Beruflich Dokumente
Kultur Dokumente
EXCAVATOR
SK210-8
ACERA MARK 8
TIER III
REVISION HISTORY
Issue Issue Date Applicable Machines Remarks
First Edition 01-2007 SK210-8 ACERA MARK 8 TIER III YN91ZU0007P1 NA
Any use of editorial or pictorial content is strictly prohibited without express written permission from
Kobelco Construction Machinery America, LLC . Carol Stream, IL 60188 U.S.A..
SK210 - 8 TABLE OF CONTENTS
SPECIFICATIONS SECTION
0-SAFETY
0.1 GENERAL SAFETY INFORMATION ................................................................................... 0-2
0.2 SAFETY PRECAUTIONS .................................................................................................... 0-3
1-OUTLINE
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3
1.1.1 PREPARATION BEFORE DISASSEMBLING ..........................................................1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING.........................................1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3
1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-4
1.1.5 HYDRAULIC PARTS ................................................................................................1-5
1.1.6 WELD REPAIR .........................................................................................................1-5
1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-5
1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-6
2-SPECIFICATIONS
2.1 NAME OF COMPONENTS ................................................................................................2-3
2.2 GENERAL DIMENSIONS ..................................................................................................2-4
2.2.1 SK210–8 [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3
(1.05cu•yd) Bucket Shoe] .........................................................................................2-4
2.2.2 SK210–8 [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3
(0.92cu•yd) Bucket Shoe] .........................................................................................2-4
2.3 WEIGHT OF COMPONENTS ............................................................................................2-5
2.4 TRANSPORTATION ..........................................................................................................2-7
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-7
2.4.2 DIMENSIONS OF ATTACHMENT............................................................................2-8
2.5 SPECIFICATIONS AND PERFORMANCE........................................................................2-9
2.5.1 SPEED AND CLIMBING CAPABILITY .....................................................................2-9
2.5.2 ENGINE ....................................................................................................................2-9
2.5.3 HYDRAULIC COMPONENTS ..................................................................................2-9
2.5.4 WEIGHT....................................................................................................................2-9
2.6 TYPE OF CRAWLER.........................................................................................................2-10
2.7 COMBINATIONS OF ATTACHMENT................................................................................2-12
2.8 ENGINE SPECIFICATIONS ..............................................................................................2-13
2.8.1 SPECIFICATIONS ....................................................................................................2-13
-
3-ATTACHMENT DIMENSIONS
3.1 BOOM ................................................................................................................................3-3
3.1.1 BOOM DIMENSIONAL DRAWING ...........................................................................3-3
3.1.2 BOOM MAINTENANCE STANDARD .......................................................................3-4
3.2 ARM ...................................................................................................................................3-6
3.2.1 ARM DIMENSIONAL DRAWING ..............................................................................3-6
3.2.2 ARM MAINTENANCE STANDARD ..........................................................................3-7
3.3 BUCKET AND PIN .............................................................................................................3-10
3.3.1 BUCKET AND PIN DIMENSIONAL DRAWING........................................................3-10
3.3.2 BUCKET AND PIN DIMENSIONAL TABLE..............................................................3-11
MAINTENANCE SECTION
11-TOOLS
11.1 STANDARD TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS ..................11-3
11.2 SCREW SIZE...................................................................................................................11-5
11.2.1 CAPSCREW (BOLT) ..............................................................................................11-5
11.2.2 CAPSCREW (SOCKET BOLT)...............................................................................11-5
11.2.3 SOCKET SET SCREW ...........................................................................................11-5
11.3 TORQUE SPECIFICATIONS FOR HOSE AND FITTINGS .............................................11-6
11.3.1 JOINT (O-RING TYPE) ...........................................................................................11-6
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6
11.3.3 JOINT (ORS TYPE) ................................................................................................11-6
11.3.4 SPLIT FLANGE.......................................................................................................11-6
11.4 TORQUE SPECIFICATIONS FOR NUTS AND SLEEVES .............................................11-7
11.5 PLUG ...............................................................................................................................11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11
11.7 SPECIAL TOOLS.............................................................................................................11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND ......11-14
11.9 SUCTION STOPPER.......................................................................................................11-15
11.9.1 COMPONENTS ......................................................................................................11-15
11.9.2 DIMENSION............................................................................................................11-15
11.9.3 APPLICABLE MODEL ............................................................................................11-15
11.10 COUNTER WEIGHT LIFTING JIG..................................................................................11-16
111.10 UPPER FRAME LIFTING JIG ........................................................................................11-17
11.11 ENGINE TURNOVER STAND .........................................................................................11-18
11.13 TRACK SPRING SET JIG................................................................................................11-19
12-STANDARD MAINTENANCE TIMETABLE
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR....12-4
22-HYDRAULIC SYSTEM
22.1 SUMMARY..............................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS ......................................................22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS...............................22-8
22.4 NEUTRAL CIRCUIT................................................................................................22-8
22.5 TRAVEL CIRCUIT ..................................................................................................22-10
22.6 BUCKET CIRCUIT ..................................................................................................22-12
22.7 BOOM CIRCUIT .....................................................................................................22-14
22.8 SWING CIRCUIT ....................................................................................................22-18
22.9 ARM CIRCUIT ........................................................................................................22-20
22.10 COMBINED CIRCUIT .............................................................................................22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ..................................................22-30
23-ELECTRICAL SYSTEM
23.1 ELECTRIC CIRCUIT DIAGRAM ......................................................................................23-3
23.2 ELECTRICAL EQUIPMENT LIST ....................................................................................23-7
23.3 HARNESS........................................................................................................................23-9
23.3.1 HARNESS LIST ......................................................................................................23-9
23.3.2 INSTRUMENT PANEL ASSY .................................................................................23-10
23.3.3 CONTROLLER INSTALL........................................................................................23-11
23.3.4 TUNER INSTALL ....................................................................................................23-11
23.3.5 UPPER ELECTRIC ASSY ......................................................................................23-12
23.3.6 UPPER HARNESS ASSY.......................................................................................23-13
23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) ..........................................................23-24
23.3.8 CAB HARNESS ASSY............................................................................................23-30
23.3.9 BOOM HARNESS ASSY ........................................................................................23-33
23.3.10 INSTALLING BOOM LIGHT ...................................................................................23-33
23.3.11 INSTALLING UPPER LIGHT ..................................................................................23-34
23.3.12 FLASHER LAMP INSTALL .....................................................................................23-35
21.1.13 ALARM ASSEMBLY ...............................................................................................23-36
24-COMPONENTS SYSTEM
24.1 HYDRAULIC COMPONENTS..........................................................................................24-3
24.1.1 HYDRAULIC PUMP, REGULATOR .......................................................................24-3
24.1.2 CONTROL VALVE..................................................................................................24-21
24.1.3 PILOT VALVE (ATT)...............................................................................................24-59
24.1.4 PILOT VALVE (TRAVEL)........................................................................................24-63
24.1.5 SWING MOTOR UNIT ............................................................................................24-65
24.1.6 TRAVEL MOTOR....................................................................................................24-75
24.1.7 SWIVEL JOINT .......................................................................................................24-89
24.1.8 CYLINDER..............................................................................................................24-91
24.2 ELECTRIC EQUIPMENT .................................................................................................24-97
24.2.1 ELECTRIC EQUIPMENT LIST ...............................................................................24-97
24.2.2 SPECIFICATION OF ELECTRIC EQUIPMENT .....................................................24-100
-
25-AIR CONDITIONER SYSTEM
25.1 BASIC AIR CONDITIONER SYSTEM (HVAC AIR CONDITIONER) ...............................25-2
25.1.1AIR CYCLE ......................................................................................................................25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2.1 COMPONENT.........................................................................................................25-5
25.2.2 CONSTRUCTION ...................................................................................................25-6
25.3 PIPING .............................................................................................................................25-9
25.3.1 AIR CONDITIONER................................................................................................25-9
25.3.2 RECEIVER DRYER ASSY .....................................................................................25-11
25.4 FUNCTION.......................................................................................................................25-12
25.4.1 MECHANISM OF COOLING CIRCUIT ...................................................................25-12
25.4.2 COOLING CIRCUIT ................................................................................................25-14
25.4.3 COMPONENT PARTS............................................................................................25-15
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION..........................................25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.6 CHARGING REFRIGERANT ...........................................................................................25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION..........................................25-24
25.6.2 OPERATING PROCEDURE...................................................................................25-25
25.6.3 CHARGING PROCEDURE.....................................................................................25-26
25.7 ELECTRIC CIRCUIT ........................................................................................................25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS..............................................................25-32
25.7.2 STRUCTURE AND OPERATION OF EACH PART AND INSPECTION ................25-34
25.8 TROUBLESHOOTING .....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE ...................................................................25-46
DISASSEMBLING SECTION
31-DISASSEMBLY AND ASSEMBLING
31.1 DISASSEMBLY & ASSEMBLY OVERVIEW....................................................................31-3
31.1.1 GENERAL INFORMATION.....................................................................................31-3
31.1.2 TORQUE SPECIFICATIONS..................................................................................31-3
32-ATTACHMENT
32.1 REMOVING AND INSTALLING .......................................................................................32-3
32.1.1 ATTACHMENT ASSEMBLY ...................................................................................32-3
32.1.2 BUCKET .................................................................................................................32-3
32.1.3 ARM ........................................................................................................................32-6
32.1.4 BOOM .....................................................................................................................32-9
32.2 DISASSEMBLING AND ASSEMBLING ...........................................................................32-13
32.2.1 CYLINDER..............................................................................................................32-13
33-UPPER STRUCTURE
33.1 OPERATOR SEAT...........................................................................................................33-3
33.1.1 OPERATOR SEAT .................................................................................................33-3
33.1.2 CAB.........................................................................................................................33-4
33.1.3 BATTERY ...............................................................................................................33-6
33.1.4 GUARD ...................................................................................................................33-7
33.1.5 UNDER COVER .....................................................................................................33-13
33.1.6 FUEL TANK ............................................................................................................33-14
33.1.7 HYDRAULIC TANK.................................................................................................33-16
33.1.8 HYDRAULIC PUMP................................................................................................33-20
33.1.9 AIR CLEANER ........................................................................................................33-25
33.1.10 MUFFLER ...............................................................................................................33-26
33.1.11 COUNTERWEIGHT................................................................................................33-28
33.1.12 RADIATOR & OIL COOLER ...................................................................................33-29
33.1.13 ENGINE ..................................................................................................................33-35
33.1.14 CONSOLE COVER.................................................................................................33-38
33.1.15 CONTROL VALVE..................................................................................................33-39
33.1.16 PILOT VALVE (FOR ATT) ......................................................................................33-42
33.1.17 PILOT VALVE (FOR TRAVEL) ...............................................................................33-43
33.1.18 SWING MOTOR UNIT ............................................................................................33-45
33.1.19 SWIVEL JOINT .......................................................................................................33-47
33.1.20 UPPER FRAME ......................................................................................................33-50
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-53
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................33-53
33.2.2 CONTROL VALVE..................................................................................................33-79
33.2.3 PILOT VALVE (ATT)...............................................................................................33-110
33.2.4 PILOT VALVE (FOR TRAVEL) ...............................................................................33-120
33.2.5 SWING MOTOR UNIT ............................................................................................33-129
33.2.6 SWIVEL JOINT .......................................................................................................33-156
34-TRAVEL SYSTEM
34.1 REMOVING AND INSTALLING .......................................................................................34-3
34.1.1 TRAVEL SYSTEM .................................................................................................34-3
34.1.2 CRAWLER ..............................................................................................................34-3
34.1.3 UPPER ROLLER ....................................................................................................34-7
34.1.4 LOWER ROLLER ...................................................................................................34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-21
34.1.6 SPROCKET ............................................................................................................34-30
34.1.7 TRAVEL MOTOR...................................................................................................34-33
34.1.8 SWING BEARING...................................................................................................34-35
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT........................................34-38
34.2.1 TRAVEL MOTOR....................................................................................................34-38
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TROUBLESHOOTING SECTION
46-TROUBLESHOOTING (BY ERROR CODES)
46.1 EVALUATION OF ACTUAL PROBLEM AT THE SITE ....................................................46-3
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING........................................46-4
46.3 MECHATRO CONTROLLER BLOWN FUSE .................................................................46-4
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-4
ENGINE SECTION
51-ENGINE
SECTION 1 - DIAGNOSTICS ............................................................................................ EW - 1-1
SECTION 2 - 6.7 L T/A ENGINE OVERHAUL ....................................................................EW - 1-2
SECTION 3 - RECHARGING AND START-UP ..................................................................EW - 1-3
SAFETY
GENERAL SAFETY INFORMATION 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
Do not operate or perform any maintenance on this and its components and is represented as fol-
machine until all instructions found in the OPERA- lows:
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine (4) It is very difficult to forecast every danger that may
may cause accidents and could result in serious in- occur during operation. However, safety can be en-
jury or death. sured by fully understanding proper operating pro-
Always keep the manual in storage. cedures for this machine according to methods
If it is missing or damaged, place an order with your recommended by Manufacturer.
dealer for a replacement.
(5) While operating the machine, be sure to perform
If you have any questions, consult your dealer.
work with great care, so as not to damage the ma-
chine, or allow accidents to occur.
(1) Most accidents, which occur during operation, are
due to neglect of precautionary measures and safe- (6) Continue studying the manual until all Safety, Oper-
ty rules. Sufficient care should be taken to avoid ation and Maintenance procedures are completely
these accidents. Incorrect operation, lubrication or understood by all persons working with the ma-
maintenance services are very dangerous and may chine.
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, local 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:
0-2
SAFETY PRECAUTIONS
0-3
(13)Always use the proper tools that are in good condi- (19)Loose or damaged fuel, lubricant and hydraulic
tion and that are suited for the job at hand. Be sure lines, tubes and hoses can cause fires. Do not bend
you understand how to use them before performing or strike high pressure lines or install ones which
any service work. have been bent or damaged. Inspect lines, tubes
(14)Reinstall all fasteners with the same part number. and hoses carefully. Do not check for leaks with
Do not use a lesser quality fastener if replacements your hands. Very small (pinhole) leaks can result in
are necessary. a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
(15)Repairs which require welding should be per-
cause personal injury. Use card-board or paper to
formed only with the appropriate reference informa-
locate pinhole leaks.
tion and by personnel adequately trained and
knowledgeable in welding procedures. Determine (20)Tighten connections to the correct torque. Make
the type of metal being welded and select the cor- sure that all heat shields, clamps and guards are in-
rect welding procedure. Use electrodes, rods or stalled correctly to avoid excessive heat, vibration
wire to provide a weld metal strength equivalent at or rubbing against other parts during operation.
least to that of the parent metal. Make sure to dis- Shields that protect against oil spray onto hot ex-
connect the battery before any welding procedures haust components in event of a line, tube or seal
are attempted. failure must be installed correctly.
(16)Do not damage wiring during removal operations. (21)Do not operate a machine if any rotating part is
Reinstall the wiring so it is not damaged nor will be damaged or contacts any other part during opera-
damaged in operation of the machine by contacting tion. Any high speed rotating component that has
sharp corners, or by rubbing against some object or been damaged or altered should be checked for
hot surface. Do not connect wiring to a line contain- balance before reusing.
ing fluid. (22)Be careful when servicing or separating the tracks
(17)Be sure all protective devices including guards and (crawlers). Chips can fly when removing or install-
shields are properly installed and functioning cor- ing a track (crawlers) pin. Wear safety glasses and
rectly before starting a repair. If a guard or shield long sleeve protective clothing. Tracks (crawlers)
must be removed to perform the repair work, use can unroll very quickly when separated. Keep away
extra caution and replace the guard or shield after from front and rear of machine. The machine can
repair is completed. move unexpectedly when both tracks (crawlers)
are disengaged from the sprockets. Block the ma-
(18)The maintenance and repair work while holding the
chine to prevent it from moving.
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
0-4
NOTE:
This Manual contains important information necessary • The Chapter "Disassembly" describes the removal
for the maintenance and repair of your hydraulic exca- and installation of assemblies mounted on the up-
vator. Information is categorized into 6 Chapters, Spec- per structure and undercarriage, and the assem-
ification, Maintenance, System, Disassembly, bling and disassembling of the associated hydraulic
Troubleshooting and Engine. equipment.
• The Chapter "Troubleshooting" describes how to
• The Chapter "Specification" describes the specifi- find faulty equipment.
cations for entire machine and material, which is in- • The Chapter "Engine" describes the engines mak-
structive for replacement and repairing ing use of the "Maintenance Manual" provided by
attachments. the suppliers.
• The Chapter "Maintenance" describes the stan-
dards and procedures, which is helpful for mainte-
nance service and adjustments for the entire Kobelco reserves the right to make improvements in
machine. design or changes in specifications at any time without
• The Chapter "System" describes the operating sys- incurring any obligation to install them on units previ-
tem such as the hydraulic system, electric system, ously sold.
components, and so on.
0-5
0-6
1
1. OUTLINE
TABLE OF CONTENTS
1-1
1. OUTLINE
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
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
extinguisher, and also where to make contact
Read Operator's Manual for emergency measure and ambulance to
before disassembling
5) Clogging of filters, oil level, oil quality, oil 4) Clean the outside surface of the machine area
contamination and looseness. to be worked on before disassembling. Drain
hydraulic oil and gear oil before putting parts on
6) Examine the problems on the basis of monthly
the work bench.
operation rate with the last inspection date and
records on hour meter. (2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop 1) Make alignment marks on parts for assembly.
1) Tools required for repair work. 2) Before disassembling, read Disassembling
Instruction in advance, and determine if the
2) Prepare the places to put the disassembled
disassembly and assembly are permitted or
parts.
not.
3) Prepare oil pans for leaking oil, etc.
3) For parts which are required to use jig and
1.1.2 SAFETY WHEN DISASSEMBLING AND tools, don’t fail to use the specified jig and tools.
ASSEMBLING 4) Parts that can not be removed in the specified
procedure, never force removal. First check for
the cause.
WARNING
1-3
1. OUTLINE
1-4
1. OUTLINE
1-5
1. OUTLINE
1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or °
C (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro µ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3
1-6
1. OUTLINE
1-7
1. OUTLINE
[MEMO]
1-8
2
2. SPECIFICATIONS
TABLE OF CONTENTS
2-1
2. SPECIFICATIONS
2-2
2. SPECIFICATIONS
BOOM CYLINDER
BUCKET
CYLINDER
CAB
SLEWING BEARING
IDLER LINK
SLEWING MOTOR
SWIVEL
JOINT FUEL TANK
HYDRAULIC TANK
BUCKET LINK
CONTROL VALVE
GUARD
MUFFLER
HYDRAULIC
PUMP
BUCKET
MONITOR PANEL
FRONT IDLER
ENGINE
IDLER ADJUST
COUNTER WEIGHT
UPPER ROLLER
LOWER ROLLER
TRAVEL MOTOR
2-3
2. SPECIFICATIONS
1315 (4'4")
43 (1'7")
Unit : mm(ft-in)
2710 (8'11")
1395 (4'7")
R2
75
0
(9
')
9450 (31')
2750 (9')
3028 (9'11")
2981 (9'9")
1060 (3'6")
(17.1")
450
800 (31.5")
4450 (14'7")
3190 (10'6")
4980 (16'4")
2.2.2 SK210–8 [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu•yd) Bucket Shoe]
Unit : mm(ft-in)
9520 (31'3")
2750 (9')
3176 (10'5")
1060 (3'6")
4450 (14'7")
4980 (16'4")
2-4
2. SPECIFICATIONS
2-5
2. SPECIFICATIONS
Unit ; kg (lb)
Model
SK210 - 8
Item
4. Lubricant and water (Assembly of following :) 550 (1,210)
4.1 Hydraulic oil 200 (440)
4.2 Engine oil 20 (44)
4.3 Fuel 310 (680)
4.4 Water 20 (44)
2-6
2. SPECIFICATIONS
2.4 TRANSPORTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 5.65m (18ft-6in) Boom+2.94m (9ft-8in) Arm+0.80m3 (1.05cu•yd) Bucket
Model
SK210-8
Item
Width 800mm (31.5in) shoes 3,190 (10ft-6in)
Weight 21,700kg (47,800 lbs)
Unit : mm (ft-in)
9480 (31'1") 2410 (7'11")
3060 (10')
3760 (10'4")
(5.72")
(3.94")
(27.6")
(9.45")
(2.38") (2.26")
SECTION AA
2-7
2. SPECIFICATIONS
Type
5.65m (18ft-6in) Boom
Item
Length× Height× Widt
5.86 × 1.57 × 0.67
h m (ft-in)
(19'3"× 5'2"× 2'2")
L× H× W
Weight kg (lbs) 1,790 (3,950)
(3) Arm
Type
2.94 m (9ft-8in) Arm 3.5 m (11ft-6in) Arm
Item
Length× Height× Widt
3.93 × 0.89 × 0.56 4.53 × 0.89 × 0.56
h m (ft-in)
(12'11"× 2'11"× 1'10") (14'10"× 2'10"× 1'10")
L× H× W
Weight kg (lbs) 1,160 (2,560) 1,280 (2,200)
2-8
2. SPECIFICATIONS
Model
SK210 - 8
Item
Swing speed min-1 {rpm} 12.5 {12.5}
Travel speed (1-speed/2-
km/h (mile/h) 3.6 / 6.0 (2.2 / 3.7)
speed)
Gradeability % (degree) 70 (35)
2.5.2 ENGINE
2.5.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 21,700 (47,800)
Upper structure 9,500 (21,000)
Lower machinery
7,980 (17,600)
(800mm grouser shoe)
Attachment
5.65m (18 ft-6in) Boom+2.94m (9ft-8in) Arm 3,660 (8,030)
+0.80m3 (1.05cu•yd) Bucket
2-9
2. SPECIFICATIONS
Grouser shoe
600 (23.6) LC 2,990 (9'10") 44 (6.38)
Use 600mm (23.6") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
2-10
2. SPECIFICATIONS
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2-11
2. SPECIFICATIONS
2-12
2. SPECIFICATIONS
[MEMO]
2-13
2. SPECIFICATIONS
2-14
3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
3-1
3. ATTACHMENT DIMENSIONS
3-2
3. ATTACHMENT DIMENSIONS
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING
Fig. 3-1 Boom dimensional drawing
Unit : mm (ft-in)
STD —
5.65M (18ft-6in) BOOM
YN02B00408F1 —
No NAME DIMENSION
A Boom length 5,650 (18'6") —
B Boom foot width 670 (26.4") —
C Boom end inner width 347 (13.7") —
D Boom end outer width 482 (19") —
E Height of boom cylinder rod pin 1,008.5 (3'4") —
F Height of arm cylinder (head side) pin 1,203.5 (3'11") —
G Distance between pins of boss R2,589 (8'6") —
H Distance between pins of bracket R2,829.5 (9'3") —
I Arm cylinder (head side) inner width 126 (4.96") —
J Outer width of bracket on the arm cylinder (rod side) 468 (18.4") —
mounting
d1 Boom foot pin dia. ø 90 (3.54") —
d2 Boom cylinder (rod side) pin dia. ø 85 (3.35") —
d3 Pin dia. of boom end. ø 90 (3.54") —
d4 Arm cylinder (head side) pin dia. ø 85 (3.35") —
3-3
3. ATTACHMENT DIMENSIONS
A
C
Unit : mm (in)
Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.020 + 0.217 + 0.237
ø 90 (+0.0008) (+0.0085) (+0.0093)
A Boom foot YN02B01719P1
(3.5433) - 0.020 + 0.071 + 0.051
(-0.0008) (+0.0028) (+0.0020)
+ 0.243 + 0.283
0
Boom cylinder ø 85 - 0.040
(+0.010) (0.011)
B YN02B01720P1
(Head side) (3.3465) + 0.085 + 0.085 More
(-0.0016) Replace
(+0.0033) (+0.0033) than 2.5
bushing
+ 0.247 + 0.267 2.0 (0.1)
or pin
Boom cylinder (+0.0097) (+0.0105) (0.08)
C YN02B01721P1
(Rod side) + 0.020 + 0.093 + 0.073
ø 85 (+0.0008) (+0.0037) (+0.0097)
(3.3465) - 0.020 + 0.230 + 0.250
Arm cylinder (-0.0008) (+0.009) (+0.010)
D YN02B01722P1
(Head side) - 0.065 + 0.045
(-0.003) (+0.002)
3-4
3. ATTACHMENT DIMENSIONS
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
670
Boom
(26.4) 0.5 (0.02) 831
A-A Boom foot L1 PL1
676 or less (32.7)
Upper frame
(26.6) 2.0 2.5
105 (0.08) (0.10)
Boom cylinder
Boom cylinder (4.13) 0.6~1.0 241
B-B L2 PL2
(Head side) 111 (0.02~0.04) (9.49)
Upper frame Shim
(4.37)
adjust
105
Boom cylinder L3 ment
Boom cylinder (4.13) 0.6~2.0 3.0 4.0 736
C-C PL3
(Rod side) 468 (0.02~0.08) (0.12) (0.16) (29.0)
Boom L3'
(18.4)
120
Arm cylinder
Arm cylinder (4.72) 0.6~1.0 2.0 2.5 260
D-D L4 PL4
(Head side) 126 (0.02~0.04) (0.08) (0.10) (10.2)
Boom
(4.96)
3-5
3. ATTACHMENT DIMENSIONS
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
Unit : mm (ft-in)
2.94m (9ft-8in) ARM YN12B00820F1
Code NAME DIMENSION Code NAME DIMENSION
C Arm length 2,940 (9'8") N Bracket inner width 126 (4.96")
Distance between pins of boss
D R874 (34.4") O Bracket inner width 111 (4.37")
and bracket
D1 I.D of boss ø110 (4.33") P Idler link dimension 630 (24.8")
D2 I.D of boss ø85 (3.35") Q Bucket link dimension 610 (24")
Height between pins of boss and
D4 I.D of boss ø105 (4.13") R 31 (1.22")
center
Distance between pins of boss
E R2,169 (7'1") d1 Pin dia. ø80 (3.15")
and bracket
Distance between pins of boss
F R420 (16.5") d2 Pin dia. ø70 (2.76")
and boss
Height between pins of boss and
G 665.5 (26.2") d3 Pin dia. ø85 (3.35")
bracket
Height between pins of boss and
H 312 (12.3") d4 Pin dia. ø90 (3.54")
bracket
K Arm top end boss width 325 (12.8") d5 Pin dia. ø80 (3.15")
L Arm link section boss width 323 (12.7")
M Boss width 342 (13.5")
3-6
3. ATTACHMENT DIMENSIONS
E
F
D, D'
B
C
G
Unit : mm (in)
Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.253 +0.313
(+0.0100) (+0.0123)
A Arm point
–0.020 +0.080 +0.100
ø80 (-0.0008) (+0.0031) (+0.0039)
YN12B02215P1
(3.1496) –0.060 +0.220 +0.280
Bucket link (-0.0024) (+0.009) (+0.0110)
B
(Bucket side) +0.076 +0.096
(+0.0030) (+0.0038)
3-7
3. ATTACHMENT DIMENSIONS
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X L3 PL5
X L6
X L5
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D
SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-8
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
325
Arm
(12.79) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
326 or less (0.08)
Bucket
(12.83) 481
325 (18.9)
Link side
(12.79)
B-B Bucket link L2 — — PL2
327
Bucket
(12.87)
323 2.5
Idler link Arm 0.5 1.0
C-C L3 (12.72) (0.10) PL3
(Arm connection) (0.02) (0.04)
Link side -
Bucket link Rod side -
D-D (Idler link L4 323 427
Link side
connection) (12.72) (16.8)
0.6~1.0 2.0 Shim
105 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (4.13)
D’-D’ L4’ -ment
(Rod side) 111
Link side
(4.37)
105
Head side
Bucket cylinder (4.13) 235
E-E L5 PL5
(Head side) 111 (9.25)
Arm
(4.37) 0.6~2.0 3.0 4.0
120 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (9.72) 260
F-F L6 PL6
(Rod side) 126 (10.2)
Arm
(4.96)
342
Arm
(13.46) 0.5 1.0 2.5 505
G-G Arm foot L7 PL7
347 (0.02) (0.04) (0.10) (19.9)
Boom
(13.66)
3-9
3. ATTACHMENT DIMENSIONS
*r2
A d2
α
B
*r1
E d1
I D
t1 Io t6
F
t2 t3
t5 t4
3-10
3. ATTACHMENT DIMENSIONS
3-11
3. ATTACHMENT DIMENSIONS
3-12
11. TOOLS
11
TABLE OF CONTENTS
11-1
11. TOOLS
11-2
11. TOOLS
11-3
11. TOOLS
11-4
11. TOOLS
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 27 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
11-5
11. TOOLS
11-6
11. TOOLS
SLEEVE NUT
B
d
d
11-7
11. TOOLS
11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
A
No.
O. D : A H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
A
11-8
11. TOOLS
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
PF screw
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
#
$ %
() !
, -+./0
&# *+( "
'& *+( "
'& *+( "
Female
11-10
11. TOOLS
70(2.76)
16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)
70(2.76)
42(1.65)
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )
32 (1.26) 2421T232 50
81(3.19) 90(3.54)
20.5(0.807)
11-11
11. TOOLS
Allen wrench
ZT22A10000 Pump
1 Nominal
suction
B : 10, C : 11.3
Additional M10 X 22
threading
for M10 eye bolt
Plug ZE72X12000 For slinging the
4
PF3/4 swing motor
O-ring
PF3/4
M10
M8 Eye bolt
Plug
ZF83P22000
(Nominal
tube dia. 22)
6 Reference nut Flare hose
Reference
ZS91C00800
Eye bolt
ZF93N22000 M8 X 18
Nut Addtional
threading for
M8 Eye bolt
11-12
11. TOOLS
Table11-4
M8 Eye bolt
M8 X 18
Plug YN01H01001P1
Additional
threading
Nominal
7 1-14UNS HEX 27 Flare hose
M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
8 1 3/16-12UN HEX 36 Flare hose
Plug ZE25F08000
PF1/2 For slinging the
9 Weld
Coupling swivel joint
half Coupling half
PF 1/2
11-13
11. TOOLS
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound
11-14
11. TOOLS
2 Nut
3 Cover
4 O-ring
11.9.2 DIMENSION
50
(1.97")
R8
O113 (4.45")
2
M8 NUT
O8 (1.315")
600 (23.6")
+0.5
M8 O100 0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
Fig. 11-2 Dimension of suction stopper
Applicable
SK115SR
SK135SR
SK235SR
SK200-6E
SK100-2
SK120-2
SK100-3
SK120-3
SK200-6
SK200-8
model
SK100
SK120
Part No.
24100P978F2
11-15
11. TOOLS
Size Vertical
Part No. lifting load
d L kg (lbs)
M8 15 ZS91C00800 80 (176)
M10 18 ZS91C01000 150 (331)
M12 22 ZS91C01200 220 (485)
M16 27 ZS91C01600 450 (992)
M20 30 ZS91C02000 630 (1390)
M24 38 ZS91C02400 950 (2090)
L
d
M30 45 ZS91C03000 1500 (3310)
M36 55 ZS91C03600 2300 (5070)
M42 65 ZS91C04200 3400 (7490)
M48 70 ZS91C04800 4500 (9920)
11-16
11. TOOLS
Q'ty : 2 sets
Material : Mild steel
Fig. 11-4 Upper frame lifting jig
11-17
11. TOOLS
11-18
11. TOOLS
M30
Retainer nut
Retainer plate
)
.6"
(12
(27.6")
Stand
(15.0")
Hydraulic jack
Base
Fig. 11-6 Track spring set jig
11-19
11. TOOLS
[MEMO]
11-20
12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ... 12-4
12-1
12. STANDARD MAINTENANCE TIME TABLE
12-2
12. STANDARD MAINTENANCE TIME TABLE
PREFACE
(1) Working Conditions
1) Workers :
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
2) Equipment :
Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The
maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
3) Place :
A level area where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance time× Preparation time
2) Direct maintenance time : Net time actually spent for maintenance
3) Spare time :
Time needed to move machines for service, prepare safety operations, discuss work, and process the needs
of the body.
(3) Extra time (not included in the standard service time)
1) Repair time :
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time :
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
3) Indirect time :
Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
(4) Applicable machine for estimation of standard maintenance time
1) Standard machine
2) A well maintained and controlled machine with a standard combination of attachments which is used in a
general environment.
12-3
12. STANDARD MAINTENANCE TIME TABLE
12-4
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.6
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.2
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 2.4
07 • Tooth Replace 1 pc. 0.6
08 • Side cutter Replace 1 pc. 1.2
09 • Bushing Replace 1 pc. 0.6
12-5
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.2
80 Boom cylinder O/H 2 7.0
01
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.
12-6
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
52 Cover (2) Detach/attach 1 pc. 0.1
53 Cover (3) Detach/attach 1 pc. 0.1
54 Cover (4) Detach/attach 1 pc. 0.1
55 Cover (5) Detach/attach 1 pc. 0.1
02 Cab & Guard
12-7
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.5
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0
12-8
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
96 Swing motor O/H 1 pc. 3.6
97 Swing reduction gear O/H 1 pc. 4.2
12-9
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
Detach/attach 1 set Removing and installing pump 3.2
Detach/attach 1 set Removing and installing air cleaner 0.4
1 set Removing and installing muffler 0.4
03 Swing frame
Detach/attach
12-10
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
51 Travel motor ASSY Detach/attach One side After removing track link 1.7
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 0.9
54 • Motor mounting bolt Detach/attach One side 0.5
04 Travel system
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
Diode
D-4 Diode Replace 1 0.3
06 Electric equipments
12-11
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include Counterweight removing and installing. 1.0
E-12 Battery Replace 2 0.4
E-13 Travel alarm Replace 1 0.3
06 Electric equipments
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Swing flusher & work light (left) Replace 1 0.2
L-4 Swing flusher & work light (right) Replace 1 0.2
L-5 Room light Replace 1 0.2
L-6 Boom work light (right) Replace 1 0.2
L-7 Cab work light Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include Counterweight removing and installing. 1.0
M-2 Governor motor Replace 1 0.5
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.5
PSV-B P2 bypass cut proportional valve Replace 1 Include proportional valve block removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 bypass cut proportional valve Replace 1 0.5
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
12-12
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Grid heater relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-8 Travel alarm relay Replace 1 0.1
R-9 Cab work light relay Replace 1 0.1
R-11 Cab work light relay 2 Replace 1 0.1
R-19 Flasher relay Replace 1 0.3
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
06 Electric equipments
Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.5
SE-12 Engine oil level sensor Replace 1 Include under cover removing and installing 0.5
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-14 Coolant thermo sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Engine water temperature sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5
12-13
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-3 2-speed travel SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-4 Safety lever lock SOL Replace 1 Include proportional valve block removing and installing. 0.5
Switch
06 Electric equipments
12-14
12. STANDARD MAINTENANCE TIME TABLE
[MEMO]
12-15
12. STANDARD MAINTENANCE TIME TABLE
12-16
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD .............................................................. 13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE.....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ........................................................................... 13-6
13.3.1 MEASUREMENT OF ENGINE SPEED..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1 TRAVEL SPEED..................................................................................................... 13-12
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR....................................................................... 13-14
13.6 MEASURING SWING PERFORMANCES....................................................................... 13-15
13.6.1 SWING SPEED ......................................................................................................13-15
13.6.2 PERFORMANCE OF SWING BRAKE ................................................................... 13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE .................................................. 13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2 CYLINDER LEAK CHECK......................................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT..................................................................13-21
13.9.2 ENGINE CONTROL ...............................................................................................13-22
13.9.3 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) ... 13-24
13.9.4 OPERATIONS IN THE EVENT MECHATRO CONTROLLER FAILURE................ 13-29
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-2
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 50 - 50 LOW throttle
Measure the engine
Engine speed
not required
Adjustment
speed at multi display on
B mode Hi idle 2000 + 50 - 50 Perform all
the gauge cluster, or min-1
A mode Hi idle 2000 + 50 - 50 measurement with
measure with diesel
Decel 1050 + 50 - 50 the air-conditioner
speed meter.
S mode Hi idle 1800 + 50 - 50 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 34.3 (4970) + 0.7 (+100) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 0.7 (+100) - 0.5 (-73) RH and LH
RV —
13-4
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Standard
Inspection item Unit
value
Sprocket revolution 1st speed 30.5 ~ 27.5
min-1
(RH,LH) 2nd speed 50.4 ~ 45.6
Up 2.5 ~ 3.1
Boom
Down 2.2 ~ 2.8
Operating speed
55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 160
ATT amount of drift Boom cylinder 14 mm / 10min (At no load)
Arm cylinder 11
Amount of horizontal play at the bucket tooth 30 ~ 50 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE
NO.2 ENG
G-3 SPEED SET 1000
MEAS 1000
G-5 ENG OIL PRS. LIVE
WATER TEMP. 20 O
FF
MODE H
H-1 ACCEL VOLTS 0.3V
POS. 0%
G-1 MOTOR STEP 30
POS. 0%
COIL A 1.5A
COIL B 1.5A
G-2 LIMIT SW. OFF
13-6
13. MAINTENANCE STANDARD AND TEST PROCEDURE
B1
After releaving air pressure in the hydraulic oil
tank, open the cover take an sample oil from the a1 a2
hydraulic tank, and measure with the instrument for
Fig. 13-3 Gauge port on main pump
analysis. If the measured value is higher than the
standard value, replace the return filter or change
the hydraulic oil.
13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE
PLUG FOR
OR8 : ARM (R) OPTIONAL RELIEF
MACHINE
FRONT
MACHINE
FRONT
13-8
13. MAINTENANCE STANDARD AND TEST PROCEDURE
A3
a5
Dr3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm 0-:
Fig. 13-9 Over load relief valve
No. of turns of adjust screw Pressure change MPa (psi) (Boom, bucket, arm sections)
13-10
13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 30, 38 mm,
Tightening torque : 118 N•m (87 lbf•ft)
4 !
: 12 mm Fig. 13-10 Swing over load relief valve
13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-12
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
C
GUIDE FRAME
Fig. 13-17 Method of measurement
13-13
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-14
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Fig. 13-22 Measuring position of swing brake
performances
Swing brake performance Unit : degree
Measuring Reference value
position Standard value for remedy Service limit
Swing 180 75 85 90
13-16
13. MAINTENANCE STANDARD AND TEST PROCEDURE
2) Fully stroke the swing motion motor. Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 (1.6)
13-17
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-18
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-20
13. MAINTENANCE STANDARD AND TEST PROCEDURE
M-2:
GOVERNOR
MOTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE
GOVERNOR
MOTOR
SEMS-BOLT
9.60 N.m (7.08 lbf.ft) SEMS-BOLT
TIGHTING TORQUE 23.5 N.m (17.3 lbf.ft)
TIGHTING TORQUE
SEMS-BOLT
CAPSCREW
3 PLACES
19.6 N.m (14.5 lbf.ft)
APPLY LOCTITE #242 SECTION AA
TIGHTING TORQUE
SEMS-BOLT
4.4 N.m (3.25 lbf.ft)
TIGHTING TORQUE
(3.15
")
BRACKET
HIGH LOW
CALCULATION
BASIS POSITION
HIGH LOW
(6.23~7.49")
LEVER ASSY
BRACKET
(0.158")
LEVER ASSY
SECTION BB
DETAIL AA
23.5 N.m (17.3 lbf.ft) 10.7 N.m (7.89 lbf.ft) 10.7 N.m (7.89 lbf.ft)
TIGHTING TORQUE TIGHTING TORQUE TIGHTING TORQUE
NUT NUT ROD
NUT
LEVER ASSY
(0.158~0.748") (0.158~0.748")
(0.512~1.10") (0.512~1.10")
(6.23~7.49")
SECTION CC
13-22
13. MAINTENANCE STANDARD AND TEST PROCEDURE
ler.
2) The C-1 controller computes the input voltage,
and outputs a command to the governor motor
(M-2) and raises the governor level of the engine
OIL SEAL
to the swing angle corresponding to the accel
dial setting value.
3) The limit switch in the governor motor is the start-
ing point of the governor motor.
LIMIT
SWITCH
CONNECTOR
MOTOR
CONNECTOR
Fig. 13-34C
(3) Work mode select switch
If the work mode select switch is pressed, a signal MULTI DISPLAY
is transmitted to the C-1 controller and changes the
work modes in the order of H - B - A - S and back to
H again.
WASHER SWITCH
WIPER SWITCH
T SWITCH
Fig. 13-34D
13-23
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.9.3.3 PREPARATION
((1) Warm the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the HVAC OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error codes are displayed because the adjustment
data is not entered.
A215, A225, A015, A025, A035
Any error codes other than those shown above may suggest machine faults. Repair the machine according to
Error Code List.
13-24
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.9.3.4ADJUSTING PROCEDURE
4) Start the engine, press the selector switch on gauge cluster and "MEMORY
ENG" is displayed. The engine speed is automatically increased, and the
adjustment of the engine is performed.
(When trying to limit engine speed, press the selector switch on gauge cluster
at the speed as it is, and the adjustment of engine is terminated. The torque
adjustment and unloading adjustment required later are not performed, and
default value is written.)
5) When normal HIGH idling speed is detected, the adjustment is completed. And
FINISH ENG
"FINISH ENG" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared, PUMP PRESSURE
C-1 2.0M C-2 2.0M
and the adjustment of engine is completed. The torque adjustment and STEP
400
unloading adjustment required later are not performed, and default value is
written.)
13-25
13. MAINTENANCE STANDARD AND TEST PROCEDURE
and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA
2) When the unloading valve operates to the specified value, the adjustment of
UNLOAD" is displayed.
The speed is shifted to the speed corresponding to acceleration potentiometer.
(4) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) When the adjustment of the engine can not be performed, “ERROR ENG" will ENGINE SPEED
2000rpm
PUMP PRESSURE
be displayed. The displayed engine speed will be 50rpm lower than the last C-1 2.0M C-2 2.0M
STEP
value. 400
Possible causes of the error: a speed read error, pump load applied to the
engine or unusual stepping command applied to the govenor motor in the
course of adjustment.
a. Check the speed sensor: Check that it is free from incorrect readings of
speed due to engine vibration.
b. Check load applied to pump: Check that it is free from abnormal pressure
spikes during adjustment of engine through adjustment screen.
13-26
13. MAINTENANCE STANDARD AND TEST PROCEDURE
2) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Condition 2:
The adjustment will not complete although the pump proportional valve current
reaches the specified value.
13-27
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(6) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge
cluster pressed for 5~10 seconds, then release. If the engine is started, the
following screen will not be displayed.
2) Keep the buzzer stop switch on gauge cluster pressed for 5 seconds and then
release. The adjustment selection screen will be displayed. If adjustment data
ADJUST
READY
is not entered in the mechatro controller, "READY" is displayed. When the FEED
adjustment operation is performed, "FIN" is displayed.
The lever lock solenoid will be automatically released, disabling all operations.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and
select "ADJUST UNLOAD". (See Fig. 13-35)
Like the output adjustment, when adjustment data is not entered in mechatro
controller, "READY" is indicated. When the adjustment operation is performed,
"FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".
START ENG
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are displayed. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140
5) Start the engine, press the selector switch on the gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is displayed. The engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
6) When the unloading valve reaches the specified value, the adjustment of
UNLOAD" is displayed.
The speed is shifted to the speed corresponding to the acceleration
potentiometer.
The adjusting current value for the P1 and P2 unloading proportional valves is
shown on the display. The adjusting range is usually 520~635mA.
13-28
13. MAINTENANCE STANDARD AND TEST PROCEDURE
The emergency mode should be only used in case of emergency. Troubleshoot and repair the problem as soon as
possible.
13-29
13. MAINTENANCE STANDARD AND TEST PROCEDURE
[MEMO]
13-30
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21-1
21. MECHATRO CONTROL SYSTEM
21-2
21. MECHATRO CONTROL SYSTEM
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the
conditions before and after each conversion, refer to the hydraulic system and the electric system.
21-3
21. MECHATRO CONTROL SYSTEM
SE-29
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
21-5
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
21-6
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER
SECONDARY PRESSURE
21-7
21. MECHATRO CONTROL SYSTEM
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
21-8
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
((1) When starting the boom up operation, the boom up operating pilot pressure switches the boom spool and the
boom up conflux spool. This is input to the low pressure sensor.
(2) The output voltage of the low pressure sensor is input to the mechatro controller. The mechatro controller
processes the pilot signal and outputs a command according to the input voltage to the P1 and P2 proportional
valves and the P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by the mechatro controller. This changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload
pressure control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and
consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-9
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
21-10
21. MECHATRO CONTROL SYSTEM
21-11
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
((1) When starting arm-in operation, the arm-in operating pilot secondary pressure switches the arm 1 spool and is
input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to the mechatro controller.
(3) The low pressure sensor output voltage is input to the mechatro controller. The mechatro controller processes
the pilot signal and outputs a command according to the input voltage to the P2 pump proportional valve and P2
unload proportional valve.
(4) It also outputs a command according to the input pressure output by the potentiometer to the reverse
proportional valve for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by the mechatro
controller. The reverse proportional valve for the arm 2 spool is controlled to spool stroke according to engine
speed and changes the recirculation rate to prevent the cavitation from occurring even if pump delivery rate is
low due to low engine speed.
21-12
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
((1) When starting arm-out operation, the arm-out operating pilot pressure switches the arm 1 and arm 2 spool and
is input to the low pressure sensor.
(2) The output voltage of the low pressure sensor is input to the mechatro controller. The mechatro controller
processes the pilot signal and outputs a command according to the input voltage to the P1 and P2 proportional
valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by the mechatro controller. It then changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload
pressure control valves.
(4) With the original hydraulic pressure command, the arm 1 and arm 2 spools are switched. In addition with the
command output by the mechatro controller,the P1 and P2 pumps and P1 and P2 unload valves are switched.
The delivery oil on the P2 pump side confluxes the delivery oil on the P1 pump side during arm-out operation.
21-13
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload proportional valves and travel straight proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
(4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
21-14
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-15
21. MECHATRO CONTROL SYSTEM
(1) When starting the bucket digging (dump) operation, the bucket digging operating pilot pressure switches the
bucket spool and is input to the low pressure sensor.
(2) The engine speed command output by the accel potentiometer is input to the mechatro controller.
(3) The output voltage of the low pressure sensor is input to the mechatro controller. The mechatro controller
processes the pilot signal and outputs a command according to the input voltage to the P1 and P2 pump
proportional valves, P1 and P2 unload proportional valves andthe travel straight proportional valve.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by the mechatro controller. It then changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload
valves and travel straight valve of the control valve.
(5) The tandem passage is connected to the P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
(6) The ATT boost solenoid valve turns the solenoid valve ON according to the engine speed, and outputs
secondary pressure and actuate the stroke limiter, then controls the stroke of bucket spool.
The control of the spool stroke prevents cavitation even if the engine speed is low and pump delivery rate is low.
(7) When P1 pump pressure was raised at the cylinder stroke end the solenoid valve is closed according to the
pump pressure. When the pump pressure is high, the boost solenoid valve does not work to control the stroke
limit of bucket spool.
21-16
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
21-17
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
21-18
21. MECHATRO CONTROL SYSTEM
21-19
21. MECHATRO CONTROL SYSTEM
21-21
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER SECONDARY PRESSURE
(1) Change mechatro controller to “PRESSURE DRAING MODE’ by operating the switch on the gauge cluster. For
details on changing the mode, see “How to switch to pressure release mode” in item 22.11.1.
(2) Once the mechatro controller stores it as the pressure release control, regardless of each input signal (operating
pilot, accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to the P1, P2 pump proportional valves and fixes the P1, P2 pump to
minimum tilt angle.
2) Outputs a command of pressure release and outputs a command of pressure release control to the ECU and
fixes the engine speed to the pressure release control speed.
3) Outputs maximum command to the P1 and P2 unload valves and each pilot secondary pressure fixes the
P1 and P2 unload valves to the maximum opening.
(3) The mechatro controller senses the output voltage from the main pump high pressure sensor, determines the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on the gauge cluster.
(4) Each pump delivery oil is unloaded to the tank return allowing the remaining pressure (trapped pressure) to be
released by operating each control lever and switching spool with the unload valve opened.
21-22
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
1) Nibbler circuit
1) Select A mode through the gauge cluster.
2) The Nibbler display will display on the gauge cluster.
3) The return oil from the nibbler passes through the selector valve and option spool and flows to the tank return
line of the main control valve.
4) When selecting A mode through the gauge cluster, the breaker pressure sensor has no function to output.
It is normal when there is no output from the sensor in A mode, that an error will display on the gauge cluster.
(2) Breaker circuit
1) Select B mode through the gauge cluster.
2) Breaker display is shown on the gauge cluster.
3) The return oil from the breaker passes through the selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through the gauge cluster, the breaker pressure sensor outputs a signal.
It is normal when there is an output from the sensor in B mode, that an error will display on the gauge cluster.
21-23
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
21-24
21. MECHATRO CONTROL SYSTEM
SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
21-25
21. MECHATRO CONTROL SYSTEM
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For work with a breaker, always select the "B mode".
A mode
10:25 For the work with a crusher (nibbler), select "A mode".
21-26
21. MECHATRO CONTROL SYSTEM
Depending on the attachment, it is required to change the flow rate for the service circuit. Change the flow rate in
accordance with the procedure shown below.
The last set flow rate will be been stored and the default flow rate is 210L/min. The adjustment (increase or
decrease) of the flow rate is changeable by 10L/min steps.
10:25 Flow
rate 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m
A B
(b) (c)
21-27
21. MECHATRO CONTROL SYSTEM
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 5,000 Hr
• The display automatically changes to the main screen, if switch is not pressed for 30 seconds.
• For the setting procedure of maintenance time to be performed for the next oil and filter change, see 21.2.6
SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-28
21. MECHATRO CONTROL SYSTEM
H
1) Display function for operator ......... Screen usually displayed during operation
1.1 Clock display function ......... Current time is displayed.
1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional
valve, etc., this displays error code.
1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning
contents with the symbol and statement. (For warning contents, see items
shown below.)
1.4 Machine condition display ......... Displays machine operating condition.
2) Display function for maintenance ......... Displays remaining time up to replacement/change of following
items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and
displays in order of recent occurrence.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output
adjustment and unload adjustment, etc.
5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve
command, etc. output by mechatro controller
6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are
not detected by self diagnosis and displays the results.
HIGH ENG
AUTO IDLE STOP W006 CHARGE ERROR
WATER TEMP.
WARM FINISH WARM-UP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 CHANGE ENG OIL
ERROR
SWING BRAKE
ENGINE STOP
DISENGAGED
21-29
21. MECHATRO CONTROL SYSTEM
CONTROL
Pressure sensor, Governor Motor SERIAL COMMUNICATION
INPUT Proportional valve, Battery relay Gauge cluster
Selector valve (SOL) (Buzzer sound)
12
Swing flasher
13 right relay
Swing flasher
14 left relay
Travel alarm
15 relay
P1 side option AIS relay 2
16
P2 side option Engine stop
17 relay
Safety lock
18 lever relay
19
Adjustment Safety relay
21 data sector 1
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust data
Cluster
31 communication
21-30
21. MECHATRO CONTROL SYSTEM
21-31
21. MECHATRO CONTROL SYSTEM
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 1000 No load setting rpm B-1 BOOM RAISE
MEAS 1000 Actual rpm 3.5V 2.6M Sensor voltage / Pressure converted value
Engine oil pressure B-2 BOOM LOWER
G-5 ENG OIL PRS. LIVE
Coolant temp. sensor, and switch 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP. 20 O
B-3 ARM OUT
FF Work mode
3.5V 2.6M Sensor voltage / Pressure converted value
MODE H Potentiometer voltage B-4 ARM IN
H-1 ACCEL VOLTS 0.3V Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
POS. 0% Numbers of step B-5 BUCKET DIG
G-1 MOTOR STEP 30 3.5V 2.6M Sensor voltage / Pressure converted value
Step % lndication
POS. 0% B-6 BUCKET DUMP
COIL A 1.5A A phase current
3.5V 2.6M Sensor voltage / Pressure converted value
COIL B 1.5A B phase current
G-2 LIMIT SW. OFF Limit switch
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
B-19 DOZER 2
3.5V 2.6M Sensor voltage / Pressure converted value
21-32
21. MECHATRO CONTROL SYSTEM
8 18
NO.8 PROPO-VALVE NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI2 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) pressure DI4 OFF ON/OFF indication
COMP. 600mA 4.5M DI5 OFF ON/OFF indication
MEAS. 600mA 4.5M Set value in computer / Converted value from pressure DI6 OFF ON/OFF indication See
D-3 S-TRAVEL Measured value / Converted value from DI7 OFF ON/OFF indication Mechatro
COMP. 600mA 4.5M pressure DI8 OFF ON/OFF indication controller
MEAS. 600mA 4.5M DI9 OFF ON/OFF indication connector
D-6 ARM IN-2-SPEED Set value in computer / Converted value from pressure DI10 OFF ON/OFF indication
COMP. 600mA 4.5M Measured value / Converted value from DI11 OFF ON/OFF indication
MEAS. 600mA 4.5M pressure DI12 OFF ON/OFF indication
DI13 OFF ON/OFF indication
Set value in computer / Converted value from pressure DI14 OFF ON/OFF indication
9 19
NO.9 PROPO-VALVE NO.19 DIGITAL INPUT
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI16 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI17 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI21 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI22 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 OFF ON/OFF indication
DI26 OFF ON/OFF indication
DI27 OFF ON/OFF indication
DI28 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
4.5V 90 Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
4.5V 30͠ Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW OFF Glow switch DI33 OFF ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER LIVE Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER OFF Command from grid heater DI40 OFF ON/OFF indication
ENG OIL LEVEL LIVE Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. OFF Set value in computer DO6 COMP. OFF Set value in computer
MEAS. OFF Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
12 22
NO.22 DIGITAL OUTPUT
DO8 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO9 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO10 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO11 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO12 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO13 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO14 COMP. OFF Set value in computer
MEAS. OFF Measured value
21-33
21. MECHATRO CONTROL SYSTEM
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current
21-34
21. MECHATRO CONTROL SYSTEM
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment
21-35
21. MECHATRO CONTROL SYSTEM
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
21-36
21. MECHATRO CONTROL SYSTEM
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 400 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA
21-37
21. MECHATRO CONTROL SYSTEM
21-38
21. MECHATRO CONTROL SYSTEM
21-39
21. MECHATRO CONTROL SYSTEM
21-40
21. MECHATRO CONTROL SYSTEM
3) Display error codes and hour meter reading of occurrence on gauge cluster.
• The hour meter reading and 4 error codes are displayed at a time.
• If more than 4 error codes exist, 4 codes are displayed at a time for 10 seconds.
4) Paging (Up and down)
All the stored error codes will be erased. Partial deletion is not possible.
21-41
21. MECHATRO CONTROL SYSTEM
For details of how to use, refer to "Section 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
21-42
21. MECHATRO CONTROL SYSTEM
Washer
Interval of replacement of parts is shown below. switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
•Hydraulic oil : 5,000 Hr switch select switch
time is stored. H
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance
time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
21-43
21. MECHATRO CONTROL SYSTEM
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
21-44
21. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn the key switch to the ON position to display the main screen (a). Press the select switch (8) to display
"SWITCH STATUS - CLOCK CONTRAST" select screen (b).
2. Press FEED (4) or FEED (5) to move the cursor to "SWITCH STATUS - CLOCK CONTRAST" screen
(c). Press the select switch (8) and the "ADJUST CLOCK - ADJ CONTRAST" screen (d) will be displayed.
3. Press FEED (4) or FEED (5) to move the cursor to "ADJUST CLOCK- ADJ CONTRAST". Press select
the switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) will be displayed.
4. Press the select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the increase FEED (4) or decrease FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (dim) →99999 (bright). The default set value is 55555.
6. Press the select switch (8) and the set values are stored in memory. The contrast adjustment is completed,
and the display will return to the main screen (a).
21-45
21. MECHATRO CONTROL SYSTEM
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
21-46
21. MECHATRO CONTROL SYSTEM
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V㧕
26 GP 0V
27 CANH1 CAN communication
Spare
28 CANL1 CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Extra pressure release Output EARTH/OPEN
33 DO 24 Spare Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
21-47
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved
21-48
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN104 1 GA 0V
2 A17 Boom head (over load) Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Spare Input 0.5㨪4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Engine coolant Input
Resistor
14 GA temperature
15 A22 Fuel level Input
Resistor
16 GP
17 A23 Spare Input
Resistor
18 GA
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Extra pressure source Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Starting point of accel motor Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
3 +24V Battery relay output side 20~32V
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
9 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
21 GND Battery (-) 0V
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Output +0~800mA
Spare
26 D7- -0~800mA
27 D8+ Output +0~800mA
Spare
28 D8- -0~800mA
29 D9+ Output -0~800mA
Spare
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
21-49
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase Output +24V 1.5A
4 F1- Accel motor A phase Output +24V 1.5A
5 F2+ Accel motor B phase Output +24V 1.5A
6 F2- Accel motor B phase Output +24V 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ +0~800mA
Bypass valve Output
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 Grid heater feedback Input +24V/OPEN
2 DI 8 Engine coolant temperature Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Spare Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 Heater temp. of fuel filter Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Spare Input EARTH / OPEN
15 DI 40 Heater temperature Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved
21-50
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Water separator Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 Spare Input GND / OPEN
6 DI 16 Wiper rise up㩩 Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Spare Input GND / OPEN
10 DI 21 Spare Input +24V / OPEN
11 DI 22 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation Input
GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Spare Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 Spare Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Spare Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved Reserved
25 H1+ Spare 0~5V
26 H2- 0V
27 H2+ Spare 0~5V
28 H2- 0V
Connector No. Pin No. Port name Function Input/putput Signal level
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Spare Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Spare Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP Spare 0V
17 TXD2 Spare Tranmission RS232C communication
18 RXD2 Spare Reception RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Spare Shiled GND
22 DO 10 Spare SV 24V/OPEN
21-51
21. MECHATRO CONTROL SYSTEM
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
No. Item name Wire color No. Item name Wire color
Gauge cluster →Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller →Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 Reserved — 7 White
ON)
GND (RS232C
4 Reserved — 8 Black
communication)
3) Function
a. Processes signals by communication between the gauge cluster and the mechatro controller, displays
input in lamps, LCDs and actuates the buzzer.
b. Outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
4) Summary of display and drive item
21-52
21. MECHATRO CONTROL SYSTEM
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
22 1 3 1 3
11
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
21-53
21. MECHATRO CONTROL SYSTEM
2) Circuit diagram
21-54
21. MECHATRO CONTROL SYSTEM
21-55
21. MECHATRO CONTROL SYSTEM
21-56
21. MECHATRO CONTROL SYSTEM
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
Vcc GND
SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
21-57
21. MECHATRO CONTROL SYSTEM
[MEMO]
21-58
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY.......................................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS............................................................... 22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-8
22.4 NEUTRAL CIRCUIT......................................................................................................... 22-8 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-10
22.6 BUCKET CIRCUIT...........................................................................................................22-12
22.7 BOOM CIRCUIT .............................................................................................................. 22-14
22.8 SWING CIRCUIT ............................................................................................................. 22-18
22.9 ARM CIRCUIT ................................................................................................................. 22-20
22.10 COMBINED CIRCUIT ......................................................................................................22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ...........................................................22-32
22-1
22. HYDRAULIC SYSTEM
22-2
22. HYDRAULIC SYSTEM
22.1 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety,
mass volume handling and low fuel consumption.
Table22-1
Perfor- Device
mance Function Features
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Holding valve for boom (Option) Prevention of boom falling when boom head side piping breaks
Multi control valve (Option) Changeable to 2 operating pattern with only 1 lever.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
22-3
22. HYDRAULIC SYSTEM
22-4
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
Paste here
Book Code No. S5YN2218E01
22
22-1
22. HYDRAULIC SYSTEM
22-2
22. HYDRAULIC SYSTEM
22.1 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass volume handling and low fuel consumption.
Table22-1
Perfor- Device
mance Function Features
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Holding valve for boom (Option) Prevention of boom falling when boom head side piping breaks
Multi control valve (Option) Changeable to 2 operating pattern with only 1 lever.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
22-3
22. HYDRAULIC SYSTEM
22-4
22. HYDRAULIC SYSTEM
22.2.1 STANDARD
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL
12 CT2 CP2
BOOM
BL
SE1 SE2 SE3 SE4
P P P P
SE7 SE8
P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1 SENSOR 1 2 3 4 5 6 7 8
BLOCK
BR CP1
AR PCa
PBr CCb
PAs 1 2 3 4 5 6 7 8
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1
TRAVEL
(ROD)Bc
37.7MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
17
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
17
A8 ARM2
PSV-A
T2 P2 YN01Z00175P1 01
13
22-5
22. HYDRAULIC SYSTEM
NOTE:
PTb 1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
TRAVEL 2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
P1 UNLOAD PRIORITY
PCb
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W: , W/O: )
M CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
P2 UNLOAD CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 UNLOAD P2 UNLOAD
51
LEFT
NIBBLER
NOTE 4
HYD.TANK 53 RIGHT
BREAKER
PBo 52
OPTION
PAo NIBBLER & BREAKER
PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa
B C1 C2 A
SOL/V BLOCK LEVER
A1 LOCK P
SE-11
50 SV-13
Ps C PL
P
SE-29
YN01Z00162P1 01
22-6
22. HYDRAULIC SYSTEM
22-7
22. HYDRAULIC SYSTEM
22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly,
FOR HYDRAULIC CIRCUITS (1) Type : when the servo piston moves rightward, the
This section describes the following.
Electric flow controlled variable displacement spool (652) is moved leftward by the feedback
Blue (1) Bypass cut valve and unload valve control
pump. lever.
Feed, drain circuit (2) Safety lock lever and pilot circuit The operation is maintained until the opening of
less than 0.44 MPa (64 psi) (2) Principle :
(3) Pump positive flow control spool sleeve is closed.
Green The current command I to the pump’s solenoid
(4) Pump P-Q (Pressure-Quantity) curve control proportional valve controls the delivery rate of the
Return, make up circuit, 22.4.4 PUMP P-Q CURVE CONTROL
0.44~0.59 MPa (64~86 psi) pump. OPERATION
22.4.1 OPERATION OF BY-PASS CUT VALVE
Purple AND UNLOADING VALVE HOUSED IN (3) Operation : (1) Type :
Secondary pilot pressure, CONTROL VALVE 1) Flow rate rise operation (Eg. P1 pump) Electrical flow control type variable pump
(including proportional vlave) By operating any of control levers, the
(1) By-pass cut valve (2) Principle :
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve
On starting engine, P1 and P2 unloading Perform an operation of the value from pump high
Red rises, and the rising pressure is transformed to
proportional valves (PSV-D, PSV-B) output pressure sensor to P-Q curve control value, and
Primary pilot pressure, the rise of output voltage corresponding to the
secondary pressure according to the command send a command to the pump solenoid proportional
(including proportional vlave) pressure input by the low pressure sensor.
output by mechatro controller, and this pressure valve.
5 MPa (725 psi) Mechatro controller signal-processes this
exerts on PBp1 and PBp2 ports, and consequently (3) Operation :
Orange change of voltage, resulting in rise of command
the by-pass cut spool is switched to CLOSE side. The pump high pressure sensor converts the
Main pump drive pressure, current value I to the pump proportional
The by-pass cut spool is usually held on CLOSE pressure to the output voltage corresponding to the
5~34.3 MPa (725~4970 psi) solenoid valve and consequently the pump flow
side after the engine started. And it is switched to pump delivery pressure.
Blue tone rate rises. This is called "Positive Control
OPEN side only when failure occurred on pump The mechatro controller converts the voltage output
At valve operation System".
proportional valve and mechatro controller. by the high pressure sensor to the P-Q curve
Red valve As the pump command current value rises, the
(2) Unloading valve control value. On the other hand, select the pump
When solenoid proportional valve (reducing) secondary pressure of proportional solenoid
On starting engine, like by-pass cut valve, the positive control command current value from the
is operating valve also rises. On the regulator attached on
secondary pressures output by P1 and P2 low pressure sensor in lower order, and the values
Red solenoid the pump, the spool (652) through piston (643)
unloading proportional valves (PSV-D, PSV-B) are output to respective pump proportional valve as
In active and exciting is pushed leftward, and stops at the position
exert on PCb and PCa ports, consequently the P1 a command current.
Displaying the flow circuit and standby circuit when where being in proportion to the force of pilot
and P2 unloading valves are switched to OPEN With this operation, the pump power is controlled so
operating. spring (646).
side. as not to be exceed the engine power, therefore
Regarding the electrical symbols in this manual, refer to The tank port connected to the large bore of
engine dose not stall.
the electric circuit diagram. 22.4.2 SAFETY LOCK LEVER AND PILOT servo piston (532) opens, and the piston
CIRCUIT moves leftward by delivery pressure P1 of the
(1) Purpose : small bore resulting in the increase of tilt angle
To protect attachment from unexpected movement ( ).
for safety. The servo piston and spool (652) are
connected to feedback lever (611). Therefore
(2) Principle :
when servo piston moves leftward, the spool
Cut pressure source of pilot valve for operation.
(652) also moves rightward by means of
(3) Operation :
feedback lever. With this movement, the
If the safety lock lever (red) is pushed forward after
opening of spool sleeve closes gradually, and
the engine starts, the limit switch (SW-11) is turned
the servo piston stops at the position the
on. The timer relay is actuated one second later
opening closed completely.
which causes the solenoid (SV-4) of the solenoid
2) Flow rate reduction operation
valve block (13) to be energized and makes the
As the current value I of mechtro controller
pilot operating circuit to stand by.
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the delivery
pressure P1 usually flows into the large bore of
piston through the spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of area,
22-8
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
651
652 M
1 29.0MPa
611 D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
643
a3
532 8
646 a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa
1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
22-9
22. HYDRAULIC SYSTEM
22-10
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa
1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
22-11
22. HYDRAULIC SYSTEM
22.6 BUCKET CIRCUIT 5) The secondary pressure delivered in travel 3) With the function of pilot circuit, the oil flow is
straight proportional valve (PSV-C) is led to switched from bucket spool, and is fed into
This section describes the following.
PTb port provided in control valve (2) and shifts bucket cylinder head side through AC port of C/
(1) Bucket digging pilot circuit
the travel straight valve one stage. V (2). On the other hand, the return oil from
(2) Auto accel operation cylinder rod (R) side is throttled by bucket spool
22.6.2 AUTO ACCELERATION OPERATION
(3) Flow control in the work mode and returns to tank circuit from BC port of C/V
(1) Principle : (2).
(4) Bucket digging travel straight main circuit
Auto acceleration actuates according to signals
(5) Bucket spool stroke limiter References :
from low pressure sensor.
• In bucket dumping operation, the travel straight
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING (2) Operation :
valve also switches like digging operation,
(1) Mechatronics : <When lever is set to neutral position>
resulting in confluence with travel straight.
In the event where the sensor does not receive
1) When the operation for bucket digging is • When the bucket operation and other operation
signal for 4 seconds or more even though the
performed, the pilot proportional secondary are simultaneously performed, the travel straight
acceleration dial is set to MAX position, the engine
pressure is delivered through port 1 of the right valve does not actuate, resulting in single flow of
speed should be raised to 1000rpm.
pilot V (9), flows to PAc port, and acts on the low bucket circuit.
<When lever is operated>
pressure sensor (SE-1), and at the same time
When the pressure 0.6MPa (87psi) is input to low 22.6.5 BUCKET SPOOL STROKE LIMITER
the bucket spool is switched.
pressure sensor in STD specification (travel,
2) The voltage output by low pressure sensor (1) Purpose :
bucket, swing, arm), proportional voltage from low
inputs in mechatro controller. The mechatro To secure simultaneous operability of boom and
pressure sensor inputs in mechatro controller, and
controller performs signal processing and arm on boosting up attachment pressure (Pump
then the engine speed returns to the dial set
outputs current corresponding to the increase flow rate decreases.) and to prevent cavitations at
position corresponding to the lever operation.
of pump flow rate to pump proportional valves low engine speed
(PSV-P1) and (PSV-P2) on the P1 and P2 22.6.3 STAND-BY CURRENT CONSTANT (2) Operation :
pump sides, and at the same time the CONTROL On boosting up attachment pressure, pilot primary
command current is output to P1 unloading (1) Principle : pressure exerts on PCc port of C/V(2) through
valve (PSV-D), P2 unloading valve (PSV-B) and When the engine speed is intermediate speed or attachment booster solenoid valve, operates stroke
travel straight proportional valve (PSV-C). lower, command current value to have the pump limiter of bucket spool, and throttle oil path of spool.
In the following pages, the relation of operation delivery rate constant is output. As a result, P1 pump pressure increases, making
of low pressure sensor to both the increase of the simultaneous operation of boom up and bucket
(2) Operation :
pump flow rate and unloading proportional digging possible.
Even if the engine speed specified by acceleration
valve is the same. Therefore the explanation is Even though the engine speed is low, similarly the
potentiometer is low speed, as the delivery rate
omitted. cavitations can be prevented by actuating the
corresponds to the intermediate speed, the
3) The secondary pressure output by P1 pump stroke limiter.
actuator moves earlier than the movement
proportional valve (PSV-P1) and P2 pump equivalent to the control lever angle rate in light
proportional valve (PSV-P2) exerts on pump load operation.
regulator, actuating the pump onto the delivery
flow increase side. 22.6.4 BUCKET DIGGING AND TRAVEL
STRAIGHT CONFLUENCE (CONFLUX)
4) The secondary pressure delivered in P1
MAIN CIRCUIT
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2 and (1) Operation :
PCa ports provided in control valve (2). 1) The oil delivered through A1 port of P1 pump
The secondary pressure from proportional goes into P1 port of C/V (2), opens load check
valve which has exerted on PBp1 and PBp2 valve LCc through parallel circuit and enters in
ports holds the by-pass cut spool on CLOSE bucket spool.
side, like the operation in the lever neutral 2) On the other hand, the oil delivered through P2
position. port of P2 pump goes into P2 port of C/V (2),
The secondary pressure from proportional confluences with oil from P1 pump through
valve which has exerted on PCb and PCa ports travel straight valve, and goes into bucket
switches the unloading spool in CLOSE side. spool. (Confluence of oil from 2 pumps)
22-12
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
CT1 BLOCK
PAr PB1
BR CP1
AR PCa
1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control
22-13
22. HYDRAULIC SYSTEM
22-14
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
CT1 BLOCK
PAr PB1
BR CP1
AR PCa
1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.
22-15
22. HYDRAULIC SYSTEM
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of portáC of the right pilot valve (9) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
PBb port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the Bb port.
3) Then, the proportionl secondary pressure fed
On that occasion, the oil returning from the head
into C/V (2) PBb port and branches off in two
(H) goes through the recirculation path in the boom
lines and switches boom spool and releases
spool, pushes the check valve in the spool open, is
boom lock valve.
recirculated to the Bb port and is supplied to the rod
22.7.4 PREVENTION OF NATURAL FALL BY (R). When the (R) pressure is larger than the head
LOCK VALVE AND ACTUATION AT (H) pressure, the check valve in spool closes.
LOWERING Thereupon, the recirculation is stopped.
(1) Purpose :
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.
22-16
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa 1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-5 BOOM CIRCUIT : Boom down operation & prevention of boom falling.
22-17
22. HYDRAULIC SYSTEM
22-18
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa 1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-6 SWING CIRCUIT : Swing operation (LH)
22-19
22. HYDRAULIC SYSTEM
22.9 ARM CIRCUIT with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
This section describes the following operations.
side through Aa port of C/V (2).
(1) Arm in, light-load operating pilot circuit
3) The return oil from arm cylinder (R) side flows
(2) Arm in, light-load variable normal recirculation main
in Ba port of C/V (2) and passes through the Ba
circuit / internal conflux main circuit
port because the arm lock valve CRar is open,
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT and is flowed into arm 2 spool through arm 1
CIRCUIT spool.
(1) Purpose : 4) Because arm 2 spool is switched to normal
Speed-up and Anticavitation when the arm is at recirculation position, causing restriction of
light loaded. passage to tank, the return oil from arm cylinder
(R) side flows into arm cylinder (H) side.
(2) Principle :
The oil returning from the arm cylinder rod (R) is • Because, at light load, the pressure in
recirculated variably to the head (H) at arm 2 spool cylinder rod (R) side is higher than that in
in C/V. the head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated in
(3) Operation :
the head (H) side, resulting in the speed up
1) When the arm in operation is performed, the
of arm-in operation at light load.
secondary pilot proportional pressure gets out
5) Cavitations prevention control in arm-in
of port 7 of the left pilot valve (9) and acts upon
operation
the low pressure sensor (SE-7).
Command current is output to arm 2 solenoid
At the same time, the pressure is branched off
proportional valve by signal processing of E/G
in two flows, acts upon the Paa1 port and the
speed and arm-in pilot pressure, accordingly
PLc2 port, changes over the arm spool and the
the arm 2 spool is switched to neutral
arm lock valve CRar. releases.
(cavitations prevention) position, resulting in
2) The output voltage by the low pressure sensor
cavitations prevention.
is input into mechatro controller, and is pilot
signal-processed, and is output to P1, P2 pump
Position of arm 2 spool
proportional valve (PSV-P1), (PSV-P2) and arm
2 inverse proportional valve (PSV-A). Neutral position
(Anticavitation position)
3) The secondary pressure from pilot proportional Normal recirculation position
valve, which is reduced by arm 2 inverse Recirculation
proportional valve (PSV-A) switches arm 2
spool.
From arm out
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE
P/V
From arm 2 inverse
NORMAL RECIRCULATION, INTERNAL proportional valve
CONFLUX MAIN CIRCUIT
Reference :
(1) Operation : In light-load arm-in operation (normal recirculation,
1) The P2 pump delivery oil flows in travel left conflux), when the attachment to which the circuit in
section through P2 port of C/V (2) and is P1 pump side is applied is operated, the meter-in
branched off in by-pass circuit and parallel path of arm 2 spool is closed, resulting in single flow
circuit, but because arm 1 spool is switched, the operation.
delivery oil which goes through parallel circuit
opens load check valve LCa and is flowed into
arm 1 spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and the flows in travel
straight section and travel right tandem path.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2,
goes through arm 2 spool, and confluences
22-20
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa 1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & anti cavitation function
22-21
22. HYDRAULIC SYSTEM
This section describes the following operations. 4) The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
(4) Arm in, heavy load operating sequence confluxed
Position of arm 2 spool
main circuit
Neutral position Recirculation cut position
22.9.3 ARM IN, HEAVY LOAD OPERATING
PILOT CIRCUIT
From arm out
(1) Operation :
P/V
1) In arm-in operation, when the heavy loading is
From arm 2 inverse
applied to arm and the P2 pump pressure proportional valve
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
22-22
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa 1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function
22-23
22. HYDRAULIC SYSTEM
This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH ARM
(5) Arm out pilot circuit LOCK VALVE
(6) Arm out 2 pumps conflux main circuit (1) Purpose :
To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve
weight of the arm and bucket.
22.9.5 ARM OUT PILOT CIRCUIT (2) Principle :
(1) Operation : Complete seat of the return circuit against the arm
1) When the arm out operation is performed, the spool of the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out (3) Operation :
of port 8 of the left pilot valve (9), and acts upon 1) When the secondary pressure for arm
the low pressure sensor (SE-8). At the same operation disappears and the arm cylinder
time, the oil is branched off in two flows and act stops, the pressure on the rod (R) side passes
upon the PBa1 and Pba2 ports of C/V (2). through the selector of the lock valve from the
2) The operating proportional secondary pressure Ba port of C/V, acts the back pressure on the
flowed in Pba1 port of C/V (2) switches the arm lock valve CRar and seats the lock valve.
1 spool. 2) Since the oil flow into the arm spool from the
3) Then, the operating secondary pressure flowed lock valve is shut off completely, natural fall of
in PBa2 port of C/V (2) switches the arm 2 spool the arm due to oil leaks through the arm spool
valve. is prevented.
22-24
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
BOOST
15 14 PL
CMR1
CHECK ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa 1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function
22-25
22. HYDRAULIC SYSTEM
22-26
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa 1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
22-27
22. HYDRAULIC SYSTEM
The combined operation during travel independent op- 22.10.4 BOOM UP / TRAVEL, MAIN CIRCUIT
eration is described in this section. (1) Purpose :
(1) Boom up / travel, pilot circuit Even if the attachment is operated during travel op-
(2) Boom up / travel, main circit eration, the travel speed does not change.
(2) Principle :
22.10.3 BOOM UP / TRAVEL, PILOT CIRCUIT
The travel action and the attachment action are
(1) Operation : actuated by different pumps.
<Operation: Different point of pilot circuit from sin-
(3) Operation :
gle operation >
1) P1 pump delivery oil flows through P1 port of C/
1) The mechatro controller outputs command
V(2) and branches off in P1 parallel circuit and
current to travel straight solenoid proportional
travel straight spool.
valve after signal processing, and the solenoid
P2 pump delivery oil flows through P2 port of C/
valve outputs secondary pressure and acts on
V(2) and branches off in P2 tandem circuit and
PTb port of C/V (2).
travel straight spool.
2) Then the pressure of PTb port moves spool
2) The delivery oil flowed into P1 parallel circuit of
travel priority valve to the end.
P1 pump opens check valve CT1 and LCb and
flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool
of P1 pump opens check valve CT2 because
the travel straight spool is shifted, and flows in
boom conflux spool and exerts on boom up
operation with the internal oil conflux.
(In travel independent operation, P1 pump
delivery oil exerts on swing operation of
attachment.)
3) The delivery oil flowed into P2 tandem circuit of
P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel straight spool
of P2 pump flows in right travel spool because
the travel straight spool is shifted and exerts on
the right travel operation.
(In travel independent operation, P2 pump
delivery oil exerts on travel operation.)
4) Some part of the pump output flows to the travel
straight spool notch restriction. Travel speed is
not affected by simultaneous attachment oper-
ation because the flow is not fed to the notch
while travel independent operation is actuated.
22-28
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX BLOCK
PAr CT1 PB1
BR CP1
AR PCa 1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-11 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel independent function.
22-29
22. HYDRAULIC SYSTEM
In this section, the independent operation is omitted 22.10.6 SWING / ARM IN, SWING PRIORITY MAIN
and describes difference in combined operation. CIRCUIT
(3) Swing / Arm in light load, pilot circuit (1) Purpose :
(4) Swing / Arm in, swing priority main circuit Stable swing speed.
(2) Principle :
22.10.5 SWING / ARM IN LIGHT LOAD, PILOT
Raise the oil pressure flowing to arm cylinder, and
CIRCUIT
give a priority of the delivery of P2 pump to swing
(1) Operation : operation.
1) On operating swing (left) and arm in motions (3) Operation :
simultaneously, mechatro controller outputs
1) The swing main circuit operates with P2 pump
command current to travel straight solenoid
flow. But on P2 pump circuit side, the flow goes
proportional valve (PSV-C) and arm 2 solenoid
to the swing circuit and arm circuit
inverse proportional valve according to signal
simultaneously because the swing circuit and
processing, and this proportional valve outputs
arm circuit are parallel. Then since the return oil
secondary pressure, which acts on PTb port
from arm cylinder rod (R) side is restricted in
and PAa2 port of C/V(2).
the arm 2 spool because the arm 2 spool is
2) PTb port pressure switches the travel straight switched to forced recirculation position, the
spool 2 steps, and the PAa2 port pressure pressure of return oil is raised, causing the rise
switches the arm 2 spool to the forced of circuit pressure on the arm cylinder head (H)
recirculation position. side.
2) At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".
22-30
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
CT1 BLOCK
PAr PB1
BR CP1
AR PCa
1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
LCAP2
SV-2 PBa2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-12 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
22-31
22. HYDRAULIC SYSTEM
22-32
22. HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
118kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPTION) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3 SENSOR 1 2 3 4 5 6 7 8
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
CT1 BLOCK
PAr PB1
BR CP1
AR PCa
1 2 3 4 5 6 7 8
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 YN01Z00175P1 01
13
Fig. 22-13 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
22-33
22. HYDRAULIC SYSTEM
[MEMO]
22-34
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
23-1
23. ELECTRIC SYSTEM
23-2
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
Paste here
Book Code No. S5YN2318E01
23
23-1
23. ELECTRIC SYSTEM
23-2
23. ELECTRIC SYSTEM
(1/4)
23-3
23. ELECTRIC SYSTEM
(2/4)
LC03Z00064P1 01
23-4
23. ELECTRIC SYSTEM
(3/4)
LC03Z00064P1 01
23-5
23. ELECTRIC SYSTEM
(4/4)
LC03Z00064P1 01
23-6
23. ELECTRIC SYSTEM
GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
MECHATRO CONTROLLER YN22E00214F1 L-1 BOOM WORK LIGHT (LH) 2456R248
C-1
(C) CONTROLLER
(TCO-60-2) (HARD) L-2 FRAME WORK LIGHT (RH) 2456R442F1
C-2 GAUGE CLUSTER YN59S00021F1 SWING FLASHER (LH) & REAR
L-3 YM80S00001F1
AIR-CON CONTROLLER WORK LIGHT
C-4 AIR CON ACCESSORY
(L) LIGHT
(INCLUDING PANEL) SWING FLASHER (RH) & REAR
L-4 YM80S00001F2
WORK LIGHT
L-5 ROOM LIGHT YT80S00001P1
L-6 BOOM WORK LIGHT (RH) 2456R442F1
D-5 DIODE ACCESSORY OF RELAY BOX L-7 CAB WORK LIGHT FRONT 1 YN80S00010F2
D-6 DIODE L-8 CAB WORK LIGHT FRONT 2
D-9 DIODE L-15 CAB WORK LIGHT FRONT 3 YN80S00010F2
D-10 DIODE L-16 CAB WORK LIGHT FRONT 4
D-11 DIODE YN02D01001P1 L-17 BACK LIGHT
D-12 DIODE ACCESSORY OF RELAY BOX L-18 CAB WORK LIGHT REAR YN80S00010F2
D-13 DIODE STARTER MOTOR ENGINE ACCESSORY
(D) DIODE
M-1
(M) MOTOR
D-14 DIODE M-2 GOVERNOR MOTOR YN20S00002F1
D-16 DIODE M-3 WIPER MOTOR YN53C00012F2
D-17 DIODE M-4 WASHER MOTOR YT54C00003F1
D-18 DIODE YN02D01001P1 ARM 2 SPEED
D-19 DIODE PSV-A INVERSE YN35V00049F1
PROPO. VALVE
D-20 DIODE (YN35V00047F1)
P2 UNLOAD YN35V00048F1
D-21 DIODE PSV-B SOLENOID
PROPO. VALVE
D-22 DIODE VALVE ASSY
TRAVEL STRAIGHT
E-1 FUSE AND RELAY BOX YN24E00016F1 PSV-C
(P) PROPORTIONAL
PROPO. VALVE
SOLENOID VALVE
E-2 ALTERNATOR ENGINE ACCESSORY
PSV-D P1 UNLOAD
E-3 HOUR METER YT58S00006P1 PROPO. VALVE
E-5 HORN HIGH LC53S00001D1
OPT. RELIEF ADJUSTEMENT
E-6 HORN LOW LC53S00001D2 PSV-E
PROPO. SOL 1 REFER TO
E-7 TUNER AM/FM YN54S00045P1
OPT. RELIEF ADJUSTEMENT SCHEMATIC
E-8 SPEAKER LEFT YN54S00006P1 PSV-I
PROPO. SOL 2 HYD. LINES
E-9 SPEAKER RIGHT
E-10 RECEIVER DRYER YN54S00041P1 PSV-R CONTROL PROPO. SOL
E-11 AIR-CON COMPRESSOR YX91V00001F1 P1 PUMP
PSV-P1 YN35V00052F1
E-12 BATTERY 2411U22 PROPO. VALVE
PUMP ACCESORY
E-13 TRAVEL ALARM YN53S00004F1 P2 PUMP
(E) ELECTRIC FITTINGS
PSV-P2
E-14 CIGARETTE LIGHTER YN81S00003P1 PROPO. VALVE
E-19 WATER SEPARATOR HEATER ENGINE ACCESSORY
E-20 FUEL FILTER HEATER
E-21 GRID HEATER
E-22 DC - DC CONVERTER YN77S00017F1
E-23 12V SOCKET YN81S01002P1
E-24 MEGA FUSE YN73E00009F1
E-25 FUSE BOX (40A) YN73E00021F1
E-26 SEAT HEATER
E-34 FUSE BOX (100A) YN73E00020F1
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 02
23-7
23. ELECTRIC SYSTEM
GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
R-1 BATTERY RELAY YN24S00008F1 SWING PARKING
SV-1 YN35V00051F1
R-2 STARTER RELAY ENGINE ACCESSORY BRAKE SOL.
R-3 GRID HEATER RELAY YN24S00004P1 POWER BOOST (YN35V00047F1)
SV-2 YN35V00050F1
R-4 SAFETY RELAY YN24S00010P1 SOL. SOLENOID
R-5 HORN RELAY TWO SPEED VALVE ASSY
(SV) SOLENOID
SV-3
R-6 WORKING LIGHT RELAY SELECT SOL.
R-8 TRAVEL ALARM RELAY
SV-4
R-9 CAB WORKING LIGHT RELAY
R-11 CAB WORKING LIGHT RELAY 2 YN24S00010P1 SV-6 REVOLUTION RIGHT SOL.
R-12 REVOLUTION RIGHT RELAY SV-7 REVOLUTION LEFT SOL.
R-13 REVOLUTION LEFT RELAY SV-9 NIBBLER OPEN SOL. REFER TO
(R) RELAY
(SW) SWITCH
SW-15 YN50S00040DD
PRESSURE SENSOR : SWITCH
SE-1 YX52S00013P1 SW-19 WIPER INTERLOCK SWITCH YN50S00004P1
BUCKET DIGGING
SW-20 POWER BOOST SWITCH (RH) YN50E00017P1
PRESSURE SENSOR :
SE-2 SW-21 POWER BOOST SWITCH (LH)
BUCKET DUMP
SE-3 PRESSURE SENSOR : BOOM UP SW-24 E/G COOLANT LEVEL SWITCH 2427U20356
PRESSURE SENSOR : SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
SE-4 SW-29 NIBBLER OPEN SWITCH 2406P5872
BOOM DOWN
SE-5 PRESSURE SENSOR : SWING SW-30 NIBBLER CLOSE SWITCH
SE-7 PRESSURE SENSOR : ARM IN SW-33 REVOLUTION RIGHT SWITCH YN03M01231P3
SE-8 PRESSURE SENSOR : ARM OUT SW-34 REVOLUTION LEFT SWITCH
SE-9 PRESSURE SENSOR : TRAVEL RH SW-35 HEAVY LIFT SWITCH YN50S00040D5
(SE) SENSOR
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 02
23-8
23. ELECTRIC SYSTEM
23.3 HARNESS
23.3.1 HARNESS LIST
The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-9
23. ELECTRIC SYSTEM
TIGHTENING TORQUE
1.5N.m (1.1lbf.ft)
INSTRUMENT PANEL ASSY YN17M00057F1 TIGHTENING TORQUE SEMS BOLT TIGHTENING TORQUE
5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS 2 PLACES INSTALL TO CAB?
TAPPING SCREW
3-2 POTENTIO METER YN52S00032P1 1 TAPPING
SEMS BOLT DUCT ASSY SCREW
3-4 KEY SWITCH YN50S00026F1 1 K250 2 PLACES
TIGHTENING TORQUE TAPPING SCREW
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2.8N.m? (2.1lbf.ft) TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
5-2 HOUR METER YT58S00006P1 1
SECTION BB SECTION DD SECTION EE
10 GAUGE CLUSTER YN59S00021F1 1
46-3 SPEAKER YN54S00050P1 2
TIGHTENING TORQUE TIGHTENING TORQUE
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) 8.5N.m (6.3lbf.ft)
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
INSTALL SEMS BOLT
TO CAB TO CAB
TIGHTENING TORQUE INSTALL SEMS TO CAB
4.1N.m (3.0lbf.ft) BOLT TO CAB
2 PLACES
SEMS BOLT
TIGHTENING TORQUE
4.1N.m (3.0lbf.ft)
SECTION AA
VIEW
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE
TIGHTENING TORQUE 0.43N.m (0.32lbf.ft) TIGHTENING TORQUE
TIGHTENING TORQUE
TIGHTENING TORQUE
. .
8.5N m (6.3lbf ft) 8 PLACES 5.0N.m (3.7lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE 4 PLACES
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT TAPPING SCREW
SEMS BOLT TIGHTENING TORQUE INSTALL SEMS BOLT
SEMS BOLT
12.0N.m (8.9lbf.ft) TO CAB
?INSTALL
SEMS BOLT
TO CAB
SEMS BOLT
4 PLACES
TIGHTENING TORQUE
5.0N.m? (3.7lbf.ft)
SECTION CC
TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
SEMS BOLT VIEW
INSTALL TAPPING SCREW TIGHTENING TORQUE
TO A/C 5.0N.m (3.7lbf.ft)
23-10
23. ELECTRIC SYSTEM
TUNER INSTALL
YN54E00010F1 (02)
UPPER
HEXAGON NUT
TOOTHED LOWER
HEXAGON NUT
LOCK WASHER
HORN WASHER
SECTION AA
2.8 N m 2.8 N m
TIGHTENING TORQUE TIGHTENING TORQUE
(70 lb.in) (70 lb.in)
VIEW I SECTION AA VIEW II
CLIP
CLIP
PUT SURPLUS
CABLE INTO CAB CLAMP CABLE WITH HARNESS
INSIDE TOGETHER
CONNECT CABLE WITH PASS CABLE THROUGH THE HOLE CABLE ARRANGEMENT
CAB SIDE ANTENNA FOR HARNESS
23-11
23. ELECTRIC SYSTEM
SEMS-BOLTS
2 PLACES
6 HORN (LOW) 3
R-3 :
GRID HEATER RELAY
5 HORN (HIGH)
SEMS-BOLTS
2 PLACES
1
26.5N.m
TIGHTENING TORQUE TIGHTENING
10.7N.m TORQUE
CONNECT SEMS BOLT R-1 :
AFTER CHECKING BATTERY PLATE
GROUND CONNECT HARNESS AS SHOWN
NO PAINT IS HERE TO AVOID SHORT CIRCUIT ON RELAY TIGHTENING
SEMS BOLT HORN (HIGH) WITH
POWER SOURCE WIRING
CONNECT HARNESS AS SHOWN HORN (LOW) ITEM 1
TO AVOID SHORT CIRCUIT ON
POWER SOURCE WIRING SEMS-BOLTS
INSTALL BOLT FROM
2 PLACES
FRONT SIDE
2 2 PLACES
TIGHTING TORQUE
2.65N.m (23 lb in)
MACHINE SCREWS
R-40 :
(BLACK) (BLACK)
FUEL FILTER
HEATER RELAY
SECTION AA
(DETAIL OF BATTERY BOX) VIEW III
(GREEN ORANGE) (GREEN ORANGE)
5 6
VIEW VIEW
23-12
23. ELECTRIC SYSTEM
NOTES:
(1) TIGHTENING TORQUE OF
CLIP BATTERY TERMINALS ARE 3.4N-M.
M-2 : (2) TIGHTENING TORQUE OF
STEPPING MOTOR GROUNDING CABLES ARE 10.7N-M.
UPPER
HARNESS
SE-12 :
ENGINE OIL
LEVEL SENSOR
CLIP
TIGHTEN AFTER
CHECKING NO. PAINT
TO AIR FILTER
E-10 :
CONNECT WITH EARTH RESTRICTION
RECEIVER DRIER
OF FLOOR PLATE SWITCH E-2 :
ALTERNATOR NOTE 1
5 4 NOTE 1
TO FRAME
WORKING LIGHT
UPPER HARNESS
CLIP
FIX HARNESS TO
THE PLATE TO
FASTEN HARNESS WITH CLIP STARTER CABLE PRO
TO THE AIR COMPRESSOR HOSE
TO ATT MAIN HARNESS
HARNESS TO PSV
BLOCK CLIP
2
TO BATTERY
RELAY BOX
FIX WHITE
TAPING POSITION
23-13
23. ELECTRIC SYSTEM
R-1 :
R-3 : BATTERY RELAY
GRID HEATER RELAY
UPP HARNESS
FIX A CONNECTOR UPP HARNESS
FIX A CONNECTOR
TO BRACKET
TO BRACKET STARTER CABLE
R-1 : R-1 :
BATTERY RELAY BATTERY RELAY (COIL)
TO BATTERY
BATT
L-3 :
SWING FLASHER LEFT
& REAR WORKING LIGHT
FIX A CONNECTOR NAME TAG : GR-G
NAME TAG : FR-87 NAME TAG : FR-87
TO BRACKET
CONNECTOR
FIX WHITE TAPING (2-TERMINALS) NAME TAG : FR-85
NAME TAG : FR-85
POSITION
23-14
23. ELECTRIC SYSTEM
E-1 :
CONNECT CONNECTOR WITH
FUSE & RELAY BOX
CN5 TAG OF ITEM 1
HARNESS C-1:
CONNECT CONNECTOR WITH
CN1-7 TAG OF ITEM 1 MECHATRO
CONNECT CONNECTOR WITH CONTROLLER
HARNESS
CN4-1 TAG OF ITEM 1
HARNESS
E-1 : CNT-2 WITH TAG CONNECTOR
FUSE & RELAY BOX OF CONNECT TO FLOOR HARNESS
GND
1P CONNECTOR OF
CONNECT TO CAB
BUNDLE UP UPP
HARNESS
FLOOR HARNES
AND CAB HARNE
GND
TIGHTEN AFTER
CHECKING NO PAINT
UPP HARNESS
VIEW VII
23-15
23. ELECTRIC SYSTEM
FIX A CORRUGATED PA
OF HARNESS TO SW. W
FIX A CORRUGATED PA
OF HARNESS TO SW. W
SE-22 : SE-23 :
PRESS SENSOR PRESS SENSOR
TO FUEL FILTER HEATER PUMP P1 PUMP P2 E-20 :
FUEL FILTER HEATER
E-19 :
WATER SEPARATOR
HEATER
DETAIL OF PUMP P1, P2 PROPORTIONAL SOL.
AND PRESS. SENSOR : PUMP P1, P2 INSTALL SW-47 :
WATER SEPARATOR
RESTRICTION SW.
WHITE TAPING
SW-8 :
AIR FILTER RESTRICTION SW
TO PUMP
FIX A HARNESS PART OF
COULGATED OF CLIP TO SW.
E-10 :
RECEIVER DRIER
FIX TO HOSE
CONNECT HARNESS OF
AIR FILTER RESTRICTION SW
DETAIL OF WATER SEPARATOR
TO AIR FILTER HEATER AND FUEL FILTER HEATER
RESTRICTION SW.
CLIP
FIX A HARNESS OF
CLIP ON GUARD SW-24 :
ENGINE COOLANT
LEVEL SW.
TO RECEIVER DRIER
23-16
23. ELECTRIC SYSTEM
SV-38:
KKSB SOL.
M-1: TIGHTEN BOTH STARTER CABLE SV-15:
STARTER MOTOR M10 TERMINAL ENGINE
51.9N.m
STOP SOL.
TIGHTENING TORQUE 15N.m
TIGHTENING TO
25.5N.m B-TERMINAL
STARTER CABLE TIGHTENING TORQUE
UPP HARNESS
E-11:
AIR COMPRESSOR GND
CLUTCH DETAIL OF ALTERNATOR
TIGHTEN AFTER
CHECKING NO. PAINT
TO GRID HEATER
25.5N.m TO AIR
ENGINE EARTH TIGHTENING TORQUE COMPRE
E-2:
ALTERNATOR CABLE
SW-6: SE-13: SW-7: TO EN
ENGNIE WATER ENGINE ENGINE OIL STOP
TEMP SW. REVOLUTION PRESS. SW. 25.5N.m
SE-14: SENSOR TIGHTENING TORQUE
FIX TO 9.6N.m COOLANT THERMO ST
ENGINE MOUNT
TIGHTENING TORQUE SENSOR MO
BRACKET
FIX WHITE TAPING
POSITION
51.9N.m
TO ENG. WATER TEMP SW. TO ENGINE
TIGHTENING
AND COOLANT THEMO SENSOR REVOLUTION
TORQUE E/G E-11: SENSOR
AIR COMPRESSOR E-13:
FIX TO PLATE CLUTCH GRID HEATER
SW-7:
ENGINE OIL
VIEW IX SE-13: PRESS. SW. DETAIL OF STEEPING MOTOR
SW-6: ENGINE
ENGINE WATER TEMP SW. REVOLUTION
SE-14: SENSOR M-2:
COOLANT THERMO SENSOR STEPPING MOTOR
51.9N.m
TIGHTENING TORQUE
ENGINE
EARTH CABLE
SW-52: TO ENGINE STOP SOL.
THERMO SW.
FOR HEATER
25.5N.m VIEW I
TIGHTENING TORQUE
23-17
23. ELECTRIC SYSTEM
SV-2:
POWER PSV-C:
BOOST TRAVEL PRIOROTY
SOL. PROPORTIOAL SOL.
SV-3: PSV-B: PSV-D:
TWO-SPEED P2 UNLOAD P1 UNLOAD
SELECT SOL. PROPORTIOAL SOL. PROPORTIOAL SOL.
PSV-A:
SV-1: ARM TWO-SPEED INVERSE
SWING PARKING PROPORTIOAL SOL.
BRAKE SOL.
SV-4:
OPERATING LEVER
LOCK SOL.
SW-24:
FIX WHITE TAPING POSTION ENGINE COOLANT
LEVEL SW.
L-2:
FRAME WORKING
LIGHT RIGHT
SE-15:
FUEL SENSOR
CONNECT A HARNESS FIX WHITE TAPING POSTION
WITH IN A CAP.
UPP FRAME
23-18
23. ELECTRIC SYSTEM
23-19
23. ELECTRIC SYSTEM
23-20
23. ELECTRIC SYSTEM
23-21
23. ELECTRIC SYSTEM
23-22
23. ELECTRIC SYSTEM
TERMINAL
60-8
TERMINAL TERMINAL
CAP YAZAKI BA712 BA708
7034-1283
7034-1283
CAP YAZAKI
SW-8 :
AIR FILTER CLOGGING
SWITCH
WHITE TAPING
AV60B CAP
CAP TERMINAL
TERMINAL BTC-135R (RED)
BTC-135L (BLACK) BC8I6 (-)
BC8I8 (+)
23.3.6-5 BATTERY GROUNDING CABLE : YYn13E01436P1
TERMINAL
AV60B 60-8
CAP TERMINAL
BC816 TAPED IN TWO TURNS
BTC-135 (BLACK)
23-23
23. ELECTRIC SYSTEM
E-1:
FUSE & RELAY BOX
SW-1: SW-1:
KEY SW. FIX A CLIP ON KEY SW.
SE-16: HOLE OF SEAT STAND
SW-10: ACCEL POTENTIO
HORN SW. LEFT (BLUE TAPING) SE-16:
SW-21: ACCEL POTENTIO
POWER BOOST SW. LEFT (OPT.) (YELLOW TAPING) FIX WHITE TAPING
SW-33: POSITION
REVOLUTION RIGHT SW. (WHITE TAPING)
SW-34: CAB HARNESS
REVOLUTION LEFT SW. (RED TAPING) TO WASHER MOTOR
SW-11:
LEVER LOCK SW.
SE-3:
PRESS. SENSOR
BOOM RAISING
SE-4:
TO WASHER
SE-8: PRESS. SENSOR
MOTOR
PRESS. SENSOR BOOM LOWERING FIX A CLIP ON HOLE
ARM OUT OF STAND BOAD.
SE-7:
FIX WHITE TAPING
FIX A HARNESS PART OF PRESS. SENSOR
POSTION
WHITE TAPING OF CLIP TO ARM IN
SE-20: CONNECTOR
PRESS. SENSOR P1 OPT. FIX A HARNESS SW-20:
OF SW. SIDE POWER BOOST SW. RIGHT (YELLOW TAPING
DETAIL aa SW-29:
10.7N m TIGHTING TORQUE NIBBLER OPEN SW. (WHITE TAPING)
TO PRESS. SENSOR WASHER MOTOR SW-30:
TIGHTEN AFTER
CHECKING NO PAINT NIBBLER CLOSE SW. (REDTAPING)
SW-5:
HORN SW. RIGHT (OPT) (BLUE TAPING)
CONNECT WITH EARTH
CABLE OF UPP FRAME
FIX WHITE TAPING POSITION
SE-9:
PRESS. SENSOR
TRAVEL LEFT FIX A CLIP ON HOLE FIX WHITE TAPING POSITION
SE-9: OF STAND BOAD. FIX A CLIP ON HOLE OF SEAT STAND
PRESS. SENSOR FASTEN FLOOR HARNESS
TRAVEL RIGHT AND LEVER SW. HARNESS
SE-11: E-7:
PRESS. SENSOR OPT. TUNER
23-24
23. ELECTRIC SYSTEM
CONNECT TO CAB
HARNESS
CONNECT TO ROTATION E-22:
PARKING CANCEL SW. DC-DC CONVERTER
TO RIGHT INST-PANEL
FLOOR HARNESS
TO UNDER FLOOR
TO LEFT
INST-PANEL
FIX TO THE LOWER PART
OF PLATE WITH CLIP
CONNECT CONNECTOR WITH CNT-2 DETAIL OF FUSE & RELAY BOX CONNECTION
TAG OF ITEM 1 HARNESS
VIEW IV
23-25
23. ELECTRIC SYSTEM
23-26
23. ELECTRIC SYSTEM
23-27
23. ELECTRIC SYSTEM
23-28
23. ELECTRIC SYSTEM
100
1PAF
YAZAKI 7123-3010
TO HARNESS (UPPER)
E-1 :
FUSE & RELAY BOX
TO CAB HARNESS
23-29
23. ELECTRIC SYSTEM
CLIP CONNECT TO
FIX WHITE TAPING CAB SUB HARNESS
CLIP POSITION
C-2 :
GAUGE CLUSTER CONNECT TO
UPPER HARNESS
CLIP TO AIR
CONDITIONER UNIT
CLIP DETAIL A
UPPER HARNESS
E-3 :
HOUR METER
M-3 :
WIPER MOTOR
SW-26 :
SW-15 :
CAB WORK LIGHT SW.
CONFLUX / SINGLE SELECT SW.
CONNECT THE SWITCH WITH "CAB LIGHT"
CONNECT THE SWITCH WITH "CONFLUX"
TAGGED NATURAL COLOR CONNECTOR
TAGGED GREEN CONNECTOR
TO AIR
SW-55 :
CONDITIONER UNIT
BOOM , DECK WORKING LIGHT SW. E-4 :
E-4 :
CONNECT THE SWITCH WITH "BOOM, DECK" CIGARETTE LIGHTER
CIGARETTE LIGHTER
TAGGED BLUE CONNECTOR
FIX WHITE TAPING
POSITION CLIP FIX TO THE BRACKET
CLIP
WR B
DETAIL B
DETAIL OF HOUR METER
23-30
23. ELECTRIC SYSTEM
23-31
23. ELECTRIC SYSTEM
23-32
23. ELECTRIC SYSTEM
BOOM HARNESS ASSY YN15E00008F3 (06) INSTALLING BOOM LIGHT YN80E00026F1 (01)
ITEM PART NAME PART No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
4 HARNESS YN15E01034P1 1 BOOM LIGHT 1 LIGHT 2456R442F1 2
CLAMP TAPING
CLAMP TO THE
TUBE FOR GREASE
A
TO CENTER OF BUCKET
INSTALL WORKING LIGHT TO FACE THE CENTER
OF BUCKET WHEN ARM IS COMPLETELY STROKED AT
TO UPPER THE END OF PUSHING SIDE AND BUCKET IS
O
FITTING GND.
SUPPLIED WITH WIRE TERMINAL
LIGHT
SECTION AA
23-33
23. ELECTRIC SYSTEM
NOTE :
TIGHTENING TORQUE OF ITEM 1
TO BE UNDER 12.8N.m (13.7 kgf.m)
MAIN HARNESS
23-34
23. ELECTRIC SYSTEM
23-35
23. ELECTRIC SYSTEM
1 3
E-13 :
TRAVEL ALARM
2
TIGHTENING
TORQUE
23.5N.m
(17.3lbf.ft)
UPP
SEMS BOLT HARNESS
VIEW
4
TRAVEL ALARM RELAY
23-36
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24-1
24. COMPONENTS SYSTEM
24-2
24. COMPONENTS SYSTEM
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
5
EYE BOLT (M10)
a3 PSV2
Dr
A3 2X4-M12
Depth 22
A1 A2
B3
a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2
Dr3 a5
A1 A2 5
1 A2
Dr3
Hydraulic ports
Code Ports name Size
No. Parts Q'TY
A1,2 Delivery port SAE 6000psi 1"
1 Main pump assy 1 B1 Suction port SAE 2500psi 2 1/2"
2 Regulator assy 2 Dr Drain port PF3/4-20
3 Gear pump assy(for pilot) 1 PSV1,2 Servo assist port PF1/4-13
4 Solenoid proportional reducing valve 2 PH1,2 Pressure sensor port PF3/8-17
5 PTO unit (option) (1) a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
24-3
24. COMPONENTS SYSTEM
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
24-4
24. COMPONENTS SYSTEM
24.1.1.2.1 CONSTRUCTION
(1) Main pump
953 806 789 532 Apply adhesive (Three Bond No.1305N) 724 901 808 954 717 151 152 211
886 214 548 531 702 792 534 A
535 732
717
261
406
824
774
111
B B
127
123
710 04
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
Tightening torque 05
Tightening torque
Item number Thread size
N.m (lbf.ft) 546
401 M20 430 (317) 414 326
406 M8 29 (21) 725
407 M6 12 (8.9) 727
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177) 407 325
806 M16 130 (96) SECTION B-B SECTION B-B
VIEW A
808 M20 240 (177) (with PTO unit)
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Drive shaft (R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 Gear #1 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Back up ring ; P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Back up ring ; G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer plate 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 4 824 Snap ring 2
157 Cylinder spring 18 531 Tilting pin ; M24X2 32 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper(L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper(S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO unit (option) (1)
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-5
24. COMPONENTS SYSTEM
434
311
312
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
24-6
24. COMPONENTS SYSTEM
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885
24-7
24. COMPONENTS SYSTEM
24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the REGULATOR
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives
the two pumps and, at the same time, drives the
auxiliary pump (OPT) arranged on another shaft. 116
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the 111
swash plate group that changes the delivery rate;
the valve block group that selects between oil
suction and delivery ; and the PTO group (OPT)
that transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft(111), cylinder
(OPT)
block (141), piston (151), shoe (152), plate (153), AUXILIARY PUMP
spherical bushing (156), and cylinder spring (157). (OPT)
The shaft is supported by bearings (123) and (124) Fig. 24-4 Construction of hydraulic pump
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of
thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it
moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate
(313) by the action of cylinder spring (157).
313
124
312
111
116
124
314
141
157
156
151
. 153
152
211
24-8
24. COMPONENTS SYSTEM
24-9
24. COMPONENTS SYSTEM
24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION
725
730
a3
656 643
438 924
D
801
722 543 755 545 541 724 B 466, 755 708 644 646 645 728
VIEW C SECTION B-B
733
756
622 621 623 625 626 887 763
SECTION A-A
At start and
emergency mode
Tightening torque
662 642 Tightening torque
Item No. Thread size
N.m
543 545 541
466 412,413 M8 29
At normal
438,439 M6 12
755 E 418 M5 6.9
466 PF 1/4 36
496 NPTF1/16 8.8
496 630 M30X1.5 160
755 E
801 M8 16
802 M10 19
SECTION E-E SECTION D-D
Fig. 24-9
24-10
24. COMPONENTS SYSTEM
24-11
24. COMPONENTS SYSTEM
24.1.1.3.2 OPERATION
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
•Total horsepower control.
Emergency mode control.
•Hydraulic positive control.
•Hydraulic total horsepower control
(2) Summary
The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control
mechanism as mentioned below:
1) Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to
attain optimum power according to the operating condition. Also, since the pump delivers only the necessary
oil flow, the machine does not consume excessive power.
Command current I
Fig. 24-10
24-12
24. COMPONENTS SYSTEM
piston toward (E). The spool is returned to its Hydraulic circuit diagram
B
original position. With this movement, the
opening of the spool sleeve gradually closes. Fig. 24-11
Once the opening is completely closed, the ser-
vo piston stops.
24-13
24. COMPONENTS SYSTEM
24-14
24. COMPONENTS SYSTEM
24-15
24. COMPONENTS SYSTEM
rate is raised. Since the feed back lever is Hydraulic circuit daigram
B
connected to servo piston and spool, the feed
back lever rotates at (X) fulcrum with the Fig. 24-15
movement of the servo piston towards (W),
consequently the spool is returned to the original
position.
With this movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
3) Priority mechanism of low tilt angle (low flow
rate) command.
As in the above explanation, the tilting
commands of flow rate control and power control
are transferred to feedback lever (611) and spool
(652) through the large bore section of lever 1
(612) and lever 2 (613), but because the pin (dia
5) is extruded in large bore (dia 9), pin (897) on
the side where making tilt angle smaller contacts
with it, consequently the bore (dia 9) of lever on
the side where larger tilt angle command is given
is free without contact with pin (897). In this
mechanical selecting manner, the command on
the side of low tilt angle of the flow rate control
and power control has a priority.
24-16
24. COMPONENTS SYSTEM
24-17
24. COMPONENTS SYSTEM
24-18
24. COMPONENTS SYSTEM
24-19
24. COMPONENTS SYSTEM
150
(40)
[3]
100
(26)
50
(13)
Min.Flow(at 2000min-1)
0 5 10 15 20 25 30 35 40 [MPa]
(725) (1450) (2175) (2900) 3625) (4350) (5075) (5800) (psi)
Delivery pressure Pd
250
(66) [4] 91kW : At emergency mode
718mA Input revolution ;2000 min-1
Q 2000min-1 220L (58.1 gal)
Input horse power ;118 kW
300mA
(Max Input torque ;665 N.m at 1200 min-1)
Min.Flow(at 2000min-1)
Tin N.m
(lbf.ft)
400mA
Tin 30L (8 gal)
0 5 10 15 20 25 30 35 40 [MPa]
(725) (1450) (2175) (2900) (3625) (4350) (7075) (5800) (psi)
Delivery pressure Pd
0 1 2 3 4 [MPa]
(145) (290) (435) 580 (psi)
Pilot pressure Pi
24-20
24. COMPONENTS SYSTEM
24.1.2.1 SPECIFICATIONS
PBL
P2 CT2
CP2
CT1
P1
Pcb PAL
CT1 T1
PTb T2
P1 unload CT2
PCb PAL
Travel PL PCb PAL Travel left PBL
AL BL
straight P2 unload
CMR1 CMR2 Ar CP2
USE FOR YN30V00101
Br PAr PCa
Travel PB1 Boom
F1
(P3) (P2)
PBa2 PAo
PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo
A
VIEW A
24-21
24. COMPONENTS SYSTEM
24.1.2.1.2 PORTS
24-22
24. COMPONENTS SYSTEM
24.1.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44001
Maximum flow rate [L/min (gal/min)] 220 (58)× 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 70× 2L/min (18.5× 2gal/min)]
When power boost pressure 37.8 (5480) [at 60× 2L/min (15.9× 2gal/min)]
Overload relief valve set pressure
39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
24-23
24. COMPONENTS SYSTEM
24.1.2.2.1 CONSTRUCTION
(1) Control valve
J
154 164 101
P2
T2 T1
PAL PBL
YT1
J
PB1 PCa
YBG1
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974 973
PAa2 PBa2
YAG
1
974
(P3)
162 162 169 155 163 162
SECTION B-B
24-24
24. COMPONENTS SYSTEM
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PA
PAo
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
24-25
24. COMPONENTS SYSTEM
$!#-
Fig. 24-25 Section (3/6)
24-26
24. COMPONENTS SYSTEM
Swing
204
203 PBs
333 Boom 333
331 Pss
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb 162
Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
164 551
Bucket
209
PCc
216 201
333 Arm 1 333
PBa1
331 331
PBc
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR 205
SECTION F-F AaR 605
Fig. 24-26 Section (4/6)
24-27
24. COMPONENTS SYSTEM
!
Fig. 24-27 Section (5/6)
24-28
24. COMPONENTS SYSTEM
24-29
24. COMPONENTS SYSTEM
24-30
24. COMPONENTS SYSTEM
24-31
24. COMPONENTS SYSTEM
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
69~78 (51~58) 101 Body ; M27 1 541 Seat 1
69~78 (51~58) 102 Plug ; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
24-32
24. COMPONENTS SYSTEM
371 361 340 319 308 317 340 361 371 350
351
Fig. 24-31 Arm 2 spool
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
308 Spool 1 16~18 (33~35) Loctite #638 350 Plug 1
317 Plunger 1 16~18 (33~35) Loctite #638 351 Plug 1
319 Plunger 1 361 O-ring 2
340 Spring 2 371 Buckup ring 2
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
301 Spool 1 16~18 (12~13) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1
24-33
24. COMPONENTS SYSTEM
101
164
171
201
321
PLc A B Dr
166 541 167 511 161
Fig. 24-33 Lock valve selector
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
101 Casing 1 10~14 (7.4~10.3) 171 Socket bolt 3
161 O-ring 4 49~59 (36~44) 201 Plug 1
164 O-ring 1 321 Spring 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
24-34
24. COMPONENTS SYSTEM
2 2E
6 ,H
Fig. 24-34 Bypass cut valve
24-35
24. COMPONENTS SYSTEM
Fig. 24-35 Swing shuttle valve cover
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
541 Steel ball 1 7.9~9.8 (5.9~7.2) 555 Plug 1
24-36
24. COMPONENTS SYSTEM
104
107
102
101
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
101 Poppet 1 20~29 (15~21) Loctite #262 104 Plug 1
102 Poppet 1 107 Spring 1
24-37
24. COMPONENTS SYSTEM
! '(
%& $*
!
)&
!
24-38
24. COMPONENTS SYSTEM
24.1.2.2.3 OPERATION
(1) In neutral position:
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of the control valve, passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517). It then returns to the hydraulic tank through
tank port T1. When the operation of the unloading valve is impossible due to a failure of electric control system,
the by-pass cut valve (606), located on the downstream of center by-pass passage (52) opens. The hydraulic
oil from hydraulic pump P1 port passes through travel straight spool (306), and then flows though the center by-
pass passage (52). It then passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (606)
on P1 side. It then flows into low pressure circuit (D) and boost check valve (517), before retuning to the hydraulic
tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) before returning to the hydraulic tank through tank port T1. When the operation
of the unloading valve is impossible, because the by-pass cut valve (606), located on the downstream of center
by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port passes through the main passage.
It then flows though the center by-pass passage (55), which passes through travel left, swing, arm 1 and option
and the by-pass cut valve (606) on P2 side. It then flows into low pressure circuit (D) and boost check valve
(517), before returning to the hydraulic tank through tank port T1.
! " !" #
" $
"%
24-39
24. COMPONENTS SYSTEM
24-40
24. COMPONENTS SYSTEM
24-41
24. COMPONENTS SYSTEM
PAc
PCc PBc
Bc Ac
LCc
321 (D)
322 304 511
(R) (H)
Fig. 24-41 In bucket digging operation (Stroke limiter ON)
24-42
24. COMPONENTS SYSTEM
!"!
24-43
24. COMPONENTS SYSTEM
(4) Boom
1) In boom up operation:
When starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves to the
right against the force of springs (321) (322). Simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCa and switches unloading spool (309).
The pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs
(325) (326). The secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches
unloading spools (310).
The oil delivered by hydraulic pump P1 flows into parallel passage (53), and opens load check valve LCb
(511). It then flows between the perimeter of boom spool (301) and casing through the U-shaped passage.
It then supplies bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through the perimeter of boom spool
(301) and the casing. It then flows through low pressure circuit (D) and boost check valve (517), and returns
to the hydraulic tank through tank port T1.
24-44
24. COMPONENTS SYSTEM
Fig. 24-44 In boom up conflux operation (Boom conflux spool)
24-45
24. COMPONENTS SYSTEM
Fig. 24-45 In boom down operation
24-46
24. COMPONENTS SYSTEM
56
PBa1 PAa1
P1
Arm 1 (D')
(D) LCAT2 LCAP2
RH (D') P1
RR 52 HH
PAa2 PBa2
(D') Dr Dr
Arm 2
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
53 (ROD)
To pilot cut valve
MU
AP2 515
328 321
308 511 LCAT2 LCAP2
Fig. 24-46 In arm out operation
24-47
24. COMPONENTS SYSTEM
56
PBa1 P1
PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
(D')
PAa2 PBa2
RR 52 RH Dr
(D) HH Dr
Arm 2
(a) To arm 1 spool
Aa (HEAD)
PBa2 PAa2 Ba
[XR]
(ROD)
53 To pilot cut valve
MU Circuit (I)
317
328 515
321 308319(D)511 LCAT2
LCAP2
Fig. 24-47 In arm in operation (At light load: arm recirculation function)
24-48
24. COMPONENTS SYSTEM
56
PBa1 PAa1 P1
(D')
(D) LCAT2 LCAP2
Arm 1 (D') P1
(D) RR 52 RH
HH
PAa2
Dr
PBa2
Dr
Arm 2
(a) To arm 1 spool
PBa2 PAa2 Aa (HEAD)
[XR] Ba
53 (ROD)
To pilot cut valve
MU
Circuit (II)
317
328 515
308 (D)
321 319 511 LCAT2 LCAP2
Fig. 24-48 In arm in operation (In heavy load operation)
24-49
24. COMPONENTS SYSTEM
Fig. 24-49 Swing operation
24-50
24. COMPONENTS SYSTEM
24-51
24. COMPONENTS SYSTEM
$
% & '
(
( )&%*
+*
!" #
Fig. 24-51 Lock valve operation (At boom spool neutral position)
24-52
24. COMPONENTS SYSTEM
A A PLc Sa Sb Dr
SECTION A-A
Sa
321 322
PBb
(D)
301
Dr
Fig. 24-52 Lock valve selector operation (At boom down operation)
24-53
24. COMPONENTS SYSTEM
[X1]
PBp1
301 302
(b)
(C)
Dr
201 101
(a)
(D)
52
24-54
24. COMPONENTS SYSTEM
PBp1
302
301
(b)
(C)
Dr
201 101
(a)
(D)
202
52
24-55
24. COMPONENTS SYSTEM
Fig. 24-55 Boost check valve operation
24-56
24. COMPONENTS SYSTEM
527
528
(D') T2
518
T1
102
517
(D)
24-57
24. COMPONENTS SYSTEM
24-58
24. COMPONENTS SYSTEM
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
PORT 1, 3 PORT 2, 4
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDLAULIC SYMBOL
24-59
24. COMPONENTS SYSTEM
24.1.3.2 CONSTRUCTION
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
Tightening Tightening
torque No. Name Q’ty torque No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-60
24. COMPONENTS SYSTEM
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-58)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216
509
221
201
24-61
24. COMPONENTS SYSTEM
24-62
24. COMPONENTS SYSTEM
24.1.4.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
24-63
24. COMPONENTS SYSTEM
5
3
8 10
3
11 12
4
10
9
9
7 6
2
24-64
24. COMPONENTS SYSTEM
24.1.5.1 SPECIFICATION
(1) General view
THREAD FOR
Port Tightening torque
M L
Symbol Port name EYE BOLT 2-M10
size N.m (lbf.ft) PB DEPTH 18
A,B Main port PF3/4 167 (123) RELIEF VALVE
B
(B PORT SIDE)
DB Drain port PF3/8 74 (55)
M Make-up port PF3/4 167 (123)
PA,PB Pressure measuring port PF1/4 36 (27) (SH)
RELIEF VALVE
A (A PORT SIDE)
DB
PA
PG IP
PG FILLING PORT
PT3/4
DB
PA PB
Grease
fitting
A B
Hydraulic diagram
24-65
24. COMPONENTS SYSTEM
(2) Specifications
24-66
24. COMPONENTS SYSTEM
24.1.5.2 CONSTRUCTION
(1) Swing motor
993
702 712
ANTI
CAVITATION
PLUNGER
351 Arrangement of brake spring
355
051 RELIEF VALVE
469
051-1
488 ANTI-REACTION
VALVE BLOCK 401
052 151
303 162 171 161
985
163 985 444 984 131 451
712 A A
472 390 391
VIEW I
702
707
706
100
980
743
742
400-1
111
400-2 052
121
400
123 994 SECTION A-A
122
114 301
124 443 491 101
24-67
24. COMPONENTS SYSTEM
24-68
24. COMPONENTS SYSTEM
Be careful about
installation direction
of retaining ring. Drive this spring pin
into 1mm lower than
the surface of spider.
24-69
24. COMPONENTS SYSTEM
24.1.5.3 OPERATION
plate
If the oil supply and discharge directions are (122) (121)
(122)
reversed, the drive shaft rotates in the opposite
direction. Low pressure oil High pressure oil
T=
2X q ; Displacement per revolution cc/rev
DIRECTIONAL VALVE
24-70
24. COMPONENTS SYSTEM
24-71
24. COMPONENTS SYSTEM
24-72
24. COMPONENTS SYSTEM
3) At anti-reaction action p t
When inertia load stops moving (point Y Fig. 24-
72), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the P<PS
right return side by the action of spring (321). L
Seat (313) tries to move to the right by the action
of spring (322), but since chamber p provides k
damping action by orifice g, the return of the seat 322 313 g r 321 311
makes a time delay with regard to the return of
Fig. 24-71 At anti-reaction action
the plunger.
Consequently, seat t opens. This makes a P Y
passage connecting the AM port and BM ports or
PS
both ports of the hydraulic motor by way of
→t→r→k. The result is that the pressures at the AM
and BM ports become equal (Pb), falling into the PB
X
condition at point Z in Fig. 24-72. Z
This prevents the hydraulic motor from swing T
shock by the closing pressure of the AM port. Fig. 24-72 Pressure change diagram of anti-
reaction operation
24-73
24. COMPONENTS SYSTEM
11 1
24-74
24. COMPONENTS SYSTEM
24.1.6.1 SPECIFICATIONS
24.1.6.1.2 SPECIFICATIONS
Model
GM38VB
Item
Rated output torque N.m (lbf.ft) 20100 / 34200 (14800 / 25200)
Working revolution min-1 48.2 / 29.6
Reduction ratio 1 / 55.617
Max. displacement cm3/rev. (cu.in/rev) 78.8 / 130.8 (4.81 / 7.98)
Hydraulic Max. revolution min-1 2680 / 1648
motor Max. pressure MPa (psi) 34.3 (4970)
2 speed chamber pilot pressure MPa (psi) 2.94~5.88 (426~853)
24-75
24. COMPONENTS SYSTEM
24.1.6.2 CONSTRUCTION
SECTION B-B
C C
SECTION C-C
SECTION A-A
24-76
24. COMPONENTS SYSTEM
24-77
24. COMPONENTS SYSTEM
24.1.6.3 OPERATION
24.1.6.3.1 HYDRAULIC MOTOR SECTION (BRAKE VALVE, PARKING BRAKE, HIGH-LOW 2 SPEED
CHANGE MECHANISM)
(1) Function
1) Function of hydraulic motor
This hydraulic motor is a swash plate type, axial piston motor and functions to convert the force of oil
pressure from the pump to rotary motions.
2) Function of brake valve
a. When trying to stop the travel motor, this brake valve controls the force of inertia meant to rotate the
travel motor with the inertia of body so as to stop the rotation with smooth braking.
b. Functions like a check valve used to prevent cavitation of hydraulic motor.
c. This brake valve opens the port used to release the parking brake when the travel motor is operated and
closes it when the travel motor stops.
3) Function of parking brake
This parking brake functions to prevent machine runaway when parking or stopping on slopes and from
slipping with the friction disk type braking mechanism. It is integrated into the hydraulic motor section.
4) Function of high and low 2 speed change mechanism.
This mechanism varies the tilt angle of the swash plate with changes of the selector valve and control piston.
Changes in the speed are in 2 steps, high speed-low torque rotation and low speed-high torque rotation.
(2) Working principle and explanation of functions
1) Hydraulic motor
Hydraulic oil delivered by the hydraulic pump enters rear flange (301) of GM motor, passes through the brake
valve and is led to the inside of cylinder block (104) through timing plate (109). The oil then flows through
only one side of [Y1-Y2] linked from the upper dead point to the lower dead point after piston (105) stroke.
Hydraulic oil flowed into one side of the cylinder block pushes each piston (4 or 5 pieces) and produces force
(F kg=P MPa× A cm2 ). This force acts on swash plate (103), and is separated into (F2, F3) because the
swash plate is fixed having angle (a degree) to the motor shaft (102) line. The radial force of the separated
force (F3) generates torque (T= F3× ri) to [Y1-Y2]. This combined force [T= (F3× ri)] makes the cylinder
block rotate using the piston as turning effort. This cylinder block transmits torque by making the motor shaft
rotate because the motor shaft and spline are connected to each other.
24-78
24. COMPONENTS SYSTEM
2) Brake valve
a. Starting an operation and during an operation
When hydraulic oil is supplied from the control valve to port A, the hydraulic oil opens valve (327) and
enters port P2 on the suction side of hydraulic motor and tries to rotate the hydraulic motor.
Simultaneously the hydraulic oil opens orifice (372) located on section X-X through passage (a) and
enters chamber (e). This hydraulic oil acts on the end face of spool assembly (323A) and generates
force, and slides the spool on the neutral condition slide rightward with the force of spring (330). At this
time the hydraulic oil pushed out of chamber (f) passes through passage b1. The oil is discharged into
port B through the orifice of the throttle valve located on section Y-Y. Because the hydraulic oil flows
through the orifice, the shock caused when starting is reduced because of the slow movement of the
spool assembly.
When the spool assembly slides, passage g is formed between rear flange (301) and the spool assembly
with the spool groove. Port PS located on the passage on the return side of hydraulic motor and port B
on the other side are connected to this passage. The return oil returns to the control valve enabling the
hydraulic motor to rotate.
Because the spool assembly slides, the hydraulic oil enters port C1 through passage c. The hydraulic oil
entered in port C1 actuates piston (112) of the parking brake and releases parking brake force. (For
details, see 24.1.6.3.1 (2)-3.)
In the event that the hydraulic oil is supplied to port B, the right valve in pair opens, and the spool
assembly moves leftward resulting in reverse rotation of hydraulic motor.
X Y
X
Y
24-79
24. COMPONENTS SYSTEM
X Y
SECTION Y-Y
X Y
24-80
24. COMPONENTS SYSTEM
X Y
SECTION Y-Y
X
Y
24-81
24. COMPONENTS SYSTEM
3) Parking brake
a. When starting operating and in operation.
Hydraulic oil is supplied from the brake valve to port C1 when starting operating and then flows into
cylinder chamber (a), which is made up of spindle (101) and piston (112). When the pressure in cylinder
chamber (a) increases over the force of spring (113), the piston moves toward the rear flange (301) side.
With the movement of this piston, the force on the separator plate (116) and the friction plate (115) is
cancelled. The movement of the friction plate installed on the cylinder block (104) of the hydraulic motor
is in a free state and the braking force to the cylinder block is released.
24-82
24. COMPONENTS SYSTEM
The torque of parking brake is set to 60% of output force of motor, if the external torque over the
parking braking torque is applied to, the motor rotates.
24-83
24. COMPONENTS SYSTEM
24-84
24. COMPONENTS SYSTEM
24-85
24. COMPONENTS SYSTEM
24-86
24. COMPONENTS SYSTEM
Sun gear1
Shaft
Spindle
Sun gear 2
Carrier
Hub (Ring gear)
24-87
24. COMPONENTS SYSTEM
24-88
24. COMPONENTS SYSTEM
VIEW Y
VIEW Z
24.1.7.2 SPECIFICATIONS
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (245 lbs)
24-89
24. COMPONENTS SYSTEM
24.1.7.3 CONSTRUCTION
2 places
VIEW Y
5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
24.1.7.4 OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem
(2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because
of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the
body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
24-90
24. COMPONENTS SYSTEM
24.1.8 CYLINDER
24.1.8.1 SPECIFICATIONS
(1) General view
B A
gth th
n ng
d le le
en
de ted
ext rac
lly ret
Fu Fully
24-91
24. COMPONENTS SYSTEM
24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder
B
-0.5
-0.5
105 0
105 0
PS1/8
PT1/4
With hole
DETAIL B (1 place) DETAIL C
T=5460 (4027)
9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21
Slit
Orientation of cut off part
of cushion bearing (13)
P/No YN01V00151F1
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 9 Wiper ring 1 17 Buckup ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Slide ring 2
4 Bushing 1 12 Socket bolt; M16× 75 12 20 Set screw; M12 1
5 Snap ring 1 13 Cushion bearing 1 21 Steel ball 1
6 Buffer ring 1 14 Cushion seal 1 22 Pin bushing 2
7 U-ring 1 15 Piston 1 23 Wiper ring 4
8 Buckup ring 1 16 Seal ring 1
24-92
24. COMPONENTS SYSTEM
B
-0.5
-0.5
120 0
120 0
PT1/4
PS1/8
With hole
DETAIL B (1 place) DETAIL C T=7890 (5820) T=56.9 (42)
9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21
25 23 22 24
Slit
Fig. 24-80 Construction of arm cylinder
P/No YN01V00175F1
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Buckup ring 1 20 Set screw; M12 1
3 Rod cover 1 12 Socket bolt; M18× 80 12 21 Steel ball 1
4 Bushing 1 13 Cushion bearing 1 22 Cushion bearing 1
5 Snap ring 1 14 Cushion seal 1 23 Cushion seal 1
6 Buffer ring 1 15 Piston 1 24 Stopper 2
7 U-ring 1 16 Seal ring 1 25 Snap ring 1
8 Buckup ring 1 17 Buckup ring 2 26 Pin bushing 4
9 Wiper ring 1 18 Slide ring 2 27 Wiper ring 4
24-93
24. COMPONENTS SYSTEM
22 21 12 T=267 (197) 21 22
B
-0.5
-0.5
105 0
105 0
PS1/8
PS1/8
With hole
DETAIL B (1 place) DETAIL C
9 8 7 6 3 4 5 11 10 2 1 13 15 16 17 18 14 19 20
P/No YN01V00153F1
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Set screw; M12 1
4 Bushing 1 12 Socket bolt; M16× 75 12 20 Steel ball 1
5 Snap ring 1 13 Cushion bearing 1 21 Pin bushing 4
6 Buffer ring 1 14 Piston 1 22 Wiper ring 4
7 U-ring 1 15 Seal ring 1
8 Buckup ring 1 16 Buckup ring 2
24-94
24. COMPONENTS SYSTEM
24.1.8.2.2 OPERATION
Pressurized oil is fed alternatively to the oil inlet and Cushion bearing (13) Chamber "A" Passege "B"
outlet provided in the cylinder. pressure acts on the Tank
piston which in turn causes the piston rod (2) to extend Piston (15)
Rod (2)
and retract.
Rod side
Head side
(1) Operation of cylinder with cushion
1) Cushion on rod side
The cushion mechanism is provided to prevent Rod cover (3)
Cushion stroke
the generation of shock when the moving speed
of the piston (15) is not reduced and strikes the Fig. 24-82 Cushion mechanism on the rod side
cylinder head (3).
Oil in chamber "A" returns to the tank through
passage "B" at a fixed flow rate in an
intermediate stroke (Fig. 24-82) of pressing head
side. Just before the end of the stroke (Fig. 24-
83), cushion ring (13) moves into passage "B".
Oil in chamber "A" passes clearance "D" and
mouth gap "C". Oil flow volume returning to tank
suddenly drops and the piston movement slows
down.
Fig. 24-83 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-84)
This design is similar to the one for cushion on
the rod side. In a state of intermediate stroke
pressing the rod side, oil in chamber "A" returns
to tank by passing through passage "B" at a fixed
flow rate.
Just before the end of the stroke, cushion
bearing (22) moves into passage "B". The oil in
chamber "A" flows through clearance "D" and
mouth gap "C" of cushion seal (23). The
returning oil volume drops suddenly and the
piston movement slows down.
Fig. 24-84 Cushion mechanism on the head side
24-95
24. COMPONENTS SYSTEM
24-96
24. COMPONENTS SYSTEM
Group
(C) Controller Code Name Parts No.
C - 1 Mechatro controller YN22E00214F1
C - 2 Gauge cluster YN59S00021F1
C - 4 Air-con controler (including panel) YN20M01468P1
D - 10 Diode
D -11 Diode YN02D01001P1
D - 12 Diode Acc of relay box
D - 13 Diode ↑
D - 14 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
D -18 Diode YN02D01001P1
D - 19 Diode ↑
D - 20 Diode ↑
D - 21 Diode ↑
D - 22 Diode ↑
E - 1 Fuse and Relay box YN24E00016F1
E - 2 Alternator Engine Accessory
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
E - 7 Tuner AM / FM YN54S00045P1
E - 8 Speaker left YN54S00006P1
E - 9 Speaker right ↑
(E) Electric fittings
24-97
24. COMPONENTS SYSTEM
24-98
24. COMPONENTS SYSTEM
24-99
24. COMPONENTS SYSTEM
24-100
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F1
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-4
Controller
YN20M01468P1
Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-101
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F1
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E-2
Alternator
Bosch NCBI 28 V 35 - ART NOT AVAILABLE
70A
YQ11 - 06001 ~
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V STAMP
LC53S0001D1 (High)
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
YN11 - 45001 ~ Basic frequency 350+20Hz low sound
YQ11 - 06001 ~ Insulation resistance More than 3M /DC500V
LC10 - 07001 ~
YC10 - 03501 ~ o 8.5
24-102
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00045P1
Radio (AM & FM)
YQ11 - 06001 ~
YC10 - 03501 ~
E - 8, 9
Speaker
YN54S00006P1
Radio
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~ Desiccant moisture 17% or over than the
weight of desiccant
YQ11 - 06001 ~ adsorption capability (Include initial absorption 2%)
LC10 - 07001 ~ Refrigerant HFC-134a
YC10 - 03501 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
24-103
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 11
Air-con compressor
!"#!"""
YX91V00001F1
$%&
Air-con
&"""'
YX03 - 01601 ~
() *
YX04 - 01773 ~
#+ &
YX05 - 02001 ~
,-#%".+ /
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 12 Type 4D-2
Battery Voltage 12V
2411U22 Capacity (5HR) 130Ah
Power Weight (Incl. fluid) Approx. 46kg (101 lbs)
Electrolyte Approx. 12 L (3.2 gal)
YQ11 - 06001 ~
YC10 - 03501 ~
499.11
3
214.12
5
252.25
6
7
4
1
24-104
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V
YN53S00004F1 Power AV 0.5 Red / Green
E - 14
Cigarette lighter
!" #$
YN81S00003P1
% ,
*
Cigarette lighter -.
YN11 - 45001 ~
& '
(%$
YQ11 - 06001 ~
LC10 - 07001 ~
)
*'+#%
YC10 - 03501 ~
/
0
*
E - 19
Heater
E - 20
Heater
24-105
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 21
Heater
Grid heater
YQ11 - 06001 ~
ART NOT AVAILABLE
E - 23
Power supply For 12V
Socket
Maker TOKAI RICA CO., LTD
YN81S01002P1
Marker P. No. 347-0385-00010
Power scoker
LC10 - 07001 ~
YC10 - 03501 ~
24-106
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 34 FUSE CAPACITY: 100 AMP
Fuse assy
YN73E00020F1
Fuse lnk box
YQ11 - 06001 ~
L - 1, 6
Type
Light (Halogen)
Bulb 28V,60W
2456R442F1
Boom work light (LH, RH)
YQ11 - 06001 ~
YC10 - 03501 ~
L-2
Type
Light Bulb 28V,60W
2456R248 Effective area of lens
24-107
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L-3
Meker Knight beam (Imasen)
Light
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Flasher lamp (LH)
Lighting cycle 90 times / min
Rear work light
YN11 - 45001 ~
AV0.85 W
YQ11 - 06001 ~ AV0.85 Y REAR WORKING
LC10 - 07001 ~ SWING LIGHT LIGHT
YC10 - 03501 ~ AMP PART NO.
HOUSING : 174259-2
L-4 TERMINAL : 171661-1
AV0.85 R
Light HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
LOCK PLATE : 1-174260-1 GND
YM80S00001F2 VIEW I
Flasher lamp (RH)
Rear work light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SECTION A-A
L-5
Bulb 24V,5W Body
Light Lens
Note) Equivalent to 2456Z322F1
YT80S00001P1
Room light
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~ Bulb
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ SECTION A-A Door
Switch
YC10 - 03501 ~
L - ,7,8,15,16,18
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YN80S00010F2
Effective area of lens 71cm2
Cab working light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-108
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
M-1
Motor
Bosch 24V
Starter motor
YN11 - 06001 ~
M-2
Motor
Drive voltage DC 24V
YN20S00002F1 Rated voltage DC 8.5V
Governor motor Rated current 1.5A / phase
Number of phases 2 phase
YT02 - 04001 ~ Excitation method 2 Excitation LIMIT SWITCH
YN08 - 33001 ~ Step angle 1.8
o MOTION RANGE
MOTOR CONNECTOR
LIMIT SWITCH CONNECTOR 1 2
6
NO. LEAD CONNECTION
NO. LEAD CONNECTION
1 BROWN A
5 WHITE COM
2 ORANGE A
6 RED NO
3 RED B
5 7 YELLOW NC
4 YELLOW B
7 3 4
HOUSING : 174359-2(AMP)
HOUSING : 174259-2(AMP)
TERMINAL : 171661-1(AMP)
TERMINAL : 171661-1(AMP)
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller
LC10 - 07001 ~
YC10 - 03501 ~
Wiper sw
OFF-Stop
Stop signal ON-Start
Reverse signal
Electric diagram
24-109
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less HOUSING AMP
GND terminal
LC10 - 07001 ~
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
WIRE PROOF PLUG AMP
172888-2
VIEW Z Terminal L
Flowing direction of
main current F HOUSING YAZAKI
o 9 X 30L
Terminal A Terminal B Terminal B Heart shrinkage tube 7123-4210-30
AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
R-2
Relay
YN24S00009P1
Starter relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-110
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-3
Relay
YN24S00004P1
Grid heater relay
YQ11 - 06001 ~
CONNECTOR SCREW
2 - POLE TERMINAL M6
R - 19
Relay
YY24S00001P1 UPPER
Flasher relay
YN11 - 45001 ~
YQ11 - 06001 ~
TERMINAL NUMBER
24-111
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R - 29, 30, 31, 32 Terminal thickness
Relay .032 + .001
(0.81 + 0.03)
YN24S00012P1
Wiper motor relay
Spark prevent relay 86
Washer motor relay 30
87A
YQ11-06001 ~
87
85
R - 40
Relay
YN24S00005P1
Fuel filter heater relay
YQ11-06001 ~ ART NOT AVAILABLE
SE - 1 ~ 5, 7 ~ 11, 20, 29
Pressure range 0~3MPa (435 psi)
Pressure sensor
Allowable max. pressure 7.0MPa (1010 psi) O-ring
(Low pressure) (P11 1B)
Rated voltage 5+0.5V DC
YX52S00013P1 HEX24 Vout
50M or more /DC50V megger
Bucket dig and dump, Insulation resistance
(Between Body terminal)
Boom up and down,
Swing,
Connection (Arrangement)
Arm in and out,
Travel RH and LH
Vcc GND
Opt.selector detect PF1/4
YN11 - 45001 ~ Tightening torque 29.4~34.3 N.m
(21.7~25.3 lbf.ft)
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SE - 12
Level sensor
504025613
E/G oil level sensor
YQ11-06001 ~
24-112
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 13 1 CONNECTION A
Speed sensor 2 CONNECTION B
VHS894101290A 3 SHIELD
E/G speed sensor SIGNAL SEQUENZ:
AT CONNECTION A THE FIRST
1/2 WAVE APPEARS POSITIV WHEN
YN11 - 45001 ~ PASSING A MAGNETIC CONDUCTING
MATERIAL
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SE - 15
Thermo sensor
YT52S00001P1
Coolant thermo sensor
YQ11-06001 ~
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
1/2 32+5
YQ11 - 06001 ~
1/4 (49.5)
LC10 - 07001 ~
EMPTY 85 +10
0
YC10 - 03501 ~
Float
24-113
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YT02 - 04001 ~
Notch part
YT03 - 05293 ~
YT04 - 07001 ~ Potentio
YN11 - 45001 ~ 3MA JM II + AMP
Bracket
YQ11 - 06001 ~ HOUSING : 174359-2
TERMINAL : 171661-1
LC10 - 07001 ~
YC10 - 03501 ~ Dial
HYDRAULIC SYMBOL
Arm 2 speed
P1 unload
Travel straight
P2 unload
Attachment boost
Swing parking
Lever lock
24-114
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
Rated voltage DC 24V
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Sleeve O-ring Solenoid Seal nut
1B P20
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
Rated voltage DC 24V
valve (8 spool) assy pressure
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SW - 1 Auto return
Switch Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ VIEW A Terminal
YC10 - 03501 ~ arrangement
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YT50E00001F1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
YT02 - 04001 ~ YAZAKI
T No.
YT03 - 05293 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
YT04 - 07001 ~ Swing parking release
YN11 - 45001 ~ Normal
YQ11 - 06001 ~
White (3) Blue (1)
LC10 - 07001 ~
YC10 - 03501 ~
24-115
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 5, 10, 20, 21
)* +,
Switch ,
(-
YN03M01861F1
! "# #$
(Right grip)
% % &
YN03M01862F1 '$! (
(Left grip)
Horn, ATT Power boost
YN11 - 45001 ~
YQ11 - 06001 ~ (( (, ./01,+ 23*" 4 (5
LC10 - 07001 ~ (( (,
%#6,+ 7 "*8 7
6 4(( (
9 '"5
YC10 - 03501 ~
SW - 6
NTC CHARACTERISTIC
Switch o
TEMP. C RESISTANCE (ohm)
PN 25 2252 +/- 10x
E/G water temp. switch 60 536 +/- 10x
YQ11 - 06001 ~ 90 195 +/- 10x
SW - 7
Type Normal close
Switch
Working pressure 75~105kPa (11~15psi)
Rating DC 24V/12W
E/G oil pressure switch
YQ11 - 06001 ~
SW - 8
Switch
YR11P00008S005
Air cleaner
Clogging switch
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-116
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 11
Switch
YN50S00041F1
Lock lever
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ !
YC10 - 03501 ~
SW - 15
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040DD Type (alternate)
Conflux / single flow Insulation resistance More than 1M / UP
DC500V megger
switching (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector
LC10 - 07001 ~
YC10 - 03501 ~
SW - 19
Switch
Rated voltage DC 12V
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
YN11 - 45001 ~
Operation force Initial motion 0.8+0.3
0 kg
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Max. stroke
24-117
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 24
Switch
2427U203S6
E/G coolant level switch
YQ11 - 06001 ~
SW - 26
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D4 Type (alternate)
Cab work light switch More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector
YC10 - 03501 ~
SW - 29, 30
Switch
2406P5872
Nibbler open switch
Nibbler closed switch
YQ11 - 06001 ~ ART NOT AVAILABLE
SW - 33, 34
Switch
YN03M01231P1
Revolution right switch
YELLOW GREEN
Revolution left switch
YQ11 - 06001 ~
24-118
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 35
Rated voltage DC 24V
Switch
Type Single pole single throw
YN50S00040D5 (alternate)
Heavy lift switch Insulation resistance More than 1M / UP
DC500V megger
YQ11 - 06001 ~
YC10 - 03501 ~
Terminal connector
Connector
Position
SW - 37
Rated voltage DC 24V
Switch
Type Single pole single throw
YN50S00040DB (alternate)
Independent travel Insulation resistance More than 1M / UP
DC500V megger
switch
YQ11 - 06001 ~
YC10 - 03501 ~ Terminal connector
Connector
Position
SW - 55
Switch
YN50S00040D1
Boom work light switch
!"" %$
#
YN11 - 45001 ~
YQ11 - 06001 ~
#
LC10 - 07001 ~ $
YC10 - 03501 ~
SW - 64
Rated voltage DC 24V
Switch
Type Single pole single throw
YN50S00040DH (alternate)
Quick coupler operation Insulation resistance More than 1M / UP
DC500V megger
switch
YQ11 - 06001 ~ Terminal connector
Connector
Position
24-119
24. COMPONENTS SYSTEM
24-120
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25-1
25. AIR-CONDITIONER SYSTEM
25-2
25. AIR-CONDITIONER SYSTEM
• Cooling
Inside or outside air is taken in through intake port. The air is passed through a filter and then flows through the
evaporator core where dehumidifying and cooling of the air takes place. The cooled air then flows back to the
cab through the air duct.
• Heater System
The heater system circulates the hot cooling water from the engine through the heater core of the HVAC system.
The intake air is heated as it flows through the heater core and then flows back inside the cab.
The heater core temperature is controlled by a water inlet valve that is connected to a temperature control switch
on the control panel. There is also an air mixing damper on the HVAC unit.
25-3
25. AIR-CONDITIONER SYSTEM
COMPRESSOR
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
25-4
25. AIR-CONDITIONER SYSTEM
27
33 30
27-1
40
32
39
27-6
27-3 27-5
27-2
35
35-7 35-6
35-1
35-2 35-5
34 35-8
35-10 35-9
25-5
25. AIR-CONDITIONER SYSTEM
25.2.2 CONSTRUCTION
(1) Air conditioner unit
49
48
6
47
46
44
31
42 31
41 F
50
3 1
45 1
43 G
1 32
1
28 1
39
37
38
B
36
27
H
9
40
A
I
2
33
25-6
25. AIR-CONDITIONER SYSTEM
14
1 1 31 16
1 5
15
31
1
3
1 61
F 1
C 1
D
4
7
G
1 1
1
26 20 13
59
29
11
21 23
22
H
24 1
B
1
8 60
D
17
18 A
I
C
10
31
19
12
1
3
31 25
52
25-7
25. AIR-CONDITIONER SYSTEM
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
25-8
25. AIR-CONDITIONER SYSTEM
25.3 PIPING
25.3.1 AIR CONDITIONER
Fig. 25-5
25-9
25. AIR-CONDITIONER SYSTEM
25-10
25. AIR-CONDITIONER SYSTEM
Fig. 25-6
25-11
25. AIR-CONDITIONER SYSTEM
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows Chemical formula CH2FCF3
through the cooling circuit changes its form from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part (in Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
the cab) to the high temperature part (outside of the
Critical density 511 kg/m3 (31.9lb/ft3)
cab). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Specific volume of saturated
Many kinds of refrigerants that change in that 0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• Easy to liquify (condense). (It does not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
25-12
25. AIR-CONDITIONER SYSTEM
25-13
25. AIR-CONDITIONER SYSTEM
25-14
25. AIR-CONDITIONER SYSTEM
25-15
25. AIR-CONDITIONER SYSTEM
25-16
25. AIR-CONDITIONER SYSTEM
25-17
25. AIR-CONDITIONER SYSTEM
25-18
25. AIR-CONDITIONER SYSTEM
1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)
25-19
25. AIR-CONDITIONER SYSTEM
Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit. Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
Fig. 25-17
25-20
25. AIR-CONDITIONER SYSTEM
Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.
EVAPORATION SENSOR
Fig. 25-20
25-21
25. AIR-CONDITIONER SYSTEM
Fig. 25-23
25-22
25. AIR-CONDITIONER SYSTEM
Fig. 25-24
25-23
25. AIR-CONDITIONER SYSTEM
• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
(2) Safety procedures must be followed when working with refrigerant R-134a to prevent possible injury.
1) Always wear safety goggles when doing any service work near and air conditioning system. Liquid refriger-
ant getting into the eyes can cause serious injury. Do the following if you get refrigerant near or in your eyes.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2) A drop of liquid refrigerant on your skin may cause frostbite. Open the fittings carefully and slowly when it is
necessary to service the air conditioning system. Your skin must be treated foe frostbite or a physician must
be seen if you get refrigerant on your skin.
3) Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from
heat and sunlight. The pressure in a container will increase with heat.
4) Always reclaim refrigerant from the system. If you are going to weld or steam clean near the air conditioner
system.
5) lways check the temperature and pressure of the air conditioner system before reclaiming refrigerant and
when you test the system.
6) Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be
inhaled.
7) Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC
R-134a and air can form a combustible gas.
25-24
25. AIR-CONDITIONER SYSTEM
(3) Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side
Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter
25-25
25. AIR-CONDITIONER SYSTEM
Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when BLUE
sound is heard.
CHARGING
3) Connect the center valve of the gauge manifold HOSE
with the charging hose of the vacuum pump. (GAS VALVE)
25-26
25. AIR-CONDITIONER SYSTEM
25-27
25. AIR-CONDITIONER SYSTEM
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-28
25. AIR-CONDITIONER SYSTEM
RECEIVER DRYER
25-29
25. AIR-CONDITIONER SYSTEM
25-30
25. AIR-CONDITIONER SYSTEM
25-31
25. AIR-CONDITIONER SYSTEM
NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING
FUSE 5A
COMPRESSOR
JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111
25-32
25. AIR-CONDITIONER SYSTEM
EVA SENSOR
SUN SENSOR
MOTOR ACTUATER
(FOR AIR MIX)
MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)
BLOWER MOTOR
BLOWER AMP
MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY
25-33
25. AIR-CONDITIONER SYSTEM
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.
25-34
25. AIR-CONDITIONER SYSTEM
(3) Relay.
A four pin relay is used for the blower OFF and
compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay.The relay ON—OFF is tripped
by the control amplifier and electronic thermostat
control. Fig. 25-36
3) Relay inspection items.
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
of polarity.
5. Inspection: Check the continuity between pins
3 and 4 using the below procedure.
20~30V applied between terminals 1-2:
Continunity present
20~30V not applied between terminals 1-2: No
continunity.
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.
When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR
25-35
25. AIR-CONDITIONER SYSTEM
actuator.
When the inner and outer damper position is set by
the inner and outer switch on the control panel, the
control unit reads the signal of the position INNER AIR SIDE
detection switch in the actuator and determines the OUTER AIR SIDE
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
25-36
25. AIR-CONDITIONER SYSTEM
25.8 TROUBLESHOOTING
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.
A
NO YES
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (less than 14.7N : OK) is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Inspect and replace.
NO YES
25-37
25. AIR-CONDITIONER SYSTEM
NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES
NO YES
Inspect and replace.
25-38
25. AIR-CONDITIONER SYSTEM
NO YES
Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
25-39
25. AIR-CONDITIONER SYSTEM
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES
CASE (2)
YES NO
25-40
25. AIR-CONDITIONER SYSTEM
Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.
No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes
Replace
25-41
25. AIR-CONDITIONER SYSTEM
25-42
25. AIR-CONDITIONER SYSTEM
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES
High pressure
is lower.
NO YES
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.
25-43
25. AIR-CONDITIONER SYSTEM
2) MODE is flickering.
3) R/F is flickering.
Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.
25-44
25. AIR-CONDITIONER SYSTEM
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
25-45
25. AIR-CONDITIONER SYSTEM
ON/OFF SW
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch.
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3) Numbers from 0 to 9 or any letter of the alphabet from A to F are displayed on the 3rd and 2nd digit of the
three digit segment. The 1st digit is indicated by "H".
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing
UP or DOWN of blower switch, and the required sensor is selected from the list below.
1 EVAPORATOR SENSOR
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.
Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
25. AIR-CONDITIONER SYSTEM
2) Example 2
3) Example 3
4) List of 3 segments
SECOND SEGMENT
25-47
25. AIR-CONDITIONER SYSTEM
[MEMO]
25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31
31-1
31. DISASSEMBLING AND ASSEMBLING
31-2
31. DISASSEMBLING AND ASSEMBLING
31-3
31. DISASSEMBLING AND ASSEMBLING
[MEMO]
31-4
32. ATTACHMENT
TABLE OF CONTENTS
32
32-1
32. ATTACHMENT
PREFACE
(1) This section describes the procedures for removal to installation, arranged by component.
(2) This section consists of 2 parts. "Removing and Installing", and "Disassembling and Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be ignored.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and faulty component.
(5) Be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the required part of the section, read the instructions, then
begin working.
32-2
32. ATTACHMENT
(D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN (A) BOOM FOOT PIN
4. BOOM
ARM CYLINDER
32.1.2 BUCKET
SECTION OF BOSS
32-3
32. ATTACHMENT
32-4
32. ATTACHMENT
8 : PLATE
(4) Adjust clearance (B) where it is more than 1.0mm
Install pin (10) until the top
(0.04in). 9 : SHIM 10 : PIN of pin is even surface
with bushing.
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).
32-5
32. ATTACHMENT
32.1.3 ARM
(3) Removing bucket cylinder rod pin (H) After adjustment of shim, the total gap
should be within 0.6~1.0mm (0.02~0.04in).
Loosen nut (9), remove capscrew M16× 140 (8), SHIM
and push out pin (H). 8
: 24mm
9
G A H SECTION D-D
H D A Install plastic shims
to bucket link side.
D
PLASTIC SHIM STEEL SHIM
Fig. 32-10 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
Install plastic shims
Loosen nut (3), remove capscrew M16× 150 (2), to bucket link side.
and push out pin (G).
3 2
SHIM
After adjustment of
shim, the total gap
should be within
: 24mm 0.6~1.0mm (0.02~0.04in).
SHIM Apply grease
to inner wall
of bushing
G
SECTION A-A
Fig. 32-11 Detail of bucket cylinder head pin (G)
32-6
32. ATTACHMENT
: 24mm
: 22 mm SHIM
Install plastic
shims to arm
Insert pin (F) into the original hole. side.
32-7
32. ATTACHMENT
CLEARANCE
: 24 mm
Tightening torque
Classfication Size
N.m lbf.ft
M14 144 106
Metric threads
M16 147 108
PF,PT threads 1/8" 16.7 12.3
32-8
32. ATTACHMENT
32.1.4 BOOM
BLOCK
STAND
: 24 mm
4 3
SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)
32-9
32. ATTACHMENT
A A
A
: 30 mm
SECTION A-A
32-10
32. ATTACHMENT
D
D
:12 mm
D
SECTION D-D
3) Removing arm cylinder head pin (D)
Fig. 32-21 Removing arm cylinder
Loosen nut (3), remove capscrew M16× 150 (2)
and pull out pin (D).
: 24mm
32-11
32. ATTACHMENT
: 27,32,36,41mm C3
C2
C3
Fig. 32-22 Removing and installing boom cylinder
2) Removing boom cylinder foot pin (B) After adjustment of shim,
the total gap should be within Apply grease
(See Fig. 32-23,Fig. 32-24) 0.6~1.0mm (0.02~0.04in). to inner wall
Loosen nut (5), remove capscrews M16× 150 (3) SHIM of bushing
and pull out pin (B). 3
B
B
: 24mm
32-12
32. ATTACHMENT
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigidity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the force of the tightening torques of the cylinder head and the
piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficient.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Air source
Used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan
An oil pan is necessary to contain oil drained from the cylinder.
(8) Other
Oil extracting hoses, wooden blocks, clean cloths and oil dry.
32-13
32. ATTACHMENT
• For the details of special tools and jigs, refer to the back pages of this manual.
AIR
OIL PAN
Fig. 32-26 Preparation
32-14
32. ATTACHMENT
25 24 12 24 25
PS1/8
PT1/4
SLIT 15
ONE HOLE
DETAIL 6 DETAIL B
DETAIL C
Piston with piston nut type
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23
SLIT
C
No. Parts name Q’ty No. Parts name Q’ty No. Parts name Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1
3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew ; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 2
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2
Note : In case of piston with piston nut type, the parts with * are not used.
32-15
32. ATTACHMENT
32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in Fig. 32-27.
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.
(2) Pull out piston rod (2) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (12) of the rod
cover in sequence.
Fig. 32-28
Cover the extended piston rod (2) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 12
Turn counterclockwise
3
Cover here with cloths
2
Fig. 32-29
32-16
32. ATTACHMENT
• At this time, the weight of piston rod (2) is loaded KNOCK THIS EDGE
on rod cover (3). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.
3
2
Fig. 32-30 Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
The piston rod assembly is heavy. Lift the end of the HORIZONTALLY
piston rod (2) with a hoist to remove. When the piston
rod (2) has been removed approximately two thirds of
its length, lift the center of the rod and complete the re- OIL PAN
moval.
Fig. 32-31 Method of drawing out the piston rod
NOTE: When lifting the plated surface of piston rod (2),
assy
do not use wire which may score the surface. Use a
strong cloth or nylon sling.
19
18
32-17
32. ATTACHMENT
WOODEN V-BLOCK
(PLACE CLOTHS)
21
23
TURN COUNTER
• Since the piston nut (21) is tightened to a high
CLOCKWISE.
torque, use a box wrench suitable for the outside 15
diameter of piston nut (21). EYE WRENCH
21
• In case the piston and piston nut are combined,
Fig. 32-36 How to loosen piston nut (21)
apply the box wrench tothe hexagonal part of
piston to loosen the piston.
32-18
32. ATTACHMENT
Take care so the rod bushing (4) and the lip of seals
(6,7,8,9) are not damaged by the thread on the piston
3 4 6 8,7 9 2
rod (2).
Fig. 32-38 Removing rod cover (3)
Cut the seal ring (16) by tapping it with a screwdriver or SCREWDRIVER (OR CHISEL)
a chisel. Be careful not to damage the seal ring groove.
BACK-UP RING SEAL
17 RING
16
32-19
32. ATTACHMENT
10
11
6
Be careful not to damage the grooves.
WOOD PIECE
WOOD PIECE
VISE
BUSHING 4
BLOCK TOOL C
32-20
32. ATTACHMENT
24 BASE
Fig. 32-44 Drawing out pin bushing (24)
32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.
(2) Do not reuse the used oil seal, O-ring, back-up ring
even if they are not damaged after inspection.
(3) After cleaning, dry all parts with compressed air.
32-21
32. ATTACHMENT
16 O-RING
Heat the rings to make them pliable. Never heat the
rings over 100°C (212.0°F) or more.
17
(2) Install the back-up ring (17) on the remaining side.
After installing, compress it immediately to prevent Fig. 32-46 How to fit seal ring (16)
expansion of the seal ring (16) with correcting jig
PRESS HERE
(H) as shown in Fig. 32-47. 16 17
CORRECTIONAL
JIG (H)
• When installing the piston, stop installation (for 3 to
5 seconds), and then push it in fully.
• After fitting, wind tape around seal ring (16) 2 or 3
times, and remove it immediately before piston (15)
is inserted in cylinder tube (1).
• Install slide rings (18) (19) at the same time when
piston (15) is inserted in cylinder tube (1).
Fig. 32-47 Installing seal ring (16)
(2) Apply grease to wiper ring (9), and install the wiper PRESS HERE. (STRAIGHT DOWN)
ring (9), with the lip side toward the groove of the
retainer tool (D). Set the retainer tool (D) on rod RETAINER TOOL (D)
cover (3) and install wiper ring (9) with press.
U-RING GROOVE
32-22
32. ATTACHMENT
(3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in INSERT U-RING INTO GROOVE FROM THIS SIDE.
their grooves in that order. Before setting packings,
coat them with hydraulic oil (or vaseline if not
available). If you forget the coating, the packings
may be scored. When attaching seals, deform them
in a heart shape as illustrated.
7
8
9
Fig. 32-50 How to fit U-ring (7)
(2) Install rod cover (3) on the piston rod (2) with
inserting guide jig (I) as shown in Fig. 32-51. Be 2
sure the lip section of U-ring is not caught on the
stepped section.
Fig. 32-51 Inserting rod cover (3)
32-23
32. ATTACHMENT
FLAT SECTION
32-24
32. ATTACHMENT
(4) Put steel ball (23) into the bore and tighten
setscrew (22).
: 6mm
After tightening the setscrew to the specified
torque, caulk the two places of the thread of the 21 V-BLOCK
piston nut side to secure the setscrew.
Fig. 32-56 Attaching slide ring (18), (19)
See para 32.2.1.7.3 for torque.
(5) Attach two slide rings (18) and (19). Take off vinyl
tape wound around the perimeter of piston (15),
apply high-quality grease (or vaseline) to slide ring
(18), (19) and attach the slide rings in a manner that
they may be coiled around the groove. Set the slide
rings about 180 degrees apart with each other so
that the slits may not point to the same direction.
32-25
32. ATTACHMENT
: 14 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-58 Tightening socket bolts (12)
32-26
32. ATTACHMENT
32-27
32. ATTACHMENT
1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone.
If the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
32-28
32. ATTACHMENT
32-29
32. ATTACHMENT
32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Back-up ring 1. Foreign matter is trapped in the 1. Remove foreign matter.
surface of piston rod. Oil bore of back-up ring
ring is formed on piston 2. Lips on outer and inner diameter 2. Replace back-up ring.
rod, and the ring grows up surfaces of back-up ring are
to oil drops, and they drip. scored.
3. Other back-up ring are failed. 3. Replace back-up ring
2. U-ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
OIL LEAKS FROM HERE bore of ring.
2. Score is present on the bore of ring. 2. Replace U-ring.
3. Other rings are failed. 3. Replace U-ring.
3. Buffer ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of ring.
2. Score is present on the bore of ring. 2. Replace buffer ring.
3. Other rings are failed. 3. Replace buffer ring.
4. Wiper ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of wiper ring.
2. Lip on the bore of wiper ring is 2. Replace wiper ring.
scored.
3. Another wiper ring is failed. 3. Replace wiper ring.
5. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.
3. Oil leaks from welds. 1. Cylinder tube 1. Welds of cylinder are broken. 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the 2. Score is present on the sliding
2. Replace seal ring..
maximum working pressure surface of seal ring.
multiplied by the area of the 1. Sliding surface of slide rings is
2. Slide ring 1. Replace slide ring.
cylinder bore, the maximum scored.
movement of the piston is 3. Piston rod 1. Elongation.Piston rod and piston 1. Replace piston rod.
more than 0.5mm (0.02") in are elongated. (Loose nut)
ten minutes.]
32-30
32. ATTACHMENT
D
For press fitting wiper
32.2.1.5.2
ring
E H
F
I
For inserting rod cover 32.2.1.5.4
32-31
32. ATTACHMENT
32-32
32. ATTACHMENT
12-S
d D Cylinder Used
5
C2 R2 R0.2 80 94 Bucket
10 12-S
85 94 Arm
25-S 85 99 Boom
oD -0.2
-0.4
oD -0.5
oD -3-4
-1
Unit : mm (inch)
B Cylinder Used
110 Arm
95 Boom
95 Bucket
32-33
32. ATTACHMENT
4 5 (0.197") )
(CHUCK)
32-34
32. ATTACHMENT
CHUCKING JIG A
32-35
32. ATTACHMENT
oD
15 (0.59") 15 (0.59")
od 10
10
Unit : mm (inch)
Class
(Nominal size) d D h
o55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
o60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15)
o65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
o70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
o75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
o80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
o85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)
o90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
o95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
C
o100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
o105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
o110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
o115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
o130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)
6) Removal of bushing
a. Move block (C) and rod cover (3) with tool
under the press.
b. Press the upper part of retainer tool (D) slowly
until bushing (4) is take out from rod cover (3)
D
(until there is a sound that the chuck tool (A)
drops on the work bench)
• The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32~52mm
(1.26in~2.04in). (But it varies according to the
difference of dimension of cylinder head.)
32-36
32. ATTACHMENT
4
Do not work under the press because it is very
dangerous.
A
8) Removal of bushing
a. Place chuck tool (A) with bushing (4)
sideways, and loosen adjuster bolt with allen
wrench and lever.
b. Place the chuck tool (A) vertically and turn the
adjuster by hand until the wedge is raised
about 5mm (0.2 in).
c. Remove the wedge from the edge of chuck.
32-37
32. ATTACHMENT
32-38
32. ATTACHMENT
32-39
32. ATTACHMENT
CHUCK(A)
BUSHING(4)
BUSHING PRESS-
FITTING PART
32-40
32. ATTACHMENT
LIFTING THREAD
ADJUSTER BOLT
WEDGE
CHUCK
32-41
32. ATTACHMENT
[MEMO]
32-42
33. UPPER STRUCTURE
TABLE OF CONTENTS
33-1
33. UPPER STRUCTURE
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.
33-2
33. UPPER STRUCTURE
33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
A1-1
seat (A1) to ease handling.
2) Move the whole control stand to its foremost A1
position.
3) Move the operator’s seat to its forward end. C1
4) Incline the reclining seat as forward as possible.
C2
(2) Remove operator’s seat. (Include upper rail.) B2
C1
1) With the above-mentioned condition, remove C2
two cap screws (B2) M8× 20 from the upper rail.
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8× 20.
1
: 6 mm
2) Remove the operator’s seat. [about 20kg (44 8
lbs).]
Carry out the following operations as required.
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (8).
33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
# & $%
$% '#($ &'
!"# $& )(# %($
33-3
33. UPPER STRUCTURE
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6× 16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6× 25 and 1 sems bolt (A39) M6× 16. And right A3
A14
panels (A4) and (A4-2) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-8) of inside on right A40
A4-8
panel (A4-2). And free the harnesses connected A29
A4
to key switch. A4-8 A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-8
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-2
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-2). (See Chapter 23)
6) Loosen sems bolts (A22) M6× 16 and (A23)
M6× 40 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2
A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-2), (A3) and (A5-2)
33-4
33. UPPER STRUCTURE
RELAY BOX
ASSY
33.1.2.2 INSTALLATION
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
33-5
33. UPPER STRUCTURE
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Opening left panel assembly (21):
1) Unlock with starter key.
2) Open left panel assembly (21).
3) Support it with stay.
: 17 mm
(3) Remove battery cable
1) Remove cable (A4) [between the earth and 21
battery (–)].
Fig. 33-8
(Always remove (-) terminal first and install it at
last.)
2) Cable (A3) [between battery (+) and (-)]
3) Cable (A2) [between battery (+) and battery
relay]
: 13 mm
: 17 mm
2) Remove plate (3).
3) Remove battery (B1).
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (3) against battery (B1), and
tighten capscrew (4).
: 17 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (A4) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
33-6
33. UPPER STRUCTURE
33.1.4 GUARD
11
23
4
21
Fig. 33-10 Arrangement of guard assy
: 19 mm
Weight : 37kg (82 lbs)
7
7
Fig. 33-11 Removing bonnet assy (11)
(2) Remove guard (5) 41b
1) Remove 4 sems bolts (41a) M12× 25 on upper
41a
side.
5
2) Remove 3 sems bolts (41b) M12× 25 on the side.
3) Remove guard (5)
41a
: 19 mm
Weight :10kg (22 lbs) C
33-7
33. UPPER STRUCTURE
: 19 mm
43
: 17 mm 4
Weight : 15kg (33 lbs)
33-8
33. UPPER STRUCTURE
: 17 mm
Weight : 10kg (22 lbs)
: 17 mm
Weight : 15kg (33 lbs)
41
15
: 19 mm 42
33-9
33. UPPER STRUCTURE
: 19 mm
Weight : 8kg (18 lbs) 4
10
12
33-10
33. UPPER STRUCTURE
: 19 mm 6
: 19 mm
Weight : 15kg (33 lbs) B
41
41
20
41
33-11
33. UPPER STRUCTURE
: 19 mm
Weight : 30kg
41
1-2
(20)Remove other brackets, as required.
33.1.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
33-12
33. UPPER STRUCTURE
33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8)
1) Remove attaching sems bolts (9) M12× 30 and (10) M12× 25.
2) Remove covers.
: 19 mm
8
1
4
10
9
2
9
9 3 9
10 7
5
9
6
33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,8)
: 19 mm
Tightening torque : 79.4 N•m (60 lbf•ft)
33-13
33. UPPER STRUCTURE
6
3
33.1.6.2 REMOVAL
(1) Remove 4 capscrews (A1) M16× 40.
B2
: 24 mm
(2) Install a suitable lifting strap to the lifting eye on the
A4
fuel tank assy (C1) and remove the fuel tank.
C1
Weight : 110kg (243 lbs) A6
(3) Remove shim (A3).
A3
A1
A8
33-14
33. UPPER STRUCTURE
33.1.6.3 INSTALLATION
(1) Installation is done in the reverse order of removal.
Tank attaching bolt (A1) M16× 40
Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 4 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Cock 1 34 (25)
33-15
33. UPPER STRUCTURE
: 17 mm C3
: 17 mm B
2) Remove cover (C3). B2
3) Remove filter element (B6). C
D
(5) Turn the handle of element assy (B), and B6 Air
breather
disassemble the removed filter element (B6). D
Disassemble parts : (B), (C), (D)× 2, (E), (F)
E
(6) Draining hydraulic oil
F Hyd.tank
Place pump in tank and draw up hydraulic oil.
Capacity of tank : 146 L (39gal)
33-16
33. UPPER STRUCTURE
33.1.7.2 REMOVAL
(1) Removal of suction hose (A3)
Remove 2 clips (A19) of the tank side and pull out
hose (A3).
2 : Flat-blade screwdriver
A19
At installing suction hose, A3
apply PERMATEX to the
inner end of both hoses. A12
9
: 17 mm 6
S/M
(3) Remove drain hose (6) of pump Dr
: 36 mm
C/V
T2 15
H/P
(4) Remove drain hose (9) of swing motor 3 Dr
: 22 mm
A1
: 22 mm
33-17
33. UPPER STRUCTURE
: 24 mm
A1
Fig. 33-37 Removing hydraulic tank
Record the shim locations.
33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installation is done in the reverse order of removal.
(4) Install 4 mounting capscrews (A1) M16× 40 with
Loctite #262. (See Fig. 33-37.)
33-18
33. UPPER STRUCTURE
B2 SUCTION
1. Two elements (D) are used as one set. STRAINER
YW50V00004F7
2. Replace O-ring (C) and packing (F) with new ones F
respectively. ELEMENT KIT
(B-100)
(7) Install return element. (See Fig. 33-32) YN52V01008R100
(8) Installing suction strainer (B2)
(9) Tighten sems bolts (C5) M10× 25 that attach tank
covers (C2), (C3). Fig. 33-38 Element & suction strainer
M10 Tightening torque : 46.1 N•m (34 lbf•ft)
33-19
33. UPPER STRUCTURE
Hyd.tank
16 15
Fig. 33-40 Removing guards
33-20
33. UPPER STRUCTURE
33.1.8.2 REMOVAL
(1) Loosen sems bolts (13) M12× 40 and remove half A13
clamp (A10). And disconnect 2 hoses (A1), (A2) A1
from the delivery side. A10
A13 A2
: 17 mm A10
(2) Remove pilot pump suction hose (1) C/V
P2 6
(See Fig. 33-42) A13
A2 A4
A10
: 36 mm
A1
(3) Remove suction hose (A3) and drain hose (6) A13 Dr
a2
1) Remove 4 capscrews (B2) M12× 30. A10
a1
C/V
: 10 mm P1
A3
2) Remove elbow (B1) of suction hose (A3) from PH2
PH1
pump.
3) Remove drain hose (6) (Dr).
B1
: 36 mm
B2
Fig. 33-41 Removing hoses
(4) Removing other hoses
2 A3
1) Disconnect hoses of the following ports. Dr3
3
B3
Psv2
Psv1
B1 A11
1 SOL/V
P1
33-21
33. UPPER STRUCTURE
PSV-P2:
Engine P2 pump
side proportional
valve
CLIP
SE-22: Using Zip-tie, clamp
Pressure sensor : the corrugated part of
P1 pump harness to the solenoid.
CLIP SE-23:
Using Zip-tie, clamp the corrugated Pressure sensor :
part of harness to the pressure sensor. P2 pump
: 17 mm
2) Draw out the power take-off assy from the 5
flywheel housing slowly, adjusting the tension of
the lifting strap.
Once the assembly is removed, make sure 2-5
insert NA (2-3) remains on the flywheel side. 2-4
3) Remove element (2-1) from the tip of the spline
4
shaft.
4) Remove 4 capscrews (2-5) M16× 45 that fasten 2-7
insert R (2-4) and remove insert R (2-4).
2-2 1
: 14 mm
2-5
5) Remove hub (2-2)
Loosen the 2 set screws (2-7) M16× 18. Remove 2-3
2-8 2-1
the hub from the splined shaft of the pump.
Fig. 33-44 Removing pump
: 8 mm
6) Remove 4 capscrews (2-5) M16× 45 that fasten
the insert NA (2-3) with the engine side flywheel,
as necessary. Then remove and spring pin (2-8)
from insert NA (2-3).
: 14 mm
7) Removing bracket (1)
Loosen 4 capscrews (3) M20× 55, and remove
bracket (1) from pump (0).
33-22
33. UPPER STRUCTURE
33.1.8.3 INSTALLATION
Installation is done in the reverse order of removal.
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install
bracket temporarily.
: 17 mm
Tightening torque : 431 N•m (318lbf•ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 3mm
(0.12in) from the end face of the spline (See Fig.
33-45 Detail aa). Then install two set screws (2-7)
and fix them together.
: 8 mm
Tightening torque : 110 N•m (81 lbf•ft)
(3) Installing insert R (2-4)
Install insert R (2-4) into hub (2-2) by means of
capscrews (2-5).
: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)
(4) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (2-4).
(5) Installing insert NA (2-3)
Put spring pin (2-8) into insert NA (2-3) and install it
to the engine flywheel by means of capscrews (2-
5).
: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)
33-23
33. UPPER STRUCTURE
Fig. 33-46 Bleed air port (Dr) in pump
33-24
33. UPPER STRUCTURE
33.1.9.2 REMOVAL
(1) Pulling out hose (3).
1) Loosen clips (5), (6) on both sides of hose (3).
2) Pulling out hose (3)
: Flat-blade screw driver
(2) Remove air cleaner assy (1) AA
: 17 mm
2) Remove air cleaner assy (1) from plate (15).
7
15
33.1.9.3 INSTALLATION
(1) Installation in the reverse order of removal with
Replacing parts
attention paid to the following items:
1) Put in air hoses (3), (4) to the end as shown in Fig.
33-48.
2) Tightening torque :
O RING (1-6)
No. Name Tightening torque N.m (lbf.ft) (YN11P00029S006)
1-8 Indicator 3.9 (2.9) FILTER ELEMENT (1-3)
(GG11P00008S002)
8 Sems bolt 39.2 (29) (Apply Loctite #262)
5,6,7 Clip 5.9 (4.4) FILTER ELEMENT (1-2)
(LO11P00023S002)
33-25
33. UPPER STRUCTURE
33.1.10 MUFFLER
33.1.10.2 REMOVAL
(1) Remove U bolt (5).
1 5
1) Remove 4 nuts (10) M8.
: 13 mm
2) Remove 2 U bolts (5).
9
(2) Remove clamp assy (4)
4
1) Remove 2 capscrews (9) M10× 35
: 17 mm A
11 3 8
2) Separate clamp assy (5) from muffler (1). 10
10
(3) Removing other parts
Remove bracket (3) as necessary.
A
: 19 mm
B
C
A
Procedure of
fastening U bolt Installing clamp side (4)
33-26
33. UPPER STRUCTURE
33.1.10.3 INSTALLATION
Installation is the reverse order of removal with
attention paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-50)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (5)
1) Place the end of clamp (5) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-50)
2) Install the hardware as shown in Fig. 33-50.
(3) Tightening torque
1) Tighten the clamp nuts to a torque of 68.6 to 98
Nm (51 to 72 lb ft)
(2) If the muffler mounting bracket (3) was re-
moved. Apply Loctite 262 to the sems bolt (8)
threads. Install and tighten the bolts to a torque
of 68.6 to 98 Nm (51 to 72 lb ft
(4) Replacement parts
Muffler (1).....................................P/N YN1200040P1
33-27
33. UPPER STRUCTURE
33.1.11 COUNTERWEIGHT
: 55 mm
33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily A3
Hook proper lifting equipment to slinging jig. Lift it
and stretch equipment to a point were there is no
slack.
Weight of counterweight ;
Approx. 4,640kg (10,230 lb)
(2)Removing counterweight C1
1) Remove 4 capscrews (A1) M27× 355.
: 41 mm A4
2) Remove shim (A4), (A5), (A6). (Select) A5
A6
3) Remove counterweight (C1).
A2
A1
33.1.11.3 INSTALLATION
(1) Install counterweight in the reverse order of A3
removal.
(2) Install shim (A4), (A5), (A6) as it was. (select)
(3) Slinging counterweight
Check that the attaching bolts can be screwed in by
hand.
(4) Apply Loctite #262 on capscrews (A1), and tighten A4,A5,A6
them with washers (A2).
: 41 mm
Tightening torque : 1270 N•m (940 lbf•ft)
(5) Remove slinging tools, and attach plugs (A3).
A1,A2
Fig. 33-53 Fastening the counterweight attaching
capscrew
33-28
33. UPPER STRUCTURE
: 19 mm
(7) Draining radiator:
Place a suitable CLEAN container under drain
valve hose.
[Water capacity of radiator : 7.9 L (2.1 gal)]
(8) Remove hose from radiator sub tank (1)
Remove clip of radiator cap side and disconnect
hose (8).
: 13 mm, 17 mm
2) Move the air conditioner condenser and receiver
tank assembly.
(10 Disconnect connector for coolant level switch (B5).
(See Fig. 33-57)
33-29
33. UPPER STRUCTURE
33.1.12.2 REMOVAL
(1) Remove radiator stay (A1).
B10
1) Remove a sems bolt (A2) M12× 35 and 3 sems
bolts (A3) M12× 30.
: 19 mm
2) Remove 2 stays (A1). B5
A3
B9
(2) Remove water hose (2),(3) A1
B1
1) Loosen the hose bands for water hose (2).
A
: Flat-blade screwdriver
2) Remove hose (2). A2
A3 A3
3) Loosen hose bands on water hose (3).
A1
: Flat-blade screwdriver
4) Remove hose (3).
A2 B
: 13 mm
2) Loosen sems bolt (21) M10× 20 from retaining
plate.
: 17 mm
3) Loosen hose bands and remove hoses (4 and 5). 4
: Flat-blade screwdriver
: 13 mm
33-30
33. UPPER STRUCTURE
and (2). 2
(6) Remove radiator assy. (See Fig. 33-57)
13
1) Remove 4 sems bolts M12× 35. 16 A2
IN
: 19 mm 15
: 19 mm
Fig. 33-59 Removing hydraulic oil hose (1), (2)
2) When lifting the engine fan, shift the radiator so
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc.
4) Removing radiator
Place a proper lifting strap in the lifting eyes of
the radiator assembly and remove.
Weight : 92kg (203 lbs)
33-31
33. UPPER STRUCTURE
33.1.12.3 INSTALLATION
(1) Installation is done in the reverse order of removal.
All removed hose clips should be clamped at their
original position.
(2) Install radiator assy
Place a proper lifting strap in the lifting eyes of the
radiator and move it to its original position. Install
hydraulic, radiator and inter-cooler hoses, inserting
hoses to their proper depth. (See Fig. 33-60) Apply
4
Permatex #980 on to the radiator hose pipes aprox-
imately 15 mm all around behind the pipe flange.
DO NOT use on the intercooler hoses.
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A2) M12× 35. 5
: 19 mm 2
Tightening torque : 121 N•m (89 lbf•ft)
3
(4) Adjust the clearance between the fan and the
radiator shroud around the circumference, as
shown below :
Circumferential direction: Fig. 33-60 Inserting width of hose
20±5mm (0.8in±0.2in)
Adjust the engine fan
39±5mm (1.5in±0.2in) so the rear is out
39mm (1.5 in) from
(5) Remove any damaged insulation. Thoroughly the radiator shroud.
clean mounting surface and install new insulation.
(6) Adding hydraulic oil and LLC (Long Life Coolant):
After completion of other installation, add hydraulic
oil and water as needed.
33-32
33. UPPER STRUCTURE
(2) Disassembly
1) Remove the 2 bolts for retaining plates (3 and 4).
Remove the remaining shroud retaining bolts.
2) Disconnect wiring connector of radiator coolant
level switch.
3) Loosen 4 sems bolts (7) M8× 20 attaching plate
assy (2), remove plate assy (2).
4) Loosen 2 capscrews (10) M10× 30 attaching
radiator core.
5) After confirming that the coolant has been
drained out completely, loosen and remove only
the radiator side of hose bands at the top and INTER
OIL
COOLER
RADIATOR
bottom of the radiator. (See Fig. 33-58)
COOLER
33-33
33. UPPER STRUCTURE
(3) Installing
Installing is done in the reverse order of removing.
33-34
33. UPPER STRUCTURE
33.1.13 ENGINE
33-35
33. UPPER STRUCTURE
33.1.13.2 REMOVAL
22
20
: 17 mm, 41 mm
(2) Remove engine mounting bolts
1) Remove the 4 nuts (10) M18 and 4 washers (11).
: 27 mm
2) Loosen 4 capscrews (9) M18× 150.
3) Remove 4 plates (8).
4) Remove upper rubber mounts (6) and (7) 2 each.
(3) Preparing engine assembly for lifting:
Prepare a mounting stand, which will firmly hold the weight of the engine assy.
1) Place a proper lifting device to the lifting lugs on the front and rear sides.
Weight: Approx. 550 kg (1,212 lbs)
Wire: ø6 (0.236")× 1m (3ft 3in) - 2pcs.
(4) Position engine on the mounting stand.
33-36
33. UPPER STRUCTURE
33.1.13.3 INSTALLATION
Installation is done in the reverse order of removal.
Be sure to install the mounting brackets in the location from where they were removed.
(1)Tightening torque
Tightening torque
No. Name Remarks
Nm (lb ft)
33-37
33. UPPER STRUCTURE
33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) While pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
: Flat-blade screwdriver
2) Loosen 3 sems bolts (16) M6× 15.
: Plus screw driver
3) While lifting right upper console cover (3A) up;
disconnect connector of tuner and antenna.
Move boot (3) upwards and remove console
cover (3A).
• Removing of boot and lever is unnecessary. Fig. 33-65 Removing plate (4)
4) Loosen 3 sems bolts (16A) M6× 15 and remove 16
lower console (4). 3A
: Plus screw driver 16
(2) Removing left-hand console cover 16A
16B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 5 16B 4 16A
65) 16B
: Flat-blade screwdriver
16C
2) Loosen 2 sems bolts (A6) M8× 20 and remove
left armrest assy.
6
: 13 mm
3) Loosen 4 sems bolts (16B) M6× 15.
: Plus screw driver
4) Remove the left upper console cover (5) in the
same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M6× 15 while lifting
left under console cover (6) up, and remove left Fig. 33-66 Removing console covers
lower console cover.
33.1.14.2 INSTALLATION
Install in reverse order of removing according to the
tightening torque table.
33-38
33. UPPER STRUCTURE
Tightening torque
Mark each hose with a port name before removing it. 284N.m(209 lbf.ft)
4 Tightening torque
235N.m (173 lbf.ft)
33.1.15.2 REMOVAL
(1) Remove 3 capscrews (4) M16× 45, and remove
control valve (1) by hoist.
: 24 mm
Weight :Approx. 232kg (512 lbs)
33.1.5.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 3 capscrews (4) M16× 45.
: 24 mm
Tightening torque : 235 N•m (173 lbf•ft)
2)
Connector / Bolt Hose nut
Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
Pss,PLc2,PBp1,PBp2,PL,
PF1/4 PB1,PTb,PCa,PCb,PCc 19 36 (27) 19 29 (21)
ORS Joint
PAa1,PBa1,Pab,PBb,Pac,
PBc,PAL,PBL,Par,PBr,Pas,
PF3/8 PBs,PAa2,PBa2,Pao,Pbo,DR 22 74 (55) 22 49 (36)
PF3/4 MU 36 162 (119) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 14 42.4 (31)
M10 Ab,Bb Sems bolt 14 57 (42)
P1,P2 17 62.2 (45)
M12 T1,T2 17 96 (70)
33-39
33. UPPER STRUCTURE
P1 P1 pump
P2 P2 pump
33-40
33. UPPER STRUCTURE
*
*
%&$ ) &$
'(& '(&
"
"
&* '(& $'+! '(&
#
#
!
$
" !
"
Fig. 33-73 Control valve ports (2/2)
33-41
33. UPPER STRUCTURE
33.1.16.2 REMOVAL
(1) Remove hoses from your side to far side in order.
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-74)
: 22 mm
(3) Turn and loosen lever (2-1) tightened in pilot valve,
and remove lever assy in a set. (See Fig. 33-74) )*+
$%
& '
!!&
) *
(4) Remove 4 capscrews (A14) M6× 25. (See Fig. 33- $& !!&
: 5 mm ,$- .).
(5) Remove pilot valve. )*+ ) *
(6) Plug hose ends. ! "
"
Plug PF1/4, PF3/8 (&
& '
#
/0 / ! "
"
Fig. 33-75 Pilot valve connector
33.1.16.3 INSTALLATION
Installation is in the reverse order of removal. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Swing (R)
Bucket (R)
(Blue)
(Red)
Swing (L)
(Gray)
33-42
33. UPPER STRUCTURE
A6
A7
A5
B1
A8
33.1.17.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and
SE-10 (A9) at the connector.
$
3 '( !45(
: 24 mm 16 %71) /$
(2) Attach tag, and discount connectors and hoses -
(A2), (A3), (A4), (A5) 0-12 %)
$ , 0. %)
: 19 mm (P port)
: 22 mm (T port, 1~4 port) /.
,
(3) Plug hose ends
0. %)
Plug PF1/4, PF3/8
!
(4) Remove 4 sems bolts (A8) M8× 20, and remove *+
*.
right and left pedals (A5), (A6).
*+
: 13 mm *
(5) Remove 4 sems bolts (A7) M10× 20 and remove
right and left lever (A1), (A2).
: 17 mm
(6) Remove 4 sems bolts (A11) M10× 30.
: 17 mm
$ !" ##
(7) Remove pilot valve lifting it upward.
(8) Plug all openings PF1/4.
%&' (!)
Fig. 33-78 Installing and Removing pilot valve
33-43
33. UPPER STRUCTURE
33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten.
Sems bolt (A11)
33-44
33. UPPER STRUCTURE
33.1.18.2 REMOVAL
(1) Remove hose. 8
S/J 9
1) Remove hose (7) from the connector in the E
: 27 mm
3) Remove hose (3) from the elbow of the PG port
(For swing parking brake) (See Fig. 33-80)
B
A
: 19 mm
4) Remove 2 hoses (A4), (A7) from the connectors
of the A, B port.
A7
: 36 mm
A4 C/V
Put in plugs PF3/4, PF1/2, and PF1/4 into the Bs C/V
As
removed ports.
2 2
1
PG
A17
A3
33-45
33. UPPER STRUCTURE
: 30 mm
1) Remove two plastic caps (2) M10 at the top of
the swing motor and install eye bolts.
: Flat-blade screwdriver
2) Place a proper lifting strap in the eye bolts and
remove the swing motor unit.
Weight of swing motor unit ;
Approx. 192kg (423 lbs) (Include reduction assy)
33.1.18.4 INSTALLATION
Install the swing motor unit in the reverse order of
Coat all the mounting surface of 1
disassembly, confirming the orientation of the swing the swing motor with Loctite #515
equivalent.
motor unit.
(1) Tighten 13 capscrews (1) M20× 55.
LEVEL GAUGE
Put sealing tape on the thread
portion of tube for level gauge.
Tightening torque 69.1 N.m (51 lbf.ft)
33-46
33. UPPER STRUCTURE
33.1.19.2 REMOVAL
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A24). (E port : PF1/2)
T : Tightening torque
of connector
A2 N.m (lbf.ft)
A4
SWIVEL JOINT
T=255
(188)
A13
T=255 (188) B2 T=36.3 (26.8)
A13
A3
A1
A24
T=108 (80)
T=108 (80)
A24
33-47
33. UPPER STRUCTURE
: 27 mm
Tightening torque : 78 N•m (58 lbf•ft) 8
2) Remove hoses (A8), (A5).
(A, C port : 1-3/16-12UN) A9
: 36 mm
Tightening torque : 177 N•m (130 lbf•ft)
3) Remove hoses (A9), (A6).
(B, D port : 1-3/16-12UN)
: 36 mm
Tightening torque : 177 N•m (130 lbf•ft)
4) Remove hose (A7).
A5
(Travel 2-speed change over port : PF1/4)
A8
: 19 mm
Tightening torque : 29 N•m (21 lbf•ft) A14
A7
: 36 mm
: 17 mm
2) Remove clip (B9). B4
: Flat-blade screwdriver
3) Remove seal (B4). Fig. 33-85 Removing seal (B4)
33-48
33. UPPER STRUCTURE
: 19 mm % &#
(See 11.7 SPECIAL TOOLS No.9 Plug)
# $
! "#
33.1.19.3 INSTALLATION
(1) Installation is done in the reverse order of removal.
Piping tightening torque
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
33-49
33. UPPER STRUCTURE
33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily
Insert two upper swing body lifting jigs and 2
counterweight fastening cap screws (A1) M27× 335
into the counterweight mounting holes from above.
Attach 2 chain blocks to the boom foot side and lift
the upper frame at four points.
Wire rope ;
ø16 (0.630")× 2.5m(8ft-2in), 2pcs.
ø16 (0.630")× 1.5m(4ft-11in), 2pcs
Chain block ; For 2,000kg (4,410 lbs) 2pcs.
Fig. 33-88 Matching mark on swing bearing and
(2) Making match marks on swing bearing
upper frame
Put match marks on the upper frame and swing
bearing.
(3) Removing upper frame attaching bolts
Remove 32 capscrews M20× 100 and a reamer bolt
(11) used to install swing bearing and upper frame.
: 30 mm
(4) Slinging upper frame
Sling according to Fig. 33-87, and remove upper
frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)
33-50
33. UPPER STRUCTURE
33.1.20.3 INSTALLATION
(1) Installation is done in the reverse order of removal. Apply Loctite #515 to the race surface
(2) Clean mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame:
Match marks and install it with a reamer bolt (11)
and a washer (12). Do not tighten at this time.
: 30 mm
Tightening torque : 392 N•m (290lbf•ft)
33-51
33. UPPER STRUCTURE
33-52
33. UPPER STRUCTURE
983 531
981 . 534
548 792
702
B 532
732 X
789 Z
535 W
886 Y
953 A
806
728
468
113
127
123
127
824 271
325 808
717
04 490 954 546901
251 312
725
401 407 490
C
124
727 886
314
717 D
141 546
157 E
156
151 153 885 727
. 886
152 467
B 725
211 466
214 406
212 261 D
774 E
710
F
A
116
724 710
717
313 326
124 F 414 05
111
C
885
Fig. 33-92 Structural exploded view of main pump
33-53
33. UPPER STRUCTURE
33-54
33. UPPER STRUCTURE
434
311
312
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
Fig. 33-93
33-55
33. UPPER STRUCTURE
: 19 mm, 36 mm
: 6 mm, 8 mm
: 6 mm
6) Remove socket bolt (401)
Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).
: 17 mm
33-56
33. UPPER STRUCTURE
33-57
33. UPPER STRUCTURE
33-58
33. UPPER STRUCTURE
33-59
33. UPPER STRUCTURE
33-60
33. UPPER STRUCTURE
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251).
251
111
: 6 mm $
Tightening torque : 29 N•m (22 lbf•ft)
"$
• Coat the oil seal in seal cover (F) with a thin
film of grease.
• Handle the oil seal with care so it is not dam-
aged.
312
• DO NOT reverse the suction and delivery
sides of the valve plate.
314
(313 :
Opposite Side)
33-61
33. UPPER STRUCTURE
: 17 mm
Tightening torque ; 430 N•m (320 lbf•ft)
: 6 mm,
Tightening torque ; 17 N•m (12.5 lbf•ft)
: 6 mm,
Tightening torque ; 29 N•m (21 lbf•ft)
Socket bolt (414) …… PTO Cover (326)
: 8 mm,
Tightening torque ; 57 N•m (42 lbf•ft)
: 19 mm, 36 mm
Tightening torque ; 36 N•m (27 lbf•ft)
Tightening torque ; 170 N•m (125 lbf•ft)
33-62
33. UPPER STRUCTURE
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.039 0.067
bore Replace piston or cylinder.
(0.0015 ) (0.0026 )
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.3
Replace piston shoe assy.
(0.004 ) (0.012 )
( )
Thickness of shoe 4.9 4.7
Replace piston shoe assy.
(t) (0.193 ) (0.185 )
Free height of cylinder spring 41.1 40.3
Replace cylinder spring.
(L) (1.618 ) (1.587 )
Combined height of retainer plate and
23.0 22.0 Replace a set of spherical bushing or
spherical bushing
(0.906 ) (0.866 ) retainer plate.
(H-h)
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
33-63
33. UPPER STRUCTURE
33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps unnecessarily, but look for
causes by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
2) Pump’s oil flow rate is extremely low and delivery pressure is not available.
33-64
33. UPPER STRUCTURE
33-65
33. UPPER STRUCTURE
33-66
33. UPPER STRUCTURE
33.2.1.2 REGULATOR
626
625
624
753
627
623
621 D 728
B 645
611
622 F
733 874 646
613
732 875 644
631 612
898 875
652
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 757
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F
A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755
641
33-67
33. UPPER STRUCTURE
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
33-68
33. UPPER STRUCTURE
: 5 mm
630 924
Fig. 33-113 Removing cover (C) (629)
33-69
33. UPPER STRUCTURE
: 5 mm
439
641
33-70
33. UPPER STRUCTURE
$"
$!&%#
$
Fig. 33-121 Removing feedback lever (611) [2]
33-71
33. UPPER STRUCTURE
"$$
$"
Fig. 33-123 Part of exploded view of regulator
33-72
33. UPPER STRUCTURE
• Make sure that the spool and the sleeve (652) SPOOL FEEDBACKLEVER (611)
move smoothly in the casing.
• Beware of the direction of the spool. Fig. 33-125 Direction of the spool (652)
• Start the pin in the feedback lever before in-
stalling.
• Make sure feedback lever is installed proper-
ly.
33-73
33. UPPER STRUCTURE
9) Installing return spring and the spring seat Fig. 33-129 Installing adjust plug (615)
(See Fig. 33-111 (A) section)
Assemble return spring (654) and spring seat
(653) into the spool hole and fit snap ring (814).
33-74
33. UPPER STRUCTURE
: 5 mm
Tightening torque ; 12 N•m (8.7 lbf•ft) $ $
Fig. 33-131 Assembling compensating parts
11) Installing spool and spring "$$
Assemble spool (642) and spring (662) into pilot
cover (641), and tighten VP plugs (466).
$$
$"
"$$
$"
Fig. 33-132 Assembling spool (642)
12) Assembling into the pilot hole and the 644,645,646
compensating hole 626
(See Fig. 33-111 (E),(D) section)
Put spring seat (644), pilot spring (646) and 625(624)
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.
: 5 mm 624,625,626
Tightening torque ; 12 N•m (8.7 lbf•ft) 627
801
14) Installing block cover (See Fig. 33-112) 629( 628 )
Attach block cover (656).
: 5 mm
630 924
Tightening torque ; 12 N•m (8.7 lbf•ft)
Fig. 33-134 Installing cover (C) (629)
This completes assembly.
33-75
33. UPPER STRUCTURE
414
117 128
216 435
826 886 711
326
128
414
115
886 262
728
885 125 468
118
125
825
710 435
435
414
262
414
33-76
33. UPPER STRUCTURE
: 27 mm
• Drain out the oil from the plugs of the front
pump and the rear pump.
4) Remove cover FLANGE SOCKET (M10)
Remove the socket bolts (414). Then remove the Tightening torque : 33N.m (25 lbf.ft)}
cover (262).
: 8 mm
5) Remove PTO gear casing 414
Remove flange socket (435) and PTO gear
casing.
: 8 mm
262 COVER
PTO GEAR CASING
414
262 COVER
Fig. 33-135 Removing gear pump
PTO
GEAR CASING
33-77
33. UPPER STRUCTURE
6) Removing the 2nd gear, the roller bearing and HOLE FOR
the bearing spacer IDLE SHAFT (115)
Draw out the spring pin (885) and remove idle
shaft (115). Then draw out 2nd gear (117), roller
bearing (126) and bearing spacer (128). 117 (126,128)
• Roller bearing (126) can not be separated
from 2nd gear (117).
118
33-78
33. UPPER STRUCTURE
J
154 164 101
P2
T2 T1
PAL PBL
YT1
J
PB1 PCa
YBG1
P2-20
PBs YS1
PAs
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974 973
PAa2 PBa2
YAG
1
974
(P3)
162 162 169 155 163 162
SECTION B-B
33-79
33. UPPER STRUCTURE
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PA
PAo
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
33-80
33. UPPER STRUCTURE
$!#-
Fig. 33-141 Section (3/6)
33-81
33. UPPER STRUCTURE
Swing
204
203 PBs
333 Boom 333
331 Pss
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb 162
Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
164 551
Bucket
209
PCc
216 201
333 Arm 1 333
PBa1
331 331
PBc
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR 205
SECTION F-F AaR 605
Fig. 33-142 Section (4/6)
33-82
33. UPPER STRUCTURE
!
Fig. 33-143 Section (5/6)
33-83
33. UPPER STRUCTURE
33-84
33. UPPER STRUCTURE
33-85
33. UPPER STRUCTURE
33.2.2.3 DISASSEMBLY
The figures in parentheses after part names in this
manual represent those item numbers in the structural
sectional drawing under Fig. 33-139 to Fig. 33-144.
(1) Place the control valve on a work bench so as to
locate back pressure check valve upwards.
33-86
33. UPPER STRUCTURE
33-87
33. UPPER STRUCTURE
33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove the
spring cover (201) and the O-ring (261) for travel.
33-88
33. UPPER STRUCTURE
33-89
33. UPPER STRUCTURE
33-90
33. UPPER STRUCTURE
33-91
33. UPPER STRUCTURE
33-92
33. UPPER STRUCTURE
(3) Secure the travel straight spool assy with vise via a
protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs
(327, 329) and stopper (336) from travel straight
spool (307).
33-93
33. UPPER STRUCTURE
(2) Swing
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264), (266). Do not disassemble
spool cover (206) further unless there is special
reason.
33-94
33. UPPER STRUCTURE
33.2.2.3.13 Removing relief valve and plug assy for relief valve port
(1) Remove the main relief valve (601) and overload
relief valve (602), (603) and (605) from the casing.
33-95
33. UPPER STRUCTURE
33-96
33. UPPER STRUCTURE
33-97
33. UPPER STRUCTURE
The plug and spring in use differ from the above (1). Do
not mix the parts when assembling parts again.
(3) Load check valve on arm 2 section Fig. 33-180 Removing plug (551),(556),(552)
Remove plug (551) and then remove poppet (515)
and spring (521).
The poppet in use differs from the above (1). Do not mix
the parts when assembling parts again.
33-98
33. UPPER STRUCTURE
Take care not leave lapping compound behind in the casing or block.
4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are
free from foreign matter.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.
33.2.2.4 REASSEMBLY
(1) Only the reassembly procedures are described. For drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural
sectional drawing. (Fig. 33-139 to Fig. 33-144)
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after
installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards."
33-99
33. UPPER STRUCTURE
Take care to prevent misassembly of parts and installation position because the parts in (1) to (5) are similar in
shape.
Do not drop poppet (606-201) and spring (606-202) when attaching by-pass cut valve.
33-100
33. UPPER STRUCTURE
33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (603), (605) and relief valve hole plug assembly (604) in
respective place to the specified torque.
During reassembly, check tag to prevent installation in the wrong port, because the port relief valves (602), (603)
are similar in shape.
Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Install spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten
socket bolt (273) to the specified torque.
(2) Place travel straight spool assembly in item (1) in casing B (102).
Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and
tighten socket bolt (273) to the specified torque.
33-101
33. UPPER STRUCTURE
Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten
socket bolt (273) to the specified torque.
(2) Place arm 2 spool assembly in option in item (1) in casing B (102).
Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
socket bolt (273) to the specified torque.
Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten
socket bolt (273) to the specified torque.
33-102
33. UPPER STRUCTURE
Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and tighten
socket bolt (273) to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.
Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Install spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and
tighten socket bolt (273) to the specified torque.
33-103
33. UPPER STRUCTURE
Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and
tighten socket bolt (273) to the specified torque.
(2) Place boom conflux spool assembly in item (1) in casing A (101).
Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Install spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and
tighten socket bolt (273) to the specified torque.
(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).
Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.
(3) Install spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
socket bolt (273) to the specified torque.
33-104
33. UPPER STRUCTURE
Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Install spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten
socket bolt (273) to the specified torque.
33-105
33. UPPER STRUCTURE
33-106
33. UPPER STRUCTURE
33.2.2.6 TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main
pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure,
load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and
reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system
is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
2. Machine does not 1) Malfunctioning travel straight valve. 1) Check pilot pressure.
move straight during • Sticking spool. • Correct sticking part with oil stone.
simultaneous
• Replace spring.
operation of travel
• Broken or deformed spring. • Remove foreign matter.
and attachment.
• Clogged small hole in spool.
2) Malfunctioning main relief valve. 2) Remove main relief valve.
33-107
33. UPPER STRUCTURE
33-108
33. UPPER STRUCTURE
33-109
33. UPPER STRUCTURE
312
302
Apply grease on
rotating and
501
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc
PORT PORT
2,4 1,3
Fig. 33-182 Pilot valve (For ATT)
Apply loctite #277 to areas marked
33-110
33. UPPER STRUCTURE
33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with clean-
ing solvent.. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Secure pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
302
33-111
33. UPPER STRUCTURE
: 24mm
301
33-112
33. UPPER STRUCTURE
211
Tag each assy and mark each port as they are re- 221
moved. Spring rates differ between ports 1-3 and 2-4.
The stroke differs according to direction.
101
217
201-1
201-2
212
211
33-113
33. UPPER STRUCTURE
212
213
33.2.3.4 ASSEMBLING
(1) Install washer 2 (217), springs (241-1), (241-2),
spring seats (216-1), (216-2) to spool (201-1), (201- 201-1 241-1 216-1
216-2
2).
201-2 241-2
217
33-114
33. UPPER STRUCTURE
221
214 213
PLUG (211)
SEAL (213)
-RING (214)
PUSH ROD
(212) Apply hydraulic oil
(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.
33-115
33. UPPER STRUCTURE
101 211
151
101
A
33-116
33. UPPER STRUCTURE
: 22mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 68.6 N•m (51 lbf•ft)
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Install boots. GREASE
301
212
33-117
33. UPPER STRUCTURE
33.2.3.6 TROUBLESHOOTING
Some times it is very difficult to find a defective section. The following table explains several probable causes. For
I
33-118
33. UPPER STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2) BUSHING
Material ; S45C
SECTION AA
A A
33-119
33. UPPER STRUCTURE
33.2.4.1 CONSTRUCTION
T=Tightening torgue
N.m (lbf.ft) 12-o
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3
g
14
q 11
T=5 (3.7) r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3~5 (2.2~3.7)
33-120
33. UPPER STRUCTURE
Fig. 33-208
(2) Switch plate removal
1) Remove :
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-209 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the
locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)
* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-209 No.3)
4) Mark out the position of the switch plate before
removing it.
Fig. 33-209
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.
33-121
33. UPPER STRUCTURE
Fig. 33-212
33-122
33. UPPER STRUCTURE
Fig. 33-213
(5) Damping plunger seals replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots. (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-214 No.1) Fig. 33-214
* Reassembly :
• Replace with a new wiper ring.
Always install the damping plunger prior to the wiper
ring, and make sure the wiper ring is correctly
positionned.
Fig. 33-215
4) Using a needle, remove the seal placed inside
the body (See Fig. 33-216 No.3, 4)
* Reassembly :
• Replace with a new seal and grease it.
3 4
Fig. 33-216
33-123
33. UPPER STRUCTURE
Hold the guides with the other hand during the removal
operation to limit the effect of the return spring.
Fig. 33-218
33-124
33. UPPER STRUCTURE
Fig. 33-219
• Inspect the return springs. If defects are
detected, replace the 4 springs.
Fig. 33-220
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))
Fig. 33-221
33-125
33. UPPER STRUCTURE
THROTTLE
Fig. 33-222
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
Fig. 33-224
33-126
33. UPPER STRUCTURE
Fig. 33-226
(9) Check valve kit removal
1) Remove the pilot control unit from the machine
CHECK VALVE
PLUG
BALL
Fig. 33-228
33-127
33. UPPER STRUCTURE
Fig. 33-229
33-128
33. UPPER STRUCTURE
33.2.5.1 CONSTRUCTION
(1) Swing motor
'(
!
! "
#$
%
#&&
%!
)
* #
+
$ $
&
$ & ### &# #
#
$
&
#
#
#%
#%
#
#
%
#
# ## #
33-129
33. UPPER STRUCTURE
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
177 (130) 051 Relief valve ; M33-P1.5 2 69 (51) 400 Anti-reaction valve ; M22-P1.5 2
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
100 Casing for anti-reaction valve 1 431 (320) 401 Socket bolt ; M20× 45 4
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 334 (250) 469 ROMH plug ; M30-P1.5 2
122 Shoe 9 472 O-ring 1
123 Set plate 1 488 O-ring ; 1B P28 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug ; PF1/4 2 706 O-ring 1
161 O-ring ; 1B P11 2 707 O-ring 1
162 O-ring ; 1B P12 2 712 Brake spring 16
163 O-ring ; 1B P6 2 742 Friction plate 3
29 (22) 171 Socket bolt ; M8× 55 4 743 Separator plate 4
301 Casing 1 0.9 (0.65) 980 Plug ; PF1/4 1
303 Valve casing 1 1.7 (1.2) 984 Plug ; PF3/8 1
351 Plunger 2 4.4 (3.3) 985 Plug ; PF3/4 3
355 Spring 2 65 (48) 993 Plug ; PT1/2 1
390 Name plate 1 98 (72) 994 Plug ; PT3/4 1
391 Rivet 2
33-130
33. UPPER STRUCTURE
Be careful about
installation direction
of retaining ring. Drive this spring pin
into 1mm lower than
the surface of spider.
33-131
33. UPPER STRUCTURE
33.2.5.2.1 Tools
Tools Remarks
Socket wrench Relief valve M33× P1.5 41mm
M8, M20 6,10,12,17mm
Allen wrench ROMH PLUG M30× P1.5 14mm
ROH PLUG PF1/4 6mm
Screwdriver Flat-bladed type, medium size 2 pcs.
10× 8× 200(0.39"× 0.31"× 7.87")
Steel bar
(key material) 1 pc.
Hammer Plastic hammer 1 pc.
10~45 (7.2~33)
Torque wrench N•m (lbf•ft) 40~180 (29~130)
120~480 (87~350)
Slide hammer bearing puller
14 (0.551")
85 (3.35")
75 (2.95")
30 (1.18")
15 (0.591")
35 (1.38") 5
2. 2")
R1 .49
M16 (0
Through
Brake piston drawing tool
100 (3.94")
44 (1.73")
8 (0.315")
M18
4
(0.158")
BRAKE PISTON
DRAWING TOOL
CASING
33-132
33. UPPER STRUCTURE
33.2.5.2.2 Disassembly
(1) General cautions:
1) Hydraulic components are precision products
and have small clearance. Therefore, assemble
and disassemble the components in a clean dust
free environment. Use clean tools and cleaning
oil. Handle components with care.
2) If a component is removed from the main body,
clean the area around the ports thoroughly and
plug them to prevent dust and water from
entering. When installing them back into the
body, do not remove the plugs untill piping is
completed.
3) Study the structural drawing before beginning
work. Prepare necessary parts according to your
purpose and the scope of work. Once seals and
O-rings are removed, they cannot be reused.
Some parts can not be supplied as single parts
and are available only as sub assy. Prepare such
parts according to the parts manual.
4) The piston and cylinder block are shop fitted
when new. If you intend to reuse them, place a
matching mark on the piston and the cylinder
block.
(2) Disassembly procedure
The figures in parentheses after part names in this
manual represent those item numbers in Fig. 33-
230
1) Draining oil
Remove the drain plug and drain hydraulic oil
from casing (301).
2) Preparation for removing the valve casing: #
Place the motor on a work bench so the drive
shaft (101) end faces down. Place a matching !! #
mark on the mating parts of casing (301) and
valve casing (303). %
%
• Choose a clean place, and lay a rubber sheet or
a cloth on a work bench. Handle the valve casing
with care to prevent damage.
!
Fig. 33-232 Removing valve casing (303)
33-133
33. UPPER STRUCTURE
: 41 mm
!##
!!
4) Loosen anti-reaction valve sub assy (052) and
remove from valve casing (303). (See Fig. 33-
232)
"$'
: 6 mm
: 17 mm
8) Place the claw of the brake piston removing jig in Fig. 33-234 Removing brake piston (702)
the concaved part of brake piston (702).
Tighten 2 bolts of jig simultaneously, and remove
!
the brake piston (702) with the jig, from the
casing.
33-134
33. UPPER STRUCTURE
443
c. Separate the outer race of roller bearing (444)
from valve casing (303), using a slide hammer
bearing puller.
Put the inner race
on the press bench.
33-135
33. UPPER STRUCTURE
33.2.5.2.3 Assembly
(1) General precautions:
1) Replace those parts found damaged during
disassembly and prepare replacement parts
beforehand.
2) Clean all parts thoroughly in cleaning solvent
and dry them with compressed air.
3) Always coat the moving parts with clean
hydraulic oil, before assembly.
4) Replace all seals and O-rings.
5) Tighten socket bolts and plugs to specified
torques, using a torque wrench.
""! "'
!
Fig. 33-239 Fitting oil seal (491), outer race of
roller bearing (443), and drive shaft (101)
33-136
33. UPPER STRUCTURE
Fig. 33-241 Inserting cylinder assy
9) Place casing (301) with oil seal (491) facing
downward. Install separator plate (743) and
friction plate (742) into casing (301), in that order.
Install four separator plates and three friction
plates..
Fig. 33-242 Installing of separator plate (743),
friction plate (742).
33-137
33. UPPER STRUCTURE
: 17 mm,
Tightening torque : 431 N•m (320 lbf•ft)
: 14 mm,
Tightening torque : 334 N•m (250 lbf•ft)
: 41 mm,
Tightening torque : 177 N•m (130 lbf•ft)
: 6 mm,
Tightening torque : 29 N•m (22 lbf•ft)
33-138
33. UPPER STRUCTURE
33.2.5.3.1 Tools
a Stand
230
o 162
Material : Mild steel
22
Spherical bearing (10) 13-o 16
190
b (Position
removing jig (I) space equally)
P.C.D 146
VIEW X
X
Spherical bearing (11)
c
removing jig (II)
Spherical bearing (10)
d
removing jig (I)
f
press-fit jig
g
Oil seal (12)
installing jig
33-139
33. UPPER STRUCTURE
33.2.5.3.2 Disassembly
The numbers in parentheses correspond to the ones in
construction drawings Fig. 33-230.
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain tube.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the joining parts of the housing
before disassembly.
33-140
33. UPPER STRUCTURE
33-141
33. UPPER STRUCTURE
JIG (a)
21
30
11
33-142
33. UPPER STRUCTURE
18
8 22
Pinions (5) can not be replaced singly. Replace them in
Fig. 33-253 Disassembling #2 spider assy
a set of four.
33-143
33. UPPER STRUCTURE
33.2.5.3.3 Assembly
(1) Preparation
1) Thoroughly clean every part with cleaning sol-
vent and dry with compressed air.
2) Check every part for signs of wear or failure.
30
33-144
33. UPPER STRUCTURE
!
Fig. 33-259
33-145
33. UPPER STRUCTURE
33-146
33. UPPER STRUCTURE
i
Install the snap ring with the sharp edge on the motor
side (top side in the position of Fig. 33-263).
28 3
17
Insert shaft (6) into spider (8) so spring pin hole (22) is
aligned. 5
18
8 22
Fig. 33-264 Assembling #2 spider assy
(5) Installing #2 spider assy
521,-4 )55;
Install #2 spider assy in spline axis of pinion shaft
(1).
33-147
33. UPPER STRUCTURE
13
: 12 mm
(10)Filling Lube Oil
Fill in 3.0L (0.8gal) of gear oil SAE90 (API Service Fig. 33-268 Installing #1 spider assy
Grade GL-4).
33-148
33. UPPER STRUCTURE
Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (in)
mm (in)
Clearance between piston and
cylinder bore
(D-d)
0.027 0.052
Replace piston or cylinder.
(0.00160) (0.00205)
@ ,
0.3
0 Replace piston and shoe assy.
(0.0112)
5.5 5.3
Replace piston and shoe assy.
J
(0.217) (0.209)
2.0 1.8
Replace.
J (0.0787) (0.0709)
33-149
33. UPPER STRUCTURE
33-150
33. UPPER STRUCTURE
2) Gears
a. Inspect that the gear teeth do not show pitting and/or excessive ware.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
3) Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing
33-151
33. UPPER STRUCTURE
G
A D
Unit : mm (in)
Code Item Repairable level Service Limit Remedy
A Wear in #1 planetary shaft ø39
0
1.53 -0.0004 Replace entire spider assy.
No flaking
B Wear in #2 planetary shaft ø29
0
0.0787 -0.0079 Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
D Thickness of thrust washer 1.6
0
0.063 -0.0079 1.3 0.0512 Replace
33-152
33. UPPER STRUCTURE
33.2.5.5 TROUBLESHOOTING
33-153
33. UPPER STRUCTURE
33-154
33. UPPER STRUCTURE
)(
"#
$
#
$% #
$
*(
!
33-155
33. UPPER STRUCTURE
2 places
VIEW Y
5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
33-156
33. UPPER STRUCTURE
33.2.6.2.1 Tools
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m× 1.5m (4ft× 5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33-157
33. UPPER STRUCTURE
33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure 2
correspond to those of a construction drawing in Fig. 1
33-270. 4
9
(1) Removing cover
1) Mark cover (4) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt
ALLEN WRENCH
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2) V-BLOCK PIPE
in a vise.
"
: 6 mm
33-158
33. UPPER STRUCTURE
Use care not to damage the body (1) when using the
spatula (f)
O-RING
GROOVE
OIL GROOVE
SEAL (5) SEAL GROOVE
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on
seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1) Apply a thin coat of hydraulic oil to O-ring (13)
and insert it in O-ring groove.
Check to make sure O-ring is not twisted
2) Install the backup ring. Slipper ring is installed,
by slightly-distorting the shape as shown in Fig.
33-277. After installing all of the seals, make sure
that they are fully installed in the seal groove with
the use of the spatula.
3) Assemble seal (5) by the same procedure above
mentioned.
33-159
33. UPPER STRUCTURE
WORK BENCH
: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)
: 6 mm, 4
Tightening torque : 30.4 N•m (22 lbf•ft)
ALLEN WRENCH
PIPE
33-160
33. UPPER STRUCTURE
33-161
33. UPPER STRUCTURE
Replace
(With back-up ring)
Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)
33-162
33. UPPER STRUCTURE
relief valve (5). While watching the pressure gauge
(for low pressure) connected to the body side and !
also by regulating low pressure relief valve (5),
" ! "
*
gradually increase the pressure and check for
+%,- .
/
outside leakage with a color check at a pressure of
0.49MPa (71psi). !
!
$ %
33.2.6.3.4 Troubleshooting
33-163
33. UPPER STRUCTURE
[MEMO]
33-164
34. TRAVEL SYSTEM
TABLE OF CONTENTS
34
34-1
34. TRAVEL SYSTEM
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
34-2
34. TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD LOWER FRAME
34.1.2 CRAWLER
: 19 mm
When using a big hammer, wear protective goggles
Fig. 34-3 Removing/fixing position of master pin
and a long-sleeved uniform so you do not injure
yourself by flying objects.
34-3
34. TRAVEL SYSTEM
34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the
figure on the right.
34-4
34. TRAVEL SYSTEM
: 19 mm
34.1.2.3 CONSTRUCTION
FLAT SHOE
2
1-6
1-1
1-8
1-4
1-3 TRIANGLE SHOE
1-8 2 RUBBER PAD SHOE 3
1-7 2
1-1
4 3
1-7 1-5 3
1-2 1-2
Fig. 34-9 Track link assy and shoe plate
SK210-8
Shoe assy
YN60D00055F2
YN60D00055F4
YN60D00055F5
No. NAME Q'TY
1 .LINK ASSY YN62D00017F3 1 1 1
1-1 ..TRACK LINK R 49 49 49
1-2 ..TRACK LINK L 49 49 49
1-3 ..BUSHING 48 48 48
1-4 ..PIN 48 48 48
1-5 ..MASTER BUSHING 1 1 1
1-6 ..MASTER PIN 1 1 1
1-7 ..COLLAR 2 2 2
1-8 ..SEAL 96 96 96
2 .SHOE 600mm 49 - -
.SHOE 700mm - 49 -
.SHOE 800mm - - 49
3 .BOLT 2420Z1292 196 196 196
4 .NUT 2420Z1293 196 196 196
34-5
34. TRAVEL SYSTEM
F E
D D G
B
Fig. 34-10
Unit : mm (in)
REPAIRAB SERVICE
No. ITEM STANDARD VALUE REMEDY
LE LEVEL LIMIT
A Link pitch 190 ± 0.1 (7.4803 ± 0.0039) 194 (7.64) 198 (7.80) Replace the link
B O.D. of bushing ø 58.78 (2.3142 ) ø 55 (2.17) ø 54 (2.13) assy if the service
C Height of link 106 ± 0.3 (4.1732 ± 0.0118) 100 (3.94) 98 (3.86) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.11
D Interference
and link ø 58.78 (+0.0043) Interference
Shaft 0.05
(2.3142) - 0.05 0
(0.0020) Replace
(-0.0020)
+ 0.1
Interference
Interference between track pin ø 36.63 (+0.0039) Interference
E Shaft 0.05
and link (1.4421) - 0.05 0
(0.0020)
(-0.0020)
- 0.03
Interference
Interference between master ø 36.50 (-0.00118) Interference
F Shaft 0.05 Replace Link
pin and link (1.43701) - 0.088 0
(0.0020)
(-0.00315)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 853 N•m (629 lbf•ft) Reassembly
Unit : mm (in)
NAME OPPOSING FLATS
30 (1.2)
Socket
(2) Jig
NAME SHAPE
34-6
34. TRAVEL SYSTEM
34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
3
4
(2) Removing upper roller (1)
1) Remove nuts on support tightening section, and
2
also remove capscrew (2) M20× 100.
1
: 30 mm
34.1.3.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING
end upward.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
2 1 3,4
34-7
34. TRAVEL SYSTEM
34.1.3.4 CONSTRUCTION
1 10 5 9
Fig. 34-13 Construction of upper roller
2) Removing snap ring (11)
Mount the end face inside upper roller (1) on
stand jig (f) and remove the snap ring (11).
B
3) Removing cover (5)
Remove the cover (5) lifting upwards utilizing the
threaded hole for the plug..
34-8
34. TRAVEL SYSTEM
!
B
Collar (3) is press fit into shaft (2). Do not remove the
collar.
1
(2) Assembly
Assembly of the upper roller is done in the reverse
order of disassembly.
f
1) Place upper roller (1) on the top end face of jig
(f), with its floating seal setting side facing down.
3) Put jig (i) into bushing (6) and press it in, using 2
the bore of the bushing and the bore of the roller
7
as guides.
7 1
3
If you fail in this operation by pressing the bushing
unevenly, the bushing will distort and is unserviceable.
Do not reuse the bushing. Do the assembly process
over using a new bushing.
Fig. 34-19 Fixing floating seal
34-9
34. TRAVEL SYSTEM
: 6mm,
Tightening torque : 23N•m (17 lbf•ft)
34-10
34. TRAVEL SYSTEM
C
A
E
F
D D
B
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. ø 140 (6.30) — —
B Width 150 (5.91) — —
Replace
C Tread dia. ø 120 (4.72) ø 107 (4.21) ø 105 (4.13)
D Tread width 33 (1.30) — —
Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 45 (1.772) Shaft
- 0.040 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.00157)
+ 0.030
Interference between Interference Clearance
F ø 50 (1.969) Hole (+0.00118)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 115 N•m (85 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 30cc (1.83cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
34-11
34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
30
Socket
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
120 (4.72)
90 (3.54)
160 (6.30)
f Stand jig
52.5(2.07)
For extruding
g
(0.709)
bushing
18
49(1.93)
For extruding
h
(1.18)
shaft
+0.1
+0.1
60(2.36)
49.5 0
44.6
Bushing fixing
i
1.756 +0.004
1.949 +0.004
jig (1.26)32
0
(1.46)37 50(1.97)
87(3.43)
34-12
34. TRAVEL SYSTEM
2 1 B2
Apply Loctite #262
T=397N.m (290 lbf.ft)
Fig. 34-23 Lower roller assy and track guide
34.1.4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame.
: 27mm,
Weight of track guide : Approx. 25kg (55 lbs)
ROLLER
LC
ITEM NAME Q'TY Fig. 34-25 Installing track guide
B2 TRACK GUIDE : YN63D00003P1 6
B5 CAPSCREW : M18X40(P=1.5) 24
: 27 mm,
Weight of lower roller : Approx. 33kg (73 lbs)
34-13
34. TRAVEL SYSTEM
34.1.4.3 INSTALLATION
(1) Installation of lower roller
Apply Loctite #262 to the mounting capscrews (2).
Install all the screws, then tighten to the specified
torque.
: 27 mm,
Tightening torque : 397N•m (290 lbf•ft)
(2) Installation of track guide
Apply Loctite #262 to the capscrews and install all
four capscrews. Tighten the cap screws to athe
specified torque.
: 27 mm,
Tightening torque : 397N•m (290 lbf•ft)
(3) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
: 19 mm,
Tightening torque : 59N•m (43 lbf•ft)
34-14
34. TRAVEL SYSTEM
34.1.4.4 CONSTRUCTION
" $ % #
LOWER ROLLER LC YF64D00001F1 &
: 6mm 2
JIG M
The shaft (3) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.
34-15
34. TRAVEL SYSTEM
JIG M
Hammer the inside surface of roller lightly so as not to
damage the surface. Put the extrusion jig (N) uniformly
over the circumference of bushing (4) and remove it a Fig. 34-32 Extruding bushing (4)
little at a time.
34-16
34. TRAVEL SYSTEM
(2) Installing % !
1) Install an O-ring (7) to groove on one side of the
shaft.
6 5
7 2
34-17
34. TRAVEL SYSTEM
PIN HOLE
• Apply grease to O-ring.
2
• Always replace O-ring with new one at
assembly. PIN HOLE
7
8) Press fitting collar (2)
Press-fit collar (2) to shaft (3).
3
• Press-fit collar (2) on aligning pin (5) hole.
: 6 mm,
Tightening torque : 23 N•m (17 lbf•ft) Fig. 34-39 Installing filling oil plug (8)
34-18
34. TRAVEL SYSTEM
+ +
*
-
)
0
Fig. 34-40 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange ø 185 (7.28) — — Reinforcement weld,
B Tread dia. ø 150 (5.91) ø 134 (5.28) ø 128 (5.04) repair or replace
C Flange width 23.5 (0.925) 18 (0.709) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 65 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft
(2.55905) - 0.090 0.7 (0.276) 1.0 (0.394) Replace bushing
(-0.00354)
+ 0.030
Interference between ø 69 (+0.00118) Interference Clearance
E Hole
roller and bushing (2.71653) - 0.020 0 0.01 (0.0004)
(-0.00079)
F Oil Engine oil API grade CD #30, 160cc (5.4) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
34-19
34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
19, 27
Socket
Allen wrench 6
(2) Jig
Unit : mm (in)
No. NAME SHAPE
K V-block
100(3.94)
Pin (5)
(0.551)
L
14
extrusion rod
16 (0.630)
200(7.87)
Bushing
N
extrusion rod
290(11.4)
160(6.30)
M Stand jig
(4.92)
125
270(10.6)
Shaft
P
(2.52)
extrusion jig
64
(1.18)
30
86(3.39)
94.5(3.72)
64.5(2.54)
Bushing
Q
fixing jig
+0.1
64.6 0
(2.543 +0.004
0 )
34-20
34. TRAVEL SYSTEM
APPLY LOCTITE #262 OR
EQUIVALENT
T=279N.m(210 lbf.ft)
1
3 2
!
34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
(3) Installing
Installation is done in the reverse order of removal.
! "
34-21
34. TRAVEL SYSTEM
34.1.5.3.1 CONSTRUCTION
!
%
!
"
!
&
" $
#
"
!#
" "$
: 5 mm
U
3
34-22
34. TRAVEL SYSTEM
34-23
34. TRAVEL SYSTEM
F
D
E
B
A
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection ø 535 (21.1) — —
B Tread dia. ø 497 (19.6) ø 490 (19.3) ø 487 (19.2) Replace
C Flange width 84 ± 0.5 (3.307±0.020) 78 (3.07) 76 (2.99)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 75 (-0.00118) Clearance Clearance
Shaft Replace
(2.95275) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
+ 0.035 Clearance
Interference between idler and ø 83 Interference
E Hole (+0.00138) 0.01
bushing (3.26771) 0
0 (0.0004)
34-24
34. TRAVEL SYSTEM
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
F Oil Engine oil API grade CD #30, 200cc (6.8 oz.) Refill
Idler rotation Rotates smoothly by hand Reassemble
34-25
34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
24
Socket
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
(0.591)
(1.18)
15
30
R Pin striking jig
(0.591)
105(4.13) 15
340 (13.4)
300(11.8)
Approx.150
(5.91)
Approx.600
(23.6)
U Stand
Approx.
400
(15.7)
2
(0.787)
105(4.13)
20
90(3.54)
jig
+0.1
74.6 0
(2.937 +0.004
0 )
103(4.06)
W Collar press fitting jig
(1.18)
30
34-26
34. TRAVEL SYSTEM
34.1.5.4.1 CONSTRUCTION
" ! % # ' & $
: 46 mm
3) Remove the grease cylinder (See Fig. 34-54)
Remove piston (6) from grease cylinder (1) in the 5
idler adjuster assy.
4) Removing oil seal (9), O-ring (8) (See Fig. 34-54)
Remove oil seal (9) and O-ring (8) from grease
cylinder (1).
V
5) Position idler adjuster
Use an appropriate strap to move the idler Fig. 34-56 Position idler adjuster
adjuster assy on the stand of the jig. Be sure the
bracket side is facing up.
34-27
34. TRAVEL SYSTEM
: 46 mm HOLDING-DOWN NUT
RETAINER PLATE
4
Fig. 34-57 Securing idler adjuster assy
7) Compression of spring (5) #
Remove spring pin (4). Press spring (5) with the
jack so that nut (3) can be removed.
: Bar ø7.5× 120
: 80 mm
34-28
34. TRAVEL SYSTEM
(2) Assembly
Assembly is done in the reverse order of W
disassembly. 1
1) Installing spring (5) and grease cylinder (1).
Insert grease cylinder (1) and collar (7) into
5
spring (5). Attach lifting eye nut (W) to screw
M52× P3 at the end of the grease cylinder. Lift
the grease cylinder with a hoist and position it in
the center of the jig stand.
: 46 mm
3) Compressing spring (5) and tightening nut (3)
HOLDING-
Extend the hydraulic jack. Compress spring (5) DOWN NUT
to the set length and install nut (3) to the thread-
RETAINER
ed end at the top of the grease cylinder (1).
PLATE
Set length of the spring : 429mm (16.9in)
2
4) Installing spring pin (4) 4
Tighten nut (3) till the holes for locking spring 3
pins (4) are aligned. Install spring pin (4).
11 7
: 80 mm 1
34-29
34. TRAVEL SYSTEM
• Face grease nipple hole downward to make Fig. 34-64 Grease cylinder (1)
air discharge easier.
: 19 mm,
Tightening torque : 59 N•m (43 lbfft)
X
E
C
A, B F
X D Y
BRACKET
DETAIL Y
SECTION XX
Fig. 34-65
34-30
34. TRAVEL SYSTEM
34.1.6 SPROCKET
34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to "34.1.2 CRAWLER".
Lift up crawler frame with attachment, and put
frame on square timbers to float and stabilize.
: 24 mm
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.
: 27 mm
Tightening torque : 279 N•m (206 lbf•ft)
Fig. 34-68 Installing sprocket completely
34-31
34. TRAVEL SYSTEM
96.07mm NUMBER OF
PITCH 21
(3.78in) TEETH
SPECIFICATION
ø58.72mm 644.602
ROLLER DIA. PITCH DIA.
(2.31in) (25.333in)
C
Fig. 34-69 Sprocket
Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
Reinforcement weld,
A O.D. of sprocket ø 659 (25.9) ø 651 (25.6) ø 649 (25.6)
repair or replace.
B Width of sprocket teeth 66±2 (2.520±0.079) 60 (2.36) 58 (2.28) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 586 (23.1) ø 578 (22.8) ø 576 (22.7)
repair or replace.
Unit : mm
NAME OPPOSING FLATS
24
Socket
34-32
34. TRAVEL SYSTEM
Unit : mm (in)
)
6"
.23
(0 6
R
823) .7
96.07(3
34-33
34. TRAVEL SYSTEM
3
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N.m(206 lbf.ft)
34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (6) M12× 25 and remove covers
(1).
$
: 19 mm
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Release pressure from travel circuit. Bleed air in Fig. 34-72 Removing and installing cover (1)
hydraulic oil tank and remove all pipes connecting
to travel motor. Plug or cap all pipes and joint
section to protect from entry of dust and dirt.
34-34
34. TRAVEL SYSTEM
: 24 mm
: 24 mm
3
34-35
34. TRAVEL SYSTEM
34.1.7.3 INSTALLING
Installation of the travel motor piping is performed in the
reverse order of removal.
1) Cleaning !" !) # &*( #! -
Check that the contact surface of travel motor
and crawler frame is free from burrs and foreign !# "( * "+) "$# ."#"
matter. !$!% !) , ()*#
!&"% *" , !(+!!$
2) Tightening torque , "+%"$$
Tighten capscrew and hydraulic pipes to the "& (!
torque specified in "Tightening Torque".
!'( !) , ")("!+
!'" "+ , +&%%+)
3) Add hydraulic oil through motor drain port to
!'( !) , *#*"+
casing before installing piping for drain. When
!'" "+ , !$&&$
first starting, operate motor at low idle and at low
! (! , "%%!)$
speed for several minutes. Check for oil leaks
and noise.
SECTION AA
34-36
34. TRAVEL SYSTEM
34.1.8.2 REMOVING
(1) Match marks
Remove upper structure, make match marks on
inner race of swing bearing and lower frame.
(2) Remove 36 capscrews (2) M20× 65 for installation
inner race.
: 30 mm
34.1.8.3 INSTALLING
(1) Cleaning
Clean completely so that installing surfaces of
swing bearing and lower frame are free from dust
and dirt.
(2) Installing
Install swing bearing on lower frame meeting the FRONT A A
: 30 mm
INNER S ZONE POSITION OF
(4) Tightening of inner race SWING BEARING
Tighten the capscrews (2) at 180 degrees intervals Fig. 34-80 Location of S mark on swing bearing
alternately to a specified torque.
: 30 mm,
Tightening torque : 563 N•m (415 lbf•ft)
(5) Filling grease
34-37
34. TRAVEL SYSTEM
34.1.8.4 CONSTRUCTION
$
ASSY PART NO. YN40F00026F1
&
No. NAME Q'TY No. NAME Q'TY
'
1 OUTER RACE 1 6 SEAL 1
%
2 INNER RACE 1 7 TAPER PIN 1 !
3 BALL 120 8 PLUG 1 #
4 RETAINER 120 9 GREASE NIPPLE(PT1/8) 1
5 SEAL 1
Fig. 34-82 Sectional view of swing bearing
"
!
Fig. 34-84 Removing balls (3) and retainers (4)
34-38
34. TRAVEL SYSTEM
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with
adhesive Cyano Bond PX-3000 or equivalent. In-
stall the seal (5) and place it on a surface plate.
2) Lower outer race (1) to the position where upper
surface of inner race (2) and lower portion of seal
groove is mated. Install an adjusting washer
under outer race (1) so that outer raceway Fig. 34-85 Fitting balls (3)
surface of ball (3) aligns with inner raceway.
EYE BOLT
3) Alternately insert a ball (3) and retainer (4), on
which grease is applied, through plug (8) hole on
outer race (1).
HOOKED ROD
Do not insert fingers into the plug hole. To insert ball (3)
and retainer (4), use a push rod to protect fingers from 4
injury . SQUARE
WOODEN BLOCK
4) Install plug (8) in outer race (1) while checking for Fig. 34-86 Fitting retainer (4)
direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 or equivalent. Install in the groove of outer
race (1).
6) After assembly, caulk the edge of taper pin (7)
with a punch.
7) Check that grease nipple (9) is properly installed
and fill with grease. Check the bearing for
smooth rotation and that there are no flaws on
seal lip portion.
• Shell Albania EP#2 ; 160cc (9.76cu•in)
34-39
34. TRAVEL SYSTEM
SECTION B-B
C C
SECTION C-C
SECTION A-A
34-40
34. TRAVEL SYSTEM
34-41
34. TRAVEL SYSTEM
34.2.1.2.1 Tools
(1) Standard tools
(2) Apparatuses
Application item
Apparatus Size Remarks Q'ty
(Use or number of relevant parts)
Work bench for
Disassembly and assembly 1 set
general-use
For rough cleaning and
Cleaning the parts Cleaning solvant 1 set
finish cleaning
Pressing capacity 9800 N
24 (Angular ball bearing) Work bench for press 1 set
(7230 lbf) or over
Pressure 0.29 to 0.49 MPa
Drying after cleaning Compressed air —
(42 to71 psi)
34-42
34. TRAVEL SYSTEM
(3) JIGS
34-43
34. TRAVEL SYSTEM
Name: Spatula
• This is used to remove timing plate (109) from rear flange
(301).
34-44
34. TRAVEL SYSTEM
34-45
34. TRAVEL SYSTEM
34.2.1.3 DISASSEMBLY
34.2.1.3.1 Preparation
The following preparations must be made before disassembly.
(1) Preparing working bench
• Prepare work bench for travel motor.
• Use a work bench which is sturdy enough for disassembly and assembly of the travel motor and has enough
space to put the parts.
• Cover the work bench with rubber sheet or vinyl sheet.
The internal parts may be slippery because they are coated by gear oil and hydraulic oil.
Be carefull when handling parts so they do not fall and injure or be damaged.
Do not use diesel fuel or kerosene to wash the diassembled parts. Always use cleaning solvent.
(1) Identify the items to be checked and any failures detected before disassembly Carry out the disassembly
according to the specified procedure.
(2) Handle parts taking care not to damage machined parts.
(3) Do not strike or pry parts. Assembly might be difficult due to burrs and damage and may cause the deterioration
of performance.
(4) If the parts removed or under disassembly are left out, rusting of parts due to moisture can occure. If it is
necessary to stop disassembly, work, protect the parts form rust.
(5) Mark the mating face of each part at the time of disassembly.
(6) Put the removed parts in order so as not to loose parts during disassembly.
(7) The removed seal and o-rings must be replaced with new ones even if no damage is found. Get new parts before
disassembling.
34-46
34. TRAVEL SYSTEM
Install two eye bolts to the tapped holes for the spindle in locations that are symmetrical each other.
Carefully clean the space between hub (1) and spindle (101) (floating seal fitting section) to remove any dirt.
Align the thread hole of hub (1) to the threaded hole of work bench and softly insert the travel motor in
attaching hole of work bench.
2) Attach the travel motor to the work bench in a location that two socket bolts are symmetrical each other.
Securely tighten the socket bolt. If not tight, there is a possibility of injury if the motor falls when turned over.
If there is pressure is inside of reduction unit, lubricating oil may be come out when loosening the drain port
plug.
3) Put an oil pan under the top end of the drain port and slowly loosen the drain port plug and drain lubricating
oil.
Use an oil pan with sufficient capacity for the lubricating oil. (5.3L.)
34-47
34. TRAVEL SYSTEM
4) If it is hard to drain the lubricating oil, slowly loosen and remove the filler port plug.
5) Remove O-ring (31) from the removed plug.
4) Install an eye bolt to the PF1/2 port and remove This picture of motor differs from actual motor.
the cover from the hub.
34-48
34. TRAVEL SYSTEM
2) Lift and remove the sun gear [2] (8) from carrier
[2] assembly by hand.
34-49
34. TRAVEL SYSTEM
34-50
34. TRAVEL SYSTEM
34-51
34. TRAVEL SYSTEM
2) Turn sideways.
3) Remove separator plate (116) and friction plate
(115).
34-52
34. TRAVEL SYSTEM
Slowly pull the shaft out being care not to damage the
lip of the oil seal (132).
34-53
34. TRAVEL SYSTEM
34.2.1.4.1 Seals
Replace all seals (O-ring, oil seal, floating seal with new one) even if no damage is seen.
Reference Allowable
Item No. Parts Trouble
value value
• Severe damage to appearance.
(1) Hub • Pitting occurs on tooth surface of ring gear. — —
• Abnormal wear such as scoring is present.
• Severe damage to appearance.
(101) Spindle — —
• Abnormal wear such as scoring is present.
(3)
Carrier assembly • Abnormal wear such as scoring is present. — —
and other
(4) Sun gear 1
(8) Sun gear 2 • Pitting occurs on tooth surface of gear.
— —
(5) Planetary gear 1 • Flaking is seen on race of bearing.
(9) Planetary gear 2
(11) Thrust washer 1 • Discoloration and abnormal wear appears
— —
(12) Thrust washer 2 on the sliding surface.
• Dent is present.
(24) Angular ball bearing • Flaking is seen. — —
• Uneven wear is present.
• Pitting occurs on roller.
(27) Needle-roller
• Abnormal wear is present on the end of — —
(28) bearing
cage.
• Sliding part is damaged due to valve (263)
(301) Rear flange — —
motion.
• Contact face between shaft and oil seal
(102) Shaft (132) was worn. — —
• Spline was worn.
(103) Swash plate • Seizure is present. — —
• Spline is worn.
• Bore surface is worn badly.
(104) Cylinder block — —
• The face between sliding surface and timing
plate (109) was scored or worn unevenly.
Clearance on Clearance on
• Clearance is present in the axial direction
Piston assembly diameter 0 to diameter 0 to
(105) between piston and shoe.
piston shoe 0.05mm 0.2mm
(106) • Shoe is worn abnormally and unevenly.
(0.002inch) (0.008inch)
• Deformation is present.
(107) Retainer plate • The sliding surface between thrust ball (108) — —
and plate is scored and worn unevenly.
34-54
34. TRAVEL SYSTEM
Reference Allowable
Item No. Parts Trouble
value value
• The sliding surface between retainer plate
(108) Thrust ball (107) and spherical sliding part is worn — —
unevenly.
(109) Timing plate • Sliding surface is seized or worn unevenly. — —
• Both end face are worn unevenly. Braking torque Braking torque
(115) Friction plate
• Special torque can not be reached. 470N•m 470N•m
(116) Separator plate
• Seizure is seen. (347lbf•ft) (347lbf•ft)
(112) Piston
• Outer circumstance is scored.
(135) D ring — —
• Wear or nibbling are seen on D ring.
(139) D ring
• Dent is present.
(149)
Taper roller bearing • Flaking is seen. — —
(150)
• Uneven wear is present.
(161) Piston
• Wear or nibbling are seen on seal. — —
(163) Seal
(323) • Outer circumstance is scored.
Spool — —
(363) • Outer circumstance is worn unevenly.
34-55
34. TRAVEL SYSTEM
34.2.1.5 ASSEMBLY
Assembly is the reverse procedure of disassembly.
34.2.1.5.1 Preparation
Prepare work bench, tools and materials similar to the disassembly specified in paragraph 34.2.1.3.
• Remove adhesive from threaded hole M10 of hub (1) using a tap.
• Remove sealant adhered on mating surface of hub (1) and cover (14) with scraper.
• Sufficiently clean all parts in cleaning solvent before assembling.
34-56
34. TRAVEL SYSTEM
34-57
34. TRAVEL SYSTEM
34-58
34. TRAVEL SYSTEM
34-59
34. TRAVEL SYSTEM
34-60
34. TRAVEL SYSTEM
JIG FOR
INSTALLING F/S (I)
FROATING
SEAL (F/S) HUB
34-61
34. TRAVEL SYSTEM
34-62
34. TRAVEL SYSTEM
34-63
34. TRAVEL SYSTEM
34-64
34. TRAVEL SYSTEM
(12)Assembling cover
1) Apply Loctite #515 sealant to the hub flange.
2) Position the cover over the hub and align the bolt
holes.
34-65
34. TRAVEL SYSTEM
(13)Lubricating
1) Add lubrication oil through filling port.
34-66
46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS
46
46-1
46. TROUBLE SHOOTING (BY ERROR CODES)
46-2
46. TROUBLE SHOOTING (BY ERROR CODES)
Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.
46-3
46. TROUBLE SHOOTING (BY ERROR CODES)
46-4
46. TROUBLE SHOOTING (BY ERROR CODES)
46-5
46. TROUBLE SHOOTING (BY ERROR CODES)
46-6
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
46-7
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-4
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-8
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-5
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-6
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-9
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-7
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-8
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-10
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-9
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-10
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
Control in the
mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-11
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-11
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-12
Error code B022
Trouble Boom down pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-12
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-13
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
SE-4 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-127F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-14
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-13
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-15
Error code B032
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-16
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
SE-8 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-131F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-14
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-17
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-18
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-15
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-19
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
SE-7 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-130F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-20
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-16
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-21
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-22
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B053 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-17
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-23
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B054 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-24
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B062 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F
CN-101F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-18
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-25
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B063 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-26
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B064 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-19
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-27
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-28
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B073 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-20
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-29
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B074 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-30
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-21
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-31
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B093 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-32
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B094 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-22
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-33
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-34
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B103 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-23
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-35
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B104 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-36
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-24
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-37
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-38
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-25
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-39
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-40
Error code B164
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-26
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-41
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B172 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-42
Error code B173
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensorWhen B173 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B173 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-27
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-43
Error code B174
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B174 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-44
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-28
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-45
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C013 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-46
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-29
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-47
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-48
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C023 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-30
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-49
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-50
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Overload detection is not available.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-31
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-51
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom When overload detection switch is ON, overload alarm sounds constantly.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-54
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-32
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-55
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-56
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-33
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-57
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-58
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-34
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-59
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-60
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-35
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-61
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-62
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-36
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-63
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-64
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-37
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-65
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-66
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-38
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-67
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-39
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-70
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-40
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-72
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-41
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-74
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
46-42
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-75
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
Table46-78
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-43
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-79
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-80
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-44
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-81
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-82
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-45
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-83
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-84
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-46
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-85
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-88
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-600F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
46-47
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-89
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
4 • Mechatro controller Check that the error is corrected after replacement of controller.
46-48
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-90
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R014 is left displayed
E-1
Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-49
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-91
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-50
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-92
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CCW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-51
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-93
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 MOTOR RELAY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-112F, CN2-1 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-94
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D13
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-52
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-95
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D14
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-96
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 23 D15
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
R-8 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-53
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-97
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-54
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-98
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-3 ENG STOP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-55
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-99
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-4 LOCK LEVER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-100
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-2 SAFETY RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
R-26 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R214 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-56
46. TROUBLE SHOOTING (BY ERROR CODES)
[MEMO]
46-57
46. TROUBLE SHOOTING (BY ERROR CODES)
46-58
47. TROUBLESHOOTING
(BY SYMPTOM)
TABLE OF CONTENTS
47
47-1
47. TROUBLESHOOTING (BY SYMPTOM)
47-2
47. TROUBLESHOOTING (BY SYMPTOM)
47-3
47. TROUBLESHOOTING (BY SYMPTOM)
47-4
47. TROUBLESHOOTING (BY SYMPTOM)
47-5
47. TROUBLESHOOTING (BY SYMPTOM)
47-6
47. TROUBLESHOOTING (BY SYMPTOM)
47-7
47. TROUBLESHOOTING (BY SYMPTOM)
47-8
47. TROUBLESHOOTING (BY SYMPTOM)
47-9
47. TROUBLESHOOTING (BY SYMPTOM)
47-10
47. TROUBLESHOOTING (BY SYMPTOM)
47-11
47. TROUBLESHOOTING (BY SYMPTOM)
47-12
47. TROUBLESHOOTING (BY SYMPTOM)
47-13
47. TROUBLESHOOTING (BY SYMPTOM)
47-14
47. TROUBLESHOOTING (BY SYMPTOM)
47-15
47. TROUBLESHOOTING (BY SYMPTOM)
47-16
47. TROUBLESHOOTING (BY SYMPTOM)
47-17
47. TROUBLESHOOTING (BY SYMPTOM)
47-18
47. TROUBLESHOOTING (BY SYMPTOM)
47-19
47. TROUBLESHOOTING (BY SYMPTOM)
(16)Travel deviation
47-20
47. TROUBLESHOOTING (BY SYMPTOM)
47-21
47. TROUBLESHOOTING (BY SYMPTOM)
47-22
47. TROUBLESHOOTING (BY SYMPTOM)
(19)Machine does not travel straight in simultaneous operation of traveling and attachment
(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)
47-23
47. TROUBLESHOOTING (BY SYMPTOM)
47-24
47. TROUBLESHOOTING (BY SYMPTOM)
47-25
47. TROUBLESHOOTING (BY SYMPTOM)
47-26
47. TROUBLESHOOTING (BY SYMPTOM)
47-27
47. TROUBLESHOOTING (BY SYMPTOM)
Check that all top ends of the connectors form a DOUBLE LOCK
PLATE FOR PLUG
even line as seen from the connector installation DOUBLE LOCK
PLATE FOR CAP
side.
If not, push wire in until connector is even and CAP
47-28
47. TROUBLESHOOTING (BY SYMPTOM)
47-29
47. TROUBLESHOOTING (BY SYMPTOM)
47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.
47-30
47. TROUBLESHOOTING (BY SYMPTOM)
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
47-31
47. TROUBLESHOOTING (BY SYMPTOM)
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
47-32
47. TROUBLESHOOTING (BY SYMPTOM)
Checking
Filters Liquid Leak, clogging
Muffler clogged
Engine oil leak
Coolant level
Trouble
47-33
47. TROUBLESHOOTING (BY SYMPTOM)
Hydraulic switch
Starter motor
Safety relay
Battery rely
Glow relay
Glow plug
Alternator
Trouble
47-34
47. TROUBLESHOOTING (BY SYMPTOM)
Factors
47-35
47. TROUBLESHOOTING (BY SYMPTOM)
Engine body
Factors
Damage of dumper
Trouble
47-36
48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS
48
48-1
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-2
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-3
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-4
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a
case no accordance of diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-5
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-6
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-7
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-8
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