Shop Manual SK330-8 PDF
Shop Manual SK330-8 PDF
MAINTENANCE SPECIFICATIONS
SHOP SK330-8
MANUAL model SK350LC-8
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
INDEX SK330-8/SK350LC-8
Book Code No. Index
Title
Distribution Year–Month No.
MAINTENANCE SPECIFICATIONS
S5YN0118E01
2006-7
OUTLINE 1
S5LC0211E01
2006-7
SPECIFICATIONS 2
S5LC0311E02
ATTACHMENT DIMENSIONS 3
2007-2
S5LC1111E01
TOOLS 11
2006-7
S5LC1211E01 STANDARD MAINTENANCE
2006-7
12
TIME SCHEDULE
S5LC1311E02 MAINTENANCE STANDARDS
2007-2
13
AND TEST PROCEDURES
S5LC2111E02 MECHATRO CONTROL
2007-2
21
SYSTEM
S5LC2211E02
2007-2
HYDRAULIC SYSTEM 22
S5LC2311E02
SYSTEM
2007-2
ELECTRICAL SYSTEM 23
S5LC2411E02
2007-2
COMPONENTS SYSTEM 24
S5LC2511E02
2007-2
AIR-CONDITIONER SYSTEM 25
_
S5YN3118E01 DISASSEMBLING
DISASSEMBLING
S5YN4618E02
2007-2
BY ERROR CODES 46
S5LC4711E02
2007-2
BY TROUBLE 47
S5YN4818E01
2006-7
TROUBLE DIAGNOSIS MODE 48
_
S5LC5111E02
ENGINE 51
2007-2
_
LC10-07001~
YC10-03501~ APPLICABLE MACHINES
0-5
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
1
1. OUTLINE
TABLE OF CONTENTS
1-1
1. OUTLINE
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
begin a meeting before starting the work.
MAKING REPAIRS
3) Before starting inspection and maintenance
1.1.1 PREPARATION BEFORE stop the engine.
DISASSEMBLING
4) Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact
Read Operator's Manual
for emergency measure and ambulance to
before disassembling
4) Visible oil leak, water leak and damage 3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness. 4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
6) Examine the problems on the basis of monthly
and gear oil before putting them on working
operation rate with the last inspection date and
bench.
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Since performance and function of hydraulic
1) Tools required for repair work.
equipment after disassembly and assembly
2) Prepare the places to put the disassembled
results in immunity from responsibility on the
parts.
manufacture’s side, disassembly, assembly
3) Prepare oil pans for leaking oil, etc. and modification without permission are strictly
prohibited.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING 2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
WARNING
3) Make match mark on parts for reassembling.
(1) Safety 4) Before disassembling, read Disassembling
1) Wear appropriate clothing, safety shoes, safety Instruction in advance, and determine if the
helmet, goggles, and clothes with long sleeves. disassembly and assembly are permitted or
not.
1-3
1. OUTLINE
1-4
1. OUTLINE
(6) Engine key off before touching terminals of starter (2) Flexible hose (F hose)
and alternator. • Even if the connector and length of hose are the
(7) Remove battery grounding terminal before same, the parts differ according to the
beginning work close to battery and battery relay withstanding pressure. Use proper parts.
with tools. • Tighten it to the specified torque, and check that
(8) Wash machine with care so as not to splash water it is free from twist, over tension, interference,
on electrical equipment and connector. and oil leak.
(9) When water has entered in the waterproofed
1.1.6 WELD REPAIR
connector, the removing of water is not easy. So
(1) The weld repair should be carried out by qualified
check the removed waterproofed connector with
personnel in the specified procedure after
care to protect it from entry of water. If moisture
disconnecting the grounding cable of battery. If the
adheres on it, dry it completely before connecting.
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
Battery fluid is dangerous. entry of spark beforehand.
The battery fluid is dilute sulfuric acid, and causes (3) Repair attachments which are damaged, giving
scald and loss of eyesight by adhering on eyes, particular attention to the plated section of piston
skin and clothes. When the fluid has adhered on rod to protect it from sparks, and don’t fail to cover
them, take an emergency measure immediately and the section with flame-proof clothes.
see a doctor for medical advice.
1.1.7 ENVIRONMENTAL ISSUES
• When it has adhered on skin ;
Wash with soap and water. (1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
• When it has got in eyes ;
Wash in water for 10 minutes or more (2) Waste disposal
immediately. The following parts follows the regulation.
Waste oil, waste container and battery
• When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or wash (3) Precautions for handling hydraulic oil
away with water. Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it was swallowed ;
Drink milk or water. • When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it has adhered on clothes ;
Wash it immediately. • When it was swallowed ;
Don’t force him to vomit it, but immediately
1.1.5 HYDRAULIC PARTS receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
(1) O-ring For spare parts, grease and oil, use KOBELCO
• Check that O-ring is free from flaw and has genuine ones.
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-5
1. OUTLINE
1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
° (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro µ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3
1-6
1. OUTLINE
1-7
1. OUTLINE
[MEMO]
1-8
2
2. SPECIFICATIONS
TABLE OF CONTENTS
2.2.2 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+2.60m (8ft-6in) Short Arm+1.60m3 (2.09cu•yd) Bucket] .................2-5
2.2.3 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+4.15m (13ft-7in) Long Arm+1.20m3 (1.57cu•yd) Bucket] ................2-5
2.3 WEIGHT OF COMPONENTS............................................................................................2-6
2.4 TRANSPOTATION ............................................................................................................2-8
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-8
2.4.2 DIMENSIONS OF ATTACHMENT ...........................................................................2-9
2.5 SPECIFICATIONS AND PERFORMANCE .......................................................................2-11
2.5.1 SPEED AND CLIMBING CAPABILITY.....................................................................2-11
2.5.2 ENGINE ....................................................................................................................2-11
2.5.3 HYDRAULIC COMPONENTS ..................................................................................2-11
2.5.4 WEIGHT ...................................................................................................................2-11
2.6 TYPE OF CRAWLER.........................................................................................................2-12
2.6.1 SK330-8....................................................................................................................2-12
2.6.2 SK350LC-8 ...............................................................................................................2-12
2.7 TYPE OF BUCKET ............................................................................................................2-13
2.8 COMBINATIONS OF ATTACHMENT................................................................................2-14
2.9 ENGINE SPECIFICATIONS ..............................................................................................2-15
2.9.1 SPECIFICATIONS....................................................................................................2-15
2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-TM) ..........................................2-16
2-1
2. SPECIFICATIONS
2-2
2. SPECIFICATIONS
BOOM
BOOM CYLINDER
BUCKET
CYLINDER
CAB
SLEWING BEARING
IDLER LINK
SLEWING MOTOR
FUEL TANK
CONTROL VALVE
BUCKET LINK
HYDRAULIC TANK
HYDRAULIC
PUMP
BUCKET GUARD
MONITOR PANEL
SHOE
FRONT IDLER
IDLER ADJUST
AIR CLEANER
COUNTER WEIGHT
LOWER ROLLER
RADIATOR AND OIL COOLER
BATTERY
TRAVEL MOTOR
2-3
2. SPECIFICATIONS
1500(4'11") 1450(4'9")
2950(9'8")
50(2")
R35
00(1
1'6"
)
11200(36'9")
3500(11'6")
3420(11'3")
3160(10'4")
1190*
(3'11")
(19.7")
500*
Q'TY OF LOWER ROLLER:7SETS[9SETS]
4650 (15'3") [4980(16'4")] (23.6") 600 3200(10'6")
5830 (19'2") [5990(19'8")]
2-4
2. SPECIFICATIONS
11280(37')
4750(15'7")
3500(11'6")
3640(11'11")
1190*
(3'11")
Q'TY OF LOWER ROLLER:7SETS[9SETS] 4650(15'3") [4980(16'4"))
5830(19'2") [5990(19'8")]
4750(15'7")
3500(11'6")
3590(11'9")
1190*
(3'11")
2-5
2. SPECIFICATIONS
Bucket}
3.1 Bucket assy (STD) 1,080 (2,380) ←
3.2 STD Arm assy (Assembly of following :) 1,900 (4,190) ←
3.2.1 STD Arm 1,250 (2,760) ←
3.2.2 Bucket cylinder *266 (590) ←
3.2.3 Idler link 33 (73) × 2 ←
3.2.4 Bucket link 142 (313) ←
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 102 (225) ←
3.3 Boom assy (Assembly of following :) 3,610 (7,960) ←
3.3.1 Boom 2,670 (5,890) ←
3.3.2 Arm cylinder *539 (1,190) ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 75 (165) ←
2-6
2. SPECIFICATIONS
Unit ; kg (lb)
Model
SK330 - 8 SK350LC - 8
Item
4. Lubricant and water (Assembly of following :) 862 (1,900) ←
4.1 Hydraulic oil 310 (684) ←
4.2 Engine oil 28 (62) ←
4.3 Fuel 484 (1,070) ←
4.4 Water 44 (97) ←
2-7
2. SPECIFICATIONS
2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm+1.40m3 (1.83cu•yd) Bucket
Model
SK330-8 SK350LC-8
Item
Width 600mm (23.6in) shoes 3,200 (10ft-6in) 3,200 (10ft-6in)
Weight 33,800kg (74,500 lbs) 34,200kg (75,400 lbs)
6")
.7(4.
116
(16.5")
420.1
SECTION AA
11218(36'10") 1800(5'11")
219.5(8.6")
4179(13'9")
660 1020(3'4")
100
(4")
(26")
528
(21")
2-8
2. SPECIFICATIONS
Type
6.50m (21ft-4in) Boom
Item
Length×Height×Width 6.75 × 1.84 × 0.83
m (ft-in)
L×H×W (22'2"× 6'0"× 2'9")
Weight kg (lbs) 3,290 (7,250)
H
L
Type 2.6m (8ft-6in) Arm + 3.30m (10ft-10in) Arm + 4.15m (13ft-7in) Arm +
1.6m 3(2.09cu•yd) Bucket 1.40m 3 (1.83cu•yd) Bucket 1.20m 3 (1.57cu•yd) Bucket
Item
Length×Height×Width 5.41 × 1.13 × 1.57 6.07 × 1.12 ×1.42 6.94 × 1.10 × 1.24
m (ft-in)
L×H×W (17'9"×3'8"×5'2") (19'11"×3'8"×4'8") (22'9"×3'7"×4'1")
Weight kg (lbs) 2,870 (6,330) 2,960 (6,530) —
H
(3) Arm
Type
2.6 m (8ft-6in) Arm 3.30 m (10ft-10in) Arm 4.15 m (13ft-7in) Arm
Item
Length×Height×Width 3.82 × 1.09 × 0.62 4.48 × 0.97 × 0.62 5.35 × 0.99 × 0.63
m (ft-in)
L×H×W (12'6"×3'7"×2'2") (14'8"×3'2"×2'2") (17'7"×3'3"×2'1")
Weight kg (lbs) 1,660 (3,660) 1,830 (4,040) —
H
2-9
2. SPECIFICATIONS
(4) Bucket
HOE BUCKET
L H
2-10
2. SPECIFICATIONS
2.5.2 ENGINE
2.5.4 WEIGHT
Unit : kg (lbs)
SK330-8 SK350LC-8
Fully equipped weight 33,800 (74,500) 34,600 (76,300)
Upper structure 15,800 (34,840) ←
Lower machinery 11,300 (24,900) 12,000 (26,460)
Attachment
6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm 6,590 (14,530) ←
+1.40m3 (1.83cu•yd) Bucket
2-11
2. SPECIFICATIONS
45 LINKS
2.6.2 SK350LC-8
48 LINKS
Use 600mm (23.6in) grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
2-12
2. SPECIFICATIONS
2-13
2. SPECIFICATIONS
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2-14
2. SPECIFICATIONS
2-15
2. SPECIFICATIONS
SHAFT TORQUE
SHAFT OUTPUT
2-16
3
3. ATTACHMENT DIMENSION
TABLE OF CONTENTS
3-1
3. ATTACHMENT DIMENSION
3-2
3. ATTACHMENT DIMENSION
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING
d4
J
I
d3 K
d1
D C
H G B
E
F
K
A
J
d2
SECTION K-K
Unit : mm (ft-in)
STD
6.50M (21ft-4in) BOOM
LC02B00164F1
No NAME DIMENSION
A Boom length 6,500 (21'4")
B Boom foot width 826 (32.5")
C Boom end inner width 405.8 (16.0")
D Boom end outer width 577 (22.7")
E Height of boom cylinder rod pin 1,115 (3'8")
F Height of arm cylinder (head side) pin 1,460.8 (4'9.5")
G Distance between pins of boss R2,955 (9'8")
H Distance between pins of bracket R3,390.5 (11'1.5")
I Arm cylinder (head side) inner width 146 (5.75")
J Outer width of bracket on the boom cylinder (rod side) mounting 564 (22.2")
d1 Boom foot pin dia. ø 125 (4.92")
d2 Boom cylinder (rod side) pin dia. ø 110 (4.33")
d3 Pin dia. of boom end. ø 110 (4.33")
d4 Arm cylinder (head side) pin dia. ø 110 (4.33")
3-3
3. ATTACHMENT DIMENSION
A
C
3-4
3. ATTACHMENT DIMENSION
3-5
3. ATTACHMENT DIMENSION
D
D C
A
L3 L3' X3
B A
PL3
X1 L1
SECTION C-C
X4
L4 PL4
PL2 PL2
PL1
X2 L2 L2 X2
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
826
Boom
(32.5) 0.5 (0.02) 1.0 1.5 1,026
A-A Boom foot L1 PL1
832 or less (0.04) (0.06) (3'4.4")
Upper frame
(32.8)
130
Boom cylinder
Boom cylinder (5.12) 0.6~1.0 2.0 2.5 286
B-B L2 PL2
(Head side) 136 (0.02~0.04) (0.08) (0.10) (11.26)
Upper frame Shim
(5.35)
adjust
130
Boom cylinder L3 ment
Boom cylinder (5.12) 0.6~2.0 3.0 4.0 877
C-C PL3
(Rod side) 564 (0.02~0.08) (0.12) (0.16) (34.5)
Boom L3'
(22.2)
140
Arm cylinder
Arm cylinder (5.51) 0.6~1.0 2.0 2.5 309
D-D L4 PL4
(Head side) 146 (0.02~0.04) (0.08) (0.10) (12.2)
Boom
(5.75)
3-6
3. ATTACHMENT DIMENSION
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
3-7
3. ATTACHMENT DIMENSION
E F
D, D'
B
C
G
3-8
3. ATTACHMENT DIMENSION
3-9
3. ATTACHMENT DIMENSION
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
L3
L1 X3
X1
X5
L5 PL5
X6 L6
PL1
SECTION E-E
PL3
SECTION A-A
SECTION C-C
L2 X4 L4
X2
PL6
SECTION F-F
PL2 X7 L7
X4' L4'
SECTION B-B PL4 PL7
SECTION D-D,D'-D' SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-10
3. ATTACHMENT DIMENSION
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
380
Arm
(14.96) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
381 or less (0.08)
Bucket
(15.10) 576
380 (22.7)
Link side
(14.96)
B-B Bucket link L2 — — PL2
382
Bucket
(15.04)
390 With in 2.5
Idler link Arm 1.0
C-C L3 (15.35) 0.5 (0.10) PL3
(Arm connection) (0.04)
Link side — (0.02)
Bucket link Rod side —
D-D (Idler link L4 390 505
Link side
connection) (15.35) (19.9)
0.6~1.0 2.0 Shim
130 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (5.12)
D’-D’ L4’ -ment
(Rod side) 136
Link side
(5.35)
130
Head side
Bucket cylinder (5.12) 299
E-E L5 PL5
(Head side) 136 (11.8)
Arm
(5.35) 0.6~2.0 3.0 4.0
140 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (5.51) 309
F-F L6 PL6
(Rod side) 146 (12.2)
Arm
(5.75)
400
Arm With in
(15.75) 1.0 2.5 577
G-G Arm foot L7 0.5 PL7
405.8 (0.04) (0.10) (22.7)
Boom (0.02)
(15.98)
3-11
3. ATTACHMENT DIMENSION
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Unit : mm (ft-in)
Type GD bucket (General Duty)
[STD]
1.20 m3 1.60 m3 1.80 m3
Capacity 1.40 m3
(1.57 cu•yd)) (2.09 cu•yd)) (2.35 cu•yd))
(1.83 cu•yd)
Part No. LC61B00115F1 LC61B00052F1 LC61B00118F1 LC61B00057F1
A R517 (20.4") ← ← ←
B R1,690 (5'7") ← ← ←
C 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
D 444 (17.5") ← ← ←
E 382 (15.0") ← ← ←
F 1,415 (4'8") 1,240 (4'1") 1,565 (5'2") 1,683 (5'6")
G 1,122 (3'8") 936 (36.9") 1,272 (4'2") 1,496 (4'11")
H 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
I 280.5 (11") 316 (12.4") 318 (12.5") 377 (14.8")
IO 280.5 (11") 315 (12.4") 318 (12.5") 376 (14.8")
d1 ø 105 (4.13") ← ← ←
d2 ø 90 (3.54") ← ← ←
3-12
3. ATTACHMENT DIMENSION
LS12B01054P1
28 (1.10")
19
(0.748")
VIEW I
SHIM t=1
(Five shims are installed
at shipping) Insert this pin flush with surface
SECTION AA
Fig. 3-8 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Plate thickness
Boss width.
Screw dia.
Capacity of
Hole dia.
A B D E F G H J M N
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 90 28 105 16 105 19 190 12 150
GD bucket M20
1.60 (2.09) LC61B00118F1 (3.54") (1.10") (4.13") (0.63") (4.13") (0.748") (7.48") (0.472") (5.91")
3-13
3. ATTACHMENT DIMENSION
)
gh
ou
thr
rill
(D
G
Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB E F øG
bucket bucket of boss
m3 (cu•yd)
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 139.8 103.8 15 40 21
GD bucket LS12B01054P1
1.60 (2.09) LC61B00118F1 (5.50") (4.09") (0.591") (1.58") (0.827")
1.80 (2.35) LC61B00057F1
3-14
11. TOOLS
11
TABLE OF CONTENTS
11-1
11. TOOLS
11-2
11. TOOLS
11-3
11. TOOLS
11-4
11. TOOLS
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 27 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
11-5
11. TOOLS
11-6
11. TOOLS
SLEEVE NUT
B
d
d
11-7
11. TOOLS
11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
A
11-8
11. TOOLS
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
PF screw
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
#
$ %
() !
, -+./0
&# *+( "
'& *+( "
'& *+( "
Female
11-10
11. TOOLS
70(2.76)
16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)
70(2.76)
42(1.65)
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )
32 (1.26) 2421T232 50
81(3.19) 90(3.54)
20.5(0.807)
11-11
11. TOOLS
Additional M10 X 22
threading
for M10 eye bolt For slinging the
Plug ZE72X16000
3 swing motor
PF1
(M port)
O-ring
PF1
M12
M8 Eye bolt
Plug
ZF83P22000
(Nominal
tube dia. 22)
5 Reference nut Flare hose
Reference
ZS91C00800
Eye bolt
ZF93N22000 M8 X 18
Nut Addtional
threading for
M8 Eye bolt
M8 Eye bolt
M8 X 18
Plug YN01H01001P1
Additional
threading
Nominal
6 1-14UNS HEX 27 Flare hose
11-12
11. TOOLS
Table11-4
M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
7 1 3/16-12UN HEX 36 Flare hose
Plug ZE25F08000
PF1/2 For slinging the
8 Weld
Coupling swivel joint
half Coupling half
PF 1/2
11-13
11. TOOLS
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound
11-14
11. TOOLS
2 Nut
3 Cover
4 O-ring
11.9.2 DIMENSION
50
(1.97")
R8
O113 (4.45")
2
M8 NUT
O8 (1.315")
600 (23.6")
M8 O100 +0.5
0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
Fig. 11-2 Dimension of suction stopper
Applicable
SK115SR
SK135SR
SK235SR
SK200-6E
SK100-2
SK120-2
SK100-3
SK120-3
SK200-6
SK200-8
SK330-8
model
SK100
SK120
Part No.
24100P978F2
11-15
11. TOOLS
11-16
11. TOOLS
Material : Wood
Unit : mm(inch)
5
1
6
3
2
6 6
4
6
6
1X1 set
5X1 set
3X1 set
6X5 sets
11-17
11. TOOLS
[MEMO]
11-18
12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST
(TEMPORARY EDITION) ................................................................................................12-15
12.2.1 MEASURING METHOD .........................................................................................12-15
12.2.2 WORKING CONDITION .........................................................................................12-15
12.2.3 STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.4 MEANING OF WORDS IN USE .............................................................................12-17
12-1
12. STANDARD MAINTENANCE TIME TABLE
12-2
12. STANDARD MAINTENANCE TIME TABLE
PREFACE
(1) Working Conditions
1) Workers :
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
2) Equipment :
Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The
maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
3) Place :
A flat land where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance time×Preparation time
2) Direct maintenance time : Net time actually spent for maintenance
3) Spare time :
Time needed to move machines for service, prepare safety operations, discuss work, and process the needs
of the body.
(3) Extra time (not included in the standard service time)
1) Repair time :
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time :
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
3) Indirect time :
Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
(4) Applicable machine for estimation of standard maintenance time
1) Standard machine
2) A well maintained and controlled machine with a standard combination of attachments which is used in a
general environment.
12-3
12. STANDARD MAINTENANCE TIME TABLE
12-4
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.9
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.2
04 • Bucket drive pin Detach/attach 1 0.2
05 • Bucket sling and movement Preparation 1 pc. 0.3
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 3.6
07 • Tooth Replace 1 pc. 0.9
08 • Side cutter Replace 1 pc. 1.8
09 • Bushing Replace 1 pc. 0.9
12-5
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.5
80 Boom cylinder O/H 2 8.0
01
12-6
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
52 Cover (2) Detach/attach 1 pc. 0.1
53 Cover (3) Detach/attach 1 pc. 0.1
54 Cover (4) Detach/attach 1 pc. 0.1
55 Cover (5) Detach/attach 1 pc. 0.1
02 Cab & Guard
12-7
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.5
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0
12-8
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
96 Swing motor O/H 1 pc. 4.0
97 Swing reduction gear O/H 1 pc. 5.0
12-9
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
144 • Others Detach/attach 1 set 0.5
145 • Mounting bolt Detach/attach 1 pc. 0.5
146 • Engine slinging Detach/attach 1 set 0.3
147 • Cleaning Cleaning 1 pc. 0.5
148 Engine O/H 1 set Reference for engine (Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
Detach/attach 1 set Removing and installing counterweight 0.9
Detach/attach 1 set Removing and installing pump 3.2
Detach/attach 1 set Removing and installing air cleaner 0.4
1 set Removing and installing muffler 0.4
03 Swing frame
Detach/attach
12-10
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
40 Sprocket See 34.1.6
41 Sprocket Replace One side After removing track link 0.9
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
Diode
D-4 Diode Replace 1 0.3
D-5 Diode Replace 1 0.3
06 Electric equipments
12-11
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM (OPT) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include counterweight removing and installing. 1.0
E-12 Battery Replace 2 0.4
E-13 Travel alarm (OPT) Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3
E-15 Fusible link Replace 1 0.2
E-27 Accel emergency mode volume Replace 1 0.5
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Swing flusher & work light (left) Replace 1 0.2
L-4 Swing flusher & work light (right) Replace 1 0.2
L-5 Room light Replace 1 0.2
06 Electric equipments
Motor
M-1 Starter motor Replace 1 Include counterweight removing and installing. 1.2
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor (OPT) Replace 1 0.5
M-9 Skylight wiper motor (OPT) Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.5
PSV-B P2 bypass cut proportional valve Replace 1 Include proportional valve block removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 bypass cut proportional valve Replace 1 0.5
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
12-12
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
R-31 Wiper motor relay arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1
Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
06 Electric equipments
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.5
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Fuel sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-3 2-speed travel SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-4 Safety lever lock SOL Replace 1 Include proportional valve block removing and installing. 0.5
Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lever lock switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
12-13
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
SW-20 Attachment power boost switch (right) Replace 1 0.3
06
12-14
12. STANDARD MAINTENANCE TIME TABLE
12.2.3.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD
ALLOWANCE TIME
(1) Net working time
The time workman works actually and the time required for measurement, cleaning, and so on is included, but
the time required for troubleshooting is not included
(2) Standard time
Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts
and so on, and for the work site clean-up.
(3) Standard allowance time
Calculate the allowance time directly required for workmen from the following equation.
Net standard time × HINO allowance rate
Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position
and so on.
12-15
12. STANDARD MAINTENANCE TIME TABLE
12-16
12. STANDARD MAINTENANCE TIME TABLE
12-17
12. STANDARD MAINTENANCE TIME TABLE
SK200-8 SK330-8
12-18
12. STANDARD MAINTENANCE TIME TABLE
SK200-8 SK330-8
12-19
12. STANDARD MAINTENANCE TIME TABLE
SK200-8 SK330-8
119 00552 Replacing crank shaft rear oil seal Single unit From fly wheel is removed condition 0.2 0.2
131 00613 Replacing intake manifold One set Include; Applying liquid gasket 2.0 2.3
132 00614 Replacing intake manifold gasket One set Include; Applying liquid gasket 2.0 2.3
Removal and installing intake pipe
133 00636 One set 1.3 1.6
(manifold side)
134 00637 Replacing intake pipe (manifold side) One set 1.3 1.6
135 00622 Replacing air intake hose One set 0.4 0.2 0.4 0.2
136 00623 Replacing air intake pipe One set 0.4 0.2 0.4 0.2
137 00626 Replacing air intake pipe One set Turbo charger to inter cooler 0.4 0.4
138 00627 Replacing air intake pipe One set Air cleaner to turbo charger 0.4 0.2 0.4 0.2
Completed
139 00675 Replacing silencer body 0.3 0.2 0.3 0.2
machine
Completed
142 00641 Tightening exhaust manifold 0.9 1.3
machine
Removal and installing exhaust Completed
143 00643 With insulator and stud bolt 2.8 3.2
manifold machine
12-20
12. STANDARD MAINTENANCE TIME TABLE
SK200-8 SK330-8
12-21
12. STANDARD MAINTENANCE TIME TABLE
SK200-8 SK330-8
12-22
12. STANDARD MAINTENANCE TIME TABLE
SK200-8 SK330-8
471 01901 Replacing main engine speed sensor One set Include; Function check 1.2 1.2
472 01902 Replacing sub engine speed sensor One set Include; Function check 1.2 1.2
Replacing coolant temperature
473 01903 One set Include; Function check 1.2 1.2
sensor
474 01904 Replacing accel sensor One set Include; Function check 1.5 1.5
475 01908 Removal and installing EGR valve One set Include; Function check 2.1 2.5
476 01909 Replacing EGR valve One set Include; Function check 2.1 2.5
479 01916 Removal and installing EGR cooler One set 1.8 1.8
480 01917 Replacing EGR cooler One set 1.8 1.8
Removal and installing closed
481 01918 One set 0.3 0.3
ventilator
482 01919 Replacing closed ventilator One set 0.3 0.3
12-23
12. STANDARD MAINTENANCE TIME TABLE
[MEMO]
12-24
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE.....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1 MEASUREMENT OF ENGINE SPEED..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1 TRAVEL SPEED.....................................................................................................13-12
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6.1 SWING SPEED ......................................................................................................13-15
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS.........................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)..........13-21
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO
CONTROLLER .......................................................................................................13-27
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-2
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23) °
C — Atmospheric temp
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — 50°C~-10°C (122°F~14°F)
not required
Adjustment
Measure the engine
B mode Hi idle 2100 + 30 - 70 Perform all
speed at multi display on min-1
A mode Hi idle 2100 + 30 - 70 measurement with
the gauge cluster.
Decel 1050 + 25 - 25 the air-conditioner
S mode Hi idle 1900 + 30 - 70 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 35.8 (5190) 0 - 2.0 (-290) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 35.8 (5190) 0 - 2.0 (-290) RH and LH
RV —
13-4
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Standard
Inspection item Unit
value
1st speed 34.3 ~ 31.1
Track link revolution STD
2nd speed 20.4 ~ 18.4
(RH,LH) sec / 3 rev
1st speed 36.4 ~ 33.2
(H mode) LC
2nd speed 21.7 ~ 19.9
Up 2.7 ~ 3.3
Boom
Operating speed
58 ~ 98 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 120
ATT amount of drift Boom cylinder 4.2 mm / 5min (At no load)
Arm cylinder 6
Amount of horizontal play at the bucket tooth 27 ~ 53 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
13-6
13. MAINTENANCE STANDARD AND TEST PROCEDURE
B1
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and a1 a2
measure with the instrument for analysis. If the
Fig. 13-3 Gauge port on main pump
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE
PLUG FOR
OR8 : ARM (R) OPTIONAL RELIEF
MACHINE
FRONT
MACHINE
FRONT
13-8
13. MAINTENANCE STANDARD AND TEST PROCEDURE
A3
a5
Dr3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
Fig. 13-6 Swing over load relief position
13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm 0-:
Fig. 13-9 Over load relief valve
No. of turns of adjust screw Pressure change MPa (psi) (Boom, bucket, arm sections)
13-10
13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 30, 38 mm,
Tightening torque : 118 N•m (87 lbf•ft)
4 !
: 12 mm Fig. 13-10 Swing over load relief valve
13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-12
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
1) Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding
Fig. 13-15 Measuring method
the preliminary run of 3~5m (10~16ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm (in) / 20m (66ft)
Measuring Reference value
position Standard value for remedy Service limit
A 240 (9.45") or less 480 (18.9") 720 (28.4")
C
GUIDE FRAME
Fig. 13-17 Method of measurement
13-13
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-14
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Fig. 13-22 Measuring position of swing brake
performances
Swing brake performance Unit : degree
Measuring Reference value
position Standard value for remedy Service limit
Swing 180 98 or less 108 118
13-16
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-17
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-18
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-20
13. MAINTENANCE STANDARD AND TEST PROCEDURE
E-27:
C-8: EMERGENCY
ACCEL
ENGINE CONTROLLER
INJECTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the adjustment data
is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the machine into the
ordinary operating condition according to Error Code List.
For machines equipped with lifting magnet, turn the generator OFF.
13-22
13. MAINTENANCE STANDARD AND TEST PROCEDURE
MULTI DISPLAY
WASHER SWITCH
WIPER SWITCH
SELECTOR SWITCH
4) After starting engine, press selector switch on gauge cluster, and "MEMORY
ENG" is displayed, the engine speed is automatically increased, and the
adjustment of engine is performed.
(When trying to limit engine speed, press selector switch on gauge cluster at
the speed as it is, and the adjustment of engine is terminated. The torque
adjustment and unloading adjustment required later are not performed, and
default value is written.)
5) When normal HIGH idling speed is detected, the adjustment is completed. And
FINISH ENG
"FINISH ENG" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared, PUMP PRESSURE
C-1 2.0M C-2 2.0M
and the adjustment of engine is completed. The torque adjustment and STEP
400
unloading adjustment required later are not performed, and default value is
written.)
13-23
13. MAINTENANCE STANDARD AND TEST PROCEDURE
2) When the unloading valve operates to the specified value, the adjustment of
UNLOAD" is displayed.
The speed is shifted to the speed corresponding to acceleration potentiometer.
(4) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) In cases where the adjustment of engine can not be performed; And ERROR ENGINE SPEED
2000rpm
PUMP PRESSURE
ENG" is displayed. C-1 2.0M C-2 2.0M
STEP
Judging condition: The read engine speed is 50rpm lower than the last value. 400
It is conceived that the error is caused by the speed read error, pump load
applied to the engine and unusual acceleration command voltage applied to
the engine controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed
due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal
increase of pump pressure during adjustment of engine through
adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration
command voltage output from mechatro controller to engine controller.
Check that signal is regularly input to the engine controller by actual
measurement of voltage or with failure diagnosis tool of engine controller.
13-24
13. MAINTENANCE STANDARD AND TEST PROCEDURE
2) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve
current reaches to the specified value.
For machines equipped with lifting magnet, turn the generator OFF.
13-25
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(6) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge
cluster pressed, and hold it for 5~10 seconds, and then release it.
(If the engine is started, the following indication is not displayed. Therefore do
not start the engine.)
2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
it and the screen for selection of adjustment type is displayed. And "ADJUST"
ADJUST
READY
is displayed. FEED
When adjustment data is not entered in mechatro controller, "READY" is
indicated. If the adjustment operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and
select "ADJUST UNLOAD". (See Fig. 13-35)
Like the output adjustment, when adjustment data is not entered in mechatro
controller, "READY" is indicated. If the adjustment operation is once
performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".
START ENG
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140
5) After starting engine, press selector switch on gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is indicated, the engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" PROPO-VALVE
D-1 300mA D-2 300mA
6) When the unloading proportional valve operates to the specified value, the
UNLOAD" is indicated.
The speed is shifted to the speed corresponding to acceleration potentiometer.
13-26
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Operating procedure:
1) Set the emergency acceleration to NORMAL position.
2) Start engine.
3) Turn the emergency acceleration to HI side and control the engine speed.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
The emergency mode should be used in only case of emergency. We recommend that the defective section is
repaired by troubleshooting as early as possible.
13-27
13. MAINTENANCE STANDARD AND TEST PROCEDURE
[MEMO]
13-28
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21-1
21. MECHATRO CONTROL SYSTEM
21-2
21. MECHATRO CONTROL SYSTEM
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the
conditions before and after each conversion, refer to the hydraulic system and the electric system.
21-3
21. MECHATRO CONTROL SYSTEM
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21-4
21. MECHATRO CONTROL SYSTEM
SE-29
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
21-5
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
21-6
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-7
21. MECHATRO CONTROL SYSTEM
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
21-8
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and
consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-9
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
21-10
21. MECHATRO CONTROL SYSTEM
21-11
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump
delivery rate is low due to low engine speed.
21-12
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
21-13
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload proportional valves and travel straight proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
(4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
21-14
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-15
21. MECHATRO CONTROL SYSTEM
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload proportional valves and travel straight proportional valve.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of control valve.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump
delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the
pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the
stroke limit of bucket spool.
21-16
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure
sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot
secondary pressure switches swing spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2
unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel
straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched
enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil
on arm cylinder rod side is recirculated into arm cylinder head side.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate
is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum
speed drop possible.
21-17
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
21-18
21. MECHATRO CONTROL SYSTEM
21-19
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER SECONDARY PRESSURE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot,
accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum
tilt angle.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes
engine speed to pressure release control speed.
3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and
P2 unload valves to the maximum opening.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to
be released by operating each control lever and switching spool with the unload valve opened.
21-20
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
21-21
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
21-22
21. MECHATRO CONTROL SYSTEM
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
21-23
21. MECHATRO CONTROL SYSTEM
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
For the work with breaker, select "B mode" without fail.
The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and
breaker.
21-24
21. MECHATRO CONTROL SYSTEM
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 210L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
10:25 Flow
rate 294 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 294 L/m rate 294 L/m
A B
(b) (c)
21-25
21. MECHATRO CONTROL SYSTEM
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
ASIA 2,000 Hr
Hydraulic oil
OCEANIA 5,000 Hr
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-26
21. MECHATRO CONTROL SYSTEM
MACHINE CONDITION
H
MULTI DISPLAY INDICATIONS
1) Display function for operator ......... Screen usually displayed during operation
1.1 Clock display function ......... Current time is displayed.
1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional
valve, etc., this displays error code.
1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning
contents with the symbol and statement. (For warning contents, see items
shown below.)
1.4 Machine condition display ......... Displays machine operating condition.
2) Display function for maintenance ......... Displays remaining time up to replacement/change of following
items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and
displays in order of recent occurrence.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output
adjustment and unload adjustment, etc.
5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve
command, etc. output by mechatro controller
6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are
not detected by self diagnosis and displays the results.
HIGH ENG
AUTO IDLE STOP WATER TEMP.
W006 CHARGE ERROR
WARM FINISH WARM-UP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 CHANGE ENG OIL
ERROR
SWING BRAKE
ENGINE STOP
DISENGAGED
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
21-27
21. MECHATRO CONTROL SYSTEM
!
21-28
21. MECHATRO CONTROL SYSTEM
Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.
21-29
21. MECHATRO CONTROL SYSTEM
21-30
21. MECHATRO CONTROL SYSTEM
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage B-4 ARM IN
POS. 100% Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
ECU OUTPUT 0.5V Accel output voltage to engine B-5 BUCKET DIG
controller 3.5V 2.6M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
B-19 DOZER 2
3.5V 2.6M Sensor voltage / Pressure converted value
21-31
21. MECHATRO CONTROL SYSTEM
7 16
NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-3 BOOM-HEAD B-13
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-4 BOOM-ROD B-14
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
PROPO-VALVE B-15
E-3 OPT RELIEF 1 Set value in computer / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
COMP. 600mA 14.5M Measured value / Converted value from pressure B-20
MEAS. 600mA 14.5M 3.5V 12.6M Sensor voltage / Pressure converted value
E-4 OPT RELIEF 2 Set value in computer / Converted value from pressure
COMP. 600mA 14.5M Measured value / Converted value from pressure
8 NO.8 PROPO-VALVE
18
NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI2 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI11 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI12 OFF ON/OFF indication
DI13 OFF ON/OFF indication
DI14 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI16 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI17 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI21 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI22 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 OFF ON/OFF indication
DI26 OFF ON/OFF indication
DI27 OFF ON/OFF indication
DI28 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
4.5V 90 Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
4.5V 30 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW OFF Glow switch DI33 OFF ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER LIVE Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER OFF Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL LIVE Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL LIVE Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. OFF Set value in computer DO6 COMP. OFF Set value in computer
MEAS. OFF Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
DO10 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO11 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO12 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO13 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO14 COMP. OFF Set value in computer
MEAS. OFF Measured value
21-32
21. MECHATRO CONTROL SYSTEM
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current
21-33
21. MECHATRO CONTROL SYSTEM
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment
21-34
21. MECHATRO CONTROL SYSTEM
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
21-35
21. MECHATRO CONTROL SYSTEM
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 9.0~13.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 9.0~13.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 750~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 750~770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 395 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA
21-36
21. MECHATRO CONTROL SYSTEM
21-37
21. MECHATRO CONTROL SYSTEM
21-38
21. MECHATRO CONTROL SYSTEM
21-39
21. MECHATRO CONTROL SYSTEM
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
All the stored items are erased. It is impossible to erase data partially.
21-40
21. MECHATRO CONTROL SYSTEM
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
21-41
21. MECHATRO CONTROL SYSTEM
time is stored. H
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance
time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
21-42
21. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
21-43
21. MECHATRO CONTROL SYSTEM
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
21-44
21. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
21-45
21. MECHATRO CONTROL SYSTEM
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
21-46
21. MECHATRO CONTROL SYSTEM
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Rotary light (yellow) Output EARTH/OPEN
33 DO 24 Rotary light (green) Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
21-47
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved
21-48
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Boom rod Input 0.5 4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Spare Input 0.5~4.5V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
17 A23 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Spare Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Spare Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Cab slow up and down Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
3 +24V Battery relay output side 20~32V
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
9 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
21 GND Battery (-) 0V
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Cab slow stop valve Output +0~800mA
26 D7- -0~800mA
27 D8+ Boom cushion Output +0~800mA
28 D8- -0~800mA
29 D9+ Arm cushion Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
21-49
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase (spare) Output +24V 1.5A
4 F1- Accel motor A phase (spare) Output +24V 1.5A
5 F2+ Accel motor B phase (spare) Output +24V 1.5A
6 F2- Accel motor B phase (spare) Output +24V 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ Spare Output +0~800mA
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 Key switch (GLOW) Input +24V/OPEN
2 DI 8 Water separetor Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Stroke end check Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Extra pressure Input EARTH / OPEN
15 DI 40 Spare Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved
21-50
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 High reach hoisting at fixed position Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 Elevator cab up check Input +24V / OPEN
11 DI 22 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation / Input
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 High reach (hoist at travel) Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Spare Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V
Connector No. Pin No. Port name Function Input/putput Signal level
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Bucket move limitation Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
18 RXD2 Reception RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 Cab up and down switching valve SV 24V/OPEN
21-51
21. MECHATRO CONTROL SYSTEM
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
No. Item name Wire color No. Item name Wire color
Gauge cluster → Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller → Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 Reserved — 7 White
ON)
GND (RS232C
4 Reserved — 8 Black
communication)
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
21-52
21. MECHATRO CONTROL SYSTEM
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
21-53
21. MECHATRO CONTROL SYSTEM
2) Circuit diagram
21-54
21. MECHATRO CONTROL SYSTEM
21-55
21. MECHATRO CONTROL SYSTEM
21-56
21. MECHATRO CONTROL SYSTEM
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
VIEW A
19 21.9 HEX
O-RING P11
PF1/4 Tightening torgue
34.3N.m (25.3lbf.ft)
21-57
21. MECHATRO CONTROL SYSTEM
[MEMO]
21-58
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY.......................................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS...............................................................22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-8
22.4 NEUTRAL CIRCUIT.........................................................................................................22-8 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-10
22.6 BUCKET CIRCUIT...........................................................................................................22-12
22.7 BOOM CIRCUIT ..............................................................................................................22-14
22.8 SWING CIRCUIT .............................................................................................................22-18
22.9 ARM CIRCUIT .................................................................................................................22-20
22.10 COMBINED CIRCUIT ......................................................................................................22-26
22.11 PRESSURE DRAINING
(RELEASING) CIRCUIT ..................................................................................................22-30
22-1
22. HYDRAULIC SYSTEM
22-2
22. HYDRAULIC SYSTEM
22.1 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety,
mass volume handling and low fuel consumption.
Table22-1
Perfor- Device
mance Function Features
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Multi control valve (Oceania) Changeable to 4 operating pattern with only 1 lever.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
Micro
22-3
22. HYDRAULIC SYSTEM
22-4
22. HYDRAULIC SYSTEM
22.2.1 STANDARD
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
22-5
22. HYDRAULIC SYSTEM
NOTE:
PTb 1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
TRAVEL 2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
P1 UNLOAD PRIORITY
PCb
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W: , W/O: )
M CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
P2 UNLOAD CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 UNLOAD P2 UNLOAD
51
LEFT
NIBBLER
NOTE 4
HYD.TANK 53 RIGHT
BREAKER
PBo 52
OPTION
PAo NIBBLER & BREAKER
PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa
B C1 C2 A
SOL/V BLOCK LEVER
A1 LOCK P
SE-11
50 SV-13
Ps C PL
P
SE-29
YN01Z00162P1 01
22-6
22. HYDRAULIC SYSTEM
22-7
22. HYDRAULIC SYSTEM
22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly,
when the servo piston moves rightward, the
FOR HYDRAULIC CIRCUITS This section describes the following. (1) Type :
Electric flow controlled variable displacement spool (652) is moved leftward by the feedback
Blue (1) Bypass cut valve and unload valve control
pump. lever.
Feed, drain circuit (2) Safety lock lever and pilot circuit The operation is maintained until the opening of
less than 0.44 MPa (64 psi) (2) Principle :
(3) Pump positive flow control spool sleeve is closed.
Green The current command I to the pump’s solenoid
(4) Pump P-Q (Pressure-Quantity) curve control proportional valve controls the delivery rate of the
Return, make up circuit, 22.4.4 PUMP P-Q CURVE CONTROL
0.44~0.59 MPa (64~86 psi) pump. OPERATION
22.4.1 OPERATION OF BY-PASS CUT VALVE
Purple AND UNLOADING VALVE HOUSED IN (3) Operation : (1) Type :
Secondary pilot pressure, CONTROL VALVE 1) Flow rate rise operation (Eg. P1 pump) Electrical flow control type variable pump
(including proportional vlave) By operating any of control levers, the
(1) By-pass cut valve (2) Principle :
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve
On starting engine, P1 and P2 unloading Perform an operation of the value from pump high
Red rises, and the rising pressure is transformed to
proportional valves (PSV-D, PSV-B) output pressure sensor to P-Q curve control value, and
Primary pilot pressure, the rise of output voltage corresponding to the
secondary pressure according to the command send a command to the pump solenoid proportional
(including proportional vlave) pressure input by the low pressure sensor.
output by mechatro controller, and this pressure valve.
5 MPa (725 psi) Mechatro controller signal-processes this
exerts on PBp1 and PBp2 ports, and consequently (3) Operation :
Orange change of voltage, resulting in rise of command
the by-pass cut spool is switched to CLOSE side. The pump high pressure sensor converts the
Main pump drive pressure, current value I to the pump proportional
The by-pass cut spool is usually held on CLOSE pressure to the output voltage corresponding to the
5~34.3 MPa (725~4970 psi) solenoid valve and consequently the pump flow
side after the engine started. And it is switched to pump delivery pressure.
Blue tone rate rises. This is called "Positive Control
OPEN side only when failure occurred on pump The mechatro controller converts the voltage output
At valve operation System".
proportional valve and mechatro controller. by the high pressure sensor to the P-Q curve
Red valve As the pump command current value rises, the
(2) Unloading valve control value. On the other hand, select the pump
When solenoid proportional valve (reducing) secondary pressure of proportional solenoid
On starting engine, like by-pass cut valve, the positive control command current value from the
is operating valve also rises. On the regulator attached on
secondary pressures output by P1 and P2 low pressure sensor in lower order, and the values
Red solenoid the pump, the spool (652) through piston (643)
unloading proportional valves (PSV-D, PSV-B) are output to respective pump proportional valve as
In active and exciting is pushed leftward, and stops at the position
exert on PCb and PCa ports, consequently the P1 a command current.
Displaying the flow circuit and standby circuit when where being in proportion to the force of pilot
and P2 unloading valves are switched to OPEN With this operation, the pump power is controlled so
operating. spring (646).
side. as not to be exceed the engine power, therefore
Regarding the electrical symbols in this manual, refer to The tank port connected to the large bore of
engine dose not stall.
the electric circuit diagram. 22.4.2 SAFETY LOCK LEVER AND PILOT servo piston (532) opens, and the piston
CIRCUIT moves leftward by delivery pressure P1 of the
(1) Purpose : small bore resulting in the increase of tilt angle
To protect attachment from unexpected movement ( ).
for safety. The servo piston and spool (652) are
connected to feedback lever (611). Therefore
(2) Principle :
when servo piston moves leftward, the spool
Cut pressure source of pilot valve for operation.
(652) also moves rightward by means of
(3) Operation : feedback lever. With this movement, the
If the safety lock lever (red) is pushed forward after opening of spool sleeve closes gradually, and
the engine starts, the limit switch (SW-11) is turned the servo piston stops at the position the
on. The timer relay is actuated one second later opening closed completely.
which causes the solenoid (SV-4) of the solenoid
2) Flow rate reduction operation
valve block (13) to be energized and makes the
As the current value I of mechtro controller
pilot operating circuit to stand by.
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the delivery
pressure P1 usually flows into the large bore of
piston through the spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of area,
22-8
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
651
652 M
1 29.0MPa
611 D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
643
a3
532 8
646 a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
22-9
22. HYDRAULIC SYSTEM
22-10
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
22-11
22. HYDRAULIC SYSTEM
22.6 BUCKET CIRCUIT 5) The secondary pressure delivered in travel 3) With the function of pilot circuit, the oil flow is
straight proportional valve (PSV-C) is led to switched from bucket spool, and is fed into
This section describes the following.
PTb port provided in control valve (2) and shifts bucket cylinder head side through AC port of C/
(1) Bucket digging pilot circuit
the travel straight valve one stage. V (2). On the other hand, the return oil from
(2) Auto accel operation cylinder rod (R) side is throttled by bucket spool
22.6.2 AUTO ACCELERATION OPERATION
(3) Flow control in the work mode and returns to tank circuit from BC port of C/V
(1) Principle : (2).
(4) Bucket digging travel straight main circuit
Auto acceleration actuates according to signals
(5) Bucket spool stroke limiter References :
from low pressure sensor.
• In bucket dumping operation, the travel straight
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING (2) Operation :
valve also switches like digging operation,
(1) Mechatronics : <When lever is set to neutral position>
resulting in confluence with travel straight.
In the event where the sensor does not receive
1) When the operation for bucket digging is • When the bucket operation and other operation
signal for 4 seconds or more even though the
performed, the pilot proportional secondary are simultaneously performed, the travel straight
acceleration dial is set to MAX position, the engine
pressure is delivered through port 1 of the right valve does not actuate, resulting in single flow of
speed should be raised to 1000rpm.
pilot V (9), flows to PAc port, and acts on the low bucket circuit.
<When lever is operated>
pressure sensor (SE-1), and at the same time
When the pressure 0.6MPa (87psi) is input to low 22.6.5 BUCKET SPOOL STROKE LIMITER
the bucket spool is switched.
pressure sensor in STD specification (travel,
2) The voltage output by low pressure sensor (1) Purpose :
bucket, swing, arm), proportional voltage from low
inputs in mechatro controller. The mechatro To secure simultaneous operability of boom and
pressure sensor inputs in mechatro controller, and
controller performs signal processing and arm on boosting up attachment pressure (Pump
then the engine speed returns to the dial set
outputs current corresponding to the increase flow rate decreases.) and to prevent cavitations at
position corresponding to the lever operation.
of pump flow rate to pump proportional valves low engine speed
(PSV-P1) and (PSV-P2) on the P1 and P2 22.6.3 STAND-BY CURRENT CONSTANT (2) Operation :
pump sides, and at the same time the CONTROL On boosting up attachment pressure, pilot primary
command current is output to P1 unloading (1) Principle : pressure exerts on PCc port of C/V(2) through
valve (PSV-D), P2 unloading valve (PSV-B) and When the engine speed is intermediate speed or attachment booster solenoid valve, operates stroke
travel straight proportional valve (PSV-C). lower, command current value to have the pump limiter of bucket spool, and throttle oil path of spool.
In the following pages, the relation of operation delivery rate constant is output. As a result, P1 pump pressure increases, making
of low pressure sensor to both the increase of the simultaneous operation of boom up and bucket
(2) Operation :
pump flow rate and unloading proportional digging possible.
Even if the engine speed specified by acceleration
valve is the same. Therefore the explanation is Even though the engine speed is low, similarly the
potentiometer is low speed, as the delivery rate
omitted. cavitations can be prevented by actuating the
corresponds to the intermediate speed, the
3) The secondary pressure output by P1 pump stroke limiter.
actuator moves earlier than the movement
proportional valve (PSV-P1) and P2 pump equivalent to the control lever angle rate in light
proportional valve (PSV-P2) exerts on pump load operation.
regulator, actuating the pump onto the delivery
flow increase side. 22.6.4 BUCKET DIGGING AND TRAVEL
STRAIGHT CONFLUENCE (CONFLUX)
4) The secondary pressure delivered in P1
MAIN CIRCUIT
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2 and (1) Operation :
PCa ports provided in control valve (2). 1) The oil delivered through A1 port of P1 pump
The secondary pressure from proportional goes into P1 port of C/V (2), opens load check
valve which has exerted on PBp1 and PBp2 valve LCc through parallel circuit and enters in
ports holds the by-pass cut spool on CLOSE bucket spool.
side, like the operation in the lever neutral 2) On the other hand, the oil delivered through P2
position. port of P2 pump goes into P2 port of C/V (2),
The secondary pressure from proportional confluences with oil from P1 pump through
valve which has exerted on PCb and PCa ports travel straight valve, and goes into bucket
switches the unloading spool in CLOSE side. spool. (Confluence of oil from 2 pumps)
22-12
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control
22-13
22. HYDRAULIC SYSTEM
22-14
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.
22-15
22. HYDRAULIC SYSTEM
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of portáC of the right pilot valve (9) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
PBb port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the Bb port.
3) Then, the proportionl secondary pressure fed
On that occasion, the oil returning from the head
into C/V (2) PBb port and branches off in two
(H) goes through the recirculation path in the boom
lines and switches boom spool and releases
spool, pushes the check valve in the spool open, is
boom lock valve.
recirculated to the Bb port and is supplied to the rod
22.7.4 PREVENTION OF NATURAL FALL BY (R). When the (R) pressure is larger than the head
LOCK VALVE AND ACTUATION AT (H) pressure, the check valve in spool closes.
LOWERING Thereupon, the recirculation is stopped.
(1) Purpose :
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.
22-16
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
22-17
22. HYDRAULIC SYSTEM
2) The voltage output by the low pressure sensor 3) The swing parking solenoid (SV-1) is excited
is input in the mechatro controller, and is signal- five seconds after the pressure of the swing low
processed. pressure sensors (SE-5) is reduced to zero.
In the case of arm in operation, the swing
3) Then, the secondary pressure led into PBs port
parking solenoid (SV-1) is excited the moment
of C/V (2) switches the swing spool.
the pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.
22-18
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-6 SWING CIRCUIT : Swing operation (LH)
22-19
22. HYDRAULIC SYSTEM
22.9 ARM CIRCUIT with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
This section describes the following operations.
side through Aa port of C/V (2).
(1) Arm in, light-load operating pilot circuit
3) The return oil from arm cylinder (R) side flows
(2) Arm in, light-load variable normal recirculation main
in Ba port of C/V (2) and passes through the Ba
circuit / internal conflux main circuit
port because the arm lock valve CRar is open,
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT and is flowed into arm 2 spool through arm 1
CIRCUIT spool.
22-20
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
22-21
22. HYDRAULIC SYSTEM
This section describes the following operations. 4) The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
(4) Arm in, heavy load operating sequence confluxed
Position of arm 2 spool
main circuit
Neutral position Recirculation cut position
22.9.3 ARM IN, HEAVY LOAD OPERATING
PILOT CIRCUIT
From arm out
(1) Operation :
P/V
1) In arm-in operation, when the heavy loading is
From arm 2 inverse
applied to arm and the P2 pump pressure proportional valve
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
22-22
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function
22-23
22. HYDRAULIC SYSTEM
This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH ARM
(5) Arm out pilot circuit LOCK VALVE
(6) Arm out 2 pumps conflux main circuit (1) Purpose :
To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve
weight of the arm & bucket.
22.9.5 ARM OUT PILOT CIRCUIT (2) Principle :
(1) Operation : Complete seat of the return circuit against the arm
1) When the arm out operation is performed, the spool of the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out (3) Operation :
of port 8 of the left pilot valve (9), and acts upon 1) When the secondary pressure for arm
the low pressure sensor (SE-8). At the same operation disappears and the arm cylinder
time, the oil is branched off in two flows and act stops, the pressure on the rod (R) side passes
upon the PBa1 and Pba2 ports of C/V (2). through the selector of the lock valve from the
2) The operating proportional secondary pressure Ba port of C/V, acts the back pressure on the
flowed in Pba1 port of C/V (2) switches the arm lock valve CRar and seats the lock valve.
1 spool. 2) Since the oil flow into the arm spool from the
3) Then, the operating secondary pressure flowed lock valve is shut off completely, natural fall of
in PBa2 port of C/V (2) switches the arm 2 spool the arm due to oil leaks through the arm spool
valve. is prevented.
22-24
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
BOOST
15 14 PL
CMR1
CHECK ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function
22-25
22. HYDRAULIC SYSTEM
22-26
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
22-27
22. HYDRAULIC SYSTEM
In this section, the independent operation is omitted 22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
and describes difference in combined operation. CIRCUIT
(3) Swing / Arm in light load, pilot circuit (1) Purpose :
(4) Swing / Arm in, swing priority main circuit Stable swing speed.
(2) Principle :
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
Raise the oil pressure flowing to arm cylinder, and
CIRCUIT
give a priority of the delivery of P2 pump to swing
(1) Operation : operation.
1) On operating swing (left) and arm in motions (3) Operation :
simultaneously, mechatro controller outputs
1) The swing main circuit operates with P2 pump
command current to travel straight solenoid
flow. But on P2 pump circuit side, the flow goes
proportional valve (PSV-C) and arm 2 solenoid
to the swing circuit and arm circuit
inverse proportional valve according to signal
simultaneously because the swing circuit and
processing, and this proportional valve outputs
arm circuit are parallel. Then since the return oil
secondary pressure, which acts on PTb port
from arm cylinder rod (R) side is restricted in
and PAa2 port of C/V(2).
the arm 2 spool because the arm 2 spool is
2) PTb port pressure switches the travel straight switched to forced recirculation position, the
spool 2 steps, and the PAa2 port pressure pressure of return oil is raised, causing the rise
switches the arm 2 spool to the forced of circuit pressure on the arm cylinder head (H)
recirculation position. side.
2) At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".
22-28
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
LCAP2
SV-2 PBa2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
22-29
22. HYDRAULIC SYSTEM
2) Output "Pressure relief control speed command When the operating lever is shifted to neutral during
value" at ECU. (Electric system) engine running, "DRAINING HYD. PRESS." is
3) Stand-by command value to P1, P2 unloading displayed on the gauge cluster while the mode
proportional valves switch is changed to pressure relieving mode. In
this time the intermittent buzzer sounds
How to switch to "Pressure release mode"
continuously. When right and left operating levers
1) Select the service diagnosis mode. are operated 4 or 5 times to their full stroke,
(Keeping pressing of the "BUZZER STOP pressure is relieved.
SWITCH" [ ] on gauge cluster, turn the starter After draining pressure is completed, turn off the
key on.) starter key and buzzer sound stops. If the pump
2) Select the service adjustment mode 1. pressure is determined to be more than 1 MPa (145
(Under the condition that "Screen No.1" of psi) by the output value of the high pressure sensor
"Service diagnosis mode 1" is indicated, or the high pressure sensors (SE-22,23) are
keeping pressing of the "BUZZER STOP broken, "FAIL DRAIN HYD. PRESS" is displayed
SWITCH", press the selector switch [ ] 3 and the buzzer sounds continuously. In that case,
times. When "LANGUAGE/LOGO", also the buzzer is not stopped unless the engine
"ADJUSTING MODE 1" and "PRESET BY key is turned to OFF. Repeat the pressure releasing
FACTORY" are displayed, press [ ] or [ ] procedure once again.
switch, and highlight "ADJUSTING MODE 1", (2) Hydraulics :
and then press "Selector Switch" again.) If the travel straight valve is turned to the pressure
3) When "ADJUSTING MODE 1" screen is release position, the oil delivered by each pump is
displayed, press [ ] or [ ] switch, and "DRAIN unloaded to the tank passage. If the spools are
HYD. OFF" screen appears. switched by pilot operation, the remaining pressure
from the actuators may be relieved to the tank
4) Press "Selector Switch" and highlight "OFF",
circuit, i.e. the main circuit pressure may be
and press [ ] switch to change to "DRAIN
released.
HYD. ON", and then press "Selector Switch"
again.
22-30
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
22-31
22. HYDRAULIC SYSTEM
[MEMO]
22-32
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
23-1
23. ELECTRIC SYSTEM
23-2
23. ELECTRIC SYSTEM
DC-DC CONVERTER,
ROOM LIGHT TUNER
CIGARETTE LIGHTER
HORN, HORN RELAY
GAUGE CLUSTER
IT CONTROLLER
MACHINE No. YQ11-06001-
AUTO GREASE
CONTROLLER
CONTROLLER
CONTROLLER
LEVER LOCK
LC10-07001-
BATTERY RELAY
MECHATRO
MECHATRO
C-8 : ENGINE CONTROLLER ENG. HARNESS
YC10-03501-
BACK UP
BACK UP
SUPPLY
TUNER
ENG. SPEED SENSOR
FOR ECU
SH7 SHIELD
E-1 : FUSE & RELAY BOX
EGR VALVE 1
R-26 :
LEVER LOCK RELAY
EGR VALVE 2
SK330-8
SOLENOID,
HIGH REACH,
LMN/BH
AIR CON.
AIR CON.
RADIATOR COOLANT
LEVEL CONTROLLER,
FLASHER, REAR WORK
LIGHT, TRAVEL ALARM,
ONE WAY CALL
DC-DC CONVERTER
WORK LIGHT
GAUGE CLUSTER
WIPER, WASHER
ROOF WIPER
OPT. 1
OPT. 3
OPT. HAND CONTROL
INJECTOR 2
E-12 : E-12 :
BATTERY BATTERY SH2 SHIELD
STARTER CABLE
INJECTOR 3
SH3 SHIELD
E27 :
ACCEL REDUNDANT
R-1 : VOLUME
E-15 : BATTERY RELAY INJECTOR 4
FUSIBLE LINK
SH4 SHIELD
R-23 :
AUTO IDLE STOP RELAY 1 R-24 : R-25 : INJECTOR 5
AUTO IDLE ENG. EMERGENCY
STOP RELAY 2 STOP RELAY SH5 SHIELD
KEY ON
POSITION
INJECTOR 6
PREHEATING
SH6 SHIELD
START
TERMINAL
ENGINE START
ACC
OFF
ON
IN THE CASE OF
R-3 : SK330-8, SK350LC-8
GLOW RELAY GLOW
CYLINDER
DISCRIMINATION
G SENSOR
C-5 :
CONTROL : (SENSOR POWER RADIATOR COOLANT SW-27 :
SOURCE, CPU) LEVEL CONTROLLER RADIATOR COOLANT LEVEL SW.
OUT SOURCE :
(PSV, SOL. MOTOR)
R-28 : ALTERNATOR RELAY
23-3
23. ELECTRIC SYSTEM
SE-3 : BOOM UP
POSITION
INJECTOR 1
SE-4 : BOOM DOWN
RELEASE
NORMAL
SW-4 :
TERMINAL SWING PARKING BRAKE RELEASE SW.
INJECTOR 2 SE-7 : ARM IN SV-1 :
SWING PARKING BRAKE SOL.
SE-8 : ARM UP
INJECTOR 3 SV-3 : TWO SPEED SELECT SOL.
SE-5 : SWING
SV-2 : POWER BOOST SOL.
IN CASE OF
INJECTOR 4 SK200-8, SE-9 : TRAVEL RIGHT PSV-B : P2 UNLOAD
SK210LC-8 PROPORTIONAL SOL.
SE-22 : PUMP P1
PSV-D : P1 UNLOAD
PROPORTIONAL SOL.
SE-23 : PUMP P2
PSV-A : ARM TWO-SPEED INVERSE
PROPORTIONAL SOL.
SE-11 : P2 OPT.
PSV-P2 : PUMP P2
PROPORTIONAL SOL.
OPT
SW-20 : POWER BOOST SW. RIGHT
SHIELD
(2/4)
LC03Z00036P1 02
23-4
23. ELECTRIC SYSTEM
SW-15 : R-31 :
CONFLUX/SINGLE SELECT SW. PREVENT SPARK RELAY
R-29 :
WIPER MOTOR RELAY L-5 : ROOM LIGHT
OPT
M-3 : WIPER MOTOR
R-30 :
WIPER MOTOR REVERSING RELAY
SW-44 :
EXTRA PRESS. SW.
EU
GROUND
OUTPUT AIR CON.
AMP.
SW-19 : WIPER INTERLOCK SW.
EU
COOLING
UNIT
ROOF WIPER
TO 4/4
(3/4)
LC03Z00036P1 02
23-5
23. ELECTRIC SYSTEM
FROM 3/4
SE-25 :
PRESS SENSOR : BOOM ROD E-2 :
ALTERNATOR
SV-7 :
SW-34: REVOLUTION
SE-17 : BOOM POTENTIO. R-13 : REVOLUTION LEFT SOL
REVOLUTION LEFT SW.
OPT. LEFT RELAY
AUTO GREASE
SE-19 : ARM POTENTIO. REVOLUTION N&B
SW-41 :
OFF
TERMINAL
HIGH REACH
CRANE SW.
(FIXED)
(TRAVEL)
OPT.
HIGH REACH CRANE
SV-14 :
QUICK COUPLER OPERATION SOL. L-4 :
SWING FLASHER RIGHT & WORKING LIGHT 9P CONNECTOR
SWING FLASHER & WORKING LIGHT
SW-59 :
QUICK COUPLER SW-37 :
OPERATION SW. TRAVEL INDEPENDENT SW.
EU OPT. USA
QUICK COUPLER
DOWNLOAD
(4/4)
LC03Z00036P1 02
23-6
23. ELECTRIC SYSTEM
(TCO-60-2) (HARD) L-2 DECK WORK LIGHT (RH) YT80S00002F2 BUCKET DIGGING
C-2 GAUGE CLUSTER YN59S00021F2 SWING FLASHER (LH) & REAR PRESSURE SENSOR :
L-3 YM80S00001F1 SE-2
(L) LIGHT
AIR-CON CONTROLLER WORK LIGHT BUCKET DUMP
C-4 YN20M01468P1
(INCLUDING PANEL) SWING FLASHER (RH) & REAR SE-3 PRESSURE SENSOR : BOOM UP
L-4 YM80S00001F2
ENGINE COOLANT LEVEL WORK LIGHT PRESSURE SENSOR :
C-5 VHS834701230B SE-4
(SE) SENSOR
CONTROLLER L-5 ROOM LIGHT YT80S00001P1 BOOM DOWN
C-8 ENGINE CONTROLLER VH89661E0010 L-6 BOOM WORK LIGHT (RH) YW80S00001F1 SE-5 PRESSURE SENSOR : SWING
D-4 DIODE HARNESS ACCESSORY L-7 CAB WORK LIGHT FRONT (For SE.Asia) YT80S00002F2 SE-7 PRESSURE SENSOR : ARM IN
(M) MOTOR
D-5 DIODE ACCESSORY OF RELAY BOX M-1 STARTER MOTOR VHS281002894A SE-8 PRESSURE SENSOR : ARM OUT
D-6 DIODE M-3 WIPER MOTOR YN53C00012F2 SE-9 PRESSURE SENSOR : TRAVEL RH
D-9 DIODE M-4 WASHER MOTOR YN54C00001F1 SE-10 PRESSURE SENSOR : TRAVEL LH
(D) DIODE
D-10 DIODE M-9 ROOF WIPER MOTOR YN76S00005P1 SE-11 (PRESSURE SENSOR : P2 OPT.)
D-12 DIODE ARM 2 SPEED SE-13 E/G SPEED SENSOR VHS894101290A
D-13 DIODE PSV-A INVERSE YN35V00049F1 SE-15 FUEL SENSOR YN52S00045F1
D-14 DIODE PROPO.VALVE SE-16 ACCEL POTENTIOMETER YN52S00032P1
(P) PROPORTIONAL
D-15 DIODE P2 UNLOAD (YN35V00047F1) SE-20 (PRESSURE SENSOR : P1 OPT.) LC52S00019P1
SOLENOID VALVE
PSV-B YN35V00048F1
D-16 DIODE PROPO.VALVE SOLENOID SE-22 PRESSURE SENSOR : PUMP P1 YN52S00048P1
D-17 DIODE TRAVEL STRAIGHT VALVE ASSY SE-23 PRESSURE SENSOR : PUMP P2
PSV-C
E-1 FUSE AND RELAY BOX YN24E00016F2 PROPO.VALVE SWING PARKING
SV-1 YN35V00051F1
E-2 ALTERNATOR VHS270402500 P1 UNLOAD BRAKE SOL.
(SV) SOLENOID
PSV-D
E-3 HOUR METER YT58S00006P1 PROPO.VALVE POWER BOOST
SV-2 (YN35V00047F1) YN35V00050F1
E-5 HORN HIGH LC53S00001D1 P1 PUMP SOL
PSV-P1 YN35V00052F1 SOLENOID
E-6 HORN LOW LC53S00001D2 PROPO.VALVE (LC10V00014F1) TWO SPEED
SV-3 VALVE ASSY
E-7 TUNER AM/FM (For Oceania) YN54S00046P1 P2 PUMP PUMP SELECT SOL
PSV-P2
E-8 SPEAKER LEFT (For Oceania) YN54S00050P1 PROPO.VALVE SAFETY LOCK
SV-4
E-9 SPEAKER RIGHT (For Oceania) R-1 BATTERY RELAY YN24S00008F1 LEVER SOL
E-10 RECEIVER DRYER YN54S00041P1 R-2 STARTER RELAY VHS283001271A SW-1 KEY SWITCH YN50S00026F1
E-11 AIR-CON COMPRESSOR YX91V00001F1 R-3 GLOW RELAY VHS286201420A SWING PARKING BRAKE RELEASE
SW-4 YN50S00047P1
E-12 BATTERY YN72S00014P1 R-4 SAFETY RELAY YN24S00010P1 SWITCH
E-13 TRAVEL ALARM (For Australia) YN53S00004F1 R-5 HORN RELAY SW-5 HORN SWITCH (RH) YN50E00017P1
(E) ELECTRIC FITTINGS
E-14 CIGARETTE LIGHTER YN81S00003P1 R-6 WORKING LIGHT RELAY SW-7 E/G OIL PRESSURE SWITCH VHS835301471D
E-15 FUSIBLE LINK LC13E01175S002 R-8 TRAVEL ALARM RELAY (For Australia) SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 R-10 CAB WORK LIGHT RELAY (For SE.Asia) SW-10 HORN SWITCH (LH) YN50E00017P1
R-19 FLASHER RELAY YY24S00001F1 SW-11 SAFETY LOCK LEVER SWITCH YN50S00041F1
R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1 SW-13 TRAVEL ALARM SWITCH (For Australia) YN50S00040DF
R-24 AUTO IDLE STOP RELAY 2 (CONFLUX/SINGLE SELECT
SW-15 YN50S00040DD
R-25 ENGINE EMERGENCY STOP RELAY SWITCH)
(R) RELAY
(SW) SWITCH
R-26 LEVER LOCK RELAY SW-17 (SKYLIGHT WIPER SWITCH) YN50S00040D9
R-28 ALTERNATOR RELAY SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
WIPER MOTOR RELAY SW-20 POWER BOOST SWITCH (RH) YN50E00017P1
R-29 YN24S00012P2
(NORMAL ROTATION) SW-21 POWER BOOST SWITCH (LH)
WIPER MOTOR RELAY SW-27 COOLANT LEVEL SWITCH VHS834601510A
R-30
(REVERSE ROTATION) SW-28 WATER SEPARATOR SWITCH VHS233002800A
WIPER MOTOR RELAY SW-55 BOOM WORK LIGHT SWITCH YN50S00040D1
R-31
(ARC PREVENTION)
R-32 WASHER MOTOR RELAY
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 02
23-7
23. ELECTRIC SYSTEM
23.3 HARNESS
23.3.1 HARNESS LIST
The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-8
23. ELECTRIC SYSTEM
TIGHTENING TORQUE
YN17M00053F1 (09) SE. Asia 1.5N.m (1.1lbf.ft)
INSTRUMENT PANEL ASSY TIGHTENING TORQUE SEMS BOLT TIGHTENING TORQUE
YN17M00054F1 (09) Oceania
5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS 2 PLACES INSTALL TO CAB
TAPPING SCREW
3-2 POTENTIO METER YN52S00032P1 1 TAPPING
SEMS BOLT DUCT ASSY SCREW
3-10 KEY SWITCH YN50S00026F1 1 K250 2 PLACES
TIGHTENING TORQUE TAPPING SCREW
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2.8N.m (2.1lbf.ft) TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
5-2 HOUR METER YT58S00006P1 1
SECTION BB SECTION DD SECTION EE
10 GAUGE CLUSTER YN59S00021F2 1
46-3 SPEAKER YN54S00050P1 2
TIGHTENING TORQUE TIGHTENING TORQUE
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) 8.5N.m (6.3lbf.ft)
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT TO CAB
INSTALL SEMS BOLT
INSTALL SEMS TO CAB
TIGHTENING TORQUE TO CAB
4.1N.m (3.0lbf.ft) BOLT TO CAB
2 PLACES
SEMS BOLT
TIGHTENING TORQUE
4.1N.m (3.0lbf.ft)
SECTION AA
VIEW
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE
TIGHTENING TORQUE 0.43N.m (0.32lbf.ft) TIGHTENING TORQUE
TIGHTENING TORQUE TIGHTENING TORQUE
. .
8.5N m (6.3lbf ft) 8 PLACES 5.0N.m (3.7lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE 4 PLACES
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT TAPPING SCREW
SEMS BOLT TIGHTENING TORQUE INSTALL SEMS BOLT
SEMS BOLT
12.0N.m (8.9lbf.ft) TO CAB
INSTALL
SEMS BOLT
TO CAB
SEMS BOLT
4 PLACES
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SECTION CC
TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
SEMS BOLT VIEW
INSTALL TAPPING SCREW TIGHTENING TORQUE
TO A/C 5.0N.m (3.7lbf.ft)
23-9
23. ELECTRIC SYSTEM
HORN WASHER
SEMS BOLT
TIGHTENING
TORQUE
2.8N.m (2.1lbf.ft)
VIEW
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SEMS BOLT
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
CLIP
CLIP
PUT SURPLUS
CABLE INTO CAB CLAMP CABLE WITH HARNESS
INSIDE TOGETHER
CONNECT CABLE WITH PASS CABLE THROUGH THE HOLE CABLE ARRANGEMENT
CAB SIDE ANTENNA FOR HARNESS
23-10
23. ELECTRIC SYSTEM
BRACKET
GLOW RELAY
HORN (LOW)
SEMS BOLT
HORN (HIGH)
TIGHTENING TORQUE
15.5N.m (11.4lbf.ft)
STARTER RELAY
B TERMINAL
NUT C TERMINAL
BATTERY RELAY BOX TIGHTENING TORQUE
17.5N.m (12.9lbf.ft)
2 PLACES
SEMS BOLT
TIGHTENING
TORQUE
10.7N.m (7.9lbf.ft)
TIGHTENING TORQUE
10.7N.m (7.9lbf.ft)
CONNECT SEMS BOLT
AFTER CHECKING CONNECT HARNESS AS SHOWN
GROUND
NO PAINT IS HERE TO AVOID SHORT CIRCUIT ON
SEMS BOLT HORN (HIGH)
POWER SOURCE WIRING
CONNECT HARNESS AS SHOWN HORN (LOW)
TO AVOID SHORT CIRCUIT ON
POWER SOURCE WIRING SEMS BOLT
INSTALL BOLT FROM
TIGHTENING TORQUE
FRONT SIDE
11.7N.m (8.6lbf.ft)
MAX
(BLACK) (BLACK)
VIEW VIEW
23-11
23. ELECTRIC SYSTEM
TO ATT HARNESS
UPPER HARNESS
STARTER CABLE
23-12
23. ELECTRIC SYSTEM
SE-28 :
GLOW RELAY TIGHTENING TORQUE PRESS SENSOR :
C TERMINAL
CONNECT TO 3.8N.m (2.8lbf.ft) EXTRA PRESS (OPT)
2P CONNECTOR B TERMINAL USE NUT OF ATTACHED
FOR HARNESS STARTER RELAY
OF ATTACHED CLIP
FIX A HARNESS BY CLIP
CLIP ON SOL. BLOCK BEHIND
FIX WITH THE CLIP
CLIP
WHEN THERE IS NO OPTION
STARTER RELAY OF SE-28, 29, SV-13,
TIE UP THIS HOSE HERE CLIP
FIX A HARNESS OF CLIP
SV-13 : ON PIPE METAL FITTING
CLIP INSTALL THE LOCK OF
THE FUSE BOX COVER UPWARD OPT SELECTOR SOL
CLIP
FIX TWO HARNESS
WITH CLIP
TIE UP CORRUGATED PART OF
CLIP HARNESS WITH SOLENOID VALVE
CONNECT THIS CONNECT THIS USING PLASTIC TIE
TERMINAL WITH TERMINAL WITH
PSV-P1 :
STARTER CABLE BATTERY CABLE PSV-P2 : PUMP P2 PROPORTIONAL SOL.
PUMP P1
TIGHTENING TORQUE TIGHTENING TORQUE
PROPORTIONAL SOL. TIE UP CORRUGATED PART OF
7.8N.m (5.8lbf.ft) MAX 7.8N.m (5.8lbf.ft) MAX TO PUMP
HARNESS WITH PRESSURE SENSOR
USING PLASTIC TIE PROPORTIONAL SOL FIX WHITE TAPING POSITION
UPPER HARNESS
CLIP CLIP
STARTER CABLE
CLIP
BATTERY RELAY CABLE
CLIP
FIX WHITE TAPING
POSITION
CLIP
UPPER HARNESS FIX A HARNESS
SE-23 : ON GUARD
TO GUARD PRESS SENSOR :
CLIP SE-22 : PUMP P2
FIX CONNECTOR PRESS SENSOR :
TO THE BRACKET PUMP P1
VIEW
BATTERY RELAY
VIEW
23-13
23. ELECTRIC SYSTEM
C-1 :
CAB SUB HARNESS
MECHATRO CONTROLLER
34P CONNECTOR 32P CONNECTOR 31P CONNECTOR C-8 :
ENGINE CONTROLLER CONNECT THE "CNT-2" TAGGED
WITH "CN-1F" TAG WITH "CN-3F" TAG WITH "CN-5F" TAG
CONNECTOR WITH FLOOR HARNESS
35P (A) CONNECTOR 35P (B) CONNECTOR
WITH "CN-2F" TAG WITH "CN-4F" TAG
VIEW
CONNECT WITH
C-1 : MECHATRO CONTROLLER CONNECT CONNECTOR CONNECT CONNECTOR
BLUE CONNECTOR TO
WITH "CN4-2" WITH "CN1"
ACCELERATION
TAG OF ITEM 1 : HARNNESS TAG OF ITEM 1 : HARNNESS
EMERGENCY VOLUME
SET A WHITE TAPING PART OF UPP HARNESS
TO WHITE TAPING PART OF FLOOR HARNESS.
AND FIX TO FLOOR HARNESS. CLIP
31P CONNECTOR 17P CONNECTOR CONNECT 1P CONNECTOR TO CAB SUB HARNESS R-19 :
16P CONNECTOR
TAG : CNT-3 FLASHER RELAY
28P CONNECTOR 24P CONNECTOR
FIX WHITE TAPING POSITION OF UPPER HARNESS
VIEW AND ECU HARNESS TO THE FLOOR HARNESS WITH CLIP
CLIP
CLIP
FLOOR HARNESS
TIE UP UPPER HARNESS,
FLOOR HARNESS,
ECU HARNESS AND
C-8 : CAB SUB HARNESS
ENGINE CONTROLLER
23-14
23. ELECTRIC SYSTEM
TO STARTER
TIE UP CORRUGATED PART OF
CLIP HARNESS WITH SWITCH USING
PLASTIC TIE
CLIP
VIEW
CLIP
FIX WHITE TAPING POSITION FIX WHITE TAPING POSITION
CLIP
FIX A HARNESS OF
CLIP ON GUARD UPPER HARNESS
STARTER CABLE
VIEW
AIR FILTER CLOGGING SW. INST VIEW
23-15
23. ELECTRIC SYSTEM
CLIP
CLIP
CLIP
CLIP
FIX WHITE TAPING
POSITION
UPPER HARNESS
STARTER CABLE
CLIP
CLIP UPPER HARNESS ECU HARNESS CLIP FIX WHITE TAPING
VIEW (DETAIL OF ALTERNATOR) FIX WHITE TAPING POSITION
POSITION
ENGINE GROUND CABLE
VIEW VIEW
TIGHTENING TORQUE
12 ~ 15N.m (8.9 ~ 11.1lbf.ft)
CLIP
FIX A WHITE TAPING
OF HARNESS BY
VIEW
CLIP ON BRACKET UPPER HARNESS
23-16
23. ELECTRIC SYSTEM
SW-56 :
CLIP FUEL SUPPLY AUTO STOP SW.(OPT)
FIX A 2P CONNECTOR ON BRACKET
L-2 :
DECK WORK
LIGHT (RH) CLIP
SE-15 : E-13 :
FUEL SENSOR TRAVEL ALARM
CONNECT A HARNESS FIX WHITE TAPING POSITION
INSIDE OF CAP CLIP
INSTALL THE "ALARM"
TAGGED CONNECTOR
ON BRACKET
UPPER FLAME
CLIP
CLIP
FIX A HARNESS IT THROUGH
UNDER THE BRACKET OF
CLIP SW-28 : FASTEN HARNESS
WATER SEPARATOR SW.
FIX WHITE TAPING
POSITION
CLIP
FIX TO UPP HARNESS
CLIP DETAIL A
FIX WHITE TAPING
POSITION
C-1 :
SV-3 :
MECHATRO CONTROLLER E-1 :
TWO-SPEED SELECT SOL.
PSV-B:P2 FUSE AND RELAY BOX SW-16 :
SV-1 : ARM TWO-SPEED INVERSE PROPORTIONAL SOL. FIX ENGINE ROOM LIGHT
SV-2 :
SWING PARKING BRAKE SOL. CONNECTOR TO THE BRACKET
POWER BOOST SOL. PSV-C :
SV-4 : TRAVEL STRAIGHT PROPORTIONAL SOL.
LEVER LOCK SOL. PSV-D :
P1 UNLOAD PROPORTIONAL SOL. CAB SUB HARNESS
PSV-A :
CONNECT TO ROTATION
WHITE TAPING POSITION ARM TWO-SPEED INVERSE PROPORTIONAL SOL.
PARKING RELEASE SW.
CLIP
FIX UPPER HARNESS AND "CNT-2" WITH TAG, CONNECTOR OF
ECU HARNESS TO THE FLOOR HARNESS CONNECT TO FLOOR HARNESS CLIP
FIX A HARNESS WITH
CLIP ON HOLE OF
FIX WHITE TAPING POSITION OF GUARD
UPPER HARNESS AND ECU HARNESS
TO THE FLOOR HARNESS
TIE UP UPPER HARNESS,
FLOOR HARNESS,
CLIP UPPER HARNESS
ECU HARNESS AND
FIX WHITE TAPING POSITION CAB SUB HARNESS
FLOOR HARNESS
ECU HARNESS
VIEW
23-17
23. ELECTRIC SYSTEM
E-6 :
HORN LOW
L-2 : SEALING PLUG TO BE SV-8 :
TAPING AFTER DECK WORKING ARM PUSH/
SUPPLY INSERTED IN TO ALL
BUNDLED LIGHT RIGHT PULL PORT
WITH SUPPLY SELECT SOL.
TAPING AFTER WITH
BUNDLED SW-56 :
FUEL SUPPLY
AUTO STOP SW. SE-13 :
ENGINE SPEED SENSOR
SEALING PLUG TO BE M-11 : SUPPLY
INSERTED IN TO ALL FUEL SUPPLY PUMP WITH
TAPING SE-44 :
TAPING TAPING AFTER
WHITE TAPING SEALING PLUG TO BE EXTRA PRESS. SW SHIELD UNCONNECTED
BUNDLED
SEALING PLUG TO BE INSERTED IN TO ALL SEALING
INSERTED IN TO ALL PLUG
TAPING TAPING
SUPPLY TAPING
WITH SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL
E-5 :
HORN HIGH SUPPLY SUPPLY
SEALING WITH WITH E-2 : ALTERNATOR
PLUG
SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL SEALING PLUG
INSTALL CTB-5 (2 PIECES) TO BE INSERTED CAP TO BE INSTALLED
TO ENGINE SUB
IN TO ALL
SUPPLY SE-11 : SE-5 :
WITH EXTRA PRESS. BUCKET DUMP
RELEASING SOL CUT SOL WHITE TAPING
SE-28 : SUPPLY
TAPING PRESS. SENSOR WITH
EXTRA PRESS
DOUBLE
SPLICE SEALING PLUG TO BE
INSERTED IN TO ALL
TAPING L-1 :
BOOM WORKING LIGHT TAPING AFTER SE-5 :
SEALING PLUG TO BE PRESS SENSOR :
BUNDLED INSERTED IN TO ALL SWING
WHITE TAPING
SEALING SUPPLY TAPING AFTER
PLUG WITH BUNDLED WHITE TAPING
TAPING
WHITE TAPING
TAPING
INSTALL CTB-6 (2 PIECES)
WHITE TAPING
SEALING PLUG TO BE
INSERTED IN TO ALL
WHITE TAPING SUPPLY SUPPLY
SEALING WITH WITH
PLUG
SUPPLY
CORRUGATE TUBE WITH
TAPING TAPING SEALING
SEALING PLUG
SUPPLY SEALING PLUG TO BE PSV-F : OPT, RELIEF PSV-1 : OPT, RELIEF PV-16 :
PLUG SEALING PLUG TO BE
WITH INSTALL CTB-6 (2 PIECES) INSERTED IN TO ALL ADJUSTMENT ADJUSTMENT BUCKET CONTROL SOL
PROPORTIONAL SOL 1 PROPORTIONAL SOL 2 INSTALL CTB-6 (2 PIECES) INSERTED IN TO ALL
WHITE TAPING
SUPPLY SUPPLY SUPPLY
WITH WITH WITH
SW-8 :
SEALING PLUG TO BE AIR FILTER
INSERTED IN TO ALL CLOGGING SW.
23-18
23. ELECTRIC SYSTEM
SUPPLY
WITH
SV-4 : WHITE TAPING
OPERATING SW-27 :
LEVER LOCK SOL RADIATOR COOLANT LEVEL SW
CAP TO BE INSTALLED
SV-2 :
POWER BOOST SOL. INSTALL CTB-3
TAPING GLOW RELAY
TAPING
PSV-P2 : (COMMON)
PUMP P2
PROPORTIONAL SOL.
PSV-B : TAPING
WHITE TAPING
P2 UNLOAD
PROPORTIONAL SOL. DOUBLE
SE-23 : INSTALL CTB-3 SPLICE
PRESS SENSOR :
PUMP P2 WHITE TAPING
CAP TO BE INSTALLED
PSV-C :
TRAVEL STRAIGHT SE-22 : GLOW RELAY (NO)
PROPORTIONAL SOL. PRESS SENSOR :
PUMP P1
SUPPLY
SW-28 : WITH
WHITE TAPING
WATER SEPARATOR SW. R-1 :
PSV-D : BATTERY RELAY (COIL) R-2 :
P1 UNLOAD L-13 : STARTER RELAY (COIL)
PROPORTIONAL SOL. TRAVEL ALARM
SEALING PLUG TO BE L-3 :
INSERTED IN TO ALL SWING FLASHER LEFT
& REAR WORKING LIGHT
SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL
WHITE TAPING SEALING PLUG TO BE
INSERTED IN TO ALL
TAPING AFTER
BUNDLED
SUPPLY
WITH
SUPPLY
WITH TAPING AFTER
BUNDLED TAPING
WHITE TAPING
PSV-A :
ARM TWO-SPEED SEALING PLUG TO BE
INVERSE INSERTED IN TO ALL
L-4 :
PROPORTIONAL SOL. SWING FLASHER RIGHT L-10 : WHITE TAPING
& REAR WORKING LIGHT HIGH REACH
ROTARY LIGHT
SUPPLY SUPPLY
WITH WITH
SEALING PLUG TO BE
INSERTED IN TO ALL SEALING PLUG TO BE SW-16 :
INSERTED IN TO ALL ENGINE ROOM LIGHT
23-19
23. ELECTRIC SYSTEM
WHITE TAPING
WHITE TAPING
R-19 :
FLASHER RELAY
DOUBLE
SPLICE
DOUBLE TAPING
SPLICE
C-5 :
RADIATOR COOLANT LEVEL
CONTROLLER
DOUBLE
SPLICE
TAPING
TO FLOOR HARNESS
TO GLOW
WHITE TAPING
23-20
23. ELECTRIC SYSTEM
WIRE WIRE WIRE SIZE FROM CONNECTION TO WIRE WIRE WIRE SIZE FROM CONNECTION TO WIRE WIRE
WIRE SIZE FROM CONNECTION TO
NO COLOR NO COLOR NO COLOR
SHIELDED
CABLE
(2 CORE)
23-21
23. ELECTRIC SYSTEM
3.8 (0.15")
300 (11.8")
2870 (9'5")
16 ")
TERMINAL (0.63") 0. 33
50 (1.97") 50 (1.97") 8.4(
(0.89")
WHITE TAPING
22.5
YAZAKI 7034-1283 (2.76") (27.6") (12.2") (9.45") (2.76")
CORRUGATE TUBE
TO BE INSTALLED CAP TERMINAL
TERMINAL
WIRE No.35
TERMINAL TERMINAL
INSTALL CORRUGATE TUBE CAP TO BE
INSTALLED
CAP CAP
SUPPLY YAZAKI 7034-1283
WITH
CAP TAPING
YAZAKI 7034-1283
40 (1.57")
20 (0.79")
TWO TERMINALS ARE IN TOUCH WITH
EACH OTHER TO THEIR BACK AND
BUNDLED BY TAPING, CAP TO BE INSTALLED
TERMINAL DETAIL A
CAP TERMINAL
440 (17.3")
40 (1.57")
TERMINAL
TERMINAL
CAP TAPED IN TWO TURNS
23-22
23. ELECTRIC SYSTEM
E-27:
TO FUSE & RELAY BOX ACCEL REDUNDANT
RESISTOR
WHITE TAPING
WHITE TAPING
SEALING
PLUG
SUPPLY WITH
SUMITOMO 6409-0073 TO HARNESS (FLOOR)
TAPING
SUPPLY WITH
SUMITOMO 6409-0603
TAPING
SUPPLY WITH
SUMITOMO 6409-0072
TAPING
WHITE TAPING
WHITE TAPING
23-23
23. ELECTRIC SYSTEM
23.3.6-6 ECU HARNESS (2/2) : LC13E01185P3 23.3.6.7 FLOOR GROUNDING CABLE : LE13E01006P1
100 (3.94")
WIRE WIRE
WIRE SIZE FROM CONNECTION TO
WIRE WIRE
WIRE SIZE FROM CONNECTION TO
LA308 5B E E 5B E
NO COLOR NO COLOR
1PAM
YAZAKI 7122-3010
450 (17.7")
TERMINAL TERMINAL
SHIELDED CABLE
(2 CORE)
CORRUGATED TUBE TO BE INSTALLED
TAPED DOUBLY
LE-SS 180 (7.09")
SHIELDED CABLE
(2 CORE)
CAP TO BE INSTALLED
LE-SS
SHIELDED CABLE
CAP
(2 CORE) YAZAKI 7034-1280
LE-SS
SHIELDED CABLE
(2 CORE)
SHIELDED CABLE
(2 CORE)
TERMINAL TERMINAL
HEAT SHRINKAGE TUBE TO BE INSTALLED
LE-SS
CONNECTORS SELECTION TABLE
SHIELDED CABLE
(2 CORE)
CONNECTOR PART. NUMBER CONNECTOR PART. NUMBER
LE-SS
NAME MANUFUC, NAME MANUFUC,
SHIELDED CABLE HOUSING TERMINAL HOUSING TERMINAL
(PIN NUM,) (PIN NUM,)
(2 CORE)
LE-SS
SHIELDED CABLE
(2 CORE)
23-24
23. ELECTRIC SYSTEM
HARNESS (ECU)
ENGINE HARNESS ASSY LC16E00010F1 (02)
ENGINE ACCESSORY
FIX A HEATER HOSE AND
ITEM PART NAME PART No. Q'TY REMARKS AIR CON. ACCESSORY
FIX AN AIR CON. ACCESSORY HARNESS BY CLIP OF INT
1 HARNESS LC16E01029P2 1 ENGINE SUB HARNESS OF CLIP TO HOLE
OF AIR COMPRESSOR
20 HARNESS LC16E01028P1 1 AIR CONDITIONER SUB CLIP
B TERMINAL
FIX A HEATER HOSE AND
AIR CON. ACCESSORY
HARNESS BY CLIP
NEAR THE BRED.
CLIP
CLIP
TIGHTENING TORQUE INSTALL BOLT AND BOLT OF
25.5N.m (18.8lbf.ft) AIR COMPRESSOR TOGHETHER AIR CON. SUB HARNESS
STARTER CABLE
TIGHTENING TORQUE
3.2 ~ 4.4N.m (2.4 ~ 3.2lbf.ft)
ALTERNATOR (B)
HARNESS
(ENGINE SUB)
ALTERNATOR (L, R)
SW-7 :
ENG. OIL PRESS. SW.
ENGINE SIDE
FIX THE PLATE TO
ENGINE BRACKET
TIGHTENING TORQUE
25.5N.m (18.8lbf.ft) E-2 : ALTERNATOR
23-25
23. ELECTRIC SYSTEM
E-11 :
SW-7 : ENGINE OIL PRESS. SW. TO UPPER HARNESS TO AIR COMPRESSOR
TO UPP HARNESS
E-2 : ALTERNATOR
E-2 : ALTERNATOR
SEALING PLUG
23-26
23. ELECTRIC SYSTEM
SE-3 :
UPPER HARNESS ASSY LC13E00032F1 (10)
PRESS SENSOR :
NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS
SE-4 :
PRESS SENSOR : BOOM RAISING
MADE INTO THE FOLLOWING.
ITEM NAME PARTS No. Q'TY REMARKS
BOOM LOWERING CLIP
1 HARNESS YN13E01449P3 1 FLOOR
SE-1 : HARNESS
4 HARNESS LC13E01186P1 1 CAB SUB HARNESS TO WASHER MOTOR PRESS SENSOR :
BUCKET DIGGING
9 CABLE LE13E01005P1 1 FLOOR HARNESS GROUND SE-2 :
PRESS SENSOR : SE-7 : SW-1 :
BUCKET DUMP PRESS SENSOR : KEY SW.
ARM IN
SE-8 : SW-16 :
PRESS SENSOR : ACCEL POTENTIO
E-1 : FUSE & RELAY BOX ARM OUT
SW-1 : KEY SWITCH
CLIP
USE THE HOLE OF SEAT FASTEN HARNESS BY CLIP CAB HARNESS
SE-16 : WITH BRACKET OF MULTI CLIP
STAND AND FIX HARNESS BUNDLE AFTER
ACCEL POTENTIO NOT USE CLIP CASE BY MULTI
WITH CLIP * CLIP HARNESS DIVERGES
FIX WHITE TAPING
DETAIL A : A CASE OF MULTI
POSITION
(For Oceania)
TO WASHER MOTOR
FIX A HARNESS ON SENSOR
BLOCK WITH CLIP
TO WASHER MOTOR
FIX A HARNESS TO CLIP OF
CLIP CAB SIDE COVER
VIEW
PUSH CONTROL LEVER MOST FRONTWARD
AND FIX THIS SLACK HARNESS WITH CLIP
SE-1 :
SW-12 :
PRESS SENSOR :
SW-35 : OVER LOAD ALARM SELECT SW.
BUCKET DIGGING
HEAVY LIFT SW. CONNECT SWITCH TO TAGGED
SE-8 : SE-2 : CONNECT SWITCH "OVER L" CONNECTOR
PRESS SENSOR : PRESS SENSOR : TO TAGGED "HEAVY"
ARM OUT SW-13 : CONNECTOR
SE-7 : SE-3 : BUCKET DUMP
PRESS SENSOR : PRESS SENSOR : TRAVEL ALARM SW.
BOOM RAISING IN CASE OF TRAVEL SW-40 :
ARM IN SE-4 :
FIX A CORRUGATERD ALARM SPEC., ROTARY LIGHT SW.
PRESS SENSOR : CONNECT SWITCH TO CONNECT SWITCH TO TAGGED "ROTARY"
TUBE NOT CONTACT
M-CONNECTOR BOOM LOWERING TAGGED "ALARM" CONNECTOR
LOCK OF CONNECTOR
DETAIL A : A CASE OF SENSOR TOWER CONNECTOR
SENSOR CLIP
(For SE. Asia) FIX A HARNESS
OF SW. SIDE
CLIP CLIP
FIX A HARNESS PART OF CLIP
SE-20 : PRESS SENSOR : P1 OPT WHITE TAPING WITH CLIP FIX A CLIP ON HOLE
OF STAND SIDE
TIGHTENING TORQUE 10.7N.m (7.9lbf.ft)
TIGHTEN AFTER CHECKING NO PAINT HERE CLIP
FIX A CLIP ON HOLE SW-20 :
NUT
FLOOR HARNESS GROUND OF STAND SIDE POWER BOOST SW. RIGHT
TO PRESS SENSOR, FASTEN FLOOR HARNESS
TUNER CONNECT WITH EARTH MULTI, (YELLOW TAPING)
CABLE OF UPPER WITH LEVER SW.
OVER LOAD ALARM SW. WASHER MOTOR SW-33 :
FRAME HARNESS
HEAVY LIFT SW. REVOLUTION RIGHT SW. (OPT)
TOGETHER
(RED TAPING)
TRAVEL INDEPENDENT CHANGE SW.
SE-10 : SW-5 :
ATT BOOST SW. (RH)
PRESS SENSOR : HORN SW. RIGHT (OPT) (BLUE TAPING)
HORN SW. (RH)
TRAVEL LEFT
ATT BOOST SW. (LH)
SE-9 :
HORN SW. (LH) PRESS SENSOR :
DC-DC CONVERTER TRAVEL RIGHT E-7 :
WASHER MOTOR TUNER CLIP
SE-11 : CLIP FIX WHITE TAPING
PRESS SENSOR : FIX WHITE TAPING POSITION
P2 OPT CLIP FIX A CLIP ON HOLE
POSITION
FIX WHITE TAPING OF SEAT SIDE
THROUGH THE HARNESS
POSITION
AT SEAT SIDE OF BRACKET
CLIP
FIX WHITE TAPING POSITION TO THE FRONT SIDE OF FLOOR PLATE
23-27
23. ELECTRIC SYSTEM
SW-10 : E-1 :
HORN SW. LEFT (OPT) (BLUE TAPING) FUSE & RELAY
SW-21 : BOX C-1 :
POWER BOOST SW. LEFT (OPT)
MECHATRO CONNECT THE "CNT-2" TAGGED
(YELLOW TAPING) C-8 : ENG. CONTROLLER CONTROLLER CONNECTOR WITH "UPPER HARNESS"
SW-34 :
REVOLUTION LEFT SW. (OPT)
(RED TAPING) CONNECT TO SWING
PARKING RELEASE SW.
CONNECT TO SWING
DETAIL OF FUSE & RELAY BOX CONNECTION PARKING RELEASE SW.
23-28
23. ELECTRIC SYSTEM
SE-9 :
PRESS SENSOR :
TRAVEL RIGHT
SW-1 :
KEY SW.
SE-20 :
PRESS SENSOR : SE-16 :
P1 OPT ACCEL POTENTIO
TAPING AFTER
BUNDLED TO ECU HARNESS
WHITE TAPING
TAPING
WHITE TAPING WHITE TAPING
WHITE TAPING TAPING
SUPPLY WITH
WHITE TAPING
SUPPLY WITH DOUBLE TO UPPER HARNESS
SPLICE
AMP 1565123-1 WHITE TAPING
DOUBLE
SPLICE
SW-43 :
JIB PRESS SW.
TO FRAME GND. M-4 :
WASHER MOTOR
TAPING
SEALING PLUG TO BE
INSERTED IN TO ALL
SW-4 :
SWING RELEASE SW.
SE-8 : SE-1 :
PRESS SENSOR : PRESS SENSOR :
ARM OUT BUCKET DIGGING
SE-4 : SE-3 :
PRESS SENSOR : PRESS SENSOR :
BOOM LOWERING BOOM RAISING
23-29
23. ELECTRIC SYSTEM
"
$
#
!
" !"
23-30
23. ELECTRIC SYSTEM
23-31
23. ELECTRIC SYSTEM
TO HARNESS (UPPER)
E-1 :
FUSE & RELAY BOX
TO CAB HARNESS
100 (3.94")
1PAF
YAZAKI 7123-3010
23-32
23. ELECTRIC SYSTEM
E-23 :
12V SOCKET
E-9 :
SPEAKER RIGHT
CONNECT TO
FLOOR HARNESS
CLIP
SW-41 :
HIGH REACH CRANE SW.
E-3 : CONNECT THE SWITCH
HOUR METER WITH "CRANE" TAGGED
BLACK CONNECTOR
SW-15 :
SW-17 : SW-26 :
M-3 : CONFLUX / SINGLE SELECT SW.
ROOF WIPER SW. CAB WORK LIGHT SW.
WIPER MOTOR CONNECT THE SWITCH WITH "CONFLUX"
CONNECT THE SWITCH CONNECT THE SWITCH WITH "CAB LIGHT"
TAGGED GREEN CONNECTOR
WITH "WIPER" TAGGED TAGGED NATURAL COLOR CONNECTOR
SW-55 :
BOOM , DECK WORKING LIGHT SW. NATURAL COLOR
E-4 :
CONNECTOR E-4 :
CONNECT THE SWITCH WITH "BOOM, DECK" CIGARETTE LIGHTER
CIGARETTE LIGHTER
TAGGED BLUE CONNECTOR
TO AIR
CONDITIONER UNIT FIX TO THE BRACKET
WR B
DETAIL B
DETAIL OF HOUR METER
23-33
23. ELECTRIC SYSTEM
DOUBLE
WHITE TAPING SPLICE
DOUBLE
TAPING AFTER SPLICE
BUNDLED
TO CAB WORKING LIGHT
TO CAB WORKING LIGHT
DOUBLE
SPLICE E-9 :
DOUBLE
SPLICE SPEAKER RIGHT
WHITE TAPING
TO ROOF WIPER
E-23 : SHIELD UN-CONNECTED
12V SOCKET
TAPING TAPING C-2 :
GAUGE CLUSTER
DOUBLE
SW-19 : SPLICE
WIPER INTERLOCK SW. E-3 :
DOUBLE SW-17 : HOUR METER
TO CAB GND. SPLICE ROOF WIPER
SW-41 : SW-15 :
SW.
HIGH REACH CONFLUX / SINGLE
CRANE SW. SELECT SW.
TO ROTALY LIGHT C-4 : E-14 :
TO HARNESS (FLOOR) CIGARETTE LIGHTER
AIR CONDITIONER UNIT WHITE TAPING SW-55 :
TO HARNESS (UPP)
DOUBLE BOOM, DECK
SPLICE
WORKING LIGHT SW.
SW-26 :
CAB WORK LIGHT
SW.
DOUBLE
SPLICE
WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED
TAPING
TO CAB HARNESS
23-34
23. ELECTRIC SYSTEM
23-35
23. ELECTRIC SYSTEM
BOOM HARNESS ASSY LC15E00008F1 (05) INSTALLING BOOM LIGHT LC80E00004F1 (04)
ITEM NAME PARTS No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
1 HARNESS 2479Z3130D1 1 BOOM HARNESS 1 LIGHT YW80S00001F1 2
TO UPPER
HARNESS POINT THIS LAMP TO BUCKET BOTTOM CENTER.
INSTALL THE LAMP SO THAT THE LIGHT BEAM POINTS THE
BOTTOM OF BUCKET, IN THE CONDITION THAT AREM IS
23.3.10-1 BOOM HARNESS : 2479Z3130D1 EXTENDED FULLY (ARM OUT) AND BUCKET IS CLOSED FULLY. 1
YAZAKI
CAP : 7120-1010
TERMINAL : 7115-1050
TIGHTENING TORQUE
18.6N.m (13.7lbf.ft)
SECTION AA
YAZAKI
CAP : 7120-1010 YAZAKI
TERMINAL : 7115-1050 HOUSING : 7122-2810
BRANCH WITH SPLICE TERMINAL : 7114-2020
23-36
23. ELECTRIC SYSTEM
INSTALLING UPPER LIGHT YN80E00049F1 (01) CAB LIGHT INSTALL YN80E00058F1 (02) SE. Asia
ITEM PART NAME PARTS No. Q'TY REMARKS ITEM PART NAME PARTS No. Q'TY REMARKS
1 LIGHT YT80S00002F2 1 1 LIGHT YT80S00002F2 1
6 HARNESS YN02C01760P1 2
7 SWITCH YN50S00040D4 1
8 RELAY YN24S00010P1 1
6
bb
OPT WORK CONNECT TOINST-PANEL
LIGHT RELAY 8 HARNESS
7
CONNECT WITH
MAIN HARNESS
VIEW
VIEW
VIEW
aa
NOTE :
ITEM 1, TIGHTENING TORQUE 18.6N.m (13.7lbf.ft)
23-37
23. ELECTRIC SYSTEM
ITEM PART NAME PARTS No. Q'TY REMARKS ITEM PART NAME PARTS No. Q'TY REMARKS
1 FLASHER LAMP YM80S00001F1 1 FOR LH 1 ALARM YN53S00004F1 1
2 FLASHER LAMP YM80S00001F2 1 FOR RH 3 SWITCH YN50S00040DF 1
4 RELAY YN24S00010F1 1
TIGHTENING
CONNECT WITH CONNECTOR OF SWING
TORQUE
FLASHER (SUPPLIED WITH UPP HARNESS) 23.5N.m
(17.3lbf.ft)
SEMS BOLT
E-13 :
TRAVEL ALARM
1
UPP
HARNESS
VIEW
1 2
SW-13 :
TRAVEL ALARM SW.
CONNECT WITH NAME TUBE OF "ALARM"
3
4
SHOWING REAR VIEW (C/W) TRAVEL ALARM RELAY
23-38
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24-1
24. COMPONENTS SYSTEM
24-2
24. COMPONENTS SYSTEM
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
5
EYE BOLT (M10)
a3 PSV2
Dr
A3 2X4-M12
Depth 22
A1 A2
B3
a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2
Dr3 a5
A1 A2 5
1 A2
Dr3
Hydraulic ports
Q'TY Code Ports name Size
No. Parts
SE.Asia Oceania A1,2 Delivery port SAE 6000psi 1"
1 Main pump assy 1 B1 Suction port SAE 2500psi 2 1/2"
2 Regulator assy 2 Dr Drain port PF3/4-20
3 Gear pump assy(for pilot) 1 PSV1,2 Servo assist port PF1/4-13
4 Solenoid proportional reducing valve 2 PH1,2 Pressure sensor port PF3/8-17
5 PTO unit 1 a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
24-3
24. COMPONENTS SYSTEM
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
Main pump
Item Gear pump
SE. Asia Oceania
Pump assy LC10V00014F1 LC10V00015F1 -
Parts No.
Single Pump LC10V00020F1 YN10V00014F3
Pump model K5V140DTP1K9R-YT0K-HV ZX10LGRZ2-07G
Max.displacement capacity cm3 140 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2100
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 37.8 (5480)
Max. flow L/min (gal/min) 294 (78) X 2 at 7.8MPa (1130 psi) 21 (5.5)
Max. input horse power kW (PS) 195 (265) 3.4 (4.6)
Max. input torque N.m (lbf.ft) 886 (653) 14.7 (10.8)
Part No. LC10V01005F1
Model KR3S-YTOK-HV
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control
24-4
24. COMPONENTS SYSTEM
24.1.1.2.1 CONSTRUCTION
(1) Main pump
953 806 789 532 Apply adhesive (Three Bond No.1305N) 724 901 808 954 717 151 152 211
886 214 548 531 702 792 534 A
535 732
717
261
406
824
774
111
B B
127
123
710 04
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
Tightening torque 05
Tightening torque
Item number Thread size
N.m (lbf.ft) 546
401 M20 430 (317) 414 326
406 M8 29 (21) 725
407 M6 12 (8.9) 727
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177) 407 325
806 M16 130 (96) SECTION B-B SECTION B-B
VIEW A
808 M20 240 (177) SE.Asia Oceania
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Drive shaft (R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 Gear #1 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Back up ring ; P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Back up ring ; G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer plate 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 32 824 Snap ring 2
157 Cylinder spring 18 531 Tilting pin ; M24X2 2 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper(L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper(S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO unit 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-5
24. COMPONENTS SYSTEM
434
311
312
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
24-6
24. COMPONENTS SYSTEM
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885
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 REGULATOR
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives
the two pumps and, at the same time, drives the
auxiliary pump (OPT) arranged on another shaft. 116
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the 111
swash plate group that changes the delivery rate;
the valve block group that selects between oil
suction and delivery ; and the PTO group (OPT)
that transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft(111), cylinder
OCEANIA
block (141), piston (151), shoe (152), plate (153), AUXILIARY PUMP
spherical bushing (156), and cylinder spring (157). (OPT)
The shaft is supported by bearings (123) and (124) Fig. 24-4 Construction of hydraulic pump
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of
thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it
moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate
(313) by the action of cylinder spring (157).
313
124
312
111
116
124
314
141
157
156
151
. 153
152
211
24-8
24. COMPONENTS SYSTEM
24-9
24. COMPONENTS SYSTEM
24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION
725
730
a3
656 643
438 924
D
801
722 543 755 545 541 724 B 466, 755 708 644 646 645 728
VIEW C SECTION B-B
733
756
622 621 623 625 626 887 763
SECTION A-A
At start and
emergency mode
Fig. 24-9
24-10
24. COMPONENTS SYSTEM
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-YTOK 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.
Command current I
Fig. 24-10
24-12
24. COMPONENTS SYSTEM
feed back lever rotates at (F) fulcrums with the Hydraulic circuit diagram
B
movement of the servo piston towards (E),
consequently the spool is returned to the original Fig. 24-11
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
24-13
24. COMPONENTS SYSTEM
24-14
24. COMPONENTS SYSTEM
consequently the flow rate is also reduced. Since !() )
0
the feed back lever is connected with servo
piston and spool, the feed back lever rotates at Fig. 24-14
(R) fulcrum with the movement of the servo
piston towards (Q), consequently the spool is
returned to the original position. With this
movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
24-15
24. COMPONENTS SYSTEM
rate is raised. Since the feed back lever is Hydraulic circuit daigram
connected to servo piston and spool, the feed B
24-16
24. COMPONENTS SYSTEM
24-17
24. COMPONENTS SYSTEM
24-18
24. COMPONENTS SYSTEM
24-19
24. COMPONENTS SYSTEM
300 1471
(79) (1085)
2100min-1: Hmode Input revolution ;2100 min-1
Q Input horse power ;195 kW (265ps)
1900min-1: S Input torque ;886 N.m (653lbf.ft)
250
(66) [1]
Reference value in ( ).
[2] Two pumps are loaded at the same time
[3]
Delivery flow rate Q [ L/min ](gal/min)
200 981
(53) (724)
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
(26) (360)
0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
300 725mA Pd
1471
(79) 290L(77gal) (1085)
Q 2000min-1
300mA 12.0MPa [4] 156kW (212ps) (Pf=0MPa) (72 gal)
(1740psi) : At emergency mode
288L Input revolution ;2100 min-1 271L
250
(P t e
(66)
A
4. rg
[4]
I-Q Curve
)(7 m
Pd=7.8MPa at Qmax
10 od
Reference value in ( ).
Delivery flow rate Q [ L/min ](gal/min)
(53)
Pf:Power shift pressure (Reference value)
23.8MPa
147L
150 (39gal)
(40)
100 490
(26) (360)
Tin N.m (lbf.ft)
38.0MPa
Input torque
Tin (5510psi)
50 84L
(13) (22gal)
Min.Flow(at 2100min-1)
400mA
30L
(8gal)
0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
Pd
0 1 2 3 Pilot pressure 4 [MPa]
(145) (290) (435) Pi (580)(ps)
24-20
24. COMPONENTS SYSTEM
24.1.2.1 SPECIFICATIONS
PBL
P2 CT2
CP2
CT1
P1
Pcb PAL
CT1 T1
T2
PTb P1 unload CT2
PCb PAL
Travel PL PCb Travel left PBL
PAL AL BL P2 unload
straight CMR1 CMR2 Ar CP2
USE FOR YN30V00101
Br PAr PCa
PBr Travel PAr PB1 Boom
F1
PB1
Ab right conflux CCb Bs
PAb CP1 (HEAD) As
Bb PBs Swing
Boom PBb PBs PAs
(ROD) Aa
PBb Pss
LCb CRb PC LCs
PAc Bucket PCc PBa1 Pss
Ac Bc PBc Arm 1 PLc2 CRa (HEAD) PAa1
PBa1
(HEAD) (ROD) Ba
LCc LCa
PCAP2 LCAT2 MU PBa2 PAo (ROD)
PAa2 Arm 2 PBa2 PAo Option PBo
Ao Bo
LCo
PBp1 PBp2
(P3) (P2)
PBa2 PAo
PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo
A
VIEW A
24-21
24. COMPONENTS SYSTEM
24.1.2.1.2 PORTS
24-22
24. COMPONENTS SYSTEM
24.1.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44031
Maximum flow rate [L/min (gal/min)] 294 (78) × 2
Maximum set pressure [MPa (psi)] 37.8 (5481) (Pump port)/ 39.7 (5757) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 135×2 L/min (at 36×2 gal/min)]
When power boost pressure 37.8 (5480) [at 125×2 L/min (at 33×2 gal/min)]
Overload relief valve set pressure
39.7 (5757) [at 30 L/min (at 8 gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5481) [at 30 L/min (at 8 gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
24-23
24. COMPONENTS SYSTEM
24.1.2.2.1 CONSTRUCTION
(1) Control valve
J
154 164 101
P2
T2 T1
PAL PBL
YT1
J
PB1 PCa
YBG1
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102
973 973
PTb PCb
P1-20
973
973
PBr PAr
YT1
973
PAb PBb
YB 2
974 973
PAa2 PBa2
YA
G2
974
(P3)
162 162 169 155 163 162
SECTION B-B
24-24
24. COMPONENTS SYSTEM
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
D 978x2 D
PBs
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PA
PAo
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
24-25
24. COMPONENTS SYSTEM
$!#-
Fig. 24-25 Section (3/6)
24-26
24. COMPONENTS SYSTEM
Swing 204
203 PBs
333 Boom
PBb Pss
333
331
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb
Bs 162
161
301
264 266
264
266
BbR 160 PAs 206
602 PAb
559 SECTION E-E
560 164 551
Bucket
208
209
PCc
216 201
333 Arm 1 333
331 PBa1
PBc
331
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Fig. 24-26 Section (4/6)
24-27
24. COMPONENTS SYSTEM
201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao
521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205
205
SECTION G-G
T2
161
P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164
SECTION H-H
24-28
24. COMPONENTS SYSTEM
PBp1 PBp2
207
160 606 606
278x5 266
264 264
SECTION J-J
SECTION K-K
24-29
24. COMPONENTS SYSTEM
24-30
24. COMPONENTS SYSTEM
24-31
24. COMPONENTS SYSTEM
24-32
24. COMPONENTS SYSTEM
24-33
24. COMPONENTS SYSTEM
101
164
171
201
321
PLc A B Dr
166 541 167 511 161
Fig. 24-34 Lock valve selector
24-34
24. COMPONENTS SYSTEM
2 2E
6 ,H
Fig. 24-35 Bypass cut valve
24-35
24. COMPONENTS SYSTEM
Fig. 24-36 Swing shuttle valve cover
24-36
24. COMPONENTS SYSTEM
104
107
102
101
24-37
24. COMPONENTS SYSTEM
CMR1
PL CMR2
PTb PBL
Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL
CT1
(T3) Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr CCb
PBs
Dr
LCb LCs Pss
(HE AD) Ab
PAa1 Arm 1
PBb
LC c Aa (HEAD)
Bucket PAc
CRa
(ROD) B c PLc2
(HEAD) Ac
Ba (ROD)
PCc
PBc
LCAT2
LCAP2 LCo
Ao
Bo
PBo
PBa2
MU
PBp1 PB p2
(P3) (P4)
24-38
24. COMPONENTS SYSTEM
24.1.2.2.3 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
(D)
Pss
606
517 52
306
YA1 YBG1
T1
P2
P1
P2-20
YAG2 YK2 Y B2 YT1
P1-20
309
310
55 606
(D)
PBc
Connected to low
pressure circuit of P2
PCc
side casing
24-39
24. COMPONENTS SYSTEM
24-40
24. COMPONENTS SYSTEM
24-41
24. COMPONENTS SYSTEM
PAc
PCc PBc
Bc Ac
LCc
321 (D)
322 304 511
(R) (H)
Fig. 24-42 In bucket digging operation (Stroke limiter ON)
24-42
24. COMPONENTS SYSTEM
!"!
24-43
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.
(R) (R)
(H) (H)
PAb PBb
24-44
24. COMPONENTS SYSTEM
Fig. 24-45 In boom up conflux operation (Boom conflux spool)
24-45
24. COMPONENTS SYSTEM
(R)
(R)
(H) (H)
53 511 321
317 514 322
301 BH chamber
LCb CRb
Bb Ab
PAb PBb
(D)
24-46
24. COMPONENTS SYSTEM
56
PBa1 PAa1 P1
(D')
Arm 1 (D) LCAT2 LCAP2
RH (D') P1
RR HH PAa2 PBa2
52 Dr Dr
(D')
Arm 2 To arm 1 spoo
Aa (HEAD)
PAa2 Ba
PBa2 (ROD)
To pilot cut valve
53
MU
515
328
321 308 511 LCAT2 LCAP2
Fig. 24-47 In arm out operation
24-47
24. COMPONENTS SYSTEM
56
PBa1 PAa1 P1
(D')
Arm 1 (D) LCAT2 LCAP2
(D') P1
RR 52 RH PAa2 PBa2
(D) HH Dr Dr
Arm 2
(a) To arm 1 spool
Aa (HEAD)
PBa2 PAa2
[XR] Ba
(ROD)
53 To pilot cut valve
MU Circuit (I)
317
328 515
308 (D)
321 319 511 LCAT2 LCAP2
Fig. 24-48 In arm in operation (At light load: arm recirculation function)
24-48
24. COMPONENTS SYSTEM
56
PBa1
PAa1
P1
Arm 1 (D')
(D') (D)
LCAT2 LCAP2
RR 52 RH P1
(D) HH
PAa2 PBa2
Dr Dr
Arm 2 (a)
24-49
24. COMPONENTS SYSTEM
Fig. 24-50 Swing operation
24-50
24. COMPONENTS SYSTEM
24-51
24. COMPONENTS SYSTEM
$
% & '
(
( )&%*
+*
!" #
Fig. 24-52 Lock valve operation (At boom spool neutral position)
24-52
24. COMPONENTS SYSTEM
A A PLc Sa Sb Dr
SECTION A-A
Sa
321 322
PBb
(D)
301
Dr
Fig. 24-53 Lock valve selector operation (At boom down operation)
24-53
24. COMPONENTS SYSTEM
[X1]
PBp1
301 302
(b)
(C)
Dr
201 101
(a)
(D)
52
24-54
24. COMPONENTS SYSTEM
PBp1
302
301
(b)
(C)
Dr
201 101
(a)
(D)
202
52
24-55
24. COMPONENTS SYSTEM
Fig. 24-56 Boost check valve operation
24-56
24. COMPONENTS SYSTEM
527
528
(D') T2
518
T1
102
517
(D)
24-57
24. COMPONENTS SYSTEM
24-58
24. COMPONENTS SYSTEM
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
PORT 1, 3 PORT 2, 4
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDLAULIC SYMBOL
24-59
24. COMPONENTS SYSTEM
24.1.3.2 CONSTRUCTION
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
Tightening Tightening
torque No. Name Q’ty torque No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-60
24. COMPONENTS SYSTEM
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-59)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216
509
221
201
Fig. 24-60 When the lever is tilted
(3) Lever held (See Fig. 24-61)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4)
rises above a set value, ports (2,4) and the P port
close while ports (2,4) and the T port open. When
the pressure at ports (2,4) falls below a set value, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT
24-61
24. COMPONENTS SYSTEM
24-62
24. COMPONENTS SYSTEM
24.1.4.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
24-63
24. COMPONENTS SYSTEM
5
3
8 10
3
11 12
4
10
9
9
7 6
2
24-64
24. COMPONENTS SYSTEM
24.1.5.1 SPECIFICATION
(1) General view
Tightening
Symbol Port name Port size torque
N.m (lbf.ft)
A,B Main port SAE 3/4"
DB Drain port PF1/2 108 (80)
M Make-up port PF1 216 (159)
PA,PB Pressure measuring port 2-PF1/4 36 (27)
PR Parking brake release port PF1/4 36 (27)
Gear oil level gauge or
IP,L,AR Air breather port or PT3/4 98 (72)
Gear oil filling port
IP, L, AR
12- 22 Through
DB
B
PB
M
PR PA
A
THREAD FOR
EYE BOLT 2-M12
PR
DB
RELIEF VALVE
PB PA
M DB
A,B
M
PA PB PR
A B
Hydraulic diagram
24-65
24. COMPONENTS SYSTEM
(2) Specifications
24-66
24. COMPONENTS SYSTEM
24.1.5.2 CONSTRUCTION
(1) Swing motor
702 712
351
401
488 469
051-1 051
100
151
162 052 161 171
303 984
A A 163 985 391 390 444
131
451
472 400-1
400-2
712 400 052
706
986
742
743
994
111
491 101
121 123 122 124 114 301 443
24-67
24. COMPONENTS SYSTEM
24-68
24. COMPONENTS SYSTEM
34
22 11 27 25 24 3
4
SURFACE
5 OF LUBE OIL
10 3
23 6 20 35
7 8 3 VIEW
11 15
26 12
9 17 30 36, 37, 38, 39
14 31
3
28
29 18
33 32
13
21 19 16
2
1
DETAIL aa
aa
24-69
24. COMPONENTS SYSTEM
24.1.5.3 OPERATION
T=
2X q ; Displacement per revolution cc/rev
DIRECTIONAL VALVE
24-70
24. COMPONENTS SYSTEM
24-71
24. COMPONENTS SYSTEM
24-72
24. COMPONENTS SYSTEM
3) At anti-reaction action p t
When inertia load stops moving (point Y Fig. 24-
73), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the P<PS
right return side by the action of spring (321). L
Seat (313) tries to move to the right by the action
of spring (322), but since chamber p provides k
damping action by orifice g, the return of the seat 322 313 g r 321 311
makes a time delay with regard to the return of
Fig. 24-72 At anti-reaction action
the plunger.
Consequently, seat t opens. This makes a P Y
passage connecting the AM port and BM ports or
PS
both ports of the hydraulic motor by way of
→t→r→k. The result is that the pressures at the
AM and BM ports become equal (Pb), falling into PB
X
the condition at point Z in Fig. 24-73. Z
This prevents the hydraulic motor from swing T
shock by the closing pressure of the AM port. Fig. 24-73 Pressure change diagram of anti-
reaction operation
24-73
24. COMPONENTS SYSTEM
ring gear (8) is fixed, planetary pinion (4) revolves about Fig. 24-75 Planetary mechanism
sun gear (3) with the planetary shaft and spider (5). Swing motor
Bearing 1
24-74
24. COMPONENTS SYSTEM
24.1.6.1 SPECIFICATION
(1) Appearance
PILOT PORT
G(PF) 1/4 (P)
BEARING CENTER
VALVE PORT
2-G (PF) 1
(VA,VB)
DRAIN PORT
2-G (PF)1/2
18-M24 (D1,D2)
G (PF) 3/4
FILL PORT
LEVEL PORT OIL LEVEL
G (PF) 3/4
DRAIN PORT VIEW Y
Fig. 24-77 Travel motor
Rotation direction
Tightening
Oil inlet Oil outlet Rotation direction Port
Port size torque Function
port port (Viewed from valve port side) name
N•m (lbf•ft)
VA VB Right (Clockwise) P PF1/4 36 (26.6) Pilot (2 speed changeover) port
VB VA Left (counter clockwise) D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement
24-75
24. COMPONENTS SYSTEM
(2) SPECIFICATIONS
24-76
24. COMPONENTS SYSTEM
24.1.6.2 CONSTRUCTION
24-77
24. COMPONENTS SYSTEM
24-78
24. COMPONENTS SYSTEM
!
!
!
!
!
24-79
24. COMPONENTS SYSTEM
24-80
24. COMPONENTS SYSTEM
Fig. 24-82
(2) Parking Brake
Parking brake is released when high pressure oil, selected by the brake valve portion that is connected directly
to the rear cover (24), is applied to the brake piston (21). Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates (19), inserted into the casing (1),
and friction plates (20), coupled to cylinder block (13) by the outer splines.
When no pressure is activated on the brake piston (21), it is pushed by the brake springs (55) and it pushes
friction plates (20) and separating plates (19) towards casing (1) and generates the friction force which brakes
the rotation of cylinder block (13) and hence the shaft (9).
24-81
24. COMPONENTS SYSTEM
TO COUNTERBALANCE VALVE
(BRAKE VALVE)
LOAD
APPLICATION POINT
24-82
24. COMPONENTS SYSTEM
CAP
CONNECTING PISTON (57-5)
PORT B (57-4)
VALVE SEAT
(57-3)
PORT A
24-83
24. COMPONENTS SYSTEM
SPRING SPRING
24-84
24. COMPONENTS SYSTEM
24-85
24. COMPONENTS SYSTEM
24-86
24. COMPONENTS SYSTEM
SPRING
SPRING
24-87
24. COMPONENTS SYSTEM
24-88
24. COMPONENTS SYSTEM
VIEW Y
VIEW Z
24.1.7.2 SPECIFICATIONS
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (245 lbs)
24-89
24. COMPONENTS SYSTEM
24.1.7.3 CONSTRUCTION
2 places
VIEW Y
5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
24.1.7.4 OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem
(2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because
of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the
body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
24-90
24. COMPONENTS SYSTEM
24.1.8 CYLINDER
24.1.8.1 SPECIFICATIONS
(1) General view
B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu
Center distance of
Part No. of Cylinder bore / pins Dry weight
Use Stroke Cushion
cylinder assy Rod Dia. Full extend B / Full kg (lbs)
retract A
ø140 / ø100 1,550 3,651 / 2,101 With cushion on
Boom LC01V00044F1 269 (593)
(5.51" / 3.94") (5'1") (11'12" / 6'11") rod side
SE.Asia LC01V00054F2 ø170 / ø120 1,788 4,281/ 2493 With cushion on
Arm 504 (1,111)
Oceania LC01V00054F1 (6.69" / 4.72") (5'10") (14'1" / 8'2") both sides
SE.Asia LC01V00055F2 ø150 / ø100 1,193 3,005 / 1,812 With cushion on
Bucket 265 (584)
Oceania LC01V00055F1 (5.91" / 3.94") (3'11") (9'10" / 5'11") rod side
24-91
24. COMPONENTS SYSTEM
24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder
B
-0.5
-0.5
130 0
130 0
With hole
DETAIL B (1 place) DETAIL C
T=8000 (5900)
T=56.9 (42.0)
9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21
Slit
Orientation of cut off part
of cushion bearing (13)
P/No LC01V00044F1
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Buckup ring 1 20 Set screw; M14 1
3 Rod cover 1 12 Socket bolt; M18×80 12 21 Steel ball 1
4 Bushing 1 13 Cushion bearing 1 22 Pin bushing 1
5 Snap ring 1 14 Cushion seal 1 23 Wiper ring 2
6 Buffer ring 1 15 Piston 1 24 Pin bushing 1
7 U-ring 1 16 Seal ring 1 25 Wiper ring 2
8 Buckup ring 1 17 Buckup ring 2
9 Wiper ring 1 18 Slide ring 2
24-92
24. COMPONENTS SYSTEM
B
-0.5
-0.5
140 0
140 0
DETAIL B
T=17000(12540)
22
9 7,8 6 4 5 3 12 10,11 2 1 13 15 16 19 21 23 27 25 24
14 17 18 20 26
With hole
(1 place)
Orientation of cut
off part of cushion
bearing (13)
SLIT SLIT
LC01V00054F2 SE.Asia
P/No
LC01V00054F1 Oceania
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 11 Buckup ring 1 21 Piston nut 1
2 Piston rod 1 12 Socket bolt; M22×95 12 22 Set screw; M16 1
3 Rod cover 1 13 Cushion bearing 1 23 Steel ball 1
4 Bushing 1 14 Cushion seal 1 24 Cushion bearing 1
5 Snap ring 1 15 Piston 1 25 Cushion seal 1
6 Buffer ring 1 16 Seal ring 1 26 Stopper 2
7 U-ring 1 17 Buckup ring 2 27 Snap ring 1
8 Buckup ring 1 18 Slide ring 2 28 Pin bushing 2
9 Wiper ring 1 19 Slide ring 2 29 Wiper ring 4
10 O-ring 1 20 Shim 1
24-93
24. COMPONENTS SYSTEM
24 23 12 T=520 (384) 23 24
B
-0.5
-0.5
130 0
130 0
DETAIL B
21
9 8 7 6 3 4 5 12 11,10 2 1 13 14 15 16 17 18 19 20 22
With hole
(1 place)
LC01V00055F2 SE.Asia
P/No
LC01V00055F1 Oceania
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Shim 1
4 Bushing 1 12 Socket bolt; M20×95 12 20 Piston nut 1
5 Snap ring 1 13 Cushion bearing 1 21 Set screw; M14×2 1
6 Buffer ring 1 14 Piston 1 22 Steel ball 1
7 U-ring 1 15 Seal ring 1 23 Pin bushing 4
8 Buckup ring 1 16 Buckup ring 2 24 Wiper ring 4
24-94
24. COMPONENTS SYSTEM
24.1.8.2.2 OPERATION
If pressurized oil is fed alternatively to the oil inlet and Cushion bearing (13) Chamber "A" Passege "B"
outlet provided in the cylinder, force acts on the piston Tank
which in turn causes the piston rod (2) to extend and Piston (15)
Rod (2)
retract.
Rod side
Head side
(1) Operation of cylinder with cushion
1) Cushion on rod side
The cushion mechanism is provided to prevent Rod cover (3)
Cushion stroke
the generation of shock when the moving speed
of piston (15) is not reduced and strikes cylinder Fig. 24-98 Cushion mechanism on the rod side
head (3).
An oil in chamber "A" returns to the tank by
passing through passage "B" at a fixed flow rate
in a intermediate stroke state (Fig. 24-98) of
pressing head side. Next, in a state of just before
stroke end (Fig. 24-99), cushion ring (13)
plunges into passage "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-99 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-100)
This construction is similar to the one of cushion
on rod side. In a state of intermediate stroke
pressing rod side, an oil in chamber "A" returns
to tank by passing through passage "B" at a fixed
flow rate.
Next, in a state of just before stroke end, cushion
bearing (22) plunges into passage "B". At this
time, the oil in chamber "A" flows only through
clearance "D" and mouth gap "C" of cushion seal
(23). So the returning oil volume drops suddenly
and the piston movement slows down.
Fig. 24-100 Cushion mechanism on the head side
24-95
24. COMPONENTS SYSTEM
24-96
24. COMPONENTS SYSTEM
D - 10 Diode
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 15 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
E - 1 Fuse and Relay box YN24E00016F2
E - 2 Alternator VHS270402500
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
(E) Electric fittings
24-97
24. COMPONENTS SYSTEM
valve
solenoid valve
(YN35V00047F1)
PSV - B P2 unload propo. valve YN35V00048F1
Solenoid valve assy
PSV - C Travel straight propo. valve ↑
PSV - D P1 unload propo. valve ↑
PSV - P1 P1 pump propo. valve (YN10V00023F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay VHS283001271A
R - 3 Glow relay VHS286201420A
R - 4 Safety relay YN24S00010P1
R - 5 Horn relay ↑
R - 6 Working light relay ↑
R - 8 Travel alarm relay (for Australia) ↑
R - 9 Cab working light relay (for SE.Asia) YN24S00010P1
(R) Reray
24-98
24. COMPONENTS SYSTEM
24-99
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F2
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-4
Controller
YN20M01468P1
Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-100
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-5
Rated voltage DC24V
Controller
Maker's (Hino) P/No. S8347-01230
VHS834701230
Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-8
Controller Maker's P/No. 89661-E0010
VH89661E0010 Rated voltage 24V (DC)
Engine controller Working voltage 16~32V (DC)
Operating voltage
LC10 - 07001 ~ (at starter ON) 9~32V (DC)
YC10 - 03501 ~ Back-up source
(reference value) 5mA MAX (BAT=24V)
24-101
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F2
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E-2
Alternator M6
B terminal
VHS270402500
B
Generator
LC10 - 07001 ~
YC10 - 03501 ~
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-102
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V
LC53S0001D1 (High) STAMP
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
YN11 - 45001 ~ Basic frequency 350+20Hz low sound
YQ11 - 06001 ~ Insulation resistance More than 3M /DC500V
LC10 - 07001 ~
YC10 - 03501 ~ o 8.5
E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00046P1
Radio (AM & FM)
(Oceania)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 8, 9
Maker SOKEN Co., Ltd.
Speaker
Maker parts No. SOK104A004
YN54S00050P1
Rated input 10W
Radio
Impedance 8
LY01 - 00101 ~
Frequency 33.3Hz
LC10 - 07001 ~
YC10 - 03501 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~ Desiccant moisture 17% or over than the
weight of desiccant
YQ11 - 06001 ~ adsorption capability (Include initial absorption 2%)
LC10 - 07001 ~ Refrigerant HFC-134a
YC10 - 03501 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
24-103
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 11
Air-con compressor
!"#!"""
YX91V00001F1
$%&
Air-con
&"""'
YX03 - 01601 ~
() *
YX04 - 01773 ~
#+ &
YX05 - 02001 ~
,-#%".+ /
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 12
Type 115F51
Battery
Voltage 12V
YN72S00014P1
Capacity (5HR) 96Ah
Power
Weight (Incl. fluid) Approx. 26.5kg (58.4 lbs)
YN11 - 45001 ~
Electrolyte Approx. 6.7 L (1.77 gal)
YQ11 - 06001 ~
LC10 - 07001 ~ Negative
terminal
Positive
terminal
YC10 - 03501 ~
(0.67")
(0.67")
Taper
Taper
17
17
17.9 19.5
(0.705") (0.768")
502 (19.76")
180 (7.09")
210 (8.27")
215 (8.47")
24-104
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V
YN53S00004F1 Power AV 0.5 Red / Green
E - 14
Cigarette lighter
!" #$
YN81S00003P1
% ,
*
Cigarette lighter -.
YN11 - 45001 ~
& '
(%$
YQ11 - 06001 ~
LC10 - 07001 ~
)
*'+#%
YC10 - 03501 ~
/
0
*
E - 15
Fusible link
LC13E01175S002
Fuse
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 27
Resistance 2
Rated voltage DC 5V
Resister for emergency
Resistance 2 TOCOS
(Potentio meter) Parts E-27 RA30YME20FB202
YN52S00052P1
Engine emergency After soldering,
insulate this part
volume with heat shrinkable tube
Clip
YN11 - 45001 ~
Adhesive
YQ11 - 06001 ~
LC10 - 07001 ~
Fix this resistance with tape HOUSING : 172131-5
YC10 - 03501 ~ PVC tube (Black) TERMINAL : 170340-1
Dial
VIEW I
24-105
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L - 1, 6
Light (Halogen)
YW80S00001F1
Boom work light (LH, RH)
LC08 - 06201 ~
YC08 - 03001 ~
LC09 - 06201 ~
YC09 - 03701 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
L - 2,7
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Deck work light
Cab working light front
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
L-3
Meker Knight beam (Imasen)
Light
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Flasher lamp (LH)
Lighting cycle 90 times / min
Rear work light
YN11 - 45001 ~
AV0.85 W
YQ11 - 06001 ~ AV0.85 Y REAR WORKING
LC10 - 07001 ~ SWING LIGHT LIGHT
YC10 - 03501 ~ AMP PART NO.
HOUSING : 174259-2
L-4 TERMINAL : 171661-1
AV0.85 R
Light HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
LOCK PLATE : 1-174260-1 GND
YM80S00001F2 VIEW I
Flasher lamp (RH)
Rear work light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SECTION A-A
24-106
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~ Bulb
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ SECTION A-A Door
Switch
YC10 - 03501 ~
M-1 B Terminal : M8X1.25
Rated output DC 24V, 15kW A
Motor
Yazaki P/No.
VHS281002894A Terminal : 7114-6047
Pinion gear
Connector : 7282-3013-30 (Black)
Starter motor Hino P/No. : 82580-6720
YN11 - 45001 ~ Mating connector
Hino P/No. : 82580-6730
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
VIEW A
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller
LC10 - 07001 ~
YC10 - 03501 ~
Wiper sw
OFF-Stop
Stop signal ON-Start
Reverse signal
Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-107
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less HOUSING AMP
GND terminal
LC10 - 07001 ~
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
WIRE PROOF PLUG AMP
172888-2
VIEW Z Terminal L
Flowing direction of
main current F HOUSING YAZAKI
o 9 X 30L
Terminal A Terminal B Terminal B Heart shrinkage tube 7123-4210-30
AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
Blue
Vynil tube (Red) M6
Terminal C Terminal B
Electric diagram
Tape
M6
24-108
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-3
Hino P/No. S2862-01420A
Relay
Rated voltage DC 24V
VHS286201420A
Rated load 100A flow
Glow relay
Min. operating voltage DC 18V or less
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
S terminal
YC10 - 03501 ~
(Red)
Name plate
F terminal
Connector
090 II Non water-proof male 2P blue
SW terminal Hino P/No. 82580-7320A
Yazaki P/No. 7282-1020-90
Mating connector
090 II Non water-proof female 2P
Hino P/No. 82580-7330A
L terminal Yazaki P/No. 7383-1020-**
Electric diagram
R - 4,5,6,8,9,23,
24,25,26,28,45 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Rated voltage DC 24V
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Travel alarm relay
Cab working light relay
Auto idle stop relay 1, 2
Engine emergency stop relay Pin assignment
Lever lock relay
Alternator relay
Wiper motor relay
Washer motor relay
Boom cyl. working light relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Terminal arrangement
24-109
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R - 19
Relay
YY24S00001P1 UPPER
Flasher relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
TERMINAL NUMBER
R - 29,30,31,32
Maker's P/No. V23134-A0053-C643
Relay
Parts name Relay
YN24S00012P2
Rated voltage DV 24V
Wiper motor relay
Washer motor relay Contact 1C
YN11 - 45001 ~ * Accessory of relay box
YQ11 - 06001 ~
Pin assignment
LC10 - 07001 ~
YC10 - 03501 ~
SE - 1 ~ 5, 7 ~ 11,20
Pressure sensor
(Low pressure)
!
LC52S00019P1
Bucket dig and dump,
( )* +, - "$$-+"
Boom up and down, ' +, -
" "*+- "$$-+" .-(/-
Swing, +- $(/ $
"$$-+"$ 0"1*$% 2 3#45653#&
+- $(/ 2 4545#
Arm in and out, & " 0-7 &4 %"/ /(+-
Travel RH and LH and other 3 "1+ 1+ 0( $-** *-(/ 2 45656#&
YN11 - 45001 ~ "8-
YQ11 - 06001 ~ "# $%
&' && .&!
LC10 - 07001 ~
YC10 - 03501 ~
SE - 13
Output voltage 2.8V or more
Speed sensor
Clearance 1.0mm
VHS894101290A Sumitomo : 090-II (4P : B)
E/G speed sensor P/No. : 6188-0265
Hino. P/No.
YN11 - 45001 ~ Sensor side : 82580-6120A (B)
Harness side : 82580-6130A (B)
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
M16 x 1 Hex. : 17
Hex. : 22
Tightening torque : 47N.m (34.7 lbf.ft)
24-110
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
1/2 32+5
YQ11 - 06001 ~
1/4 (49.5)
LC10 - 07001 ~
EMPTY 85 +10
0
YC10 - 03501 ~
Float
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YT02 - 04001 ~
Notch part
YT03 - 05293 ~
YT04 - 07001 ~ Potentio
YN11 - 45001 ~ 3MA JM II + AMP
Bracket
YQ11 - 06001 ~ HOUSING : 174359-2
TERMINAL : 171661-1
LC10 - 07001 ~
YC10 - 03501 ~ Dial
24-111
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
PSV - A, B, C, D
Proportional solenoid valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F1)
YN35V00048F1
YN35V00049F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
HYDRAULIC SYMBOL
Arm 2 speed
P1 unload
Travel straight
P2 unload
Attachment boost
Swing parking
Lever lock
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
Rated voltage DC 24V
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Sleeve O-ring Solenoid Seal nut
1B P20
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
Rated voltage DC 24V
valve (8 spool) assy pressure
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-112
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 1 Auto return
Switch
Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ VIEW A Terminal
YC10 - 03501 ~ arrangement
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
YN11 - 45001 ~ YAZAKI
T No.
YQ11 - 06001 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
LC10 - 07001 ~ Swing parking release
YC10 - 03501 ~ Normal
SW - 5, 10, 20, 21
)* +,
Switch ,
(-
YN03M01861F1
(Right grip)
! "# #$
% % &
YN03M01862F1 '$! (
(Left grip)
Horn, ATT Power boost
YN11 - 45001 ~
YQ11 - 06001 ~ (( (, ./01,+ 23*" 4 (5
LC10 - 07001 ~ (( (,
%#6,+ 7 "*8 7
6 4(( (
9 '"5
YC10 - 03501 ~
SW - 7
Type Normal close
Switch
Working pressure 39.2~58.8kPa (5.7~8.5psi)
VHS835301471D
Rating DC 24V/12W
E/G oil pressure switch More than 100M / 090 II Water proof connector
Insulation resistance DC500V megger
YN11 - 45001 ~ Color : Black
Hino P/No. : 82580-6830
YQ11 - 06001 ~ Yazaki P/No. : 7383-1114
LC10 - 07001 ~
YC10 - 03501 ~
24-113
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 8
Switch
YR11P00008S005
Air cleaner
Clogging switch
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SW - 11
Switch
YN50S00041F1
Lock lever
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ !
YC10 - 03501 ~
SW - 15
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040DD Type (alternate)
Conflux / single flow More than 1M /
Insulation resistance DC500V megger UP
switching (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector
LC10 - 07001 ~
YC10 - 03501 ~
24-114
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 17
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D9 Type (alternate)
Roof window wiper More than 1M /
Insulation resistance DC500V megger UP
switch (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector
LC10 - 07001 ~
YC10 - 03501 ~
SW - 19
Switch
Rated voltage DC 12V
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
YN11 - 45001 ~
Operation force Initial motion 0.8+0.3
0 kg
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Max. stroke
SW - 26
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D4 Type (alternate)
Cab work light switch More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector
YC10 - 03501 ~
SW - 27
Purpose Coolant level detection
Switch
Working temperature -40 ~130
VHS834601510A
Coolant level switch Hino P/No. : 82580-71708
Sumitomo P/No. : 6188-0110
YN11 - 45001 ~
Electrode side
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ CONNECTOR
Housing side
(To ground) Mating connector
M18, P=1.5 Hino P/No. : 82580-71808
Sumitomo P/No. : 6189-0189
24-115
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 28
Switch
VHS233002800A
Fuel filter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Fuel outlet
Fuel inlet
YC10 - 03501 ~
Deposit container
Drain
SW - 55
Switch
YN50S00040D1
Boom work light switch
!"" %$
#
YN11 - 45001 ~
YQ11 - 06001 ~
#
LC10 - 07001 ~ $
YC10 - 03501 ~
24-116
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25-1
25. AIR-CONDITIONER SYSTEM
25-2
25. AIR-CONDITIONER SYSTEM
• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.
• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.
25-3
25. AIR-CONDITIONER SYSTEM
COMPRESSOR
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
25-4
25. AIR-CONDITIONER SYSTEM
27
33 30
27-1
40
32
39
27-3 27-4
27-2
35
35-8 35-6
35-11
35-1
35-2 35-5
34 35-7
35-10 35-9
25-5
25. AIR-CONDITIONER SYSTEM
25.2.2 CONSTRUCTION
(1) Air conditioner unit
49
47
48
46 44
31
42 31
41
50
3 1
45 1
A
1 32 43
39
37
38
36
40
B
2
33
25-6
25. AIR-CONDITIONER SYSTEM
14 16
6 1 1 31
1
5
15
1
31
62
1 3
1 1
D
E 4
7
28 1
A 1 1
27
1
20
26
13
C 60
11
29
23
21 22
24 82
24
83
51 54 79
9 63
78 23 C 84 61
17
E
18
31
D
B
10
19
12
1 25
3
31
77
25-7
25. AIR-CONDITIONER SYSTEM
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
25-8
25. AIR-CONDITIONER SYSTEM
25.3 PIPING
25.3.1 AIR CONDITIONER
35 6
7
JAM NUT FOR
TENSION PULLEY
T=46.1 (33)
50
33 3
10 13 6
17
54
14
25 21
1 22
INITIAL BELT TENSION 5 23
49 25
When the belt is pushed
by the force of 27N,
51
adjust the deflection N
of N part to be 5mm 4 15 25
9
10
11
6 12
52 25
3
32
25
57
6 58 50
52
E 30
D
40
27
C
B
A
25
1
12 E
25
16
2 25
25
39 25
25
8
34
8
56
1 59
2 25
24 24
53
8
5 24
8 5 18
8
6
2
6 6
20
8 55 11
C A B
Fig. 25-5
1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings.
2. Refrigerant volume : 900±50 g (2±0.1 lbs)
3. Tightening torque : T=N•m (lbf•ft)
25-9
25. AIR-CONDITIONER SYSTEM
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Hose : L = 4150 1 24 Clip 3
2 Hose : L = 3050 1 25 Clip 13
3 Bracket 2 27 Air conditioner assy 1
4 V-belt 1 30 Panel 1
3.92~4.9 (2.9~3.6) 5 Clip 4 32 Compressor assy 1
46.1 (34.0) 6 Sems bolt : M10×25 7 33 Pulley assy 1
4.9 (3.6) 7 Sems bolt : M6×20 2 34 Condenser 1
10.7 (7.9) 8 Sems bolt : M8×20 5 35 Air dryer assy 1
23.5 (17.3) 9 Capscrew : M8×100 4 39 Filter 1
10 Washer 6 40 Solar radiation sensor 1
11 Tube for S hose : L = 2450 1 49 Connector 1
12 Tube for heater : L = 3300 1 23.5 (17.3) 50 Sems bolt : M8×25 4
13 Tube for L hose : L = 1800 1 51 Clip 1
14 Tube for D hose : L = 2100 1 52 Clip 2
15 Tube for L hose : L=180 1 53 Bracket 1
16 Tube for heater : L = 1800 1 23.5 (17.3) 54 Capscrew : M8×20 2
17 Bracket 1 55 Grommet 1
18 Hose : L = 130 1 56 Grommet 1
3.92~4.9 (2.9~3.6) 20 Clip 2 4.4 (3.2) 57 Capscrew : M6×50 4
21 Bracket 1 58 Washer 4
46.1 (34.0) 22 Capscrew : M10×50 3 59 Tube for L hose : L=100 1
23 Washer 3 46.1 (34.0) 60 Sems bolt : M10×20 2
32 COMPRESSOR ASSY
S HOSE (5)
L TUBE (10)
25-10
25. AIR-CONDITIONER SYSTEM
A
5
8
A
C
5
6
6
B
4
5
3
10 3
2 11
8
9
1
6 5
7
B C
Fig. 25-6
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew : M8×25 2 9 S tube 1
4 Capscrew : M6×25 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1
25-11
25. AIR-CONDITIONER SYSTEM
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows
Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Many kinds of refrigerants that change in that Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.
25-12
25. AIR-CONDITIONER SYSTEM
25-13
25. AIR-CONDITIONER SYSTEM
effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-7 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-8 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.
25-14
25. AIR-CONDITIONER SYSTEM
25-15
25. AIR-CONDITIONER SYSTEM
25-16
25. AIR-CONDITIONER SYSTEM
25-17
25. AIR-CONDITIONER SYSTEM
25-18
25. AIR-CONDITIONER SYSTEM
1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)
25-19
25. AIR-CONDITIONER SYSTEM
Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
Fig. 25-17
25-20
25. AIR-CONDITIONER SYSTEM
Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.
EVAPORATION SENSOR
Fig. 25-20
25-21
25. AIR-CONDITIONER SYSTEM
Fig. 25-23
25-22
25. AIR-CONDITIONER SYSTEM
Fig. 25-24
25-23
25. AIR-CONDITIONER SYSTEM
• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
25-24
25. AIR-CONDITIONER SYSTEM
(3) Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side
Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter
25-25
25. AIR-CONDITIONER SYSTEM
Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when BLUE
sound is heard.
CHARGING
3) Connect the center valve of the gauge manifold
HOSE
with the charging hose of the vacuum pump. (GAS VALVE)
25-26
25. AIR-CONDITIONER SYSTEM
25-27
25. AIR-CONDITIONER SYSTEM
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-28
25. AIR-CONDITIONER SYSTEM
25-29
25. AIR-CONDITIONER SYSTEM
25-30
25. AIR-CONDITIONER SYSTEM
25-31
25. AIR-CONDITIONER SYSTEM
NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING
FUSE 5A
COMPRESSOR
JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111
25-32
25. AIR-CONDITIONER SYSTEM
EVA SENSOR
SUN SENSOR
MOTOR ACTUATER
(FOR AIR MIX)
MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)
BLOWER MOTOR
BLOWER AMP
MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY
25-33
25. AIR-CONDITIONER SYSTEM
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and
the signal input by each switch through control
panel with the function of the built-in micro
Fig. 25-34
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.
25-34
25. AIR-CONDITIONER SYSTEM
(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.
When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR
25-35
25. AIR-CONDITIONER SYSTEM
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
25-36
25. AIR-CONDITIONER SYSTEM
25.8 TROUBLESHOOTING
"HL.*" is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on panel is flashing. Inspect and correct or replace parts.
NO YES
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.
A
NO YES
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (less than 14.7N : OK) is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Inspect and replace.
NO YES
25-37
25. AIR-CONDITIONER SYSTEM
NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES
NO YES
Inspect and replace.
25-38
25. AIR-CONDITIONER SYSTEM
NO YES
Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
25-39
25. AIR-CONDITIONER SYSTEM
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES
CASE (2)
YES NO
25-40
25. AIR-CONDITIONER SYSTEM
Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.
No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes
Replace
25-41
25. AIR-CONDITIONER SYSTEM
25-42
25. AIR-CONDITIONER SYSTEM
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES
High pressure
is lower.
NO YES
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.
25-43
25. AIR-CONDITIONER SYSTEM
2) MODE is flickering.
3) R/F is flickering.
Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.
25-44
25. AIR-CONDITIONER SYSTEM
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
25-45
25. AIR-CONDITIONER SYSTEM
(2) Operation of monitor mode
ON/OFF SW
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch.
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd
digit of segment in three digits. The 1st digit is indicated by "H".
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing
UP or DOWN of blower switch, and the required sensor is selected from the list below.
1 EVAPORATOR SENSOR
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.
Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
25. AIR-CONDITIONER SYSTEM
2) Example 2
3) Example 3
4) List of 3 segments
SECOND SEGMENT
25-47
25. AIR-CONDITIONER SYSTEM
[MEMO]
25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31
31-1
31. DISASSEMBLING AND ASSEMBLING
31-2
31. DISASSEMBLING AND ASSEMBLING
31-3
31. DISASSEMBLING AND ASSEMBLING
[MEMO]
31-4
32. ATTACHMENT
TABLE OF CONTENTS
32
32-1
32. ATTACHMENT
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
32-2
32. ATTACHMENT
3. ARM
(G) BUCKET
CYLINDER HEAD PIN
(J) BUCKET DRIVE PIN
BUCKET CYLINDER (I) IDLER LINK PIN BUCKET LINK
IDLER LINK (H) BOOM CYLINDER
(H) BUCKET CYLINDER ROD PIN (K) BUCKET ATTACHING PIN HEAD PIN
32.1.2 BUCKET
O-RING
2
1
SECTION A-A
Fig. 32-3 Removing capscrew (1)
32-3
32. ATTACHMENT
32-4
32. ATTACHMENT
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).
32-5
32. ATTACHMENT
32.1.3 ARM
9,10
H
: 30mm
SECTION D-D
Fig. 32-10 Detail of bucket cylinder rod pin (H)
: 30mm
SHIM
After adjustment of shim,
the total gap should be
within 0.6~2.0mm
(0.02~0.08in).
G
SECTION A-A
32-6
32. ATTACHMENT
A
A
: 24 mm
32-7
32. ATTACHMENT
CLEARANCE
: 30 mm
Tightening torque
Classfication Size
N.m lbf.ft
M16 147 108
Metric threads M16 279 206
(BOOM TOP)
M20 181 133
1/8" 16.7 12.3
PF,PT threads
1/4" 36.3 26.8
32-8
32. ATTACHMENT
32.1.4 BOOM
BLOCK
STAND
4,5
: 30 mm
4,5
(4) Preparing for disconnecting cylinder pipes C
Retract the above mentioned cylinder rod, and 3
place one side of cylinder on stand. (See Fig. 32- 3
17) SHIM
SHIM
Apply grease to inner wall
of bushing
SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)
32-9
32. ATTACHMENT
: 41 mm
: 12 mm A2
A3
32-10
32. ATTACHMENT
(7) Removing boom foot pin (A) Install plastic shims to boom side.
1) Remove capscrew (3) M20×60, and plate (2).
D
D
32-11
32. ATTACHMENT
Install plastic F1 A
shim to After adjustment of
cylinder side. shim, the total gap
should be within
Plug : Tools section 11.5.2-(4) Plugs for ORS fitting 0.6~1.0mm 2,3
(0.02~0.04in).
Tools section 11.5.2-(5) Plugs for half clamp SHIM Apply
grease
to inner
:41 mm wall of
bushing
:12 mm
D
2) Removing arm cylinder head pin (D) SECTION D-D
Loosen nut (3), remove capscrew M20×180 (2) Fig. 32-21 Removing arm cylinder
and pull out pin (D).
: 30mm
D1
Plug both end of disconnected pipes. C1
C2
: 41mm B
E2 C2
32-12
32. ATTACHMENT
2) Removing boom cylinder foot pin (B) Apply grease to inner wall
(See Fig. 32-23,Fig. 32-24) of bushing
Loosen nut (5), remove capscrews M20×190 (4) 4,5 B
and pull out pin (B).
B Install plastic
4,5 shim to
cylinder side.
: 30mm
CLEARANCE
Tightening torque
Classfication Size
N.m lbf.ft
Metric threads M20 181 133
1/8" 16.7 12.3
PF,PT threads 1/4" 36.3 26.8
3/8" 73.5 54.2
32-13
32. ATTACHMENT
32-14
32. ATTACHMENT
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-15
32. ATTACHMENT
• For the details of special tools and jigs, refer to the back pages of this manual.
AIR
OIL PAN
Fig. 32-26 Preparation
32-16
32. ATTACHMENT
25 24 12 24 25
PS1/8
PT1/4
SLIT 15
ONE HOLE
DETAIL 6 DETAIL B
DETAIL C
Piston with piston nut type
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23
SLIT
C
No. Parts name Q’ty No. Parts name Q’ty No. Parts name Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1
3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew ; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 2
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2
Note : In case of piston with piston nut type, the parts with * are not used.
32-17
32. ATTACHMENT
32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in Fig. 32-27.
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.
(2) Pull out piston rod (2) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (12) of the rod
cover in sequence.
Fig. 32-28
Cover the extended piston rod (2) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 12
Turn counterclockwise
3
Cover here with cloths
2
Fig. 32-29
32-18
32. ATTACHMENT
• At this time, the weight of piston rod (2) is loaded KNOCK THIS EDGE
on rod cover (3). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.
3
2
Fig. 32-30 Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
tip of the piston rod (2) with a hoist and draw it out.
However, when piston rod (2) has been drawing out to
approximately two thirds of its length, lift it in its center OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out
of piston rod (2) is lifted, do not use a wire rope which
the piston rod assy
may score the surface, but use a strong cloth belt or a
rope.
19
18
32-19
32. ATTACHMENT
:6 mm
21
23
Fig. 32-35 Removing setscrew (22) and ball (23)
(3) Loosen and remove piston nut (21) or [piston (15)].
TURN COUNTER
• Since piston nut (21) is tightened to a high torque,
CLOCKWISE.
use a eye wrench suitable for the outside diameter 15
of piston nut (21). EYE WRENCH
21
• In case that piston and piston nut are combined,
Fig. 32-36 How to loosen piston nut (21)
apply the eye wrench to hexagonal part of piston
and loosen the piston directly.
32-20
32. ATTACHMENT
Cut the seal ring (16) by tapping it with a screwdriver or SCREWDRIVER (OR CHISEL)
a chisel. Take care not to strike it too hard, otherwise
the groove may be damaged. BACK-UP RING SEAL
17 RING
16
32-21
32. ATTACHMENT
BLOCK TOOL C
32-22
32. ATTACHMENT
24 BASE
Fig. 32-44 Drawing out pin bushing (24)
32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.
(2) Do not use the used oil seal, O-ring, back-up ring,
etc. even if they are not damaged after inspection.
(3) After cleaning, dry all parts by compressed air, and
put them on the working bench taking care not to
damage them.
32-23
32. ATTACHMENT
Heat them, and they may be soften. But never heat
them over 100°C (212.0°F) or more.
(2) Fit back-up ring (17) on the other side. After fitting,
correct it immediately to prevent from expansion of Fig. 32-46 How to fit seal ring (16)
seal ring (16) with correcting jig (H) as shown in Fig.
32-47.
• For piston, stop it once tentatively (for 3 to 5
seconds), and then push it in fully.
• After fitting, wind tape around seal ring (16) 2 or 3
times, and remove it immediately before piston (15)
is inserted in cylinder tube (1).
• Fit slide rings (18) (19) at the same time when
piston (15) is inserted in cylinder tube (1).
Fig. 32-47 Installing seal ring (16)
(2) Apply grease to wiper ring (9), and fit wiper ring (9), PRESS HERE. (STRAIGHT DOWN)
directing the lip side toward the groove of retainer
tool (D). And set retainer tool (D) on rod cover (3) RETAINER TOOL (D)
and press fit wiper ring (9) with press.
U-RING GROOVE
32-24
32. ATTACHMENT
(3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in INSERT U-RING INTO GROOVE FROM THIS SIDE.
their grooves in that order. Before setting packings,
coat them with hydraulic oil (or vaseline if not
available). If you forget the coating, the packings
may be scored. When attaching seals, deform them
in a heart shape as illustrated.
7
8
9
Fig. 32-50 How to fit U-ring (7)
(2) Install rod cover (3) on piston rod (2) with inserting
guide jig (I) as shown in Fig. 32-51 paying attention
for the lip section of U-ring not to be caught on the
stepped section.
Fig. 32-51 Inserting rod cover (3)
32-25
32. ATTACHMENT
FLAT SECTION
Direct slit toward
piston side
Fig. 32-52 Cushion mechanism on extension side
(2) When cushion is installed on the retraction side, fit
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.
2) Put cushion seal on it, directing the slit machined
side toward the piston side.
3) Fit cushion bearing on it directing the flattening
side as shown in Fig. 32-53.
! " # "
4) Put stopper in the groove. Push cushion bearing
to stopper fully, and drive snap ring. Use plastic Fig. 32-53 Cushion mechanism on retraction side
mallet in order not to damage the rod, cushion
bearing.
32-26
32. ATTACHMENT
: 6mm
After tightening the setscrew to a specified torque,
caulk the two places of the thread of the piston nut 21 V-BLOCK
side to secure the setscrew.
Fig. 32-56 Attaching slide ring (18), (19)
See para 32.2.1.7.3 for torque.
(5) Attach two slide rings (18) and (19). Take off vinyl
tape wound around the perimeter of piston (15),
apply high-quality grease (or vaseline) to slide ring
(18), (19) and attach the slide rings in a manner that
they may be coiled around the groove. Set the slide
rings about 180 degrees apart with each other so
that the slits may not point to the same direction.
32-27
32. ATTACHMENT
: 14 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-58 Tightening socket bolts (12)
32-28
32. ATTACHMENT
port and store the cylinder. (Fig. 32-61)
32-29
32. ATTACHMENT
1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone.
If the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
32-30
32. ATTACHMENT
32-31
32. ATTACHMENT
32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Back-up ring 1. Foreign matter is trapped in the 1. Remove foreign matter.
surface of piston rod. Oil bore of back-up ring
ring is formed on piston 2. Lips on outer and inner diameter 2. Replace back-up ring.
rod, and the ring grows up surfaces of back-up ring are
to oil drops, and they drip. scored.
3. Other back-up ring are failed. 3. Replace back-up ring
2. U-ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
OIL LEAKS FROM HERE bore of ring.
2. Score is present on the bore of ring. 2. Replace U-ring.
3. Other rings are failed. 3. Replace U-ring.
3. Buffer ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of ring.
2. Score is present on the bore of ring. 2. Replace buffer ring.
3. Other rings are failed. 3. Replace buffer ring.
4. Wiper ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of wiper ring.
2. Lip on the bore of wiper ring is 2. Replace wiper ring.
scored.
3. Another wiper ring is failed. 3. Replace wiper ring.
5. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the 2. Score is present on the sliding
2. Replace seal ring..
maximum working pressure surface of seal ring.
multiplied by the area of the 1. Sliding surface of slide rings is
2. Slide ring 1. Replace slide ring.
cylinder bore, the maximum scored.
movement of the piston is 3. Piston rod 1. Elongation.Piston rod and piston 1. Replace piston rod.
more than 0.5mm (0.02") in are elongated. (Loose nut)
ten minutes.]
32-32
32. ATTACHMENT
D
For press fitting wiper
32.2.1.5.2
ring
E H
F
I
For inserting rod cover 32.2.1.5.4
32-33
32. ATTACHMENT
32-34
32. ATTACHMENT
12-S
(1.97")
(0.08") d D Cylinder Used
(0.08") 5 (0.2")
C2 R2 R0.2 90 (3.54") 103 (4.06") Bucket
(0.008")
10 12-S
100 (3.94") 113 (4.45") Boom (Head Side)
-0.2 (-0.008")
-0.4 (-0.016")
-0.5 (-0.02")
-1 (-0.04")
Unit : mm (inch)
B Cylinder Used
115 (4.53") Boom, Bucket
135 (5.32") Arm
32-35
32. ATTACHMENT
)
4
5 (0.197")
(CHUCK)
32-36
32. ATTACHMENT
CHUCKING JIG A
32-37
32. ATTACHMENT
oD
15 (0.59") 15 (0.59")
od 10
10
Unit : mm (inch)
Class
(Nominal size) d D h
o55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
o60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15)
o65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
o70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
o75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
o80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
o85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)
o90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
o95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
C
o100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
o105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
o110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
o115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
o130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)
6) Removing of bushing
a. Move block (C) and rod cover (3) with tool
under the press.
b. Press the upper part of retainer tool (D) slowly
until bushing (4) is take out from rod cover (3)
D
(until there is a sound that the chuck tool (A)
drops on the work bench)
• The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32~52mm
(1.26in~2.04in). (But it varies according to the
difference of dimension of cylinder head.)
32-38
32. ATTACHMENT
4
Do not work under the press because it is very
dangerous.
A
8) Removing of bushing
a. Place chuck tool (A) with bushing (4)
sideways, and loosen adjuster bolt with allen
wrench and lever.
b. Place the chuck tool (A) vertically and turn the
adjuster by hand until the wedge is raised
about 5mm (0.2 in).
c. Remove the wedge from the edge of chuck.
32-39
32. ATTACHMENT
32-40
32. ATTACHMENT
32-41
32. ATTACHMENT
CHUCK(A)
BUSHING(4)
BUSHING PRESS-
FITTING PART
32-42
32. ATTACHMENT
5) Press-fitting of bushing
Push the head of retainer (D) with press, and
press fit bushing (4) to the specified position of
rod cover (3) slowly.
LIFTING THREAD
ADJUSTER BOLT
WEDGE
CHUCK
32-43
32. ATTACHMENT
[MEMO]
32-44
33. UPPER STRUCTURE
TABLE OF CONTENTS
33-1
33. UPPER STRUCTURE
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.
33-2
33. UPPER STRUCTURE
33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
A1-1
seat (A1) to ease handling.
2) Move the whole control stand to its foremost A1
position.
3) Move the operator’s seat to its forward end. C1
4) Incline the reclining seat as forward as possible.
C2
(2) Remove operator’s seat. (Include upper rail.) B2
C1
1) With the above-mentioned condition, remove C2
two cap screws (B2) M8×20 from the upper rail.
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8×20.
1
: 6 mm
8
2) Remove the operator’s seat. [about 20kg (44
lbs).]
Carry out the following operations as required.
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (8).
33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
A4
A5
A2
# & $%
$% '#($ &' A6
!"# $& )(# %($
A1
33-3
33. UPPER STRUCTURE
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6×16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71), (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×25 and 1 sems bolt (A39) M6×16. And right A3
A14
panels (A4) and (A4-2) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-8) of inside on right A40
A4-8
panel (A4-2). And free the harnesses connected A29
A4
to key switch.
A4-8 A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-8
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-2
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-2). (See Chapter 23)
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×40 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2
A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-2), (A3) and (A5-2)
33-4
33. UPPER STRUCTURE
RELAY BOX
ASSY
33.1.2.2 INSTALLATION
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60)
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
33-5
33. UPPER STRUCTURE
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open left panel assy (21).
1) Open it with starter key.
2) Open left panel assy (21).
3) Fix it with stay.
: 17 mm
(3) Remove battery cable
1) Remove cable (C4) [between the earth and
battery (–)]. 21
(Always remove (-) terminal first and install it at
Fig. 33-8
last.)
2) Cable (C2) [between battery (+) and (-)]
+"
3) Cable (C3) [between battery (+) and battery
relay] +
: 13 mm
A4
A3
B1
33-6
33. UPPER STRUCTURE
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (A3) against battery (B1), and
tighten capscrew (A4).
: 17 mm,
Tightening torque : 10.8N•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.
: 13 mm
33-7
33. UPPER STRUCTURE
33.1.4 GUARD
5 11
23
6
21
Fig. 33-11 Arrangement of guard assy
: 19 mm
Weight : 60kg (132 lbs)
%
Fig. 33-12 Removing bonnet assy (11)
(2) Remove guard (7) %
1) Remove 3 sems bolts (38) M12×25 on upper !&
side. !'
: 19 mm
Weight : 11kg (24 lbs)
33-8
33. UPPER STRUCTURE
!" !'
: 19 mm
Weight :
guard (8) : 13kg (29 lbs)
!'
guard assy (5) : 23kg (51 lbs)
Fig. 33-14 Removing guard (5),(8)
(4) Remove stay (3)
1) Remove 2 sems bolts (38) M12×25.
2) Remove 2 sems bolts (40) M12×40. 3
3) Remove stay (3).
38
: 19 mm
Weight : 8.6kg (19 lbs)
40
: 17 mm 4
Weight : 17kg (37 lbs)
33-9
33. UPPER STRUCTURE
: 17 mm
Weight : 17kg (37 lbs)
!
Fig. 33-18 Removing panel assy (23)
(8) Remove panel assy (22)
22
1) Unlock and open panel assembly (22).
2) Remove 4 nuts (4) M10.
3) Remove panel assy (22).
: 17 mm
Weight : 17kg (37 lbs)
$
!&
!&
33-10
33. UPPER STRUCTURE
: 19 mm
Weight :
beam (11) : 6.8kg (15 lbs)
pillar (10) : 17kg (37 lbs)
panel (4) : 3kg (6.6 lbs)
!'
!'
Fig. 33-21 Removing beam (11), pillar (10), panel (4)
(11)Remove beam (6), pillar (9), (12) 11
Remove battery relay box in advance and remove
pillar (12). (See Chapter 23) 39
39
39
39
: 19 mm
"' !'
Weight : 1.2kg (2.6 lbs)
3) Loosen 2 sems bolts (38) M12×25. Fig. 33-23 Removing and installing of plate (49)
(Refer to Fig. 33-22)
4) Loosen 5 sems bolts (5) M12×30.
: 19 mm
5) Remove guard assy (13)
Weight : 17kg (37 lbs)
33-11
33. UPPER STRUCTURE
: 19 mm
Weight :
guard assy (2) : 12kg (26 lbs)
guard assy (1) : 20kg (44 lbs) 5
: 19 mm
3
2) Remove guard assy (4), guard (3)
Weight :
guard assy (4) : 8kg (18 lbs)
guard (3) : 11kg (24 lbs)
39
33-12
33. UPPER STRUCTURE
: 19 mm
Weight : 30kg
39
1-2
(17)Remove other brackets, as required.
33.1.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
33-13
33. UPPER STRUCTURE
33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8)
1) Remove attaching sems bolts (9) M12×30.
2) Remove covers.
: 19 mm
!" #$%$& ! "
!" #$%$& !$ "
!" #$%$& !$ "
!" #$%$& !$ "
!" #$%$& !$ "
!" #$%$& !$ "
!" #$%$& ! $ "
!" #$%$& ! $ "
33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,8)
: 19 mm
Tightening torque : 79.4 N•m (60 lbf•ft)
33-14
33. UPPER STRUCTURE
33.1.6.2 REMOVAL
(1) Remove 6 capscrews (A1) M16×45. B2
: 24 mm
(2) Hook the wire to the lifting eye on the fuel tank assy
A6 C1
(C1) and remove the fuel tank. A4
Weight : 203kg (448 lbs)
(3) Remove shim (A3).
A3
A1
A8
Fig. 33-30 Removing fuel tank
33-15
33. UPPER STRUCTURE
33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M16×45
Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 6 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Stop valve 1 34 (25)
33-16
33. UPPER STRUCTURE
: 17 mm C
2) Remove cover (C3). B2
D
3) Remove filter element (B6).
B6
D
(5) Turn the handle of element assy (B), and Air
breather
disassemble the removed filter element (B6). D
Disassemble parts : (B), (C), (D)×3, (E), (F)
E
(6) Draining hydraulic oil
F Hyd.tank
Place pump in tank and draw up hydraulic oil.
Capacity of tank : 186 L (49gal)
33-17
33. UPPER STRUCTURE
33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3)
Remove 2 clips (A17) of the tank side and pull out
hose (A3). A17
2 : Flat-blade screwdriver
A16
A3
At installing suction hose,
apply PERMATEX to the
inner end of both hoses.
: 36 mm C/V
T2 18
3) H/P
Remove drain hose (6) of swing motor 3 Dr
: 22 mm
A1
: 22 mm
33-18
33. UPPER STRUCTURE
: 30 mm
A3
(7) Remove shim (A3).
A1
Fig. 33-38 Removing hydraulic tank
33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M20×45 with
Loctite #262. (See Fig. 33-38.)
33-19
33. UPPER STRUCTURE
33-20
33. UPPER STRUCTURE
Hyd.tank
38
17
16
33-21
33. UPPER STRUCTURE
33.1.8.2 REMOVAL
(1) Loosen 8 capscrews (A19) M12×40 and remove
half clamp (A11). And disconnect 2 hoses (A1),
(A2) from the delivery side. A3
: 10 mm A19
(2) Remove pilot pump suction hose (1)
(See Fig. 33-43) A11 4
: 36 mm A8
(3) Remove suction hose (A3) and drain hose (4) A11
Dr3 2 22 Drain
B3
3
*Psv1 12 19 Pilot primary pressure P1 side
Psv1
33-22
33. UPPER STRUCTURE
Engine
side
SE-22: SE-23:
Pressure sensor : Pressure sensor :
P1 pump P2 pump
Fig. 33-44 Removing connector
(6) Remove main pump
0
1) Put a wire sling on the hydraulic pump and
tension the wire sling a little. Loosen 8
3
capscrews (4) M10×35.
: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of 4
1
the wire rope.
On that occasion, the assembly is drawn out with
the insert NA (2-3) remaining on the flywheel 2-6
2-4
side.
3) Remove element (2-1) from the tip of the spline
shaft.
4) Remove 4 capscrews (2-6) M20×50 that fasten
2-5
insert R (2-4) and remove insert R (2-4). 2-7
2-2 2-3
: 17 mm
5) Remove hub (2-2)
If you loosen 2 set screws (2-7) M20×25, hub
2-8 2-1
comes off from the spline shaft of the pump.
2
: 17 mm 2-9
6) Remove 4 capscrews (2-5) M20×60 that fasten
the insert NA (2-3) with the engine side flywheel,
as necessary. Then remove and spring pin (2-8) Fig. 33-45 Removing pump
from insert NA (2-3).
: 17 mm
7) Removing bracket (1)
Loosen 4 capscrews (3) M20×55, and remove
bracket (1) from pump (0).
33-23
33. UPPER STRUCTURE
33.1.8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install
bracket temporarily.
: 17 mm
Tightening torque : 431 N•m (318lbf•ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 3mm
(0.12in) from the end face of the spline (See Fig.
33-46 Detail aa). Then install two set screws (2-7)
and fix them together.
: 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 R (2-4)
Install insert R (2-4) into hub (2-2) by means of
capscrews (2-6) coated with Loctite #262.
: 17 mm
Tightening torque : 465 N•m (343 lbf•ft)
(5) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (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).
: 17 mm
Tightening torque : 465 N•m (343 lbf•ft)
33-24
33. UPPER STRUCTURE
: 10 mm
Tightening torque : 66.7 N•m (49 lbf•ft)
(11)Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
3
56 (2.2")
(12)Installing the hose (See Fig. 33-43) (0.118") DRAIN HOLE (Bottom)
DETAIL aa VIEW I
33-25
33. UPPER STRUCTURE
33.1.9.2 REMOVAL
(1) Pulling out hose (3).
aa
3 Insert width of hose : 45 mm
1) Loosen clips (5) on both sides of hose (3). 6 (1.77")
2
6 bb
2) Pulling out hose (3)
: Flat-blade screw driver
(2) Remove air cleaner assy (1)
1) Remove 4 sems bolts (7) M10×25 ENGINE
A
5
: 17 mm
1 1-8
2) Remove air cleaner assy (1) from plate (4). 4
")
.77 1-2
(1
45 Insert width
of hose
1-3
DETAIL aa DETAIL bb 1-6
A
33.1.9.3 INSTALLATION
(1) Installing is the reverse order of removing with
attention paid to the following items:
1) Put in air hoses (2), (3) to the end as shown in
Fig. 33-49.
2) Tightening torque : FILTER ELEMENT (1-3) FILTER ELEMENT (1-2)
(LC11P00018S003) (LC11P00018S002)
No. Name Tightening torque N.m (lbf.ft) O-RING (1-6)
1-8 Indicator 3.9 (2.9) (EB11P00001S003)
33-26
33. UPPER STRUCTURE
33.1.10 MUFFLER
33.1.10.2 REMOVAL
(1) Remove U bolt (4).
1) Remove 4 nuts (10) M8.
: 13 mm "
2) Remove 2 U bolts (4).
(2) Remove clamp assy (5)
1) Remove 2 capscrews (9) M10×35
: 17 mm
2) Separate clamp assy (5) from muffler (1).
(3) Removing other parts
Remove brackets (2) as necessary.
: 19 mm
) &
&
* %$
! "# !$%&&
$$
' %
'$
& $
#'
(
$$ $
#'
33-27
33. UPPER STRUCTURE
33.1.10.3 INSTALLATION
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-51)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (5)
1) Place the end of clamp (5) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-51)
2) Install the clamp assy (5) in the illustrated
direction.
(3) Tightening torque :
33-28
33. UPPER STRUCTURE
33.1.11 COUNTERWEIGHT
33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily C1
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. 8,130kg (17,920 lb)
(2) Removing counterweight (C1)
1) Remove 4 capscrews (A1) M36×420.
: 55 mm
2) Remove shim (A3), (A4), (A5). (Select)
3) Remove counterweight (C1).
A3
A4
A5
A1
A2
33.1.11.3 INSTALLATION
(1) Install counterweight in the reverse order of
removing.
(2) Install shim (A3), (A4), (A5) as it was. (select) Less than two shim
adjustment
(3) Slinging counterweight A3,A4,A5
Check that the attaching bolts can be screwed in by
hand.
(4) Apply Loctite #262 on capscrews (A1), and tighten
them with washers (A2).
: 55 mm A1,A2
Tightening torque : 2,940 N•m (2,170 lbf•ft) Fig. 33-54 Fastening the counterweight attaching
(5) Remove slinging tools, and install bonnet assy (11). capscrew
33-29
33. UPPER STRUCTURE
: 19 mm
(7) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose
8
for draining water.
[Water capacity of radiator : 11L (2.9gal)] 40
35
: 13 mm, 17 mm
2) Move a set of air-conditioner condenser and
receiver tank. Fig. 33-56 Removing hose of sub tank (1)
(10)Disconnect connector of coolant level switch (B5).
(See Fig. 33-58) $
!# %
#
!
$
!
#%
#
Fig. 33-57 Moving condensers and receiver tank
33-30
33. UPPER STRUCTURE
33.1.12.2 REMOVAL
(1) Remove radiator stay (A1), (A6). *
1) Remove 4 sems bolt (A2) M12×35.
: 19 mm
2) Remove 2 stays (A1), (A6). *
*!
(2) Remove water hose (2),(3)
1) Loosen the hose bands (33) for water hose (2). *
* *
: Flat-blade screwdriver )
2) Remove hose (2).
*&
3) Loosen hose band (33) on water hose (3).
: Flat-blade screwdriver )$
4) Remove hose (3).
*'
)
)
)"
Fig. 33-58 Removing radiator assy
(3) Remove hoses (4)(5) for inter-cooler ! !
$ '
1) Remove two fixing U-bolts (22) from tube (13). !"
% '
$ "
: 13 mm #
%
2) Loosen 2 sems bolts (29) M8×25. !
!! "
!! !
: 17 mm %
!
# &
3) Loosen hose bands (32) and remove hose (4). &
: Flat-blade screwdriver
4) Loosen hose bands (32), (34) and remove hose
(6). !
!! !
: Flat-blade screwdriver "
5) Loosen hose bands (32) and remove hose (5). 35
!
#
: Flat-blade screwdriver !
: 17 mm
33-31
33. UPPER STRUCTURE
15
9
21
A
Fig. 33-60 Removing hydraulic oil hose (1), (2)
33-32
33. UPPER STRUCTURE
33.1.12.3 INSTALLATION
(1) Installing is done in the reverse order of removing. 97
")
(1.
And removed clips of hose should be clamped at (1 .58
") 50
40
original position.
")
58
(2) Install radiator assy (1.
40
: 30 mm
")
Tightening torque : 500 N•m 369 lbf•ft) (1.
58
40
(4) Adjust the clearance between the fan and the
")
97
radiator shroud all around the circumference, as 50
(1.
")
below : (1.
97
50
Circumferential direction:
18±3mm (0.71in±0.12in)
Back and forth:
44±5mm (1.73in±0.2in) Fig. 33-61 Inserting width of hose
33-33
33. UPPER STRUCTURE
(2) Disassembly
1) Loosen each 2 bolts (22) at head and bottom of
shroud, remove upper plate (20) and lower plate
(19).
2) Disconnect wiring connector of radiator coolant
level switch. Inter- Radiator Oil
cooler cooler
3) Loosen 6 sems bolts (22) M10×20 attaching
plate assy (21), remove plate assy (21).
4) Loosen 2 capscrews (15) M10×50 attaching
radiator core.
5) After confirming that the coolant has been
drained out completely, loosen and remove only
the radiator side of hose bands (33) at the top
and bottom of the radiator. (See Fig. 33-59)
DRAIN VALVE
6) Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Weight : 20kg (44lbs)
Confirm the missing of rubber bushing (14)
14
under the radiator core.
7) Loosen 2 capscrews (15) M10×50 attaching the Detail of radiator
core mounting part
top of the inter-cooler core.
8) Loosen and remove only the inter-cooler side of
hose bands (32) at the top and bottom of the
inter-cooler. (See Fig. 33-59)
9) Lift and remove inter-cooler using lifting eyes
and hoist on the inter-cooler.
Confirm the missing of rubber bushing (14)
22
under the inter-cooler. 19
VIEW A
33-34
33. UPPER STRUCTURE
(3) Installing
Installing is done in the reverse order of removing.
33-35
33. UPPER STRUCTURE
33.1.13 ENGINE
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)
THERMOSTAT GASKET
OIL PLUG
ASSY
FUEL FILTER
OIL FILTER ELEMENT
ELEMENT
STARTER
ENGINE
V BELT (3 PIECES)
33-36
33. UPPER STRUCTURE
33.1.13.2 REMOVAL
22 22
12
12
23 23
15 15
13 14
13 14
11
19 19
28 21
24
25
B C
5
6
2
7
3
A
6
8
17
20 30
18
33
16 C A
35 29
28
10 C
31
32
36
33-37
33. UPPER STRUCTURE
: 17 mm, 41 mm
(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
1) Loosen 4 nuts (19) M18.
: 27 mm
2) Loosen 4 capscrews (23) M18×150.
3) Remove 4 plates (14).
4) Remove upper rubber mounts (13) and (14) 2 each.
(4) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 685 kg (1,510 lbs)
Wire: ø6 (0.236")×1m (3ft 3in) - 2pcs.
(5) Position engine on the stand stably.
(6) Remove 4 rubber mounts (13), (14).
33.1.13.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Tightening torque
Tightening torque
No. Name Remarks
N.m (lbf.ft)
6 Bolt 26.5 (20)
20 Sems bolt 46.1 (34)
Apply Loctite
21 Sems bolt 46.1 (34) #262
Apply Loctite
22 Sems bolt 115 (85) #262
Apply Loctite
23 Capscrew 226 (167) #271
33-38
33. UPPER STRUCTURE
33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
: Flat-blade screwdriver
2) Loosen 3 sems bolts (16) M6×15.
: Plus screw driver
3) During lifting right upper console cover (3A) up;
disconnect connector of tuner and antenna.
Move boot (3) upwards and remove console
cover (3A).
• Removing of boot and lever is unnecessary. Fig. 33-66 Removing plate (4)
4) Loosen 3 sems bolts (16A) M6×15 and remove 16
lower console (4). 3A
: Plus screw driver 16
(2) Removing left-hand console cover 16A
16B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 5 16B 4 16A
66) 16B
: Flat-blade screwdriver
16C
2) Loosen 2 sems bolts (A6) M8×20 and remove left
armrest assy.
6
: 13 mm
3) Loosen 4 sems bolts (16B) M6×15.
: Plus screw driver
4) Remove the left upper console cover (5) in the
same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M6×15 while lifting
left under console cover (6) up, and remove left Fig. 33-67 Removing console covers
lower console cover.
33.1.14.2 INSTALLATION
Install it in reverse order of removing according to the
tightening torque table.
A6
Item Bolts Tightening torque N.m (lbf.ft)
33-39
33. UPPER STRUCTURE
33.1.15.2 REMOVAL
(1) Attach tag on which hose name is entered to the
2
remote control hoses between multi control valve 8 P/V 5
and pilot V, and write numbers P1 to P8 on it. P/V P/V 1
See Tools 11.5 PLUG (3) P/V
4 P2 P5
: 19 mm, 22 mm P/V
P8 0 P1
(2) Attach tag on which hose name is entered to the 7 6
remote control hoses between multi control valve P/V P4 P6 P/V
and main control valve, and write numbers C1 to C8
P7
on it. 3
See Tools 11.5 PLUG (3) P/V P3
: 19 mm, 22 mm
(3) Remove 4 sems bolts (B9) M8×20, and remove Fig. 33-70 Connection between multi control valve
multi control valve (0) with bracket (B5) from and P/V
machine.
33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of removing PBb
PBc B16
(2) Relations between pilot valve and multi control C/V C/V PBs
valve hose C4 C/V
C2
C5 C1
P/V Hose ISO Multi Mark-
Port Size Color Control pattern port ing C6
1 3/8 Red Bucket digging P1 1 0 PBa1
2 3/8 Blue
Right side
Bucket dump P2 2
C / V C / V CPAc
/V
3 3/8 Green Boom up P3 3 PAs
4 3/8 Gray Boom down P4 4 C8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - - C3
C/V
5 3/8 Gray Swing left P5 5 PAb
C7
6 3/8 Red Swing right P6 6 C/V
Left side
PAa1
7 3/8 Blue Arm in P7 7
8 3/8 Green Arm out P8 8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - -
B5
B11
(3) Tightening torque
Fig. 33-71 Removing hoses between main C/V and
multi C/V
33-40
33. UPPER STRUCTURE
3 Tightening torque
235N.m (173 lbf.ft)
33.1.16.2 REMOVAL
(1) Remove 4 capscrews (3) M16×45, and remove
control valve (5) by hoist.
: 24 mm
Weight :Approx. 252kg (556 lbs)
33.1.16.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 4 capscrews (3) M16×45.
: 24 mm
Tightening torque : 284 N•m (209 lbf•ft)
2)
Connector / Bolt Hose nut
Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
Pss,PLc2,PBp1,PBp2,PL,
PF1/4 PB1,PTb,PCa,PCb,PCc 19 36 (27) 19 29 (21)
ORS Joint
PAa1,PBa1,Pab,PBb,Pac,
PBc,PAL,PBL,Par,PBr,Pas,
PF3/8 PBs,PAa2,PBa2,Pao,Pbo,DR 22 74 (55) 22 49 (36)
PF3/4 MU 36 165 (122) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 14 42.4 (31)
M10 Ab,Bb Sems bolt 14 57 (42)
P1,P2 17 62.2 (45)
M12 T1,T2 17 96 (70)
33-41
33. UPPER STRUCTURE
P1 P1 pump
P2 P2 pump
33-42
33. UPPER STRUCTURE
*
*
%&$ ) &$
'(& '(&
"
"
&* '(& $'+! '(&
#
#
!
$
" !
"
Fig. 33-74 Control valve ports (2/2)
33-43
33. UPPER STRUCTURE
33.1.17.2 REMOVAL
(1) Remove hoses from your side to far side in order.
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-75)
: 22 mm
(3) Turn and loosen lever (2-1) tightened in pilot valve,
and remove lever assy in a set. (See Fig. 33-75) )*+ ) *
$%
& '
!!&
(4) Remove 4 capscrews (A14) M6×25. (See Fig. 33- $& !!&
33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Bucket (R)
Swing (R) (Blue)
(Red)
Swing (L)
(Gray)
33-44
33. UPPER STRUCTURE
A6
A7
A5
B1
A8
33.1.18.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and A14
A9
SE-10 (A9) at the connector. A1
T : Tightening torque
: 24 mm N.m (lbf.ft)
SE-9
(2) Attach tag, and discount connectors and hoses 6
(A2), (A3), (A4), (A5) T=16.7 (12)
A9 5 T T=30 (22)
: 19 mm (P port) P
A2
33-45
33. UPPER STRUCTURE
33.1.18.3 INSTALLATION
Install it in the reverse order of removal and tighten it.
Sems bolt (A14)
33-46
33. UPPER STRUCTURE
33.1.19.2 REMOVAL
(1) Remove hose. E 5
S/J
Dr
1) Remove hose (7) from the connector in the 7 C/V
Mu
makeup port M. 6
M A16 HYD.
: 41 mm A19 TANK
A
2) Remove 2 hoses (5), (6) from the Tee in the drain B A1
port Dr.
C/V
As
: 36 mm A2
C/V
3) Remove hose (A5) from the elbow of the PG port Bs
: 19 mm
4) Loosen 8 capscrews (A19) M10×30 and remove
half clamp (A16). And disconnected A,B port
hoses (A1), (A2) from the motor.
A5
PG
1
S/V
A2
33-47
33. UPPER STRUCTURE
: 30 mm
1) Remove two plastic caps (2) M12 at the top of
the swing motor and install eye bolts.
: Flat-blade screwdriver
2) Put a wire sling in the eye bolts and remove the
swing motor unit.
Weight of swing motor unit ;
Approx. 446kg (983 lbs) (Include reduction assy)
33.1.19.4 INSTALLATION
Install the swing motor unit in the reverse order of
1
disassembly, confirming the orientation of the swing
Coat all the mounting
motor unit. surface of the swing
motor with Loctite #515
(1) Tighten 14 capscrews (1) M24×70. equivalent.
: 36 mm
Detail of swing motor unit assy mount
Tightening torque : 932N•m (687 lbf•ft) Apply
Loctite #262
(2) Fill inside from motor drain port to casing with
hydraulic oil before piping for drain
(3) Piping tightening torque
33-48
33. UPPER STRUCTURE
33.1.20.2 REMOVAL
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A9). (E port : PF1/2)
A B
C D
(TRAVEL MOTOR) (TRAVEL MOTOR)
VB (LOWER) VA (LOWER)
REVERSE A,B,C,D-PF1 REVERSE
(LH) (RH)
VA (UPPER) E-PF1/2 VB (UPPER)
F-PF1/4
FORWARD FORWARD
T : Tightening torque
of connector
N.m (lbf.ft)
SWIVEL JOINT
B A4
F
B2
T=36.3 (26.8)
A2
T=255 (188)
C
T=255
A
(188) D
A10
E
B3
T=108 (79.7)
A3
A1
T=108 (79.7)
B3 A9
E
A9
33-49
33. UPPER STRUCTURE
: 36 mm
Tightening torque : 177 N•m (130 lbf•ft)
3) Remove hoses (A4), (A7).
(B, D port : 1-3/16-12UN) A3
A9
: 36 mm A16
Tightening torque : 177 N•m (130 lbf•ft)
A8
4) Remove hose (A8).
(Travel 2-speed change over port : PF1/4)
: 19 mm
Tightening torque : 29 N•m (21 lbf•ft) Fig. 33-84 Disconnecting the hoses on the top part
of swivel joint
(3) Remove whirl-stop of swivel joint.
27 26 Tightening torque
1) Loosen the nut (27) M24. 157N.m (116 lbf.ft)
: 36 mm
mm
13 At assembling,
this distance
should be 13mm (0.512in).
3) Remove plate (B5), seal (B4). Fig. 33-86 Removing seal (B4)
33-50
33. UPPER STRUCTURE
: 19 mm % &#
(See 11.7 SPECIAL TOOLS No.9 Plug)
# $
! "#
33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Piping tightening torque
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
33-51
33. UPPER STRUCTURE
33.1.21.2 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.
(2) Marking match marks on swing bearing
Put match marks on upper frame and swing
bearing.
: 36 mm
(4) Slinging upper frame
Sling according to Fig. 33-88, and remove upper
frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)
33-52
33. UPPER STRUCTURE
33.1.21.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (11)
and a washer (12) temporarily.
33-53
33. UPPER STRUCTURE
983 531
981 . 534
548 792
702
B 532
732 X
789 Z
535 W
886 Y
953 A
806
728
468
113
127
123
127
824 271
325 808
717
04 490 954 546901
251 312
725
401 407 490
C
124
727 886
314
717 D
141 546
157 E
156
151 153 885 727
. 886
152 467
B 725
211 466
214 406
212 261 D
774 E
710
F
A
116
724 710
717
313 326
124 F 414 05
111
C
885
Fig. 33-93 Structural exploded view of main pump
33-54
33. UPPER STRUCTURE
33-55
33. UPPER STRUCTURE
434
311
312
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25 lbf.ft)
Fig. 33-94
33-56
33. UPPER STRUCTURE
: 19 mm, 36 mm
: 6 mm, 8 mm
: 6 mm
: 17 mm
Fig. 33-95 Remove socket bolt (401)
33-57
33. UPPER STRUCTURE
33-58
33. UPPER STRUCTURE
33-59
33. UPPER STRUCTURE
312
• The valve plate may come off during the
operation under 7).
314
(313 :
Opposite Side)
33-60
33. UPPER STRUCTURE
33-61
33. UPPER STRUCTURE
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251).
251
111
: 6 mm $
Tightening torque : 29 N•m (22 lbf•ft)
"$
• Coat the oil seal in seal cover (F) with a thin
film of grease.
• Handle the oil seal with sufficient care so it is
not scored.
312
• Do not mistake the suction and delivery sides
of the valve plate.
314
(313 :
Opposite Side)
33-62
33. UPPER STRUCTURE
: 17 mm
Tightening torque ; 430 N•m (320 lbf•ft)
: 6 mm
Tightening torque ; 17 N•m (12.5 lbf•ft)
: 6 mm,
Tightening torque ; 29 N•m (21 lbf•ft)
Socket bolt (414) …… PTO Cover (326)
: 8 mm,
Fig. 33-111 Installing regulator and PTO cover
Tightening torque ; 57 N•m (42 lbf•ft)
: 19 mm, 36 mm
Tightening torque ; 36 N•m (27 lbf•ft)
Tightening torque ; 170 N•m (125 lbf•ft)
33-63
33. UPPER STRUCTURE
mm (in)
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.043 0.070
bore Replace piston or cylinder.
(0.0017 ) (0.0028 )
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.3
Replace piston shoe assy.
(0.004 ) (0.012 )
( )
Thickness of shoe 5.4 5.0
Replace piston shoe assy.
(t) (0.213 ) (0.197 )
Free height of cylinder spring 47.9 47.1
Replace cylinder spring.
(L) (1.886 ) (1.854 )
Combined height of retainer plate and
23.8 22.8 Replace a set of spherical bushing or
spherical bushing
(0.937 ) (0.898 ) retainer plate.
(H-h)
Cylinder over pin dia. (spline in cylinder) 35.17 35.57
Replace cylinder, spherical bushing.
spline in spherical bushing. (1.385 ) (1.400 )
33-64
33. UPPER STRUCTURE
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
2) Pump’s oil flow rate is extremely low and delivery pressure is not available.
33-65
33. UPPER STRUCTURE
33-66
33. UPPER STRUCTURE
33-67
33. UPPER STRUCTURE
33.2.1.2 REGULATOR
626
625
624
753
627
623
621 D 728
B 645
611
622 F
733 874 646
613
732 875 644
631 612
898 875
652
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 757
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F
A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755
641
33-68
33. UPPER STRUCTURE
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
33-69
33. UPPER STRUCTURE
: 5 mm
630 924
Fig. 33-114 Removing cover (C) (629)
33-70
33. UPPER STRUCTURE
: 5 mm
439
641
33-71
33. UPPER STRUCTURE
$"
$!&%#
$
Fig. 33-122 Removing feedback lever (611) [2]
33-72
33. UPPER STRUCTURE
"$$
$"
Fig. 33-124 Part of exploded view of regulator
33-73
33. UPPER STRUCTURE
• Make sure that the spool and the sleeve (652) SPOOL FEEDBACKLEVER(611
move smoothly in the casing.
• Beware of the direction of the spool. Fig. 33-126 Direction of the spool (652)
33-74
33. UPPER STRUCTURE
33-75
33. UPPER STRUCTURE
: 5 mm
Tightening torque ; 12 N•m (8.7 lbf•ft) $ $
Fig. 33-132 Assembling compensating parts
11) Installing spool and spring
"$$
Assemble spool (642) and spring (662) into pilot
cover (641), and tighten VP plugs (466).
$$
$"
"$$
$"
Fig. 33-133 Assembling spool (642)
12) Assembling into the pilot hole and the 644,645,646
compensating hole 626
(See Fig. 33-112 (E),(D) section)
Put spring seat (644), pilot spring (646) and 625(624)
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.
: 5 mm 624,625,626
Tightening torque ; 12 N•m (8.7 lbf•ft) 627
801
14) Installing block cover (See Fig. 33-113) 629( 628 )
Attach block cover (656).
: 5 mm
630 924
Tightening torque ; 12 N•m (8.7 lbf•ft)
Fig. 33-135 Installing cover (C) (629)
This completes assembly.
33-76
33. UPPER STRUCTURE
414
117 128
216 435
826 886 711
128 326
414
115
886 262
728
885 125 468
118
125
825
710 435
435
414
262
414
33-77
33. UPPER STRUCTURE
: 27 mm
• Drain out the oil from the plugs of the front
pump and the rear pump.
4) Remove cover FLANGE SOCKET (M10)
Remove the socket bolts (414). Then remove the Tightening torque : 33N.m (25 lbf.ft)}
cover (262).
: 8 mm
5) Remove PTO gear casing 414
Remove flange socket (435) and PTO gear
casing.
: 8 mm
262 COVER
PTO GEAR CASING
414
262 COVER
Fig. 33-136 Removing gear pump
PTO
GEAR CASING
33-78
33. UPPER STRUCTURE
6) Removing the 2nd gear, the roller bearing and HOLE FOR
the bearing spacer IDLE SHAFT (115)
Draw out the spring pin (885) and remove idle
shaft (115). Then draw out 2nd gear (117), roller
bearing (126) and bearing spacer (128). 117 (126,128)
• Roller bearing (126) can not be separated
from 2nd gear (117).
118
33-79
33. UPPER STRUCTURE
T2 T1
PAL PBL
PB1 PCa
PBs PAs
Pss
PBa1 PAa1
PAo PBo
(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102
973 973
PTb PCb
973
973
PBr PAr
973
PAb PBb
974 973
PAa2 PBa2
974
(P3)
162 162 169 155 163 162
SECTION B-B
33-80
33. UPPER STRUCTURE
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
D 978x2 D
PBs
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PA
PAo
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
33-81
33. UPPER STRUCTURE
$!#-
Fig. 33-142 Section (3/6)
33-82
33. UPPER STRUCTURE
Swing 204
203 PBs
333 Boom
PBb Pss
333
331
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb
Bs 162
161
301
264 266
264
266
BbR 160 PAs 206
602 PAb
559 SECTION E-E
560 164 551
Bucket
208
209
PCc
216 201
333 Arm 1 333
331 PBa1
PBc
331
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Fig. 33-143 Section (4/6)
33-83
33. UPPER STRUCTURE
201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao
521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205
205
SECTION G-G
T2
161
P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164
SECTION H-H
33-84
33. UPPER STRUCTURE
PBp1 PBp2
207
160 606 606
278x5 266
264 264
SECTION J-J
SECTION K-K
33-85
33. UPPER STRUCTURE
33-86
33. UPPER STRUCTURE
33.2.2.3 DISASSEMBLY
The figures in parentheses after part names in this
manual represent those item numbers in the structural
sectional drawing under Fig. 33-140 to Fig. 33-145.
(1) Place the control valve on a work bench so as to
locate back pressure check valve upwards.
33-87
33. UPPER STRUCTURE
33-88
33. UPPER STRUCTURE
33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove the
spring cover (201) and the O-ring (261) for travel.
33-89
33. UPPER STRUCTURE
(3) Fix the boom conflux spool with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (325),
(326) and stopper (339) from boom conflux spool
(305).
(2) Draw out the assy of boom spool (301), spring seat
(331), springs (321), (322), stopper (336) and bolt
(333) from casing B (102).
33-90
33. UPPER STRUCTURE
(3) Fix the boom spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from boom spool (301). Do
not disassemble boom spool (301) further unless
there is special reason.
(2) Draw out the assy of swing spool (303), spring seat
(331), springs (321), (322), stopper (336) and bolt
(333) from casing A (101).
(3) Fix the swing spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from swing spool (303).
33-91
33. UPPER STRUCTURE
33-92
33. UPPER STRUCTURE
(3) Fix the arm 1 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 322)
and stopper (336) from arm 1 spool (302).
(3) Fix the arm 2 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 328)
and stopper (340) from arm 2 spool (308). Do not
disassemble arm 2 spool (308) further unless there
is special reason.
33-93
33. UPPER STRUCTURE
(3) Fix the option spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (323, 324)
and stopper (336) from option spool (311).
(3) Fix the travel straight spool assy with vise via a
protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs
(327, 329) and stopper (336) from travel straight
spool (307).
33-94
33. UPPER STRUCTURE
(2) Swing
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264), (266). Do not disassemble
spool cover (206) further unless there is special
reason.
(3) Boom
Loosen socket bolts (273) and remove spool cover Fig. 33-172 Removing spool cover (205),(206)
(206) and O-ring (264). Do not disassemble spool
cover (208) further unless there is special reason.
33-95
33. UPPER STRUCTURE
33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and overload
relief valve (602), (603) and plug assy (604) from
the casing.
33-96
33. UPPER STRUCTURE
33-97
33. UPPER STRUCTURE
33-98
33. UPPER STRUCTURE
The plug and spring in use differ from the above (1). Do
not mix the parts when assembling parts again.
(3) Load check valve on arm 2 section Fig. 33-181 Removing plug (551),(556),(552)
Remove plug (551) and then remove poppet (515)
and spring (521).
The poppet in use differs from the above (1). Do not mix
the parts when assembling parts again.
33-99
33. UPPER STRUCTURE
Take care not leave lapping compound behind in the casing or block.
4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are
free from foreign matter.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.
33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural
sectional drawing. (Fig. 33-140 to Fig. 33-145)
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after
installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards."
33-100
33. UPPER STRUCTURE
Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar
in shape.
Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve.
33-101
33. UPPER STRUCTURE
33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (603) and relief valve hole plug assembly (604) in
respective place to the specified torque.
Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief
valves (602), (603) are similar in shape.
Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten
socket bolt (273) to the specified torque.
(2) Place travel straight spool assembly in item (1) in casing B (102).
Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and
tighten socket bolt (273) to the specified torque.
33-102
33. UPPER STRUCTURE
Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten
socket bolt (273) to the specified torque.
(2) Place arm 2 spool assembly in option in item (1) in casing B (102).
Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
socket bolt (273) to the specified torque.
Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten
socket bolt (273) to the specified torque.
33-103
33. UPPER STRUCTURE
Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and tighten
socket bolt (273) to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.
Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and
tighten socket bolt (273) to the specified torque.
33-104
33. UPPER STRUCTURE
Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and
tighten socket bolt (273) to the specified torque.
(2) Place boom conflux spool assembly in item (1) in casing A (101).
Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and
tighten socket bolt (273) to the specified torque.
(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).
Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
socket bolt (273) to the specified torque.
33-105
33. UPPER STRUCTURE
Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten
socket bolt (273) to the specified torque.
33-106
33. UPPER STRUCTURE
33-107
33. UPPER STRUCTURE
33.2.2.6 TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main
pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure,
load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and
reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system
is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
2. Machine does not 1) Malfunctioning travel straight valve. 1) Check pilot pressure.
move straight during • Sticking spool. • Correct sticking part with oil stone.
simultaneous
• Replace spring.
operation of travel
• Broken or deformed spring. • Remove foreign matter.
and attachment.
• Clogged small hole in spool.
2) Malfunctioning main relief valve. 2) Remove main relief valve.
33-108
33. UPPER STRUCTURE
33-109
33. UPPER STRUCTURE
33-110
33. UPPER STRUCTURE
312
302
Apply grease on
501 rotating and
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc
PORT PORT
2,4 1,3
Fig. 33-183 Pilot valve (For ATT)
Apply loctite #277 to areas marked
33-111
33. UPPER STRUCTURE
33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
302
33-112
33. UPPER STRUCTURE
: 24mm
301
33-113
33. UPPER STRUCTURE
211
101
217
201-1
201-2
212
211
33-114
33. UPPER STRUCTURE
212
213
33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2
217
33-115
33. UPPER STRUCTURE
221
214 213
PLUG (211)
SEAL (213)
-RING (214)
PUSH ROD
(212) Apply hydraulic oil
(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.
33-116
33. UPPER STRUCTURE
101 211
151
101
A
33-117
33. UPPER STRUCTURE
: 22mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 68.6 N•m (51 lbf•ft)
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE
301
212
33-118
33. UPPER STRUCTURE
33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.
33-119
33. UPPER STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
29 (1.14") (1)
Material ; SCM415 (N)
26.5 (1.04") Carburizing and Quenching
(2) BUSHING
23.5 (0.925")
Material ; S45C
(0.512")
13
19 (0.748") SECTION AA
69 (2.72")
54 (2.13")
50 (1.97")
46 (1.81")
25 (0.984")
A A
(0.669")
17
23 (0.906")
27 (1.06")
31 (1.22")
16
(1.63") * (1) and (2) are tight fitted
)
12"
(0.5 3
R1
(0 R5
12.5 (0.492")
.2 .8
28 R
") (0. 4.5 C0.5
17
7") (0.02")
(0.374")
9.5
C0.5
(0.02")
33-120
33. UPPER STRUCTURE
33.2.4.1 CONSTRUCTION
T=Tightening torgue
N.m (lbf.ft) 12-o
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3 (2.2)
g
14
T=5 (3.7) q 11
r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3-5 (2.2~3.7)
33-121
33. UPPER STRUCTURE
Fig. 33-209
(2) Switch plate removal
1) Remove :
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-210 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the
locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)
* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-210 No.3)
4) Mark out the position of the switch plate before
removing it.
Fig. 33-210
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.
33-122
33. UPPER STRUCTURE
Fig. 33-213
33-123
33. UPPER STRUCTURE
Fig. 33-214
(5) Damping plunger seals replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots. (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-215 No.1) Fig. 33-215
* Reassembly :
• Replace with a new wiper ring.
Always place the damping plunger prior to the wiper
ring, and make sure the wiper ring is correctly
positionned.
Fig. 33-216
4) Using a needle, remove the seal placed inside
the body (See Fig. 33-217 No.3, 4)
* Reassembly :
• Replace with a new seal and grease it.
3 4
Fig. 33-217
33-124
33. UPPER STRUCTURE
Fig. 33-219
33-125
33. UPPER STRUCTURE
Fig. 33-220
• Inspect the return springs. If defects are
detected, replace the 4 springs.
Fig. 33-221
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))
Fig. 33-222
33-126
33. UPPER STRUCTURE
THROTTLE
Fig. 33-223
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
Fig. 33-225
33-127
33. UPPER STRUCTURE
Fig. 33-227
(9) Check valve kit removal
1) Remove the pilot control unit from the machine
CHECK VALVE
PLUG
BALL
Fig. 33-229
33-128
33. UPPER STRUCTURE
Fig. 33-230
33-129
33. UPPER STRUCTURE
33.2.5.1 CONSTRUCTION
(1) Swing motor
702 712
351
401
488 469
051-1 051
100
151
162 052 161 171
303 984
A A 163 985 391 390 444
131
451
472 400-1
400-2
712 400 052
706
986
742
743
994
111
491 101
121 123 122 124 114 301 443
33-130
33. UPPER STRUCTURE
Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N•m (lbf•ft) N•m (lbf•ft)
177 (130) 051 Relief valve ; M33-P1.5 2 391 Rivet 2
051-1 O-ring ; 1B G30 2 69 (51) 400 Anti-reaction valve ; M22-P1.5 2
052 Anti-reaction valve sub 1 400-1 O-ring ; 1B P20 2
100 Casing for anti-reaction valve 1 400-2 Backup ring 2
101 Drive shaft 1 431 (320) 401 Socket bolt ; M20×45 4
111 Cylinder 1 443 Roller bearing 1
114 Spring plate 1 444 Roller bearing 1
121 Piston 9 451 Pin 2
122 Shoe 9 539 (398) 469 ROMH plug ; M36-P1.5 2
123 Set plate 1 472 O-ring 1
124 Shoe plate 1 488 O-ring ; 1B P34 2
131 Valve plate 1 491 Oil seal 1
36 (27) 151 Plug ; PF1/4 2 702 Brake piston 1
161 O-ring ; 1B P11 2 706 O-ring 1
162 O-ring ; 1B P12 2 707 O-ring 1
163 O-ring ; 1B P6 2 712 Brake spring 14
29 (22) 171 Socket bolt ; M8×55 4 742 Friction plate 3
301 Casing 1 743 Separator plate 4
303 Valve casing 1 2.7 (2.0) 984 Plug ; PF1/2 1
351 Plunger 2 5.6 (4.1) 985 Plug ; PF1 1
355 Spring 2 0.9 (0.65) 986 Plug ; PF1/4 1
390 Name plate 1 98 (72) 994 Plug ; PT3/4 1
33-131
33. UPPER STRUCTURE
34
22 11 27 25 24 3
4
SURFACE
5 OF LUBE OIL
10 3
23 6 20 35
7 8 3 VIEW
11 15
26 12
9 17 30 36, 37, 38, 39
14 31
3
28
29 18
33 32
13
21 19 16
2
1
DETAIL aa
aa
33-132
33. UPPER STRUCTURE
33.2.5.2.1 TOOLS
Tools Remarks
Relief valve M33×P1.5 41mm
Socket wrench
Anti-reaction valvevalve M22×P1.5 24mm
M8, M20 6,10,12,17mm
Allen wrench ROMH PLUG M36×P1.5 17mm
ROH PLUG PF1/4, PF1/2, PF1 6mm, 8mm, 14mm
Screwdriver Flat-bladed type, medium size 2 pcs.
10×8×200(0.39"×0.31"×7.87")
Steel bar
(key material) 1 pc.
Hammer Plastic hammer 1 pc.
10~45 (7.2~33)
Torque wrench N•m (lbf•ft) 40~180 (29~130)
120~480 (87~350)
Slide hammer bearing puller
14 (0.551")
85 (3.35")
75 (2.95")
30 (1.18")
15 (0.591")
35 (1.38")
5
2. 2")
R1 .49
M16 (0
Through
Brake piston drawing tool
100 (3.94")
44 (1.73")
8 (0.315")
M16
4
(0.158")
BRAKE PISTON
DRAWING TOOL
CASING
33-133
33. UPPER 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 do not 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 can not be supplied as single parts
and available only in sub assy. 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.
702
• 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 have
dents.
101 301
Fig. 33-233 Removing valve casing (303)
33-134
33. UPPER STRUCTURE
: 41 mm
!##
!!
4) Loosen anti-reaction valve sub assy (052) and
remove from valve casing (303). (See Fig. 33-
233)
"$'
: 6 mm
: 17 mm
33-135
33. UPPER STRUCTURE
33-136
33. UPPER STRUCTURE
33.2.5.2.3 ASSEMBLY
(1) General precautions
1) Repair those parts damaged after disassembly
and prepare replacement parts beforehands.
2) Clean all parts thoroughly in cleaning oil and dry
them with jet air.
3) Always coat the moving parts with clean
hydraulic oil, before assembly.
4) Replace such seals as O-ring and oil seal in
principle.
5) Tighten socket bolts and plugs to specified
torques, using a torque wrench.
444
3) Shrinkage fit the inner race of roller bearing (444)
to drive shaft (101). Fig. 33-239 Assembling the inner race of bearings
(443), (444)
• This operation is necessary only when the oil
seal is removed.
Fit oil seal (491) to casing (301). On that
occasion, coat the lip of the oil seal with
grease and check the direction of it, before
fixing it.
443 491
101 301
Fig. 33-240 Fitting oil seal (491), outer race of
roller bearing (443), and drive shaft (101)
33-137
33. UPPER STRUCTURE
443 301
101
Fig. 33-242 Inserting cylinder assy
9) Replace casing (301) with oil seal (491) facing
downward and assemble separator plate (743) 743
and friction plate (742) into casing (301), in that
order. 742
Assemble four separator plates and three friction
plates.
491 301
PG PORT
Fig. 33-243 Installing of separator plate (743),
friction plate (742).
33-138
33. UPPER STRUCTURE
: 17 mm,
Tightening torque : 431 N•m (320 lbf•ft)
: 17 mm,
Tightening torque : 539 N•m (398 lbf•ft)
: 41 mm,
Tightening torque : 177 N•m (130 lbf•ft)
: 6 mm,
Tightening torque : 29 N•m (22 lbf•ft)
33-139
33. UPPER STRUCTURE
33.2.5.3.1 TOOLS
230 (11.8")
a Stand
130 (5.1")
removing jig
190 (7.48")
(0.354")
Material : Mild steel
Oil seal (16) 162 (6.38")
d
9
installing jig
installing jig
(2.36")
33-140
33. UPPER STRUCTURE
33.2.5.3.2 DISASSEMBLY
The numbers in parentheses correspond to the ones in
construction drawings Fig. 33-231.
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain tube.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the joining parts of the housing
before disassembly.
MATCHING
2) Removing swing motor assy MARK
Loosen all socket bolt (27) (M20). Attach eye
bolts (M12) in the lifting bolt holes in the top
surface of the swing motor and lift the assy by
crane.
If it is hard to remove the swing motor assy from
the reduction unit, float it by inserting a flat-blade Fig. 33-245 Removing swing motor assy
screwdriver in the groove of the flange.
5
: 17 mm 3
33-141
33. UPPER STRUCTURE
: 24mm
• When oil seal (16) is separated from housing
(15), oil seal (16) and is pinion (1) are 15
removed together.
Fig. 33-250
33-142
33. UPPER STRUCTURE
JIG (a)
18
13
33-143
33. UPPER STRUCTURE
15
JIG (c)
Fig. 33-254 Removing spherical bearing
(upper) (12) and oil seal (14)
(4) Disassembling spider assy
25 11 22
1) Disassembling #1 spider assy 4
1. Remove retaining ring (25) with a plier (i).
22 5
2. Remove thrust washers (22), pinion (4) needle
bearing (11).
26
Fig. 33-256 Disassembling #2 spider assy
Pinions (7) can not be replaced singly. Replace them it
in a set of four.
33-144
33. UPPER STRUCTURE
33.2.5.3.3 ASSEMBLY
(1) Preparation
1) Sufficiently clean every part with wash oil and dry
it with compressed air.
33-145
33. UPPER STRUCTURE
15
33-146
33. UPPER STRUCTURE
: 24mm
Tightening torque : 279N•m (206 lbf•ft)
(Apply Three Bond #1360K)
• To prevent the loosing of capscrew (34) tie up the
! "#
capscrew with wire (35) as shown in right figure. $
%& '
Fig. 33-262 Installing pinion (1)
5) Set housing assy so that the pinion directs
JIG (f)
downward.
Fig. 33-263
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.
33-147
33. UPPER STRUCTURE
i
Fix the snap ring with the sharp edge on the motor side
(top side in the position of Fig. 33-266).
25 4
Insert shaft (10) into spider (9) so spring pin hole (26) is
aligned.
11
Inthis case direct the oil hole of shaft (10) to outside of
spider assembly. 23
26
Fig. 33-267 Assembling #2 spider assy
(5) Installing #2 spider assy
#2 SPIDER ASSY
Insert #2 spider assy in spline axis of shaft (2).
33-148
33. UPPER STRUCTURE
Align
maching
marks.
15
: 10 mm
15
(10)Filling Lube Oil
Fill in 7.4L (2.0gal) of gear oil SAE90 (API Service Fig. 33-271 Installing #1 spider assy
Grade GL-4).
33-149
33. UPPER STRUCTURE
Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (in)
mm (in)
Clearance between piston and
cylinder bore
(D-d)
0.032 0.062
Replace piston or cylinder.
(0.0013) (0.0024)
@ ,
0.3
0 Replace piston and shoe assy.
(0.0112)
6.0 5.8
Replace piston and shoe assy.
(0.236) (0.228)
J
4.0 3.6
Replace.
J (0.157) (0.142)
33-150
33. UPPER STRUCTURE
33-151
33. UPPER STRUCTURE
2) Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
3) Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing
33-152
33. UPPER STRUCTURE
Unit : mm (in)
Code Item Repairable level Service Limit Remedy
A Wear in #1 planetary shaft ø43
0
1.693" -0.0004" Replace entire spider assy.
No flaking
B Wear in #2 planetary shaft ø29
0
1.693" -0.0004" Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
D Thickness of thrust washer +0.1 +0.0039"
1.4 0.0551" Replace
1.6 -0.1 0.063" - 0.0039"
Wear in shaft
0
F (Diameter of part coming in contact ø150 -0.100 0
5.91" -0.0004" ø149.9 5.90" Replace
with oil seal )
Apply Three-Bond 1360K and
G Socket bolt tightening torque M20— 539 N•m (398 lbf•ft)
tighten to specified torque.
Gear oil SAE90
H Lube oil 7.4 L (2.0 gal) Replenish or replace.
(API Service Grade GL-4)
33-153
33. UPPER STRUCTURE
33.2.5.5 TROUBLESHOOTING
33-154
33. UPPER STRUCTURE
33-155
33. UPPER STRUCTURE
)(
"#
$
#
$% #
$
*(
!
33-156
33. UPPER STRUCTURE
2 places
VIEW Y
5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
33-157
33. UPPER STRUCTURE
33.2.6.2.1 Tools
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33-158
33. UPPER STRUCTURE
33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure 2
correspond to those of a construction drawing in Fig. 1
33-273. 4
9
(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
ALLEN WRENCH
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2) V-BLOCK PIPE
in a vise.
"
: 6 mm
33-159
33. UPPER STRUCTURE
O-RING
GROOVE
OIL GROOVE
SEAL (5) SEAL GROOVE
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on
seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (13) thinly and insert
it in O-ring groove.
Check the twist of O-ring
33-160
33. UPPER STRUCTURE
WORK BENCH
: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)
33-161
33. UPPER STRUCTURE
ALLEN WRENCH
PIPE
33-162
33. UPPER STRUCTURE
33-163
33. UPPER STRUCTURE
Replace
(With back-up ring)
Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)
33-164
33. UPPER STRUCTURE
Open stop valve (6) on the side of low pressure
relief valve (5) and while watching the pressure
!
gauge (for low pressure) connected to the body
" ! "
*
side and also by regulating low pressure relief valve
+%,- .
/
(5), gradually increase the pressure and check for
outside leakage with a color check at a pressure of !
!
$ %
33.2.6.3.4 Troubleshooting
33-165
33. UPPER STRUCTURE
[MEMO]
33-166
34. TRAVEL SYSTEM
TABLE OF CONTENTS
34-1
34. TRAVEL SYSTEM
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of Part I. Removing and installing assy, and Part II. Disassembling and assembling.
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
34-2
34. TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD
LOWER FRAME
GREASE NIPPLE OF 3. UPPER ROLLER
THE TRACK SPRING
ADJUSTER 4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage
34.1.2 CRAWLER
: 19 mm
34-3
34. TRAVEL SYSTEM
34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the
figure on the right.
34-4
34. TRAVEL SYSTEM
: 19 mm
34.1.2.3 CONSTRUCTION
1-3
1-8 1
1-1
1-7 7
1-4
1-2 3,4,5
1-6
1-5
1-9 1-10
1-11 6
Fig. 34-9 Track link assy & shoe plate
SK330-8 SK350LC-8
SHOE LC60D00010F3 SHOE LC60D00011F3
ASSY LC60D00010F1 ASSY LC60D00011F1
No. NAME Q'ty No. NAME Q'ty
1 •Link assy LC62D00004F1 1 1 2 •Link assy LC62D00004F2 1 1
1–1 ••Track link R 43 43 2–1 ••Track link R 46 46
1–2 ••Track link L 43 43 2–2 ••Track link L 46 46
1–3 ••Master link R 2 2 2–3 ••Master link R 2 2
1–4 ••Master link L 2 2 2–4 ••Master link L 2 2
1–5 ••Bushing 43 43 2–5 ••Bushing 46 46
1–6 ••Pin 43 43 2–6 ••Pin 46 46
1–7 ••Master bushing 2 2 2–7 ••Master bushing 2 2
1–8 ••Master pin 2 2 2–8 ••Master pin 2 2
1–9 ••Collar 4 4 2–9 ••Collar 4 4
1–10 ••Seal 86 86 2–10 ••Seal 92 92
1–11 ••Pin 2 2 2–11 ••Pin 2 2
3 •Shoe 600mm 45 — 3 •Shoe 600mm 48 —
5 •Shoe 800mm — 45 5 •Shoe 800mm — 48
6 •Bolt LC60D01001P1 180 180 6 •Bolt LC60D01001P1 192 192
7 •Nut 2420Z1414 180 180 7 •Nut 2420Z1414 192 192
34-5
34. TRAVEL SYSTEM
E F
G D D
B
C
H
Fig. 34-10
Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
215.9±0.15 220 224
A Link pitch Replace the link
(8.5000±0.0059) (8.66) (8.82)
assy if the service
B O.D. of bushing ø 68.0 (2.6772
+0.0020
0 ) ø 64 (2.52) ø 63 (2.48)
limit is exceeded
C Height of link 124±0.25 (4.8819±0.0098) 118 (4.65) 116 (4.57)
Basic
Tolerance Fit Fit
dimension
Interference between bushing
D + 0.05 Interference
and link ø 68.0 Interference
Shaft
(+0.0020) 0.05
(2.6772) 0 Replace
0 (0.0020)
+ 0.05 Interference
Interference between track pin ø 46.0 Interference
Shaft
E (+0.0020) 0.05
and link (1.8110) 0
0 (0.0020)
+ 0.05 Interference
Interference between master ø 45.63 Interference
Shaft
Unit : mm
Name Opposing flats
19, 32
Socket
(2) Jig
Name Shape
34-6
34. TRAVEL SYSTEM
34.1.3.2 REMOVING
(1) Preparation for removal " ! !
Remove crawler (Above mentioned).
: 30 mm
34.1.3.3 INSTALLING
Installing is done in the reverse order of removing. Center of machine
(1) Inspection
Before reassembling, check it that it rotates smooth
manually and for leakage.
3,4
1
(2) Installing upper roller (1)
1) To install the upper roller, turn up nut (4) toward
the center of machine.
2,3
2) Insert it until collar comes in contact with support.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
34-7
34. TRAVEL SYSTEM
34.1.3.4 CONSTRUCTION
11 8 6
: 10mm
2
13
6) Removing shaft (2)
Put the extrusion jig (h) against the end face of 3
shaft (2) and push shaft (2) with collar (3) for
floating seal (13), using a press or hammer.
f
34-8
34. TRAVEL SYSTEM
(2) Assembly
Assembly of the upper roller is done in the reverse
1
order of disassembly.
1) Place upper roller (1) on the top end face of jig f
(f), with its floating seal setting side facing down.
3) Put jig (i) into bushing (6) and press it in, using 13
13
the bore of the bushing and the bore of the roller
as guides. 3 1
34-9
34. TRAVEL SYSTEM
34-10
34. TRAVEL SYSTEM
C
D D
F
J H
Unit : mm (in)
No. Item Standard value Service limit Remedy
A Dia. ø 185 (7.28) ø 175 (6.89)
Reinforcement
B Tread dia. ø 160 (6.30) ø 150 (5.91)
weld, repair or
C Width 95 (3.74) 85 (3.35)
replace
D Flange width 19 (0.748) 15 (0.591)
Basic
Tolerance Standard Limit
dimension
Clearance between shaft and -0.025
E
bushing ø 65 (-0.0010) Clearance Clearance
Shaft
F (+0.0012)
and bushing (2.7559) — 0
0
Tightening torque of socket
H 114.7 N•m (85 lbf•ft) Apply loctite #262
bolt
J Oil Engine oil API grade CD #30, 100cc (6.1cu•in) Refill or replace
Roller rotation Roller rotates smoothly by hand.
34-11
34. TRAVEL SYSTEM
Unit : mm
Name Opposing flats
30
Socket
(2) Jigs
Unit : mm (in)
No. Name Shape
160 (6.30")
120 (4.72") 200 (7.87")
f Stand jig
50 (1.97")
For extruding
h
(1.18")
shaft
(1.953" +0.004" )
+0.1
0
0
69.5
(2.74")
64.6
Bushing fixing
i
jig
20 65 (2.56")
(0.787")
85
(3.35")
34-12
34. TRAVEL SYSTEM
" 1
! # 2 Apply loctite #262
T=731N.m (540 lbf.ft)
34.1.4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wooden) at the front and
back of the lower frame. SAFETY BLOCK
(SQUARE
TIMBERS)
(2) Removing track guide (See Fig. 34-25)
Remove capscrews (8) M24×52 and remove track Fig. 34-24 Preparation for removal
guide (5).
: 36mm
Weight of track guide : Approx. 40kg (88 lb)
9 2 5 9
8 SK330-8 8
(3) Remove lower roller
Remove capscrews (2) and remove lower roller (1).
: 32 mm
9 2 5 9
Weight of lower roller : Approx. 57kg (126 lb) 8 SK350LC-8 8
34.1.4.3 INSTALLATION
(1) Installation of lower roller
Lower SK330-8 STD LC01F00019F1
Coat mounting capscrews (2) with Loctite #262 and
group SK350LC-8 LC LC01F00017F1
fasten all four capscrews temporarily. Then tighten
them to a specified torque. No. Name Q'ty
2 Track guide LC63D00004P1 2 2
: 32 mm 5 Capscrew ; M24 X 52 8 8
Tightening torque : 731N•m (540 lbf•ft) 8 Capscrew ; M24 X 35 16 16
(2) Installation of track guide 9 Washer 16 16
Capscrews (8) with Loctite #262 and fasten all four
capscrews temporarily. Then tighten them to a
specified torque.
: 36 mm
Tightening torque : 932N•m (690 lbf•ft)
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
34-13
34. TRAVEL SYSTEM
34.1.4.4 CONSTRUCTION
4 1 6 7 5 2 8
: 6mm 2
34-14
34. TRAVEL SYSTEM
34-15
34. TRAVEL SYSTEM
(2) Installing 7 3
1) Attach O-ring (7) to one side
Install O-ring (7) to groove on shaft.
• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-32 Attach O-ring (7) to one side
reassembling.
34-16
34. TRAVEL SYSTEM
• Grease O-ring.
• Replace O-ring with new one without fail at 2
reassembling. PIN HOLE
7
: 6 mm,
Tightening torque : 23 N•m (17 lbf•ft) Fig. 34-37 Installing filling oil plug (8)
34-17
34. TRAVEL SYSTEM
C C
G
A
E
B
Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
A O.D. of flange ø 216 (8.50) — — Reinforcementwel
B Tread dia. ø 175 (6.89) ø 160 (6.30) ø 154 (6.06) d, repair or replace
C Flange width 27 (1.06) — —
Basic
Tolerance Fit Fit
dimension
Clearance between shaft
-0.060
D and bushing
ø 75 (-0.0024) Clearance Clearance Replace bushing.
Shaft
(Wrapped bushing)
(2.9528) -0.090 0.7 (0.276) 1.0 (0.394)
(-0.0035)
Interference between ø 83 ±0.030 Interference Clearance
Hole
E
roller and bushing (3.2677) (±0.0012) 0.01 (0.0004) 0
F Oil Engine oil API grade CD #30, 430cc (26.14cu•in) Refill
Execute air leak test at 0.2MPa (28psi) before tightening the
G Plug (8)
plug.
Roller rotation Rotates smoothly by hand. Reassembly
34-18
34. TRAVEL SYSTEM
Unit : mm
Name Opposing flats
19, 32, 36
Socket
Allen wrench 6
(2) Jig
Unit : mm (in)
No. Name Shape
150 (5.91")
Pin (5)
L
extrusion rod
16 (0.630")
300 (11.8")
Bushing
N
extrusion rod
400 (15.7")
150 (5.91")
175 (6.89")
M Stand jig
400 (15.7")
P Shaft extrusion jig
(2.91")
74
104 (4.09")
(1.18")
30
100 (3.94")
70 (2.76")
74.6 +0.1
0
(2.94" +0.004
0 )
34-19
34. TRAVEL SYSTEM
Apply loctite #262 or equivalent
T=540N.m (400 lbf.ft)
1
3 2
!
&
"# $ ' (
%
""
34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
(3) Installing
Installing is done in the reverse order of removing.
square timbers.
34-20
34. TRAVEL SYSTEM
34.1.5.3.1 CONSTRUCTION
'$%
4 VIEW I
$%& 1
()$%& * +
'#& ',-
: 5 mm
U
2
34-21
34. TRAVEL SYSTEM
34-22
34. TRAVEL SYSTEM
34-23
34. TRAVEL SYSTEM
204 (8.03")
C
D
A
B
Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
A Dia. Of idler projection ø 609 (24.0) — —
B Tread dia. ø 564 (22.2) ø 557 (21.9) ø 554 (21.8) Replace
C Flange width 102 (4.02) 96 (3.78) 94 (3.70)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and – 0.072
D
ø 85 (-0.0028) Clearance Clearance
Shaft
bushing
(3.3465) –0.126 1.5 (0.059) 2.0 (0.079)
Replace bushing.
(-0.0050)
+ 0.035
Interference
Interference between idler and ø 89 (+0.0014) Clearance
Hole
E 0.01
bushing (3.504) 0 0
(0.0004)
(0)
F Oil Engine oil API grade CD#30, 350cc (21.4cu•in) Refill
Idler rotation Rotates smoothly by hand. Reassemble
34-24
34. TRAVEL SYSTEM
Unit : mm
Name Opposing flats
30
Socket
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. Name Shape
18 (0.71")
(1.18")
30
R Pin striking jig
150 15
(5.91") (0.591")
400 (15.7")
(3.31")
350 (13.8")
U Stand
Applox
500 (20")
2 Piece
(0.71")
115 (4.53")
18
100 (3.94")
V
jig
+0.1
84.6 0
(3.33" +0.004
0 )
120 (4.72")
W Collar Press fitting jig
(1.18")
30
34-25
34. TRAVEL SYSTEM
34.1.5.4.1 CONSTRUCTION
C F
A, B
D
34-26
34. TRAVEL SYSTEM
34.1.6 SPROCKET
34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to Section 2. "Crawler",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize. (See 34.1.2,
CRAWLER)
:30 mm
1
3
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.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
34-27
34. TRAVEL SYSTEM
215.9mm
Pitch Number of teeth 21
(8.5in)
Specification
ø68mm
Roller dia. Pitch dia. 732.47 (28.8in)
(2.68in)
C
A
Fig. 34-56 Sprocket
Unit : mm (in)
No. Name Standard value Repairable level Service limit Remedy
Reinforcement weld,
A O.d. Of sprocket ø 755 (29.7) ø 747 (29.4) ø 745 (29.3)
repair or replace.
B Width of sprocket teeth 85
0
(3.35 -0.157 ) 79 (3.11) 77 (3.03) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 664.05 (26.1) ø 656 (25.8) ø 654 (25.7)
repair or replace.
Unit : mm
Name Opposing flats
30
Socket
34-28
34. TRAVEL SYSTEM
34-29
34. TRAVEL SYSTEM
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 6
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 1
the inner pressure from the hydraulic circuit.
When you press the valve from above the gum cap
Fig. 34-59 Removing and installing cover (1)
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) M12×25 and also remove
cover (1).
: 19 mm
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Remove all pipes connecting to travel motor. Then
plug up all pipes and joint section to protect them
from entry of dust.
Fig. 34-60 Removing and installing hydraulic pipe
: 19mm, 27mm, 32mm, 41mm
Refer to hydraulic pipe plug 5-1 (Refer to LC11
Tools).
plug for flare hose 5-2 (3) (Refer to LC11 Tools)
34-30
34. TRAVEL SYSTEM
: 30 mm
6-3
: 36 mm
3
34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the
reverse order of removal.
1) Cleaning
Check that contact surface of travel motor and
$%& %. / 1+ /%
crawler frame is free from burr and stain. $&' .+&2.+ 3 4
+/ /.(2/. 5
+
6&/&
2) Tightening torque $&( ,+.2,'
+( / + +.12'(
Tighten capscrew and hydraulic pipes to the
torque specified in "Tightening Torque".
! )!%*' %. &.
' &%
0
" )!+*' +/ %%1 10
# +, ,
( ,, ''% +&,
3) Before pipng for draining, fill casing with
)!%*' %. +/ &/
/
hydraulic oil from drain port of motor.
)!%*&- &0- %(1 1(
At starts the machine, run the motor slowly at )!+*' +/ %/& %&(-
engine low idling for several minutes, and check )!% '% &,, %11
oil leakage and abnormal sound from motor.
34-31
34. TRAVEL SYSTEM
SECTION AA
Fig. 34-64 Swing bearing assy
34.1.8.2 REMOVING
(1) Matchmarks
SWING BEARING
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. OUTER RACE
INNER RACE
(2) Remove thirty six capscrews (2) M24×80 for
installation inner race. MATCHMARKS
: 36 mm
GREASE BATH
34-32
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 stain.
(2) Installing
Install swing bearing on lower frame meeting the Front
matchmarks and positioning the S mark on inner
race as shown in the Fig. 34-67.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.
: 36 mm
Inner S zone position
(4) Regular tightening of inner race of swing bearing
Tighten the capscrews (2) at 180 degrees intervals Fig. 34-67 Location of S mark on swing bearing
alternately to a specified torque.
: 36 mm 1
Tightening torque : 932 N•m (690 lbf•ft)
(5) Filling grease.
Fill grease bath with 28.7kg (63 lb) of grease 2 Apply Loctite #262 or equivalent
(NIHON GREASE CO.LTD EP-2K) or equivalent. T=932N.m (690 lbf.ft)
SECTION AA
Fig. 34-68 Removing and installing capscrew (2)
34.1.8.4 CONSTRUCTION
34-33
34. TRAVEL SYSTEM
"
!
To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into 4
plug hole.
SQUARE WOODEN BLOCK
4) Fit plug (8) to outer race (1) while checking it for
direction and position of taper pin hole. Fig. 34-73 Inserting retainer (4)
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 equivalent and fit it in the groove of outer
race (1).
6) 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 Alvania EP#2 240cc (14.64cu•in)
34-34
34. TRAVEL SYSTEM
34-35
34. TRAVEL SYSTEM
34-36
34. TRAVEL SYSTEM
34-37
34. TRAVEL SYSTEM
34.2.3.1 TOOLS
(2.76")
(0.79")
20
70
100 (3.94")
(1.46")
37
P.C.D. 251 (9.88")
o 280 (11.0")
o 215 (8.47")
o 195 (7.68")
(1.58")
(0.95")
o 40
o 24
2-M18X35 (1.38")
(0.26")
o 6.5
2 - 20 (0.79")
drill hole
20 (0.79")
100 (3.94")
25 (0.98") ")
0.08
R2(
In case of using Hex. socket
head bolt for mounting
100 (3.94")
(1.42")
8.2 (0.32")
.5 )
o 36
o 67.5 (2.66")
(0
o 90 (3.54")
3
(0.12")
Jig for inserting oil seal
Jig for inserting rear bearing
34-38
34. TRAVEL SYSTEM
34.2.3.2 DISASSEMBLY
a. GENERAL INSTRUCTIONS
(1) Generally, hydraulic equipment is precisely
manufactured and clearances between each parts
are very narrow.
Therefore, disassembling and assembling works
should be performed on the clean place where
dusts hardly 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 put the
plugs so that no dust and / or water may invade.
Take off these plugs just before the piping works
when re-attach 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 fall parts on your
foot while lifting them.
b. DISASSEMBLY PROCEDURES
(1) Removing accessory valves
Before disassembling motor, remove accessory
valves.
34-39
34. TRAVEL SYSTEM
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.
34-40
34. TRAVEL SYSTEM
: 14mm
Put the matching mark on both valve plate (54) and rear
cover (24) so that valve plate (54) should not be
reversed on re-assembling.
51
34-41
34. TRAVEL SYSTEM
34-42
34. TRAVEL SYSTEM
Be aware of shifter piston (6) popping out. Fig. 34-81 Enlargement figure of matching surface
of casing
16) Shaft (9) can comes out now.
34-43
34. TRAVEL SYSTEM
34-44
34. TRAVEL SYSTEM
GREASE
34-45
34. TRAVEL SYSTEM
(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), (8) into casing (1).
34-46
34. TRAVEL SYSTEM
10 - Plain washer 18
34-47
34. TRAVEL SYSTEM
Guide pin
: 14mm
Tightening torque : 324N•m (239 lbf•ft)
34-48
34. TRAVEL SYSTEM
: 32 mm
Tightening torque : 98~117.6N•m (72.3~86.7 lbf•ft)
34-49
34. TRAVEL SYSTEM
34-50
34. TRAVEL SYSTEM
Lap together the surfaces of both cylinder block and valve plate to remedy
their roughness. (Lap with #1200 powder)
Allowable
Check Items Criteria Disposition
Hardness
Swash plate Over HS78 HS74 Replace
(2) Clearance between piston and Allowable
Check Items Criteria Disposition
cylinder block Clearance
Outer diameter of 0.01mm (0.0004") 0.05mm
Measure outer dia. of piston and piston d max - d min (0.0020")
bore of cylinder block at least 3 Inner diameter of 0.01mm (0.0004") 0.022mm
Replace piston
places in the longitudinal direction cylinder bore (0.0009")
or cylinder block
with micrometer, and obtain: D max - D min
Clearance D-d 0.037~0.047mm 0.065mm
max. outer dia. = d max (0.0015"~0.0019") (0.0026")
min. outer dia. = d min
min. inner dia. = D min
max. inner dia. = D max
In exchanging pistons, replace all of nine pistons at the same time
34-51
34. TRAVEL SYSTEM
(1.34" +0.008"
+0.004" )
Dial gauge o34 ( +0.2
+0.1)
85 (3.35")
Piston
Jig
MagnetStand
26 (1.02")
Shoe
Work stand
o32 (1.26")
Method Play
o43 (1.69")
Jig
Fig. 34-92 Method
Allowable
ITEM & MEASURING METHOD Check Items Criteria Disposition
Roughness
(4) Parking brake torque
Replace all
After completion of assembly, set
902N•m 812N•m separator and
the torque wrench on the shaft Parking brake torque
(670 lbf•ft) (600 lbf•ft) friction plates
end, and measure the braking
springs
torque generated when the shaft
starts to rotate.
Standard of replacing friction and
separating plate.
34-52
34. TRAVEL SYSTEM
(6) Bearing Replace bearings (10), (51) before hour meter of host machine indicates
10,000 hours.
Replace bearing (10), (51) after
decided hours.
• 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 If the wear of splines is less than 0.3 mm (0.012"), the spline is reusable.
Replace if the wear of splines
exceeds the allowable value.
(8)Overload relief valve Replace relief valve part as an assembly each time the host machine works
for 10,000 hours.
Do not try to adjust the valve,
since special hydraulic test bench
is required for inspecting and
adjusting the pressure.
34-53
34. TRAVEL SYSTEM
34-54
34. TRAVEL SYSTEM
34-55
34. TRAVEL SYSTEM
34.2.7.1 TOOLS
jigs and measuring instruments.
(7.87")
390
200
(15.4")
t=16 (0.63")
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.
• The numbers in the parentheses after part names correspond to those in the assembly drawing on Fig. 34-
76.
34-56
34. TRAVEL SYSTEM
: 8mm
25
24
17
34-57
34. TRAVEL SYSTEM
10
(11,12,13,14)
34-58
34. TRAVEL SYSTEM
: 14mm
Fig. 34-101 Disassembling housing assy
34-59
34. TRAVEL SYSTEM
20
2) Tap carrier pins 1 (20) out from carrier 1 (16).
16
3) Remove thrust washers 1 (18), planetary gears
1 (17) and needle bearings (19).
16
4) Knock out spring pins 6×36 (21) from carrier pins
16
1 (20) for re-assembling.
18
When carrier pin 1 (20) or planetary gear 1 (17) is
needed to be exchanged, three pins or three gears
should be all exchanged. 17 19
17
Fig. 34-104 Disassembling carrier 1 assy
34-60
34. TRAVEL SYSTEM
14
13
When carrier pins 2 (13) are to be re-used, mark each 9
pin with its mated hole of carrier 2 (9) to assure the 9
same combination as before.
34-61
34. TRAVEL SYSTEM
34.2.8 ASSEMBLING
(1) GENERAL INSTRUCTIONS
9
1) Clean every part by kerosene and dry them by air
blow. Surfaces to be applied by Loctite must be
degreased by solvent.
10 (11,12)
34-62
34. TRAVEL SYSTEM
: 14mm
Tightening torque : 377.3N•m (278 lbf•ft)
34-63
34. TRAVEL SYSTEM
34-64
34. TRAVEL SYSTEM
34-65
34. TRAVEL SYSTEM
34-66
34. TRAVEL SYSTEM
(10)Installing cover
1) Apply Loctite#515 on mating surfaces of cover 24
(24) and ring gear (3) and install cover (24) on
ring gear (3). LOCTITE #515
3
: 14mm
Tightening torque : 147.1N•m (108 lbf•ft)
34-67
34. TRAVEL SYSTEM
Fig. 34-121
Maintenance standards
Mark Items Criteria Allowable limit Disposition
Smooth, without abnormal Replace 3 pieces
A Wear of planetary shaft ←
wear or seizure as a set
Replace (Replace 3
Smooth, without abnormal Not over 1.6mm (0.063") of
B Condition of tooth surface pieces as a set for
wear or seizure pitching nor cracks at root
planetary gears)
Adjust shim
Thrust clearance of angular From -0.08 mm To 0.02 mm
C ← thickness
bearings (2) (-0.0031"~0.0008")
[Refer to 34.2.8(6)]
Thickness of thrust washer 1 From 3.3 mm To 3.7 mm 0.1 mm (0.004")
D Replace
(18) (0.13"~0.15") of wear
Thickness of thrust washer 2 5.5±0.2mm 0.1 mm (0.004")
E Replace
(11) (0.21"~0.22") of wear
4.5±0.16mm 0.15 mm (0.006")
F Thickness of thrust plate (23) Replace
(0.171"~0.183") of wear
G Lubrication oil 2,000 working hours (engine hour meter) Replace
34-68
34. TRAVEL SYSTEM
34-69
34. TRAVEL SYSTEM
[MEMO]
34-70
46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS
46
46-1
46. TROUBLE SHOOTING (BY ERROR CODES)
46-2
46. TROUBLE SHOOTING (BY ERROR CODES)
Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.
46-3
46. TROUBLE SHOOTING (BY ERROR CODES)
46-4
46. TROUBLE SHOOTING (BY ERROR CODES)
46-5
46. TROUBLE SHOOTING (BY ERROR CODES)
46-6
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
46-7
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-4
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-8
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-5
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-6
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-9
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-7
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-8
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-10
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-9
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-10
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
Control in the
mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-11
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-11
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-12
Error code B022
Trouble Boom down pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-12
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-13
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
SE-4 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-127F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-14
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-13
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-15
Error code B032
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-16
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
SE-8 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-131F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-14
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-17
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-18
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-15
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-19
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
SE-7 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-130F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-20
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-16
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-21
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-22
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B053 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-17
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-23
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B054 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-24
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B062 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F
CN-101F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-18
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-25
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B063 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-26
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B064 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-19
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-27
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-28
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B073 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-20
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-29
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B074 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-30
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-21
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-31
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B093 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-32
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B094 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-22
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-33
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-34
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B103 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-23
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-35
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B104 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-36
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-24
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-37
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-38
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-25
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-39
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-40
Error code B164
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-26
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-41
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B172 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-42
Error code B173
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B173 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-27
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-43
Error code B174
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B174 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-44
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-28
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-45
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C013 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-46
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-29
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-47
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-48
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C023 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-30
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-49
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-50
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-31
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-51
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-52
Error code C043
Trouble Boom rod pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C043 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-32
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-53
Error code C044
Trouble Boom rod pressure sensor’s power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-54
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-33
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-55
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-56
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-34
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-57
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-58
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-35
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-59
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-60
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-36
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-61
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-62
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-37
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-63
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-64
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-38
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-65
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-66
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-39
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-67
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-40
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-70
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-41
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-72
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-42
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-74
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
46-43
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-75
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
Table46-76
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.
46-44
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-77
G043
When cranking is executed for five seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed after
starting the engine.
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.
46-45
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-78
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-79
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-46
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-80
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-81
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-47
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-82
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-83
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-48
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-84
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-85
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-49
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-86
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-87
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20°C.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-5 WATER TEMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
46-50
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-88
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-600F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-89
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
4 • Mechatro controller Check that the error is corrected after replacement of controller.
46-51
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-90
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R014 is left displayed
E-1
Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-52
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-91
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-53
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-92
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CCW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-54
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-93
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 MOTOR RELAY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-112F, CN2-1 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-94
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D13
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-55
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-95
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D14
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-96
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 23 D15
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
R-8 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-56
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-97
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-57
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-98
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-3 ENG STOP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-58
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-99
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-4 LOCK LEVER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-100
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-2 SAFETY RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
R-26 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R214 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-59
46. TROUBLE SHOOTING (BY ERROR CODES)
[MEMO]
46-60
47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS
47
47-1
47. TROUBLESHOOTING (BY TROUBLE)
47-2
47. TROUBLESHOOTING (BY TROUBLE)
47-3
47. TROUBLESHOOTING (BY TROUBLE)
47-4
47. TROUBLESHOOTING (BY TROUBLE)
47-5
47. TROUBLESHOOTING (BY TROUBLE)
47-6
47. TROUBLESHOOTING (BY TROUBLE)
47-7
47. TROUBLESHOOTING (BY TROUBLE)
47-8
47. TROUBLESHOOTING (BY TROUBLE)
47-9
47. TROUBLESHOOTING (BY TROUBLE)
47-10
47. TROUBLESHOOTING (BY TROUBLE)
47-11
47. TROUBLESHOOTING (BY TROUBLE)
47-12
47. TROUBLESHOOTING (BY TROUBLE)
47-13
47. TROUBLESHOOTING (BY TROUBLE)
47-14
47. TROUBLESHOOTING (BY TROUBLE)
47-15
47. TROUBLESHOOTING (BY TROUBLE)
47-16
47. TROUBLESHOOTING (BY TROUBLE)
47-17
47. TROUBLESHOOTING (BY TROUBLE)
47-18
47. TROUBLESHOOTING (BY TROUBLE)
47-19
47. TROUBLESHOOTING (BY TROUBLE)
(16)Travel deviation
47-20
47. TROUBLESHOOTING (BY TROUBLE)
47-21
47. TROUBLESHOOTING (BY TROUBLE)
47-22
47. TROUBLESHOOTING (BY TROUBLE)
(19)Machine does not travel straight in simultaneous operation of traveling and attachment
(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)
47-23
47. TROUBLESHOOTING (BY TROUBLE)
47-24
47. TROUBLESHOOTING (BY TROUBLE)
47-25
47. TROUBLESHOOTING (BY TROUBLE)
47-26
47. TROUBLESHOOTING (BY TROUBLE)
47-27
47. TROUBLESHOOTING (BY TROUBLE)
47-28
47. TROUBLESHOOTING (BY TROUBLE)
47-29
47. TROUBLESHOOTING (BY TROUBLE)
47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.
47-30
47. TROUBLESHOOTING (BY TROUBLE)
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
47-31
47. TROUBLESHOOTING (BY TROUBLE)
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
R-30: Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.
47-32
47. TROUBLESHOOTING (BY TROUBLE)
Checking
Filters Liquid Leak, clogging
Muffler clogged
Engine oil leak
Coolant level
Trouble
47-33
47. TROUBLESHOOTING (BY TROUBLE)
Hydraulic switch
Starter motor
Safety relay
Battery rely
Glow relay
Glow plug
Alternator
Trouble
47-34
47. TROUBLESHOOTING (BY TROUBLE)
Factors
47-35
47. TROUBLESHOOTING (BY TROUBLE)
Engine body
Factors
Damage of dumper
Trouble
47-36
48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS
48
48-1
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-2
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a
case no accordance of diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-3
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-4
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2
PUMP" of No.10 are not given a diagnosis.
48-5
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-6
51. ENGINE
PREFACE
This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of HINO MOTOR.
51
51-1
51. ENGINE
51-2
63. MOUNTING
THE NIBBLER & BREAKER
TABLE OF CONTENTS
63-1
63. MOUNTING THE NIBBLER & BREAKER
63-2
63. MOUNTING THE NIBBLER & BREAKER
PREFACE
This manual deals with items necessary for changing standard specification machine to one with a nibbler & breaker
specification. Follow the procedure given here in when changing the machine specification in the field (service shop).
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC32T01411F1 Upper structure modification KIT No. NIBBLER & BREAKER ASIA LC10-07001~
YC10-03501~
LC32T01411F2 Upper structure modification KIT No. NIBBLER & BREAKER OCEANIA LC10-07001~
YC10-03501~
LC03M00015F1 • CONTROLS OPERATORS ASIA
LC03M00025F1 • CONTROLS OPERATORS OCEANIA
6 YN55M00004F1 •• PEDAL ASSY (1) ASIA, OCE.
6-1 YN26M00066P1 •• MAT, FLOOR (1) Cut STD mat
6-2 YN03M01852P1 •• PEDAL 1
6-3 YN03M01858P1 •• RUBBER 1
6-4 YN03M01684P1 •• LOCK ASSY 1
6-5 ZM73C08020 •• SEMS-BOLT 2
6-6 ZM73C10020 •• SEMS-BOLT 2
63-3
63. MOUNTING THE NIBBLER & BREAKER
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC68H00063F1 • CONTROL LINES, REMOTE ASIA, OCE
1 YN30V00080F1 •• VALVE, PILOT 1
2 2420R349D090 •• HOSE 2
3 2420R349D160 •• HOSE 1
4 2420R349D400 •• HOSE 1
5 HH25X04004G2 •• CONNECTOR 1
6 ZH22X04000 •• CONNECTOR 1
7 ZH32X04000 •• ELBOW 2
8 ZE72X04000 •• PLUG 1
9 YX52S00013P1 •• SENSOR, PRESS 1
10 HM83C10030G1 •• SEMS-BOLT 2
11 ZH22X04006 •• CONNECTOR 1
63-4
63. MOUNTING THE NIBBLER & BREAKER
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC33H00043F1 • HYD. TANK ASSY (1) ASIA, OCE.
2 LC33H00028F1 •• HYD. TANK ASSY (1)
2-6 LC52V01001F1 ••• FILTER ELEMENT (1)
2-6-R100 LS52V01001R300 •••• ELEMENT KIT
2 YN52V01011P1 •• FILTER ELEMENT 3
5 ZD11G09000 •• O-RING 1
6 YN52V01008S005 •• PACKING 1
8 ZD11G19000 •• O-RING 1
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC42H00178F1 • HYD. LINES, BOOM ASIA, OCE. LC10-07001~
YC10-03501~
1 LC42H00155F1 •• HYD. LINES, BOOM (1)
2 LC42H00169P1 •• HYD. LINES, BOOM (1)
2-1 LC42H01795P1 ••• TUBE 1
2-2 LC42H01796P1 ••• TUBE 1
2-3 LC42H01780P1 •••• TUBE 1
2-4 LC42H01781P1 •••• TUBE 1
2-5 LS42H01021D1 ••• HOSE 2
2-6 YN42H02582P1 ••• PLUG 4
2-7 LC42H01909P1 ••• BRACKET 1
2-9 LC42H01914P1 ••• CLAMP 1
63-5
63. MOUNTING THE NIBBLER & BREAKER
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
2-10 YN42H02348P1 ••• CLAMP 8
2-11 YN42H02363P1 ••• CLAMP 12
2-12 ZE13X20001 ••• CLAMP, HALF 8
2-14 ZD12P03800 ••• O-RING 4
2-15 ZM73C12030 ••• SEMS-BOLT 12
2-17 ZS18C12050 ••• CAPSCREW 2
2-18 ZS28C14050 ••• CAPSCREW 16
2-19 ZW16H12000 ••• WASHER 8
2-20 ZW26K14000 ••• LOCK WASHER 16
2-21 LC42H01269P1 ••• CLAMP 2
2-22 ZS18C12065 ••• CAPSCREW 6
3 LC42H00177F1 ••• HYD. LINES, BOOM (1)
3-1 LC42H01916P1 ••• BRACKET 1
3-2 LC42H01915P1 ••• BRACKET 1
3-3 ZM73C12040 ••• SEMS-BOLT 3
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC43H00111F1 • ARM; STD ASIA, OCE. LC10-07001~
YC10-03501~
1 LC43H00101F1 •• HYD. LINES, ARM (1)
1-1 LC43H01269P1 ••• TUBE 1
1-2 LC43H01270P1 ••• TUBE 1
1-3 LC43H01011D2 ••• HOSE 2
1-4 24100P3133F1 ••• VALVE, STOP 2
1-5 LC43H01223P1 ••• CONNECTOR 2
1-6 ZE13X20001 ••• CLAMP, HALF 12
1-7 YN42H02361P1 ••• CLAMP 8
1-8 YN42H02321P1 ••• BUSHING 4
1-9 ZM73C12030 ••• SEMS-BOLT 8
1-10 ZS18C08025 ••• CAPSCREW 8
1-11 ZS28C14050 ••• CAPSCREW 16
1-12 ZS28C14070 ••• CAPSCREW 8
1-13 ZN18C14011 ••• NUT 8
1-14 ZW26K14000 ••• LOCK WASHER 16
1-16 YN43H01151P1 ••• WASHER 8
1-17 ZD12P03800 ••• O-RING 8
2 YN43H00200F1 ••• HYD. LINES, ARM (1)
2-1 YN43H01663P1 ••• BRACKET 2
2-2 ZS18C16040 ••• CAPSCREW 4
63-6
63. MOUNTING THE NIBBLER & BREAKER
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
2-3 ZW16H16000 ••• WASHER 4
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC43H00122F1 •• ARM ASIA, OCE. LC10-07001~
YC10-03501~
1 LC43H00123F1 •• HYD LINES, ARM (1)
1-1 LC43H01283P1 •• TUBE 1
1-2 LC43H01284P1 •• TUBE 1
1-3 LS30H01078DC •• HOSE 2
1-4 24100P3133F1 •• VALVE STOP 2
1-5 LC43H01223P1 •• CONNECTOR 2
1-6 ZE13X20001 •• CLAMP HALF 12
1-7 YN42H02361P1 •• CLAMP 16
1-8 YN42H02321P1 •• BUSHING 8
1-9 ZD12P03800 •• O-RING 8
1-10 ZM73C12035 •• SEMS-BOLT 16
1-11 ZS18C08025 •• CAPSCREW 8
1-12 ZS28C14050 •• CAPSCREW 16
1-13 ZS28C14070 •• CAPSCREW 8
1-14 ZN18C14011 •• NUT 8
1-15 YN43H01151P1 •• WASHER 8
1-16 ZW26K14000 •• LOCK WASHER 16
2 YN43H00200F1 •• HYD. LINES, ARM (1)
2-1 YN43H01663P1 •• BRACKET 2
2-2 ZS18C16040 •• CAPSCREW 4
2-3 ZW16H16000 •• WASHER 4
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC43H00107F1 • ARM ASIA, OCE LC10-07001~
YC10-03501~
1 LC43H00106F1 •• HYD. LINES, ARM (1)
1-1 LC43H01259P1 •• TUBE 1
1-2 LC43H01260P1 •• TUBE 1
1-3 LC43H01011DB •• HOSE 2
1-4 24100P3133F1 •• VALVE, STOP 2
1-5 LC43H01223P1 •• CONNECTOR 2
1-6 ZE13X20001 •• CLAMP, HALF 12
63-7
63. MOUNTING THE NIBBLER & BREAKER
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
1-7 YN42H02361P1 •• CLAMP 8
1-8 YN42H02321P1 •• BUSHING 4
1-9 ZM73C12030 •• SEMS-BOLT 8
1-10 ZS18C08025 •• CAPSCREW 6
1-11 ZS28C14050 •• CAPSCREW 16
1-12 ZS28C14070 •• CAPSCREW 8
1-13 ZN18C14011 •• NUT 8
1-14 YN43H01151P1 •• WASHER 8
1-15 ZD12P03800 •• O-RING 8
1-16 ZW26K14000 •• LOCK WASHER 16
2 YN43H00200F1 •• HYD LINES, ARM (1)
2-1 YN43H01663P1 •• BRACKET 2
2-2 ZS18C16040 •• CAPSCREW 4
2-3 ZW16H16000 •• WASHER 4
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
1 YN43H00004F1 •• CONNECTOR ASSY 2 NPK
1 YN43H00005F1 •• CONNECTOR ASSY 2 TOKU, KRUPP
1 YN43H00006F1 •• CONNECTOR ASSY 2 NIBBLER
63-8
63. MOUNTING THE NIBBLER & BREAKER
63.2 SUMMARY
63.2.1 GENERAL PRECAUTIONS
(1) Application of Nibbler & Breaker
Nibbler & Breaker ........... Applicable only when nibbler and breaker are mounted.
(2) Modifying Nibbler & Breaker
There are specific procedures to be followed when modifying nibbler & breaker. Therefore, when they are to be
modofied at our service shop, contact the nearest breaker and nibbler manufacturer's office, and obtain
instructions, so that you install the pipes and handle the machinery correctly.
(3) Differences Between Breaker Circuit and Nibbler Piping
• Breaker Piping:
There is a single oil flow from pump P2 to the breaker. The oil returns to the hydraulic tank directly. The flow is
single flow.
If the return oil from the breaker is fed back to the control valve, the pulsation of the breaker is transmitted to the
oil cooler. This causes the machine to break down.
• Nibbler Piping:
The oil flows to the nibbler is conflux flow : the oil flow is changed to the rod and the head of the nibbler cylinder.
63-9
63. MOUNTING THE NIBBLER & BREAKER
ARM
HYDRAULIC
PIPING
STOP
VALVE UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
ARM
SELECTOR VALVE
(ADD-ON VALVE)
ARM TOP
PIPING
HYDRAULIC
BREAKER
OPERATING
PEDAL
FLOOR MAT
SINGLE / CONFLUX
FLOW SELECT SWITCH
MAIN CONTROL VALVE
REMOTE CONTROL PIPING
63-10
63. MOUNTING THE NIBBLER & BREAKER
63-11
63. MOUNTING THE NIBBLER & BREAKER
P2 P1 T1 T2
PTb
P1 TRAVEL
UNLOAD PRIORITY
PCb
M
P2 UNLOAD
MAIN PUMP
PCa
51
LEFT NIBBLER
PBo 52
OPTION NIBBLER & BREAKER
PAo PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa
50-1 SV-13
Ps C PL
P
SE-29
Fig. 63-2
63-12
63. MOUNTING THE NIBBLER & BREAKER
Add this hydraulic circuit to the standard circuit of SK330-8, SK350LC-8 for completion.
Switch position
Spec. Work mode Conflux/single Circuit flow
select
A Conflux Conflux
Nibbler
A Single Single
Breaker B Single Single
• Nibbler operating
When using NIBBLER according to specification of NIBBLER installed choose conflux or single flow by "CONFLUX
/ SINGLE flow select switch"
63-13
63. MOUNTING THE NIBBLER & BREAKER
4-M14-18
Fig. 63-3
P R
HYDRAULIC SYMBOL
Fig. 63-4
63-14
63. MOUNTING THE NIBBLER & BREAKER
HYDRAULIC CIRCUIT
OPERATING TORQUE
2.45 25 100 9.8
0.35+0.15 (24.0+1.5)
1.95 20 80 7.84
A 1.47 15 60 5.88
(4.5) 4.61
0.98 10 40 3.92
0.54+0.1 (5.5+1)
0.49 5 20 1.96
(11.3) 1.11
OPERATING ANGLE
Fig. 63-5
63-15
63. MOUNTING THE NIBBLER & BREAKER
Reference
No. Item Assy No. Main modification points
pages
ASIA LC03M00015F1 Add pedal assy and cutout of STD
5.2 Controls, operators 63-17
OCEANIA LC03M00025F1 floor mat
ASIA YN64H00190F1 Add selector valve and overload relief
5.3 Valve install 63-18
OCEANIA ↑ valve
ASIA LC64H00105F1
Main valve Add N&B valve control lines 63-19
OCEANIA ↑
ASIA LC68H00063F1
Remote valve Add P/V control lines 63-22
Control OCEANIA ↑
5.4
lines ASIA LC64H00090F1
Block Change to 1 option block 63-24
OCEANIA ↑
ASIA LC64H00088F1
Block control Add control lines 63-26
OCEANIA ↑
ASIA LC03H00055F1
5.5 Hyd. lines upper Add N&B lines 63-28
OCEANIA ↑
ASIA LC33H00043F1
5.6 Hyd. tank assy Replace return filter 63-33
OCEANIA ↑
ASIA YN17M00049F1
5.7 Panel assy, instrument Add single/conflux flow sw. 63-34
OCEANIA YN17M00052F1
ASIA YN22T00334F2
5.8 Name plate install Add label 63-35
OCEANIA LC22T00094F3
63-16
63. MOUNTING THE NIBBLER & BREAKER
63-17
63. MOUNTING THE NIBBLER & BREAKER
Fig. 63-8
(2) Parts to be disused
When the selector valve is installed, the parts shown in Table63-3 is disused from the standard machine.
Table63-3
Control valve (STD) LC30V00028F1
No. Part No. Name Q’ty Remarks
213 YN30V00101S213 Plate 1
275 ZS23C12035 Capscrew 4 M12×35
63-18
63. MOUNTING THE NIBBLER & BREAKER
• Before starting the modification work, check parts according to the Additional Parts List.
• When disconnecting and reconnecting pipes, take care, so as not to allow dirt and foreign matter to enter.
Table63-4
LC64H00105F1 ASIA
Controls lines, valve
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 LC64H00083F1 Control lines, valve (1) Base
2 LC64H00109F1 Control lines, valve (1) N&B
2-1 2444R963D11 Hose 1 PF1/4 L=550
2-2 2444Z2892 Tee 1 2-PF3/8-PF1/4
2-3 HH25X04004G2 Connector 1 PF1/4 with filter
2-4 YX52S00013P1 Sensor, press 1
2-5 2444Z2894 Elbow 2 PF1/4
63-19
63. MOUNTING THE NIBBLER & BREAKER
Fig. 63-10
63-20
63. MOUNTING THE NIBBLER & BREAKER
63-21
63. MOUNTING THE NIBBLER & BREAKER
63-22
63. MOUNTING THE NIBBLER & BREAKER
Fig. 63-12
(2) Parts to be disused
Concerning the remote control lines, the parts listed in Table63-7 and Fig. 63-18 are disused from the standard
machine.
Table63-7
LC03H00052F1 ASIA
Hyd. lins upp
↑ OCEANIA
No. Part No. Name Q’ty Remarks
3 ZE72X06000 Plug 1
63-23
63. MOUNTING THE NIBBLER & BREAKER
63-24
63. MOUNTING THE NIBBLER & BREAKER
Fig. 63-14
63-25
63. MOUNTING THE NIBBLER & BREAKER
63-26
63. MOUNTING THE NIBBLER & BREAKER
63-27
63. MOUNTING THE NIBBLER & BREAKER
Fig. 63-16
(3) Parts to be disused
Concerning the block control lines, the parts listed in Table63-12 and Fig. 63-18 are disused from the standard
machine.
Table63-12
LC03H00052F1 ASIA
Hyd. lines, Upp
↑ OCEANIA
No. Part No. Name Q’ty Remarks
3 ZE72X06000 Plug 1
63-28
63. MOUNTING THE NIBBLER & BREAKER
63-29
63. MOUNTING THE NIBBLER & BREAKER
• Before starting the modification work, check parts according to the Additional Parts List.
• When disconnecting and reconnecting pipes, take care, so as not to allow dirt and foreign matter to enter.
• At assembly, use care of O-ring do not come off.
• Regarding the tightening torque of O-ring type joints, hydraulic hoses and Nut sleeve joints, refer to the
Remarks of Fig. 63-29 and the Tightening Torque Table.
Tightening torque
Tightening torque
Thread size Spanner (mm)
N•m (lbf•ft)
M12 19 121 (89)
Table63-13
LC03H00055F1 ASIA N&B
Hyd. lines, Upper
↑ OCEANIA N&B
No. Part No. Name Q’ty Remarks
1 LC03H00047F1 Hyd. lines, Upper (1) Base
2 LC03H00053F1 Hyd. lines, Upper (1) N&B
2-1 LC03H01264D1 Hose 1 1-1/4 L=1550
2-2 LC03H01263D1 Hose 1 1-1/4-1 L=1680
2-3 LQ03H01282D2 Hose 1 1-1/2 L=950
2-4 ZE12Q16000 Plug 1 1"
2-5 ZE12X16000 Clamp half 2
2-6 ZE13X20001 Clamp half 6
2-7 ZS18C14045 Capscrew 4
2-8 ZS28C14050 Capscrew 8
2-9 HM83C10030G1 Sems-bolt 4
2-10 HM83C10035G1 Sems-bolt 4
2-11 HM83C12035G1 Sems-bolt 4
2-12 ZW26K14000 Lock washer 8
2-13 ZD12P03400 O-ring 2
2-14 ZD12P03800 O-ring 3
2-15 ZD12P04800 O-ring 2
2-16 ZW26X14000 Lock washer 4
63-30
63. MOUNTING THE NIBBLER & BREAKER
63-31
63. MOUNTING THE NIBBLER & BREAKER
Fig. 63-18
63-32
63. MOUNTING THE NIBBLER & BREAKER
CAPSCREW
WASHER
COVER
SPRING
Turn this handle,
and remove element
CHECK VALVE
5
AIR BREATHER
HYD.TANK
PLATE
6
63-33
63. MOUNTING THE NIBBLER & BREAKER
Fig. 63-22
63-34
63. MOUNTING THE NIBBLER & BREAKER
63-35
63. MOUNTING THE NIBBLER & BREAKER
63-36
63. MOUNTING THE NIBBLER & BREAKER
63-37
63. MOUNTING THE NIBBLER & BREAKER
63-38
63. MOUNTING THE NIBBLER & BREAKER
2-6
2-3
2-1
2-6
2-4
2-2
2-19, 2-22
2-11
2-16
2-16 2-10
2-9
2-15
2-19, 2-22
2-15
2-7 2-17, 2-19
2-11
2-11
63-39
63. MOUNTING THE NIBBLER & BREAKER
3-1
3-3
3-2
3-3
1-3
1-3
1-3
1-3
1-2
1-3
1-1
SECTION AA, BB
Fig. 63-27
63-40
63. MOUNTING THE NIBBLER & BREAKER
63-41
63. MOUNTING THE NIBBLER & BREAKER
63-42
63. MOUNTING THE NIBBLER & BREAKER
1-4
1-10, 1-16
1-4
1-7 1-8
1-10, 1-16
1-12
1-6
1-5
1-17
1-17
1-13
63-43
63. MOUNTING THE NIBBLER & BREAKER
2-1
2-1
2-3, 2-2
63-44
63. MOUNTING THE NIBBLER & BREAKER
63-45
63. MOUNTING THE NIBBLER & BREAKER
63-46
63. MOUNTING THE NIBBLER & BREAKER
1-1 1-16, 1-12, 1-9, 1-6 1-3 1-6, 1-9, 1-12, 1-16
1-2 1-16, 1-12, 1-9, 1-6 1-3 1-6, 1-9, 1-12, 1-16
1-4
1-11, 1-15
1-4
1-15, 1-11
1-10 1-10
1-13
1-6
1-5
1-9 1-7 1-8
1-9
1-14
63-47
63. MOUNTING THE NIBBLER & BREAKER
63-48
63. MOUNTING THE NIBBLER & BREAKER
1-4
1-10, 1-14
1-4
1-7 1-8
1-14, 1-10
1-9 1-9
1-12
1-6
1-5
1-15
1-15
1-13
63-49
63. MOUNTING THE NIBBLER & BREAKER
Connector assy
for NPK YN43H00004F1
No. Part No. Name Q'ty Remark
1 2444P1744D3 Connector 1
2 2444T2406 Plug 1 PF1-1/4
3 ZD12P03800 O-ring 1 1B P38
Connector assy
for TOKU, KRUPP YN43H00005F1 2 M45X1.5 1 3
No. Part No. Name Q'ty Remark
1 2444P1745D4 Connector 1
2 2420Z1228D5 Plug 1
3 ZD12P03800 O-ring 1 1B P38
PF1-1/4
1 YN43H01006P1 Connector 1
2 2444T1329D6 Plug 1
3 ZD12P03800 O-ring 1 1B P38
PF1-1/4
63-50
63. MOUNTING THE NIBBLER & BREAKER
63-51
63. MOUNTING THE NIBBLER & BREAKER
1) Switch position
Fig. 63-36
• Nibbler
63-52
63. MOUNTING THE NIBBLER & BREAKER
B
Unlocked
Make sure to set the pedal lock to "LOCKED"
position while the breaker or nibbler is not used.
Unexpected contact with UNLOCKED position of
pedal may cause severe injury or death.
Do not put foot on the pedal except at the time of
operation using pedal. Fig. 63-38
63-53
63. MOUNTING THE NIBBLER & BREAKER
This is a general outline of how breakers should be used and may differ with excavator models. Always contact the
breaker manufacturer before field mounting.
The pulse oscillation is 350×20%= 70kgf/cm2 (1000psi). Therefore, if it is more than this level, an accumulator
must be installed.
max
min
Max. press-Min. press<System press X 20%
• Low pressure side :
Measure the inlet pressure of the line filter on the breaker side by actuating the breaker at full engine
revolution in the B mode, and in case the maximum pressure exceeds 55kgf/cm2 (780 psi), install a low
pressure accumulator.
Max. <55kgf/cm2 (780 psi)
Regarding the capacity and the charge pressure of accumulators, contact the breaker manufacturer before
installation.
63-54
63. MOUNTING THE NIBBLER & BREAKER
PLUG
N&B
LOW PRESSUSE SIDE
(RETURN)
N&B
HIGH PRESSUSE
SIDE
BOOM
Fig. 63-39 Relief valve mounting
6
4
2
3
TO TANK
RETURN SIDE
5 1
63-55
63. MOUNTING THE NIBBLER & BREAKER
In the case of a breaker for which the engine revolution is limited, the breaker does not increase impact power
and cycles even at full engine revolution.
Since extra hydraulic oil returns to the hydraulic oil via the relief valve, it causes the hydraulic oil temperature to
rise and the fuel consumption to increase. Plaster the label (furnished by the breaker maker) indicating the
revolution (Check the engine revolution.), to the throttle potentiometer position. Always observe the indicated
revolution.
Piping work is not required in some cases if a high-low changeover function is not necessary at user’s request.
On that occasion, it is necessary to fix the changeover valve contained in the breaker to the low speed side
beforehand. Consult with the breaker manufacturer in that case. It is prohibited to use the high-low speed
changeover valve without laying high-low speed piping and without fixing the high-low speed changeover valve.
HIGH-LOW SPEED
CHANGEOVER VALVE
TO CONTROL VLAVE
TO TANK
CHECK VALVE
Fig. 63-41
63-56
63. MOUNTING THE NIBBLER & BREAKER
63.9 REFERENCE
(1) Typical combinations are quoted from breaker manufacturer’s catalog use as below, but concerning applicable
breaker models, decide it after consultation with the breaker manufacturer.
When fitting a breaker, read through reminders on the use of breakers and cautions instructed by breaker
manufacturers.
Table63-26
Manufacturer Applicable Working press Oil volume used Total weight kg Total length Bucket capacity
breaker kgf/cm2 (psi) L/min (gal/min) (lbs) mm (in) m3 (cuyd)
120~140 160~200 1,450 2,156
H-10XB
(1,710~1,990) (42.2~52.8) (3,200) (84.9 )
NPK
130~150 35~60 410 1,644
H-4XE
(1,850~2,130) (9.24~15.8) (900) (64.7 )
100~140 110~140 1,000 0.55~0.70
TNB-10B
(1,420~1,990) (29.0~37.0) (2,210) (0.72~0.92)
120~140 140~160 1,400 0.70~0.90
TNB-14B
(1,710~1,990) (37.0~42.2) (3,100) (0.92~1.18)
100~160 45~80 391 1,476 0.25~0.35
TOKU TNB-6E
(1,420~2,280) (11.9~21.1) (860) (58.1 ) (0.33~0.46)
120~170 100~140 997 1,850 0.55~0.70
TNB-10E
(1,710~2,420) (26.4~37.0) (2,200) (72.8 ) (0.72~0.92)
130~170 130~170 1,550 2,190 0.70~0.90
TNB-14E
(1,850~2,420) (34.3~44.9) (3,400) (86.2 ) (0.92~1.18)
150~160 80~110 1,100~1,250 2,278 0.50~0.90
MKB1100
(2,130~2,280) (21.1~29.0) (2,430~2,760) (89.7 ) (0.65~1.18)
KRUPP
150~180 90~130 1,120~1,200 0.55~1.00
MKB1200
(2,130~2,560) (23.8~34.3) (2,470~2,650) (0.72~1.31)
150~170 100~120 1,330 [1,596] 0.60~0.90
TAISEI TF-150
(2,130~2,420) (26.4~31.7) (2,930) (62.8 ) (0.78~1.18)
160~180 125~150 1,400 2,119
FURUKAWA HB20G
(2,280~2,560) (33.0~39.6) (3,100) (83.4 )
[ ] Excludes chisels
63-57
63. MOUNTING THE NIBBLER & BREAKER
[MEMO]
63-58