 : PRESS SENSOR : ARM IN.

SE-2 : PRESS SENSOR : BUCKET DUMP.

SE-8 : PRESS SENSOR : ARM OUT.

CLIP

FASTEN HARNESS BY CLIP WITH BRACKET OF MULTI.

CLIP

CLIP

BUNDLE AFTER HARNESS DIVERGES.

SE-3 : PRESS SENSOR : BOOM RAISING. SE-7 : PRESS SENSOR : ARM IN.

SE-4 : PRESS SENSOR : BOOM LOWERING.

SE-8 : PRESS SENSOR : ARM OUT.

FIX WHITE TAPING POSITION.

CLIP

VIEW VI DETAIL OF aa : CASE OF MULTI

DETAIL OF aa : CASE OF SENSOR TOWER

23-39

23. ELECTRICAL SYSTEM 23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (3/3) FIX A CABSUB HARNESS TO THE FLOOR HARNESS. FIX WHITE TAPING POSITION.

FIX TO THE FUSE & RELAY BOX BRACKET.

CLIP

CLIP

FIX A CLIP OF FLOOR HARNESS ATTACHED TO PLATE.

FLOOR HARNESS CABSUB HARNESS

FIX TO THE BRACKET.

UPP HARNESS

CLIP

FIX WHITE TAPING POSITION.

FLOOR HARNESS

SECTION BB

CLIP

SECTION AA

CLIP

FIX A CABSUB HARNESS TO THE FLOOR HARNESS.

E-1 : FUSE & RELAY BOX

13

C-1 : MECHATORO CONTROLLER

FIX A CABSUB HARNESS TO THE FLOOR HARNESS.

CLIP

SW-4 : ROTATION PARKING CANCEL SW.

CONNECT THE YELLOW TAPING OF CONNECTOR WITH CAB HARNESS.

CLIP

FIX TO A HIGH NUT.

CONNECT THE BROWN TAPING OF CONNECTOR WITH CAB HARNESS. CONNECT THE GREEN TAPING OF CONNECTOR WITH UPP HARNESS.

CLIP

VIEW VI

VIEW V

FIX A CLIP AFTER OFFICIAL ASSEMBLING

CLIP

FIX WHITE TAPING POSITION.

NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS MADE INTO THE FOLLOWING. CLIP

CLIP

FIX TO THE HARNESS OF AIR CONDITIONER UNIT.

HARNESS 22P CONNECTOR

34P CONNECTOR

TO RIGHT INST-PANEL.

22P CONNECTOR TO UNDER FLOOR.

CONNECT CONNECTOR WITH "CN2-1" TAG OF ITEM 1 : HARNESS

CONNECT CONNECTOR WITH "CN2-2" TAG OF ITEM 1 : HARNESS

CONNECT CONNECTOR WITH "CN17" TAG OF ITEM 1 : HARNESS

FIX WHITE TAPING POSITION.

CONNECT THE YELLOW TAPING OF CONNECTOR WITH CAB HARNESS.

CLIP

FRONT FIX TO THE HARNESS OF AIR CONDITIONER UNIT.

CLIP

PLATE TO LEFT INST-PANEL.

FRONT

SEMS-BOLT

TIGHTENING TORQUE 9.6 N.m (7.08 lbf.ft)

FRONT

DETAIL OF FUSE & RELAY BOX CONNECTION

23-40

28P CONNECTOR

VIEW IV

CONNECT CONNECTOR WITH "CN3-1" TAG OF ITEM 13 : HARNESS

CONNECT CONNECTOR WITH "CN3-2" TAG OF ITEM 13 : HARNESS

VIEW III

CONNECT CONNECTOR WITH "CN2-3" TAG OF ITEM 1 : HARNESS

23. ELECTRICAL SYSTEM 23.3.8-1 FLOOR HARNESS (1/5) : LC13E01414P1

23

23-41

23. ELECTRICAL SYSTEM 23.3.8-1 FLOOR HARNESS (2/5) : LC13E01414P1

23-42

23. ELECTRICAL SYSTEM 23.3.8-1 FLOOR HARNESS (3/5) : LC13E01414P1

23

23-43

23. ELECTRICAL SYSTEM 23.3.8-1 FLOOR HARNESS (4/5) : LC13E01414P1

23-44

23. ELECTRICAL SYSTEM 23.3.8-1 FLOOR HARNESS (5/5) : LC13E01414P1

23

23-45

23. ELECTRICAL SYSTEM 23.3.8-9 FLOOR GROUNDING CABLE : LE13E01005P1 23.3.8-13 CAB SUB-HARNESS : LC13E01428P1

FLOOR GROUNDING CABLE : LE13E01005P1 TOWARO THE END OF LA TERMINAL

100 (3.94") 100 (3.94") 120 (4.72")

1PAF

YAZAKI 7123-3010

TOWARO THE CENTER OF THE HOLE OF LA TERMINAL

CAB SUB-HARNESS : LC13E01428P1

23-46

23. ELECTRICAL SYSTEM 23.3.9 CAB HARNESS ASSY (1/2) CAB HARNESS ASSY ITEM

LS14E00007F1

PART NAME

PART No.

Q'TY REMARKS

1

HARNESS

LS14E01013P1

1

6

HARNESS

YN11E01205P1

1

HOUR METER

7

HARNESS

YN13E01580P1

1

POWER SUPPLY SOCKET

SW-35 : HEAVY LIFT SW. CONNECT WITH NAME TAG OF "HEAVY".

FIX TO WITH TOGETHER UPP HARNESS, FLOOR HARNESS AND AIR CONDITIONER HARNESS.

(01)

SW-37 : INDEPENDENT TRAVEL SW. CONNECT WITH NAME TAG OF "TRAVEL".

CLIP

WHITE TAPING

FIX TO FLOOR HARNESS.

CLIP

AIR CONDITIONER HARNESS FLOOR HARNESS UPP HARNESS

SW-1 : KEY SW.

CONNECT THE CONNECTOR WITH YELLOW TAPING TAG TO THE FLOOR HARNESS. CONNECT WITH SPEAKER.

CONNECT WITH NAME TAG OF "BOOM, DECK". SW-55 : BOOM, DECK WORKING LIGHT SW.

CONNECT WITH NAME TAG OF "CAB LIGHT". SW-26 : CAB WORK LIGHT SW.

CONNECT TO THE EARTH OF KEY SW.

CLIP

CONNECT WITH WIPER INTERLOCK SW.

SE-16 : ACCEL POTENTIO

SW-17 : ROOF WIPER SW. CONNECT WITH NAME TAG OF "WIPER".

FIX TO AIR CONDITIONER HARNESS.

CLIP

CONNECT WITH CAB WORK LIGHT.

TO ROOF WIPER.

CONNECT TO THE ACCEL POTENTIO.

DETAIL OF aa

DETAIL OF THE SWITCH JOINT.

POWER SUPPLY SOCKET

CONNECT WITH NAME TAG OF " "

CLIP

CONNECT THE CONNECTOR TO THE HOUR METER.

WHITE TAPING

23 C-2 : GAUGE CLUSTER

6

7

CONNECT WITH NAME TAG OF "E"

CLIP

FIX TO THE DUCT.

E-3 : HOUR METER

CLIP

WHITE TAPING

M-3 : WIPER MOTOR

ITEM 1 HARNESS

CONNECT TO FLOOR HARNESS.

1 DETAIL OF A POWER SUPPLY SOCKET.

DETAIL OF HOUR METER.

23-47

23. ELECTRICAL SYSTEM 23.3.9 CAB HARNESS ASSY (2/2)

438 (17.2")

CLIP

WHITE TAPING CONNECT WITH CONNECTOR OF DC-DC CONVERTER.

CLIP

FIX TO BRACKET

CLIP

E-3 : HOUR METER

SEMS-BOLT GND

CLIP

CLIP

WHITE TAPING

WHITE TAPING

WHITE TAPING

WHITE TAPING

THE 2P CONNECTOR CONNECT WITH CAB SIDE HARNESS TIGHTENING TORQUE 4.4 N.m (3.25 lbf.ft) TIGHTEN AFTER CHECKING NO PAINT. THIGHTEN WITH TWO EYELET TERMINALS.

CLIP

CLIP

WHITE TAPING

FIX A BRANCH HARNESS TO THE MAIN HARNESS DOWNWARD.

CLIP

THE 6P CONNECTOR FIX TO BRACKET

25 (0.98")

CLIP

BUNDLED SPEAKER HARNESS BY CLIP.

WHITE TAPING

20 (0.79")

CONNECT WITH CAB WORK LIGHT. CONNECT WITH ROOM LIGHT.

M-3 : WIPER MOTOR

FIX TO THE CLIP OF CAB.

VIEW II

CLIP

WHITE TAPING

CONNECT THE CONNECTOR WITH RED TAPING TAG TO UPP HARNESS.

TO AIR CONDITIONER UNIT. CONNECT THE CONNECTOR WITH YELLOW TAPING TAG TO A CABSUB HARNESS.

VIEW I FIX TO BRACKET

CLIP

CLIP

WHITE TAPING

FIX TO THE CLIP OF CAB.

VIEW III

23-48

435 (17.1")

FIX TO THE INT.

C-2 : GAUGE CLUSTER

185 (7.28")

415 (16.3")

190 (7.48")

VIEW IV

VIEW V

CONNECT THE CONNECTOR WITH BLUE TAPING TAG TO UPP HARNESS.

CONNECT THE CONNECTOR WITH BROWN TAPING TAG TO A CABSUB HARNESS.

P-13 CAB HARNESS GROUND WIPER INTERLOCK SW. HOUR METER WIPER MOTOR IT CONTROLLER DC-DC CONVERTER CAB WORKING LIGHT SW. FLASHER RELAY CAB WORKING LIGHT FRONT 1 GAUGE CLUSTER DC-DC CONVERTER (FOR CAMERA) KEY SW. EARTH AIR CONDITIONER UNIT DC-DC CONVERTER (KCMA) P-19 CAB HARNESS GROUND OVER LOAD ALARM SELECT SW. (EU) INDEPENDENT TRAVEL SW. (KCMA) CAB WORKING LIGHT BOOM,DECK WORKING LIGHT SW.

23. ELECTRICAL SYSTEM 23.3.9.1 CAB HARNESS (1/4) : LS14E01013P1

23

23-49

23. ELECTRICAL SYSTEM 23.3.9.1 CAB HARNESS (2/4) : LS14E01013P1

23-50

23. ELECTRICAL SYSTEM 23.3.9.1 CAB HARNESS (3/4) : LS14E01013P1

23

23-51

23. ELECTRICAL SYSTEM 23.3.9.1 CAB HARNESS (4/4) : LS14E01013P1 23.3.9.6 HOUR METER HARNESS : YN11E01205P1

CAB HARNESS (4/4) : LS14E01013P1

23-52

HOUR METER HARNESS : YN11E01205P1

23. ELECTRICAL SYSTEM 23.3.9.7 POWER SUPPLY SOCKET HARNESS : YN13E01580P1

23

23-53

23. ELECTRICAL SYSTEM 23.3.10 BOOM HARNESS ASSY 23.3.10-2 BOOM HARNESS : LC15E01053P1

23.3.11 BOOM LIGHT INSTALL BOOM LIGHT INSTALL

BOOM HARNESS ASSY BOOM HARNESS ASSY ITEM 1

LC15E00051F1

PART NAME HARNESS

PART No.

Q'TY

REMARKS

ITEM

LC15E01053P1

1

BOOM HARNESS

1

I

1

II

FIX WITH WELDED CLIP. FIX WHITE TAPING PART

(04)

PARTS No.

Q'TY REMARKS

YW80S00001F1

2

FIX WITH WELDED CLIP.

1

DETAIL OF aa

FIX WHITE TAPING PART FIX WITH WELDED CLIP.

FIX WHITE TAPING PART TO THE HOSE FOR GREASE CLIP

FIX WHITE TAPING PART FIX WITH WELDED CLIP.

VIEW I

NAME LIGHT

LC80E00004F1

aa

FIX WHITE TAPING PART

FIX WITH WELDED CLIP.

BOOM LIGHT INSTALL

FIX TO THIS POSITION CONNECT WITH MAIN HARNESS

TO CENTER OF BUCKET

VIEW II

BOOM HARNESS : LC15E01053P1 F-8

1

WHITE TAPING

SPLICE 85A AND 85C WHITE TAPING

WHITE TAPING

LOCK WASHER F-7

CN-110M

REMOVE LOCK WASHER ATTACHED TO LIGHT

SECTION AA

NOTE: TIGHTENING TORQUE: 18.6N.m(13.7 lbf.ft)

23-54

23. ELECTRICAL SYSTEM 23.3.12 UPPER LIGHT INSTALL UPPER LIGHT INSTALL UPPER LIGHT INSTALL ITEM 1

PART NAME LIGHT

LQ80E00014F1

(02)

PART No.

Q'TY

YT80S00002F2

1

REMARKS

1

NUT (SUPPLIED EITH LIGHT)

BRACKET

LIGHT HARNESS

SEMS-BOLT

TIGHTENING TORQUE 46.1 N.m (34 lbf.ft)

SECTION AA

23 GROMMET

VIEW I NOTE 1. TIGHTENING TORQUE OF ITEM 1 TO BE 18.6 N.m (13.72 lbf.ft)

23-55

23. ELECTRICAL SYSTEM 23.3.13 FLASHER LAMP INSTALL 23.3.14 TRAVEL ALARM ASSY TRAVEL ALARM ASSY

FLASHER LAMP INSTALL FLASHER LAMP INSTALL ITEM

LC80E00025F1

PART NAME

ALARM ASSY

(01)

PART No.

Q'TY

REMARKS

ITEM

LC53E00008F1

NAME

PARTS No.

(01)

Q'TY REMARKS

1

FLASHER LAMP

YM80S00001F1

1

FOR LH

1

ALARM

YN53S00004F1

1

2

FLASHER LAMP

YM80S00001F2

1

FOR RH

3

RELAY

YN24S00010P1

1

I

III

aa

2

bb

1

CLIP

REST HARNESS IS BUNDLED THIS POSITION AND FASTEN. UPP HARNESS

TO SWING FLASHER COUNTER WEIGHT

DETAIL aa

FORWARD

CONNECT WITH CONNECTOR OF SWING FLASHER (SUPPLIED WITH UPP HARNESS)

CLIP

DETAIL bb

CONNECT WITH CONNECTOR OF SWING FLASHER (SUPPLIED WITH UPP HARNESS) UPP HARNESS

CLIP TO SWING FLASHER

TO SWING FLASHER

IV FORWARD

CLIP

UPP HARNESS

II

COUNTER WEIGHT

23-56

CLIP

FIX TO THE CONNECTOR WITH CLIP REMAINING LENGTH OF THE ALARM SIDE HARNESS.

UPP HARNESS

TO SWING FLASHER

FORWARD

1

VIEW II

REST HARNESS IS BUNDLED THIS POSITION AND FASTEN.

CLIP

UPP HARNESS

TIGHTENING TORQUE : 23.5 N-m (17.3 lbf-ft) SEMS-BOLT

E-13: TRAVEL ALARM

VIEW III

VIEW IV

3

TRAVEL ALARM RELAY

DETAIL OF FUSE & RELAY BOX

FORWARD

VIEW I

VIEW I

24. COMPONENTS SYSTEM

24. COMPONENTS SYSTEM TABLE OF CONTENTS

24.1 HYDRAULIC COMPONENTS ............................................................................24-3 24.1.1 HYDRAULIC PUMP - REGULATOR ..........................................................24-3 24.1.2 CONTROL VALVE .....................................................................................24-22 24.1.3 PILOT VALVE (ATT) ...................................................................................24-60 24.1.4 PILOT VALVE (TRAVEL) ...........................................................................24-64 24.1.5 SWING MOTOR UNIT ...............................................................................24-66 24.1.6 TRAVEL MOTOR .......................................................................................24-77 24.1.7 SWIVEL JOINT ..........................................................................................24-91 24.1.8 CYLINDER .................................................................................................24-93 24.2 ELECTRICAL EQUIPMENT ...............................................................................24-99 24.2.1 ELECTRICAL EQUIPMENT LIST ..............................................................24-99 24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ........................................24-102

24

Book Code No. S5LC2426E01 24-1

24. COMPONENTS SYSTEM

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC2426E01 NA

September, 2010 SK350-9: YC

24-2

24. COMPONENTS SYSTEM

24.1

HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP - REGULATOR 24.1.1.1 SUMMARY (1) Outside view and Hydraulic port

5 EYE BOLT (M10)

a3

PSV2

Dr

2X4-M12 Depth 22

A3

A1

B3

VIEW

a4

PSV1

MAX. FLOW RATE ADJUSTING SCREW

PH1 PH2 PSV1

4 MIN. FLOW 2 RATE ADJUSTING SCREW

A2

4

PSV2

PSV2 2

a3

MIN. FLOW RATE ADJUSTING SCREW

PH1 PH2

PH2 PH1

a4

a1

3

a2

a1 a2 B3

B3 B1

Dr

B1

A1

A3 Dr3 a5

A2

5 1

Dr3

A2

Hydraulic ports Parts

No.

Q'TY

Code

Ports name

Size

1

Main pump assy

1

A1,2

Delivery port

SAE 6000psi 1"

2

Regulator assy

2

B1

Suction port

SAE 2500psi 2 1/2"

3

Gear pump assy (for pilot)

1

Dr

Drain port

4

Solenoid proportional reducing valve

2

PSV1,2 Servo assist port

PF1/4-13

5

PTO unit (option)

1

PH1,2 Pressure sensor port

PF3/8-17

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

Hydraulic Pump - Regulator

24-3

PF3/4-20

24

24. COMPONENTS SYSTEM (2) Hydraulic circuit diagram

(KDRDE5K)

PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (FRONT) (REAR) (KR3S-YT2K-V) (KR3S-YT2K-V) (KDRDE5K) Solenoid proportional reducing valve (PSV-2)

Solenoid proportional reducing valve (PSV-1)

Regulator

Regulator

a4

Dr

a3 Engine

Main pump

a5 B1

Dr3

B3

Gear pump for pilot

A3

PTO gear case (Option)

Hydraulic Circuit Diagram Of Pump (3) Specifications

Main pump

Item Pump assy

Parts No.

With PTO.

Without PTO.

LC10V00030F2

LC10V00029F2

Single Pump

Revolution

Pressure

Rated Rated ATT boost pressure

Max. flow Max. input horse power Max. input torque

Regulator

YN10V00014F3

K5V140DTP119R-YT0K-HV

ZX10LGRZ2-07G

cm3

140 X 2

10

min-1(Clockwise seen from shaft end)

2100 34.3 (4980)

MPa (psi)

5.0 (725)

37.8 (5480)

L/min (gal/min)

294 (78) X 2 at 7.8MPa (1130 psi)

21 (5.5)

kW (PS) N.m (lbf.ft)

195 (265)

3.4 (4.6)

886 (653)

14.7 (10.8)

Part No.

LC10V01005F2

Model

KR3S-YT2K-V

Control function Others

Weight

-

LC10V00033F1

Pump model Max.displacement capacity

Gear pump

Electric flow control, positive flow control, total power control at emergency mode and power shift control

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

kg (lb)

141 (310)

24-4

143 (315)

24. COMPONENTS SYSTEM 24.1.1.2 HYDRAULIC PUMP 24.1.1.2.1 CONSTRUCTION (1) Main pump

886 717

953 806

789 532 Apply adhesive (Three Bond No.1305N) 724 A 214 548 531 702 792 534 535 732

901 808 954

717

151

152

211

261 406 824 774 111 B

B

127 123 04

710 212 401 251 490

271

153 156 157

Tightening torque Item number

Thread size

401 406 407 414 466 467 468 490 531,532 806 808

M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20

No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313

468 728

313 124 710 116 467 466 312 885 314 141 727 725

Tightening torque N.m (lbf.ft) 430 (317) 29 (21) 12 (8.9) 57 (42) 36 (27) 74 (55) 170 (125) 11 (8.1) 240 (177) 130 (96) 240 (177)

546

414

725 727

407

271

113 05

326

325 VIEW A

SECTION B-B

SECTION B-B (Option)

No. Q'ty No. Parts Q'ty Parts Parts 724 O-ring ; 1B P8 1 314 Valve plate (L) 1 Drive shaft (F) 725 O-ring ; 1B P11 1 325 Sensor block 1 Drive shaft (R) 727 O-ring ; 1B P14 1 326 Cover 1 Gear #1 728 O-ring ; 1B P24 8 401 Socket bolt ; M20X210 2 Roller bearing 732 O-ring ; 1B P18 4 406 Socket bolt ; M8X20 2 Needle bearing 774 Oil seal 3 407 Socket bolt ; M6X55 3 Bearing spacer 789 Back up ring ; P18 4 414 Socket bolt ; M10X20 2 Cylinder block 792 Back up ring ; G35 2 466 VP plug ; PF1/4 18 Piston 806 Nut ; M16 2 467 VP plug ; PF3/8 18 Shoe 808 Nut ; M20 4 468 VP plug ; PF3/4 2 Retainer plate 824 Snap ring 32 490 Plug ; NPTF1/16 2 Spherical bushing 885 Valve plate pin 2 531 Tilting pin ; M24X2 18 Cylinder spring 886 Spring pin 2 532 Servo piston ; M24X2 2 Shoe plate 901 Eye bolt ; M10 2 534 Stopper(L) 2 Swash plate 953 Socket screw ; M16X35 2 535 Stopper(S) 2 Tilting bushing 954 Set screw ; M20 2 546 Spacer 2 Swash plate support 04 Gear pump 2 548 Feed back pin 1 Seal cover (F) 05 PTO unit (Option) 2 702 O-ring ; 1B G35 2 Pump casing 2 710 O-ring ; 1B G95 1 Valve block 4 717 O-ring ; 1B G145 1 Valve plate (R) The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

24-5

Q'ty 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1

24

24. COMPONENTS SYSTEM (2) Gear pump (For pilot)

700

354

351

Suction port : PF3/4 Tightening torque : 73.5N.m (54.2 lbf.ft)

433

434 Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft) 311 312 732 307

710

435

361

No.

353

Parts

850

310 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft)

Q'TY

No.

308 309

434

466 725

Parts

355

Q'TY

307 308 309 310 311

Poppet Seat Ring Spring Adjust screw

1 1 1 1 1

361 433 434 435 466

Front case Flange socket; M8X40 Flange socket; M8X55 Flange socket; M8X20 VP plug; PF1/4

1 2 2 4 1

312 351 353 354 355

Lock nut; M14X1.5 Gear case Drive gear Driven gear Filter

1 1 1 1 1

700 710 725 732 850

Ring O-ring; 1B G95 O-ring; 1B P11 O-ring; 1B P16 Locking ring

1 1 1 1 1

24-6

24. COMPONENTS SYSTEM (3) PTO gear case (Option)

125 711 118

825

468 728

710

117 126 326 115 128 826

262

414

435

886 885

No.

Parts

Q'TY

No.

Parts

Q'TY

115 117 118 125 126

Idle shaft 2nd gear 3rd gear Ball bearing Roller bearing

1 1 1 2 1

435 468 710 711 728

Flange socket; M10X20 VP plug; PF3/4 O-ring; 1B G80 O-ring; 1B G85 O-ring; 1B P24

4 1 1 1 1

128 262 326 414

Bearing spacer Cover Gear case Capscrew; M10X20

2 2 1 4

825 826 885 886

Snap ring Snap ring Spring pin Pin

1 1 1 2

24

24-7

24. COMPONENTS SYSTEM 24.1.1.2.2 OPERATION The pump assy is equipped with two pumps arranged on the same axis that are connected with gear (116) and distribute the rotating power to the gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the auxiliary pump (OPT) arranged on another shaft. The pump assy consists largely of the rotary group, the main part of the pump that makes rotary on; the swash plate group that changes the delivery rate; the valve block group that selects between oil suction and delivery and the PTO group (OPT) that transmits the drive power to the auxiliary pump.

REGULATOR

116 111

PTO GEAR CASE OPT AUXILIARY PUMP (OPT)

Construction Of Hydraulic Pump (1) Rotary group The rotary group consists of shaft(111), cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156), and cylinder spring (157). The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure. Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance. The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder block (141) is also pressed against valve plate (313) by the action of cylinder spring (157).

124

313

312 111 124 314 141

211

151 . 153 152

156

116

157

Rotary Group

24-8

24. COMPONENTS SYSTEM (2) Swash plate group The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), tilting pin (531), and servo piston (532). The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support. The hydraulic force controlled by the regulator flows into the hydraulic chamber that is provided on both sides of the servo piston. This moves the servo piston to the right and left. The result is that the swash plate swings on the swash plate support via the spherical part of the tilting pin and changes the tilting angle (a).

532 531

214 211 212

251

Swash Plate Group (3) Valve block group The valve block group consists of valve block (312), valve plates (313 or 314), and valve plate pin (885). The valve plates having two crescent-shaped ports are installed to valve block (312) to feed oil and recycle it from cylinder block (141). The oil switched over by the valve plate is connected with the external pipe by way of the valve block.

313 312

116 141

111

314 885

Valve Block Group (4) PTO group (Option) The PTO group is composed of 1st gear (116), 2nd gear (117) and 3rd gear (118). The 2nd and the 3rd gear are supported by bearings (125) and (126) respectively and installed to the valve block. Now, if the shaft is driven by the engine, the cylinder block rotates together by the spline linkage. If the swash plate is inclined, the pistons arranged in the cylinder block make reciprocating motion with respect to the cylinder while rotating with the cylinder block. If we keep an eye on a single piston, it makes a motion away from the valve plate (oil suction process) in the first 180 deg. and a motion toward the valve plate (oil delivery process) in the remaining 180 deg. If the swash plate is not inclined (zero tilting angle), the piston does not stroke i.e. delivers no oil. The shaft rotation is taken up by the 1st gear (116) and transmitted to the 2nd gear (117) and the 3rd gear (118), in that order, to drive the gear pump that is linked to the 3rd gear.

24-9

117 126

118 125

24 125

PTO Group

24. COMPONENTS SYSTEM 24.1.1.3 REGULATOR 24.1.1.3.1 CONSTRUCTION PSV

413

PSV

B

418 079

757

D 439

438

725

730

656 438

722

a3

643

924

D 543 755 545 541 724

801

466, 755

B

708

VIEW C

646 645

644

728

SECTION B-B 641 655

654

836

651

652

601 624

734 612

897

876

874

858

755 A

412

629

653

615

814

614

631

630 628 627

C

613 875 A

898

802

732 611

753 733 622

621

625

623

626 887

763

756

SECTION A-A

At start and emergency mode

Tightening torque 662 543

545

541

466 755

496

755

SECTION E-E

642 At normal

E

E

SECTION D-D

24-10

Item No.

Thread size

412,413 438,439 418 466 496 630 801 802

M8 M6 M5 PF 1/4 NPTF1/16 M30X1.5 M8 M10

Tightening torque N.m (lbf-ft) (21) 29 (8.9) 12 6.9 (5.1) (27) 36 8.8 (6.5) (118) 160 (12) 16 (14) 19

24. COMPONENTS SYSTEM No. 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627

Parts Socket bolt ; M8X50 Socket bolt ; M8X70 Socket bolt ; M5X12 Socket bolt ; M6X20 Socket bolt ; M6X25 VP plug ; PF1/4 Plug ; NPTF1/16 Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcrum plug Adjusting plug Compensating piston Piston case Compensating rod Spring seat (C) Outer spring Inner spring Adjusting stem (C)

Q'ty 2 2 2 8 5 3 17 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1

No. 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 662 708 722 724 725 728 730

Parts Adjusting screw (C) Cover (C) Lock nut ; M30X1.5 Sleeve (For PF) Pilot cover Spool Pilot piston Spring seat (Q) Adjusting stem (Q) Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-ring ; 1B G75 O-ring ; 1B P6 O-ring ; 1B P8 O-ring ; 1B P10 O-ring ; 1B P18 O-ring ; 1B P22

Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 8 1 1 1

No. 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 041 079

Parts O-ring ; 1B P16 O-ring O-ring ; 1B G25 O-ring ; 1B P9 O-ring ; 1B P11 O-ring ; 1B P26 O-ring ; 1B P12.5 O-ring ; 1B G35 Nut ; M8 Nut ; M10 Snap ring Snap ring Snap ring Pin ; 4X11.7L Pin ; 4X8L Pin ; 5X8L Pin Pin ; 5X19L Pin ; 11.5X11.8L Socket screw ; M8X20 Sub-check valve

Q'ty 1 1 1 1 7 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1 Solenoid proportional reducing valve

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

24

24-11

24. COMPONENTS SYSTEM 24.1.1.3.2 OPERATION (1) Control function Control function ......

Electric flow control. -Positive flow control. -Total horsepower control. Emergency mode control. -Hydraulic positive control. -Hydraulic total horsepower control.

(2) Summary The regulator KR3S-YT0K for the in-line type axial piston pump K5V series is composed of the control mechanism as mentioned below: 1. Electric flow control and positive flow control The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control (positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to attain optimum power according to the operating condition. Also, since the pump delivers only the necessary oil flow, the machine does not consume excessive power. 2. Constant power control at emergency mode When the electromagnetic proportional pressure-reducing valve cannot output the secondary pressure due to the trouble, the spool for emergency mode is switched automatically, and the control is switched from electric control to hydraulic control (emergency mode). In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power control section of regulator on each pump through pump inside passage and shifts respective control to the same power set value. In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is automatically reduced; consequently the input torque is controlled to the constant value or less. (When the speed is constant, the input power is also constant.) This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in the condition where the power is controlled, the overloading of engine is automatically prevented regardless of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power control is not worked. With this mechanism, it is possible to obtain proper power for the working condition. This regulator is made up of the above two kinds of control system, but when both controls are actuated together, the low tilt angle (low delivery rate) command precede on mechanical operation described later.

24-12

(3) Explanation of operation 1. Flow rate electrical control The pump delivery rate is controlled according to the command current value corresponding to the movement of control devices. This relation is shown in right figure.

Delivery flow rate Q

24. COMPONENTS SYSTEM

Command current I

a. Flow rate increase (See right Fig.) As the command current value I rises, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve rises, and by pressing pilot piston (643) in (A) direction it stops at the position the secondary pressure P2 balances the pilot spring force (646). The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (B) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (C) fulcrum in the same arrow direction as (B). Consequently the spool (652) connected to feedback lever moves towards (D). When the spool moves towards (D), the port CL connected to tank port is open and the pressure in servo piston large bore diameter chamber is released, consequently the servo piston (532) moves towards (E) according to delivery pressure Pd1 in small bore diameter piston chamber, resulting in the rise of flow rate. Since the feed back lever is connected to the servo piston and spool, the feed back lever rotates at (F) fulcrums with the movement of the servo piston towards (E), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

CL port : Connect with large diameter chamber of servo piston

652

B 876

D

646 613 F 897

875 611 643

A C 532

E (KDRDE5K)

Psv A

Pd1

CL port a3

Hydraulic circuit diagram B

24

24-13

24. COMPONENTS SYSTEM

3. Power control (In emergency mode) When the load pressure rises, the pump tilt angle is reduced preventing the overloading of engine as shown in right Fig. The operation of power control is the same as the flow rate control, and is explained below.

613 CL port : Connect with large diameter chamber of servo piston

652

G 646 H 876

J

875 611 643

I

K

532 (KDRDE5K)

Psv A

Pd1 CL port a3

Hydraulic circuit daigram

B

Delivery flow rate Q

b. Flow rate decrease (See right Fig.) As the command current value I is reduced, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve is reduced, and by pressing pilot piston (643) in (G) direction it stops at the position the pilot spring force (646) balances the secondary pressure P2. The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (H) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (I) fulcrum in the same arrow direction as (H). Consequently the spool (652) connected to the feedback lever moves towards (J). When the spool moves towards (J), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and port CL. The servo piston small bore diameter chamber constantly receives delivery the pressure Pd1, consequently the servo piston moves towards (K) according to the difference of area resulting in the reduction of tilt angle, and finally the flow rate is reduced. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (L) fulcrum with the movement of servo piston towards (K), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

Delivery output (Pd1)

24-14

L 897

24. COMPONENTS SYSTEM a. Overload prevention operation (See right Fig.) Because the delivery pressure Pd1 acts on the compensating rod stepped section with the rise of self pump delivery pressure Pd1 the compensating rod (623) is pushed towards (M), and moves to the position the delivery pressure Pd1 balances the spring force of outer spring (625) and inner spring (626). The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (N) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (O) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected with feedback lever moves towards (P). When the spool moves towards (P), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and CL port. Since the delivery pressure Pd1 is constantly led to servo piston large bore diameter chamber, the servo piston moves towards (Q) according to the difference of area, resulting in the reduction of tilt angle, consequently the flow rate is also reduced. Since the feed back lever is connected with servo piston and spool, the feed back lever rotates at (R) fulcrum with the movement of the servo piston towards (Q), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

625 897 896 626 612 R N

CL port : Connect with large diameter chamber of servo piston

G

652 H P

646

875 623 611

M

621 O

Q

532 (KDRDE5K)

Psv A

Pd1 CL port a3

Hydraulic circuit daigram B

24

24-15

24. COMPONENTS SYSTEM b. Flow rate recovery operation (See right Fig.) Because the compensating rod (623) is pushed towards (S) with the force of outer spring (625) and inner spring (626) with reduction of self pump delivery pressure Pd1, and moves to the position the spring force of outer spring (625) and inner spring (626) balances the delivery pressure Pd1. The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (T) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (T) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected to feedback lever moves towards (V). As the spool moves towards (V), CL port is open and connected to tank port, the pressure of servo piston large bore diameter chamber is released and the servo piston (532) moves towards (W) with delivery pressure Pd1 in small bore diameter chamber, and consequently the flow rate is raised. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (X) fulcrum with the movement of the servo piston towards (W), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

625 897 876 612 626 X T

S

CL port : Connect with large diameter chamber of servo piston

G

652 H J 875

V

623 611

621 U

W

532 (KDRDE5K)

Psv A

Pd1 CL port a3

Hydraulic circuit daigram

B

3. Priority mechanism of low tilt angle (low flow rate) command As the said explanation, the tilting commands of flow rate control and power control are transferred to feedback lever (611) and spool (652) through the large bore section of lever 1 (612) and lever 2 (613), but because the pin (dia 5) is extruded in large bore (dia 9), pin (897) on the side where making tilt angle smaller contacts with it, consequently the bore (dia 9) of lever on the side where larger tilt angle command is given is free without contact with pin (897). In this mechanical selecting manner, the command on the side of low tilt angle of the flow rate control and power control has a priority.

24-16

4. Power shift control As shown in right Fig., the pump set power is controlled according to the movement of control by power shift pressure Pf. As power pressure Pf rises, the compensating rod (623) moves rightward through pin (898) and compensating piston (621). Consequently like the overloading prevention operation of power control, the pump tilt angle becomes smaller and the power setting value is reduced. Conversely, if the power shift pressure Pf is reduced, the power set value is raised. The power shift pressure Pf of this pump is ordinary set to 0MPa, but in emergency mode, the power shift pressure Pf is raised to 4.9 MPa.

Delivery flow rate Q

24. COMPONENTS SYSTEM

Delivery pressure (Pd1)

24.1.1.3.3 ADJUSTING THE REGULATOR The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency mode control) control characteristics, flow control characteristics using the adjust screw.

Adjust screw no.

954

No. of turns for tightening

1/4

Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min (gal/min)

Delivery flow rate Q

(1) Adjusting the maximum flow (See construction Fig.) Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it). Tightening set screw (954) decreases the delivery rate, as indicated in right Fig.. Only the maximum flow varies, but other control characteristics remain unchanged.

No change 5.8 (1.5)

Input current I (Pilot pressure Pi)

Adjusting The Max. Delivery Flow

24

24-17

24. COMPONENTS SYSTEM

Adjust screw no.

953

No. of turns for tightening

1/4

Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min (gal/min)

Delivery flow rate Q

(2) Adjusting the minimum flow (See construction Fig.) Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or loosening it). Tightening socket screw increases the delivery rate, as indicated in right Fig.. Other control characteristics remain unchanged in the same way as maximum flow adjustment, care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action).

No change 4.6 (1.2)

Input current I (Pilot pressure Pi)

Adjusting The Min. Delivery Flow (3) Adjusting the input horsepower (At emergency mode) Since the regulator is of total horsepower control type, turn the adjust screws of both the front (No.1) and rear (No.2) pumps when changing horsepower set values. Adjust the horsepower settings of both pumps to a same level. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values will by halved when only one pump is loaded.

Adjust screw no.

628

No. of turns for tightening

1/4

Delivery flow rate Q

1. Adjusting the Outer Spring (See constuction Fig.) (At emergency mode) Adjust it by loosening lock nut (630) and by tightening adjust screw (628) (or loosening it). Tightening the adjust screw shifts the control chart to the right and increases the input horsepower, as indicated in right Fig.. Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626), return the adjust screw C (627) by NX1.48 turns at first.

Increase delivery pressure MPa (psi) 2.06 (299) Increase in input torque N.m (lbf.ft)

50 (36.9)

Delivery pressure (Pd1)

Adjusting The Input Horsepower (1)

24-18

24. COMPONENTS SYSTEM

Adjust screw no.

627

No. of turns for tightening

1/4

Increase inflow L/min (gal/min)

Delivery flow rate Q

2. Adjusting the Inner Spring (See construction Fig.) (At emergency mode) Adjust it by loosening nut (802) and by adjust screw (C) (627) (or loosening it). Tightening the adjust screw increases the flow and then the input horsepower, as indicated in right Fig.. And the input torque raises.

12 (3.2)

Increase in input torque N.m (lbf.ft) 58.7 (43.3)

Delivery pressre (Pd1)

Adjusting The Input Horsepower (2)

Adjust screw no.

924

No. of turns for tightening

1/4

Increase Pilot pressure MPa (psi)

0.18 (26)

Decrease in delivery flow L/min (gal/min)

18.5 (4.9)

Delivery flow rate Q

(4) Adjusting the flow control characteristics (See construction Fig.) Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the control chart to move to the right as shown in right Fig..

Input current I (Pilot pressure Pi)

Adjusting The Flow Control Characteristics

24

24-19

24. COMPONENTS SYSTEM 24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter LC33-II" (1) When the engine is overloaded, Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start checking from para. 3). 1. Check that the power shift command current I is normal 2. The power shift pressure is low. -Check the dither of amp. -Replace solenoid proportional reducing valve. 3. Stick of compensating piston (621) and compensating rod (623) -Disassemble and clean it. 4. Stick of pin (898) -Disassemble and clean it. (2) The max. flow rate is not delivered. 1. Check that pilot differential pressure Pi is normal. 2. Stick of pilot piston (643) -Disassemble and clean it. 3. Stick of spool (652) -Disassemble and clean it. 4. Stick of pin (898) -Disassemble and clean it. Note: When the damage of part is severe, replace the part with new one.

24-20

24. COMPONENTS SYSTEM 24.1.1.4 CONTROL CURVE OF PUMP 300

1471

(79)

(1085)

2100min-1: Hmode

Q

;2100 min-1

Input revolution Input horse power ;195 kW (265ps) Input torque ;886 N.m (653lbf.ft)

1900min-1: S

250

[1]

(66)

Delivery flow rate Q [ L/min ](gal/min)

[3]

Reference value in ( ). Two pumps are loaded at the same time

[2]

981

200

(724)

(53)

150 (40)

[1] 183kW (249ps) H mode at traveling or optional working [2] 154kW (209ps) H mode at operating attachment [3] 149kW (203ps) S mode at operating attachment

100

490

(360)

Input torque Tin N.m (lbf.ft)

(26)

50

(13)

Min.Flow(at 2100min-1)

0

5 (725)

10 (1450)

300 (79)

Q

2000min-1 300mA

Delivery flow rate Q [ L/min ](gal/min)

(66)

200 (53)

12.0MPa (1740psi) 288L (76gal)

I-Q Curve Pd=7.8MPa at Qmax (1131psi)

25 (3625)

30 (4350)

35 (5075)

40[MPa] (5800)(psi) 1471 (1085)

[4] 156kW (212ps) : At emergency mode i) ps e 10 od )(7 m Pa ncy 9M e 4. rg f= me (P t e A

250

15 Delivery 20 (2175) pressure (2900) Pd 725mA 290L(77gal)

(Pf=0MPa)

(72 gal)

271L Input revolution ;2100 min-1 Input horse power ;195 kW (265ps) Input torque ;886 N.m (653lbf.ft)

[4] Reference value in ( ). 981 Two pumps are loaded at the same time (724) Pf:Power shift pressure (Reference value) 23.8MPa 147L (39gal)

150 (40)

100

490

50

38.0MPa (5510psi) 84L (22gal)

Tin

(13)

Min.Flow(at 2100min-1)

400mA 30L (8gal) 0

5 (725)

10 (1450)

0

1 (145)

2 (290)

15 Delivery 20 (2175) pressure (2900) Pd 3 Pilot pressure 4 [MPa] Pi (580)(ps) (435)

24-21

25 (3625)

30 (4350)

35 (5075)

Input torque Tin N.m (lbf.ft)

(360)

(26)

40[MPa] (5800)(psi)

24

24. COMPONENTS SYSTEM 24.1.2 CONTROL VALVE 24.1.2.1 SPECIFICATIONS 24.1.2.1.1 OUTSIDE VIEW PTb

PBL

CT2

P2 (P6)

CP2

CT1

(P5) P1

Pcb

(P6)

PTb

Travel straight PBr

PAb

Br

LCb

Ac (HEAD)

Ab

PCb

PCb

Travel right

PAr

PAr

Boom

PBb

Dr Ar

CRb (ROD)

Bucket

LCAP2 LCAT2

PCc

PBa2

PB1 PBs

PCc

PBc

Arm 2

PAa2

PAL

Travel left

PAL

P1 unload

Ar

Bc

LCc

T1

T2 PL

(HEAD)

Bb (ROD)

PAc

CP1

(P5)

(P6)

CT1 CMR1 SMR2

PAL

MU

PBb

PBa1

PBa2

Pss

PAo

CT2

Swing Arm 1

PAo

Option

LCs PLc2 CRa Ba (ROD)

P2 unload PAs

Aa (HEAD)

PAa1

LCa

PBo LCo

Ao

PBa2

PCa

Bs

As

Pss

PBa1

PBL

BL

CP2

Boom confluence CCb

PB1 PBs

AL

Bo

PAo PAa2

Arm 2 Bucket

Option

PBo

PAc

PAa1

Arm 1 PAa PAs

Boom Travel right

PAb PBr

Swing PCa (T3)

Travel straight

PTb

PBL

(P6)

A Outside View

24-22

Travel left (CT2)

PBo PAa2

(P5)

VIEW A

P2 unload

24. COMPONENTS SYSTEM 24.1.2.1.2 PORTS Port size

Tightening torque

Ports

PF3/4

150 to 180 N-m (111 to 133 lbf-ft)

MU (T3) (P5) (P6)

Pluged Pluged Pluged

PF3/8

69 to 78 N-m (51 to 58 lbf-ft)

PAa1 PBa1 PAb PBb PAc PBc PBL PBr PAs PBs PAa2 PBa2 PAo PBo DR

Arm 1 (in) pilot port Arm 1 (out) pilot port Boom (up) pilot port Boom (down) pilot port Bucket (digging) pilot port Bucket (dump) pilot port Travel left (reverse) pilot port Travel right (reverse) pilot port Swing (right) pilot port Swing (left) pilot port Arm 2 (in) pilot port Arm 2 (out) pilot port Option pilot port Option pilot port Drain port

PF1/4

34 to 39 N-m (25 to 29 lbf-ft)

Pss PLc2 PAL PAr PL PB1 PTb PCa PCb PCc

Swing pilot high pressure select port Lock valve select pilot port Travel left (forward) pilot port Travel right (forward) pilot port Attachment boost port Boom (up) conflux pilot port Travel straight pilot port Unload valve (P2 side) pilot port Unload valve (P1 side) pilot port Bucket (digging) stroke limiter pilot port

M12

83 to 110 N-m (61 to 81 lbf-ft)

P1 P2 T1 T2

Pump port (P1 side) Pump port (P2 side) Tank port 1 Tank port 2

M10

49 to 65 N-m (36 to 48 lbf-ft)

Ar Br AL BL As Bs Ab Bb Aa Ba Ac Bc Ao Bo

Right travel motor port (forward) Right travel motor port (reverse) Left travel motor port (forward) Left travel motor port (reverse) Swing motor port (right) Swing motor port (left) Boom cylinder head side port (up) Boom cylinder rod side port (down) Arm cylinder head side port (in) Arm cylinder rod side port (out) Bucket cylinder head side port (digging) Bucket cylinder rod side port (dump) Optional pilot port Optional pilot port

24-23

Description

24

24. COMPONENTS SYSTEM 24.1.2.1.3 SPECIFICATIONS Item

Specifications

Model

KMX15YD/B44131

Maximum flow rate [L/min (gal/min)]

294 (78)X2

Maximum set pressure [MPa (psi)]

37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)

Main relief valve set pressure [MPa (psi)] When power boost pressure

Std 34.3 (4970) [at 135X2L/min (36X2gal/min)] 37.8 (5480) [at 125X2L/min (33X2gal/min)]

Overload relief valve set pressure (Boom head, Bucket head, Arm rod) [MPa (psi)]

39.7 (5760) [at 30L/min (8gal/min)]

Overload relief valve set pressure (Boom rod, Bucket rod, Arm head) [MPa (psi)]

37.8 (5480) [at 30L/min (8gal/min)]

24-24

24. COMPONENTS SYSTEM 24.1.2.2 CONSTRUCTION AND OPERATION 24.1.2.2.1 CONSTRUCTION (1) Control valve

154

164

(P5)

101

P2

T1

T2

PBL

PAL

PCa

PB1

PAs

PBs Pss PBa1

PAa1

PAo

PBo

163

162 162 163 SECTION A A 164 154 (P6)

P1

102 973

973 PTb

PCb

973

973

PAr

PBr

973 PAb

PBb PBc PCc

973 PAc

974

973

973 PBa2

PAa2

974

162

162

163

SECTION B B

Section (1/6)

24-25

162

24

24. COMPONENTS SYSTEM

A (P6)

H

B

273x10

273x10 P1 unload (Travel straight)

C

PCb

PAL

Travel left C

977 PAr

Travel right

PB1

Boom confluence (P2 unload)

978x2

D

H

D PBs

Boom

Swing

E

E

PBb

PCc

Pss

PBa1

Bucket

Arm 1

F

F PAo PA

PBa2 MU

Arm 2

Option

G

G K

K

B

A PBa2

PAo

274x4

275x4 213

212

PBo PAa2

273x10 273x10

Section (2/6)

24-26

24. COMPONENTS SYSTEM 202 333 331 336 329 327

P1 unload

Travel left

PCb

202 333 331

PAL

336

601 331 261 309

MR

324 323

PL

159

AL

511 521

512 522

CP2

551 164 162

CMR2

552 562 562 552 522 512

CMR1

331 261 306 163 162

BL

163

307 261 331 327 329 336 331 333 202 202 333 331 336 324 323

264 205

PBL

SECTION C-C

PTb

Travel straight

Travel right

Boom conflux

PAr

202 333 331

PB1

339

306

326 325 331 261

161

511 521

331 261

163 511 521 551 164 163

CCb

Ar

CP1

551 164

Br

161

310

(T3)

264 205

551 164 305

PBr

SECTION D-D PCa

P2 unload

Section (3/6)

24-27

164 154 261 331 327 329 336 331 333 202

24

24. COMPONENTS SYSTEM Swing

203 333 331 336 322 321 603

L

331 211 261 266 160 160 514 524 556 164 511 521 551 164

204

PBs

Boom

PBb

333

Pss

331 336

AbR

322

L

321

266

As

CRb Ab

LCb

LCs

Bb Bs

331 261 303 161 162 163 511 523 556 164 162 161

301 264

266 BbR

602 210

PAb

164 551

209 216 333 331 336 322 321 602

Q

Q

160

264 206

PAs

SECTION E-E Bucket

PCc

Arm 1

PBa1

PBc

BaR

BcR

331 261

L

L

304 CRa

Bc

511 521 551 164

Ba LCc

LCa

201 333 331 336 322 321 603 331 261 211 160 514 524 556 164 511 521 551 164

Ac

162

Aa

161 264 603 205

PAc AcR

302 264

PAa1

SECTION F-F

Section (4/6)

24-28

AaR

205 602

24. COMPONENTS SYSTEM 201 333 331 340 328 321

Arm

201

Option

PBa2

333

PAo

331 336

331 261

324 AoR

323 604 331

MU

308

261 311

162 162 162 511 521 551 164 515 521

Ao

511 521

LCAT2 LCo LCAP2

551

551 164

164 Bo

162 161

604 264

BoR

264

Q

Q

PBo

205

210

PAa2

SECTION G-G

T2

161 P1

511 521

T1

163

CT1

551 164

163 162 511 521

P2 CT2

551 164

SECTION H-H

Section (5/6)

24-29

24

24. COMPONENTS SYSTEM

207 160 278x5

266

264

264

527

606

606

528 T2

517

T1

163

518

SECTION J-J SECTION K-K

563 564

SECTION L-L

SECTION Q-Q

Section (6/6)

24-30

24. COMPONENTS SYSTEM Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

No.

NAME

Q'TY

101 Casing A

1

311 Option spool

1

102 Casing B

1

321 Spring

5

3

322 Spring

4

323 Spring

3

324 Spring

3

325 Spring

1

326 Spring

1

220~250(162~184) 154 Plug PF3/4 20~24(15~18)

159

Plug PT1/4 MEC (Pre-coat bolt)

1

7.8~9.8(5.8~7.2)

160

Plug PT1/16 MEC (Pre-coat bolt)

5

161 O-ring

7

327 Spring

3

162 O-ring

15

328 Spring

1

163 O-ring

11

329 Spring

3

164 O-ring

19

331 Spring seat

24

201 Cover

3

202 Cover

6

333 Spacer bolt

12

203 Cover

1

336 Stopper

10

204 Sub cover

1

339 Stopper

1

205 Cover

5

340 Stopper

1

206 Cover

1

511 Poppet

11

512 Poppet

2

514 Poppet

2

207

9.8~14(7.2-10.3)

Tightening torque N-m (lbf-ft)

Back pressure check valve cover

16~18(11.8~13.3) Loctite #262

1

209 Cover

2

515 Poppet

1

210 Cover

2

517 Poppet

1

211

Lock valve selector sub

2

518 Poppet

1

521 Spring

11

212 Plate

1

522 Spring

2

213 Plate

1

523 Spring

1

216 Piston

1

524 Spring

2

261 O-ring

12

527 Spring

1

264 O-ring

10

266 O-ring

4

230~260(170~192) 551 Plug

13

273 Socket bolt

40

130~150(96~111)

552 Plug

2

98~120(72~89)

274 Socket bolt

4

230~260(170~192) 556 Plug

3

98~120(72~89)

275 Socket bolt

4

25~34(18~25)

278 Socket bolt

5

301 Boom spool sub

1

302 Arm 1 spool

1

69~78(51~58)

601 Main relief valve

1

303 Swing spool

1

69~78(51~58)

602 Port relief valve

3

304 Bucket spool

1

69~78(51~58)

603 Port relief valve

3

305 Boom conflux spool

1

69~78(51~58)

604 Relief valve plug assy

2

306 Travel spool

2

98~120(72~89)

606 Bypass cut valve

2

307 Travel straight spool

1

140~180(103~133) 973 Socket bolt

8

308 Arm 2 spool sub

1

140~180(103~133) 974 Socket bolt

2

25~34(18~25)

528 Spring

13~17(9.59~12.5)

1

562 O-ring

2

563 Plug

2

564 O-ring

2

309 P1 unload spool

1

977 Name plate

1

310 P2 unload spool

1

978 Rivet

2

24-31

24

24. COMPONENTS SYSTEM (2) Main relief valve (Two step relief) (601)

Main Relief Valve (Two Step Relief) Tightening torque N-m (lbf-ft) 69 to 78 (51 to 58)

No.

NAME

103 104 121 122 123

Plug; M27 Adjust screw C-ring Spacer C-ring

124 125 163 512 521 541 561

Q'TY

Tightening torque N-m (lbf-ft)

No.

NAME

1 1 1 1 1

562 611 613 614 621

Back up ring Poppet Stopper Piston Spring

1 1 1 1 1

Filter stopper Filter O-ring Plunger Spring

1 1 1 1 1

28 to 31 (21 to 23)

652 661 663 664 671

Adjust screw O-ring O-ring O-ring Lock nut; M14

1 1 1 1 1

Seat O-ring

1 1

46 to 52 (34 to 38)

673

Lock nut; M24

1

24-32

Q'TY

24. COMPONENTS SYSTEM (3) Over load relief valve (602,603)

Over Load Relief Valve Tightening torque N-m (lbf-ft) 69 to 78 (51 to 58) 69 to 78 (51 to 58)

No.

NAME

Q'TY

Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

101 102 161 162 123

Body; M27 Plug; M27 O-ring O-ring C-ring

1 1 1 1 1

541 561 562 563 564

Seat O-ring Backup ring O-ring Backup ring

1 1 1 1 1

124 125 301 511 521

Filter stopper Filter Piston Plunger Spring

1 1 1 1 1

611 612 621 651 661

Poppet Spring seat Spring Adjust screw O-ring

1 1 1 1 1

522

Spring

1

671

Lock nut; M14

1

28 to 31 (21 to 23)

24

24-33

24. COMPONENTS SYSTEM (4) Arm 2 spool (308)

308

318 341 362 372 352

Arm 2 Spool Tightening torque N-m (lbf-ft)

No. 308 318 341

NAME Spool Plunger Spring

Tightening torque N-m (lbf-ft)

Q'TY 1 1 1

No.

33 to 35 (24 to 26) Loctite #638

351 362 372

NAME

Q'TY

Plug O-ring Buckup ring

1 1 1

(5) Boom spool (301)

301

317

340

361 371

350

Boom Spool Tightening torque N-m (lbf-ft)

No. 301 317 340

NAME Spool Plunger Spring

Tightening torque N-m (lbf-ft)

Q'TY 1 1 1

16 to 18 (12 to 13) Loctite #638

No. 350 361 371

NAME Plug O-ring Buckup ring

Q'TY 1 1 1

(6) Travel straight spool (307)

307

361 371 350

Travel Straight Spool

Tightening torque N-m (lbf-ft) 16 to 18 (12 to 13) Loctite #638

No.

NAME

Q'TY

307 350

Spool Plug

1 1

24-34

Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

361 371

O-ring Buckup ring

1 1

24. COMPONENTS SYSTEM (7) Lock valve selector (211)

Lock Valve Selector Tightening torque N-m (lbf-ft)

No. 101 161 164 166 167

NAME Casing O-ring O-ring O-ring O-ring

Q'TY 1 4 1 1 1

Tightening torque N-m (lbf-ft) 10 to 14 (7.4 to 10.3) 49 to 59 (36 to 44)

No.

NAME

171 201 321 511 541

Socket bolt Plug Spring Spool Sleeve

Q'TY 3 1 1 1 1

24

24-35

24. COMPONENTS SYSTEM (8) Bypass cut valve (606) 202

301

P

T

Dr 102

101

201

Bypass Cut Valve Tightening torque N-m (lbf-ft) 98 to 120 (72 to 89) 25 to 29 (18 to 21)

No.

NAME

Q'TY

Tightening torque N-m (lbf-ft)

101 102 201

Plug O-ring Adjusting screw

1 1 1

25 to 29 (18 to 21)

24-36

No. 202 301

NAME O-ring Lock nut

Q'TY 1 1

24. COMPONENTS SYSTEM (9) Swing shuttle valve cover (204)

Swing Shuttle Valve Cover Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

166 202 541

O-ring Cover Steel ball

1 1 1

Tightening torque N-m (lbf-ft) 25 to 29 (18 to 21) 7.9 to 9.8 (5.9 to 7.2)

No.

NAME

Q'TY

542 554 555

Seat Plug Plug

1 1 1

24

24-37

24. COMPONENTS SYSTEM (10)Boost check valve (517)

104

107 102 101

Boost Check Valve Tightening torque N-m (lbf-ft)

No. 101 102

NAME Poppet Poppet

Q'TY 1 1

Tightening torque N-m (lbf-ft) 20 to 29 (15 to 21) Loctite #262

24-38

No. 104 107

NAME Plug Spring

Q'TY 1 1

24. COMPONENTS SYSTEM 24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM P1

PL PTb

(P6)

T1

(P5)

T2

P2

CT1

CMR1

CMR2

PBL

Travel straight

PAL

PCb

P1 unload

CT2

CP2

(T3)

Travel right

PCa

PAr CP1

Br Ar PBr

Boom confluence P2 unload

PB1 CCb PBs

Dr

Boom

Travel left

AL BL

LCs

LCb

Pss PAs

PAb

Swing

As Bs (RO D) Bb

PBa1

LCa

CRb

(HE AD) Ab PAa1

Arm 1

PBb Aa (HEAD)

LCc

Bucket

PAc

CRa (ROD) Bc (HEAD) Ac

PCc PBc

Arm 2

PAa2

PLc2 Ba (ROD)

LC AT2 LCo

LCAP2

PAo

Option

Ao Bo PBo

PBa2 MU

Hydraulic Circuit Diagram

24

24-39

24. COMPONENTS SYSTEM 24.1.2.2.3 OPERATION (1) In neutral position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system, because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though the center bypass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. (D) Pss

606

517

52 306

YP1

YS1

YA1

YT1

YBG1

T1

P2

P1

P1-20

YT1

Y B2

YK2

P2-20

YAG2

309 55

310

606 PBc PCc

In Neutral Position

24-40

(D)

Connected to low pressure circuit of P2 side casing

24. COMPONENTS SYSTEM (2) Actuation in travel operation 1. In travel independent operation On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310). The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into A side of right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2 flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump P1. But in the meantime, the return oil from the B sides of left and right travel operations passes through between the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation.

In Left Reverse Travel (At PBL Is Pressurized)

24

24-41

24. COMPONENTS SYSTEM 2. In travel straight operation When actuator other than travel operation and the travel operation are operated simultaneously in the said item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward. With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel straight spool (307) closes and the pump line on the travel sides is independent from pump line on actuator.

Movement Of Travel Straight Spool

24-42

24. COMPONENTS SYSTEM (3) Actuation in bucket operation 1. In bucket digging operation On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac). In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is low, the pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation, the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may be occurred on bucket cylinder head side (H). (Stroke limiter ON) 53 216

PAc

PCc

PBc

Bc 321 322

304

(D)

Ac

LCc 511

(R)

(H)

In Bucket Digging Operation (Stroke Limiter ON)

24

24-43

24. COMPONENTS SYSTEM 2. In bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc). In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through low pressure circuit (D'), and returns to the hydraulic tank through tank port T1. The return oil does not pass through boost check valve (517).

In Bucket Dumping Operation

24-44

24. COMPONENTS SYSTEM (4) Boom 1. In boom up operation On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCa and switches unloading spool (309). And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spools (310). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab). In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.

301

(R)

(R)

(H)

(H)

53

(D) Bb

511 LCb

Ab

321 322

514 CRb

PAb

BH chamber

PBb

In Boom Up Operation (Boom Spool)

24

24-45

24. COMPONENTS SYSTEM 2. In boom up conflux operation The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side.

In Boom Up Conflux Operation (Boom Conflux Spool)

24-46

24. COMPONENTS SYSTEM 3. In boom down operation On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is connected to the drain circuit. The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through Ushaped passage, and is supplied to boom cylinder rod side (R) through port (Bb). In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)

(R)

(R)

(H) 511

53

317 301 Bb

(H)

LCb

Ab

CRb

514 BH chamber

PAb

321 322

PBb

(D)

In Boom Down Operation

24-47

24

24. COMPONENTS SYSTEM (5) Arm operation 1. In arm out operation On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R). In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D') and casing inside passage (HH) and then flows into low pressure circuit (D') through between the perimeter of arm 2 spool (308) and casing. The return oil in low pressure circuit (D') returns to hydraulic tank through tank port T1 without passing through boost check valve (517). (R) AR chamber 514 211 CRar

322 321

(H)

Ba

511

LCa

302

Aa

56 PAa1

PBa1

P1 (D') (D)

Arm 1 RR

RH

(D')

HH

52

LCAT2 LCAP2 PBa2 Dr

PAa2 Dr

P1

(D') Arm 2

To arm 1 spoo Aa (HEAD)

PAa2

PBa2

To pilot cut valve

53 MU

328

515 321

308

Ba (ROD)

511 LCAT2 LCAP2

In Arm Out Operation

24-48

24. COMPONENTS SYSTEM 2. In arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is released. And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves leftward against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa). In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302). The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function) And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through tank port T1.

24

24-49

24. COMPONENTS SYSTEM

322 321

AR chamber 514

211

(H)

(R) CRar

511 LCa Ba

302

Aa

56 PBa1

PAa1 Arm 1

(D') (D)

Arm 2

RH

RR 52 (a)

PAa2 [XR] 53

LCAT2 LCAP2 P1 PBa2 Dr To arm 1 spool Aa (HEAD)

Ba (ROD) To pilot cut valve

Circuit (I)

MU

321

(D') (D)

PAa2 Dr

HH

PBa2

328

P1

308 (D) 319 511 LCAT2 LCAP2

317 515

In Arm In Operation (At light load: Arm Recirculation Function)

24-50

24. COMPONENTS SYSTEM 3. In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (aU), almost all the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1. The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.

AR 322 321 chamber 514 211

(R)

(H)

CRar Ba

511 LCa

302

Aa

56 PBa1

PAa1 Arm 1

(D') (D)

(D') (D) Arm 2

RR

52

RH

HH

P1

LCAP2

P1 PBa2 Dr

PAa2 Dr

(a) PAa2 [XR]

PBa2

To arm 1 spool Aa (HEAD)

Ba (ROD)

53

To pilot cut valve

MU

Circuit (II) 515

328 321

LCAT2

317

308 319 (D) LCAP2 511 LCAT2

In Arm In Operation (In Heavy Load Operation)

24-51

24

24. COMPONENTS SYSTEM (6) Swing operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss. The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs). In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

Swing Operation

24-52

24. COMPONENTS SYSTEM (7) Spool actuation for operation in option This spool is used to control the attachment in option like Nibbler (Crusher), etc. Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (323) (324), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through Ushaped passage and is supplied to actuator for attachment through port (Ao). In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The operation where the pilot pressure acts on PBo port is the same as the above. * The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil passage is used as passage to connect to N&B selector valve.

Spool Actuation For Operation In Option

24

24-53

24. COMPONENTS SYSTEM (8) Lock valve operation The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder. 1. At boom spool neutral position (Arm spool makes the same operation.) When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed the lower side as shown in the below Fig. and restricts the leaking to the minimum.

Lock Valve Operation (At Boom Spool Neutral Position)

24-54

24. COMPONENTS SYSTEM 2. In boom down operation (In arm in operation) Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the below Fig.. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514). And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR through spring chamber (321). With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as shown in the below Fig. is released. And since lock valve poppet (514) receives holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open. The said operation, in boom down operation, is performed before making the opening (meter out opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the operation has no effect on the operability of boom down operation. In case of arm-in operation, the operation is the same. Return oil from boom cylinder head

RH CHAMBER 514

Lock valve selector BH CHAMBER

511

541

Sb CRb

PLc

Ab

Dr

(a)

A

(b)

PLc Sa Sb

A Sa

321 Dr

SECTION A-A

321

322

PBb

(D) Dr

301

Lock Valve Selector Operation (At Boom Down Operation)

24

24-55

24. COMPONENTS SYSTEM (9) By-pass cut valve This by-pass cut valve is located on the most downstream of P1 side center by-pass passage (52) and P2 side center by-pass passage (55). And this by-pass cut valve controls the flow of hydraulic oil from each center by-pass passage to low pressure passage (D). 1. In normal operation Adjusting screw (201) is tightened up to end in normal operation. Tapered end of adjusting screw (202) is seated on the seat of casing, and flow between center by-pass passage (52) and low pressure passage (D) is blocked. Consequently, in normal operation, center by-pass passage (52) is always blocked from low pressure passage (D). And the hydraulic oil delivered by pump P1 does not flow through center by-pass passage (52), but returns to hydraulic tank through P1 unload spool (309).

201

Dr

(D) 52

By-Pass Cut Valve (In Normal Operation)

24-56

24. COMPONENTS SYSTEM 2. At the time when failure occurred When the electric system is failed, P1 unload spool (309) stops at neutral position. Hydraulic oil entered from P1 pump is blocked with P1 unload spool (309). And pump pressure rises to set pressure of main relief valve because oil flows through center by-pass passage (52) and it is blocked with by-pass cut valve (606). Meanwhile, the hydraulic oil flows from center by-pass passage (52) flows low pressure passage (D) through by-pas cut valve (606). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position. And passage to low pressure passage (D) is blocked, but because center by-pass passage (52) is connected to low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.

201 301

Dr

(D)

52

By-Pass Cut Valve (In Condition Of Failure)

24

24-57

24. COMPONENTS SYSTEM (10)Boost check valve, By-pass check valve 1. Boost check valve The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage. a. In normal operation The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure generated by spring (527) is used as the boost pressure for the low pressure passage. But the return oil used for the arm out and bucket dumping operation does not pass through boost check valve (517), but returns from low pressure passage (D') to hydraulic tank through tank port T1. b. In make up operation When supplying to make up the flow rate through low pressure passage (D) after the swing operation is suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic oil is made up from hydraulic tank into low pressure passage (D). When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving section in ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make up the deficient flow rate.

Boost Check Valve Operation

24-58

24. COMPONENTS SYSTEM 2. By-pass check valve Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage. When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2.

527

528 (D')

T2

518 T1

102

517

(D)

By-Pass Check Valve Operation

24

24-59

24. COMPONENTS SYSTEM 24.1.3 PILOT VALVE (ATT) 24.1.3.1 OUTLINE (1) Outside view

Single operating angle Single operating angle (Port 2, 4) (Port 1, 3)

5-PF3/8 T=49.0 (36.1)

The adjust nut (opposing flats : 22) : Fix adjust nut (opposing flats : 22) when the lever is installed by means of spanner or the like. Then tighten the mating lock nut to 41 + 3 N.m (302.2 lbf.ft).

PF1/4 T=29.4 (21.7)

VIEW A

T=Tightening torque : N.m (lbf.ft)

LQ30V00033F1

Part No.

PV48K2058

Model

Refer to the curve below

Operating torque

6.9 MPa (1000 psi)

Max. primary pressure

5.0 MPa (725 psi)

Primary pressure

20 L/min (5.3gal/min)

Rated flow

Approx. 1.9 kg (4.2 lbs)

Weight

A

(580)4.0

3.0(2.2)

(377)2.6

SINGLE OPERATING TORQUE

2.19(1.62)

2.0(1.5)

(290)2.0

1.91(1.41)

(145)1.0

1.0(0.74)

(87)0.6

1.05(152) 0.86(125)

0

0.8

2

4

0.83(0.61)

6 6.4 7 0

Secondary pressure [MPa (psi)]

(493)3.4

(435)3.0

0

(580)4.0

4.0(3.0) SECONDARY PRESSURE

4.0(3.0) SECONDARY PRESSURE

(493)3.4

(435)3.0

3.0(2.2)

(377)2.6

1.0(0.74)

(87)0.6

0

0.83(0.61)

1.05(152) 0.86(125)

0

0.8

2

4

6

8

8.8

0 9.4

PUSH ROD STROKE (mm) 0

5 10 15 19 Operating angle (deg.) P

1

2.0(1.5)

(145)1.0

PUSH ROD STROKE (mm) 0

2.28(1.68)

SINGLE OPERATING TORQUE

(290)2.0

T

3 2 HYDRAULIC SYMBOL

24-60

4

5 10 15 20 Operating angle (deg.)

25

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

PORTS 2, 4

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

Secondary pressure [MPa (psi)]

PORTS 1, 3

24. COMPONENTS SYSTEM 24.1.3.2 CONSTRUCTION

Apply Loctite #277

312 302 501

301 *246-1

Apply grease on top section

212 *246-2 151

213

*218

211

214

Secondary pressure adjusting shim

216-2

216-1

241-2

241-1

201-2

201-1

217

221

101

PORTS 2, 4

Tightening torque N-m (lbf-ft)

Apply grease on rotating and sliding sections. Be careful the assembling direction

No.

NAME

PORTS 1, 3 Pilot Valve (ATT)

Q'TY

101 151 201-1 201-2 211

Casing Plate Spool Spool Plug

1 1 2 2 4

212 213 214 216-1 216-2

Push rod Seal O-ring: 1B P20 Spring seat Spring seat

4 4 4 2 2

Washer 2 (Shim)

4

217

Tightening torque N-m (lbf-ft)

47.1 (34.7) 68.6 (50.6)

Note) The parts marked * may not be equipped depending on valve type.

24-61

No.

NAME

Q'TY

*218 221 241-1 241-2 *246-1

Seat Spring Spring Spring Spring

4 4 2 2 2

*246-2 301 302 312 501

Spring Joint: M14 Circular plate Adjust nut: M14 Boots

2 1 1 1 1

24

24. COMPONENTS SYSTEM 24.1.3.3 OPERATION (1) Lever in neutral (See right Fig.) The action of spring (509) (for secondary pressure setting) that determines the output pressure of the pilot valve does not act upon spool (201). Therefore, spool (201) (for return) is pushed up by spring (221) [spring seat (216)]. The output ports (2,4) connect with the T port. The result is that the output pressure is equal to the tank pressure. 216 509 221 201 PORT (2,4)

PORT (1,3)

Lever In Neutral (2) When the pilot lever is tilted (See right Fig.) When the lever is tilted and the push rod (511) strokes, the spool (201) [spring seat (216)] moves downward to make the port P to connect with the port 2, 4, with the result that the oil of the pilot pump flows to the port 2 ,4 to produce a pressure.

511

216

201 PORT (2,4)

PORT (1,3)

When The Lever Is Tilted (3) Lever held (See right Fig.) When the pressure at ports (2,4) rises to a level equivalent to the action of spring (509) that is set by tilting the lever, the hydraulic pressure balances the spring action. When the pressure of ports (2,4) rises above a set value, ports (2,4) and the P port close while ports (2,4) and the T port open. When the pressure at ports (2,4) falls below a set value, ports (2,4) and the P port open while ports (2,4) and the T port close. Thus the secondary pressure is kept constant.

509

T PORT P PORT

PORT (2,4)

PORT (1,3)

When The Lever Is Held

24-62

24. COMPONENTS SYSTEM (4) Operation in the area where the tilting angle of the lever is large. (varies with the model) If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts the bottom of the bore of the push rod. This keeps the output pressure connected with the P port pressure. Furthermore, on a model in which a spring seat and a spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever is turned beyond a certain angle. This causes the secondary pressure gradient to change by the spring action. Thereafter, the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure connected with the P port.

24

24-63

24. COMPONENTS SYSTEM 24.1.4 PILOT VALVE (TRAVEL) 24.1.4.1 OUTLINE (1) Outside view

Port size

Tightening torque Port name N.m (lbf.ft)

PF3/8

30 (22)

PF1/4 16.7 (12.3)

Function

1

LH travel forward port

2

LH travel reverse port

3

RH travel forward port

4

RH travel reverse port

T

Tank port

5

LH travel pressure sensor port

6

RH travel pressure sensor port

P

Pilot primary pressure port

(2) Specifications P Item

Specifications

Part No.

YN30V00105F1

Type

6TH6NRZ

Primary pressure

4.9MPa (711psi)

Secondary pressure

0.54~2.35MPa (78~341 psi)

Rated flow

25 L/min (6.6 gal/min)

Weight

Approx. 8kg (18 lbs) 1

(3) Performance characteristics Secondary pressure [MPa (psi)]

Secondary pressure

2.35 + 0.15 (340 + 22) 0.54 + 0.1 (78 + 15) 0 (4.7 + 0.5) 6.4 + 0.64 7.7 + 0.77 (5.7 + 0.6) 12.7 + 1.27 (9.4 + 0.9)

Operating torque

[N.m (lbf.ft)]

T

1 30' 2 30'

11 30' 12 30'

Pedal angle (degree)

Operating torque Control diagram

24-64

5

2 3 Hydraulic symbol

6

4

24. COMPONENTS SYSTEM 24.1.4.2 Construction and operation The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve. The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6). Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger (5). The dumper system is made up of plunger (8), orifice (9) and return spring (10). In stationary condition, the pedal is held in neutral position by return spring (10). In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for dumper system. The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the flow rate of hydraulic oil led through orifice (9).] Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring (3) first moves the control spool (2) downwards, and then closes the passage between control port and the return pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control spool reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it starts retaining the condition. The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according to the mutual relations between the control spool (2) and control spring (3). The closed circuit pressure control makes proportional control of selector valve and high responsibility of hydraulic pump and motor possible in relation with the characteristics of foot pedal (1) position and control spring (3).

1

5 3 8

3 11

10 12

4 10 2 9

9 7

6

2 control ports 1-3

P line

control ports 2-4 T line

24

24-65

24. COMPONENTS SYSTEM 24.1.5 SWING MOTOR UNIT 24.1.5.1 SPECIFICATION (1) General view

Port name

Symbol

Port size

Tightening 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)

2-PF1/4

36 (27)

PF1/4

36 (27)

PT3/4

98 (72)

PA,PB Pressure measuring port PG

Parking brake release port Gear oil level gauge or IP,L,AR Air breather port or Gear oil filling port

IP, L, AR 12- 22 Through

DB B PG

A

PB PA

M

THREAD FOR EYE BOLT 2-M12 PG DB

RELIEF VALVE

PB PA M A,B

M PB

PA

A

PG

B

Hydraulic diagram

24-66

DB

24. COMPONENTS SYSTEM (2) Specifications Swing motor unit part No.

LC15V00027F2 Type

M5X180CHB-10A-60D/295

Part No.

Hydraulic motor

Anti-reaction valve block

LC15V00022F2

Displacement

cm3 (in3)

180.1 (11.0)

Working pressure

MPa (psi)

32.4 (4700)

Max. flow

L/min (gal/min)

294 (77.7)

Braking torque

N-m (lbf-ft)

860-1120 (634-827)

Release pressure

MPa (psi)

2.4~5.0 (348~725)

Relief set pressure

MPa (psi)

29 (4205)

Weight

kg (lbs)

72.5 (160)

Type Weight

Hydraulic motor assy weight

2KAR6P72/240-712 kg (lbs)

2.5 (5.5)

kg (lbs)

75 (165)

Part No.

LC32W00011F1

Speed reduction type

Planetary 2-stage

Reduction ratio Reduction unit

27.143

Lubicate oil Lubicate oil volume

Gear oil SAE90 (API class GL-4 grade) L (gal)

Grease

Total weight

7.4 (1.96) Extreme pressure lithium base #2 grease

Grease volume

kg (lbs)

Approx. 1.7 (3.7)

Weight

kg (lbs)

371 (818)

kg (lbs)

446 (983)

24

24-67

24. COMPONENTS SYSTEM 24.1.5.2 CONSTRUCTION (1) Swing motor

702 712

351

ARRANGEMENT OF BRAKE SPRING

355 401 488

469

051-1 051

151 162 052 161 303

100 171

A

163 A

985 391 390 444

984 131 451

472

400-1 400-2

712

400 707

702

706 986 742 743

994

111

121 123 122 124 114 301 443

491 101

24-68

SECTION A-A

052

24. COMPONENTS SYSTEM

Tightening torque N-m (lbf-ft)

No.

177 (130)

051

36 (27)

29 (21)

Q'TY

Tightening torque N-m (lbf-ft)

Relief valve; M33-P1.5

2

69 (51)

051-1 O-ring; 1B G30 052 Anti-reaction valve sub 100 Casing for anti-reaction valve 101 Drive shaft

2 1 1

NAME

431 (318)

No.

NAME

Anti-reaction valve; M22P1.5 400-1 O-ring; 1B P20 400-2 Backup ring 401 Socket bolt; M20X45 400

Q'TY 2 2 2 4

1

443

Roller bearing

1

444 451 469 472 488

Roller bearing Pin ROMH plug; M36-P1.5 O-ring; W1516,WG44 O-ring; 1B P34

1 2 2 1 2

111 114 121 122 123

Cylinder Spring plate Piston Shoe Set plate

1 1 9 9 1

124 131 151 161 162

Shoe plate Valve plate Plug; PF1/4 O-ring; 1B P11 O-ring; 1B P12

1 1 2 2 2

491 702 706 707 712

Oil seal Brake piston O-ring; W1516,WG42 O-ring; W1516,WG45 Brake spring

1 1 1 1 14

163 171 301 303 351

O-ring; 1B P6 Socket bolt; M8X55 Casing Valve casing Plunger

2 4 1 1 2

2.7 (2.0) 5.6 (4.1) 0.9 (0.66)

742 743 984 985 986

Friction plate Separator plate Plug; PF1/2 Plug; PF1 Plug; PF1/4

3 4 1 1 1

355 390 391

Spring Name plate Rivet

2 1 2

98 (72)

994

Plug; PT3/4

1

539 (398)

24

24-69

24. COMPONENTS SYSTEM (2) Swing reduction unit

20

22 11 27 25 24 4 5 10

3 SURFACE OF LUBE OIL

23 7 11 26 9 14 28 29

3 6 8 15 12 17

34

3

VIEW 30 31

3

35, 36, 37, 38

18 32

33 13 16 2 1

21 19

DETAIL aa

aa

Tightening torque N-m (lbf-ft)

No.

Parts

Q'TY

Tightening torque N-m (lbf-ft)

No.

Parts

Q'TY

1

Pinion

1

20

Plate

1

2

Shaft

1

21

Ring

1

3

#1 Sungear

1

22

Thrust washer

6

4

#1 Planetary pinion

3

23

Thrust washer

8

5

#1 Spider assy

1

24

Snapring

1

6

#2 Sungear

1

25

Snapring

3

7

#2 Planetary pinion

4

26

Spring pin

4

8

Ring gear

1

27

Capscrew ; M20X200

12

9

#2 Spider assy

1

28

Grease fitting

1

10

Shaft

4

29

Relief fitting

1

11

Needle bearing

11

69.1±4.4 (51±3)*2

30

Tube

1

12

Roller bearing

1

69.1±4.4 (51±3)*2

31

Elbow

1

13

Roller bearing

1

69.1±4.4 (51±3)*2

32

Plug

1

14

Oil seal

1

33

Cap

2

15

Housing

1

34

Capscrew

3

16

Oil seal

1

35

Shim ; t=0.1

1

17

Sleeve

1

36

Shim ; t=0.2

1

18

Sleeve

1

37

Shim ; t=0.3

1

19

Plate

1

38

Shim ; t=0.5

1

539±54 (398±40)*1

279±30 (206±22)*1

*1 : Apply Three Bond #1360K. *2 : Apply seal tape or Loctite #577. *3 : Apply Loctite #515.

24-70

24. COMPONENTS SYSTEM 24.1.5.3 OPERATION 24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR If the high pressure oil flows into the cylinder through the inlet port (a) of valve plate (131), as shown on the figure on the right, the hydraulic pressure acts upon piston (121) and creates force F in the axial direction. The force F may be divided into force F1 vertical to shoe plate (124) via shoe (122) and force F2 at right angles with the shaft. The force F2 is transmitted to cylinder block (111) via pistons (121) and causes drive shaft to turn so as to produce a rotating moment. The cylinder block (111) has nine pistons equally arranged. Rotating torque is transmitted to drive shaft by turns by pistons connected to inlet port of high pressure oil. If the oil supply and discharge directions are reversed, the drive shaft rotates in the opposite direction. Theoretical output torque T can be given by the following equation.

Operation Of Hydraulic Motor

24

24-71

24. COMPONENTS SYSTEM 24.1.5.3.2 VALVE CASING SECTION (1) Operation of anti-cavitation check plunger Since the system using this type of motor is not equipped with a valve having a counterbalance function, the motor is rotated beyond the oil feed rate in some cases. The system has check plunger(351) and sucks in deficient oil, in order to prevent cavitation from occurring due to oil deficiency.

Operation Of Anti-Cavitation Check Plunger (2) Operation of relief valve 1. Consider where the relief valve is pressurized. The pressure at the P, R ports is equal to the tank pressure at the beginning, as shown in below Fig.. The relief valve begins to operates when the hydraulic pressure that is determined by the product of the pressure-receiving area A1 of plunger(301) and the pressure P balances the hydraulic pressure that is determined by the product of the pressure-receiving area A2 of the plunger(301) and the pressure Pg of chamber g. Thereafter, the pressure of chamber g rises and the piston 1 (302) begins to stroke. The load to spring (321) increases by this movement of the piston. As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1 till Ps. This process is explained in the following in the relationships between the movements of the components shown in (2) to (4) of below Fig. and the relief pressure :

Functional Explanation Of Relief Valve (1)

Functional Explanation Of Relief Valve (2)

a. Condition shown in above Fig.. If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor m of plunger (301). The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of spring (321), the relief valve performs relieving action by the pressure P1. This relationship is expressed as : P1XA1=FSP1+Pg1XA2 where FSP1 : primary set load value of spring (321)

24-72

24. COMPONENTS SYSTEM b. Condition shown in below Fig.. The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the left. On that occasion, since the machine turns to the left while discharging the oil of chamber h arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston 1 (302), chamber h serves as a dumping chamber. The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief pressure P rises smoothly.

P

P R

R

Functional Explanation Of Relief Valve (3)

Functional Explanation Of Relief Valve (4)

c. Condition shown in above Fig.. The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust plug (401). Therefore, the relief valve keeps its normal relieving action whereby the relief pressure is held at P2. In the processes 1 to 3 above, the relief pressure changes as shown in above Fig..

(4)

PS (3) P1

(2) (1) t1

Condition 2. Function when the relief valve pressure is reduced Let us consider the pressure of the P port is reduced. When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank pressure level. The result is that the plunger (301) which is now open moves to the left and is seated on seat (341). At the same time, the piston 1 (302) moves to the right by the action of spring (321) and returns to the condition of above Fig..

24

24-73

24. COMPONENTS SYSTEM (3) Operation of anti-reaction valve

Hydraulic Circuit Diagram For Anti-reaction Valve 1. Neutral condition: Above Fig. illustrates the relationship between the neutral condition of the anti-reaction valve and the hydraulic circuits. Now, let us consider a braking condition in which brake pressure generates on the AM port side.

L

k 322

313

321

311

Neutral Condition 2. When brake pressure occurs: If pressure (P) generates at the AM port, it passes through the passage L, the hole on the shaft of seat (313) and the passage m of plunger (311) and is led to the n chamber. When the pressure P rises above a value (Ps) set by spring (321), plunger (311) compresses spring (321) and shifts it to the left. Seat (313) compresses weak spring (322) as pushed by plunger (311) and moves to the left.

24-74

m

n

P=PS L

322

313

321

When Brake Pressure Occurs

311

24. COMPONENTS SYSTEM 3. At anti-reaction action When inertia load stops moving (point Y below Fig.), brake pressure (P) tries to fall. When P t--> r--> k. The result is that the pressures at the AM and BM ports become equal (Pb), falling into the condition at point Z in below Fig.. This prevents the hydraulic motor from swing shock by the closing pressure of the AM port. p

t

P

Y

PS P high pressure side (DIS) of compressor Blue hose: Low pressure side (LO) of gauge manifold --> low pressure side (SUC) of compressor

HIGH PRESSURE GAUGE GAUGE MANIFOLD HIGH PRESSURE VALVE(CLOSED) RED

LOW PRESSURE GAUGE (CLOSED)LOW PRESSURE VALVE BLUE HIGH PRESSURE SIDE DIS

YELLOW LOW PRESSURE SIDE SUC COMPRESSOR VACUUM PUMP(STOP)

Do not mistake the high pressure hose for the low pressure hose in any circumstances when connecting them. Put the hose in firmly till a clicking sound is heard. 3. Connect the center valve of the gauge manifold with the charging hose of the vacuum pump.

BLUE RED CHARGING HOSE (GAS VALVE)

Connecting Gauge Manifold

Some kinds of gauge manifolds are not equipped with an open/close valve in the center.

25-24

25. AIR CONDITIONER SYSTEM (2) Vacuum making (See right Figure) 1. Open the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold. 2. Turn on the switch of the vacuum pump and make vacuum for more than 30 minutes.

LOW PRESSURE VALVE(OPEN) (CLOSE) HIGH PRESSURE VALVE(OPEN) More than (CLOSE) 30 min

GAUGE MANIFOLD

3. When vacuum making for a specified duration is over (degree of vacuum : less than - 750 mmHg), close the high pressure valve and the low pressure valve on the gauge manifold. DIS

4. Then turn off the vacuum pump.

SUC

Vacuum Making Operation (3) Air-tightness Check Close the high pressure valve and the low pressure valve on the gauge manifold. Leave it as it is for more than five minutes and make sure that the gauge indication does not return toward 0.

If the gauge indication goes toward 0, there is a leak somewhere. Retighten pipe joints, make vacuum again and make sure of no leakage.

25-25

25

25. AIR CONDITIONER SYSTEM 25.5.3.2 GAS CHARGING OPERATION (1) Charging from high pressure side (See right Figure) 1. After making vacuum repeatedly, change the charging hose (yellow) on the gauge manifold from the vacuum pump to the service can.

AIR PURGE

2. Air purge Open the service can valve. (However, close the high and low pressure valves on the gauge manifold.) Then push the gas valve on the side service port on the low pressure side of the gauge manifold, using a screw driver, to let out the air in the charging hose by the pressure of the refrigerant (See right Figure). The operation ends when a hissing sound is heard. 3. Open the high pressure valve on the gauge manifold and charge in refrigerant. [Charge in gaseous refrigerant to a gauge pressure of 0.1MPa (14psi).] After charging, close the high pressure valve on the gauge manifold and the service valve. (See right Figure)

CLOSE

SCREW DRIVER

OPEN SERVICE CAN VALVE

YELLOW BLUE

RED

Gas Charging Operation

LOW PRESSURE VALVE(CLOSE) BLUE

HIGH PRESSURE VALVE (OPEN) (CLOSE) RED FILL IN 1~1.5 CANS OF REFRIGERANT

DIS SERVICE CAN VALVE (OPEN) (CLOSE) CHARGE

YELLOW

SUC

Gas Charging Operation (High Pressure Side)

Do not run the compressor during this work. Otherwise the refrigerant flow in reverse direction which causes the service can and the hoses to explode. This is very dangerous. (2) Checking for gas leak Check for gas leaks in the cycle, using a gas leak detector (electric type). Retighten and correct leaking points.

Use the leak tester for R134a. Do not use one for flon gas service as it provides poor sensitivity.

25-26

25. AIR CONDITIONER SYSTEM (3) Charging from low pressure side (See right Figure) 1. Make sure that the high-pressure and low-pressure valves on the gauge manifold and the service can valve are closed. 2. Start the engine and run the revolution from 1400 to 1600 rpm and close the cab door and the windows. 3. Turn on the air-conditioner switch, set the fan switch to Max and the temperature control switch to cool Max. 4. When charging gas, set the discharge pressure of the compressor from 1.4 to 1.6 MPa (200 to 230psi).

25 LOW PRESSURE VALVE OPEN CLOSE

HIGH PRESSURE VALVE(CLOSE) RED (CLOSE SECURELY)

WHEN AIR BUBBLES IN THE SIGHT GLASS DISAPPEAR

DIS

YELLOW BLUE SERVICE CAN VALVE(OPEN)

SUC COMPRESSOR OPERATION

SERVICE CAN (DO NOT TURN OVER)

Gas Charging Operation (Low Pressure Side) 5. Open the low pressure valve on the gauge manifold and the service can valve and fill in refrigerant until air bubbles in the sight glass of the receiver disappear. (See Figure "Gas Charging Operation") [Total amount of gas to be charged: 850g to 950g (1.89 to 2.11 lbs)] 6. When refrigerant charge is completed, close the low pressure valve on the gauge manifold and the service can valve.

SIGHT GLASS

RECEIVER DRYER

Receiver Dryer

Do not open the high pressure valve of the gauge manifold. Do not turn over the service can. The compressor valve may be damaged because the refrigerant is sucked in a liquid state.

25-27

25. AIR CONDITIONER SYSTEM (4) Criterion for checking the amount of refrigerant filled in JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER PROPER LEVEL

After A/C is turned on, only a little bubbles are seen and thereafter light milky white is seen.

OVERCHARGE

After A/C is turned on, no air bubbles are seen.

UNDERCHARGE

After A/C is turned on, continuous air bubbles are seen.

If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor. If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated. Moreover, the circuit pressure gets abnormally high: Always keep a proper level. (5) Removing Gauge Manifold When the refrigerant level has been checked, disconnect the charging hoses from the compressor as follows. 1. Press the "L" shape metal fitting on the charging hose (blue) on the low pressure side against the service valve of the compressor to avoid leakage of the refrigerant. As soon as the nut has been removed, disconnect the charging hose from the service valve. 2. Leave the high pressure side as it is until the high pressure gauge reading falls. [below 1MPa (140psi)]. 3. Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure side.

25-28

25. AIR CONDITIONER SYSTEM

25

This page is blank for editing convenience.

25-29

25. AIR CONDITIONER SYSTEM

25.6

ELECTRIC CIRCUIT

25.6.1 WIRING DIAGRAM AND CONNECTORS

PRESSURE SWITCH (RECEIVER DRYER)

FUSE 20A

WORK LIGHT POWER SUPPLY FOR NIGHT LIGHTING SWITCH POWER FOR COMPRESSOR CLUTCH POWER FOR CONTROL AMPLIFIER

MAIN KEY SW

FUSE 5A FUSE 5A

FUSE 15A

COMPRESSOR

NOTE) 1. THe double chain lines indicate the wiring on the excavator side. 2. The connector colors indicate the cord colors seen from the connecting part. 3. Unless otherwise specified, wire diameters are 0.5. 4. Use the fuses that are specified capacity in this diagram.

LIGHT PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE

Electric Diagram (1/2)

25-30

A/C MAIN POWER

25. AIR CONDITIONER SYSTEM

Night lighting signal Mg. C output Blower amplifier output Blower OFF relay Monitor of blower power source Potentio Potentio Potentio

Air inlet sensor Evaporator sensor Solar sensor sensor

Amplifier power source Amplifier grounding

25

AIR INLET SENSOR

EVA SENSOR

SOLAR SENSOR COMPRESSOR RELAY

FUSE (5A)

MOTOR ACTUATER (FOR AIR MIX)

MOTOR ACTUATER (FOR MODE) BLOWER OFF RELAY

BLOWER MOTOR

FAN DRIVER

MOTOR ACTUATER (REC/FRESH)

Electric Diagram (2/2)

25-31

25. AIR CONDITIONER SYSTEM 25.6.2 STRUCTURE AND OPERATION OF EACH PARTS (1) Control panel The control unit is integrated into the control panel, and processes the signal input by each sensor, etc. The signal input by each switch through the control panel with the function of the built-in micro computer comprehensively controls each actuator (Air inlet / outlet mode select, air mix), blower motor and compressor on the output side. The self-diagnosis performance is provided to facilitate the trouble shooting.

Control Panel

(2) Fan driver The power transistor shifts the blower motor into variable speed with base current from the control unit.

2

3

1

Check over the continuities between terminals of the fan driver.

2

3

1

Blower Controller TERMINAL NO. 1 2 3

CONTINUITY CONTINUED

TESTER

NOT CONTINUED CONTINUED(DIODE PARALLEL AND FORWARD DIRECTION FLOW)

25-32

25. AIR CONDITIONER SYSTEM (3) Relay Four-electrode relay is used for the blower OFF relay and compressor relay.

25

1. Blower OFF relay The blower OFF relay turns on after receiving the signal from the control amplifier. When the blower OFF relay turns on, the source voltage is supplied to the blower motor and the blower motor starts running. 2. Compressor relay The relay ON-OFF is switched by the control amplifier and electronic thermostat control. 3. Relay specification and inspection a. Coil resistance: 320 ohms b. Specified voltage: DC20V to 30 V c. Be careful about the coil polarity of relay. d. Inspection: Inspect the continuity between terminals 3 and 4 as follows. 20 to 30 V applied between terminals 1-2: Continued 20 to 30 V not applied between terminals 1-2: Not continued (4) Motor actuator Air mix actuator is located in at the center of the airconditioner unit, and opens and closes the air mix damper through the link motion. The air mix actuator incorporates the potentiometer which is switched by the linked shaft with the actuator. When the target air mix door position is determined through the temperature control switch, the control unit reads the level of the potentiometer of the actuator. And it determines the rotating direction of the motor in either normal rotation or reverse rotation. And the motor rotates, the contact point is moved, and when the contact point is detached or the output signal of the control unit turns OFF, the motor stops.

25-33

Control panel

Motor actuator M

Both Motor Actuators

25. AIR CONDITIONER SYSTEM < Connector arrangement >

< Motor input > Terminals Rotational direction

Potentio resistance characteristic - Between electrodes 120 degrees C Total resistance 4.7 kilo-ohms When 5 volt is applied to circuit between (6) and (4) (+ at (6) and - at (4))

Output voltage between (5) and (4)

(5) Mode actuator The mode actuator is located in the outlet of the air conditioner unit. And it opens or closes the mode door through link motion. The mode actuator incorporates a potentiometer which is switched by the linked shaft with the actuator. When the target air mix door position is determined through the temperature control switch, the control unit reads the level of the potentiometer on the actuator. And it determines the rotating direction of the motor in either normal or reverse rotation. And the motor rotates, the contact point is detached or the output signal of the control unit turns OFF, the motor stops.

Circuit board characteristic

(6) The actuator for air inlet / outlet (12V) The actuator for inlet and outlet air mode select is installed on the blower intake unit, and opens and closes the inlet or outlet air damper through the link motion. The actuator for the inlet and outlet air mode select incorporates the position detection switch which is switched with the movement of the shaft in the actuator. When the inlet or outlet damper position is set by the inlet and outlet switch on the control panel, the control unit reads the signal of the position detection switch in the actuator and determines the rotation direction of motor in either normal rotation or reverse rotation. And the motor rotates, the position detection switch also rotates and makes it stop at the set position of the inlet or outlet air damper. (7) Evaporator sensor - air inlet sensor This sensor is used to control the evaporator outlet temperature with the compressor ON-OFF to protect the evaporator from freezing, and this evaporator sensor functions as a sensor of this control. Evaporator sensor and air inlet sensor specifications Terminal resistance: at 0 degree C: 7.2 kilo-ohms at 25 degree C: 2.2 kilo-ohms

25-34

AMPLIFIER

MOTOR ACTUATOR

INNER AIR SIDE OUTER AIR SIDE LIMITER

Evaporator Sensor - Air Inlet Sensor

25. AIR CONDITIONER SYSTEM (8) Solar sensor This solar sensor, which is used to correct the solar radiation to the auto air conditioner detects the strength and solar orientation of sunbeam after transforming them into current by means of photo diode.

Disconnect solar sensor connecter from harness. Using voltmeter, measure the voltage between connector terminals. The measured voltage should be varied by intensity of sunshine. (When there is no sunshine, measured voltage is almost 0 volt.)

25 Solar Sensor

Measure the voltage in the voltage measurement mode (V mode). Measurement in resistance mode (Ohm mode) causes the damage to components. (9) Dual pressure switch This dual pressure switch is attached on the L-hose and is used to turn OFF the compressor, and employs dual type (for high and low pressure control) to protect the cooler cycle from possible failure at the time when abnormal pressure was generated on the high pressure side. SPECIFICATION OF DUAL PRESSURE SWITCH 0.02MPa(2.9psi) 0.59MPa(86psi) ON OFF

0.20MPa(29psi)

3.14MPa(455psi)

(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)

Dual Pressure Switch

25-35

25. AIR CONDITIONER SYSTEM

25.7

TROUBLESHOOTING Air temperature does not fall.

Note : M/A is motor actuator * is any of the numbers 0 to 9.

If AUTO switch or A/C switch is pressed, "HL.E" is indicated on the set temp. display of the panel. NO

YES

. Connector for air mix M/A is disconnected or in poor contact. . Air mix M/A is failed. . Main harness shows poor continuity.

*

"HL. " is shown on the set temp. display of the panel. NO

YES A snow mark ( ) on panel is flashing.

A snow mark ( ) on the panel is flashing.

NO

Check and correct or replace parts.

YES

. Inner air sensor or harness is disconnected or shorted. . Inner air sensor connector is disconnected or in poor contact.

. Both inlet air sensor and .

See section monitor mode.

evaporator sensor are disconnected or shorted. Controller failed.

See section monitor mode.

Check and correct or replace parts.

A NO

YES

. Evaporator sensor connector is disconnected or in poor contact. . Evaporator sensor is disconnected or shorted.

Outlet temp. falls if temp. is set at LO and the outlet mode is changed to vent mode. NO

YES

Air mix damper is in LO (COOLMAX). NO

See section monitor mode. Cool air flowing into inlet air sensor

Check and correct or replace parts.

YES Turn compressor clutch on and off. Check and correct electric circuits.

M/A stops halfway.

Refer to Troubleshooting for refrigeration cycle. NO M/A failed or controller is out of order. Replace.

NO Controller is faulty or inlet air sensor is faulty. Check and replace.

YES

. Check, correct or replace M/A lever link. . After cleaning lever link, apply grease.

25-36

YES Check duct or eliminate cause for cool air intrusion.

25. AIR CONDITIONER SYSTEM

Air temperature does not rise.

Note : * is any of the numbers 0 to 9.

HL.E is shown on the set temp. display of the panel. NO

YES

. Connector for air mix M/A is disconnected or in poor contact. . Air mix M/A is failed. . Main harness shows poor continuity.

*

"HL. " is shown on the set temp. display of the panel. NO

YES

. Inlet air sensor or harness is disconnected or shorted. . Inlet air sensor connector is disconnected or in poor contact.

Check and correct or replace parts.

See section monitor mode. Check and correct or replace parts.

Outlet temp. rises at FOOT mode if temp. is set at HI (HOT MAX). NO

YES

Air mix damper is in HI (HOT MAX). NO

Warm air is flowing into inlet air sensor.

YES NO

M/A action stops, halfway.

Controller or inlet air sensor is out of order. NO

M/A failed or controller is out of order.

YES

Check warm water piping.

YES

Check and replace.

. Check, correct or replace M/A lever link. . Clean lever link and apply grease.

Replace.

25-37

Check duct or eliminate causes for warm air entry.

25

25. AIR CONDITIONER SYSTEM

Blower motor does not run.

Note 1)

At air flow HI, battery voltage acts on both terminals (+) and (-) of blower motor. NO

YES

Battery voltage acts on red (+) and body of blower motor. NO

Voltage acts on yellow wire and grounding of blower amplifier. NO

YES

YES

Controller is out of order. Is there continuity between yellow wire and black wire? Replace

Wire harness is faulty. Check and correct or replace.

NO

Battery voltage acts on white / green wire and grounding of blower motor relay. NO Check and repair harness or replace.

Replace.

YES

Check blower motor relay. Blower motor Note 2) rotates if green / red wire and red wire of blower motor relay are directly connected. NO

Blower motor fails.

YES

Eliminate cause and replace blower amplifier.

Blower turns if orange wire of blower motor relay is connected with ground. NO Replace relay.

YES Check and correct harness or replace controller.

Note 1) In the connector connected condition, measure the voltage. Note 2) During direct connecting test, turn off starter key switch and work light.

25-38

YES Check and repair harness.

25. AIR CONDITIONER SYSTEM

Blower motor speed does not change.

25

CASE (1)

*

"HL. " is shown on the set temp. display of the panel.

Replace blower amplifier controller.

NO

*

Note) is any of the numbers 0 to 9.

YES

. Inlet air sensor or harness is disconnected or shorted. . Inlet air sensor connector is disconnected or in poor contact. See section monitor mode. Check and correct or replace parts.

25-39

25. AIR CONDITIONER SYSTEM

Magnet clutch does not engage.

Snow mark ( ) lights on, when A/C switch is pressed. No

Yes

Snow mark ( ) flickers and E is shown on panel display. To A On page 25-36.

Voltage acts on clutch. No

Voltage is applied to pressure switch harness. No

Pressure switch fails or refrigerant pressure is out of order.

Yes

Check clutch fuses.

Clutch faulty.

Yes

Voltage acts on red / blue wire and ground (Black) connector of excavator. No

Yes

Refer to troubleshooting for refrigeration cycle.

Check air-conditioner harness. No

Replace harness.

Yes Replace controller.

Inlet air and outlet air do not change over.

Inlet / outlet air mode display on operation panel is flickering. No

Yes Connector of inlet/outlet air M/A is disconnected or in poor contact. Or M/A failed or main harness failed.

M/A lever does not work due to foreign matter. M/A lever is broken. No M/A failed

Yes Remove foreign matter and replace parts.

Replace

25-40

Inspect or replace.

25. AIR CONDITIONER SYSTEM

Modes do not change.

Mode display (Mark of body) on control panel is flickering. No

Yes Mode M/A connector is disconnected or in poor contact. M/A failed or main harness is faulty.

M/A rod does not disengage. No

Yes

Repair. Each damper lever does not disengage. No Repair.

Yes

Check and replace.

When rod is removed and cam is operated by hand, it is heavy. No Yes

M/A or controller is out of order. Replace.

. Cam or damper shaft does not work due to foreign matter or is broken . Malfunction occurs due to contaminated grease.

. Remove foreign matter or replace parts. . Clean cam and apply new grease.

25-41

25

25. AIR CONDITIONER SYSTEM

Trouble of refrigeration cycle.

Both high and low pressures are lower. Low pressure is higher.

NO Cooling does not work if run at high speed.

Air bubbles are seen in sight glass.

YES Oil comes out from piping and parts.

YES NO NO Expansion valve Expansion valve Natural is clogged or is frozen or leak from maladjusted. intruded by water. hose. Adjust or replace After making expansion valve. vacuum, refill Charge gas. refrigerant and replace receiver.

YES

NO

Air bubbles are seen in sight glass.

YES Gas leaks from pipe joints and parts. Retighten or replace parts.

High pressure is lower.

Compressor cylinder does not get hot.

Compressor cylinder gets very hot.

Expansion valve is maladjusted. (too much open)

Compressor does not discharge well.

Replace expansion valve.

Replace compressor

High pressure is lower. Air bubbles are seen in sight glass. YES

NO High pressure gets lower slowly.

Condenser is contaminated or clogged.

High pressure circuit before receiver is clogged up.

YES

Remove clogging or replace parts.

Clean condenser.

25-42

NO Air bubbles are hard to go out even if water is poured on condenser. Air is mixed. Make vacuum and refill refrigerant.

25. AIR CONDITIONER SYSTEM

25.8 1.

SELF-DIAGNOSIS

When error occurs in input circuit of motor actuator drive line, the error can be displayed on the monitor of the LCD display.

Detection of wiring disconnection of motor actuator Location of error Air mixture Air outlet mode Internal and external air selector 2.

Display of failures “HL.E” is displayed on temperature indication Human-shaped display is flashing Recirculation and fresh air selector display is flashing

When error occurs in evaporator sensor and intake air sensor, the error can be displayed on the monitor of the LCD display.

Detection of evaporator sensor and intake air sensor Location of error Evaporator sensor

Intake air sensor

Display of failures “E” is indicated on first decimal place of temperature indication “HL” is indicated on temperature indication “The figure from 0 to 9” is indicated on first decimal place of temperature indication

HL. 0 to HL. 9

3. Detection of each sensor error by monitor mode function (Detection of failure control of control panel) • When the air conditioner is in operating condition, press the internal and external air selector switch (6) and main power switch (1) for one second or more simultaneously. And the display of the monitor mode begins. To return the display to the previous display, operate the two switches according to above mentioned same operation. • Normal condition, disconnection and short circuit of intake air sensor, evaporator sensor and solar sensor are indicated in segment of the display. • Normal condition and short circuit of the solar sensor is indicated in the segment of the display. (* Detection of disconnection is not indicated.)

25-43

25

25. AIR CONDITIONER SYSTEM

Solar sensor

Example : Special use 7-segment for monitor

2

Error contents of indication Sensor Short circuit Disconnection indication indication Intake 㪇 㪇 䌆䋶䌈 䋰䌃䌈 air sensor Evaporator 㪈 㪈 䌆䋶䌈 䋰䌃䌈 sensor Solar 㪇㪚㪟㪉 sensor Example: Short circuit of solar sensor

3-digits segment list 㪇

㪈

㪉

㪊

㪋

Second digit of segment

㪌

㪍

㪎

㪏

㪐

㪘

㪙

㪚 㪛

Intake air sensor disconnection indication “0CH0” 㪇 Evaporator sensor disconnection indication “0CH1” Solar sensor short circuit indication “0CH2” Example : Position of digit indication Second digit : F

Third digit : F Example: At normal condition

Third digit of segment

7 segments indication of only use for monitor 7 segments Sensor indication Intake 0 air sensor Evaporator 1 sensor

㪈 㪉 㪊 㪋 㪌 㪍 㪎 㪏 㪐 㪘 㪙 㪚 㪛 㪜 㪝

25-44

㪜

㪝

Each sensor is normal

Intake air sensor short circuit indication “F6H0” Evaporator sensor short circuit indication “F6H1”

31. DISASSEMBLING AND ASSEMBLING

31. DISASSEMBLING AND ASSEMBLING TABLE OF CONTENTS

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ............. 31-3 31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ...................... 31-3 31.1.2 INDICATION OF TIGHTENING TORQUE ................................................. 31-3

31

Book Code No. S5YN3129E01 31-1

31. DISASSEMBLING AND ASSEMBLING

Issue

Data of Issue

First Edition

December, 2008

↑

Applicable Machines

Remarks

SK200-8: YN12-56001~ SK210LC-8: YQ12-08001~

S5YN3129E01 (SE Asia & Oceania)

May, 2009

SK235SR-2: YF06-02501~ SK235SRLC-2: YU06-03001~

(OCE)

↑

June, 2009

SK125SR: YV06-05501~ SK125SRL: LD06-01801~ SK135SR-2: YY06-15001~ SK135SRLC-2: YH06-08001~

↑ (SE Asia & Oceania)

↑

July, 2009

SK140LC-8: YP09-05001~

↑ (SE Asia)

↑

↑

SK70SR-2: YT06-18001~

↑ (SE Asia & Oceania)

↑

August, 2009

SK80MSR-2: LF06-04501~

↑ (Oceania)

↑

September, 2009

SK225SR: YB06-03501~ SK225SRLC: LA06-02501~

↑

November, 2009 SK850LC: LY02-00151~ SK140LC-8: YP09-T0101~ SK130-8: LP09-T0101~ SK130L-8: LX07-T0101~

(OCE)

↑

↑

↑ (SE Asia) ↑

↑

February, 2010

↑

June, 2010

SK80CS-2: LF06-04501~

↑

↑

E80BMSR: LF06-04501~

↑

↑

E70BSR: YT06-18001~

↑

↑

SK70SR-2: YT06-18001~

↑

July, 2010

E135BSRLC: YH06-08001~

↑

↑

SK140SRLC: YH06-08001~

↑

August, 2010

SK460-8: LS11-02501~ SK480LC-8: YS11-02001~

↑ SE Asia & India (HS Engine)

↑

↑

E235BSR(N)LC: YU06-03001~

↑ (NHK-EUR)

↑

↑

SK235SRLC-2: YU06-03001~

↑

↑

E225BSR: YB06-03501~ E225BSRLC: LA06-02501~

↑

↑

SK215SRLC: LA06-02501~

↑ ↑

September, 2010 E385CLC: YC ↑

(TKCM) (NA) (NHK)

(NA)

↑

↑ (NHK-EUR) (NA)

(NA)

↑

↑

↑ (NHK-EUR) (NA)

NA

31-2

↑

↑ (NHK-EUR)

(NHK)

SK350-9: YC

↑

↑ ↑ ↑

31. DISASSEMBLING AND ASSEMBLING

31.1

EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY This chapter is consist of 3-Section as follows. (1) ATTACHMENTS : Chapter 32 1) Removing and Installing 2) Disassembling and Assembling a. Cylinder (2) UPPER STRUCTURE : Chapter 33 1) Removing and Installing 2) Disassembling and Assembling a. Hydraulic pump b. Control Valve c. Pilot Valve (ATT) d. Pilot Valve (Travel) e. Slewing Motor f. Swivel Joint (3) TRAVEL SYSTEM : Chapter 34 1) Removing and Installing 2) Disassembling and Assembling a. Travel Motor

31.1.2 INDICATION OF TIGHTENING TORQUE Tightening torque is indicated as follows, for example; T=98N-m(72 lbf-ft) Tolerance is to 10% unless otherwise specified. •

Refer to "Chapter 11 TOOLS" for standard tightening torque.

31

31-3

31. DISASSEMBLING AND ASSEMBLING

31-4

32. ATTACHMENTS

32. ATTACHMENTS TABLE OF CONTENTS

32.1 REMOVING AND INSTALLING .........................................................................32-3 32.1.1 ATTACHMENT ASSY ................................................................................32-3 32.1.2 BUCKET ....................................................................................................32-3 32.1.3 ARM ...........................................................................................................32-6 32.1.4 BOOM ........................................................................................................32-9 32.2 DISASSEMBLING AND ASSEMBLING .............................................................32-14 32.2.1 CYLINDER .................................................................................................32-14

32

Book Code No. S5LC3226E01 32-1

32. ATTACHMENTS

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC3226E01 NA

September, 2010 SK350-9: YC

PREFACE (1) This Manual describes all the procedures from removing to attaching, and arranging them by item. (2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling". (3) The removing and installing can be performed in the procedure specified in the Table of Contents, but in view of actual repairing or time saving some processes can be omitted. (4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective sections. (5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then start working.

32-2

32. ATTACHMENTS

32.1

REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY (D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN ARM CYLINDER

4. BOOM

(A) BOOM FOOT PIN

(F) BOOM TOP PIN (E) ARM CYLINDER ROD PIN 2. BUCKET

BOOM CYLINDER

3. ARM (G) BUCKET CYLINDER HEAD PIN

(J) BUCKET DRIVE PIN BUCKET LINK

BUCKET CYLINDER

(I) IDLER LINK PIN IDLER LINK (H) BUCKET CYLINDER ROD PIN

(K) BUCKET ATTACHING PIN

(H) BOOM CYLINDER HEAD PIN

Front Attachment And Position

32.1.2 BUCKET 32.1.2.1 REMOVING BUCKET (1) Put the machine in position to remove bucket.

Position To Remove Bucket (2) Removing capscrew (1) Loosen the double nut (2) and pull out the capscrew (1). 1

O-RING

2

1 SECTION A-A

Removing Capscrew (1)

32-3

32

32. ATTACHMENTS (3) Removing bucket attaching pin (K) Lift up bucket, position it so the bucket attaching pin (K) is not loaded, adjust bucket link, and pull out bucket attaching pin (K).

K

Removing Bucket Attaching Pin (4) Removing bucket drive pin (J) Put bucket on the ground, position it so the bucket drive pin (J) is not loaded, adjust bucket link, and pull out pin (J). Store the removed pin (J) in original position again.

J

Removing Bucket Drive Pin 32.1.2.2 ATTACHING BUCKET (1) Attaching bucket drive pin (J) Attach bucket drive pin (J) first, then continue in the reverse procedure of removing. J

Attaching Bucket

When aligning the pin holes, do not put your finger in the pin holes, align them visually. Check the seals for damage and replace as necessary. When inserting the pin, coat the shaft with grease.

32-4

32. ATTACHMENTS 32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE Adjustment of clearance between bucket and arm (1) Shift O-ring (3) toward the bucket boss, using a spatula. (a-->b) (2) When adjusting clearance (B), bring the nonadjusting side of the bucket in contact with the arm. (3) Measure clearance (B) and check that it is within 1.0 mm (0.04 in). (4) Adjust clearance (B) where it is more than 1.0 mm (0.04 in). (5) An average of 5 shims (10) of 1mm (0.04in) thickness are set in the plate (13) fixed by the three capscrews (7). The clearance can be decreased by 1mm (0.04in) if one shim is removed. Tools: Socket: 30mm, Tightening torque : 314 N-m (232 lbf-ft) (6) After adjustment, tighten the capscrews evenly. -The gap exceeding the specified dimension causes early wear. (7) Operate the bucket and confirm that the total sum of both clearance is within 1.0 mm (0.04 in). (8) Replace O-ring (3) on its original position.

381 11 : WASHER 8 : LOCK WASHER 7 : CAPSCREW

+1.0 +0.039" -0.5 (15" -0.020" )

New bucket

B b

3 : O-RING

a

12 : BUSHING 13 : PLATE

10 : SHIM 9 : PIN Install pin (9) until the top of pin is even surface with bushing.

Adjusting Clearance Between Bucket And Arm

When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3). Remove shims (10), push out bushing (12) rightwards by means of three capscrews (7) and adjust clearance (B) so it settles within the standard value evenly all around.

32

32-5

32. ATTACHMENTS 32.1.3 ARM 32.1.3.1 REMOVING ARM (1) Put the machine in position to remove arm. Extend the arm cylinder, retract the bucket cylinder and bring the arm down on the ground.

Position To Remove Arm (2) Disconnecting piping of bucket cylinder Release pressure in hydraulic tank, place oil pan to prepare for oil leaking, and disconnect pipes. When the removal of the bucket cylinder is not required, skip to procedure (6).

OIL PAN

Disconnecting Piping Of Bucket Cylinder

Plug both ends of disconnected pipes. Plug: Tools section 11.5.2-(4) Tools section 11.5.2-(5) (3) Removing bucket cylinder rod pin (H) 1. Loosen nut (10), remove capscrew M20X160 (9), and push out pin (H).

After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in). SHIM

Tools: Spanner: 30mm

9,10

H

SECTION D-D

Detail Of Bucket Cylinder Rod Pin (H) 2. Retract cylinder rod. A

D D

32-6

A

32. ATTACHMENTS (4) Removing cylinder head pin (G) Loosen nut (3), remove capscrew M20X165 (2), and push out pin (G).

3

2

Tools: Spanner: 30mm SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in). SECTION A-A

G

Detail Of Bucket Cylinder Head Pin (G) (5) Removing bucket cylinder Sling the tube of the bucket cylinder with a nylon sling, and remove it. Bucket cylinder weight: 260 kg (573 lbs)

Slinging Bucket Cylinder

(6) Removing arm cylinder rod pin (E) Put a wooden block between the arm cylinder and the boom. Loosen nut (3), remove capscrew M20X180 (2), and push out the arm cylinder rod pin (E). Tools: Spanner: 30mm Retract arm cylinder rod, and return pin (E) to the original position (hole). BLOCK

Install plastic shims to cylinder side.

B

Apply grease to inner wall of bushing 2,3

B E A A SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in). SECTION B-B

Detail Of Arm Cylinder Rod Pin (E)

32-7

32

32. ATTACHMENTS (7) Removing boom top pin (F) Loosen capscrew M16X35 (2), plate (1) and pull out boom top pin (F).

Install plastic shims to arm side. Apply grease to inner wall of bushing

Tools: Spanner: 24mm Insert pin (F) into the original hole.

F 1,2 Apply Loctite #242

After adjustment of shim, the total gap should be within 0.5mm (0.02in). SECTION A-A

Detail Of Boom Top Pin (F) (8) Slinging arm assy Sling arm with nylon sling and remove it. Arm weight: 1,275 kg (2,811 lbs)

Slinging Arm Assembly

32.1.3.2 ATTACHING ARM

1. When aligning the pin holes, do not put your finger in the pin holes, align them visually. 2. Check the seals for damage and replace as necessary. 3. When inserting the pin, coat the shaft with grease. 4. Pin lock nut handling procedure Tools: Spanner: 30mm

(0.02")

Install the arm in the reverse order of removing, paying attention to the following:

CLEARANCE

5. When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins and decide the thickness of shims by referring to the Maintenance Standard. 6. When attaching the shims, attach the resin shim first and then fill the gap with iron shims. 7. Tightening torque

Classfication

Size

147

108

279

206

181

133

1/8"

16.7

12.3

1/4"

36.3

26.8

M16 M16

Metric threads (BOOM TOP) M20 PF,PT threads

Tightening torque lbf.ft N.m

32-8

32. ATTACHMENTS 32.1.4 BOOM 32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM When removing and attaching the boom in the position shown in the below Figure. Remove and attach the boom foot pin (A). Removing and attaching of cab and guard are required.

32.1.4.2 REMOVING BOOM (1) Put the machine in position to remove the boom. Place the top end of the boom down on block, etc. giving attention for the arm cylinder rod not to be extended. BLOCK

Position To Remove Boom (2) Lifting up boom cylinder temporarily Remove the right and left boom cylinders one side according to the following procedure: Lift up boom cylinder temporarily to prevent it from dropping.

A A

C

STAND

Lifting Up Boom Cylinder Temporarily (3) Press the boom cylinder rod pin (C) At the one side of pin (C), loosen nut (5), remove capscrew (4) (M20X190), and remove collar (3). And push pin (C) to the end of boom boss.

Install plastic shim to cylinder side. SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in).

SHIM

Tools: Spanner: 30mm

4

3 C

3 5 SECTION A-A Detail Of Boom Cylinder Rod Pin (C)

(4) Preparing for disconnecting cylinder pipes Retract the above mentioned cylinder rod, and place one side of cylinder on stand. (See right Fig.)

32-9

32

32. ATTACHMENTS (5) Disconnecting the arm cylinder and bucket cylinder pipings Release pressure from the arm and bucket circuit and bleed air in hydraulic tank. Then disconnect pipe at (A1), (A2), (A3), (A4) and hose (5), (6), (8), (10).

A1

Tools: Spanner: 41mm Tools: Allen wrench: 12mm

A2

After disconnection of pipe, plug every pipe. ORS Plug: See Tools 11.5.2-(4). Half clamp: See Tools 11.5.2-(5).

A3

A4

6 8 10 5

Boom Piping Disconnection (6) Lifting up boom assembly temporarily Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded. Weight of single boom: 2,670 kg (5,890 lbs)

A

A A

Boom Assy Temporary Lift Up Procedure (7) Removing boom foot pin (A) 1. Remove capscrew (3) M20X60, and plate (2). Install plastic shims to boom side.

Tools: Spanner: 30mm After adjustment of shim, the total gap should be within 0.5mm (0.02in).

2. Draw out pin (A).

A 3 Apply loctite 2 #242 to bolt.

Apply grease to inner wall of bushing

2

SECTION A-A

Details Of Boom Foot Pin (A) Section

32-10

32. ATTACHMENTS (8) Hoisting boom assembly Hoist and remove boom assembly. Weight of single boom: 2,670 kg (5,890 lbs)

D

D

Boom Assy Hoisting Procedure (9) Completion of removal of front attachments When the removing and attaching of cylinders are not required, the work is finished. (10)Removing and installing arm cylinder 1. Disconnect hose (F1) and (F2) at position A. After disconnection of hose, plug both ends of hose. Plug: TOOLS 11.5.2-(4) Plugs for ORS fitting 11.5.2-(5) Plugs for half clamp Tools: Spanner: 41mm Tools: Allen wrench: 12mm

F2

G1

2. Removing arm cylinder head pin (D) Loosen nut (3), remove capscrew M20X180 (2) and pull out pin (D).

Install plastic shim to cylinder side.

Tools: Spanner: 30mm 3. Removing arm cylinder Weight of arm cylinder: 504 kg (1,110 lbs)

After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in). SHIM

F1

A 2,3 Apply grease to inner wall of bushing

D SECTION D-D

Removing Arm Cylinder

32-11

32

32. ATTACHMENTS (11)Removing and installing boom cylinder 1. Disconnect hose (C2) at position B. And plug both ends. Plug: Tools 11.5.2-(4) Plugs for ORS fitting : Tools 11.5.2-(5) Plugs for half clamp Tools: Spanner: 41mm

D1

C1

E1 C2 E2

C2

B

Removing And Installing Boom Cylinder 2. Removing boom cylinder foot pin (B) (See right Fig., below Fig.) Loosen nut (5), remove capscrews M20X190 (4) and pull out pin (B). Tools: Spanner: 30mm 3. Remove boom cylinder (2). Weight of boom cylinder: 269 kg (590 lbs) 4. Remove the other boom cylinder the same way.

4,5

Apply grease to inner wall of bushing B Install plastic 4,5 shim to cylinder side.

B

After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in). SECTION B-B

Removing And Installing Boom Cylinder Head Pin (B)

32-12

32. ATTACHMENTS 32.1.4.3 ATTACHING BOOM (1) Attaching boom foot pin (A) First of all, insert boom foot pin (A) and install the boom assembly. Attach it in the reverse procedure of removing, paying attention to the following points. 1. When aligning the pin holes, do not put your finger in the pin holes, align them visually. 2. Check that the dust seals are not damaged and replace as necessary. 3. When inserting the pin, coat the shaft with grease. 4. Refer to paragraph 32.1.3.2 about installing jam nuts. 5. When installing boom and cylinder, check the clearance of the mounting section in the thrust direction, and decide the thickness of the shim according to the maintenance standard. 6. When attaching the shims, attach the resin shim first and then fill the gap with iron shims. 7. Tightening torque

Boom Foot Pin (A)

Tightening torque lbf.ft N.m

Classfication

Size

Metric threads

M20

181

133

1/8"

16.7

12.3

1/4"

36.3

26.8

3/8"

73.5

54.2

PF,PT threads

A

32

32-13

32. ATTACHMENTS

32.2

DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER 32.2.1.1 PREPARATION BEFORE DISASSEMBLY Before assembly, secure a dust free workshop and the necessary equipment and facilities. 32.2.1.1.1 WORK AREA The following working area is required for disassembly: (1) Ample space For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this reason, the first condition is that the working area is long enough for the work. In terms of width, it is also necessary to keep sufficient space for disassembly. Pay attention to where the cleaning and measuring equipment are placed and where the work can be performed. (2) Suitable working environment The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding operation should not be performed in the neighborhood of the working area to keep it clean. 32.2.1.1.2 APPARATUS The following equipment is required for disassembly: (1) Hoist or crane The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable of making level and linear movement under load for retracting and extending the piston rod and the cylinder tube. (2) Work bench The work bench must have strength capable of accommodating the total length of the cylinder in its most retracted condition and withstand the repulsive force of the tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficient. (3) Support stand If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent damage to seals. (4) Hydraulic source A hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak tests after completion of assembly. (5) Compressed air source It is used for drying after oil draining and cleaning of the cylinder. (6) Cleaning bath, cleaning oil and detergent (7) Oil pan and oil reservoir An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work. An oil reservoir is required to collect oil spilt on the floor and waste oil. (8) Others Oil extracting hoses, wooden blocks, clean cloths and oil dry to soak up the spilt oil.

32-14

32. ATTACHMENTS 32.2.1.1.3 NECESSARY TOOLS List of Tools and Jigs Tool/Jig Hammer

Remarks

Tool/Jig

1. Steel hammer 2. Wooden or plastic mallet

Spatula

Metal one with smooth corners.

Gimlet

A sharp-point tool may be used in place of a gimlet.

Special jig

1. For removing and press-fitting bushing. (A), (D), (C) 2. For press-fitting wiper ring. (D) 3. For inserting and reforming seal ring. (E),(F),(G),(H) (See para 32.2.1.9 for detail)

Screwdriver A few types of large and small sizes Chisel

Vise

Wrench

•

Flat chisel

One having an opening wide enough to hold cylinder head O.D. and tube mounting pins (clevis) 1. Eye wrench 2. Allen wrench 3. Extension pipe for wrenches

Remarks

Rust remover Measuring 1. Slide caliper instruments 2. Micrometer 3. Cylinder gauge (Fig. "Cylinder gauge") 4. V-block

For the details of special tools and jigs, refer to the back pages of this manual.

32.2.1.1.4 EXTERNAL CLEANING The cylinder taken off the excavator has dust and foreign matter, and grease is usually adhered to the clevis part. For this reason, remove external soil and contamination from the cylinder with water and steam before bringing it into the workshop. The following describes the construction of the boom cylinder. When disassembling and servicing the cylinder, confirm the construction of the cylinder referring to Parts Manual. 32.2.1.1.5 DISCHARGING OIL Place a wooden block on the work bench and place the cylinder on it to prevent it from rotating. Blow compressed air into ports A and B alternately to actuate the piston rod till the hydraulic oil in the cylinder is drained out. At this time, connect a suitable hose to each port so that the hydraulic oil will not gush out.

Cylinder Gauge

WOODEN BLOCK PORT B V BLOCK PORT A

AIR OIL PAN

Preparation

32

32-15

32. ATTACHMENTS 32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)

25

24

12

24

25 B

PS1/8

PT1/4 15

SLIT

DETAIL 6

9

8

7

6

ONE HOLE

DETAIL B

4

5

3

DETAIL C

11 10

2

1

Piston with piston nut type

13 14

15

17 16 18 19 *20 *21 22 23

SLIT

C

Construction Of General Cylinder No.

NAME

Q'TY

No.

NAME

Q'TY

No.

NAME

Q'TY

1 2 3 4 5

Cylinder tube Piston rod Rod cover Bushing Snap ring

1 1 1 1 1

10 11 12 13 14

O-ring Back-up ring Socket bolt Cushion bearing Cushion seal

1 1 12 1 1

19 20 21 22 23

Slide ring Shim Piston nut Setscrew; M12 Steel ball

2 *1 *1 1 1

6 7 8 9

Buffer ring U-ring Back-up ring Wiper ring

1 1 1 1

15 16 17 18

Piston Seal ring Back-up ring Slide ring

1 1 2 2

24 25

Pin bushing Wiper ring

2 4

Note: In case of a piston with a piston nut type, the parts with * are not used.

32-16

32. ATTACHMENTS 32.2.1.3 DISASSEMBLY • • •

When disassembling and servicing the cylinder, check the construction and the availability of service parts as well as necessary tools and jigs in separate Parts Manual. The figures in parentheses after part names correspond to those in the Figure "construction of general cylinder" The following explanation and quantities are for a general use cylinder which has separated piston and a piston nut. In case that piston and piston nut are combined, the construction differs from the separated type, refer to the sentence in parenthesis.

32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD (1) Hold the clevis section of the tube in a vise. (2) Pull out piston rod (2) about 200 mm (8in). Because the piston rod is heavy, finish extending it with air pressure after the above-mentioned oil draining operation.

200mm (8")

2

Use vise mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means. (3) Loosen and remove the socket bolts (12) on the rod cover in sequence. (4) Strike the corner of the rod cover flange by means of a plastic mallet till rod cover (3) comes off.

ALLEN WRENCH

12

Turn counterclockwise

3 2

Cover here with cloths

Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged.

32

32-17

32. ATTACHMENTS •

At this time, the weight of piston rod (2) is loaded on rod cover (3). Therefore, lift the top end of the piston rod with a hoist to the extent that only the rod weight may be held.

KNOCK THIS EDGE WITH A PLASTIC MALLET.

LIFT HERE.

1

3

2

Drawing Out Piston Rod Assembly (2). (5) Draw out the piston rod assembly from the cylinder tube (1).

1

LIFT HERE. PULL STRAIGHT SIDEWAYS HORIZONTALLY

OIL PAN

Method Of Drawing Out The Piston Rod Assembly

Since the piston rod assembly is heavy in this case, lift the tip of the piston rod (2) with a hoist and draw it out. However, when the piston rod (2) has been drawn out to approximately two thirds of its length, lift it in the center to draw it out completely. However, since the plated surface of the piston rod (2) is lifted, do not use a wire rope that may score the surface, but use a strong cloth belt or rope.

(6) Place the removed piston rod on a horaizontal wooden V-block. PISTON ROD ASSY

-Cover the V-block with cloths.

WOODEN V-BLOCK (PLACE CLOTHS)

Method Of Placing The Piston Rod (7) Remove slide ring (18) and (19) from piston (15).

15 Remove slide ring by widening the slit toward the arrow

19 18 Remove Slide Ring (18) And (19)

32-18

32. ATTACHMENTS 32.2.1.3.2 REMOVING PISTON ASSY (1) Fix piston rod (2) by holding its clevis section in a vise. Fix the piston rod (2) securely as the piston nut (21) is tightened to a high torque.

15

2

3

WOODEN BLOCK

21

WOODEN V-BLOCK (PLACE CLOTHS)

How To Loosen Piston Nut (21)

Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston (15), though the rod diameter remains the same. It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is used, put cloths or something over the rod to prevent it from damage.

(2) Scrape off the caulked part of setscrew (22) on the piston nut (21) by means of a hand drill and loosen the setscrew (22) and remove ball (23).

22

DRILL

Tools: Allen wrench: 6mm

21 23 Removing Setscrew (22) And Ball (23) (3) Loosen and remove piston nut (21) or [piston (15)].

TURN COUNTER CLOCKWISE. EYE WRENCH

15

21 How To Loosen Piston Nut (21)

Since the piston nut (21) is tightened to a high torque, use a eye wrench suitable for the outside diameter of the piston nut (21). In case the piston and piston nut are combined, apply the eye wrench to the hexagonal part of piston and loosen the piston directly.

32-19

32

32. ATTACHMENTS (4) Remove piston (15) by tapping with a plastic mallet, supporting weight of the piston (15) with hoist.

15 4 Removing Piston (15)

In case the piston and piston nut are combined, the shim (20) is not used.

(5) After removing the cushion bearing (13) and cushion seal (14), separate the rod cover (3) from the piston rod (2). If it is too hard to slide it, knock the flanged part of the rod cover (3) with a plastic mallet. But when drawing it out, lift the rod cover (3) by hoist and pull it straight out horizontally.

LIFT WITH A HOIST.

STRIKE WITH A PLASTIC MALLET.

PULL STRAIGHT. NOTE: DO NOT DAMAGE PISTON ROD SURFACE.

3

4 6 8,7 9 2 Removing Rod Cover (3)

Take care so the rod bushing (4) and the lip of packings (6,7,8, and 9) are not damaged by the threads on the piston rod (2).

32-20

32. ATTACHMENTS 32.2.1.3.3 DISASSEMBLING PISTON ASSY (1) Remove seal ring (16) and back-up ring (17). HAMMER SCREWDRIVER (OR CHISEL) BACK-UP RING

17

16

USE CARE NOT TO DAMAGE THE GROOVE.

15

SEAL RING

O-RING

Removing Seal Ring (16) And Back-up Ring (17)

Cut the seal ring (16) by tapping it with a screwdriver or a chisel. Take care not to strike it too hard, otherwise the groove may be damaged. 32.2.1.3.4 DISASSEMBLING ROD COVER ASSY (1) Remove O-ring (10) and back-up ring (11). Remove back-up ring (11) and O-ring (10) in that order. Remove back-up ring (11) and O-ring (10) by pulling and stretching them with a spatula.

SPATULA

10 11 3

Removing The Outer Circumferential Seal Of Rod Cover (3) (2) Remove buffer ring (6), U-ring (7) and back-up ring (8). Each seal is fixed in the groove on the bore. Stab each seal with a gimlet and pull it out of the groove.

GIMLET

8 3

7 6

Removing The Inner Circumferential Seal Of Rod Cover (3)

Take care in this operation not to damage the grooves.

32-21

32

32. ATTACHMENTS (3) Remove the wiper ring (9). When taking out the wiper ring (9), fix the rod cover (3) in a vise.

HAMMER SCREWDRIVER

3 9

WOOD PIECE

WOOD PIECE

VISE

Removing Wiper Ring (9) (4) Remove the snap ring (5) and bushing (4). Remove snap ring (5) first, and then remove bushing (4). The bushing (4) is press fitted in the rod cover (3), so push it out with a press with a jig as shown in the Figure. See para 32.2.1.9.3 (1) for removing.

CHUCK ASSY TOOL A

PRESS HERE

BUSHING 4

BLOCK TOOL C

Removing Rod Bushing (4) 32.2.1.3.5 REMOVING PIN BUSHING (1) Apply driver to wiper ring (25) of cylinder tube (1) and piston rod (2), and strike it by hammer lightly. (2) Push out the pin bushing (24) that is press fitted in cylinder tube (1) and piston rod (2) with press.

PUSH WITH A PRESS. JIG J

2

24

BASE

Drawing Out Pin Bushing (24) 32.2.1.4 CLEANING (1) After disassembly the cylinder, wash all parts with commercial detergent. (2) Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after inspection. (3) After cleaning, dry all parts with compressed air, and put them on the work bench taking care not to damage them.

Never use benzene(gasoline, thinner, etc.) because it may damage the rubber, etc.

32-22

32. ATTACHMENTS 32.2.1.5 ASSEMBLING PIN BUSHING Start assembling the following sub assy -Cylinder tube assy -Piston assy -Rod cover assy 32.2.1.5.1 ASSEMBLING PIN BUSHING (1) Press fit pin bushing (24) in cylinder tube (1) and piston rod (2) respectively with press. (2) Press fit wiper ring (25) in the upper and lower sides of the cylinder tube (1) and piston rod (2) respectively with a press.

PUSH WITH A PRESS

2

24

OIL HOLE LOCATION

Press Fitting Of Pin Bushing (24)

Before press fitting, apply grease on wiper ring and boss hole. Before press fitting the pin bushing, align the position of the oil hole. 32.2.1.5.2 ASSEMBLING OF PISTON ASSY (1) The fitting of seal ring (16) requires a special tool as shown the Figure. The seal ring (16) is pushed in by press, etc. with pushing tool as shown in the Figure. The O-ring on seal ring (16) and back-up ring (17) on one side should be installed beforehand.

PRESS HERE METAL (G) PRESS JIG (E) SLIDE JIG (F)

15 16

O-RING

17 How To Fit Seal Ring (16)

Heat them, and they may soften. But never heat them over 100° C (212° F degrees).

32

32-23

32. ATTACHMENTS (2) Fit back-up ring (17) on the other side. After fitting, correct it immediately to prevent it from expansion of the seal ring (16) with correcting jig (H) as shown in right Figure.

16

17

PRESS HERE

CORRECTIONAL JIG (H)

Installing Seal Ring (16)

For the piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully. After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston (15) is inserted in cylinder tube (1). Fit slide rings (18 and 19) at the same time when piston (15) is inserted in cylinder tube (1). 32.2.1.5.3 ASSEMBLING ROD COVER ASSY (1) Press fit bushing (4) in rod cover (3) with bushing press-fitting jig (A). Then, fit snap ring (5) in the groove. Apply hydraulic oil on the internal surface of rod cover (3).

PRESS HERE. (STRAIGHT DOWN)

4

PRESS FITTING JIG (A) GROOVE FOR FIXING SNAP RING (5)

3

Press bushing till bushing comes in contact with this face.

The snap ring (5) cannot be fitted when the bushing (4) is not press-fitted fully to the stop end. (2) Apply grease to wiper ring (9), and fit wiper ring (9), directing the lip side toward the groove of retainer tool (D). Set retainer tool (D) on rod cover (3) and press fit wiper ring (9) with press.

PRESS HERE. (STRAIGHT DOWN) RETAINER TOOL (D)

9 U-RING GROOVE

Press Fitting Of Bushing (4)

32-24

32. ATTACHMENTS (3) Fit buffer ring (6), back-up ring (8) and O-ring (7) in their grooves in that order. Before setting packings, coat them with hydraulic oil (or vaseline if not available). If you forget the coating, the packings may be scored. When attaching seals, deform them in a heart shape as illustrated. INSERT U-RING INTO GROOVE FROM THIS SIDE.

PUSH BAR (WOOD OR PLASTIC)

10 11

Tube side

3

Inserting A Seal Into The Inner Circumference Of Rod Cover

6 7 8 9 How To Fit O-ring (7)

O-ring (7) is harder than other packings and it would be difficult to deform them in a heart shape. In such a case, put a O-ring in the groove obliquely by hand as deep as possible and push in the last part with a push bar till it is set with a click. Buffer ring (6) should be fitted taking care of the fitting direction. The reverse fitting may cause deformation, damage, etc. of the piston due to high pressure generated between the buffer ring and O-ring. If O-ring (7) is set upside down, the lip may be damaged. Check that it is positioned correctly. Attach back-up ring (11) on the open air side of O-ring (10). (See above Figure).

32.2.1.5.4 INSERTING ROD COVER ASSEMBLY TO PISTON ROD Inserting rod cover (3) to piston rod assembly by the following procedure. (1) Fix piston rod assembly on work bench. (2) Install rod cover (3) on piston rod (2) with inserting INSERT GUIDE JIG (I) guide jig (I) as shown in Figure. Pay attention that PUSH the lip section of the O-ring is not caught on the stepped section.

3

2 Inserting Rod Cover (3)

32 For the rod the outer diameter of the piston installing section is small, insert spacer on the faucet section of the rod first, and attach an inserting guide jig. Apply hydraulic oil on the inserting guide jig and outer surface of the piston rod lightly to make the insertion smooth.

32-25

32. ATTACHMENTS 32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD (1) Install the cushion on the extraction side, cushion bearing (13) and cushion seal (14) by the following procedure. 1. Put the cushion seal (14) on it, directing the slit PISTON machined side toward the piston side. 13 2. Fit cushion bearing (13) on it directing the flattening 14 side as shown in right Figure.

FLAT SECTION Direct slit toward piston side

Cushion Mechanism On Extension Side (2) When the cushion is installed on the retraction side, fit the cushion bearing (13) and cushion seal (14) by the following procedure. 1. Fit cushion bearing before fitting piston nut. The nut attached obstructs the fitting of cushion bearing. Direct slit toward thread side 2. Put cushion seal on it, directing the slit machined THREADED PART side toward the piston side. 3. Fit cushion bearing on it directing the flattening side as shown in the Figure. PISTON ROD 4. Put a stopper in the groove. Push the cushion bearing to stopper fully, and drive the snap ring. Use a plastic mallet in order not to damage the rod and cushion bearing. SNAP RING

CUSHION SEAL (Slit 1 place)

STOPPER CUSHION BEARING (Divide into 2 portions)

Cushion Mechanism On Retraction Side

The cushion seal and cushion bearing should be fitted taking care of the fitting direction. If they are fitted in the reverse direction, the cushion is not effective. After installing the cushion, be sure that the cushion bearing moves up and down, and right and left.

32-26

32. ATTACHMENTS (3) Insert shim (20), and tighten piston nut (21) or [piston (15)] till it gets tight. Always tighten the piston nut (21) or [piston (15)] of each piston to the specified torque (Refer to 32.2.1.7.3).

21

EYE WRENCH

Tightening Piston Nut (21)

In case the piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to the hexagonal part of the piston and loosen the piston directly. Always correct the threads in the piston nut (21) or [piston (15)] before fixing the piston nut, using a tapping. Insufficient tightening torque causes an inner leak and damage to threads. Over tightening torque causes a bulge of the cushion bearing and a deformation of the piston contacted surface. Clean and decrease (with solvent) the parts of the piston assembly, and dry them, then tighten the piston assembly.

(4) Put the steel ball (23) into the hole and tighten setscrew (22). Tools: Allen wrench: 6mm

ANTI-LOOSENING

22 CAULKING

20

2

23

After tightening the setscrew to a specified torque, caulk the two places of the thread on the piston nut side to secure the setscrew. See para 32.2.1.7.3 for torque. V-BLOCK

21 Attaching Setscrew (22) (5) Attach two slide rings (18 and 19). Take off the vinyl tape wound around the perimeter of piston (15). Apply high-quality grease (or vaseline) to the slide rings (18 and 19) and attach the slide rings in a manner that they may be coiled around the groove. Set the slide rings about 180 degrees apart of each other so the slits do not point the same direction.

22

21

18

19

2

V-BLOCK

Attaching Slide Ring (18 and 19)

32

32-27

32. ATTACHMENTS 32.2.1.5.6 OVERALL ASSEMBLY (1) Place a V-block on a work bench (a wooden V-block is preferable.). Place the cylinder tube assy (1) on it and fix the assembly by passing a wooden bar through the clevis pin hole to lock the assembly. (2) Insert the piston rod assembly into the cylinder tube assembly, while lifting and moving the piston rod assembly with a hoist. In this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube mouth and the circumference of the piston. Align the center of the piston rod assembly with the center of the cylinder tube assembly and put it in straight. When inserting, make sure that slide rings (18 and 19) on the perimeter of the piston are not out of the grooves. (3) Tighten socket bolt (12). Match the bolt holes of the rod cover flange to the threaded holes in the cylinder assembly, and screw in the socket bolts (12) one by one. Tighten the bolts to a specified torque, taking care so the bolts are not tightened unevenly. See para. 32.2.1.7.3 for torque. Tools: Allen wrench: 14mm

12

1

PLACE CLOTH

LIFT

STRAIGHT

PREVENT TURNING WITH WOODEN BAR.

ALLEN WRENCH TURN CLOCKWISE

Inserting Piston Rod Assembly

Tightening Socket Bolts (12)

Take care not to damage the rod surface by accidentally slipping a wrench. Covering the rod surface with cloth is recommended to prevent damage to it.

32-28

32. ATTACHMENTS 32.2.1.6 INSPECTION AFTER ASSEMBLY (1) No-load functional test Place the cylinder level at no load, operate the piston rod 5 to 6 strokes by the directional valve and make sure that it operates without failure.

DIRECTIONAL VALVE

H

PUMP

R

HYDRAULIC CYLINDER

External Leak Test

Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) for the cylinder. Grease coatings on the O-rings and the seals of the rod cover may come out. Wipe it off and retest the cylinder in such a case. (2) Leak test 1. Apply test pressure to the retracting and extending sides of the cylinder for three minutes independently, and check that the rod section and the welds have external leaks and permanent deformation. For an internal leak test, connect the cylinder with a test unit as shown in the Figure below. 2. After completing the test, apply a plug to each port and store the cylinder. For storage, place the cylinder on wooden V-blocks and bring the cylinder to the most retracted condition. CYLINDER ASSY MEASURE THE INTERNAL LEAK. PLUG

PLUG

How To Store The Cylinder

FROM DIRECTIONAL VALVE

Internal Leak Test

32

32-29

32. ATTACHMENTS 32.2.1.7 MAINTENANCE STANDARDS 32.2.1.7.1 INSPECTION AFTER DISASSEMBLY Visually inspect all parts after cleaning to see that excessive wear, cracks and other damage are not present. (1) Inspection Item Parts Name

Piston rod

Cylinder tube

Rod cover

Inspecting Portion

Inspection Item

Remedy

1. Neck of rod pin

Presence of crack

Replace

2. Weld on rod hub

Presence of crack

Replace

3. Stepped part to which piston is attached

Presence of crack

Replace.

4. Threads

Presence of seizure

Recondition or replace

5. Bend

Measure degree of bend (See Fig. "Measuring method")

Refer to Table "Example of measurement"

6. Plated surface

Check that: 1) Plating is not worn off to base 1) Replace or replate metal 2) Replace or replate 2) Rust is not present on plating. 3) Recondition, replate or 3) Scratches are not present. replace.

7. Rod

Wear of O. D.

Recondition, replate or replace.

8. Bushing at mounting part

Wear of I. D.

Replace

1. Weld on bottom

Presence of crack

Replace

2. Weld on head

Presence of crack

Replace

3. Weld on hub

Presence of crack

Replace.

4. Tube interior

Presence of damage

Replace if oil leak is seen.

5. Bushing at mounting part

Wear on inner surface

Replace

1. Bushing

1) Wear on inner surface 2) Flaw on inner surface

1) See para. 32.2.1.7.2 2) Replace if score is deeper than coating.

(2) Repair method Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores on the piston rod, observe the following procedure: 1. Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep it can be caught by your finger nail. 2. In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone. If the score or the indention is excessive, replace or replate the damaged part. • •

Always regrind after replating. The thickness of the plating must be a maximum of 0.1 mm (0.004 in). In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the surface.

32-30

32. ATTACHMENTS 32.2.1.7.2 LIMIT OF SERVICEABILITY Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod. Damaged rods and tubes will damage the seals and O-rings. (1) Clearance between piston rod and rod bushing Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm (0.01in). (2) Bend of piston rod The allowable bend of the rod is a maximum of 1mm / 1m (0.04"/3'3"). For measurement, support both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center between the two V-blocks and turn the piston rod. Read the difference between the maximum and minimum deflection on the dial indicator. Table shows an example of measurement.

Example of Measurement Distance between Deflection of the dial indicator in the middle of the rod. Remedy V-blocks mm (in) m (ft-in) 1 (3’3")

1 (0.04")

Replace

Measuring Method

Even if the bend is within the above limit, the cylinder may not operate smoothly because of a localized bend. Beware of it during function test after assembly. Replace the rod if the cylinder makes a squeaking noise or does not operate smoothly. 32.2.1.7.3 TIGHTENING TORQUE

B

Unit : N.m (lbf.ft)

A C Cylinder

A Piston nut or [Piston]

B

C

Socket bolt

Setscrew

Boom

8000 (5900)

367 (270)

56.9 (42)

Arm

17000 (12540) 711 (520)

96.6 (71)

Bucket

10000 (7380) 520 (380)

56.9 (42)

32.2.1.7.4 VOLUME OF OIL LEAK The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION AFTER ASSEMBLY 32.2.1.6 (2). Cylinder

Volume of Internal Oil Leak

Boom

1.0 cc (0.06 cu-in) or below / 3 min

Arm

1.0 cc (0.06 cu-in) or below / 3 min

Bucket

1.0 cc (0.06 cu-in) or below / 3 min

32-31

32

32. ATTACHMENTS 32.2.1.8 TROUBLESHOOTING

Table32-4 Trouble

Failed Parts

1. Oil leak through sliding 1. Back-up ring surface of piston rod. Oil ring is formed on piston rod, and the ring grows up to oil drops, and they drip.

2. U-ring OIL LEAKS FROM HERE

Cause

Remedy

1. Foreign matter is trapped in the bore of back-up ring

1. Remove foreign matter.

2. Lips on outer and inner diameter surfaces of back-up ring are scored.

2. Replace back-up ring.

3. Other back-up ring are failed.

3. Replace back-up ring

1. Foreign matter is trapped in the bore of ring.

1.Remove foreign matter.

2. Score is present on the bore of ring. 2. Replace U-ring.

3. Buffer ring

3. Other rings are failed.

3. Replace U-ring.

1. Foreign matter is trapped in the bore of ring.

1.Remove foreign matter.

2. Score is present on the bore of ring. 2. Replace buffer ring.

4. Wiper ring

5. Piston rod

3. Other rings are failed.

3. Replace buffer ring.

1. Foreign matter is trapped in the bore of wiper ring.

1.Remove foreign matter.

2. Lip on the bore of wiper ring is scored.

2. Replace wiper ring.

3. Another wiper ring is failed.

3. Replace wiper ring.

1. Score is present on the sliding surface of piston rod.

1.Smooth out the sliding surface with an oilstone. If leakage occurs even if the sliding surface is finished below 1.6S, rod packings may be scored. Disassemble and inspect it and replace rod packings as required. If leak will not stop by that treatment, replace piston rod.

2. Hard chromium plating has peeled 2. Replate. off 2. Oil leaks from the 1. O-ring circumference of rod cover. 2. Backup ring

1. O-ring is damaged.

1. Replace O-ring.

1. Back-up ring is damaged.

1. Replace back-up ring.

3. Cylinder tube 1. Swelling of cylinder tube.

1. Replace cylinder tube.

1. Cylinder tube 1. Welds of cylinder are broken.

1. Replace cylinder tube.

1. Piston seal

1. Remove foreign matter

OIL LEAKS FROM HERE 3. Oil leaks from welds.

WELDS 4. Cylinder falls by it-self.

[When the rod is loaded with a static load equal to the maximum working pressure multiplied by the area of the 2. Slide ring cylinder bore, the maximum movement of the piston is 3. Piston rod more than 0.5mm (0.02") in ten minutes.]

1. Foreign matter is trapped in the sliding surface of seal ring. 2. Score is present on the sliding surface of seal ring.

2. Replace seal ring..

1. Sliding surface of slide rings is scored.

1. Replace slide ring.

1. Elongation.Piston rod and piston are elongated. (Loose nut)

32-32

1. Replace piston rod.

32. ATTACHMENTS 32.2.1.9 JIGS LIST 32.2.1.9.1 SPECIAL JIG LIST (POSSIBLE TO SUPPLY) When assembling, the following jigs are required.

Table32-5 Application

A For removing and press fitting bushing

Described paragraph

Shape

D 32.2.1.3.4, 32.2.1.5.2

C

EDGE OF CHUCK

D

For press fitting wiper ring

32.2.1.5.2

E

H F

For correcting seal ring

32.2.1.5.2

G INSERTING JIG

CORRECTING JIG

I For inserting rod cover

32.2.1.5.4

For above jigs, contact our dealer. (The Jig No. List provided by cylinder maker is shown on the following page.)

32

32-33

32. ATTACHMENTS Special Jig No. List (1) For jigs for rod cover, select jig corresponding to respective rod diameter. (2) For jigs for piston, select jig corresponding to the cylinder bore.

Jig for rod cover removing & installing

Jig for seal ring inserting & correcting

Application rod diameter [mm (in)]

Kit No. of maker

65 (2.56")

3006J-56001

70 (2.76")

3007J-06001

75 (2.95")

3007J-56001

80 (3.15")

3008J-06001

85 (3.35")

3008J-56001

90 (3.54")

3009J-06001

95 (3.74")

3009J-56001

100 (3.94")

3010J-06001

105 (4.13")

3010J-56001

110 (4.33")

3011J-06001

115 (4.53")

3011J-56001

120 (4.72")

3012J-06001

Application cylinder bore [mm (in)]

Kit No. of maker

95 (3.74")

3009J-51001

100 (3.94")

3010J-01001

105 (4.13")

3010J-51001

110 (4.33")

3011J-01001

115 (4.53")

3011J-51001

120 (4.72")

3012J-01001

125 (4.92")

3012J-51001

130 (5.12")

3013J-01001

135 (5.32")

3013J-51001

140 (5.51")

3014J-01001

145 (5.71")

3014J-51001

150 (5.91")

3015J-01001

160 (6.30")

3016J-01001

170 (6.69")

3017J-01001

32-34

32. ATTACHMENTS 32.2.1.9.2 OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP) (1) Bushing removing jig (Symbol J)

R0.2

(0.008")

MATERIAL : Mild steel

5 (0.2") 10 25-S

12-S -0.2 (-0.008") -0.4 (-0.016")

12-S

(0.08") R2

-3 (-0.12") -4 (-0.16")

-0.5 (-0.02") -1 (-0.04")

(0.08") C2

80 (3.15") (0.59")(0.59") 50 15 15 (1.97")

D d 90 (3.54") 103 (4.06") 100 (3.94") 113 (4.45") 110 (4.33") 123 (4.84")

Unit : mm (inch) Cylinder Used Bucket Boom (Head Side) Arm, Boom (Rod Side)

Bushing Removing Jig (2) Wrench for piston nut or [piston]

Unit : mm (inch) B 115 (4.53") 135 (5.32")

Cylinder Used Boom, Bucket Arm

B Wrench For Piston Nut Or [Piston]

32

32-35

32. ATTACHMENTS 32.2.1.9.3 SPECIAL JIG HANDLING PROCEDURE (1) How to remove bushing from rod cover. 1. Attaching chuck assembly tool Insert tool in rod cover slowly until the edge top end of the chuck assembly reaches to the end of the bushing (4). • Special attention must be paid so that the inner surface of the rod cover is not damaged by the edge of the tool. • Attach top in position 5mm (0.2 in) from the bushing end face so that the edge does not protrude from the end face.

4

5 (0.197")

(CHUCK)

2. Tightening chuck assy tool temporarily a. Fit allen wrench to the head of adjuster bolt on the top end of tool, and insert lever in the round hole on the rear end of tool. b. Fix it with allen wrench and lever to the position where the tool does not drop even if the rod cover is raised, inclining it forward and rearward. • •

Move rod cover onto the work bench with tool attached. Be careful not to drop it on your feet, etc.

A

32-36

32. ATTACHMENTS 3. Attaching tools for retainer Put retainer on the press bench directing the wiper ring fitting section of the rod cover upward, then put the retainer tool (D) on the rod cover. -Fit retainer tool as shown in the right Figure, directing the large diameter section (flange section) upward. -Clean the surface of the press bench, and take care that the tool bottom face is not damaged by foreign matter like dust, chips, etc.

4. Cutting into of the edge of chuck Press the upper section of the retainer tool gradually so the edge of chuck tool (A) cuts into the bushing surface. Set the pressing force to 2 to 3 tons (4410 to 6615 lbs).

D FLANGE

PRESS HERE

After completion of pressing, tighten the adjuster bolt again by hand. -Press it with retainer tool (D).

CHUCKING JIG A

32

32-37

32. ATTACHMENTS 5. Setting of tools for block Prepare block (C), and put rod cover (3) on it aligning them. Select the corresponding block (C) in shape, dimensions, etc. from the table shown below. 15 (0.59") 15 (0.59")

oD od

10

h

10 Unit : mm (inch) Class (Nominal size) o55 (2.17) o60 (2.36) o65 (2.56) o70 (2.76) o75 (2.95) o80 (3.15) o85 (3.35) o90 (3.54) o95 (3.74) o100 (3.94) o105 (4.13) o110 (4.33) o115 (4.53) o130 (5.12)

d

D

h

62 (2.44) 67 (2.64) 72 (2.83) 77 (3.03) 82 (3.23) 87 (3.43) 92 (3.62) 97 (3.82) 102 (4.02) 107 (4.21) 112 (4.41) 117 (4.61) 122 (4.80) 137 (5.39)

88 (3.46) 96 (3.78) 96 (3.78) 100 (3.94) 110 (4.33) 112 (4.41) 124 (4.88) 135 (5.31) 145 (5.71) 145 (5.71) 150 (5.91) 165 (6.50) 170 (6.69) 190 (7.48)

80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54)

C

6. Removing bushing a. Move block (C) and rod cover (3) with tool under the press. b. Press the upper part of retainer tool (D) slowly until bushing (4) is removed from the rod cover (3) (until there is a sound that the chuck tool (A) drops on the work bench) -The force of 3 tons (6615 lbs or less) is necessary to press it out. The stroke of press ram is about 32 to 52 mm (1.26 in to 2.04 in). (But it varies according to the difference of dimension of the cylinder head.) -Press it with retainer tool (D). When the block and rod cover assembly are not aligned, interrupt the work and align the block and rod cover assembly.

32-38

D

32. ATTACHMENTS 7. Removing rod cover a. Remove block (C) with rod cover (3) near side, remove retainer tool (D) from rod cover (3), and then move rod cover (3). b. Take out the chuck tool (A) with bushing from block (C).

4 A

C

D

Do not work under the press because it is very dangerous. 8. Removing bushing a. Place chuck tool (A) with bushing (4) sideways, and loosen adjuster bolt with allen wrench and lever. b. Place the chuck tool (A) vertically and turn the adjuster by hand until the wedge is raised about 5mm (0.2 in). c. Remove the wedge from the edge of chuck •

Clean the surface of work bench, and be careful that the tool is not damaged by foreign matters like dust, chips, etc.

4

A

32

32-39

32. ATTACHMENTS 9. Tightening of adjuster bolt Tighten the chuck tool (A). The bushing (4) is removed to the extent that there is no gap between the chuck and the wedge upper face, turning the adjuster bolt by hand. -This special tool differs according to the corresponding piston rod diameter. -The chuck edge is an important portion. Take care of handling and storage.

32-40

32. ATTACHMENTS (2) Rod cover bushing press-fitting procedure 1. Temporary setting of head bushing Put rod cover (3) on the press-working bench directing the tube connection upward.

•

Set bushing (4) on the inner surface of rod cover (3) temporarily. Make sure that the inner and outer surfaces of bushing (4) are free from foreign matter.

4

3

2. Setting chuck assy tool (A) Insert the chuck assy tool (A) in a temporary-set bushing (4) directing the flange downward, and set it on rod cover (3). • Be sure that the adjuster bolt is tightened to the extent that there is no gap between the adjuster of the chuck assembly (A) and wedge. ADJUSTER BOLT WEDGE

A

3

32

32-41

32. ATTACHMENTS 3. Attaching retainer tool Put retainer tool (D) on the wedge stepped section of the chuck assembly tool (A) slowly directing the flange upward. -Align chuck assy (A) and the wedge.

4. Preparation for press-fitting Move the rod cover that the chuck tool (A) and retainer tools are attached under the press.

PRESS RAM

-Adjust it so the press ram is centered to the tool. RETAINER(D)

CHUCK(A) BUSHING(4)

BUSHING PRESSFITTING PART

32-42

32. ATTACHMENTS 5. Press-fitting of bushing Push the head of retainer (D) with the press, and press fit bushing (4) to the specified position on the rod cover (3) slowly. -The pressing force should be held at 5 tons (11025 lbs) or less, keeping the required force for the press-fitting. -Raise the pressure gradually adjusting the force by means of a pressure adjusting valve on press unit. -Be sure that the end face of the bushing is located on the interior of the groove for the snap ring. When it is located, press fit and adjust the location again.

STEP OF WEDGE

LIFTING THREAD RETAINER JIG (D)

ADJUSTER BOLT

WEDGE CHUCK TOOL ASSY (A) CHUCK

BLOCK TOOL (C)

32

Bushing removing and press fitting jig (For reference only)

32-43

32. ATTACHMENTS

32-44

33. UPPER SLEWING STRUCTURE

33

33. UPPER SLEWING STRUCTURE TABLE OF CONTENTS

33.1 REMOVING AND INSTALLING .........................................................................33-3 33.1.1 OPERATOR SEAT .....................................................................................33-3 33.1.2 CAB ............................................................................................................33-5 33.1.3 BATTERY ...................................................................................................33-8 33.1.4 GUARD ......................................................................................................33-10 33.1.5 UNDER COVER ........................................................................................33-18 33.1.6 FUEL TANK ...............................................................................................33-19 33.1.7 HYDRAULIC TANK ....................................................................................33-21 33.1.8 HYDRAULIC PUMP ...................................................................................33-25 33.1.9 AIR CLEANER ...........................................................................................33-30 33.1.10 MUFFLER ..................................................................................................33-32 33.1.11 COUNTERWEIGHT ...................................................................................33-34 33.1.12 RADIATOR & OIL COOLER ......................................................................33-35 33.1.13 ENGINE .....................................................................................................33-42 33.1.14 CONSOLE COVER ....................................................................................33-46 33.1.15 CONTROL VALVE .....................................................................................33-47 33.1.16 PILOT VALVE (FOR ATT) ..........................................................................33-50 33.1.17 PILOT VALVE (FOR TRAVEL) ...................................................................33-52 33.1.18 SWING MOTOR UNIT ...............................................................................33-53 33.1.19 SWIVEL JOINT ..........................................................................................33-55 33.1.20 UPPER FRAME .........................................................................................33-58 33.2 DISASSEMBLING AND ASSEMBLING .............................................................33-60 33.2.1 HYDRAULIC PUMP - REGULATOR ..........................................................33-60 33.2.2 CONTROL VALVE .....................................................................................33-86 33.2.3 PILOT VALVE (ATT) ...................................................................................33-119 33.2.4 PILOT VALVE (FOR TRAVEL) ...................................................................33-132 33.2.5 SWING MOTOR UNIT ...............................................................................33-142 33.2.6 SWIVEL JOINT ..........................................................................................33-171

Book Code No. S5LC3326E01 33-1

33. UPPER SLEWING STRUCTURE

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC3326E01 NA

September, 2010 SK350-9: YC

PREFACE (1) This Manual describes all the procedures from removing to installing, arranging them by item. (2) This Manual consists of [Removing and Installing] and [Disassembling and Assembling]. (3) The removing and installing can be performed in the procedure specified in the Table of Contents, but in view of actual repairing or time saving some processes can be omitted. (4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective sections. (5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize the work procedure, before starting work. (6) Disconnect the negative terminal from the battery first, when the removing and the installing of the electric component and wiring are performed. (7) The explanatory notes and figures in this manual may differ from the actual machine by the difference in specification.

33-2

33. UPPER SLEWING STRUCTURE

33.1

REMOVING AND INSTALLING

33

33.1.1 OPERATOR SEAT 33.1.1.1 REMOVAL (1) Preparation for removal 1. Remove the head rest (A1-1) on the operator's seat (A1) to ease handling. 2. Move the whole control stand to its foremost position. 3. Move the operator's seat to its forward end. 4. Incline the reclining seat as far forward as possible. (2) Remove operator's seat. (Include upper rail) 1. With the above-mentioned condition, remove two cap screws (B2) M8X20 from the upper rail. Then move the control stand to its rearmost end and remove two capscrews (B2) M8X20. Tools: Allen wrench: 6 mm 2. Remove the operator's seat. [about 28 kg (62 lbs).] Carry out the following operations as required. 3. Remove seat belt (C1) and bracket (C2). 4. Remove armrest (A3)(A4). 5. Remove bracket assembly (1), rail (7).

A1-1 A1

C1

7/16

C4

C4

7/16

B2 C1 C2 C3

7

1

Disassembling And Assembling Seat

33-3

33. UPPER SLEWING STRUCTURE 33.1.1.2 INSTALLATION Install it in reverse procedure of removing according to the tightening torque table.

Tightening position Capscrew (B2) Sems bolt (C3) Sems bolt (A6) Capserew (A5)

Allen wrench HEX

Tightening torque N·m (lbf·ft)

6 17 13 13

23 (17) 46.5 (34.3) 23 (17) 23 (17)

A4 A5 A3 A2

A5

A1

A6

Disassembling and Assembling Armrest Reference : Movement on rail Upper rail.....Fixed on lower surface of seat [Forward 80mm (0.26in), backward 80mm (0.26in)] 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)] Suspension stroke [Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]

33-4

A6

33. UPPER SLEWING STRUCTURE 33.1.2 CAB

33

33.1.2.1 REMOVAL (1) Remove floor mat. (2) Remove cover assembly (A8). 1. Remove cover (A9) and loosen 4 sems bolts (A38) M6X20. Tools: Phillips screwdrive 2. Disconnect harness connector of power socket and remove cover assembly (A8). (3) Removal of cover assembly (A10). 1. Remove cover (A11) and loosen 2 sems bolts (A38) M6X20. Tools: Phillips screwdriver 2. Remove cover assembly (A10). (4) Removal of harness connector. (See Chapter 23 "Electric System") 1. Disconnect connectors on cab harness at rear right of cab. 2. Disconnect antenna cable for tuner located at rear left of cab. 3. Disconnect harness for cab light located at rear left of cab. (5) Removal of cover assembly (A1). 1. Loosen 2 sems bolts (A38) M6X20. Tools: Phillips screwdriver 2. Disconnect harness connector of hour-meter and remove cover assembly (A1). (6) Remove plastic tube for window washer located at right front of cab.

A9 A8 A38

A38

(7) Removal of mechatro-controller 1. Loosen 4 sems bolts (B11) M6X25. 2. With harnesses connected, remove the mechatro controller, and place it in front of it temporally.

A38

A38

A38

A10

A1

A38 A11

Disassembly And Assembly Of Right Panels (A1), (A8) And (A10)

MECHATRONICS CONTROLLER

4 PLACES

B11

RELAY BOX ASSY

Removal Of Mechatro-Controller

33-5

33. UPPER SLEWING STRUCTURE (8) Removal of cab attaching bolts 1. Loosen 4 capscrews (C1) M12X35.

C1

C1

C1 C1 Removing And Installing Cab Mounting Bolts (9) Slinging cab 1. Remove 2 plastic plugs at the front ceiling of the cab, and attach 3 eyebolts. Then hook slinging wires to eyebolts as shown in figure. 2. Then lift up cab slowly, avoiding interference with surroundings. Wire with hook; Length 1.5m (4ft 11in) X Dia. 12mm (0.4in) X 3pcs. Weight of cab; Approx. 480kg (1060lbs)

EYE BOLT M16

EYE BOLT M12

Slinging Cab

33.1.2.2 Installation Install it in reverse order of removing according to the Tightening Torque Table.

Tightening position Capscrew (C1)

Allen wrench HEX(mm)

Tightening torque N·m (lbf·ft)

19

80 (66)

Sems bolt M6 (A38)(B11) Plus driver

5.0 (3.7)

33-6

33. UPPER SLEWING STRUCTURE 33.1.3 BATTERY

33

33.1.3.1 REMOVING (1) Open left panel assembly (B1), (B2). 1. Open it with starter key. 2. Open left panel assembly (B1). 3. Fix it with a stay. (2) Remove battery cover (3). Loosen sems-bolt (A8) M10 and remove battery cover (A3). Tools: Spanner: 17 mm

B2 B1 (3) Remove battery cable 1. Remove cable (C4) [between the earth and battery (-)]. (Always remove (-) terminal first and install it at last.) 2. Cable (C2) [between battery (+) and (-)] 3. Cable (C3) [between battery (+) and battery relay] Tools: Spanner: 13 mm

C4

C3

C2

Removing And Installing Battery Cable (4) Remove battery (B1) 1. Loosen 2 capscrews (A5) M10X235. Tools: Socket 17 mm 2. Remove plate (A4). 3. Remove battery (B1).

A4

A5 A3

A8

A

A B1 FRONT OF MACHINE

ISOMETRIC DRAWING A5

A4 A3

A8

SECTION AA Removing And Installing Battery

33-7

33. UPPER SLEWING STRUCTURE

Follow the battery removal order. Start removing battery from grounding side, and finish attaching to grounding side. If this order is missed, shortcircuits may occur.

33.1.3.2 INSTALL (1) Install the battery in the reverse order of removing. Hold down plate (A4) against battery (B1), and tighten capscrew (A5). Tools: Socket: 17 mm, Tightening torque : 10.8 N-m (8.0 lbf-ft) (2) Installing grounding cable Install grounding cable (C4) last. Especially care must be taken that the grounding face is free from painting, rust, etc. Tools: Socket: 13 mm

33-8

33. UPPER SLEWING STRUCTURE 33.1.4 GUARD

33

33.1.4.1 PREPARATION FOR REMOVAL (1) Remove guards in the following procedure. Remove the guards in the order of (F1)-->(F2)->(C1)-->(A23)-->(A17)-->(A18)--> (D1)-->(H4)-->(G1)-->(E1)-->(B1)-->(B2)--> (B3)-->(H2)-->(H1). (2) All the locked covers open with the starter key.

D1

H1, H2, H4

E1

G1

A18

A17

B3 A23 C1

F1

F2 B1

F2

Arrangement Of Guard Assembly 33.1.4.2 REMOVE GUARD (1) Remove bonnet assembly (F1 and F2).

F1

1. Unlock and open bonnet assembly (F1). 2. Remove 4 nuts (10) M12.

B B

3. Remove bonnet (F1).

A

Tools: Socket: 19 mm Weight: Bonnet (F1) : 31 kg (68 lbs) Bonnet (F2) : 21 kg (46 lbs)

C C

A

4. Remove 4 nuts (10) M12 and 2 sems bolts (9) M12X45.

F2

5. Remove bonnet (F2).

10

SECTION AA 4 9 SECTION CC

SECTION BB Removing Bonnet Assembly (F1 and F2)

33-9

33. UPPER SLEWING STRUCTURE (2) Remove guard (C1) and guard (A23), (A24).

C1, 9

1. Remove 8 sems bolts (9) M12X25. 2. Remove guard (C1) Tools: Socket: 19 mm Weight: Guard (C1) : 15 kg (33 lbs) Guard (A23) : 10 kg (22 lbs) Guard (A24) : 5 kg (11 lbs) 3. Remove 9 sems bolts (33) M12X25. 4. Remove guard (A23).

A24, 33

A23, 33

5. Remove 2 sems bolts (33) M12X25. 6. Remove guard (A24).

Removing Guard (C1), (A23), (A24) (3) Remove guard (A17 and A18) and guard assembly (D1).

A17 A18

33

1. Remove 4 sems bolts (33) M12X25.

A

2. Remove guard (A17). 3. Remove 4 sems bolts (52) M12X25.

B

4. Remove guard assembly (A18).

A B

5. Remove 17 sems bolts (4) M12X25.

33

6. Remove guard (D1).

52 52

Tools: Socket: 19 mm Weight: guard (A17) : 7kg (15 lbs) guard (A18) : 10kg (22 lbs) guard (D1) : 15kg (33 lbs)

A17

A18

SECTION BB

SECTION AA

D1, 4 Removing Guard (A17, A18, and D1)

33-10

33. UPPER SLEWING STRUCTURE (4) Remove cover (H4).

33

1. Remove 2 sems bolts (3) M12X25. 2. Remove cover (H4). 2 PLACES

Tools: Socket: 19 mm Weight: Cover (H4) : 2.9kg (6.4 lbs)

H4, 3

Removing Cover (H4) (5) Remove stay (G1) and stay (E1).

G1

1. Remove 4 capscrews (6) M12X65. 2. Remove plate (2 and 7) and stay (G1). 3. Remove 2 capscrews (5) M10X55.

aa

E1

4. Remove a capscrews (6) M12X60. 5. Remove 2 capscrews (7) M16X65.

2

6. Remove clamp (3 and 4) and remove stay (E1). Tools: Socket: 17 mm Tools: Socket: 19 mm Tools: Socket: 24 mm Weight: stay (G1) : 9kg (20 lbs) stay (E1) : 6kg (13 lbs)

bb

3

7

7

6

3 DETAIL aa

2 DETAIL bb

Removeing Stay (G1 and E1)

33-11

5

33. UPPER SLEWING STRUCTURE (6) Remove panel assembly (B1). 1. Unlock panel assembly (B1). 2. Remove 4 nuts (4) M12.

4

3. Remove panel assembly (B1). Tools: Socket: 19 mm Weight: 13 kg (29 lbs)

B1

Removing Panel Assembly (B1) (7) Remove panel assembly (B2).

4

1. Remove 4 nuts (4) M12. 2. Remove panel assembly (B2). Tools: Socket: 19 mm Weight: 14 kg (31 lbs)

B2

Removing Panel Assembly (B2) (8) Remove panel assembly (B3).

B3

1. Unlock and open panel assembly (B3). 2. Remove 4 nuts (4) M12. 3. Remove panel assembly (B3). Tools: Socket: 19 mm Weight: 13 kg (29 lbs)

4

Removing Panel Assembly (B3)

33-12

33. UPPER SLEWING STRUCTURE (9) Remove panel assembly (A31).

A31, 33

1. Remove 3 sems bolts (33) M12X25.

33

2. Remove panel assembly (A31). Tools: Socket: 19 mm Weight: 2 kg (4.4 lbs)

Remoring Panel Assembly (A31) (10)Remove guard (A25, A26, and A27). 1. Remove 10 sems bolts (33) M12X25 and guard assembly (A25, A26, and A27) in order. Tools: Socket: 19 mm Weight: guard (A25) : 4.4kg (9.7 lbs) guard (A26) : 1.1kg (2.4 lbs) guard (A27) : 2.5kg (5.5 lbs)

A26, 33

A25, 33

A27, 33

Removing Guard (A25, A26, and A27). (11)Remove guard (D2). Remove the battery relay box in advance and remove guard (D2). (See chapter 23). 1. Remove 2 sems bolts (4) M12X25. 2. Remove 5 sems bolts (4) M12X25. 3. Remove guard (D2). Tools: Socket: 19 mm Weight: guard (D2) : 6.3kg (13.9 lbs)

D2, 4 Removing Guard (D2)

33-13

33. UPPER SLEWING STRUCTURE (12)Remove beam (A7 and A12) and pillar (A5). 1. Remove 6 sems bolts (33) M12X25 and remove beam (A7). 2. Loosen 2 sems bolts (33) M12X25. 3. Remove pillar (A5). 4. Remove 3 sems bolts (33) M12X25 and remove beam (A12). Tools: Socket: 19 mm Weight: pillar (A5) : 5.4kg (11.9 lbs) beam (A7) : 8kg (17.6 lbs) beam (A12) : 6.3kg (13.9 lbs)

A5, 33

A12, 33

A7, 33 Removing And Installing Beam (A7 and A12) And Pillar (A5)

(13)Remove bracket assembly (A13) and guard (A14).

33

1. Remove 3 sems bolts (33) M12X25.

A13, 33

2. Remove bracket assembly (A13). 3. Remove 3 sems bolts (33) M12X25. 4. Remove 2 sems bolts (34) M12x30. 5. Remove guard (A14). Tools: Socket: 19 mm Weight: Bracket assembly (A13) : 4.8kg (10.6 lbs) guard (A14) : 11.4kg (25.1 lbs)

33 A14

34

Removing Bracket Assembly (A13) And Guard (A14) (14)Remove cover assembly (C5).

C5, 9

1. Remove 4 sems bolts (9) M12X 25. 2. Remove cover assembly (C5). Tools: Socket:19 mm Weight: Cover assembly (C5) : 0.5kg (1.1 lbs)

Removing Cover Assembly (C5)

33-14

33. UPPER SLEWING STRUCTURE (15)Remove guard assembly (C2 and C3).

C3, 9 1. Remove 7 sems bolts (9) M12X25. Tools: Socket: 19 mm

33

2. Remove guard assembly (C2), (C3). Weight: Guard assembly (C2) : 9.6kg (21.2 lbs) Guard assembly (C3) : 5.5kg (12.1 lbs)

C2, 9 Removing Guard Assembly (C2 and C3) (16)Remove cover (C4). Loosen 3 sems bolts (9) M12X25, remove cover (C4). Tools: Socket: 19 mm Weight: Cover (C4) : 2.9kg (6.4 lbs)

and

9 C4 Removing Cover (C4) (17)Remove plate (A28) and guard assembly (A22).

A22, 33

1. Remove 2 sems bolts (33) M12X25. 2. Remove plate (A28). 3. Remove 6 sems bolts (33) M12X25. 4. Remove guard assembly (A22). Tools: Socket: 19 mm Weight: Plate (A28) : 0.7 kg (1.5 lbs) Guard assembly (A22) : 11.1 kg (24.5 lbs)

A28, 33 Remove Plate (A28) And Guard Assembly (A22)

33-15

33. UPPER SLEWING STRUCTURE (18)Remove cover assembly (H1).

H1-6 H2, 3

1. Remove 4 sems bolts (3) M12X25. 2. Remove plate (H2). Unlock the locks and cover (H1-2).

H1-2 H1, 3

3. Remove 4 sems bolts (H1-6) M10X20. 4. Remove cover (H1-2). 5. Remove 4 sems bolts (3) M12X25. 6. Remove cover assembly (H1).

Remove Cover Assembly (H1) 33.1.4.3 INSTALLATION (1) Installing is done in the reverse order of removing. (2) Tightening torque

Unit : N.m (lbf.ft) Size

Nut

Sems bolt

M10 M12 M16

46.5 (34.3) -

46.1 (34.0) 80 (59) 191 (140.9)

33-16

H1-6

33. UPPER SLEWING STRUCTURE 33.1.5 UNDER COVER

33

33.1.5.1 REMOVAL (1) Remove under cover (1, 2, 3, 4, 5, 6, 7, 10, and 11). 1. Remove attaching sems bolts (8) M12X30 and sems bolts (9) M12X40. 2. Remove covers. Tools: Socket: 19 mm

8, 10 4, 8 3, 8 6, 9

2, 8 1, 8

8, 11

7, 8 5, 9 FORWARD

Q'ty and weight for removing sems bolts of cours Under cover (1) 6 pcs. 6.3kg (14 lbs) Under cover (2) 6 pcs. 4.7kg (10 lbs) Under cover (3) 4 pcs. 0.7kg (1.5 lbs) Under cover (4) 4 pcs. 1.6kg (3.5 lbs) Under cover (5) 5 pcs. 4.9kg (11 lbs) Under cover (6) 7 pcs. 4.7kg (10 lbs) Under cover assy (7) 4 pcs. 5.0kg (11 lbs) Under cover (10) 4 pcs. 2.1kg (4.6 lbs) Under cover (11) 4 pcs. 4.6kg (10 lbs) Under Cover Assembly

33.1.5.2 INSTALLATION (1) Install under cover (1, 2, 3, 4, 5, 6, 7, 10, and 11). Tools: Socket: 19 mm Tightening torque: 80 N-m (59 lbf-ft)

33-17

33. UPPER SLEWING STRUCTURE 33.1.6 FUEL TANK 33.1.6.1 PREPARATION FOR REMOVAL (1) Draining fuel. (See Figure). 1. Unlock cap (B2) with a starter key and open it. 2. Loosen valve (A7) under the tank. 3. Draining fuel. Capacity of tank: 580 L (153 gal) (2) Remove stay (E1 and G1) and cover (H4). (See 33.1.4 GUARD)

FORWARD

aa

(3) Remove the connector for level sensor (A4). (See Figure)

12

(4) Remove fuel hose.

RETURN

21

SUCTION

1. Loosen clip (21) and remove hoses (8 and 12). 2. Install plugs that match the hose inside diameter.

8

21

DETAIL aa Removing Fuel Hose (8 and 12)

33-18

33. UPPER SLEWING STRUCTURE 33.1.6.2 REMOVAL (1) Remove 6 capscrews (A1) M20X50. Tools: Socket: 30 mm Tank capacity: 580 liters (153 gal)

B2

(2) Hook the wire to the lifting eye on the fuel tank assembly (C1) and remove the fuel tank. Weight: 191 kg (421 lbs)

C1

33

I

II

(3) Remove shim (A3).

A3

A1

A4, A5

TIGHTENING TORQUE 1.96N.m (1.45 lbf.ft) 5 PLACES

A7 VIEW II

VIEW I Removing Fuel Tank

Record the shim locations.

33.1.6.4 INSTALLATION (1) Installing is done in the reverse order of removing. Tank attaching bolt (A1) M20X50 Tools: Socket: 30 mm, Apply Loctite #262 Tightening torque: 370 N-m (273 lbf-ft)

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. (2) Tightening torque

No.

Name

Q'ty

Tightening torque N.m (lbf.ft)

A1

Capscrew

6

370 (273)

A5

Machine screw

5

1.96 (1.4)

A7

Cock

1

34 (25)

33-19

33. UPPER SLEWING STRUCTURE 33.1.7 HYDRAULIC TANK 33.1.7.1 PREPARATION FOR REMOVAL (1) Remove bonnet assembly (F1 and F2), panel assembly (B3), guard (A17 and A18), and the other guards necessary to remove the hydraulic oil tank. (See 33.1.4 GUARD.)

A17 F1

A18 B3

F2 Remove Guard (2) Release internal pressure of tank. Remove cap on air breather and push valve (head of bolt) with your finger.

Cap Push

Air breather Element No. YN57V00005S002

Bleeding Internal Pressure Of Tank

Keep pressing until the hissing stops.

33-20

33. UPPER SLEWING STRUCTURE (3) Remove cover (C3). 1. Remove 6 sems bolts (C9) M10X25. Tools: Socket: 17 mm

C9 C9

C2

2. Remove cover (C3).

C3

3. Remove suction strainer (B4). (4) Remove cover (C2).

B

1. Remove 6 capscrews (C9) M10X25. Tools: Socket: 17 mm

C

B4

D

2. Remove cover (C2).

B7

D

3. Remove filter element (B7).

Air breather

D

(5) Turn the handle of element assembly (B), and disassemble the removed filter element (B7). Disassemble parts: (B), (C), (D), X3, (E), and (F)

E

Hyd.tank

F

(6) Draining hydraulic oil. Place pump in tank and draw up hydraulic oil. Capacity of tank: 386 L (49 gal) Remove Cover (C2), (C3) 33.1.7.2 REMOVAL (1) Draw out the suction hose (A3). Remove 2 clips (A13) on the tank side and pull out hose (A3). Tools: 2: Flat-blade screwdriver A12 A3

At installing suction hose, apply PERMATEX to the inner end of both hoses.

A13

Removing And Installing The Suction Hose (2) Disconnecting the main pipe return hose

4

1. Remove 2 sems bolts (11) M12X35 and remove return hose (1). Tools: Spanner: 19 mm

11, 10

1

3

2. Remove drain hose (4) of pump. Tools: Spanner: 36 mm 3. Remove drain hose (6) of swing motor. Tools: Spanner: 36 mm

Removing Main Piping Return Hose

33-21

33

33. UPPER SLEWING STRUCTURE (3) Disconnecting pilot return hose 1. Remove pilot hose (A1). Tools: Spanner: 22 mm A1

2. Remove pilot hose (A11). Tools: Spanner: 22 mm

C/V DR

3. Remove pilot hose (A14). Tools: Spanner: 22 mm

A14 S/V T

PT T

A11

Remove Pilot Return Hose (4) Remove drain hose (4) of pilot pump Tools: Spanner: 22 mm

4

Removing Pump Drain Hose (5) Remove hydraulic tank attaching bolt Remove 4 capscrews (A1) M20X45. Tools: Socket: 30 mm (6) Slinging hydraulic oil tank Place a wire sling, using the lifting plate on top of the tank. Tank weight: Approx : 207 kg (456 lbs) (7) Remove shim (A3). A3 A1

Removing Hydraulic Tank

Record the shim locations.

33-22

33. UPPER SLEWING STRUCTURE 33.1.7.3 INSTALLATION (1) Cleaning hydraulic oil tank.

33

(2) Cleaning suction hose. (3) Cleaning mount of tank. Installing is done in the reverse order of removing. (4) Install 4 mounting capscrews (A1) M20X45 with Loctite #262. (See Figure "Removing Hydraulic Tank".) Tools: Socket: 30 mm, Apply Loctite # 262 Tightening torque: 370 N-m (273 lbf-ft)

If the gap (looseness) between tank mount and frame exceeds 1mm (0.04 inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank. (5) Connection of suction hose (A3). (See Figure "Removing And Installing The Suction".)

O-RING

1. Apply PERMATEX on pipe side of hose connection and insert it.

C

2. Put the hose with clip (A12). Tightening torque: 5.39 N-m (4.0 lbf-ft) (6) Assembling return element Assemble filter element by the use of element kit (B-200). (See Fig."Remove cover", Right Fig.)

B2 SUCTION STRAINER LC50V00006F2

(7) Install return element (B6). (See Fig. "Remove cover") (8) Installing suction strainer (B2).

D

F ELEMENT KIT (B-200) LS52V01002R300

Element And Suction Strainer

(9) Tighten sems bolts (C5) M10X25 that attach tank covers (C2 and C3). M10 Tightening torque : 46.5 N-m (34 lbf-ft)

1. Three elements (D) are used as one set. 2. Replace O-ring (C) and packing (F) with new ones respectively.

Replace O-ring fitted on the back side of tank cover with new one.

33-23

33. UPPER SLEWING STRUCTURE 33.1.8 HYDRAULIC PUMP 33.1.8.1 PREPARATION FOR REMOVAL (1) Release pressure in hydraulic oil tank. (See 33.1.7 HYDRAULIC TANK)

C9

(2) Remove six capscrews (C9) M10X25.

C3

(3) Remove cover (C3). Tools: Socket: 17 mm

Suction stopper

(4) Take out suction strainer.

Suction strainer

(5) Install suction stopper. For suction stopper, see chapter 11. Tools.

Hyd.tank

Suction Stopper Installing (6) Remove guards A24

A23

1. Remove bonnet assembly (F1), (F2). 2. Remove panel assembly (B3), guard (A23), (A24), (A25), (A26), (A27). 3. Remove those parts that are required to remove the hydraulic pump such as the fuel filter assembly.

A26

A25

A27

Removing Guards

33-24

33. UPPER SLEWING STRUCTURE 33.1.8.2 REMOVAL (1) Loosen 8 capscrews (A15) M12X90 and remove half clamp (A4). And disconnect 2 hoses (A1 and A2) from the delivery side. Tools: Allen wrench: 10 mm

A15

33

A4

(2) Remove pilot pump suction hose (1). (See below Fig.) Tools: Spanner: 36 m (3) Remove suction hose (A3) and drain hose (4).

A4 A2

1. Remove 4 capscrews (B2) M12X30. Tools: Allen wrench: 10 mm

A1

2. Remove elbow (B1) of suction hose (A3) from pump.

B2 B1

A3

Removing Hoses (4) Removing other hoses. 1. Disconnect hoses of the following ports. 2. Attach tags to hoses to identify. 3. Put a plug in the hoses and the pump.

Port

Hose No.

Dr3

4

22

Drain

*Psv1

4

19

Pilot primary pressure P1 side

*Psv2

3

19

Pilot primary pressure P2 side

Psv1

A11

Remarks

Tool

19, 22

TANKPUMP Dr3

A3

Dr3

4

B3

3

Pilot pump delivery

4 Psv2 Psv1

2

B1

PUMP B1PUMP B3

A11

S/V P1PUMP Psv1

P1

Removing Other Hoses

Remove the parts marked * only if necessary.

33-25

33. UPPER SLEWING STRUCTURE (5) Remove connector. Fix a harness part of coulgated for solenoid of clip.

PSV-P1:

Remove 4 connectors on all pressure sensors and proportional valves.

P1 pump proportional valve

PSV-P2:

CLIP

P2 pump proportional valve

Side of engine

CLIP

To guard

Control proportional solenoid.

CLIP

White taping

SE-22:

Pressure sensor : P1 pump

SE-23:

Pressure sensor : P2 pump

CLIP

Fix a harness part of coulgated for press sensor of clip.

Removing Connector (6) Remove main pump 1. Put a wire sling on the hydraulic pump and tension the wire sling a little. Loosen 8 capscrews (4) M10X35. Tools: Socket: 17 mm 2. Remove the power take-off assembly from the flywheel housing slowly, adjusting the tension of the wire rope. In this occasion, the assembly is drawn out with the insert NA (2-3) remaining on the flywheel side. 3. Remove element (2-1) from the tip of the spline shaft. 4. Remove 4 capscrews (2-6) M20X50 that fasten insert R (2-4) and remove insert R (2-4). Tools: Allen wrench: 17 mm 5. Remove hub (2-2) If you loosen 2 set screws (2-7) M20X25, hub comes off from the spline shaft of the pump. Tools: Allen wrench: 17 mm 6. Remove 4 capscrews (2-5) M20X60 that fasten the insert NA (2-3) with the engine side flywheel, as necessary. Then remove spring pin (2-8) from insert NA (2-3). Tools: Allen wrench: 17 mm 7. Removing bracket (1) Loosen 4 capscrews (3) M20X55, and remove bracket (1) from pump (0).

33-26

Removing Pump

33. UPPER SLEWING STRUCTURE 33.1.8.3 INSTALLATION Installing is done in the reverse order of removing. (1) Installing bracket (1) Tighten bracket (1) with capscrew (3) and install bracket temporarily. Tools: Allen wrench: 17 mm Tightening torque: 431 N-m (318 lbf-ft) Apply Loctite #262 (2) Installing hub (2-2) Put hub (2-2) into the pump spline till it enters 3mm (0.12 in) from the end face of the spline (See below Figure Detail aa). Then install two set screws (2-7) and fix them together. Tools: Allen wrench: 17 mm Tightening torque: 210 N-m (155 lbf-ft) (3) Install spring pin (2-9) Put spring pin (2-9) into hub (2-2). (4) Installing insert (2-4) Install insert (2-4) into hub (2-2) by means of capscrews (2-6) coated with Loctite #262. Tools: Allen wrench: 14 mm Tightening torque : 465 N-m (343 lbf-ft) (5) Installing element (2-1) Put element (2-1) into hub (2-2) and insert (2-4). (6) Installing insert NA (2-3) Put spring pin (2-8) into insert NA (2-3) and install it to the engine flywheel by means of capscrews (2-5). Tools: Allen wrench: 17 mm Tightening torque: 465 N-m (343 lbf-ft) (See Figure "Removing Pump" about above mentioned (1) to (5).) (7) Installing the pump (See Figure "Removing Pump") Lift the pump with bracket (1). Place coupling (2) in the groove of element (2-1) to receive insert NA (23). (8) Coat 8 capscrews (4) M10X35 with Loctite #262 and put them in place. Tools: Socket: 17 mm Tightening torque : 64.7N-m (48 lbf-ft) (9) Fasten hoses (A1 and A2) on the delivery side with half clamp (A11) and capscrews (A19) M12X40. (See Fig."Removing hoses") Tools: Allen wrench: 10 mm Tightening torque: 62.2 N-m (46 lbf-ft) (10)Install suction hose (A3) with 4 capscrews (B2) M12X30. (See Figure "Removing Hoses") Tools: Allen wrench: 10 mm Tightening torque : 66.7 N-m (49 lbf-ft) (11)Install the hydraulic piping by referring to "HYDRAULIC SYSTEM".

2-6 2

aa 2-7

T=210N.m (155 lbf.ft)

2-8

SPRING PIN (4 places)

T=465N.m (343 lbf.ft) Do not use Loctite (The attached bolts are coated with micro capsule coating)

3 1

T=431N.m (318 lbf.ft) Apply Loctite #262

4

T=64.7N.m (48 lbf.ft) Apply Loctite #262

4

3 (0.118")

56 (2.2")

DETAIL aa

DRAIN HOLE (Bottom)

VIEW I

Installing Hydraulic Pump

33-27

33

33. UPPER SLEWING STRUCTURE (12) Installing the hose (See Figure "Removing Other Hoses")

(13) Installing pressure sensor connector and proportional valve connector. (14) Remove suction stopper. (15) Install suction strainer.

When the pump is replaced, replenish more than 1L (0.26 gal) of hydraulic oil from the drain port (Dr). (16) Bleed air in pump Bleed air by loosening the drain port (Dr). (17) Check hydraulic oil level. (18) Start engine and check it for oil leak and noise. (19) Attach drain down pipe under engine muffler. (20) Install guards (See Figure "Removing Guard Assembly (16) And Guard (14),(15),(17). Figure "Removing Guards")

Dr

Bleed Air Port (Dr) In Pump

33-28

33. UPPER SLEWING STRUCTURE 33.1.9 AIR CLEANER

33

33.1.9.1 PREPARATION FOR REMOVAL (1) Opening panel assembly (B1 and B2). (See 33.1.4 GUARD)

F1

(2) Open bonnet assembly (F1). (See 33.1.4 GUARD) (3) Unplug terminals on indicator (1-8) wiring. (See Figure below)

B2 B1 Preparation For Removal 33.1.9.2 REMOVAL (1) Pulling out hose (3). 1. Loosen clips (5 and 6) on both sides of hose (3). 2. Pulling out hose (3). Tools: Flat-blade screw driver (2) Remove air cleaner assembly (1). 1. Remove 4 sems bolts (7) M10X25 Tools: Socket: 17 mm 2. Remove air cleaner assembly (1) from bracket (4). CLIP INSTALLATION POSITION

CLIP INSTALLATION POSITION

5 25(0.98") 25(0.98") 5

FORWARD

1

I

25 (0.98")

III II

45 45 (1.77") (1.77")

7 50 (1.97")

ALLOWANCE FOR INSERTING HOSE

5 5

26 (1.02")

VIEW I

ALLOWANCE FOR OVERLAP WITH DUCT ALLOWANCE FOR INSERTING HOSE

2

4

3

10

5

1-8

2-MX0.7 TIGHTENING TORQUE 1.68N.m (1.24 lbf.ft)

8, 9 30 (1.18")

INSERT IN HOLE OF DUCT

7

5

10 A

1

VIEW III

1-8

18 (0.71")

1-2

CLIP INSTALLATION POSITION

VIEW II Removing Air Cleaner

33-29

1-6

1-3 A

33. UPPER SLEWING STRUCTURE 33.1.9.3 INSTALLATION (1) Installing is the reverse order of removing with attention paid to the following items: 1. Install air hoses (2 and 3) to the end as shown in Figure "Preparatiom For Removal". 2. Tightening torque:

No. 1-8

Name Indicator

Tightening torque N.m (lbf.ft) 3.9 (2.9)

7

Sems bolt

39.2 (29) (Apply Loctite #262)

10

Sems bolt

80.0 (59)

5,6

Clip

5.9 (4.4)

FILTER ELEMENT (1-3) FILTER ELEMENT (1-2) (LC11P00018S003) (LC11P00018S002) O-RING (1-6) (EB11P00001S003)

33-30

33. UPPER SLEWING STRUCTURE 33.1.10 MUFFLER

33

33.1.10.1 PREPARATION FOR REMOVAL (1) Remove bonnet assembly (F1 and F2), and guards (A23 and C1).

C1

A23

F1

(2) Remove panel assembly (B3).

B3

(3) Remove guards (A25, A26, and A27). (See Figure "Removing Guard (A25, A26, and A27)".)

F2 Preparation For Removal 33.1.10.2 REMOVAL (1) Remove 2 connectors. (2) Remove 2 nuts (8) and 2 clips (9). (3) Remove a nut (21) and a clip (9). (4) Remove 4 bolts (10). (5) Remove 5 sems bolts (22) and 2 sems bolts (23). (6) Remove 4 nuts (7). (7) Remove filter assembly (1). (8) Loosen bolts (1-5) located on flanges on both sides, remove only the central filter part.

10

HOSE

1-5 1

A 1-5 8, 9

MAUNT

23

A FORWARD

22 MAUNT

20, 21 SECTION AA

7

33-31

33. UPPER SLEWING STRUCTURE 33.1.10.3 INSTALLATION (1) Installing is the reverse order of removing. (2) Tightening torque:

No.

Name

Tightening torque N.m (lbf.ft)

7

Nut

51 (38)

8

Nut

22 (16)

10

Bolt

59 (44)

21

Nut

22 (16)

22

Sems bolt

108 (80)

23

Sems bolt

108 (80)

33-32

33. UPPER SLEWING STRUCTURE 33.1.11 COUNTERWEIGHT

33

33.1.11.1 PREPARATION FOR REMOVAL (1) Remove bonnet assembly (F1 and F2). (See 33.1.4 GUARD)

F1

F2 Lifting Up Counterweight 33.1.11.2 REMOVAL (1) Lifting up counterweight temporarily Hook wire rope to slinging jig, and lift it and stretch wire rope to the degree where it is providing no slack temporarily. Weight of counterweight; (Semi-weighted) Approx. 8,800kg (19,400 lb) (2) Removing counterweight (C1) 1. Remove 4 capscrews (A1) M36X420. Tools: Socket: 55 mm 2. Remove shim (A3, A4, and A5). (Select) A3, A4, A5

3) Remove counterweight (C1). A1, A2

Removing Counterweight 33.1.11.3 INSTALLATION (1) Install counterweight in the reverse order of removing. (2) Install shim (A3, A4, and A5) as it was. (select) (3) Slinging counterweight Check that the attaching bolts can be screwed in by hand. (4) Apply Loctite #262 on capscrews (A1), and tighten them with washers (A2). Tools: Socket: 55 mm Tightening torque : 2940 N-m (2170 lbf-ft) (5) Remove slinging tools, and install bonnet assembly (F1 and F2).

Less than two shim adjustment A3,A4,A5

A1,A2

Fastening The Counterweight Attaching Capscrew

33-33

33. UPPER SLEWING STRUCTURE 33.1.12 RADIATOR & OIL COOLER 33.1.12.1 PREPARATION FOR REMOVAL (1) Bleed air from the hydraulic tank and install the suction stopper.(See 33.1.7 and 33.1.8)

10 4

(2) Remove bonnet assembly (F1 and F2) (See 33.1.4 GUARD) (3) Remove battery (See 33.1.3 BATTERY). (4) Remove beam (A12), (A-33). (See 33.1.4 GUARD) Removing Under Cover (4 and 10)

(5) Open panel assembly (21). (See 33.1.4 GUARD) (6) Removing under cover installed on lower side of radiator.

FORWARD

7

9

12

1. Remove 8 sems bolts (9) M12X30. 27

2. Remove cover (4 and 10). Tools: Socket: 19 mm

26

(7) Drain radiator. Place 18L (4.8 gal) container under drain valve for draining water. [Water capacity of radiator : 11L (2.9 gal)]

20, 21 20, 21 18 22

(8) Remove hose from radiator sub tank (1). Remove clip on radiator cap side and disconnect hose (9).

17

(9) Disconnect hose (7). 8

1

Removing Hose Of Sub Tank (1)

Do not loosen the joints on the hoses related to the air-conditioner. Otherwise the refrigerant leaks.

33-34

29

33. UPPER SLEWING STRUCTURE (10) Move air-conditioner condenser and receiver tank and fuel cooler.

33

1. Loosen 4 sems bolts (23) M8X25 and 2 sems bolts (8) M8X20. Tools: Socket: 13 mm 2. Move a set of air-conditioner condenser and receiver tank and fuel cooler. (11) Disconnect coolant level switch (B5). (See Figure "Removing Radiator Assembly")

23 34

8

58 62

23

3

Moving Condensers And Receiver Tank And Fuel Cooler

33-35

33. UPPER SLEWING STRUCTURE 33.1.12.2 REMOVAL (1) Remove radiator stay (A1). 1. Remove 4 sems bolts (A2) M12X35. Tools: Spanner: 19 mm

A1 A2

2. Remove 2 stays (A1 and A6).

A4, A3

(2) Remove water hoses (2 and 3. 1. Loosen the hose bands (23) for water hose (2). Tools: Flat-blade screwdriver 2. Remove hose (2).

A2

A1

A3, A4

3. Loosen hose band (23) on water hose (3). Tools: Flat-blade screwdriver

Removing Radiator Assembly

4.Remove hose (3). (3) Remove hoses (4 and 6) for inter-cooler.

23 24

1. Loosen 4 sems bolts (28) M8X20 from tube (10). Tools: Spanner: 13 mm

4

FORWARD

2. Loosen 2 sems bolts (29) M8X25. Tools: Spanner: 13 mm 3. Loosen hose bands (24 and 25) and remove hose (4). Tools: Flat-blade screwdriver

25

24 23 6 3

4. Loosen hose bands (24) and remove hose (5). Tools: Flat-blade screwdriver

23 FORWARD

5. Loosen hose bands (24) and remove hose (6). Tools: Flat-blade screwdriver 24 5 24 28

29 10

Removing Hose For Radiator / Inter-Cooler

33-36

33. UPPER SLEWING STRUCTURE (4) Remove guards (13, 14, and 15). (See Figure "Removimg Hose Of Sub Tank") 1. Remove 2 sems bolts (27) M8X16 from clip (26). 2. Remove 7 sems bolts (30) M10X20

11 26, 27 FORWARD

30

33

13

14 18

30

22

15

2. Remove guard (13), (14), (15). Tools: Spanner: 13, 17 mm

30

Remove Guard (13, 14, and 15) (5) Disconnecting hydraulic oil hoses (1 and 2).

O/C OUT -TANK

1. Place an oil pan under the hose joint. Loosen 4 sems bolts (13) M12X40, and remove hoses (1) and (2).

1

(6) Remove radiator assembly. (See Figure "Removing radiator assembly") 1. Remove 4 sems bolts (A4) M20X45. Tools: Spanner: 30 mm Tools: Socket: 30 mm 2. When lifting the engine fan, shift the radiator so it does not interfere with the engine fan. 3. Plug up pipe ends with clean cloth, etc.

2

4. Removing radiator Place a wire sling in the lifting eyes of the radiator assembly and remove the assembly by crane. Weight: 177 kg (390 lbs)

33-37

C/V T1 -O/C IN

Removing Hydraulic Oil Hose (1 and 2)

33. UPPER SLEWING STRUCTURE 33.1.12.3 INSTALLATION (1) Installing is done in the reverse order of removing. And removed clips on hoses should be clamped at original position. (2) Install radiator assembly. Place a wire sling in the lifting eyes of the radiator and move it to original position temporally. Install hydraulic hoses, radiator hoses and hoses on inter-cooler. Regarding inserting width of hose (See Figure "Inserting Width Of Hose"). (3) Radiator attaching bolt. Apply Loctite #262 on 4 sems bolts (A4) M20X45. Tools: Socket: 30 mm Tightening torque : 500 N-m (369 lbf-ft) (4) Adjust the clearance between the fan and the radiator shroud all around the circumference, as below : Back and forth: 82 to 92mm (3.2 in to 3.6 in) (5) Clean the plastering area of the insulation thoroughly before plastering it. (6) Add hydraulic oil and LLC (Long Life Coolant) as required. After completion of other installation, Add hydraulic oil and water as required. Coolant volume of engine body : 16 L (3.5 gal) Coolant capacity of radiator : 13.4 L (3.5 gal) Hydraulic oil capacity of oil cooler : 9.6 L (2.5 gal) ")

50 ") 97 (1.

3 (1. 0 18" )

97

38 ") 50 (1.

40 (1.58")

(1 40 .5 8" )

(1.

60 (2.36")

50

50

(1.

50 7") 9 (1.

40(

97

")

1.5

8")

Inserting Width Of Hose

(87 mm) (ALL AROUND)

TIGHTEN ITEM 3 BOLT WITH REGULAR TORQUE, AFTER LAY TO BE 82 TO 92 (3.2in TO 3.6in) ALL AROUND.

RADIATOR SHROUD. FAN RUBBER

15

PUT THE FAN RUBBER OVER THE PROJECTION OF E/G FAN RING AT THE ALL CIRCUMFERENCE. E/G FAN RING NOT TO RUN ON THE PROJECTION OF E/G FAN RING.

FAN 0

Back-And-Forth Adjusting Position Of Radiator

33-38

33. UPPER SLEWING STRUCTURE 33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE (1) Preparation for disassembly and assembly 1. Remove one under cover at the bottom of the radiator. 2. Wait till the engine coolant cools down so you do not get burned. Then remove the cap of the radiator, discharge the coolant by opening the drain valve located at the back bottom and receive it in a container. * In case of removing inter cooler only, the above mentioned work is not necessary. (2) Disassembly 1. Loosen each 2 bolts (6-5) at head and bottom of shroud, remove upper plate (6-2) and lower plate (6-3). 2. Disconnect wiring connector of radiator coolant level switch. 3. Loosen 6 sems bolts (6-5) M10X20 attaching plate assembly (6-4), remove plate assembly (18). 4. Loosen 2 capscrews (15) M10X50 attaching radiator core. 5. After confirming that the coolant has been drained out completely, loosen and remove only the radiator side of hose bands (23) at the top and bottom of the radiator. (See Figure "Removing Hose For Rafiator/inter-cooler") 6. Lift and remove radiator core using lifting eyes and hoist on the radiator core. Weight: 25 kg (55 lbs) Confirm that the rubber bushing (14) is not missing under the radiator core. 7. Loosen 2 capscrews (15) M10X50 attaching the top of the inter-cooler core. 8. Loosen and remove only the inter-cooler side of hose bands (24) at the top and bottom of the inter-cooler. (See Figure "Removing Hose For Radiator/inter-cooler")

15

15

15

33

3

6-5 6-2

6-5 6-4

RADIATOR COOLANT LEVEL SWITCH

Intercooler

Radiator

18

Oil cooler

DRAIN VALVE

14 Detail of radiator core mounting part

6-5 6-3 VIEW A

Removing Radiator And Inter-Cooler

33-39

33. UPPER SLEWING STRUCTURE 9. Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler. Confirm that the rubber bushing (14) is not missing under the inter-cooler. 10. Disconnection of oil cooler hose. Disconnect hoses (1 and 2) from upper and lower areas of the cooler, and drain hydraulic oil. (See Figure "Removing Hydraulic Oil Hose (1 and 2)" 11. Lift cooler temporally using cooler head flange for slinging. 12. Loosen 4 bolts (3) M10 attaching oil cooler. 13. Lift the oil cooler.

There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler. Removing these components can be done as necessary. (3) Installing Installing is done in the reverse order of removing.

33-40

33. UPPER SLEWING STRUCTURE 33.1.13 ENGINE

33

33.1.13.1 PREPARATION FOR REMOVING (1) Remove battery ground (See 33.1.3 BATTERY). (2) Remove bonnet and guard (See 33.1.4 GUARD). Remove under cover (See 33.1.5 UNDER COVER). (3) Remove air cleaner hose (See 33.1.9 AIR CLEANER). (4) Remove counterweight (See 33.1.11 COUNTERWEIGHT). (5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER). (6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose. (7) If necessary, remove pump, muffler and radiator. (8) Remove harness connector (Refer to ELECTRIC SYSTEM). 1. Remove E/G ground cable. 2. Starter cable-Starter B terminal. 3. Remove the connector that connects the upper harness with the engine and ECU harness. 4. Upper harness.

P22-Alternator B terminal CN-136-E/G speed sensor CN-141, CN142-Pump proportional valve CN-139, CN-140-P1,P2 pump pressure sensor CN-212-Glow M-1-Starter motor C terminal

Prepare a stand, which withstands the weight of the engine assembly and can hold the removed engine firmly. (Refer to Tools)

THERMOSTAT

GASKET

OIL PLUG ASSY

OIL FILTER ELEMENT

FUEL FILTER ELEMENT

ALTERNATOR

BELT BELT

ENGINE

Outside View Of Engine

33-41

STARTER V BELT (COMPRESSOR)

33. UPPER SLEWING STRUCTURE 33.1.13.2 REMOVAL

15

cc

aa

1

16

bb 16

dd

50

42 15 DETAIL aa

5

26 DETAIL bb

DETAIL dd

Dismounting And Mounting Engine (1/2)

33-42

33. UPPER SLEWING STRUCTURE

33

ee

28

ff

21 40 19 39

27

28 21

25

27

DETAIL ee

28

28 20 21

27 25

21 27

DETAIL cc

19

20

25

25 DETAIL ff

Dismounting And Mounting Engine (2/2)

33-43

33. UPPER SLEWING STRUCTURE (1) Remove hose on engine oil filter. Place oil pan under the connection of filter (1), and disconnect hoses (15, 16, and 42) at * positions. Tools: Spanner: 19 mm, 41 mm (2) Plug connector and hose on filter side. (3) Loosen engine mounting bolt on frame. 1. Loosen 4 nuts (25) M18. Tools: Socket: 27 mm 2. Loosen 4 capscrews (28) M18X130. 3. Remove 4 plates (21). 4. Remove upper rubber mounts (19) and (20) 2 each. (4) Slinging engine body 1. Sling engine hooking wire to lifting lugs on the front and rear sides. Weight: Approx. 705 kg (1,555 lbs) Wire: 6 dia. (0.236")X1 m (3 ft 3 in) - 2 pcs.

Prepare a stand, which withstands the weight of the engine assembly and can hold the removed engine firmly. (Refer to "Tool".) (5) Position engine on the stand stably. (6) Remove 4 rubber mounts (19 and 20).

33.1.13.3 INSTALLATION Installing is done in the reverse order of removing. (1) Tightening torque

No.

Name

5 Bolt M12

Tightening torque N.m (lbf.ft)

Remarks

26.5 (20)

26 Capscrew M10

46.1 (34)

50 Sems bolt M10

46.1 (34)

27 Sems bolt M12

115 (85)

28 Capscrew M18

226 (167)

39 Sems bolt M8

35 (26)

40 Sems bolt M8

35 (26)

Apply Loctite #262 Apply Loctite #262 Apply Loctite #271 Apply Loctite #262 Apply Loctite #262

33-44

33. UPPER SLEWING STRUCTURE 33.1.14 CONSOLE COVER

33

33.1.14.1 REMOVAL (1) Removing right-hand console cover 1. Press into the "A" part of rubber boot which is tucked into console, and remove right rubber boot (3-4) from console. 2. Loosen 3 sems bolts (1-18) M6X16 and remove lower console (1-3). Tools: Plus screw driver

3-4 A

Removing Boot (4) (2) Removing left-hand console cover 1. Remove left boot (3-4) same way as right console cover. (See above Figure) Tools: Flat-blade screwdriver

1-18 1-18

1-18

1-3

1-4

2. Loosen 2 sems bolts (1-18) M6X16. Tools: Plus screw driver 3. Remove the left upper console cover (1-4) in the same way as right-hand console cover. 4. Loosen 2 sems bolts (1-18) M6X16 while lifting left under console cover (1-5) up, and remove left lower console cover.

1-5 1-18

1-18

I

VIEW I Removing Console Covers

33.1.14.2 INSTALLATION Install it in reverse order of removing according to the tightening torque table.

Item

Bolts

Tightening torque N.m (lbf.ft)

1-18

Sems bolt M6

5.0 (3.7)

A6

Sems bolt M8

23.0 (17.0)

A6

Removing Left Armrest

33-45

33. UPPER SLEWING STRUCTURE 33.1.15 CONTROL VALVE 33.1.15.1 PREPARATION FOR REMOVING (1) Remove guard (8). (See 33.1.4 GUARD) (2) Remove under cover (5). (See 33.1.5 UNDER COVER) 5

(3) Install the suction stopper to the hydraulic oil tank. (4) Remove the hoses in Figure "Control Valve Ports (1/2)" and Figure "Control Valve Ports (2/2)".

Tightening torque 284N.m(209 lbf.ft)

3 3

Tightening torque 235N.m (173 lbf.ft)

Removing The Standard Main Control Valve

Mark each hose with a port name before removing it.

33.1.15.2 REMOVAL (1) Remove 4 capscrews (3) M16X45, and remove control valve (5) by hoist. Tools: Spanner: 24 mm Weight: Approx. 252 kg (556 lbs) 33.1.15.3 INSTALLATION (1) Installing is done in the reverse order of removal. 1. Install control valve by tightening 4 capscrews (3) M16X45. Tools: Spanner: 24 mm Tightening torque: 284 N-m (209 lbf-ft)

Tread size

PF1/4

PF3/8 PF3/4 M10 M12

Connector / Bolt Ports Pss,PLc2,PAL,Par,PL, PB1,PTb,PCa,PCb,PCc PAa1,PBa1,Pab,PBb,Pac, PBc,PBL,PBr,Pas,PBs, PAa2,PBa2,Pao,Pbo,DR,XAb MU Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc Ab,Bb P1,P2 T1,T2

Name

Hose nut

Opposing Tightening Opposing Tightening torque torque flats flats N.m (lbf.ft) N.m (lbf.ft)

19

36 (27)

19

29 (21)

22 36 14 14 17 17

74 (55) 162 (119) 42.4 (31) 57 (42) 62.2 (45) 96 (70)

22 36

49 (36) 118 (87)

ORS Joint

Sems bolt

33-46

Remarks

33. UPPER SLEWING STRUCTURE (2) Check for oil leaks and operation.

Functions

Ports

Ports on upper sides LEFT

Ports

Functions

RIGHT PBa2 Arm 2 out

Option Arm (R) relief valve

PAo

Mu

-

PBb

Arm 1 out PBa1 Swing (LH)

PBs

Boom conflux

PB1

Travel left forward

PAL

Tank return

PAr -

T2

Make-up line Bucket (R)relief valve Boom down Boom (H) relief valve Travel right forward Main relief valve

PCb

P1 unload

P1

P1 pump

P2

P2 pump

AC

Bucket digging

Bb

Boom down

BR

Travel right reverse

Ports on rear sides (on machine) LEFT

RIGHT

Ports on right sides (on machine) Bucket dump

BC

Bucket dump

PBc

Bucket (H) stroke limit

PCc

Boom up

Ab

Drain

Dr

Travel right forward

AR

ATT power boost

PL

UPPER SIDE

LOWER SIDE

Control Valve Ports (1/2)

33-47

33

33. UPPER SLEWING STRUCTURE

Function

Ports Option

Bo

Ports on left side (on machine) LOWER SIDE

UPPER SIDE

Ports

Function

Ao

Option

Ba

Arm 1 out

Arm 1 in

Aa

PLc2 Arm in lock release

Swing left

Bs

Pss

Swing low pressure sensor

Travel left reverse

BL

As

Swing right

AL

Travel left forward

T1

Tank return

Ports on lower side (on machine) LEFT SIDE

RIGHT SIDE

Travel left reverse

PBL

PTb

Travel straight

P2 unload

PCa

PBr

Travel right reverse

Swing right

PAs

PAb

Boom up

-

-

Boom (R) relief valve

-

Bucket (H) relief valve

Arm (H) relief valve

Arm in PAa1 Option

PBo

PAc

Bucket digging

PAa2 Arm 2 in Control Valve Ports (2/2)

33-48

33. UPPER SLEWING STRUCTURE 33.1.16 PILOT VALVE (FOR ATT)

33

33.1.16.1 PREPARATION FOR REMOVING The removing procedure for right and left is the same. The preparation for the left side is described here. (1) Put attachment on ground, stop engine and release pressure in tank. (2) Remove left console cover (1-4 and 1-5) assembly referring to Section 33.1.14CONSOLE COVER.

3-1-6

A

(3) Disconnect harness connector for horn at * position.

3-4

3-3

(4) Attach a tag to the hose to make assembly work easier. Installing And Removing Boot And Lever Part 33.1.16.2 REMOVAL (1) Remove hoses from your side to far side in order. Tools: Spanner: 19 mm, 22 mm

A16

(2) Move the boot (3-4) up and loosen nut (3-3). (See above Figure) Tools: Spanner: 22 mm

PILOT VALVE

(3) Turn and loosen lever (3-1-6) tightened in pilot valve, and remove lever assembly in a set. (See above Figure)

Tightening torque 49N.m (36 lbf.ft) PF3/8 Valve side Opposing flats 22

(4) Remove 4 capscrews (A16) M6X25. (See right Figure) Tools: Allen wrench: 5 mm

Opposing flats 19 Mark "F"

PF3/8

(5) Remove pilot valve. 1

(6) Plug hose ends. Plug PF1/4, PF3/8

Tightening torque 29.4N.m (22 lbfft) PF1/4

Hose side 4,5 8,T port connector

P port connector (With filter)

Pilot Valve Connector

33-49

PF1/4

33. UPPER SLEWING STRUCTURE 33.1.16.3 INSTALLATION Install it in the reverse order of removal and tighten it. Tools: Allen wrench: 5 mm Tightening torque: 11.8 N-m (11 lbf-ft): capscrew (A16)

THE FRONT OF MACHINE BUCKET (R) (BLUE) 2

BOOM (R) (GRAY) T

ARM (R) (GREEN)

SWING (R) (RED) 2

T

T

1 P

3

P 4 BUCKET (H) (RED) BOOM (H) (GREEN) P

RH

33-50

3 P

4

SWING (L) (GRAY)

ARM (H) (BLUE)

LH Pilot Valve Port Position

Make sure of the tightening torque for capscrews, because pilot valve is made of aluminum.

T 1

33. UPPER SLEWING STRUCTURE 33.1.17 PILOT VALVE (FOR TRAVEL)

33

33.1.17.1 PREPARATION FOR REMOVING (1) Release pressure in hydraulic oil tank (See 33.1.7 HYDRAULIC TANK). (2) Remove under cover (1) (See 33.1.5 UNDER COVER). (3) Remove floor mat (B1).

A1

A2

A5

A6

A3

A4

A9 A8 B1

A7 Removing Floor Mat, Pedal And Lever

33.1.17.2 REMOVAL

33.1.17.3 INSTALLATION Install it in the reverse order of removal and tighten it. Sems bolt (A7) Tools: Spanner: 13 mm T = 23.5 N-m (17.3 lbf-ft) Sems bolt (A8) Tools: Socket: 17 mm T = 35 N-m (25.8 lbf-ft) Sems bolt (A9) Tools: Socket: 13 mm T = 23.5 N-m (17.3 lbf-ft)

33-51

33. UPPER SLEWING STRUCTURE 33.1.18 SWING MOTOR UNIT 33.1.18.1 PREPARATION FOR REMOVING (1) Park machine on firm level ground and place attachment on ground. (2) Remove the guard (8). (See 33.1.4 GUARD) (3) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure in the circuit by operating the control lever. (See 22.11 HYDRAULIC SYSTEM PRESSURE DRAINING(RELEASING) CIRCUIT) (4) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other information. 33.1.18.2 REMOVAL (1) Remove hose. 1. Remove hose (8) from the connector in the makeup port M. Tools: Spanner: 41 mm 2. Remove 2 hoses (2), (3) from the Tee in the drain port Dr. Tools: Spanner: 36 mm 3. Remove hose (A4) from the elbow of the PG port (For swing parking brake) (See below Fig.) Tools: Spanner: 19 mm 4. Loosen 8 capscrews (A24) M10X30 and remove half clamp (A30). And disconnected A,B port hoses (A7), (A4) from the motor. Tools: Allen wrench: 8 mm Put in plugs half clamp, PF1, PF3/4, PF1/2, and PF1/4 into the removed ports. S/J

E

2

Dr

8 M

C/V Mu

2

2

3

A4

HYD. TANK

A30 A24

A B

A7 C/V As

A4

5

PG S/V A2

C/V Bs

5

Removing Swing Unit Piping Removing Swing Unit (2) Removing the swing unit Remove 14 capscrews (5) M24X70. Tools: Socket: 36 mm 1. Remove two plastic caps (2) M10 at the top of the swing motor and install eye bolts. Tools: Flat-blade screwdriver 2. Put a wire sling in the eye bolts and remove the swing motor unit. Weight of swing motor unit; Approx. 446kg (983 lbs) (Include reduction assembly)

33-52

33. UPPER SLEWING STRUCTURE 33.1.18.3 PREPARATION FOR INSTALL (1) Clean mating surfaces of swing motor unit and upper frame. Tools : spatula, wash oil (2) Apply Loctite #515 on entire mounting surface of swing motor unit.

33

33.1.18.4 INSTALLATION Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the swing motor unit. (1) Tighten 14 capscrews (5) M24X70. Tools: Socket: 36 mm Tightening torque : 932 N-m (687 lbf-ft) Apply Loctite #262 (2) Fill inside through motor drain port to casing with hydraulic oil before piping for drain. (3) Piping tightening torque.

Tool

Tightening torque N.m (lbf.ft)

Size

Port

M10

A,B

: 8mm

70.6 (52)

PF1/4

PG

: 19mm

29 (21)

PF3/4

Dr

: 36mm

118 (87)

PF1

M

: 41mm

137 (101)

Apply loctite #515 Apply to all round of mounting face for motor, swing.

SETTING POSITION OF SWING MOTOR ASSY Put sealing tape on the thread portion of tube for level gauge. Tightening torque 108N.m (80 lbf.ft)

LEVEL GAUGE

5 Installing Swing Motor Unit

33.1.18.5 PREPARATION FOR DRIVE (1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient. Amount of oil : 7.4 L (2.0 gal) (2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leaks and noise.

33-53

33. UPPER SLEWING STRUCTURE 33.1.19 SWIVEL JOINT 33.1.19.1 PREPARATION FOR REMOVING Remove boom piping hose. 33.1.19.2 REMOVAL (1) Remove travel motor hose and tube. 1. Remove 2 hoses (A9). (E port: PF1/2) Tools: Spanner: 27 mm, Tightening torque: 78.5 N-m (58 lbf-ft) 2. Remove tubes (A1), (A2). (C, Dport: PF1) Tools: Spanner: 41 mm, Tightening torque: 255 N-m (188 lbf-ft) 3. Remove tubes (A3), (A4). (A, B port: PF1) Tools: Spanner: 41 mm, Tightening torque: 255 N-m (188 lbf-ft) 4. Remove 2 hoses (A10). (F port: PF1/4) Tools: Spanner: 19 mm, Tightening torque: 29.4 N-m (22 lbf-f)

(LEFT SIDE)

B

A

(MOTOR)

(MOTOR)

E C

D F

F

VA (LOW) BACK VB (TOP) FORWARD

(RIGHT SIDE)

VA (LOW) BACK VB (TOP) FORWARD

P D2

P D1

T : Tightening torque of connector N.m (lbf.ft) SWIVEL JOINT F

B2

A4

B

T=36.3 (26.8) A2 T=255 (188)

A

T=255 (188)

C D

A10

E

B3

A3

T=108 (79.7) A1

T=108 (79.7) B3

A9

E

A9

Removing Piping (Lower Side)

33-54

33. UPPER SLEWING STRUCTURE (2) Disconnecting the hoses on the top part of the swivel joint. 1. Remove drain hose (2). (E port: PF3/4) Tools: Spanner: 36 mm Tightening torque: 118 N-m (87 lbf-ft)

A16

33

2

2. Remove hoses (A6 and A8). (A, C port : 1-3/16-12UN) Tools: Spanner: 36 mm Tightening torque: 177 N-m (130 lbf-ft)

A9

3. Remove hoses (A9 and A16). (B, D port : 1-3/16-12UN) Tools: Spanner: 36 mm Tightening torque: 177 N-m (130 lbf-ft) 4. Remove hose (A7). (F port : Travel 2-speed change over port: PF1/4) Tools: Spanner: 19 mm Tightening torque: 29 N-m (21 lbf-ft)

A6 A8 A15 A7

Disconnecting The Hoses On The Top Part Of Swivel Joint (3) Remove whirl-stop of swivel joint. 1. Loosen the nut (10) M24.

9 Tightening torque

10

157N.m (116 lbf.ft)

2. Remove a capscrew (9) M24X130. Tools: Spanner: 36 mm

mm 13 At assembling,

this distance should be 13mm (0.512in).

Removing Whirl-stop Nut & The Capscrew (4) Remove joint for piping (See Figure "Removing Piping (Lower Side)", and sbove Figure) 1. Remove 2 connectors (B2). (F port) 2. Remove connector (A15) (F port) for travel 2speed change over. (PF1/4). Tools: Spanner: 19 mm (5) Remove seal (B1). 1. Remove 6 sems bolts (B4) M10X25. Tools: Socket: 17 mm

TIGHTENING TORQUE 2 N.m (1.5 lbf.ft)

B1

B3

B2

FOR WATERPROOF, APPLY LOCTITE #572 OR #577. TIGHTENING TORQUE 14.7 N.m (11 lbf.ft)

B4

Removing Seal (B1)

2. Remove clip (B3). Tools: Flat-blade screwdriver 3. Remove plate (B2), seal (B1).

33-55

33. UPPER SLEWING STRUCTURE (6) Remove capscrew for installation. Attach eye bolt, lift it up temporarily, and remove 3 capscrews (C2) M12X25. Tools: Socket: 19 mm (See 11.7 SPECIAL TOOLS No.9 Plug)

EYE BOLT

C

E

F

A

LOWER FRAME

C2 CAPSCREW M12X25 Loctite #262 T=108N.m (80 lbf.ft)

C1 SWIVEL JOINT

Removing Capscrew For Installation (7) Slinging the swivel joint Weight: Approx. 24 kg (53 lbs) 33.1.19.3 INSTALLATION (1) Installing is done in the reverse order of removing. Piping tightening torque (2) Check for oil leaks and the hydraulic oil level. (3) Check for operating.

33-56

Tightening torque N.m (lbf.ft) O-ring type Hydraulic hose Connector 29 (22) 36 (27)

Size PF

Tool. HEX

1/4

19

3/8

22

74 (54)

49 (36)

1/2

27

108 (80)

78 (58)

3/4

36

162 (120)

118 (87)

1

41

255 (180)

137 (100)

1-3/16-12UN

36

-

177 (130)

33. UPPER SLEWING STRUCTURE 33.1.20 UPPER FRAME

33

33.1.20.1 PREPARATION FOR REMOVING (1) Remove attachment. (See chapter 32) (2) Remove cab (See 33.1.2 CAB). (3) Remove guard (See 33.1.4 GUARD). (4) Remove counterweight (See 33.1.11 COUNTERWEIGHT). (5) Remove swivel joint (See 33.1.19 SWIVEL JOINT).

Temporarily Lift Upper Frame 33.1.20.2 REMOVAL (1) Lifting up upper frame temporarily. Temporarily lift the unit at three points: the upper frame lifting jig (Refer to Tool "chapter 11"), the 2 lifting holes near the boom foot pin and the angle steel at the back of the upper frame.

MATCH MARK

(2) Mark matching marks on swing bearing. Put match marks on upper frame and swing bearing. Matching Mark On Swing Bearing And Upper Frame (3) Removing upper frame attaching bolts. Remove 34 capscrews (10) M24X135 and a reamer bolt (11) used to install swing bearing and upper frame. Tools: Socket: 36 mm (4) Slinging upper frame. Sling according to above Figure, and remove upper frame and put it on a stand. Weight: Approx. 5 ton (11,000 lbs)

Removing Upper Frame Attaching Bolts

33-57

33. UPPER SLEWING STRUCTURE 33.1.20.3 INSTALLATION (1) Installing is done in the reverse order of removing. (2) Clean mating surfaces of upper frame and swing bearing. (3) Apply Loctite #515 to the inside of the capscrews on the contact surface. (4) Slinging upper frame Match marks and install it with a reamer bolt (8) temporarily. Tools: Socket: 36 mm Apply Loctite #262 (5) Install swing bearing Install 34 capscrews (7) M24X135. Tools: Socket: 36 mm Apply Loctite #262 Tightening torque : 932 N-m (687 lbf-ft) Install a reamer bolt (8). Tools: Socket: 36 mm Tightening torque : 932 N-m (687 lbf-ft) Apply Loctite #515 to the race surface over the whole circumference (shaded area) on the inside of capscrew.

OUTER (S) ZONE POSITION

Apply Loctite #262 equivalent. T=932N.m (687 lbf.ft) 7, 8

Bearing Mount Reamer Bolt Position (*) Apply Loctite To Shaded Area

Confirm the reamer bolt positions referring to above Figure.

33-58

33. UPPER SLEWING STRUCTURE

33.2

DISASSEMBLING AND ASSEMBLING

33

33.2.1 HYDRAULIC PUMP - REGULATOR 33.2.1.1 HYDRAULIC PUMP 33.2.1.1.1 Structural exploded view (1) Main pump 983

953 806

981

789 535 886

531 . 548 B

732

534 792 702 532

X Z

W Y

A

728 468

113 123 127 824

127 271 717 490

04

808 954 546901

325

251 401

725

407

312 490 C

124 314

156

B 212

151 . 152

157

717

141

886

727

D

546

153

E

885 886

211

214

261 710

406

727 467 725 466

D E

774

F

A 116 717 124

724

710

313 F

111

C 885

Structural Exploded View Of Main Pump

33-59

326 414

05

33. UPPER SLEWING STRUCTURE

Marks (W), (X), (Y), and (Z) in Figure "Structural Exploded View Of Regulator" show the position where the regulator is installed.

No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313

Name Shaft(F) Shaft(R) 1st gear Roller bearing Needle bearing Bearing spacer Cylinder block Piston Shoe Retainer Spherical bushing Cylinder spring Shoe plate Swash plate Tilting bushing Swash plate support Seal cover (F) Pump casing Valve block Valve plate (R)

Q'ty 1 1 1 2 2 3 2 18 18 2 2 18 2 2 2 2 1 2 1 1

No. 314 325 326 401 406 407 414 466 467 468 490 531 532 534 535 546 548 702 710 717

Name Valve plate (L) Sensor block Cover Socket bolt ; M20X210 Socket bolt ; M8X20 Socket bolt ; M6X55 Socket bolt ; M10X20 VP plug ; PF1/4 VP plug ; PF3/8 VP plug ; PF3/4 Plug ; NPTF1/16 Tilt pin ; M24X2 Servo piston ; M24X2 Stopper (L) Stopper (S) Spacer Feed back pin O-ring ; 1B G35 O-ring ; 1B G95 O-ring ; 1B G145

Q'ty 1 1 1 8 4 3 4 2 2 4 32 2 2 2 2 2 2 2 2 4

No. 724 725 727 728 732 774 789 792 806 808 824 885 886 901 953 954 04 05

Name O-ring ; 1B P8 O-ring ; 1B P11 O-ring ; 1B P14 O-ring ; 1B P24 O-ring ; 1B P18 Oil seal Backup ring P18 Backup ring G35 Nut ; M16 Nut ; M20 Stop ring Valve plate pin Spring pin Eye bolt ; M10 Socket screw ; M16X35 Set screw ; M20 Gear pump PTO gear case

No. 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1

The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. Tightening torque of bolt, plug, nut and servo piston No.

Thread size

401 406 407 414 466 467 468 490 531,532 806 808

M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20

Tightening torque N.m (lbf.ft) 430 (317) 29 (21) 12 (8.9) 57 (42) 36 (27) 74 (55) 170 (125) 8.8 (6.5) 240 (177) 130 (95) 240 (177)

33-60

33. UPPER SLEWING STRUCTURE (2) Gear Pump (For Pilot)

700

354

351

33 Suction port : PF3/4 Tightening torque : 73.5N.m (54.2 lbf.ft)

433

434 Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft) 311 312 732 307

710

435

361

No.

353

Parts

850

310 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft)

Q'ty

No.

308 309

434

466 725

Parts

355

Q'ty

307 308 309 310 311

Poppet Seat Ring Spring Adjust screw

1 1 1 1 1

361 433 434 435 466

Front case Flange socket; M8X40 Flange socket; M8X55 Flange socket; M8X20 VP plug; PF1/4

1 2 2 4 1

312 351 353 354 355

Lock nut; M14X1.5 Gear case Drive gear Driven gear Filter

1 1 1 1 1

700 710 725 732 850

Ring O-ring; 1B G95 O-ring; 1B P11 O-ring; 1B P16 Locking ring

1 1 1 1 1

33-61

33. UPPER SLEWING STRUCTURE 33.2.1.1.2 Disassembly and assembly of main pump (1) Tools The right list shows the tools required for removal and installation. (2) Disassembling procedure 1. Selecting a place for disassembly. -Choose a clean place. -Spread rubber sheet or cloth on work bench to protect parts. 2. Cleaning Remove dust and rust, etc. on pump surface with wash oil.

Tool Name

Allen wrench

Eye wrench Socket wrench Wrench ; Double

single

Part Size mm

Size

Item No.

5

M6

407

6 8 14

M8 M10

406

17 19 24 30 36

414 953 401 M20 PF1/4 466 806 M16 808, 954 M20 PF3/4 468 M16

Crescent wrench Medium size 1pc.

Flat bladed 2pcs. Driver Hammer Plastic Plier Snap ring Steel bar 10X8X200 Torque wrench 3. Drain oil. Drain out the oil in the pump casing by removing drain port plug (466), (468). Tools: Spanner: 19 mm, 36 mm -Drain out oil from the plug of the front pump and the rear pump. 4. Removing regulator and PTO gear casing. Remove the socket bolts [412, 413, and 414 (See Figure "Structural Exploded View Of Main Pump", Figure "Structural Exploded View Of Regulator")]. Then remove the regulator and the PTO cover (326). Tools: Allen wrench: 6 mm, 8 mm -Regarding the disassembly of the regulator, refer to article of Regulator.

33-62

REGULATOR

33. UPPER SLEWING STRUCTURE 5. Remove gear pump. Remove the socket bolts (435). Then remove the gear pump (04). Tools: Allen wrench: 6 mm

312

271 401

33

6. Remove socket bolt (401). Loosen socket bolts (401) that fasten swash plate support (251), pump casing (271) and valve block (312). Tools: Allen wrench: 17 mm

Remove Socket Bolt (401) 7. Disassembling the pump casing and the valve block. Place the pump level on a work bench with its mounting surface on the regulator facing down. Then separate pump casing (271) and valve block (312). -When facing the mounting surface of the regulator down, place a rubber sheet on a work bench so as not to score the mounting surface. -When the pump casing has been separated from the valve block, remove out the 1st gear (116) at the same time. 8. Removing the cylinder assembly. Remove cylinder (141) from pump casing (271) in parallel to shaft (111). At the same time remove piston (151), plate (153), spherical bushing (156) and cylinder spring (157).

312

Disassembling The Pump Casing (271) And The Valve Block (312)

271 141(151)(157) 153 156

-Use care so as not to score the sliding surface of the cylinder, spherical bushing, shoe and the swash plate.

Drawing Out The Cylinder Assembly

33-63

271

33. UPPER SLEWING STRUCTURE 9. Remove seal cover (F). Remove socket bolt (406) M8 and seal cover F (261). Tools: Allen wrench: 6 mm

406 261

-The seal cover (F) may be drawn out with ease if it is taken out by tightening bolts in the tapped holes (M6 tap) of the seal cover (F). -An oil seal is fitted to seal cover (F). Therefore, use care so as not to score the oil seal.

Removing Seal Cover F (261) 10.Separating the swash plate support and the pump casing. Knock lightly on the mounting flange of swash plate support (251) from the pump casing (271) side and separate the swash plate support from the pump casing.

271

251

Separating The Swash Plate (251) Support And The Pump Casing (271) 11. Remove shoe plate and swash plate. Draw out shoe plate (211) and swash plate (212) from pump casing (271).

271

212(211)

Removing Shoe (211) And Swash Plate (212)

33-64

33. UPPER SLEWING STRUCTURE 12.Drawing out the shaft. Tap lightly the shaft end (111 and 113) by means of a plastic hammer and draw out the shaft from the swash plate support.

251

33 111(113)

Drawing Out The Shaft (111 and 113) 13.Remove valve plate. Remove valve plate (313 and 314) from valve block (312). -The valve plate may come off during the operation under 6).

312

314 (313 :

Opposite Side)

Removing Valve Plates (313 and 314) 14.Remove other parts. If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271). And remove needle bearing (124) from valve block (312).

531

806

-When removing the tilting pin, use care so as not to score the head of the tilting pin using the jig. -It is hard to separate the tilting pin from the servo piston in some cases as Loctite is coated on the mating part between them. Use care so as not to score the servo piston by applying undue force. -Do not draw out needle bearings except when their service life has ended. -Do not loosen hex nuts (806 and 808) on valve block (312) and swash plate support (251). A set flow rate changes.

534

535

532

808

271

312

251

Removing Other Parts

33-65

124

33. UPPER SLEWING STRUCTURE (3) Installing procedure 1. Precautions to be exercised during installation. Assembly is the reverse order of disassembly, but notice the following. a. b. c. d. e. f.

Repair scored parts at disassembly. Get replacements ready beforehand. Wash parts sufficiently in cleaning oil and dry them with compressed air. Do not forget to coat the sliding areas and bearings with clean hydraulic oil. In principle, replace sealing parts such as O-rings and oil seals. Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench. Do not mix up front pump parts with rear pump parts.

2. Installing swash plate support. Attach swash plate support (251) to pump casing (271) by tapping the swash plate support lightly with a plastic hammer.

271

-When the servo piston, the tilting pin, the stopper, (L) and stopper (S) have been removed, install them to the pump casing beforehand. -When tightening servo piston and tilting pin, use a jig so as not to damage the head of the tilting pin and feedback pin. Coat the screwed part with Loctite #262.

251

Installing Swash Plate Support (251) 3. Installing swash plate. Place the pump casing with its mounting surface of the regulator facing down, insert the tilting bushing of the swash plate into tilting pin (531), and fit swash plate (212) to swash plate support (251) properly. -Confirm by the fingers of your hands that swash plate moves smoothly. -The shaft should install easily if grease is applied to the sliding parts of swash plate and swash plate support. -Do not damage the sliding surface of shoe plate.

251 271(531)

212

Installing Swash Plate (212)

33-66

33. UPPER SLEWING STRUCTURE 4. Installing shaft. Install shaft (111) fitted with bearing (123), bearing spacer (127) and snap ring (824), to swash plate support (251).

33 251

-Do not knock on the shaft with a hammer. -Fix the bearing by lightly tapping the outer race of it by means of a plastic hammer and set it exactly to the end by using a steel rod.

123 127,824

111

Installing Shaft (111) 5. Installing seal cover. Assemble seal cover (F) (261) to pump casing (271) and fix it with socket bolts (406). Tools: Allen wrench: 6 mm Tightening torque: 29 N-m (22 lbf-ft)

271 261

-Coat the oil seal in seal cover (F) with a thin film of grease. -Handle the oil seal with sufficient care so it is not scored.

406

Installing Seal Cover F (261) 6. Inserting piston cylinder sub. Assemble the piston cylinder sub [cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156) and cylinder spring (157)]. Align the spherical bushing with the cylinder spline and insert them into the pump casing.

141(151,152,157) 156 153

Inserting Piston Cylinder Sub

33-67

33. UPPER SLEWING STRUCTURE 7. Installing valve plate. Install valve plate (313 and 314) to valve block (312) by aligning pin.

312

-Do not mistake the suction and delivery sides of the valve plate.

314 (313 : Opposite Side)

Installing Valve Plates (313 and 314) 8. Installing valve block. Install valve block (312) to pump casing (271) and fasten them together with socket bolts (401). Tools: Allen wrench: 17 mm Tightening torque ; 430 N-m (320 lbf-ft) -Work will be promoted if assembly is started from the rear pump. -Exercise care so as not to mistake the direction of the valve block (312). (Install it so the regulator is up as seen from the front side and the suction flange is on the right.) -Insert the 1st gear into the valve block beforehand and connect it with the spline of the shaft. 9. Installing gear pump. Install gear pump (04) and fasten together with socket bolts (435). Tools: Allen wrench: 6 mm, Tightening torque; 17 N-m (12.5 lbf-ft) 10.Installing regulator and PTO cover. Pinch feedback pin of tilting pin in feedback lever of the regulator and PTO cover (326). Install the regulator and fasten socket bolts (412 and 413). (See Figure "Structural Exploded View Of Regulator"] Socket bolt (412)(413): For regulator Tools: Allen wrench: 6 mm, Tightening torque; 29 N-m (21 lbf-ft) Socket bolt (414): PTO Cover (326) Tools: Allen wrench: 8 mm, Tightening torque; 57 N-m (42 lbf-ft)

312

271

Installing Valve Block (312)

REGULATOR

Installing Regulator And PTO Cover

-Do not mistake the front regulator for the rear regulator. 11. Installing drain port plug. The work is complete when drain port VP plugs (466 and 468) have been set. Tools: Allen wrench: 19 mm, 36 mm Tightening torque; 36 N-m (27 lbf-ft) Tightening torque; 170 N-m (125 lbf-ft)

33-68

401

33. UPPER SLEWING STRUCTURE 33.2.1.1.3 Maintenance standards (1) Replacement standards for abrasive parts Replace or readjust parts that exceed the following standards of wear. However, always replace such parts that show excessive damage on appearance.

Part name and inspection item

Standard dimension

Recommende dvalue forreplacement

33

Remedy

Clearance between piston and cylinder bore

(D-d)

0.039 (0.0015 )

0.067 (0.0026 )

Replace piston or cylinder.

Gap between piston and caulked part of shoe

( )

0 - 0.1 (0.004 )

0.3 (0.012 )

Replace piston shoe assembly.

Thickness of shoe

(t)

4.9 (0.193 )

4.7 (0.185 )

Replace piston shoe assembly.

Free height of cylinder spring

(L)

41.1 (1.618 )

40.3 (1.587 )

Replace cylinder spring.

(H-h)

23.0 (0.906 )

22.0 (0.866 )

Replace a set of spherical bushing or retainer plate.

Combined height of retainer plate and spherical bushing

D

d

h

H

Combination of retainer plate and spherical bushing Height=H-h

Clearance between piston and cylinder bore : D-d

t L Gap between piston and shoe : thickness of shoe : t

Free height cylinder spring : L

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face). Valve plate (sliding section) Swash plate (shoe plate face) Cylinder (sliding section) Roughness of each surface

Surface roughness requiring correction

3-Z

Standard surface roughness (correction value)

Less than 0.4Z (lapping)

33-69

33. UPPER SLEWING STRUCTURE 33.2.1.1.4 Troubleshooting (1) Locating causes of troubles The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location extremely difficult. However, faults would be found out easily if the following check items were attended to. 1. Inspecting the filter and drain oil. Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on it as the shoe and the cylinder wear off. In case metallic particles are found in large quantities, the elements may be damaged. In that case check the drain oil in the pump casing as well. 2. Checking for abnormal vibration and sound. Check that the pump does not vibrate and make an abnormal sound. Check that the hunting of the regulator and the attached valve’s relief valve are of regular frequency. In case vibration and sound are abnormal, the pump may be making a cavitation or is internally broken. 3. When two pumps are used. In case two single pumps or motors are used or when a double pump is used; change pump pipelines. This will make clear that the pumps are faulty or the circuit after the pumps are faulty. 4. Pressure measurements. If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes by measuring pressures. (2) Troubleshooting 1. Overloading to engine Cause

Remedy

Remarks

1. Revolution and pressure are higher than set values.

1) Set pressure to specified value.

2. Regulator torque is set higher than normal.

2) Readjust regulator.

2) Refer to Regulator Manual.

3. Pump’s internal parts are seized or broken.

3) Replace damaged parts.

3) Check filter and drain oil to see if abnormal wear particles are present..

4. Regulator is piped incorrectly.

4) Pipe regulator correctly.

33-70

33. UPPER SLEWING STRUCTURE 2. Pump's oil flow rate is extremely low and delivery pressure is not available. Cause

Remedy

Remarks

1. Regulator is out of order

1) Repair regulator.

1) Refer to Regulator Manual.

2. Pump's internal parts are seized or broken.

2)Replace damaged parts.

2)Check filter and drain oil.

3. Attached pump is out of order

3) Replace damaged parts.

3) Remove attached pump and check shaft joint.

4. Attached valve is out of order.

4) Check attached valve. Particularly poppet, seat and spring.

4) Refer to Manual for Attached Valve.

5. Regulator is piped incorrectly.

5) Pipe correctly.

3. Abnormal Sound and Vibration Cause

Remedy

Remarks 1-1) The boost pressure is low. 1-2) The attached pump is in trouble. 1-3) The suction pipe is inhaling air. 1-4) The suction resistance is high.

1. Cavitation

1) Prevent cavitation. Check that hydraulic oil is not clouded.

2. Caulked part of shoe is broken.

2) Replace piston shoe and shoe plate.

3. Cylinder is cracked

3) Replace cylinder.

4. Pump is installed improperly.

4) Correct installation.

5. Regulator is hunting.

5) Repair regulator,

5) See Regulator Manual.

6. Relief valve in attached valve is hunting.

6) Repair attached valve.

6) See the Manual for Attached Valve.

33-71

33

33. UPPER SLEWING STRUCTURE

This page is blank for editing convenience.

33-72

33. UPPER SLEWING STRUCTURE 33.2.1.2 REGULATOR 33.2.1.2.1 Structural exploded view

33 626 625 624

753 627

623 621

732 631 898

B

D

F

622 733

874 613

875 612

652

644 875 643 G

836 654 653 814

646

A

651

728

645

611

655

E

C

897

438

630

629 802 756

763

628

924 412 413

656 757

438

Y 418

079

D

X

E 601

722

496

755

W

Z 041 755

466

734 887

876 615

439

A

B

642 755

C

F 876 614

724 730 725

8-724 041 755

466

641

Structural Exploded View Of Regulator

33-73

755

755 858

G

708 662

801

466

755 858

33. UPPER SLEWING STRUCTURE

Marks (W), (X), (Y), and (Z) in Figure "Structural Exploded View Of Main Pump" the position where the regulator is installed.

No. 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627

Name Socket bolt ; M8X50 Socket bolt ; M8X70 Socket bolt ; M5X12 Socket bolt ; M6X20 Socket bolt ; M6X25 VP plug ; PF1/4 Plug ; NPTF1/16 Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcrum plug Adjust plug Compensating rod Piston case Compensating rod Spring seat (C) Outer spring Inner spring Adjusting stem (C)

Q'ty 2 2 2 8 5 3 17 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1

No. 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 662 708 722 724 725 728 730

Name Adjust screw (C) Cover (C) Lock nut ; M30X1.5 Sleeve (For PF) Pilot cover Spool Pilot piston Spring seat (Q) Adjust stem (Q) Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-ring ; 1B G75 O-ring ; 1B P6 O-ring ; 1B P8 O-ring ; 1B P10 O-ring ; 1B P18 O-ring ; 1B P22

Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 8 1 1 1

No. 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 041 079

Name O-ring ; 1B P16 O-ring O-ring ; 1B G25 O-ring ; 1B P9 O-ring ; 1B P11 O-ring ; 1B P26 O-ring ; 1B P12.5 O-ring ; 1B G35 Nut ; M8 Nut ; M10 Snap ring Snap ring Snap ring Pin ; 4X11.7L Pin ; 4X8L Pin ; 5X8L Pin Pin ; 4X19L Pin ; 7.5X11L Socket screw ; M8X20 Check valve sub Solenoid proportional reducing valve

No. 1 1 1 1 7 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1

The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. Tightening torque of bolt, plug and nut No.

Thread size

412,413 438,439 418 466 496 630 801 802

M8 M6 M5 PF 1/4 NPTF1/16 M30X1.5 M8 M10

Tightening torque

N.m (lbf.ft) 29 (21) 12 (8.9) 6.9 (5) 36 (26) 8.8 (6.5) 160 (118) 16 (12) 19 (14)

33-74

33. UPPER SLEWING STRUCTURE 33.2.1.2.2 Disassembly and assembly (1) Tools The right list shows the tools required for removal and installation.

33

(2) Disassembling procedure 1. Selecting a place for disassembly. -Choose a clean place. -Spread rubber sheet or cloth on work bench to protect parts from damaging. 2. Cleaning Remove dust and rust, etc. on regulator surface with wash oil.

3. Remove regulator (See Figure "Structural Exploded View Of Regulator") Remove socket bolts (412 and 413) and separate the regulator from the pump body. Tools: Allen wrench: 6 mm 4. Remove port plate (See Figure "Structural Exploded View Of Regulator") Remove socket bolt (438) and separate the port plate (656). Tools: Allen wrench: 5 mm

438 656

413

412 629

438 601 Removing Regulator

5. Remove cover (See Figure "Structural Exploded View Of Regulator"). Remove socket bolts (438) and remove cover (C) (629). Tools: Allen wrench: 5 mm -The cover is equipped with adjust screws (628), adjust stem (627), lock nut (630), hex nut (801) and set screw (924). Do not loosen these screws and nuts. If they are loosened, preadjusted set pressure and flow values change.

624,625,626 627 801 629( 628 )

630 924 Removing Cover (C) (629)

33-75

33. UPPER SLEWING STRUCTURE 6. Remove compensating parts. (See Figure "Structural Exploded View Of Regulator" (D) section, See Figure "Removing Cover (C) (629), Figure "Removing Compensating Parts") After removing the cover (C) (629) sub assembly, take out outer spring (625), inner spring (626) and spring seat (624) from the compensating part. Then take out adjust stem (645), pilot spring (646) and spring seat (644) from the pilot part. -Adjust stem (645) comes out easily if an M4 bolt is used.

M4 BOLT

645

644,646

629

Removing Compensating Parts 7. Remove pilot cover and the set spring. Remove socket bolt (439) and pilot cover (641). Once the pilot cover comes off, separate set spring (655) from the pilot section. (Figure "Structural Exploded View Of Regulator" (A and B) section) Tools: Allen wrench: 5 mm

439 641 Removing Pilot Cover (641) And Set Spring (655) 8. Remove spring seat, return spring and sleeve. (Figure "Structural Exploded View Of Regulator" (A section) Remove snap ring (814). Then remove spring seat (653), return spring (654) and sleeve (651). -Sleeve (651) is equipped with snap ring (836). -When removing snap ring (814), return spring (654) comes out: Use care so as not to lose it.

814(653) 654, 651(836)

Removing Spring Seat (653), Return Spring (654) And Sleeve (651)

33-76

33. UPPER SLEWING STRUCTURE 9. Remove adjust plug. (Figure "Structural Exploded View Of Regulator" (F and G section) remove snap ring (858) and take out fulcrum plug (614) and adjust plug (615). -Fulcrum plug (614) and adjust plug (615) come off easily if a M6 bolt is used.

858

614

615 614

Removing Fulcrum Plug (614) Removing Adjust Plug (615) 10.Remove lever (Figure "Structural Exploded View Of Regulator" (G section) Remove lever 2 (613). Do not draw out pin (875). -The work is eased if tweezers is used.

613(875)

Removing Lever 2 (613) 11. Remove feedback lever. Draw out pin (874) and remove feedback lever (611). -Push out pin (874) [pin dia : o4mm (0.157in)] from above with a slender steel rod so as not to interfere with lever 1 (612).

874

611

611

Removing Feedback Lever (611) [1]

Removing Feedback Lever (611) [2]

33-77

33

33. UPPER SLEWING STRUCTURE 12.Remove lever (Figure "Structural Exploded View Of Regulator" (F section). Remove lever 1 (612). Do not draw out pin (875).

612

611

875 13.Remove pilot piston and spool. (Figure "Structural Exploded View Of Regulator" (C and A section) Draw out pilot piston (643) and spool (652).

874 897 613 875

643 14.Remove piston casing, compensating piston and compensating rod (Figure "Structural Exploded View Of Regulator" (B section) Draw out piston casing (622), compensating piston (621) and compensating rod (623). -Piston casing (622) comes out from the opposite side of the piston casing if compensating rod (623) is pushed out.

623 621

622 733 732 631

652

898

814

653

654

655

836

651

Part Of Exploded View Of Regulator 15.Remove spool (642) and spring (662). Remove VP plug (466) from pilot cover (641), and draw out spool (642) and spring (662).

466

This completes disassembly.

662 642 466 641 Part Of Exploded View Of Regulator

33-78

33. UPPER SLEWING STRUCTURE (3) Installing procedure: Assembly is the reverse order of disassembly. Do the work paying attention to the following: • • • • •

Repair those parts that were damaged during disassembly and prepare replacement parts beforehand. If foreign matter enters, it causes malfunction; clean parts thoroughly in cleaning oil, blow them with compressed air and assemble parts in a clean place. Always tighten bolts and plugs to the specified torque. The tolerance of torque should be within 10%. Do not fail to coat the moving parts with clean hydraulic oil before assembly. In principle, replace seals such as O-rings.

1. Installing compensating rod (Figure "Structural Exploded View Of Regulator" (B section). Assemble compensating rod (623) into the compensating hole of casing (601). 2. Assembling lever. Put the pin pressed in lever 1 (612) into the groove of the compensating rod (623). Then assemble the lever to the pin (875) that is pressed in the casing.

623 612 875

611 874 897 613

875

Part Of Exploded View Of Regulator 3. Assembling spool and sleeve (See Figure "Structural Exploded View Of Regulator" (A section). Assemble spool (652) and sleeve (651) into the spool hole of the casing.

PIN (874)

(652) SPOOL

-Make sure that the spool and the sleeve move smoothly in the casing. -Beware of the direction of the spool.

Direction Of The Spool (652)

4. Assembling feedback lever. Assemble feedback lever (611). Then put pin (874) into the pin hole of the feedback lever. -The work is eased if the pin is put in the feedback lever a little beforehand. -Take care so as not to mistake the direction of the feedback lever.

FEEDBACK LEVER (611)

FEEDBACK LEVER (611)

LEVER 1 (612) SODE

LEVER 2 (613) SIDE (FULCRUM PLUG AND ADJUST PLUG SIDES)

Assembling Feedback Lever (611)

33-79

33

33. UPPER SLEWING STRUCTURE 5. Assembling pilot piston (See Figure "Structural Exploded View Of Regulator" (C section). Assemble pilot piston (643) into the positive control hole of the casing. -Make sure that the pilot piston moves smoothly. 6. Assembling lever (See Figure "Structural Exploded View Of Regulator" (G section). Place pin (875) pressed in lever 2 (613) into the groove of the pilot piston and assemble lever 2 (613).

613(875)

Assembling Lever 2 (613) 7. Installing fulcrum plug (See Figure "Structural Exploded View Of Regulator" (F section). Assemble fulcrum plug (614) so pin (875) pressed in the fulcrum comes in the pin hole of lever 2 (613). Then fit snap ring (858).

614(875,858)

Installing Fulcrum Plug (614) 8. Installing adjust plug (See Figure 33-111 (G section). Insert adjust plug (615) and fit a snap ring (858).

858

-Use care so as not to mistake the holes into which the fulcrum and adjust plug are inserted. -At this point, operate the feedback lever and make sure that the gap is not too much and that the lever moves smoothly.

615 614

Installing Adjust Plug (615) 9. Installing return spring and the spring seat (See Figure "Structural Exploded View Of Regulator" (A section). Assemble return spring (654) and spring seat (653) into the spool hole and fit snap ring (814).

652 814 653 654

Installing Return Spring (654) And Spring Seat (653)

33-80

33. UPPER SLEWING STRUCTURE 10.Assembling compensating parts (See Figure "Structural Exploded View Of Regulator" (A and B section) Assemble set spring (655) into the spool hole. Place compensating piston (621) and piston casing (622) into the compensating hole and attach pilot cover (641). Then fasten them together with socket bolts (438 and 439). Tools: Allen wrench: 5 mm Tightening torque; 12 N-m (8.7 lbf-ft)

33

622(621) Assembling Compensating Parts

11. Installing spool and spring. Assemble spool (642) and spring (662) into pilot cover (641), and tighten VP plugs (466).

466

662 642 466 641 Assembling Spool (642) 12.Assembling into the pilot hole and the compensating hole (See Figure "Structural Exploded View Of Regulator" (E and D) section). Put spring seat (644), pilot spring (646) and adjust stem (645) into the pilot hole. Then assemble spring seat (624), inner spring (626) and outer spring (625) into the compensating hole. -Do not mistake the direction of the spring seat.

644,645,646

626 625(624)

Assembling Into The Pilot Hole And Compensating Hole 13.Installing cover. Attach cover (C) (629) fitted with adjust screws (628 and 925), adjust stem (627), lock nut (630), nut (801) and socket bolt (924). Then fasten them with socket bolts (438). Tools: Allen wrench: 5 mm Tightening torque; 12 N-m (8.7 lbf-ft) 14.Installing block cover (See Figure "Removing Regulator"). Attach block cover (656). Tools: Allen wrench: 5 mm Tightening torque; 12 N-m (8.7 lbf-ft) This completes assembly.

624,625,626 627 801 629( 628 )

630 924 Installing Cover (C) (629)

33-81

33. UPPER SLEWING STRUCTURE 33.2.1.3 PTO GEAR CASING (Option) 33.2.1.3.1 Structural exploded view

Tightening torque N-m (lbf-ft)

33 (25)

No.

Parts

Q'ty

115 117 118 125 126

Idle shaft 2nd gear 3rd gear Ball bearing Roller bearing

1 1 1 2 1

128 262 326 414

Bearing spacer Cover Gear casing Socket bolt; M10X20

2 2 1 4

Tightening torque N-m (lbf-ft) 33 (25) 74 (54)

33-82

No.

Parts

Q'ty

435 468 710 711 728

Flange socket; M10X20 VP plug; PF3/4 O-ring; 1B G80 O-ring; 1B G85 O-ring; 1B P24

4 1 1 1 1

825 826 885 886

Snap ring Snap ring Spring pin Pin

1 1 1 2

33. UPPER SLEWING STRUCTURE 33.2.1.3.2 Disassembly and assembly (1) Tools The right list shows the tools required for removal and installation.

Tool name

Dimension

Allen wrench

Opposing flats 8,10mm

Plier

For snap ring RR-20 For snap ring RR-72

(2) Disassembling procedure 1. Selecting a place for disassembly. -Choose a clean place. -Spread rubber sheet or cloth on work bench to protect parts from damaging. 2. Cleaning Remove dust and rust, etc. on pump surface with wash oil. 3. Drain oil Drain out the oil in the pump casing by removing drain port plug (468). Tools: Spanner: 27 mm -Drain out the oil from the plugs of the front pump and the rear pump. 4. Remove cover Remove the socket bolts (414). Then remove the cover (262). Tools: Allen wrench: 8 mm 5. Remove PTO gear casing Remove flange socket (435) and PTO gear casing. Tools: Allen wrench: 8 mm

Removing PTO Gear Casing

Removing Gear Pump 6. Removing the 2nd gear, the roller bearing and the bearing spacer. Draw out the spring pin (885) and remove idle shaft (115). Then draw out 2nd gear (117), roller bearing (126) and bearing spacer (128). -Roller bearing (126) can not be separated from 2nd gear (117).

Removing 2nd Gear (117)

33-83

33

33. UPPER SLEWING STRUCTURE 7. Removing the 3rd gear and the ball bearing. Remove snap ring (825) and draw out 3rd gear (118) and ball bearing (125). -Ball bearing (125) can not be separated from 3rd gear (118).

Removing 3rd Gear (118) And Ball Bearing (125) (3) Installing procedure Assembly is a reverse order of disassembly, but notice the following. 1. 2. 3. 4. 5. 6.

Repair scored parts at disassembly. Get replacements ready beforehand. Wash parts sufficiently in cleaning oil and dry them with compressed air. Do not forget to coat the sliding areas and bearings with clean hydraulic oil. In principle, replace sealing parts such as O rings and oil seals. Tighten socket bolts and plugs to specified torques in Service Standard, using a torque wrench. Do not mix up front pump parts with rear pump parts.

33.2.1.3.3 Maintenance standards In case a pitching (1 pit is more than 1mm (0.039in), while the area ratio is more than 5%.) is seen on the gear tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive damage.

33-84

33. UPPER SLEWING STRUCTURE 33.2.2 CONTROL VALVE

33

33.2.2.1 SECTIONAL VIEW 1.

Outside view 154

164

(P5)

101

P2

T1

T2

PBL

PAL

PCa

PB1

PAs

PBs Pss PBa1

PAa1

PAo

PBo

163

162 162 163 SECTION A A 164 154 (P6)

P1

102 973

973 PTb

PCb

973

973

PAr

PBr

973 PAb

PBb PBc PCc

973 PAc

974

973

973 PBa2

PAa2

974

162

162

163

SECTION B B

Section (1/6)

33-85

162

33. UPPER SLEWING STRUCTURE

A (P6)

H

B

273x10

273x10 P1 unload (Travel straight)

C

PCb

PAL

Travel left C

977 PAr

Travel right

PB1

Boom confluence (P2 unload)

978x2

D

H

D PBs

Boom

Swing

E

E

PBb

PCc

Pss

PBa1

Bucket

Arm 1

F

F PAo PA

PBa2 MU

Arm 2

Option

G

G K

K

B

A PBa2

PAo

274x4

275x4 213

212

PBo PAa2

273x10 273x10

Section (2/6)

33-86

33. UPPER SLEWING STRUCTURE 202 333 331 336 329 327

P1 unload

Travel left

PCb

202 333 331

PAL

336

601 331 261 309

MR

324 323

PL

159

AL

511 521

512 522

CP2

551 164 162

CMR2

552 562 562 552 522 512

CMR1

331 261 306 163 162

BL

163

307 261 331 327 329 336 331 333 202 202 333 331 336 324 323

264 205

PBL

SECTION C-C

PTb

Travel straight

Travel right

Boom conflux

PAr

202 333 331

PB1

339

306

326 325 331 261

161

511 521

331 261

163 511 521 551 164 163

CCb

Ar

CP1

551 164

Br

161

310

(T3)

264 205

551 164 305

PBr

SECTION D-D PCa

P2 unload

Section (3/6)

33-87

164 154 261 331 327 329 336 331 333 202

33

33. UPPER SLEWING STRUCTURE Swing

203 333 331 336 322 321 603

L

331 211 261 266 160 160 514 524 556 164 511 521 551 164

204

PBs

Boom

PBb

333

Pss

331 336

AbR

322

L

321

266

As

CRb Ab

LCb

LCs

Bb Bs

331 261 303 161 162 163 511 523 556 164 162 161

301 264

266 BbR

602 210

PAb

164 551

209 216 333 331 336 322 321 602

Q

Q

160

264 206

PAs

SECTION E-E Bucket

PCc

Arm 1

PBa1

PBc

BaR

BcR

331 261

L

L

304 CRa

Bc

511 521 551 164

Ba LCc

LCa

201 333 331 336 322 321 603 331 261 211 160 514 524 556 164 511 521 551 164

Ac

162

Aa

161 264 603 205

PAc AcR

302 264

PAa1

SECTION F-F

Section (4/6)

33-88

AaR

205 602

33. UPPER SLEWING STRUCTURE 201 333 331 340 328 321

Arm

201

Option

PBa2

333

PAo

331 336

331 261

324 AoR

323 604 331

MU

308

261 311

162 162 162 511 521 551 164 515 521

Ao

511 521

LCAT2 LCo LCAP2

551

551 164

164 Bo

162 161

604 264

BoR

264

Q

Q

PBo

205

210

PAa2

SECTION G-G

T2

161 P1

511 521

T1

163

CT1

551 164

163 162 511 521

P2 CT2

551 164

SECTION H-H

Section (5/6)

33-89

33

33. UPPER SLEWING STRUCTURE

207 160 278x5

266

264

264

527

606

606

528 T2

517

T1

163

518

SECTION J-J SECTION K-K

563 564

SECTION L-L

SECTION Q-Q

Section (6/6)

33-90

33. UPPER SLEWING STRUCTURE Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

No.

NAME

Q'TY

101 Casing A

1

311 Option spool

1

102 Casing B

1

321 Spring

5

3

322 Spring

4

323 Spring

3

324 Spring

3

325 Spring

1

326 Spring

1

220~250(162~184) 154 Plug PF3/4 20~24(15~18)

159

Plug PT1/4 MEC (Pre-coat bolt)

1

7.8~9.8(5.8~7.2)

160

Plug PT1/16 MEC (Pre-coat bolt)

5

161 O-ring

7

327 Spring

3

162 O-ring

15

328 Spring

1

163 O-ring

11

329 Spring

3

164 O-ring

19

331 Spring seat

24

201 Cover

3

202 Cover

6

333 Spacer bolt

12

203 Cover

1

336 Stopper

10

204 Sub cover

1

339 Stopper

1

205 Cover

5

340 Stopper

1

206 Cover

1

511 Poppet

11

512 Poppet

2

514 Poppet

2

207

9.8~14(7.2-10.3)

Tightening torque N-m (lbf-ft)

Back pressure check valve cover

16~18(11.8~13.3) Loctite #262

1

209 Cover

2

515 Poppet

1

210 Cover

2

517 Poppet

1

211

Lock valve selector sub

2

518 Poppet

1

521 Spring

11

212 Plate

1

522 Spring

2

213 Plate

1

523 Spring

1

216 Piston

1

524 Spring

2

261 O-ring

12

527 Spring

1

264 O-ring

10

266 O-ring

4

230~260(170~192) 551 Plug

13

273 Socket bolt

40

130~150(96~111)

552 Plug

2

98~120(72~89)

274 Socket bolt

4

230~260(170~192) 556 Plug

3

98~120(72~89)

275 Socket bolt

4

25~34(18~25)

278 Socket bolt

5

301 Boom spool sub

1

302 Arm 1 spool

1

69~78(51~58)

601 Main relief valve

1

303 Swing spool

1

69~78(51~58)

602 Port relief valve

3

304 Bucket spool

1

69~78(51~58)

603 Port relief valve

3

305 Boom conflux spool

1

69~78(51~58)

604

306 Travel spool

2

98~120(72~89)

606 Bypass cut valve

307 Travel straight spool

1

140~180(103~133) 973 Socket bolt

308 Arm 2 spool sub

1

140~180(103~133) 974 Socket bolt

2

309 P1 unload spool

1

977 Name plate

1

25~34(18~25)

528 Spring

13~17(9.59~12.5)

33-91

1

562 O-ring

2

563 Plug

2

564 O-ring

2

Relief valve plug assembly

2 2 8

33

33. UPPER SLEWING STRUCTURE 310 P2 unload spool

1

978 Rivet

33-92

2

33. UPPER SLEWING STRUCTURE 33.2.2.2 PREPARATION FOR DISASSEMBLY (1) General precautions 1. As all the hydraulic components are precisely machined, it is essential to carry out disassembly and reassembly in an especially clean location. 2. When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or sand. 3. Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm that each cap is in place and then clean the exterior of the assembly. Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench. 4. When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed spool, or the end cover. Handle the valve with care. 5. Tests (for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after disassembly and reassembly require a hydraulic testing apparatus. For this reason, do not disassemble hydraulic units that you are capable of disassembling but cannot test or adjust. Prepare beforehand washing fluid, hydraulic oil, grease, etc. . (2) Tools Prepare the following tools before disassembling the control valve. No.

Tools

Q'TY

Remarks

a

Vise

1

b

Box end wrench

1 of each size

24mm, 27mm, 32mm

c

Allen wrench

1 of each size

5mm, 6mm, 10mm, 12mm, 14mm, 22mm

d

Spanner

1

e

Loctite #262

1

f

Spatula

1

g

Pincers

1

h

Adjustable wrench

1

32 mm

33.2.2.3 DISASSEMBLY The figures in parentheses after part names in this manual represent those item numbers in the structural sectional drawing under Figure "(Section 1/6) to Figure Section 6/6)" (1) Place the control valve on a work bench so as to locate back pressure check valve upwards.

Preparation For Disassembly

Disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate mounting surfaces.

33-93

33

33. UPPER SLEWING STRUCTURE 33.2.2.3.1 Disassembling P1 unload spool (1) Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for P1 unload spool.

Removing Spring Cover (202) For P1 Unload Spring Cover (2) Draw out, from casing B (102), as a assembly of P1 unload spool (309), spring seat (331), springs (327 and 329), stopper (336) and bolt (333).

Drawing Out P1 Unload Spool Assembly (309)

When drawing out the spool assembly, use care so as not to score casing B (102). (3) Fix the P1 unload spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (327), (329) and stopper (336) from P1 unload spool (309).

Disassembling P1 Unload Spool Assembly (309)

33-94

33. UPPER SLEWING STRUCTURE 33.2.2.3.2 Disassembling the travel spool (left travel and right travel) (1) Loosen the socket bolts (273) and remove the spring cover (201) and the O-ring (261) for travel.

Removing Spring Cover (201) (2) Draw out the assembly of travel spool (306), spring seat (331), springs (323 and 324), stopper (336) and bolt (333) from casing A (101) or casing B (102).

Drawing Out Travel Spool (306) Assembly

When drawing out the spool assembly, take care so as not to score casing A (101) or casing B (102). (3) Fix the travel spool assembly with a vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (323 and 324) and stopper (336) from travel spool (306).

Removing Right Travel Spring Cover (201)

Disassembling Travel Spool (306) Assembly

33-95

33

33. UPPER SLEWING STRUCTURE 33.2.2.3.3 Disassembling the boom conflux spool (1) Loosen socket bolts (273) and remove spring cover (201) for boom conflux and O-ring (261). (2) Draw out the assembly of boom conflux spool (305), spring seat (331), springs (325), (326), stopper (339) and bolt (333) from casing A (101).

Removing Spring Cover (202)

When drawing out the spool assembly, use care so as not to score casing A (101). (3) Fix the boom conflux spool with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (325 and 326) and stopper (339) from boom conflux spool (305).

Drawing Out Boom Conflux Spool (305) Assembly 33.2.2.3.4 Disassembling the boom spool (1) Loosen socket bolts (273) and remove spring cover (203) for boom spool and O-rings (261 and 266). (2) Draw out the assembly of boom spool (301), spring seat (331), springs (321 and 322), stopper (336) and bolt (333) from casing B (102).

Removing Spring Cover (203)

When drawing out the spool assembly, take care so as not to score casing B (102).

33-96

33. UPPER SLEWING STRUCTURE (3) Fix the boom spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321 and 322) and stopper (336) from boom spool (301). Do not disassemble boom spool (301) further unless there is special reason.

33

Drawing Out Boom Spool (301) Assembly 33.2.2.3.5 Disassembling The Swing Spool (1) Loosen the socket bolts (273) and remove the spring cover sub (204) and the O-rings (261 and 266) for swing. Do not disassemble spring cover sub (204) further unless there is special reason. (2) Draw out the assembly of swing spool (303), spring seat (331), springs (321 and 322), stopper (336) and bolt (333) from casing A (101).

Removing Spring Cover Sub (204)

When drawing out the spool assembly, use care so as not to score casing A (101). (3) Fix the swing spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321 and 322) and stopper (336) from swing spool (303).

Drawing Out Swing Spool (303) Assembly

33-97

33. UPPER SLEWING STRUCTURE 33.2.2.3.6 Disassembling bucket spool (1) Loosen socket bolts (273) and remove bucket spring cover (209) and O-ring (261).

Removing Spring Cover (209) (2) Draw out the assembly of bucket spool (304), spring seat (331), springs (321 and 322), stopper (336) and bolt (333) from casing B (102).

Drawing Out Bucket Spool (304) Assembly

When drawing out the spool assembly, use care so as not to score casing B (102). (3) Fix the bucket spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321 and 322) and stopper (336) from bucket spool (304). (4) When needed to disassemble the spring cover of bucket spool, loosen plug (551) with casing B (102) installed. After removed cover (209) from casing B (102), remove plug (551) and then take out piston (216). Disassembling Bucket Spring Cover (209)

33-98

33. UPPER SLEWING STRUCTURE 33.2.2.3.7 Disassembling arm 1 spool (1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 1 spool.

33

(2) Draw out the assembly that consists of arm 1 spool (302), spring seat (331), spring (321, 322), stopper (336) and bolt (333) from casing A (101).

Removing Arm 1 Spring Cover (201)

When drawing out the spool assembly, use care so as not to score casing A (101). (3) Fix the arm 1 spool assembly with a vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), springs (321 and 322) and stopper (336) from arm 1 spool (302).

Disassembling Arm 1 Spool (302) Assembly 33.2.2.3.8 Disassembling arm 2 spool (1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 2 spool. (2) Draw out the assembly which consists of arm 2 spool (308), spring seat (331), spring (321 and 328), stopper (340) and bolt (333) from casing B (102).

Removing Arm 2 Spring Cover (201)

When drawing out the spool assembly, use care so as not to score casing B (102).

33-99

33. UPPER SLEWING STRUCTURE (3) Fix the arm 2 spool assembly with a vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321 and 328) and stopper (340) from arm 2 spool (308). Do not disassemble arm 2 spool (308) further unless there is special reason.

Disassembling Arm 2 Spool (308) Assembly 33.2.2.3.9 Disassembling option spool (1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) from option spool. (2) Draw out the assembly that consists of option spool (311), spring seat (331), spring (323 and 324), stopper (336) and bolt (333) from casing A (101).

Removing Option Spring Cover (201)

When drawing out the spool assembly, use care so as not to score casing A (101). (3) Fix the option spool assembly with a vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), springs (323 and 324) and stopper (336) from option spool (311).

Drawing Out Option Spool Assembly (311)

33-100

33. UPPER SLEWING STRUCTURE 33.2.2.3.10 Disassembling travel straight spool (1) Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for travel straight.

33

(2) Draw out the assembly of travel straight spool (307), spring seat (331), springs (327 and 329), stopper (336) and bolt (333) from casing B (102).

Drawing Out Travel Straight Spool (307) Assembly

When drawing out the spool assembly, take care so as not to score the casing B (102). (3) Fix the travel straight spool assembly with a vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (327 and 329) and stopper (336) from travel straight spool (307). 33.2.2.3.11 Disassembling P2 unload spool (1) Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261). (2) Draw out the assembly that consists of P2 unload spool (310), spring seat (331), springs (327 and 329), stopper (336) and bolt (333) from casing A (101).

Removing P2 Unload Spring Cover (202)

When drawing out the spool assembly, use care so as not to score casing A (101).

33-101

33. UPPER SLEWING STRUCTURE (3) Fix the P2 unload spool assembly with a vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), springs (327 and 329) and stopper (336) from P2 unload spool (310).

Drawing Out P2 Unload Spool Assembly (310) 33.2.2.3.12 Removing spool covers (1) Travel, bucket, arm 1, arm 2 and option. Loosen socket bolts (273) and remove spool cover (205) and O-ring (264). (2) Swing Loosen socket bolts (273) and remove spool cover (206) and O-rings (264 and 266). Do not disassemble spool cover (206) further unless there is special reason. (3) Boom Loosen socket bolts (273) and remove spool cover (206) and O-ring (264). Do not disassemble spool cover (208) further unless there is special reason. Removing Spool Cover (205, 206, and 208)

33-102

33. UPPER SLEWING STRUCTURE 33.2.2.3.13 Removing relief valve and plug assembly for relief valve hole (1) Remove the main relief valve (601) and overload relief valve (602 and 603) from the casing.

Removing Main Relief Valve (601)

Distinguish overload relief valve between (602) and (603) with a tag to prevent them from being confused during reassembly, as they are the same in appearance and shape but differ in pressure setting. Regarding the disassembly of the relief valves themselves, do not disassemble it.

Removing Overload Relief Valve (602) And (603) Removing Plug Assembly (604) For Relief Valve Hole

33-103

33

33. UPPER SLEWING STRUCTURE 33.2.2.3.14 Removing by-pass cut valve (1) Remove by-pass cut valve (606) from the casing.

Removing By-Pass Cut Valve (606) 33.2.2.3.15 Removing lock valve selector valve sub (1) Loosen socket bolts (211 thru 171) and (279), and remove lock valve selector sub (211) and emergency cab manual lowering device (215) from the casing. Further disassembly of the lock valve selector sub (211) and emergency boom manual lowering device (215) is not allowed.

Removing Lock Valve Selector Sub (211)

33-104

33. UPPER SLEWING STRUCTURE 33.2.2.3.16 Removing back pressure check valve (1) Loosen socket bolt (278) and remove back pressure check valve (207) from the casing.

33

Removing Back Pressure Check Valve Cover (207) (2) Remove springs (527 and 528), boost check valve poppet sub (517) and by-pass check valve poppet (518) from the casing. The further disassembly of boost check valve poppet sub (517) is not allowed. Replace control valve so the spool cover face directs downward.

Removing Boost Check Valve Sub (517) And ByPass Check Valve Poppet (518)

When replacing, be careful not to score the spool cover. 33.2.2.3.17 Removing plate (1) Loosen socket bolts (274 and 275), and remove plates (212 and 213). (2) After removing plates, remove all O-rings (162 and 163) remaining on the casing side.

Removing Plate (212 and 213)

33-105

33. UPPER SLEWING STRUCTURE 33.2.2.3.18 Removing check valve (1) Remove plugs from load check valve, conflux check valve, etc. and then remove poppet (511) and spring (521). (2) Load check valve on the swing section. Remove plug (556) and then remove poppet (511) and spring (523). (3) Load check valve on arm 2 section. Remove plug (551) and then remove poppet (515) and spring (521).

Removing Plug (551, 556, and 552)

The plug and spring in use differ from the above (1). Do not mix the parts when assembling parts. The poppet in use differs from the above (1). Do not mix the parts when assembling parts. (4) Lock valve Remove plug (556) and then remove poppet (514) and spring (524). (5) Main relief valve Remove plug (552) and then remove poppet (512) and spring (522).

Removing Poppet (511, 512, 514, and 515)

The plug, poppet and spring in use differ from the above (4). Do not mix the parts when assembling parts. The plug, poppet and spring in use differ from the above (5). Do not mix the parts when assembling parts. The plugs in which the procedure for disassembly is not included in the above procedure are usually used to block auxiliary holes and holes caused by casting. Do not disassemble further. 33.2.2.3.19 Disassembling casing Further disassembly of the casing is not allowed.

33-106

33. UPPER SLEWING STRUCTURE 33.2.2.3.20 Inspection after disassembly Thoroughly clean all disassembled parts with wash oil, and dry them with compressed air. Place each part on a clean sheet of paper or cloth for inspection. (1) Control valve 1. Inspect the entire surface of each part for burrs, scratches, cuts, and other defects. 2. Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust. 3. If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping. 4. Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches, dents, and the like. Remove any small defects with an oil stone or lapping compound. 5. Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are free from foreign matter. 6. Replace any broken or deformed spring with a new one. 7. If a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures. 8. Replace all O-rings with new ones.

Take care not to leave lapping compound behind in the casing or block. (2) Relief valve 1. Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact surface is even all over. 2. Manually confirm that the main poppet slides smoothly onto and off the seat. 3. Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from defects such as scratches. 4. Confirm that each spring is free from breakage, deformation, and excessive wear. 5. Confirm that the orifices of the main poppet and its seat are not clogged. 6. Replace all O-rings with new ones. (Between casing and seal) 33.2.2.4 REASSEMBLY (1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures. (2) Figures in parentheses after part names in this instruction represent those item numbers in the structural sectional drawing. (Figure "Section 1/6)" to Figure "Section 6/6)" (3) Precautions on reassembling O-ring. 1. Confirm that O-rings are free from defects caused by poor handling. 2. Apply a thin coat of grease or hydraulic oil to O-rings and their mating parts. 3. Do not stretch O-rings to the extent that they become permanently set. 4. When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after installation, and can cause oil leaks. 5. Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance Standards."

33-107

33

33. UPPER SLEWING STRUCTURE 33.2.2.4.1 Installing check valve (1) Load check valve, conflux check valve, and so on. Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (9 places) (2) Load check valve of swing section Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (1 place) (3) Load check valve of arm 2 section Attach poppet (515) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (1 place) (4) Lock valve section Attach poppet (514) and spring (524) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (2 places) (5) Main relief valve section Attach poppet (512) and spring (522) in place, place O-ring (562) in plug (552) and tighten them to the specified torque. (2 places)

Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar in shape. 33.2.2.4.2 Assembling plate (1) Place O-rings (162 and 163) in casing. (2) Attach plates (212 and 213) and tighten socket bolts (274 and 275) to the specified torque. Replace control valve so that this plate face directs downward. 33.2.2.4.3 Assembling back pressure check valve (1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527 and 528). (2) Attach O-rings (264 and 266) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278) to the specified torque. 33.2.2.4.4 Assembling lock valve selector sub (1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211 thru 171) to the specified torque. 33.2.2.4.5 Assembling by-pass cut valve (1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque.

Take care to prevent dropping poppet (606-201) and spring (606-202) when attaching by-pass cut valve.

33-108

33. UPPER SLEWING STRUCTURE 33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly (1) Tighten main relief valve (601), port relief valves (602 and 603) and relief valve hole plug assembly (604) in respective place to the specified torque.

Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief valves (602 and 603) are similar in shape. 33.2.2.4.7 Assembling p2 unload spool (1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327 and 329) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform the P2 unload spool (310) because of careless over clamping. (2) Place P2 unload spool assembly in item (1) in casing A (101).

Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place. (3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten socket bolt (273) to the specified torque.

33-109

33

33. UPPER SLEWING STRUCTURE 33.2.2.4.8 Assembling travel straight spool (1) Hold the mid section of the travel straight spool (307) with a vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327 and 329) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform the travel straight spool (307) because of careless over clamping. (2) Place the travel straight spool assembly in item (1) in casing B (102).

Place the travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place. (3) Attach spring cover (202) with O-ring (261) attached to the spring side of the travel straight spool assembly, and tighten socket bolt (273) to the specified torque. 33.2.2.4.9 Assembling spool in option (1) Hold the mid section of the spool in option (311) with a vise provided with a protection plate (aluminum plate, etc.), fit spring seat (331), springs (323 and 324) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform option spool (311) because of careless over clamping. (2) Place the option spool assembly in item (1) in casing A (101).

Place option spool assembly in casing A (101) carefully. Do not squeeze it into place. (3) Attach spring cover (201) with O-ring (261) attached to the spring side of the option spool assembly and tighten socket bolt (273) to the specified torque.

33-110

33. UPPER SLEWING STRUCTURE 33.2.2.4.10 Assembling arm 2 spool (1) Hold the mid section of the arm 2 spool (308) with a vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321 and 328) and stopper (340) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform the arm 2 spool (308) because of careless over clamping. (2) Place the arm 2 option spool assembly in item (1) in casing B (102).

Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place. (3) Attach spring cover (201) with O-ring (261) attached to the spring side of the arm 2 spool assembly and tighten socket bolt (273) to the specified torque. 33.2.2.4.11 Assembling arm 1 spool (1) Hold the mid section of the arm 1 spool (302) with a vise provided with a protection plate (aluminum plate, etc.) and fit spring seat (331), springs (321 and 322) and stopper (336), and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform the arm 1 spool (302) because of careless over clamping. (2) Place the arm 1 spool assembly in item (1) in casing A (101).

Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place. (3) Attach spring cover (201) with O-ring (261) attached to the spring side of the arm 1 spool assembly, and tighten socket bolt (273) to the specified torque.

33-111

33

33. UPPER SLEWING STRUCTURE 33.2.2.4.12 Assembling bucket spool (1) Hold the mid section of bucket spool (304) with a vise provided with a protection plate (aluminum plate, etc.), fit spring seat (331), springs (321 and 322) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform bucket spool (304) because of careless over-clamping. (2) Place the bucket spool assembly in item (1) in casing B (102).

Place the bucket spool assembly in casing B (102) carefully. Do not squeeze it into place. (3) Attach spring cover (209) with O-ring (261) attached to the spring side of the bucket spool assembly and tighten the socket bolt (273) to the specified torque. (4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque. 33.2.2.4.13 Assembling swing spool (1) Hold the mid section of swing spool (303) with a vise provided with a protection plate (aluminum plate, etc.), fit spring seat (331), springs (321 and 322) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform swing spool (303) because of careless over-clamping. (2) Place the swing spool assembly in item (1) in casing A (101).

Place the swing spool assembly in casing A (101) carefully. Do not squeeze it into place. (3) Attach spring cover sub (204) with O-rings (261 and 266) attached to the spring side of swing spool assembly and tighten socket bolt (273) to the specified torque.

33-112

33. UPPER SLEWING STRUCTURE 33.2.2.4.14 Assembling boom spool (1) Hold the mid section of boom spool (301) with a vise provided with a protection plate (aluminum plate, etc.), fit spring seat (331), springs (321 and 322) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform boom spool (301) because of careless over clamping. (2) Place the boom spool assembly in item (1) in casing B (102).

Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place. (3) Attach the spring cover (203) with O-rings (261 and 266) attached to the spring side of the boom spool assembly and tighten the socket bolt (273) to the specified torque. 33.2.2.4.15 Assembling boom conflux spool (1) Hold the mid section of the boom conflux spool (305) with a vise provided with a protection plate (aluminum plate, etc.), fit spring seat (331), springs (325 and 326) and stopper (339) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform the boom conflux spool (305) because of careless over-clamping. (2) Place the boom conflux spool assembly in item (1) in casing A (101).

Place the boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place. (3) Attach the spring cover (202) with O-ring (261) attached to the spring side of the boom conflux spool assembly and tighten the socket bolt (273) to the specified torque.

33-113

33

33. UPPER SLEWING STRUCTURE 33.2.2.4.16 Assembling travel spool (travel right and left) (1) Hold the mid section of the travel spool (306) with a vise provided with a protection plate (aluminum plate, etc.), fit spring seat (331), springs (323 and 324) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform the travel spool (306) because of careless over clamping. (2) Place the travel spool assembly in item (1) in casing A (101) or casing B (102).

Place the travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place. (3) Attach spring cover (201) with O-ring (261) attached to the spring side of the travel spool assembly and tighten socket bolt (273) to the specified torque. 33.2.2.4.17 Assembling P1 unload spool (1) Hold the mid section of the P1 unload spool (309) with a vise provided with a protection plate (aluminum plate, etc.), fit spring seat (331), springs (327 and 329) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333). Take care not to deform the P1 unload spool (309) because of careless over-clamping. (2) Place the P1 unload spool assembly in item (1) in casing A (101).

Place the P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place. (3) Attach the spring cover (202) with O-ring (261) attached to the spring side of the P1 unload spool assembly and tighten socket bolt (273) to the specified torque.

33.2.2.4.18 Assembling spool cover, and so on (1) Travel, bucket, arm 1, and arm 2, option Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque. (2) Swing Place O-rings (264 and 266) in spool cover (206) and tighten socket bolt (273) to the specified torque. (3) Boom Place O-ring (264) in spool cover (208) and tighten socket bolt (273) to the specified torque.

33-114

33. UPPER SLEWING STRUCTURE 33.2.2.5 MAINTENANCE STANDARDS 33.2.2.5.1 Inspection of components

33 Parts name

Inspection item

Criterion and remedy

Casing

Look for scratches, rusting and corrosion.

If any of the following parts are damaged, replace the casing. Sliding part of casing hole and spool, particularly the land, to which holding pressure is applied. Area of sealing part that is in contact with O-ring. Sealing and seating part of main or overload relief valve. Area of seating part or sliding part of poppet. Sealing part of plug. Defects of other parts that seem to prevent normal function.

Spool

Look for scratches, galling, rusting and corrosion.

If a detectable defect with your fingernail is found on the sliding part of the outer circumference, replace the spool. If the spool damages the O-ring or does not move smoothly, repair or replace the spool.

Insert the spool in the casing bore, and move it while turning it. Poppet

Look for damage on the poppet and the spring. Insert the poppet in the casing, and move it.

If spring is damaged, replace it. If the seat of poppet or spring are damaged, correct or replace it. If the poppet moves lightly without catching, it is normal. If damaged heavily, replace.

Spring and related parts

Look for rust, corrosion, deformation, and breakage of the spring, spring seat, stopper, spacer bolt and cover.

Main relief valve Port relief valve By-pass cut valve

Look for rust and damage on outer surface. Replace. Inspect the contact face of the valve seat. If damaged, replace. Inspect the O-ring, backup ring, and seal. As a general rule, replace all parts with new ones. (Between casing and seal)

33-115

33. UPPER SLEWING STRUCTURE 33.2.2.6 TROUBLESHOOTING (1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure, load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and reassembly procedures in this manual. (2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system is to be disassembled, take dust protection measures beforehand. (3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like. (4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks. 33.2.2.6.1 Control valve Trouble

Cause

Remedy

1. Travel does not occur. Slow to start up (or poor power). Slow response.

Malfunctioning main relief valve. Foreign matter between main poppet and seat. Foreign matter between poppet and seat. Sticking main poppet. Broken or deformed spring. Clogged main poppet throttle. Loosened adjusting screw

Check travel relief valve pressure Disassemble and clean. If damaged heavily, replace the assembly as a unit. Same as above. Correct sticking part with oil stone. Replace spring. Remove foreign matter. Readjust, and tighten lock nut to specified torque.

2. Machine does not move straight during simultaneous operation of travel and attachment.

Malfunctioning travel straight valve. Sticking spool. Broken or deformed spring. Clogged small hole in spool.

Check pilot pressure. Correct sticking part with oil stone. Replace spring. Remove foreign matter.

Malfunctioning main relief valve.

Remove main relief valve.

3. Excessive natural falls of attachment under its own weight when spool is in neutral.

Excessive clearance between casing and spool.

Replace spool.

Spool is not completely in neutral position. Foreign matter between casing and spool, or sticking spool. Broken or deformed spring. Clogged pilot circuit.

Check secondary pilot pressure. Disassemble, clean and smooth sticking part with oil stone. Replace spring. Remove foreign matter.

Malfunctioning overload relief valve. Refer to item 1. 1) above. (See 33.2.2.3.20 (2) Foreign matter between valve seat and casing.

Check overload relief valve pressure. (See 33.2.2.3.20 (2)) -Clean and check damage on seat surface.

Lock valve function is faulty. (Arm, boom) Foreign matter between poppet seat and casing. Poppet is stuck. Broken or deformed spring. Selector spool is stuck.

Replace Disassemble, clean. Correct stuck part with oil stone or replace. Replace spring. Replace lock valve selector assembly.

33-116

33. UPPER SLEWING STRUCTURE

Trouble

Cause

Remedy

4. When raising Malfunctioning load check valve. attachment, at first it Foreign matter between poppet and drops. casing. Sticking poppet. Broken or deformed spring. 5. Bucket, boom, arm or swing does not operate. Slow to start up (or poor power).Slow response.

6. Boom conflux does not operate.

Disassemble and clean. If heavily damaged, replace control valve. Correct sticking part with oil stone. Replace spring.

Malfunctioning main spool. Excessive clearance between casing and spool. Foreign matter between casing and spool. Sticking spool. Broken or deformed return spring. Clogged pilot circuit.

Check secondary pilot pressure. Replace spool. Disassemble and clean. Correct stuck part with oil stone. Replace spring. Remove foreign matter.

Malfunctioning main relief valve. Refer to item 1. 1) above. (See 33.2.2.3.20 (2))

Check main relief valve pressure. Refer to item 1. 1) above. (See 33.2.2.3.20 (2))

Malfunctioning overload relief valve. Refer to item 1. 1) above. (See 33.2.2.3.20 (2))

Check overload relief valve pressure. (See 33.2.2.3.20 (2))

Malfunctioning conflux valve. Excessive clearance between casing and spool. Foreign matter between casing and spool. Sticking spool. Broken or deformed return spring. Clogged pilot circuit.

Measure pilot pressure. Replace spool. Disassemble and clean. Correct stuck part with oil stone. Replace spring. Remove foreign matter.

33-117

33

33. UPPER SLEWING STRUCTURE 33.2.2.6.2 Relief valve Trouble

Cause

Remedy

1. No pressure rise.

Main or pilot poppet of relief valve is sticking and valve is open, or there is foreign matter on valve seat.

Check for foreign matter on each poppet. Confirm that each component slides smoothly. If failure is found, replace it in an assembly.

2. Unstable relief pressure.

Main or pilot poppet of relief valve seat is damaged.

If failure is found, replace it an assembly.

3. Incorrect relief pressure setting.

Wear due to foreign matter.

Replace damaged assembly

3. Excessive natural Loosened locknut or adjusting screw. falls of attachment under its own weight when spool is in neutral.

Adjust pressure.

4. Oil leak.

Damaged seat. Damaged O-ring.

Confirm that each component operates smoothly. Replace damaged or worn component. If failure is found, replace it an assembly.

Sticking component due to foreign matter.

Confirm that there are no scratches, scores, or foreign matter present before reassembling. If failure is found, replace it an assembly.

33-118

33. UPPER SLEWING STRUCTURE 33.2.3 PILOT VALVE (ATT)

33

33.2.3.1 CROSS-SECTIONAL VIEW

Apply Loctite #277

312 302 501

301 *246-1

Apply grease on top section

212 *246-2 151

213

*218

211

214

Secondary pressure adjusting shim

216-2

216-1

241-2

241-1

201-2

201-1

217

221

101

PORTS 2, 4

Tightening torque N-m (lbf-ft)

Apply grease on rotating and sliding sections. Be careful the assembling direction

No.

PORTS 1, 3 Pilot Valve (For ATT)

Parts

Q'ty

101 151 201-1 201-2 211

Casing Plate Spool Spool Plug

1 1 2 2 4

212 213 214 216-1 216-2

Push rod Seal O-ring: 1B P20 Spring seat Spring seat

4 4 4 2 2

Washer 2 (Shim)

4

217

Tightening torque N-m (lbf-ft)

47.1 (34.7) 68.6 (50.6)

Note) The parts marked * might not be equipped depending on valve type.

33-119

No.

Parts

Q'ty

*218 221 241-1 241-2 *246-1

Seat Spring Spring Spring Spring

4 4 2 2 2

*246-2 301 302 312 501

Spring Joint: M14 Circular plate Adjust nut: M14 Boots

2 1 1 1 1

33. UPPER SLEWING STRUCTURE 33.2.3.2 DISASSEMBLY (1) Plug each port of the pilot valve, and clean it with kerosine. P port: PF1/4 1 to 4 and T port: PF3/8 (2) Fix the pilot valve with a vise via a protective plate (Alminum plate etc.), and remove boots (501).

501

Removing Boot (501) (3) Remove adjusting nut (312) applying spanners to adjusting nut (312) and circular plate (302). Tools: Spanner: 22 mm, 32 mm

312

302

Removing Adjusting Nut (312)

33-120

33. UPPER SLEWING STRUCTURE (4) Remove circular plate (302) Tools: Spanner: 32 mm

302

33

Removing Circular Plate (302)

Circular Plate Is Removed Installing Jig A (5) Turn joint (301) in counterclockwise with Jig A to remove. Jig A: See page 33.2.3.7(1). Tools: Spanner: 24 mm

301

Removing Joint (301)

When the force of return springs (221) are strong, never loosen joint (301). If loosened, it might result in jumping out of plate (151), plug (211) and push rod (212). Remove joint (301) pressing plate (151) downward with two fingers.

33-121

33. UPPER SLEWING STRUCTURE (6) Remove plate (151) When the force of return springs (221) are strong, press plate to let it come up slowly.

151

Removing Plate (151) When the force of return springs (221) are weak, plug is left in casing (101) due to sliding resistance of O-ring (214). Tools: Pull plug (211) out with a driver.

211 Removing Plug (211)

To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is completely released. (7) Remove push rod (212), plug (211), pressure reducing valve assembly (spool), and return springs (221) from casing (101).

212 211 221

101 Removing Push Rod, Plug, Pressure Reducing Valve And Spring

Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.

33-122

33. UPPER SLEWING STRUCTURE (8) Push springs (241-1 and 241-2) in the range of 7 mm (0.276 in) so that the movement of the spring seats (216-1 and 216-2) and shift the seats (216) in a side direction, and remove spools (201-1 and 201-2) through the larger hole of the seat.

216-1 216-2

33

201-1 201-2 Removing Spool (201)

Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4) (9) Remove spools (201-1 and 201-2), spring seats (216-1 and 216-2), spring (241-1 and 241-2), and washer (217).

241-1 241-2

216-1 216-2

217

201-1 201-2 Disassembling Pressure Reducing Valve (10)Remove springs (*246-1 and *246-2) and spring seat (*218) from push rod (212).

*218

*246-1 *246-2

214

212 211 Disassembling Push Rod

The parts marked * might not be equipped depending on valve type.

33-123

33. UPPER SLEWING STRUCTURE (11)Pull out push rod (212) from plug (211). (12)Remove O-ring (214) from plug (211).

212 Removing Push Rod (212) (13)Remove inside seal (213) from plug (211) with small driver.

213 Removing Seal (213) 33.2.3.3 CLEANING PARTS (1) Clean parts with wash oil roughly. (2) Clean parts with wash oil completely. (3) Dry parts by swabbing clean rag. (4) Apply rust preventives on parts. 33.2.3.4 ASSEMBLING (1) Fit washer (217), springs (241-1 and 241-2), and spring seats (216-1 and 216-2) to spools (201-1 and 201-2).

201-1

241-1

201-2

241-2

216-1 216-2

217 Assembling Pressure Reducing Valve

33-124

33. UPPER SLEWING STRUCTURE (2) Push spring (241-1 and 241-2) in the range so that the movement of spring seats (216-1 and 216-2) in a side direction, and install spool (201-1) through the larger hole of spring seat. (See Figure "Removing Spool (201)"

216-1 216-2

33

201-1 201-2 Installing Spools (201-1), (201-2)

Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4) (3) Place spring (221) into ports 1 and 3 of casing (101), and then install pressure reducing valve assembly in it. Place springs (221) into ports 2 and 4 and install it.

PRESSURE REDUCING VALVE ASSY

221

101

Installing Pressure Reducing Valve Assembly

Install the removed respective assembly into respective holes.

33-125

33. UPPER SLEWING STRUCTURE (4) Fit O-ring (214) and seal (213) into plug (211). -Apply hydraulic oil on surface of push rod.

SEAL (213)

PLUG (211)

211

PUSH ROD (212)

213

214

-RING (214) Apply hydraulic oil

For the assembling direction of seal (213).

Installing O-ring (214) and Seal (213) (5) Insert push rod (212) in plug (211) and install spring (*246-1) and spring seat (*218) to push rod (212) on port 1 and 3 side. Insert push rod (212) in plug (211) and install spring (*246-2) and spring seat (*218) to push rod (212) on port 2 and 4 side.

212

211

*246-1 *246-2

*218

Assembling Push Rod, Spring (*246-1 and *246-2) and Seat (*218)

The parts marked * might not be equipped depending on valve type. (6) Fit plug (211) assembly to casing (101). 1. When the force of spring (211) is weak, it stops at the position where it is pushed in by the sliding resistance of O-ring (214).

101

211 Installing Plug Assembly

33-126

33. UPPER SLEWING STRUCTURE 2. When the force of spring (221) is strong, attach plate (151) and press 4 push rods by hand at the same time, and tighten joint (301) temporarily. -Install spool (201) straight and evenly into the hole of casing (101). Take care so that plug (211) and plate (151) do not jump out of casing (101).

301

33

151 Installing Plug Assembly And Plate (151) (7) Install joint (301) on casing (101) with jig A securely. Jig A : See 33.2.3.7 JIG. Tightening torque : 47.1 N-m (32.8 to 37.2 lbf-ft)

101

A

Installing Joint (301) (8) Install circular plate (302) to joint (301) (9) Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular plate returning. Tools: Spanner: 32 mm Tools: Socket: 22 mm Apply Loctite #277 to threads of joint. Tightening torque: 68.6 N-m (51 lbf-ft)

312

302

Installing Circular Plate (302)

Screw it in until it comes in contact with 4 push rods (212) equally. Over screwing it in may cause malfunction of machine.

33-127

33. UPPER SLEWING STRUCTURE (10)Apply heat-resisting grease to joint (301) rotating section and the top of push rod (212). (11)Cover it with boots. (12)Spray rust preventives through each port and attach plug respectively.

GREASE

212

301

Applying Grease To Joint Section And Push Rod

33-128

33. UPPER SLEWING STRUCTURE 33.2.3.5 MAINTENANCE STANDARDS Check item

Leakage

Spool Push rod Looseness of control section

Standard

Remarks

When leakage quantity reaches to 1000 cc/ min. or more where handle is set in neutral position, or to 2000 cc/min. or more in operation; replace spool with new one. If leaking, even if the spool is replaced, replace pilot valve assembly with new one.

Conditions Primary pressure 2.94 MPa (426 psi) Hydraulic oil viscosity 23 cSt

When the wear of sliding section is 10 μm more than the that of non sliding section; replace it with new one.

This condition may be the same as the above.

When the wear of top is 1 mm (0.04 in) or more, replace it with new one. When looseness of 2 mm (0.08 in) or more on circular plate (302) on control section and joint section (301) due to wear; replace them with new ones.

In case of the looseness due to the loosening on tightening section, adjust it.

When trouble such as noise, hunting, drop of primary pressure, etc. has occurred in operation, and it does not restore after taking Stability of operation corrective action according to below 33.2.3.6 (TROUBLESHOOTING); replace pilot valve assembly with new one.

O-rings, etc. should be replaced with new ones at every disassembling. If socket bolt (125) was loosened, seal washer (121) should be replaced.

33-129

33

33. UPPER SLEWING STRUCTURE 33.2.3.6 TROUBLESHOOTING It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer to the estimated causes and corrective actions. The following table explains general phenomenon, estimated causes and corrective actions. However, most machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore, corrective action other than those described in this table are often required. The following table does not cover causes and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and causes. Phenomenon

Possible Cause

Corrective action

1. Primary pressure is insufficient. 2. Secondary pressure springs (241) are broken or fatigued. Secondary pressure 3. Clearance between spool (201) and casdoes not rise. ing (101) is abnormally large. 4. Handle has a looseness.

1. Secure primary pressure. 2. Replace with new ones.

1. Sliding parts are caught. Secondary pressure 2. Tank line pressure varies. is unstable. 3. Air has mixed into pipeline.

1. Repair the unsmoothed section. 2. Bring pressure directly to oil tank. 3. Bleed air by operating it several times.

Secondary pressure 1. Tank line pressure is high. is high. 2. Sliding parts are caught.

1. Bring pressure directly to oil tank. 2. Correct.

33-130

3. Replace spool (201). 4. Disassembly and reassembly or replace handle section.

33. UPPER SLEWING STRUCTURE 33.2.3.7 JIG (1) Jig for removing and installing joint (301)

33

33-131

33. UPPER SLEWING STRUCTURE 33.2.4 PILOT VALVE (FOR TRAVEL) 33.2.4.1 CONSTRUCTION T=Tightening torgue N.m (lbf.ft)

12-o 12-o

5

7-h

12-o 12-y

12-y 12-x

12-x

13 6

8

f d Loctite 262 g T=3 g

10

q

T=5 (3.7)

14 r

11

15

u t T=4 (3) 15

7-i T=30 (22) 7-k T=1.2 (0.9) 7-h

15

7-j

u 17

t

r

u t T=4 (3) 14 q T=5 (3.7)

21

Loctite 262 r w'

z

21

21 21 T=3~5 (2.2~3.7)

Exploded View Of Pilot Valve No.

Parts

Q'TY

No.

Parts

Q'TY

5 6 6-d 6-f 6-g

Rubber boots Foot pedal (Switch plate) Switch plate Regulation screw M8X28 Set screw M5X8

2 (2) 2 4 4

12-x 12-y 13 14

Seal 14dia.X20dia.X3dia. Wiper ring Damper spring Check valve kit

6 6 4 (2)

7 7-h 7-i 7-j 7-k

Retaining plate kit Plate Capscrew M10X20 Shaft Set screw M4X10

(1) 1 2 2 2

14-q 14-r 15 15-u 15-t

Plug M8 Ball M6, 35 Orifice Plug M6 Orifice M6, 0.6dia.

2 2 (4) 4 4

8 10 11 12 12-o

Flange kit Control spool Return spring Damper flange kit Damper plunger 14 dia.

4 4 4 (4) 4

17 17-w' 17-r 17-z 21

Shuttle valve kit Shuttle valve & orifice Ball M6, 35 Orifice M5, 0.8dia. Plug

(2) 2 2 2 4

33-132

33. UPPER SLEWING STRUCTURE 33.2.4.2 DISASSEMBLY AND ASSEMBLY (1) Boot replacement

33 The pilot control unit does not need to be removed from the machine to perform this operation. 1. Remove both faulty boots. (using a flat screw driver if necessary) 2. Replace both boots with a new one. * Reassembly: First fit the lower part of the rubber boot on the retaining plate between the 2 switch plates. Then put the lower part in the external groove of the retaining plate. Finish by fitting the upper part of the rubber boot on the switch plate.

(2) Switch plate removal 1. Remove: The pilot control unit from the machine. Both rubber boots (See 33.2.4.2 (1)) 2. Remove the screw locking the axis using a 2 mm socket wrench. (See right Fig. No.1) * Reassembly: Apply a droplet of Loctite #262 on the locking screw thread. Torque :1.2 N-m (0.89 lbf-ft) 3. Fit a M3 screw on the switch plate axis in order to remove it (Using pliers if necessary). (See right Fig. No.2) * Reassembly: Position the axis so that the hole is aligned with the locking screw as shown on the picture (See right Fig. No.3) 4. Mark out the position of the switch plate before removing it. 5. Repeat the operation for the second switch plate. 6. Reassemble parts in reverse order.

33-133

33. UPPER SLEWING STRUCTURE (3) Switch plate adjustment

If the switch plate is replaced, it is necessary to adjust the regulation screws. 1. Unscrew the 2 locking screws using a 2,5 mm socket wrench (See right Fig.) * Reassembly: Apply a droplet of Loctite #262 on the locking screw thread. Torque :3N-m 2.2 (lbf-ft) 2. Set the switch plate horizontally. 3. Screw on simultaneously both regulation screws using a flat screw driver (5,5X150) until feeling some resistance.

Do not misadjust the two damping screws. (See below Fig.) 4. Tighten the locking screws to hold the regulation screws in position. 5. Repeat the operation for the second switch plate making sure both switch plates are parallel. (See above Fig.) Regulation screws to adjust

Damping screws already adjusted and glued

SWITCH PLATE

The figure is shown from the backside.

33-134

33. UPPER SLEWING STRUCTURE (4) Retaining plate removal 1. Remove The pilot control unit from the machine. Both rubber boots (See 33.2.4.2 (1)) Both switch plates (See 33.2.4.2 (2)) 2. Unscrew simultaneously both screws holding the retaining plate using a 8 mm socket wrench. (See right Fig.) * Reassembly: Apply a droplet of Loctite #262 on the screw thread. Torque :30N-m (22 lbf-ft)

33

3. Lift the retaining plate to remove it. (See right Fig.) * Reassembly: Use the retaining plate to insert the 4 guides into the body simultaneously and perpendicularly. (See right Fig. left side) 4. Reassemble parts in reverse order. 5. Drain the pilot control unit (See 33.2.4.3).

(5) Damping plunger seals replacement 1. Remove The pilot control unit from the machine. Both rubber boots. (See 33.2.4.2 (1)) Both switch plates (See 33.2.4.2 (2)) The retaining plate (See 33.2.4.2 (4))

1 2. Remove the wiper ring of the damping plunger (1). (See right Fig. No.1) * Reassembly: Replace with a new wiper ring. 3. Remove the damping plunger (2). (Rihgt Fig. No.2)

33-135

WIPER RING

2

DAMPER PLUNGER

33. UPPER SLEWING STRUCTURE

Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly positionned. 4. Using a needle, remove the seal placed inside the body (See right Fig. No.3, 4) * Reassembly : Replace with a new seal and grease it.

3 Squeeze the seal between your fingers to obtain a 8shape. (See right Fig. No.5) Insert the seal within the groove with your fingers (lip in bottom position). (See right Fig. No.6, 7) Push the seal against the side using the round head of a small socket wrench. (Right Fig. No.8)

5. 6. 7. 8.

4

5

6

7

8

Repeat the operation for the other 3 assemblies. Extract the damping springs from the body (using flat nose pliers). Inspect the damping springs. If defects are detected, replace the 4 springs. Reassemble parts in reverse order.

During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage nor twist it.

33-136

33. UPPER SLEWING STRUCTURE (6) Guide/plunger and regulation unit replacement 1. Remove The pilot control unit from the machine. Both rubber boots (See 33.2.4.2 (1)) Both switch plates (See 33.2.4.2 (2)) The retaining plate (See 33.2.4.2 (4)) 2. Guide/plunger replacement: Insert the end of a thin screwdriver between the guide and the body, carefully lift the guide to remove it from the body. 3. Remove the guide / plunger assembly. 4. Repeat the operation for the other 3 subassemblies. 5. Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-assemblies.

Hold the guides with the other hand during the extraction operation to limit the effect of the return spring. 6. Guide/plunger and regulation unit replacement. Extract the regulation units from the body (using flat nose pliers). Inspect the regulation units. If defects are detected on the parts, replace the 4 units. 7. Return spring replacement : Extract the return springs from the body (using flat nose pliers).

33-137

33

33. UPPER SLEWING STRUCTURE Inspect the return springs. If defects are detected, replace the 4 springs. 8. Reassemble parts in reverse order.

(7) Throttle kit replacement 1. Remove The pilot control unit from the machine. Both rubber boots (See 33.2.4.2 (1)) Both switch plates (See 33.2.4.2 (2)) The retaining plate (See 33.2.4.2 (4)) The damping plungers and springs (See 33.2.4.2 (5))

2. Unscrew the screw using a 3mm socket wrench. (See right Fig.) * Reassembly: Apply a droplet of Loctite #262 on the screw thread Screw on until it sets just above the body. (See right Fig.) 3. Unscrew the throttle using a 3 mm socket wrench. * Reassembly: Torque:4N-m (3 lbf-ft) 4. Repeat the operation for the other 3 assemblies. 5. Replace with new screws and new throttles. 6. Reassemble parts in reverse order.

33-138

33. UPPER SLEWING STRUCTURE (8) Shuttle valve kit removal 1. Remove the pilot control unit from the machine.

33

The pilot control unit does not need to be disassembled to perform this operation. 2. Unscrew the shuttle valve using a 4 mm socket wrench. (See right Fig.) * Reassembly: Thoroughly clean the body to remove any trace of loctite. Apply a droplet of Loctite #242 on the shuttle valve thread. Torque: 4N-m (3 lbf-ft)

Wait for 8 hours before using the machine to let the Loctite #242 dry completely. 3. Put the body up-side-down to remove the shuttle valve and the ball. (See below Fig.) 4. Unscrew the throttle using a 2,5 mm socket wrench. * Reassembly: -Hand tighten. 5. Repeat the operation for the other subassemblies. 6. Inspect the shuttle valves, balls and throttles. If defects are detected, replace all the assemblies.

33-139

33. UPPER SLEWING STRUCTURE 7. Reassemble parts in reverse order.

(9) Check valve kit removal 1. Remove the pilot control unit from the machine

The pilot control unit does not need to be disassembled to perform this operation.

2. Unscrew the check valve plug using a 4 mm socket wrench. (See right Fig.) * Reassembly: Drain the pilot control unit (See 33.2.4.3) Torque: 5N-m (3.7 lbf-ft) 3. Put the body up-side-down to remove the ball. 4. Repeat the operation for the second check valve kit.

5. Inspect the check valve plugs, O-rings and balls. If defects are detected, replace all the assemblies. (See right Fig.) 6. Reassemble parts in reverse order.

33-140

33. UPPER SLEWING STRUCTURE 33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT (1) When removing the retaining plate, the throttle kit or the shuttle valve kit, it is necessary to drain the pilot unit. (2) Reassemble the pilot unit control completely. (3) Install the pilot unit control in the machine. (4) Slightly unscrew the check valve plug using a 4mm socket wrench. (See right Fig.) (5) Switch on the machine. (6) Operate the pedal gently until the bubbles disappear. (7) Tighten the check valve plug. Torque: 5 N-m (3.7 lbf-ft) (8) Repeat the operation for the other check valve plug.

33-141

33

33. UPPER SLEWING STRUCTURE 33.2.5 SWING MOTOR UNIT 33.2.5.1 CONSTRUCTION (1) Swing motor

702 712

351

ARRANGEMENT OF BRAKE SPRING

355 401 488

469

051-1 051

151 162 052 161 303

100 171

A

163 A

985 391 390 444

984 131 451

472

400-1 400-2

712

400 707

702

706 986 742 743

994

111

121 123 122 124 114 301 443

491 101

Swing Motor

33-142

SECTION A-A

052

33. UPPER SLEWING STRUCTURE

Tightening torque N-m (lbf-ft)

No.

177 (130)

051

36 (27)

29 (21)

Q'TY

Tightening torque N-m (lbf-ft)

Relief valve; M33-P1.5

2

69 (51)

051-1 O-ring; 1B G30 052 Anti-reaction valve sub 100 Casing for anti-reaction valve 101 Drive shaft

2 1 1

NAME

431 (318)

No.

NAME

Anti-reaction valve; M22P1.5 400-1 O-ring; 1B P20 400-2 Backup ring 401 Socket bolt; M20X45 400

Q'TY 2 2 2 4

1

443

Roller bearing

1

444 451 469 472 488

Roller bearing Pin ROMH plug; M36-P1.5 O-ring; W1516,WG44 O-ring; 1B P34

1 2 2 1 2

111 114 121 122 123

Cylinder Spring plate Piston Shoe Set plate

1 1 9 9 1

124 131 151 161 162

Shoe plate Valve plate Plug; PF1/4 O-ring; 1B P11 O-ring; 1B P12

1 1 2 2 2

491 702 706 707 712

Oil seal Brake piston O-ring; W1516,WG42 O-ring; W1516,WG45 Brake spring

1 1 1 1 14

163 171 301 303 351

O-ring; 1B P6 Socket bolt; M8X55 Casing Valve casing Plunger

2 4 1 1 2

2.7 (2.0) 5.6 (4.1) 0.9 (0.66)

742 743 984 985 986

Friction plate Separator plate Plug; PF1/2 Plug; PF1 Plug; PF1/4

3 4 1 1 1

355 390 391

Spring Name plate Rivet

2 1 2

98 (72)

994

Plug; PT3/4

1

539 (398)

33-143

33

33. UPPER SLEWING STRUCTURE (2) Swing reduction unit

20

22 11 27 25 24 4 5 10

3 SURFACE OF LUBE OIL

23 7 11 26 9 14 28 29

3 6 8 15 12 17

34

3

VIEW 30 31

3

35, 36, 37, 38

18 32

33 13 16 2 1

21 19

DETAIL aa

aa

Sectional View Of Swing Reduction Unit Tightening torque N-m (lbf-ft)

No.

Parts

Q'T Y

Tightening torque N-m (lbf-ft)

No.

Parts

Q'T Y

1

Pinion

1

20

Plate

1

2

Shaft

1

21

Ring

1

3

#1 Sungear

1

22

Thrust washer

6

4

#1 Planetary pinion

3

23

Thrust washer

8

5

#1 Spider assembly

1

24

Snapring

1

6

#2 Sungear

1

25

Snapring

3

7

#2 Planetary pinion

4

26

Spring pin

4

8

Ring gear

1

27

Capscrew ; M20X200

12

9

#2 Spider assembly

1

28

Grease fitting

1

10

Shaft

4

29

Relief fitting

1

11

Needle bearing

11

69.1±4.4 (51±3)*2

30

Tube

1

12

Roller bearing

1

69.1±4.4 (51±3)*2

31

Elbow

1

13

Roller bearing

1

69.1±4.4 (51±3)*2

32

Plug

1

14

Oil seal

1

33

Cap

2

15

Housing

1

34

Capscrew

3

16

Oil seal

1

35

Shim ; t=0.1

1

17

Sleeve

1

36

Shim ; t=0.2

1

18

Sleeve

1

37

Shim ; t=0.3

1

19

Plate

1

38

Shim ; t=0.5

1

539±54 (398±40)*1

279±30 (206±22)*1

33-144

33. UPPER SLEWING STRUCTURE 33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR 33.2.5.2.1 Tools

33 Tools Socket wrench

Allen wrench

Remarks

Relief valve M33 P1.5 Anti-reaction valve M22 P1.5

41mm 24mm

M8, M20

6,10,12,17mm

ROMH PLUG ROH PLUG

M36 P1.5

17mm

PF1/4, PF1/2, PF1 6mm, 8mm, 14mm

Screwdriver

Flat-bladed type, medium size 2 pcs.

Steel bar

10 8 200(0.39" 0.31" 7.87") (key material) 1 pc.

Hammer

Plastic hammer 1 pc.

Torque wrench N•m (lbf•ft)

10~45 (7.2~33) 40~180 (29~130) 120~480 (87~350)

Slide hammer bearing puller 14 (0.551")

85 (3.35") 75 (2.95") 30 (1.18")

35 (1.38")

15 (0.591")

" 92

)

8 (0.315")

30 (1.18") 14 (0.55")

100 (3.94")

M16 Through

M16 (0.158")

44 (1.73")

Brake piston drawing tool

.4 (0

DRAWING TOOL

o 8 (0.315")

BRAKE PISTON CASING

33-145

33. UPPER SLEWING STRUCTURE 33.2.5.2.2 Disassembly (1) General cautions 1. Hydraulic components are precision products and have small clearance. Therefore, assemble and disassemble in a less dusty clean place. Use clean tools and cleaning oil and handle components with full care. 2. If a component is removed from the main body, clean the area around the ports thoroughly and plug them up so no dust and water can enter. When fitting them back to the body, do not remove the plugs till piping is completed. 3. Study the structural drawing before the work begins and prepare necessary parts according to your purpose and the scope of work. Seals and O-rings once removed can not be used again. Some parts cannot be supplied as single parts and are available only in sub assemblies. Prepare such parts according to the parts manual. 4. The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a matching mark on the piston and the cylinder block. (2) Disassembly procedure The figures in parentheses after part names in this manual represent those item numbers in Figure "Swing Motor". 1. Draining oil Remove the drain plug and drain hydraulic oil from casing (301). 2. Preparation for removing the valve casing. Fix the motor on a work bench so the drive shaft (101) end comes down. On that occasion, put a matching mark on the mating parts of casing (301) and valve casing (303). Choose a clean place, and lay with a rubber sheet or a cloth on a work bench. Handle the valve casing with care so parts do not get damaged.

052 051

303 712 702

101

301

Removing Valve Casing (303) 3. Loosen relief valve (051) and separate it from valve casing (303). Tools: Spanner: 41 mm 4. Loosen anti-reaction valve sub assembly (052) and remove from valve casing (303). (See above Fig.) Tools: Allen wrench: 6 mm 5. Separate ROMH plug (469) from valve casing (303) and draw out spring (355) and plunger (351). Tools: Allen wrench: 17 mm

Removing Relief Valve (051), Anti-Reaction Valve (052), Anti-Cavitation Plunger (351) And Valve Casing (303)

33-146

33. UPPER SLEWING STRUCTURE 6. Loosen socket bolt (401) and separate valve casing (303) from casing (301). If the socket bolt (401) is loosened, the valve casing floats off the casing (301) by the force of the brake spring (712). Then separate valve plate (131) from valve casing (303). Tools: Allen wrench: 17 mm 7. Draw out brake spring (712) from brake piston (702).

33

Removing Brake Piston (702) 8. Put the claw of the brake piston removing jig in the concaved part of brake piston (702). Tighten 2 bolts of jig simultaneously, and draw out the brake piston (702) with the jig, from the casing. 9. Lay the motor on its side again and draw out cylinder block (111) from drive shaft (101). Then draw out piston (121), set plate (123), spring (114) and shoe plate (124).

123 121 111 122

124 101

301

742

743

Drawing Cylider Block (111), Piston Sub Assembly, Friction Plate (742) And Separator Plate

Handle the parts with care so you do not score the sliding surfaces of cylinder block (111) and shoe (122).

33-147

33. UPPER SLEWING STRUCTURE 10.Draw out friction plate (742) and separator plate (743) from casing (301). 11. Draw out drive shaft (101) from casing (301), while lightly tapping the side face of valve casing (303) in drive shaft (101), using a plastic mallet. -Do the following work as required.

Removing Drive Shaft (101) a. Draw the inner race of roller bearing (443) from drive shaft (101) using a press. Do not reuse the removed bearing. b. Draw out the outer race of roller bearing (443) from casing (301), by lightly tapping a steel rod from the oil seal (491) housing side. (Do not reuse the bearing.) c. Separate the outer race of roller bearing (444) from valve casing (303), using a slide hammer bearing puller.

Removing Inner Race Of Roller Bearing (443)

33-148

33. UPPER SLEWING STRUCTURE 33.2.5.2.3 Assembly (1) General precautions 1. Repair those parts damaged after disassembly and prepare replacement parts before hand. 2. Clean all parts thoroughly in cleaning oil and dry them with compressed air. 3. Always coat the moving parts with clean hydraulic oil before assembly. 4. Replace such seals as O-rings and oil seals in principle. 5. Tighten socket bolts and plugs to specified torques, using a torque wrench.

33

(2) Assembly procedure The figures in parentheses after part names in this manual represent those item numbers in the Figure "Swing Motor". 1. Preparation for assembly Place casing (301) on a proper bench so the valve casing (303) faces upward. This operation is necessary only when the roller bearing is removed. 2. Shrink fit the inner race of roller bearing (443) into drive shaft (101).

Assembling The Inner Race Of Bearings (443 and 444) 3. Shrink fit the inner race of roller bearing (444) to drive shaft (101). This operation is necessary only when the oil seal is removed. Fit oil seal (491) to casing (301). On this occasion, coat the lip of the oil seal with grease and check the direction of it before fixing it. 4. Assemble the outer race of roller bearing (443) into casing (301) by lightly tapping the steel rod. 5. Attach drive shaft (101) to casing (301). 443

491

101

301

Fitting Oil Seal (491), Outer Race Of Roller Bearing (443), And Drive Shaft (101)

33-149

33. UPPER SLEWING STRUCTURE 6. Place casing (301) as shown in Right Fig. and insert shoe plate (124). On this occasion, the shoe plate does not come off if it is coated with grease.

Inserting Shoe Plate (124) 7. Set the set plate (123) and spring (114), then set piston sub-assembly (121 and 122). 8. Assemble piston sub assembly (121 and 122) fixed in retainer plate (123) into cylinder (111). Match it to the spline of drive shaft (101) and insert it in place.

Inserting Cylinder Assembly 9. Replace casing (301) with oil seal (491) facing downward and assemble separator plate (743) and friction plate (742) into casing (301), in that order. Assemble four separator plates and three friction plates.

743 742

491

301

Position of separator plate (743)

PG PORT

Installing Of Separator Plate (743), Friction Plate (742)

33-150

33. UPPER SLEWING STRUCTURE

Assemble the same phases of four slits in the gears of friction plate (742). Assemble four slits in the four claws of separator plate (743) in the position shown in Figure "Installing Of Separator Plate (743), friction Plate (742)." 10.Fit O-rings (706 and 707) to casing (301). In this case, if the O-rings are coated with grease, they are hard to tear off when brake piston (702) is inserted. 11. Assemble brake piston (702) into casing (301). 12.Assemble brake spring (712) into brake piston (702). In this case, make sure the spring is placed securely in the spot faced part of the brake piston. This operation is necessary only when the roller bearing (444) is removed.

Assembling Brake Piston 13.Insert the outer race of roller bearing (444) into valve casing (303), while lightly tapping the steel rod placed on the outer race, using a hammer. 14.Assemble valve plate (131) into valve casing (303) and fit O-ring (472) in it. 15.Install valve casing (303) to casing (301) and fasten them with socket bolts (401). Tools: Allen wrench: 17 mm, Tightening torque: 431 N-m (320 lbf-ft) 16.Fit plunger (351) and spring (355) to valve casing (303). Then tighten ROMH plug (469) fitted with O-ring (488) against valve casing (303). Tools: Allen wrench: 17 mm, Tightening torque: 539 N-m (398 lbf-ft) 17.Fit relief valve (051) to valve casing (303). Tools: Spanner: 41 mm, Tightening torque: 177 N-m (130 lbf-ft) 18.Fit anti-reaction sub assembly (052) to valve casing (303). Tools: Allen wrench: 6 mm, Tightening torque: 29 N-m (22 lbf-ft)

33-151

33

33. UPPER SLEWING STRUCTURE 33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT 33.2.5.3.1 Tools

Code

Tool name

Remarks

a

Q520 (20.5") Q390 (15.4") 230 (11.8")

Material : Mild steel

Stand

o 180 (7.1") o 153 (6.0")

Spherical bearing (13) removing jig

130 (5.1")

b

t=4.5 (0.177")

Spherical bearing (12) removing jig

o

Material : Mild steel

d

Oil seal (16) installing jig

0 10 4") .9 (3

Q190 (7.48") Q162 (6.38")

9 (0.354")

c

o 150 (5.91") o 132 (5.2")

o 186 (7.32")

f

Oil seal (14) installing jig

g

Spherical bearing (12) press-fit jig

o 160 (6.3")

o 125 (4.92") o 195 (7.68")

33-152

9 (0.354")

120 (4.72") or more

Spherical bearing (13) press-fit jig

60 (2.36")

e

33. UPPER SLEWING STRUCTURE

Code

Tool name

Remarks

i

Snap ring plier

For shaft

j

Torque wrench

140 N-m (100 lbf-ft) class

k

Plastic hammer (Wooden mallet)

m

Press

n

Flat-bladed screw driver

p

General tools

Allen wrench, Steel bar

Thread sealant

Three Bond #1360K

Sealant

Loctite #515

q

33

30 ton (66150 lb) class

33.2.5.3.2 Disassembly The numbers in parentheses correspond to the ones in construction drawings Figure "Swing Motor." (1) Preparation 1. Before disassembly, clean the outside of the reduction unit thoroughly and check for damage and scoring. 2. Drain gear oil from the reduction unit. 3. Disconnect the drain tube. 4. Matching Mark To facilitate the reassembly of the unit, put a matching mark on the joining parts of the housing before disassembly. (2) Disassembling swing motor from reduction unit 1. Preparation for disassembly. Place the reduction unit assembly on a stable work bench as shown in Right Figure. Remove plug (32), drain out oil and put a matching mark on the matching surface shown in the figure on the right. 2. Removing swing motor assembly. Loosen all socket bolts (27) (M20). Attach eye bolts (M12) in the lifting bolt holes in the top surface of the swing motor and lift the assembly by crane. If it is hard to remove the swing motor assembly from the reduction unit, float it by inserting a flatblade screwdriver in the groove of the flange. Tools: Allen wrench: 17 mm

27

MATCHING MARK

32

Removing Swing Motor Assembly

33-153

33. UPPER SLEWING STRUCTURE (3) Disassembling reduction unit 1. Remove #1 sun gear (3). 2. Removing #1 spider assembly (5). The spider assembly (5) [consisting of thrust washer (22), #1 pinion (4), needle bearing (11) and snap ring (25)] can be removed from the spline easily if it is lifted up in this position.

5

3

4

8

15

Removing #1 Sun Gear And #1 Spider Assembly 3. Removing ring gear (8). Attach eye bolts (M16) to the top surface of ring gear (8) and lift the ring gear lightly with a wire sling. Put a flat-blade screwdriver (n) into the matching surface of ring gear (8) and housing (15) and remove ring gear (8) by lightly tapping the outer circumference of the ring gear with a plastic mallet (k).

#2 SPIDER ASSY 8

15

Removing Ring Gear (8) 4. Remove #2 sun gear and #2 spider assembly. Draw out #2 sun gear (6) and remove the #2 spider assembly. Regarding the disassembly of the #2 assembly, refer to paragraph (4) which will come up later.

#2 SPIDER ASSY 6

Removing #2 Spider Assembly Particularly if no failure is found, the further disassembly (under condition shown in Right Fig.) is not allowed. Check on parts for possible failure according to the inspection procedure shown in item 33.2.5.4.2 separately in this condition. And we recommend that the pinion shaft and housing assembly are replaced together as one set. But if it is unavoidably necessary to replace a part of them, follow the procedure shown below. If no failure is found in this step, the disassembly later is not required.

33-154

33. UPPER SLEWING STRUCTURE 5. Remove pinion (1) Place housing (reduction) (15) upwards. Loosen 3 capscrews (M16X40) and remove plate (20). Attach eyebolt (M8) to pinion (1) and hoist pinion (1). Tools: Socket: 24mm

EYE BOLT (M8)

34

33

20 1 16

When oil seal (16) is separated from housing (15), oil seal (16) and pinion (1) are removed together. 15

6. Remove plate (19) Remove ring (21) from groove of housing (15) using flat blade driver (n). And remove plate (19).

DRIVER 19

21 15

Removing Plate (19) 7. Pulling out shaft Pull shaft (2), sleeve (18) and spherical bearing (lower) (13) out by means of press while supporting housing (15) as shown in the figure.

PRESS 2 12

Spherical bearing (upper) (12) and oil seal (14) are left in the housing.

14 18 15 13

JIG (a)

Pulling Out Shaft (2)

33-155

33. UPPER SLEWING STRUCTURE 8. Removing spherical bearing (lower) (13). Pull sleeve (18) and spherical bearing (lower) (13) out by means of jigs (b) while supporting pinion shaft assembly as shown in the figure. Press force : 30t Do not use the removed bearing.

PRESS PLATE JIG (b)

18

13 2

Removing Spherical Bearing (Lower) (11) 9. Removing spherical bearing (upper) Set housing (15) as shown in the figure, insert jig (c) between bearing (12) and oil seal (14) and remove bearing (12) by striking it from the upper side. 10.Remove oil seal (14) from housing (15).

HAMMER (k) FLAT-BLADE STEEL BAR SCREWDRIVER 14

Do not use the removed oil seal and bearing. 12

15

JIG (c)

Removing Spherical Bearing (Upper) (12) And Oil Seal (14) (4) Disassembling spider assembly (1) Disassembling #1 spider assembly a. Remove retaining ring (25) with a plier (i). b. Remove thrust washers (22), pinion (4), and needle bearing (11).

25

11 22 4 22

Disassembling #1 Spider Assembly

33-156

5

33. UPPER SLEWING STRUCTURE

The shaft attached to spider assembly (5) is caulked. When replacing parts, replace the spider assembly as a set. Pinions (4) cannot be replaced separately. Replace them it in a set of three. (2) Disassembling #2 spider assembly a. Drive spring pin (26) into shaft (10) using steel bar 8 to 9 in diameter. b. Draw out shaft (10) from spider (9) and remove thrust washer (23), pinion (7) and needle bearing (11).

23

7

10

9

11 23

26

Disassembling #2 Spider Assembly

Pinions (7) cannot be replaced separately. Replace them it in a set of four.

33-157

33

33. UPPER SLEWING STRUCTURE 33.2.5.3.3 Assembly (1) Preparation 1. Sufficiently clean every part with wash oil and dry it with compressed air. 2. Check on every part for failure. (2) Assembling pinion (1), shaft (2) 1. Attach oil seal (16) to pinion (1) by means of jig (d). JIG (d)

16

1

Attaching Oil Seal (16) 2. Applying gear oil. Apply gear oil to the perimeter of the axis of shaft (2) lightly to prevent seizure. 3. Fitting spherical bearing (lower) Seal sufficient grease in spherical bearing (lower) (13) and after inserting sleeve (18), press fit it in shaft (2) by means of jig (e). Press force : 4~5t Since the bearing is formed with a partition at the center section, seal grease in it from both sides.

Fitting Spherical Bearing (Lower)

33-158

33. UPPER SLEWING STRUCTURE 4. Apply sufficient grease to the pinion shaft assembly. Grease : Lithium extreme-pressure grease (SHELL Albania EP2 or equivalent): 1.7kg (3.75 lbf)

33

Apply Grease (3) Placing shaft assembly. 1. Place housing (15) on level bench. 2. Attach eye bolt to screw (M10) at the axis end of shaft assembly, and perpendicularly hang up pinion shaft assembly and place it in the housing. Horizontally orient the outer race of spherical bearing and insert it in by striking lightly. If the outer race is tilted, it is hard to insert even if striking. Then do not force to insert it in, but take it away once and horizontally orient the outer race twice and insert it in again.

15

Placing Pinion Shaft Assembly 3. Assembling plate (19). Place plate (19) and attach ring into groove of housing, and fix plate.

19

21 15

Assembling Plate (19)

33-159

33. UPPER SLEWING STRUCTURE 4. Installing pinion (1) Attach eyebolt (M18) to pinion (1), and hoist it, then insert into shaft (2). Install pinion (1) securely by hammering. Attach plate (20) to shaft (2) by tightening 3 capscrews (34) (M16X40), and install it on pinion (1). Tools: Socket: 24mm Tightening torque : 279N-m (206 lbf-ft) (Apply Three Bond #1360K)

a

24

b 20 1 2 15

Adjust this gap to be within 0.05 to 0.15mm (0.002 to 0.006 inch) by shim.

20

34 VIEW b

SHIM

DETAIL a

Installing Pinion (1) 5. Set housing assembly so that the pinion directs downward. 6. Fit oil seal (14) in housing (15) by means of jig (f).

JIG (f)

Apply Loctite #515 to the perimeter of oil seal. Fill one third (1/3) of the space of the grooveshaped section provided on the oil seal (12) lip with grease. Insert it horizontally giving attention to the lip on oil seal so it is not damaged.

14 15

7. Press fit spherical bearing (upper) (12) in shaft (2) and housing (15) at the same time by means of jig (g). In this case insert sleeve (17) in advance.

Spherical Bearing (Upper) Press-Fitting

33-160

33. UPPER SLEWING STRUCTURE (4) Assembling spider assembly 1. Assembling #1 spider assembly a. Coat the bore surface of pinion (4) with grease. Put pinion (4) on thrust washer (22) and assemble needle bearing (11) into the bore surface.

25

33

11 22 4 5

22

Assembling #1 Spider Assembly b. Fit thrust washers (22) and pinion (4) as in below Fig. and fit snap ring (25) by means of pliers (i). Motor side

SNAP RING (25)

i

22 5 25

4

Fixing Snap Ring

Fix the snap ring with the sharp edge on the motor side (top side in the position of above Fig.). 2. Assembling #2 Spider assembly a. Coat the bore surface of pinion (7) with grease. Put pinion (7) on thrust washer (23) and fit needle bearing (11) to the bore surface. b. Fit thrust washer (23) and pinion (7) as in Right Fig. insert shaft (10) into spider (9) and drive spring pin (26).

GEAR SIDE

Caulk two points with a punch.

Beware the direction of spring pin

6~7mm (0.24~0.28 in) 23

7

SLIT

VIEW I

6~7mm (0.24~0.28 in)

10

11 23 26

Assembling #2 Spider Assembly

33-161

9

33. UPPER SLEWING STRUCTURE

Insert shaft (10) into spider (9) so spring pin hole (26) is aligned. In this case, direct the oil hole of shaft (10) to outside of spider assembly. (5) Installing #2 spider assembly Insert #2 spider assembly in spline axis of shaft (2). #2 SPIDER ASSY

Assembling #2 Spider Assembly (6) Installing #2 sun gear (3) Install #2 sun gear (3) directing the spline upward. 3

Installing #2 Sun Gear (3) (7) Installing ring gear (8) Apply a thin film of sealant Loctite #515 to the matching surface of housing (15) and ring gear (8) and assemble them, aligning the gear teeth according to the matching marks made before disassembly.

#2 SPIDER ASSY 8 Align maching marks. 15

Installing Ring Gear (8)

33-162

33. UPPER SLEWING STRUCTURE (8) Installing #1 spider assembly 1. Mesh the #1 spider assembly with ring gear (8) and set them in place. 2. Mesh #1 sun gear (3) with #1 pinion (4) and set them in place.

3

#1 SPIDER ASSY 8

4

15

Installing #1 Spider Assembly (9) Fit drain tube (30) and plug (32). Tools: Allen wrench: 10 mm (10)Filling Lube Oil Fill in 7.4L (2.0gal) of gear oil SAE90 (API Service Grade GL-4). (11) Installing swing motor assembly. Attach eye bolts (M12) in the tapped holes of the swing motor and put a wire sling in them. Coat the matching surface of ring gear (8) with sealant Loctite #515. Insert the spline joint of the swing motor and match the matching marks. Coat socket bolts (27) with sealant Three-Bond 1360K and fasten them. Tools: Allen wrench: 17 mm, Tightening torque: 539 N-m (398 lbf-ft)

M20 X 200 27

MACHING MARKS

Installing Swing Motor Assembly

33-163

33

33. UPPER SLEWING STRUCTURE 33.2.5.4 MAINTENANCE STANDARDS 33.2.5.4.1 Swing motor (1) Replacement standards for parts The following are the standards to determine whether or not parts may be reused from values taken at disassembly. These are only general standards and in case the motor displays poor performance or parts show extreme damage and discoloration before disassembly, it is important to determine how many parts should be replaced, depending upon the purpose of disassembly and the remaining service life of the motor that the user expects.

Item

Standard Dimension mm (in)

Recommended Value for Replacement mm (in)

0.032 (0.0013)

0.062 (0.0024)

Replace piston or cylinder.

0

0.3 (0.0112)

Replace piston and shoe assy.

6.0 (0.236)

5.8 (0.228)

Replace piston and shoe assy.

4.0 (0.157)

3.6 (0.142)

Replace.

Remedy

Clearance between piston and cylinder bore (D-d)

Gap between piston and caulked part of shoe ( )

Thickness of shoe (t)

Thickness of friction plate

33-164

33. UPPER SLEWING STRUCTURE (2) Standard for correcting sliding surfaces If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the parts. Standard for correcting sliding surfaces Name of parts

• •

Standard surface roughness

Surface roughness requiring correction

Shoe

0.8-Z (Ra=0.2) (lapping)

3-Z (Ra=0.8)

Shoe plate

0.4-Z (Ra=0.1) (lapping)

3-Z (Ra=0.8)

Cylinder

1.6-Z (Ra=0.4) (lapping)

12.5-Z (Ra=3.2)

Valve plate

0.8-Z (Ra=0.2) (lapping)

6.3-Z (Ra=1.6)

Lap each sliding surface to a standard roughness level or finer. If the spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts in pairs.

33-165

33

33. UPPER SLEWING STRUCTURE 33.2.5.4.2 Swing reduction gear (1) Inspection at disassembly 1. Spacer and thrust washer a. Inspect that the parts are not seized or worn abnormally or unevenly. b. Inspect and measure the parts to see that the wear does not exceed the allowable values. 2. Gears a. Inspect that the gear teeth do not show pitting and seizure. b. Inspect by dye penetrant examination that the bottom of the teeth do not show cracks. 3. Bearing Turn the bearing and check that it does not develop abnormal sounds, catching and other faults. Do not reuse spherical bearing. 4. O-rings and oil seals Do not reuse O-rings and oil seals; always replace them with new ones at reassembly. (2) Inspection after assembly 1. Operation Check to see that the #1 sun gear (3) is not faulty when turned by hand. 2. Checking for oil leaks and oil condition Check for oil leak. Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish with gear oil SAE90 (API Service Grade GL-4).

33-166

33. UPPER SLEWING STRUCTURE (3) Maintenance standards

33 LUBE OIL LEVEL

Unit : mm (in) Code

Item

A

Wear in #1 planetary shaft

B

C

Wear in #2 planetary shaft

Gears

Condition of tooth face

Repairable level ø43

0 -0.009

ø43

0 -0.009

D

Thickness of thrust washer

1.6

E

Thickness of thrust washer

1.6

+0.1 -0.1

H

Wear in shaft 0 (Diameter of part coming in contact ø150 -0.100 with oil seal ) Socket bolt tightening torque Lube oil

Gear oil SAE90 (API Service Grade GL-4)

1.693"

0 -0.0004"

No flaking

There should be no cracks. +0.1 -0.1

G

0 -0.0004"

There should be no pitting exceeding 1.6mm (0.0630in) dia, abnormal wear or seizure.

Condition of tooth flank

F

1.693"

Service Limit

Remedy Replace entire spider assy. Replace four shafts as a set. Replace (Planetary pinion should be replaced in a set of four.)

0.063"

+0.0039" 0.0039"

1.4

0.0551"

Replace

0.063"

+0.0039" 0.0039"

1.4

0.0551"

Replace

ø149.9

5.90"

Replace

5.91"

0 -0.0004"

M20 — 539 N•m (398 lbf•ft)

Apply Three-Bond 1360K and tighten to specified torque.

7.4 L (2.0 gal)

Replenish or replace.

33-167

33. UPPER SLEWING STRUCTURE 33.2.5.5 TROUBLESHOOTING 33.2.5.5.1 Swing motor (1) Hydraulic motor does not rotate. Trouble Pressure does not rise.

Cause

Remedy

1. Relief valve pressure in circuit is not adjusted correctly. 2. Malfunction of relief valve. 2-1. Sticking plunger. 2-2. Orifice on plunger is clogged. 3. Plunger seat is faulty. 4. Anti-reaction valve seat is faulty.

Pressure rises

1. Overload. 2. Moving parts are seized. 3. Brake release pressure is not working on the motor 4. Brake piston is stuck. 5. Spool for releasing brake is stuck. 6. Friction plate is seized.

1. Set to correct value. 2. Correct the stuck areas or replace the plunger. 2-1. Correct the stuck areas or replace the plunger. 2-2. Disassemble and clean. 3. Check the seat surface and replace the plunger if scored. 4. Replace the anti-reaction valve cartridge or block. 1. Eliminate overload. 2. Inspect and repair piston, shoe and cylinder valve plate. 3. Check circuit and correct it. 4. Disassemble and check. 5. Disassemble and check. 6. Disassemble, check and repair.

(2) Rotating direction is reverse. Trouble Rotating direction is reverse.

Cause

Remedy

1. Motor's assembling direction is reversed. 2. Piping inlets and outlets are reversed.

1. Assemble correctly. 2. Pipe correctly.

(3) Revolution does not rise to set value. Trouble

Cause

Remedy

Revolution does not rise to set value

1. Oil inflow is deficient. 2. Oil leaks are excessive due to high temperature. 3. Sliding surfaces are worn or damaged.

1. Check pump's delivery rate and circuits to motor. 2. Lower oil temperature. 3. Replace.

33-168

33. UPPER SLEWING STRUCTURE (4) Brake torque is insufficient. Trouble

Cause

Brake torque isinsufficient.

1. Friction plate is worn.

Remedy

1. Disassemble and check. Replace if wear is beyond standard value. 2. Disassemble and check. 2. Brake piston is stuck. 3. Brake release pressure is not released. 3. Check and correct circuit. 4. Disassemble and check. 4. Break release spool is stuck. 5. Disassemble and check. Replace damaged 5. Spline of friction plate is damaged. part.

(5) The swing motor drifts much. Check the drain rate of the hydraulic motor. If it is less than 4 L/min (1.1 gal/min), you should think that the motor is not faulty. Trouble

Cause

Remedy

The swing motor 1. Relief valve malfunctions. Same as (1). drifts much when 2. Plunger seat is faulty. it is actuated by 3. Seat of the anti-reaction valve is no good. external torques. (e.g. Machine is on a slope.)

1. Replace. Same as (1). 2. Replace. 3. Replace the anti-reaction valve cartridge or block.

(6) Oil leaks 1) Oil leak from oil seal Trouble Oil leaks from oil seal

Cause

Remedy

1. Lip of seal catches contaminant and damaged. 2. Shaft is damaged or worn.

1. Replace oil seal. 2. Shift the lip and shaft positions or replace oil seal. 3. Repair drain piping if clogged up.

3. Casing inner pressure has risen abnormally high, with the result that lip of oil seal is flipped. 4. Disassemble and correct. 4. Shaft is rusted. 2) Oil leak from matching surface Trouble Oil leak from matching surface

Cause

Remedy 1. Set O-ring correctly and assemble it. 2. Replace. 3. Disassemble and correct. 4. Tighten to specified torque or replace.

1. O-ring is missing. 2. O-ring has a scratch. 3. Seal surface has a scratch. 4. Bolt is loose or damaged.

33-169

33

33. UPPER SLEWING STRUCTURE 33.2.5.5.2 Reduction unit

33-170

33. UPPER SLEWING STRUCTURE 33.2.6 SWIVEL JOINT

33

33.2.6.1 CONSTRUCTION VIEW

Construction Of Swivel Joint No.

Part name

Q'TY

No. 7 8 9 12 13

1 2 3 4 5

Body Stem Thrust plate Cover Seal

1 1 1 1 5

6

Seal assembly

1

33-171

Part name O-ring (G95 1A) Socket bolt (M8X20) Socket bolt (M8X30) Plug O-ring (P80)

Q'TY 1 2 3 1 2

33. UPPER SLEWING STRUCTURE 33.2.6.2 DISASSEMBLY AND ASSEMBLY 33.2.6.2.1 Tools

No. a b

Tool Name

Used for

Remarks 1. Steel hammer

Hammer

2. Wooden or plastic mallet Rubber mat Wrench

Disassembly Assembly

c

750 mm (30in) square or more 1. Allen wrench 2. Double-ended and single-ended wrench 3. Extension pipe

d

Torque wrench

Assembly

98 N•m (72 lbf•ft)

Pin e

Grind the tip of "a nail" to shape as a screwdriver.

Disassembly

Spatula

Make from a hack-saw blade

Disassembly Assembly

f

Approx. 120mm (4.72in)

Vinyl tape

g

Vise

h

Loctite

i

Lubricating oil

j

Cleaning oil

Disassembly Assembly

Remove the edge completely and make corner round smooth.

Vise movable over 150mm (6in) # 242 Hydraulic oil or vaseline

33.2.6.2.2 Apparatus (1) Hoist or crane The lifting device should be capable of lifting the swivel joint assembly. (2) Work bench The work bench should have an area of 1.2mX1.5m (4ftX5ft). (3) Others Also prepare cloth, wooden block and oil pan. 33.2.6.2.3 Cleaning outside Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil. • Keep all ports plugged up while cleaning.

33-172

33. UPPER SLEWING STRUCTURE 33.2.6.2.4 Disassembly The part numbers used in this disassembly procedure correspond to those on a construction drawing in Figure "Construction Of Swivel Joint". (1) Removing cover 1. Mark cover (4) and body (1) with matching marks for convenient reassembly. 2. Place a V-block on a work bench, place a swivel joint set on the side, fix it and loosen socket bolt (9) by means of a pipe and wrench. Alternately, the swivel joint may be fixed by holding stem (2) in a vise. Tools: Allen wrench:6 mm

Removing Cover (4) 3. Remove cover (4) from body (1) and draw out Oring (7) from cover (4).

Removing O-ring (7) (2) Removing thrust plate Loosen socket bolt (8) fastening thrust plate (3), in the same manner as the removing of the above-mentioned cover. Tools: Allen wrench:6 mm

Removing Thrust Plate (3)

When removing thrust plate (3) by fixing body (1), support stem (2) so it does not fall down.

33-173

33

33. UPPER SLEWING STRUCTURE (3) Removing stem Place body (1) on a V-block. Put a wooden block against stem (2) via the body so about half of the stem is covered by the wooden block and knock it out using a mallet. By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand. Stem weight: 10.5 kg (23 lbs)

Drawing Out Stem (2) (4) Removing sealing parts 1. Remove rings (13) of seal assemblies (6) and (5) with spatula (f).

Removing O-Ring (13)

Pay attention to the body (1) so it is not damaged by the top edge of spatula (f). 2. Pierce slipper ring of seal assemblies (6) and (5) with pin (e) and remove them from the seal groove. Right Fig. shows only one pin, but use two pins to remove it securely.

Removing Out Seal Assembly (5)(6)

33-174

33. UPPER SLEWING STRUCTURE 33.2.6.2.5 Assembly Prior to assembly, clean each part (excluding the O-ring and seal), and arrange in the sequence of assembly. Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (13). (1) Assembling seals to body 1. Apply hydraulic oil to O-ring (13) thinly and insert it in O-ring groove. Check the twist of O-ring 2. Slipper ring is assembled, after first inserting the backup ring, by slightly-distorting the shape as shown in Right Fig. Also after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula. 3. Assemble seal (5) by the same procedure as above.

Inserting Slipper Ring (6)

Remove grease, hydraulic oil and vaseline from the groove of seal. And insert seal (5). Seals (5) have no back-up ring. (2) Assembling stem Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease or vaseline and slowly insert stem (2) into body (1).

Inserting Stem (2)

If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly. The clearance between body (1) and stem (2) is about 0.1mm (0.004in). Push stem straight along the shaft center.

33-175

33

33. UPPER SLEWING STRUCTURE (3) Assembling thrust plate 1. While holding stem (2) and body (1), match the hole of thrust plate (3) and the stem (2) hole. 2. Next, after removing any oil from the thread of socket bolt (8), coat it with Loctite #242 and tighten to stem (2). Tools: Allen wrench:6 mm, Tightening torque: 30.4 N-m (22 lbf-ft)

Tightening Socket Bolt (8) (4) Assembling cover After installing O-ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (9) with Loctite #242 and tighten it, which will then complete the assembly. Tools: Allen wrench:6 mm, Tightening torque : 30.4 N-m (22 lbf-ft)

Tightening Socket Bolt (9)

33-176

33. UPPER SLEWING STRUCTURE 33.2.6.3 MAINTENANCE STANDARDS 33.2.6.3.1 Inspection procedure and remedy

33 Interval 2,000 hr 4,000 hr In principle, disassemble and check regardless of oil leakage or not. When disassembled for repair

Check Item Seal for oil leakage outside

Checking Procedure Check oil leakage outside

Remedy Replace O-ring or dust seal , if any oil leakage can be found. Replace all sealing parts such as slipper seal with back-up ring and Oring.

All sealing parts

All sliding parts

Check abnormal wear, scoring or corrosion caused by foreign debris or seizure.

Repair or replace, referring to their limit of service.

All parts

Check them for seizure, foreign debris, abnormal wear, and defective seals.

Repair or replace, referring to their limit of service. O-rings and dust seals should be replaced.

33.2.6.3.2 Service limit of the parts Parts Sliding surface with sealing sections

Body, Stem

Sliding surface between body and stem other than sealing sections

Sliding surface with thrust plate

Cover

Sliding surface with thrust plate

Maintenance Standards

Remedy

Plating worn or peeled due to seizure or contamination.

Replace

1. Worn abnormally or damaged more than 0.1 mm (0.004 in) in depth due to seizure or contamination.

Replace

2. Damaged less than 0.1 mm (0.004 in) in depth.

Smooth with oilstone.

1. Worn more than 0.5 mm (0.02 in) or abnormally.

Replace

2. Worn less than 0.5 mm (0.02 in).

Smooth

3. Damage due to seizure or contamination repairable within wear limit 0.5 mm (0.02 in).

Smooth

1. Worn more than 0.5 mm (0.02 in) or abnormally.

Replace

2. Worn less than 0.5 mm (0.02 in).

Smooth

3. Damage due to seizure or contamination repairable within wear limit 0.5 mm (0.02 in).

Smooth

33-177

33. UPPER SLEWING STRUCTURE Parts

Maintenance Standards

Remedy

1) Protruded excessively from seal groove.

Replace (With back-up ring)

2) Slipper ring 1.5mm (0.06in) narrower than seal groove, or narrower than back-up ring.

Slipper ring

1.5mm (0.02in) (max.)

Replace (With back-up ring)

BACKUP RING 3) Worn unevenly more than 0.5mm (0.02in)

Replace (With back-up ring)

33-178

33. UPPER SLEWING STRUCTURE 33.2.6.3.3 Inspection after assembly After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in Right Fig. (1) High pressure port (A, B, C, D and F port) Install a directional valve and pressure gauge to the stem side port and body side port respectively, and while watching the pressure gauge (for high pressure) installed on the body side and also by regulating the high pressure relief valve (7), gradually increase the pressure and when the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) and lock in the hydraulic oil in the swivel. Keep stop valve (6) on the low pressure relief valve side closed at this time. Check that it is free from looseness, deformation, breakage, etc. under three minutes of pressurizing. And, the oil leakage must be checked for the first 1 minute, and if there is a pressure drop for any reason, the pressure drop should be in 10% of the trapped pressure. This checking must be carried out for every circuit.

Hydraulic Circuit For Inspection Equipment (2) Low pressure port (E port) Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side. Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure) connected to the body side and also by regulating the low pressure relief valve (5), gradually increase the pressure and check for outside leakage with a color check at a pressure of 0.49 MPa (71 psi).

33-179

33

33. UPPER SLEWING STRUCTURE 33.2.6.3.4 TROUBLESHOOTING

Trouble

Cause

Remedy

1. External leakage of hydraulic oil

Defective O-ring & seal

Replace all seals.

2. Internal leakage of hydraulic oil

1) Defective slipper seal 2) Sliding face worn excessively

1) Replace all seals. 2) Replace assembly.

3. Swivel stem seized

1) Stem and body seized

1) Grind and hone. Replace assembly, if stem and body are too loose and causing oil leakage. 2) Reinstall Secure 2 to 3 mm (0.08 to 0.12 in) allowance for bolt stopper.

2) Inappropriate swivel stopper bracket 4. Loose swivel stem and cover Socket bolt tightened insufficiently.

33-180

Retighten.

34. TRAVEL SYSTEM

34

34. TRAVEL SYSTEM TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING .........................................................................34-3 34.1.1 TRAVEL SYSTEM .....................................................................................34-3 34.1.2 CRAWLER .................................................................................................34-3 34.1.3 UPPER ROLLER .......................................................................................34-8 34.1.4 LOWER ROLLER ......................................................................................34-15 34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ..............................................34-23 34.1.6 SPROCKET ...............................................................................................34-29 34.1.7 TRAVEL MOTOR ......................................................................................34-32 34.1.8 SWING BEARING ......................................................................................34-35 34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT .................................34-39 34.2.1 TRAVEL MOTOR .......................................................................................34-39 34.2.2 CONSTRUCTION OF REDUCTION UNIT ................................................34-41 34.2.3 TRAVEL MOTOR ASSEMBLY ...................................................................34-42 34.2.4 TRAVEL MOTOR ASSEMBLY ...................................................................34-50 34.2.5 TRAVEL MOTOR .......................................................................................34-55 34.2.6 TRAVEL MOTOR TROUBLESHOOTING ..................................................34-58 34.2.7 REDUCTION UNIT DISASSEMBLY ..........................................................34-61 34.2.8 ASSEMBLING ............................................................................................34-67 34.2.9 MAINTENANCE STANDARD ....................................................................34-73

Book Code No. S5LC3426E01 34-1

34. TRAVEL SYSTEM

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC3426E01 NA

September, 2010 SK350-9: YC

PREFACE (1) This Manual describes all the procedures from removing to attaching, arranging them by item. (2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling. (3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving, some processes can be omitted. (4) The removing and attaching procedure does not completely cover all possible situations because of differences in field conditions and defective sections. (5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then start working.

34-2

34. TRAVEL SYSTEM

34.1

REMOVING AND INSTALLING

34.1.1 TRAVEL SYSTEM

34 8. SWING BEARING 2. CRAWLER 7. TRAVEL MOTOR 5. FRONT IDLER

6. SPROCKET

GUARD

LOWER FRAME 3. UPPER ROLLER

GREASE NIPPLE OF THE TRACK SPRING ADJUSTER

4. LOWER ROLLER

Designation And Location Of Undercarriage

34.1.2 CRAWLER 34.1.2.1 REMOVING CRAWLER (1) Position the machine to remove crawler. (2) Pushing out master pin. 1. Find the master pin and place it in its removing/fixing position shown in right Figure. 2. Loosen the grease nipple and slacken crawler tracks. Tools: Socket: 19 mm

Crawler Removing Position

When loosening the grease nipple of the adjuster, do not loosen it more than one turn.

34-3

34. TRAVEL SYSTEM Where grease does not come out well, move the machine back and forth. The over loosening of grease nipple may cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple. 3. Pushing out master pin. Remove stopper pin at the end of the master pin, hold a tool against the master pin, and hit it with a hammer. (Refer to Fig. "Press Fitting Of Master Pin")

STOPPER PIN

REMOVING / FIXING POSITION OF MASTER PIN

Removing/Fixing Position Of Master Pin

When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by flying objects. (3) Removing crawler Put attachment on ground so that weight is not loaded to the lower frame, and remove track link assy rotating sprocket.

Removing Crawler Tracks

Crawler track end section may fall on the ground incurring danger of injury. Please keep well away from the equipment.

34-4

34. TRAVEL SYSTEM 34.1.2.2 INSTALLING Installing is done in the reverse order of removing. (1) Checking crawler track installation direction. Place the track links on the ground so they converge, facing the front idler, as shown in the figure on the right.

Front idler side

34

Installing Direction Of Crawler (2) Installing crawler 1. Preparation for installation. Treat paint flaking protection with care not to damage lower flame. 2. Winding crawler. Insert a crowbar into the master pin hole, lift the lower frame 1 to 2 cm above the ground level by holding it by hand so the machine body weight is not exerted on the shoe. Retract the sprocket to help push the back winding of the crawler. (3) Preparation for press fitting master pin. 1. Preparing for installation. Put square wood under the shoe plate. 2. Aligning master pin holes. Aligning master pin holes through the fine adjustment turning sprocket.

Winding Crawler

When using a big hammer, exercise care so you are not injured by flying objects the same way as when pushing out the master pin. Coat the master pin with molybdenum disulfide grease, before pressing it in. (4) Press fitting of master pin. Apply the press fitting jig on master pin, and strike it with a mallet to press fit.

Press fitting jig on master pin

Press Fitting Of Master Pin

34-5

34. TRAVEL SYSTEM (5) Set the stopper pin. (6) Adjusting crawler track tension (See right Fig.) After installing, adjust tension of crawler. Tools: Socket: 19 mm

A

Adjusting Crawler Track Tension 34.1.2.3 CONSTRUCTION

1-3

1-8

1

1-1 1-4

7

1-7 1-2 1-6

3,4,5

1-5 1-11

1-9

1-10

6

Track Link Assy And Shoe Plate

SK350LC-9 SHOE LC60D00011F3 ASSY LC60D00011F1 NAME No. .Link assy LC62D00004F2 2 2-1 ..Track link R 2-2 ..Track link L 2-3 ..Master link R 2-4 ..Master link L 2-5 ..Bushing 2-6 ..Pin 2-7 ..Master bushing 2-8 ..Master pin 2-9 ..Collar 2-10 ..Seal 2-11 ..Pin .Shoe 600mm 3 .Shoe 800mm 5 .Bolt LC60D01001P1 6 .Nut 2420Z1414 7

Q'TY 1 1 46 46 46 46 2 2 2 2 46 46 46 46 2 2 2 2 4 4 92 92 2 2 48 - 48 192 192 192 192

34-6

34. TRAVEL SYSTEM 34.1.2.4 MAINTENANCE STANDARDS

G

E D B

F D

34 C

A

H

No.

ITEM

215.9 (8.5000

A Link pitch

+0.05

B O.D. of bushing C

68.0 0

Height of link

124

Interference between bushing and link

0.15 0.0059) +0.0020

(2.6772 0

0.25 (4.8819

Basic dimension D

REPAIRABLE SERVICE LEVEL LIMIT

STANDARD VALUE

220 (8.66) )

0.0098)

Tolerance

64 (2.52)

224 (8.82)

Replace the link assy if the service 63 (2.48) limit is exceeded

118 (4.65)

116 (4.57)

Fit

Fit

68.0 (2.6772)

+0.05 Interference Interference 0.05 Shaft (+0.0020) 0 0 (0.0020)

E

46.0 Interference between track pin (1.8110) and link

Interference +0.05 Interference 0.05 Shaft (+0.0020) 0 (0.0020) 0

F

Interference between master pin and link

45.63 (1.7965)

Interference +0.05 Interference 0.05 Shaft (+0.0020) 0 (0.0020) 0

G

Clearance between links

H

Tightening torque of shoe bolt

1.5 (0.06) (both side)

8 (0.32) (both side) 1180 N.m (870 ft.lbs)

REMEDY

10 (0.39) (both side)

Replace

Replace link

Replace Reassembly

34.1.2.5 TOOLS AND JIGS (1) Tightening tools

(2) Jig

Unit : mm NAME Socket

NAME

OPPOSING FLATS 19, 32

Master pin fixing jig for iron crawler

34-7

SHAPE

34. TRAVEL SYSTEM 34.1.3 UPPER ROLLER 34.1.3.1 UPPER ROLLER ASSY UPPER ROLLER ASSY No. ITEM 1 2 3 4

NAME ROLLER ASSY CAPSCREW WASHER NUT

LC64D00003F1 Q'TY 4 4 8 4

REMARKS 24100N7035F3 M20X150

34.1.3.2 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) M20X150. Tools: Socket: 30 mm

4

3

3

2

1

Removing Upper Roller 34.1.3.3 INSTALLING Installing is done in the reverse order of removing. (1) Inspection Before reassembling, check that it rotates smooth manually and for leaks. (2) Installing upper roller (1). 1. To install the upper roller, turn up nut (4) toward the center of machine. 2. Insert it until collar comes in contact with support. 3. Apply Loctite #262 on capscrew M20X150, and tighten it to the specified torque. Tools: Socket: 30 mm Tightening torque: 539 N-m (400 lbf-ft)

Center of machine

3,4

1

2,3

Installing Upper Roller

34-8

34. TRAVEL SYSTEM 34.1.3.4 CONSTRUCTION

ROLLER ASSY PART No. 24100N7035F3 No. 1 2 3 4 5 6

NAME ROLLER SHAFT COLLAR PLATE COVER BUSHING

Q’TY No. 8 1 9 1 10 1 11 1 13 1 1

5

Q’TY NAME 1 O-RING 1A P95 SOCKET BOLT 2 PLUG PT1/4 1 SNAP RING 1 FLOATING SEAL 1

4

13

1

3

10

34

11

8

6

Construction Of Upper Roller 34.1.3.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1. Draining out oil. Remove plug (10) and drain out oil. Tools: Allen wrench: 6 mm 2. Removing snap ring (11). Mount the end face inside upper roller (1) on stand jig (f) and separate snap ring (11), using snap ring pliers. 3. Removing cover (5). Take off cover (5) upwards, utilizing the screwed hole for the plug.

11 9 4

8 10 5

f

4. Removing O-ring (8). Separate O-ring (8) from cover (5). 5. Removing plate (4). Loosen 2 socket bolts (9) and draw out plate (4) from roller (1). Tools: Allen wrench: 10mm 6. Removing shaft (2). Put the extrusion jig (h) against the end face of shaft (2) and push shaft (2) with collar (3) for floating seal (13), using a press or hammer.

Construction Of Upper Roller

h 2 13 3

f

Extruding Shaft

34-9

2

34. TRAVEL SYSTEM 7. Removing floating seal (13). (Upper roller side) Take out floating seal (13) from roller (1).

13 1

Taking Out Floating Seal 8. Removing floating seal (13). (Shaft side) Remove from collar (3), floating seal (13) that is located on the side where shaft (2) was disassembled.

13 3 2

Removing Floating Seal And Extruding Bushing

Collar (3) is press fitted into shaft (2). Therefore do not disassemble it. 9. Removing bushing (6). Since the bushing is thin, machine it on a lathe or scrape it off, take care not to damage the bore of roller (1). If the bushing is not worn much, mount upper roller (1) on jig (f), insert jig (g) into the end face of bushing (6) and push it out with a press.

Push with press. i 6

1 f

Pushing In Bushing

34-10

34. TRAVEL SYSTEM (2) Assembly Assembly of the upper roller is done in the reverse order of disassembly. 1. Place upper roller (1) on the top end face of jig (f), with its floating seal setting side facing down. 2. Confirm that the outer surface of bushing (6) is not scuffed and coat the outer surface of the inserting side of the bushing, with molybdenum disulfide grease. 3. Put jig (i) into bushing (6) and press it in, using the bore of the bushing and the bore of the roller as guides.

13

13

3

1

2

Fixing Floating Seal

If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In that case, do not reuse the bushing as it may develop malfunctioning after assembly. 4. Installing floating seals (13). Two floating seals (13) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1).

2

1

Prior to placing floating seal (13) in, apply engine oil lightly to seal surface. 5. Inserting shaft (2). Coat shaft (2) with a thin film of oil and insert it into upper roller (1).

Inserting Shaft

34-11

34

34. TRAVEL SYSTEM 6. Installing plate (4). Mount upper roller (1) on the stand jig (f) and attach plate (4) to the end face of the shaft with bolt (9). Tools: Allen wrench: 10 mm, Tightening torque: 114.7 N-m (85 lbf-ft) 7. Installing O-ring (8) Fit O-ring (8) to the groove of cover (5). Apply grease to O-ring. 8. Installing cover (5). Attach cover (5) to upper roller (1). Use a press in this operation as a press fit is required. 9. Installing snap ring (11). Fix snap ring (11) into upper roller (1), using snap ring pliers.

11 9

8

4 5 1

f

Installing Cover 10.Filling oil. Fill in 100cc (6.1cu-in) of engine oil API grade CD #30 through the plug hole in cover (5). 11. Installing plug (10). Wind seal tape around plug (10) and screw it into the plug hole of cover (4). Tools: Allen wrench: 6mm, Tightening torque: 23 N-m (17 lbf-ft)

5 1

After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by hand. f

Filling Oil

34-12

34. TRAVEL SYSTEM 34.1.3.6 MAINTENANCE STANDARD

C D

D

J

F

E

B

A

34

H

Unit : mm (in) No. A B C D

ITEM Dia.

185 (7.28)

175 (6.89)

Tread dia.

160 (6.30)

150 (5.91)

Width

95 (3.74)

85 (3.35)

Flange width

19 (0.748)

15 (0.591)

Basic dimension E

SERVICE LIMIT

STANDARD VALUE

Clearance between shaft and bushing

F

Interference between roller and bushing

H

Tightening torque of socket bolt

J

Oil Roller rotation

65 (2.5591)

70 (2.7559)

Tolerance

Standard

Shaft

-0.025 (-0.0010) -0.040 (-0.0016)

Clearance 㧙

Hole

+0.030 (+0.0012) 0

Interference 㧙

REMEDY Reinforcement weld, repair or replace

Limit Clearance 0.8 (0.0315) Replace bushing. Clearance 0

114.7 N.m (85 lbf.ft)

Apply loctite #262

Engine oil API grade CD #30, 100cc (6.1cu.in)

Refill or replace

Roller rotates smoothly by hand.

34-13

34. TRAVEL SYSTEM 34.1.3.7 TOOLS AND JIGS (1) Tightening tools

Unit : mm NAME

OPPOSING FLATS 30

Socket

6, 10

Allen wrench (2) Jigs

Unit : mm (in) No.

NAME

SHAPE

Bushing fixing jig

(1.18")

i

50(1.97")

64.6

(2.74")

(1.953" +0.004" ) 0

h

For extruding shaft

+0.1 0

Stand jig

69.5

f

200 (7.87")

160 (6.30") 120 (4.72")

20 65 (2.56") (0.787")

85 (3.35")

34-14

34. TRAVEL SYSTEM 34.1.4 LOWER ROLLER 34.1.4.1 LOWER ROLLER ASSY

ROLLER ASSY NAME No. 1 LOW ROLLER 2

LC LC64D00004F3 REMARKS Q'TY

CAPSCREW

18

LC64D00005F1

72

M22 X 105

1 2 Apply loctite #262 T=731N.m (540 lbf.ft)

Lower Roller Assy And Track Guide 34.1.4.2 REMOVAL (1) Preparation for removal 1. Loosen the tension of the crawler, lift up the lower frame by the front attachment and stop the engine in that position. 2. Place a safety block (wood) at the front and back of the lower frame.

SAFETY BLOCK (SQUARE TIMBERS)

Preparation For Removal (2) Removing track guide. Remove capscrews (8) M24X52 and remove track guide (5). Tools: Socket: 36 mm, Weight of track guide : Approx. 39 kg (86 lbs) LOWER GROUP

No. 2 5

SK350LC-9

LC

LC01F00034F1

NAME TRACK GUIDE ; LC63D00004P1 CAPSCREW ; M24 X 52

Q'TY 2 8

2

5

SK350LC-9

Installing Track Guide (3) Remove lower roller. Remove capscrews (2) and remove lower roller (1). Tools: Socket: 32 mm, Weight of lower roller: Approx. 57 kg (126 lbs)

Installing Lower Roller

34-15

34

34. TRAVEL SYSTEM 34.1.4.3 INSTALLATION (1) Installation of lower roller. Coat mounting capscrews (2) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified torque. Tools: Socket: 32 mm, Tightening torque: 731 N-m (540 lbf-ft) (2) Installation of track guide. Capscrews (5) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified torque. Tools: Socket: 36 mm, Tightening torque: 932 N-m (690 lbf-ft) (3) Adjusting tension of crawler. Tighten grease nipple and fill it with grease. Tools: Socket: 19 mm, Tightening torque: 59 N-m (43 lbf-ft)

34.1.4.4 CONSTRUCTION

Lower roller No. 1 2 3 4 5 6 7 8

Name ROLLER COLLAR SHAFT BUSHING PIN FLOATING SEAL O-RING PLUG

4 1 6

LC64D00005F1 Remarks Q'ty 1 2 1 2 2 2 1A G70 2 PT1/4 2

2

7 5 2

3

Construction Of Lower Roller

34-16

8

34. TRAVEL SYSTEM 34.1.4.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1. Remove plug (8) and drain out oil. Tools: Allen wrench: 6mm 2. Removing pin (5). Put both ends of lower roller assembly on the Vshaped blocks (K), apply push-out bar (L) on upper end face of pin (5), and push pin (5) out striking with mallet.

L 2

34

5

K

Pushing Out Collar Fixing Pin (5) 3. Removing collar (2), O-ring (7). Put lower roller on jig (M) for repair stand so that the shaft (3) is perpendicularly located, apply pushout jig (P) on shaft end on upper side, and push shaft (3) until the O-ring (7) separate from collar (2) with press or mallet, and take out collar (2). 4. Removing shaft (3) Reverse the top and bottom of the lower roller, push shaft (3), and remove collar (2) and O-ring (7) as one unit.

7

Jig P 2 1 3 Jig M

Removing Shaft (3), Collar (2)

The shaft (3) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil container beforehand. 5. Removing collar (2), O-ring (7). Remove O-ring (7) from shaft (3) that was drawn out in the previous paragraph. 6. Removing floating seal (6). Remove floating seal (6) from collar (2).

6

2

Removing Floating Seal (6)

34-17

34. TRAVEL SYSTEM 7. Removing floating seal (6). Remove floating seal (6) from roller (1).

6 1

Removing Floating Seal (6) 8. Removing bushing (4). Since thickness of bushing (4) is thin [thickness is 3.9mm (0.154in)], remove it with a lathe or strip it with care, so as not to damage inner hole of roller. When the wear of bushing is not too much, place upper roller (1) on jig (M) for repair stand and apply the end of push-out jig (N) on the end face of bushing (4) end, and push it out striking it with mallet.

N 1

4

Jig M

Extruding Bushing (4)

Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (N) uniformly over the circumference of bushing (4) and extrude it perpendicularly little by little. (2) Installing 1. Attach O-ring (7) to one side. Install O-ring (7) to groove on shaft.

7

3

Grease O-ring. Replace O-ring with new one without fail at reassembling. Attach O-ring (7) To One Side

34-18

34. TRAVEL SYSTEM 2. Press fitting bushing (4). Align inner hole of roller (1) and bushing (4) and press fit it vertically in capacity of press fit load of 5 ton (10,000 lbs), in the condition that bushing pushin jig (Q) is inserted into bushing (4).

Jig Q 4

Apply molybdenum disulfide grease on press-fit section of bushing, and press fit it in ordinary temperature. Bushing which fails to press-fit because of the oneside pressing should not be fitted.

34

Press Fitting Bushing (4) 3. Press fitting collar (2). Fit O-ring (7) to the one side of shaft (3) mating pin hole of collar (2) where floating seal (6) is fit with pin hole of shaft (3) in advance. Use the press capacity of 17 ton (37500 lbs) or more.

PRESS PIN HOLE 2

6

Care should be taken not to damage O-ring (7) while press-fitting collar (2) to shaft (3).

PIN HOLE 3

Press Fitting Collar (2) 4. Inserting pin (5). Press-fit pin (5) to pin hole on aligning pin holes of shaft (3) and collar (2).

6 5

3

2

Inserting Pin (5) 5. Attach floating seal (6) to roller side. Fit floating seal (6) to inner holes on both ends of roller (1).

1

Check that the seal surface is free from flaws, rust, etc. before reusing the floating seal.

6

6. Inserting roller (1). Insert roller (1) from the side where collar (2) is not press-fitted to the shaft (3).

3 2

7

Inserting Roller (1)

34-19

7

34. TRAVEL SYSTEM 7. Installing O-ring (7). Install O-ring (7) to groove on shaft. Grease O-ring. Replace O-ring with new one without fail at reassembling.

Press

2

8. Press fitting collar (2). Press-fit collar (2) to shaft (3). Press-fit collar (2) on aligning pin (5) hole.

PIN HOLE

7

3

9. Inserting pin (5). Press-fit pin (5) in to the pin hole mating pin hole of collar (2) with pin hole on the end side of shaft (3).

Installing O-Ring (7), Collar (2) 10.Filling oil. Remove plug (8) and fill in 430cc (26.14cu-in) of engine oil API grade CD #30. 11. Check it for leaks. Before tightening plug (8), check it for leaks with air pressure of 0.2MPa (29psi). 12.Installing plug (8). Apply oil resistant sealant on plug (8), and tighten it in the plug hole on the collar (2) end face. Tools: Allen wrench: 6 mm, Tightening torque: 21.6 to 24.5 N-m (15.9 to 18.1 lbf-ft)

8 Apply anaerobic sealant Tightening torque 23N.m (17 lbf.ft)

2

Installing Filling Oil Plug (8)

After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by hand.

34-20

34. TRAVEL SYSTEM 34.1.4.6 MAINTENANCE STANDARD

C

G

34

A

B

E

D

C

Lower Roller (Track Roller)

Unit : mm (in) No. A B C

D

ITEM

STANDARD VALUE

O.D. of flange Tread dia.

216 (8.50) 175 (6.89)

Flange width

27 (1.06)

Clearance between shaft and bushing (Wrapped bushing)

E

Interference between roller and bushing

F

Oil

G

Plug (8) Roller rotation

Basic dimension

Shaft

83 (3.2677)

Hole

-0.060 (-0.0024) -0.090 (-0.0035)

(

SERVICE LIMIT

㧙 160 (6.30)

Tolerance

75 (2.9528)

REPAIRABLE LEVEL

㧙 154 (6.06)

㧙

㧙

Fit

Fit

Clearance 0.7 (0.276)

Clearance 1.0 (0.394)

0.030 Interference 0.0012) 0.01 (0.0004)

REMEDY Reinforcement weld, repair or replace

Replace bushing.

Clearance 0

Engine oil API grade CD #30, 430cc (26.14cu.in)

Refill

Execute air leak test at 0.2MPa (28psi) before tightening the plug. Rotates smoothly by hand.

34-21

Reassembly

34. TRAVEL SYSTEM 34.1.4.7 TOOLS AND JIGS (1) Tightening tools

Unit : mm NAME

OPPOSING FLATS 19, 32, 36

Socket

6

Allen wrench (2) Jig

Unit : mm (in) NAME

K

V-block

L

Pin (5) extrusion rod

N

Bushing extrusion rod

SHAPE

6.5 (0.26")

No.

16 (0.630")

150 (5.91")

300 (11.8")

175 (6.89")

P

Shaft extrusion jig

400 (15.7") (2.91")

Stand jig

74

M

150 (5.91")

400 (15.7")

70 (2.76")

Q

30 (1.18") 100 (3.94")

104 (4.09")

Bushing fixing jig 74.6 +0.1 0 (2.94" +0.004 ) 0

34-22

34. TRAVEL SYSTEM 34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) 34.1.5.1 FRONT IDLER ASSY

FRONT IDLER ASSY No. 1 3 4 7

Name IDLER ASSY CAPSCREW GREASE NIPPLE IDLER ADJUST ASSY

Apply loctite #262 or equivalent T=540N.m (400 lbf.ft) 1

LC52D00026F4 Q'ty 1 2 1 1

Remarks

7

3

LC52D00032F1 M20 X 55

34

LC54D00009F4 The grease nipple is on the outer side of the frame 4 T=58.8N.m (43 lbf.ft)

Front Idler Assembly 34.1.5.2 REMOVING (1) Preparation for removal. Remove crawler. (Above mentioned) (2) Removing idler assembly. Sling idler assembly, and push it forward with bar. Weight of front idler assembly (one side): 362 kg (798 lbs). (3) Installing Installing is done in the reverse order of removing.

BAR

Removing And Installing The Front Idler

Keep away from the front side of front idler. (4) Where idling assembly (1) has to be separated. Loosen capscrew (3), and separate idler assy (1) from idler adjuster assy (7). Tools: Socket: 30 mm Weight of idler assy : 176 kg (388 lbs) Weight of idler adjuster assy : 190 kg (419 lbs)

1

7

The separated idler assy (1) should be placed on square timbers.

3

Separating Idler Assy (1) From Idler Adjuster

34-23

34. TRAVEL SYSTEM 34.1.5.3 IDLER ASSY 34.1.5.3.1 CONSTRUCTION

IDLER ASSY No. 1 2 3 4 5 6 7 8

NAME IDLER COLLAR SHAFT BUSHING PIN FLOATING SEAL O-RING PLUG

LC52D00032F1 Q'TY 1 2 1 2 2 2 2 2

REMARKS

6 2 7 5 3

LC52D00033P1 LC52D01017P1

8

I

4 1

VIEW I

1A G80 PT1/8 Idler Assembly

34.1.5.3.2 REMOVING AND INSTALLING (1) Removing 1. Drain oil. Remove plug (8) on the side of collar (2) to drain. Tools: Allen wrench: 5 mm 2. Removing pin (5). Apply pin push bar (jig R) to the top of pin, and push out striking bar (jig R) lightly with hammer.

5

R

Removing Pin (5) 3. Removing collar (2). Put idler (1) on stand (U), apply push-out jig (S) on shaft (3), push out shaft (3) with collar (2), then remove collar (2).

Push with press 3

S 2 1

U 2

Removing Collar (2) 4. Removing collar (2) from shaft (3). If removal of collar (2) on the opposite side is required, turn over front idler and proceed with the procedure described in Par. 3.

Push with press

3

S

2

U

Removing Collar (2)

34-24

34. TRAVEL SYSTEM 5. Removing bushing (4). With idler (1) mounted on the stand, tap bushing (4) lightly by hammer, while placing the bushing drawing rod (T) against the end face of bushing (4) evenly all around, till it comes out. 6. Removing floating seals (6). Take out floating seals (6) from idler (1) and collar (2). If you intend to re-use floating seals (6), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing card board between the sealing faces. 7. Removing O-ring (7). Separate O-ring (7) from shaft (3). (2) Assembly 1. Pressing in bushing (4). Align inner hole of idler (1) and bushing (4) and press fit it vertically with press so that jig (V) for bushing press-fitting is inserted into bushing (4). 2. Installing O-ring (7). Fit O-ring (7) to O-ring groove on shaft (3). Apply grease to O-ring.

1

T

4

U

Removing Bushing (4)

4

1

Push with press V

Pressing In Bushing (4) 3. Installing collar (2). Press fit the O-ring (7) installed side of shaft (3) into collar (2), and drive pin (5). 4. Installing floating seal (6). Fit the half of floating seal (6) on each side of collar (2) and idler (1).

PRESSING 3

2 5

Installing Collar (2), Shaft (3) 5. Inserting idler (1). Insert floating seal (6) fitted side of idler (1) into shaft (3). 6. Installing floating seal (6). Fit floating seal (6) on the other side of idler (1).

3

6 1

Inserting Idler (1) And Installing Floating Seal (6)

34-25

34

34. TRAVEL SYSTEM 7. Installing collar (2) Fit the half of floating seal (6) on the other collar (2), press fit it in shaft (3), and drive pin (5) in with hummer. 8. Filling oil-Inspection Fill in 350cc (21.36cu-in) of engine oil API grade CD #30 through the plug hole of collar (2), wind seal tape and tighten plug (8). Tools: Allen wrench: 5 mm Tightening torque : 17 N-m (12 lbf-ft)

8

2 5 1

Installing Collar (2) And Filling Oil After installing the idler assy to the idler adjuster assy, make certain there are no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly. 34.1.5.3.3 MAINTENANCE STANDARD 204 (8.03") C

D

E

B

A

F

Front Idler

Unit : mm (in)

564 (22.2)

REPAIRABLE LEVEL 㧙 557 (21.9)

SERVICE LIMIT 㧙 554 (21.8)

102 (4.02)

96 (3.78)

94 (3.70)

Fit

Fit

Clearance 1.5 (0.059)

Clearance 2.0 (0.079)

No.

ITEM

STANDARD VALUE

A B C

Dia. Of idler projection

609 (24.0)

Tread dia. Flange width

Basic dimension D

Clearance between shaft and bushing

E

Interference between idler and bushing

F

Oil Idler rotation

85 (3.3465)

Tolerance Shaft

-0.072 (-0.0028) -0.126 (-0.0050)

REMEDY Replace

Replace bushing.

+0.035 Interference 89 Clearance (+0.0014) Hole 0.01 (3.504) 0 0 (0.0004) (0) Engine oil API grade CD #30, 350cc (21.4cu.in)

Refill

Rotates smoothly by hand.

Reassembly

34-26

34. TRAVEL SYSTEM 34.1.5.3.4 TOOLS AND JIGS (1) Tightening tools

Unit : mm NAME

OPPOSING FLATS 30

Socket Allen wrench

5

No.

NAME

SHAPE

R

Pin striking jig

34

(2) Jigs

30 (1.18")

18 (0.71")

Unit : mm (in)

15 150 (5.91") (0.591")

Shaft push out jig

16 (0.63)

S

84 (3.31")

400 (15.7")

350 (13.8")

T

Bushing drawing rod

Applox 200 (8") Applox 800 (32")

U

Stand Applox 500 (20")

Bushing press fitting jig

82 (3.23")

V

84.6

100 (3.94")

115 (4.53")

18 (0.71")

2 Piece

+0.1 0

(3.33" +0.004 ) 0

30

W Collar press fitting jig

(1.18")

120 (4.72")

34-27

34. TRAVEL SYSTEM 34.1.5.4 IDLER ADJUSTER ASSY 34.1.5.4.1 CONSTRUCTION

LC54D00009F4

IDLER ADJUSTER ASSY No. 1 2 3 4 5 6 7 8 9 10

Name

Q'ty

GREASE CYLINDER SPRING BRACKET NUT SPRING PIN OIL SEAL O-RING PISTON PIN COLLAR

1 1 1 1 1 1 1 1 2 1

3

4

5

2

1

6 7

Remarks

M64 X P3 10 X 90

9

Idler Adjuster Assembly

1B G90

34.1.5.4.2 MAINTENANCE STANDARD No.

10

ITEM

STANDARD VALUE

A

Installed length of spring

554mm (21.8in)

B

Free length of spring

C

Stroke

53mm (2.09in)

D

Set length

797mm (31.4in)

E

Outside view of piston

F

Tightening torque of grease nipple

About. 660.5mm (26.0in)

Nor scoring and rusting 59N-m (43 lbf-ft)

E

C

F

A, B D

34-28

8

34. TRAVEL SYSTEM 34.1.6 SPROCKET 34.1.6.1 REMOVING (1) Preparation for removal. Remove crawler referring to "34.1.2 CRAWLER". Lift up crawler frame with attachment, and put it on square timbers to float and stabilize.

34

Preparation For Removal (2) Removing sprocket. Loosen 26 capscrews (3) M20X55, for the attaching of the sprocket by means of a socket and remove the sprocket (1). Weight of sprocket: 75 kg (165 lbs) Tools: Socket: 30 mm

3

1

Removing Sprocket 34.1.6.2 INSTALLING (1) Check before installing. Check the mating portion of the travel reduction unit and the sprocket, eliminate burrs and contamination thoroughly and install the sprocket. (2) Installing sprocket temporarily. Coat the sprocket attaching capscrews (3) with Loctite #262 and fasten the sprocket temporarily. (3) Installing sprocket completely. Remove the wooden blocks under the frame, bring the machine down on the ground and tighten the sprocket. Tools: Socket: 30 mm Tightening torque: 539 N-m (400 lbf-ft)

34-29

Installing Sprocket Completely

34. TRAVEL SYSTEM 34.1.6.3 MAINTENANCE STANDARD (LC51D01008P1)

PITCH

215.9 mm (8.5 in)

NUMBER OF TEETH

21

ROLLER DIA.

ø 68 mm (2.68 in)

PITCH DIA.

ø 732.47 mm (28.8 in)

SPECIFICATION

C

A

B

Sprocket

Unit : mm (in) NAME

STANDARD VALUE

A O.D. of sprocket

755 (29.7)

No.

0

REPAIRABLE LEVEL

0

B Width of sprocket teeth

85 -4 (3.35 -0.157)

C O.D. of sprocket bottom

664.05 (26.1)

745 (29.3) Reinforcement weld, repair or replace.

79 (3.11)

77 (3.03)

656 (25.8)

654 (25.7) Reinforcement weld, repair or replace.

(1) Tools

Unit : mm

Socket

Remedy

747 (29.4)

34.1.6.4 TOOLS AND JIGS

NAME

SERVICE LEVEL

OPPOSING FLATS 30

34-30

Replace.

34. TRAVEL SYSTEM (2) Sprocket tooth profile gauge: W

34

0 -4 (30.

5"

0 -0.15 ) 7"

(0.256")

6.5

P.C.D 732.47 (28.84") +2

.21 0 R34 +0.08" ) 5" 0 (1.3

(0.256")

6.5

60

215.9

1.5 (8.50"

0.591")

775

R34 . (1.3 21 +02 5" +0.08 " 0 )

")

664.05 (26.14

R-5 (0.2")

Tooth Profile Gauge (Full Scale)

34-31

34. TRAVEL SYSTEM 34.1.7 TRAVEL MOTOR 34.1.7.1 TRAVEL MOTOR

TRAVEL MOTOR No. 1 1-1 1-2 1-3 2

NAME

Q'TY TRAVEL MOTOR ASSY (2) TRAVEL MOTOR ASSY 2 2 SPROCKET 52 CAPSCREW 36 CAPSCREW

LC53D00012F1

Apply loctite #262 or equivalent T=539N.m (400 lbf.ft)

1-1

REMARKS

1-3

LC53D00013F1 LC15V00031F1 LC51D01008P1 M20 X 55 M24 X 65

1-2 2

Apply loctite #262 or equivalent T=932N.m (690 lbf.ft)

Installing Travel Motor

34.1.7.2 REMOVING (1) Preparation for removal. Remove crawler, lift up crawler frame using attachment, and put it on square timbers to float and stabilize. To release inner pressure from the hydraulic circuit after stopping the engine. Put the starter switch in the "ON" position and, with the safety lock lever in operating condition, operate the left / right travel lever in full stroke several times and press the travel 1-2 speed change switch several times to release the inner pressure from the hydraulic circuit. When you press the valve from above the gum cap of the air breather on top of the hydraulic tank, the internal pressure of the hydraulic tank is released. (2) Removing cover (1). Remove sems bolt (6) M12X25 and also remove covers (1). Tools: Socket: 19 mm (3) Preparation of oil pan.

34-32

6

1

Apply loctite #262 or equivalent T=115N.m (85 lbf.ft)

Removing And Installing Cover (1)

34. TRAVEL SYSTEM (4) Removing hydraulic pipe. Release pressure from travel circuit, and bleed air in hydraulic oil tank, then remove all pipes connecting to travel motor. Then plug up all pipes and joint section to protect them from entry of dust. Tools: Spanner: 19 mm, 27 mm, 32 mm, 41 mm Refer to "Hydraulic pipe plug" 5.1 (See Chapter 11. TOOLS) "Plug For Flare Hose" 5.2 (3) (See Chapter 11. TOOLS)

34 Removing And Installing Hydraulic Pipe

(5) Removing sprocket. Removing twenty two (one side) capscrews (6-3) M20. Tools: Socket: 30mm

6-3

Removing And Installing Sprocket (6) Loosening travel motor attaching bolts (3). Apply match marks on travel motor and crawler frame, and remove eighteen (one side) capscrews (3) M24. Tools: Socket: 36mm

REMOVE PIPES (DISCONNECT)

3

Removing And Installing Travel Motor Attaching Bolts (7) Slinging travel motor assembly. Sling travel motor with nylon sling applied on the side close to sprocket installing section and remove the motor. Weight of motor: About. 400 kg (882 lbs)

Slinging Travel Motor

34-33

34. TRAVEL SYSTEM 34.1.7.3 INSTALLING Installing of the travel motor piping is performed in the reverse order of removal. 1. Cleaning. Check that the contact surface of travel motor and crawler frame are free from burr and stain. 2. Tightening torque. Tighten capscrew and hydraulic pipes to the torque specified in "Tightening Torque". 3. Fill inside from motor drain port to casing with hydraulic oil before piping for drain. When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.

NAME

SIZE

Tightening TOOLS No. torque REMARKS HEX N.m (lbf.ft)

SEMS BOLT M12

19

6

83 (61)

M24

36

3

932+93 (690+69)

M20

30

6 3

539+54 (398+40)

CAPSCREW FLARELESS PF1/4 19 NUT FOR PF3/4 36 PIPES, 35 X 5.0 55 SLEEVE

29.4 (21.7) 118 (87) 441 (325)

PF1/4 PF1/2 CONNECTOR PF3/4 PF1

36 (26.6) 108 (80) 162 (120) 255 (188)

34-34

19 27 36 41

Apply Loctite #262

34. TRAVEL SYSTEM 34.1.8 SWING BEARING 34.1.8.1 SWING BEARING ASSY

SWING BEARING ASSY No.

NAME

1 2

SWING BEARING CAPSCREW

LC40F00019F1 Q'TY

REMARKS

1 LC40F00018F1 36 M24 X 80

34 Front

Inner S zone position of swing bearing

1

2

SECTION AA Swing Bearing Assembly 34.1.8.2 REMOVING (1) Matchmarks. Remove upper structure, apply matchmarks on inner race of swing bearing and lower frame. (2) Remove 36 capscrews (2) M24X80 for installation of inner race. Tools: Socket: 36 mm

SWING BEARING OUTER RACE INNER RACE MATCHMARKS

Matchmarks (3) Removing grease. Remove grease in grease bath. (4) Removing swing bearing. Attach eyebolt on swing bearing and sling it. Weight of swing bearing: 540 kg (1190 lbs)

SWING BEARING EYE BOLT

GREASE BATH

Removing And Installing Swing Bearing

34-35

34. TRAVEL SYSTEM 34.1.8.3 INSTALLING (1) Cleaning. Clean it completely so that installing surfaces of swing bearing and lower frame are free from dust and dirt. (2) Installing. Install swing bearing on lower frame meeting the matchmarks and positioning the S mark on inner race as shown in the right Figure. (3) Temporary fastening of inner race. Coat the threads of the capscrews (2) with Loctite #262 and tighten all the capscrews (2) temporarily. Tools: Socket: 36 mm

Front

Inner S zone position of swing bearing

Location Of S Mark On Swing Bearing (4) Regular tightening of inner race. Tighten the capscrews (2) at 180 degrees intervals alternately to a specified torque. Tools: Socket: 36 mm, Tightening torque: 932 N-m (690 lbf-ft) (5) Filling grease. Fill grease bath with 28.7 g (63 lbs) of grease "NIPPON Grease NIGLUBE EP-2K" or equivalent.

1

2 Apply Loctite #262 or equivalent T=932N.m (690 lbf.ft)

SECTION AA Removing And Installing Capscrew (2) 34.1.8.4 CONSTRUCTION

ASSY PART No. No.

NAME

1 2

OUTER RACE

3 4 5

6

LC40F00018F1 Q'TY No.

1 INNER RACE 1 BALL 105 RETAINER 105 SEAL 1

6 7 8 9

NAME SEAL TAPER PIN PLUG GREASE NIPPLE (PT1/8)

1

Q'TY 1 1 1 1

8

9

7

3,4 5

2

Sectional View Of Swing Bearing

34-36

34. TRAVEL SYSTEM 34.1.8.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1. Remove seal (5) fitted in the groove in the outer circumference under inner race (2) and seal (6) fitted in the groove in the inner circumference on top of outer race (1) and place them level on a square wooden block or something. 2. Remove taper pin (7), using a hammer and an extrusion rod. 3. Remove plug (8), utilizing a pull bolt inserted in the screwed hole (M10) in the center of the plug and using a puller.

EYE BOLT 7

2

6

1 SQUARE WOODEN BLOCK 8 5

Disassembling Swing Bearing 4. While rotating outer race (1) little by little, take out ball (3) and retainer (4) through plug hole, in that order.

1

3

4

2

Removing Balls (3) And Retainers (4) (2) Installing 1. Thoroughly remove the grease from the groove of seal (6) located on the inner surface of the outer race (1) and from the groove of the seal (5) located on the surface of the inner race (2). Apply the adhesive (Cyano Bond PX-3000 or equivalent) to the seal (5) and stick the seal (5) into the groove continuously. Then place the inner race (2) on wood blocks flatly.

1 PUSH ROD

6 2

SQUARE WOODEN BLOCK

5

3

Fitting Balls (3) 2. Lower outer race (1) to the position where upper surface of inner race (2) and lower portion of seal groove is mated, put adjusting washer under outer race (1) so that outer raceway surface of ball (3) aligns with inner raceway, and support it. 3. Insert ball (3) and retainer (4), where grease is applied, through plug (8) hole on outer race (1), alternately.

EYE BOLT

HOOKED ROD

4 SQUARE WOODEN BLOCK

Fitting Retainer (4)

34-37

34

34. TRAVEL SYSTEM

To insert ball (3) and retainer (4), use a push rod, etc., to protect from injury from inserting fingers into plug hole. 4. Fit plug (8) to outer race (1) while checking it for direction and position of taper pin hole. 5. Apply adhesive (Cyano Bond PX-3000 or equivalent) to the seal (6) and stick the seal to the groove of outer race (1) continuously. Join each joint of the seal (6) with adhesive (Cyano Bond PX-3000 or equivalent). 6. After completion of assembly, caulk the edge of taper pin (7) by punching. 7. Check that grease nipple (9) is properly fitted, and fill it with grease. Then, check bearing for smooth rotation and flaws on seal lip portion. Shell Albania EP#2; 240 cc (14.64 cu-in)

34.1.8.5 MAINTENANCE STANDARD Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING PERFORMANCES in "Maintenance Standard and Test Procedure" in this manual.

34-38

34. TRAVEL SYSTEM

34.2

DISASSEMBLING AND ASSEMBLING OF EQUIPMENT

34.2.1 TRAVEL MOTOR

34

Travel Motor No.

NAME

No.

1 2 3 4 5

Casing NPT 1/16 plug Oil seal Retaining ring IRTW68 Expander plug MB800-040

23 24 25 26 27

6 7 8 9 10

Shifter piston Piston seal Steel ball 25 Shaft Bearing HR33209J

11 12 13 14 15

NAME

No.

NAME

D-ring (big dia.) Rear cover NPT 1/16 plug (MEC) Spool assy (M4V RBV) Spring holder (M4V RBV)

44 45 46 47 48

Check valve Check valve spring M6 restrictor (0.6) O-ring 1B P12.5 M6 restrictor (0.8)

28 29 30 31

Spring (M4V150RBV) M42 plug (M4V RBV) O-ring 1B G40 Pilot valve spool dia. Ǿ10 (M4V290)

49 50 51 52 53

O-ring 1B P15 O-ring 215.57X2.62 Bearing HR32207C Shim Parallel pin M6 8X12

Pivot Swash plate Cylinder block Cylinder spring Spring holder

32 33 34 35 36

Pin (MRC03) Spring holder (MRC03) Spring (MRC03) G3/8 pilot valve plug O-ring 1B P14

54 55 56 57 58

Valve plate Brake spring HEX. socket head bolt M18X50 Overload relief valve ORV240L Coupling

16 17 18 19 20

Ball joint Shoe retainer Piston assy Separating plate Friction plate

37 38 39 40 41

Connector (MRC03) G1/4 plug O-ring 1B P11 Restrictor (brake valve) Restrictor spring (brake valve)

59 60 61

Retaining ring C-type 40 G1/2 plug O-ring 1B P18

21 22

Brake piston D-ring (small dia.)

42 43

G1/8 plug O-ring 1B P8

34-39

34. TRAVEL SYSTEM •

Overload relief valve

Structure Of Overload Relief Valve No.

Name

No.

Name

57-1

Socket

57-8

Shim

57-2

Valve

57-9

Adjusting spring

57-3

Valve seat

57-10

O-ring 1B P7

57-4

Coupling piston

57-11

Backup ring T2 P7

57-5

Cap

57-12

O-ring 1B G25

57-6

Pilot body

57-13

Backup ring T2 G25

57-7

Piston

34-40

34. TRAVEL SYSTEM 34.2.2 CONSTRUCTION OF REDUCTION UNIT

34

Reduction Unit No.

NAME

No.

NAME

No.

NAME

1

Housing

10

Thrust washer 2

19

Carrier pin 1

2

Bearing 245BA35S1GS

11

Needle bearing FBNP-608660

20

Spring pin 6X36

3

Ring gear

12

Carrier pin 2

21

Sun gear 1

4

HEX.socket head bolt M18X110

13

Spring pin 10X50

22

Thrust plate

5

Floating seal 368

14

Sun gear 2

23

Cover

6

Shim

15

Carrier 1

24

HEX.socket head bolt M10X30

7

Lock washer

16

Planetary gear 1

25

Plug G3/4

8

Carrier 2

17

Thrust washer 1

26

O-ring 1B P24

9

Planetary gear 2

18

Needle bearing FBNP-406040

34-41

34. TRAVEL SYSTEM 34.2.3 TRAVEL MOTOR ASSEMBLY 34.2.3.1 TOOLS

Specifications etc.

Name Hex. key

Width across flat 5, 6, 8, 10, 14 mm

Snap ring plier

For bore Dia. 32mm - 58mm, for shaft.... Dia. 60mm - 80mm

Plastic hammer

1 piece

Screw driver

Minus (-), medium size, 2 pieces

Torque wrench

For 98.1N䍃m, 324N䍃m, 441N䍃m (72.4 lbf䍃ft, 239 lbf䍃ft, 325 lbf䍃ft)

Gear (bearing) puller

Work size : dia. 75 X width 45 can be handled(e.g. Asahi-tool GP75)

Others

Seal tape, kerosene, grease, hydraulic oil, shop cloth, Compressed air, etc. e.g. Supertool co., ltd unicrump FT-6 160 (6.3")

20

(0.79")

10 (0.394")

70 (2.76")

21 (0.83")

37 (1.46") o 195 (7.68")

Jig for pulling out brake piston (2pieces) Hex. socket head bolt 2-M6 X100 (3.94")

o 24 (0.95") o 40 (1.58")

2-M18X35 (1.38") 2 - 20 (0.79") drill hole

o 12 (0.47")

o 6.5 (0.26")

o 60 (2.36")

o 215 (8.47")

P.C.D. 251 (9.88")

o 280 (11.0")

100 (3.94")

20 (0.79")

100 (3.94")

Jig for pulling out brake piston (2pieces) 25 (0.98") R2

100 (3.94")

In case of using Hex. socket head bolt for mounting rear cover

50 (1.97") 15 (0.59")

M18

25 (1.26") 100 (3.94") Guide pin for rear cover (2 pieces)

10 - Plain washer 18

.5 ) R0 .02" (0

o 55 (2.17") o 87.5 (3.45") o 90 (3.54")

3 (0.12") 8.2 (0.32") More than 10mm (0.394")

Jig for inserting brake piston

Jig for inserting oil seal

34-42

o 42 (1.65") o 36 (1.42")

120 (4.72")

2-M18X50 (1.97")

")

08

(0.

3 (0.12")

Jig for inserting rear bearing

34. TRAVEL SYSTEM 34.2.3.2 DISASSEMBLY a. GENERAL INSTRUCTIONS (1) Generally, hydraulic equipment is precisely manufactured and clearances between each part is very narrow. Therefore, disassembling and assembling work should be performed in a clean place where dust does not gather. Tools and kerosene to wash parts should also be clean and handled with great care. (2) When motor is removed from the host machine, wash around the ports sufficiently, and insert plugs so that no dust and / or water may invade. Take off these plugs just before the piping work when reassembling it to the host machine. (3) Before disassembling, review the sectional drawing and prepare the required parts, depending on the purpose and the range of disassembling. Seals, O-rings, etc., if once disassembled, are not reusable. There are some parts that should be replaced as a sub-assembly. Consult with the parts book in advance. (4) The piston can be inserted to whichever cylinder block for the initial assembling. However, their combination should not be changed if they are once used. To reuse them, put the matching mark on both pistons and cylinder block before disassembling. (5) Take great care not to pinch your hand between parts while disassembling nor let parts fall on your foot while lifting them. b. DISASSEMBLY PROCEDURES (1) Removing accessory valves. Before disassembling motor, remove accessory valves.

According to disassembling purpose, select the valves to be removed. However, you cannot disassemble the motor without removing the overload relief valve (57).

Disassemble motor after cooling it to ambient temperature to prevent burns.

34-43

34

34. TRAVEL SYSTEM

1. Remove M42 plug (29) and O-ring (30). 2. Remove spring (28), spring holder (27) and spool assy (26).

Put the matching mark on both spool assy (26) and rear cover (24) so that spool assy (26) should not be reversed on re-assembling. It is impossible to disassemble this spool assy (26) further because spool assy (26) is fixed by adhesive. 3. Remove plug (42), O-ring (43), check restrictor spring (41) and restrictor (40). 4. Remove overload relief valves (57).

When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to fall into the rear cover (24) or lose it. 5. Remove pilot valve plug (35) and then, remove O-ring (36), pilot valve spring (34), spring holder (33), pilot valve spool (31) and pin (32). 6. Remove coupling (58).

34-44

34. TRAVEL SYSTEM (7) Disassembling motor. 1. Place the motor with the shaft horizontal, remove Hex. socket head bolts M18X50 (56) of rear cover (24) leaving two on the diagonally upper and lower positions. Tools: Allen wrench: 14mm 2. Install two guide pins diagonally into rear cover (24). (Purpose: Prevention of falling rear cover) 3. Loosen slowly and simultaneously the remaining two Hex. socket head bolts M18X50 (56). 4. Remove rear cover (24) and brake springs (55), taking care cylinder block (13) is not coming out stuck with rear cover (24).

Hole for releasing brake (Left) GUIDE PIN

34

Removing Rear Cover

Do not fall, at this moment, valve plate (54), brake springs (55), outer race of rear bearing (51) and/or O-rings (50), (47), and (49). There are shims (52) under the outer race of rear bearing (51). Do not to lose them. 5. Remove valve plate (54) without pulling out cylinder block (13).

Put the matching mark on both valve plate (54) and rear cover (24) so that valve plate (54) is not reversed on reassembling. 6. Using removed Hex. socket head bolts M18 X50 (56), fasten two mount metals so as to push in cylinder block (13) without damaging it; then inner race of rear bearing (51) comes out. (See right Fig.) 7. Put two fingers of gear (bearing) puller under the inner race of rear bearing (51), and remove the race.

51

Removing Rear Bearing

34-45

34. TRAVEL SYSTEM 8. Attaching a hand on brake piston (21), supply compressed air through oil hole for releasing brake and push out the piston (21).

Hole for releasing brake

Enlargement Figure Of Matching Surface Of Casing

Be aware of brake piston (21) popping out. In case of using jig for pulling out brake piston (21), install jigs to M6 thread (2 places) of brake piston (21) and pull out brake piston (21). 9. Put a mark on piston assembly (18), and put a matching mark on cylinder block (13) so that they can be reassembled at the same position as before. 10.Remove rotary group: cylinder block (13), spring holder (15), nine piston assys (18), shoe retainer (17), ball joint (16) and cylinder spring (14) as an assembly. 11. Remove separating plates (19) and friction plates (20). 12.Remove nine piston assemblies (18), shoe retainer (17) and ball joint (16) from rotary group simultaneously. 13.Remove spring holder (15) and cylinder springs (14).

Paper pipe Matching mark

Removing Cylinder Block

34-46

34. TRAVEL SYSTEM

Put piston assemblies (18) into the cylinder block (13) matching the matching mark with shoe retainer (17) as if assembled. The purpose is to put piston assemblies (18) in the same bore of cylinder block (13) as before when reassembled. Take care not to scratch sliding surfaces. Do not reuse damaged ones. It is impossible to disassemble piston and shoe because they are calked together.

34 Above disassembling is mentioned as a motor only and naturally can be applied to the motor with reduction gears. The situation is easier for motors with reduction gears because the shaft is rather restricted by a gear to move. 14.Remove swash plate (12). 15.Do not detach shifter piston assy (6), (7), and (8). If it needs to be detached; attach a hand on shifter piston and supply plant air through the hole shown in Fig.19 and push it out.

Hole for shifting shifter piston

Enlargement Figure Of Matching Surface Of Casing

Be aware of shifter piston (6) popping out. 16.Shaft (9) can come out now. 17.If front bearing (10) happen to be changed, remove inner races and outer races using bearing puller if needed and exchange to new ones as an assembly.

Remove Swash Plate

34-47

34. TRAVEL SYSTEM

When changing bearings (10 and 51); shaft (9), casing (1) or rear cover (24), it affects the clearance of the bearings. Therefore, shim (52) should be adjusted. Shim (52) adjustment should be performed by measuring correctly the clearance for shim and change to a shim that meets the clearance. (See Fig. "Deciding Shim Thickness") Other jigs and tools are needed to measure and decide the thickness of the shim. Do not remove pivots (11). If you need to disassemble them, put matching marks on pivots (11) with swash plate (12). Never detach oil seal (3) only for the purpose of inspecting it. If disassembled, remove retaining ring IRTW68 (4) first and remove oil seal (3). Never fail to replace oil seal (3) with a new one. 18.Deciding shim (52) thickness for tapered roller bearings.

Deciding Shim Thickness

This work should be done only when you have changed bearings (10 and 51), shaft (9), casing (1) or rear cover (24). 1. Measure the assembling width "E" (See above Figure).

Take care not to incline shaft (9). 2. Measure the depth "F" of rear cover (24).

Measure them at 4 places on the circuit, then calculate their mean value. 3. When thickness of shim (52) to be used is placed as "S", the clearance "Y" can be calculated as follows: Y=F-(E+S) 4. Select one or two shims (52) so as the clearance "Y" to comes to 0-0.1 mm (0~0.004") (clearance) on this unit.

34-48

34. TRAVEL SYSTEM (3) Disassembling overload relief valve. As a rule, overload relief valve (57) should be handled as one service part. If there is any trouble with the overload relief valve (57) , replace as an assembly.

34

Disassembling Overload Relief Valve

Valve seat (57-3) is fitted in bore of socket (57-1) at clearance fit. When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to lose it. When assembling overload relief valve (57) to rear cover (24), apply grease sufficiently on engagement part, to prevent valve seat (57-3) from dropping.

GREASE

Engagement Part

34-49

34. TRAVEL SYSTEM 34.2.4 TRAVEL MOTOR ASSEMBLY 34.2.4.1 GENERAL INSTRUCTIONS (1) Wash each part sufficiently with kerosene, and blow them with compressed air. (2) Assemble sliding parts after coating clean hydraulic oil on them. (3) Take great care not to pinch your hand between parts or tools while assembling, or let parts fall on your foot while lifting them. 34.2.4.2 ASSEMBLING PROCEDURES (1) Coat outer surface of oil seal (3) and inner face of casing (1) with grease. Using jig, rightly and evenly press in the oil seal (3) into casing (1). (2) Fix oil seal (3) with retaining ring (4). (3) Put the outer race of bearing (10) on casing (1) (this fit is loose), and press the inner race on shaft (9) (this fit is tight).

Jig for Inserting oil seal

Inserting Oil Seal

It is easier to fit inner race if the inner race is heated or boiled under 100 degrees centigrade. Never over heat! (4) Insert shaft (9) into casing (1) after coating grease on the contact surface to oil seal (3) lip. (5) Put shifter piston assy (6), (7), and (8) into casing (1).

Insert shifter piston assembly so it is not tilted. When inserting shifter piston assy, apply grease sufficiently on piston seal (7) and take a great care not to cut piston seal (7).

34-50

34. TRAVEL SYSTEM (6) Insert pivots (11) into the casing (1). Take care to match the matching mark with casing (1) and also to coincide the direction of the sliding traces on sphere surface with those contact traces on the swash plate (12) if the motor was operated. (7) Apply grease sufficiently on three spherical recesses of swash plate (12) and assemble it in casing (1).

34

Assembling Swash Plate (8) Insert piston assemblies (18), shoe retainer (17), ball joint (16), spring holder (15), and cylinder spring (14) onto cylinder block (13) as shown, and then insert the whole assembly to shaft (9).

Assembling Rotary Group

Piston assemblies (18) should be inserted into the same bore as before.

34-51

34. TRAVEL SYSTEM (9) Rightly knock in the inner race of rear bearing (51) to the rear end of shaft (9) by using jig (A1) and plastic hammer (A2). (10)Install all the separating plates (19) and friction plates (20) alternately between casing (1) and cylinder block (13), adjusting on the notches and splines. Separating plates (19) come both first and last. (11)Insert brake piston (21) into casing (1) using inserting jig (B) after attaching D-rings (22 and 23) to brake piston (21).

Plastic hammer

Jig for inserting rear bearing

Or

Jig for inserting brake piston 10 - Plain washer 18

Inserting Brake Piston

Apply grease sufficiently on D-rings (22 and 23). Insert brake piston (21) by using inserting jig, not to tilt. Two kinds of D-rings are used on brake piston (21). The larger one (23) is first inserted into the hole, then the smaller one (22) enters. It is impossible to see how the smaller ring goes into the hole. Therefore, never push it forcibly into the hole. Otherwise, it may be scraped off by the edge of the hole of casing (1).

When changing bearings (10 and 51), shaft (9), casing (1) or rear cover (24), it affects the clearance of the bearings. Therefore, shim (52) should be adjusted. Refer to Chapter 34.2.3.2 b (2)-18) "Deciding Shim (52) Thickness For Tapered Roller Bearings" and decide shim (52) thickness.

34-52

34. TRAVEL SYSTEM

(12)Install two guide pins diagonally on casing (1). (Purpose: Guide for installing rear cover) (13)Lay down rear cover (24) to mount valve plate (54) coinciding matching mark made prior to disassembling and also place brake springs (55) with ample grease to be attached to rear cover (24) while assembling. Also set shim (52), outer race of rear bearing (51) and O-rings (50), (47), and (49) on rear cover (24). (14)Insert rear cover (24) to casing (1) along the guide pin, and install two Hex. socket head bolts M18X50 (56) diagonally upper and lower position and tighten them to assemble rear cover (24) parallel. Then, install the rest of the Hex. socket head bolts M18X50 (56) and remove guide pin and install the two the remaining bolts. Tools: Allen wrench: 14mm, Tightening torque :324N-m (239 lbf-ft)

Guide pin

34

Inserting Brake Piston

When removing outer race of rear bearing (51); install shim (52) without fail. Confirm that O-rings (47), (49), and (50) are installed to rear cover (24). (15)Assemble coupling (58). (16)Assemble spring (34), spring holder (33), pilot valve spool (31) and pin (32) to rear cover (24), and then install pilot valve plug (35) with O-ring (36). Tightening torque : 49.0~58.8N-m (36.1~43.4 lbf-ft) (17)Assemble overload relief valves (57). Tools: Spanner : 32 mm Tightening torque : 98~117.6N-m (72.3~86.7 lbf-ft)

Assembling Accessory Valves

Valve seat (57-3) is fitted in bore of socket (57-1) at clearance fit. When assembling overload relief valve (57) to rear cover (24); valve seat (57-3) easily comes off, so take great care not to lose and apply grease sufficiently on engagement part so valve seat (57-3) does not drop off.

34-53

34. TRAVEL SYSTEM (18)Assemble restrictor (40) and restrictor spring (41) to rear cover (24), and then install G1/8 plug (42) with O-ring (43). Tightening torque : 14.7N-m (10.8 lbf-ft)

In case of assembling NEW restrictor (40), fit valve seat of restrictor (40) with rear cover (24). After inserting restrictor (40) to rear cover (24), knock restrictor (40) slightly by hammer. (19) Inserting spool assy (26) to rear cover (24) coinciding matching mark made prior to disassembling, and then assemble spring holder (27) and spring (28).

Spool assembly (26) is not symmetrical. Insert spool assy (26) in an appropriate direction. (20) Assemble M42 plug (29) with O-ring (30). Tightening torque : 441~461N-m (325~329 lbf-ft)

34.2.4.3 INITIAL PRE-CONDITIONING OPERATION (1) Drain charge. Fill up hydraulic oil in the motor casing after assembling. The M4V290/170F motor has two drain ports (G1/2). Bleed air in motor casing from un-piping port (upper side). (2) Initial Pre-conditioning operation. Operate motor 5 minutes at low speed mode and low-idle, check if there are abnormal noises or leaks of oil.

34-54

34. TRAVEL SYSTEM 34.2.5 TRAVEL MOTOR 34.2.5.1 MAINTENANCE STANDARD OF PARTS The followings are the general maintenance standards. However, it is important to determine which parts should be replaced, depending on the characteristics before disassembling, damage and discoloration of exterior view, the purpose of disassembling, the expected remaining service life, etc..

ITEM & MEASURING METHOD (1) Sliding surface of: cylinder block, valve plate and swash plate Measure the surface roughness by roughness tester. Measure the surface hardness of swash plate by hardness tester.

JUDGING CRITERIA & DISPOSITION Check Items Surface roughness; cylinder block valve plate swash plate

Criteria

below 0.4Z

Allowable Roughness below 3.0Z

Disposition Replace or Repair

Lap together the surfaces of both cylinder block and valve plate to remedy their roughness. (Lap with #1200 powder)

(2) Clearance between piston and cylinder block Measure outer dia. of piston and bore of cylinder block at least 3 places in the longitudinal direction with micrometer, and obtain: max. outer dia. = d max min. outer dia. = d min min. inner dia. = D min max. inner dia. = D max

Check Items

Criteria

Allowable Hardness

Disposition

Swash plate

Over HS78

HS74

Replace

Check Items

Criteria

Allowable Clearance

Outer diameter of piston d max - d min Inner diameter of cylinder bore D max - D min

0.01mm (0.0004")

0.05mm (0.0020")

0.01mm (0.0004")

0.022mm (0.0009")

Clearance D-d

0.037~0.047mm (0.0015"~0.0019")

0.065mm (0.0026")

Disposition

Replace piston or cylinder block

In exchanging pistons, replace all of nine pistons at the same time

34-55

34

34. TRAVEL SYSTEM ITEM & MEASURING METHOD

JUDGING CRITERIA & DISPOSITION

(3) Play between piston and shoe

Check Items

With the jig of Fig, hold down the shoe on work stand, and pull up the piston vertical direction to measure the play between piston and shoe. (See Fig)

Play between calked piston and shoe

Criteria

Allowable Roughness

Disposition

0~0.1mm (0~0.004")

0.3mm (0.018")

Replace piston

(1.34" +0.008" +0.004" ) o34 ( +0.2 +0.1)

85 (3.35")

Dial gauge

Piston Jig MagnetStand

26 (1.02")

Shoe Work stand

Method

o32 (1.26")

Play

o43 (1.69") Jig

Method

ITEM & MEASURING METHOD

Check Items

Criteria

Allowable Roughness

Disposition

902N㨯m (670 lbf㨯ft)

812N㨯m (600 lbf㨯ft)

Replace all separator and friction plates springs

(4) Parking brake torque After completion of assembly, set the torque wrench on the shaft end, and measure the braking torque generated when the shaft starts to rotate. Standard of replacing friction and separating plate. When measuring parking brake torque, it needs to disassemble traveling unit to motor and reduction gear portion, and it's so hard. The right allowable value is a standard of replacing friction and separating plate If it is impossible to disassemble traveling unit, refer to the right value.

Parking brake torque

Standard of replacing friction and separating plate Measure the total thickness of 6 pieces of friction plate and 7 pieces of separating plate. And if the total thickness is below the following allowable value, replace all separating and friction plates and springs. Criteria: 33.04 mm (1.30") (Dimension in the drawing) Allowable Thickness : 31.5 mm (1.24")

34-56

34. TRAVEL SYSTEM ITEM & MEASURING METHOD

JUDGING CRITERIA & DISPOSITION

(5) Shaft Measure the wear at contacting surface of oil seal (3) with the surface roughness tester.

If the depth of shaft wear is less than 0.05 mm (0.002"), the shaft is reusable.

(6) Bearing Replace bearing (10), (51) after decided hours.

Replace bearings (10), (51) before hour meter of host machine indicates 10,000 hours.

• In case of replacing the shaft (9), replace oil seal (3) at the same time.

• In case replacing the bearings(10), (51), replace both inner and outer races at the same time. • Also the bearing shims (52) must be re-adjusted when replaced shaft (9) and/or bearings (10), (51). Contact dealers for jigs and tools required. (7) Splines Replace if the wear of splines exceeds the allowable value.

If the wear of splines is less than 0.3 mm (0.012"), the spline is reusable.

Replace relief valve part as an assembly each time the host machine works (8) Overload relief valve for 10,000 hours. Do not try to adjust the valve, since special hydraulic test bench is required for inspecting and adjusting the pressure.

34.2.5.2 TIGHTENING TORQUE

Item (29) (35) (38) (42) (56) (57) (60)

Description

Size

Plug Plug (Pilot valve) Plug Plug Hex. socket head bolt Overload relief valve Plug

M42 G3/8 G1/4 G1/8 M18 M27 G1/2

34-57

Tightening torque N䍃m (lbf䍃ft) 441~461 (325~340) 49.0~58.8 (36.1~43.4) 29.4 (21.7) 14.7 (10.8) 324 32.4 (239 23.9) 98.1~118 (72.4~87.0) 98.1 (72.4)

34

34. TRAVEL SYSTEM 34.2.6 TRAVEL MOTOR TROUBLESHOOTING CAUSE OF TROUBLE AND REMEDY The followings are the general instructions to be followed when some troubles occur with hydraulic motors.

34.2.6.1 GENERAL INSTRUCTIONS (1) Judge the nature of abnormality before trouble shooting, and ascertain if the same symptom has occurred before or not. Review if the motor itself is actually the issue. (2) In many cases, the wear is caused by dust. Take great care to prevent dust from entering in disassembling and assembling. (3) All the parts especially those of moving parts should be carefully handled, and be careful not to score or scratch the sliding surfaces. (4) Be careful not to score the seating surface for O-rings, etc.. We recommend you to replace O-rings with the new ones, if once disassembled.

34.2.6.2 CAUSE OF TROUBLE AND REMEDY (1) Hydraulic motor never starts Symptom

Cause

Remedy

Pressure never increases

Malfunction of built-in relief valve.

Repair or replace relief valve

Pressure increases

1. Parking brake is not released (Clogging of restrictor) 2. Parking brake is not released (Spool is installed in wrong direction) 3. Stuck friction or separating plate of parking brake portion 4. Stuck brake piston

1. After inspection of clogging, repair or replace 2. Re-install the spool in correct direction

5. Seizure of sliding portion 6. Malfunction of spool (Stick between spool and body) (Clogging of restrictor)

34-58

3. Replace friction and separating plate 4. Repair outer dia. of brake piston or replace it. 5. Check, repair or replace piston shoe, swash plate, cylinder block valve plate etc. 6. Repair or replace

34. TRAVEL SYSTEM (2) Hydraulic motor rotates weakly Symptom

Cause

Remedy

Set pressure of overload valve is correct, but brake is released belated

Malfunction of spool (Stick between spool and body)

Repair or replace

Parking brake is released, but motor is hard to start

High oil viscosity.

Raise oil temperature or change the hydraulic oil

Parking brake is released, but motor starts weakly

1. Parking brake is not completely released. (Clogging in choke of pressure release passage) 2. Relief valve catches small particles 3. Seizure of sliding portion

1. Check clogging of choke

2. Wash relief valve, check or replace seat 3. Check, repair or replace sliding portion

(3) Drive shaft never rotate up to the set value Symptom Rotation of drive shaft never reaches the set value

Cause

Remedy

1. Shortage of oil coming in 2. Large wear or flaw made on shoe, cylinder block or valve plate

1. Check oil flow or hydraulic circuit to motor. 2. Check, repair or replace the parts

(4) Brake refuses to work Symptom

Cause

Remedy

Brake refuses to work

Malfunction of parking brake 1. Worn friction plate 2. Broken spring

Check, repair or replace brake piston, friction plate, spring, etc.

Brake works on counter lever operation

Malfunction of spool 1. Stick between spool and body 2. Stick of check valve or that by small particle 3. Clogging of restrictor

Repair or replace, or clean up

34-59

34

34. TRAVEL SYSTEM (5) Oil leakage Symptom Oil leakage

Cause

Remedy

1. Loose Hex. socket head bolt or plug 2. O-ring is torn off 3. Oil leaks inside gear casing

1. Fasten it with given torque 2. Replace O-ring 3. Replace oil seal

(6) Would not shift from high to low Symptom Would not shift from high to low

Cause

Remedy

Stick of spool in pilot valve

Replace pilot valve assembly

(7) Abnormal noise Symptom

Cause

Remedy

Malfunction of spool Abnormal noise Air is caught inside brake valve appears together with big vibration when brake is slowly applied or oil is supplied to other circuits while motor is running Stick between spool and body

Bleed air

Repair or replace

(8) Hunting occurs while descending the slope Symptom

Cause

Remedy

Severe hunting while inching

Malfunction of spool Stick between spool and body Restrictor is not seated completely

Interference with parking brake Permanent set or broken spring

Repair or replace

34-60

Repair or replace

34. TRAVEL SYSTEM 34.2.7 REDUCTION UNIT DISASSEMBLY 34.2.7.1 TOOLS Jigs and measuring instruments.

No. 1

Application

Tools Torque wrench

0~490N䍃m (0~360 lbf䍃ft)

2

Allen wrench

Opposing flats 8mm, 14mm

3

Stand

34

200 (7.87")

500 min (19.7") 390 (15.4") t=16 (0.63")

4

Micro depth meter

0~15mm (0~0.591")

5

Caliper

0~150mm (0~5.91")

6

Eye bolt

M10, M20 3pcs. each

7

Pin

Spring pin (14), (21)

8

Press machine

It is used to insert the angular bearing and fix the lock washer.Capacity 3 tons (6610 lb)

9

Others

Cleaning oil, Detergent, Gear oil, Grease, Loctite#242, #515, Seal tape, rag and others

5.5X80 (3.15"),

9.5X60 (2.36")

34.2.7.2 DISASSEMBLY (1) Preparation before removal 1. The travel unit removed from the machine has dust and mud. Wash them with cleaning oil. 2. Loosen drain or oil filling plug (26) and drain the oil out of the reduction unit.

When oil is hot, pressure is built up inside. Take care as the oil gushes out in some cases. 3. Marking matching marks. Put a matching mark on the outside of each matching surface so it may be installed where it was. The numbers in the parentheses after part names correspond to those in the assembly drawing in Fig. "Reduction Unit".

34-61

34. TRAVEL SYSTEM (2) Setting reduction unit (or whole propelling unit) on work stand 1. Remove Hex. socket head bolts M10X30 (24) at 3 places from cover (23) almost equally apart from each other, then install M10 eye bolts. Lift up the unit using them and place it on work stand with cover (23) upward.

Setting Propelling Unit On Work Stand

Take great care not to pinch your hand between parts while disassembling or let parts fall on your foot while lifting them. Lift the parts up horizontally. (3) Removing cover. 1. Remove the rest of Hex. socket head bolts M10X30 (24) that secure cover (23). Tools: Allen wrench: 8mm 2. As the cover (23) is adhered to ring gear (3), remove cover (23) by lightly hammering slantwise upward with wooden bar aiming at projection of cover (23).

24 23

Removing Bolts 23

16

Removing Cover

34-62

34. TRAVEL SYSTEM (4) Removing carrier 1 assembly 1. Remove thrust plate (22). 2. Screw three M10 eye bolts in carrier 1 (15) and lift up and remove carrier 1 as sub-assy (15), (16), (17), (18), (19), (20). 3. Remove sun gear 1 (21).

15 16 (17,18,19,20)

34

Removing Carrier 1 Assembly (5) Removing carrier 2 assembly 1. Remove sun gear 2 (14). 2. Screw three M10 eye bolts in carrier 2 (8) and lift up and remove carrier 2 as sub-assy (8), (9), (10), (11), (12), and (13).

8

9 (10,11,12,13)

Removing Carrier 2 Assembly (6) Disassembling housing assy 1. Take off lock washers (7) by tapping on screw driver or on similar tool placed at parting surface of them.

7

Removing Lock Washer

34-63

34. TRAVEL SYSTEM 2. Screw three M10 eye bolts in ring gear (3) almost equally apart from each other, then lift it up horizontally and remove housing assembly including ring gear (3), housing (1), angular bearing (2), a piece of floating seal (5) and Hex. socket head bolts M18X110 (4) together.

(7) Disassembling housing assembly 1. Screw three M20 eye bolts in housing (1) almost equally apart from each other. Lift up the housing assy and place it on work stand with housing (1) upward. Put a matching mark outside of housing (1) and ring gear (3). 2. Remove floating seal (5) from housing (1). 3. Remove Hex. socket head bolts M18X110 (4), leaving two of them diagonally. Tools: Allen wrench: 14mm 4. Loosen the rest two Hex. socket head bolts M18X110 (4) and tap lightly on the head of them, then the ring gear (3) can be easily removed from housing (1).

Over 300 (11.8")

Removing Housing Assembly

Disassembling Housing Assembly

Take care not to damage the sliding surface of floating seal (5) or its O-ring. Bearings (2) have been tightly press fitted in housing (1). Do not remove the bearings (2), or otherwise their exchange is required. In case bearings (2) are removed, do not reuse them. New bearings (2) should be used and shim (6) adjusting will be required.

34-64

34. TRAVEL SYSTEM (8) Removing floating seal 1. Remove a piece of floating seal (5) on motor side. 5

34 Removing Floating Seal (23) (9) Disassembling carrier 1 assembly 19 15

Disassembling Carrier 1 Assembly

When carrier pins 1 (19) are to be reused, mark each pin with its mated hole of carrier 1 (15) to assure the same combination as before. 1. Knock spring pins 6X36 (20) fully into carrier pins 1 (19). 2. Tap carrier pins 1 (19) out from carrier 1 (15). 3. Remove thrust washers 1 (17), planetary gears 1 (16) and needle bearings (18). 4. Knock out spring pins 6X36 (20) from carrier pins 1 (19) for reassembling.

20 19

15

15 15

17

16

16

18

Disassembling Carrier 1 Assembly

When carrier pin 1 (19) or planetary gear 1 (16) is required to be exchanged, three pins or three gears should be all exchanged.

34-65

34. TRAVEL SYSTEM (10)Disassembling carrier 2 assy

When carrier pins 2 (12) are to be reused, mark each pin with its mated hole of carrier 2 (8) to assure the same combination as before. 1. Knock spring pins 10X50 (13) fully into carrier pins 2 (12). 2. Tap carrier pins 2 (12) out from carrier 2 (8). 3. Remove thrust washers 2 (10), planetary gears 2 (9) and needle bearings (11). 4. Knock out spring pins 10X50 (13) from carrier pins 2 (12) for reassembling.

13 12 8

8

9

8

10

11

Disassembling Carrier 2 Assembly

When carrier pin 2 (12) or planetary gear 2 (9) is required to be exchanged, three pins or three gears should be all exchanged.

34-66

34. TRAVEL SYSTEM 34.2.8 ASSEMBLING (1) GENERAL INSTRUCTIONS 1. Clean every part with kerosene and dry them with compressed air. Surfaces to be applied by Loctite must be degreased with solvent. 2. Check every part for any abnormalilty. 3. Each Hex. socket head bolt should be used with Loctite #242 applied on its threads. 4. Apply gear oil slightly on each part before assembling. 5. Take great care not to pinch your hand between parts while assembling or let parts fall on your foot while lifting them. (2) Assembling carrier 2 assy 1. Install planetary gears 2 (9), needle bearings (11) and thrust washer 2 (10) into carrier 2 (8). 2. Install carrier pins 2 (12) into carrier 2 (8) where the holes for spring pins 10X50 (13) are to be in line with those of carrier 2 (8). 3. Install spring pins 10X50 (13) into carrier 2 (8) and at the same time into carrier pins 2 (12). (Sink spring pins of 1 - 2 mm (0.04"~0.08") from surface) 4. Caulk carrier 2 (8) on diagonally position to prevent spring pin 10X50 (13) from coming out.

Refer to right figure "Detail of Calking".

Detail of Calking

34-67

8

9 (10,11)

34

Assembling Carrier Assembly

9 (10,11)

13 8

Drive Spring Pin

34. TRAVEL SYSTEM (3) Assembling carrier 1 assy 1. Install planetary gears 1 (16), needle bearings (18) and thrust washers 1 (17) into carrier 1 (15). 2. Install carrier pins 1 (19) into carrier 1 (15) where the holes for spring pins are to be in line with those of carrier 1 (15). 3. Install spring pins 6X36 (20) into carrier 1 (15) and at the same time into carrier pins 1 (19). (Sink spring pins 1 - 2 mm (0.04"~0.08") from surface) 4. Caulk carrier 1 (15) on diagonally position to prevent spring pin 6X36 (20) from coming out.

Caulking position 13

Caulking The Spring Pin

(4) Installing main bearing and floating seal 1. Install main bearing (2) to inner surface of housing (1). 2. Install a piece of floating seal (5) on motor casing and also install another piece of floating seal (5) on housing (1). 5

Correct

Incorrect Incorrect

Install Direction Of Floating Seal (5) Install Floating Seal (5)

34-68

34. TRAVEL SYSTEM (5) Assembling housing assy 1. Apply Loctite #515 on mating surfaces of housing (1) and ring gear (3) without a gap. 2. Install three M20 eye bolts equally apart on housing (1). Using the eye bolts, hang the housing (1) by wire rope and place it on ring gear (3), coinciding matching marks. 3. After applying Loctite #242 on the threads of 25 pieces of Hex. socket head bolts M18X110 (4), tighten them with torque wrench. Tools: Allen wrench: 14mm, Tightening torque : 377.3N-m (278 lbf-ft)

LOCTITE #515

34

Assembling Housing Assy 20 (0.79")

20 (0.79")

Soak 20mm (0.79") length from the tip of bolt in Loctite #242.

How To Apply Loctite #242

Clean the groove for floating seals (5) to eliminate oil, dust, paint or other foreign material. Apply gear oil slightly on sliding surfaces of floating seals (5) before assembling, but strictly dry on O-rings and on its grooves. Confirm that O-ring of floating seals (5) are not twisted and that floating seals are correctly installed. i.e. parallel as shown to each other between housing (1) and motor casing after assembled. (See Fig. "Install Direction Of Floating Seal") -It is recommended to use jig to install floating seal. (6) Deciding shim thickness for angular bearings

This work should be done only when you have to change motor casing, housing (1), bearings (2) or lock washers (7). Otherwise use the same shim (6) as before.

34-69

34. TRAVEL SYSTEM 1. Fit in two bearings (2) on housing (1) pressing their outer races. 2. Press inner races of two bearings (2) lightly and evenly, measure the assembling width "A" of inner races. 3. Measure the motor side assembling width "B" for bearings (2). 4. Measure the groove width "C" of motor casing. 5. Measure the thickness "D" of lock washers (7). D C

A B

S

Deciding Shim Thickness

Measure them at 4 places evenly apart on the circumferences, then calculate and use those mean values. Measure them to the accuracy of 0.01 mm (0.0004"). 6. When thickness of shim (6) to be used is placed as "S", the clearance "X" can be calculated as follows: X=(B+C)-(A+D+S) 7. Select a shim (6) so as the clearance X comes to -0.08 mm (interference)~ +0.02 mm (clearance) (-0.0031"~0.0008") on this unit. (7) Installing housing assy 1. Place motor on work stand with the shaft upward, and put the selected shim (6) on the bearing matching surface of motor casing. 2. Install three M10 eye bolts on ring gear (3) almost equally apart and lift it up. Descend it concentric with motor and place bearings (2) on housing (1) into motor casing. Use press machine and press inner race of bearing (2) in to full depth.

Press

Pressing Housing Assy In

34-70

34. TRAVEL SYSTEM 3. While pressing inner race of bearing (2), install lock washers (7) into groove.

34

Installing Lock Washer

(8) Assembling carrier 2 assy 1. Install three M10 eye bolts equally apart on carrier 2 (8). Using the eye bolts, hang the carrier 2 assy with wire rope and place three planetary gears 2 (9) as shown in right Figure, place carrier 2 assy into ring gear (3) and mesh the splines to those of the motor. 2. Insert and mesh sun gear 2 (14) on center.

CARRIER 2

VB

NOTCH (CARRIER 2)

PLANETARY GEAR 2

VA

PORT

Installing Direction Of Carrier 2 8

SUN GEAR 2 (14)

Assembling Carrier 2 Assy

Positioning carrier 2 assy as shown in Figure "Installing Direction Of Carrier 2" is important to obtain better lubrication.

34-71

34. TRAVEL SYSTEM (9) Assembling carrier 1 assy. Face sharp edged side to cover (23). (See Fig. "Assembling Carrier 1 Assy") (10)Installing cover. 1. Apply Loctite #515 on mating surfaces of cover (23) and ring gear (3) and install cover (23) on ring gear (3). 2. After applying Loctite #242 on the threads of 18 pieces of Hex. socket head bolts M10X30 (24), tighten them with torque wrench. Tools: Allen wrench: 8mm, Tightening torque : 68.6N-m (50.6 lbf-ft)

23 LOCTITE #515 3

24

Installing Cover (23) (11) Filling gear oil. 1. Fill gear oil (SAE #90 API class GL-4 or GL-5, 9.5 litters (2.5 gal)) from two G3/4 ports. 2. Tighten taper screw plugs (25). Tools: Allen wrench : 14mm Tightening torque : 147.1N-m (108 lbf-ft)

34-72

34. TRAVEL SYSTEM 34.2.9 MAINTENANCE STANDARD 34.2.9.1 INSPECTION BEFORE ASSEMBLING (1) Thrust washer 1. Check if there is seizure, abnormal wear or uneven wear. 2. Check if the wear is over the allowable limit. (2) Gears 1. Check if there is pitting or seizure on the tooth surface. 2. Check if there are clacks on the root of tooth with a die check. (3) Bearings Rotate by hand to see if there is something unusual such as noise or uneven rotation. (4) Floating seal Check flaw or score on sliding surfaces or on O-rings.

34

34.2.9.2 MAINTENANCE STANDARD OF PARTS The following are the general maintenance standards. However, it is most important to determine which parts should be replaced, depending on the characteristics shown before disassembling, damage or discoloration on exterior view, the purpose of disassembling, the expected remaining service life etc.

D

E

C

A B F G

Maintenance standards Mark A B C D E F G

Items

Criteria

Allowable limit

Disposition

Replace 3 pieces as a set Replace (Replace 3 Condition of tooth Smooth, without abnormal Not over 1.6mm (0.063") of pieces as a set for pitching nor cracks at root planetary gears) surface wear or seizure Adjust shim Thrust clearance of From -0.08 mm To 0.02 mm thickness angular bearings (2) (-0.0031"~0.0008") [Refer to 34.2.8(6)] Thickness of thrust From 3.3 mm To 3.7 mm 0.1 mm (0.004") Replace washer 1 (18) (0.13"~0.15") of wear 0.1 mm (0.004") Thickness of thrust 5.5 0.2mm Replace (0.21"~0.22") of wear washer 2 (11) 0.15 mm (0.006") Thickness of thrust 4.5 0.16mm Replace (0.171"~0.183") of wear plate (23) Wear of planetary shaft

Lubrication oil

Smooth, without abnormal wear or seizure

2,000 working hours (engine hour meter)

34-73

Replace

34. TRAVEL SYSTEM 34.2.9.3 TIGHTENING TORQUE Use torque wrench when tightening the following Hex. socket head bolts and plugs.

ITEM

Description

Size

4

Hex. socket head bolt

M18X110

25

Hex. socket head bolt

M10X30

26

Taper plug

G3/4

Tightening torque N䍃m (lbf䍃ft) 378 37.8 (279 28) (with applying Loctite#242) 68.6 6.8 (50.6 5) (with applying Loctite#242) 147 14.7 (108

11)

34.2.9.4 INSPECTION AFTER ASSEMBLED (1) Quantity of lubrication. After installing the propelling unit, position the drain port at the lowest position and check if lubrication oil comes out when loosening the level plug. (2) Rotating inspection. Put the unit on the test stand and rotate with no load and check if there are abnormal noises or leaks of oil. Take care not to overspeed the motor. Rotate within specified flow rate.

34-74

46. TROUBLE SHOOTING (BY ERROR CODES)

46. TROUBLE SHOOTING (BY ERROR CODES) TABLE OF CONTENTS

46.1 46.2 46.3 46.4

JUDGMENT OF ACTUAL THING AT SITE ....................................................... 46-3 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................... 46-4 THE BLOWN FUSE OF MECHATRO CONTROLLER ...................................... 46-5 TROUBLESHOOTING BY ERROR CODE ........................................................ 46-6

46

Book Code No. S5LC4625E01 46-1

46. TROUBLE SHOOTING (BY ERROR CODES)

Issue First Edition ↑

Data of Issue

Applicable Machines

S5LC4625E01 NHK

September, 2010 E385CLC: YC ↑

Remarks

SK350-9: YC

NA

↑

Preface Troubleshooting provides a process for locating the cause of trouble in the order that trouble occurred. This manual describes how to solve the specific phenomenon systematically as early as possible. For troubleshooting concerning the inside of equipment, refer to troubleshooting for each section of equipment.

Attending The Field To Verify Actual Thing

46-2

46. TROUBLE SHOOTING (BY ERROR CODES)

46.1

JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible. Verify model, serial number, situation of trouble and field, and notify person of arrival time. (2) Verify background of why trouble occurred. 1. Model name and serial number 2. Kind of attachment Check that the combination of attachment is proper or that the operating method is not unreasonable. 3. Operating time by hour-meter 4. History of trouble occurred and additional works. 5. Recurrence of past trouble, or problems on the additional works. Verifying Background That Trouble Occurred (3) How to diagnose trouble. 1. Verify defective part. 2. Make the condition of trouble again. 3. Where defective parts cannot be verified, surmise causes systematically. 4. Verify reasons for surmise. 5. Report methods, procedure, and period for repairing to user.

Confirm The Symptoms Of The Trouble (4) Explanation of the cause of trouble.

46

1. Explain the cause of trouble to clients. For example, oil leak through piston is caused by flaws on the piston rod. And the method of using the machines should be explained so that the same kind of trouble does not reoccur. 2. Treatment of damaged parts The damaged parts to be claimed and returned are evidence so they should be handled with care. Protect them from entry of water, soils, etc. into port of hydraulic unit, etc. and return them. And also use care not to flaw and damage those surfaces.

46-3

Diagnosing Fail By Means Troubleshooting

46. TROUBLE SHOOTING (BY ERROR CODES)

46.2

CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting. No.

Classes of failure

Troubleshooting

A

When error code after self-diagnosis is displayed on gauge cluster.

Carry out troubleshooting according to the error code.

B

When no failure is detected currently, but error code after self diagnosis remains in trouble history.

When it is hard to recreate the failure situation, cancel the data in the history and reproduce the failed situation or suppose the cause according to the troubleshooting by error code, and then repair it.

C

When error code after self diagnosis is not displayed or has not remained in the history

Carry out troubleshooting according to instructions in Chapter 47 "TROUBLESHOOTING BY TROUBLE". Carry out troubleshooting according to instructions in Chapter 48 "TROUBLE DIAGNOSIS MODE".

46-4

46. TROUBLE SHOOTING (BY ERROR CODES)

46.3

THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of the mechatro controller has blown, the following display appears on the gauge cluster. (1) The blown fuse of the mechatro controller a. Blown fuse 5A of mechatro controller: "DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller program is not executed. b. Blown fuse 20A of mechatro controller. The controller functions normally but the power supply applied when the controller drives the solenoid, etc. stops. Many error codes are displayed on the gauge cluster. D013, D023, D033, D063, E013, E023, F021

46

46-5

46. TROUBLE SHOOTING (BY ERROR CODES)

46.4

TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the troubleshooting referring to applicable page in the contents of error codes.

Error Code

Trouble

Described page

A025

Pump propo. valve adjustment (B adjustment) is not adjusted yet or has failed.

46-9

A035

Unload valve adjustment (C adjustment) is not adjusted yet or has failed.

46-9

A215

Written data of ROM adjustment data is incorrect.

46-10

A225

Writing of ROM adjustment data is incorrect.

46-10

A235

Written data of ROM hour meter data is incorrect.

46-11

A245

Writing of ROM hour meter data is incorrect.

46-11

A255

Writing of proportional valve adjustment data is incorrect.

46-12

B012

Incorrect output of boom up pressure sensor.

46-12

B013

Disconnection of boom up pressure sensor.

46-13

B014

Short-circuit of boom up pressure sensor.

46-14

B022

Incorrect output of boom down pressure sensor.

46-14

B023

Disconnection of boom down pressure sensor.

46-15

B024

Short-circuit of boom down pressure sensor.

46-16

B032

Incorrect output of arm out pressure sensor.

46-16

B033

Disconnection of arm out pressure sensor.

46-17

B034

Short-circuit of arm out pressure sensor.

46-18

B042

Incorrect output of arm in pressure sensor.

46-18

B043

Disconnection of arm in pressure sensor.

46-19

B044

Short-circuit of arm in pressure sensor.

46-20

B052

Incorrect output of bucket digging pressure sensor.

46-21

B053

Disconnection of bucket digging pressure sensor.

46-21

B054

Short-circuit of bucket digging pressure sensor.

46-22

B062

Incorrect output of bucket dump pressure sensor.

46-22

B063

Disconnection of bucket dump pressure sensor.

46-23

B064

Short-circuit of bucket dump pressure sensor.

46-24

B072

Incorrect output of swing pressure sensor.

46-24

B073

Disconnection of swing pressure sensor.

46-25

B074

Short-circuit of swing pressure sensor.

46-25

B092

Incorrect output of travel right pressure sensor.

46-26

B093

Disconnection of travel right pressure sensor.

46-26

B094

Short-circuit of travel right pressure sensor.

46-27

B102

Incorrect output of travel left pressure sensor.

46-27

B103

Disconnection of travel left pressure sensor.

46-28

B104

Short-circuit of travel left pressure sensor.

46-28

B113

Disconnection of pressure sensor of optional selector positioning.

46-29

46-6

46. TROUBLE SHOOTING (BY ERROR CODES)

Error Code

Trouble

Described page

B114

Short-circuit of pressure sensor of optional selector positioning.

46-29

B162

Incorrect output of P1 optional side pressure sensor.

46-30

B163

Disconnection of P1 side optional pressure sensor.

46-31

B164

Short-circuit of P1 side optional pressure sensor.

46-32

B172

Incorrect output of P2 optional side pressure sensor.

46-33

B173

Disconnection of P2 side optional pressure sensor.

46-34

B174

Short-circuit of P2 side optional pressure sensor.

46-35

C012

Incorrect output of P1 pump pressure sensor.

46-35

C013

Disconnection of P1 pump pressure sensor.

46-36

C014

Short-circuit of P1 pump pressure sensor.

46-36

C022

Incorrect output of P2 pump pressure sensor.

46-37

C023

Disconnection of P2 pump pressure sensor.

46-37

C024

Short-circuit of P2 pump pressure sensor.

46-38

C033

Disconnection of boom head pressure sensor.

46-38

C034

Short-circuit of boom head pressure sensor.

46-39

C043

Disconnection of boom rod pressure sensor.

46-39

C044

Short-circuit of boom rod pressure sensor.

46-40

D012

Failure of output transistor ON at P1 unload proportional valve.

46-40

D013

Disconnection of P1 unload proportional valve.

46-41

D022

Failure of output transistor ON at P2 unload proportional valve.

46-41

D023

Disconnection of P2 unload proportional valve.

46-42

D032

Failure of output transistor ON at travel straight proportional valve.

46-42

D033

Disconnection of travel straight proportional valve.

46-43

D062

Failure of output transistor ON at arm in high speed proportional valve.

46-43

D063

Disconnection of arm in high speed proportional valve.

46-44

D152

Proportional bypass valve and output transistor ON are failure.

46-44

D153

Proportional bypass valve's wiring is disconnected.

46-45

E012

Failure of output transistor ON at P1 pump proportional valve.

46-45

E013

Disconnection of P1pump proportional valve.

46-46

E022

Failure of output transistor ON at P2 pump proportional valve.

46-47

E023

Disconnection of P2 pump proportional valve.

46-48

E032

Optional relief adjusting proportional valve 1 and output transistor ON failure.

46-49

E033

Optional relief adjusting proportional valve 1's wiring is disconnected.

46-49

E042

Optional relief adjusting proportional valve 2 and output transistor ON failure.

46-50

E043

Optional relief adjusting proportional valve 2's wiring is disconnected.

46-50

F011

Failure of output transistor OFF and GND short of attachment boost SOL valve.

46-51

F013

Failure of output transistor ON and disconnection of attachment boost SOL valve.

46-52

F021

Failure of output transistor OFF and GND short of swing parking SOL valve.

46-52

F023

Failure of output transistor ON and disconnection of swing parking SOL valve.

46-53

46-7

46

46. TROUBLE SHOOTING (BY ERROR CODES)

Error Code

Trouble

Described page

F031

Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve.

46-53

F033

Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve.

45-54

F041

Failure of output transistor OFF and GND short of optional selector SOL valve.

46-54

F043

Failure of output transistor ON and disconnection of optional selector SOL valve.

46-55

G032

Overrun of speed sensor of direct input Mechatro-controller.

46-55

G033

Disconnection of speed sensor of direct input Mechatro-controller.

46-56

G042

Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller.

46-57

G043

Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller.

46-58

H013

Disconnection of acceleration potentio

46-59

H014

Power short-circuit of acceleration potentio.

46-59

H023

Disconnection of boom angle potentio.

46-60

H024

Power short-circuit of boom angle potentio.

46-60

H033

Disconnection of arm angle potentio.

46-61

H034

Power short-circuit of arm angle potentio.

46-61

H091

Failure of GND short-circuit of fuel sensor.

46-62

H093

Disconnection of fuel sensor.

46-62

I111

Received error of CAN1 communication (passive error).

46-63

I113

Received error of CAN1 communication (time-out).

46-63

I121

Transmission of CAN1 communication is abnormal (Busoff).

46-64

I211

Reception of CAN1 communication is abnormal (passive error).

46-64

I213

Reception of CAN2 communication is abnormal (passive error).

46-65

I221

Transmission of CAN2 communication is abnormal (Busoff).

46-65

K014

Adhesion of battery relay terminal.

46-66

R014

Failure of arc prevention relay of wiper motor.

46-67

R024

Failure of normal rotation relay of wiper motor.

46-67

R034

Failure of reverse rotation relay of wiper motor.

46-68

R044

Failure of washer motor relay.

46-68

R134

Failure of swing right flasher relay.

46-69

R144

Failure of swing left flasher relay.

46-69

R154

Failure of travel alarm relay.

46-70

R164

Failure of auto idling stop relay 2.

46-70

R174

Failure of engine forcible stop relay.

46-71

R184

Failure of lever lock relay.

46-71

R214

Failure of safety relay.

46-72

Z010

Common rail pressure error.

46-73

46-8

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-1 Error code

A025

Trouble

Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment).

Judging condition

Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.

Symptom

Deviated from the rated output, but no problem in normal operation.

Control in the event of failure

Workable with the default proportional valve output.

Returned in normal condition

The pump proportional valve adjustment is completed normally.

Service diagnosis checking screen

Screen No.

9

E-1 P1 PUMP

Screen No.

9

E-2 P2 PUMP

Screen No.

Checking object

Checking contents and remedy.

1

-Checking

Carry out pump adjustment (B adjustment). When "ERROR PUMP" is displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

3 Table 46-2 Error code

A035

Trouble

Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment).

Judging condition

The adjustment of unload valve is missed. Or the adjusting value cannot be set in the adjusting range.

Symptom

It is not normal output, but no problem in normal operation.

Control in the event of failure

Work with the aid of output by default proportional valve.

Returned in normal condition

The adjustment of unload valve has completed normally.

Service diagnosis checking screen

Screen No.

8

D-1 P1 UN-LOAD (BP-CUT)

Screen No.

8

D-2 P2 UN-LOAD (BP-CUT)

Screen No.

Checking object

Checking contents and remedy

1

-Checking

Carry out adjustment of unload valve (C adjustment). When "ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed".

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

3

46-9

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-3 Error code

A215

Trouble

The data of ROM adjustment is written incorrectly.

Judging condition

Check adjustment data, and judge that the content of memory is correct or not. (Trouble history only).

Symptom

No affect.

Control in the event of failure

Control at side of correct memory data.

Returned in normal condition

It does not regain. Replace controller.

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3 Table 46-4 Error code

A225

Trouble

The data of ROM adjustment is written incorrectly.

Judging condition

Check adjustment data, and judge the data is correct or not.

Symptom

It is not normal output, but no problem in normal operation.

Control in the event of failure

Control can be done by default value.

Returned in normal condition

It does not regain. Replace controller.

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3

46-10

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-5 Error code

A235

Trouble

The data of ROM hourmeter is written incorrectly.

Judging condition

Check hourmeter memory, and judge that the data is correct or not. (Trouble history only)

Symptom

No affect.

Control in the event of failure

Control at side of correct memory data.

Returned in normal condition

It does not regain. Replace controller.

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3 Table 46-6 Error code

A245

Trouble

The data of ROM hourmeter is written incorrectly.

Judging condition

Check hourmeter memory, and judge that the data is incorrect.

Symptom

The hour meter data which was judged as an error is taken as 0 Hr. No problem in normal operation.

Control in the event of failure

Normal control is available.

Returned in normal condition

It does not regain. Replace controller.

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object 1

46

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3

46-11

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-7 Error code

A255

Trouble

The data of proportional valve adjustment is written incorrectly.

Judging condition

Check proportional valve adjustment data, and judge the data is incorrect.

Symptom

It is not normal output, but no problem in normal operation

Control in the event of failure

Using fixed value of proportional valve correction data, usual control is done.

Returned in normal condition

It does not regain. Replace controller.

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object 1

Checking contents and remedy

Mechatro controller

Check that the error is corrected after replacement of controller.

2 3 Table 46-8 Error code

B012

Trouble

Boom up pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The boom up operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-1 BOOM RAISE

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom up pressure sensor SE-3

When B012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom up pressure sensor and controller CN-126F CN-101F

When B012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-12

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-9 Error code

B013

Trouble

Boom up pressure sensor's wiring disconnects.

Judging condition

The input voltage from boom up pressure sensor is less than 0.1V.

Symptom

The boom up speed slows down.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-1 BOOM RAISE

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom up pressure sensor SE-3

When B013 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom up pressure sensor and controller CN-126F CN-101F

When B013 is displayed after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-13

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-10 Error code

B014

Trouble

Boom up pressure sensor's power source is shortcut.

Judging condition

The input voltage from boom up pressure sensor is 4.7V or more.

Symptom

The boom up speed slows down.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-1 BOOM RAISE

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom up pressure sensor SE-3

When B014 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom up pressure sensor and controller CN-126F CN-101F

When B014 is displayed after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-11 Error code

B022

Trouble

Boom down pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The boom down operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-2 BOOM LOWER

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom down pressure sensor SE-4

When B022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom down pressure sensor and controller CN-127F CN-101F

When B022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-14

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-12 Error code

B023

Trouble

Boom down pressure sensor's wiring is disconnecting.

Judging condition

The input voltage from boom down pressure sensor is 0.1V or less.

Symptom

The boom down operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 pump to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1 unload proportional valve to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-2 BOOM LOWER

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom down pressure sensor SE-4

When B023 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom down pressure sensor and controller CN-127F CN-101F

When B023 is displayed after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-15

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-13 Error code

B024

Trouble

Boom down pressure sensor's power source is shortcut.

Judging condition

The input voltage from boom down pressure sensor is 4.7V or more.

Symptom

The boom down operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1 unload proportional valve to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-2 BOOM LOWER

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom down pressure sensor SE-4

When B024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom down pressure sensor and controller CN-127F CN-101F

When B024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-14 Error code

B032

Trouble

Arm-in pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The arm-out operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-3 ARM OUT

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-out pressure sensor SE-8

When B032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between arm-out pressure sensor and controller CN-131F CN-101F

When B032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-16

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-15 Error code

B033

Trouble

Arm-out pressure sensor's wiring is disconnecting.

Judging condition

The input voltage from arm-out pressure sensor is 0.1V or less.

Symptom

Shock at stopping of arm-out is great.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-3 ARM OUT

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-out pressure sensor SE-8

When B033 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between arm-out pressure sensor and controller CN-131F CN-101F

When B033 is displayed after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-17

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-16 Error code

B034

Trouble

Arm-out pressure sensor's power source is shortcut.

Judging condition

The input voltage from arm-out pressure sensor is 4.7V or more.

Symptom

Shock at stopping of arm-out is great.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-3 ARM OUT

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-out pressure sensor SE-8

When B034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between arm-out pressure sensor and controller CN-131F CN-101F

When B034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-17 Error code

B042

Trouble

Arm-in pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The arm-in operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-4 ARM IN

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-in pressure sensor SE-7

When B042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between arm-in pressure sensor and controller CN-130F CN-101F

When B042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-18

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-18 Error code

B043

Trouble

Arm-in pressure sensor's wiring is disconnecting.

Judging condition

The input voltage from arm-in pressure sensor is 0.1V or less.

Symptom

Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA. Set output of arm 2 arm-in proportional valve to 200mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-4 ARM IN

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-in pressure sensor SE-7

When B043 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between arm-in pressure sensor and controller CN-130F CN-101F

When B043 is displayed after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-19

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-19 Error code

B044

Trouble

Arm-in pressure sensor's power source is shortcut.

Judging condition

The input voltage from arm-in pressure sensor is 4.7V or more.

Symptom

Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA. Set output of arm 2 arm-in proportional valve to 200mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-4 ARM IN

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-in pressure sensor SE-7

When B044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between arm-in pressure sensor and controller CN-130F CN-101F

When B044 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-20

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-20 Error code

B052

Trouble

Bucket digging pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the bucket digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The bucket digging operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-5 BUCKET DIG

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch SE-1 on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between bucket digging pressure sensor and controller CN-124F CN-101F

When B052 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-21 Error code

B053

Trouble

Bucket digging pressure sensor's wiring is disconnected.

Judging condition

The input voltage from bucket digging pressure sensor is 0.1V or less.

Symptom

The bucket digging speed slows down a little.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-5 BUCKET DIG

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch SE-1 on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between bucket digging pressure sensor and controller CN-124F CN-101F

When B053 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-21

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-22 Error code

B054

Trouble

Bucket digging pressure sensor's power source is shortcut.

Judging condition

The input voltage from bucket digging pressure sensor is 4.7V or more.

Symptom

The bucket digging speed slows down a little.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-5 BUCKET DIG

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch SE-1 on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between bucket digging pressure sensor and controller CN-124F CN-101F

When B054 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-23 Error code

B062

Trouble

Bucket dump pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the bucket dump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The bucket dump operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-6 BUCKET DUMP

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Bucket dump pressure sensor SE-2

When B062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between bucket dump pressure sensor and controller CN-125F CN-101F

When B062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-22

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-24 Error code

B063

Trouble

Bucket dump pressure sensor's wiring is disconnected.

Judging condition

The input voltage from bucket dump pressure sensor is 0.1V or less.

Symptom

The bucket dump speed slows down a little.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-6 BUCKET DUMP

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Bucket dump pressure sensor SE-2

When B063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between bucket dump pressure sensor and controller CN-125F CN-101F

When B063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-23

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-25 Error code

B064

Trouble

Bucket dump pressure sensor's power source is shortcut.

Judging condition

The input voltage from bucket dump pressure sensor is 4.7V or more.

Symptom

The bucket dump speed slows down a little.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-6 BUCKET DUMP

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Bucket dump pressure sensor SE-2

When B064 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between bucket dump pressure sensor and controller CN-125F CN-101F

When B064 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-26 Error code

B072

Trouble

Swing pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the swing pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The swing operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

6

B-7 SWING

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Swing pressure sensor SE-5

When B072 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between swing pressure sensor and controller CN-169F CN-103F

When B072 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-24

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-27 Error code

B073

Trouble

Swing pressure sensor's wiring is disconnected.

Judging condition

The input voltage from swing pressure sensor is 0.1V or less.

Symptom

The swing operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

B-7 SWING

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Swing pressure sensor SE-5

When B073 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between swing pressure sensor and controller CN-169F CN-103F

When B073 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-28 Error code

B074

Trouble

Swing pressure sensor's power source is shortcut.

Judging condition

The input voltage from swing pressure sensor is 4.7V or more.

Symptom

The swing operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

46

B-7 SWING

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Swing pressure sensor SE-5

When B074 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between swing pressure sensor and controller CN-169F CN-103F

When B074 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-25

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-29 Error code

B092

Trouble

Travel right pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the travel right pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The travel right operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

6

B-9 TRAVEL (R)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel right pressure sensor SE-9

When B092 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between travel right pressure sensor and controller CN-301F CN-102F

When B092 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-30 Error code

B093

Trouble

Travel right pressure sensor's wiring is disconnected.

Judging condition

The input voltage from Travel right pressure sensor is 0.1V or less.

Symptom

The Travel right operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

B-9 TRAVEL (R)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel right pressure sensor SE-9

When B093 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between travel right pressure sensor and controller CN-301F CN-102F

When B093 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-26

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-31 Error code

B094

Trouble

Travel right pressure sensor's power source is shortcut.

Judging condition

The input voltage from Travel right pressure sensor is 4.7V or more.

Symptom

The Travel right operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

B-9 TRAVEL (R)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel right pressure sensor SE-9

When B094 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between travel right pressure sensor and controller CN-301F CN-102F

When B094 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-32 Error code

B102

Trouble

Travel left pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the travel left pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The travel left operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

6

B-10 TRAVEL (L)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel left pressure sensor SE-10

When B102 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between travel left pressure sensor and controller CN-302F CN-102F

When B102 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-27

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-33 Error code

B103

Trouble

Travel left pressure sensor's wiring is disconnected.

Judging condition

The input voltage from Travel left pressure sensor is 0.1V or less.

Symptom

The Travel left operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

B-10 TRAVEL (L)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel left pressure sensor SE-10

When B103 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between travel left pressure sensor and controller CN-302F CN-102F

When B103 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-34 Error code

B104

Trouble

Travel left pressure sensor's power source is shortcut.

Judging condition

The input voltage from Travel left pressure sensor is 4.7V or more.

Symptom

The Travel left operability becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

B-10 TRAVEL (L)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel left pressure sensor SE-10

When B104 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between travel left pressure sensor and controller CN-302F CN-102F

When B104 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-28

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-35 Error code

B113

Trouble

Option selector position detect pressure sensor's wiring is disconnected.

Judging condition

The input voltage from option selector position detect pressure sensor is 0.1V or less.

Symptom

When Breaker mode is selected, option selector valve error is indicated.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

9

F-4

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Option selector position detect pressure sensor SE-29

When B113 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F

When B113 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-36 Error code

B114

Trouble

Option selector position detect pressure sensor's wiring is disconnected.

Judging condition

The input voltage from selector position detect pressure sensor is 4.7V or more.

Symptom

When Breaker mode is selected, option selector valve error is indicated.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

9

F-4

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Option selector position detect pressure sensor SE-29

When B114 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F

When B114 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-29

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-37 Error code

B162

Trouble

P1 side option pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P1 side option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The P1 side option operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-16 P1 OPT.

Screen No. Screen No.

Checking object

3

Checking contents and remedy

1

-P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch SE-20 on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 side option pressure sensor and controller CN-304F CN-102F

When B162 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-30

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-38 Error code

B163

Trouble

P1 side option pressure sensor's wiring is disconnected.

Judging condition

The input voltage from P1 side option pressure sensor is 0.1V or less.

Symptom

The P1 side option does not work.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1 unload proportional valve to 750mA. But normal control is done when the left control pedal selection is ON.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-16 P1 OPT.

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch SE-20 on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 side option pressure sensor and controller CN-304F CN-102F

When B163 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-31

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-39 Error code

B164

Trouble

P1 side option pressure sensor's wiring is disconnected.

Judging condition

The input voltage from P1 side option pressure sensor is 4.7V or more.

Symptom

The P1 side option does not work.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of boom-up, set output of P1 unload proportional valve to 750mA. But normal control is done when the left control pedal selection is ON.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-16 P1 OPT.

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch SE-20 on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 side option pressure sensor and controller CN-304F CN-102F

When B164 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-32

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-40 Error code

B172

Trouble

P2 side option pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P2 side option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The P2 side option operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

5

B-17 P2 OPT.

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 side option pressure sensor SE-11

When B172 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 side option pressure sensor and controller CN-303F CN-102F

When B172 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-33

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-41 Error code

B173

Trouble

P2 side option pressure sensor's wiring is disconnected.

Judging condition

The input voltage from P2 side option pressure sensor is 0.1V or less.

Symptom

The selection of conflux does not work.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-17 P2 OPT.

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 side option pressure sensor SE-11

When B173 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 side option pressure sensor and controller CN-303F CN-102F

When B173 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-34

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-42 Error code

B174

Trouble

P2 side option pressure sensor's wiring is disconnected.

Judging condition

The input voltage from P2 side option pressure sensor is 4.7V or more.

Symptom

The selection of conflux does not work.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to constant current. (Current when all operation is in neutral.) Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

5

B-17 P2 OPT.

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 side option pressure sensor SE-11

When B174 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 side option pressure sensor and controller CN-303F CN-102F

When B174 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-43 Error code

C012

Trouble

P1 pump pressure sensor outputs error

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P1 pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The P1 pump operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

7

C-1 PUMP P1

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 pump pressure sensor SE-22

When C012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 pump pressure sensor and controller CN-139F CN-103F

When C012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-35

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-44 Error code

C013

Trouble

P1 pump pressure sensor's wiring is disconnected.

Judging condition

The input voltage from P1 pump pressure sensor is 0.1V or less.

Symptom

The delicate operability of P1 pump related attachment becomes poor.

Control in the event of failure

Set P1 pump pressure to 25MPa and control pump.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

C-1 PUMP P1

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 pump pressure sensor SE-22

When C013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 pump pressure sensor and controller CN-139F CN-103F

When C013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-45 Error code

C014

Trouble

P1 pump pressure sensor's power source is shortcut.

Judging condition

The input voltage from P1 pump pressure sensor is 4.7V or more.

Symptom

The delicate operability of P1 pump related attachment becomes poor.

Control in the event of failure

Set P1 pump pressure to 25MPa and control pump.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

C-1 PUMP P1

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 pump pressure sensor SE-22

When C014 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 pump pressure sensor and controller CN-139F CN-103F

When C014 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-36

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-46 Error code

C022

Trouble

P2 pump pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P2 pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The P2 pump operability becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

7

C-2 PUMP P2

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 pump pressure sensor SE-23

When C022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 pump pressure sensor and controller CN-140F CN-103F

When C022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-47 Error code

C023

Trouble

P2 pump pressure sensor's wiring is disconnected.

Judging condition

The input voltage from P2 pump pressure sensor is 0.1V or less.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the event of failure

Set P2 pump pressure to 25MPa and control pump.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

C-2 PUMP P2

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 pump pressure sensor SE-23

When C023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 pump pressure sensor and controller CN-140F CN-103F

When C023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-37

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-48 Error code

C024

Trouble

P2 pump pressure sensor's power source is shortcut.

Judging condition

The input voltage from P2 pump pressure sensor is 4.7V or more.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the event of failure

Set P2 pump pressure to 25MPa and control pump.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

C-2 PUMP P2

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 pump pressure sensor SE-23

When C024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 pump pressure sensor and controller CN-140F CN-103F

When C024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-49 Error code

C033

Trouble

Boom head pressure sensor's wiring is disconnected.

Judging condition

The input voltage from boom head pressure sensor is 0.1V or less.

Symptom

Indication load value of High-reach crane becomes abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

C-3 BOOM-HEAD

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom head pressure sensor SE-24

When C033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom head pressure sensor and controller CN-706F CN-104F

When C033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-38

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-50 Error code

C034

Trouble

Boom head pressure sensor's power source is shortcut.

Judging condition

The input voltage from boom head pressure sensor is 4.7V or more.

Symptom

Indication load value of High-reach crane becomes abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

C-3 BOOM-HEAD

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom head pressure sensor SE-24

When C034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom head pressure sensor and controller CN-706F CN-104F

When C034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-51 Error code

C043

Trouble

Boom rod pressure sensor's wiring is disconnected.

Judging condition

The input voltage from boom rod pressure sensor is 0.1V or less.

Symptom

Indication load value of High-reach crane becomes abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

46

6

C-4 BOOM-ROD

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom rod pressure sensor SE-25

When C043 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom rod pressure sensor and controller CN-705F CN-104F

When C043 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-39

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-52 Error code

C044

Trouble

Boom rod pressure sensor's power source is shortcut.

Judging condition

The input voltage from boom rod pressure sensor is 4.7V or more.

Symptom

Indication load value of High-reach crane becomes abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

6

C-4 BOOM-ROD

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Boom rod pressure sensor SE-25

When C044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between boom rod pressure sensor and controller CN-705F CN-104F

When C044 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-53 Error code

D012

Trouble

P1 unload proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

Option conflux can not be done.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-1 P1 UN-LOAD (BP-CUT)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 unload proportional valve PSV-D

When D012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 unload pressure sensor and controller CN-120F CN-105F

When D012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-40

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-54 Error code

D013

Trouble

P1 unload proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

Option conflux can not be done.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-1 P1 UN-LOAD (BP-CUT)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 unload proportional valve PSV-D

When D013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P1 unload pressure sensor and controller CN-120F CN-105F

When D013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-55 Error code

D022

Trouble

P2 unload proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

Independent operations of boom up and of bucket digging/dump become slow.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-2 P2 UN-LOAD (BP-CUT)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 unload proportional valve PSV-B

When D022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 unload proportional valve and controller CN-118F CN-105F

When D022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-41

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-56 Error code

D023

Trouble

P2 unload proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

Independent operations of boom up and of bucket digging/dump become slow.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-2 P2 UN-LOAD (BP-CUT)

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 unload proportional valve PSV-B

When D023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between P2 unload proportional valve and controller CN-118F CN-105F

When D023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-57 Error code

D032

Trouble

Travel straight proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

Travel deviation occurs by combined operation of travel and attachment.

Control in the event of failure

Set Travel straight proportional valve output to 0mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-3 S-TRAVEL

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel straight proportional valve PSV-C

When D032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Travel straight proportional valve and controller CN-119F CN-105F

When D032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-42

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-58 Error code

D033

Trouble

Travel straight proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

Travel deviation occurs by combined operation of travel and attachment.

Control in the event of failure

Set Travel straight proportional valve output to 0mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-3 S-TRAVEL

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel straight proportional valve PSV-C

When D033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Travel straight proportional valve and controller CN-119F CN-105F

When D033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-59 Error code

D062

Trouble

Arm-in spool 2 proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

Operability of combined operation with arm-in becomes poor.

Control in the event of failure

Set Arm-in spool 2 proportional valve output to 0mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-6 ARM IN-2-SPEED

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-in spool 2 proportional valve PSV-A

When D062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F

When D062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-43

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-60 Error code

D063

Trouble

Arm-in spool 2 proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

Operability of combined operation with arm-in becomes poor.

Control in the event of failure

Set Arm-in spool 2 proportional valve output to 0mA.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

7

D-6 ARM IN-2-SPEED

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Arm-in spool 2 proportional valve PSV-A

When D063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F

When D063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-61 Error code

D152

Trouble

Proportional bypass valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

Operability of combined operation with travel becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No.

12

D-15

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Proportional bypass valve PSV-R

When D152 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Proportional bypass valve and controller CN-299 CN-106F

When D152 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-44

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-62 Error code

D153

Trouble

Proportional bypass valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

Operability of combined operation with travel becomes poor.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No.

12

D-15

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Proportional bypass valve PSV-R

When D153 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Proportional bypass valve and controller CN-299 CN-106F

When D153 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-63 Error code

E012

Trouble

P1 pump proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

6

E-1 PUMP P1

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 pump proportional valve PSV-P1

When E012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

-Wiring between P1 pump proportional valve and controller CN-141F CN-105F

When E012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-45

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-64 Error code

E013

Trouble

P1 pump proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

6

E-1 PUMP P1

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P1 pump proportional valve PSV-P1

When E013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

-Wiring between P1 pump proportional valve and controller CN-141F CN-105F

When E013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-65 Error code

E022

Trouble

P2 pump proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

6

E-2 PUMP P2

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 pump proportional valve PSV-P2

When E022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

-Wiring between P2 pump proportional valve and controller CN-142F CN-105F

When E022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-47

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-66 Error code

E023

Trouble

P2 pump proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the event of failure

Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)

Returned in normal condition

Not returned automatically under normal condition. Switch the power OFF once and turns on it again.

Service diagnosis checking screen

Screen No.

6

E-2 PUMP P2

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-P2 pump proportional valve PSV-P2

When E023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

-Wiring between P2 pump proportional valve and controller CN-142F CN-105F

When E023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-48

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-67 Error code

E032

Trouble

Optional relief adjusting proportional valve 1 and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

Does not relieve at setting pressure.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No.

7

E-3 Optional relief 1

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Optional relief adjusting proportional valve 1 PSV-E

When E032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Optional relief adjusting proportional valve 1 and controller CN-148F CN-105F

When E032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-68 Error code

E033

Trouble

Optional relief adjusting proportional valve 1 wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

Does not relieve at setting pressure.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No.

7

E-3 Optional relief 1

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Optional relief adjusting proportional valve 1 PSV-E

When E033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Optional relief adjusting proportional valve 1 and controller CN-148F CN-105F

When E033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-49

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-69 Error code

E042

Trouble

Optional relief adjusting proportional valve 2 and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000mA or more.

Symptom

Does not relieve at setting pressure.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No.

7

E-4 Optional relief 2

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Optional relief adjusting proportional valve 2 PSV-I

When E042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Optional relief adjusting proportional valve 2 and controller CN-132F CN-106F

When E042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-70 Error code

E043

Trouble

Optional relief adjusting proportional valve 2 wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)

Symptom

Does not relieve at setting pressure.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No.

7

E-4 Optional relief 2

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Optional relief adjusting proportional valve 2 PSV-I

When E043 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

-Wiring between Optional relief adjusting proportional valve 2 and controller CN-132F CN-106F

When E043 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-50

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-71 Error code

F011

Trouble

ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

ATT boost is not available.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is 24V level while exciting command is output.

Service diagnosis checking screen

Screen No.

3

F-1 POWER BOOST

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-ATT boost solenoid valve SV-2

When F011 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between ATT boost solenoid valve and controller CN-117F CN-105F

When F011 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-51

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-72 Error code

F013

Trouble

ATT boost solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24V level while exciting command is not output.

Symptom

ATT boost is not available or is leaving available.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is grounding level while exciting command is not output.

Service diagnosis checking screen

Screen No.

3

F-1 POWER BOOST

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-ATT boost solenoid valve SV-2

When F013 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between ATT boost solenoid valve and controller CN-117F CN-105F

When F013 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-73 Error code

F021

Trouble

Swing parking solenoid valve and output transistor OFF are failure, and grounding is shortcircuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Swing parking is not available.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is 24V level while exciting command is output.

Service diagnosis checking screen

Screen No.

3

F-2 SWING-BRAKE

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Swing parking solenoid valve SV-1

When F021 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between swing parking solenoid valve and controller CN-123F CN-105F

When F021 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-52

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-74 Error code

F023

Trouble

Swing parking solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24V level while exciting command is not output.

Symptom

Swing parking is not available or is leaving available.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is grounding level while exciting command is output.

Service diagnosis checking screen

Screen No.

3

F-1 POWER BOOST

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Swing parking solenoid valve SV-1

When F023 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between swing parking solenoid valve and controller CN-123F CN-105F

When F023 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-75 Error code

F031

Trouble

Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is shortcircuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Travel 2 speed is not obtainable.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is 24V level while exciting command is output.

Service diagnosis checking screen

Screen No.

3

F-3 1/2-TRAVEL

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the SV-3 connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between travel 1, 2speed solenoid valve and controller CN-122F CN-105F

When F031 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-53

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-76 Error code

F033

Trouble

Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24V level while exciting command is not output.

Symptom

Travel 2 speed is not obtainable or is keeping 1 speed.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is grounding level while exciting command is not output.

Service diagnosis checking screen

Screen No.

3

F-3 1/2-TRAVEL

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the SV-3 connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between travel 1, 2speed solenoid valve and controller CN-122F CN-105F

When F033 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-77 Error code

F041

Trouble

Option selector solenoid valve and output transistor OFF are failure, and grounding is shortcircuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Option selector valve does not change to breaker side.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is ground level while exciting command is output.

Service diagnosis checking screen

Screen No.

7

F-4 OPT SELECT

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Option selector solenoid valve SV-13

When F041 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between option selector solenoid valve and controller CN-251F CN-105F

When F041 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-54

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-78 Error code

F043

Trouble

Option selector solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24V level while exciting command is not output.

Symptom

Option selector valve does not change to breaker side or it does not change from breaker to nibbler.

Control in the event of failure

Normal control

Returned in normal condition

The feed-back signal is ground level while exciting command is not output.

Service diagnosis checking screen

Screen No.

9

F-4 OPT SELECT

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Option selector solenoid valve SV-13

When F043 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

-Wiring between option selector solenoid valve and controller CN-251F CN-105F

When F043 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-79 Error code

G032

Trouble

Mechatro controller direct input speed sensor is overrun.

Judging condition

Engine rpm input is 3000rpm or more. (Only trouble history)

Symptom

Operate without problem.

Control in the event of failure

Receive rpm from engine controller and control the rpm.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Screen No.

2

G-3 MEAS 2 (receive from engine controller)

Screen No.

Checking object

Checking contents and remedy

1

-Engine speed sensor SE-13

Measure the resistance between terminals of speed sensor. Normal value: 1.6 to 2.0 kilo-ohms

2

-Wiring between engine speed sensor and controller CN-136F CN-106F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Especially check wiring for false disconnection and noise included.

3

-Mechatro controller

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)

46-55

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-80 Error code

G033

Trouble

Mechatro controller direct input speed sensor, Disconnection

Judging condition

Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.

Symptom

Operate without problem.

Control in the event of failure

Receive rpm from engine controller and control the rpm.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Screen No.

2

G-3 MEAS 2 (receive from engine controller)

Screen No.

Checking object

Checking contents and remedy

1

-Engine speed sensor SE-13

Measure the resistance between terminals of speed sensor. Normal value: 1.6 to 2.0 kilo-ohms

2

-Wiring between engine speed sensor and controller CN-136F CN-106F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)

46-56

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-81 Error code

G042

Trouble

Mechatro controller direct input speed sensor and received data from engine controller are overrun.

Judging condition

Engine rpm input is 3000rpm or more. (Only trouble history)

Symptom

Operate without problem.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Screen No.

2

G-3 MEAS 2 (receive from engine controller)

Screen No.

Checking object

Checking contents and remedy

1

-Engine speed sensor SE-13

Measure the resistance between terminals of speed sensor. Normal value: 1.6 to 2.0 kilo-ohms

2

- Wiring between engine speed sensor and controller CN-136F CN-106F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Especially check wiring for false disconnection and noise included.

3

-Wiring between ECU engine speed sensor and controller pressure sensor and controller

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Especially check wiring for false disconnection and noise included.

4

-Mechatro controller

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)

5

-Engine controller

Check that the error is corrected after replacement of controller.

46

46-57

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-82 Error code

G043 When cranking is executed for five seconds or more, this error code might be displayed. In case that the engine does not start, check by the table of "Section 47.3 Engine related Troubleshooting". Execute the following check when the error code G043 is displayed after starting the engine.

Trouble

Mechatro controller direct input speed sensor and received data from engine controller are disconnected.

Judging condition

Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller indicate excess low engine rpm.

Symptom

Engine speed down may cause extension by abrupt loading.

Control in the event of failure

Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Screen No.

2

G-3 MEAS 2 (receive from engine controller)

Screen No.

Checking object

Checking contents and remedy

1

-Engine speed sensor SE-13

Measure the resistance between terminals of speed sensor. Normal value: 1.6 to 2.0 kilo-ohms

2

-Wiring between engine speed sensor and controller CN-136F CN-106F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Wiring between ECU engine speed sensor and controller pressure sensor and controller

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

4

-Mechatro controller

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)

5

-Engine controller

Check that the error is corrected after replacement of controller.

46-58

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-83 Error code

H013

Trouble

Accel potentiometer is disconnected.

Judging condition

The input voltage from accel potentiometer is 0.1V or less.

Symptom

LOW idling is fixed.

Control in the event of failure

LOW idling is fixed.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

2

H-1 ACCEL VOLT.

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Accel potentiometer SE-16

Measure the resistance between terminals of speed sensor. Normal value: 1.6 to 2.4 kilo-ohms Turn the potentiometer and measure resistance between signal and GND.

2

-Wiring between accel potentiometer and controller CN-402F CN-102F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-84 Error code

H014

Trouble

Accel potentiometer's power source is shortcut.

Judging condition

The input voltage from accel potentiometer is 4.7V or more.

Symptom

LOW idling is fixed.

Control in the event of failure

LOW idling is fixed.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

2

H-1 ACCEL VOLT.

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Accel potentiometer SE-16

Measure the resistance between terminals of accel potentiometer. 1.6 to 2.4 kilo-ohms Turn the potentiometer and measure resistance between signal and GND.

2

-Wiring between accel potentiometer and controller CN-402F CN-102F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-59

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-85 Error code

H023

Trouble

Boom angle potentiometer's wiring is disconnected.

Judging condition

The input voltage from boom angle potentiometer is 0.1V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Screen No. Service diagnosis Screen No. checking screen Screen No.

10

H-2 BOOM

Checking object

Checking contents and remedy

1

-Boom angle potentiometer SE-17

Measure the resistance between terminals of boom angle potentiometer. 4.0 to 6.0 kilo-ohms Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms

2

-Wiring between accel potentiometer and controller CN-702F CN-103F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-86 Error code

H024

Trouble

Boom angle potentiometer's power source is shortcut.

Judging condition

The input voltage from boom angle potentiometer is 0.1V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Screen No. Service diagnosis Screen No. checking screen Screen No.

10

H-2 BOOM

Checking object

Checking contents and remedy

1

-Boom angle potentiometer SE-17

Measure the resistance between terminals of boom angle potentiometer. 4.0 to 6.0 kilo-ohms Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms

2

- Wiring between boom angle potentiometer and controller CN-702F CN-103F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-60

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-87 Error code

H033

Trouble

Arm angle potentiometer's wiring is disconnected.

Judging condition

The input voltage from arm angle potentiometer is 0.1V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Screen No. Service diagnosis Screen No. checking screen Screen No.

10

H-3 ARM

Checking object

Checking contents and remedy

1

-Arm angle potentiometer SE-19

Measure the resistance between terminals of arm angle potentiometer. 4.0 to 6.0 kilo-ohms Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms

2

-Wiring between arm angle potentiometer and controller CN-703F CN-103F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-88 Error code

H034

Trouble

Arm angle potentiometer's power source is shortcut.

Judging condition

The input voltage from arm angle potentiometer is 0.1V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the event of failure

Normal control

Returned in normal condition

It returns automatically in normal condition.

Screen No. Service diagnosis Screen No. checking screen Screen No. Checking object

10

H-3 ARM

Checking contents and remedy

1

-Arm angle potentiometer SE-19

Measure the resistance between terminals of arm angle potentiometer. 4.0 to 6.0 kilo-ohms Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms

2

-Wiring between arm angle potentiometer and controller CN-703F CN-103F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-61

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-89 Error code

H091

Trouble

Fuel sensor grounding is short-circuited.

Judging condition

The input voltage from fuel sensor is 0.1V or less.

Symptom

Warning for low fuel level is indicated.

Control in the event of failure

Fuel level becomes 0%.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

8

H-9 FUEL LEVEL

Screen No. Screen No.

Checking object

Checking contents and remedy

1

- Fuel sensor potentiometer SE-15

Move fuel sensor and measure the resistance between terminals of fuel sensor. EMPTY 95 ohms to FULL 5 ohms

2

-Wiring between fuel sensor and controller CN-152F CN-104F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-90 Error code

H093

Trouble

Fuel sensor's wiring is disconnection.

Judging condition

The input voltage from fuel sensor is 4.7V or more.

Symptom

Warning for low fuel level is indicated.

Control in the event of failure

Fuel level becomes 0%.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

8

H-9 FUEL LEVEL

Screen No. Screen No.

Checking object

Checking contents and remedy

1

- Fuel sensor potentiometer SE-15

Move fuel sensor and measure the resistance between terminals of fuel sensor. EMPTY 95 ohms to FULL 5 ohms

2

-Wiring between fuel sensor and controller CN-152F CN-104F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-62

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-91 Error code

I111

Trouble

Reception of CAN1 communication is abnormal. (Passive error)

Judging condition

Reception from engine controller can not receive correctly.

Symptom

It has been affected little.

Control in the event of failure

Keep the last receiving condition.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Wiring between ECU and controller CN-3F CN-101F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. (There is a possibility of false disconnection.)

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-92 Error code

I113

Trouble

Reception of cluster communication is abnormal. (Time-out error)

Judging condition

Reception from gauge cluster can not receive correctly. It has been affected little.

Symptom

It has been affected little.

Control in the event of failure

It can be operated in condition that coolant temperature is 20C degrees.

Returned in normal condition

It returns automatically in normal condition.

Service diagnosis checking screen

Screen No.

2

G-5 WATER TEMP

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Wiring between ECU and controller CN-3F CN-101F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-63

46

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-93 Error code

I121

Trouble

Transmission of CAN1 communication is abnormal. (Busoff)

Judging condition

Transmission from mechatro controller can not receive correctly.

Symptom

It has been affected little.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Wiring between ECU and controller CN-12F CN-101F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. (There is a possibility of false disconnection.)

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-94 Error code

I211

Trouble

Reception of CAN1 communication is abnormal. (Passive error)

Judging condition

Reception from gauge cluster can not receive correctly.

Symptom

Switch operation of gauge cluster can not be done.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Wiring between gauge cluster and controller CN-601F CN-106F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-64

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-95 Error code

I213

Trouble

Reception of CAN2 communication is abnormal. (Time-out)

Judging condition

Reception from gauge cluster can not receive correctly.

Symptom

Switch operation of gauge cluster can not be done.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

Screen No. Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Wiring between gauge cluster and controller CN-601F CN-106F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

Table 46-96 Error code

I221

Trouble

Transmission of CAN2 communication is abnormal. (Busoff)

Judging condition

Transmission from mechatro controller can not receive correctly.

Symptom

It has been affected little.

Control in the event of failure

Normal control

Returned in normal condition

Normal control

Service diagnosis checking screen

46

Screen No. Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Wiring between ECU and controller CN-601F CN-106F

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. (There is a possibility of false disconnection.)

2

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-65

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-97 Error code

K014

Trouble

Battery relay contact welded

Judging condition

The power 24V is continuously supplied to controller for 40 seconds or more while the key switch ON signal turned OFF

Symptom

The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.

Control in the event of failure

Normal control with key switch OFF

Returned in normal condition

Turn key switch ON. Or when the power supply 24V to mechatro controller is stopped

Service diagnosis checking screen

Screen No.

4

K-1 AIS RELAY 2

Screen No.

4

K-3 KEY SWITCH OFF

Screen No.

Checking object

Checking contents and remedy

1

-Battery relay R-1 CN-256F

Turn key switch off and disconnect the connector (CN-256F) on the battery relay coil. If 24V power lives on battery relay secondary side, check on battery relay for failure and replace it if failed.

2

-Auto idle stop relay 2 R-24 -Alternator relay R-28

Turn off the key switch, and remove the connector (CN-256F) on the battery relay coil side. If power of battery relay on secondary side falls, remove either auto idling stop relay 2 or alternator relay. The failure may be occurred in case where the power falls after the relay was removed, and therefore check on the relay unit and replace it with new one if failed.

3

-Wiring between auto idle stop relay/alternator relay and controller CN-109F, CN2-1 -Fuse & relay box E-1

When K014 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and K014 is left displayed Replace fuse/relay box.

4

-Mechatro controller

Check that the error is corrected after replacement of controller.

46-66

46. TROUBLE SHOOTING (BY ERROR CODES) Table46-98 Error code

R014

Trouble

Wiper motor arc prevention relay error

Judging condition

The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power source.

Symptom

Wiper does not move.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

19

PREVENT ARC

Checking object 1

Checking contents and remedy

• Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay, R-31 check relay unit for failure, replace it with new one if failed.

When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between wiper motor arc prevention relay and controller CN-109F, CN2-1 • Fuse & relay box E-1

When R014 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R014 is left displayed Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table46-99 Error code

R024

Trouble

Wiper motor forward rotation relay error

Judging condition

The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the power source.

Symptom

Wiper does not move.

Control in the event of failure

Relay output is stopped.

46

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

19

Checking object

CW MOTOR RLY

Checking contents and remedy

1

• Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay, relay check relay unit for failure, replace it with new one if failed. R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between wiper motor forward rotation relay and controller CN-109F, CN2-1 •Fuse & relay box E-1

When R024 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R024 is left displayed Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

46-67

46. TROUBLE SHOOTING (BY ERROR CODES) Table46-100 Error code

R034

Trouble

Wiper motor reverse rotation relay error

Judging condition

The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power source.

Symptom

Wiper does not move after forward rotation.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

19

CCW MOTOR RLY

Checking object

Checking contents and remedy

1

• Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay, relay check relay unit for failure, replace it with new one if failed. R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between wiper motor forward rotation relay and controller CN-109F, CN2-1 •Fuse & relay box E-1

When R034 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R034 is left displayed Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table46-101 Error code

R044

Trouble

Washer motor relay error

Judging condition

The mechatro controller output line to washer motor relay is short-circuited with the power source.

Symptom

Washer motor does not move.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

19

Checking object 1

• Washer motor relay R-32

MOTOR RELAY

Checking contents and remedy When error is cancelled after removing washer motor relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between washer motor relay and controller CN-112F, CN2-1 •Fuse & relay box E-1

When R044 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R044 is left displayed Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

46-68

46. TROUBLE SHOOTING (BY ERROR CODES) Table46-102 Error code

R134

Trouble

Swing flasher right relay error

Judging condition

The mechatro controller output line to swing flasher right relay is short-circuited with the power source.

Symptom

Right swing flasher does not light.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

16

D13

Checking object 1

Checking contents and remedy

• Swing flasher relay R-19

When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0

, it is in abnormal condition.

2

• Wiring between swing flasher When R134 is left displayed with the relay removed relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table46-103 Error code

R144

Trouble

Swing flasher left relay error

Judging condition

The mechatro controller output line to swing flasher left relay is short-circuited with the power source.

Symptom

Left swing flasher does not light.

Control in the event of failure

Relay output is stopped.

46

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

Checking object 1

• Swing flasher relay R-19

17

D14

Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0

, it is in abnormal condition.

2

• Wiring between swing flasher When R144 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line (as shown right upper relay and controller CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

46-69

46. TROUBLE SHOOTING (BY ERROR CODES) Table46-104 Error code

R154

Trouble

Travel alarm relay error

Judging condition

The mechatro controller output line to travel alarm relay is short-circuited with the power source.

Symptom

Travel alarm does not actuate.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

17

D15

Checking object 1

Checking contents and remedy

• Travel alarm relay R-8

When error is cancelled after removing of travel alarm relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between travel alarm relay and controller CN-109F, CN2-2 •Fuse & relay box E-1

When R154 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R154 is left displayed. Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table46-105 Error code

R164

Trouble

Auto idle stop relay 2 relay error

Judging condition

The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.

Symptom

Power source for mechatro controller often turns off. Auto idle stop relay 2 does not actuate.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

4

Checking object 1

• Auto idle stop relay 2 relay R-24

K-1 AIS RELAY 2

Checking contents and remedy When error is cancelled after removing of auto idle stop relay 2, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between auto idle stop relay 2 and controller CN-109F, CN2-2 •Fuse & relay box E-1

When R164 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R164 is left displayed. Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

46-70

46. TROUBLE SHOOTING (BY ERROR CODES) Table46-106 Error code

R174

Trouble

Engine forcibly stop relay error

Judging condition

The mechatro controller output line to engine forcibly stop is short-circuited with the power source.

Symptom

When key switch is turned off but engine does not stop. Engine auto idle stop function does not actuate.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

4

Checking object 1

• Engine forcibly stop relay R-25

K-3 ENG STOP

Checking contents and remedy When error is cancelled after removing of engine forcibly stop relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between engine forcibly stop relay and controller CN-109F, CN2-2 • Fuse & relay box E-1

When R174 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R174 is left displayed. Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

46

46-71

46. TROUBLE SHOOTING (BY ERROR CODES) Table46-107 Error code

R184

Trouble

Safety lock lever relay error

Judging condition

The mechatro controller output line to safety lock lever relay is short-circuited with the power source.

Symptom

Safety lock lever timer does not actuate.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

4

K-4 LOCK LEVER

Checking object 1

Checking contents and remedy

• Safety lock lever relay R-26

When error R184 is cancelled after removing of safety lock lever relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1

When R184 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R184 is left displayed. Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table46-108 Error code

R214

Trouble

Safety relay error

Judging condition

The mechatro controller output line to safety relay is short-circuited with the power source.

Symptom

Safety relay does not actuate.

Control in the event of failure

Relay output is stopped.

Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.

4

Checking object 1

• Safety lock lever relay R-26

K-2 SAFETY RLY

Checking contents and remedy When error R214 is cancelled after removing of safety relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1

When R214 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R214 is left displayed. Replace fuse/relay box.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

46-72

46. TROUBLE SHOOTING (BY ERROR CODES) Table 46-101 Error code

Z010

Trouble

Common rail pressure error

Judging condition

Common rail pressure is low than the specified level.

Symptom

Usual operation has no problem. However, if the engine continues to drive under this condition, it may cause the engine failure by the breakage of injector.

Control in the event of failure

Control the engine usually. (Warning by only error code and buzzer.)

Returned in normal condition

After the starter switch is turned off, if the engine is normal, when the starter switch is turned on, the error code is not displayed. And the engine returns to normal condition automatically. When the engine does not return to normal condition, check the injector.

Service diagnosis checking screen

Screen No.

22

Engine oil pressure

Screen No. Screen No.

Checking object

Checking contents and remedy

1

-Fuel line, pressure sensor for common rail

Check the leakage from piping and the failure of pressure sensor for common rail. Check the “ENG oil press” of display number 28 on service diagnosis screen whether the value is within the specified value. When the value deviates from the specified value, repair the piping or replace the sensor. (Contact our service for the specified value.)

2

-Injector

By using “HINO DX”, measure the common rail pressure. Check the all injector, because there is a possibility of failure. If the failure is found, replace the injector. (Contact our service for detail.)

3

-Fuel, fuel filter

Check clogging of fuel filter, contamination in the fuel tank, and breakage of the hose. If the failure is found, clean or replace the parts. And investigate the fuel and filter that are used by customer. In addition, confirm the user’s handling method for injection nozzle and fuel tank. If poor handling is found, ask for the improvement.

46-73

46

46. TROUBLE SHOOTING (BY ERROR CODES)

46-74

47. TROUBLESHOOTING (BY TROUBLE)

47. TROUBLESHOOTING (BY TROUBLE) TABLE OF CONTENTS

47.1 HYDRAULIC SYSTEM ...................................................................................... 47-3 47.2 ELECTRIC SYSTEMS ....................................................................................... 47-36 47.2.1 WIRING CHECKING PROCEDURE ......................................................... 47-36 47.2.2 TROUBLE .................................................................................................. 47-38 47.3 ENGINE RELATED TROUBLESHOOTING ....................................................... 47-41

47

Book Code No. S5LC4726E01 47-1

47. TROUBLESHOOTING (BY TROUBLE)

Issue First Edition

Data of Issue

Applicable Machines

Remarks S5LC4726E01 NA

September, 2010 SK350-9: YC

47-2

47. TROUBLESHOOTING (BY TROUBLE)

47.1

HYDRAULIC SYSTEM

Preface: The troubleshooting for the failures shown below are explained here. Identify the failure and trouble, and carry forward the troubleshooting in order of the failure item number. (1) All controls do not function/slow (2) Engine down/stalled (3) Move at lever neutral position (4) Poor fine operability (5) Slow boom up, insufficient power (6) Slow boom down, insufficient power for lifting up body (7) Slow arm in, insufficient power (8) Slow independent arm out (in the air) (9) Slow bucket digging (10)Slow bucket dumping (11)Swing operation not functioned/slow (12)Noise during swing operation (13)Swing on a slope drifts when control lever is in neutral position (14)Swing drifts when swing operation is stopped (15)Slow travel speed/weak (16)Travel deviation (17)Travel 1st/2nd speed not changed (18)Travel parking on a slope is not held (19)Travel does not run straight when both crawlers and attachment are operated simultaneously (20)Slow breaker (crusher) operation, weak power (21)Option selector valve malfunction: not switched to breaker circuit (22)Option selector valve malfunction: not switched to nibbler circuit

47

47-3

47. TROUBLESHOOTING (BY TROUBLE) (1) All controls do not function/slow No.

Sections

Contents/normal value

Corrective action, others

1

Fuse

Check fuse No.4 (10A)

If the fuse is blown out, check on the short-circuited section.

2

Safety lever lock switch

Carry out service diagnosis

No.4 K-4 switch: Push down the lever and it turns on, push up and it turns off.

3

Safety lever lock switching

Check that the Measure both terminals of solenoid Check solenoid unit for solenoid is connector. 24V by pushing the possible failure. switched correctly lever down, 0V by pushing it up Check harness for possible failure.

4

Safety lever lock relay

Carry out service diagnosis

5

Pilot pressure sensor

Stop engine stop Check 5V power for controller and key is on position. All pilot low pressure sensors are 0MPa to 0.1MPa.

6

Solenoid valve for safety lock lever

Measure pressure of solenoid A1 port

About 0MPa by pushing the lever up, and 4MPa or more by pushing it down.

Replace solenoid valve

7

Pilot line filter

Disassemble and check it visually

Check filter for clogging

Clean filter

8

Pilot gear pump

Measure pilot primary pressure at gear pump

Check that it is 4MPa or more in high idling

Check gear pump and the relief valve for possible failure

9

Multi control valve (in case that travel is operable)

Change position

Since all are blocked due to poor switching performance, check that the lever select pattern is set to the proper position.

10

Carry out service Actual measuring current value of P1/ diagnosis P2 unload proportional valve

11

Secondary pressure of P1, P2 unload proportional valve

Measure the proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block

No.4 K-4 lock lever: Push down the lever and it turns off, push up and it turns on.

No.7 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.3 Boom up full lever & relief

Check action of switch by tester, or check that the power voltage is lowered by pushing the lever down.

Check action of relay by tester

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Replace proportional valve Check that P1/P2 unload secondary pressures are within the range of 0.5 to 1.2MPa in boom up full lever and high idling operation

47-4

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

Corrective action, others

12

Carry out service Actual measuring current value of P1/ diagnosis. P2 pump proportional valve

No.9 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

13

Secondary pressure of pump proportional valve

Measure the pump proportional valve secondary pressure directly in idling operation. (Ports a3, a4)

Check that the pump proportional valve secondary pressure is 2.7 MPa or more in right (left) travel full lever and high idling operation Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve

Replace proportional valve

14

Main relief pressure

Carry out service diagnosis

See Service Diagnosis Data List Operation No.3, Boom up full lever & relief

Measure the relief pressure actually

15

Check set pressure

Check that P1 Reset or replace and P2 pump pressures are 32 MPa or more in boom up full lever, high idling and H mode operation.

16

Pump regulator

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring free from breakage, damage, etc.

Replace

17

Pump

Visual check

When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.

Replace

47

47-5

47. TROUBLESHOOTING (BY TROUBLE) (2) Engine down/stalled No.

Sections

Contents/normal value

1

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

2

Secondary pressure of P1, P2 pump proportional valve

3

Corrective action, others

No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No. 1 Operation is nil

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that the P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation.

Replace proportional valve

Pressure sensor of P1, P2 pump

Check pressure

See Service Diagnosis Data List Operation No.1, Operation is nil Operation No.3, Boom up full lever & relief

Check pressure sensor and replace it if necessary

4

Pump regulator

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.

Replace

5

Pump

Visual check

When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.

Replace

47-6

47. TROUBLESHOOTING (BY TROUBLE) (3) Move at lever neutral position No.

Sections

Contents/normal value

Corrective action, others

1

Pilot pressure sensor

Carry out service diagnosis

Check that the targeted pilot pressure of sensor is 0MPa in high idling

Check remote control valve

2

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

3

Main spool

Check targeted spool visually

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

4

Over load relief valve

Check targeted spool visually

Free from dust entered in port relief Replace valve. Seat is free from abnormality.

5

Lock valve poppet (in case of boom and arm)

Check targeted poppet visually

Seat is free from abnormality

Replace

6

Lock valve selector Exchange lock (in case of boom valve selector of and arm) boom/arm and boom/arm

Check that the trouble is reversed

Replace

7

Holding valve spool for boom (in case of boom)

Check that smooth sliding of spool in sleeve

Free from abnormal resistance against sliding

Replace Do not pull spool out of sleeve forcibly.

8

Holding valve relief valve for boom (in case of boom)

Check targeted spool visually

Filter free from abnormal contamination

Replace

9

Cylinder

Check targeted cylinder visually

Make sure there is no problem of the seals by disassembling and investigating

Replace cylinder or seals

47

47-7

47. TROUBLESHOOTING (BY TROUBLE) (4) Poor fine operability No.

Sections

Contents/normal value

Corrective action, others

1

Pressure sensor

Carry out service diagnosis

See Service Diagnosis Data List Operation No. 1 Operation is nil All low pressure sensors are 0 MPa to 0.1 MPa

Replace pressure sensor

2

Actual measuring Carry out service current value of P1/ diagnosis P2 unload proportional valve

No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No. 1 Operation is nil

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

3

Secondary pressure of unload proportional valve

Check that the P1/P2 unload Replace proportional secondary pressures is within the valve range of 2.7 MPa or more in control lever neutral and high idling operation

4

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

5

Secondary pressure of P1, P2 pump proportional valve

6

Slow return check valve of pilot line (in case of boom up or arm out)

Measure the proportional valve secondary pressure directly at the ports A7 and A8 of 8 sections solenoid block

No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No. 1, Operation is nil

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Measure the pump proportional valve secondary pressure directly. (Ports a3, a4)

Check that the P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation

Replace proportional valve Check regulator

Visual check

Check that the slow return check valve installed on pilot line is free from dust

Clean and replace

47-8

47. TROUBLESHOOTING (BY TROUBLE) (5) Slow boom up, insufficient power No.

Sections

Contents/normal value

1

Boom up pressure sensor

Carry out service diagnosis

See Service Diagnosis Data List Operation No.3 boom up full lever and relief

2

Remote control valve

Measure directly remote control pressure of boom up

Check that the pressure is 3.0 MPa Check remote control or more in boom up full lever and valve high idling operation When equipped with multi control valve, check it while changing lever pattern

3

Pump pressure sensor

Carry out service diagnosis for P1, P2 pump pressures in operation.

See Service Diagnosis Data List Operation No.4, boom up full lever and in operation

When there is difference between P1 and P2 pump pressures, check high pressure sensor.

4

Carry out service Actual measuring current value of P1/ diagnosis P2 unload proportional valve

No.7 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.3 Boom up full lever & relief

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

5

Secondary pressure of P1, P2 unload proportional valve

Check that the P1/P2 unload Replace proportional secondary pressures are within the valve range of 0.5 to 1.2 MPa in boom up full lever and high idling operation

6

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.4 boom up full lever & in operation

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

7

Secondary pressure of P1, P2 pump proportional valve

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that the P1/P2 pump proportional valve pressures are within the range of 2.3 to 3.2 MPa in boom up full lever and high idling operation

Replace proportional valve

8

P2 by-pass cut valve

Only P2 pressure is low.

Visual check

Poppet should be tightened. Clean and replace Seated surface should be free from damage and entry of foreign matter.

9

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is not broken

Measure the proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block

47-9

Corrective action, others Check and replace pressure sensor Check remote control valve

47

Replace

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

Corrective action, others

10

Visual check Lock valve poppetB other P1 and P2 pressures are low.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

11

Conflux check valve

Only P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

12

Holding valve for Visual check boom (poppet)

Both P1 and P2 pressures are high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

13

Boom spool

Only P1 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding Spring is free from breakage.

Replace (Check on the casing side for damage)

14

Check boom spool and recirculation

Only P1 pressure is low.

Disassembly and investigation

Free from abnormal resistance against sliding Spring is free from breakage.

Replace spool assembly

15

Conflux spool

Only P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding. Spring is free from breakage. Free from abnormal damage, etc on outside surface.

Replace (Check on the casing side for damage)

16

Main relief valve

Relief pressure is low.

Check set pressure

See Service Diagnosis Data List Operation No.3 boom up full lever and relief

Reset or replace

17

Over load relief valve

Relief pressure is low.

Visual check (Head side)

Pressure is 32MPa or more in When only relief pressure boom up full lever and high idling. of boom up is low, replace Free from dust entered in over load valve relief valve. Seat is free from abnormality

47-10

47. TROUBLESHOOTING (BY TROUBLE) (6) Slow boom down/insufficient power for lifting up body No.

Sections

Contents/normal value

Corrective action, others

1

Boom down pressure sensor

Carry out service diagnosis

See Service Diagnosis Data List Operation No.5 boom down full lever & in operation

2

Remote control valve

Measure remote control pressure of boom down directly

Check that the pressure is 3.0 MPa Check remote control or more in boom down full lever valve. and high idling operation When equipped with multi control valve, check it while changing lever pattern.

3

Actual measuring current value of P1 unload proportional valve

Carry out service diagnosis

P1 unload valve (cut valve) -See Service Diagnosis Data List Operation No.5 boom down full lever & in operation

4

Secondary pressure of P1 unload proportional valve

Measure the proportional valve secondary pressure directly at the ports A7 of 8 sections solenoid block.

Check that the P1 unload Replace proportional secondary pressures are within the valve range of 1.1 to 1.4 MPa in boom down full lever and high idling operation

5

Actual measuring current value of P1 pump proportional valve

Carry out service diagnosis

No.6 E-1 P1 pump See Service Diagnosis Data List Operation No.5 boom down full lever & in operation

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

6

Secondary pressure of P1 pump proportional valve

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that the P1 pump proportional valve pressures are within the range of 1.9 to 2.5 MPa in boom down full lever and high idling operation

Replace proportional valve

7

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

Check that the value has not changed regardless of operation See Service Diagnosis Data List Operation No. 1, Operation is nil Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

Check pressure sensor of travel In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Travel straight proportional valve secondary pressure

Measure directly High idling pressure is 0.8 MPa or the travel straight less regardless of neutral or proportional valve operation secondary pressure.

8

47-11

Check and replace pressure sensor. Check remote control valve.

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Replace proportional valve

47

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

9

Remote control valve

10

Contents/normal value Check targeted remote control valve

Corrective action, others

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

Lock valve poppet Visual check

Boom down is low.

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface.

Replace (Check on the casing side for damage)

11

Holding valve (poppet)

Boom down is slow.

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface.

Replace (Check on the casing side for damage)

12

Boom spool

Boom down is slow.

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

Replace (Check on the casing side for damage)

13

Check boom spool Disassembly and and recirculation investigation

Machine cannot be lifted by and supported with boom.

Free from abnormal resistance against sliding. Spring is free from breakage.

Replace spool assembly

14

Spool of bypass valve

Visual check

When removing, there is no abnormal resistance against sliding. Free from abnormal damage etc. on outside surface. Spring should be free from breakage.

Replace the spool (Check on the casing side for damage.)

15

Main relief valve

Relief pressure is low.

Check set pressure

See Service Diagnosis Data List Operation No.3, boom up full lever and relief

Reset or replace

16

Over load relief Visual check valve

Machine cannot be lifted and supported with boom.

Free from dust entered in port relief Replace valve. Seat is free from abnormality.

47-12

47. TROUBLESHOOTING (BY TROUBLE) (7) Slow arm in, insufficient power No.

Sections

Contents/normal value

1

Arm in pressure sensor

Carry out service diagnosis

2

Remote control valve pressure

Measure directly Check that pressure is 3.0 MPa or remote control more in arm in full lever and high pressure of arm in idling operation

Check remote control valve When equipped with multi control valve, check it while changing lever pattern

3

Pump pressure sensor

Carry out service diagnosis for P1, P2 pump pressures in operation.

See Service Diagnosis Data List Operation No.7 arm in full lever and in operation

When there is difference between P1 and P2 pump pressures, check high pressure sensor

4

Carry out service Actual measuring current value of P1/ diagnosis P2 unload proportional valve

No.7 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.6, Arm in full lever & relief

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

5

Secondary pressure of P1, P2 unload proportional valve

Check that P1/P2 unload Replace proportional secondary pressures are within the valve range of 0.5 to 1.2 MPa in arm in full lever and high idling operation.

6

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

7

Secondary pressure of P1, P2 pump proportional valve

Measure the pump proportional valve secondary pressure directly. (Ports a3, a4)

Check that P1/P2 pump Replace proportional proportional valve pressures are valve 2.7 MPa or more in arm in full lever and high idling operation. (Secondary pressure is affected by oil temperature and attachment weight)

Actual measuring current value of arm in spool 2 proportional valve

Carry out service diagnosis

See Service Diagnosis Data List Operation No.1, Operation is nil Operation No.6, Arm in full lever & relief Operation No.7, Arm in full lever & in operation

8

Measure the proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block.

See Service Diagnosis Data List Operation No.6 arm in full lever and relief

Corrective action, others

No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.7 Arm in full lever & in operation

47-13

Check and replace pressure sensor Check remote control valve

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

47

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

9

Secondary pressure of arm in spool 2 proportional valve

Measure directly the proportional valve secondary pressure at ports A8 (arm 2 spool) of 8 sections solenoid block.

Check that the secondary pressure Replace proportional of proportional valve secondary valve pressures are within the range of following: Lever neutral: 0MPa Motion in the air: 1.7 to 2.2MPa Arm in relief: 2.5MPa or more

10

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

Check that the value has not changed regardless of operation See Service Diagnosis Data List Operation No. 1, Operation is nil Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

Check pressure sensor of travel In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

11

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block

0.8 MPa or less in high idling operation regardless of neutral/ operation

Replace proportional valve

12

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

13

Main relief valve

Relief pressure is low.

Check set pressure

See Service Diagnosis Data List Operation No.3, boom up full lever and relief

Reset or replace

14

Over load relief valve

P1, P2 pressure is low.

Visual check (Head side)

Pressure is 32 MPa or more in arm in and relief. Free from dust in over load relief valve. Seat is free from abnormality.

When only relief pressure of arm in is low, replace valve

15

Over load relief valve

P1, P2 pressure is low.

Visual check (Rod Pressure is 32 MPa or more in arm When only relief pressure side) out and relief. of arm out is low, replace Free from dust entered in over load valve relief valve. Seat is free from abnormality.

16

Arm 1 spool

P1, P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

47-14

Corrective action, others

Replace (Check on the casing side for damage)

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

Corrective action, others

17

Arm 2 spool

P1, P2 pressure is high or low.

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

Replace (Check on the casing side for damage)

18

Check arm 2 spool and recirculation

Arm in power is poor.

Disassembly and investigation

Free from abnormal resistance against sliding. Spring is free from breakage.

Replace spool assembly

19

Check lock valve Visual check poppet

Both P1, P2 pressures are high.

Free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface.

Replace (Check on the casing side for damage)

47

47-15

47. TROUBLESHOOTING (BY TROUBLE) (8) Slow independent arm out (in the air) No.

Sections

Contents/normal value

Corrective action, others

1

Arm out pressure sensor

Carry out service diagnosis

See Service Diagnosis Data List Operation No.8, Arm out full lever and relief

2

Remote control valve

Measure directly remote control pressure of arm out

Check that the pressure is 3.0,MPa Check remote control or more in arm out full lever and valve high idling operation When equipped with multi control valve, check it while changing lever pattern

3

Pump pressure sensor

Carry out service diagnosis for P1, P2 pump pressures in operation.

See Service Diagnosis Data List Operation No.9, Arm out full lever and in operation

When there is difference between P1 and P2 pump pressures, check high pressure sensor

4

Carry out service Actual measuring current value of P1/ diagnosis P2 unload proportional valve

No.7 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.8, Arm out full lever & relief

In case where the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

5

Secondary pressure of P1, P2 unload proportional valve

Check that P1/P2 unload Replace proportional secondary pressures are within the valve range of 0.5 to 1.2,MPa in arm out full lever and high idling operation

6

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

7

Secondary pressure of P1, P2 pump proportional valve

Measure the proportional valve secondary pressure directly at ports A7 and A5 of 8 sections solenoid block

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.9, Arm out full lever & in operation

Check and replace pressure sensor Check remote control valve

In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Check that P1/P2 pump Replace proportional proportional valve pressures are valve within the range of 1.7 to 2.9 MPa in arm out full lever and high idling operation (Secondary pressure is affected by oil temperature and attachment weight)

47-16

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

8

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

Check that the value has not changed regardless of operation See Service Diagnosis Data List Operation No. 1, Operation is nil Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

Check pressure sensor of travel In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

9

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure at ports A6 (travel straight) of 8 sections solenoid block

High idling pressure is 0.8 MPa or less regardless of neutral/ operation.

Replace proportional valve

10

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

11

Main relief valve

Relief pressure is low.

Check set pressure

See Service Diagnosis Data List Operation No.3, boom up full lever and relief

Reset or replace

12

Over load relief valve

P1, P2 pressure is low.

Visual check (Rod Pressure is 32,MPa or more in arm When only relief pressure side) out and relief. of arm out is low, replace Free from dust entered in over load valve relief valve. Seat is free from abnormality.

13

Arm 1 spool

P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding, Free from abnormal damage, etc on outside surface, Spring is free from breakage.

Replace (Check on the casing side for damage)

14

Arm 2 spool

P1 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding, Free from abnormal damage, etc on outside surface, Spring is free from breakage.

Replace (Check on the casing side for damage)

Free from abnormal resistance against sliding Spring is free from breakage.

Replace spool assembly

Free from abnormal resistance against sliding, Free from abnormal damage, etc on outside surface,

Replace (Check on the casing side for damage)

15

Check arm 2 spool and recirculation

Both P1, P2 pressures are low.

16

Check lock valve Visual check poppet

Both P1, P2 pressures are high.

Disassembly and investigation (spring side)

47-17

Corrective action, others

47

47. TROUBLESHOOTING (BY TROUBLE) (9) Bucket digging is slow No.

Sections

Contents/normal value

Corrective action, others

1

Bucket digging pressure sensor

Carry out service diagnosis

See Service Diagnosis Data List Operation No.12, Bucket digging full lever and relief

2

Remote control valve

Measure directly remote control pressure of bucket digging

Check that the pressure is 3.0 MPa Check remote control or more in bucket digging full lever valve and high idling operation When equipped with multi control valve, check it while changing lever pattern

3

Pump pressure sensor

Carry out service diagnosis for P1, P2 pump pressures in operation.

See Service Diagnosis Data List Operation No.13, Bucket digging full lever and in operation

When there is difference between P1 and P2 pump pressures, check high pressure sensor

4

Carry out service Actual measuring current value of P1/ diagnosis P2 unload proportional valve

No.7 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.12, Bucket digging full lever & relief

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

5

Secondary pressure of P1, P2 unload proportional valve

Check that P1/P2 unload Replace proportional secondary pressures are within the valve range of 0.5 to 1.2 MPa in bucket digging full lever and high idling operation

6

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.13, Bucket digging full lever & in operation

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

7

Secondary pressure of P1, P2 pump proportional valve

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that the P1 pump proportional valve pressures are 2.7 MPa or more and P2 pump proportional valve pressure is 2.0 to 2.6 MPa in bucket digging full lever and high idling operation.

Replace proportional valve

8

Attachment boost Carry out service solenoid command diagnosis

9

Attachment boost solenoid secondary pressure

Measure the proportional valve secondary pressure directly at ports A7 and A5 of 8 sections solenoid block

Measure switching valve secondary pressure

Check and replace pressure sensor Check remote control valve

No.3 POWER BOOST Check harness Bucket digging COMP OFF, MEAS Replace solenoid valve OFF Check that the pressure is 0 MPa in bucket digging full lever and high idling operation

47-18

Replace solenoid valve

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

10

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

See Service Diagnosis Data List Operation No.12, Bucket digging full lever & relief

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

11

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure at ports A6 (travel straight) of 8 sections solenoid block

Check that the travel straight secondary pressure is 2.7 MPa or more in bucket digging full lever and high idling operation

Replace proportional valve

12

P2 by-pass cut valve

Only P2 pressure is low.

Visual check

Clean or replace Poppet should be tightened. Seated surface should be free from damage and entry of foreign matter.

13

Check stroke Visual check limiter

Both P1, P2 pressures are high.

When piston is removed from cover, it is free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage.)

14

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

15

Main relief valve

Check set pressure

See Service Diagnosis Data List Operation No.3, Boom up full lever and relief

Reset or replace

16

Travel straight spool

P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

17

Visual check Bucket spool

Both P1, P2 pressures are high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

Over load relief valve

Free from dust entered in over load Replace relief valve. Seat is free from abnormality.

18

Contents/normal value

Check targeted spool visually

47-19

Corrective action, others

47

47. TROUBLESHOOTING (BY TROUBLE) (10)Bucket dump is slow No.

Sections

Contents/normal value

Corrective action, others

1

Bucket dump pressure sensor

Carry out service diagnosis

See Service Diagnosis Data List Operation No.14, Bucket dump full lever and relief

2

Remote control valve

Measure directly remote control pressure of bucket dump

Check that the pressure is 3.0 MPa Check remote control or more in bucket dump full lever valve and high idling operation When equipped with multi control valve, check it while changing lever pattern

3

Pump pressure sensor

Carry out service diagnosis for P1, P2 pump pressures in operation.

See Service Diagnosis Data List Operation No.15, Bucket dump full lever and in operation

When there is a difference between P1 and P2 pump pressures, check high pressure sensor

4

Actual measuring Carry out service current value of P1/ diagnosis P2 unload proportional valve

No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.14, Bucket dump full lever & relief

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

5

Secondary pressure of P1, P2 unload proportional valve

Check that the P1/P2 unload Replace proportional secondary pressures are within the valve range of 0.5 to 1.2 MPa in bucket dump full lever and high idling operation. Replace proportional valve.

6

Actual measuring Carry out service current value of P1/ diagnosis P2 pump proportional valve Carry out service diagnosis.

7

Secondary pressure of P1, P2 pump proportional valve

8

Actual measuring current value of travel straight proportional valve

Measure the proportional valve secondary pressure directly at ports A7 and A5 of 8 sections solenoid block

Check and replace pressure sensor Check remote control valve

No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.15, Bucket dump full lever & in operation

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that the P1 pump proportional valve pressure is 2.7 MPa or more and P2 pump proportional valve pressure is 2.7 MPa or more in bucket dump full lever and high idling operation.

Replace proportional valve

Carry out service diagnosis

See Service Diagnosis Data List Operation No.14, Bucket dump full lever & relief

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

47-20

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

9

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure at ports A6 (travel straight) of 8 sections solenoid block

Check that the travel straight secondary pressure is 2.7 MPa or more in bucket dump full lever and high idling operation

10

P2 by-pass cut valve

Only P2 pressure is low.

Visual check

Clean and replace Poppet should be tightened. Seated surface should be free from damage and entry of foreign matter.

11

Check stroke limiter

Pilot pressure is low.

Visual check

Free from abnormal damage and wear on outside of piston inside cover

Replace (Check on the casing side for damage.)

12

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

13

Main relief valve

Relief pressure is low.

Check set pressure

See Service Diagnosis Data List Operation No.3, Boom up full lever and relief

Reset or replace

14

Travel straight spool

P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

15

Visual check Bucket spool

Both P1, P2 pressures are high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

16

Over load relief valve

Free from dust entered in over load Replace relief valve. Seat is free from abnormality.

Check targeted spool visually

47-21

Corrective action, others Replace proportional valve

47

47. TROUBLESHOOTING (BY TROUBLE) (11) Swing does not move/slow No.

Sections

Contents/normal value See Service Diagnosis Data List Operation No.11, Swing full lever and in operation

Corrective action, others

1

Swing pressure sensor

Carry out service diagnosis

2

Remote control valve

Measure directly Check that the pressure is 3.0 MPa Check remote control remote control or more in boom up full lever and valve pressure of swing high idling operation When equipped with multi control valve, check it while changing lever pattern

3

Swing parking brake solenoid

Carry out service diagnosis

No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF

Check swing pressure sensor Check harness

4

Swing parking brake solenoid

Measurement of solenoid valve A2 port

Lever neutral: 0 MPa In operation: 4 MPa or more

Replace solenoid valve

5

Shuttle valve

Pilot pressure is low.

Visual check

No contamination on spool cover (short side) and orifice No damage on spool cover (long side) and shuttle

Clean or replace

6

Pump pressure sensor

Carry out service diagnosis for P2 pump pressures in operation

See Service Diagnosis Data List Operation No.11 Swing full lever and in operation

Check high pressure sensor

7

Actual measuring current value of P2 unload proportional valve

Carry out service diagnosis

No.7 D-2 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.11, Swing full lever & in operation

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

8

Secondary pressure of P2 unload proportional valve

Measure the proportional valve secondary pressure directly at ports A5 of 8 sections solenoid block

Check that P2 unload secondary pressures are within the range of 0.5 to 1.2 MPa in swing full lever and high idling operation

Replace proportional valve

9

Actual measuring current value of P2 pump proportional valve

Carry out service diagnosis

No.6, E-2 P2 pump See Service Diagnosis Data List Operation No.11, Swing full lever & in operation

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

10

Secondary pressure of P2 pump proportional valve

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that the P2 pump proportional valve pressure is 2.7 MPa or more in swing full lever and high idling operation

Replace proportional valve

47-22

Check and replace pressure sensor Check remote control valve

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

Corrective action, others

11

Actual measuring current value of travel straight proportional valve (Check this trouble by only swing operation)

Carry out service diagnosis

Check that the value has not changed regardless of operation See Service Diagnosis Data List Operation No. 1, Operation is nil Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

Check pressure sensor of travel In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

12

Secondary pressure of travel straight proportional valve (Check this trouble by only swing operation)

Measure directly the proportional valve secondary pressure at ports A6 (travel straight) of 8 sections solenoid block

0.8 MPa or less in high idling operation regardless of neutral/ operation

Replace proportional valve

13

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

14

Visual check Travel straight spool

P2 pressure is low.

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

Replace (Check on the casing side for damage)

15

Swing spool

P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

Replace (Check on the casing side for damage)

16

Swing relief valve

Relief pressure is low.

Check set pressure

See Service Diagnosis Data List Operation No.10, Swing full lever and relief

Reset or replace

17

Swing motor

Visual check

Inner parts (cylinder block, piston, valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)

Replace

47

18

Swing reduction gear oil

Take sample oil from swing reduction gear drain

Sampling oil does not include a lot of metal powder.

Disassemble and inspect reduction gear

19

Swing reduction

Visual check

Tooth surface is not worn abnormally and is not chipped.

Replace

47-23

47. TROUBLESHOOTING (BY TROUBLE) (12)Noise occurred at swing operation No.

Sections

Contents/normal value

Corrective action, others Check swing pressure sensor Check harness

1

Swing parking brake solenoid

Carry out service diagnosis

No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF

2

Measurement of solenoid valve A2 port

Lever neutral: 0 MPa In operation: 4 MPa or more

Replace solenoid valve

3

Boost check valve (Sound of cavitation at stopping)

Visual check

When removing, free from abnormal resistance against sliding. Spring is free from breakage.

Replace

4

By-pass check valve (Sound of cavitation at stopping)

Visual check

When removing, free from abnormal resistance against sliding. Spring is free from breakage.

Replace

5

Swing motor (Brake valve/ friction plate)

Visual check

Disassemble and inspect abnormal wear and scuffing

Replace

6

Swing motor piston Visual check

When removing, free from abnormal resistance against sliding. Spring is free from breakage.

Replace

7

Swing reduction gear oil

Take sample oil from swing reduction gear drain.

Sampling oil does not include a lot of metal powder.

Disassemble and inspect reduction gear

8

Swing reduction

Visual check

Tooth surface has no abnormally worn and chipped.

Replace

47-24

47. TROUBLESHOOTING (BY TROUBLE) (13)Swing drifts on a slope while swing control lever is in neutral position No.

Sections

Contents/normal value

Corrective action, others

1

Swing pressure sensor

Carry out service diagnosis

Engine stop & starter key ON All pilot low pressure sensors are within range of 0 to 0.1 MPa.

Check and replace pressure sensor

2

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage

Replace

3

Swing parking brake solenoid

Carry out service diagnosis

No.3, F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF

Check swing pressure sensor Check harness Check parking brake release switch

4

Measurement of solenoid valve A2 port

Lever neutral: 0MPa In operation: 4MPa or more

Replace solenoid valve

5

Swing motor (Brake valve/ friction plate)

Visual check

Disassemble and inspect abnormal wear and scuffing

Replace

6

Parking brake

Visual check

Piston and friction plate do not have abnormal resistance against sliding Free from spring damage

Replace

(14)Swing drifts at stopping No.

Sections

Contents/normal value

Corrective action, others

1

Shuttle valve

Pilot pressure is low

Visual check

Clean or replace No contamination on spool cover (short side) and orifice. No damage on spool cover (long side) and shuttle.

2

Swing pressure sensor

Carry out service diagnosis

Engine stop & starter key ON All pilot low pressure sensors are within range of 0 to 0.1 MPa.

Replace pressure sensor

3

Swing relief valve

Relief pressure is low.

Check set pressure

See Service Diagnosis Data List Operation No.10, Swing full lever and relief

Reset or replace

4

Anti-reaction valve

Visual check

Free from dirt entering Sliding part should be free from foreign matter entering, abnormal damage and wear.

Clean or replace

5

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

6

Swing motor

Visual check

Inner parts (cylinder block, piston, valve brake, etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate, etc)

Replace

47-25

47

47. TROUBLESHOOTING (BY TROUBLE) (15)Travel speed is slow/poor No.

Sections

Contents/normal value

Corrective action, others

1

Travel right and left Carry out service pressure sensor diagnosis

See Service Diagnosis Data List Operation No.18 Travel right full lever and idling Operation No.19, Travel left full lever and idling

Check and replace pressure sensor Check remote control valve

2

Remote control valve

Check that pressure is 2.1 MPa or more in travel right (left), forward (reverse) full lever and high idling operation

Check remote control valve

3

Carry out service Actual measuring current value of P1/ diagnosis P2 unload proportional valve

No.7 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

4

Secondary pressure of P1, P2 unload proportional valve

5

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

6

Secondary pressure of P1, P2 pump proportional valve

Measure directly remote control pressure of travel right and left

Measure the proportional valve secondary pressure directly at ports A7 and A5 of 8 sections solenoid block

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that P1/P2 unload Replace proportional secondary pressures are within the valve range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.2 MPa Travel left (P2 unload): 0.5 to 1.2 MPa No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

Check that P1/P2 unload Replace proportional secondary pressures are within the valve range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more

47-26

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

Corrective action, others

7

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

Check that the value has not changed regardless of operation See Service Diagnosis Data List Operation No. 1, Operation is nil Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

Check voltage of low pressure sensor other than sensor for the travel*-In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure

8

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure

0.8 MPa or less in high idling operation regardless of neutral/ operation

Replace proportional valve

9

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice

Replace

10

Travel straight spool

P1 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

Replace (Check on the casing side for damage)

11

Travel spool

Pump pressure is high.

Visual check of targeted spool

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

Replace (Check on the casing side for damage)

12

Travel motor relief valve

Check set pressure

Check that the P1 and P2 pump pressures are 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling

If P1 is low, right travel motor Afs relief valve has failed. If P2 is low, left travel motor Afs relief valve has failed.

13

Travel motor

Visual check

Inner parts (piston, cylinder block, valve plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)

Replace

47

14

Parking brake in travel motor

Visual check

When removing, free from abnormal resistance against sliding. No sticking on friction plate and separator plate

Replace

15

Travel reduction gear oil

Take sample oil from travel reduction gear drain

Sample oil does not include a lot of metal powder.

Disassemble and inspect reduction gear

16

Travel reduction

Visual check

Tooth surface is not worn abnormally and is not chipped.

Replace

47-27

47. TROUBLESHOOTING (BY TROUBLE) (16)Travel deviation No.

Sections

Contents/normal value

Corrective action, others

1

Travel right and left Carry out service pressure sensor diagnosis

See Service Diagnosis Data List Operation No.18, Travel right full lever and idling Operation No.19, Travel left full lever and idling

2

Remote control valve

Measure directly remote control pressure of travel right and left

Check that the pressure is 2.1 MPa Check remote control or more in travel right (left), forward valve (reverse) full lever and high idling operation

3

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

Check that the value has not changed regardless of operation See Service Diagnosis Data List Operation No. 1, Operation is nil Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

Check voltage of low pressure sensor other than sensor for travel. In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

4

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure

0.8 MPa or less in high idling operation regardless of neutral/ operation

Replace proportional valve

5

Actual measuring Carry out service current value of P1/ diagnosis P2 unload proportional valve

No.7 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) See Service Diagnosis Data List Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

6

Secondary pressure of P1, P2 unload proportional valve

7

Carry out service Actual measuring current value of P1/ diagnosis P2 pump proportional valve

Measure the proportional valve secondary pressure directly at ports A7 and A5 of 8 sections solenoid block

Check and replace pressure sensor Check remote control valve

Check that the P1/P2 unload Replace proportional secondary pressures are within the valve range of following in travel right (left), forward (reverse) full lever and high idling operation. Travel right (P1 unload): 0.5 to 1.2 MPa Travel left (P2 unload): 0.5 to 1.2 MPa No.6 E-1 P1 pump E-2 P2 pump See Service Diagnosis Data List Operation No.18, Travel right full lever & idling Operation No.19, Travel left full lever & idling

47-28

In case the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

8

Secondary pressure of P1, P2 pump proportional valve

Measure the pump proportional valve secondary pressure directly (Ports a3, a4)

Check that the P1/P2 unload Replace proportional secondary pressures are within the valve range of following in travel right (left), forward (reverse) full lever and high idling operation. Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more

9

Exchange P1 for P2

Exchange delivery pipe of P1 for P2

Check the direction of deviation

If the direction is changed, inspect a pump. If the direction has not changed, inspect a valve and travel unit.

10

Remote control valve

Check targeted remote control valve

Check that the spool is free from abnormal damage and spring is free from breakage. Check sealing ability of shuttle valve and entry of dust in orifice.

Replace

11

Travel straight spool

P1 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface. Spring is free from breakage.

Replace (Check on the casing side for damage)

12

Travel spool

Pump pressure is high.

Visual check of targeted spool

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage

Replace (Check on the casing side for damage)

13

Travel motor relief valve

Check set pressure

Check P1 and P2 pump pressures are 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling

If P1 is low, right travel motor Afs relief valve is failed. If P2 is low, left travel motor Afs relief valve is failed. Replace as necessary

14

Travel motor

Visual check

Inner parts (piston, cylinder block, valve plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)

Replace

15

Travel reduction gear oil

Take sample oil from travel reduction gear drain

Sampling oil does not include a lot of metal powder.

Disassemble and inspect reduction gear

16

Travel reduction

Visual check

Tooth surface is not worn abnormally and is not chipped.

Replace

47-29

Corrective action, others

47

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

Corrective action, others

17

Pump regulator

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.

Replace

18

Pump

Visual check

When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.

Replace

(17)Travel 1/2 speed cannot be switched (In case of traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the speed may not change from 1st to 2nd because this machine is equipped with the function of automatic speed change.) No.

Sections

Contents/normal value

1

Travel 1/2 speed switching solenoid

Carry out service diagnosis

Switch travel 1/2 speed to 2nd speed No.3 F-3 1/2-TRAVEL Lever neutral COMP OFF, MEAS OFF Travel operation COMP ON, MEAS ON

Check pressure sensor Check harness Check travel 1/2 speed switch on gauge cluster

2

Travel 1/2 speed switching solenoid

Measure A3 port pressure on solenoid valve

Lever neutral: 0 MPa In operation: 4 MPa or more

Replace solenoid valve

3

1/2 speed switching spool in travel motor

Visual check

Check that the spool is free from abnormal damage and spring is free from breakage

Replace (Check on the casing side for damage)

4

1/2 speed switching orifice in travel motor

Visual check

Free from entry of dust

Remove dust or replace

5

Tilting piston in travel motor

Visual check

Free from abnormal wear on piston Replace and seal (Check on the casing side for damage)

47-30

Corrective action, others

47. TROUBLESHOOTING (BY TROUBLE) (18)Machine does not stay on a slope in traveling No.

Sections

Contents/normal value

Corrective action, others

1

Pilot pressure sensor

Carry out service diagnosis

Engine stopped and starter key switch is ON Targeted pilot low pressure sensor is in range of 0 to 0.1 MPa

Check pressure sensor and replace as necessary Check remote control valve

2

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

3

Parking brake in travel motor

Visual check

When removing, free from abnormal resistance against sliding Spring free from breakage, damage, etc.

Replace

4

Orifice of passage for parking brake in travel motor

Visual check

Free from entry of dust

Remove dust or replace

(19)Machine does not travel straight in simultaneous operation of traveling and attachment No.

Sections

Contents/normal value

1

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

No.7 D-3 S-TRAVEL should be COMP 730 mA and MEAS 700 to 760 mA in both travel full lever and in boom up full lever at high idling

Check voltage of low pressure sensor other than travel sensor-In case the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

2

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure

Check secondary pressure is within range of 2.7 to 3.0 MPa in both travel full lever and in boom up full lever at high idling

Replace proportional valve

3

Travel straight spool

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

47-31

Corrective action, others

47

47. TROUBLESHOOTING (BY TROUBLE) (20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight) No.

Sections

Contents/normal value

Corrective action, others

1

Pressure sensor for optional attachment

Carry out service diagnosis

See Service Diagnosis Data List Operation No.16, P2 side OPT full lever and relief

2

Remote control valve

Measure directly remote control pressure of travel right and left

Check that the pressure is 2.1 MPa Check remote control or more in optional attachment full valve 0 lever and high idling operation

3

Carry out service Actual measuring current value of P1/ diagnosis P2 unload proportional valve

4

Secondary pressure of P1, P2 unload proportional valve

Measure the Replace proportional Check that P1/P2 unload proportional valve secondary pressures are within the valve secondary range of 0.5 to 1.2 MPa pressure directly at ports A7 and A5 of 8 sections solenoid block

5

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

See Service Diagnosis Data List Operation No.16, P2 side OPT full lever & relief

Check voltage of low pressure sensor other than sensor for optional attachment. In case where the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

6

Secondary pressure of travel straight proportional valve

Measure directly the proportional valve secondary pressure at ports A6 (travel straight) of 8 sections solenoid block

Check that the travel straight secondary pressure is 2.7 MPa or more in optional attachment full lever and high idling operation

Replace proportional valve

7

P1 by-pass cut valve

Only P1 pressure is low.

Visual check

No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)

Clean or replace

See Service Diagnosis Data List Operation No.16, P2 side OPT full lever and relief

47-32

Check and replace pressure senso Check remote control valve

In case where the reading is largely differed from the actual measured value, check proportional valve and controller for possible failure.

47. TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

Corrective action, others

8

Relief pressure

Check set pressure

-See Service Diagnosis Data List Operation No.16, P2 side OPT full lever and relief (Set value of factory shipment is 24.5MPa)

Reset or replace

9

Remote control valve

Check targeted remote control valve

Check sealing ability of shuttle valve and entry of dust in orifice.

Replace

10

Visual check Travel straight spool

P1 pressure is high

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

11

Spool for optional attachment

P1, P2 pressures are high

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage

Replace (Check on the casing side for damage)

12

Over load relief valve

Check targeted spool visually

Free from dust entered in over load Replace relief valve Seat is free from abnormality.

(21)Selector valve for option malfunctions: Breaker circuit is not obtained. (Indication of failure is displayed. For reference, see "Table : Action of optional selector solenoid valve") No.

Sections

Contents/normal value

Corrective action, others

1

N&B selector spool Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage

2

N&B selector solenoid

Screw for emergency

Check that the error indication has Replace solenoid valve disappeared by turning emergency screw

3

N&B selector solenoid

Carry out service diagnosis

No.9, F-4 Option selector is B mode COMP ON, MEAS ON Spool position BRK Selector switch BRK

Check solenoid valve Check harness

4

N&B selector pressure sensor

Carry out service diagnosis

No.13 B-11 Data List 3.0 MPa at B mode and 0.0 MPa at A mode

Check pressure sensor Check harness

47-33

Replace (Check on the casing side for damage)

47

47. TROUBLESHOOTING (BY TROUBLE) (22)Selector valve for option malfunctions: Nibbler circuit is not obtained. (Indication of failure is displayed. For reference, see "Table : Action of optional selector solenoid valve") No.

Sections

Contents/normal value

Corrective action, others

1

N and B selector spool

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage

Replace (Check on the casing side for damage)

2

N&B selector solenoid

Carry out service diagnosis

No.9, F-4 Option selector is A mode COMP OFF, MEAS OFF Spool position N Selector switch NIB

Check solenoid valve Check harness

47-34

47. TROUBLESHOOTING (BY TROUBLE) Action of optional selector solenoid valve

No.

Engine condition

Safety lock lever SW's input

1

Running

ON

OFF

A

OFF

Nibbler

Normal

-

-

2

Running

ON

OFF

A

ON

Breaker

Normal

"SELECTOR VALVE FAILURE"

[F042] displayed simultaneously

3

Running

ON

OFF

A

OFF

Breaker

Normal

"SELECTOR VALVE FAILURE"

-

4

Running

ON

OFF

A

ON

Nibbler

Normal

-

[F042] displayed

5

Running

ON

OFF

B

ON

Breaker

Normal

-

-

6

Running

ON

OFF

B

OFF

Nibbler

Normal

"SELECTOR VALVE FAILURE"

[F043] displayed simultaneously

7

Running

ON

OFF

B

ON

N&B

Normal

"SELECTOR VALVE FAILURE"

-

8

Running

ON

OFF

B

OFF

Breaker

Normal

-

[F043] displayed

9

Running

ON

OFF

-

-

-

Failure

"SELECTOR VALVE FAILURE"

[B113] displayed

10

Stopping

-

-

-

-

-

-

-

-

11

-

OFF

-

-

-

-

-

-

-

12

-

-

ON

-

-

-

-

-

-

Safety lock lever relay's output

Work mode

Optional selector valve COMP. MEAS.

Spool position

Selector valve detecting pressure sensor

Warning display

Failure diagnosis display

47

47-35

47. TROUBLESHOOTING (BY TROUBLE)

47.2

ELECTRIC SYSTEMS

47.2.1 WIRING CHECKING PROCEDURE Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding. (1) Checking for disconnection between connectors. (When both ends measurement is easy because of short distance between connectors) Measure the resistance using tester. Pull out opposite connector first. When the resistance is zero (0), it is in normal condition.

CONNECTOR

WIRE TESTER

(When both ends measurement is difficult because of long distance between connectors) JUMPER Measure the resistance using tester. WIRE Pull out opposite connector first. Where the resistance is zero (0), if the terminal on one TESTER side is connected to frame body grounding with jumper wire, it is in normal condition. FRAME BODY GROUNDING The resistance is 1 M-ohm or more when the terminal on one side is not connected to frame body grounding with jumper wire, it is in normal condition. (2) Checking for presence or absence of short-circuit with machine body Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M-ohm or more, it is in normal condition. (3) Checking for presence or absence of short-circuit between wirings. Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M-ohm or more, it is in normal condition.

TESTER

FRAME BODY GROUNDING

TESTER

INSERT (4) Checking connector terminal for contact Insert male terminal into female terminal unit, and then MALE TERMINAL FEMALE TERMINAL check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one. Clean the dirty terminal.

Do not insert the male terminal, the thickness is different. It may cause loose connection.

47-36

47. TROUBLESHOOTING (BY TROUBLE) (5) Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal. When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified. Since the voltage may vary between with connector connected and with connector not connected. Measure the voltage with each connector connected whenever possible. (6) Checking the general view of connector a. Check the terminal crimped condition. Pull one electric cable with about 3 kg force, and make sure that the cable does not come out of the terminal. When it comes out, replace the terminal and crimp it again. b. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. c. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side.

CRIMPED PART

RUBBER PLUG RECEPTACLE. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB.CONTACT RUBBER PLUG

(7) When abnormality occurs at intervals When the abnormality situation cannot be reoccurred during checking operation, try the following operations. a. Check that the variable of display exists or not on the service diagnosis screen, while shaking the harness or giving shock by operating the machine. b. Check that the variables of resistance and voltage exist or not using tester while shaking the harness. c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised. (8) Checking on body grounding Check attaching bolts of grounding terminal for loosening. And also check that there is no loose connection due to corrosion. There are multiple groundings like a centralized grounding box shown in the figure and battery grounding, engine grounding, horn grounding fixed together with horn, body grounding placed on attaching section of boom working light.

47 Block of grounding is located under floor plate of cab.

47-37

47. TROUBLESHOOTING (BY TROUBLE) 47.2.2 TROUBLE (1) Engine does not stop. (2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display. (3) Auto accel does not actuate. (The engine speed does not automatically slow down.) (4) Auto accel does not actuate. (The engine speed does not automatically speed up.) (5) Wiper does not function. (1) Engine does not stop. No.

Sections

Contents/normal value

Corrective action, others

1

Starter key switch

Check signal of starter key switch ON by carrying out service diagnosis.

No.4, K-3 Key switch OFF at starter, key switch OFF position ON at starter, key switch ON position

Check continuity between terminals of starter switch using tester

2

Engine forcible stop relay

When ON is displayed with the starter switch OFF, then pull out R-25 engine forcible stop relay and carry out the service diagnosis.

No.4, K-3 Key switch OFF at starter, key switch OFF position ON at starter, key switch ON position

Check on engine forcible stop relay

3

Wiring

Voltage between line No.62 among starter switch, engine forcible stop relay, mechatro controller and the body grounding

0 V when starter switch is OFF

Check harness Check diode D-9 between starter switch and auto idling stop relay 1

(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display. No.

Sections

Contents/normal value

Corrective action, others

1

Fuse

No.1 fuse (5A)

Not blown fuse

Check harness Replace fuse

2

Mechatro controller

Accel control

Engine speed varies according to accel potentiometer operation. (Use remote control because the auto accel function is working)

Check mechatro controller and replace as necessary

3

Wiring

See "WIRING CHECKING Transmission circuit PROCEDURE" line No.770 from mechatro controller to gauge cluster

4

Gauge cluster

Gauge cluster

Replace gauge cluster

47-38

Repair wiring

47. TROUBLESHOOTING (BY TROUBLE) (3) Auto accel does not actuate. (The engine speed does not automatically slow down). No.

Sections

Contents/normal value

Corrective action, others

1

Engine coolant temperature

Check engine coolant temperature by carrying out service diagnosis.

No.2 G-5 WATER TEMP auto accel does not work in the temperature -5° C (23° F) or less. Warm up and raise the coolant temperature to -5° C (23° F) or more

2

Gauge cluster

Indication of auto accel

Mark "Display/not display" for auto Replace gauge cluster accel switches by auto accel switch operation on gauge cluster.

3

Low pressure sensor

Service diagnosis

Each control pressure of No.5 and No.6 is in the range of 0 to 0.1 MPa at control lever neutral position.

Replace engine coolant sensor

Check low pressure sensor

(4) Auto accel does not actuate. (The engine speed does not automatically speed up.) No. 1

Sections Low pressure sensor

Contents/normal value Service diagnosis

Each control pressure of No.5 and No.6 is raised with control lever operated.

Corrective action, others Check low pressure sensor

47

47-39

47. TROUBLESHOOTING (BY TROUBLE) (5) Wiper does not function

Wiping range of forward and reverse movements

Wiper motor Rise up limit switch's ON range Reverse limit switch's ON range

Rise up (storing) position Upper reversing position Lower reversing position

No.

Sections

Contents/normal value

Corrective action, others

1 Fuse

Check fuse No.20

Replace fuse

2 SW-19: Wiper interlock switch

Service diagnosis No.14 DI25 Check wiper interlock switch Wiper switch display (DI25) is OFF with front window closed. and repair it if necessary Check according to "WIRING CHECKING PROCEDURE" and repair it if necessary

3 Rise up limit switch built- Service diagnosis No.19 Wiper system in wiper motor Reverse limit switch Switch action in operation

Check according to "WIRING CHECKING PROCEDURE"

Normal condition

4 R-31: Arc prevention relay R-29: Forward rotation relay R-30: Reverse rotation relay

Rise up limit switch

ON

OFF

OFF

Reverse limit switch

ON

ON

OFF

Service diagnosis No.19 Wiper system STOP

START

Arc prevention relay

OFF

ON

ON

ON

ON

OFF

ON

ON

ON

OFF

Forward rotation relay

OFF

ON

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

ON

Reverse rotation relay

OFF

OFF

OFF

OFF

OFF

OFF

ON

ON

ON

OFF

OFF

When started by forward rotation:

(STOP)

Check that the relay is worked as shown in the table. * When the limit switch does not change in OFF after 4 seconds from the wiper startup, turn OFF all relay's outputs.

47-40

(STOP)

(REVERSE)

Check that the relay is excited. Check relay & fuse box and replace it if necessary.

(FORWARD)

ON

47. TROUBLESHOOTING (BY TROUBLE)

47.3

ENGINE RELATED TROUBLESHOOTING Checking Liquid

Muffler clogged

Air leak between turbocharger and intake manifold

Poor or deteriorated battery

Contamination of water and fuel with oil

Oil level of oil pan

Coolant level

Improper fuel in use

Breather hose crushed or clogged

Fan belt slipped, fan pulley worn

Oil filter clogged

Fuel filter clogged

Trouble

Air cleaner clogged

Shortage of fuel level

Factors

Engine oil leak

Leak, clogging

Leak, clogging of fuel system and intruding of air

Filters

Faulty starting

Faulty engine starting/engine does not rotate.

Poor output Insufficient rotation

Poor start ability (Take a long time)

Engine poor run-up (Low follow-up ability)

Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating Exhaust smoke is black Exhaust smoke is white

Other failures

Larger oil consumption (or blue exhaust gas)

47

Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration

47-41

47. TROUBLESHOOTING (BY TROUBLE)

Electric equipment

Faulty starting

Faulty engine starting/engine does not rotate.

Poor output Insufficient rotation

Poor start ability (Take a long time)

Engine poor run-up (Low follow-up ability)

Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating Exhaust smoke is black Exhaust smoke is white

Other failures

Larger oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration

47-42

Hydraulic switch

Safety relay

Starter motor

Glow relay

Engine side

Alternator

Battery relay

Loose connection of battery cable terminal

Starter switch key

Startup circuit wiring

Shovel side Malfunction of unload valve and low pressure sensor

Failure of hydraulic system

Peeling of space insulation around radiator

Trouble

Radiator core clogged/fin clogged and crushed

Factors

Failure of radiator pressure cap

Loose mounting bolts, damage of mounting rubber

Shovel side

Glow plug

Checking

47. TROUBLESHOOTING (BY TROUBLE)

Fuel system

Intake and exhaust system

Lubrication Cooling system system

Failure of thermostat (Not open)

Damage of EGR cooler Failure of oil pump Failure of relief valve Failure of regulator valve Leak and crush of hydraulic piping Damage of water pump

Seizing and interference of turbocharger

Seal of turbocharger worn, damaged

Turbocharger oil drain tube clogged

Fuel leak into the head cover

Improper fuel injection time

Trouble

Failure of supply pump

Failure of injector

Factors

Faulty starting

Faulty engine starting/engine does not rotate.

Poor output Insufficient rotation

Poor start ability (Take a long time)

Engine poor run-up (Low follow-up ability)

Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating Exhaust smoke is black Exhaust smoke is white

Other failures

Larger oil consumption (or blue exhaust gas) Early contamination of oil

47

Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration

47-43

47. TROUBLESHOOTING (BY TROUBLE)

Faulty starting

Faulty engine starting/engine does not rotate.

Poor output Insufficient rotation

Engine poor run-up (Low follow-up ability)

Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating Exhaust smoke is black Exhaust smoke is white

Other failures

Larger oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration

47-44

Damage of flywheel gear

Damage of dumper

Wear and damage of rear oil seal and seal surface

Hole due to cavitation

Wear of piston ring and liner, ring stick

Damage and seizing of piston and connecting rod

Wear and failure of valve and valve guide

Strainer clogged, damage of oil pipe

Poor start ability (Take a long time)

Damage of cylinder head and head gasket

Damage of engine oil cooler core and O-ring

Trouble

Failure of injection holder sleeve

Engine body

Factors

51. ENGINE

51. ENGINE 51 PREFACE This service manual explains the single engine. Note that this manual is edited without modification by based on the service manual of HINO MOTOR.

Book Code No. S5LC5125E02 51-1

51. ENGINE

Issue First Edition Revision

Date of Issue

Applicable Machines

S5LC5125E01 (NA)

September, 2010 SK350-9 : YC May, 2011

Remarks

S5LC5125E02 (NA)

SK350-9 : YC

51-2

HINO DIESEL ENGINE WORKSHOP MANUAL J08E-UV

(Shovel) KSS-Z4J8-002E 2011.2

GENERAL

1

STANDARD VALUE

2

PARTS TO BE PREPARED

3

ENGINE MOUNTING/DISMOUNTING

4

FUEL SYSTEM

5

EMISSION CONTROL

6

ELECTRICAL

7

INTAKE

8

ENGINE MECHANICAL

9

EXHAUST

10

COOLING

11

LUBRICATION

12

STARTING AND CHARGING

13

TURBOCHARGER

14

AIR COMPRESSOR

15

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

16

ENGINE DIAGNOSIS CODE

17

For your information: This documentation does not contain any descriptions in regard to the hatched part "15. Air Compressors".

GENERAL

1–1

ENGINE

1 GENERAL General information

Warning................................................................... 1-2 How to read this manual ........................................ 1-3 Precautions for work ............................................... 1-8 Tightening of engine bolts and nuts ...................... 1-12 Tightening of flare nuts and hoses........................ 1-14 Taper thread sealant for piping ............................. 1-15 Assembly of joints and gaskets for piping ............. 1-16 Handling of liquid gasket....................................... 1-18 Failure diagnosis table for each problem .............. 1-19 Failure diagnosis procedures................................ 1-20 Failure diagnosis using HinoDX ............................ 1-22 Connection method of HinoDX ............................. 1-26 Engine number ..................................................... 1-27

1

1–2

GENERAL

Warning JP30ZCE010102001

Observe the following precautions to work safely and to prevent damage to customers' machine. This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who perform service with the way not specified in this manual may not only damage the vehicle, but also put service engineers and surrounding people in danger. • Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality. • Items described in this manual are the procedures to be observed in service and repair. For service and repair according to this procedure, be sure to use the special tools designed for each purpose. • If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles may be impaired. Never use a method or tool not recommended. • This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or “Caution” are not absolute for safety.

1–3

GENERAL

How to read this manual JP30ZCE010102002

1.

Scope of repair work (1)

Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement, assembly˜disassembly and inspection˜adjustment" and "Final inspection".

(2)

This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement, assembly˜disassembly and inspection˜adjustment" in the second process. Explanation of "Final inspection" in the third process is omitted here.

(3)

2.

a.

Jacking and lifting

b.

Cleaning and washing of removed parts as required

c.

Visual inspection

Standard value (1)

3.

Although the following work is not described in this manual, it should be performed in actual work.

Standard value, limit, action and tightening torque described in the text are summarized in tables.

Items to be prepared (1)

Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually equipped in general service shop are omitted.

4.

How to read sections and titles (1) (2)

Sections are classified according to J2008, SAE standard. For areas that show system names like "Engine control system", "Inspection", "Adjustment", "Replacement", "Overhaul", etc. of components are described.

(3) (4)

For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described. Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in the illustration. Major names and tightening torque are listed in the table.)

! CAUTION

• The part layouts in this manual are inserted based on illustrations and part numbers of the parts catalog CD-ROM issued in June, 2010. (Some areas do not show exploded view. They will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts catalog for confirmation of illustrations and part numbers and for ordering parts.

1–4 5.

GENERAL How to read troubleshooting (1)

Failure diagnosis in this manual describes Step 2 and Step 3 below :

(1) Question

"Step 1"

Hear from customers for conditions and environments of failures and check the fact. Perform diagnosis inspection, status inspection,

(2) Pre-inspection (3) Reproduction method

"Step 2"

function inspection and basic inspection. Check the failure status. If it is difficult to reproduce the problem with status inspection, use the reproduction method. Summarize inspection results obtained from Step 2.

(4) Troubleshooting for each diagnosis code (5) Troubleshooting for each

"Step 3"

Perform inspection systematically according to troubleshooting procedures for each diagnosis code or failure status.

failure status

Check if failure occurs again after repair. If it is difficult to (6) Confirmation test

"Step 4"

reproduce a failure, perform the confirmation test under the conditions and environment of the failure.

(2)

Pre-inspection • Pre-inspection is performed in the following steps : Diagnosis inspection o Diagnosis deletion o Failure status check (Use the reproduction method if not reproduced.) o Diagnosis reconfirmation • Estimate the failure system before the reproduction test. Attach a tester and evaluate estimated failure together with failure status. Refer to the troubleshooting chart for

Preinspection

estimated cause of a failure. • An error code is displayed if a failure occurs instantaneously. If any specific failure is not found, perform troubleshooting using the reproduction method. • Failure status check If failure is reproduced, perform Step 2 o Step 3 o Step 4. If failure is not reproduced, use the reproduction method (simulation of external conditions or check of each wire harness and connector, etc.)

1–5

GENERAL 6.

How to read explanation details (1)

Part layout

Example

9–17

ENGINE MECHANICAL [J08E]

Timing Gear Cover and Flywheel Housing Part layout JP04117090402003

Part name code

Part catalog Fig. No. SAPH041170900182

11308

Flywheel housing

11390

End plate

11309

Oil seal retainer

9828A

Front oil seal*

11357

Gasket*

9828B

Rear oil seal*

11357A

Gasket*

*Parts not to be reused.

Description of part name code

Left: Part name code (nut)

Tightening torque 9069H

M14 : 171.5N m{1, 750kgf cm}

9419A

M16 : 196N m{2, 000kgf cm}

9069J

M12 : 97N m{990kgf cm}

9419B

M16 : 196N m{2, 000kgf cm}

It is the ID number for parts to prepare electronic data. It is not required for repair work.

SAPH30ZCE0100043

1–6 7.

GENERAL Definition of terms Terms in this manual are defined as follows : (1)

Direction (Individual unit) • Front/back direction The power input side is front and the output side is back. • Rotating direction When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is left rotation. • Vertical direction With a unit mounted on the machine main unit, the upward direction is upper and the downward direction is lower. • Left/right direction When viewed from the rear, the left direction is left and the right direction is right.

(2)

Standard value ˜˜˜˜˜˜˜Basic dimension excluding tolerance and clearance generated by tolerances when two parts are joined

(3)

Repair limit˜˜˜It is the value requiring repair. Symbol of + or - with the value means increase or decrease to the standard value.

(4)

Operation limit˜˜˜It is the value requiring replacement. Symbol of + or - with the value means increase or decrease to the standard value.

(5)

Warning˜˜˜˜˜˜˜˜˜˜˜It is an item that may result in risk of human life or serious injury by incorrect handling.

(6)

Caution˜˜˜˜˜˜˜˜˜˜˜It is an item that should not be performed including inhibited work or an item that require attention in working procedures.

(7)

Reference˜˜˜˜˜˜˜˜˜˜˜It is supplementary explanation in work.

1–7

GENERAL 8.

Unit (1)

SI unit is used in this manual. SI unit is the international unit to unify the conventional different international units into one unit per quantity and to promote smooth technical communications.

(2)

This manual shows both the SI unit and conventional units. The conventional units are shown in { }. Conversion value*1

Item

SI unit

Conventional unit

Force

N

kgf

1kgf=9.80665N

Torque*2

N˜m

kgf˜cm

1kgf˜cm=0.0980665N˜m

kgf/cm2 Pressure

Pa mmHg r/min

Rotational speed min

-1

(1[Conventional unit] = X [SI unit])

1kgf/cm2=98.0665kPa =0.0980665MPa 1mmHg=0.133322kPa 1rpm=1r/min

rpm

1rpm=1min-1

Spring constant

N/mm

kgf/mm

1kgf/mm=980665N/mm

Volume

L

cc

1cc=1mL

Efficiency

W

PS

1PS=0.735499kW

Calorific value

W˜h

cal

1kcal=1.13279W˜h

Fuel consumption rate

g/W˜h

g/PS˜h

1g/PS˜h=1.3596g/kW˜h

*1

: X means the value when 1 [Conventional unit] is converted to the SI unit. It is used as the conversion factor from the conventional unit to the SI unit.

*2

: The conversion value of the torque may vary depending on the unit. Observe the standard values described for each unit.

1–8

GENERAL Safety information

Precautions for work JP30ZCE010101001

1.

General precautions To ensure safety in work and to prevent accidents, observe the following items : (1)

Appearance a.

Wear safety goggles.

b.

Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.

c.

Bind long hair at the back.

d.

Be sure to wear a cap and safety shoes.

(2)

Safety work a.

Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.

b.

Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during operation of the engine.

c.

Remove the starter key when the engine is not started.

d.

Start the engine at a well ventilated place so that carbon monoxide may not be filled.

e.

Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.

f.

Since the battery fluid is poisonous and corrosive, be careful for handling.

g.

Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may occur.

h.

If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine, resulting in injury.

i. 2.

To tow a failure machine, refer to “Towing” in the "Operation manual" of the machine.

Precautions for service work Pay attention to the following points before service work (1)

Preparation before disassembly a.

Prepare general tools, special tools and gauges before work.

b.

To disassemble a complicated area, put a stamp or match mark on the location not functionally affected to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the battery before work.

c. (2)

Perform inspection according to the procedure in the text before disassembly. Inspection during disassembly Every time parts are removed, check the area where the parts are assembled and check for deformation, damage, wear or scratch.

(3)

Arrangement of disassembled parts Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.

(4)

Washing of disassembled parts Clean and wash parts to be reused well.

(5)

Inspection and measurement Inspect and measure parts to be reused as required.

(6)

Assembly a.

Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct parts in the correct order.

b.

Be sure to use genuine parts for parts to be replaced.

c.

Use new packing, gasket, O–ring and cotter pin.

d.

Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas where application of oil is required, and apply specified grease to the oil seal lip before assembly.

(7)

Check of adjustment Make adjustments to the service standard values using a gauge or tester.

GENERAL 3.

1–9

Precautions for electric system (1)

Removal of battery cable a.

In an electric system, remove the cable from the battery minus (-) terminal to prevent burnout due to short-circuit.

Loosen

b.

When the battery cable is removed, the battery terminal may be damaged. Loosen the nut completely and never pry it for removal.

SAPH30ZCE0100002

(2)

Handling of electronic parts a.

Do not give impact on electronic parts such as computer and relay.

b.

Do not place electronic parts at a high temperature and humidity area.

c.

Do not expose electronic parts to water in washing of a vehicle.

SAPH30ZCE0100003

(3)

Handling of wire harness a.

Mark clamps and clips to prevent interference of a wire harness with body edge, sharp edge and bolts. Be sure to reassemble it to the original position.

b.

When parts are assembled, be careful not to pinch a wire harness.

SAPH30ZCE0100004

1–10

GENERAL (4)

Handling of connector a.

When a connector is removed, hold the connector (as shown by the arrow in the left) and pull it out. Do not pull the wire harness.

b.

Unlock the locking connector before pulling.

c.

Insert the locking connector completely until it clicks.

d.

To insert a test lead into the connector, insert it from the back of the connector.

e.

If it is difficult to insert a test lead from the back of the connector, prepare a harness for inspection.

SAPH30ZCE0100005

GENERAL 4.

1–11

Precautions for electric welding Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding circuit, resulting in damage to electric and electronic parts. Observe the following items for electric welding. (1)

Turn "OFF" the starter switch.

(2)

Make sure that switches are "OFF".

(3)

Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.

(4)

Disconnect connectors of each computer.

(5)

Remove all fuses. (For locations of fuses, refer to "Electrical Chapter".)

(6)

Be sure to connect grounding of the electric welding machine near the welding area. Connect grounding from a bolt (plated bolt) or a frame near the welding area. Remove paint of the frame for connection of grounding from the frame. The seal and the bearing etc. that please make sure do not enter between the weld and the ground section.

(7)

Other precautions a.

Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they

b.

Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also

may not be exposed to spatter. maintain welding quality. (8)

After welding, connect and assemble in the order of the fuse and the minus terminal of the battery disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same color.

(9)

After reassembly, check the function if it operates correctly. General information

1–12

GENERAL

Tightening of engine bolts and nuts JP30ZCE010102003

1.

Tightening torque of general standard bolts (1)

For bolts with seatings Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter x Pitch

7T

9T

M8 x 1.25 (Coarse thread)

28.5 {290, 21}

36 {370, 27}

M10 x 1.25 (Fine thread)

60 {610, 44}

74.5 {760, 55}

M10 x 1.5 (Coarse thread)

55 {560, 41}

68.5 {700, 51}

M12 x 1.25 (Fine thread)

108 {1100, 80}

136 {1390, 101}

M12 x 1.75 (Coarse thread)

97 {990, 72}

125 {1280, 93}

M14 x 1.5 (Fine thread)

171.5 {1750, 127}

216 {2210, 160}

M14 x 2 (Coarse thread)

154 {1570, 114}

199 {2030, 147}

Remark

Bolt with number “7” on the head

Bolt with number “9” on the head

! CAUTION

(2)

• 8T bolt is in accordance with 7T bolt.

For bolts with washers Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter x Pitch

4T

7T

9T

M6 x 1 (Coarse thread)

6 {60, 4}

10 {100, 7}

13 {130, 9}

M8 x 1.25 (Coarse thread)

14 {140, 10}

25 {250, 18}

31 {320, 23}

M10 x 1.25 (Fine thread)

29 {300, 22}

51 {520, 38}

64 {650, 47}

M10 x 1.5 (Coarse thread)

26 {270, 20}

47 {480, 35}

59 {600, 43}

M12 x 1.25 (Fine thread)

54 {550, 40}

93 {950, 69}

118 {1200, 88}

M12 x 1.75 (Coarse thread)

49 {500, 36}

83 {850, 61}

108 {1100, 80}

M14 x 1.5 (Fine thread)

83 {850, 61}

147 {1500, 108}

186 {1900, 137}

M14 x 2 (Coarse thread)

74 {750, 54}

132 {1350, 98}

172 {1750, 127}

Bolt with number “4” on Remark

the head

Bolt with number ”7” on

Projection bolt Stud

the head Stud with C

with R surface at free

surface at free end

Bolt with number “9” on the head

end

! CAUTION

• 8T bolt is in accordance with 7T bolt.

R surface (4T)

C surface (7T)

SAPH30ZCE0100006

1–13

GENERAL 2.

Precoated bolt Precoated bolt is the bolt with application of seal lock agent at the thread. (1)

When re-application of lock agent is required a.

When precoated bolts are removed

b.

When precoated bolts are moved due to tightening check (for loosening or tightening)

Seal Lock Agent

• Check torque with the lower limit of the

NOTICE

tightening torque allowable value. If

SAPH30ZCE0100007

movement is found, tighten the bolt according to the procedure below. (2)

Re-use method of precoated bolt lock a.

Clean bolt and screw holes. (Clean screw holes for replacement.)

b.

Dry completely by blowing air.

c.

Apply the specified seal lock agent to the thread of the bolt.

3.

Plastic region tightening method (angle method)

! CAUTION

• Some engines are tightened with the plastic region tightening method. • Since it is different from the conventional method, tighten it according to the instruction in the text.

Example One turn by 90q Tighten it 90q

One turn by 90q One turn by 45q

Tighten it 45q (Second time)

Two turn by 90q

Tighten it 90q (Second time)

Tighten it 90q (First time)

Tighten it 90q (First time)

SAPH30ZCE0100008

(1)

Parts tightened Cylinder head bolt, crankshaft main bearing cap bolt, connecting rod bearing cap bolt, etc.

! CAUTION

• Measure the overall length of the bolt before assembly and replace the bolt if the length exceeds the operation limit. Apply engine oil to bolt seating and bolt thread in assembly.

(2)

Tightening method after tightening to seating torque Tightening of 90q, 135q(90qonce and 45qonce) and 180q(90qtwice) is available.

1–14

GENERAL

Tightening of flare nuts and hoses JP30ZCE010102004

1.

Tightening torque of pipe flare nut Unit : N˜m{kgf˜cm, lbf˜ft} Pipe outer diameter

Tightening torque

2.

I4.76

I6.35

I8

I10

I12

I15

15r5

21r1

32r3

44r5

64r5

66r2.5

{153r50,

{214r10,

{326r31,

{449r51,

{653r51,

{673r25,

11r3.6}

15r0.7}

24r2.2}

32r3.6}

47r3.6}

47r1.8}

Tightening torque of hoses Unit : N˜m{kgf˜cm, lbf˜ft}

Type

Hose outer diameter I10.5 fitting

Hose outer diameter I13, I20, I22, fitting at

Hose outer diameter PF3/8 fitting

packing

21.5r1.5 {215r15, 15r1} Air hose

Only meter gauge

46r2.5 {469r25, 33r1.8}

—

46r2.5 {469r25, 33r1.8}

—

10 {100, 7} Brake hose

3.

Packing 51.5r7.5 {525r75, 15r1}

Lock nut tightening torque of brass joint Unit : N˜m{kgf˜cm, lbf˜ft}

Screw nominal size Tightening torque

M14

M16

M20

M22

M24

48r10

66r13

120r36

130r30

150r30

{489r102,

{673r204,

{1224r367,

{1326r306,

{1530r306,

35r7}

47r14}

89r26}

96r22}

110r22}

1–15

GENERAL

Taper thread sealant for piping JP30ZCE010102005

The taper thread of the air pipe joint has application of sealant [Loctite # 575 (by Japan Loctite)]. Follow the procedures below for connection or disconnection of pipes. 1.

For disconnection

Removal of joint (Example: Use of magnetic valve)

(1)

Magnetic valve Frame

Air pipe (Flare joint) (No application of sealant)

Air hose

The sealant ( # Loctite 575) has strong sealing feature. The return torque of the taper joint is increased about 1.5 times the initial tightening torque. When the joint is disconnected, use a long wrench for disconnection

Since sealant is applied to this area, remove accessories with the joint attached

(2)

When a joint at a poorly accessible area is replaced, remove accessories first and disconnect the joint.

SAPH30ZCE0100009

2. 1/4 turn

For connection (1)

Amount of application: 0.1 g/piece

For application of sealant ( # Loctite 575), wipe the sealing area completely with a rag or thinner. Apply sealant directly to about three ridges for quarter round with offset of one ridge from the end. Tighten it according

3 threads 1 thread

to the tightening torque in the table below. Remove dirt completely from the mating part (female) before tightening.

SAPH30ZCE0100010

! CAUTION

• If your eye or skin comes in contact with sealant, wash it off immediately with water.

Tightening torque of taper joint

Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter Material 1/4

Steel

Aluminum or brass

(2)

3/8

1/2

49r10

64r15

{500r100,

{650r150,

36r7}

47r10}

25r5

34r5

44r5

{250r50,

{350r50,

{450r50,

18r3}

25r3}

32r3}

When a sealing tape is replaced with sealant, remove the tape completely first as in (1).

! CAUTION

• Be careful to prevent entry of dirt or foreign matter in the pipe.

(3)

If air leak is found after assembly with application of sealant, air leak cannot be stopped with additional tightening. Assemble the part again according to (1) and (2).

1–16

GENERAL

Assembly of joints and gaskets for piping JP30ZCE010102006

1.

Tightening torque of joints Unit : N˜m{kgf˜cm, lbf˜ft} Sealing method

Screw size

Metal sealing method Gasket sealing method

(Flare pipe type, nipple connector type)

(Aluminum + Rubber or Copper) Type A M8

13 {130, 9}

M10

20 {200, 14}

M12

25 {250, 18}

20 {200, 14}

M14

25 {250, 18}

31 {320, 23}

M16

29 {300, 22}

39 {400, 29}

M18

39 {400, 29}

59 {600, 43}

M20

*39 {400, 29}

64 {650, 47}

M24

69 {700, 51}

M28

*127 {1300, 94}

2.

Type B

11 {110, 8}

20 {200, 14}

Joint assembly procedure and subsequent inspection (1)

Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint, gasket, etc.).

(2)

Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten pipes finally after temporary tightening to prevent leak.

(3)

After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.

(4)

Observe the values above for each tightening torque. *When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened or removed, be sure to replace it with a new part. This is not necessary for normal retightening.

1–17

GENERAL 3.

Examples of joint methods in various pipes Metal sealing method Gasket sealing method

Type A

Type B

(Flare pipe type)

(Nipple connector type)

Joint bolt

Flare pipe Connector Flare nut

Gasket

Sealing surface: 3 places Nut Connector nipple

Joint bolt Sealing surface : 4 places One piece eye joint with sleeve

Flare connector

Gasket

Gasket Gasket

Sealing surface : 5 places

Gasket

Joint bolt

Lock washer

Bracket

Sealing surface: 5 places

Nut

Nut

Sealing surface : 8 places

Connector nipple

Sealing surface: 1 place

Sealing surface: 1 place Flare connector

Nut

Lock washer

Box nut

3-way joint Sealing surface : 8 places Joint pipe

Bracket Sealing surface : 3 places

One piece eye joint without sleeve Joint bolt

Sealing surface: 4 places

Joint bolt

Joint pipe

Sealing surface: 6 places

1–18

GENERAL

Handling of liquid gasket JP30ZCE010102007

1.

Application of liquid gasket and part assembly procedure (1)

Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent deposit of oil, moisture, dirt, etc. Be sure to overlap parts at the beginning and at the end of application.

(2)

Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the liquid gasket again if offset occurs.

(3)

Assemble parts within 20 minutes after application of the liquid gasket. If 20 minutes has passed, remove the liquid gasket and apply it again.

(4) 2.

Start the engine at least 15 minutes or more after assembly of parts.

Removal of parts (1)

When parts are removed, do not pry one place only. Remove parts by prying each other using collar or clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the engine.

3.

Others (1)

When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in a cartridge, use the application gun.

Winding tool

Application gun

Tube: 150 g

Cartridge type: 300 g

For a tube, desired application width may be obtained from the cut position at the nozzle end. 1 : Approx. 2 mm at the 1st section cut 2 : Approx. 5 mm at the 2nd section cut

Nozzle of tube General information Description of function

1–19

GENERAL

Failure diagnosis table for each problem JP30ZCE010301001

Causes and actions are described for each item.

Engine mechanical

JP03Z01020601001

Status Engine overheat (coolant)

Cause Insufficient coolant

Action 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

Clogging of radiator

Cleaning of radiator

(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

Non-synchronous injection timing

Adjust injection timing.

pressure)

Faulty fuel injection pressure

Adjust injection pressure

Faulty fuel

Replace with correct fuel

Faulty injector

Replace injector

Engine overheat (lubrication

Deterioration of engine oil

Replace engine oil

unit)

Faulty oil pump

Replace oil pump

Insufficient engine oil

Replenish engine oil

Large engine oil consumption

Wear of piston ring and cylinder

Replace piston ring and cylinder

(piston, cylinder liner and piston

liner

liner

ring)

Damage to piston ring

Replace piston ring and cylinder liner

Faulty fixing of piston ring

Replace piston ring and cylinder liner

Faulty assembly of piston ring

Replace piston ring and cylinder liner

Faulty engine oil

Replace engine oil

Faulty piston ring joint

Reassemble piston ring

Large engine oil consumption

Wear of valve stem

Replace valve and valve guide

(valve and valve guide)

Wear of vavle guide

Replace valve guide

Faulty assembly of valve stem seal

Replace stem seal

Excessive oil lubrication to rocker

Inspection of clearance between

arm

rocker arm and rocker arm shaft

Large engine oil consumption

Faulty oil level gauge

Replace with correct level gauge

(others)

Excessive filling of engine oil

Fill with appropriate amount of oil.

Leak of engine oil

Repair or replace the part of oil leak.

Piston seizure (in operation)

Sudden stop of engine

Perform warm-up before stop of engine

Piston seizure (lubrication unit)

Insufficient engine oil

Replenish engine oil

Deterioration of engine oil

Replace engine oil

Incorrect engine oil

Replace with correct engine oil.

Low oil pressure

Inspection of lubrication unit

Faulty oil pump

Replace oil pump

Piston seizure

Abnormal combustion

Refer to overheat section.

Piston seizure

Cooling unit

Refer to overheat section. SAPH30ZCE0100024

1–20

GENERAL

Failure diagnosis procedures JP30ZCE010301002

1.

Display of failure code (1)

If the system has an error, the failure code is displayed on the multiple display of cluste