HYDRAULIC EXCAVATOR SHOP SK200-8 MANUAL model SK210:c-8 INDEX SPECIFICATIONS SECTION MAINTENANCE SECTION SYSTEM SECTION Sac DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION PROCEDURE OF INSTALLING OPTIONS SECTION KOBELCO Book Code No. SSYN0018E01 0-1GENERAL SAFETY INFORMATION [Awarning] Do not operate or perform any maintenance on this machine until all instructions found in the OPERA- ‘TOR’S MANUAL and this MANUAL have been thor- ‘oughly read and understood. Improper operation or maintenance of this machine ‘may cause accidents and could result in serious in- jury or death. Always keep the manual in storage. Ifitis missing or damaged, place an order with an authorized our Distributor for a replacement. Ifyou have any questions, please consult an autho- rized our Distributor. (1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safe- ty rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the man- ual and on the machine should be read and under stood by all personnel before starting any work with or on the machine. (2) Operation, inspection, and maintenance should be ‘carefully carried out, and safety must be given the first priority. Messages of safety are indicated with ‘marks. The safety information contained in the ‘manual is intended only to supplement safety codes, insurance requirements, focal laws, rules and regulations. (3) Messages of safety appear in the manual and on the machine : All messages of safety are identified by either word of "DANGER", WARNING" and “CAUTION’. 1) DANGER: indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows: WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows: [A WARNING] 2) 0-2 3) CAUTION: indicates a potentially hazardous situation which, if not avoided, may result in mi- nor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as fol- lows: [Acaution) (4) Itis very difficult to forecast every danger that may ‘occur during operation. However, safety can be en- sured by fully understanding proper operating pro- Cedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the ma- chine, of allow accidents to occur. (6) Continue studying the manual until all Safety, Oper- ation and Maintenance procedures are completely understood by all persons working with the ma- chine.SAFETY PRECAUTIONS ‘The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR'S MANUAL for the machine. Improper performance of lubrication or mainte~ nance procedures are dangerous and could result in injury or death, Read and understand the MAN- UAL before performing any lubrication or mainte- nance. ‘The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important o use caution when performing service work. A knowledge of the system and or components is im- portant bofore the removal or disassembly of any com- ponent. Because of the size of some of the machine compo- rents, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting proce- dures when removing any components. Weight of com- ponents table is shown in the section ; ‘SPECIFICATIONS. ‘The following is a list of basic precautions that must al- ways be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine (2) Always wear protective glasses and protective shoes when working around machines. In particu- lar, wear protective glasses when using hammers, punches or drifts on any part of the machine or at- tachments. Use welders gloves, hoodigoggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fit- ting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery, (8) Disconnect the battery and hang a "Do Not Oper- ate" tag in the Operators Compartment. Remove ig- nition keys, (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine 50 itdoes not roll while working on of under the ma- chine, Hang a *Do Not Operate" tag in the Opera- tors Compartment. (8) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack 0-3 stands, capable of supporting the machine, before performing any disassembly, [AWARNING| Do not operate this machine unless you have read and understand the instructions in the OP- ERATOR’S MANUAL. Improper machine opera- tion is dangerous and could result in injury or death. (6) Relieve all pressure in air, oll or water systems be- fore any lines, fitings or related items are nected or removed. Always make sure all raised ‘components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. (7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the ma- chine. f this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correct- ly to prevent it from dropping unexpectedly, (8) Use steps and grab handles when mounting or dis- ‘mounting @ machine. Clean any mud or debris from steps, walkways or work platforms before using. ‘Always face to the machine when using steps, lad- ders and walkways. When it is not possible to use the designed access system, provide ladders, scaf- folds, or work platforms to perform safe repair oper- ations. To avoid back injury, use a hoist when lifting com- ponents which weigh 20kg (45ibs) or more. Make sure all chains, hooks, slings, etc., are in good con- dition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in fines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capsorews or nuts located at opposite ends of the cover or device and carefully ry cover loose to relieve any spring or other pres- sure, before removing the last two capscrews or nuts completely, (12)Be careful when removing filer caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liq- uuids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot, ie @)(13)Always use the proper tools that are in good condi-_(21)Do not operate a machine if any rotaling 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)Reinsiall all fasteners with the same part number. balance before reusing. Donot use a lesser quality fastenerifreplacements _(22)Be careful when servicing or separating the tracks are necessary. (crawiers). Chips can fly when removing or install (18)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- Jong sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away ‘from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged frorn the sprockets. Block the ma- erence information and by personne! adequately ‘rained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and eleotrodes, rods or wire to provide @ weld metal strength equivalent at chine to prevent it from moving. least to that of the parent metal. Make sure to dis- connect batlery before any welding procedures are attempted. (16)Do not damage wiring during removal operations. Reinstall the wiring so its 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 toa 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 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 faling attachment. Don't fell 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. Donot bend ‘strike high pressure tines 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 ‘@ high velocity oll 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 stalled correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oll spray onto hot ex- haust components in event of a line, tube or seal failure must be installed correctly. 0-4‘Book Code No. INDEX $k200-8 SK2101C-8 Title Distribution Year-Month ‘SSYNO118E01 20068 OUTLINE ‘S5YNO218E01 NEE SPECIFICATIONS ‘SSYNO318E01 30068 /ATTACHMENT DIMENSIONS ‘SSYN1118E01 0088 TOOLS S5YN1218E01 STANDARD MAINTENANCE] 2006-8 TIME SCHEDULE ‘SSYN1318E01 MAINTENANCE STANDARD 2006-8 AND TEST PROCEDURE ‘S5YN2118E01 MECHATRO CONTROL 2006-08 SYSTEM ‘SSYN2218E01 cnees HYDRAULIC SYSTEM ‘SSYN2318E01 a tes Fag ELECTRIC SYSTEM SSYN2418E01 a fies Fag COMPONENTS SYSTEM ‘S5YN2518E01 |AIR-CONDITIONER SYSTEM ag ‘S5YN3118E01 ry DISASSEMBLING om 2006-8 Fe & ASSEMBLING [i ba SBvN219E01 Fy ‘ATTACHMENT a ‘S5YN3318E01 g UPPER STRUCTURE 2006-8 4 oe rat TRAVEL SYSTEM Ko soynastaeot BY ERROR CODES Seer: BY TROUBLE cd sevnasiaen4 Sm TROUBLE DIAGNOSIS MODE i sovnerigrnt ENGINE ca YN41-45001~ Yoroe00: a APPLICABLE MACHINES 0-5NOTE: This Manual is prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specitica- tion, Maintenance, System, Disassembly, Trouble- shooting, Engine, and Installation Procedures for Optional Attachment. ‘The Chapter “Specification” describes the specifi- cations for entire machine and material, which are instructive for replacement and repairing of attach- ments. ‘The Chapter "Maintenance" describes the material, which is helpful for maintenange 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 Allachment” describes the supplements added on request as required 0-6 This Manual may be properly revised due to the im- provement of products, modification of specifications, elc, And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries. For the section in which the description is hardly under- stood, contact our distributor. ‘The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are con- tained. Therefore, the order must be placed with re- ‘spective formal number with due confirmation on the Parts Manual for applicable machine.1. OUTLINE ‘TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS w..rnnsesennssennet 13 1.1.4 PREPARATION BEFORE DISASSEMBLING... Satta 4.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING. nnn AQ 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ...ccscsesuen 4.1.4 ELECTRICAL EQUIPMENT td 1.1.5 HYDRAULIC PARTS 7 7 7 7 wot 5 1.1.6 WELD REPAIR... soon . 15 1.1.7 ENVIRONMENTAL ISSUES aa 15 1.2 INTERNATIONAL UNIT SYSTEM 16 Book Code No. S5YN0118E01 144. OUTLINE [ Issue Date of issue Applicable Machines Remarks | | 'SK330~-8 : LC10-07001~ S8YNO118E01 | i K | ies eee stu 2006 | sxas0L¢-8 : Y010-03601~ (ASIA, OCE) ‘ ‘August 2008 8200-8: YNtT-46001~ + Kl [SK210LC-8 : YQ11-06001~4. OUTLINE 4.1. GENERAL PRECAUTIONS FOR 2) Attach "Don't operate" tag to control lever, and MAKING REPAIRS begin a meeting before starting the work 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 i extinguisher, and also where to make contact for emergency measure and ambulance to prepere for accidents and fire 5) Choose a hard, lever and safe place, and put attachment on the ground without fail 6) Use hoist, ets, to remove parts of heavy weight (23kg [50 lb] or more) 7) Use proper tools, and change or repair defective tools. (1) Knowledge of operating procedure Read Operator's Manual carefully to understand the operating procedure. (2) Cleaning machines Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the service shop, causes making less efficient work and damage of 8) Machine and attachment required to workin the parts lifting condition should be supported with (2) Inspecting machines supports or blocks securely. Confirm the disassembling section before starting 4.4.3. DISASSEMBLING AND ASSEMBLING work, determine the disassembly procedure taking HYDRAULIC EQUIPMENT the conditions in work shop into account, and request to procure necessary parts in advance, (4) Recording Record the following items to keep contact and (1) Removing hydraulic equipment assy Prevent malfunction from recurring, 1) Before removing pipes, release the pressure of 41) Inspecting date, place hydraulic oil tank, or open the cover on the 2) Model name, Serial number and Record on Tetum side to tank, and take out the filter. hour mater 2). Drain the oil in the removed pipes into pan to prevent the ol! rom spilling on the ground 3) Pipes with plugs or caps to prevent ail leaking, entry of dust, ete 4) Clean the outside surface of equipment, otc before disassembling, and drain hydraulic ot and gear oil before putting them on working bench, 3} Trouble condition, place, cause 4) Visible oil leak, water leak and damage 5) Clogging of filters, oil level, oi quality, oil contamination and looseness. 6) Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter. (8) Arrangement and cleaning in service shop 1) Tools required for repair work, (2) Disassembling hydraulic equipment 41). Since performance and function of hydraulic equipment after disassembly and assembly 2 peer the places to put the disassembled results in immunity from responsibility on the La manufacture’s side, disassembly, assembly 3) Prepare oil pans for leaking oil, ete. and modification without permission are strictly prohibited, 4.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING 2) IFitis unavoidably necessary to disassemble and modify, it should be carried out by experts oF personnel qualified through service training, (1) Sefety 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 @ 4) 15) 5) For parts which are required to use jig and tools, don't fal to use the specified jig and tools. For parts which can not be removed in the specified procedure, never force removal. First check for the cause. The removed patts should be pul in order and tagged so as to install on proper places without confusion, 8) a) 8) For common parts, pay attention to the quantity and places Inspecting parts 1) Check that the disassembled paris are free from adherence, interference and uneven working face. 2) Measure the wear of parts and clearance, and record the measured values. 3), If an abnormality is detected, repair or replace the parts. Reassembling hydraulic equipment 41) During the parts cleaning, ventilate the room. 2) Before assembly, clean parts roughly first, and then completely. 3) Remove adhering oll by compressed air, and apply hydraulic oll or gear oil, and then assemble them, 4), Replace the removed O-ring, back-uprings and oll seal with new ones, and apply grease oil on them before assembling 5) Removes dirt and water on the surtace on which liquid sealant ere applied, decrease them, and apply liquid sealant on them, 6) Before assembling, remove rust preventives on new parts 7). Use special tools to fit bearings, bushing and oi seal 8) Assemble parts matching to the marks. 9) After completion, check that there is no omission of parts. Installing hydraulic equipment 1) Confirm hydraulic oil and lubrication oi 2) Air release is required in the following cases ; 4. Change of hydraulic oi Replacement of parts on suction pipe side Removing and attaching hydraulic pump Removing and attaching swing motor Removing and attaching travel motor Removing and attaching hydraulic cyl 1-4 114 (AWARNING| If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. 3) For air bleed of hydraulic pump and swing ‘motor, loosen drain plug on the upper part, start engine, and run in fow idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. For air bleed of travel motor and hydraulic, cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. 4) [WARNING] For cylinder, don’t move it to the stroke end at beginning. 5) Air in pilot circuit can be bleed out by only operating digging, swing and travating motions thoroughly Check hydraulic oil level Move attachments to hydraulic oil cheok position, and check hydraulic oil level of tank. Refill oii the oil level is lower than the specified level How to check oil level of hydraulic ail tank 8) [eee eet ed Or et ora of tank {ie indiestore oe macs, the any 'Sacceptabie ELECTRICAL EQUIPMENT (1) The disassembly of electrical equipment is not allowed. (2) Handle equipment with care s0 as not to drop itor bump it. (8) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire (4) Check that connector is connected and locked completely. (8) Engine key off before removing and connecting connector,4, OUTLINE (6) Engine key off before touching terminals of starter, and alternator. (7) Remove battery grounding terminal before beginning work close to battery and battery relay with fools. (8) Wash machine with care so as not to splash water ‘on electrical equipment and connector. (9) When water has entered in the waterproofed connector, the removing of water is not easy. So. check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting, [AS WARNING] Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes ‘scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. + When it has adhered on skin ; Wash with soap and water. + When it has got in eyes ; Wash in water for 10 minutes or moro immediately. + When it has spilled out in large quantity ; Use sodium bicarbonate to neutralize, or wash away with water. + When it was swallowed ; Drink milk or water. + When it has adhered on cloth Wash it immediately. 4.4.5 HYDRAULIC PARTS: (1) O-ring + Check that O-ring is free from flaw and has elasticity before fitting. + Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated. So, choose proper O-ring. + Fit O-ring so as to be free from distortion and bend. + Floating seal should be put in pairs. (2} Flexible hose (F hose) + Evenifthe connector and length of hose are the same, the parts difer according to the withstanding pressure. Use proper parts. + Tighten ttotne spectig torque, and check that I its free from twist, over tension, interference and cil leak 1.1.6 WELD REPAIR (1) The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the grounding cable of battery. Ifthe grounding cable is not disconnected, the electrical equipment may be damaged. (2) Remove parts which may cause fire due to the entry of spark beforehand. Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don't fail to cover the section with flame-proof clothes. @ 4.1.7 ENVIRONMENTAL ISSUES (1) Engine should be started and operated in the place where air can be sufficiently ventilated. (2) Waste disposal The foliowing parts follows the regulation. Waste oil, waste container and battery (8) Precautions for handling hydraulic oi! Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes on handling it + When it has got in eyes Wash eyes with water until the stimulusis gone. + When itwas swallowed : Don't force him to vorit it, but immediately receive medical treatment. + When it has adhered on skin ; Wash with soap end water. (4) Others For spare parts, grease and oil, use KOBELCO genuine ones4. OUTLINE 1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations Introduction Tablet-4 Atthough this manual uses the SI units system. Outline QUANTITY [UNIT SYMBOL | FORMULA of SI units system is described here. Frequency hertz He tHe=tis Given hereinunder are an excerpt of the units that are Force Inewton N ig: mis? related to this manual Proscure and 1. Etymology of SI Units stress [Pesce i Ar English : International System of units Energy, Work 2. Construction of SI Unit System and Quantity of joule J Nem heat Base units Power __|watt Wi, ws Tabet | ___ Fea) _[ Brive units Quantity of | ouiomb c ee ‘Supplemen | r-|of base unts electricity ro [Stunts Lt taryunte Table 1-3 y [ st unit 1 | Table 1-2 a Electrie isystem|f =" Peers. potential | caring peculiar one sesignatons afore, | it v WIA jh [ebe'm4 | Voltage, and a El iv Prefixes of SI pone {n-th power of 10, where n is an integer force a Quantity of slaticelectricty (1) Basic Units and Electric |'*"° 7 Ae Tablet-1 capacitance (QUANTITIES DESIGNATION | SIGN Electric on 9 VIA Length Meter ™ resistence a Mass Kilogram kg Celcius [Peleus Tins Second > temperature [229728 & co | 27a.15)« Current lAmpere. degree. Thermodynamic Kelvin K Muminance Jur. us Simin temperature Gram molecule Mol mol ree oe Luminous intensity Candela cd Tablet-5 PREFIX POWER eee aya DESIGNATION SIGN Tablet-2 Giga 6 10" QUANTITIES DESIGNATION | SIGN Mega M ‘108 Piain angle Radian rad Kilo k 10° Solid angle [Steradian st Hesto h 10° Deca da 10 (3) Derived Units of Basie Units Seal 5 08 Tablet-3 Conti c 10° QUANTITIES DESIGNATION SIGN Mi m 108 ‘Area [Square meter mm Micro a 10 Volume Cubic meter me Nano n 102 Velocity [Meter per second ms Pico B 10 Acceleration [Meter per second / second | mis? Density Kilogram per cubic meter_|_kglm* 1-6(6) Unit Conversion Table ‘QuanTimes [vis | S1_[ REMARKS Mass kg | kg Force kgf | ON ‘Akgf=9.807N 807Nem Torque kgfm | Nem | kat Pressure | kgtfom? | MPa__ tkgfom'=0.098MPa Motive power| PS | kW | 1PS=0.7355kW Revolution | rp.m_| minx | trp.m=tmin- 1-7 4, OUTLINE4, OUTLINE [MEMO]2. SPECIFICATIONS TABLE OF CONTENTS 2.4. NAME OF COMPONENTS 23 2.2 GENERAL DIMENSIONS. : 24 2.24 $K200-8/SK210LC-8 [5.65m (18f-in) Boom +2. 94m (9-8) Standard Arm+0.80m?(1.05curyd) Bucket Shoe}...2-4 22.2 SK200-8/SK210LC-8 [5.65m (18f-6in}+2.4m (7ft-10in) Short Arm+0.93me (1.22curyd) Bucket Shoe].....24 2.2.3 SK200-B/SK210LC-8 [5.65m (18f1-6in) Boom+3.5m (148-Gin) Long Arm+0.70m (0.92curyd) Bucket SHOE)... 25: 2.3 WEIGHT OF COMPONENTS 26 24 TRANSPOTATION sn DB 241 OVERALL DIMENSIONS OF MACHINE ON A TRAILER, 28 24.2 DIMENSIONS OF ATTACHMENT 7 7 oo 2-8 2.5 SPECIFICATIONS AND PERFORMANCE ... . 7 244 25.1 SPEED AND CLIMBING CAPABILITY. 244 25.2 ENGINE... 7 seit 244 2.8.3 HYDRAULIC COMPONENTS 24 254 WEIGHT eal lt 214 2.6 TYPE OF CRAWLER. sos Seeeseeeeeaeee 242 27 TYPE OF BUCKET. se os F en BAZ, 2.8 COMBINATIONS OF ATTACHMENT. oo 7 a 243 2.9. ENGINE SPECIFICATIONS .escscunns 244 2.9.1 SPECIFICATIONS sons : ror 244 2.9.2 ENGINE CHARACTERISTIC CURVE (HINO JOSE-TA) 215 Book Code No. S5YN0218E01 2-12. SPECIFICATIONS issue Date of Issue ‘Applicable Machines Remarks SK200-8 : YN11-45001~ ISsyNO218E01 First edit 1, 2006 eee SK210LC-8 : Y11-06001~ (ASIA, OCE)2. SPECIFICATIONS 2.41 NAME OF COMPONENTS ARM CYLINDER ARM BUCKET, CYLINDER SLEWING BEARING IDLER LINK: SLEWING MOTOR FUEL TANK FUEL TANK | wyomauuc tan CONTROL VALVE BUCKET, SHOE AND TRACK LINK. FRONT IDLER IDLER ADJUST _-—~ UPPER ROLLER, ROTALY MULTI CONTROL VALVE (OPTION) LOWER ROLLER BATTERY 232. SPECIFICATIONS 2.2 GENERAL DIMENSIONS 2.24 $K200-8/SK210LC-8 [5.65m (18f-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m (1.05cusyd) Bucket Shoe] i lil Unit : mm(ft-in) iil 8 t a | ealhnrents b | _arrasi989 see 2200 (92°) ——— 2 pe99) (IF Note Dimensions marked * do not include the height of the shoe lug, [ Jinclude LC specifications, 2.2.2 $K200-B/SK210LC-8 [5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m' (1.22curyd) Bucket Shoe] Unit : mmift-in) 242. SPECIFICATIONS 2.2.3 SK200-8'SK210LC-8 [5.65m (18ft-Gin) Boom+3.5m (11ft-6in) Long Arm+0.70m: (0.82euryd) Bucket Shoe] ss0¢ary _Unit: mm(fe-in) Dimensions marked * do not include the height of the shoe lug, [ Jinolude LC specifications. 2-52. SPECIFICATIONS 2.3 WEIGHT OF COMPONENTS Unit; kg (Ib) Model $K200-8 SK210L0-8 item Machine complete 20,200 (44,500) | 20,600 (45,400), 1. Upper frame assy (Assembly of following :) 9,500 (27.000) = 1.4 Upper frame 41,770 (3,900) . 4.2 Counter weight (Semi-weighted) 4,840 (10,280) + 4.3Cab 260 (570) + 1.4 Engine *840 (1,190) « 1.8 Hydraulic oll tank 7150 (330) . 1.6 Fuel tank "110 (240) - 1.7 Slewing motor (including reduction unit) 210 (460) | « 1.8 Control valve *230(510) | « 1.9 Boom oylinder “170 (875) x2 < 4.10 Pin (for mounting boom) 70 (180) « 4.41 Pump "130 (290) © 4.42 Radiator (including intercooler) 790 (200) « 2. Lower frame assy (Assembly of following :) 2.4 Lower frame 2.2 Slewing bearing 2.3 Travel motor (Including reduction unit) 2.4 Upper roller 2.5 Lower roller 2.6 Front idler 2.7 Idler adjuster 2.8 Sprocket 2.9 Swivel joint 2.40 Track link with 600mm (23.6in) shoes assy Track link with 700mm (27.6in) shoes assy Track link with 800mm (31.Sin) shoes assy 6730 (74,840) 2,260 (4,980) 250 (550) 280 (670) x2 | 20 (44) x 2 30 (66) x14 | 110(240)x2 | 100 (220) x 2 50 (110) x2 *30 (66) 4,260 (2,780) x 2 1,470 (3,240) x 2 1,600 (3,530) x 2 7,430 (18,720) 2,420 (5,340) 30 (66) x 16 4,350 (2,980) x 2 1,560 (3,840) x 2 4.700 (3,750) x 2 2.10.4 Track link assy 540 (1.120) x2_| 540 (1,190) x2 3, Attachment (Assembly of following / STD -) 3.420 (7,540) = {5.65m (18ft-6in) Boom + 2.94m (9ft-Bin) Arm + 0.80m° (1curyd) Bucket} 3.1 Bucket assy (STD) 640 (1,410) ‘ 3.2 STD Arm assy (Assembly of following :) 1,050 (2,318) . 3.2.1 STD Am 1660 (1,455) . 3.2.2 Bucket cylinder "140 (310) - 3.2.3 Idler link 20 (Ad) x2 . 3.2.4 Bucket link 90 (198) « 3.2.5 Pin (2pes. for mounting bucket cylinder / 2pcs. for mounting bucket)| 100 (220) + 3.3 Boom assy (Assembly of following :) 1,730 (3.818) = 3.3.4 Boom 1,310 (2,890) = 3.3.2 Arm cylinder "255 (580) « 3.3.3 Pin (Mounting arm + Mounting arm cylinder) 80 (180) e 262. SPECIFICATIONS, Unit; kg (Ib) : Model 7 aa 8K200- 8 SK210LC-8 Item 4. Lubricant and water (Assembly of following |) 550 (1.270) < 441 Hydraulic oll 200 (440) « 4.2 Engine oil 20 (48) « 4.3 Fuel 310 (680) © 4.4 Water 20 (44) < (Chote) Marks * show dry weight. 272. SPECIFICATIONS 24 TRANSPOTATION 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER (1) 5.65m (18f-6in) Boom+2.94m (9ft-Bin) Arm+0.80r» (1,05curyd) Bucket Mode] SK200-8 SK200LC-8 item ‘Width 600mm (23.6in) shoes 2,800 (Sf-2in) 2,990 (9it-40in) Weight 20,200kg (44,500 Ibs} 20,6009 (48,400 tbs) Unit : mm (ftein) 2280 (759) s7s0(i2s) mean woe cater), ese aey SECTION AA * marks indicate LC specifications, 282. SPECIFICATIONS 2.4.2 DIMENSIONS OF ATTACHMENT (1) Boom Type| item LengthxHeighbawiath eer m (fein) Weight kg (Ibs) 5.85m (18f1-6in) Boom 5:2" 22 1,670 (3,680) 1.87 x 0.67 (2) ARM AND BUCKET 2.4m (7ie10in) Arm + 0.93m »(1.22cusyd) Bucket 2.94m (9feBin) Arm + 0.80m >(1,05euryd) Bucket 3.5m (T1f-6in) Arm + 0.70m2 (0.82curyd) Bucket 475 x 0.9% 1.33 (157211) 5.29 0.9 x1.16 (aT ar2"11"%4') 5.88 x 0.9 1.08 (1935211"937") 1,740 (3.840) 1,680 (3,700) 1,880 (4,150) 2.4 m (T-10in) Arm 2.94 m (9ft-in) Arm 3.5 m (1Mft-6in) Arm 3.40 x 0.86 x 0.56 (CN232"10°% 110") 3.94 x 0.86 x 0.56 (1241x2401 10") 4.53 x 0.87 x 0.56 (14'10"%2'10°%1'10") Type Item LengthxHeighbWith LxHxW m (in} Weight kg (68) (3) Arm Type| Item: LengitntHeighbavviath LxHxW m (fein) Weight kg (Ibs) 41,020 (2,250) 4,044 (2.300) 4,260 (2,780) 292. SPECIFICATIONS (4) Bucket Type Hoe bucket LongthoeHeighbWidth Tg] 197 x 4.26 0.87 [1.87 x 120x107 | 1.37 x 1.26% 1.16 [1.97 x 1.26 4.33 Lew aexa2%2t07) | (eraser) | 4era'25a'10") | (4'et4'2sa'4") Weight ig (Ibs)]__ 520 (1,150) 630 (1,390) (640 (1,410) 740 (7,560) Bucket capacity mcuvd| 0.51 (0.67) 0.70 (0.92) | STD0.80(1.05) | _0.93(1.22) Type Hoe bucket [Slope finishing bucket LengthaHeighixWiath ig g| 137%1.26%1.16 | 1.26%0.90%2.20 LHW (aorxa'2'x3t0) | (artxatt'x7'3") Weight kg (Ibs)|__750 (1,650) 890 (7.960) Buoket capacity inv curyd| 0.80 (1.05) HD 0.82 (1.07) © Slope finishing bucket 2-102. SPECIFICATIONS 25 SPECIFICATIONS AND PERFORMANCE 2.5.1 SPEED AND CLIMBING CAPABILITY ee Meee $k200- 8 sK210Lc-8 ttem Swing speed imin= ep) 72.5 (12.5) Travel -speedi2- Favel speed (t-speed/2- a (miei) 3616.0 (2.2/8.7) speed) : a 7 Gradeabiity ‘% (degree) 70 (35) oe 252 ENGINE Eaghe meae EGRET Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-cherger ‘4-112 mmx 130 mm | (4.41 in 5.12 in) Type Number of cylinders—BorexStroke Total displacement I 5.123 L (312.61 ourin) Rated oulput/ Engine speed 144 KW (155 PS)/ 2,000 min* Maximum torque / Engine speed | 572 Nem (422 Ibfefty 1,600 mint Starter i T Hf 24. V7 5.0KW Alternator 7 2A VI12KW. ina 2.5.3 HYDRAULIC COMPONENTS. Hydraulic pump iz Variable displacement axial piston pump x 2 + gear pump x 1 Hydraulic motor (swing) ‘Axial piston motor x 1 BH Variable displacement axial piston motor x2 (with counterbalance valve) Control valve B-spool control valve x1 Cylinder (Boom, Arm, Bucket) Oil cooler Air-cooled type Hydraulic motor (travel) Double action cylinder 2.5.4 WEIGHT Unit: kg (Ibs) Fully equipped weight 20,200 (44,500), 20,600 (45,400) Upper structure 9,500 (21,000) < Lower machinery 7 (600mm grouser shoe) 6,730 (14,840) 7,130 (18,720) ‘Attachment 7 §.65m (18 ft-6in) Boom+2.94m (Stt-Bin) Arm 3,420 (7,540) | « +0.80m (1,05euryd) Bucket 2412. SPECIFICATIONS 26 TYPE OF CRAWLER Shape Shoe width mm (in) Sere eee Ground realy kPa Grouser shoe Socam |STD 2,800 (9'2") 45 (6.53) Lc 2,990 (9'10") 43 (6.24) ISTO 2,900 (9'6") 40 (5.80) le uc | 3,090(102") 38 (6.51) STD | _3,000(910") 35 (6.08) 46 LINKS| 800 (31.5) Lc. 3,190 (108") 33 (4.79) Note) Use 600mm (23.6") grouser shoes on rough ground (areas covered with racks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, ete.) 27 TYPE OF BUCKET ee stuck ge weer | TERI | Number] W or wio | “=#25UY| woignt ith side] Without side | oftace teu tooth | side cut mycurya) [P| cutter | cutter | “| SIE CUBE | ghover_| Ko (bs) Hoe bucket 0.39 520 | 70 (210" (26") | yes }9.51(067)) iggy) | 870210") | 77028 3 w (1150) 0.62 tl a 630 0.70 (0.82)} (5,99) | 1080 ('7)) 980(9") | 5 w YES | 360) {Covania Sty) 0.59 oe er) | w Yt 640 Meas) | (ory | P1608 10] 1.080 6) 5 eS | 410) {SE Asia STO} 1 | 0.80 (1.05)| 0.59 ane er w bo Side pin. | (077) | 2780 (910%) 1,080 (96) | 4 YES | 460) type 0.67 . : 710 | 990429] song) | 1990449] 122004 | 5 w YES | c's) 2-122. SPECIFICATIONS. 2.8 COMBINATIONS OF ATTACHMENT A oe Bucket ‘Available Arm Type [NeaPes capacity) — Struck | 2.84m (a-Si) Arm | 8.5m (THf-Gin) | 2.4m (7R-10in) Arm li im (curya) me (curya) _ (STD) |__+arm (Sh 0.51 (0.67) 0,39 (0.51) oO Oo O° 9.70 (0.92) 0.52 (0.68) ° 9° Oo [Oceania STD} 0.89 (0.7) ® A ° Hoe bucket 0.80 (1.05) (SE.Asia STO] 0.80 (1.08) 0.59 (0.77) ° A ° Side pin type 0.93 (1.2) 0.67 (0.88) A x Breaker - — oO ° Nibbler = = O° ° Note © Standard combination O General operation : Excavation or loading of sand, gravel, and clay A Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel) Prohibited combination : There are problems from the view points of strength and stability. + Use the attachments recommended by KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibilty ARCAUTION Hf any other bucket, except for the backhoe bucket, is tuned over and used for excavation, damage to the arm and bucket may occur, 2-4132. SPECIFICATIONS 29 ENGINE SPECIFICATIONS 2.9.1 SPECIFICATIONS Applicable machine Engine model Type, ‘SK200- 8, SK210LC -8 HINO JOSE-TA Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger Number of cylindersBoraxStroke om (in) 4x 112 x 190 (4.41 x 5.12) Total displacement ce (cusin) 5,123 (313) Compression ratio 18.0 Rated output Maximum torque kW (PS) at min’) Nem (ibeft) at 194 (155) at 2,000 572 (422) at 1,600 mins High iting min 2,000 #30 Low idling rain 1.000 +30 Injection starting pressure MPa (psi) 50 (7.250) ‘Thermostat action erica 380 (170) 1963 (194) Firing order 7-3-4-2 MPa (ps) ‘Compression pressure 3.4-3.7 (499-537) at 280 at mins Fuel injection timing o Valve clearance Open Chose iébefore top | d0°after bottom Valve clearance Intoke valve | 0:8 mmatoosl | Ges oint | dead point Cxnaust vane | 048 mnatcoe |store bolton | 1Sraer top dead dead point point Starter capacity Vk 245.0 Generator capacity (Alternator) VxA 24x60 Cooling fan drive method 650 (25.6") x suction type 7 fans, V-belt drive, pulley ratio Crank / Fan= 0.89 Full evel 18.0 (4.76) Engine oi! quantity L (gal) Low level 18.0 (3.96) Total 21.5 (6.68) Dry weight kg (ibs) 580 (7,260) Fuel consumption ratio GikWen (Gipsy) 217 (160) Allowable inclination (Limited by E/G lubrication) Dimension (LxWxH) Rotating direction mm {in) Front / Rear and Right / Left: 35° 1,063 x 725 x 895 (@i-5.86in x 26 bin x 89.2in) Counterclockwise seeing from fiywheel side 2442.9.2 ENGINE CHARACTERISTIC CURVE (HINO JO5E-TA) Condition to be measured: The net value is indicated, measuring without cooling fan. ‘© marks show the rated point 2. SPECIFICATIONS, (N +m) 600 (kw) i rm 8 — 500 @ | e 120) 400 & T y i — 7 300 100) | 5 807 7 5 3 E | % 60}— llg/kW-h) 40 260 & é | Zz + aI 240 2 g 3 20 — 220 8 [| | | 4 — + 200 4 | | g | : O00 1000 400 1800-2200 2600 3000 ENGINE SPEED (min-1) Fuel consumption volume Fuel consumption rate X kW X Load factor (@) 0.835 X 1000 = PATON x tak x 0.835 X 1000 a: Standard load factor (0.70~0.80) w 29.6 a. Lh Fuel consumption in regular operation (load factor 0.70-0. 20.7 Linm23.7 Lih 2415 80)2. SPECIFICATIONS [MEMO] 2-16TABLE OF CONTENTS 3.4 BOOM eae a 3.1.1 BOOM DIMENSIONAL DRAWING... 3.1.2 BOOM MAINTENANCE STANDARD. 3.2 ARM. 3.2.1 ARM DIMENSIONAL DRAWING. 3.22 ARM MAINTENANCE STANDARD 3.3 BUCKET . Set 3.3.1 BUCKET DIMENSIONAL DRAWING 9.3.2 BUCKET DIMENSIONAL TABLE 3.3.3. LUG SECTION DIMENSIONAL DRAWING 3.3.4 BOSS SECTION DIMENSIONAL DRAWING. 34 3. ATTACHMENT DIMENSIONS 312 312 312 343 344 Book Code No. S5YN0318E013. ATTACHMENT DIMENSIONS issue Date of Issue “Applicable Machines Remarks jSK200-8 : YNT1-45001~ IS8YNO318E01 First ect A [erect wgust, 2008 | e<940LC-8 : YQ11-06001~ (ASIA, OCE}3. ATTACHMENT DIMENSIONS 3.41 344 BOOM BOOM DIMENSIONAL DRAWING SECTION X-X ig. 3-1 Boom dimensional drawing Unit: mm (fein) STD = 5.65M (181t-6in) BOOM ee 7 No NAME DIMENSION. ‘A Boomlength 5,650 (186") = B [Boom foot wiath 670 (26.4") ~ [Boom end inner with 347 (13.7") - D —_|Boom end outer width 482 (19°) - E__ [Height of boom cylinder rod pin 4,008.5 (3: - F Height of arm oylinder (head side) pin 1,203.5 (311 i G _|pistance between pins of boss R2,589 (8'6") - H [Distance between pins of bracket 2,829.5 (9'3") - | |Arm cylinder (head side) inner width 126 (4.96") = J Outer wicth of bracket on the arm cylinder (rod side) 468 (18.4") - mounting 1 [Boom foot pin dia 6 90 (354°) = 2 [Boom cylinder (rod side) pin dia 0 85 (3.35") - 63 Pin dia. of boom end. 0 90 (3.54") - d4__|Arm cylinder (head side) pin dia. 9 85 (3.35") = 3-33. ATTACHMENT DIMENSIONS 34.2 BOOM MAINTENANCE STANDARD (1) Clearance of pin and bushing on boom section ASIA eee Unit : mm (in) ‘Sandard value Clearance 1 sym} in | Repai tal Item Pin partNo. | a. aig | Pin aia ate S| Standard oe Service | Remedy tolerance| value | lit tolerance| level | +0020) +0217 | +0287 @ 90. |(+0,0008)| +0.0088)| (+0,0003) A | Boomtoot | YNO2B01719P4 eee (3.5433)} -0.020 | +0.071 | +0054 (-0.0008) | (+0.0028)| (+0.0020) 9 | 70243 | = 0.288 Boom cylinder 085 | 0.010)| (0.011) 8 ‘YNo2B01720: acao | (Head side) | YN0?°P1720P1 Jos a4gsy), OR, | +0.085 | +0.085 | More ou HH ( ) |¢+0.0083)] (+0.0033)| than | 25 teeing +o.020 | +0247 | +0267 | 20 | (on) [Nn Boom cylinder | | (+0.0008) (+0.0097)} (+0.0105) | (0.08) i © | (Rod sidey | YN°B01721P4 =0.020 | +0.093 | +0.073 685 | (0.0008) | (#0.0037)| (+0.0097) | (3.3465) + 0.030 | +0.252 | +0.282 ‘Acm oylinder (+0,0012)] ¢+0.0098)| (40.0111) © | Head side) | YN0E01889P1 -0.030 | -0.099 | +0.069 I (-0.0042} | (-0.0039) | (+0.0027) 3-43. ATTACHMENT DIMENSIONS OCEANIA Unit: mm {in) 1 Standard valve Clearance sym. i ue tem Pin part No. india. | PY" | standard | PP" | service | Remedy bol Pin dia id bie tolerance | value limit tolerance level +0020 | +0217 | +0297 A | Boom foot | ywoaBor7iget | 290, |(+0.0008) (+0.0085)) (0.0008) (3:5433)} -0.020 | +0071 | +0051 (-0.0008) | (+0.0028)] (+0.0020) i + 0.283 | +0289 ° Boom cylinder 088 (+0.010)} (0.011) -0.010 © | ead side) | YN02801720°1 | 2465) doote | *2085 | +0.085 | More Be {-0-00%6) | 40.0033) (+0.0033)} than | 25 ines soar | +0267 | 20 | (a) |Ponne Boom cylinder i (+0.0097)} (+0.0105) | (0.08) © | Rod sidey | YNO#BOI72IPT +0.020 | +0.093 | +0.073 9.85 |(+0.0008) (+0.0037)| (+0.0097) |(3.3465)| -0.020 | +0.230 | +0.250 ‘Arm cylinder (-0.0008)] (+0.009) | {+0.010) | D | load side) | YN02BO1722°4 | ogee -rboie I (+0.003) | (+0,002) 3-53, ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom eylinder installation section [La PL4 ea | xa] 2) SECTION B-B SECTION AA Fig, 3-3 Clearance in thrust direction on the boom cylinder installation section Unit ; mm (in) ‘Clearance X adjusted with shim Basic size fislori Eas) Pin length Sec item Remedy Siandard |Reparabie| Service No.| Size No.} Length vatue | ievel_|_ timit Boom oo AA [Boom foot tr LE84L| 05 (0.02) pur] 23! cee 676 | orless (327) i (26.6) 20 | 258 Bot ellen 105 (0.08) | (0.10) ep [Boom cylinder vt tp L419} 06-10 pil 241 (Head side) 411 | (0.02~0.04) (9.49) Upper trame aan Shim a adjust i t cc [Boom oxtiner POMevInEeT | 4) 443) | 6-20 | 30 | 40 pus) 738 | (Rod side) “) 468 | (0.02~0.08)} (0.12) | (0.18) (28.0) Boom Ls (18.4) [Arm oylinder ies pup [Armeylinder 7 ig L472) | 06-10 | 2.0 28 [ay 4) 260 (Head side) 726 | (0.02-0.04)] (0.08) | (0.10) (10.2) fee (4.38) 3-63.2 324 ARM ARM DIMENSIONAL DRAWING 3, ATTACHMENT DIMENSIONS SECTION Y-Y SECTION 2-2 Fig. 3-4 ARM DIMENSIONAL DRAWING YN12500904F1 (ASIA) Unit : men (fein) 2.94m (9f-8i S4m (91-8in) ARM) 3800802F1 (CE) Code] NAME DIMENSION |Code] NAME DIMENSION C_|Arm iength 2,940 (98")_| _N_|Bracket inner with 126 4.96") Distance between pins of boss : iia aepuaneelt R874 (84.4") | [Bracket inner width 111 (437°) Dit [LD of boss, 2110 (433°) | P [idler ink dimension 530 (248°) D2 |1.D of boss: 085 (3.35")_|_Q_|Bucket link dimension 610 24") BE loeb ease: 2105 (4.13%) | R [Relontbeween pins ofboss andl 3 7, 55 loenter Distance between pins of boss ae 7 Fs loa ereelat R2,169 (7'1") | dt [Pin dia 280 (3.15") Distance between pins of boss F in 5 epee R420 16.5") | 42 |Pin dia. 270 (2.76") Height between pins of boss and 7 7 & racket 665.5 (26.2") | 03 [Pin dia 085 (2.35") Height between pins of boss and : 7 Hl precket 3212.3") | d4 |Pindia 290 (3.54") K_[Arm top end boss width 325 (12.8") | a5 |Pindia 280 (3.159) [Arm link section boss width 323 (127°) M_[Boss width 342 (13.5°) 3-73. ATTACHMENT DIMENSIONS 3.2.2 ARM MAINTENANCE STANDARD (4) Clearance of pin and bushing Fig, 3-5 Clearance of pin and bushing on arm section ASIA Unit: men Gin) ‘Standard dimensions ‘Glearance No. ltom FinpatNo, | gig | Pindia. | Bushingid.| Standard | Repairatie| Senice | Remody tolerance | tolerance | value | _level_| _ limit 70.253 | +0333 Seeere (70,0100) | (0.0131) A. |Anm point 0.020 | +0.080 | +0.100 280 | (0.0008) | (+0.0031) | (+0.0039) 'y12802407P4 ae (3.1496)| -0.080 [+0284 | 70.204 [Bucket ink 0.0031) | (+0.0172) | (0.0143) (Bucket sida) 40.158 | 40.178 (10.0081) | (+0.0069) 0.253 | 0.313 ter tok on o70 0.0100) | (0.0123) © Connectespan}ywraR024061 E20) a osretiooa os of arm) (40.0076) | (+0.0078) o +0232 | 0.292 1p [Bucket ink ©) | (40.003) | (20.0715) (Idler link side) 0.060 | 40.161 | 40.161 Ha z (+0.0063) | (+0.0063)| 2.0 25 an eiieenaa (0.0024) | _¢ 2B02412P1 s0.338 | oe) | oon | sho py [Bucket oyinger 080 (40.0133) orpin (Rod side) (9.1498) 0.278 | 40.141 (+0,0109) | (0.0086) +0.141 | 40.308 ‘Bucket cylinder (10.0056) | (40.0121) © loca ane) |YN1280241304 paren Sta (0.0012) (90.0044) 0.030 [+0252 | 40.282 JArm cylinder 685 | (0.0012) | (+0,0089) | (40.0111) F Jerod side) |YNO2BOTEIOPT | 3 3455) 40.079 | +0.049 (0.0031) | (+0.0019) +0.020 | 40.202 | 10.312 ‘Arm foot nfo 090 | (40.0008) | (0.0118) | (+0.0123) i coon Pan |YNIZBO2415P1 | 13 5433)| 0.020 | 20.195 | 40.175 0.0008) | (40.0077) | (+0.0089) 3-83. ATTACHMENT DIMENSIONS OCEANIA Unit: mm fin} ‘Standard dimensions Clearance No. Item PinpartNo. [oo iq | Pindia. |Bushingid.| Standard [Repairable] Service | Remedy tolerance | tolerance | value | level | limit +0283 | +0313 Saas (40.0100) | (+0.0123) Ast ene -0.020 | +0080 | +9.100 80 | (0.0008) | (+0.0031) | (10.0039) peeeoeeioet (3.1496) | -0.060 40.220 +0.280 [Bucket ink 0.0024) | (0.009) | (40.0110) (Bucket side) 40.076 | +0.006 (+0.0030) | (0.0038) 0.285 | 40.325 ater ink fi 070 (0.011%) | 0.0120) © feomerosnennszeczwer |, “0.0112) | (40.0128 {+0,0050) | (+0.0050) © [+0205 | 0.285 [cet ine (©) | 0.008) | ¢eo.ot00) ter tink side) ~o01 | 19.083 | 0.043 Replace (-0.0016) {+0.002)_| (+0.0020) 20 25 YN12B02217P1 ¢ 40.285 | (0.08) | (0.01) | Pests o Bucket cylinder 080 (+0.0110) e (os side) (0.1496) so2a5 | 40.089 {0.010} | (0.0040) 10.089 [40.265 Bucket oyinder (+0.008) | (0.0700) & [Pym | yropozzters 0.088 (+0.0030) et +0.020 [so250 | 0.250 cylinder 285 | (0.0008) | (0.009) | (+0.0100) [Rod side) [*N07B04722P1 | ig 34555] 0.020 | 0.065 | +0.088 (6.0008) |[email protected]) | (0.0020) 0218 | 40.234 ‘Arr foot 990 (40.008) | (+0.0090) 6 omectes pad|ucrasozos¢r1 | |, 24, aera evanar (46.003) | (+0.0020)3. ATTACHMENT DIMENSIONS (2) Clearance of arm and cylinder installing sections in thrust direction SECTION C-0. SECTION E-€ SECTION F-F PL? LPs SECTION B-B SECTION D-D SECTION GG Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction 3-103. ATTACHMENT DIMENSIONS Unit : mm (in) Clearance X adjusted with shim Pin en feed (total of both sides) ee Sec. item Smee Remedy No.| Size | Sandard |Repaitablel vice imi] No,| Length value_| level 326 acm (1279)|1.0(0.04)| 2.0 A |Acm poi Pl eee puke || 228 | orless | (0.08) st : (12.83) 481 18.9) Link side ; Pen ee 2-8 |Buoket link wpe _ 7 PL Bucket ea 323 25 ater ink cc jae am | is | c27 Ave on | 8 |Pvs (eam connection eas - ) Bucket lnk Rod side 7 D-D | (ler tink Lincaise | Lt] 32 aor connection) eta (12.72) (16.8) os-1.0] 20 Shim Rod side 108 | 024-002} (0.08) ne adjust [Bucket link (4.13) bo uw -ment (Rod side) eae 11 (437) 105 exe [Pucketoyincer TPES || v4.13) pis) 28 (Head sice) reat 111 (0.25) «sr | 0620] 30 40 720 | o.oe-a08)) (0.12) | (0.18) R ecg [Armoylinder ease | 1272) pie] 260 |(Rod side) ty 126 (10.2) (4.98) cm ae (1346)| 05 | 1.0 25 505 6.6 Jarmt oe boom | | 8a | 002) | oa | 10) |) e199) (13.66) 3-113. ATTACHMENT DIMENSIONS 3.3 BUCKET 3.3.1. BUCKET DIMENSIONAL DRAWING (1) Hoe bucket Fig. 3-7 Bucket dimensional drawing No. NAME: No. NAME: ‘A [Distance between pin and bracket G [inner width of bucket bottom B [Distance between bucket pin and tooth end H [Bucket outer width of front side C Inner width of bucket top end 1 |Pitch between teeth D [inner width of tug fo |Pitch between teeth E__[lnner width of bracket dt_[Outer dia. of bushing F _ [Outer width of side cutter 02 [Pin dia, 3.3.2 BUCKET DIMENSIONAL TABLE Unit: mm (fin) Tye Hoe bucket (SE. Asia S10) opis) 0.80 m* ee 0.54 me 0.70 m* 0.93 1.08 ewe) | oper) | (OST euya)) | (OS2euyd) | (1.24 cua) Side pin type PartNo | YN61B00272F1 | YN61B0025eF1 | YNeiB002e7F1 | YNOiBOOZSGR1 | YNeTBOOZEErI A Ra30 16.9") © © € © 8 Ri,440 (49°) © = e © ¢ 1,008 (33") © Tie (28°) 925 (364°) 1176 (407) D 399 (15.7") © © © e E 327 12.9") © a © © F 1.187 (8) © 868 (34.2") 7,073 66) 1330 (44°) G 863 (34") < 572 (22.5°) 765 (30.9") 7,036 (95) x 7.087 (36°) < 76 (30.2") 979 (38.5") 7.230 (4) 1 224 (6.82") © 300,(11.8") 203 (7.99") 266 (10.5") 0 224 (6.82") = 300 (17.8°) 203-(7.98") 286 (10.5) at 095 (3.74) © e © © 2 280 (3.15") = © © & 3-123. ATTACHMENT DIMENSIONS 3.3.3 LUG SECTION DIMENSIONAL DRAWING y 8 | Ba i q | | ‘i oo x an a Boss a 1 vyastB01002°1 139) Apply ust prevention o : » / oF} ON go | i a | ; cL \ Boss SEM lveinstateg MSeVtthis pin tush with surface ye61801002P1 ‘at shipping) SECTION X-X DETAIL B Fig. 3-8 Dimension of lug section Unit : mm (ft-in) g 2° g | als gs 2 Cepacty of BES aE ede e/ele/$ ‘Type of —_ PatNoot js }/2]/s | 8/3 )/S] 8/3) 38) 2 puceet | BERL | ket ge ;e;e/e/e]elel sigs ‘cuye) fre;e)2le)s)eie)a)é eis i|2l|Flé isle slai 8 aAlepi[olelri[eo[Hiuluin [SE. Asia STD] bat (nas) | uesa00arar | [Oceania ST] | | Hoe 0,80 (1.05) YN61B00258F1 | ps0 | 25 | 995 | 13 | e180 25 16170 | 36 | 140, bucket | PT LB | oben] Fy SE] FOR) | 1016 | 0 B8ey BE [coy els }o.s1(0.67) — | YNetBooze7F4 | 0.70 (0.92) YN61B00280F1 | o.93(1.21) — |YNetBo0288F1 | | | | L 3-43,3. ATTACHMENT DIMENSIONS 3.3.4 BOSS SECTION DIMENSIONAL DRAWING A go seer) Fig, 3-9 Dimension of boss section Unit : mm (ft-in) Wwe] Comes | oma | pes orf mae | PenMeet | re | on | yp Foc | oof e | F | oo | a T | 1 bucket] m’ (cue) ISE. Asia STO) 25 0.80(1.08) | YNe1B00272F1 [Oceania TD] 0.20 (1.05) | YN61800258F') YestBor602°1 0510.67) | ynexeco287F1 0.70(0.92) | vnereocze6r1 0.93(1.21) _[yne1B00288"+ Hoe bucket a fuss} ss] a | oe | ow | os 319} 4157 | 4399 | sry | (150 | (oes | 5124] (nosey 3-1411. TOOLS TABLE OF CONTENTS 11.1, TIGHTENING TORQUES FOR CAPSCREWS AND NUTS 143 11.2, SCREW SIZE. ange 145 41.2.1 CAPSCREW (BOLT) 115 11.22 CAPSCREW (SOCKET BOLT) ...... att 115 41.23 SOCKET SET SCREW..... enn eB 11.3 TIGHTENING TORQUE FOR HOSE AND FITTING 116 11.3.4 JOINT (O-RING TYPE} oo ene 116 14.32 HYDRAULIC HOSE (30° FLARE TYPE) 116 11.3.3 JOINT (ORS TYPE). edt . 116 11.34 SPLIT FLANGE fae seninnne 1B 11.4 TIGHTENING TORQUES FOR NUTS ANDO SLEEVES. 7 445 PLUG felt 118 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT. 7 118 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT 119 11.6 SPECIAL SPANNER FOR TUBE vn 7 1444 417 SPECIAL TOOLS.....cn ms nme ese AZ 14.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......14-14 11.9 SUCTION STOPPER. a . 5 11-15 14.8.4 COMPONENTS. . sees AB: 119.2 DIMENSION oo 11.8.3 APPLICABLE MODEL 11-15 14.10 COUNTER WEIGHT LIFTING JIG laa aoc 11-16 11.11 UPPER FRAME LIFTING JIG... ent 1-17 11.12 ENGINE MOUNTING PEDESTAL... . 14-18 14.13 TRACK SPRING SET JIG ... #7 7 fs 14-19 Book Code No, S5YN1118E01 14-411. TOOLS Issue “Date of Issue Applicable Machines “Remarks _ First edition August, 2006 SK200-8 : YN17-45001~ ISK210LC-8 : YQ11-06001~ SSYN1118E01 (ASIA, OCE} 11-241.4 11. TOOLS TIGHTENING TORQUES FOR CAPSCREWS AND NUTS Tables Tablet1-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given. Overtightening cf bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques. Tabie11-1 Tightening torque for metric coarse threads (not plated) Unit : Nem (lbfeft) classification 487 7 10.97 Nominal size |No lubrication| Oil lubrication] No lubrication] Oil lubrication] No lubrication] Oil lubrication ie 7 44x05 | 37404 | gext0 | g1soe | 174s18 | 14.7418 204) | (27403) | (7140.7) | 6.0206) | (12.813) | (10.8#1.1) Me paizg | to7et1 | 9.0209 | 235820 | 19.6120 | 422839 | 25.9239 (7.9208) | (6620.7) | (17.381.5) | (14.681.5) | (31.1229) | (26.082.9) Mio Pets 21.642.0 | 17.9818 | 46.1249 | 39.283.9 | 83.438.8 | 70.626.9 (15.981.4) | (13.2813) | (34.0836) |_(28.942.9) |_61.5%65) | (62.185.1) wiz pays | 96939 | stasze [ 7oae7e [osreb | tasers | 12iei2 (26.822.9) | (23.242.4) |_(68.685.8) | (49.2851) |_(10511) | _(69.288.9) an 87.9259 | 49.0949 | 126818 106210 | 226820 | 191319 __| 42.7244) | (36.1836) | (92.980.6) | (78.227.4) | (167218) | (141814) Naaeeeet 86.386 | 74.5469 | 191820 veisté | 343eg9 | 284820 | (05.146.5) | (55.086.1) |_(1ate15)_|_(119#42) | (253429) | (209821) Mis 122412 103210 285429 226420 461448 402239 (90.038.9) | (75.887.2) | (195321) | (167215) | (955296) | (297429) ieneeeetpeae test? | tadeta [373239 | 314229 | 667469 | 559559 (ia7s13)_| (voss10) | (275829) | (232421) | (ao2e5t) | (412%44) 22 226220 192420 00849 | 422839 902488 755878 (167215) | (142415) | (@eges6) | (attez) | (esses) | (557258) Meee 204229 | 235129 | 637209 | 620249 | tie0st18 | 941z98 "| rz) | (73s24) | a7oss1y | (a8aes6) | (856887) | (694272) iat agia39 | 363x990 | oats98 | 7e5e78 | 17003167 | 13702137 (318#29) | (260s29) | (eoae72) | (S84#58) | (12508123) (10104101) aot 586259 | 490249 | 12852127 | 107es108 | 23008235 | 19402196 (434244) | (961236) | (948294) | (796280) | (17002173) | (14902145) ron 794s78 | 667869 | ‘17262177 | 14512147 | 31108314 | 26102265 a _ (686258) | (492851) _| (12702131) | (1070#108) | (22908232) | (19302195) seed 7030208 | 863388 | ve6ss186 | a010e402 | 33602333 (7e0e72) | (637465) _| (16408167) | (13708137) | (29604297) | (24808246) 11-311, TOOLS Table11-2 Tightening torques for metric fine threads (not plated) Torque value Unit : Nem (Ib) Classification 487 TT 409 Nominal size _ [No lubrication] Oil ubrication|No lubrication] Oil lubrication| No lubrication] Oil lubrication Me pao | Msett | Obe10 [245220 [ 206120 | 441239 | 97.983.9 (9.3408) | (7.00.7) | (18.121.6) | (15.281.5) | (2522.9) | (27.5#2.9) Mio peta5 | 226820 | 187218 | 4atsa9 | 412439 | a7ce8e | 73.569 (16.7218) | (13.881.4) | (95.543.6) |_(90.942.9) | (64.4265) | (54.225.1) Miz Pei2g | 392839 | 22229 [ e62s88 | 71.0260 | 154216 129813 (28.9429) | (24.6821) | (62.9465) | (52.885.1) | (114812) | (95.280.6) wie parg | 922288 | 775278 | 196820 169817 363239 304829 (68.046.5) | (67.2258) | (145215) | (126813) | (268820) | (224221) hoes 186219 155216 | 402430 333229 | 726269 |” 608269 (i37et4y | (is4et2y | (297820) | (24x21) | (635851) | (448244) toateeeepue 314228 265229 | 686269 s60n59 | 12402118 | 1030298 (22421) | (1gss21) | (606851) | (a20eaay | (e15387) | (760872) heats 627359 saot49 | 13002137 | i167e118 | 25008255 | 20808206 (470244) | (991296) | (10302101) |_ (#53287) | (1840%188) | (15901152) Hegemon 859288 706270 | 1e60st@6 | 18508155 | 3360x934 | 27908275 (ezge65) | (62te52y | (93708137) | (11408114) | (2470#248) | (20608203) Waeeeeipes yo7os108 | 8eze8e | 23308226 | 19402196 | 42002422 | 35008363 (7eoxe0) | (esese5) | (17202167) | (14302145) | (3100#811) | (25804260) 11-441. TOOLS 11.2 SCREW SIZE 41.24 CAPSCREW (BOLT) Nominal [8mm | Nominal [8mm screw size sorew size | 7 Tool size 7 Too! size “Me | 10 "M36 55 MB 13 a2 cy M0 7 Mas 70 Miz 18 Mae 75 (4) 22. MSE 85 M16 27, (M60) 90) (Mia) a7 Med 95 M20 30. (M68) 100) (422) 32 M72 105) M24 36 M76 110 (M27) at M80 115 M30 46 ath 11.2.2 CAPSCREW (SOCKET BOLT) Nominal Simm] Norinal [Bm er 820 en | OS ra ia) 28 | Wao | a (M4) 3 (M22) 7 d {MS) 5 M24 19 M6 5 (M27) 419 MB é M30. 22 Mio | 8 __ M36 27 wiz [40 | wae a2] wig [easy | MiG | 14 M48 36 (wt6) 14 MSZ 36 Sunes 11.2.3 SOCKET SET SCREW Nominal [Bini] Nomnal [Bam seen 6 ogi sae [SCM S2®| ool aze é w25 [127 | wea we [ 48 | Mio 18 we 2 [wig] ws | 28 | te “| 6 5 M6 3 M20 70 | ise Peay 11-511. TOOLS 11.3. TIGHTENING TORQUE FOR HOSE AND FITTING 44.3.1 JOINT (O-RING TYPE) Size Wrench Tightening toraue PA ia Neale o-niNe opine 178 4 4722 (1321.5) / 7 14 19 3642 (2787.5) LL: 2, 7 3/8 22 7a (5524) ae " 5 1g —_| 3/4 36 16220.8 (11927) _ 1 41 25529.8 (18847) HYDRAULIC HOSE (30° FLARE TYPE) Size Tightening torque (PF) Wrench(mm) site A 178 id 7512.0 (1181.5) 14 79 2084.9 (2120.8) 3/8 22 4924.9 (9613.6) 1/2 27 TeE4.9 (5843.6) 3/4 36 11620.8 (6727.2) ace 41 137215 (101211) #4 7 11.3.3 JOINT (ORS TYPE) Tightening Torque Unified screw size | Opposing flats ightening Torqu: CONNECTOR O-RING FITTING Unified screw size | Nem (loft) i y) 6 177216 (131813) 41 206226 (162216) 47116612 UN 46 206: east) NUT i 11.3.4 SPLIT FLANGE ___ Tightening torque Nem (Ibi) FUNGEHEAD | CLAMP HALE size | Standard pressure | 534,| Hipressure | ao ta / series eg series cae f 20.6 MPa 41.2MPa 37a | 35.8856 (2544) [WHO | 90.5256 esa) | wi ny j 7_| 42.4256 (3124) [M10] 62.2856 (4624) | M12 1 « |ASS \ “Viral “55.147.1 (4185) | wo |__93.528.4 (6926) | Mid || ce 11/2] 70684 (6286) | mi2 | 169811 (12528) | M16 I 2 81.948.4 (6086) | M12 | 22411 (20838) | M20 So 1-611. TOOLS 11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES ‘Table11-3 indicates standard tightening torques applicable to cases where no particutar note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections, Always lighten nuts and sleeves to proper torques. Tablet1-3 Working Tube size | Opposing] Tightening torque Manufacturer's name| Pressure OD xthickness | flats Nem (Ibft) i MPa (psi) mm (in) (HEX) mm 10x15 | 9.8 (3627.2) (osesvoose) | 1 49:020.8 (9647-2) 2152.0 | 3212 (8728.7) (0.591x0.079) a ited teed 21825 : ie Nippon A.M.C. 29.4270) | io-r0970.098) 32 1a7e15 (190811) 2223.0 16422 (16081 (0.866%0.118) = beeen ett 226x4.0 275827 (2008: coon at 5427 (200820) 285%5.0 #44 (3308: Ihara Koatu 29.4 (4270) (1.3600.197) 55 saveae (930839) 7 SLEEVE san NUT as| So | WAL. 4 Tube size Paris No. Tube size | Opposing Paris No. ed Thara Koatu | Nippon AMG ed flats thara Koatu_ | Nippon AMC. a (HEX) mm é 293806000 = 8 14 2F93N06000 = a 293808000 = 7 Zr93noeo00 [ 40 ZFS3S10000 | ZA93S10000 19 ZF93N10000 | ZAG3N10000 42 ZF93S12000 = 22 2F93N12000 = 18 2F23815000 | ZAe3S15000 | 27 ZFO3N15000 | ZA93N15000 18 2F93818000 | ZA93S18000 ae ZF9anie000 | ZA9SN18000 22 2F93S22000 | 2A93822000 [ 36 2F93N22000 | _ZA93N22000 28 ZF93S28000 | ZA93S28000 a ZF9aNza000 | ZA93N26000 32__ | zFe3s32000 = 50 2F93N32000 = 38 2F93835000 | ZA93S35000 55 ZF93N95000 | ZAS3N35000 38 7793838 = 60 ZF93N38000 i 1-711. TOOLS 11.5 PLUG 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT (1) Cap nut (Joint plug) (2) Plug (Tube plug) Sleeve Nut Type joint body (3) Nut dscrew i Applicable tube Cap nut parts T sorew lOpposing flats No. BLA ZFe3HO6000 | Mi2x15 14 | 14 ZF83H10000_| M16.x 1.5 3HoBoo0 _| Mt 2F83H12000_| M18 x15 ZF@3H15000_| M22 x 1.5 ZF83H18000_| M26 x 1.5 ZF83H22000_| M30x 1.5 ZF63H28000_| 36x 1.5 ‘Applicable tube | Plug parts No. O.D'A 6 2F63P06000 8 ZF83P08000 40. ZF&3P 10000 2 ZF83P 12000 15__ | _2F83P 15000 18 ‘ZF83P 18000 22 | _ZF83P22000 28 ZF83P28000 ‘Applicable tube | Nutparts No. | d screw |Opposing flats O.D:A | 6 __| 2FOsNO000 | MI2x45] 14 | ZF93Nosooo | Maxis] 17 jo | zFeani0000 [wiex ts] 19 12__| 2F9ani2000 | Mi8x 15] 22 78 | 2Fosnis000 | Me2xis| 27 78__| Zroaniao00 | M26xi5| 32 22 ZF93N22000 | M30 x 1.5 6 26__| 2F93N26000 | waex15| 41 32 __| 2FOsNS2000 [WAZ x15] 50 35__| ZF93N35000 | masx15| 55 ~~36__ | 2F93n36000 [M48 x15] 60 11-811. TOOLS 11.5.2. PLUG FOR HYDRAULIC EQUIPMENT (1) PF screw Plug paris No. |2 mm] O-ring paris No. | Nominal O-ring E72x04000 | 19 | Z012P07100 | 18 Pit E72x06000 | 22 | Z2D12P01400 18 Pia ‘2E72x08000 | 27 | ZD12P01800 4B P18 2E72x12000 | 36 | Z2D12P02400 1B P24 PF screw Ze72x16000 |_41 | 2D12P02900 18 P29 (2) PT screw B PT screw PT screw| Plug parts No. Bmm rie | Zee2To2000 | _5 pri | Ze82T04000 | 6 PT3/8. 2E82T06000 8 pri | zee2toso00 | 10 praia_| Ze82T12000 | 14 pti | ze62T16000_|_17 PT114 | ZE82T20000 22 prise | zee2t24000 | 22 (3) Plug for (F) flare hose PF screw PF screw] Plug parts No. [8mm pra | 2442272001 | 24442272602 PR _| 24047272603, . Praia _| 2444z272004 Opposing flats B PFt 24442272805 PF screw) Plug parts No. | E mm | F mm. PFi4 | 244az2720D1 | 14 | 19 praie_| 24a4z272002 | 17 | 22 pet2 | 2aaaza72903 | 23 | 27 pra4 | 2aaqz2720D4 [27 | 36 “Opposing pe1_| 2asazzr2005 | 36_| 41 fats E Prt ia | 2agaz272006_| 40 | 50 11-914. TOOLS {4) Plug for ORS joints Male ‘Sorew size | Applicable ‘Opposing | O-ring [Nominal A hose 0.0 | PUG ParSNO. pus iex| parts No._| O-ring 114UNS | 021.7 |YNOTHO1001P1, 27 _|ZD12A01600| 1BAt6 13/16-12UN| 927.2 |YNO1HO1002P1) 36 |ZD12A01800| 1B A18 17/16-12UN| 634.0 |YNO1HO1003P1) 41 | ZD12A02100) 1B A21 Female Screw size | Applicable’ Opposing A | tube 0.0 | Plug parts No. inate (HEX) st A 1-14UNS 921.7 |YNO1HO1004P1} 32 13/16-12UN| 027.2 [YNO1HO1005P1) 36 1 7/6-12UN| 934.0 [YNO1HO1006P1} 41 (6) Pig for hal clamp 40H For standard pressure : 20.6 MPa (2990 psi) Plug O-ring Size} parte, [CMM] D mm mm |Hmm part No. sre |zer2008000| 38.10 | 1748 S59 | aszoi02 314 |Z£12012000| 47.63 | 22.23 | 188°} 11 jzD12P02600 + |ze12@18000| 52.37 | 26.19 |88:75°| 11 212P03400 4114 2€12020000] 58.72 | 30.18 |“.58") 11 'z012P03800 For high pressure : 41.2 MPa (5970 psi) Plug T ‘O-ring Size | partno, [ORm|Dmm| Emm Hmm) anno 112 |ze13008000] 4.49 | 10.24 |*857"| 9 [2aaszeato1 314 |2€13012000| 50.80 | 23.80 |S.) 11 |z12P0z600 1 |2E13Q16000] 57.15 | 27.76 | Se/e> | 13. [zD12P02400 1114 2613020000) 66.68 | 31.75 |“4,5&| 15 |zp12Pcse00 14-1011. TOOLS 11.6 SPECIAL SPANNER FOR TUBE Applicable tube diameter Part No HEX (mm) Drawing of a special spanner mm (in) mm (in) 182781, 2 16 (0.881) | 24217160 ar oe0) anit sr) 127 (0800332) 701210 gt 18 (0.709) | 2421T138 32 Pane, woe Boo) ee = ox OE ago) 2F SO 800335) 702.76) 420.9) TA ges oH 22 (0.866) 24217130 36 (0.908), eran NEEL [Bessy ne 12740500332) 7091429) Seopa 28 (1.10) 2421715 at dl ne ae Ne. HEX 2043.15), 10014.29) gest] 28 (4.10) 24217234 46 ok Or} parteno. FAH sa) a 19.08% (07603) 80(3.18) , 1004.20) Fe5(0 045) | 32 (1.26) 24217232 50 od [Poe nee" 119.087 (0.76038) 816,19), 9003.58 35 (1.38) 24217314 55 ad exes 11-1111. TOOLS 11.7. SPECIAL TOOLS Tablot1-4 No.| Tools name [Tools No ‘Shape Applicable % [E Allen wrench | zrooq10000 | 5 x Pump 1 Nominal oe eee B:10,C:11.3 vas. L Commercial oo angth (Lt) - ut ength = Requied length 40 (1.87°) - 10 (0.98") = 30 (1.18°) ‘Spanner or 2 socket |General toots Heh Nominal 8 : 17 3 | Spanner | 2712A36000 Swing motor Nominal $ : 36 AB port 81 (3.19°) - 16 (0.63") = 65 (2.56") ‘Addiional M10 X22 forti0 Bye bot 7 Plug 2€72X12000 Jor M10 eye bol For slinging the PRS/4 swing motor Pron ‘O-ring 410 Eve bot Eye bot | 2891C01000 : For slinging the One. or swing motor commercial & equivatent : Flare hose ¢ t Fm T ! iB Eye bolt Pl i 2F83P22000 (Nominal wed 22 aeinrant | Fare tose Eye tor | 2897000800 ve 2F93N22000 ¢ iasie: Nut ' CAdationas i treading for Me Eye bot 11-12Tablet1-4 11. TOOLS Me Eye bolt 8X 18 Plug YNOTHO10011 Esko + reading Norninal \ 7 | 4414UNs | Flare nose Eye bot | 2891C00800 | _AAAUNS a MB Eye bolt | | MB x18 ‘Aadtiona Plug | YNotHot002e1 threding NX Nominal 8 | taner2un | y Flare hose Eye bot | 2S91C00800 ee Piug 2E25F 08000 i‘ PrI2 For slinging the Coupling swivel joint halt TORX driver seems For instrument 10 proof) — | Point shape renal eevee 730 | \ (For M6) 11-1311. TOOLS 11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND (1) For general use ue Manufacturer ae Loctite | Three-Bona | Fou tow #242 1 300K | strongth Screw locki crew locking aa ia Middle compound strength High ial 1908 | strength Sealing commons | #585 te15 | Sealing (2) For specific location No. |__Use | Manufacturer] Name Equivalent Aoplicable (Manufacturer; Loctite) #1904 |Anti-seizure loyiinder Three-Bond |#1218 gray #8609 Swing motor #1211 white #52011 | wing motor fe r3038 leon [Main pump (Manufacturer; Theee- Bond) Beate #222 # 134an Main purnp 1 & #277 [#1907 Pilot valve adhesive (Manufacturer; Three- Bond) Loctite Parmatexosd |v 1121 Hydraulic ol tank Sumitomo Chemical Co., {cyano Bond PO-t Hose Ls Shel Shell Alvenia EP2 |New Molyknock Grease 2 |Swing bearing grease bath petroleum 11-1411. TOOLS 11.9 SUCTION STOPPER 41.9.4 COMPONENTS No. | NAME PARTS No. [QTY — SUCTION STOPPER ASSY [24100P076F2| 4 [ROD 24207486001] 1 Sines 2_[NUT zn16co8007 | 1 — 3 [COVER lataTat2302| 1 It 4 [O-RING |4579106 1 | 2Nut 7 3 cover 4 O-1ing Fig. 11-1 Components of suction stopper 11.9.2 DIMENSION 20 cal eet T *e 113 (4.45") M8 NUT 7 _Iil os 0.3155 dl ; g a Ty & fags e og s| ge, es e & 3 @ Bel Sl 8) | Grsacn et “| RRO. Sorry | “ie (4.25") COVER Fig. 11-2 Dimension of suction stopper 4193 APPLICABLE MODEL NN Applicable xclale wl model slzlele/S)S\/8le/#l Ble ~ S18) S/S /S/8/2/28/8/ 818/818) [roto 9-1 515 | 5151515151551 81515 | 8 | | 2a100Po7er2 e[olofofofofolofolofofolo] 11-15,11. TOOLS 11.10 COUNTER WEIGHT LIFTING JIG (1). Standard eye boit Fig. 11-3 Eye bolt 11-16 Size] Vera MB [mao (ate 18 18 PartNo. | atin | j ant | Meta | Z5eiG00800| 80(176) | 2891001000] 150 (331) | M12 22. 2891001200 220 (486) Mi6 27 2891001600| 450 (982) [zo 30 2391602000 | 630 (1390), 24 38 891602400 950 (2080) [so 45 2891603000 | 1500 (3310) use| 55. 2391603600 |2300 (5070) aa] [maa 2400 (7480) [4500 (9820)|41. TOOLS 11.11 UPPER FRAME LIFTING JIG aa ra 7) | | 130(8.12°) 65 (0.748")19 80 B15) Qty :2 sets Material : Mild steel Fig. 11-4 Uppor frame lifting jig 1-1711. TOOLS 11.12 ENGINE MOUNTING PEDESTAL 245 (2.65) Material : Wood Unit ; mm (inch) 6 4 ar Als =H g TT] alts z z é ® 744 (29.3) 409 taf 945 (97.2) 5 °. 1 6 215 500 toa Tay 2X 1 piece 4X1 piece 1X tpiece 400 (157) 570 26.4) EE 430 (185) +s dig ayer a | boca a a tT a Es ras q ‘150 \) 3 @ als 2 leo 3 124(0.95) a" | 2 124,098) 5X1 piece 3X1 plece “670 (26.8). foo e572) 2 | 6X8 ples Sl ect fe 4049.93) Ee Tao OY 0.30, Fig, 11-5 Engine stand 11-1811. TOOLS 11.13 TRACK SPRING SET JIG M30 _ Retainer nut S~ Retainer plate 700 380 Base Fig, 14-6 Track spring set jig 11-1911. TOOLS [MEMO] 11-2012. STANDARD MAINTENANCE TIME TABLE q ‘TABLE OF CONTENTS 12.1. STANDARO WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4 12.2. ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) cnn . vanes AB: 12.2.4 MEASURING METHOD 7 ne 1246 12.2.2 WORKING CONDITION... ene 2A 42.2.3 STANDARD TIME CONSTITUENT. Fl 12-48 12.24 MEANING OF WORDS IN USE 1247 Book Code No, SSYN1218E01 12412, STANDARD MAINTENANCE TIME TABLE Issue “Date of Issue Applicable Machines [_____ Remarks [SK200-8 YN11-45001~ SBYN1218E01 First edit ju eee August, 2006 SK210LC—8 : YQ11-06001~ (ASIA, OCE) 12-212, STANDARD MAINTENANCE TIME TABLE PREFACE, (1) Working Conditions 1) Workers More than one worker shall be ‘st 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 ‘Aflat land where work may be performed and to which a service car or a truck crane is accessible. (2) Range of standard maintenance time i 1) Standard maintenance time=Direct maintenance timexPreparation 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. (8) Extra time (not included in the standard service time) 1). Repair time Machining, sheet metal, welding, melt cutting, folding and extracting tolls, servicing parts, and painting. 2) Items excluded from service time because of uncertainty in time Receiving 2 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 paris 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 erane trucks. (4) Applicable machine for estimation of standard maintenance time 1) Standard machine 2) A.well maintained and controlled machine with a standard combination of attachments which is used in a general environment. 12-312, STANDARD MAINTENANCE TIME TABLE 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR (1) Standard maintenance time table 1) 2) 4) 5) Units of working time : 6 minutes = 0.1 hour Calculating method of standard maintenance time Maintenance time=Working timexNumber of workers (Working time=Maintenance time+Number of workers) When more than one operation is going on ‘Add each standard service time. A pure time (readily started) is given exceptcovers easily removed by hand. Assy works include the following works marked with black dot « OIH : The removing and attaching time is not included ‘Abbreviations in the table. AIC Air conditioner cv Control valve on Over haul ASSY — : Assembly cyl Cylinder SOL: Solenoid ATT —: Attachment BIG Engine sw Switch BRG Bearing Fhose : Flexible hose v Valve (2) Classification of working code No. Group Remarks Ee 01 [Attachment Indicates installing, removing, replacement anc overhaul 7 02 |cab & Guard 03 [Swing frame 04 [Travel system 95 [Etestie Indicaies the instaling, removing and replacer ent of single items lequipments i 09 (|E/Grelation Indicates overhaul of the single engine. ot |(Materiais prepared by manufacturer ) (8) Conditions for standard service time of the engine 1) 2) 3) Tools designated by B/G maker are used Genuine parts are changed Correct working procedures are observed. + The time required for works specified in this Chapter shows the total time for maintenance. 12-412. STANDARD MAINTENANCE TIME TABLE croup Location MORO yi Remarks is (00 [Bucket relation ‘See 3212 PEE IEEE 01 [Bucket ASSY Deizenvatacn| 1 pe. [Include adjustment. 06 02 |+ Bucket ataching and detaching postion | Preparation} 1 pc. on 03 |+ Bucket attaching pin Betachiatacn| 1 Include stopper pin. on 04 |+ Bucket drive pin Detachiatach| 1 on 05 |+ Bucket sling and movement Preparation] 1 pe. 02 06 | Bucket (single) OI | 4 pc. | Notinclude attaching and detaching | 2.4 07 |+ Tooth Replace | 1pc. | 06 08 |+ Side cutter Replace | 1 pe. 12 09 |+ Bushing Replace | 1 po. 06 10 [Arm relation [See 92.1.3 11 [arm ASSY SESE Detachiatech| 1 po. 5 12 12 |+ Bucket cylinder attaching and | Preparation} 1 po. | 04 detaching position and piping 13. |+ Bucket cylinder rod pin Detachattach | 1 pc. {Include stopper pin on 14 |+ Bucket cylinder head pin Detachiatch | 1 pc. |include stopper pin on 18 |+ Bucket cylinder assy Detactiatach | 1 pe. on 46 |+ Arm cylinder rod pin etaeriatacn] 1 pe. |Include stopper pin ot 47 |+ Boom top pin Detzchiatiacn| 1 po. [Include wire stop pin. o4 i 48 |+ Arm sting and movement etacniatach) 1 pe. 02 2 [30 [Boom relation [Seoda.1.4 5 [31 [Boom ASSY T Betcnatacn| 1 pe 14a 32 |+ Boom attaching and detaching posiion| Preparation] 1 pe. on 33 |+ Boom cylinder temporary slinging Preparation} 2 pes 02 34 [+ Boom cylinder rad pin Detachiatiach | 2 Include two stopper pins. | 02 35 |+ Boom cylinder piping Detactvaticn| 2 pc. 02 26 |+ Arm & bucket piping Detachiatacn| 1 pe. 02 37 |+ Boom assy temporary slinging | Betachvatacn | 4 po. | o1 38 |+ Boom foot pin Betachitiacn| 1 [Include stopper pin. 02 39 |+ Boom assy slinging Detachiatacn| 1 po oz 40 |/Arm cylinder attaching and detaching | Detacnatach | 1 pc. 04 41. |+ Arm cylinder piping Detechisticn| 4 pe. 02 42 |» Arm cylinder head pin Detactvatach | 1 pc. |Include stopper pin on 43 |+ Arm cylinder slinging Cetachatacn | 1 pe. on 50 |Boom oyinder attaching and detaching | Detactattach| 2 pes. 07 51 |+ Boom cylinder piping Detachatach | 2 03 52 |+ Boom cylinder head pin Detachiatisch | 2 pes 02 53 |+ Boom cylinder slinging Detechiattacn| 2 02 60 |Bucket cylinder oir 1 36 61 |+ Pin bushing Replace | 1 _ | include seal. 12 70_|arm cyindar om 1 36 12-512, STANDARD MAINTENANCE TIME TABLE Group Location Moree) Unit Remarks a 71 |» Pin bushing Replace | 1 set include seal 12 ~ | 80 (Boom cylinder ort 2 70 © | a1 |+ Pin bushing Replace | + set include seal 42 10. |Cab relation See 38.12 11 [ca assy Datechetacn| 7 po. 14 12 |+ Front lower glass, floor mat Detzcnetact| 4 po, each oa 18 |+ Seat rear cover top, bottom Detacniatac | 4 places| 02 14 |+ seat rear cover top, bottom Detachiataeh 4 pe. each 02 46 |+ Right side panel (include NC duct) | Oetechatach| 3 03 16 |+ Cable and hamess (electric) | ewenattach) 6 02 17 |+ Cab mounting bott Detacattaeh | 8 pes. 02 18 |+ Cab slinging Detaciattach |3 places! 02 20 [Guard relation See 33.14 21 [Bonnet assy (11) Deiachitacn| 1 pe. 02 22 [Guard (5) Dstachiatacn| 1 pe 02 23. |Guard (6) Detachatacn| 4 pe 02 24 |Guard assy (3) Detaciatacs] 4 pe. 02 25 |Stay (7) etaratacn| 4 pe. 02 B] 25 [ouars2) outaowatach | 1 po 02 G | 27 |Panel assy (21) Dotachvattach | 1 pe. 0.2 |) 26 [Panel assy (23) Detecnatach) 1 pe 02 8 | 29 |Panet assy (22) Detachiatacn] 4 pe 02 | 30 [Guard assy (18) etacwataen] 1 pe. 02 31 [Guard (14) Detachatacn| 1 po 02 92. |Guard (15) etaevatacn| + po 02 38. [Guard (17) Detacatacn| 1 pe 02 34 |Pllir (14) etacvatacn| 1 po. 02 35 [Beam (4) etachitaen] 1 pe 02 36 [Pillar (10) Detachatacn| 1 pe 02 37 [Pillar (12) Detactvateen| 1 pe. 02 38. |Guard assy (18) Detacvatisen} 1 po 02 39 [Guard assy (13) Detaciataen | 1 pe 02 40 | Guard (19) Detachiatacn| 1 pe 02 41. Cover (2) Detach} 4 pe. 02 42 |Guard assy (1) etachatacn| 1 pe 02 43 |cuard assy (3) atachsttacn| 4 pe 02 44 {Plate (20) Detachatiacn | pe 02 45 | Cover assy (1) etacnanacn| 1 po 02 Note: The numbers the peronthesis ike guard (14) match the guard numbers on the upper structure, 12-612, STANDARD MAINTENANCE TIME TABLE Group Location busibadead fet Remarks ee done Hour 80 [Under cover relation See 33.1.8 61 [Cover (1) Deieenatacn | 4 po. oA 52 |Cover (2) ataciatach | 1 po o4 53 [cover (3) Detechlatach| 1 po oa 84 [cover (4) Detachiatach| 1 po oA 85 [Cover (5) Detaciatacn| 1 po. on Z| 56 |cover (6) Delacistach | 4 po ot | 87 (Cover (7) Detactten | 4 po o4 | 58 |cover (8) Datacivataen| 4 pe ot é 3 [[o0" [counterweight retafion e035 1 |Counterweight ASSY Deachiatech| 1 po 06 62 |+ Counterweight iting eye bot | Detaavarach| 1 get oA 63 |+ Counterweight temporary singing |Preperation| 1 pe. 02 84 |+ Counterweight mounting bolt | oetentataen} 1 pe. 02 65 |+ Counterweight slinging Detnetattien| 1 pe ot 70 [intake relation See 33.1.9 11 |Aircleaner ASSY Derschiataen| 7 pe. 04 12 |+ Hose (3) Detachotecn| 4 of 48 [+ Air cleaner mounting bolt Detacvntach| 1 sat 02 14 |» Element Replace | 1 01 20 [Exhaust relation fs0033.1.10 24 [Muifier ASSY Deacniatacn| 1 pe 04 22 |+ Ubolt otachianaen| 1 pe. 02 9 | 23 | Clamp ASSY etaevataen| 1 pe 02 a ‘© |_30 [Radiator relation S00 33.1.12 3 | 31 [Radiator ASSY Deaciatech| 1 pe. 40 & | 32 [+ Cootant (Luc) Replace | 1 pe 03 33 |++ Concentration of coolant Measuring | 1 pe 02 aa |+ arc condenser betactiatach| 1 pe. 03 a8 |+ Stay Delachatach] 1 po. 01 38 |+ Bracket ewctatacn | 4 63 37 |+ Sub tank hose Detachatacn] 4 po. oa 38 |+ Fan guard Detaciataen| 1 pe. 03 39 |+ Water hose (radiator~£/G) | oetecvatacn) 2 08 40 |+ Radiator mounting bolts removing | Detachatiacn| 1 set 02 41 |+ Under cover etacnaieen| 1 pe. oa 42 |+ Hydraulic oi tank suction stopper | Detacivatacn| 1 pe 02 43. |+ Hydraulic oll piping Detachietacn| 1 pe os. "Note: The aumnbers in he parenthesis ike cover (2) maich the guard numbers on the upper stuciure 12-712. STANDARD MAINTENANCE TIME TABLE croup Location WIRE ya romans el 44 |* Inter cooler hose & tube Detachiatiach | 2 pos. 05 {EIG to inter cooler) 45 | Radiator titing or hoisting Detacrvatacn| 1 pe. 02 46 |- Radiator inter cooler core & oil cooler | Cleaning | 1 pe. 4.0 50_[Fuel relation See 33.16 51 [Fuel tank ASSY Detachiatiacn| 1 po. 18 52 |+ Fuel Replace | 1 pc. 03 53 |+ Hose (water separator side) Detechitiach) 2 on 84 |+ Water separator Detechiatach | + po. O41 85 |+ Tube (tank side) Detachiattach| 1 o4 57 [+ Fuel tank installing bolts Detzchiattach| 1 pe. 03 68 |+ Tank slinging Detachiatiach| 1 pe. oa [Other necessary works Betechiatich} 1 po. [Removing and installing guard | 0.4 60_|Hydrauic oil tank relation [See 33.17 61 [Hydraulic oil tank ASSY Detacnvatach | 1 po. 30 © | 85 f+ Cover Detechiatach | 4 po. 02 5 + Hydraulic oil Replace | 1 pc. 05 a | 68 |+ Pilot drain hose Detechiatach | 1p. 02 3 + Pump suction hose Detachattach | 1 po. 08 © | 70 [+ Mounting dott Dotaciatach | 1 pe. 02 © | 71 |+ Hydraulic oil tank slinging Delaoniattach | 1 po. 03 72 |e Return fiter Replace | 1 02 73 |+ Suction fter Cleaning | 1 02 80_|Pump relation See 33.18 @1 [Pump ASSY Detachvatach | 4 pec 32 82 |+ Hydraulic oll tank cover Detachiattach | 1 pe. 02 83 |+ Strainer & stopper Dotachattach| 1 po. 03 84 |+ Piping Detzchiatach| 1 set 1.0 85 |+ Guard Detachlatach| 5 pcs. 10 86 [+ Pump slinging Detachiatach | 1 pe. 05 87 |+ Cleaning Cleaning | 1 pe ot 88 |+ Vent air Adjust. | 1 po ot 89. |Pump ASSY on | 1 pe 40 90_| Swing motor unit relation [See 33.14.19 91 | Swing motor ASSY Detachiatach| 1 pe. 24 92 |+ Piping Detachatach| 1 set 10 93 |+ Mounting bot Detachattach | 1 pe. 07 94 |+ Unit singing Detechvatach | 1p. 05 95_|+ Cleaning and sealant Cleaning |_1 set 02 12-842, STANDARD MAINTENANCE TIME TABLE Group Location Merete Pe Unit Remarks oe 96 [Swing motor om | te. 36 97 | Swing reduction gear om | 4 pe. 42 700 [Swivel oint relation See $3.1.20 701 [Swivel joint ASSY Detachiatacn | 1 26 102 |+ Piping (Top part only) Detachiaiacn| 1 set os 103 |+ Whirl stop bolt Detachiatacn | 4 02 104 |+ Cover Dotachiatiacn| 1 04 405 |+ Joint & elbow Detacriatach| 1 set 04 406 |+ Mounting bott Detachiatach| 1 sot 04 107 |+ Swivel joint slinging Detachiatach| 4 04 108 |+ Cleaning Cleaning | 1 set 03 109 | Swivel joint OM | set |Removing and installing guard] 3.6 other necessary works Cetachiatach| 1 set |Lower piping 06 10 | Mull control valve (For Oceania) See 33.115 1H [+ Mull CIV ASSY Detachiatach| 1 (Alter removing guard 17 g | 112 Joie hose name on muni Cv comecting nose] Oetaciatach] 1 set 03 | 113 |+ Piping Detachiatach| 1 set 0s | 114 [+ Mounting bott Detachiatach| 1 set 03 Z| 215 |+ cleaning Cleaning | 4 set 02 8 JOther necessary works Detechiatiach| 1 set |Guerd 04 1120 [Main control valve See 35.116 121 [Main control valve ASSY Detactiattach| 1 pc 26 122 |+ Attach tag to port name of pipe | Preparation! 1 pe. 06 123 |+ Piping Detachiatach| 1 set 17 12d |+ Bracket mounting bolt Detacniatach| 1 pe. on 425 |+ Valve slinging Detachiatach| 1 pe oa 4126 |Main control valve ASSY Detachiatach| 1 set 60 Jother necessary works Detacvatach| 1 set [Guard 04 190 [Valve relation OPT 131 [Solenoid valve ASSY Detacwatach| 1 10 192 |+ Attach tag to port name of pipe [Preperation] 1 02 133 |+ Piping Detachiatach| 1 sot 08 14 |+ Mounting bolt Detactvatacn| 4 03 140 [Engine (ES) mounting relation see 33.113 141 [Engine ASSY Detacwatacn| 1 pe. [Alte removing pump & radiator | 1.8 142 |+ Hames connector & grounding & | Detastvatech| 1 po. 03 cable connection 143 |+ Fuel hose Detachiatech| 1 pe oA 12-912. STANDARD MAINTENANCE TIME TABLE Group Location Peat Unit Remarks fae 144 [+ Others Detaewatacn| 1 set 05 145 |+ Mounting bott Detachiatach| 4 pe. 08 146 |+ Engine stinging Cetgcrianach| 1 set 02 147 |+ Cleaning Cleaning | 1 pe. 03 148 | Engine OH | set Reference for engine (Chapter 51) Other necessary works Detachlotsch| 1 set |Removing and instaling guard | 0.6 Cetacratech| 1 set {Removing an stating Counterweignt | 0.6 Detacratach| 1 set |Removing and installing pump | 3.2 Detachiatach) 1 set_ [Removing and installing aircleaner| 0.4 2 DetacWatach| 1 set [Removing and installing muffler | 0.4 = Detachiatiacn| 1 set |Removing and installing radiator | 4.0 5 ® 1780 [upper trame [See 8.1.21 8 1751 lUpper frame ASSY Deiechatach| 1 pe. [After removing swivel joint 13 182 |+ Mounting bolt Detachiataen| 1 set 04 188 |+ Upper frame slinging Detacwatiacn| 1 pec 04 184+ Cleaning Cleaning | 4 pe. 03 185 |+ Sealant Apply | 1 pe. 02 Other necessary works Detachiatach| 1 set [Cab 14 Deizevatacn| 1 set [Guard oa Cotechatacn| 4 aet_|Counterweight 00 Detachiatiach| 1 set [Boom 14 00 [Travel relation See 34.12 01 [Track link ASSY Detachatiach |One sidelinclude adjustment of tension | 4.5 02 |+ Track ink staching end detaching ostion | Preparation One side| of 03 |+ Master pin Detachattacn [One side| 0s 04 |+ Track link extending and winding | detachiataen One side! 0s 05 Shoe plate Replace | 1 pc o4 g & [10 [Upper rotter relation See 34.13 3 A [Upper rotor ASSY Oeiachiatach| 1 [After removing track link 02 3 | 12 |Upperrotter on 1 10 © [20 [Lower roller relation [See 34.14 21 [Lower roller ASSY Detachiatach| 1 02 22 |Lower roller on 1 15 30. [Front idler relation See 34.1.5 31 [Front idler ASSY Detactvatach [One side|Atter removing track tink 06 32 |Front idler ASSY stinging Detachatach |One side| 02 33 | Front idler ASSY Detaching |One side 03 34 [idler ASSY of _ [one sice| 10 12-10412. STANDARD MAINTENANCE TIME TABLE Group Location wort Pe nit Remarks ae 36 [idler adjuster ASSY OI One side| Replace spring 24 36 |+ Grease cylinder OI One side| 08 40 [Sprocket see 34.1.6 41 [Sprocket Replace [One sidel After removing track link 06 50_ [Travel motor relation See 34.1.7 51 [Travel motor ASSY Detachiatiach [One side Afier removing track link 17 52 |+ Motor cover Detachiatach |One side| ot 53 |+ Hydraulic piping Detachiatiach |One side| 0.9 ¢ | 54 [+ Motor mounting bok Detachiatach |One side! 08 5 | 55 |+ Motor stinging Detachiatiach |One side} ot 2 | 56 [Motor cleaning Cleaning |One side| O41 & | 57 [Travel motor OHH |One side| 36 5 58. | Travel reduction gear Ol [One side! 36 {80_[Swivel joint relation 81 [Pipe on ewival joint travel side Deiachianach| 1 pe. [nce tomar aay ova evden | 08 62 | Swivel joint OH} 1pc. |See33.2.6 36 70 [Swing bearing jsee04.1.0 71 [Swing bearing ASSY Detachvatacn| 1 pe. After removing upper frame 07 72. | Swing bearing mounting bolt Detachatiacn | 1 po. 0s 73. |Swing bearing slinging etacratiacn| 1 pe. 03 [Controller 6-1 |Conirolier (KPSS) Replace | 1 08 6-2 |Gauge cluster Replace | 1 10 -4 |Air conditioner Amplifier Replace | 1 20 Diode 2 | 0-4 [Diode Replace | 1 08 & | 0-5 |Diode Replace. 1 03 3 | 06 [Diode Replace | 1 03 2 | 0-9 [Diode Replace 1 03 Bono cece asa ap i 8 |D-12|Diode Replace | 4 03 D-13|Diode Replace | 1 03 D-14|Diode Replace | 1 03 0-15 | Diode Replace | 1 03 0-16 | Diode Replace | 1 03 0-17 |Diode Replace | 1 03 12-1112. STANDARD MAINTENANCE TIME TABLE Group Location ote T unit Remarks oe D-16 [Diode Replace | 1 03 D-19 Diode Replace | 4 03 0-20 [Diode Replace | 4 03 Electric equipments Ext [Fuse & relay box Replace | 1 08 &-2 |Alternator Replace | 4 10 €-3 |Hour meter Replace | 1 03 E-5 |Hoxn (High) Replace | 4 03 £-6 [Hom (Low) Replace | 1 03 £-7 [Tuner AM & FM (OPT) Replace | 1 08 E-6 |speaker lett Replace | 1 03 E-9 |Speaker right Replace | 1 03 E-10| Receiver dryer Replece | 1 _|Include gas sealing 40 -11 |air compressor Replace | 1 |eeriecoutereohirrornganciessing. | 1.0, E-12| Battery Replace | 2 04 e | E13 Travel alarm (OPT) Replace | 1 os 5 | E-14| cigarette ignter Replace | 1 03 S | £215 [Fusible tink Replace | 1 02 8 | g-24JoPs antenna Replace | 1 05 % | -25|PDC antenna (IT controller) Replace 1 or 1 |e20z7|Acoo!amergency mode resistance 12 | Replace | ‘pair 08 Light T-1 [Boom work ight iat Replace | 1 [Bub 02 L-2 |Work tight right Replace | 1 02 8 [Swing fusher & work light (lft) Replace | 4 02 L4 [Swing fusher & work light (ight) | Replace | 1 02 LS |Room light Replace | 1 02 L-6 [Boom cylinder work light (right) Replace | 1 02 ‘Motor 1M [Starter motor Replace | 1 [incite Comwatntronovnganéwatairg | 1.0 M3 | Winer motor Replace | 4 08 Mt [Washer motor Replace | 4 08 M8 [Grease motor (OPT) Replace | 4 08 M9 | Skylight wiper motor (OPT) Replace | 4 08 Propotional vaive PSvAlAim variable recreuation propotonalveive | Replace | 4 08 psv.s/P2 bypass cut proportional valve | Replace | 1 rowcenorenouredecrrenanyosesuing | 0.8 Psv-c|Travel straight proportional valve | Replace | 1 08 12-1212, STANDARD MAINTENANCE TIME TABLE Group Location [Work 0 66) ni Remarks ae Psv.0|P1 bypass cut proportional valve | Replace | 1 0s psves]P1 pump proportional valve Replace | 1 0s sve2|P2 pump proportional valve Replace | 1 os Relay Ht Re [Battery relay Replace | 1 03 R-2 [Starter rotay Replace | 1 03 R-3 [Glow relay Replace | 1 03 R-4 [Safety relay Replace | 1 ot R65 |Hom relay Replace | 1 ot R6 [Work light retay Replace | 1 ot R.23| Auto idle stop relay 4 Replace | 1 ot R-24 | Auto idle stop relay 2 Replace | 1 4 | R-25|£/G emergency stop relay Replace | 1 ot | R-26 | Safety lock lever relay Replace | 4 on R-28| Alternator relay Replace | 1 | a4 R-29| Wiper motor relay (Normal rotation) | Replace | 1 o4 |R-30|Wiper motor relay (Reverse rotation) | Replace | 1 of § | R-31|Wiper motor relay arc prevention relay! Replace 1 04 = | R-82|Washer motor relay Replace | 1 on 3 |__|Sensor sania S| | 8 Pressure sensor : Bucket digging | Replace | 1 03 Pressure sensor : Bucket dump Replace | 1 | 03 Pressure sensor : Boom up Replace | 1 03 SE-4) Pressure sensor : Boom down Replace | 4 os SE-5|Pressure sensor : Swing Replac 1 03 ‘SE-7|Pressure sensor : Arm in Replace | 1 03 ‘SE-8 Pressure sensor : Arm out Replace | 1 03 SE-9/Pressure sensor : Travel right Replace | 1 |inclute uncer coverremeving andintating) 0.5 /SE-10) Pressure sensor : Travel left Replace | 1 jinclate undercover removing andinstating! 0.5 SE-11| Pressure sensor : P2 side OPT. Replace | 1 |inclie undercover removing andinstating) 0.5 [se-13] Engine speed sensor Replace | 1 |Inctuse undercover removing ancintating| 0.5 ISE-15)Engine water temperature sensor | Replace | 1 —_|incuse guard emoving nd instating | 0.5 ISE-16| Accel potentio Replace | 1 05 SE.20|Prossure sensor: Pt side :P1 side (OPT}] Replace | 1 |incudeundercover removing andinstling| 0.5 SE-22)Pressure sensor : P1 pump Replace | 1 0s 'SE-23| Pressure sensor : P2 pump Replace | 1 0s Solenoicl | SV-1 | Swing parking SOL T Replace | 1 [imusscronen vive necro aonasing | 0.5 SV-2| Attachment boost pressure SOL Replace | 1 |racovoporiaraitasrencigandnsaing | 0.5 12-13,12. STANDARD MAINTENANCE TIME TABLE Group Local ote Unit Remarks [ents ‘SV-3|2-speed travel SOL "| Replace | 1 (navapemnavanncrnon onic | 0.5 8V-4| Safety lever lock SOL Replace | 1 |rewencroroutvsvenscrreningwaieaivn, | 0.6 a ‘Switch 7 B /swalkey owitch Replace | 1 03 § |Sw-4|Swing parking release switch Replace 1 03 E |we7fenain of pressure teh repace | 41 03 5 |SW-8|Clogged air filter switch Replace 1 03 i | sw-t0 Horn switch (left) Replace 1 03 © | sw-ti|Safety lever lock switch Replace | 1 03 ‘sW-19] Wiper interlock switch Replace | 1 03 sw-20]Attachment power boost switch (right)| Replace | 4 03 sw-27]Engine cooting coolant level switch | Replace | 1 03 eee EEE eee 12-1412, STANDARD MAINTENANCE TIME TABLE, 12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) Preface This standard working time is based on the work time required for service of engine like disassembly, check, adjustment and assembly and so on under a following condition This standard working time is provided under the following conditions. 12.24 MEASURING METHOD (1) The time from the worker beginning working at the regular position of machine to the returning to the reguler position after completion of the work is counted as working time. (2) The measuring unit is in 0.1 minute, and then round up the fractions. (3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted 2s the working time. But light work which can be carried out easily by a person and the efficient is higher is counted as a workman 12.2.2. WORKING CONDITION 42.224 TOOLS, INSTRUMENT (1) Hand tool: ‘Tools which are commercially available and each workman usually carries (2) Common tool Tools which are commercially available and each workman do not usually carry but the storing place is specitied (3) Special tool; Tools especially prepared by HINO Motors Lid. and the storing place is specified (4) Machine tool ; ‘When measuring equipment and instrument are used, the time required to move parts lo the specified place is included but the time waiting for tool is not included as a general rule 12.22.2 WORKING PROCEDURE The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor's Ltd. Service Technical Dept. Training Group. 12.2.2.3 STANDARD WORKMAN QUALIFICATION, Workmen shall basically acquire 2~3 years of maintenance experience of HINO 122.3 STANDARD TIME CONSTITUENT 1223.1 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 Standard time Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts and s0 on, and for the work site clean- Standard allowance time Calculate the allowance time directly required for workmen from the following equation 2 2 Net standard time x 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 12.232 ALLOWANCE RATE, STANDARD PREPARATION TIME 12.2.3.2.4 HINO allowance rate (0.15~0.75) (1) Basic rate : 0.10 (2) Working posture allowance (Fatigue coefficient): Take any one of the followings according to the work contents. Standing work : 0.05 Work in bent posture : 0.19 Work while lying : 0.15 (3) Difficult work allowance : 0.30 (4) Seized rusted section (For new vehicle) : 0.50 Take any one of above (3) and (4). Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.08 = 0.15 Max, allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75 12.2.3.2.2 STANDARD WORKING TIME (1) Working standard time : 3 minutes {One time for a set of works) (2) Special toot standard time : 3 minutes (One time for @ set of works) (3) Standard time of non-portable machine : 3 minutes (For single work) (4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more) (One time for a set of works) (5) Test : 15 minutes (One time for a set of works) (6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes (One time for a set of works) (7) General cleaning : 2 minutes (One time for a set of works) (8) Safety treatment like wheel stopper, and so on : 3 minutes (9) Visual checks : 2 minutes The preparation time is classified into as described above, and only items required for the every work are selected, calculated and counted as preparation time of the work. 12-1642. STANDARD MAINTENANCE TIME TABLE 12.2.4 MEANING OF WORDS IN USE + Completed machine : When detaching, replacing and adjusting the specified parts, it means the time which is determined by addition of the preparation time, net working time and standard allowance time of the work. + Single unit When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed machine’. + Removal and installation The work to remove specified parts from machine and to attach the parts, and then to perform necessary adjustment + Simultaneous replacement to perform necessary adjustment + Adjustment The work to carry out necessary adjustment with the specified parts removed or attached + Overhaul ‘The work to remove specified assembled parts from machine, disassemble and check them, and then to attach the spare parts to machine and to perform necessary adjust mert + Include Explains the contents of work to make the specified work range clear + Exclude ‘Shows the wark which is not included in the specified primary work + Unit Time is shown by hour. 424742. STANDARD MAINTENANCE TIME TABLE seam [_ see Work No. Work ‘Work unit Works a 7 Poser] aro = = Sonaa| rg anon : eer eee eaustnent eet machine _|Valve clearance adjustment es a 2 | 00109 [enone aausimen 8 set Comotdl a setandronae advent | — = sal Ea wai oe a | otis |eompression messing Cont enna or oa “8 a Jand battery specific gravity measurement 6 asarz {Replacing oytinder, block, piston, ing ‘Single unit |From engine is removed condition | 27.4 316 tnd ne smuteneouty Reolcng cork sat nap «| er sna From engines erove conatin | 20.8 a8 90013 and liner simultaneously. 7 epee eee nang ener son oe ve Sec thon Replacing cylinder block ‘Seto uni clade: Instaling expansion plug kneck | 24 isa bn | ors” Reinang cance Signi Prom anghe wvoved onlin | wa 12 | oorar_[Repacg wank shat taa boarg [slew Pom enghe serove anaton [134 wa enor aon fructose po poe uc. vabe appre 15 | 00181 |Ensine ova st st ranting 0s as Crete Reo tein pa, one sate, wr meee ot Sac outa una ge Fe Taso a a | Fow sone creecrg oa 17 | e018 [renueno aston ser | NB os] os fos] os rom io & cmneaig SO 12 | cor fresacna stn ane ht EN o2 [oz] 02 19 | 00185 | Replacing cylinder aner ‘Single unit Free nian Eanes elt o4 a4 [os oa enovedcandtons From pion &comoaing wae 20 | 00157 Replacing connecting rod ‘Single unit. ei oa ree 03 03 | 03] 03 removed condone ern comeing ol wa orga a | ootse sige vt earn ca] ot | oe] ox ns; Resning | aoe [Repsdng pamson og cage alae fea | aa 41 | 00202 [vane ceaance achstnent —_|oTHRS! 1" 20 wr] came Reoicigwckoranborcoa? 15 = i per 15 | name [Posen re Cnwset [rca Renova and ita wpe] — 48 44 | o0a04 [Replacing recker chamber cr ‘One set 13 14 sos Removalandinsatng cera [Conon 4s | ooava [Perey cian 26 a 46 | 00018 [Resa ck em cee 26 aa «7 | onare |restcng ckeram aureon [monte 28 us 46 | 0018 [Renting oteram san (COR 28 ea 20 | 0322 |pemottans isting osnae eas | ome! Sone Renoaesinetio) 108 Gamo ie, Ve eg ore Placing oy i mactine | Exclude; Replacing of valve guide i te 12-1812, STANDARD MAINTENANCE TIME TABLE TET ‘Work No. Work Work unit Works oy > ae Te rican | * [ria nt: va ang cence: Roping of ave gi * etal tyne asd tsa 1 esas =| Oretheallot oa machine |water pressure test and replacing Pee te ea se | 1225 [Renting oer nead gasket | O=BCE a2 14 s+ | axe |renacna ve Comat ava 96 132 156 arid] coe; Reva ana aig of enag vate ai 4 35 | ooser relae ve sing ee ° ee een] Eco: Renal ad ang olcng ae em a sr | exe [roping peo narnia 3 oa Reval ad ang ow 61 | 00376 ot el ‘One set 12] 02 | 16] 02 rain og Removal ans isling cash wit Sonia Pee [epee [camshaft gear) machine ad a ‘ih ano ard nea Nir Indie; png Retains cinder ead lt; Reoval a sting of 63 | 00352 | (one piece end one set require same Single unt erat ce Co 65 lovinder nead,replecing valve guide, eee |water pressure test and replacing rave sea Uno 0 | 0285 Jeeps eve out vaiott wo| 08 | 20] 0 | o86i Raped son a See oa [aa Poe [2 Repicig eter ar va | worr Fron cone eeqae san] UES os on rau Fensargrosaram suse | yaa, 74 | oosre Jtoneneransone serene same on on ounce Inoue), tana 7 | 00072 lpepesnoroserambusnne | Uae’ oa] os [al os Gtr ORO ToT ane 76 | 00374 |Ropiecing valve ying yeoron os} os | os] os Include; Valve tapping Unit oFT [From cyinder head is removed finder |condition Unit oF [From cylinder head le removed cofinaer lconsivon 77 | 00375. |Repiacing vaive soring o2z| o2 | o2] o2 78 | 00300 |reptacing valve stem seal os] 03 | os] os ‘81 | 00406 Removal and instaling supply pump | One set include: Function check 23 23 4 _| 00411 _|Tigtuening of! pan ‘Shale unt [From engine s removed condition | 05 05 ‘85 00412 [Removal and instaling oll pan ‘Single unt [From engina ie romoved condition | 05 os 26 | 00413 _|Repisong oll pan ‘Shaie unt [From engine Is emmoved canaition | 0.7 07, 87_| 00414 |Repiacing ol pan gasket ‘Sogie unt From engine is emoved cendition | 07. oF '28_| 00421 [Replacing oi pan rain cock ‘Sagte unt [From engine is removed cendiion [05 05 '80_| 00422, Replacing i pan drain cack gasket_| Single wit From engine is removed cendiion [05 05 ‘22 | 00843 [Replacing breatner hose ‘Shale una [From angina is emaved cendtion | v2 | 02 [03 | 02 ‘93 | 0084 [Replacing of level gauge Shale unit [From engine is removed cendiion | 0.4 ot 34 | "00645 [Repiacin oi level gauge guide| Single wit From enginais removed cendtion | 02 02 85 | 00446 [Replacing cilievel gauge bracket | Sioge wnt From engine is removed cendtion | 0.2 02 402 | 00512 [Replacing ty wheat housing ‘Sngle unit [From engine s removed cenation | 2a 3a 103 | 00541 [Replacing fy wheot housing gasket _| Single unt [Fram engine s removed condition | Sa 5a 104 | 00542 [Replacing rear end plate ‘Singin unt [From engine le removed candlion | 5.4 54 105 | "06649 _[Reolacing rear end plate gasket | Single uni | From enine is eemoved condition | 5.8 5a 106 | 00515 [Replacing crank shaft rear oilseal__| Single vot| From engine is removed condition | 5.4 5a 12-1942. STANDARD MAINTENANCE TIME TABLE: ‘sama _[_ saws ‘Work No. Work ‘Work unit Works ea 7 ed wren * lore Tia_| ode [ Raping cocoa on acon | sage wl cm ty wherivomoved con | 92 2 121 [co [Reisng ile meted Cnet [no Poplin tgugankot_—_| 20 23 122 | oste_[Repaong ie nado gsi | One et [neue Aspling tad geet | 20 2a Femoral and nt eke ae 88 One et 1 1 Sore {manifols side) a iu 7B eae |Rencns io be (nated 3s] Ones a m 125-| coat” [Reiang arate hse ‘ne set os | aS fo | oa 72e-[ coset [Repacng ania oe nest oa o2 | 04] oa 157_| ones [raniang ara oe One at [Fut carperronmeressar | oa oa 728 | ona [Rang rhe ps Qooset [Ar cumnor iota charger | 04 [03 0a | 02 120 | coors [renin tence voay Sonoma os| ez [os] 02 vez | cones [rahonngeiuctmenicis [ove 00 3 14a | copes. [Removal and instoing exhaust COPEIEES pp insulator and stud bolt 28 32 mane rae ont nae: Rpincng Hud Ba vow Pe ete ear nee ‘vachine_Jone and insulator (Tl system) bas ae c 14s | e054 [Renan ena mant goer | STE! 2s a 146 | 00546 | Replacing exhaust heat insulator Compe | rarger a ft 24 28 1a | toast Rernng tune Onesat we we 1ao-[_opes3_[Reiaing exnast pip gaaker_—[ Ones mH 8 12-[_opes [Reval adnetng to carer | One cl 29 zs 185. [_o00a7_[Reiacng to carer ness ccna Repaeng aa 2 ver | onus elaig isto hrgeraiaare [9 ., |ne:Ronevlondinisog | = ie oe oe ec ye | oman [Renodng arin irowirerToneg a i coveromani) emorl and ring erg ard vege wvoroved naan 122 | oor fing oar cover roount|nsud;Renovalandrstatingst | 54 ss whens) yin end ape cree creer om gn aroved sonar s20 | oor [Reentrina e agent ne Removal andsiaingat | 64 sa epee cylinder head cng ting or co oa Froming gor cove Woman 1 eget 7 190 | oorte (ly wheel housing) re jcondition fi ti alc ning gence ie Framing parca broad : beats ear end plate} A leondition as head atc ng um cove a Placing timing ge 7 From timing gear cover is removed s20 | oorte [poet ent | 10 10 fem en tonsa) sg gor re romorel 199 | 00725 [reporter warinany [Sogou i 02 0 om in pear coer ev 14 | onrae frees tr gor (ut gen ON OW 1 To4 os 125 | oorae | repan tergar anata) | Spm ENGGEATCOvarG removes [9 oa 198 | ox7a7 [resacng ier gearanan ut) | sapeum[m iia ope coverBremores Tg on Tar wares [Reagan tage a oa 201 | 00738 [Replacing cam ice gear Siglo we [HOM ena OFF covers removed | gg o4 12-2012, STANDARD MAINTENANCE TIME TABLE, Saas ‘Work No. Work Work unit ‘Works cu ae] 7 aa mos] ' [ore Fra ing aero od soning comidgew sat |S wl 2ez | corer [Reining comidger srt | se wu oa 0 zea | corer [rep coneat Sige on emt Tea 28 201 | corse [esaong canst gar cageua|Fom rg eeremerirenees | ay 08 zai | ora [Resa spy oa wa i 2a [ent [ralng cans moe ores 2 Fn 257 | onse_jrelcig ck sta onto” [ eset a2 22 epg ant sao of zea | ors [Pei = 28 esac a Sa on aos ee Lear [retainer gasket rere f i ait | 92m [oncnineton ig eae 08 28 za | Ga” [Rese pma new Gorse ‘a 3a 227 | oni [onmr tl ng Hor —[ Ow a 08 0 225 st Peng tough ee vave [Oe ne 08 a0-[enk_Recg hl iycion pos] onset ae [er [ae [oe 258 | coast [recrg titer asentiy | onset 8 os 21 | toast [Ropacrg il tacaticgn ——[ Oreo 38 23 262 [ene [Rainy thse rt 8 08 2st | tare [reacrg tlatoponn [eet 98 8 27a_| oor [Ralerg ate cage [Onset rm 28 fesnor tan Rar a7 | cova nese on 0s 0907 |reguiator valve) Fao a arate wre ae eee (il fiter regulator valve) One set a fa i ain [reacrg ete ensy abo [ Ones a ra 200 vt [eseng i erst va ig Oe 28 3 Beet lovee reg we 201 ng ge ing sage ii tom engrelermoredcenatin | 6 a cin) nog ger coe 2a tor [reaiig opamp Sageua [fmm ogra waatcnaon | FB a 220 | onet[Reacra ssw ga Sage [ru one omovies ts 257 [tort [ovr f ain Seo Fam ese emoredenion [ES 3s zan_[ ond _[Reinng sun stoma | ows a 1 Zar ut? [esny ssn stanor Og —[ nese 1 3 aut | oss Resin ot ge nese oa) oa [oa] 8 az | ast [Reinga fee Ones da [oa [oa [88 203 [16 [Ree oot : ov 92 [ez [82 227 [eae [Revove nding wap | Oot [adda Fig sade eats —[ 40 2 22e [010 [Resi wae pp reset [nce Fling erg cintie [40 2 san | eto [ovied swamp Sia 38 oa gat [oer [Rena wae nao ily [seo 8 0 234-[ ron [Rencng wae pm asin gal | One set [Ud gi 2 ‘a sez [rise _[Roaang csi fn crest a8 a 2a [rie [Repeang hd ncouing [esa 08 fo 2at [tue [Resiasy erro arg Ove et ni Fg ogra cain [3 i 225 | 01 [Rosary mest snp Ger Ono te: Finger secitun [1 i oer | oa [Pena memonit ina 6 | orcs le ng ene ceciin | 10 1 230 | ore feng most neat [PS Ses ere a te 12-2142. STANDARD MAINTENANCE TIME TABLE, Samoa [aia ‘Work No. Work Work unit Works oy 7 aaa 7 P| crimn| * [ores ics Cracing romper 939 | 01049 | Checking thermostat Cone set |/AOUsei Checking eee bi 10 rave wt opening 2ai_| 08% [Repnchgcatrowe Saat ae [ aa [aa | ea 222 | 054 [pepiacng dno hose Onwsel os} a2 [oa | a2 2aa-[_01071 [Reig fd an ceung i 03 03 oae [01072 [Rela cooing tn i 03 03 2a [0107p water puro 1 Fem cng on onovodcnston! 17 7 | 010% Owe noes ; 0 oa 22 | 01401 |Renovlandinsaingalsnaer —| Svea oa 8 102 | 010 [Reino teat nwa 08 03 104 [01406 TRepacig aura supp att | On at 1 ‘a 05 [1408 |Reoteng Vat oneal 3 as 222" | e100 [Rome and ig pay | One et [ia Funclan ek 20 20 729 | oven [Resaca say ouno nese ne: Faton one 20 20 Rerovel ond iting coninon a aan | otaao |288enby ‘One set |Include; Function check 38 38 et resets res into Resadng cannon esoney 41 | oveos [tres sng possi | One st [nce Funton check as a8 nie) «a2 | ors [Femeatendisisinginsor cont uncon chuck 28 a ent ns Fanon check an «a2 | orto [researc steno “4 40 eee = machine _|reprogramming «x4 | oraor [femora anaisiaing necro. a [incie;Funaon check rs] oz | re] 02 sendy nda; Fan eck end 145 | 01000 |resocns eject: esemby one et 2a| 02 [24] 02 ea [ [reprogramming Renova and rang pcr ob wae | ova neat fae; Funaton ch 8 18 ue [names assembly i cer | ere [Peres meer hese] on tina Raton heck 18 ‘8 ‘| ene a nani ow dango | One wt [nde; Funton ck iz[ oa [7a] 0a | 01812 IRepocr to dumper One st nde; Fnaion check i2[ 23] te] 08 450 | one [Remevlancnnatino resize | on ae: Funcon heck 12 12 ai] oie [reece rena ute Set nce; Fondion cs 2 z 452 | orere [Femesracommenateretsue | oe nce: Funston check 12 2 GEE | are ecg mn ang speed esr] On et nde: Funan crak 2 @ 1454 | 01617 [Resacng ab erie speed enor | One at [nde Func check 12 2 tong cook epee 455 | overs [Reena suis ‘one set linclude: Function check 12 12 56 | 18d esac il peratr ansr | One at [nc: Fneion cack 2 7 257 [01820 |fesoeng ec srsr ne et ne, Funcion deck 5 is 40 | o1eza [Faveetereimatinaesie | Tia; uncon hack 03 03 461 | 01824 feet meet 4 include; Function check 03 03 165 | raze |Renucrg pc Seat fae Frain ae ia[ a faa oa ec 464 | 01827 Placing fuel ps ‘One set |inclide; Function check 12 on 42 On [conn ts sup um) | TBH |Rensorg tt estope poe) Gre se rae Fnson ches 7 a 169"| e160 [hwhing atae ofprensozed ad One st nau, Funcion deck a rH 12-2212, STANDARD MAINTENANCE TIME TABLE Sao Werk Ho Wor Work unt Works [Ar o1901_ [Replacing main engine speed sensor] One sel |inolude: Function check - i | [Tare_[ 1902 |Repiacing sub engine speed sensor | One set [inde Function 12 epiacng coolant lempersture ] ans ete Pe One set inclue; Function check hie 12 (aa Reniacing secl sensor Gre wet linha; Funcion check | A a5 Removal and insating EGR waive | One st [ncude: Function creck [aa 476 [Replacing EGR vaWve | nw eat [indo; Function chack zi | 479 Removal and instating EGR cooler | One set 1 480 | O17 [Replacng EGR cooler | One sat a Tas Removal and insaling dos 4e1 | ore dediaietuichietel ‘one set os entiator Gee | 1570 Replacing dosed ventiator Ones os 12-2342. STANDARD MAINTENANCE TIME TABLE [MEMO] 12-2413. MAINTENANCE STANDARD AND TEST PROCEDURE TABLE OF CONTENTS 13.1, HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED...13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE... aie 13-4 19.3. MEASUREMENT OF ENGINE SPEED.......... ect 13-6 43.3.1 MEASUREMENT OF ENGINE SPEED....... : re AE 18.4 MEASUREMENT OF HYDRAULIC PRESSURE ee wo AT 18.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE........ see ABT 13.4.2 PLACE TO INSTALL PRESSURE GAUGE..... : 13-7 43.4.3 PRESSURE ADJUSTMENT POSITION 138 4844 PROCEDURE FOR ADJUSTING RELIEF VALVE. i ntsc 410 18.5 MEASURING TRAVEL PERFORMANCES... serene BND 13.5.1 TRAVEL SPEED cnn ieee elated ssn AZ 19.5.2 DEVIATION OF TRAVEL..... oo a 13-12 19.53 PERFORMANCES OF PARKING BRAKE 13-13 13.54 DRAIN RATE OF TRAVEL MOTOR. : seer AAG 13.6 MEASURING SWING PERFORMANCES. Belt 43-45, 13.6.1 SWING SPEED........ ne aa soe AB 13.6.2 PERFORMANCE OF SWING BRAKE ws... oo ABB 13.6.3 PERFORMANCE OF SWING PARKING BRAK: 13:46 13.64 DRAIN RATE OF SWING MOTOR 1847 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES. : 13-48 13.7.1 OPERATING TIME OF CYLINDERS tet i oe AB 13.7.2 OIL TIGHTNESS OF CYLINDERS Sai i 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 1292 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A:B-C ADJUSTMENT) ..13-24 42.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPVENT OF MECHATRO. CONTROLLER 13-27 Book Code No. S5YN1318E01 13-113. MAINTENANCE STANDARD AND TEST PROCEDURE Issue Date of Issue ‘Applicable Machines Remarks {SK200-8 : YN11-45001~ SSYN1318E04 Frstediion | August, 2008 |xosquc-8. Yar1-06001~ (ASIA, OCE) 13-213. MAINTENANCE STANDARD AND TEST PROCEDURE 13.1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED (1) Application @ @ 4) When the machine is new ; Confirm that the performances are in accordance with standard specifications as compared to the performance standards, 2) At specific self inspection ; (Rule by country) Use the data for the criterion, for the purpose of correction, adjustment and replacement. 3) When performances are deteriorated Determine whether itis caused by 2 fault or end of service life after long hours of operation, to be used for safety and economical considerations. 4) When main components are replaced ; For example, use data to restore performances of pumps and others. Terminology 4) Standard values ; Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standaré shoes). 2) Reference values for remedy Values at which readjustment is required, In order to ensure performance and safety its strictly prohibited touse the machine over the specified values. 3). Service limit ; This is the limit value at which reconditioning is impossible without replacement of paris. If the value is expected fo exceed the service limit before next inspection and correction are performed, replace the parts immediately. The operation over the specified values causes increase of damage and requires the down time of machine, and also causes satety problems. Cautions to be Exercised at Judgment 1) Evaluation of measured data ; Disagreement of measuring conditions, variations of data peculiar to é new machine, and measuring errors are tobe evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values. 2). Determining correction, adjustment or replacement ; Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels, Therefore, determine correction, adjustment ot replacement, depending upon the operating hours, kind of work and circumstances in which the machines placed, and concition the machine performances to its most desirable levels. ‘Other Cautions to be Exercised 4) Parts liable to degrade Rubber products, such as, hydraulic hoses. O rings, and oil seals deteriorate with ime ; replace them at regular intervals or at overhauls 2), Parts requiring regular replacement ; Out of critical hoses that are necessary to secure safety, we designate Very Important Paris (V.1.P) and recommend tht they should be replaced regulariy. 3). Inspection and replacement of oils and greases ; In performing maintenance, itis necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication oracedures. Refer to the operators manuals as well 13-313, MAINTENANCE STANDARD AND TEST PROCEDURE 13.2 PERFORMANCE INSPECTION STANDARD TABLE Note The mode is already "S" mode when power is thrown. Unless otherwise specified, measure it on "H" mode. Tabiet3-1 7 ‘Measuring Postion | Standard Tolerance wa |i] Measuring eee Position | Size | Port value Hi bo nk | Pont condition g [Cleaves orate oiftyaunconintank | MSY — PP ET leanntre *2 [Hydraulic oll temperature | Tank surtace socizal +5 can] _-5(@3) -¢ |_—_|Amearhercteme 8 ae fre~s0re [Water temperature Radiator surface racer] + 15659) 180) CF] [raoreotasey 5 Hi mode Le ilo 1000) “a0 LOW throtie 3 } H mode Hi idle beaeerid — 2000] + 30) EB [Futtthrottio (1 ite) 5 B mode Hiidie_|ePredstmelieisplay on] zooo] +3, || BS |Performall Be erence tte gauge ctuster, or Sod Fini] BB =| 5 Lam measure with diesel - eee §| 2 Doce! | oroed moter 050+ 30) Ey) E |i ai-condtioner S mode Hi idle 1800) + 30} - 30 OFF", Pitt primary pressure circuit | pump ‘a | 5017265) +05 073) of [Prt [arias a 3 ATT Et at 94.3 (4970) + 0.7 (+100), - 0.5(-73) MR1 Boom: 3 Pe a2 ¢ C73) Up £2] toon S| spatsano] voce) -osero] | wet 3 ost [re a AEE ee wom LE ay | S78 80] 9) -40¢se0] | ORS [Boom down Ble H 92.7 5760) ol-socecq] — [ORS [Boom up 5 R| 2 30,7 6760] of 5.0 (858) [ORS [Armout 8) 2 | am & 22 gg wa] § [Pru 31.6 (5400 o| 4.0 (580) yee ORT [Armin g| 2 rR} § 37.8 (5480) | -4.0(-566)) (8 | ORZ [Bucket dump 5) 3 ral at ez} = ee A = 39.7 (5760)] 9] - 5.9 -868)) OR1 |Bucket digging EL Boag LRH ao | Bioaaasl| = 60 6870] >| ‘ORE [Swing RH E 9 (aH 22.0 14208) + 6.0 (+870) a} [Tors [Swing LH FW = eis] te at | 343.4970) +07 (+100) -05¢72) —|simuttaneous ois EW operation of travet a LH rv a2 | 34.3 (4970) +0.7 (+100) - 0.5 (-73)] IRH and LH 13-413, MAINTENANCE STANDARD AND TEST PROCEDURE Inspection iter Standard | Unit zs - value [Sprocket revolution tstspesd [805-275] (RH.LH) 2nd speed —_| 50.4 ~ 45.6 Up__| 25-34 Boom 2 Down | 22~28 8 [Operating time of ae In 3.0~36 | . 2 cylinder Out 23-29] %° [Atnoload) & Diggit ~ | s Bucket |Diasing | 22-26 | g Dumping | 4.7~23 | i RH | ‘Swing speed jj 42~54 | secs trev LH ‘stspeed | ron shoe | 19.5 ~ 21.5 Travel speed | sec / 20 m 2na speea| Iron shoe | 11.9 ~ 13.1 ‘Amount of travel 2nd speed 0~240 | mms20m deviation ut Parking brake dritt | 15 degree gradient| 0 | mm/Smin g |Performance of Swing [Neutral postion after a & [brake 120" ful speea swing | 887 | degree E |Pertormance of Swing aaa Tre 5 i 8 [parking brake 15 degree gradient | 0 mm ® Tip ofthe bucket tooth] 160 ATT amount of arift Boom cylinder 414 |mm/10min|(At no load) __[ arm eviinder " [Amount of horizontal play at the bucket tooth] 30-50 | mm (Crete) ‘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 @) (a) ofew a feo (7) @B) LH RH CONTROL LEVER 13-513, MAINTENANCE STANDARD AND TEST PROCEDURE 13.3 MEASUREMENT OF ENGINE SPEED 13.3.4 MEASUREMENT OF ENGINE SPEED (1) Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90°C (140 to 194°F) at surface of radiator upper tank. The E/G coolant ter-perature gauge is used to measure. The range in white color shows the temperature of approx. 65 to 105°C (149 to 221°F), 0 confirm that the pointer indicates the temperature within the white range. Engine speed measured value through service diagnosis (See Fig. 13-2) 1) Turn "ON" the starter switch with the buzzer stop ‘switch pressed, 2) A program No. and an actual engine revolution are displayed as the No.2 Item. 3) The screen advances like No.2, No.2....each time the “Wiper switch” on the gauge cluster is, pushed, 4) The soreen returns like No.45, No.44....each time the "Washer switch" is pushed. 5) The display does not disappear unless the starter switch is turned to"OFF” GAUGE CLUSTER, LAWASHER ‘SWITCH fey 7 WIPER SWITCH SCREEN CHANGE SWITCH Fig. 13-1 Switch for E/G speed indication Fig. 19-2 Service diagnosis for E/G speed measuring (Example) 13-643. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4 13.44 (1) Hydrautic equipment 6.9 MPa (1000psi) pressure gauge : {unit 49 MPa (7100psi) pressure gauge : 2 units Pressure measuring equipment and instrument for analysis : 1 set (2) Measuring cleanliness of hydraulic oil (A\WARNING| After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil. 13.42 PLACE TO INSTALL PRESSURE GAUGE (1) Main circuit After releasing the pressure in hydraulic oil tank. and system, replace plugs PF 1/4 of main pump gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa (7100 psi Pilot circuit Replace pilot gauge plug (a8) with plug PF 1/4 for pressure measurement, and attach pressure gauge 6.9 MPa (1000 psi) 2 13-7 MEASUREMENT OF HYDRAULIC PRESSURE PREPARING TO MEASURE HYDRAULIC PRESSURE, Povo Fest eave) Fig. 13-3 Gauge port on main pump13, MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.3 PRESSURE ADJUSTMENT POSITION (1) Main control valve (sods PLUG FOR OR8:ARM(R) OPTIONAL RELIEF MACHINE FRONT 7 \ MRI (MAIN RELIEF ORS-BOOM(H)_ OR2: BUCKET (R) (ATT & TRAVEL) \VIEW FROM THE TOP OF THE MACHINE OR4:BOOM(R) ORI: BUCKET (H) ORT :ARM(H) PLUG FOR OPTIONAL RELIEF VIEW FROM THE BOTTOM OF THE MACHINE Fig, 13-4 Relief valve position on main control valve 13-843, MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pilot relief valve ‘The pilot relief valve PR1 is focated on the gear pump that is attaches to the main pump. PRI ADJUST SCREW FOR PILOT RELIEF i Fig. 13-5 Pilot relief vaive position (3) Swing over load relief The swing motor is equipped with plugs PA,PB for pressure measuremert, but the measurement is carried out using gauge ports (a1) and (a2). (See Fig. 13-3) SWINGLEFT SWING RIGHT OVERLOAD RELIEF OVERLOAD RELIEF ‘ORS ORS Fig, 13-6 Swing over load relief position 13-943, MAINTENANCE STANDARD AND TEST PROCEDURE. 13.44 PROCEDURE FOR ADJUSTING RELIEF VALVE (1) Pilot relief valve Adjust it with adjust screw (311) ae 24 mm, Tightening torque : 29.4 Nem (22 tbfft) = emm No. of turns of adjust screw |Pressure change MPe (psi) tun ‘Approx. 2.1 (305) (2) 2-stage main relief valve (Commom for travel and ATT sections) Start from the boosting side, first, Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustmenton the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment a 32mm Tightening torque : 27.4~31.4 Nem (20~23 Ibfeft) 22 mm, Tightening torque : 27.4~34.4 Nem (20-23 Ibfft) A 19mm, Adjust screw 6mm No. of turns of adjust screw |Pressure change MPa (osi) Boosting side f tum | Approx. 17.6 (2560) _ STD side t tum ‘Approx. 17.6 (2560) (3) Over load relist vaive (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw 2) a 22mm, Tightening torque : 27.4~34.4 Nem (20-23 Ib © -emm No. of turns of adjust screw | Pressure change MPa (psi) turn Approx. 17.7 (2560) 13-10 = LOCK NUT HEX24 Sst Fig. 13-1 Pilot relief vaive HEXG2 HEX19 1 2 Fig. 13-8 Main relief vaive (Travel section, ATT common section) Fig. 13-9 Over load relief valve (Boom, busket, arm sections)13, MAINTENANCE STANDARD AND TEST PROCEDURE (4) Over load relief valve (Swing) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap @). a® -50, 38 mm, Tightening torque : 118 Nem (87 lot) © s 12mm Fig, 13-10 Swing over load relief valve No.of turns of adjust screw [Pressure change MPa os) rn | Approx 10 (1450) (5) Travel over load relief vaive ‘This valve was adjusted by valve maker. Do not replace any inner parts except for O-ring. Fig. 13-11 Travel over load relief valve 13-1143. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5 MEASURING TRAVEL PERFORMANCES 13.5.4 TRAVEL SPEED (1) Purposes Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system, (2) Conditions Hydraulic oil temperature ; 45~55°C (113-131°F) Crawler on the right and left sides are tensioned evenly. Preparation Attach the reflection panel with a magnet to the travel motor cover. ‘Swing the swing frame through 90°as shown in Fig, 13-12 and make the crawler on one side take off the ground, using the attachment. Measurement Engine revolution; Hi idle 2-speed travel switch; 1st speed and 2nd speed Measuring points ; Right and left Method, example 1 ; ‘Measure revolution with a stroboscope Method, example 2 ; Measure the revolutions per minute visually @ 13.5.2 DEVIATION OF TRAVEL 1) Purpose Measure the amount of deviation at 20m (66ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system Condition Hydraulic oil temperature ; 45~65°C (113~131°F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution; Hi idle @ 13-12 PANEL Fig. 13-13 Adhering position of reflection panel Sprocket revolution Unit = mine vessveneni ten] SS? S| Seale R[H mode tstspeed| 30.5~27.6 | 23.8-21.5 | 19.4 or ess LH] Himode 2nd speed] 60,4-45.6 | 90.3~35.6 | 32.2 ortess Fig. 13-14 Travel position13, MAINTENANCE STANDARD AND TEST PROCEDURE (3) Preparation 41) Straight course more than 30m (108A) 2) Travel posttion in which the bottom of the bucket is lifted by about 30cm (if), (4) Measurement 1) Measure the max. deviation distance of the circuler arc in the 20m (86ft) length, excluding the preliminary run of 35m (10~16it). 2) Operate the travel lever at the same time 13.5.3. PERFORMANCES OF PARKING BRAKE (1) Purpose Confirm that the parking brake holds @ stopped Condition ofthe machine in 2 no-load travel position and ona 18 degree slope. (2) Condition A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position (3) Preperation Place an angle meter on the shoe plate and confirm that it makes an angle more than 15 degree. Hang 2 perpendicular in parallel with the guide frame rib on the track frame and puit a mark (matching mark) on the shoe plate. Measurement Five minutes after the engine stops, measure the movement distance of the matching mark. 4 13-13 Travel deviation Fig, 13-15 Measuring method Unit: mm (in) / 20m (884) Teasuring ‘A__ [240 (9.88) ortess| [Peerence val) ‘orretnedy (480 (18.9) | 720284)” Standard value Service BOOM FOOT PIN AL = ee Fig. 13-16 Parking brake operating position GUIDE FRAME Fig, 13-17 Method of measurement Parting ake Unt: maya ee a c 0 10.04) | _2(0.08)13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5.4 DRAIN RATE OF TRAVEL MOTOR (1) Purpose To measure the drain rate ofthe travel motor and to confirm the performances of the travel motor. (2) Conditions Hydraulic cil temperature ; 45~55°C (113-131°F) Engine revolution; Hi idle (3) Preparation 41) Place a stopper under the RH and LH travel sprockets. 2) Stop the engine and release pressure from the hydraulic circuit 8) Connect a hose with the drain port of the travel motor and take drain in a container. (4) Measurement ; at Travel Lock (A. WARNING| Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper “B" in some cases. (See Fig. 13-18) 4) Start the engine and relieve pressure at the full stroke of the travel lever. 2) Measure the drain rate for 30 seconds of relieving 13-14 FORWARD <— : 210 (954 (0.3947) + i é. ROTARY DIRECTION Fig. 13-18 Location of stopper applied to travel sprocket Fig, 13-19 Method of measuring the drain rate of travel motor ‘Travel deviation Unit : Liga30sec MSaEPO | eancard vue Perera | Service mit Drain rate | 9124) | 16(42) | 23164)13, MAINTENANCE STANDARD AND TEST PROCEDURE 13.6 13.6.1 SWING SPEED (1) Purpose Measure the swing time and confirm the performances between the hydraulic pump end the swing motor of the swing drive system (2) Conditions Hydraulic oll temperature ; 45~55°C (113-131°F) Firm, level ground Engine revolution; Hi idle (3) Preparation Put the bucket empty and extend the boom, arm and bucket cylinder fully ‘And the machine becomes a position of minimum reach, (4) Measurement ‘Swing the machine by bringing the swing lever tots full stroke, Measure the time required to make two turns after one tum of preliminary run and calcutate the time required for one turn MEASURING SWING PERFORMANCES. Fig. 13-20 Swing speed measuring position (at the 13.6.2 PERFORMANCE OF SWING BRAKE (1) Purpose paeenpeaeey Confirm the braking torque performances by the Masaueg ‘positon. swing reliaf valve, wipers (2) Conditions mea Hydraulic oil temperature ; 45-55°C (113-131°F) eee Firm, level ground Engine revolution; Hi idle (3) Preparation 1) Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. 2) Puta matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side, Place two poles (flags) on the front and back of the extended fine of the matching mark, 13-15, min. reach) Unit: secrev sanard vas ESS] Service nt ase | seo | 7. BOOM FOOT PIN Fig. 13-21 Swing brake performance measuring position13, MAINTENANCE STANDARD AND TEST PROCEDURE (4) Measurement 4) When operating in regular swing speed, by shiffing lever to neutral position at pole position the swing operation stops. 2) Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length {m) of the circumference of the swing race ‘Amount of deflection of ‘Swing drift matching marks [m (ft-in)) MEASURING THE LENGTH OF THE ARC OVER ‘THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON == OUTER RACE NATCHING MARKS ONINNER RACE Fig. 13-22 Measuring position of swing brake : : erformances angle (") = “Circumferential length of _* 360 it swing race [m ("in}] Swing brake performance Unit: degree MeeSHE | tandara cua] eee] Service limit Swing 100°] 75° as" ° 13.6.3 PERFORMANCE OF SWING PARKING BRAKE (1) Purpose To confirm the mechanical performances of the swing parking brake thatis fitted to the inside of the swing motor, (2) Conditions Ona slope of 1 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully ang extend the buokat oylinder fully. And move the boom so that the arm top pin is positioned at same. height with boorn foot pin. (3) Preparation Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Puta maiching mark on the outer race side and on the inner race side. Measurement When five minutes has passed afler the engine stops, measure the length of the movement of the matching marks, ‘4 Fig. 13-23 Swing parking brake performance measuring position MEASUREING THE LENGTH OF THE ARC OVER: ‘THE QUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE MATCHING MARKS. CON INNER RAC Fig. 13-24 Measuring position of swing parking brake performances ~ieasuring | postion. c 1 (0.04) | 2 (0.08) 13-1613, MAINTENANCE STANDARD AND TEST PROCEDURE: 13.6.4 DRAIN RATE OF SWING MOTOR (1) Purpose Measure the drain rate of the swing motor and confirm the performances of the swing motor. Conditions Hydraulic oil temperature : 45~55°C (113~131°F) Firm, level ground Engine revolution: Hi idle Preparation 4) Slop the engine. 2) Release pressure from inside the hydraulic circuit 3) Disconnect the swing motor drain hose from Its end returning to the hydraulic oil tank and take olin a container. 4) Put @ plug to the tank side. Measurement ; at Swing Lock 1) Start the engine and put the side faces of bucket 2 @ Travel devia unit ys08e0 against the inside of the right or left shoe plates. tae ee on ara een oantaowe 2) Relieve the swing motor at full stroke of the ce Standard value" “er vemedy swing motion. Drain rate | 2.40.55) | 52(7.4) 3) Collect the amount of drained oil in a container for 20 seconds. 13-1719, MAINTENANCE STANDARD AND TEST PROCEDURE 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES 13.7.1. OPERATING TIME OF CYLINDERS. (1) Purpose Measure the operating time of the boom, arm and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system. (2) Condition Hydraulic oll temperature : 45~55°C (113-131°F) Engine revolution; Hi idle ‘Operating time excluding the cushion stroke (3) Preparation Firm level ground with the bucket empty (4) Measurement 1 : Boom up and down With the boom operating lever at full stroke, measure the required operating time of the bucket between the ground surface and its highest postion. (AWARNING) When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ; never put the bucket against concrete or other solid material. Measurement 2 ; Arm in and out, bucket digging and dump In position in which the tooth of the bucket rises to a level of about 30cm (ft) above ground, measure the full stroke operating time required with the arm and bucket operating levers at full stroke. 13-18 30m (1) Fig. 13-26 Measuring position for bucket digging and dump anton ry Cj most react sap. Bucs eps mes extended — =) Fig. 13-27 Measuring position for boom up and down motions, Ores Fig, 13-28 Measuring position for arm in and out motions Cylinder Operating time Unit: sec Nsaston® _|Standar vave|“rvoneay "| Service lit o 22-28 | 26-36 38 ® 17-23 | 22-28 30 @ 25-31 | 3240 | 4 @ 2228 | 28-36 Se @ 30-36 | 3846 50- © 23-29 | 20-37 313, MAINTENANCE STANDARD AND TEST PROCEDURE 13.7.2 OIL TIGHTNESS OF CYLINDERS (1) Purpose Confirm that the cylinder oil tight by checking the moving length of the cylinder rods. (2) Condition Hydraulic oll temperature ; 45~55°C (113-131°F) Firm, level ground After cylinders are replaced, bleed off alr from the oylinders, before checking for oil tightness. Retract the arm cylinder rod 50mm (2in) from stroke ‘end so that the piston does not match 2 same range of the cushioning mechanism (3) Preparation Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position. And ‘extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin (4) Measurement Measure the items five minutes after the engine is, turned off. BOON FOOT PIN AS ARM TO? Pin Fig. 13-29 Ol tightness of elinder Unit: mmvinsmin Measee [cuncae vatue S| Service tt A | 71026) | 110043) | 1400.55) B 6 (0.24) 9 (0.35) 14 (0.43) c = = D 120 (47) | 160163) 13-1913, MAINTENANCE STANDARD AND TEST PROCEDURE 13.8 MEASURING PERFORMANCES OF SWING BEARING (1) Purpose Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing, (2) Condition Firm, level ground ‘The swing bearing mounting bolts are not loosened, ‘The swing bearing is lubricated well, not making ‘abnormal sound during turning, (3) Preparation 4) Install a dial indicator to the magnetic base and fix it (0 the lower frame, 2) Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero. (4) Measurement 1 (Measuring position 1 and 2) 1) Measure the displacement of the outer race in the axial direction in position 1 {The arm at 90°~110" and the crawler front is lifted by attachment about 30cm (1it)] and in position 2, using a dial indicator. (5) Measurement 2 (Measuring position 3) 1) Retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that, the arm top pin is positioned at same height with, boom foot pin. Then swing the bucket right and left by man power. But in this case, the gap of the attachment is included, 13-20 Location oF MOUNTING BOLTS TH! ee BEARING DIAL INDICATOR RING LOWER FLAME Fig. 13-30 How fo measure the axial play of swing bearing ¥ “en in| GEESE) Fig. 13-31 Measuring position 1 BOOM FOOT ARM TOP ES Fig, 13-32 Measuring position 2 ‘Axa play of swing bear ng MERE Standard vue] Eres] Serica Fmt rn O18 | 25-33] 36: {0.03~0.07) | (0.09~0.13) (0.14) Unit: mm (in) ARM TOP, Pin ra Fig, 13-33 Measuring position 3 Fhhanlotmowmestoetpofbusel__ Unt nm (ey WERE? | stniac he [Ean | Sova lnt uot Seaneranl aoe [aT13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9 MECHATRO CONTROLLER 13.9.4 ENGINE CONTROL INPUT / OUTPUT er: ce: EVERGENC’ ENGINE CONTROLLER ACCEL \ \ \ Et 2 FUSEARELAY BOX GAUGE CLUSTER | PuMe PROPORTIONAL cH VALVE MECHSTRO CONTROLLER Fig, 19-34 INPUT / OUTPUT 13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) 13.9.21 PURPOSE OF THE ADJUSTMENT, There are 3 kinds of adjustment of mechatro controller as shown below, every adjustment is an essential function to ensure performance of machine. (1) Adjustment of engine ("A" adjustment) This adjustment is performed to set the relation between the acceleration command veltage output from mechatro controller to engine controller and the engine speed. (2) Adjustment of pump (°8" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output. (3) Adjustment of unloading valve (*C* adjustment) This adjustment is performed fo correct the open variation of unloading valve to improve the operability further. 139.22 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED; When the following parts are replaced or repaired, carry out the adjustment without fal (1) Mechatro controler (2) Engine or engine controller (3) Hydraulic pump or hydraulic pump proportional valve (4) Unloading proportional valve, spool of unloading valve 13-2113, MAINTENANCE STANDARD AND TEST PROCEDURE 139.23 PREPARATION (1) Raise the oil temperature to about 50°C (122°F) to warm up the engine. (2) Tuen the air-con OFF, (3) Turn the starter key switch OFF to stop the engine. When the mechatto controler was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, A015, A025, AUS 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 jote For machines equipped with lifing magnet, tum the generator OFF. 13-2213. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.4 ADJUSTING PROCEDURE (=a) = MUTT IseLAr BUZZER STOP SWITCH —_ _- WORK MODE SELECT SWITCH ca _- WASHER SWITCH \ bes ob cs Bee | | ey a setecr siren A rR SCH Fig, 13-35 Gauge cluster (1) Adjustment of engine ("A" adjustment) Procedure 1) Turn starter key switch ON keeping the work mode selector switch on the MULTI DISPLAY gauge cluster pressed, and hold it for 5~10 seconds, and then release it. If (EXAMPLE) the engine is started, the following indication is not displayed. Therefore do not . cote rane) 10:25 [Him 2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release KOTUST it and the screen for selecting adjustment is displayed. When adjustment data READY is not entered in mechatro controller, "READY" is inicated. If the adjustment ees ‘operation is once performed, "FIN" is indicated. ova ‘And the lever lock solenoid is automatically released, disabling all operations. 2) Press selector switch on gauge cluster to display “START ENG". STS ngine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration crema command voltage) are indicated ke Fass 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 itis, 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 is displayed. aid (Press the buzzer stop switch on gauge cluster while this dispiay is appeared, — [xaos and the adjustment of engine is completed, The torquo adjustment ang ig uinigading adjustment requied later are not performed, and defauit value is written) 13-23413. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Adjustment of pump ("B" adjustment) Procedure 1) The adjustment automatically shifts from engine to pump, the speed shifts from LOW idling to HIGH idling, And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased. ‘The "ENGINE SPEED", P1, P2 "PUMP PRESSURE® and P1, P2 pump "PROPO-VALVE" current (command value) are indicated. 2) After detection of the engine rated speed, the adjustment of pump is automatically completed. And “FINISH PUMP" is displayed (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.) (3) Adjustment of unioading valve ("C* adjustment) Procedure 4) The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And ‘MEMORY UNLOAD" is displayed. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P41, P2 "PROPO. VALVE" voltage (command value) are indicated 2) When the unloading valve operates to the specified value, the adjustment of Unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiomete: The adjusting currant value is indicated on the display of current of P41, P2 unloading proportional valves. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.) (4) Corrective actions taken when the adjustment can not be performed; 1) In cases where the adjustment of engine can not be performed; And ERROR ENG" is displayed Judging condition: The read engine speed is SOrpm lower than the last value. 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 itis free fromwrong reading of speed due fo engine vibration b. Checking load applied to pump: Check that itis free from abnormal ease of pump pressure during adjustment of engine through adjustment screen. c. Checking acceleration command voliage: 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 MEMORY PUMP FINISH PUMP TWEMORY UNLOAD] FINISH UNLOAD ERROR ENG13. MAINTENANCE STANDARD AND TEST PROCEDURE 2) In cases where the adjustment of pump can not be performed: And "ERROR PUMP" is displayed. Lecce Judging concition 1 see, P1 and P2 average pump pressure at the time when the adjustment is Pee ce aan completed is 25MPa or less. Judging condition 2: The adjustment does not complete although the pump proportional valve current reaches to the specified value. ‘The P1 and P2 pump pressures usually increase to 33~38MPa, When the pressure does not increase; 2. Identify the reason why the pressure does not increase, + Check that the relief vaive operates normally. + Check that the hydraulic circuit is free from leak of pressure, + Check that the pressure sensor functions normally. And s0 on. b. Identity the reason why the actual flow rate does not increase, + Check that the pump proportional valve operates normally + Check that the pump regulator operates normally. And 80 on, 3) In cases where unloading valve can not be performed; And "ERROR UNLOAD" is displayed. Cees Judging condition anne ‘The pump pressure does not increase up to the pressure in the range of the Se aean specified adjustment, Or the increased pressure is held as it is Judging condition 2 Pressure sensor of either P1 pump or P2 pump Is failed. Normally the pump pressures of P1 end p2 pumps gradually increase to 10-25MPa (it may be affected by operating oil temperature.) When the pump pressure does not increase; a. Identify the reason why the pressure does not increase, + Check that the relief valve operates normally, + Check that the hydraulic circuit is free from leak of pressure, + Check that the pressure sensor functions normally And so on. (8) Other precautions: 41) In the event of a failure, there is case where the adjusiment may not be performed normally. First serve the machine, and perform the adjustment work. 2)In the condition where large load is constantly applied to engine, the adjustment could not be performed normally. (Note) For machines equipped with ting 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 vaive only. Procedure 1) Tum starter switch ON keeping the work mode selactor switch on the gauge MULT DISPLAY cluster pressed, and hold it for 5~10 seconds, and then release it (EXAMPLE) {If the engine is started, the following indication is not displayed, Therefore do 10:25 not start the engine.) i [Hse 2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release ADJUST itand the screen for selection of adjustment type is displayed. And “ADJUST READY is displayed FEED When adjustment data is not entered in mechatro controller, "READY" is ova 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 (4) and wiper switch (¥), and [ADIUST UNLOAD] select "ADJUST UNLOAD". (See Fig. 13-35) READY Like the output adjustment, when adjustment data is not entered in mechatro a controller, "READY" is indicated. If the adjustment operation is once va performed, "FIN" is indicated. 4) Press selector switch on gauge cluster to display "START ENG”. SoRxe “ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ns command voltage) are indicated, actor, = 5) Alter starting engine, press selector switch on gauge cluster and "MEMORY TEMORV ON UNLOAD" is indicated, the engine speed is automatically increased and the lemme ttt adjustment of unloading valve is performed bs icone “ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" keene {acceleration command current) are indicated. 6) When the unloading proportional valve operates to the specified value, the FINISH UNLOAD adjustment of unloading proportional valve automatically completes. "FINISH | evanesneco UNLOAD" is indicated, sion ‘The speed is shifted to the speed corresponding to acceleration potentiometer, JPR oe sn The value of adjusting current is indicated on the display of current of 1 anc P2 unloading proportional vaives. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.) 13-26,13, MAINTENANCE STANDARD AND TEST PROCEDURE. 13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER (1) Engine emergency mode When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating ‘emergency acceleration (E-27) provided on the seat rear side. (Gee Fig. 13-34) Operating procedure: 1) Set the emergency acceleration to NORMAL position. 2) Start engine, 3} Turn the emergency acceleration to HI side and control the engine speed 4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping, Never increase the engine speed immediately after starting engine. Itis 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. EE (2) Pump emergency mode In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to ‘emergency mods, making the operation with the power shift control of puma and the constant power control by means of self-pressure possible, But be careful that, at emergency mode, tie accuracy of inching becomes poor, the frequency of engine down is increased, and the engine stalls in LOW speed condition. | AACAUTION| The emergency mode should be used in only case of emergency. We recommend that the defective section Is repaired by troubleshooting as early as possible. 13-2713, MAINTENANCE STANDARD AND TEST PROCEDURE [MEMO] 13-2821. MECHATRO CONTROL SYSTEM TABLE OF CONTENTS 21.1 SUMMARY OF MECHATRO CONTROL SYSTEM. 2n44 214.2 244.3 244 2145 21.48 244.7 2148 21.1.9 24.41.10 244.41 24442 214.13 2hAt4 MECHATRO CONTROL SYSTEM IN GENERAL UNLOAD VALVE CONTROL. POSITIVE CONTROL & P-Q CONTROL BOOM UP CONFLUX CONTROL ARM IN RECIRCULATION & CONFLUX CONTROL, ‘ARM-IN ANTI-CAVITATION CONTROL ARM-OUT CONFLUX CONTROL 7 BUCKET DIGGING (DUMP) CONFLUX CONTROL BUCKET DIGGING ANTI-CAVITATION CONTROL... SWING PRIORITY CONTROL TRAVEL STRAIGHT CONTROL PRESSURE RELEASE CONTROL N&B SWITCH CONTROL (OPTION) OPTION CONFLUX CONTROL (OPTION). 24.2 MEGHATRO CONTROLLER. 24.24 21.22 21.23 2424 225 21.26 2127 24.28 SUMMARY OF MULTI DISPLAY SELF DIAGNOSIS DISPLAY. SERVICE DIAGNOSIS DISPLAY FUNCTION TROUBLE HISTORY DIAGNOSIS... TROUBLE DIAGNOSIS MODE SET PROCEDURE OF MAINTENANCE SCHEDULE ADJUSTING PROCEDURE OF DISPLAY MECHATRO CONTROL EQUIPMENT 21-1 Bd 21-4 21.6 BE 207 21-9 21-10 QA wn 2113 21-14 21-16 21-47 21-18 21-20 21.24 21-22 21-23, 24-23 21-28 21-30 21-40 2184 21-82 2-43 24-47 Book Code No. S5YN2118E0121, MECHATRO CONTROL SYSTEM E __tssue Date of issue ‘Applicable Machines Remarks )SK200-8 : YN11-45001~ S6YN2118E01 [_Fistediton | August 2008 |exrio.c-a var.06001~ (ASIA, OCE) 24-2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 (unction of the mechatro controller related apparaluses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system. 21-321. MECHATRO CONTROL SYSTEM 21.1. SUMMARY OF MECHATRO CONTROL SYSTEM 24.1.4 MECHATRO CONTROL SYSTEM IN GENERAL ELECTRIC ‘CONTROLLER INPUT SIGNAL, HYDRAULIC PILOT SECONDARY PRESSURE | VOLTAGE OUTPUT 1 ‘SOLENOID PROPORTION VALVE SECONDARY PRESCURE 'SQENOO PROPORTIONAL VALVE PRBUAY PRESSURE UA CRCUT PILOT VALVE: FoRATT oie Q sen |GAUGE CLUSTER Loo oseuy PSE ron ss once eons ta once coueren green canoe senior ioe zien hirer ee pect le ACCEL DIAL Se48 928 SERIAL COMMUNICATION ca MECHATRO CONTROLLER us ENGINE INJECTOR seecv senso} Mm sel] Pov-P2 HIGH PRESSURE SENSOR. (FOR PtP 2pes) Mm NeECTOR QO ] :516 SPEED SENSOR can conmuntcanion | © ‘Loweressure sensor | a +--+ ENGINE CONTROLLER, © aT es HAVEL Sn) ENGINE SEED coo corer eon an 7" BROPORTIONSL COiRiAIGCiReNT, ea Bitrcencr wove xccet oi << ACCEL DIAL POTENTIOMETER: 24-424. MECHATRO CONTROL SYSTEM 1 sez © JAR OUT reg) OUNP DOWN FORWARD FORWARD LEFT ARM OUT f ® VLe@ @ | @ @ sv-13 8 8) 8) |32 2! 8 2 ze 2 Pane g 5 ° 5 2] e 5 @ S/S lz] §] 5 [88 £ 5 2 z\@ 8| 5 i me | 2) 8 |2lalis| zZlelele]2] a l3e | 3 3 3/2/e8/.2)2]/8]21]s] 2 22 2 {e8/.2/2/8|2)2)2 | £) 2 |S|@leseb) 2] 2/4) 8) 8 fe | © | Pip2 & | (i) (3) (8) a oxcons UP | Reverse reverse | RGHT anes / w | SOLENOID VALVE i3_ Zo ce 7 i Oo] [Drcot SWING MOTOR PAIENG RELEASE ©) h t eee EEE * f tf "Ave: MOTOR TZ GREED Sse i BOOM CYLINDER, BRON EEorcumon Boow eaten w os B eg 1 . 8) e|2/8 EF} 8 oS olBioe|]4 a 3 2) /)2|¢ Slelelele| ales = s1eyalslzelalel= s/2/2/5/2/2/2|& glzle#lsele]2@] a] 3 smucrunoen few SuTenruux pov Jes fal Noses als = BUCKET CYUNDER DIGGING / DUMP CONFLUX ob bgeeel — 1 PROPORTIONAL VALVE SOLENOIDVALVE BLOCK ot 24-521, MECHATRO CONTROL SYSTEM 24.1.2. UNLOAD VALVE CONTROL + Zz 8 2 é g r @ 8 2 | le INES a & PL a evecrort| _ HB fl ors efl8 IvaLve elleffel gd glle//e]|2 Ellz||é z © zi/SliSilzs cor Ea) = a ULEIL 2] (2 [2 PLOT pLoT (EFT), Risen) Paanen valve O VALVE PILOT VALVE: PLOT VALVE = FOR TRAVEL Letel too PLOTSIGNAL | orb Jpeonontrons. WaLve pave PLOTSIGNAL | PROCESS __i paSORT ONAL VALE PSV. Fi: 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 untoad pressure proportional vaives 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 24.4.3 POSITIVE CONTROL & P-Q CONTROL e 8 E = ra e i oe ey Hue aliel|e ‘|| ele{]e le S218 @ az UlEt/ 8/2) 8 i. (een) irichr) | OPLOT CyALoT b QDvave O vave PILOT VALVE FOR TRAVEL sete Qarsre low iow IPRESSURE| PRESSURE lsensor | SENSOR Poa PEP. fpeoroRrioNaL bt PaOPorTioNAL fvatve conto) "| vatve ave. Re -| FRo=ozmonm VALE #8 pe ee PiLoF SNA PROCESS i PILOT SECONDARY PRESSURE [LN Ee pi-PRoPoRTENAL Ye SECONDARY PRESSING21. MECHATRO CONTROL SYSTEM (1) Positive control 1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. 3) Each pump proportional valve outputs pilot secondary pressure according to the command output by ‘mechatro controller and changes the titing angle of each pump and controls the delivery rate 4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and consequently the working speed according to the lever manipulated movement will be obtained. (2) P-Q contro! 1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and the mechatro controller processes pilot signal and operates the command according to the input voltage (load pressure). 2) The lower value between command vaiues calculated by positive control and operated value found by P-Q Control {operated value found in item 1)} is selected and is output to each pump proportional valve es command value. 3) Each pump proportional vaive outputs pilot secondary pressure according to the command output by mechatro controller and changes titing angle of each pump and controls the delivery rate. 4) With this operation, the delivery rate according to lever manipulated movernent is fed to actuator and consequently working speed will be obtained according to lever movernent. POSITIVE CONTROL P-Q CONTROL ett Po Pee y (BLOTSGNAL PROCESS) e F SIGRAL PROCESS 133 ' | 33 1 ag 33 ise i i BE t 1 ge" | fs” if2 | 182 I 2 a8 (a8 i | 28 i i : PUMP DELIVERY PRESSURE 24-824. MECHATRO CONTROL SYSTEM 21.1.4 BOOM UP CONFLUX CONTROL 2 4é 8 3 te z= 5 8 nae 8 8 5 8 # lsstecror-y HB ee = ble we “1 31/21) eg g g ails sI/2| = & g E Ballz 51/2) elle Elli] og We 2||& eye ge 7 & Pot Th | fae + | Low PRESSURE SENSOR PLOT SIGNAL | aie PROCESS: ifP2PuRe i Peer. i oaiie Pa UP PLOT SECONDARY PRESSURE | PLOTSIGNAL | PROCESS { [Pree L PeOLOeroNL ‘vate ror | UP ALOT SECONDARY PressuRE | PLOT SIGNAL ! PROCESS |JEzacoaD | FeStoRrona. | 1 Wave PS | UPPUOTSECONGRRY PressuRE i PLOTSIGNAL § aos FROCESS PROPORTIONAL wwecHatRO _:LuRveeuvo | controtter: pi: PROPORTIONAL VALVE SECONDARY PRESSURE (1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up contlux ‘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 P't and P2 proportional valves and Pt and 2 unload proportional valves. (3) Each proportional valve outputs pilot proportional valve secondary pressure according fo the command output by mechatro controller and changes P'1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve. (4) With original hydraulic pressure command, boom mein spool and boom up confiux 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 oll on P'1 pump side confluxes delivery oll on P2 pump side during boom up operation, 21-921, MECHATRO CONTROL SYSTEM 21.1.5 ARMIN RECIRCULATION & CONFLUX CONTROL | 2 8 3 sored f ha 8 8) 1 8| | Le 3 g tec = HSH 2448 7 He saroria [lets g as ene amas |& || | [5 All os WEEE Puor aS ge vow Tit rreseure, | oeessune ENON OD Sign a Punto Fi PILOT SIGNAL (tie PROCE: =e Lo SECONDARY PRESSURE PILOT SIGNAL DK process | EE paeese (eee ae a POPOMPPRESSURE = ECHATRO CONTROLLER | pr:PROPORTIONAL VALVE SECONDARY PRESSURE 21-1021, MECHATRO CONTROL SYSTEM (1) Recirculation and confiux (Low loading) 1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the arm-in independent operation, to P1 pump proportional vaive, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool 3) Primary pressure of reverse proportional vaive for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional vaives output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve. 4) The arm 1 spool is switched according to original oll pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in Pt ancl P2 pumps delivery oil during arm operation (2) Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool The reverse proportional valve for atm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked, 21-1424, MECHATRO CONTROL SYSTEM 24.1.6 ARM-IN ANTI-CAVITATION CONTROL, 5 4? 5/| 21/8 )] 2 : eel 8}| ei PILOT $ ge vA 2 #5 a Low eessure| Acc cea porEtmo 37 muorgona) eee ARUN PLOY SECONDARY PRESSURE : ai PILOT SIGNAL: _ ARUTNPILOT SECONDARY PRESSURE i ol : 8) ee) ee ave roan — “yeas? S500. $260. CoMaN ted a ENGINE SPEED (COMMAND VALUE) CHATRO CONTROLLER | pl: PROPORTIONAL VALVE ‘SECONDARY PRESSURE (1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low pressure sensor. (2) The engine speed command output by accel potentiometer is input to mechatro controller. (3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2 unload proportional vaive. (4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool (8) Each proportional valves output pilot secondary pressure according to each command output by mechatro controller, and consequently since the reverse proportional vaive for arm 2 spool is controlled to spoo! 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24, MECHATRO CONTROL SYSTEM 24.1.7 ARM-OUT CONFLUX CONTROL 8 g = 4é le | Ile g rk z . e ise el} Lei] lel |i 8 a lseLecToR 4 Hh he 2 fH feos hwe |SITE Tie g glfs{/elts Elle {|= 2 = S||s SILEl Elle] |2 oe UES ai]8 2 sé | Low | Pressure © SENSOR See et PLOTSIGNAL eat PROCESS [PZPUHE Ae Se 1 OUT PLOT SECONDARY PRESSURE ferme | PROPORTIONAL "fave sae4 TTPTTOY SECONEARY PRESSURE Fanswaet [PZ UNLOAD FeoboeronaL : ‘aero | | sew GOTFTSECOTOR onessone | 1 pl i i PM} Frama I FeOReRta veorrao (WANeesu San OUR) i pROpORTIONAL vaLvE |" SECONDARY PRESSURE (1) On starting arm-out operation, arm-out operating pilot pressure switches arm 4 spool and arm 2 spool and is input to low pressure sensor. ‘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 P+ and P2 unload proportional valves 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. 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 P+ pump side during erm-out operation. 2 @ 21-1321, MECHATRO CONTROL SYSTEM 21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL, 8 g k 5 e| hse £ Ley) e 8 & IseectoR - +] % = 4 ey bn pave || Sl] elle g @/al[8]fs wm /8]/8)/S|lol 2 #/(2//3][2} g PILOT & Ovaive LE] me Seema PLOT SIGNAL | | beopeeriona, LI La oT BRE BY PDT Secours ae ; i lavor sional | “NK _ P= i = "VRE Pavibs uc SE BO PT SECOUDIRYPRESSRE A PLOT siGnaL | Hl NE KET OSG BON FUG SC OONRY FRESH pi FanEsaAGr lpaocmrons [sae pave IMECHATRO| au essune|CONTROLLER pt: PROPORTIONAL VALVE 2 ‘SECONDARY PRESSURE (1) On starting bucket digging (cump) 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. (8) 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 streight valve switched and P1 pump delivery olllconfluxes P2 pump delivery oil because of P2 unload valve switched. 24-1421. MECHATRO CONTROL SYSTEM 21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL, [|s | se g & 8| | Le é I ¢ eT) {1 ef] g 3 al alpeyle] |] wm |5|/2|) $}|2 z elle leiistle! || 5) (2) (5}/3h LEI 98 e{l#) || Pitot 3 gE | VALE = ma + saan | A PILOT SIGNAL | ETOIGEING PLOT SecoNDARY PRESSURE i PILOT SIGNAL, OCs. KET DIGGING PLOT SECONDARY PRESSURE t PILOT SIGNAL; P PROCESS PILOT SIGNAL m PROCESS FREE STR backer ‘BUOKET DISEING PLOT SECONDARY PRESSURE BUCKET DIGGING PLOT SEOCNDARY PRESSURE i ai i eNGo ave MECHATRO | CONTROLLER i: PROPORTIONAL VALVE SECONDARY PRESSURE 21-1521, MECHATRO CONTROL SYSTEM (1) On starting bucket digaing (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 P71 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 bby mechairo controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of control valve. (6) 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 unioad 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 tow. (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 contra! the stroke limit of bucket spool. 21-1621. MECHATRO CONTROL SYSTEM 21.410 SWING PRIORITY CONTROL FLW Pr UNLOAD T OOK L CONF Nee lsetecror| Jualve En = eUCKET ‘ARI 1 SPEED ‘TRAVEL LEf ARM 2 SPEED OPTION | teaver aici [soo P2UNLOAD TRAVEL STRAIGHT Low ) eressure | Sersom PILOT SIGNAL | PROCESS PINE PROPORTIONAL Vane POV LPR Peoporiowa. LH whtve av PEONCORS PROPORTIONAL VALVE PSV PROPORTIONAL biti PILOT SIGNAL S 84 PLOT BEOONOAT TERE STRAGAT eenauans BeoeoRTnn, VALVE Pe eeRERETON] | frsersemororow] eesSter is [Soar | pl: PROPORTIONAL VALVE SECONDARY PRESSURE (1) During arm-in operation, arm operating pilot secondary pressure switches arm spool andis 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 machatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P41 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool (3) Each proportional vaive outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P41 and P2 unioad 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 fo the arm cylinder head side, and consequently the return oil ‘on arm oylinder 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, 211721, MECHATRO CONTROL SYSTEM 2A cPriowaL PILOT VALVE (ert) (eich) OF VALVE TRAVEL TRAVEL STRAIGHT CONTROL ; ccm veconreux J 1 PI UNLOAD - ] ew 8 & & lle seLecTor 3 & BHe we | Tere g #sl/e/2 erlaligllo| |2 z 8\|3 wad (5 ]/2)|2/}e, fs ee ULE}E} Leh l2 z Be PLOT PILOT a a Wave © VANE “ nooo TRAVEL STRAIGHT SIGNAL | por siowat \ PLOT SIGNAL Process AY PRESSURE Le PLOTSIGNAL =— ave oa “Ea a | LCT SECONDARY PRESSURE ‘SECONDARY PRESSURE PLor signa eeu [psooess ror crea I 24-18(1) Judgment travel straight 2 1) During travel operation (right and lef), pilot pressure switches each spool and is input to low pressure sensor 2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on, 3) On turing travel straight signal on, the following commands are output to each proportional valve. on carrying out attachment system operation, Operation of each proportional valve (Basically attachment operation is actuated by Pt pump and travel operation is actuated by P2 pump in travel straight condition.) 1) 2 3) 4) 5) Travel straight proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating 24, MECHATRO CONTROL SYSTEM (Goom, arm, bucket, swing, option) pilot pressure during operation. P1 unload proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation P2 unload proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation, 4 pump proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation P2 pump proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation, ~ ATT aperatorl Boom | Am | Bucxet | Swing | Option In travel operation (P1} oO Oo in travel operation (P2) Oo Oo. oO. 21-1921. MECHATRO CONTROL SYSTEM 21.112 PRESSURE RELEASE CONTROL ppatssenetasmanesssinoaaa 4é hus Q BL LE 5 a ae) fat] tle é{] ailellallé wae |B Ells llel_ [Ff -e Weyelelis 3 ge GAUGE CLUSTER ot 3 ze be!) LS | ENGINE SPEE! ‘CONTROL PILOT SIGNAL f Ee ee es] PILOT SIGNAL | AES EE | PILOT SIGNAL PROCESS ieee PROTSIGHAL ‘pee process IIR ER oa secre NEY 4 "pr: PROPORTIONAL VALVE ONTROULER, "SECONDARY PRESSURE (1) Press "Enter SW" on gauge cluster and select switch change mode, Press enter SW of & ¥ switch displayed on pressure release control screen. After the characteris reversed, select control ON with ¥ switch and press “Enter SW", and the mechatro controller decides it as pressure release mode. (2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot accel potentiometer, etc.) the mechatro controller, 1). Outputs minimum tit angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum tit angle 2) Outputs command of pressure release and outputs cornmand of pressure release control to ECU and fixes, engine speed to pressure release control speed. 3) Outputs maximum commend to Pt and P2 unload valves and each pilot secondary pressure fixes P1 and 2 unload valves to the maximum opening (8) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump Pressure and displays "DRAINING HYD. PRESS" or "FAlL 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 spoo! with the unload vaive opened 21-20