Kobelco MARK IV Hydraulic Excavator Serviceman's Handbook Manual - PDF DOWNLOAD

SERVICEMAN’S HANDBOOK HYDRAULIC EXCAVATOR

MARK IV

KSOH-IV-USA-REV.0-04/99

03/04

Service Orientation Handbook

1. Service Support 2. General Specifications 3. Machine Familiarization – Operation and Control 4. Cylinder and Motor Cycle Times 5. Pressure Setting Procedure 6. Mechatronics 7. Optional Equipment

READ, UNDERSTANDAND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURESFOUND IN THE OPERATORS MANUALBEFOREATTEMPTINGANY OPERATION,INSPECTIONOR MAINTENANCEOF THIS MACHINE, ATTACHMENT OR SYSTEMS. KOBELCOCANNOTANTICIPATE EVERYPOSSIBLE CIRCUMSTANCE THAT MIGHT INVOLVE A POTENTIAL HAZARD.THE WARNINGS IN THE OPERATORS MANUALAS WELL AS IN THESE SPECIAL INSTRUCTIONSAND ON THE PRODUCTARE THEREFORE NOT ALL INCLUSIVE. IF ATOOL, PROCEDURE,WORK METHOD OR OPERATINGTECHNIQUENOT SPECIFICALLY RECOMMENDED

BY KOBELCOIS USED, YOU MUSTSATISFY YOURSELFTHAT IT IS SAFE FOR YOU AND OTHERS.YOU SHOULDALSO ENSURETHAT THE PRODUCTWILL NOT BE DAMAGED OR MADEUNSAFEBY THE OPERATION, LUBRICATION, MAINTENANCEAND/OR REPAIR PROCEDURES YOU CHOOSE. (Lea, entienda y siga todas las precauciones de seguridad y procedimientos que contiene el manualdel operador antes de intentar cualquier operacidn, inspeccidn, mantenimientoen los implementos o sistemas de esta mdquina. Kobelco no puede abarcar todas las circunstancias que originen situaciones de peligro. Consecuentemente,las advertencias mencionadastanto en el manualdel operador comoen estas instrucciones especiales sirven sdlo comogu(a. Si se utiliza alguna herramienta, procedimiento, m6todo de trabajo o tdcnica de operacidn no recomendadopor Kobelco, usted sera responsable de su seguridad como la de terceros.

As(mismo,deberd serciorarse de que el producto se encuentre en buen estado de trabajo y sea seguro para su operacidn, lubricacidn o mantenimiento.)

SHUTOFFTHE ENGINE(Pare e/motor): 1. Movethe machineto a firm, level area and place the attachmentson the ground.Placethe throtle control in low idle, shut off the engineandplacethe safety lock lever in the locked(UP)position shownin figure. (Mueva/a maquina hacia un /ugar con terreno firme y nive/aclo. Co/oquee~ ace/erador en re~ant1;apaguee~ motory/evantela palancade seguridad,ta/ como/o indica /a figura )

ALWAYSPLACE THE ATTACHMENTS ON THE GROUND AND PLACETHE SAFETYLEVERIN THE LOCKED(UP) POSITIONBEFORELEAVINGTHE CAB TO PREVENTANY OPERATIONOF THE HYDRAULIC CONTROLS. (Siempre coloque los implementos sobre el suelo y levante la palancade seguridadantes de salir de la cabinapara prevenir cualquier operaci6nde los controleshidraulicos.)

St0~nt-04/99

Kobelco

Mark

IV

Kobelco America Inc. SlOrem*05199

National Accounts S. Warren White NATIONAL ACCOUNTSMANAGER Stafford, TX. (Ext. 222) Chris Donnelly SERVICE SUPPORT- NATIONAL ACCOUNTS Stafford, TX(Ext. 285)

Terry Ficken SERVICE SUPPORT- NATIONAL ACCOUNTS Stafford, TX. (Ext. 297)

FIELD SERVICE: Scott Emmans John Adams SERVICE SUPPORT MANAGER SERVICE SUPPORT MANAGER Gotham, ME. 04038 Reynoldsburg, OH. 43068 PHONE: 207.839.0437 PHONE: 614.864.5863 FAX: 207.839.0464 FAX: 614.864.7661

Nelson Evans SERVICE SUPPORTMANAGER Lake City, FL. 32024 PHONE: 904.752.1318 FAX: 904.758.8065

Jose Longoria Clermont Couture SERVICE SUPPORT MANAGER SERVICE SUPPORT MANAGER Richardson,TX. (Dallas) Breakyville, Quebec, CANADA G0S1E1 PHONE: 972.235.2578 PHONE: 418.832.7762 FAX: 972.680.8060 FAX: 418.832.7763

Tayne Ivie SERVICE SUPPORTMANAGER Lehi, UT. 84043 PHONE: 801.766.8593 FAX: 801.766.8594

Rich Archibald SERVICE SUPPORTMANAGER 1005 South Blake Rd. Spokane, WA92216 PHONE:509.922.23705 FAX: 509.924.2818

8/12/99

L:~S ERVICE~LIST618 .DOC

Joel Escalante SERVICE SUPPORTMANAGER - LATIN AMERICA Stafford, TX. PHONE:281.240.4800 (Ext. 224) FAX: 281.240.1511

Date:

KOBEID:)

Dealer Name

Dealer Code

ModelNo.

~ddress

Serial No.

~itv Engine Model

~tntA

Engine SIN

Attachment Type

IZiD Code

BoomCyl. (L.H) P/N Make

ArmCyl. PIN

Hour Meter

BoomCy!. (R.H) PIN ArmAssy. P/N

PIN Bkt. Mfg.

Bkt. Cyl. PIN

S,’N

Place a "C" in the column if the item is incorrect. Place a "1" In the columnif the item is incorrect, and explain by item number underthe comments section. Fill in the blanks provided besides the items whenrec{uirod.

lmllmlmllm/B

1 Appearance Good Poor 2 Glass Dirty Broken 3 Paint Defects Cab Upper Frame Lower Frame Attachments Counterweight 4 Cab Dirty Mounting

11 Proper MachineOpera, on 12 Support Packages ManualMissing

~’~t~ 13 EngineOil Level 14 Engine Coolant __ F 15 EngineCoolant level 16 Hydraulic Oil Level 17 Swing Gear Bath 18 SwingReduction Unit 19 Travel ReductionUnit - L.H 20 Travel ReductionUnit - R.H 21 Lubdcate Attachments ~ 22 CheckFuel Water Sep.

¯

’

Instrumentpanels

~

Seat assembly Cabogerdtion levers Switches/controls Cabframe Air Cond./ Heatin.qUnit Gauge/WamingLamps 5 Decals

23 Air System Conne~ons Misassembly LooseConnectors HosesLeskinfl 24 Exhaust Connections Mlsassembly LooseConnectors

Missing 6 Hoses,Tubes,Fittings Powertrain Upper- Loose/Routing Lower- Loose/Routing Attach.- Loose/Routing 7 All Bolts & Fasteners Powertrain components Upper

Hyd. SwingMotor/Rod. 10 Proper Track Adjustment

. . . .

Tubes Leaking 25 Fuel System Connections Misassembly

Adhesive Misapplied / Damaged WrongDecal

Lower Attach.

8 Wiring Hamsss Routing / Misassembly Conne~onsloose Missing 9 ComponentFluid Leakage Engine Assembly Hyd. Control Valve Hyd. Main Pump Hyd. Travel Motor/Rod.

43 AD5ISVP(#18 of 24 item check) Eng. Low(no load) mA Eng.Low(armrelief) mA Eng.High(no load) mA

.

,

~57

,,

. , . .

Decal

Mode

rnA mA. mA. mA. mA. rpm . rpm . rpm . rpm mm

46 47 48 50 51 52

BoomCvl - Out Boom Cyl. - In ArmCyl. - Out ArmCvl. - In BucketCyl. - Out Bucket~1. - In

secs secs secs secs seca secs

53 54

SwingSpeed- LH Swin,qSpeed- RI-I

secs secs

F~

LooseConnectors HosesLeaking 26 Oil & Fuel Filters Loose/ Leaking 27 FanBelt Adjustment 28 Air CleanerElements Missing Damaged Misassembled ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯

Eng.High (arm relief) 44 I1 pump(# 20 of 24 item check) Eng.Low(no load) Eng.Low(armrelief) Eng.High(no load) Eng.High(armrelief) 45 Eng. Speed Rpm LowIdle (LH Target) LowIdle (RHActual) Hi.qh Idle (LHTamet) HighIdle (RHActual)

29 Pilot SystemPressure psi 30 Travel Main Relief- R psi 31 Travel MainRelief- L psi 32 RV1 Main Reliefw/H.L. psi 33 RV2Main Reliefw/H.L. psi __.__~.

34 RV1Main Relief oel 35 RV2Main Relief 36 SwingPort Relief- L __L. osi 37 SwingPort Relief- R psi 38 a3prop0ruonal val~ ......

. .

55 Workand CabLights Missssembled Misaligned Inoperable 56 Swing Flashers Mlsassembled Mlsaligned Inoperable Horn Defective Missssembled 58 Pilot Lever Lock Switch Mlsassemblod Travel Alarm Defective Misassembled 59 Battery Electrolyte Level Charge Mounting/connection

. ¯ . ¯

. . . .

39 40 41 42

P1 P2 P3 P4

Main Main Main Main

pal

.

si.L. psi psi

Comments: {.Please enter line item # and DsscfiDtion)

CompletedBy:

CompletedDate: S/Orent.05/99

12755 South Kirkwood Stafford, TX 77477 Phone 281.240.4800 Fax: 281.240.5026

Kobelco America Inc.

Toassist you with finding and solving the problemyou are having, pleasecheckand record the following items. Havingthis informationwhencalling for assistancewill help locate your problemquicker.

All HydraulicpressuresandEngineR.P.M.Settings are taken in H Mode if Applicable.

Machine Model

Machine Serical Number

Machine Hours

Hydraulic Oil Temp.

MaximumEngine R.P.M.

Engine Idle Speed

Pilot Pressure P3

Travel Left P2

Travel Right P1

Note: Travel PressureMustbe checkedby engagingboth Right and Left Travel Motorsat the sametime.

Power Boost SK200 & Up P1 Main

Power Boost SK200 & Up P2 Main

MainRelief P1

MainP2 Relief

Pf Pressure SK150and Up Operator Controls H Modelow Idle Controlsin Neutral H ModeFull Throttle Controlsin Neutral H ModeLow Idle Bothtravel MotorsStalled H ModeFull Throttle Both Travel MotorsStalled H ModeLowIdle Both Travel and ArmOut Stalled H ModeFull Throttle Both Travel Motorsand Armin Stalled S/0R~.05t99

Engine R.P.M.

PF Pressure

KOBELCOMARKIV 24 ITEM CHECK Model: R.P.M. SensorDisplay NO. 1 2 3 4

5

P/No $1 Wtmp $2 Oprs $3 CPU $4 Smode

6

$5 Hmod

7 8

$6 Att S 7 Des

9 10 12 13

S 8 Bzsp S 9 Jpin S 10 Keys S 11 Lims S 12 Boom

14

Adl boom

15

Ad2 Acel

16 17 18

Ad3 MotA Ad4 MotB Ad5 isvP

19

~Ad6isvB

2O

IIPump

21

12 Boom

22

POS

23

R.P.M.

24

18V

Serial Number: Resistance: Engine Running Engine Stopped

Hours: VoltageA. C.: Remarks SK300Mitsubishi Only S.D. Mode H. FC. Mode H. Mode S. FC. D. Mode Decel SWON Decel SWOFF Lever Operating

LeverNeutral Slewing LowIdle HighIdle LowIdle HighIdle LowIdle (No Load) High Idle (No Load LowIdle (ArmOverRelief) HighIdle (Armover Relief) LowIdle HighIdle LowIdle (No Load) HighIdle (No Load) LowIdle (ArmOverRelief) HighIdle (Armover Relief) LowIdle HighIdle Low Idle

HighIdle Tar.qet

Actual LowIdle HighIdle S Mode FC Mode S/Or~t~5~9

Kobelco

Mark

IV

KOBELCD Kobelco America Inc. StOmnt.05199

NOTES

S/Orent-05?99

GENERAL SPECIFICATIONS TORQUESPECIFICATIONS A. CAPSCREWS & NUTS 1. Metric CoarseThreadStandard TighteningTorqueValues.Makecertain to tighten all Capscrews & Nutsto propertorquevalues.

Classification NOMINAL SIZE

4 T 7 T 10 T NOLUBRICATION OIL LUBRICATIONNOLUBRICATION OIL LUBRICATIONNOLUBRICATION OIL LUBRICATION

M6

P=I

M8

P=1.25

0.45±0°05 (3.2_-_+0.4) 0.38±0.04(2.7±0.3) 0.98±0.1 (7.1:=0.7) 0.83±0.08(6.0±0.6)1.77±0.18(12.8±1.3 1.5±0.15(01.8±1.1) 1.09±0.11(7,9±0.8) 0.92±0.09(6.6¢0.7) 2.4-.=0.2(17.3±1.4) 2.0±0.2(14.4±1.4) 4.3±0.4(31.0±2.9) 3,6±0.4(26.0±2.9)

M10

P=1.5

2.2±0.2(15.9±1.4)

M12

P=1.75

2.2±0.2(26.7±2.9)

3.2±0.3(23.1±2.2)

M14

P=2

5.9±0.6(42.6±4.3)

5.0±’0.5(36.1±3.6) 12.8±1.3(92.5±9.4) 10.8±1.1(78.0±7.9)

M16

P=2

9.0±,09(64.9~6.5)

7.6±0.7(54.8±5.1) 19.5:.-.-.-~.0 (140±14.4) 16.4-±1.6(118±11.5) 35±4 (252--.-~8.9)

M18

P=2.5

12.4±1.2(89.6±8.7) 10,5±1.0(75.8±7.2)

27±3 (195.+.22)

23.+,.2(166±14)

49±5(354±36)

41±4(296±29)

M20

P=2.5

17.5±1.7(126±12.3) 14.7±1,4(106±10.1)

38±4(2744-29)

32±3(231±22)

68±7(491±51

57±6(412±43)

M22

P=2.5

23±2(166±14)

19.6±2.0(142±14)

51±5 (368±36)

43±4(310±29)

92±9(663±65)

77±7(555±58)

M24

P=3

30±3(217±22)

24±3 (173--~22.)

65±7(469±51)

53±5(383±36)

118±12(852±87)

96±10(693±72)

M27

P=3

44±4(318±29)

36~3(260±22)

96±10(693±72)

M30

P=3.5

604-6(433±43)

50±5(361±36)

131±13(946±94)

M33

P=3.5

81~8(585±58)

68±7(491±51)

176±18(1270±130) 148±15(1070±110)317±32 (2290.-.-.-.-~00) 266±27(1920±200)

105±10(758±72)

88±9(636±65)

227±23(1640±170) 190±19(1370±140)343±34(2480.+.250) 343±34(2480±250)

M36

P=-4

1.83=0.10 (13.2=1.3)4.7±0.5(33.9~3.6)

4:0"*-0.4(28.9±2.9) 8;5±0.9(61.3±6.5) 7.2--’0.7(52.0±5.1)

8.1=0.8(58.5±5.8) 6.8±0.7(49.1±5.1) 14.6±1.5(105±10.8 12.3±1.2(88.8±8.7)

78±8(563±58)

23_+.2(166±14)

19.5±1.9(140±14) 29±3 (209-’-_21.6)

173±17(1250±120) 140±14(1010±100)

110±11~94±79) 235¢2.4(1700±170) 198±20(1430±140)

TORQUE VALUE UNIT- kgf-m (ft.

Ibs.

2. MetricFine ThreadStandard Tightening TorqueValues.Makecertain to tightenall Capscrews & Nutsto propertorquevalues.

Classification NOMINAL SIZE

4

T

7

T

10

T NOLUBRICATION OIL LUBRICATIONNOLUBRICATION OIL LUBRICATION NOLUBRICATION OIL LUBRICATION

M8

P=1.25

M10

P=1.5

M 12

P=1.75

1.15-±0.11 (8.3:L-0.8) 0.97-.=0.1 (7.0±0.7) 2.5±0.2(18.0±1.4) 2.1±0.2(15.2±1.4) 4.5±’0.4(32.5±2.9) 3.8±0.4(27.4-+.2.9) 2.3±0.2(16.6±1.4) 1.91¢0.19(13.8±1.4) 4.9±0.5(35.44-3.6) 4.2i-0.4 (30.3±2.9) 8.9±0.9(64.2¢6.5) 7.5±0.7(54.2=5.1) 4.0±0.4(28.9~2.9) 3.4±0.3(24.5±2.2) 8.7±0,9 (62.8-.-.-.-.~.5)7.3±0.7(52.7±5.1) 15.7±1.6(113±13) 13.24-1.3(95.3¢9.4)

M16

P=2

9.4±0.9(67.9-±6.5)

7.9±0.8(57.0±5.8)

20.4-~(144±14)

17.2±1.7(124±12)

37±4 (267:.+_.29)

31±3 (224..,~-~2)

M20

P-2.5

19±9(137±14)

15.8±1.6(114±14)

41 ~ (296±29)

34±3(246+~2)

74±7(535±51)

624-6(448-.~3)

M24

P=3

32=3(231±22)

27±3 (195:.-.-.-~2)

70±7(506±51)

58±6(419±43)

126±12(910:~7)

105±10(758±72)

M30

P=3.5

65±6(469±43)

54±5(390±36)

i 42.,’-14(1030±100)118±12(852±87) 255±26(1840±190) 212±21(t530±150)

M36

P=4

91±9(6574-65)

238±23(1720±170) 198±20(1430±140)428±43(30904-310) 357±36(2580±260)

v

109"±11(787±79)

u

TORQUE VALUE UNIT-kgf-m (ft.

, ,

T

O.D.(e)

MANUFACTURER’S NAME

NIPPONA.M.C.

IHARA KOATO

s~.,-o5~

WORKINGPRESSURE z (PSI) kgf/cm

300(4270)

300(4270)

TUBESIZE O.D. X THICKNESS mm(in)

Ibs.)

OPPOSINGFLATS mm DimensionB

TORQUEVALUE = (ft. Ibs.) kgf-cm

10 X 1.5 (0.394X 0.059)

19

5±1(0.36=0.07)

15 X 2.0 (0.591X 0.079)

27

12±1.2(0.88±0.09)

18X 2.5 (0.709X 0.098)

32

15±1.5(1.09±0.11)

22X 3.0 (0.866X 0.118)

36

22¢2.2(1.59=0.16)

28 X4.0(1.10 X 0.197)

41

28±2.8(2.03=0.20)

35 X 5.0 (1.38 X 0.20)

55

45±4.5(3.25=0.33)

Page 2-1

GENERAL SPECIFICATIONS TUBE & HOSE PLUGS

NUTS & SLEEVES SLEEVE

TUBE O.O.(O) 6

PART NUMBER IHARA KOATO NIPPONA.M.C. ZF93S06000

8

ZF93S08000

10

ZF93S10000

12

ZA93S10000

ZF93S12000

15

ZF93S15000

ZA93S15000

18

ZF93S18000

ZA93S18000

22

ZF93S22000

ZA93S22000

28

ZA93S28000

32

ZF93S28000 ZFg3S32000

35

ZF93S35000

ZA93S35000

38

ZF93S38000

NUT

TUBE DIA. 10mm

"A" INTERNAL (For Hose End) ZF83P10000

15ram

ZF83P15000

"B" NUT (Use With "A") ZF93N10000 ZF93N15000

18mm

ZF83P18000

ZF93N18000

ZF83H18000

22mm

2444T1338D4

ZF03N22000

2444T1329D4

28mm

ZF83P28000

ZF93N28000

2444T1329D5

35ram

ZF63P35000

ZF93N35000

ZF83H35000

"C" EXTERNAL (For Tube End) ZF83H10000 ZF83H15000

MALE PF PLUGS

"A"

O.D.

I

PLUG SIZE PF1/4 TUBE O.D.(£1) 6

l

°60

O.D. 10) PART NUMBER

"A"

"B"

-

"C"

"D"

O.D LENGTI" LENGTF 2444Z2728D1 13.5 16.5 24.5

FLATS 14

PART NUMBER IHARA KOATO NIPPONA.M.C. ZF93N06000

PF3/8

2444Z2728D2 16.6

17.5

25.5

17

PF1/2

2444Z2728D3 20.6

20.0

31.0

PF3/4

2444Z2728D4 26.2

21.5

34.0

22 27

PF1

2444Z2728D5 33.3

23.5

36.0

8

ZFg3N08000

10

ZF93N10000

12

ZF93N12000

15

ZF93N15000

ZA93N15000

18

ZF93N18000

ZA93N18000

22

ZF93N22000

ZA93N22000

28

ZFg3N28000

ZA93N28000

32

ZF93N32000

35

ZFg3N35000

38

ZF93N38000

ZA93N10000

FEMALEPF CAPS

ZA93N35000

SIZE PF1/4

Overtightening or undertightening of ~utsandsleeves in bite typetubefittings maycause oil leaksto develope throughpipe connections.

Alwaystighten Nuts& Sleeves to propertorquevalues.

PF3/8 PF1/2 PF3/4 PR1

PART NUMBER 2444Z2729D1 2444Z2729D2 2444Z2729D3 2444Z2729D4 2444Z2729D5 Unit: mm

36 Unit: mm

GENERAL SPECIFICATIONS FLARETYPEFITTING JOINTS Overtighteningof Flare Type(UnionNut Type) metal joints maycausedamage to nuts, seat surfaces andpreventoptimum sealing resulting in oil leaks.

1. PIPE THREADE Unit: kg-m (ft. Ibs.) NOMINALSIZE

NOTE: ¯ THOROUGHLY CLEANALL TUBE ANDHOSES WITH A CLEANINGSOLVENTAND DRY WITH AIR BEFOREASSEMBLY. 2. UNIFIED THREADS

TORQUEVALUE

114" 3/8" ‘= I/2

THREADSIZE

unit:kg-m (ft. Ibs.) TORQUEVALUE

2.5=0.3(18.1--1.8)

7/16"-20

2=().2(14.5--.1.4)

5=0.5(36.2=3.6)

1/2"-20

3=0.3(21.7.-~.2.2)

6=0.6(43.4¢4.3)

9116"-18

4~-0.4(28.9=2.9)

3/4"

12=1.2(86.8=8.7)

518"-18

4=0.4(28.9=2.9)

I ii

14=1.4 (101=10)

3/4"-16

5=0.5(36.2=3.6)

1-1/4"

17=1.7 (123=12)

7/8"-14

6=0.6(43.4=4.3)

1-112"

21=2.1 (152=15)

1-1/16"-12

12=1.2(86.8=8.7)

42=4.2 (304=30)

1-5/16"-12

14=1.4 (101=.10)

1-5/8"-12

17=1.7 (123=12)

II 2

N2 (NYLON)TUBEFITTING JOINTS 1. Cleantube and makecertain tube end is trimmed smooth.

2. Insert tubeinto fitting until tubeendis securely seatedin fitting body.

3. "13ghtenthe nut by hand.

4. Usea spannerwrench,securily tighten nut by turning 1-1/4 turns. SeeFigure1.3.

PLASTIC SLEEVE

BOD Y

~~

..... t

NUT

NYLON TUBE

SPECIAL SPANNERWRENCHES

TUBE PARTNo. A B C D E F G DIA. 15 7O 22 12.7 8 40 16 2421T160 27 (.591) (1.06) (2.76) (.865) (.50) (.315)(1.57) (.630) 18 (.709)

70 22 12.7 11 42 19 2421T138 32 (1.26) (2.76) (.856) (.50) (.433)(1.65) .748)

22 (.866)

7O 22 12.7 11.5 48 23 2421T130 36 (1.42) (2.76) (.866) (.50) (.453)(1.89) {.906)

28 (1.10)

109 22 12.7 14.5 6O 29 2421T115 41 (1.614)(4.29) (.866) (.50) (.571)(2.36) 1.14)

35 (1.38)

9O 45 2O 20.5 81 41 2421T314 55 (2.17) (3.54) (1.77) (.7S7) (.807)(3.19)!(1.61)

FIGURE1.3

Unit: mm (inches)

1.4 NOISELEVEL A. ThefollowingSpecificationsare applicableto all machines.

MODEL 7M CAB SKl15 oz

74

74

SK130

74

74

SK150

74

74

SK200

73

72

SK220

72

73

SK270

72

73

SK300

76

76

SK400

78

77

Unit: db

GENERAL SPECIFICATIONS INSPECTION & MAINTENANCE CHART This chart is for lefference only. Follow the chart

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONS FOUNDIN THIS MANUALBEFORE . PERFORMING INSPECTION& MAINTENANCE.

in operators manual by serial number, for proper inspection and maintenance procedures.

SYSTEM PERFORM

MAINTENANCETO LOCATION

COMPONENT 8

CHECKCOOLANT LEVEL

RESERVOIR

CHECKBELTTENSION FRONTOF ENGINE !~:~,i:u~ ~ ~i .............................................

DRAINWATER SEPARATOR R.H. SIDE OF ENGINE

INTERVAL( HOURSON HOURMETER) 120 250 500 1,000 2,000

,/

/ ~ ~.~:~~~.:~. ~

/

............................................... ..................................................

CLEANPRE-FILTERBOWL PUMP DOOR

N!~ ¯

/

CHANGE ENGINEOIL

OIL PAN

¯

/

CHANGE FUELFILTER

R.H. SIDE OF ENGINE

¯

/

CHECKAIR INTAKESYSTEM HOSES& CLAMPS

¯

/

CHECKBELTTENSIONER FRONTOF ENGINE

¯

RADIATOR

RADIATOR

~:~ ~i,~,

~

~

~

¯ .............. . .....~

CHANGEENGINE COOLANT

/

/ ..........

CLEANRADIATOR

~,.~

I/’

CHECKENGINE ELECTRICALCOMPLETE ENGINE

ENGINE

5O

~.~

~ ~ ......... /

~,~ ~ ,~

ADJUSTVALVECLEARANCE

ENGINETOP

CHECKHYDFUNCTIONS

CAB

/

CHECKHOSES/LINES

HYDRAULICSYSTEM

/

HYDRAUUC ¯ CHANGE RETURN FILTER HYDRAUUC TANK / I ~........................................ !~ o~~ ~ ~!~~!~i ,~, t~,,~ ~:~ ~i ~,~,~, ~, ,,~ ~?~’~ S~,,~ ~ : ~,~: ~"~::~ ’~i~ ,~’~ i~i~ .......................... ~ ~.............. ~: ..... ¯ .................... ................................ ..................... ~ .....................

CHANGE HYDRAULIC OIL HYDRAULIC TANK ,/ CHANGEHYDRAULIC TANK BREATHER ELECTRICAL BATTERYELECTROLYTE

,/ ¯

,/"

HYDRAULIC TANK

BA’I’rERIES

¯

i/

Regular Inspection & MaintenanceRequired.

Brsak-ln (After first 50 Hours)Inspection & MaintenanceRequired.

Page2-4

s~o,,=,-o~,~

GENERAL SPECIFICATIONS SYSTEM

MAINTENANCETO PERFORM

COMPONENT LOCATION ~,. ~

UPPER FRAME

8

~.~:~~,~ ...... ~,~i /

CHECKSWITCHES

CAB

CHECKSWINGBRAKE

CAB

/

CHECKBUZZER

CAB

/

CHECKHORN

CAB

/

CHECKSWINGREDUCTION OIL LEVEL& FILL

UPPER FRAME

.... ~% CHECKSLEWINGRING & PINION WEAR

50

120

~i~’~-~.~

..... ~,~..... ~ ........ ~! .............. ~?~’~’~’~ .......ii

¯ ~ ~’~

~ i

~ ......... ;;-~,~

SIGHT WINDOW IN BATTERYBOX

/

CHECKSWIVEL JOINTSEALS SWIVELJOINT

GREASESLEWINGRING

INTERVAL ( HOURS ONHOURMETER) 250 500 1,000 2,000

/

SLEWINGRING

,/

¯

N

~’HANGESWINGREDUCTION SWINGMOTOR UNITOIL

CHECKFOROIL LEAKS COMPLETESYSTEM

./ ~ = ~ ~ ~-~;~

CHECKSTEPS

FRAMERAILS

/

CHECKTRACKS& LINKS

TRACKS

/

CHECKIDLER WEAR

REAROF TRACKS

,/

CHECKTRACKTENSION

RAISE TRACKS

,/

~. ! ¯

LOWER FRAME

CHECKTRAVELREDUCTION TRAVELMOTORS UNITOIL LEVEL& FILL

¯

CHECKBOLTS/HARDWARE ENTIREMACHINE

~I’

CHECKBUCKET TEETH& SIDE CUTTERS

BUCI~’T

GREASEARMPINS

ARM

/

,/

ATTACHMENT

,/ ¯

/

RegularInspection & MaintenanceRequired.

Break-In(After first 50 Hours)Inspection& Maintenance Required.

s/o~.,-o~,~

Page2-5

GENERAL SPECIFICATIONS FLUIDS & FILTERS Thefollowingchartslist all the necessary lubricants, oils, greases,fuels, coolants and filters required for the KOBELCO MarkIV Hydraulic Excavators.

Required Fluids & Quantities TYPE FLUID*

HYDRAULIC

LOCATION OF USE HYDRAULICTANK HYDRAULICSYSTEM ENGINEOIL PAN

SK115DZ

SK130

SK150

SK200

SK220

SK270

100Liters (26 GAL)

100Liters

100Liters

155Liters

185Liters

185Liters

282Liters

310Liters

(26 GAL.)

(41 GAL)

(49 GAL)

(49 GAL)

(75 GAL)

140Liters

(26 GAL) 140Liters

140Liters

275Liters

310Liters

310Liters

420Liters

(82 GAL) 600Liters

(37 GAL)

(37 GAL)

(37 GAL)

(73 GAL)

(82 GAL)

(82 GAL)

9.SLiters

9.5Liters

9.5Liters

14.2Liters

14.2Liters

14.2Liters

(111 GAL) (159 GAL) 34 Liters 34Liters

(2.5 GAL)

(2.5 GAL)

(2.5 GAL)

(3.7 GAL)

(9.0 GAL)

TOTAL ENGINEVOLUME11 Liters (2.9 GAL) UPPERROLLER

MOTOROIL

LOWERROLLER

20cc X2

11Liters

11 Liters

(3.7 GAL) (3.7 GAL) 17 Liters 17 Liters

(2.9 GAL) 20cc X2

(2.9 GAL) 20cc X4

(4.5 GAL) (4.5 GAL) 20cc X4 20cc X4

SK300

17Liters

SK400

(9.0 GAL) 38 Liters

38Liters (4.5 GAL) (10.0 GAL) (10.0 GAL) 50cc X4 50cc X4 50cc X4

(.005GALX2){.005GALX2)[.005GALX4)(.005GALX4)(.005GALX4)(.01GALX4) (.01GALX4) (.01GALX4) 150cc X12 150cc X12 220c¢ X14 300cc X14 300cc X14 250cc X16 250cc X16 500cc X16 (.04GALX12)[.04GALX12)[.05GALX14)(.08GALX14)(.08GALX14){.07GALX16)[.07GALX16)(.13GALX16]

IDLER SWING MOTOR REDUCTION UNIT TRAVEL MOTOR REDUCTION UNIT

200cc X2 200cc X2 200cc X2 200cc X2 200cc X2 300cc X2 300cc X2 400cc X2 (.05 GALX2) (.05GALX2) (.05GALX2)(.05GALX2)(.05GALX2) (.08GALX2) (.08GALX2)(.11GALX2) 5.8 Liter 12Liter 6.2 Liter 12Liter 16 Liter 16Liter (1.5 GAL)

(1.6 GAL) (3.2 GAL) (3.2 GAL) (4.2 GAL) (4.2 GAL) 3 Liter X2 3 Liter X2 3 Liter X2 6 Liter X2 7.5 Liter X2 7.5 Liter X2

GEAROIL

ATTACHMENT PINS

GREASE

SLEWINGRING GEAR TRACKTENSION

MOS= GREASE

COOLANT !

FUEL

(2.3GALX2) (2.6GALX2) "U" JOINT "U" JOINT "U" JOINT "U" JOINT "U" JOINT "U" JOINT "U" JOINT "U" JOINT EACHSIDE EACHSIDE EACHSIDE EACHSIDE EACHSIDE EACHSIDE EACHSIDE EACHSIDE 15 15 15 15 15 17 15 15 PLACES PLACES PLACES PLACES PLACES PLACES PLACES PLACES 1 PLACE 1 PLACE 1 PLACE 1 PLACE 1 PLACE 1 PLACE 1 PLACE 3 90= X 4 90° X 4 90° X 4 PLACES 90° X 4 90° X 4 90° X 4 90° X 4 2 PLACES 2 PLACES 2 PLACES 2 PLACES 2 PLACES 2 PLACES 2 PLACES 2 PLACES

ADJUSTMENT

AS REQ’D

SWINGGEAR

9.0 kg

SUMP(BATH)

(19.8Ibs)

RADIATOR

7.5 Liters

COOLINGSYSTEM

(2.0 GAL) 17 Liters

ENGINE TOTALVOLUME FUELTANK

19 Liter

(5.7 GAL) (10.3 GAL) 8.8 Liter X2 10 Uter X2

TRAVEL MOTOR OPERATING LEVERJOINT

EP

21.5 Liter

REDUCTION UNIT REDUCTION UNIT

iiiiiiii iiii

(.8 GALX2) (.5 GALX2) (.8 GALX2) (1.SGALX2)12.0GALX2) (2.0GALX2)

SWING MOTOR

AS REQ’D AS REQ’D AS REQ’D AS REQ’D 6,4 kg 8.3 kg 8.7 kg 11.3 kg (18.3Ibs) (24.9Ibs) (14.1Ibs) (19.2Ibs) 7 Uters 7.5 Uters 8.5 Uters 7.3 Liters

AS REQ’D AS REQ’D AS REQ’D 14 kg 26 kg 14 kg (30.8Ibs) (30.9Ibs) (57.3Ibs) 7.3 Liters

12.6 Liters 23.9Liters (2.0 GAL) (2.2 GAL) (1.54 GAL) (1.92 GAL) (1.92 GAL) (3.3 GAL) (6.3 GAL) 17 Uters 19 Liters 24 Liters 26 Liters 26 Liters 43 Liters 55 Liters

(4.5 GAL) (4.5 GAL) (5.0 GAL) (6.2 GAL) (7.0 GAL) (7.0 GAL) (11.4 GAL) 250 LITERS 250 LITERS250 LITERS 300 LITERS310 LITERS 310 LITERS 580 UTERS650 LITERS (82 GA~ (153 GAL) (172 GAL) (66 GAL) (66 GAL) (66 GAL) (79 GAL) (82 GAL)

* Refer to LUBRICANT SPECIFICATIONS (Page 2-7) for properoil, grease,fuel, andcoolantclassifications.

Page 2-6

s,o~,,~

GENERAL SPECIFICATIONS LUBRICATIONSPECIFICATIONS Thefollowinginformation is designed to allowusageof the properoils, greases,fuels andcoolants in variousclimatesandcertainworking conditions.

LUBRICANT HYDRAUUCOIL (ANTI-WEAR, ANTI-OXIDANT AND NON-FOAMING)

FRIGID -30°C - 15°C (-22OF~ 59°F)

FRIGID -20°C. 30°C (-4OF_ 86OF)

CLIMATE ZONE FRIGID-WARM -25°C ~ 40°C (-13°F ~104°F)

WARM .5°C ~ 40°C (230F~ 104°F)

VERY HOT 5°C ~ 55°C (41°F- 131°F)

* MobilDTE13M oil with HighViscosity Index

ISOVG22

ISOVG32

ISOVG32S*

ISOVG46

ISOVG68

LUBRICANT

CLIMATE ZONE

ENGINEOIL* A.PJ. CLASSIFICATION FOR"SERVICE

I I

CE" I

* ALL ENGINES SHIPPEDFROMFACTORY I WITHSAE15W40 OIL IN ENGINE OIL PAN. I

FRIGID -30°C ~ 10°C (-22°F ~ S0°F)

WARM -5°C. 40°C (23°F ~ 104°F)

VERYHOT 40°C and Above (1040F and Above)

SAE5W30

SAE15W40

SAE15WS0

LUBRICANT

FUEL

LUBRICANT ENGINEOIL (FOR GENERAL PURPOSE LUBRICATION)

CLIMATE ZONE FRIGID -15oc.-25oc (-5°F --13°F)

WARM -5oc. -15oc (5OF~ 23OF)

VERYHOT -5°C and Above (23°F and Above)

JIS SPECIALNo.3 LIGHT OIL

JIS NOo3UGHTOIL

JIS No.2 LIGHTOIL

FOR ROLLERSANDIDLERS ON ALL MODELS. FORSWINGMOTORREDUCTIONUNIT AND TRAVELMOTORREDUCTIONUNITS ON THE FOLLOWING MODELS:SK100 - SK270 A.P.I. Classification for "Service CE" - SAE30

LUBRICANT GEAROIL (FOR SK300 ~ SK460 SWINGMOTOR AND TRAVELMOTOR REDUCTION UNITS) LUBRICANT

EXTREMEPRESSURE GEAROIL #90 GRADEGL-4 BY A.P.I.

GENERALLUBRICATION

SWINGGEAR SUMP(BATH)

:.XTREME PRESSURE MULTI-PURPOSE GREASE GREASE

CLASSIRCATION

N.LG.I. No.2 LITHIUMBASE,

N.L.G.I. No.2 LITHIUMBASEWITH MoS 2 GREASE

EP TYPE GREASE LUBRICANT ENGINE COOLANT (50% MIXTURE)

s,O,o.,-os~

ANTI-FREEZE(LLC) -340C(-29.2OF)

Page2-7

GENERALSPECIFICATIONS

FILTERS Thefollowinginformation is designed to allowusage of the correct filter elements.

SYSTEM

HYDRAULIC

LOCATION OF FILTER USE RETURNFILTER

SK115 Dz-SK160 24046Z15

ELEMENT TANK SUCTION STRAINER TANK BREATHER FILTER ELEMENT PILOT MANIFOLD BLOCKFILTER *BREAKERRETURNLINE ELEMENT(OPTIONAL) ENGINEOIL FILTER

ENGINE

**AIR CLEANER INNER ELEMENT

SK300-SK330

SK400-SK46(

24046Z73

24046Z18

24046Z18 2446R146S1

2446R307F2

2446R330F1

2446R347F1

2446U260S2

2446U260S2

2446U260S2

2446U260S2

2446R351F1

2446R351 F1

2446R351F1

2446R351F1

2446R351F1

2446U233S2

2446U233S2

2446U233S2

2446U233S2 (](2)

2446U233S2 (X2)

~* 3908616

ENGINEFUELFILTER CARTRIDGE(SECONDARY) ENGINEFUEL FILTER CARTRIDGE (PRIMARY)

*~ 3908616

2451U180-1

2451U180-1

2446R277S6

2446R255S6

2446R254S6

2446R273S1

2446R274S1

2446R277S5

2446R255S5

2446R254S5

2446R353S3

2446R352S3

~* 3903640

3903640***

3903640***

2451U180-2N

2451U180-2N

*~ 3925274

*~ 3925274

3925274*** ME717651

ME717651

FUEL FEEDPUMP GAUZEFILTER WATERSEPARATOR ASSEMBLY/SCREEN

OPERATOR

CAB HEATER

CAB

FILTER ELEMENT

u

i

AIR CLEANER OUTERELEMENT

FUEL

24046Zl8

SK220~ 270

2446R307F2

3908616***

CARTRIDGE

SK200-SK21(

3908633***

3908633***

3908633***

2446U234S13

2446U234S13

(ASSEMBLY)

(ASSEMBLY)

(ASSEMBLY)

(SCREEN)

(SCREEN)

24100U1496S12 24100U1496S12 24100U1496S12 24100U1496S12

2479U371S28

WITH OPTIONALFACTORYBREAKERKIT EC & MIDDLEEAST SPEC. MACHINES-NO AIR CLEANERINNER ELEMENT CONTACTAN AUTHORIZEDCUMMINSDEALER.

Page2-8

s/o~.,-05~

Kobelco

Mark

IV

Kobelco America Inc. SJOmnt-04/99

SERIAL NUMBERSTATUS MARKIV

SK115DZ

LPU-5001~

SK130IV SK130LC IV

LPU-0201~ YPU-2001~

SK150LC IV SK150LC IV/MC

YMU-1414~ 1500 YMU-1501~

ED180

YLU-0001~

SK200IV SK200 IV/MC

YNU-0201~ 0395 YNU-0501~

SK200LC IV SK200LC IV/MC

YQU-0200~ 2962 YQU-3101~

SK220IV SK220 IV/MC SK220IV NLC SK220 IV NLC/MC

LQU-0101~ 0016 LQU-0101~ LLU-5001~ 5058 LLU-5101~

SK220LCIV SK220LCIV/MC

LLU-1201~ 1681 LLU-1801~

SK270IV LC SK270 IV LC/MC

LBU-0001~ 0120 LBU-0201

SK300LC IV SK300 LC IV/MC

YCU-0301- 0602 YCU-0603,0607, 0611~

SK400LC IV SK400LC IV/MC

YSU-0202~ 241 YSU-0242~

America Inc.

SJOmnt+04/99

MACHINE FAMILIARIZATION FAMILIARIZATION All operators, service mechanicsand personnel responsible for operation, inspection and maintenanceof the machineshould becomethoroughly familiar with the controls and components,and their functions, before working with, or on, this equipment.

Studythe information in this section to becomefamiliar with the controls and componentsof this machine.

GENERAL MACHINE NOMENCLATURE The Nomenclaturedrawing below (Figure 2.1 ) points out locations of major componentsof the KOBELCO SK115LCMark IV Hydraulic Excavator.

Study these areas and locate these componentson the machine. Specific information regarding these componentsare explained on the following pages of this section.

-OPERATORCAB (SEEFIGURE 2.2)

-ARM CYUNDER

-- BOOMWORK LIGHT BOOM

-- SWIVELJOINT SLEWING RING SWINGMOTOR --

MIRROR MAIN CONTROL VALVE HANDRAIL FUELTANK --

CYLINDER

HYDRAULIC OIL RESERVOIR --

LINK

ENGINE MUFFLER

IO

-BOOMCYUNDER (1 EACH SIDE)

LINK

PUMP ACCESS DOOR HYDRAUUC PUMPS --

REARWORK LIGHT SWING FLASHER

BUCKET --

,~

co.o,s OPERATOR

CUMMINS 4BT3.9 TRACK SPRING (1 EACHSIDE) MOUNTING STEP (2 EACH SIDE)

-- REAR COUNTERWEIGHT

(600ramSTANDARD) LOWER ROLLER (6 EACHSIDE) ENGINEAIR CLEANER ACCESSDOOR BA’I’FERIES -TRAVEL MOTORSPROCKET

RADIATOR

-- HIYDRAUUC OIL COOLER ENGINECOOLANT RESERVOIR L

FIGURE2.1

SK115DZ ~ SK130LC IV OPERATIONAND CONTROLS The following information is given tO locate and explain the function of the Operator Control Switches for the Models SK115DZ~ SK130. Use this information in conjunction with the Electrical Schematics when troubleshooting particular circuits.

L.H. TRAVELLEVER L.H.TRAVEL

PEDALS

R.H.TRAVEL LEVER DOZER LEVER R.H.TRAVEL PEDALS

~

L.H. #17- HORN

REST

~

L.H. OPERATINGCONTROL LEVER

SAFETY LEVER

#19- #28- CLUSTERGAUGE "-" PANEL m THROI"I’LE CONTROL LEVER #1- KEY SWITCH SWITCH FOR DOZER CONTROL

#5 ~ #9 (A - E) R.H. SWITCF

#8 &#12 ~ 16 SWITCH PANEL

~

’-~4V CIGARE’I-rE LIGHTER 12V POWERSUPPLY

1.

KEY SWITCH HEAT - Gridheaterair-intake.

OFF - Disconnects electrical power to all electrical components.

ACC - Allowsuseof electrical accessories.

ON- Supplies electrical powerto all machine elec~’ical circuits. starterto allowstartingof the START-Engages engine,

4.TRAVEL

OFF- Depress Buttononceto turn "OFF".

TTO~N~ ON- Depress Button onca to turn "ON".

BU

5.

2.

REAR WORK LIGHT

o

R (lIIll~H 1 ON-DepressButton once to turn "ON’.

OFF- Depress Buttononceto turn "OFF".

BUTTON -3.

SPEED SELECT SWITCH

WIPER & WASHER SWITCH OFF-TurnsWiper"OFF’.

OFF~ ~~ ~ -. This position allows intermittent operation of -- wiper. )- Thispositionallowscontinuous operation of -- wiper.

PUSH DOWN - Causes washerto spray washerfluid ontowindshield.

~

FRONTWORK LIGHT 0

,~F

(~

ON- Depress Buttononceto turn "ON".

OFF- Depress Buttononceto turn "OFF".

BUTTON __I

Page3-2

~o==.o5~

SK115DZ ~ SK130LC IV OPERATIONAND CONTROLS 7. HYDRAULIC;)ILTEMPERATUREALARMLAMP

15.WORKLIGHT SWITCH(EUROPESPEC)

~ ~

ON- Lampilluminates when Hydraulic OiITemperature is 3°C(26.6°1=)or lower.

OFF-Lampgoes out whenHydraulic Oil Temperature reaches10°C (40°F).

Normaloperating temperatureof hydraulic oil is 45°C55°C(113OF- 131OF).

Depress this sideof switchto turn off all worklights.

16. ROTARY LIGHT SWITCH(EUROPESPEC)

8. DOZERCONTROL Toenergizesolenoidfor flow divider valve.

Depress this side of switchto turn on rotarylight.

Depress this sideof switchto turn off rotary light.

17. HORNSWITCH

9. HEAT& AIR CONTROLS

C

Depress this side of switchto turn on all worklights.

Locatedon top of L.H. OperatorControl.

Depressto soundhorn. Releaseto stop soundingof horn.

18. ENGINE EMERGENCY STOP CONTROL

~E

"~’~: Located at lower R.H. side of operator seat.= Pull control out to stop enginein caseoj emergency

A - FANSWlTCH Pushcontrol downto increase flow 1. OFFTurn switchcountemlockwise of warmwaterto heatercore. to left mostposition.

2. LOW Turn switch clockwise to D- INSIDE/OUTSIDEAIR first dot.

CIRCULATION CONTROL 3. MEDIUM Turn switch clockwise to second Pull control up to circulate outside dot. air into cab.

4. FAST Turn switch clockwiseto third dol Pushcontrol downto stop circulation of outsideair into cab.

B - PLUGS - Toallow installation of optional equipment.

E- DEFROSTERSELECT CONTROL Pull controlup for air circulation C - HEAT TEMPERATURE CONfromunderseat.

TROL Pushcontrol downfor air circulaPull control "UP" to reducethe tion behindseat. flow of warmwaterto heatercore.

19. FUELLEVELMETER F- Full tank, approximately 250liters (66 Gal.) e~

E- Emptytank, approximately 3 liters (8 Gal.) of fuel in Tank.

20. ENGINE COOLANTTEMPERATURE METER RED-Indicates enginecoolant temperatureis abovesafe operating temperature.ReduceengineRPMor stop engineand allow to cool.

WHITE-Engine safe operating temperaturerange.

BLUE-Enginecold range.

~~e

21. ENGINEHOURMETER 10 I01 01 01 01 01 Indicates actual hours enginehas ran.

10. 24V CIGARETTELIGHTER

B

ON- Pushin.

OFF-Lighter "POPS"out.

Thelighter shouldpop out within 30 seconds.

If it doesn’t,haveit repaired.

Donot uselighter for a 12Vpowersource.

22. FUELLEVELLAMP

I~

11.12V POWERSOURCE

Illuminateswhen fuel tanklevel is 14liters (3,7 Gal.)or less.

Refuel immediatelyif Fuel Level Lampis illuminated.

23. ENGINEOIL PRESSURE LAMP ilp~

To allow use of accessoriesrequiring a 12VDC powersource.

Illuminates whenOil Pressureis belowsafe operatingpressure.

Stop EngineImmediately and checkoil level if lamp comes on during operationof the machine.

24. BATTERYCHARGELAMP

!

12. AUTODECELERATION SWITCH(Europe ONLY)

~"~ Illuminates whenelectrical chargingsystemis not functioning properly.

Checkthe charging systemif light comeson during operation.

Depressthis side to turn Auto Decel"ON", This will drop engineRPM to 1050,

25. ~

13. TRAVELALARMCANCELSWITCH Depressagain to turn Travel Alarm"OFF" AlwaysuseTrevel Alarm during allTrevel Operations

14. ENGINESTARTAID ICON Thisiconwill displayafter keyswitchis turnedto "HEAT" position.This systemservesto warmthe engineair intake when starting in coldclimates.

s~o~.,~s~

ENGINE COOLANTTEMPERATURE LAMP Illuminates whenengineco°lent temperaturerises ab°ve105°C(211°F)" If lamp comeson reduce engine RPMimmediately and stop operation to allow engineto cool downto safe operating temperature.

-- Depressthis side to turn Auto Decel "OFF".

26. HIGH TRAVELSPEEDLAMP 1~ Illuminates when the Travel Speed Select switch is "ON".

27. DIRTY ENGINEAIR CLEANER LAMP P,~dl

Illuminateswhenengineair cleanerelement(s)are full of debris.

If illuminated, clean or replaceelement(s)immediately.

u

28. ENGINESTARTAID LAMP

Page 3-3

SK150/160LC

~ SK270LC IV OPERATION AND CONTROLS

The following information is given to locate and explain the function of the Operator Control Switches for the Models SK150~ SK270.Usethis information in conjunction with the Electrical Schematicswhentroubleshooting particular circuits.

1. KEY SWITCH

@

4.WIPER & WASHERSWITCH HEAT - Grid heater air-intake.

OFF- Disconnectselectrical powerto all electrical components.

ACC- Allows use of electrical accessories.

ON- Supplieselectrical powerto all machine electdcalcircuits.

START- Engages starter to allowstarting of the engine.

2.THROTTLE POTENTIOMETER

~~

Electrically controls engineRPM,in conjunctionwith CPU and steppingmotor,by rotating switch clockwiseor countemlockwise.

LO- Lowestengine RPM.Idle position.

No Load, 850 RPM~ 900 RPM HI- Highest engineRPM.Hi Idle position.

No Load- 2355 RPM~ 2405 RPM

3. KPSS MODESWITCH H - For best machineperformancein heavy digging operations.

S - Best machineperformanceand control in light duty operations.

FC- Bestperformance whereprecision fine control is required.

D - For fine meteringof travel operations.

Page3-4

~

~;>

OFF-Turns Wiper "OFF". positionallowsintermittentoperationof wiper. ~-This >This position allowscontinuousoperationof wiper. ~ PUSHDOWNCauseswasher to spray washer fluid onto windshield.

5. HEAVYLIFT SWITCH

~ 6.

DEPRESS this side to turn HeavyLift Mode"ON" DEPRESS this side to turn HeavyLift Mode"ON’.

HYDRAULIC OILTEMPERATURE ALARM LAMP ON- Lampilluminates whenHydraulic OilTemperature

--~’/

3°C (26"6°F) I°wer" OFF- isLamp goes out or when Hydraulic Oil Temperature reaches10°C(40°F).

NormaloperaUng temperature of hydraulic oil is 45~C .55°C (113°F~ 131°1=).

7. 24V CIGARETTE LIGHTER ON-Pushin.

OFF-Lighter "POPS"out.

Thelighter shouldpopout within 30 seconds.

If it doesn’t, have it repaired.

Donot use lighter for a 12Vpowersource.

s/o~.,.0~

SK150/160LC ~ SK270LC IV OPERATIONAND CONTROLS 8.12V POWERSOURCE To allowuseof accessoriesrequirlng a 12VDC powersource.

(~

9. KPSS RELEASESWITCH

....

~

RELEASE - Moveswitch up to release KPSSModeSwitch only whenCPUtrouble is displayed on Gauge ClusterDisplay.

KPSS Moveswitch downto engageKPSSMode Switchafter testing andrepair are complete KPSS RELEASESWITCH SHOULDONLY BE MOVED

BY SERVICETECHNICIAN.

10. EXTRA& BREAKER SWITCH(OPTIONAL)

~

-- DEPRESS this side to turn switch "ON".

-- DEPRESS this side to turn switch "OFF’.

11. ENGINESTARTAID ICON This icon will display after keyswitchis turnedto "HEAr"position.

This systemservesto warmthe engineair intake whenstarting in coldclimates.

18.WORKLIGHT SWITCH(EUROPESPEC)

~ ~

Depreasthis side of switch to turn on counterweight & cabworklights.

Depress this sideof switchto turn off worklights.

19, ROTARY LIGHT SWITCH(EUROPESPEC) Depreas this sideof switchto turn on rotarylight.

Depress this sideof switchto turn off rotary light.

20. HORNSWITCH

~__

Locatedon top of L.H.OperatorControl.

Depressto soundhorn. Releaseto stop soundingof horn.

21. ENGINE EMERGENCY STOP CONTROL Locatedat lowerR.H.side of operatorseat.

Pull control out to stop enginein caseof emergency

22. HEAT& AIR CONTROLS

12. SWINGFLASHERSWITCH

~

ON-Depressthis side of switch to turn swingflashers "ON".

OFF-Depressthis side of switch to turn swingflashers "OFF".

13.WORKLIGHTS SWITCH(KAI SPEC)

~

Depreasthis side of switch to torn on Boomand Front Frame workinglights.

Return switchto centerpositionto torn off all workinglights.

Depress this side of switchto turn on all workinglights.

14. AUTOACCELSWITCH

~

-- Depressthis side to turn Auto Accel "ON’.

This will drop engineRPM to 1050.

-- Depressthis side to turn Auto Accei "OFF".

15, TRAVELSPEEDSELECTSWITCH

~

Depressandreleasethis side to travel in 2nd(Hi-Speed).

Depressand releaseto return to 1st (Normal)travel speed.

16. TRAVELALARMCANCEL SWITCH

~

Depreeaagain to turn Trevel Alarm"OFF" AlwaysueaTravelAlarmduring allTravel Operations

17. BUZZERSTOP/TIMESET SWITCH

A- FAN SWITCH Pushcontrol downto increaseflow.

1.OFF Turn switch cu ntemlockwise to of warmwaterto heatercore. left mostposition.

2. LOW Turnswitch clockwiseto first dot D- INSIDE/OUTSIDEAIR 3. MEDIUM Turn switch clockwise to secondi CIRCULATION CONTROL dot, Pull control up to circulate 4. FAST Turn switch clockwiseto third do outsideair into cab.

Pushcontroldownto stop circulaB- PLUGS - Toallow installation of tion of outsideair into cab. optional equipment.

E- DEFROSTERSELECT CONTROL C- HEATTEMPERATURE CONTROl Pull controlupfor air circulation Pull control "UP"to reducethe flo~ fromunderseat. of warmwaterto heatercore.

Pushcontrot downfor air circulation behindseat.

23. VARIABLELOADINGMODESWITCH(OPTIONAL) TheOptfonalVariable LoadingModeis designedfor use in repetitive loading operationswherea combination of Boom andSwingoperatfonsare utilized. Rotationof the switchmetersthe amount of hydraulicoil flowing to the Boomand SwingSpools of the MainControl Valve for precise timing of Boomand SwingLocation.

CLOCIG~ISE rotation flows moreoil to Swing and less to Boom.

COUNTERCLOCKWISE rotation flows more oil to Boomand less to Swing.

~[~

24, GAUGECLUSTERDISPLAY The GaugeCluster Display serves manypurposes. See Section 11 Page3-5 for explanalJonof the functions and displaysof the Gauge ClusterDisplay.

25. POWERBOOSTSWITCH Other vital functionsof the Buzzer Stop/TimeSet Switch are described in SectionII andSection Vl of this Manualas well as the OperatorManual.

s/~.,-os~,

Locatedon top of R.H.OperatorControl.

--Depress to activate PowerBoost.

Releaseto de-activate PowerBoost.

Page 3-5

SK300/330LC IV ~ SK400/460LC IV OPERATIONAND CONTROLS The following information is given to locate and explain the function of the Operator Control Switches for the Models SK300t330~ SK400/460.Use this information in conjunction with the Electrical Schematics whentroubleshooting particular circuits.

TRAVEL LEVERS & PEDALS

#20- HORNBU’I’rON

OPERATOR

(Also See: Page 6-4)

/

SAFETY LOCK LEVER LH.

SINGLE PEDAL TRAVEL

#25-

~IL’~

~4 GAUGE "--" ’

r~j j

CONTROL~__

\ ~

CLUSTER DISPLAY R.H. OPERATOR CONTROL

/--

~

POWER BOOST SWITCH

#3-

KPSS

MODE SWITCH

#2-THROttLE POTENT]OMETER

~- #23--

L

!. #11-

ETHER INJECTION

VARIABLE LOADING (OPTIONAL)

SWITCH m -Q~J; \

~ #10-

EXTRA SWITCH -"

(oFnONAL)

/:

I’

~/~

,

"

#24- EMERGENCYENGINE STOP CONTROLNOTE: SK4001SK460 IS ELECTRIC SOLENOID NOT

~#1

KEYSWITCH

’~O

~ R.HICONSOLE

,o

~ ~ #7-

MODE

SWITCH

PANEL

#4 - #6 & #22 (A ~ E) 24V

CIGARETTE

LIGHTER

#5 CAP -J

4.

1. KEY SWITCH HEAT-No function. Donot use. electrical powerto all OFF- Disconnects electrical components.

ACC- Allows useof electrical accessories.

ON" Supplieselectrical powerto all machine electricalcircuits.

START- Engages starter to allowstarting of the engine.

2.THROTTLE POTENTIOMETER

allowsintermittentoperationof wiper. ~-Thisposition

O~~ OFF-Turns Wiper"OFF’.

~

=’= ~ /

~- This position allows continuous operation of wiper.

PUSHDOWNCauseswasher to spray washerfluid onto windshield.

5. HEAVYLIFT SWITCH

Electrically controls engineRPM in conjunctionwith CPU and steppingmotorby rotating switch clockwiseor counterclockwise.

LO- LowestengineRPM.Idle position.

No Load- 850 RPM~ 900 RPM HI - HighestengineRPM.Hi Idle position.

No Load- 1930 RPM~ 1970 RPM

WIPER & WASHERSWITCH

DEPRESS this side to turn HeavyLift Mode"ON".

DEPRESS this side to turn HeavyLift Mode"OFF’.

6.

HYDRAULIC OILTEMPERATURE ALARM LAMP ON-Lampilluminates whenHydraulic Oil Temporatureis 3°C(26.6°F)or lower.

OFF-Lampgoes out whenHydraulic Oil Temperature reaches10°C(40°F).

Normaloperatingtemperatureof hydraulic oil is 45°C .55oC(113°F. 131OF).

3. KPSS MODE SWITCH

s

H - For Pest machineperformancein heavy digging operations.

S- For pest machineperformance andcontrol in light duty operations.

FC- For pest performancewhereprecision fine controlis required.

D- For fine meteringof travel operations.

7. 24V CIGARETTE LIGHTER ’ ON-Pushin.

OFF-Lighter "POPS"out.

Thelighter shouldpopout within 30 seconds.If it doesn’t, have it repaired.

Donot uselighter for a 12Vpowersource.

~.~

SK300/330LC IV ~ SK400/460LC IV OPERATION ANDCONTROLS 8.12V POWERSOURCE

18. WORKLIGHT SWITCH(EUROPESPEC)

(~

Depressthis side of switch to turn on counterweight & cabworklights.

Depress this side of switchto turn off worklights,

To allow useof accessoriesrequiring a 12VDC powersource.

19. ROTARYLIGHT SWITCH(EUROPESPEC)

9, KPSSRELEASESWITCH RELEASE - Moveswitch up to release KPSSMode Switch only whenCPUtrouble is displayed on GaugeCluster Display.

KPSS- Moveswitch clown to engageKPSSModeSwitch after testing andrepair are complete.

KPSS RELEASESWITCH SHOULDONLY BE MOVED

BY SERVICETECHNICIAN.

~--~---~_~_

10. EXTRA& BREAKER SWITCH(OPTIONAL)

~

-- DEPRESS this side to turn switch "ON’.

~

Deprsss this side of switchto turn on rotary light.

Depress this sideof switchto turn off rotarytight.

20. HORNSWITCH

~

__ Locatad on top of LH. Operator Control.

Depressto soundhorn. Releaseto stop soundingof horn.

21. ENGINE EMERGENCY STOP CONTROL

-- DEPRESS this side to turn switch "OFF".

Locatedat lowerR.H.side of operatorseat.

Pull control out to stop enginein caseof emergency

11. ENGINESTARTAID ICON Thisicon will display after keyswitchis turnedto =HEAT" position.

This systemservesto warmthe engineair intake whenstarting in cold climates.

22. HEAT& AIR CONTROLS D

12. SWINGFLASHERSWITCH

~

OFF-Depressthis side of switch to turn swingflashers "OFF".

A

i

""

A- FAN SWITCH 1. OFFTurn switch countemlockwise to left mostposition.

13.WORKLIGHTS SWITCH(KAI SPEC) 2. LOWTurn switch clockwise to first dot.

Depressthis side of switch to turn on Boomand Front Frame 3. MEDIUM Turn switch clockworkinglights. wiseto seconddot.

Return switchto Centerpositionto turn off all workinglights.

4. FASTTurn switch clockwise to third dot.

Depress this sideof switchto turn onall workinglights.

B-- PLUGSTo allow installation of optional equipment.

14. AUTOACCELSWITCH

~

Depressthis side to turn AutoAccel"ON".Thiswill drop engine RPM to 1050.

Depressthis side to turn AutoAccel"OFF",

15.TRAVEL SPEEDSELECTSWITCH

~

Depressandreleasethis side to travel in 2nd(Hi-Speed).

Depressand releaseto return to 1st (Normal)travel speed.

16.TRAVEL ALARMCANCELSWITCH

~

-- Depressagain to turn Travel Alarm "OFF" AlwaysuseTravelAlarmduring allTravel Operations

Pushcontrol downto increaseflow of warmwaterto heatercore.

D--INSIDE/OUTSIDEAIR CIRCULATION CONTROL Pull control up to circulate outside air into cab.

Pushcontrol downto stop circulation of outsideair into cab.

E- DEFROSTERSELECT CONTROL Pull controlup for air circulation from underseaL C- HEATTEMPERATURE CONTROL Pushcontrol downfor air circulaPull control "UP" to reducethe flow tion behindseat. of warmwaterto heatercore.

23.VARIABLE LOADINGMODESWITCH(OPTIONAL)

Q [~

TheOptional Variable LoadingModeis designedfor use in repetitive loadingoperationswherea combination of Boom and Swingoperationsare utilized. Rotafionof the switch meters the amountof hydraulic oil flowing to the Boomand Swing Spoolsof the MainControl Valvefor precise timing of Boom and SwingLocation.

CLOCKWISE rotation flows moreoil to Swingand less to Boom, COUNTERCLOCKWISE rotation flows more oil to Boomand less to Swing.

24. GAUGECLUSTERDISPLAY

17. BUZZERSTOP/rIME SET SWITCH

~

)6®I

-- Depressand release to stop buzzer sounding.

-- Depressand hold to changetime display.

Other vital functionsof the BuzzerStop/TimeSet Switch are described in Section II and Section VI of this Manualas well as the OperatorManual.

s~o.,.,-o5/~

The GaugeCluster Display serves manypurposes. SeeSection 11 page3-5 for explanationof the functions anddisplays of the GaugeCluster Display.

25. POWERBOOSTSWITCH Locatedon top of R.H.OperatorControl.

Depressto activate PowerBoost.

Releaseto de-activate PowerBoost.

Page 3-7

ED180 OPERATION AND CONTROLS OPERATOR CAB NOMENCLATURE The Operator Cab Nomenclature(Figure 2.2), points out locations of Operator Controls of the KOBELCO ED180Mark IV Hydraulic Excavator Operator Cab.

Study these areas and locate these componentson the machine. Specific information regarding these componentsare explained on the following pages of this section.

LEFTTRAVELLEVER (REMOVABLE)

RIGHTTRAVELLEVER (REMOVABLE) RIGHTTRAVEL PEDAL

LEFTTRAVEL

RIGHTTRAVEL PEDAL (ONEWAYTRAVEL)

PEDAL~

RIGHTFOOT’REST LEFTTRAVEL PEDAL ~ (ONEWAYTRAVEL) LEFT

I~ GAUGE CLUSTERDISPLAY

FOOTREST ~

.~-- ~ "~ t

¯ I’-.J] SAFETYLOCKLEVER--~ (FOR HYDRAULICS)

~

~’1/ "~

I~ ....

-""

[ ""

1

I t,r l,

FI ~’ c%°Z~".o"~°~TO.

II

.=4~’ ¯ ~-~

~

~ ~’t~q \ ~ ~i~

"’

LEVER /

RIGHTCONTROL

~-3=..,.’--’,...-L.L~ [’~’~’~’~

- DOZER

/CONTROL ~--.4 ’,~’K---~"~--C--C--C--C--C--C--~

/ ~ t~

~

i

....

~

THROTTLE

OMETER ENG,NE /llr !/ ~~POTENT, EMERGENCY STOPI I~ ~ ~J~

CON OL ....L--I ,

KEYSW,TCH

, ~ ~ , ~,,.

~-

I~tt tit ! i i t I t’.

STORAGE I I COMPARTMENT LEFT ARMREST~ (ADJUSTABLE)

t~k ! "-’~%,--J~

" ~

/

LEFTSIDE t~ ---- ~ IJ I SW,TC. PANEL 1~lo~’J:1 I , ! ’ !

II

~~11

.’~

~ ~

’

~- ~ - " " ~ "~ ~=

~

/ E’-’ -’~/J,/Jt’Jl.JflJ’%L’~.~’,,-LEFTCONTROL

LEVER

t, r ~ /

~-

h-/ /"i’

.,41

~

------r" -

I

~ ~ "~ HEAD REST (ADJUSTABLE)

SW,TCH

. t JZ_:~

/

RIGHTARMREST (ADJUSTABLE)

OPERATORS SUSPENSION SEAT (3 WAYADJUSTABLE)

FIGURE 2.2

Page3-8

s~o~.,.o~

GAUGE CLUSTER CONTROL Mark IV Water Temperature Gauge Therelationshipbetween the bar positionsof the watertemperature gauge,andthe coolingwatertemperature is shownbelow.

Note: at a every 500hour interval, the icon picturedin the controller will appear.Push the buzzer stop switch twice to remove icon.

23 OIL SUPI

mation,turn to Mechatronics Page1-5.

Ll ormorein r-I] 1 RedBar (Overheat)

105 + 3°C 97 + 5° C °C 90+5 82+5° C °C 75+5

6 Green Bars (Normalrange)

°C 67+5 < 67° C

Page3-10

102 - 108° C 92 - 102° C °C 85~ 95

216 - 226° F 198 ~ 216° F °F 185-203

77- 87°C °C 70~ 80 62~ 72 °C

171~ 189° F °F 158~176 144~162°F < 153 ° F

S,Or~.,-05J99

ED180 OPERATION AND CONTROLS 6, DOZERBLADE CONTROLSWITCH

Left Tilt Pull the DozerBladejoystick to the left (side motion) to lower the left blade corner. Releasethe joystick. Thejoystick will return to the HOLD position.

TheDozerblade control switchis located on the left side control console.This switchis a twoposition rocker switch, andis usedto turn "ON" or "OFF"the DozerBlade function.

Depress this side of the switchto turn "ON"the DozerBlade function.

Depress this side of the switchto turn "OFF"the DozerBlade function.

NOTE It is necessarythat the DozerControl Switch be kept in the "OFF"position during excavatingfunctions for proper machineperformance.

7. DOZER BLADE CONTROLS FIGURE2.26a & 2.26b TheDozerBaldecontrol is a single joystick locatedon the right side consolenext to the Boom/ Bucketjoystick. a. Float Depressthe thumb-buttonin the Dozerblade control joystick to makethe blade float. Depress it again to restore normalblade function. If the blade raise and lower functions are not responding,depressthe button once moreto reset. b.

Lower Pushthe Dozer Blade joystick forward to lower the blade. Releasethe joystick. The joystick will return to the HOLD position.

C. Hold TheDozerBlade joystick will return to the HOLD positon, whenthe joystick is released from either the Loweror Raisepostion. d. Raise Pull the Dozer Blade joystick backwardto raise the blade. Releasethe joystick. The joystick will return to the HOLD position. e, RightTilt Pushthe Dozerblade joystick to the right (side motion)to lowerthe right bladecorner.

Releasethe joystick. Thejoystick will return to the HOLD position.

Hold The Dozer Blade joystick returns to the HOLD postion whenthe joystick is realsed.

Themovement of the blade will stop.

i°

®

AngleLeft A rockerswitch located on the front side of the Dozerblade joystick controls blade angling. Depressthe left side of the rocker switch to retract the left end of the Dozer Bladetowardsthe left track.

Angle Right A rocker switch located on the front side of the DozerBladejoystick controls blade angling. Depressthe right side of the rocker switch to retract the right end of the Dozer Bladetowardsthe right track.

®

FIGURE2.26a

®

®

®

@

s/o=,,-osJ99

FIGURE2.26b

Page 3-9

Kobelco

Mark

IV

Kobelco America Inc.

NOTES

S/Orent-(15/99

CYLINDERS AND MOTOR CYCLE TIMES HydraulicCylinders CYLINDERCYCLETIME TEST

CONFIGURATION

FOR

SK150THROUGHSK460

l/

I

~THROTrLE I

t

CONTROL

NOTE Themeasuring time of the cylinder cycle doesnot include the cushion stroke times. Only measuretime up to the beginningof the cushionstroke.

A,

a.

Tools & Equipment Thefollowing tools and equipment will be required to performthe cylinder cycletimetest: 1. Stopwatch.

2. Thermometer to read Hydraulic Oil temperature.

MachineSettings & Site Conditions 1. Machine throttle in "High"idle position.

2. Hydraulicoil temperatureat 45°Cto 55°C (113°Fto 131°F).

3. Firm,level testingsite.

4. Verify that engineRPM’s are correct to specifications.

FIGURE 3.1

ARMOUT CYLINDERRETRACTED

BUCKETIN CYLINDEREXTENDED

FIGURE 3.2 DONOTTIME CUSHIONSTROKEOF CYLINDERDURINGTEST

C. Boom Cylinder Cycle TimeTest 1. Movethe machine to a firm, level testing area.

2. Placethe machinethrottle control to "HIGH" idle and the KPSSWorkModeSwitch to "H" Mode.SeeFigure 3.1 NOTE The SK115and SK130machinesdo not have the KPSS WorkMode Switch. Performthe test in the High Idle positiononly.

3.

4.

5.

6.

Fully extendthe BucketCylinder. SeeFigure3.2.

Fully retract the ArmCylinder. SeeFigure3.2.

LowerBoom until bucket rests on the ground.

RaiseBoom (extendingthe cylinders) at full stroke of the control andmeasure the time for the boomcylinder to reachthe cushionstroke.

Recordthe time. SeeFigure 3.3.

7. Lowerthe boom (retracting cylinders)at full stroke andmeasure the time for the bucketto reachgroundlevel. Recordthe time. SeeFigure 3.3.

8. Repeatsteps 5 and 6 two moretimes and record the stopwatchreadings.Average the readings and comparethe averageto the BoomCylinder CycleTimeSpecification Chart.

FIGURE 3.3 BOOMCYLINDERCYCLETIMESPECIFICATIONS MODEL CYLINDERPOSITION SKl15 EXTENSION SKl15 RETRACTION SK130 SK130 S K150 SK160 ED180 ED180 SK200 SK210 SK220 SK250 SK270 SK270 SK300 SK330 SK400 SK460

H-MODE 2.5 - 3.1

EXTENSION

2.1 - 2.7 2.5 - 3.1

RETRACTION EXTENSION

3.0 - 3.6 3.0 - 3.6

RETRACTION EXTENSION

2.1 - 2.7 3.0 - 3.6

RETRACTION EXTENSION

2.1 - 2.7 2.5 -3.1

RETRACTION EXTENSION

2.3 - 2.9 2.7 - 3.3

RETRACTION EXTENSION RETRACTION EXTENSION

2.4 2.7 2.4 2.7 -

RETRACTION EXTENSION RETRACTION

2.6 - 3.2 2.9 - 3.5 2.8 - 3.4

3.0 3.3 3.0 3.3

Unit: Seconds S/Omnt~15/99

Page 4-1

CYLINDERS AND MOTORCYCLE TIMES HydraulicCylinders

J

=CAUTION

CONFIGURATION I=OR ~"r~ T"RO~.E I SK150THROUGHSK460I / / Jl CONTROLI

THIS TEST IS DESIGNED FOR STANDARD BOOM, ARM AND BUCKET. IF THE MACHINE BEING TESTED HAS ANY OPTIONAL EQUIPMENT, CHECK TO MAKE CERTAIN THERE WILL BE NO INTERFERENCE WITH THE CAB BEFORE PERFORMINGTHE TEST !!

D, Arm Cylinder Cycle Time Test

FIGURE3.4

NOTE The measuringtime of the cylinder cycle does not include the cushion stroke times. Only measuretime up to the beginning of the cushion stroke.

Movethe machineto a firm, level testing area. , 2. Place the machinethrottle control to "HIGH" idle and The KPSSWork Mode Switch to "H" Mode. See Figure 3.4.

BOOMUP BUCKET OUT CYLINDER EXTENDED CYLINDER RETRACTED FIGURE3.5 DONOTTIMECUSHION STROKE OF CYLINDER DURING TEST

NOTE The SKl15 and SK130 and machines do not have the KPSSWork ModeSwitch. Perform the test in the High Idle position only.

3.

4.

5.

6.

Fully extend BoomCylinder. SeeFigure 3.5.

Fully retract Bucket Cylinder. SeeFigure 3.5.

Fully extendthe Arm(retracting cylinder).

At full stroke of the control, bring the armall the way in (extending cylinder) and measurethe time it takes for the arm cylinder to reach the cushion stroke. Recordthe time. See Figure 3.6.

7. At full stroke of the control, fully extendthe arm (retracting cylinder) andmeasurethe time takes until the cylinder reaches the cushion stroke. Recordthe time. See Figure 3.6.

8. Repeat steps 6 and 7 two more times.

Average the recorded times and comparethe average to the Arm Cylinder Cycle Time Specification Chart.

9. Repeat steps 5 through 8 in the "FC" mode.

Comparethe average readings to the Arm Cylinder Cycle Time Specification Chart.

FIGURE3.6 ARMCYLINDERCYCLETIME SPECIFICATIONS MODELCYLINDER POSITION SKl15 EXTENSION SKl15 RETRACTION SK130 EXTENSION SK130 RETRACTION SK150 EXTENSION S K160 RETRACTION ED180 EXTENSION ED180 RETRACTION SK200 EXTENSION SK210 RETRACTION

s~o

SK250 SK270 SK270 SK300 SK330 SK400 SK460

EXTENSION RETRACTION EXTENSION RETRACTION EXTENSION RETRACTION EXTENSION RETRACTION

H-MODE 3.7- 4.1 2.4- 3.0 3.7- 4.3 2.4- 3.0 3.6- 4.2 2.6- 3.2 3.6- 4.2 2.6- 3.2 3.7- 4.3 2.9- 3.5 3.8- 4.4 3.0- 3.6 3.8- 4.4 3.0- 3.6 4.5- 5.3 2.8- 3.4 4.2- 5.0 2.8- 3.3 Unit: Seconds

CYLINDERS AND MOTORCYCLE TIMES Hydraulic Cylinders E. BucketCylinder Cycle TimeTest NOTE Themeasuring time of the cylinder cycle doesnot include the cushion stroke times. Only measuretime up to the beginningof the cushionStroke,

~ THROTTLE ~ CONFIGURATION I I CONTROL ~JFOR SKlSO THROUGH =~L

~1SK460 ~--~"~--J"~JJ

f~

,~

~-~KPSS~~(---~"~d~f

~(~

WORK MOO. 1. Movethe machine to a firm, level testing area.

Placethe machinethrottle control to "HIGH" idle and TheKPSSWorkModeSwitch to "H" Mode.SeeFigure 3.7.

SWITCHX~,~.~ \x~

FIGURE 3.7 ARMAT 90° TO ARMCYLINDERROD

NOTE The SKl15 and SK130and machinesdo not have the KPSSWorkModeSwitch. Performthe test in the High Idle positiononly. to full height using "BoomUp" con3. RaiseBoom trol.

4. Adjustthe armuntil the armis at 90° to arm cylinder. SeeFigure3.8. until the armtip is parallel with the 5. Lowerboom boom foot. SeeFigure 3.8.

6. Bringbucketall the wayin.

7. Operate bucketout (retracting cylinder)at full stroke of control and measure the time it takes for the bucketcylinder to reachthe cushion stroke (if equipped).Recordthe time. Seefigure 3.9. the bucketin (extendingcylinder) at full 8. Operate stroke of control andmeasure the time it takes for the bucketcylinderto reachthe cushionstroke (if equipped).Recordthe time. SeeFigure3.9.

9. Repeatsteps 7 and 8 two moretimes. Average the readingsandcompareto the BucketCylinder CycleTimeSpecification Chart.

ARMTIP EVEN WITH BOOMFOOT

FIGURE 3.8

BUCKETIN BUCKETOUT CYLINDEREXTENDED CYLINDERRETRACTED FIGURE 3.9 BUCKET CYLINDER CYCLE TIME SPECIFICATIONS MODEL

CYLINDERPOSITION

SKl15 SKl15

EXTENSION RETRACTION

SK130 SK130

EXTENSION RETRACTION

S K15O SK160

EXTENSION RETRACTION

E D180 E D180

EXTENSION RETRACTION

SK200 SK210 SK220

EXTENSION RETRACTION

SK25O SK270

EXTENSION RETRACTION EXTENSION

SK270 SK300 SK330 SK400

RETRACTION EXTENSION RETRACTION EXTENSION

SK460

RETRACTION

H-MODE 3.4 - 4.0 2.0 - 2.6 3.4 - 4.0 2.0 - 2.6 3.9 - 4.5 2.2 - 2.8 3.9 - 4.5 2.2 - 2.8 3.5- 4.1 1.9- 2.5 3.7 - 4.3 2.2 - 2.8 3.7 2.2 2.4 1.9 -

4.3 2.8 3.0 2.5

2.7 - 3.3 2.2 - 2.8 Unit: Seconds

S/Orent-05/99

Page 4-3

CYLINDERS AND MOTOR CYCLE TIMES HydraulicCylinders CYLINDERDRIFT A. Tools & Equipment Thefollowing tools andequipment will be required to performthecylinderdrift test: 1. Measuringtape.

2. Stopwatch.

3. Devicefor markingstarting points.

4. Thermometer for hydraulic oil temperature.

B,

Co

CYL CYL CYL(X2)

1.5M (4’i11")

I FIGURE3.10

MachineSettings & Site Conditions 1. Machineengine "OFF".

2. Hydraulic oil temperatureat 45°Cto 55°C (113°Fto 131°F).

3. Firm,level testing site.

CylinderDrift Test 1. Move the machine to a firm, level test site and allow the hydraulicoil temperature to reach45°C to 55°C(113°Fto 131°F).

2. Operatethe armout control until armis completelyout(retra.ctingcylinder), 3. Operatethe bucketout control until bucketis completely out (retracting’cylinder).

4. Adjust the boom up or downwith control until bucketis 1.5m(4’-11") fromgroundlevel tip of teeth. SeeFigure3.10.

5. Turn engine"OFF"and allow machineto sit for three minutes.

6. After three minutes,measure the distancesthe Boom,Armand Bucket Cylinders have moved.

Recordthe distances, 7. Repeatsteps 4 through6 two moretimes and averagethe measurements.Compare the averageto the CylinderDrift SpecificationChart.

8. Start the engine.

9. Operatethe bucketin control until bucketis completelyin (cylinder extended).

10. Adjustthe boom until the tip of the bucket teeth are 1.5m(4’-11") fromgroundlevel. See figure 3.11.

11. Turn engine"OFF"and allow machineto set for minutes.

12° Measure the distancefrom the tip of the bucket teeth to groundlevel andrecord the reading.

13. Repeatsteps 8 through12 two moretimes and recordthe readings.

14. Averagethe readings and compareto the Cylinder Drift Specification Chart, (BUCKET FALL-TOPEND).

Page 4-4

1.5M

FIGURE3.11

CYLINDERDRIFT SPECIFICATIONCHART MODEL BOOM DOWN (RETRACT) SKl15 MAXIMUM SKl15 10mm(0.4") SK130 MAXIMUM SK130 SK150 SK160 ED180 ED180 SK200 SK210 SK220 SK250

ARM DOWN BUCKETIN BUCKETFALL (EXTEND) (EXTEND) (TOPEND) MAXIMUM MAXIMUM MAXJ10MIN 40mm(1.6") 15mm(0.6") 300mm(12") MAXIMUM MAXIMUM MAX./10MIN

10mm(0.4") 40mm(1.6") 15mm(0.6") 300mm(12") MAXIMUM MAXIMUM MAXIMUM MAX/10MIN 170mm(6.7") 5mm(0,2") MAXIMUM MAXIMUM MAXIMUM MAX/10MIN 170mm(6.7") 5mm(0.2") MAXIMUM MAXIMUM MAXIMUM MAX/10MIN 10ram(0.4") 40mm(1.6") 20mm(0.8") 320mm(13") MAXIMUM MAXIMUM MAXIMUM MAX/10MIN 15mm(0.6") 50mm(2.0") 20mm(0.8") 360mm(14") MAXIMUM MAXIMUM MAXIMUM MAX/10MIN

SK270 SK270 15mm(0.6") 50ram(2.0") 20mm(0.8") 360mm(14") SK300 MAXIMUM MAXIMUM MAXIMUM MAX/10MIN SK330 20mm(0.79") 60mm(2.36")35mm(1.38")400mm(15.7") SK400 MAXIMUM MAXIMUM MAXIMUM MAXJ10 MIN SK460 20mm(.79") 35mm(1.38")35mm(1.38") 500mm(19.7") Unit: mm(inches)

s~o~.,.os~

CYLINDERS AND MOTOR CYCLE TIMES Swing Speed SWING SPEED A. Tools & Equipment.

1. Stopwatch 2. Devicefor MarkingStarting Point 3. Measuring Tape B. MachineSettings & Site Condition 1. Machine throttle in "High"Idle position.

2, Hydraulicoil temperature at 45°Cto 55° (113°Fto 131°F).

3. Firm,level testing site.

4, Verify that engineRPM’sare to correct specification.

C. Swing SpeedTest 1. Movethe machineto a firm, level testing area.

ARMOUT CYLINDERRETRACTED

BUCKETOUT CYLINDERRETRACTED

FIGURE4.1 ~BUCKETOUT CYLINDERRETRACTED ARMOUT CYLINDERRETRACTED

WARNING ¯ MAKECERTAIN THE TEST AREAWILL ALLOW 360° SWINGOF THE MACHINE. ¯ MAKECERTAIN NO PERSONSOR OTHER EQUIPMENT ARE WITHIN 10 FEET OF THE SWINGAREA. 2. Movethrottle to High Idle andplace KPSS switch in "H" mode.

NOTE The SK115and SK130machinesdo not have the KPSS mode switch. Performthe test with throttle lever in the High Idle position.

3. Operatethe ArmOut Control until armis completely out (retracting cylinder). SeeFigure4.1.

4. Operatethe BucketOut Control until bucketis completelyout (retracting cylinder). SeeFigure 4.1.

5. Adjust boomup or downuntil bucketteeth are 1.5m(4’-11 ") fromgroundlevel. SeeFigure4.2.

.........

Turn on Swing Flasher and soundhorn BEFORE starting swingmotion. SeeFigure 4.3.

6. After soundinghornandwith swingflashers on, operateswingcontrol at full stroke for two complete rotations clockwise,Timethe last rotation andrecord the reading. Bring swingto a completestop.

7. Repeatsteps 3 through 5 two moretimes and averagethe readings. Compare the averageto the SwingSpeedSpecification Chart.

8, Repeatsteps 2 through7 swingingcounterclockwise.

1.5M

(4’il ") FIGURE 4.2 SWINGFLASHER SWITCH

I

~H. CONSOLE

~

HORNIS LOCATED ONTOPOFL.H. CONTROL

FIGURE4.3 SWING SPEED SPECIFICATIONS MODEL SKl15 SKl15 SK130 SK130 SK150 SK160 ED180 SK200 SK210 SK220 SK250 SK270 SK300 SK330 SK400 SK460

CLOCKWISE/COUNTERCLOCKWISE 4.6- 5.0 4.6- 5.0 4.6- 5.0 4.6- 5.0 5.3- 5.7 5.3 - 5.7 5.3 - 5.7 4.6 - 5.0 4.6- 5.0 4.9- 5.4 4.9- 5.0 4.8- 5.4 5.5- 6.1 5.5- 6.1 6.5- 7.1 6.5- 7.1 Unit: Seconds per Revolution

CYLINDERS AND MOTOR CYCLE TIMES Travel Performance TRAVEL SPEED A. Tools & Equipment 1. Stopwatch 2. Deviceto markstarting point of tracks.

B. MachineSettings & Site Condition 1. Machine throttle in "High"idle position.

2. Test will be performedwith KPSSModeSwitch in "H", "FC" and "D" Modes.

3. Hydraulic oil temperatureat 45°Cto 55°C (113°Fto 131°F).

4. Firm,level testing area.

5. Verify that engineRPM’s are at correct specification.

C. Travel SpeedTest 1. Movemachine to a firm, level testing area.

2. Allowthe hydraulicoil to reacha temperature of 45°Cto 55°C(113°Fto 131°F).

3. OperateSwingRight Control until machineis sitting across(perpendicular)tracks.

4. Operatethe Boom,Armand Bucket Controls until bucketis on ground.SeeFigure7.4.

Control until bottomof right track 5. OperateBoom is approximately300mm (12") off ground.See Figure 7.4. Makereferencemarkon track.

6. PlaceThrottle Controlin "HI-IDLE"position and KPSSSwitch in "H" Mode.SeeFigure 7.5.

7. PlaceTravel SpeedSelect Switchin 1 (~lh,) Speed.SeeFigure 7.5.

8.

Operatethe Right TravelControlfull forward andmeasure the time it takesfor track to make three completerevolutions. Recordthe time.

9. RepeatStep 7 ands8 two moretimes. Average the readings and compareto Travel Speed SpecificationChart.

10. PlaceTravel SpeedSelect Switchin 2(~1~) speedandrepeat steps 8 and 9.

11. Place KPSSSwitch in "FC" Mode,place Speed Select Switchin 2(4p) speedandoperateRight TravelControl in full reverse.Recordreading and repeat two moretimes. Averagereadings and compareto Travel SpeedSpecification Chart.

Switch in "D" Mode,place Travel 12. Place KPSS SpeedSelect Switchin 1 (~IIt,) Speed,operate Right TravelControlfull forwardandrecord reading. Repeattwo moretimes, average readingsand compareto Travel SpeedSpecification Chart.

13. Repeatstep 12 with SpeedSelect Switch in 2(4p) speed.

14. Repeatsteps 4 through13 with Left Track approximately300mm (12") off ground.

** Note:Thetravel cycletime for ED180 havenot beenreleasedfrom engineering as of 07/1999.Usetimeslisted for approximate valuesonly.

SpeedSelection

* 1(,tiEr *’2(

Page 4-6

4p

Unit:

Seconds SlOrenz-05t99

CYLINDERS AND MOTORCYCLE TIMES TravelPerformance TRAVEL SPEED A. Tools & Equipment 1. Stopwatch 2. Deviceto markstarting point of tracks.

B, MachineSettings & Site Condition 1. Machine throttle in "High"idle position.

2. Test will be performedwith KPSSModeSwitch in "H", "FC" and"D" Modes.

3. Hydraulicoil temperatureat 45°Cto 55°C (113°Fto 131°F).

4. Firm,level testing area.

5. Verify that engineRPM’s are at correct specification.

FIGURE7.4 SK150 ~ SK460 ILLUSTRATED

ISPEED SELECT~ SWITCH, .~..~’-..

~..,~-J ~ k.~.~.... ~THROTTLE.~

L~

C. Travel SpeedTest

FIGURE5.5 TRAVELSPEEDSPECIFICATION CHART

SK400/460 FORWARD FORWARD

31.6 ~ 36.5 19.4 ~ 22.1 35.6 ~ 40.3 57.4 ~ 96.0 36.3 ~ 57.0

SpeedSelection

Unit: Seconds S/Orent-05/99

Page 4-7

CYLINDERS AND MOTORCYCLE TIMES Travel Performance TRAVELDEVIATION A. Tools & Equipment 1. MeasuringTape30M(100’) Capacity 2. LineParallel to Machine in soil B. MachineSettings & Site Condition throttle in "High"idle position.

1. Machine 2. KPSSModeSwitch in "H" ModePosition 3. Hydraulicoil temperatureat 45°Cto 55°C (113°Fto 131°F).

4. Firm,level testing area.

5. Verify that engineRPM’s are at correct specification C. Travel DeviationTest 1. Movemachine to a firm, level testing area. of 2. Allowthe hydraulicoil to reacha temperature 45°Cto 55°C(113°Fto 131 °F).

3. Operatethe Boom,Armand Bucket Controls until attachment is in a transportposition. See Figure7.1.

4. Scribe(draw)a line parallel to machine in the soil for a distanceof 20M(65’-7") fromfront machinetracks. SeeFigure 7.2.

5. MoveThrottle Control to "HI-IDLE"Position and place KPSS Switch in "H" Mode.SeeFigure 7.3. bothtravel controlstogetherat full for6. Operate wardspeedfor the 20M(65’-7") Distance.

SeeFigure 7.2.

7. Measureand record dimension"A". SeeFigure 7.2.

8. Repeatsteps 6 and 7 two moretimes. Average the readingsand compareto Travel Deviation SpecificationChart.

9. Repeatsteps 1 through8 with undercarriage °. turned 180

A’I’FACHMENTIN TRANSPORTPOSITION

FIGURE7.1 ----------~A

IIIII IIII IIII

IIIIIIIIIIIIIII LINEINSOIL

©

IIIIIIIII IIII

I

1

20M(65’-7") DISTANCE

FIGURE7.2

I

I CONFIGURATION FOR SK150 THRU SK4601 / -.-~.~._~ /../ f~

PLACE THROTTLE CONTROL

.

¯ ,.

FIGURE7.3

TRAVELDEVIATION SPECIFICATION CHART

I

MODELI ALL

STANDARD"A" 0 to 1200mm(0’-0" to 3’-11") Unit: mm(Inches)

Page4-8

s~.,-os,~

Kobelco

Mark

IV

KobelcoAmerica Inc. S/Or~t-05-99

MEASURING & ADJUSTING PRESSURES TABLE OF CONTENTS 5-6 2.1MACHINE PREPARATION ...........................................................................................................................

5-1 A.Tools &Equipment Required ............................................................................................................................

5-1 B.Machine Settings &SiteConditions ............................................................................................................

5-1 5-2 C.Machine Preparation Procedures ......................................................................................................

5-2 D.MainandPortReliefPressure Measurement AndAdjustment Notes ..............................................................

2.2MAIN PILOT CIRCUIT ...................... .............................................................................................................

A. MainPilot ReliefValvePressure Measurement Procedures ..........................................................................

B. Main PilotReliefValve Adjustment Procedures ............................................................................................

5-3 5-3 5-3

2.3TRAVEL CIRCUIT ................................................................................................................. ........................ 5-4 5-4 A.TravelMain ReliefValve Pressure Measurement ..........................................................................................

5.4 B. Travel Main ReliefValve Pressure Adjustment ..............................................................................................

2.4ATTACHMENT CIRCUIT"HEAVY LIFT".......................................................................................................

A. AttachmentMainRelief ValvePressureMeasurement with "HEAVY LIF’I" or"PowerBoost"Mode ON..............

B. Attachment MainRelief ValvePressureAdjustment with "HEAVY LIFT"or "PowerBoost"Mode ON................

5-6 5-5 5-5

2.5ATTACHMENT CIRCUIT - NORMAL LIFT......................................................................................................

A. AttachmentMainRelief ValvePressureMeasurement with "HEAVY LIFT" or "PowerBoost" Mode OFF............

B, Attachment MainRelief ValvePressureAdjustment with "HEAVY LIFT" or"PowerBoost"ModeOFF................

5-6 5-6 5-6

2.6SWING CIRCUIT ..........................................................................................................................................

A. Swing PortReliefValve Pressure Measurement ...........................................................................................

B. Swing PortReliefValve Pressure Adjustment ..............................................................................................

5-7 5-7 5-7

OPTIONAL TROUBLESHOOTING PRESSURES 5-8 2.7LOW PRESSURE CIRCUIT ...........................................................................................................................

5-8 ¯ ..........................

A. LowPressure ReliefValvePressure Measurement ............................................................

5-8 B.Low Pressure ReliefValve Pressure Adjustment ..........................................................................................

2.8NEGATIVE CONTROL CIRCUIT ....................................................................................................................

A. Negative Control Pressure Measurement .....................................................................................................

B. Negative Control Pressure Adjustment ........................................................................................................

5-9 5-9 5-9

~.........................................................................................................

5-10 2.9 POWER SHIFT(Pf) CIRCUIT ............

5-10 A.Power Shift(Pf)Pressure Measurement .................................................................................................

3-10 B. Power Shift(Pf)Pressure Adjustment .....................................................................................................

NOTES ............................................................................................................................................................... 5-11 5-12 ~ 5- 22 3.11 PERFORMANCE INSPECTION SPECIFICATION CHARTS ANDILLUSTRATIONS ...........................

A.SK115Dz ........................................................................................................................................ 5-12 5-13 5-14 5-15 B.SK130 ................................................................................................ ¯ ...........................................

5-16 5-17 C,SK150~SK160 .................................................................................................................................

5-18 5-19 D.SK200~SK270 ...............................................................................................................................

5-20 5-21 ¯ E.SK300~SK330 ...............................................................................................................................

5-22 5-23 F.SK400-SK460 ................................................................................................................................

S/Orcnt-05-99

MEASURING& ADJUSTING PRESSURES ill

2.1 MACHINEPREPARATION A. Tools & EquipmentRequired 2 (10,000psi) PressureGauges.

1. Two700kg/cm 2 (1,500)psi) PressureGauges, 2. Two105kg/cm 2 (1,000 psi) PressureGauge.

3. One70kg/cm 4. Two1/4 X 1/4 X 1/4 PT"Tee"adaptorfittings.

5. GeneralHandor powertools to removeand replacehydraulic fittings and components.

MACHINEIN HYDRAUUC OIL CHECKPOSITION

FIGURE2.1 SK100 ~ SK330 ILLUSTRATED

NOTE It maybe necessary to modifyhandtools in order to reach certain components for adjustment.

....

6. Thermometer to readhydraulic oil temperature.

7. Specialtools for lockingTravelMotors.

B, MachineSettings & Site Conditions 1. Attachment in HydraulicOil CheckPosition. at 45°Cto 550C 2. Hydraulic Oil Temperature (113°Fto 131°F).

3. KPSSModeSwitch in H-Mode.

4. ThrottleControlin "Hi-Idle" position.

5. Firm,level testingsite.

FIGURE2.2

C. MachinePreparation Procedures 1. Movethe machine to a firm, level testing area.

2. Operatethe attachmentcontrols until the machineis in the HydraulicOil Checkposition.

SeeFigure 2.1.

3. Allowthe hydraulicoil to reacha temperature of 45°Cto 55°C(113°Fto 131°F).

4. Turn engine"OFF".

5. Releasehydraulictank pressureby removing capfrom pressurerelief valve anddepressing relief valvestem.SeeFigure2.2.

¯ BE EXTREMELY CAUTIOUSWHILE RELEASING HYDRAULICTANK PRESSUREOR REMOVING LINES ANDFITTINGS, VAPORS ANDOIL MAYBE EXTREMELY HOT. ¯ WEARAPPROVED SAFETYCLOTHES, SHOES, GLOVESAND HARDHAT WHENPERFORMING ANY MAINTENANCEOR TEST PROCEDURES. 6. OpenMain PumpAccess Door and removethe Test Port Plug(P3) fromOutputPort on Pilot 2 SystemGearPumpand install 105kg/cm (1,500 psi) PressureGauge.SeeFigure 2.3.

2 (10,000psi) PressureGauges 7. Install 700kg/cm into al Port on pumpP1and into a2 Port on pumpP2. SeeFigure 2.4.

FIGURE2.3 SK100 THROUGHSK160 CONFIGURATION \

SK200 THROUGHSK460 CONFIGURATION

:/. ’ .,..

FIGURE2.4

ASURING & ADJUSTING PRESSURES 8. Start engir ,~edfy the engine RPM’sare within spec : anges.

9. Performthe ;: 7~-}arypressuretests andadjustmentsin the ~derthey are listed below. a. MainPilot Relief Pressure. b. Travel MainRelief Pressures. c. Attachment MainRelief Pressuresin "HEAVYLIFT" ON. d. Attachment MainRelief Pressuresin normal modewith "HEAVY LIFT" OFF. e, SwingPort Relief Pressures Pressure 10. Perform the following OPTIONAL Testsas required.(Notnecessarilyas listed). a. Attachment CylinderPort Relief Pressures. b. LowPressureRelief Valve Pressures. c, NegativeControl Pressures. d. PowerShift (Pf) Pressures D. MainandPort Relief PressuresMeasurement and AdjustmentNotes 1. If pressuregaugereadingsare within specificationsfor the particular machine beingtested, it is not necessary to adjust Relief ValvePressures.

2. During adjustmentof the two stage attachment mainrelief valves for P1andP2 pumps,perform measurement and adjustmentof the boost (heavylift) stageof themainrelief valvesfirst.

Then, completethe normalmainattachment relief pressuremeasurement andadjustment.

SeeFigures2.15A& 2.18Afor "HeavyLift" and "Normal"adjustmentscrewsand Iocknut~ 3. Measurement and adjustmentof attachment cylinder port relief valvesare not necessary during normal pressure measurement’procedures. If measurement and adjustmentof an attachment port relief valveis required,it may be necessaryto increasethe openingpressuresof the attachment mainrelief valvesand possiblythe travel mainrelief valves. Mark themaccordinglyfor easeof readjustment.

4. Install propersize pressuregaugesat correct locations, 5. Confirmthat enginerpm’sare within specifications.

6.Confirmthat enginecoolantandhydraulicoil are at normaloperating temperatures.

7. Performall testing and adjustmentprocedures observingall applicablesafety requirements.

8. Performance Inspection StandardCharts are on Pages2-15 through2-22 and are organized

by ModelNumber.

Page 5-2

9. Recordall Gauge readingsand compare to that particular machine’sc~hart BEFORE makingany adjustments.

10. All PressureTests are conducted with machine in "H" Mode and enginein "HI-IDLE," unless otherwisespecified in test procedure.

NOTE Whenadjusting, pressuresare increased and decreased as follows: CLOCKWISE ROTATION-Increase COUNTERCLOCKWISE ROTATION-Decrease E. VERIFYINGENGINERPM- SK150 - SK460 1. Start Engine.

2. Depressthe BuzzerStop Switch 5 Times.This will changethe Gauge Cluster Display from Clock to EngineRPM.SeeFigure A. BUZZER STOP SWITCH

FIGUREA NOTE The WarningBuzzersoundswhile the Engine’s RPMis being displayedto avoid the RPM display being left on duringnormalmachineoperationandaffect the other system displays andwarnings.

3. To retumGauge Cluster Displaybackto normal, depressthe buzzerstop switch onetime.

NOTE TheEngineRPM Display can be broughtbackat any time by depressingthe BuzzerStop Switchone time.

If the poweris turned"OFF",it will be necessary to repeat stepsI and 2 to get the EngineRPM on the display. display show"0"while 4. Shouldthe EngineRPM the engineis running, checkand correct the following areas: a. RPMSensor Adjustment b. RPMSensorResistance Value c. Electrical Harnessand Connections F. VERIFYINGENGINERPM-SK100~ SK130 Install anexternal Tachometer to enginein order to verify engineRPM. S/Orem-05-99

MEASURING& ADJUSTING PRESSURES 2.2 MAIN PILOT CIRCUIT A. MainPilot Relief Valve Pressure MeasurementProcedures 1, Performmachinepreparation proceduresas described in 2.1 MACHINE PREPARATION. 2. Start engineandplacethrottle control in HiIdle position. SeeFigure2.5.

3, Place KPSSModeSwitch in "H"-Mode. See Figure2.5.

4. Donot operateany controls. Thenread the pressure gauge. Recordreading and compare to chart for specific modelbeingtested on pages2-15 through2-22.

B. MainPilot Relief ValveAdjustment Procedures 1. Locatethe MainPilot Relief Valvemounted to the side of the HydraulicOil Tankin the Manifold Assembly.

SeeFigure 2.6.

2. Remove protective cap. SeeFigure 2.7.

Loosenthe adjusting screwIocknut. See Figure2.8.

3. Adjustuntil specified pressureaccordingto properchart for specific machinebeing adjusted is achieved. ’ NOTE 1 CompleteTurn Adjusts PressureApproximately: 2 (200 psi) 14.4kg/cm I/4 TurnAdjustsPressureApproximately: 2 (51.2 psi) 3.6kg/cm

ICO"F’G°",T,O. I ~-~"~’CE I FORSK150THRUSK4601//I -~ ~"/--~/1 J I ~" "

THROTrLE CONTRQL~.

IN "HI" ~"~

KPSS

\.

FIGURE2.5

.

¯

~

~

/ ,,,, I FIGURE2.6

i ] .~.-"~.~.o’~-~.~ f.. / ~’.......,_....~\J.~

i’l

PROTECTIVE ~ ~ CAP

4. After correct pressureis obtained,tighten adjusting screwIocknut,beingcareful not to overtighten. SeeFigure2.8.

5. Install protectivecapandtighten. Becareful not to overtightencap. SeeFigure2.7.

6. Verify pressureafter tighteningIocknutandcap.

FIGURE2.7

j FIGURE2.8 S/Or~-O~-,9

Page 5-3

MEASURING& ADJUSTING PRESSURES SPECIAL TOOL LOCATION FOR SPECIAL TOOL LOCATION FOR 2.3 TRAVELCIRCUIT REVERSE STALL FORWARD STALL A. Travel MainRelief Valve PressureMeasurement 1. PerformMachinePreparation Proceduresas described in 2.1 MACHINE PREPARATION. 2. Start engineandinstall specialtool (refer to page5-3 for tool dimensions) into sprocketon eachside Of machine for stalling forwardmotion of TravelMotors.SeeFigure2.9.

!

I ¯ MAKE CERTAIN SPECIALTOOLIS SEATED AGAINSTCRAWLER FRAMEANDBETWEEN SPROCKET TEETH. NEVERALLOW SPECIAL TOOLTO RESTAGAINSTCRAWLER FRAMECORNER REINFORCEMENTS. ENGAGE TRAVELSLOWLY & CAREFULLY UNTIL TOOLIS POSITIONED CORRECTLY 3. Movethrottle control to "HI-IDLE"place KPSS ModeSwitch in "H"-ModeSeeFigure 2.10.

4. PlaceTravelSpeedSelect switchin 2nd(41~) speedposition. SeeFigure 2.10. bothTravelcontrolstogetherto full for5. Operate wardtravel position andhold. SeeFigure2.11.

2 (10,000psi) 6. Recordreading from 700kg/cm Pressure Gauges.

Reposition specialtool in sprocketsto stall 7. reversetravel. SeeFigure2.9.

8. Repeatsteps 3 and 4.

9. Operate bothtravel controlstogetherto full reversetravel andhold. Seefigure 2.11, 2 (10,000psi) 10. Recordreading from 700kg/cm Pressure Gauges.

11. Compare readingsto chart for specific model being tested on pages2-15 through2-22.

B. Travel MainRelief PressureAdjustment 1. LocateTR1andTR2on the maincontrol valve.

SeeFigure 2.12 for SK200~460 exampleand refer to the Performance Inspection Standard Illustration for the particular machine beingadjusted (Pages2-15--2-22).

2. Loosenlock nuts andadjust eachTravel Main Relief until properpressureis achieved.

NOTE TR1-Right TravelMainRelief Valve TR2-LeftTravel MainRelief Valve 2 (1640psi) 1 Rotation=Approximately115kg/cm 2 (825psi) 1/4 Rotation=Approximately 58kg/cm 3. After adjustment, securelytighten adjustingmain Iocknuts,beingcareful not to overtighten.

Page5.-4

FIGURE2.9 CONFIGURATION FORSK150THRU SK460

CO.OL/

SWITCH FIGtIRE 2.10

WORK MODE SWITCH

OPERATE BOTH TRAVEL LEVERS TOGETHER FULLSTROKE

!

FIGURE2.11

/t ",-:E:~----~’:r-~J~J)

-

,

FIGURE2.12

~o~-~

MEASURING & ADJUSTING PRESSURES 2.4 ATTACHMENT CIRCUIT- "HEAVYLIFT" ("HEAVYLIFT IS ONSK200~ SK460ONLY) A. Attachment MainRelief Valve Pressure MeasurementWith "HEAVYLIFT" ModeON 1. Performmachinepreparation proceduresas described in 2.1 MACHINE PREPARATION. ¯ 2. Movethrottle control to "HI-IDLE"place KPSS ModeSwitch in "H"-ModeSeeFigure 2.13.

3. Place"HeavyLift" Switchin the "ON"position.

SeeFigure 2.14.

4. Operate bucketin (digging) control until bucket is completely in, thenhold.

2 (10,000psi) 5. Recordreading from 700kg/cm PressureGaugeat al port on P1 MainPump.

FOR

SKI~

TRRU

SKIS0

I

/

/

CONTROL

FIGURE2.13

¯ MAKECERTAIN THEREARENOOBJECTS IN THE PATHOF THE BOOM 6. OperateBoom UpControl until boomis completely up andhold.

2 (10,000 psi) 7. Recordreading from 700kg/cm PressureGaugeat a2 port on P2 Main Pump.

8. Compare readingsfrom steps 5 and7 to proper chart for particular machine beingtested.

B. Attachment MainRelief Valve Pressure AdjustmentWith "HEAVYLIFT" ModeON I. Locate MR1and MR2AttachmentMain Relief Valveslocatedon the maincontrol valve. See Figure2.15 for SK200 example and refer to the Performance InspectionStandardchart illustration on the particular machine beingadjusted (Pages2-15-2-22) for proper location of MR1 and MR2adjustmentMain AttachmentRelief Valves.

2. Loosenlock nuts and adjust each Attachment MainRelief Valveuntil properpressureis achieved.SeeFigure 2.15A. NOTE MR1-BucketIn (Digging) M R2- BoomUp 2 (1640psi) 1/2 Rotation=Approximately 115kg/cm 2 (825 psi) 1/4 Rotation=Approximately 58kg/cm 3. After adjustment,securely tighten Attachment MainRelief ValveIocknuts.Becareful not to overtighten.

FIGURE2.14 SK300 ILLUSTRATED

L FIGURE2.15

. EAw u~ --~ ~ ~ ADJUSTMENT \ Jl’~’~

US~ENT

(POWERBOOST) \ X

HEAVY LIFT ---"-..~....~ SCREW

(POWER BOOST)I~ ADJUSTMENT LOCK NUT

EW

ADJUSTMENT N°RMAL LOCK NUT

= i!--

J~

, ATTACHMENT MAIN RELIEF

! - ~:===="

v,vE

’ ’

(MR1 ORMR2) (SK200 ~SK460ONLY)

FIGURE2.15A S/Orent-05-99

Page5-5

MEASURING& ADJUSTING PRESSURES 2.5 ATTACHMENTCIRCUIT- NORMAL LIFT A. AttachmentMain Relief Valve Pressure Measurement With "HEAVY LIFT" Mode OFF 1. Perform machine preparation procedures as described in 2.1 MACHINEPREPARATION. 2. Movethrottle control to "HI-IDLE", place KPSS ModeSwitch in "H"-Mode See Figure 2.16.

3. Place "Heavy LiNe Switch in the "OFF" position. SeeFigure 2.17.

4. Operatebucket in control until bucket is completely in andhold.

5. Record reading from 700kg/cm2 (10,000 psi) Pressure Gaugeat al port on P1 Main Pump.

¯ MAKECERTAINTHEREARENO OBJECTSIN THE PATH OF THE BOOM

I

CONRGURATION " I .~THROTTLE FOR SK150 THRUSKdS01 / CONTROL

FIGURE 2.16

"OFF" \

f.,.~~

6. Operate boomup control until boomis completely up andhold.

2 (10,000 psi) 7. Record reading from 700kg/cm Pressure Gaugeat a2 port on P2 Main Pump.

8. Comparereadings from steps 5 and 7 to proper chart for particular machinebeing tested.

B. Attachment Main Relief Valve Pressure Adjustment With "HEAVY LIFT" Mode OFF 1. Locate MR1and MR2Attachment Main Relief Valves located on the main control valve. See Figure 2.18 and refer to the PerformanceInspection Standardchart illustration on the particular machinebeing adjusted (Pages 2-15-2-22) for proper location of MR1and MR2 Main AttachmentRelief Valves.

2. Loosenlock nuts and adjust each Attachment Main Relief Valve until proper pressureis achieved. Seefigure 2.18A for adjustment points.

NOTE MR1-Bucket In (Digging) MR2-BoomUp (Raise) z (1640 psi) 1/2 Rotation= Approximately 115kg/cm 2 1/4 Rotation= Approximately 58kg/cm (825 psi) 3. After adjustment,securely tighten adjusting main Iocknuts, being careful not to overtighten.

4. Place "HEAVYLIFT" Switch in "ON" position.

5. Re-check pressures by operating the Bucket In and BoomUp Controls and comparing Pressure Gaugereadings with proper chart for the particular machinebeing tested.

Page5-6

FIGURE 2.17

.

SK300ILLUSTRATED

N, " !, ~--~,- -’-~

FIGURE 2.18

n

NORMAL ADJUSTMENT LOCKNUT

’~ ~ ~1 "~ll=

F

NORMAL ADJUSTMENT SCREW

!!

A’B’ACHM ENT-------~

II

MA,N RELIEF I II

VALVE (MR1ORMR2)

i :i ’ !1

t

F|GURE 2.18A

~o~=-o~.,,

MEASURING& ADJUSTING PRESSURES 2.6 SWINGCIRCUIT A. SwingPort Relief Valve Prc,:~ are Measqrement 1. Performmachinepreparation proceduresas described in 2.1 MACHINE PREPARATION. 2. Movethrottle control to "HI-IDLE,"place KPSS ModeSwitch in "H"-ModeSeeFigure 2.19.

3. Operateboomdowncontrol until bucketteeth penetratesoil approximately305mm (12"). See Figure2.20.

4. Operate swingcontrolto the left andhold, stall2 ing swing. Recordreading from 700kg/cm (10,000psi) PressureGauge installed to test port a2 on P2 Main Pump.

5. Operateswingcontrol to the right andhold, 2 stalling swing. Recordreading from 700kg/cm (10,000psi) PressureGauge installed to test port a2 on P2 Main Pump.

CONFIGURATION

4. After adjustment,securelytighten Port adjusting Iocknuts,beingcareful not to overtighten, andinstall rubberprotectivecovers.

NOTE Adjustmentproceduresfor the SK120-130 require the use of internal shimsonly. Noexternal adjustmentpoints are available.

/ff"~THROTTLE /] CONTROL

FIGURE2.19

B. SwingPort Relief Valve PressureAdjustment 1. LocateRV11and RV12SwingPort Relief Valve Adjustmentpoints located in the SwingControl ValveAssembly on SwingMotor. SeeFigure 2.21 and refer to the Performance Inspection Standard chart illustration on the particular machinebeing adjusted(Pages2-15~2-22), for properlocation of RVll and RV12adjust mentpoints.

2. Remove rubber protective covers and loosen lock nuts on RV11and RV12.

3. Adjust RV11and RV12until proper pressures are achieved.

NOTE RV11-Right SwingPort Relief Valve RV12-Left SwingPort Relief Valve 2 (1420 psi) 1 Rotation=Approximately100kg/cm 2 V4 Rotation=Approximately25kg/cm(356 psi)

""]

FIGURE2.20 SK300 ILLUSTRATED

k’-" ,f--.

f’"

I!F II .; R’

":t JJ,H"~,

5=,..

,, I

FIGURE2.21

$/Otmlt-05-99

Page5-7

MEASURING & ADJUSTING PRESSURES 2.7 LOWPRESSURE CIRCUIT A. LowPressureRelief Valve Pressure Measurement

WARNING ¯ WHENPERFORMING THIS TEST, DO NOT OPERATEANY HYDRAULICCONTROLSl ¯ ANY MOVEMENT OF HYDRAULICCONTROLS WILL CAUSEEXTENSIVE DAMAGE TO GAUGES! 1. Performmachinepreparation proceduresas described in 2.1 MACHINE PREPARATION 2 (1500 psi) PressureGauges using 105kg/cm in al and a2 Test Ports on P1 and P2 Main Pumps.

2. Movethrottle control to "HI-IDLE,"PlaceKPSS ModeSwitch in "H"-ModeSeeFigure 2.33. DO NOT TOUCHHYDRAULICCONTROLS. ~ (1500 psi) 3. Recordreading from 105kg/cm PressureGauges at al anda2 test ports on P1 and P2 Main Pumps.Reduceengine RPM to "LO"idle.

4. Place KPSSModeSwitch in "D"-Modeand movethrottle to "HI-IDLE".SeeFigure2.33. DO NOT TOUCHHYDRAULICCONTROLS. 5. Recordreading from PressureGaugesat al and a2 test ports on P1 and P2 MainPumps.

6. Compare readingsto properchart for specific machinebeing tested.

B. LowPressureRelief Valve Pressure Adjustment 1. Shouldadjustmentof the LowPressureRelief Valvesbe necessary,refer to the ShopManual for the Specific Machine being adjusted.

FIGURE2.33

SK300ILLUSTRATED

"--- ----

’--"

~}

liIi

P2

I

LOW PRESSURE

I~ t L~

REUEFVA’VE ..........

FIGURE2.34

NOTE TheLowPressureRelief Valvesare not adjustableexternally. Theyare adjustedusing intemalShims.

2. TheLowPressureRelief Valvesare located in the endsectionsof the MainConb’olValve.See Figure 2.34 for SK200~460 and Performance InspectionSpecificationchartsandillustraUons for specific model.

Page 5-8

s~o,,=-o~-99

MEASURING& ADJUSTING PRESSURES 2.8 NEGATIVECONTROL CIRCUIT A. I~,gative Control PressureMeasurement 1. Performmachinepreparation proceduresas described in 2.1 MACHINE PREPARATION. 2. Install one1/4 X 1/4 X 1/4 PF"TEE"fitting at Pil port on P1 Main PumpRegulator. See 2 (1500psi) Figure 2.35. Install one105kg/cm PressureGaugeonto "TEE".

3. Install one1/4 X 1/4 X 1/4 PF"TEE"fitting at Pi2 port on P2 Main PumpRegulator. See 2 (1500psi) Figure 2.36. Install one 105kg/cm PressureGaugeonto "TEE".

4. Start engine,move throttle control to "HI-IDLE," and place KPSSModeSwitch in "H"-ModeSee Figure2.37.

5. Donot operateany Hydraulic Controls. Record 2 (1500 psi) Pressure readings from 105kg/cm Gauges at Pil andPi2 test ports.

6. Place KPSSModeSwitch in "D"-Modeand leavethrottle at "HI-IDLE."SeeFigure2.37.

7. Recordreading from PressureGaugesat Pil andPi2 test ports.

8. Compare readingsto proper chart for specific machinebeing tested.

SK300 ILLUSTRATED

~-._._._

s,:’::::’::=o

B. Negative Control PressureAdjustment 1. Shouldadjustmentof the negativecontrol pressurebe necessary,refer to the Shop Manualfor the specific machine beingadjusted.

NOTE Adjustment of the low pressurerelief valvesalso changes negativecontrol pressure.Thelow pressurerelief valves are not adjustableexternally. Theyare adjustedusinginternal shims.

2. Thelowpressurerelief valvesare locatedin the endsections of the maincontrol valve. See Figure 2.38 for SK200~460 and Performance Inspectionspecificationchartsandillustrations for specific model.

II

INSTALL TEE AND GAUGE

FIGURE2.36

MODE

~"J I

FIGURE2.37 SK300 ILLUSTRATED

¯ " -~-/

’ ~, t!

_ =og

FIGURE2.38 s~o~-os-99

Page 5-9

MEASURING & ADJUSTING PRESSURES 2.9 POWER SHIFT (Pf) CIRCUIT(SK150-SK460ONLY) A. PowerShift (Pf) PressureMeasurement 1. Performmachinepreparation proceduresas described in 2.1 MACHINE PREPARATION. 2 (1000psi) PressureGauge 2. Install one70kg/cm in a3 test port onpowershift SolenoidValve.

SeeFigure 2.39.

SK300 ILLUSTRATED

°

ii!

NOTE PowerShift (Pf) is also referred to as: TheSecondary Pressureof KPSSElectromagneticProportionate Solenoid ReducingValve.

Placethe throttle control in the "HI-IDLE"position. SeeFigure2.40.

2 (1000psi) with 4. Recordreadingsfrom 70kg/cm no operationof HydraulicControlsin the following KPSSModeSwitch settings: a, "H" Mode b. "S" Mode c. "FC" Mode d. "D" Mode 5. Locate the KPSSReleaseSwitch behind operators seat. Remove rubber grommetand place KPSSReleaseSwitch in the "RELEASE" position. SeeFigure2.41.

6. Place Machinein "H" Modeand record reading 2 (1000psi) PressureGauge from 70kg/cm without anyoperationof hydrauliccontrols.

7, Place the KPSSReleaseSwitch in the "KPSS" position. SeeFigure2.41.

8. Place the "HEAVY LIFT" Switch in the "ON" position. SeeFigure 2.40. (SK200~SK460 only) 9, Recordreading from Pressure Gauge.Compareall readingsto properchart for specific chinebeingtested. .

ma-

VIEWED

FROM UNDER R.H.

SIDE

OF REAR COUNTE~

FIGURE2.39

FIGURE2.40 KPSS SWITCH BEHIND GROMMET

./

B. PowerShift (Pf) PressureAdjustment Shouldit be necessary to adjust the PowerShift (Pf) Pressure, contact: KOBELCO Product SupportDepartment for (Pf) PressureAdjustment Instructions andAssistance.

2A.oMOg EOgOMg ’U FIGURE2.41

S/Or~t.05-99

Page 5-10

NOTES

s/o,,.=-os.99

Page5-11

MEASURING& ADJUSTING PRESSURESSK115DZ MIC LPU-5001~

PERFORMANCE INSPECTION& SPECIFICATION SK115DZ

MAIN CONTROLVALVE BOOM

RV5

BUCKET

c~,---]:~.q ~~ ._~ k-pis LE~"~AVEL ~.vlo POp1-.

co,toxs,o

Pig~_~

~LI~II~=

A2 Pop2-.--"

~ ,;,,=;.j.,..i~

jr,,.i,,,,ij

.EGA’nVECO.’r.o.

MR2 RELIEF VALVE

RV9

LTRAVELPREFERENTIA

~ ¢....._j

L SPOOLASSE.,...L,’ ~ ~ "---.," ~ ’r,.~ T--’/~ ’-’--

SWING CONTROL VALVE SWING SHOCKLESS VALVES

RV11~ , ~ ~..~,.,~ ~

AM~

-

SWING PORT RELIEF VALVES ~1] ]t"f RV11 & RV12 _ ~ .,..

RV12 j=~

~

--R (RETURN) ,,,

PIA

BM

TRAVEL MOTOR ASSEMBLY C1- CASEDRAIN-PORT J

OIL PORT

TRAVEL-PORT REUEF VALVES RV13 &RV14

i

O O

Page 5-12

2-SPEED SIGNAL

PORT ~

OILBPORT---’~

’

--

OIL RLUCHECK PORT

--

OIL DRAIN PORT

( (

I

C2- CASEDRAIN-PORT

s/o~-o5-99

MEASURING& ADJUSTING PRESSURESSK115DZ M/C LPU-5001~ INSPECTIONITEM Cleanliness of HydraulicOil Temperature of HydraulicOil EngineCoolantTemperature STANDARDS FOR TESTING

.= I= ill

LowIdle Hi- Idle

PRESSURE MEASURING J, Uj~nl CONDITION, Point READING FROM SPECIRCATION FUNCTION HydraulicOil Tank Class: NAS7-9 N/A TakeSample HydraulicOil TankSurface ’C- 45-55°F-113-131 N/A AmbientTemperature -10oC_ 50oc RadiatorSurface !°C- 60-90°F-140-1941 N/A (14°F ~ 122oF) 850~900 RPM Throttle@"LO"-Idle Externally Mounted 2335-2370 RPM Throttle@"HI"- Idle Tachometer

z

ziii PILOTCIRCUIT

MAIN RELIEFS

PORT RELIEFS

LOWPRESSURE REUEFS

Om

AutoAcceI-Decel "ON" (Optional) o,[o]tVjl "-ro]il=l~ I PRIMARYPRESSURE F TRAVEL R

Gear Pump Main Pump

ATTACHMENT

RH HH BUCKET ROD (DO NOTADJUST) HEAD BOOM ROD (DO NOTADJUST) HEAD ARM ROD (DO NOTADJUST) HEAD F RH TRAVE~ (DONOTADJUST) F LH R R SWING L U DOZER D Enginein "HI" Idle Cont~’olsin Neutral

m

850 -1000RPM

Main Pump Main Pump Main Pump Main Pump

Main PumpPFI~

Main Pump Main Pump Main Pump

~5

Throttle@"HI"- Idle

P3 al a2

47 -53 670-750 P3 Engine - Hi Idle at Hi Idle, 350-355 4980-505C TR1 Engine Simultaneous LH/RH 350-355 4980-505( TR2 ! Operation Travel Stalled.

al a2 al a2 al a2 al a2 al al a2 a2 a2 a2 al a2 al a2

300-305 4270-434C MR1 BucketDigging 300-305 4270-434C MR2 BoomRaising 330-340! 4694,4836 RV8 Bucket Dump 330-340 4694,4836 RV7 BucketDigging 330-340 4694-483( RV6 BoomLowering 330-340 4694-4836 RV5 BoomRaising 330-340 4694-4836 RVl0 ArmOut(CylinderIN) 330-340 4694-4836 RV9 ArmIn (Cylinder OUT) 360-370 5120-5263 RV14 "H’-Mode,Engineat Hi Idle.

SimultaneousLH/RHTravel 360-370 5120-5263 RV13 Engaged 360-370 5120-5263 RV13 "H"-Mode,Engineat Hi Idle.

LH/RHTravel 360-370 5120-52~ RV14 Simultaneous En~la~led 280-310 3982-4409 RV11 BucketLock,Stall Swing 280-310 3982-4409 RV12 BucketLock,Stall Swing 260~28( 3982~4409 HV15 BladeUpandStall 260-28( 3982,4409 RV16 BladeDown andStall 455-668 Internal Enginein "HI" Idle 32-47 455-668 Shims Controlsin Neutral 32,47 Low

NEGATIVE CONTROL PRESSURES

Pressure Enginein "HI" Idle Controlsin Neutral

Main Pump

Pil Pi2

32-47 32-47

455-668 455-668

Relief Enginein "HI" Idle Valves Controlsin Neutral

TEST PORTLOCATIONS:

al & a2TestPorts

Pil Test Port ~_o__

PORT,~:~

P3 Test Port

s;o~=-o~-~

NOTE: Take Measurements with Engineat "HI" Idle unlessotherwise specified. Thestandard toleranceshall be an allowablerangein field measurements.

Pi2 TestPort

Page5-13

~SURING & ADJUSTING PRESSURES SK130 MIC SK130

YPU- 2001~

MAIN CC’ ~ ~OL VALVE

--

T1

....

P5

r Pil

~~

/~

llld ~--L

ARM

RAISE

F TR2

RVI~-~~

RV7

I/I ~-

~..~

PAIN

Ab

i’-"

~

PA

(~L :r

~-H

III

"~’

AI

PB1

P~- 1 ~:1_®!o_~:-~

NEGATIVE

CONTROL "7 =-"i=-’f-~ ",~.J’~iJ LTRAVELPREFERENTIA pop2--/IZj/~; ~’~

"~,_~--DR, RE.EFVALVE .R=

L 7;;

I::::~"<_

LRV, SPOO’ASSE.’V TJ~

SWING CONTROLVALVE & MOTORASSEMBLY P

SWING CON~O,.~ F----" ~-- P"

.-~. I~1-~%-._

P

~~~~pp

I-I’14~ ~- PP

PA

~

~---R BOTTOMVIEW ~PA

I ~,’~’,~111I I

~RV’2wING J~-~"~(’~.." "~ .~l}m.~~

MOTOR[~ ~_ ~~ GAUGE PORT

~ ~ N~’~"<~’~""-CASE R~/~I~~ T SWING SHOC~Q.ESS VALVE

I

GAUGE /~~.S.WING

DRAIN p

l

l I~Jl TOP VIEW ,,=, r¢~ -~

PORT-Dr

OR

REDUCTION UNIT

LEFT SIDE VIEW

j

I

~ 17’

I

RIGHTSIDE VIEW

~ TRAVEL MOTORASSEMBLY C1- CASEDRAIN PORT OIL PORT

OIL

.o

TRAVEL

RV13

FI’TCRH~CK

°It &

2-SPEED SIGNAL PORT ~ RV14~~~$

1

OIL PORT B

/

C2- CASE DRAIN-PORT

Page5-14

OIL DRAIN PORT

MEASURING& ADJUSTING PRESSURESSK130 M/C YPU- 2001~ INSPECTIONITEM Cleanliness of HydraulicOil Temperature of HydraulicOil STANDARDS FOR TESTING

EngineCoolantTemperature

=h n" ILl

LowIdle Hi- Idle

PRESSURE MEASURING Adiustmer~ CONDITION, Point READINGFROM SPECIFICATION FUNCTION HydraulicOil Tank Class: NAS7-9 N/A TakeSample HydraulicOil TankSurface°C- 45-55°F- 113-131 N/A AmbientTemperature -10°C ~ 50°C RadiatorSurface °C- 60-90°F- 140~194 N/A (14OF- 122OF) 850-900RPM Throttle @"LO"-Idle ExternallyMounted 2335-2370RPM Throttle@"HI"- Idle Tachometer Oca

z_ o zILl

Auto AcceI-Decel "ON" (Optional) KohvJI"-,lel~l~n~L

PILOTCIRCUIT

MAIN REUEFS

PORT REUEFS

LOWPRESSURE REUEFS

NEGATIVE CONTROL PRESSURES

850 -1000 RPM

Throttle@"HI"- Idle LU-~

L’f;~l[¢;_ ~_,;j-_-!¢t TJ=11"-Zl] =I I ¯ xll||ll i f

PRIMARYPRESSURE F TRAVEL R A’rFACHMENT

RH HH BUCKET ROD DONOTADJUST) HEAD BOOM ROD DONOTADJUST) HEAD ARM ROD DONOTADJUST) HEAD F RH R TRAVEL DO NOTADJUST) F LH i R R SWING L Enginein "HI" Idle Controlsin Neutral

Gear Pump

47-53 670-750 P3 350-355 ¢980-5050 TR1 350-355 ¢980-5050 TR2

Engine - Hi Idle

al a2 al Main Pump a2 al Main Pump a2 al Main Pump a2 al Main PumpPF1/4 al a2 a2 a2 Main Pump a2

300-305 300-305 330-340 330-340 330-340 330-340 330-340 330-340 360-370 360-370 360-370 360~370 280-310 280-310

BucketDigging BoomRaising Bucket Dump BucketDigging BoomLowering BoomRaising ArmOut(CylinderIN) ArmIn (CylinderOUT)

al a2

32.-47 32,.-47

Main Pump

P3 al a2

Main Pump

Main Pump

¢270-4340 MR1 ¢270-4340 MR2 4694-4836 RV8 4694-4836 RV7 4694-4836 RV6 4694-4836 RV5 4694-4836 RV10 4694-4836 RV9 5120-5263 RV14 5120-5263 RV13 5120-5263 RV13 5120-5263 RV14 3982~4409 RV11 3982-4409 RV12

Engineat Hi Idle.

Simultaneous LH/RH OperationTravel Stalled.

’H’-Mode,Engineat Hi Idle.

SimultaneousLH/RHTravel Engaged "H’-Mode,Engineat Hi Idle.

SimultaneousLH/RHTravel Engaged

BucketLock,Stall Swing BucketLock,Stall Swing

455-668 Internal Enginein "HI" Idle 455-668 Shims Controlsin Neutral Low Pressure

Enginein "HI" Idle Controlsin Neutral

Main Pump

Pil Pi2

32-47 32-47

465-668 455-668

Relief Enginein "HI" Idle Valves Controlsin Neutral

TEST PORTLOCATIONS:

I \.",, r-;, Pil

al & a2TeetPorts on Main Pumps

Pil Teat Port on P1 Regulator

NOTE: TakeMeasurements with Engine at "HI"Idle unlessotherwise specified.Thestandard toleranceshallbe an allowable rangein field measurements.

% P3Test Port on Pilot Gear Pump

s~o~-o~.99

Pi2Teat Port on P2 Regulator

Page 5-15

MEASURING & ADJUSTINGPRESSURES SK150 - SK160 M/C SK150 ~ SK160

YMU - 1501~

MAINCONTROL VALVE TR1-RV8--, MR1

X1 -I-

/---

~

INDEPENDENT V~ BLOCK

°

~I "~"----

PS

el Cel

X

X~_ TR2

~ --Pis

POP1

RV10

ARMRAISE

~’--RV P,I-~

‘0 --

\

--DR2AI:ONFLUXSPOOL--~

PZ

P3-I o

T O

’~’W P"J~ IYT~ NEOATIVECONTROL--~ __ rRAVEL B1

L DR1

PREFERENTIAL SPOOL ASSEMBLY

RELIEF VALVE MR2

--

RV9

SWINGCONTROL VALVE RV1,

~

RV12

~w..o s.oc.~.ssv.~v,-~ ~~~__sw..o s.oc~.,ssv.~w ~~ ~

FR

-

BM

PiA

PiA

p

_r ,,F_____J

TRAVEL MOTOR ASSEMBLY OIL FILL PORT

,.o~;,.v.b,,,,..,,~, ,..-,,,;,~:~:~s,o,,,,~t.,, ~

~ Page5-16

CASE DRAIN PORT- C2

E

, , ;

--

OIL CHECKPORT

OIL DRAIN PORT

~o~.~

MEASURING & ADJUSTINGPRESSURES SK150 ~ SK160 M/C YMU- 1501~ INSPECTIONITEM Cleanliness of HydraulicOil Temperature of HydraulicOil

PRESSURE Adjustment MEASURING CONDITION, Point READING FROM SPECIFICATION FUNCTION HydraulicOil Tank Class: NAS7-9 N/A Take Sample HydraulicOil TankSurface °C-45-55°F- 113-.131 N/A AmbientTemperature -10°C - 500C Radiator Surface °£;-60-90°F- 140-194 N/A (14°F - 122°F) 850-900 RPM Throttle @"LO"-Idle Gauge Cluster Display o c._o, 2365-2400RPM or ~=8 ~ ThrottTe@"HI"- Idle 1950-2050 RPM ~o®~ E Throttle @"HI"- Idle Externally Mounted 1550-1650 RPM a.’~ ¢p.=_ Throttle @"HI"- Idle Tachometer 1000-1100 RPM ~.:~~ Throttle @"HI"- Idle

EngineCoolant Temperature STANDARDS LowIdle FOR 3i Hi- Idl~ TESTING "S" or "D" Mode "FC" Mode Auto AcceI-Decel"ON" COMPONENT PILOTCIRCUIT PRIMARYPRESSURE Gear Pump I RH - MainPump TRAVEL LH MAIN RELIEFS ATTACHMENT RH -iMaln Pump LH BUCKET ROD (DO NOTADJUST). HEAD -Main Pump BOOM ROD (DO NOTADJUST) HEAD -Main Pump ARM ROD (DO NOTADJUST) HEAD Main Pump PORT RELIEFS F TRAVEL RHR " Main PumpPF 1/4 (DO NOTADJUST) F jLH R

.= .,=,

mE

RH LH VARIABLELOADINGMODELOADINGMODE Upper (OPTION) SWITCH Lower INDEPENDENT RH LOW PRESSURE "D" MODE-OFF LH RELIEFS INDEPENDENT RH "D" MODE-ON LH INDEPENDENT RH NEGATIVE "D" MODE-OFF LH CONTROL INDEPENDENT RH PRESSURES "D" MODE-ON LH PROPORTIONAL H¯ S ¯ FC¯ D SOLENOID KPSS Release VALVE Boost SWING

Eiim

Main Pump Flow ~stribu~n ,S~d~ Main Pump Main Pump Main Pump Main Pump Gear Pump

670-750 PR1 "H"-Mode,End/HiIdle P3, 47-53 Engineat Hi Idle. al 350-355 4980-5050 TR1 "H"-Mode, SimultaneousLH/RHOperation a2 350-355 4980-5050 TR2Travel Stalled.

al a2 al a2 al a2 al a2 al al a2 a2 a2 a2

300-305 4270-4340 MR1 BucketDigging 300-305 4270-4340 MR2 BoomRaising 330-340 4700~4835 RV8 Bucket Dump 330-340 4700-4835 RV7 BucketDigging 330-340 4700-4835 RV6 BoomLowering 330-340 4700-4835 RV5 BoomRaising 330-340 4700-4835 RV10 ArmOut(CylinderIN) 330-340 4700-4835 RV9 ArmIn (Cylinder OUT) Engineat Hi Idle.

360-370 5120-5260 BY14 "H"-Mode, SimultaneousLH/RHTravel 360-370 5120-5260 RV13 360-370 5120-526( RV13 "H’-Uede,Engineat Hi Idle.

SimultaneousLH/RHTravel 360-370 5120-526( RV14 E~ 235-295 3340~420a RV11Bucket Lock, Stall Swing 235-295 3340-420( RV12Bucket Lock, Stall Swin~ 17-18 242-256 Internal "S"Mode, Engin "HI" Idle 11.5-12.5163.6-177.~ Shims"S"Mode,Engin "HI" idle al Engin "HI" Idle 32-47 455-668 Internal "H" Mode, a2 32-47 455-668 ShimsControls in Neutral al 0-7 0-100 Internal "D" Mode, Engin "HI" Idle 0-100 a2 0-7 ShimsControls in Neutral Pil 32-47 455-668 Low’H" Mode,Engin "HI" Idle Pi2 32-47 455-668 PressureControlsin Neutral Pil 28-38 398-540 Relief ’D" Mode,Engin "HI" Idle Pi2 28-38 398-540 Valves Controlsin Neutral a3 13.3-16.3 0-43 Pf Enginein "HI" Idle a3 32-40 74-145 S°len°id:controls in Neutral Valve

TEST PORTLOCATIONS:

al & a2Test Ports

PI1 Test Port

a3Test Port

h

P3Test Port

~o,=~5.~

Pi2 Test Port

Install GaugeHere

NOTE: TakeMeasurements with Engineat "HI" Idle unlessotherwise specified. Thestandard toleranceshall bean allowablerangein field measurements.

VARIABLELOADINGMODI

Page5-17

MEASURING& ADJUSTING PRESSURESSK200 - 270 M/C YQU-3101-

SK200 ~ SK270

MAIN CONTROL VALVE

PAt (Advance) ~ \

PAb PAC

P1 LOW \

PAl (Advance)

P2 NEUTRAL CUT PRESSURE I PORT T

\

\

\

,

’1

IF,.~.~;~1;~:,-2~---~ -~T

t /- Dr2

%PORT

~

o [~

"--~/

NEUTRAL

~.1-~\ ~!/ 7 CUT PRESSURE

~

~ /--PB1

-BOOM

PA’ P;EJESFU RE \

POP2~ ~I’~-"

j~

2~

ARM

CONFLUENT SPOOL

~

VIEW A-A

VALVE e

PZ

PB

TRAVELPREFERENTIAL SPOOL

C1 PBr (Retreat)

TR1 TR2

- TRAVELPREFERENTIAL PRESSURE PORT

FRONTVIEW RVI1--

-- Piga Pigc

VIEWB-B

SWINGCONTROL VALVE RV12 SWINGSHOCKLESS VALVE

SWINGSHOCKLESS VALVE C PA ,PiB

P3

P2 LOWPRESSURE .OGI( VALVE REUEFVALVE MR2 SEQUENCE --

Dr1

LEFTSIDE

(~--~1--.-

Pi3

~B1

~

I I

~

C

Pi PRESSURE MEASURING PORT

Luu

iA ~ PRESSURE MEASURING PORT

TRAVEL BRAKE MOTOR ASSEMBLY VA

TRAVELPORT RELIEFVALVE

IIl~,II

II Iq I ~ ¯ If ~

Page 5-18

TRAVELPORT REUEFVALVE

Dr

s~o~-05.~

MEASURING& ADJUSTING PRESSURESSK200 ~ 270 M/C YQU-3101~ PRESSURE ~djustment MEASURING CONDITION, Point READINGFROM SPECIFICATION FUNCTION Cleanliness of HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A FakeSample Temperature of HydraulicOil HydraulicOil TankSurface ~C-45-55OF-113-131 N/A AmbientTemperature -10oc _ 50oc STANDARDS EngineCoolantTemperature RadiatorSurface ’C- 60-90°F- 140-194 N/A (14OF-122OF) FOR TESTING LowIdle Gauge Cluster Display 850-900 RPM Throttle@"LO"-Idle Hi-Idle or 2335-2370 RPM ~z .~ Throttle@"HI"- Idle "S" or "D" Mode Externally Mounted 1950-2050 RPM Throttle@"HI"- Idle "FC" Mode Tachometer 1550-1650 RPM Throttle@"HI"- Idle Auto AcceI-Decel"ON" 1000-1100 RPM Throttle@"HI"- Idle I’dS]-’| ii II;.~i rz-d~r,! ~ [el;t1[¢’I =I[~I PILOTCIRCUIT PRIMARYPRESSURE Gear Pump P3 47-53 670-750 P3 "H"-Mode, Eno,]Hi Idle F al 350-355 4980-5050 TR1 "H’-Mode,Engineat Hi idle.

TRAVEL Main Pump Simultaneous LH/RH ODeration R a2 350-355 4980-5050 TR2 Travel Stalled.

BOOST MAIN RH al !315-330 4480-4694 MR1 BucketDigging PRESSURE HH Main Pump RELIEFS a2 ~315~3304480-4694 MR2 BoomRaisin,q al 300-305 4270-4340 MR1 BucketBigging ATTACHMENT RH Main Pump a2 300~305 4270-4340 MR2 BoomRaising HH BUCKET ROD 330-340 4694-4836 RV8 Bucket Dump al (DO NOTADJUST) HEAD Main Pump a2 330-340 4694-4836 RV7 BucketDigging al BOOM ROD 330-340 4694.4336 RV6 BoomLowering (DO NOTADJUST) HEAD Main Pump a2 330-340 4694-4836 RV5 BoomRaising ARM ROD al 330-340 4694-4836 RVl0 ArmOut(CylinderIN) PORT (DO NOTADJUST) HEAD Main Pump a2 330~340 4694~4836 RV9 ArmIn (CylinderOUT) RELIEFS al 360-370 5120-5263 RV14 ¯ H’-Mode,Engineat Hi Idle.

RH SimultaneousLH/RHTravel TRAVEL al 360-370 5120-5263 RV13 Entailed Main PumpPF1/4 (DO NOTADJUST) "H"-Mode, Engineat Hi Idle. a2 360-370 5120-5263 RV13 LH "ALH/RHTravel a2 360-370 5120-5263 RV14 Simultaneous En~laQed R a2 280-310 3982--4409 RV11 BucketLock,Stall Swing SWING Main Pump L a2 280-310 3982-4409 RV12 BucketLock,Stall Swing Flow CPU VARIABLELOADING LOADINGMODE Upper Distribution 18.5-19.5 263-277 "S"Mode, Engin "HI" Idle ADJ "S"Mode, SWITCH MODE(OPTION) Lower Solenoid Valve Engin "HI" Idle 13.5-14.5 192-206 "S" INDEPENDENT RH Main Pump al 32-47 455-668 Internal "H" Mode, Engin "HI" Idle "D" MODE-OFF LH a2 32-47 455-668 Shims Controlsin Neutral LOW PRESSURE INDEPENDENT RH al 0-7 0-100 Internal "D" Mode, Engin "HI" Idle RELIEFS "D" MODE-ON LH Main Pump a2 0-7 0-100 Shims Controlsin Neutral INDEPENDENT RH Pil 32-47 455-668 Low "H" Mode, Engin "HI" Idle NEGATIVE "D" MODE-OFF LH Main Pump Pi2 32-47 455,-.668PressureControls in Neutral CONTROL INDEPENDENT RH Pil 0-7 0-100 Relief ’D" Mode, Engin "HI" Idle PRESSURES Main Pump "D" MODE-ON LH Pi2 0-7 0~100 Valves Controlsin Neutral H-S.FC-D PROPORTIONAL a3 0-3 0-43 Pf Enginein "HI" Idle SOLENOID KPSS Release GearPump a3 13.3-16.3 189-232 Solenoid Controlsin Neutral VALVE Boost a3 32-40 455-569 Valve INSPECTIONITEM

I

TEST PORTLOCATIONS:

I

..... ’ al & a2Test Ports

Pil Test Port

NOTE: a3Test Port stall GaugeHere

PORT~~

P3Test Port

----::

.

"

Pi2Test Port

~ VARIABLELOADING

Take Measurements In "H" Modeunlessotherwis~ specified. Thestandard toleranceshall be an allowablerangein field measurements.

MEASURING & ADJUSTINGPRESSURES SK300 ,"-

SK330 MIC

SK300~ SK330

YCU-0611PAl

MAIN CONTROL VALVE POp1--~ PA1--~

P2NEUTRAL CUTPRESSURE PORT

PAl Dr3

P1 LOW PRESSURE \

\

BOOM CONFLUENT SPOOL

\ _3_ RELIEF \ VALVE

"

Pi,-~ \ PLI-~ \ ~c~ \tCUT P1NEUTRAL--~ PRESSURE

.~lC

°r’lN LEFT SIDE ¯

ARM---J

CONFLUE~

~ Pi2 i ~ .pi ~ Pisd

MR2

SPOOL

RIGHTSIDE

Pis

o

PB1

VALVE ~~

LOW PRESSURE RELIEF VALVF ~ 3

TRAVEL PREFERENTIAL7 S PAl SPOOL / // f~--T2 PAr o~

/-

PO~

PORT E\

~r ~J

~

’

[-- PBI

PBr---~

Pigc PZ

PAa

Rgb PBr --

TR2

Dr3VIEW A-A

PB

~t

FRONTVIEW

SWING CONTROL VALVE RV11

C1

_ ~-~

RV12

~FPI

PiA~

VIEW B-B

Piga Hgc

-R

r

PiB

U

U

SWING SHOCKLESS VALVE

TRAVEL MOTOR ASSEMBLY PILOT SELECTOR VALVE

P D1

~

~

B A

Page5-20

OVERLOAD EI~F VALVE

MEASURING PORT

~o,=.o, ~

MEASURING& ADJUSTINGPRESSURESSK300 ~ SK330 M/C YCU-0611PRESSURE

INSPECTIONITEM Cleanlinessof HydraulicOil Temperature of HydraulicOil EngineCoolantTemperature STANDARDS FOR I LowIdle ¯ TESTING ~ Hi- Idle ~ "S" or"D" Mode m "FC" Mode

~diustmem ME~.3URING CONDmON, po~.t READING FROM SPECIRCATION FUNCTION HydraulicOil Tank Class:NAS7--9 N/A TakeSample = HydraulicOil TankSurface’C- 45-5. °F-113--131 N/A AmbientTemperature -10°C~ 80°C RadiatorSurface ’C- 60-9£°F-140-194 N/A (14OF_122oF) 850-900 RPM ~ .

Throttle@"LO"-Idle Gauge Cluster Display 2065-2100 RPM ~=< =_u.

Throttle@"HI"- Idle or 1670-1760 RPM =-~ = Throttle@"Hr’-Idle ExternallyMoui~te,3 1370-1430 RPM ~ o.~= Throttle@"HI"- Idle Tachometer 1000-1100 RPM ~:~< Throttle@"HI"-Idle

AutoAcceI-Decel "ON" ~’L~I I :hrj del~vd’Je]~l=~l PILOTCIRCUIT PRIMARYPRESSURE Gear Pump RH TRAVEL Main Pump LH MAIN BOOST - RH -Main Pump REUEFS PRESSURE LH ATTACHMENT - RH -Main Pump LH BUCKET . ROD.Main Pump (DO NOTADJUST)HEAD BOOM ROD (DONOTADJUST) HEADMain Pump ARM ROD PORT (DONOTADJUST) HEADMainPump REUEFS F

P3 47-53 670-750 PR1 "H"-Mode, Eng/HiIdle Engine at HiIdle. al 350-355 4980-505(; TR1 "H"*Mode, SimuitaneousLH/RH a2. 350 "355 4980-505C TR2 Ope rationTravel Stalled. al 330-345 4695-491C MR1 BucketDigging a2 330-345 4695-491C MR2 BoomRaising al 300-3054270-434(] MR1 BucketDigging a2 300-3054270-434(] MR2 BoomRaising al 330-340 4695-4837 RV8 Bucket Dump a2 345-35,= 4910-505C RV7 BucketDigging al 330-340 4695-4837 RV6 BoomLowering a2. 345-355 4910-5050 RV5 BoomRaising al 345-355 4910-5050 RV10 ArmOut(CylinderIN) a2 330-340 4695-4837 RV9 ArmIn (CylinderOUT) Engineat Hi Idle. al 350-360 4980-512(] RV14 "H"-Mode, SimultaneousLH/RHTravel TRAVEL RH-Ral 350-360 4980-512(] RV13 Engaged Main PumpPF 1/4 (DO NOTADJUST) F a2 at Hi Idle.

350-360 4980-512( RV13 "H’-aode, Engine LH -LH/RHTravel R a2. 350-360 4980-512(] RV14 Simultaneous Enqaqed RH a2 225-325 3200-4625 RVll BucketLock,Stall Swing SWING ’ LH Main Pump a2 225-325 3200-4625 RV12 BucketLock,Stall Swing Flow VARIABLELOADINGLOADINGMODE Upper cPu "S"Mode, 17-18 242-256 Engin "HI" Idle Diatdbution MODE(OPTION) SWITCH Lower Solenoid 11.5-12.5163.6-177.~ A.~ "S"Mode, Engin "HI" Idle Valve al INDEPENDENT RH 32-47 455-668 Internal "H" Mode, Engin "HI" Idle, LOWPRESSURE "D" MODE-OFF LH Main Pump a2 32-47 455-668 Shims Controlsin Neutral REUEPS INDEPENDENT RH al 0-7 0-100 Internal "D"Mode, Engin "HI" Idle Main Pump "D" MODE-ON LJ’I a2 0-7 0-100 Shims Controlsin Neutral INDEPENDENT RH Pil 32-47 455-668 Low "H"Mode, Engin "HI, Idle NEGATIVE "D" MODE-OFF LH Main Pump Pi2 32-47 455-668 PressureControlsin Neutral CONTROL Pil INDEPENDENT RH 28-38 398-540 Relief ’D" Mode, Engin "HI" Idle PRESSURES "D" MODE-ON LH Main Pump Pi2 28-38 398-540 Valves Controlsin Neutral H¯ S¯ FC¯ D PROPORTIONAL a3 0-43 pf 0-3 SOLENOID Release Enginein "HI" Idle KPSS Main Pump a3 13.3-16.3 189-232 Solenoid VALVE Boost a3 455-569 Valve Controlsin Neutral 32-40

TESTPORTLOCATIONS:

NOTE : al & a2Test Ports

//

~’~

P3Test Port S/Orent-05-99

Pil Test Port

a3Test Port

Pi2 Test Port

VARIABLELOADING

,~

TakeMeasurements In "H"Mode unlessotherwise specified.Thestandard tolerance shallbean allowable range in field measurements.

Page 5-21

MEASURING & ADJUSTINGPRESSURES SK400 ~ SK460 M/C YSU-0242-

SK400 ~ SK460 PBr

MAIN CONTROL VALVE

pi; is’~ -- v Pisd PL1-

Pi3

Pigc Pi2~

Piga

B1 Dr2-/ --

X

PO

LEFT SIDE

RIGHT SIDE

PAIN

PAi Dr3 View C-C

PAr

~

~

Piga FRONT VIEW

Dr3

T2

VIEWC-C

SWING CONTROL VALVE R

~

U

U

SWINGSHOCKLESS VALVE

TRAVEL MOTOR ASSEMBLY

P1

1

P2

Or Page 5-22

TRAVELPORT RELIEFVALVE

~

TRAVELPORT RELIEFVALVE ¯ ¯

Dr

Pi

Pi

G1

G2

s~o,,,=.os.~

MEASURING& ADJUSTINGPRESSURESSK400 ~ SK460 M/C YSU-242~ INSPECTIONITEM Cleanliness of HydraulicOil Temperature of HydraulicOil EngineCoolantTemperature STANDARDS LowIdle FOR I TESTING 17= _ Hi-Idle " !E3 ~ "S" or"D" Mode Z rr "FC" Mode

PRESSURE Point READINGFROM SPECIFICATION HydraulicOil Tank Class: NAS7-9 N/A HydraulicOil TankSurface°C- 45-55 °F-113-131 N/A

MEASURING CONDITION, FUNCTION TakeSample AmbientTemperature -10°C- 50°C RadiatorSurface =C- 60-90 °F-140-194 N/A (14°F- 122°F) 850-900 RPM ~ .

Throttle@"LO"-Idle Gauge Cluster Display ** 2165-2200RPM = =.9.

Throttle@"HI"-Idle or ®Ee~ ®~ E 1870-1930 RPM m Throttle@"HI"-Idle Externally Mounted 1570-1630 RPM ¢=o=~ ~= Throttle@"HI"-Idle Tachometer Throttle@"HI"- Idle

PILOT CIRCUIT PRIMARYPRESSURE RH Main Pump TRAVEL LH MAIN BOOST RH Main Pump REUEFS PRESSURE LH ATTACHMENT RH Main Pump LH BUCKET ROD Main Pump (DO NOTADJUST)HEAD BOOM ROD (DO NOTADJUS’F)HEAD Main Pump ARM ROD Main Pump , (DO NOTADJUST) PORT HEAD RELIEFS F RH-~TRAVEL MainPump PF1N (DO NOTADJUST) F LH-R RH ¯ SWING Main Pump LH F]ow VARIABLELOADINGLOADINGMODE Upper Distribution MODE (OPTION) SWITCH Lower Sc~moid~llve INDEPENDENT RH -Main I .

Pump LOWPRESSURE "D" MODE-OFF LH REUEFS INDEPENDENT RH - MainPump "D" MODE-ON LH INDEPENDENT RH NEGATIVE "D" MODE-OFF LH -Main Pump CONTROL INDEPENDENT RH - MainPump PRESSURES "D" MODE-ON LH PROPORTIONAL H.SoFCoD SOLENOID KPSS Release Main Pump VALVE Boost

al a2 al a2 al a2 al a2 al a2 al a2 al al a2 a2 a2 a2

al a2 al a2 Pil Pi2 Pil Pi2 a3 a3 a3

47-53 670-750 "H"-Mode, Eng/HiIdle "H’-Mode,Engineat Hi Idle.

350-355 4980-5050 TR1 Simultaneous LH/RHOperatior 350-355 4980-5050 TR,?. TravelStalled.

350-355 4980-5050 MR1 BucketDigging 350-355 4980-5050 MR2 BoomRaising 320-325 4550-4620 MR1 BucketDigging 320-325 4550-4620 MR2 BoomRaising 335-355 4765-5050 RV8 Bucket Dump 335-370 4765-5260 RV7 BucketDigging 315-355 4480-5050 RV6 BoomLowering 335-370 4765-5260 RV5 BoomRaising 335-355 4765-5050 RV10 ArmOut(CylinderIN) 335-355 4765-5050 RV9 ArmIn (CylinderOUT) Engineat Hi Idle.

350-365 4980-519( RV14 "H"-Mode, Simultaneous LH/RH Travel 350-365 4980-5190 RV13 Engaged "H"-Mode, Engine at Hi Idle.

350-365 4980-5190 RV13 Simultaneous LH/RH Travel 350-365 4980-5190 RV14 Enqaqed 260-300 3700-4270 RV11 BucketLock,Stall Swing 260-300 3700-4270 RV12 BucketLock,Stall Swing cPu "S"MOde, 18.5-19.5 260-280 Engin "HI" Idle ADJ 13.5-14.5 lg2.0-206.2 "B" "S"MOde, Engin "HI" Idle 32-47 455-668 Intemai "H" Mode, Engin "HI" Idle 32-47 455-668 Shims Controlsin Neutral 0-7 0-100 Internal ’D" Mode.

Engin "HI" Idle 0-7 0-100 Shims Controlsin Neutral 32-47 455-658 Low ’H" Mode, Engin "HI" Idle 32-47 455-668 Pressure3ontrolsin Neutral 28-38 398-540 Relief ’D" Mode, Engin "HI" Idle 28-38 398-540 Valves Controlsin Neutral 0-3 0-43 Pf Engine in "HI" Idle 13.3-16.3 189-232 Solenoid Controlsin Neutral 32-40 455-569 Valve

TEST PORTLOCATIONS:

I

** NOTE: on unit serial numbers YSU-0200-0241 Hi-ldle Speed= 2,200-2,220 RPM

NOTE: al & a2 Test Ports

Pil Test Port

Gaul.

Iinstall

i

P3 Test Port

a3 Test Port

Pi2 Test Port

Take Measurements In "H" Modeunless otherwise specified. Thestandard toleranceshall be an allowablerangein field measurements,

VARIABLE LOADING

Page 5-23

Kobelco

Mark

IV

Kobelco America Inc. SlOrent-05/99

KOBELCO MARK IV 24 ITEM CHECK Model: R.P.M. SensorDisplay No. 1 2 3 4

5

P/No S1 Wtmp $20prs $3 CPU $4 Smode

6

$5 Hmod

7 8

$6 Att S 7 Des

Serial Number: Resistance: Engine Running Engine Stopped

S.D. Mode H. FC. Mode H. Mode S. FC. D. Mode Decel SWON Decel SWOFFLever Operating

9 10

S 8 Bzsp S 9 JDin

11

S 1 (3 K~.v~

12 13

S 11 Lims S 12 Boom

14

Adl Acel

1R

Ad2 Boom

1R

Ad3 MotA

17 18

Ad4 MotB Ad5 isvP

19

Ad6 isvB I1 Pump

Lever Neutral Slewing Low Hi,qh

,i

20

Hours: VoltacjeA. C.: Remarks

LowIdle (No Load) HighIdle (No Load) LowIdle (ArmOverRelief) HighIdle (Armover Relief)

LowIdle (No Load) High Idle (No Load) LowIdle (ArmOverRelief) HiqhIdle (Armover Reliefl 21 22

12 Boom POS

LowIdle High Idle

23

R.P,M.

24

18V

Target

Actual

LowLdle HighIdle S Mode FC Mode

MECHATRONICS DiagnosticTwentyFourItem Check 24 ITEM L.C.D. DIAGNOSTICS Thefollowing diagnosticsprovidestesting of 24 various electrical components.

Usethis informationin conjunctionwith the AutoAcceldiagnostics.

NOTE The24 point L.C.D. Diagnosticsshould be performedwith the enginerunning and "OFF".

A.Usingthe 24 Point Diagnostics 1. Sitting in operatorseat, depressand hold downthe buzzerstop switch. See Figure6.6.

2. With buzzerstop switch depressed, turn the keyswitchto "ON".SeeFigure 6.7.

3. Releasethe buzzerstop switch. Then, depressandreleasethe buzzer stop switchfive moretimes. This will activate the L.C.D. Diagnostic system anddisplay the MechatronicsController Part Number for the particular machinebeing tested. SeeFigure 6.8.

4. To continuediagnostics, depressthe buzzerstop switch one time to advanceto the next function.

5. Recordthe readingsfrom the L.C.D. for eachfunction. Thenrepeat steps 1 through5 with the enginerunning.

NOTE Depressandhold downthe buzzerstop switch whenplacing the keyswitchto "ON"to activate the diagnostics. Then,press the buzzer stopswitchfive timesto call up the first display. SeeFigure6.8.

6.

FIGURE 6.6

WHILE HOLDING

.uzzER STOP SW~TC. "O..,",--------~~,~ TURNKEYSWITCHTO ’ON’

~

I

.-~’-~

FIGURE 6.7

I If l."~/".~./.L.f~

I ~ ~.~,~

~"~4~ GAUGE CLUSTER

~Z.__,¢’~\"~

Compare the readingsto the 24 Point L.C.D.

FIGURE 6.8

s~o~.o5~,

Page6-1

MECHATRONICS 24 Item Diagnostics Chart Note: Comparative example specificationsare with Thischartillustrates eachUC.D.display, enginerunning. in orderseen,during24 itemtest. #7 Display #1 Display S6att-Power Boostor Heavy Lift Switch (SK20O-SK460 ONLY) HeavyLift OFF-OPEN SwitchOff/NopowerBoost-OPEN Switch On/Power BoostPushed-CLOS HeavyLift ON-CLOS

DisplaysPart Number of the Mechatronics Controller(CPU) for theparticularmachine beingtested.

~. cPgPART NUMBER #2 Display

#8 Display

Slwtmp-CoolantTemperature (SK300& SK330ONLY) NormalConditions-OPEN (All Machines) Shouldwatertemperature increase to 95°C(200°F) the CPU will decrease main pumphorsepower,Undertheseconditions S1 wtmp-CLOS

STdes--Auto-Accel ControlSwitch andPressure Switch SwitchOff- CLOS Switch On- OPEN Controlsin Operation-CLOS

¯ #9 Display $2oprs-EngineOil Pressure NormalConditions-OPEN Problem in circuit or Enginenot running-CLOS

S8bzsp-Buzzer Stop Switch Normal Conditions-OPEN

S2

#10 Display

#4 Display

Sgjpin- Mechatronics Controller inner =TEST-RUN" Switch NormalConditions-CLOS

S3cpu- ControllerAdjustment (1 P) 1 pin Coupler NormalConditions-CLOS

#11 Display

#5 Display

S10keys--Keyswitch Battery(B) BatteryRelay(BR) Terminals Normal Conditions with Keyswitch in "ON"position- CLOS Keyswitch or elec. term,bad-OPEN

S4smod-KPSS Switch- S Mode In S or D Mode-CLOS Notin Sor DMode or badcircuit -OPEN In H Mode, FCMode or badcircuit-OPEN $10

10~

#12 Display

#6 Display S5hmod-KPSS Switch- H Mode In H Mode-CLOS Notin H Mode or badcircuit-OPEN In S, FCor DMode or badcircuit-OPEN

Page6-2

~

$11limp SteppingMotorLimit Switch NormalConditions-OPEN UmitSwitchBador Closed-CLOS

S/Or~t-05/99

MECHATRONICS 24 ItemDiagnostics Chart #13 Display

#19 Display AD6isvB- Digital Signalfor FlowDistribution SolenoidCoil Current (OPTIONAL) EXAMPLE: 41= 800 milliamperes (Convertsmilliamperes to Digital Signal) Normal-0-41(If variable loading mode not installed, value displayod-0)

Iso.i.l

S12boom--SwingPressure Switch With No Swing -OPEN Swinging- CLOS

#14 Display

#20 Display Signalfor positionof Throttle Potentfometer EXAMPLE:0= 0Vdc Minimum 255= 5Vdc Maximum (ConvertsVDCto Digital Signal) NormalConditions- Min. O to Max. 255

I

D1

#15 Display

11PumP-Actual Controller Instructed Milli-Amperesto PowerShift SolenoidCoil.

Normal-Min. 100 to Max.800, depending on condition of machinewhentesting.

I1

PumP

#21 Display AD2boom- Amporage converted to Digital Signalfor positionof LoadingModePotentiometer EXAMPLE:0= ovdc Minimum 255= 5vde Maximum (Converts VDCto Digital Signal) NormalConditions- Min. 0 to Max.255

boom

#16 Display

12boom- ActualControUer Instructecl Milli-Amperesto FlowDistribution Solenoid CoiL(OPTIONAL) Normal- Min. 100 to Max.800 If VariableLoadingMode not installed, value displayed-800

#22 Display AD3motADigital Signal for "A" Stepping MotorCoil Current EXAMPLE: 36-37= 1.5 amperes (Converts Amperes to Digital Signal) NormalConditions-36-37if current is normalat 1.5 amps.

POS- Actual position of SteppingMotor fromStarting Point Normal- Varieswith Throttle Potantfometer and SteppingMotorpositions.

POS

#17 Display

#23 Display

f AD4motBDigital Signal for "B" Stepping MotorCoil Current EXAMPLE: 36-37= 1.5 amperes (ConvertsAmperes to Digital Signal) NormalCond~ons36-37if current is normalat 1.5 amps.

IAD4 motB -

rPm-

Actualenginerpm(right side) comparisonto programedengine rpm(center).

Normal-Varies withThmttle Potentiometer position.

37

#18 Display

#24 Display AD5isvP- Digital Signalfor currentto PowerShift SolenoidCoil EXAMPLE: 0= 0 milliamperes 41=800 milliamperes (Convertsmilliamperes to Digital Signal) Normal-10-41 dependingon condition of machinebeingtested.

18V-Inputvoltage to Controller Normal Conditions- OVER Under 18V- UNDER

MECHATRONICS GaugeCluster Display 1. SYSTEMSTATUSICON

I~

~ This icon will display whenthe controller for the Gauge Cluster | Displayis not functioningproperly. "~ / If this icon is displayed, contact an authorizedKOBELCO ser-

NOTE:4,8,10,11,13,17-22

| "~ L 1 CHECK J vice technician for service assistance.

2. SYSTEMSTATUSICON

17. I.T.C.S.

& 24 HAVENOFUNCTIONS

CONTROLLERCPUICON

~ II& It It ~ Thisiconwill displaywhen a problem existsin theI.T.C.S.(IntelligentTotal r = ~ | | / ControlSystem).Turn Keyswitch"OFF"andbackto "ON"to try andreset lllll~lllil~ / CPU programming.

Shouldthis iconremainon display, stop operation 1LLER) 7 CONTRO andcall for serviceimmediately

[1

nents are checkedby CPUand found to be in goodworking

23. REPLACE ENGINEOIL ICON

2 order.

3. ENGINESTARTAID ICON ~ 1This icon will display should the Key Switch be turned to the "U U: |"HEAT" position.This systemserves no function due to the Ether 3 GLOW J

lnjection System.

WARNINGDISPLAYS TheBuzzerwill soundthe instant someof the following warningicons are displayed.

5. ENGINEOIL PRESSURE ICON ~ "l This iconwill display andthe Buzzerwill soundshouldthe EngineOil ,,~,IE~"~- / Pressuredrophelowsafeoperatingpressure.lfthisiconisondisplayand IPt._W~I= is sounding,stop the engineimmediately andcheckengineoil v I Buzzer / level. Fill engine to properlevel withapproved motoroil, If engine has 501LPRESS,) LOW OIL PRESSURE, the enginewill automaticallygo to =LO"Idle RPM. Thisiconwill DispLay onlyif alternator is charging.

6, ENGINE COOLANTTEMPERATURE ICON

]

Thisiconwill displayandtheBuzzer will sound should the Engine Coolant Temperature rise above safeoperating temperature.

Should this icondisplayandBuzzer sound,reduceengineRPM andstopoperationun~lenginecootsnttemperature reaches safeoperatingtemperature range.

f

==. ~ ~ Thisiconwill displayat every500hoursof machine operation to remind I1~ / operator of scheduledengineoil change.Therecommended oil change i/interval for CUMMINS engines is every250hoursof operation.Referto Manual f°r nstruot°ns°n settingthis ic°nf°r 250h°urdisplay" L 23Ol=’L=’S~jSUpp:y JOperat°r

25. STEPPINGMOTOR(GOVERNOR) FAIL ICON ~1Thisiconwill display should aproblem in the efeotricalcircuitthat causes thestepping motor fail toindextheengine throttleback to its startingpoint ~ within40 seconds after tumingthe KeySwitch"OFF" andbackto "ON". | Contactan authorized KOBELCO serviceshopfor serviceassistance.

25S/M F~:~ Should this icondisplay,the followingfunctionswitl not operateandthe engine wilt haveto bestopped usingthe Engine Emergency StopControl: 1. ThrottleControlvia machatronics system.

2. KPSS Mode Switch-All Modes 3. AutoDecal 4. Stopping enginewith KaySwitch 5. OptionalVariableLoading Mode Contactan authorized KOBELCO ServiceTechnician for by-pass andrepair procedures. ~ ~: ~&~J~

26. STEPPINGMOTOR(GOVERNOR)OFF ICON stop.ElectricalCurrent to theStepping Motor will bestopped if thecurrent to the steppingmotoris less then1 ampor morethan2 amps for 13 seconds or more.Also,the electricalcurrentto the stepping motorwill immediately stopshouldthe currantbe 6 amps or morefor 3 seconds.

Should this icondisplay,stopthe machine immediately andcall an authOrized KOBELCO serviceshopfor serviceassistance.

7. ENGINEAIR CLEANER ICON

27.TIME DISPLAYICON

~ ~: ~ | ; ’~lP" L

icon is displayed. Also, the time icon is assignedto problems whichhaveno other specific icon designation. [ ~=7~lil~ } The time will display apprOximately2 secOndsafter the "OK"

~1Thisiconwill displayandthe Buzzer will sound shouldthe Engine Air | Cleaner Efemect(s) (FILTERS) become too dirty to allowproperair | to the engine.

Shoufe this icondisplayandthe Buzzer sound, stopengine | immediately andcleanor replaceEngine Air Cleaner Element(s) asreJ quired.

Thisiconwill Display onlyif alternator is charging.

9. OVERLOAD ALARM(EUROPESPEC ONLY) ICON

//

~ /m~%:

| \

i Thisiconwill displayandthe Buzzer will sound should the Boom Cylinder | Cimuitpressure exceed the set, specifiedpressure.

Should this icondisI playandBuzzer sound,immediately stopall operation,stopengine and

the Engine C°°lantLevelfall balowsafe°per" IThisic°n will displaysh°utd I atinglevelShould this icondisplaybeforestartingtheengine,check and I fill coolant levelin theradiator andCoolant reservoir, iconwill notdisplay J if aifemator is charging anda sudden lossof coolantis experienced.

14. HYDRAULIC OIL LEVELICON- Pre-Strart Check

i | -

28. GREENL.E.D. INDICATORLAMPS

con otan autho=ed OELCO Se ice Shop ,so ceassistance~ ~ SWINGFLASHER-Rasheswith

12. ENGINECOOLANT LEVELICON- Pre-Start Check A

GAUGE, METER& INDICATORLAMPFUNCTIONS Swing Flasher "ON" and swinging.

If L.E.D. burnssteadywhile swinging,checkfor burnedswingflasher bulb. ~ 1st SPEEDTRAVELBurns steady whenin 1st (Normal) Speed.

~b ~ 2rid SPEEDTRAVELBurns steady when in 2nd (Fast) Speed. ~ AUTOACCEI./DECELBurns steady with Auto AcceVOecelMode"ON" and engineis in DecalRPM.

29. HOURMETER

"

¯ Thisiconwill display should theHydraulic Oil Levelin hydraulic oil roserI voirfall below safeoperating level.Should thisicondisplay before starting L~-; / engine,positionmachine in HydraulicOil Check position(refer to Opera/ tor Manual) and check sight gauge for oil level.

Fill hydraulic reservoir to ~; :J properlevelusingapproved hydraulic oil. Thisiconwitl not displaywith - engine runninganda lossof hydraulicoil is experienced.

15. BATTERYCHARGINGSYSTEMICON

B HOUR METER

30. FUEL LEVEL & WATERTEMPERATURE GAUGES

I

=am,,-ap~ "1 This icon will display andthe Buzzerwill soundshouldthe elec: ! -- "IP! / trical chargingsystemnot function properly. Shouldthis icon dis|: | play andBuzzersound,haveelectrical chargingsystemrapalred ~ immediately.

L

indicatorlights withinthe scale.

WATERTEMPERATUREEngine coolant temperature is indicatedby the position of the indicatorlights within the scale. Gauge rangeis 62°C- 105°C(144°F- 22f °F)

16. FUELLEVELICON Thisicon will display and the Buzzerwill soundshouldthe Fuel Levelin FuetTank reach50 liters (13.2Gal.) or less. Shouldthis icon display andbuzzersound,refill fuel tank immediately using approvedfuel oil

hDi::labe~ySa, LC~Jn.al accumulative hoursengine

FUEL WATER TEMP

MECHATRONICS Buzzer Stop/TimeSet/Oil ChangeReset Switch SK150/160~ SK400/460Mark IV

NOTE: To removethe display and to stop the buzzer,press thetopof the buzzerstop switch two times.

To changeyour engineoil reminderat an interval of less the 500hours,use the following procedure:

,

,

,Lo ~.I s

Fc

Turn the workmodeselector switch to the "D" mode.

Pressthe bottomof the buzzerstop switchandthe gaugecluster will display the numberof hours your machinehas operatedsince the last oil change.

Theoil changereminderwill be displayed only at the 500hourinterval. Todisplay the reminder sooner, you must makethe gaugeduster believe that 500hourshave elapsed. ,

BuzzerStop/TimeSet/Oil ChangeResetSwitch

-GI Buzzer Stop Pressingthe top of the switchwill turn off the buzzer in the instrumentpanel.

NOTE:The buzzer soundsunder the following Conditions: 1.

2.

3.

4.

Air cleanerclogged Oil level low Abnormal rise in coolant temperature Engineoil changereminder

,-

I

I

For Example: To reset the reminderto a 100 hour interval; press and hold the buzzerstop switch for 30 seconds,the elapsedhoursdisplay will beginto countupwards automatically. When you reach the 400 hour markreleasethe switch.

If the buzzersounds,inspect and correct any problemsthat mayexist.

23.

400

,,~ ~I[,.== ~OILSUPPLY Time Set Pressingandholdingthe bottomof the switchwill changethe readingof the clock display.

Oil ChangeReset At a regular 500 hourinterval the buzzerwill sound andthe gaugecluster will displaya reminderto change the engineoil. Change the engineoil andfilter at this time. (Ref. ServiceBulletin HE-308)

s~o~t-051,9

Thegaugedusterwill nowbelieve that 400hourshave elapsed,andthe reminderwill be displayedafter 100 morehours of operation. (400 + 100 = 500)

Theoil changerest proceduremustbe prefo/Tnedeachtime after the reminder is displayed.(If youwantandinterval less than 500 hours).

Page6-5

NOTES Pleaserefer to servicebullitensfor proper"A’ Adjustment for yourmachine.

SlOreat.05199

MECHATRONICS Pre-checks to be madeprior to performing Adjustment "A" Procedure SK200IV ~ SK270IV MIC (CumminsEngine) (,Minor changemachines;) All itemslisted beloware describedin detail on the following referencedpages, andshould be checkedandconfirmedprior to performingAdjustment"A".

NOTE Enginemust be at operating temperature before making the following pre-checks,or performingthe Adjustment"A" procedure!

A. Engine LowIdle Speed 1. Theproperenginetowidle speedis critical to a successful Adjustment"A* procedure.

2. Confirmthis speedprior to performingAdjustment =A".

3.

4.

6.

Particularly, if the injection pumphasbeenreplaced or rebuilt, the low idle speedmustbe checkedand confirmed.

An incorrect low idle speedcan causeAdjustment "A" to fail.

Refer to LowIdle SpeedAdjustmenton page6-12.

NOTE TheLowIdle Speedmustbe confirmedas per the following instructions prior to starting Adjustment "A". Once Adjustment"A" is completed, the LowIdle Speedshould then matchthe specifications given in the tables on pages 2-19 - 2-25.

B.EngineHigh Idle Speed TheproperengineHigh Idle Speedis also critical to a successfulAdjustment"A" procedure.

2. Confirmthis speedprior to performingAdjustment 1.

~=Aly.

3. Particularly, if the injection pumphas been replacedor rebuilt, the High Idle Speedmustbe checkedand confirmed.

4. Anincorrect High Idle Speedcan cause Adjustment "A" to fail.

5. Refer to LowIdle SpeedAdjustmenton page6-12.

TheHigh Idle Speedcheckis describedat the end of that procedure.

NOTE TheHigh Idle Speedmustbe confirmedas per the following instructions prior to starting Adjustment "A". Once Adjustment"A" ~s completed,the High Idle Speedshould then matchthe specificationsgiven in the tables.

C.Fuel Shut-Off SolenoidRod 1. Properadjustmentof the Fuel Shut-Off SolenoidRod is critical to a successfulAdjustment "A" procedure.

2. Confirmthis adjustmentprior to performing Adjustment"A".

3. Particularly, if the injection pump has beenreplaced or rebuilt, this mustbe checked andconfirmed.

4. Improper Fuel Shut-Off Rodadjustmentcan cause EngineSurgingor LowPower.

5. Referto note on this subject in LowIdle Speed Adjustmenton page6-12. Details of the Fuel Shut-Off Solenoidcheckare describedat the endof that procedure.

D.EmergencyStop Cable Stop Cableprior 1. Confirm adjustmentof Emergency to performingAdjustment"A" procedure.

2. ImproperStop Cable adjustmentcan causeEngine Surging or LowPower.

3. Refer to note on this subject in LowIdle Speed Adjustment on page 6-12. T~LF~gJ~Zc~.~ Cablecheckis describedat the endof that procedure.

E. RPMSensorTest 1. Properadjustmentof the RPM Sensoris critical to a successful Adjustment"A" procedure.

2. Improperadjustmentcan cause: a. Adjustment "A" to fail. b. KPSSPf pressureto be improper. c. Poor Hydraulic Systemperformance.

3. Refer to RPMSensorTest & Adjustmenton page627.

NOTE The RPMSensorTest & AdjustmentProcedureis the same for both before Minor Change(-m/c), and after Minor Change(m/c~) machines.

(SK150~ SK460w/Cummins).

ill i

s~o,o=-osJ~

Page6-6

MECHATRONICS Adjustment "A" Mechatronic Controller

MACHINE IN HYDRAULIC OIL CHECK POSITION

PerformMechatronicsAdjustment"A" usingthe following procedure: A. Conditionsto use Adjustment"A" Adjustment"A" proceduresmust be performedwhenone or moreof the following componentsbeen removed,repaired, adjustedor replaced.

1. MechatronicsController (CPU) 2. Stepping Motor Assembly 3. Linkage betweenStepping Motor and Engine Fuel PumpAssembly.

4. Engine Fuel PumpAssembly.

5. Engine

SK200IV ~ SK270 IV

FIGURE 6.9A

~ PUSHEMERGENCY STOPKNOBIN

I

/ \

LOWER R.H. ~IDE OF OPERATORs~T ~./"

~.~,~ B, Tools & EquipmentRequired 1. Special AdjustmentHarness Assembly.

KOBELCO Part Number- 2479Z2364; 2. Generalhandor powertools required for removaland replacementof components.

C. MachineSettings & Site Conditions 1. Attachment in Hydraulic Oil CheckPosition.

2. Vedfyengine RPM’sin the following work modes andsettings. a. H-Mode, S-Mode,FC-Mode,D-Modewith throttle in "Hi-Idle and"Low-Idle"positions. b. DecelRPM c. Low-Idle RPM 3. Engine Emergency Stop Knobcompletely "IN".

4. CPUAccess Panel Removed.

5. Firm,level adjustingsite.

D. Adjustment "A" - Part I Procedures 1. Movethe machineto a smooth,level area to performAdjustment"A".

2. Operatethe attachmentControlsuntil the arm, attachmentandboomare in the Hydraulic Oil CheckPosition. SeeFigure 6.9A as 3. If throttle control is possible,vedfyRPM’s describedabovein C., step 2.

Stop Knoball the 4. Pushthe engine Emergency wayin. SeeFigure 6.10A. 5. Turn Switch key to "OFF."Wait approximately4 seconds for electrical powerto automaticallyturn off.

6. Remove mechatroniccontroller accesscover.

SeeFigure 6.11A. 7. Remove toggle switch grommetand carefully place the controller toggle switchin the "TEST" position. SeeFigure 6.12A.

¯

FIGURE6.10A

REMOVE ACCESS COVER ~ ~r FIGURE 6.11A

" FIGURE 6.12A

~~.

MECHATRONICS Adjustment "A"Mechatronic ControllerSK200 IV ~ SK270 IV CAUTION ~fakecertain electrical poweris "OFF"beforemovingthe controller "TEST-RUN" toggle switch. This will avoid possible damage to the Mechatronicscontroller ano prevent loss of computermemory.

NOTE Whenthe Controller "TEST-RUN" Toggle Switch is placed in the "TEST"position, the Auto-Accel L.E.D.indicator light on the gaugecluster display will bumcontinuouslyas a reminderthat the controller toggle switchis in the "TEST’position.

8,

Locatethe controller 1P(1 Pin) coupler anddisconnect. Connectthe KOBELCO Special Adjustment HarnessAssemblyto the 1P coupler. SeeFigure 6.13A.

9°

Raise engine accesscover and removethe Linkage Lever Armfrom the steppingmotorshaft, using a 5ramallen wrench. SeeFigure 6.14A.

10.

FIGURE 6.13A

FIGURE 6.14A

Remove the Ball Joint endfromthe throttle governor lever arm. SeeFigure 6.15A. Loosenthe linkage jam nuts on the Adjustable Linkageandadjust to properdimensionfor the machinebeing adjusted. SeeFigure 6,16A. Finger tighten jam nuts andlay linkage aside.

NOTE This is a temporarystarting dimension.Final adjustment will belater in this procedure.

12.

Makesure that "OK"andthen "Clock Time"is shown on the gaugecluster display pdor to performingAdjustment"A".

FIGURE 6.15A

If any Service Function Icons are displayed.

Adjustment"A" procedurewill not be possible.

Resolveany service problemsrelating to displayed icons before attemptingto performAdjustment"A".

FIGURE 6.16A

MECHATRONICS Adjustment"A" MechatronicController SK200IV ~ SK270IV switch is in the 13. MakeCertain the CPU"TEST-RUN "TESTposition.

14. Place the KPSSModeSwitch in the "H"-Mode.

SeeFigure 6.17A. = position.

15. Place the Auto-AccelSwitchin the "ON SeeFigure 6.18A. 16. Movethe Throttle Controlto "LO-IDLE"position.

SeeFigure 6.17A. 17. PlaceKeyswitch in the "ON"position. Engineshould not be running.

NOTE Thesettings describedin steps 13 through 17 must be exactly as described.Anyother settings will not allow proper adjustmentof the Mechatronics Controller.

18,

FIGURE 6.17A AUTO-ACCEL "~’~~ SWITCH"ON" /~/,j~,~,~

~.~ ~ ..~..____

Depressand hold the Special AdjustmentHarness Switch3 to 5 secondsuntil the Gauge Cluster Dis play reads "CPU."Thenrelease switch. SeeFigure 6.19A. FIGURE 6,18A

NOTE "CPU"shouldremainonthe display. If it doesn’t, checkconditions as describedin steps 13-17andrepeatstep 18. Make certain to hold the Special AdjustmentHarnessSwitch3 to 5 seconds.

NOTE As soonas "CPU"is displayedand special adjustmentharnessswitchis released,the steppingmotorwill moveto the LowIdle position. If "CPU"goesoff display, the procedure has failed. Checkall settings ("LO"-IDLEadjustmentand SteppingMotor)and start procedureover.

19,

While holding the GovernorLever downagainst the EngineLowIdle position, locate the linkagelever arm onto the steppingmotorsplined shaft at approximately7 o’clock position andsecurethe Ball Joint to the governorarm. SeeFigure 6.20A.

FIGURE 6.19A

NOTE The7 o’clock position for the LinkageLeverArmon the Stepping MotorSplines is a starting point. Theposition could vary from the 7 o’clock to 9 o’clock position. Thelinkage should havea small amountof slack whenin position.

20. Slide the LinkageLever ArmLockon the splines until 1/16"to 1/8" of spline is visible.Tightenthe SocketHeadScrew,securingthe lever armto stepping motorshaft andtighten jam nuts on rod linkage.

Page 6-9

FIGURE 6.20A s/~=~5/~

MECHATRONICS Adjustment "A"Mechatronic ControllerSK200 IV ~ SK270 IV 21.

22.

Depressthe Special AdjustmentHarnessSwitch once.This will causethe CPUto turn powerto the steppingmotoroff.

Manuallyrotate the steppingmotorshaft until the governor lever is 0.25mm (.010") - 0.5mm (,020") fromthe Hi-Idle StopSet Bolt.

Hold in position anddepressthe Special Adjust mentHarnessSwitch onceto lock stepping motor in position (you will feel the steppingmotorlock into position). SeeFigure6.21A.

NOTE The 0.25mm (.010") - 0.5mm (.020") gap betweenthe ernor lever and the Hi-Idle Stop Set Screwmustbe maintained. If thereis nogaporgapis too small, the CPU will not completethe indexingphaseandthe procedurewill fail.

Seedirectionsat right.

--.)

GOVERNOR LEVER

ENGINE HI-IDLE SET SCREW FIGURE 6.21A

Howto Adjust Gag Follow instructions belowto adjust gap betweengovernor lever and"HI-Idle" " StopSet Bolt to 0.25- 0.5ram(.010-.020") using the Auto-Acceland BuzzerStop Switches. SeeFigure 6.23A.

Neverattempt to manuallyrotate stepping motor shaft or movelinkage oncethe stepping motorhas beenlockedin position as describedin step 22.

23.

After proper gap has beenobtained, depressthe Special AdjustmentHarnessswitch once. This will causethe SteppingMotorto index from its high position backdownto the low positionandthen CPUwill programthis setting in memory.

Donot turn key or power"OFF," proceedto Part 2 of the procedure.

1. Auto-AccelSwitch "ON" a. Eachpush of the Buzzer Stop Switch will decreasethe gap betweenthe Governor Leverandthe "Hi-Idle" StopSet Bolt approximately0.04ram(.001").

2. Auto-AccelSwitch "OFF" a. Eachpush of the BuzzerStop Switch will increase the gap betweenthe GovernorLever andthe "Hi-Idle" StopSet Bolt approximately 0.04mm (.001").

Onceproperclearancehas beenobtained,refer to step 23.

NOTE Thesteppingmotorwill cycle to the enginestop position andbackto enginestart position. Also "CPU"will leave the display. If "CPU"fails to index, restart the procedure from the beginning.

FIGURE 6.23A

SlO=,-05/~9

Page 6-10

MECHATRONICS Adjustment"A" MechatronicController SK200IV ~ SK270IV E. Adjustment"A"- Part 2 1. Start Engineandallow to run at idle until engineis at normaloperating temperature.Useattachmentrelief if necessary to heat engine.

Place KPSS Mode Switch in "H"- Mode.

2.

3. Place Auto-AccelSwitchin "OFF"position.

4. Throttle Controlin Lo-ldle position.

5. Keyswitch "ON"with Enginerunning.

NOTE Themachine settings mustbe exactly as describedin steps 1 through 5. Anyother settings will not allow successof Adjustment"A"- Part 2.

FIGURE 6.22A

6. After machine settings are as describedin steps 1-5, depressand hold the Special Adjustment HarnessSwitch for 3 to 5 secondsuntil "CPU" is visible ondisplay.

7. After "CPU"is on display andthe switch is released, the CPUwill gradually cycle the steppingmotorfrom belowLo-tdle to Hi-Idle. This programs the CPUto all steppingmotorpositions, andwill take 3 to 5 minutes.

I

NOTE If governorlever touchesthe "Hl"-Idle Set Screwduringthis cycle,the procedure will fail. If it fails, repeatprocedure "A", Part 1 and2. Referto Page6-13.

8. After this processis complete,the steppingmotorwill immediatelyreturn to the Lo-ldle position and"CPU" will leavethe display.

9. Turn key switch to "OFF"andwait approximately4 seconds for electrical powerto automaticallyturn off.

10.Remove the Special AdjustmentHarnessfrom the 1P coupler and connectcoupler together. SeeFigure 6.22A. 11. MoveCPU"TEST-RUN" Switch to "RUN"position and replace the grommet.SeeFigure 6.23A. 12. Start Engineand verify EngineRPM’saccordingto enginespecifications,

FIGURE 6.23A

...s~..:~.

.__~

NOTE If Machineis not equippedwith VariableLoadingMode,adjustment"B" is not necessary.

FIGURE 6.24A

Page6-11

s,o,=..os,99

Kobelco

Mark

IV

Kobelco America Inc. StO~t-05/99

OPTIONAL EQUIPMENT Table of Contents 7-1 - 7-2 SAFETY PRECAUTIONS ......................................................................................................................................

NIBBLER & BREAKER SYSTEM - (Machineset-up for Breaker, Tamper,etc, - Oneor Twopumpflow)....7-3 - 7-4 NIBBLER & BREAKER SYSTEM - (Machineset-up for Shear, Thumb,etc, - Oneor Twopumpflow) ........ 7-5 - 7-6 7-7 ADDITIONAL MAINTENANCE FOR BREAKER ...........................................................................................................

VANDALISM GUARD ............................................................................................................................................ 7-8 - 7-9

t CAUTION !

MOST BREAKERS AND TAMPERS REQUIRE ONE PUMP FLOW ONLYt

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURES FOUNDIN THIS MANUALBEFOREATTEMPTINGANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS,

! CAUTIONL CHECK FLOW REQUIREMENT OF ATTACHMENT BEFORE SELECTING TWOPUMPS]

l Optional equipmentoffered by KobelcoAmericaInc. I 1. BreakerKit - Hydraulicpilot operated,foot pedalcontrolled, single pump flow system.ProvidesUni-directional(oneway)oil flow fromone pump only. System has attachmentflow selector (stop) valves located on both sides of arm(refer to Figure 8.13), anda Single-Actingcontrol pedal mounted on the right handside of the travel pedalsin cab (refer Figures8.14-8.16).This circuit operatesat mainsystempressure,unlessa separaterelief valve is installed.

2. ExtraKit -

Hydraulicpilot operated,foot pedalcontrolled, separate"LowFlow"circuit. ProvidesBi-directional(twoway)oil flow froma flow divider, that usessome oil fromeachhydraulicpump.Flowdivider is electrically controlled from a dashmountedswitch (marked-"EXTRA"),in the operatorscab. (Flow divider must switched-off during normalexcavatoroperations.) A Double-actingcontrol pedal mounted on the right handside of the travel pedalsin cab(refer to Figures8.14-8.16),controlsa Bi-directional auxiliary control valve whichcontainsit’s ownmainandport relief valves.This circuit canbe set to operateat pressureslowerthan the mainsystem,but it is a "LowFlow"circuit.

3. Breaker& Extra Kit -

This kit combines both of the separatekits mentioned above.

4. Nibbler& BreakerKit ** -

This kit is the mostversatile andmostpopularoneoffered. A) It providesthe ability, to haveUni-directional (one-way)oil flow fromone or both pumps.B) It also providesthe ability, to haveBi-directional(two-way)oil flow fromoneor bothpumps.

It also usesthe hydraulicpilot operatedfoot pedal(as mentioned above),to control anauxiliary control valve, whichcanoperateas single or doubleacting. This control valvealso containsit’s ownport relief valves,for circuit protection. System hasattachment flow selector(stop) valveslocatedon both sides of arm(refer to Figure8.13).

** This kit canbe set-upto operateBreakers,Tampers, Shears,Nibblers, Thumbs, Grapples,etc.

I** This kit is explainedM this sectionbecauseof the useof several selector valves necessaryto achievethe I various off flows. Theseselector valves mustbe set correctly to preventdamage to (and providethe proper Iperformance of) the machine,andthe auxiliary equipment that is mounted.Pleaseread the set-up instructions I carefully!

S/Orent-05t99

OPTIONAL EQUIPMENT 8,1 SAFETYPRECAUTIONS Thefollowing Safety Precautionsshouldbe usedin conjunctionwith all other safety precautionsfound in this manual.

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATING PROCEDURES FOUNDIN THIS MANUALBEFOREOPERATING THE MACHINE OR ANY ATTACHMENT FIGURE8.1 A=

USE FOR INTENDEDPURPOSE-FIGURE8.1 Usethe attachmentonly for its intendedpurpose.

If not usedin accordance with the manufacturers instructions, the excessivepressureexertedon the boom,armand framestructure of the machinewill causeprematurefailure of the components¯

B. PASSENGERS Neverallow passengerson the attachmentor machine. .°" ¯

C. PROTECTIVEEQUIPMENT-FIGURE8.2 Install protective guardson the machine andclose the all windows to protect the operatorfromflying debris. Also the operatorandall personell in the vicinity of the machine shouldwearprotective gear suchas Safety shoes, HardHat, Glovesand Face Shield or Goggles¯

INSTALLGUARD ANDCLOSE WINDOWS FIGURE8.2

D, CYLINDERSFIGURE8.3 Donot operateBoom,Armor Bucketcylinders to stroke endswhenusing a breakerattachment.Doing this cancauseunduestress on the cylinder rods and result in damage¯ E. AVOIDCONTINUOUS OPERATION-FIGURE8.4 Operatethe Breakeror Nibbler in one (1) minute intervals. Operationfor longerthan one(1) minute at a time can causehigh oil temperatures anddamagethe accumulators,cylinder seals andpossibly pumpdamage¯

FIGURE8.3

FIGURE8.4

s:o=,-o5:99

Page7-1

OPTIONAL EQUIPMENT F. HOSESURGE-FIGURE8.5 Shouldthe hydraulic hosesbegin to surgeor vibrate abnormallyduring operationof a Breakeror Nibbler, immediately stop operation:rid contactan Authorized KOBELCO Service dealer for assistance. This problemoften is a reesult in damaged accumulators andcanalso result in valve failure.

~ I)) ~ ~.

~i

__i!

FIGURE8.5

G. DO NOT USE DROPPNG FORCE- FIGURE 8.6 Neveruse the droppingforce of the attachmentto breakor drive objects. This will causeextensive damage to the attachmentand machinestructure.

FIGURE8.6 H. DO NOTUSE SWINGFORCE-FIGURE8.7 Neverusethe swingforce of the machinefor pushing or sliding objects,this will causepremature failure of the attachmentand other machinecomponents.

FIGURE8.7 I. DONOTLIFT- FIGURE8.8 Neveruse an optional attachment to lift or transport objects or material. Doingso cancauseextensive damage to the attachment,the machinestructures andcauseinjury or death.

FIGURE8.8 J. WORKING RANGES-FIGURE8.9 Never operate an optional attachmentover the sides of the machine.Only operateover the front or rearof thetracks.

UNACCEPTABLEWORKRANGE

ACCEPTABLE

~

~

~ WORK RANGE

FIGURE8.9 Page 7-2

s,~,,,.o~,99

OPTIONAL EQUIPMENT NIBBLER & BREAKERSYSTEM A. MACHINESET-UP FOR BREAKEROR TAMPERUSE UNI-DIRECTIONAL- (ONE-WAY F__~O~

[ONE or TWOPUMPFLOW].

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATION PROCEDURES FOUNDIN THIS MANUALBEFOREOPERATING THE MACHINEOR ANY ATTACHMENT. 1. Pilot Circuit SelectorValve a. Locatethe Pilot SelectorValvein front of the attachmentfilter housing.SeeFigure 8.10. b. Usea 4 mmhexagonal wrenchand remove the safety bolt. SeeFigure8.10A. c. Usea spannerwrenchand turn the selector valve to align the arrow heads,stamped on the valve, as shownon Figure 8.10A,for ~, or Figure 8.10B for one pumpflow. d. Reinstall the hexagonal headsafety bolt.

SeeFigure 8.10A. 2. ReturnFlowSelector Valve a. Usea 19mmwrenchand removethe bolts that hold the panel abovethe MainControl Valve. Remove the panel and locate the ReturnFlow Selector Valvebehindthe attachment filter housing.SeeFigure8.11. b. Usea 4 mmhexagonalwrenchand remove the safety bolt. SeeFigure8.11. c. Usinga spannerwrench,turn the selector until the stampedarrowheadsare aligned as shownon Figure 8.11. d. Reinstall the hexagonalheadcapscrewand tightenit properly.

3. PumpFlowSelector Valve a. Locate the Pump Flow Selector Valve. See Figure8.12. b. Removethe HexagonalHeadCapscrew with a 4mm allen wrench. c. Usinga spanner wrench, turn the selectoruntil the stampedarrowsare aligned as shownon Figure 8.12A, to select two pumpflow, or as shownon Figure 8.12B, to select one gump_fl~. [Check flow requirement of attachmentbefore selecting two pumps/] d. Reinstall the hexagonalheadcapscrewand tightenit properly.

S/Orcnt-05/99

4. Attachment FlowSelector Valves a. Locatethe Art. FlowSelector Valveson both sides of the Arm.SeeFigure 8.13. b. Usinga spannerwrench,turn the selector valves until the stamped arrowsare aligned with the direction of the flow. Figure8.13 showthe valves on the lock position.

FIGURE8.10

FIGURE8,10B

FIGURE8.11 HAMMER& TAMPER RETURNOIL

MUSTGO THROUGH EXTERNAL FILTER ~SET

FOR - - ;

TWO PUMP

! CAUTION !

MOST BREAKERS AND TAMPERS REQUIRE ONE PUMP FLOW ONLY!

FIGURE Locatedonboth sides armby the bucketend connection.

Page 7-3

OPTIONAL EQUIPMENT B. BASIC OPERATION

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATION PROCEDURES FOUNDIN THIS MANUALBEFOREOPERATING THE MACHINEOR ANY ATFACHMENT. 1. Start Machineand place the Safety LockLever in the "UNLOCKED" (Down)position. See Figure8.13.

2. Move throttle controlto the =HI"idle position.

3. Using Boom,Armand Bucketcontrols set the Breakeror Tamper to desiredposition.

4. Release Control Pedal Lock Rod. SeeFigure 8.14.

5. Makecertain Breaker/ Tamper is in desired position andagainstmaterial to be broken,or compacted.

6. PlaceRight foot on pedal and depresswith toe to activate Breaker/ Tamper.SeeFigure 8.15.

7. Operate Breaker/Tamperfor one (1) minute then release pedal. ~:¸ ~i~iiii~i~i!

~ ~;;~

~;~ii%~i~.~i~i~(~\~’~i~’~

FIGURE8.13

FIGURE8.14

OPERATIONOF BREAKERI TAMPERLONGER THANONE(1) MINUTEINTERVALSCOULD CAUSE PREMATUREWEAROR DAMAGETO THE ATTACHMENT AND THE MACHINE. IF MATERIALIS NOTBREAKING,REPOSITION BREAKERAND REPEAT OPERATION IN ONE(1) MINUTEINTERVALS. 8. After Breaker/ Tamper operation is complete or operatoris requiredto leavethe machine, placepedallock rod in the lockedposition, see Figure8.16, positionattachment in hydraulicoil checkposition, move throttle controlto "LO"idle position andturn engine"OFF".

FIGURE8,15

NEVERLEAVETHE OPERATOR CAB WITH ENGINE RUNNING. ALWAYSLOWERTHE ATTACHMENTS TO THE GROUNDBEFORELEAVING THE CAB.

FIGURE8.16

OPTIONAL EQUIPMENT NIBBLER& BREAKERSYSTEM(Cont.)

A. MACHINESET-UP FOR NIBBLERUSE SHEAR, THUMB,GRAPPLE,ETC. BI-DIRECTIONAL - .(TWO.~ [ONE or TWOPUMPFLOW]

FIGURE

READ, UNDERSTAND AND FOLLOWALL SAFETY I I PRECAUTIONSAND OPERATIONPROCEDURES I FOUNDIN THIS MANUALBEFOREOPERATINGI THE MACHINE OR ANY ATTACHMENT. [ 1. Pilot Circuit SelectorValve a. Locatethe Pilot SelectorValvein front of the attachmentfilter housing.SeeFigure 8.17. b. Usea 4 mmhexagonalwrenchand remove the safety bolt. SeeFigure8.17A. c. Usea spannerwrenchand turn the selector valve to align the arrowheads,stamped on the valve, as shownon Figure 8.17Afor ~, or Figure 8.17B for one

FIGURE8.17B

d. Reinstall the hexagonal headsafety bolt.

SeeFigure 8.17A. 2. ReturnFlowSelector Valve a. Usea 19mm wrenchand removethe bolts that hold the panel abovethe MainControl Valve. Remove the panel and locate the ReturnFlowSelector Valvebehindthe attachment filter housing.SeeFigure 8.18. b. Use a 4 mmhexagonalwrenchand remove the safety bolt. SeeFigure8.11. c. Usinga spannerwrench,turn the selector until the stamped arrowheadsare aligned as shownon Figure 8.18. d. Reinstall the hexagonalheadcapscrewand tightenit properly.

3. PumpFlowSelector Valve a. Locate the Pump Flow Selector Valve. See Figure8.19. b. Removethe HexagonalHeadCapscrew with a 4mm allen wrench. c. Usinga spannerwrench,turn the selector until the stamped arrowsare alignedas shownon Figure 8.19A, to select two pumpflow, or as shownon Figure 8.19B to select d. Reinstall the hexagonalheadcapscrewand tightenit properly.

4. Attachment FlowSelector Valves a. Locatethe Att, FlowSelectorValveson both sides of the Arm.SeeFigure8.20. b. Usinga spannerwrench,turn the selector valves until the stamped arrowsare aligned with the direction of the flow. Figure8.20 showthe valves on the lock position.

FIGURE 8.18 ] OIL MUST GO THROUGH AUXILIARY CONTROL VALVE

SET FOR ] "I’WO PUMP FLOW

FIGURE8,19A SET FOR ONE PUMP FLOW

FIGURE8,19B ! CAUTION !

CHECK FLOW REQUIREMENT OF ATTACHMENT BEFORE SELECTING TWO PUMPS !

FIGURE8.20 Located on bothsidesof the armby the bucketend connection.

Page7-5

OPTIONAL EQUIPMENT B. BASIC OPERATION I

~,

/~

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATION PROCEDURES FOUNDIN THIS MANUALBEFOREOPERATING THE MACHINEOR ANY ATTACHMENT. 1. Start Machineand place the Safety LockLever in the "UNLOCKED" (Down)position. See Figure8.21. throttle controlto the "HI" idle position.

2. Move 3. Using Boom,Armand Bucketcontrols set the Attachment to desiredposition.

4. ReleaseControl Pedal Lock Rod. SeeFigure 8.22.

5. Usethe Boom,Armand BucketControls to position the attachment.

6. PlaceRight foot on pedal anddepresswith toe for onedirection of attachment operation,and depressbackof pedalwith heelfor oppositedirection of attachmentoperation. SeeFigure 8.23.

7. After operationis complete or operatoris required to leavethe machine,place pedal lock rod in the lockedposition, seeFigure8.24, position attachment in hydraulicoil checkposition, movethrottle control to "LO"idle position, and turn engine"OFF".

FIGURE8.21

FIGURE8.22

NEVERLEAVETHE OPERATOR CAB WITH ENGINE RUNNING. ALWAYSLOWERTHE ATTACHMENTS ON THE GROUNDBEFORELEAVING CAB. FIGURE8.23

FIGURE8.24 Page 7-6

~o,=,,-~

OPTIONAL EQUIPMENT ADDITIONAL

MAINTENANCE FOR BREAKER

(OPTIONAL

ATTACHMENT)

A. It is necessaryto performthe following maintenance schedule in regard to Hydraulic Oil and Filters along with normal inspection and maintenance as described in Section IV of this manual for the Breaker Optional Attachment.

B. ADDITIONAL HYDRAULIC RETURN FILTER The Breaker optional attachment incorporates an additional Hydraulic Return Filter mountedon an independent stand to the R.H. side of the Swing Motor. See Figure 8.25.

FIGURE 8.25

REPLACEMENT SCHEDULE COMPONENT LOCATION 1ST MAINTENANCE 2NDMAINTENANCE CHANGE HYDRAULIC OIL HYDRAULICTANK RETURN FILTER HYDRAULICTANK 25HOURS 100 HOURS OPT. RETURN FILTER BESIDESWINGMTR 25HOURS 100 HOURS

......

REGULAR MAINTENANCE EVERY600 HOURS EVERY200 HOURS EVERY200 HOURS

NOTE Contact your Kobelco Dealer to order the return filter elementfor the optional Breaker attachment, Part Number: 2446U233S2

PLEASE NOTE The above filter is for the genuine Kobelco Hydraulic Breaker or Nibbler/Breaker Kits. If your unit has another brandhydraulickit installed, it mayrequire a different filter element - please check with your local Kobelco dealer.

s~o~-0~9

Page 7-7

OPTIONAL EQUIPMENTSKl15 ~ SK130 NOTE Contactyour KobelcoDealerto order the Vandalism GuardKit P/N: KSP9120VKIT This kit containsthe supportbracketfor the Vandalism Guardsandshouldbe installed on the right side of the upperframe, belowthe fuel tank andhydraulic tank as shownin Figure 8.28. Contactthe Service Department of your nearestKobelcoDealerfor specific details on the installation of the supportbracket.

VANDALISM GUARD MOUNTING STUDS

8.5 VANDALISMGUARDP/N: KSP9120VKIT A,

SPECIAL STUDS The KOBELCO Mark IV USA Spec. cab is equippedwith special studs to accommodate installation of KOBELCO VandalismGuards.

SeeFigure 8.26.

MOUNTING Whenmounting the Vandalism Guardsto the machine, beginwith Panel1 andinstall to cabin sequence (1,2, 3, etc.). SeeFigure8.27.

C,

REMOVING Whenremovingthe guardsfrom the cab, remove in the reverseorder of installation (14113, 12, etc.). SeeFigure8.27.

D°

STORING Storage of the VandalismGuardis located outsidenextto the fuel tank andhydraulictank.

SeeFigure 8.28.

FIGURE8.26 3

/2

4

7

5

I

FIGURE8.27

FIGURE8.28 Page 7-8

S/orcat-os/99

OPTIONAL EQUIPMENTSK150 ~ SK400 NOTE Contactyour KobelcoDealer to order the Vandalism GuardKit P/N: KSP9220VKIT This kit containsthe supportbracketfor the Vandalism Guardsandshouldbe installed on the left side of the machinein the compartment wherethe air cleaner is located as shownin Figure8.28. Contactthe Parts Department of your nearestKobelcoDealerfor specific details on the installation of the supportbracket.

VANDALISM GUARD MOUNTING STUDS

8.5 VANDALISMGUARDP/N: KSP9220VKIT SPECIAL STUDS The KOBELCO Mark IV USA Spec. cab is equippedwith special studs to accommodate installation of KOBELCO VandalismGuards.

SeeFigure 8.26.

B,

FIGURE8.26

MOUNTING Whenmounting the Vandalism Guardsto the machine, beginwith Panel1 andinstall to cabin sequence (1, 2, 3, etc.). SeeFigure8.27.

C.

REMOVING When removingthe guardsfrom the cab, remove in the reverseorderof installation (14, 13, 12, etc.). SeeFigure 8.27.

O.

STORING Storageof the Vandalism Guardis locatedinside the engineair cleaner accessdoor against the cab. SeeFigure 8.28.

5

4

3

[

1 lO FIGURE8.27 STORAGE AREA

RETAINING BAR MOUNTING HOLES

FIGURE8.28 s~o~n,.o~

Page 7-9

NOTES

|

|

\

’I

|

KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. Part Number North American English 245 E NORTH AVENUE Printed in U.S.A. CAROL STREAM, IL 60188 U.S.A

KSOH-IV-USA-REV.0-04/99NA March 04 Bur