Kobelco SK210-9 Hydraulic Excavator Shop Manual - PDF DOWNLOAD

model

SK210-9

INDEX 1 SPECIFICATIONS SECTION 2 MAINTENANCE SECTION

SYSTEM

SHOP MANUAL

MAINTENANCE SPECIFICATIONS

HYDRAULIC EXCAVATOR

5 TROUBLESHOOTING 6 ENGINE SECTION

OPT.

OF INSTALLING 7 PROCEDURE OPTIONS SECTION

E / G TROUBLESHOOTING

4 DISASSEMBLY SECTION

DISASSEMBLING

3 SYSTEM SECTION

Book Code No.S5YN0042E01 0-1

GENERAL SAFETY INFORMATION

Do not operate or perform any maintenance on this machine until all instructions found in the OPERATOR’S MANUAL and this MANUAL have been thoroughly read and understood.

Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death.

Always keep the manual in storage.

If it is missing or damaged, place an order with an authorized Distributor for a replacement.

If you have any questions, please consult an authorized Distributor.

(1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death to personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

(2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

(3) Messages of safety appear in the manual and on the machine: All messages of safety are identified by one of the following words: "DANGER", "WARNING" and "CAUTION".

1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

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

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

(4) It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by the Manufacturer.

(5) While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

(6) Continue studying the manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

SAFETY PRECAUTIONS

The proper and safe lubrication and maintenance for this machine, recommended by the Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine.

Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work.

A knowledge of the system and/or components is important before the removal or disassembly of any component.

Because of the size of some of the machine components, the technician should check the weights noted in this manual. Use proper lifting procedures when removing any component. The weight of components table is shown in section; SPECIFICATIONS. The following is a list of basic precautions that must always be observed.

(1) Read and understand all Warning plates and decals on the machine before Operating, Maintaining or Repairing this machine.

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

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

(4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not roll while working on or under the machine. Hang a "Do Not Operate" tag in the Operators Compartment.

(5) Do not work on any machine that is supported only by a lift, jacks or a hoist. Always use blocks or jack stands capable of supporting the machine before performing any disassembly.

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

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

(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly.

(8) Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

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

(10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

(11)Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure before removing the last two capscrews or nuts completely.

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

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

you understand how to use them before performing any service work.

(14)Reinstall all fasteners with the same part number.

Do not use a lesser quality fastener if replacements are necessary.

(15)Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures.

Determine the type of metal being welded and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted.

(16)Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a hose or tube containing fluid.

(17)Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed.

(18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work.

(19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board to locate pinhole leaks.

(20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation.

Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

(21)Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has

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

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

INDEX

S5YN0318E01 2006-8 S5YN1118E02 2008-10 S5YN1218E01 2006-8 S5LB1301E01 2011-03 S5YN2141E01 2011-03 S5YN2242E01 2011-03 S5YN2318E02 2007-2 S5YN2442E01 2011-03 S5YN2518E02 2007-2

MAINTENANCE SPECIFICATIONS

Book Code No. Distribution Year–Month S5YN0118E01 2006-8 S5YN0218E02 2007-2

SK210-9

SYSTEM

NA

Title

Index No.

OUTLINE

1

SPECIFICATIONS

2

ATTACHMENT DIMENSIONS

3

TOOLS

11

STANDARD MAINTENANCE TIME SCHEDULE MAINTENANCE STANDARD AND TEST PROCEDURE MECHATRO CONTROL SYSTEM

33

12 13 21

HYDRAULIC SYSTEM

22

ELECTRIC SYSTEM

23

COMPONENTS SYSTEM

24

AIR-CONDITIONER SYSTEM

25

DISASSEMBLING & ASSEMBLING

31 31

ATTACHMENT

32

UPPER STRUCTURE

33

TRAVEL SYSTEM

34 34

BY ERROR CODES

46

BY TROUBLE

47

_

84392428 2011-04

E / G TROUBLESHOOTING

S5YN3118E01 2006-8 S5YN3218E02 2007-2 S5YN3342E01 2011-03 S5YN3418E02 2007-2 S5LB4601E01 2011-03 S5YN4742E01 2011-03 S5YN4818E01 2006-8

DISASSEMBLING

_

TROUBLE DIAGNOSIS MODE

48

ENGINE

51

_

46 22

47

47

24

_ _

YN13

21 13

APPLICABLE MACHINES

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

This Manual may be properly revised due to the improvement of products, modification of specifications, etc. And there are cases where the system on the actual machine and a part of the contents of this manual may differ due to the variations of specifications by countries. For the section in which the description is hardly understood, contact our distributor.

•

The Chapter "Specification" describes the specifications for entire machine and material, which are instructive for replacement and repairing of attachments.

•

The Chapter "Maintenance" describes the material, which is helpful for maintenance service and adjustments for the entire machine.

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

•

The Chapter "System" describes the operating system like hydraulic system, electric system, components, and so on.

•

The Chapter "Disassembly" describes the removal and installing of assemblies mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment.

•

The Chapter "Troubleshooting" describes how to find the equipment fault.

•

The Chapter "Engine" describes the engines making use of the "Maintenance Manual" provided by the suppliers.

•

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

2. SPECIFICATIONS

2

2. SPECIFICATIONS TABLE OF CONTENTS

2.1 NAME OF COMPONENTS .................................................................................. 2-3 2.2 GENERAL DIMENSIONS .................................................................................... 2-4 2.2.1 SK210-9 [5.65m(18ft-6in) + 2.94m(7ft-10in) Standard Arm + 0.80m3 (1.05cu-yd) Bucket] ......................................................................................................... 2-4 2.2.2 SK210-9 [5.65m(18ft-6in) + 2.4m(7ft-10in) Short Arm + 0.93m3 (1.22cu-yd) Bucket] ......................................................................................................... 2-4 2.2.3 SK210-9 [5.65m(18ft-6in) + 3.5m(11ft-6in) Long Arm + 0.70m3 (0.92cu-yd) Bucket] ......................................................................................................... 2-5 2.3 WEIGHT OF COMPONENTS .............................................................................. 2-6 2.4 TRANSPOTATION ............................................................................................... 2-8 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................... 2-8 2.4.2 DIMENSIONS OF ATTACHMENT ............................................................... 2-9 2.5 SPECIFICATIONS AND PERFORMANCE .......................................................... 2-11 2.5.1 SPEED AND CLIMBING CAPABILITY ........................................................ 2-11 2.5.2 ENGINE ....................................................................................................... 2-11 2.5.3 HYDRAULIC COMPONENTS ..................................................................... 2-11 2.5.4 WEIGHT ...................................................................................................... 2-11 2.6 TYPE OF CRAWLER ........................................................................................... 2-12 2.7 TYPE OF BUCKET .............................................................................................. 2-12 2.8 COMBINATIONS OF ATTACHMENT .................................................................. 2-13 2.9 ENGINE SPECIFICATION ................................................................................... 2-14 2.9.1 SPECIFICATIONS ....................................................................................... 2-14 2.9.2 ENGINE CHARACTERISTIC CURVE ......................................................... 2-15

Book Code No. S5YN0042E01 2-1

2. SPECIFICATIONS NOTES

2-2

2. SPECIFICATIONS

2.2

GENERAL DIMENSIONS

2.2.1

SK210-9 [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3 (1.05cu-yd) Bucket]

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

2.2.2

SK210-9 [5.65m (18ft-6in) Boom+2.4m (7ft-10in) Short Arm+0.93m3 (1.22cu-yd) Bucket

2-4

2. SPECIFICATIONS 2.2.3

SK210-9 [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu-yd) Bucket

2

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

2-5

2. SPECIFICATIONS

2.3

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

SK210-9

Fully equipped weight

21,700 (47,840)

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

9,500 (21,000) 1,770 (3,900) 4,640 (10,230) 260 (570) * 540 (1,190) * 150 (330) * 110 (240) * 210 (460) * 230 (510) * 170 (375) X 2 70 (150) * 130 (290) * 90 (200)

2. Lower frame assy (Assembly of following :) 2.1 Lower frame 2.2 Slewing bearing 2.3 Travel motor (including reduction unit) 2.4 Upper roller 2.5 Lower roller 2.6 Front idler 2.7 Idler adjuster 2.8 Sprocket 2.9 Swivel joint 2.10 Track link with 600mm (23.6in) shoes assy Track link with 700mm (27.5in) shoes assy Track link with 800mm (31.5in) shoe assy 2.10.1 Track link assy

7,130 (15,720) 2,420 (5,340) 250 (550) 260 (570) X 2 20 (44) X 2 30 (66) X 16 110 (240) X 2 100 (220) X 2 50 (110) X 2 * 30 (66) 1350 (2,980) X 2 1,560 (3,440) X 2 1,700 (3,750) X 2 540 (1,190) X 2

3. Attachment (Assembly of following :) {4.68m (15ft-4in) Boom + 2.84m (9ft-7in) Arm + 0.38m3 (0.50cu-yd) Bucket} 3.1 Bucket assy (STD) 3.2 STD Arm assy (Assembly of following :) 3.2.1 STD Arm 3.2.2 Bucket cylinder 3.2.3 Idler link 3.2.4 Bucket link 3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 3.3 Boom assy (Assembly of following :) 3.3.1 Boom 3.3.2 Arm cylinder 3.3.3 Pin (Mounting arm - Mounting arm cylinder)

2-6

3,420 (7,540) 640 (1,410) 1,050 (2,315) 660 (1,455) * 140 (310) 20 (44) X 2 90 (198) 100 (220) 1,730 (3,815) 1,310 (2,890) * 255 (560) 80 (180)

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

SK210-9

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

550 (1,210) 200 (440) 20 (44) 310 (680) 20 (44)

2 Marks * show dry weight.

2-7

2. SPECIFICATIONS

2.4

TRANSPOTATION

2.4.1

OVERALL DIMENSIONS OF MACHINE ON A TRAILER

(1) 5.65m (18ft-6in) Boom+2.94m (9ft-8in) Long Arm+0.80m3 (1.05cu-yd) Bucket Item/Shoe type Width : mm (ft-in) Weight: kg (lbs)

800mm (31.5in) 3,190 (10'6") 21,700kg (47,800 lbs)

2-8

2. SPECIFICATIONS

2.5

SPECIFICATIONS AND PERFORMANCE

2.5.1

SPEED AND CLIMBING CAPABILITY Item / Model

Swing speed :

min-1

SK210-9

{rpm}

12.8 {12.8}

Travel speed (1-speed/2-speed) : km/h (mile/h)

3.4 / 5.6 (2.1 / 3.5)

Gradeability : % (degree)

2.5.2

70 (35)

ENGINE

Engine model

F4HFE613*A003 Water-cooled, 4 cycle 6 cylinder direct injection type diesel engine with inter cooler turbo-charger electric common rail Tier 4 certified SCR

Type

6 - 104 dia. mm X 132 mm (4.02 in X 5.12 in)

Number of cylinders-BoreXStroke Total displacement

6.728 L (410 cu-in) 129 kW (175 PS) / 2,000 min-1

Rated output / Engine speed

740 N-m (545 lbf-ft)/ 1,400 min-1

Maximum torque / Engine speed Starter

24 V / 4.0kW

Alternator

2.5.3

2

24 V / 70A

HYDRAULIC COMPONENTS

Hydraulic pump

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

Hydraulic motor (swing)

Axial piston motor X 1

Hydraulic motor (travel)

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

Control valve

8-spool control valve X 1

Cylinder (Boom, Arm, Bucket)

Double action cylinder

Oil cooler

2.5.4

Air-cooled type

WEIGHT Unit : kg (lbs)

Fully equipped weight

21,700 (47,800)

Upper structure

9,500 (21,000)

Lower machinery (600mm grouser shoe)

7,130 (15,720)

Attachment 5.65m (18 ft-6in) Boom+2.94m (9ft-8in) Arm+0.80m3 (1.05cu-yd) Bucket

3.420 (7,540)

2-11

2. SPECIFICATIONS

2.6

TYPE OF CRAWLER

Shape

Shoe Width mm (in)

Overall width of crawler mm (ft-in)

Ground Pressuer kPa (psi)

600 (23.6)

2,990 (9’10”)

43 (6.24)

700 (27.6)

3,090 (10’2”)

38 (5.51)

800 (31.5)

3,190 (10’6”)

33 (4.9)

Grouser Shoe

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

2.7

TYPE OF BUCKET

2-12

2. SPECIFICATIONS

2.9

ENGINE SPECIFICATION

2.9.1

SPECIFICATIONS

Applicable machine

SK210-9

Engine model

F4HFE613S*A003 Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger electric common rail Tier 4a Certified SCR

Type Number of cylinderXBoreXStroke Total displacement

mm (in)

6 X 104 X 132 (4.09 X 5.20)

cc (cu-in)

6,728 (410)

Compression ratio Rated output with Fan

18.0 kW (PS) at

min-1

129 (175) at 2,000

N-m (lb-ft) at min-1

740 (545) at 1,400

High idling

min-1

2,000 ± 30

Low idling

min-1

1,000 ± 20

MPa (psi)

50 (7,250)

Start/Full open K (degrees F)

350 (170) / 363 (194)

Maximum torque without Fan

Injection starting pressure Thermostat action Firing order Starter capacity Generator capacity (Alternator)

1-3-4-2 V X kW

24 X 4.0

VXA

24 X 70

Cooling fan drive method

Circulating type with centrifugal pump

Engine oil quantity

L (gal)

Total 20 (5.3)

Dry weight

kg (lbs)

580 (1,280)

g/kW-h (g/ps-h)

217(160)

Fuel consumption ratio (At rated output) Allowable inclination Dimension (LXWXH)

Front / Rear and Right / Left : 35 degrees mm (in)

1,063 X 725 X 995 (3ft-5.86in X 28.5in X 39.2in)

Rotating direction

Counterclockwise seeing from flywheel side

2-14

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13. MAINTENANCE STANDARD AND TEST PROCEDURE TABLE OF CONTENTS

13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS .............. 13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE ....................................... 13-4 13.3 MEASUREMENT OF ENGINE SPEED ............................................................. 13-6 13.3.1 MEASUREMENT OF ENGINE SPEED ..................................................... 13-6 13.4 MEASUREMENT OF HYDRAULIC PRESSURE .............................................. 13-7 13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................... 13-7 13.4.2 PLACE TO INSTALL PRESSURE GAUGE ............................................... 13-8 13.4.3 PRESSURE ADJUSTMENT POSITION ................................................... 13-9 13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE .................................... 13-10 13.5 MEASURING TRAVEL PERFORMANCES ....................................................... 13-12 13.5.1 TRAVEL SPEED ........................................................................................ 13-12 13.5.2 DEVIATION OF TRAVEL ........................................................................... 13-12 13.5.3 PERFORMANCES OF PARKING BRAKE ................................................ 13-13 13.5.4 DRAIN RATE OF TRAVEL MOTOR .......................................................... 13-14 13.6 MEASURING SWING PERFORMANCES ......................................................... 13-15 13.6.1 SWING SPEED ......................................................................................... 13-15 13.6.2 PERFORMANCE OF SWING BRAKE ...................................................... 13-15 13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................... 13-16 13.6.4 DRAIN RATE OF SWING MOTOR ............................................................ 13-17 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................... 13-18 13.7.1 OPERATING TIME OF CYLINDERS ......................................................... 13-18 13.7.2 OIL TIGHTNESS OF CYLINDERS ............................................................ 13-19 13.8 MEASURING PERFORMANCES OF SWING BEARING ................................. 13-20 13.9 MECHATRO CONTROLLER ............................................................................. 13-21 13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................... 13-21 13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) ................................................................................ 13-21 13.9.3 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED ................................................................................................ 13-21

Book Code No. S5LB1301E01 13-1

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.4 13.9.5 13.9.6

PREPORATION ......................................................................................... 13-22 ADJUSTING PROCEDURE ....................................................................... 13-23 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER ..................................................................... 13-28

Issue

Date of Issue

First Edition

March, 2011

Applicable Machines SK210-9: YN13

13-2

Remarks (NA)

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1

HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

(1) Application 1. When the machine is new; Confirm that the performances are in accordance with standard specifications as compared to the performance standards.

2. At specific self inspection; (Rule by country) Use the data for the criterion, for the purpose of correction, adjustment and replacement.

3. When performances are deteriorated; Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations.

4. When main components are replaced; For example, use data to restore performances of pumps and others.

(2) Terminology 1. Standard values; Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standard shoes).

2. Reference values for remedy; Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the machine over the specified values.

3. Service limit; This is the limit value at which reconditioning is impossible without replacement of parts. If the value is expected to exceed the service limit before next inspection and correction are performed, replace the parts immediately.

The operation over the specified values causes increase of damage and requires the down time of machine, and also causes safety problems.

(3) Cautions to be Exercised at Judgment 1. Evaluation of measured data; Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values.

2. Determining correction, adjustment or replacement; Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels.

(4) Other Cautions to be Exercised 1. Parts liable to degrade; Rubber products, such as, hydraulic hoses, O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.

2. Parts requiring regular replacement; Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly.

3. Inspection and replacement of oils and greases; In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.

13-3

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2

PERFORMANCE INSPECTION STANDARD TABLE

13-4

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13

13-5

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3

MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED (1) Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90° C (140 to 194° F) at surface of radiator upper tank.

The E/G coolant temperature gauge is used to measure. The range in white color shows the temperature of approx. 65° to 105° C (149° to 221° F), so confirm that the pointer indicates the temperature within the white range.

RED WHITE

BLUE

(2) Engine speed measured value through service diagnosis (See below Fig.) 1. Turn "ON" the starter switch with the buzzer stop switch pressed.

2. A program No. and an actual engine revolution are displayed as the No.2 Item.

3. The screen advances like No.2, No.3....each time the "Up arrow switch" on the gauge cluster is pushed.

4. The screen returns like No.45, No.44....each time the "Down arrow switch" is pushed.

5. The display does not disappear unless the starter switch is turned to "OFF".

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

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

Service Diagnosis For E/g Speed Measuring (Example)

UP ARROW SWITCH BUZZER STOP SWITCH DOWN ARROW SWITCH Switch For E/G Speed Indication

13-6

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4

MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE

13

13-7

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.2 PLACE TO INSTALL PRESSURE GAUGE

13-8

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.3 PRESSURE ADJUSTMENT POSITION

13

13-9

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

13-10

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13

13-11

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5

MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED

13-12

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13

13-13

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13-14

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13

13-15

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13-16

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13

13-17

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13-18

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13

13-19

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13-20

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9 MECHATRO CONTROLLER 13.9.1 ENGINE CONTROL INPUT / OUTPUT C-8: ENGINE CONTROLLER INJECTOR

C-2: GAUGE CLUSTER

E-1: FUSE&RELAY BOX

ENGINE SPEED SENSOR

STARTER SWITCH

C-1: MECHATRO CONTROLLER

ACCEL POTENTIO METER

ENGINE

PUMP PROPORTIONAL VALVE

INPUT / OUTPUT

13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) PURPOSE OF THE ADJUSTMENT There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to ensure performance of machine.

(1) Adjustment of pump ("B" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output.

(2) Adjustment of unloading valve ("C" adjustment) This adjustment is performed to correct the open variation of unloading valve to improve the operability further.

13.9.3 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED When the following parts are replaced or repaired, carry out the adjustment without fail.

(1) Mechatro controller (2) Engine or engine controller (3) Hydraulic pump or hydraulic pump proportional valve (4) Unloading proportional valve, spool of unloading valve

13-21

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.4 PREPARATION (1) Raise the oil temperature to about 50C degrees (122F degrees) to warm up the engine.

(2) Turn the air-con OFF. (3) Turn the starter key switch OFF to stop the engine.

When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered.

A215, A225, A015, A025, A035 As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List.

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

13-22

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.5 ADJUSTING PROCEDURE

MULTI DISPLAY

WORK MODE SELECT SWITCH

UP ARROW SWITCH MENU SWITCH

BUZZER STOP SWITCH

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

MULTI DISPLAY (EXAMPLE) S

12:15

13 E

2. Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selecting adjustment is displayed.

When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.

And the lever lock solenoid is automatically released, disabling all operations.

3. Press menu switch on gauge cluster to display "START ENGINE".

"Engine SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PUMP" current (command value) are indicated.

13-23

F

ADJUST OUTPUT

FIN

ADJUST UNLOAD

FIN

ADJUST CRANE

---

ADJUST 0 CRANE

---

ADJUST LMN

---

ADJ INTERFE PREV

---

ADJUST INITIAL

---

START ENGINE ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

13. MAINTENANCE STANDARD AND TEST PROCEDURE 4. After engine starting, press the menu switch on gauge cluster, and "MEMORY PUMP" displayed.

And the adjustment shifts to pump adjustment automatically. Then the speed shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased.

The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PUMP" current (command value) are indicated.

5. After detection of the engine rated speed, the adjustment of pump is automatically completed.

And "FINISH PUMP" is displayed.

(Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.)

(2) Adjustment of unloading valve ("C" adjustment) Procedure 1. The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is displayed.

The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "UNLOAD" current (command value) are indicated.

2. When the unloading valve operates to the specified value, the adjustment of unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed.

The speed is shifted to the speed corresponding to acceleration potentiometer.

The adjusting current value is indicated on the display of current of P1, P2 unloading proportional valves. The adjusting range is usually 520 to 635 mA. Stop the engine. (The automatically stored.)

adjusted

data

is

13-24

MEMORY PUMP ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

FINISH PUMP ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

MEMORY UNLOAD ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

FINISH UNLOAD ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Corrective actions taken when the adjustment can not be performed; 1. In cases where the adjustment of pump can not be performed; And "ERROR PUMP" is displayed.

Judging condition 1: P1 and P2 average pump pressure at the time when the adjustment is completed is 25MPa or less.

Judging condition 2: The adjustment does not complete although the pump proportional valve current reaches to the specified value.

ERROR PUMP ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

The P1 and P2 pump pressures usually increase to 33~38MPa. When the pressure does not increase; a. Identify the reason why the pressure does not increase, -Check that the relief valve operates normally.

-Check that the hydraulic circuit is free from leak of pressure.

-Check that the pressure sensor functions normally.

And so on. b. Identify the reason why the actual flow rate does not increase, -Check that the pump proportional valve operates normally.

-Check that the pump regulator operates normally.

And so on.

2. In cases where unloading valve can not be performed; And "ERROR UNLOAD" is displayed.

Judging condition 1: The pump pressure does not increase up to the pressure in the range of the specified adjustment.

Or the increased pressure is held as it is.

Judging condition 2: Pressure sensor of either P1 pump or P2 pump is failed.

Normally the pump pressures of P1 and p2 pumps gradually increase to 10 to 25 MPa. (It may be affected by operating oil temperature.)

When the pump pressure does not increase; a. Identify the reason why the pressure does not increase, -Check that the relief valve operates normally.

-Check that the hydraulic circuit is free from leak of pressure.

-Check that the pressure sensor functions normally.

And so on.

13-25

13

ERROR UNLOAD ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Other precautions: 1. In the event of a failure, there is case where the adjustment may not be performed normally.

First serve the machine, and perform the adjustment work.

2. In the condition where large load is constantly applied to engine, the adjustment could not be performed normally.

For machines equipped with lifting magnet, turn the generator OFF. (5) When the adjustment of unloading valve only is performed; ("C" adjustment) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only.

Procedure 1. Turn starter switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5 to 10 seconds, and then release it.

(If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

MULTI DISPLAY (EXAMPLE) S

12:15

E

2. Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selection of adjustment type is displayed. And "ADJUST" is displayed.

When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.

And the lever lock solenoid is automatically released, disabling all operations.

3. Change the adjusting items with up arrow switch (UP) and down arrow switch (DOWN), and select "ADJUST UNLOAD". (See Fig. "Gauge cluster") Like the output adjustment, when adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.

13-26

F

ADJUST OUTPUT

FIN

ADJUST UNLOAD

FIN

ADJUST CRANE

---

ADJUST 0 CRANE

---

ADJUST LMN

---

ADJ INTERFE PREV

---

ADJUST INITIAL

---

ADJUST OUTPUT

FIN

ADJUST UNLOAD

FIN

ADJUST CRANE

---

ADJUST 0 CRANE

---

ADJUST LMN

---

ADJ INTERFE PREV

---

ADJUST INITIAL

---

13. MAINTENANCE STANDARD AND TEST PROCEDURE 4. Press menu switch on gauge cluster to display "START ENG".

"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "UNLOAD" current (command value) are indicated.

5. After starting engine, press menu switch on gauge cluster and "MEMORY UNLOAD" is indicated, the engine speed is automatically increased and the adjustment of unloading valve is performed.

"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "UNLOAD" current (command value) are indicated.

6. When the unloading proportional valve operates to the specified value, the adjustment of unloading proportional valve automatically completes.

"FINISH UNLOAD" is indicated.

The speed is shifted to the speed corresponding to acceleration potentiometer.

The value of adjusting current is indicated on the display of current of P1 and P2 unloading proportional valves. The adjusting range is usually 520 to 635 mA. Stop the engine. (The automatically stored.)

adjusted

data

is

13-27

START ENGINE ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

MEMORY UNLOAD ENGINE STEP

2290 0

ECU OUTPUT

360

P1 PUMP

390

P2 PUMP

390

P1 UNLOAD

360

P2 UNLOAD

360

P1 PRESSURE

341

P2 PRESSURE

340

FINISH UNLOAD ENGINE STEP

2040 0

ECU OUTPUT

120

P1 PUMP

350

P2 PUMP

350

P1 UNLOAD

750

P2 UNLOAD

750

P1 PRESSURE

250

P2 PRESSURE

11

13

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5.2 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER (1) Pump emergency mode In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to emergency mode, making the operation with the power shift control of pump and the constant power control by means of self-pressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor, the frequency of engine down is increased, and the engine stalls in LOW speed condition.

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

13-28

21. MECHATRO CONTROLLER

21. MECHATRO CONTROLLER TABLE OF CONTENTS

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM ........................................... 21-4 21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..................................... 21-4 21.1.2 UNLOAD VALVE CONTROL ..................................................................... 21-6 21.1.3 POSITIVE CONTROL & P-Q CONTROL .................................................. 21-8 21.1.4 BOOM UP CONFLUX CONTROL ............................................................. 21-10 21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL ................................ 21-12 21.1.6 ARM-IN ANTI-CAVITATION CONTROL .................................................... 21-14 21.1.7 ARM-OUT CONFLUX CONTROL ............................................................. 21-16 21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL ................................. 21-18 21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL .................................. 21-20 21.1.10 SWING PRIORITY CONTROL .................................................................. 21-22 21.1.11 TRAVEL STRAIGHT CONTROL ............................................................... 21-24 21.1.12 PRESSURE RELEASE CONTROL ........................................................... 21-26 21.1.13 N&B SWITCH CONTROL (OPTION) ........................................................ 21-28 21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................... 21-30 21.2 MECHATRO CONTROLLER ............................................................................. 21-33 21.2.1 SUMMARY OF MULTI DISPLAY ............................................................... 21-33 21.2.2 SELF DIAGNOSIS DISPLAY ..................................................................... 21-46 21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................... 21-47 21.2.4 TROUBLE HISTORY DIAGNOSIS ............................................................ 21-56 21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE .............................. 21-57 21.2.6 ADJUSTING PROCEDURE OF DISPLAY ................................................ 21-59 21.2.7 MECHATRO CONTROL EQUIPMENT ..................................................... 21-64

Book Code No. S5YN2141E01 21-1

21

21. MECHATRO CONTROLLER

Issue

Date of Issue

First Edition

March, 2011

Applicable Machines SK210-9: YN13

21-2

Remarks S5YN2141E01 (NA)

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

21

21-3

21. MECHATRO CONTROLLER

21.1

SUMMARY OF MECHATRO CONTROL SYSTEM

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

VOLTAGE OUTPUT L1

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

LH

RH

LH

RH

OPTION PILOT VALVE PILOT VALVE FOR TRAVEL

PILOT VALVE FOR ATT

SE-9 SE-10

MULTI CONTROL VALVE OR SENSOR BLOCK

COOLANT TEMP. GAUGE

SE-16

CAN COMMUNICATION

ARROW SW. SCREEN CHANGE BUZZER STOP MODE WASHER WIPER TRAVEL DIGGING MODE NIBBLER MODE BREAKER MODE AUTO ACCEL

LOW PRESSURE SENSOR

SE-4

(4)

SE-3

(2)

SE-1 SE-8 SE-7

L2 L3

(3)

SE-2

(1)

(8) (7)

L4

(6) SE-5

(5)

OUTPUT VOLTAGE

GAUGE CLUSTER LCD DISPLAY FOR SELECTION FUEL GAUGE

ACCEL DIAL

SE-11

SE-23 HIGH PRESSURE SENSOR

C-1

SE-22

MECHATRO CONTROLLER

A1

L5 A2

ENGINE

A3

INJECTOR SPEED SENSOR SE-13

PSV -P1 P1 PUMP PROPORTIONAL VALVE

PSV -P2 P2 PUMP PROPORTIONAL VALVE

: HIGH PRESSURE SENSOR (FOR P1,P2 : 2pcs) : INJECTOR : E/G SPEED SENSOR

CAN COMMUNICATION ENGINE SPEED COMMAND VOLTAGE

L6

C-8 ENGINE CONTROLLER

: LOW PRESSURE SENSOR (ATT : 7pcs, TRAVEL : 2pcs)

L7 VOLTAGE 24V PROPORTIONAL COMMAND CURRENT

: ACCEL DIAL POTENTIOMETER

21-4

21. MECHATRO CONTROLLER

L1

MAIN CONTROL VALVE SE-29

UP

REVERSE

L2 L3

(7)

N&B SELECTOR VALVE

(5)

SV-13

OPTION

P2 UNLOAD

TRAVEL LEFT REVERSE

ARM 1

DIGGING

P1 P2

(8)

SWING

(3)

(6)

BOOM UP CONFLUX

(3) PL1 ATTACHMENT BOOST

(4)

(1)

LEFT ARM OUT

FORWARD

DOWN FORWARD

BOOM

ARM 2

BUCKET

(2)

TRAVEL P1 UNLOAD STRAIGHT

DUMP

(8)

TRAVEL RIGHT

ARM OUT

SOL

RIGHT ARM IN

SOLENOID VALVE

L4 SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

PSV -A

PSV PSV PSV -D -C -B

SV -2

SV -3

SV -1

SAFETY LOCK LEVER

SWING PARKING BRAKE

TRAVEL 1,2 SPEED

ATTACHMENT BOOST

P2 UNLOAD

TRAVEL STRAIGHT

P1 UNLOAD

L5

ARM IN 2 SPEED

BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX

SV -4

ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX

(7) ARM IN

L6

BUCKET CYLINDER DIGGING / DUMP CONFLUX

L7 PROPORTIONAL VALVE SOLENOID VALVE

21-5

) BLOCK

21

21. MECHATRO CONTROLLER

P2

(LEFT)

(RIGHT)

OPTIONAL PILOT VALVE

PILOT VALVE

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.2 UNLOAD VALVE CONTROL

P1

PILOT VALVE

PILOT VALVE FOR TRAVEL

SE-11 SE-10

SE-9

LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4

SE-5,7,8

pi

PILOT SIGNAL PROCESS

PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

MECHATRO PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE

(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in the respective low pressure sensors.

(2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes pilot signals and outputs commands according to the input voltage to each unload pressure proportional valve.

(3) Each unload pressure proportional valve outputs pilot secondary pressure according to the command output by the mechatro controller and switches each unload spool.

(4) With this operation, the bleed opening according to the lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each of the actuators are delivered and makes each actuator start operating.

21-6

21. MECHATRO CONTROLLER

This page is blank for editing convenience.

21-7

21

21. MECHATRO CONTROLLER

P2

SE-23

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL STRAIGHT

OPTIONAL PILOT VALVE

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.3 POSITIVE CONTROL & P-Q CONTROL

P1

SE-22

SE-11

(LEFT)

(RIGHT)

PILOT VALVE

PILOT VALVE

PILOT VALVE FOR TRAVEL

SE-10

SE-9

LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4

SE-5,7,8

pi PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE COMMAND

P2 PUMP PROPORTIONAL VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi

pi

PILOT SIGNAL PROCESS PILOT SECONDARY PRESSURE

P1 PUMP PROPORTIONAL VALVE COMMAND

P1 PUMP PROPORTIONAL VALVE PSV-P1

MECHATRO CONTROLLER pi : PROPORTIONAL VALVE

SECONDARY PRESSURE

21-8

21. MECHATRO CONTROLLER (1) Positive control 1. On starting any one of the operations, pilot secondary pressure switches each spool and is input to each low pressure sensor.

2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes pilot signals and outputs commands according to the input voltage to each unload pressure proportional valve.

3. Each pump proportional valve outputs pilot secondary pressure according to the command output by the mechatro controller and changes the tilting angle of each pump and controls the delivery rate.

4. With this operation, the delivery rate according to the lever manipulated movement is fed to the actuator, and consequently the working speed according to the lever manipulated movement will be obtained.

(2) P-Q control (1) The output voltage of the high pressure sensor provided on each pump line is input to the mechatro controller and the mechatro controller processes the pilot signal and operates the command according to the input voltage (load pressure).

(2) The lower value between command values calculated by positive control and operated value found by P-Q control {operated value found in item 1) is selected and is output to each pump proportional valve as command value.

(3) Each pump proportional valve outputs pilot secondary pressure according to the command output by the mechatro controller and changes the tilting angle of each pump and controls the delivery rate.

(4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator and consequently the working speed will be obtained according to lever movement.

P-Q CONTROL

PILOT SIGNAL PROCESS

PUMP PROPORTIONAL SECONDARY PRESSURE

PUMP PROPORTIONAL SECONDARY PRESSURE

POSITIVE CONTROL

PILOT PRESSURE

PILOT SIGNAL PROCESS

21

PUMP DELIVERY PRESSURE

21-9

21. MECHATRO CONTROLLER

P2

PILOT VALVE

P1

LOW PRESSURE SENSOR SE-3

pi

PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

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

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P2 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

21-10

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.4 BOOM UP CONFLUX CONTROL

21. MECHATRO CONTROLLER (1) On starting boom up operation, boom up operating pilot pressure switches the boom spool and boom up conflux spool and is input to the low pressure sensor.

(2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes pilot signals and outputs commands according to the input voltage to the P1 and P2 proportional valves and the P1 and P2 unload proportional valves.

(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload pressure control valve.

(4) With original hydraulic pressure command, the boom main spool and boom up conflux spool are switched, and also with the command by the mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.

21

21-11

21. MECHATRO CONTROLLER

P2

LOW PRESSURE SENSOR SE-1~6

P1

LOW PRESSURE SENSOR SE-7

CONTROL PROCESS FOR 2 SPEED

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

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

PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

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

pi PILOT SECONDARY PRESSURE

pi REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

ARM PILOT SECONDARY PRESSURE

P2 PUMP PRESSURE

MECHATRO CONTROLLER

21-12

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL STRAIGHT

PILOT VALVE

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL

21. MECHATRO CONTROLLER (1) Recirculation and conflux (Low loading) 1. On starting arm-in operation, arm-in operating pilot secondary pressure is input to the arm 1 spool, arm 2 spool and low pressure sensor.

2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes pilot signasl and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.

In case of combined operation, the pilot pressure other than arm-in operation is input to the low pressure sensor and the output voltage is input to the mechatro controller. And the mechatro controller processes the pilot signal according to the combined operation and outputs commands, which is different from the arm-in independent operation to the P1 pump proportional valve, the P1 unload proportional valve and reverse proportional valve for arm-in 2 spool.

3. Primary pressure of the reverse proportional valve for the arm-in 2 spool is arm-in pilot secondary pressure and it switches the arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.)

The other proportional valves output proportional secondary pressure according to the command from the mechatro controller. These proportional valves change the delivery rate of the P1 and P2 pump, and switch the P1 and P2 unload valves.

4. The arm 1 spool is switched according to the original oil pressure command, and the P1 and P2 pumps, P1 and P2 unload spools and arm 2 spool are switched according to the command output by the mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in the P1 and P2 pumps delivery oil during arm operation.

(2) Recirculation cut The voltage output by the high pressure sensor on the P2 side is input to the mechatro controller, and when the load is raised during arm operation, the mechatro controller processes pilot signals, processing according to the pressure detected by the high pressure sensor and outputs commands to cut recirculation into the reverse proportional valve for arm-in 2 spool.

The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by the mechatro controller and switches the arm 2 spool to the recirculation cut position, and consequently the recirculation passage is blocked.

21-13

21

21. MECHATRO CONTROLLER

P2

LOW PRESSURE SENSOR SE-7

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL STRAIGHT

PILOT VALVE

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.6 ARM-IN ANTI-CAVITATION CONTROL

P1

ACCEL POTENTIO

pi

PILOT SIGNAL PROCESS

ARM IN PILOT SECONDARY PRESSURE pi

PILOT SIGNAL PROCESS

pi P2 PUMP PROPORTIONAL VALVE PSV-P2

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

ARM IN PILOT SECONDARY PRESSURE

pi REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND

ENGINE SPEED (COMMAND VALUE)

MECHATRO CONTROLLER

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

pi

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches the arm 1 spool and is input to the low pressure sensor.

(2) The engine speed command output by the accel potentiometer is input to the mechatro controller.

(3) The low pressure sensor output voltage is input to the mechatro controller, and the mechatro controller processes pilot signal processing and outputs commands according to the input voltage to the P2 pump proportional valve and P2 unload proportional valve.

(4) And also outputs commands according to input pressure output by the potentiometer to the reverse proportional valve for the arm 2 spool.

(5) Each proportional valve outputs pilot secondary pressure according to each command output by the mechatro controller, and consequently since the reverse proportional valve for the arm 2 spool is controlled to spool stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if the pump delivery rate is low due to low engine speed.

21-14

21. MECHATRO CONTROLLER

This page is blank for editing convenience.

21

21-15

21. MECHATRO CONTROLLER

P2

PILOT VALVE

P1

LOW PRESSURE SENSOR SE-8

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

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

ARM OUT PILOT SECONDARY PRESSURE

pi P2 UNLOAD PROPORTIONAL VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE pi

MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE

P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

21-16

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.7 ARM-OUT CONFLUX CONTROL

21. MECHATRO CONTROLLER (1) On starting the arm-out operation, the arm-out operating pilot pressure switches the arm 1 spool and arm 2 spool and is input to the low pressure sensor.

(2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and outputs commands according to the input voltage to the P1 and P2 proportional valves and P1 and P2 unload proportional valves.

(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload pressure control valves.

(4) With original hydraulic pressure command, the arm 1 spool and arm 2 spool are switched and also with the command output by the mechatro controller, the P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on the P2 pump side confluxes delivery oil on the P1 pump side during armout operation.

21

21-17

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR SE-1(2) pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P1 PUMP PROPORTIONAL VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P1 UNLOAD PROPORTIONAL VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

TRAVELSTRAIGHT PROPORTIONAL VALVE PSV-C

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

SECONDARY PRESSURE

21-18

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

SWING

P2 UNLOAD

PILOT VALVE

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL

21. MECHATRO CONTROLLER (1) On starting bucket digging (dump) operation, the bucket digging (dump) operating pilot pressure switches the bucket spool and is input to the low pressure sensor.

(2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and outputs commands according to the input voltage to the P1 and P2 pump proportional valves, the P1 and P2 unload proportional valves and travel straight proportional valve.

(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload valves and travel straight valve of the control valve.

(4) The tandem passage is connected to the P2 port because of the travel straight valve switched and the P1 pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve switched.

21

21-19

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR SE-1 (2)

pi

PILOT SIGNAL PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS ACCEL POTENTIO

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P1 UNLOAD PROPORTIONAL VALVE PSV-D

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS BUCKET ANTI-CAVITATION PROCESS

ATT BOOST SOLENOID VALVE SV-2

ENGINE SPEED (COMMAND VALUE)

MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE

P1 PUMP PRESSURE

21-20

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

PILOT VALVE

TRAVEL LEFT

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL

21. MECHATRO CONTROLLER (1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches the bucket spool and is input to the low pressure sensor.

(2) The engine speed command output by the accel potentiometer is input to the mechatro controller.

(3) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes pilot signals and outputs commands according to the input voltage to the P1 and P2 pump proportional valves, the P1 and P2 unload proportional valves and travel straight proportional valve.

(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload valves and travel straight valve of control valve.

(5) The tandem passage is connected to the P2 port because of the travel straight valve switched andthe P1 pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve switched.

(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary pressure, and actuates the stroke limiter and then controls the stroke of bucket spool.

The control of the spool stroke makes the prevention of cavitation possible even if engine speed is low and pump delivery rate is low.

(7) When the P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the stroke limit of the bucket spool.

21

21-21

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR pi

PILOT SIGNAL PROCESS

ARM IN PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

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

ARM IN PILOT SECONDARY PRESSURE

pi

SWING PILOT SECONDARY PRESSURE

pi

SWING PILOT SECONDARY PRESSURE

TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND

TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C

REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

MECHATRO CONTROLLER

21-22

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

P2 UNLOAD

SWING

SOLENOID

ARM 1

N&B SELECTOR VALVE

OPTION

PILOT VALVE

BOOM UP CONFLUX

21.1.10 SWING PRIORITY CONTROL

21. MECHATRO CONTROLLER (1) During arm-in operation, the arm operating pilot secondary pressure switches the arm spool and is input to the low pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot secondary pressure switches the swing spool and is input to the low pressure sensor.

(2) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes pilot signals and outputs commands according to the input voltage to the P1 and P2 proportional valves, the P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.

(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload spool, travel straight spool, and arm 2 spool.

(4) With original hydraulic pressure command, the arm 1 spool and swing spool are switched also with the command by the mechatro controller, the P1 and P2 unload spools, travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil on the arm cylinder rod side is recirculated into the arm cylinder head side.

(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and the pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible.

21

21-23

21. MECHATRO CONTROLLER

PILOT VALVE

PILOT VALVE

P2

P1

PILOT VALVE FOR TRAVEL

SE-11 SE-10

SE-9

LOW PRESSURE SENSOR

TRAVEL STRAIGHT SIGNAL

pi PILOT SIGNAL PROCESS

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P1 PUMP PROPORTIONAL VALVE PSV-P1

PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

PILOT SECONDARY PRESSURE pi

PILOT SIGNAL PROCESS

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

PILOT SECONDARY PRESSURE

21-24

P1 UNLOAD PROPORTIONAL VALVE PSV-D

MECHATRO CONTROLLER

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL STRAIGHT

(RIGHT)

P2 UNLOAD

(LEFT)

SWING

SOLENOID

ARM 1

N&B SELECTOR VALVE

OPTION

OPTIONAL PILOT VALVE

BOOM UP CONFLUX

21.1.11 TRAVEL STRAIGHT CONTROL

21. MECHATRO CONTROLLER (1) Judgment travel straight 1. During travel operation (right and left), pilot pressure switches each spool and is input to the low pressure sensor on carrying out attachment system operation.

2. The mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns the travel straight signal on.

3. On turning the travel straight signal on, the following commands are output to each proportional valve.

(2) Operation of each proportional valve (Basically attachment operation is actuated by the P1 pump and travel operation is actuated by the P2 pump in travel straight condition.)

1. Travel straight proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating (Boom, arm, bucket, swing, and option) pilot pressure during operation.

2. P1 unload proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation.

3. P2 unload proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation.

4. P1 pump proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation.

5. P2 pump proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation.

21-25

21

21. MECHATRO CONTROLLER

P2

P1

SE-23

ENGINE

PRESSURE RELEASE CONTROL

ENGINE SPEED CONTROL

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

pi

PILOT SIGNAL PROCESS

pi

pi

PILOT SIGNAL PROCESS

PILOT SIGNAL PROCESS MECHATRO CONTROLLER

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

21-26

SE-22

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

SWING PILOT VALVE

P2 UNLOAD

GAUGE CLUSTER

ARM 1

SOLENOID

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.12 PRESSURE RELEASE CONTROL

21. MECHATRO CONTROLLER (1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating the switch on the gauge cluster.

For detail of changing the mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.

(2) Once the mechatro controller decides it as pressure release control, regardless of each input signal to (operating pilot, and accel potentiometer, etc.) the mechatro controller; 1. Outputs minimum tilt angle command to the P1 and P2 pump proportional valves and fixes the P1 and P2 pump to the minimum tilt angle.

2. Outputs command of pressure release and outputs command of pressure release control to ECU and fixes engine speed to pressure release control speed.

3. Outputs maximum command to the P1 and P2 unload valves and each pilot secondary pressure fixes the P1 and P2 unload valves to the maximum opening.

(3) The mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on the gauge cluster.

(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool with the unload valve opened.

21

21-27

21. MECHATRO CONTROLLER

P2

NIBBLER MODE BREAKER MODE ATTACHMENT MODE

pi

BREAKER MODE SWITCH

MECHATRO CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

21-28

P1

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

P2 UNLOAD

SWING

ARM 1

SOLENOID

OPTION

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

BOOM UP CONFLUX

21.1.13 N&B SWITCH CONTROL (OPTION)

21. MECHATRO CONTROLLER (1) Nibbler circuit 1. Select nibbler mode by pressing the nibbler mode switch located on the gauge cluster.

2. Nibbler display appears on the gauge cluster.

3. The return oil from the nibbler passes through the selector valve and option spool and is led to the tank line of the main control valve.

4. When selecting nibbler mode through the select switch, the breaker pressure sensor has no function to output.

It is in normal when there is no output from the sensor in nibbler mode, and in cases other than above, the error display is output to the gauge cluster.

(2) Breaker circuit 1. Select breaker mode by pressing the breaker mode switch located on the gauge cluster.

2. Breaker display appears on the gauge cluster.

3. The return oil from the breaker passes through the selector valve and directly returns into the hydraulic oil tank.

4. When selecting breaker mode through the select switch, the breaker pressure sensor outputs the signal.

It is in normal when there is an output from the sensor in breaker mode, and in cases other than above, the error display is output to the gauge cluster.

21

21-29

21. MECHATRO CONTROLLER

P2

P1

LOW PRESSURE SENSOR SE-11

pi

PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE

21-30

ARM 2

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

P2 UNLOAD

SWING

SOLENOID

ARM 1

PILOT VALVE

OPTION

N&B SELECTOR VALVE

BOOM UP CONFLUX

21.1.14 OPTION CONFLUX CONTROL (OPTION)

21. MECHATRO CONTROLLER (1) Using the "OPTION SETTING" display located on the "USER MENU" screen, the flow rate is adjusted. At this time, if the setting flow rate is larger than one pump flow rate, the flow becomes automatically confluent flow.

(2) On starting option operation, option operating pilot pressure switches the option spool and is input to the low pressure sensor.

(3) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller processes the pilot signal and outputs commands according to the input voltage to the P1 and P2 pump proportional valves, the P1 and P2 unload pressure proportional valves and travel straight proportional valve.

(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload valves and travel straight valve of the control valve.

(5) The parallel passage on the P2 side is connected to the P1 port because of the travel straight valve switched and the P1 pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve switched.

21

21-31

21. MECHATRO CONTROLLER

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21-32

21. MECHATRO CONTROLLER

21.2

MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.

(1) Controls GAUGE CLUSTER

SAFETY LOCK LEVER

RIGHT CONTROL LEVER WITH ATT BOOST SW. STARTER SWITCH

FUSE & RELAY BOX

ACCEL DIAL

B DETAIL A SWING PARKING BRAKE RELEASE SWITCH

21 A

DETAIL B (2) Gauge cluster

18

S

2

12:15

1 E

9

F

11

6

7 13 16 10

8 5 4

17

3

14 15

12

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

21-33

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

21. MECHATRO CONTROLLER (3) Screen selection by work mode select switch The mode after the engine starting is always the start from "S" mode. The work mode is switched in order of "S" to "E" to "H" to "S" each time the work mode select switch is pressed.

Select proper work mode shown below according to the work condition and the purpose. For the selected work mode, refer to the upper left corner of display.

• • •

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

S

12:15

E

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

S

12:15

E

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

E

F

12:15

E

F

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

H

12:15

E

21-34

F

F

21. MECHATRO CONTROLLER (4) Screen selection by attachment mode switich This switch is used for switching the attachment mode.

Attachment mode display Press Digging mode switch (1) to select Digging mode from attachment modes. And selected Digging mode is indicated. Press Nibbler mode switch (2) to select Nibbler mode from attachment modes. And selected Nibbler mode is indicated. Press Breaker mode switch (3) to select Breaker mode from attachment modes. And selected Breaker mode is indicated.

Depending on the attachment employed, select the applicable mode from "Digging", "Nibbler" and "Breaker".

Before working, confirm whether the appropriate attachment has been selected.

S

E

F

2

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

Attachment Mode

12:15

3 1

Switch Position

Displays of Multi-Display S

Selection of Attachment

12:15

Digging Mode

Select in case of digging E

S

21

F

12:15

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

Nibbler Mode E

S

F

12:15

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

Breaker Mode E

21-35

F

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

Regarding the adjustment of flow rate and relief pressure for Nibbler and Breaker, the settings of 10 patterns are available.

S

12:15

E

F

3

4 7 2

1

8

5

6

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10 440 198 Flow rate L/min 132 396 352 308 264 220 176 154 Nibbler Pressure A MPa Not set yet Not set yet Not set yet Not set yet Not set yet 25 Not set yet Not set yet Not set yet Not set yet (Crusher) Pressure B MPa Not set yet Not set yet Not set yet Not set yet Not set yet 25 Not set yet Not set yet Not set yet Not set yet

Flow rate L/min Breaker Pressure B MPa

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10 220 198 176 154 132 110 88 66 44 30 30 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet

Both Nibblers are set in conditions "SET 6" as factory default in the above table at shipping.

Both Breakers are set in conditions "SET 1" as factory default in the above table at shipping. * The meaning of "Not set yet" shows that 50 MPa as pressure is the temporary value.

Set the flow rate and relief pressure in accordance with the next procedure.

And these setting values in the above adjustment are selectable by using after-mentioned "Flow rate and Relief pressure Selection".

21-36

21. MECHATRO CONTROLLER 1. When using Nibbler

TURN STARTER KEY SWICH ON No.1 + MAIN CONT. P/N XLB22E00026F1 PRIGRAM VERSION 1-VER 00.07 2-VER 00.00

(a)

(b)

+

SERVICE MENU

(C) SERVICE ADJUST1-2

(d) NIBBLER SETTING

CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 01.00

NIBBLER SETTING

SERVICE DIAGNOSIS

AUTO ACCEL

SET1

472 L/min

25 MPa

25 MPa

SET1

472 L/min

25 MPa

25 MPa

TROUBLE HISTORY

START MODE

SET2

443 L/min

50 MPa

50 MPa

SET2

443 L/min

50 MPa

50 MPa

LANGUAGE & LOGO SETTING

CANCEL LOW TEMP

SET3

394 L/min

50 MPa

50 MPa

SET3

394 L/min

50 MPa

50 MPa

SERVICE ADJUST 1

CANCEL MODE

SET4

344 L/min

50 MPa

50 MPa

SET4

344 L/min

50 MPa

50 MPa

SERVICE ADJUST 2

CHECK INJECTOR

SET5

295 L/min

50 MPa

50 MPa

SET5

295 L/min

50 MPa

50 MPa

FACTORY PRESET

PRESS DRAIN

SET6

246 L/min

25 MPa

25 MPa

SET6

246 L/min

25 MPa

25 MPa

FAULT DIAG MODE

NIBBLER SETTING

SET7

221 L/min

50 MPa

50 MPa

SET7

221 L/min

50 MPa

50 MPa

BREAKER SETTING

SET8

197 L/min

50 MPa

50 MPa

SET8

197 L/min

50 MPa

50 MPa

CAMERA 1 SETTING

SET9

172 L/min

50 MPa

50 MPa

SET9

172 L/min

50 MPa

50 MPa

CAMERA 2 SETTING

SET10

148 L/min

50 MPa

50 MPa

SET10

148 L/min

50 MPa

SERVICE DIAG 1 CLUSTER DIAG 1

(e) or

BACK

ON

NEXT

BACK

DOWN

ON

NEXT

DOWN

BACK

ON

HOME

DOWN

NEXT

BACK

ON DOWN

(g) NIBBLER SETTING

f. g. h. i.

j.

k.

(f) NIBBLER SETTING

472 L/min

25 MPa

25 MPa

SET1

472 L/min

25 MPa

25 MPa

SET2

443 L/min

50 MPa

50 MPa

SET2

443 L/min

50 MPa

50 MPa

SET3

394 L/min

50 MPa

50 MPa

SET3

394 L/min

50 MPa

50 MPa

SET4

344 L/min

50 MPa

50 MPa

SET4

344 L/min

50 MPa

50 MPa

SET5

295 L/min

50 MPa

50 MPa

SET5

295 L/min

50 MPa

50 MPa

SET6

246 L/min

25 MPa

25 MPa

SET6

246 L/min

25 MPa

25 MPa

SET7

221 L/min

50 MPa

50 MPa

SET7

221 L/min

50 MPa

50 MPa

SET8

197 L/min

50 MPa

50 MPa

SET8

197 L/min

50 MPa

50 MPa

SET9

172 L/min

50 MPa

50 MPa

SET9

172 L/min

50 MPa

50 MPa

SET10

148 L/min

50 MPa

50 MPa

SET10

148 L/min

50 MPa

ON DOWN

e.

RESET

SET1

BACK

a. b. c. d.

50 MPa NEXT

NEXT RESET

BACK

ON DOWN

50 MPa NEXT RESET

Turn starter switch ON. After pressing Nibbler mode switch (3) to select Nibbler mode, turn starter switch OFF. Hold down buzzer stop switch (1) and turn starter switch ON. The service diagnosis screen (a) is displayed.

Start the engine.

Hold down buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen (b) is displayed.

Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "SERVICE ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST 1-1is displayed. Then press “UP ARROW SWITCH” (5) five times and SERVICE ADJUST 1-2 (c) is displayed.

Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "NIBBLER SETTING" display (c). Press “NEXT ARROW SWITCH” (7), and NIBBLER SETTING (d) is displayed.

There are 10 steps from "SET 1" to "SET 10". Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and select desired set number. To set desired set number, press "NEXT ARROW SWITCH" (7).

Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow rate. Then press menu switch (2) and the cursor is pointed to pressure display (f).

During pressing rear (heel side) of optional right pedal (P2 pump optional operation), use switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When the value of pressure reaches the desired pressure, press menu switch (2) to set. (If you fail to press rear (heel side) of optional right pedal, 0MPa is displayed.)

Then, the cursor is pointed to pressure (see display (g)). During pressing front (toe side) of optional right pedal (P2 pump optional operation), use switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When the value of pressure reaches the desired pressure, press menu switch (2) to set.

(If you fail to press front (toe side) of optional right pedal, 0MPa is displayed.)

Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

21-37

21

21. MECHATRO CONTROLLER 2. When using Breaker TURN STARTER KEY SWICH ON No.1 + MAIN CONT. P/N XLB22E00026F1 PRIGRAM VERSION 1-VER 00.07 2-VER 00.00

(a)

(b)

+

SERVICE MENU

(C) SERVICE ADJUST1-2

(d) BREAKER SETTING

CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 01.00

BREAKER SETTING

SERVICE DIAGNOSIS

AUTO ACCEL

SET1

246 L/min

25 MPa

SET1

246 L/min

25 MPa

TROUBLE HISTORY

START MODE

SET2

221 L/min

30 MPa

SET2

221 L/min

30 MPa

LANGUAGE & LOGO SETTING

CANCEL LOW TEMP

SET3

197 L/min

30 MPa

SET3

197 L/min

30 MPa

SERVICE ADJUST 1

CANCEL MODE

SET4

172 L/min

30 MPa

SET4

172 L/min

30 MPa

SERVICE ADJUST 2

CHECK INJECTOR

SET5

148 L/min

30 MPa

SET5

148 L/min

30 MPa

FACTORY PRESET

PRESS DRAIN

SET6

123 L/min

30 MPa

SET6

123 L/min

30 MPa

FAULT DIAG MODE

NIBBLER SETTING

SET7

98 L/min

30 MPa

SET7

98 L/min

30 MPa

BREAKER SETTING

SET8

74 L/min

30 MPa

SET8

74 L/min

30 MPa

CAMERA 1 SETTING

SET9

49 L/min

30 MPa

SET9

49 L/min

30 MPa

CAMERA 2 SETTING

SET10

30 L/min

30 MPa

SET10

30 L/min

SERVICE DIAG 1 CLUSTER DIAG 1

(e) or

BACK

ON

NEXT

BACK

DOWN

ON DOWN

NEXT

BACK

ON DOWN

NEXT

BACK

RESET

30 MPa ON DOWN

NEXT RESET

(f) BREAKER SETTING SET1

246 L/min

25 MPa

SET2

221 L/min

30 MPa

SET3

197 L/min

30 MPa

SET4

172 L/min

30 MPa

SET5

148 L/min

30 MPa

SET6

123 L/min

30 MPa

SET7

98 L/min

30 MPa

SET8

74 L/min

30 MPa

SET9

49 L/min

30 MPa

SET10

30 L/min BACK

30 MPa ON DOWN

a. b. c. d. e.

f. g. h. i.

j.

NEXT RESET

Turn starter switch ON. After pressing Breaker mode switch (4) to select Breaker mode, turn starter switch OFF. Hold down buzzer stop switch (1) and turn starter switch ON. The service diagnosis screen (a) is displayed.

Start the engine.

Hold down buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen (b) is displayed.

Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "SERVICE ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST 1-1 is displayed. Then press “UP ARROW SWITCH” (5) five times and SERVICE ADJUST 1-2 (c) is displayed.

Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "BREAKER SETTING" display (c). Press "NEXT ARROW SWITCH" (7), and BREAKER SETTING (d) is displayed.

There are 10 steps from "SET 1" to "SET 10". Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and select desired set number. To set desired set number, press "NEXT ARROW SWITCH" (7).

Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow rate. Then press menu switch (2) and the cursor is pointed to pressure display (f).

During pressing front (toe side) of optional right pedal (P2 pump optional operation), use switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When you reach the desired pressure, press menu switch (2) to set. (If you fail to press front (toe side) of optional right pedal, 0MPa is displayed.)

Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

21-38

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

6

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

7

4

5 9

3

2

1

10

8

Nibbler mode

S

12:15

E

S

12:15

USER MENU

F

USER MENU

NIBBLER SETTING

MAINTENANCE

MAINTENANCE

SET1

472 L/min

25 MPa

25 MPa

SWITCH STATUS

SWITCH STATUS

SET2

443 L/min

50 MPa

50 MPa

OPTION SETTING

OPTION SETTING

SET3

394 L/min

50 MPa

50 MPa

CONSUMPTION

CONSUMPTION

SET4

344 L/min

50 MPa

50 MPa

SCREEN SETTING

SCREEN SETTING

SET5

295 L/min

50 MPa

50 MPa

CLOCK SETTING

CLOCK SETTING

SET6

246 L/min

25 MPa

25 MPa

SET7

221 L/min

50 MPa

50 MPa

30

SET8

197 L/min

50 MPa

50 MPa

15

SET9

172 L/min

50 MPa

50 MPa

SET10

148 L/min

50 MPa

FLOW RATE

780 L/min

PRESSURE A

50 Mpa

PRESSURE B

50 Mpa

E

F

L/min

or

0 30 MIN

25

20

15

10

5

0

0.0 L/h

AVERAGE

(a)

RESET

(b)

BACK

UP

NEXT

HOME

DOWN

(c)

BACK

UP

HOME

DOWN

BACK

NEXT

UP

HOME

(d)

50 MPa NEXT

DOWN

(e)

In breaker mode

S

12:15

E

S

21

12:15

USER MENU FLOW RATE

480 L/min

PRESSURE A

50 Mpa

F E

USER MENU

BREAKER SETTING

MAINTENANCE

MAINTENANCE

SET1

246 L/min

30 MPa

SWITCH STATUS

SWITCH STATUS

SET2

221 L/min

30 MPa

OPTION SETTING

OPTION SETTING

SET3

197 L/min

30 MPa

CONSUMPTION

CONSUMPTION

SET4

172 L/min

30 MPa

SCREEN SETTING

SCREEN SETTING

SET5

148 L/min

30 MPa

CLOCK SETTING

CLOCK SETTING

SET6

123 L/min

30 MPa

F

L/min

SET7

98 L/min

30 MPa

30

SET8

74 L/min

30 MPa

15

SET9

49 L/min

30 MPa

SET10

30 L/min

or

0 30 MIN

25

AVERAGE

20

15

10

0.0 L/h

5

0 RESET

(b)

BACK

UP

HOME

DOWN

NEXT

(c)

BACK

UP

HOME

DOWN

(d)

NEXT

30 MPa

BACK

UP

HOME

DOWN

NEXT

(e)

1. After turning starter key switch ON, the main screen (a) appears.

2. When the display is main screen (a), change the attachment mode from "DIGGING MODE" to "NIBBLER MODE" or "BREAKER MODE". The flow rate indication screen (b) appears.

3. When the display is flow rate indication screen (b), press "Menu Switch" to enter into "USER MENU" display (c).

4. Move cursor to "OPTION SETTING", and press "NEXT" to enter into "OPTION SETTING" display (e).

5. When the display is "OPTION SETTING" display (e), move cursor to desired flow rate. And press the menu switch to set target flow rate.

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

21-39

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

1

2

This display shows the recommended replacement time of engine oil, time for next engine oil change and date of previous engine oil change.

S

INTERVAL

12:15

USER MENU

ENGINE OIL

MAINTENANCE

FUEL FILTER

SWITCH STATUS

HYD. FILTER

OPTION SETTING

HYD. OIL

CONSUMPTION E

REMAINDER

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

EXCHANGE DAY

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

F

SCREEN SETTING CLOCK SETTING

INTERVAL

ENGINE OIL BACK

UP

HOME

DOWN

NEXT

FUEL FILTER HYD. FILTER

(a)

HYD. OIL

INTERVAL

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

REMAINDER

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

EXCHANGE DAY

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

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

Replacement interval Item

Default

Engine oil

500 Hr

Fuel filter

500 Hr

Hydraulic oil filter

1,000 Hr

Hydraulic oil

5,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.

21-40

INTERVAL

08/12/12

REMAINDER

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

REMAINDER

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

EXCHANGE DAY

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

EXCHANGE DAY

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

21. MECHATRO CONTROLLER 1.

Remaining time display to the engine oil change This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY".

INTERVAL

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

2.

Remaining time display to the coming fuel filter replacement.

This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY".

INTERVAL

ENGINE OIL FUEL FILTER HYD. FILTER HYD. OIL

3.

Remaining time display to the coming hydraulic oil filter replacement.

This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY".

FUEL FILTER HYD. FILTER HYD. OIL

4.

Remaining time display to the coming hydraulic oil change.

This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY".

FUEL FILTER HYD. FILTER HYD. OIL

REMAINDER

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

INTERVAL

ENGINE OIL

REMAINDER

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

INTERVAL

ENGINE OIL

REMAINDER

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

REMAINDER

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

EXCHANGE DAY

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

EXCHANGE DAY

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

EXCHANGE DAY

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

EXCHANGE DAY

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

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

21-41

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

The display functions of multi display are explained below.

CLOCK DISPLAY

MACHINE CONDITION S

12:15

E

SELF DIAGNOSIS / WARNING

F

1. Display function for operator: Screen usually displayed during operation 1.1 Clock display function: Current time is displayed.

1.2 Self-diagnosis display : When abnormality is detected in the mechatro system like sensor, proportional valve, etc., this displays error code.

1.3 Warning display: When machine was thrown into dangerous state, or was failed, displays warning contents with the symbol and statement.

. Warning CAUTION ATTACHMENT

These descriptions indicate error codes.

W009

POWER BOOST ON

WARM FINISH WARM-UP DATA

CPU COMMUNICATION ERROR

LOW ENG OIL PRESS.

W005

PREHEAT

HIGH ENG WATER TEMP.

W006

CHARGE ERROR

LOW ENG WATER W004 LEVEL

LOW FUEL LEVEL

CLOGGED AIR FLTR W008

WARM AUTO WARMING UP

SWING BRAKE DISENGAGED

ENGINE STOP

CHANGE ENG OIL

CHANGE FUEL FLTR

LIFT UP LOCK LEVER BEFORE ENGINE START

ENG PREHEAT

CHANGE HYD. OIL FLTR

CHANGE HYD. OIL

W011

Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.

1.4 Machine condition display: Displays machine operating condition.

21-42

21. MECHATRO CONTROLLER 2. Display function for maintenance: Displays remaining time up to replacement/change of following items.

(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil 3. Failure history display function: Stores abnormality occurred in the mechatro system in the past and displays in order of recent occurrence.

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

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

21

21-43

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

5

1

6

TURN STARTER KEY SWICH ON No.1 + MAIN CONT. P/N XLB22E00026F1 PRIGRAM VERSION 1-VER 00.07 2-VER 00.00

(a)

(b)

+

SERVICE MENU

4

3

(C) SERVICE ADJUST1-2

2

(d) SERVICE ADJUST1-2

(e) SERVICE ADJUST1-2

SERVICE DIAGNOSIS

AUTO ACCEL

AUTO ACCEL

AUTO ACCEL

TROUBLE HISTORY

START MODE

START MODE

START MODE

LANGUAGE & LOGO SETTING

CANCEL LOW TEMP

CANCEL LOW TEMP

CANCEL LOW TEMP

SERVICE ADJUST 1

CANCEL MODE

CANCEL MODE

CANCEL MODE

SERVICE ADJUST 2

CHECK INJECTOR

CHECK INJECTOR

CHECK INJECTOR

FACTORY PRESET

PRESS DRAIN

PRESS DRAIN

PRESS DRAIN

FAULT DIAG MODE

NIBBLER SETTING

NIBBLER SETTING

NIBBLER SETTING

BREAKER SETTING

BREAKER SETTING

SERVICE DIAG 1 CLUSTER DIAG 1 CLUSTER GAUGE P/N YN59S00028F1 PROGRAM VERSION 01.00

BACK

ON

BREAKER SETTING

CAMERA 1 SETTING

OFF

CAMERA 1 SETTING

OFF

CAMERA 1 SETTING

CAMERA 2 SETTING

OFF

CAMERA 2 SETTING

OFF

CAMERA 2 SETTING

NEXT

BACK

DOWN

ON DOWN

NEXT

BACK

ON OFF

BACK OK

ON OFF ON OFF

OK

1. Hold down buzzer stop switch (1) and turn starter switch ON. The service diagnosis screen (a) is displayed.

2. Hold down buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen (b) is displayed.

3. Using "UP" switch (3) or "DOWN" switch (4), point the cursor to "SERVICE ADJUST 1" display (b). Press "NEXT" switch (5), and SERVICE ADJUST 1-2 (c) is displayed.

4. Using "UP" switch (3) or "DOWN" switch (4), point the cursor to "CAMERA 1 SETTING" display (c).

5. Press "NEXT" switch (5), and the cursor is pointed to "OFF" on display (d).

6. Press "UP" switch (3), and it points "ON" of display (e).

7. Press menu switch (2), and rearview camera is set.

8. After that screen returns to "SERVICE ADJUST 1-2" (c).

9. Turn off starter key switch.

21-44

21. MECHATRO CONTROLLER 2) Troubleshooting 1. Gauge cluster is powered on but picture does not appear and it shows blue screen.

No.

Parts

Parts/Normal condition

Corrective action

1

Power-supply box to Cab harness

Make sure the connector between powersupply box and cab harness is connected.

2

Cable to Cab harness

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

3

Cable to Camera cable

Make sure the connector between cable and Check connections. camera cable should is connected.

4

Fuse & Relay box

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

Replace fuse.

5

Setting of camera

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

Check the setting.

Check connections.

2. Gauge cluster is powered on but picture does not appear and it shows fuel consumption graph or logo.

No. 1

Parts Setting of camera

Parts/Normal condition Make sure that camera (1) of service adjustment1 is on.

Corrective action Check the setting.

21

21-45

21. MECHATRO CONTROLLER 21.2.2 SELF DIAGNOSIS DISPLAY (1) Outline This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine operation through self diagnosis. The failed items are displayed on the multi display of gauge cluster. For connector No. and pin No., refer to the section "C-1 Mechatro Controller" explained later. Electric circuit diagram or harness is available to identify wire No. and wire color.

CONTROL

(2) I/O configuration Pressure sensor, Engine controller INPUT

Proportional valve, Battery relay Selector valve (SOL)

CAN COMMUNICATION Gauge cluster (Buzzer sound)

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

S

Alphabet: Decide system failure occurred.

12:15

B 01 3

Last 2nd and 3rd digits: Specifies failed section.

Last 1 digit: Specifies failure type.

E

F

B013

A Last 2,3 digits

01 02 03 04 05 06

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

07

B

C

D

E

F

G Speed sensor

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

P2 pump

P2 unload

Arm out

Boom head

Travel straight

Arm in

Boom rod

Bucket digging Bucket dump Swing

P2 pump

Swing parking

I

K

P

R

Engine ECU

Relay output

Z

Wiper ark prevention relay

Boom angle Angle sensor for shovel Angle sensors for shovel & ECU

Travel 1,2 speed Option selector

H

Potentiometer Communication Battery relay etc Acceleration Battery relay

Wiper ark forward rotation relay Wiper ark reverse rotation relay

Arm angle

Washer motor Bucket stroke limit

Arm 2 spool for arm in

08

Refer to next page (Engine)

Fuel sensor

Travel right

09

Travel left

10

Selector position detection

11

CAN communication

12 13 14 15 P1 side option

16

Swing flasher right relay Swing flasher left relay Travel alarm relay AIS relay 2 Engine stop relay Safety lock lever relay

P2 side option

17 18 19

24

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

25

Proportional valve adjust data

21 22 23

Safety relay

Larger than Larger than normal range normal range

0 1

-

2

-

3

-

4

-

CAN error

Transistor OFF failure / Grounding short circuit

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

5

21-46

Disconnection Time is over Power source short circuit

Contact point is melted and adhered

Refer to next page (Engine)

31 Abnormal

Power source short circuit

21. MECHATRO CONTROLLER 21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION The current service diagnosis is displayed on the multi display based on the data received from the mechatro controller. This section explains the operating procedure and examples of each screen. The values in the display change according to the conditions like engine speed, attachment position, etc.

(1) Service diagnosis display screen operating procedure 1. Turn starter switch ON keeping buzzer stop switch pressed.

Buzzer stop switch

2. After logo mark is displayed, the screen changes in service diagnosis mode.

The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.

The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1".

The screen number each mode can display differs. The screen number displayed by each mode is as follows.

• Mode No.1: Screen No.1 to No.22 • Mode No.2: Screen No.1, Screen No.23 to No.27 • Mode No.3: Screen No.1, Screen No.28 to No.32 3. The screen changes each time each switch is pressed from now on.

Up arrow switch

21 Screen gains by 1 in order. (No.2-->No.3-->No.4-->...)

Down arrow switch

Screen loses by 1 in order. (No.24-->No.23-->No.22-->...)

Next arrow switch

Service diagnosis number advances from No.1 to No.3, and then returns to No.1.

(No.1-->No.2-->No.3-->No.1-->...)

Back arrow switch

Service diagnosis number advances from No.3 to No.1, and then returns to No.3.

(No.3-->No.2-->No.1-->No.3-->...)

4. Turn key switch OFF and the display of service diagnosis mode is closed.

21-47

21. MECHATRO CONTROLLER (2) Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.)

1) Service diagnosis mode No.1 No. 1

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

2

4

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

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

Contents

No. 5

P/No. indication

Displays

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

Program version indication MERIT controller program version Service diagnosis mode

Contents

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

P/NO. indication Program Version indication

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

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

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

Set value in computer Measured value Switch

21-48

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

21. MECHATRO CONTROLLER

No. 7

8

9

10

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

Contents

No. 14

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

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

Power shift Flow rate of pump P2

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

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

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

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

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

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

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

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

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

Set value in computer Measured value

16

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

Contents

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

11

13

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

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

21-49

See Mechatro controller connector

21

21. MECHATRO CONTROLLER

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

18

19

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

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

22

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

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

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

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

NO.21 MERIT SYSTEM COMMUNICATION

23

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

Contents

OFF

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

21-50

Status of communication in MERIT controller

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

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

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

24

25

Contents

No. 26

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

Displays

Contents

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

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

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

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

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

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

Program Version indication

27

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

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

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

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

28

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

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

29

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

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

Contents

No. 32

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

Displays

Contents

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

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

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

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

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

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

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

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

Service diagnosis mode P/NO. indication Program Version indication

Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated high-reach crane operating time

All accumulated starter operating time

21-51

21. MECHATRO CONTROLLER (3) Service diagnosis data list Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use these data to decide normal/abnormal status.

The numerical values in page from 21-52 to 21-56 are undecided yet.

After the actual machines are operated and measured these values, these numerical values are decided.

• • • • • • •

The values in following display are reference values with standard attachment attached machine.

The value of pressure sensor is calculated taking variation into accounts. When compared to performance check reference criteria, measure it with the aid of calibrated measuring instrument.

The current of proportional valve is not the measured value, but command value. The measured value should be confirmed by the value in the displayed value for each proportional valve.

The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value.

The value in display during operation shows the value in steady state, rather than, at start of operation.

Check on machine after sufficiently warming up machine.

The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1: No operation H mode Hi idle

Operation No.2: No operation S mode Hi idle

No.24 ARM, SWING

No.24 ARM, SWING

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

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

0.2 to 1.5 M 0.2 to 1.5 M 350 mA 350 mA 750 mA 750 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 0.0 M 1970 to 2030 0 mA

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

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

0.2 to 1.5 M 0.2 to 1.5 M 350 mA 350 mA 750 mA 750 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 0.0 M 1770 to 1830 0 mA

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

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

No.23 BOOM

No.23 BOOM

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

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

33.0 to 35.8 M 33.0 to 35.8 M 415 to 525 mA 415 to 525 mA 360 mA 360 mA 3.0 M 0.0 M 1970 to 2060 0 mA

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

21-52

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

11.0 to 16.0 M 11.0 to 16.0 M 560 to 750 mA 560 to 750 mA 360 mA 360 mA 3.0 M 0.0 M 1970 to 2060 0 mA

21. MECHATRO CONTROLLER

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

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

12.5 to 16.0 M 0.2 to 1.5 M 600 to 617 mA 350 mA 427 to 477 mA 750 mA 0.0 M 3.0 M 1970 to 2060 0 mA

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

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

No.24 ARM, SWING

No.24 ARM, SWING

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

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

33.0 to 35.8 M 33.0 to 35.8 M 415 to 525 mA 415 to 525 mA 360 mA 360 mA 350 mA 200 mA 0.0 M 3.0 M 0.0 M 0.0 M 1970 to 2060 0 mA

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

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

12.5 to 16.5 M 12.5 to 16.5 M 550 to 750 mA 550 to 750 mA 360 mA 360 mA 350 mA 400 mA 0.0 M 3.0 M 0.0 M 0.0 M 1970 to 2060 0 mA

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

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

No.24 ARM, SWING

No.24 ARM, SWING

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

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

33.0 to 35.8 M 33.0 to 35.8 M 415 to 525 mA 415 to 525 mA 360 mA 360 mA 350 mA 750 mA 3.0 M 0.0 M 0.0 M 0.0 M 1970 to 2060 0 mA

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

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

* Measure the values after a lapse of 5 minutes or after release of low temperature mode.

21-53

15.0 to 22.0 M 15.0 to 22.0 M 488 to 677 mA 488 to 677 mA 360 mA 360 mA 350 mA 750 mA 3.0 M 0.0 M 0.0 M 0.0 M 1970 to 2060 0 mA

21

21. MECHATRO CONTROLLER

Operation No.10: Swing in full lever operation & relief H mode Hi idle

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

No.24 ARM, SWING

No.24 ARM, SWING

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

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

0.2 to 1.5 M 28.0 to 35.8 M 350 mA 528 to 750 mA 750 mA 360 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 3.0 M 1970 to 2060 0 mA

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

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

0.2 to 1.5 M 10.0 to 15.0 M 350 mA 750 mA 750 mA 360 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 3.0 M 1970 to 2060 0 mA

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

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

No.25 BUCKET

No.25 BUCKET

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

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

33.0 to 35.8 M 33.0 to 35.8 M 415 to 525 mA 415 to 525 mA 360 mA 360 mA 720 mA 3.0 M 0.0 M 1970 to 2060 0 mA

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

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

4.0 to 8.0 M 4.0 to 8.0 M 650 to 750 mA 540 to 563 mA 360 mA 360 mA 720 mA 3.0 M 0.0 M 1970 to 2060 0 mA

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

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

No.25 BUCKET

No.25 BUCKET

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

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

33.0 to 35.8 M 33.0 to 35.8 M 415 to 525 mA 415 to 435 mA 360 mA 360 mA 720 mA 0.0 M 3.0 M 1970 to 2060 0 mA

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

21-54

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

6.0 to 15.0 M 6.0 to 15.0 M 577 to 750 mA 415 to 435 mA 360 mA 360 mA 720 mA 0.0 M 3.0 M 1970 to 2060 0 mA

21. MECHATRO CONTROLLER

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

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

No.27 OPT

No.27 OPT

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

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

22.5 to 26.0 M 22.5 to 26.0 M 459 to 584 mA 459 to 584 mA 360 mA 360 mA 720 mA 0 mA 0.0 M 2.0 to 2.6 M NIB --1970 to 2060 0 mA

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

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

0.2 to 1.5 M 22.5 to 26.0 M 500 mA 665 to 750 mA 750 mA 360 mA 350 mA 0 mA 0.0 M 2.0 to 2.6 M BRK --1970 to 2060 0 mA

Operation No.18: Travel right in full lever operation & travel idling H mode Hi idle

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

No.26 TRAVEL

No.26 TRAVLE

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

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

5.0 to 12.0 M 0.2 to 1.5 M 750 mA 350 mA 360 mA 750 mA 350 mA 2.0 to 2.5 M 0.0 M 0.0 M 0.0 M 1970 to 2060 0 mA

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

21-55

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

0.2 to 1.5 M 5.0 to 12.0 M 350 mA 750 mA 750 mA 360 mA 350 mA 0.0 M 2.0 to 2.5 M 0.0 M 0.0 M 1970 to 2060 0 mA

21

21. MECHATRO CONTROLLER 21.2.4 TROUBLE HISTORY DIAGNOSIS The items of error detected by the mechatro controller self diagnosis function are stored in the mechatro controller as one of history. And the errors are able to be indicated on the multi display.

A part of warning contents is stored. (The stored items are listed in warning table.)

The error code for self diagnosis is stored.

(1) How to display

(Example) 1. Hold down buzzer stop switch and turn starter switch No errors on.

The service diagnosis screen is displayed.

2. During holding down the menu switch, press buzzer Error detected stop switch three times. "SERVICE MENU" screen is in the past displayed. Using the "UP" or "DOWN" switch, point the cursor to "TROUBLE HISTORY".

Press "NEXT" switch, and "TROUBLE HISTORY" is displayed. And select "TROUBLE HISTORY" to display the trouble history diagnosis.

3. Transmit trouble history data (One or many) and hour meter to gauge cluster.

Hour meter and 10 failure data are displayed on screen.

In case of more than 10 failure data, turn a page to check next data.

4. Paging (Up and down) Press "UP ARROW SWITCH" to move the item up.

Press "DOWN ARROW SWITCH" to move the item down.

5. Turn starter switch OFF, and the display disappears.

NO ERROR

(2) How to delete contents of trouble history 1. Display trouble history screen.

2. Press work mode change switch and buzzer stop switch simultaneously for 5 seconds or more.

3. When "NO ERROR" is displayed, the deletion is completed.

4. Turn starter switch off.

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

21-56

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

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

Wiper switch Washer switch

Buzzer stop switch Screen change switch

Menu switch

Interval of replacement of parts is mentioned below.

-Engine oil: 500 Hr -Fuel filter: 500 Hr -Hydraulic filter: 1,000 Hr -Hydraulic oil: 5,000 Hr

1. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound.

2. The fuel filter change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound.

3. The hydraulic oil filter change time is displayed on the multi-display by 1000 hours as a warning, but the buzzer does not sound.

4. The hydraulic oil change time is displayed on the multi-display by 5000 hours as a warning, but the buzzer does not sound.

21-57

21

21. MECHATRO CONTROLLER Procedure

Operating Procedure

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

1

Turn starter key switch ON.

12:15

E

S

F

12:15

USER MENU MAINTENANCE SWITCH STATUS

2

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

OPTION SETTING CONSUMPTION E

F

SCREEN SETTING CLOCK SETTING

BACK

UP

HOME

DOWN

INTERVAL

USER MENU

3

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

MAINTENANCE

FUEL FILTER

SWITCH STATUS

HYD. FILTER

OPTION SETTING

HYD. OIL

CONSUMPTION

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

5

BACK

UP

HOME

DOWN

ENGINE OIL FUEL FILTER HYD. FILTER

FUEL FILTER HYD. FILTER HYD. OIL

FUEL FILTER HYD. FILTER HYD. OIL

FUEL FILTER HYD. FILTER HYD. OIL

7

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

21-58

REMAINDER

REMAINDER

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

INTERVAL

ENGINE OIL

REMAINDER

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

INTERVAL

Press "NEXT" switch to fix the value.

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

NEXT

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

INTERVAL

ENGINE OIL

ENGINE OIL

6

EXCHANGE DAY

CLOCK SETTING

HYD. OIL

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

REMAINDER

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

SCREEN SETTING

INTERVAL

4

ENGINE OIL

NEXT

REMAINDER

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

EXCHANGE DAY

INTERVAL

08/12/12

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

EXCHANGE DAY

08/12/12

INTERVAL

or

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

EXCHANGE DAY

ENGINE OIL

08/12/12

FUEL FILTER

08/12/12

HYD. FILTER

08/12/12

HYD. OIL

EXCHANGE DAY

S

REMAINDER

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

INTERVAL

08/12/12

REMAINDER

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

REMAINDER

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

EXCHANGE DAY

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

EXCHANGE DAY

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

EXCHANGE DAY

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

12:15

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

F

24. COMPONENTS SYSTEM

24. COMPONENTS SYSTEM TABLE OF CONTENTS

24.1 HYDRAULIC COMPONENTS ............................................................................24-3 24.1.1 HYDRAULIC PUMP - REGULATOR ..........................................................24-3 24.1.2 CONTROL VALVE .....................................................................................24-18 24.1.3 PILOT VALVE (ATT) ...................................................................................24-58 24.1.4 PILOT VALVE (TRAVEL) ...........................................................................24-62 24.1.5 SWING MOTOR UNIT ...............................................................................24-65 24.1.6 TRAVEL MOTOR .......................................................................................24-78 24.1.7 SWIVEL JOINT ..........................................................................................24-89 24.1.8 CYLINDER .................................................................................................24-91 24.2 ELECTRICAL EQUIPMENT ...............................................................................24-97 24.2.1 ELECTRICAL EQUIPMENT LIST ..............................................................24-97 24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ........................................24-100 24.3 SELECTIVE CATALYTIC REDUCTION (SCR) ..................................................24-117 24.3.1 EXHAUST SYSTEM SPECIFICATIONS ...................................................24-117 24.3.2 EXHAUST SYSTEM WITH SCR LAYOUT ................................................24-117 24.3.3 DEF/AdBlue® CIRCUIT SCHEME .............................................................24-118 24.3.4 DEF/AdBlue® CIRCUIT COMPONENTS ..................................................24-118 24.3.5 DEF/AdBlue® INSTRUMENTATION WARNING .......................................24-119 24.3.6 WARNING SYMBOLS ...............................................................................24-120 24.3.7 DEF/AdBlue® INSTRUMENTATION WARNING .......................................24-120 24.3.8 DEF/AdBlue® QUALITY FAULTS, FAILURES AND ENGINE POWER LOSS.....24-121 24.3.9 SCR SYSTEM TECHNICAL FAULTS, FAILURES AND ENGINE POWER LOSS LEVELS ............................................................................................................24-121 24.3.10 SCR SYSTEM RESET SYMBOLS AND VALIDATION RE-START COUNTER ....24-122 24.3.11 RESETTING THE SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM........24-122 24.3.12 VALIDATION RE-STARTS .........................................................................24-122 24.3.13 EMERGENCY RE-START .........................................................................24-122

Book Code No. S5YN0042E01 24-1

24

24. COMPONENTS SYSTEM NOTES

24-2

24. COMPONENTS SYSTEM

24.1

HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP - REGULATOR 24.1.1.1 SUMMARY (1) Outside view and Hydraulic port EYE BOLT (M10)

6 a3

2X1-M8 DEPTH 15 (FOR ATTCHING BRACKET)

5

Dr

A3

2X4-M12 DEPTH 22

PSV2 A1

A2

B3

VIEW

a4

PSV1

MAX. FLOW RATE ADJUSTING SCREW

PH1 PH2 PSV1

8

8

PSV2

PSV2 7

7 a3

MIN. FLOW RATE ADJUSTING SCREW

a4 PH1 PH2

PH2 PH1 4

a1

a1 a2 B3

a2

B3 B1

Dr

B1

A3 A1

Dr3 a5

A2 4-M12 DEPTH 18

a5 A2

1 Dr3

Hydraulic ports No.

Parts

Q'TY

Code

Ports name

Size

1

Main pump assy

1

A1,2

Delivery port

SAE 6000psi 1"

4

Gear pump assy (for pilot)

1

B1

Suction port

SAE 2500psi 2 1/2"

5

Cover

1

Dr

Drain port

6

Capscrew

4

PSV1,2 Servo assist port

PF1/4-13

7

Regulator assy

2

PH1,2 Pressure sensor port

PF3/8-17

8

Solenoid proportional reducing valve

2

a1~a4 Gauge port

PF1/4-15

a5

Gauge port

PF1/4-14

A3

Delivery port of gear pump

PF1/2-19

B3

Suction port of gear pump

PF3/4-20.5

Dr3

Drain port of gear pump

PF3/8-15

Hydraulic pump - regulator

24-3

PF3/4-20

24

24. COMPONENTS SYSTEM (2) Hydraulic circuit diagram

(KDRDE5K)

PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (FRONT) (REAR) (KR3G-YT2K-V) (KR3G-YT2K-V) (KDRDE5K) Solenoid proportional reducing valve (PSV-2)

Solenoid proportional reducing valve (PSV-1)

Regulator

Regulator

a4

Dr

a3 Engine

Main pump

Gear pump for pilot a5 B1

B3

Dr3

A3

PTO gear case

Hydraulic circuit diagram of pump (3) Specifications

Item Parts No.

Main pump

Gear pump

Pump assy

YN10V00036F2

-

Single Pump

YN10V00043F1

YN10V00014F3

K3V112DTP1K9R-YT2K-V

ZX10LGRZ2-07G

cm3

110 X 2

10

min-1(Clockwise seen from shaft end)

2000

Pump model Max.displacement capacity Revolution

Pressure

Rated Rated

34.3 (4980)

MPa (psi)

37.8 (5480)

ATT boost pressure

Max. flow Max. input horse power Max. input torque

Regulator

Weight

5.0 (725)

L/min (gal/min)

220 (58) X 2 at 7.8MPa (1130 psi)

20 (5.3)

kW (PS) N.m (lbf.ft)

114 (155)

3.4 (4.6)

544 (401)

14.7 (10.8)

Part No.

YN10V01009F2

Model

KR3G-YT2K-V

Control function

Electric flow control, positive flow control, total power control at emergency mode and power shift control

Others

With solenoid proportional reducing valve (KDRDE5K-31/30C50)

kg (lb)

141 (310)

24-4

24. COMPONENTS SYSTEM 24.1.1.2 HYDRAULIC PUMP 24.1.1.2.1 CONSTRUCTION (1) Main pump 886 717

953 806

789 532 Apply adhesive (Three Bond No.1305N) 724 A 214 548 531 702 792 534 535 732

901 808 954

717

151

152

211

261 406 824 774 111 B

B

127 123 04

710 212 401 251 490

271

153 156 157

468 728

313 124 710 116 467 466 312 885 314 141 727 725

271

113 05

Tightening torque Item number

Thread size

401 406 407 414 466 467 468 490 531,532 806 808

M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20

No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313

Tightening torque N.m (lbf.ft) 430 29 12 57 36 74 170 8.8 240 130 240

(317) (21) (8.9) (42) (27) (55) (125) (6.5) (177) (96) (177)

546 414

326

725 727

407

325 VIEW A

SECTION B-B

SECTION B-B OPT

No. Q'ty No. Parts Q'ty Parts Parts 724 O-ring ; 1B P8 1 314 Valve plate (L) 1 Drive shaft (F) 725 O-ring ; 1B P11 1 325 Sensor block 1 Drive shaft (R) 727 O-ring ; 1B P14 1 326 Cover 1 Gear #1 728 O-ring ; 1B P24 8 401 Socket bolt ; M20X210 2 Roller bearing 732 O-ring ; 1B P18 4 406 Socket bolt ; M8X20 2 Needle bearing 774 Oil seal 3 407 Socket bolt ; M6X55 3 Bearing spacer 789 Back up ring ; P18 4 414 Socket bolt ; M10X20 2 Cylinder block 792 Back up ring ; G35 2 466 VP plug ; PF1/4 18 Piston 806 Nut ; M16 2 467 VP plug ; PF3/8 18 Shoe 808 Nut ; M20 4 468 VP plug ; PF3/4 2 Retainer plate 824 Snap ring 32 490 Plug ; NPTF1/16 2 Spherical bushing 885 Valve plate pin 2 531 Tilting pin ; M24X2 18 Cylinder spring 886 Spring pin 2 532 Servo piston ; M24X2 2 Shoe plate 901 Eye bolt ; M10 2 534 Stopper(L) 2 Swash plate 953 Socket screw ; M16X35 2 535 Stopper(S) 2 Tilting bushing 954 Set screw ; M20 2 546 Spacer 2 Swash plate support 04 Gear pump 2 548 Feed back pin 1 Seal cover (F) 05 PTO unit 2 702 O-ring ; 1B G35 2 Pump casing 2 710 O-ring ; 1B G95 1 Valve block 4 717 O-ring ; 1B G145 1 Valve plate (R) The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

24-5

Q'ty 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1

24

24. COMPONENTS SYSTEM (2) Gear pump (For pilot)

700

354

351

Suction port : PF3/4 Tightening torque : 73.5N.m (54.2 lbf.ft)

433

434 Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft) 311 312 732 307

710

435

361

No.

353

Parts

850

310 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft)

Q'TY

No.

308 309

434

466 725

Parts

355

Q'TY

307 308 309 310 311

Poppet Seat Ring Spring Adjust screw

1 1 1 1 1

361 433 434 435 466

Front case Flange socket; M8X40 Flange socket; M8X55 Flange socket; M8X20 VP plug; PF1/4

1 2 2 4 1

312 351 353 354 355

Lock nut; M14X1.5 Gear case Drive gear Driven gear Filter

1 1 1 1 1

700 710 725 732 850

Ring O-ring; 1B G95 O-ring; 1B P11 O-ring; 1B P16 Locking ring

1 1 1 1 1

24-6

24. COMPONENTS SYSTEM (3) PTO gear case (OPT)

125 711 118

825

468 728

710

117 126 326 115 128 826

262

414 435

886 885

No.

Parts

Q'TY

No.

Parts

Q'TY

115 117 118 125 126

Idle shaft 2nd gear 3rd gear Ball bearing Roller bearing

1 1 1 2 1

435 468 710 711 728

Flange socket; M10X20 VP plug; PF3/4 O-ring; 1B G80 O-ring; 1B G85 O-ring; 1B P24

4 1 1 1 1

128 262 326 414

Bearing spacer Cover Gear case Capscrew; M10X20

2 2 1 4

825 826 885 886

Snap ring Snap ring Sprig pin Pin

1 1 1 2

24-7

24

24. COMPONENTS SYSTEM 24.1.1.2.2 OPERATION The pump assy is equipped with two pumps arranged on the same axis that are connected with gear (116) and distribute the rotating power to the gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the auxiliary pump (OPT) arranged on another shaft.

The pump assy consists largely of the rotary group, the main part of the pump that makes rotary on; the swash plate group that changes the delivery rate; the valve block group that selects between oil suction and delivery and the PTO group (OPT) that transmits the drive power to the auxiliary pump.

REGULATOR

116 111

PTO GEAR CASE (OPT) AUXILIARY PUMP (OPT)

Construction of hydraulic pump (1) Rotary group The rotary group consists of shaft (111), cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156), and cylinder spring (157).

The shaft is supported by bearings (123) and (124) at both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure.

Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance.

The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder block (141) is also pressed against valve plate (313) by the action of cylinder spring (157).

124

313

312 111 116 124 314 141 157 151 . 153 152

156

211

Rotary group

24-8

24. COMPONENTS SYSTEM (2) Swash plate group The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), tilting pin (531), and servo piston (532).

The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support.

The hydraulic force controlled by the regulator flows into the hydraulic chamber that is provided on both sides of the servo piston. This moves the servo piston to the right and left. The result is that the swash plate swings on the swash plate support via the spherical part of the tilting pin and changes the tilting angle (a).

532

531

214 211 212

251

Swash plate group (3) Valve block group The valve block group consists of valve block (312), valve plates (313 or 314), and valve plate pin (885).

The valve plates having two crescent-shaped ports are installed to valve block (312) to feed oil and recycle it from cylinder block (141). The oil switched over by the valve plate is connected with the external pipe by way of the valve block.

313 312

116 141

111

314 885

Valve block group

(4) PTO group (OPT) The PTO group is composed of 1st gear (116), 2nd gear (117) and 3rd gear (118). The 2nd and the 3rd gear are supported by bearings (125) and (126) respectively and installed to the valve block.

Now, if the shaft is driven by the engine, the cylinder block rotates together by the spline linkage. If the swash plate is inclined, the pistons arranged in the cylinder block make reciprocating motion with respect to the cylinder while rotating with the cylinder block. If we keep an eye on a single piston, it makes a motion away from the valve plate (oil suction process) in the first 180 deg. and a motion toward the valve plate (oil delivery process) in the remaining 180 deg. If the swash plate is not inclined (zero tilting angle), the piston does not stroke i.e. delivers no oil.

The shaft rotation is taken up by the 1st gear (116) and transmitted to the 2nd gear (117) and the 3rd gear (118), in that order, to drive the gear pump that is linked to the 3rd gear.

24-9

117 126

118 125

24 125

PTO group (OPT)

24. COMPONENTS SYSTEM 24.1.1.3 REGULATOR 24.1.1.3.1 CONSTRUCTION PSV

413

PSV

B

418 079

757

D 439

438

725 730 a3

656

643

438

924

D 722

543 755 545 541 724

801

466, 755

B

708

VIEW C

646 645

644

728

SECTION B-B

641 655

654

836

651

652

601 624

734 612

897

876

874

858

755

629

653

630

A 412

615

814

614

631

628 627 C

613 875 A

898

802

732 611

753 733 756 622

621

625

623

626 887

763

SECTION A-A

At starting or at redundance

Tightening torque 662 543

545

541

466 755

496 755

SECTION E-E

642

At working

E

E

SECTION D-D

24-10

Item No.

Thread size

412,413 438,439 418 466 496 630 801 802

M8 M6 M5 PF 1/4 NPTF1/16 M30X1.5 M8 M10

Tightening torque N.m 29 12 6.9 36 8.8 160 16 19

24. COMPONENTS SYSTEM

No. 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627

Parts Socket bolt ; M8X50 Socket bolt ; M8X70 Socket bolt ; M5X12 Socket bolt ; M6X20 Socket bolt ; M6X25 VP plug ; PF1/4 Plug ; NPTF1/16 Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcrum plug Adjusting plug Compensating piston Piston case Compensating rod Spring seat (C) Outer spring Inner spring Adjusting stem (C)

Q'ty 2 2 2 8 5 3 17 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1

No. 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 662 708 722 724 725 728 730

Parts Adjusting screw (C) Cover (C) Lock nut ; M30X1.5 Sleeve (For PF) Pilot cover Spool Pilot piston Spring seat (Q) Adjusting stem (Q) Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-ring ; 1B G75 O-ring ; 1B P6 O-ring ; 1B P8 O-ring ; 1B P10 O-ring ; 1B P18 O-ring ; 1B P22

Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 8 1 1 1

No. 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 041 079

Q'ty 1 1 1 1 7 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1 Solenoid proportional reducing valve Parts O-ring ; 1B P16 O-ring O-ring ; 1B G25 O-ring ; 1B P9 O-ring ; 1B P11 O-ring ; 1B P26 O-ring ; 1B P12.5 O-ring ; 1B G35 Nut ; M8 Nut ; M10 Snap ring Snap ring Snap ring Pin ; 4X11.7L Pin ; 4X8L Pin ; 5X8L Pin Pin ; 5X19L Pin ; 11.5X11.8L Socket screw ; M8X20 Sub-check valve

The codes in a rectangle represent adjust screws.

Do not tamper with the adjust screws as much as possible.

24

24-11

24. COMPONENTS SYSTEM 24.1.1.3.2 OPERATION (1) Control function Control function ...... Electric flow control.

-Positive flow control.

-Total horsepower control.

Emergency mode control.

-Hydraulic positive control.

-Hydraulic total horsepower control.

(2) Summary The regulator KR3G-YT2K for the in-line type axial piston pump K3V series is composed of the control mechanism as mentioned below: 1. Electric flow control and positive flow control The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control (positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to attain optimum power according to the operating condition. Also, since the pump delivers only the necessary oil flow, the machine does not consume excessive power.

2. Constant power control at emergency mode When the electromagnetic proportional pressure-reducing valve cannot output the secondary pressure due to the trouble, the spool for emergency mode is switched automatically, and the control is switched from electric control to hydraulic control (emergency mode).

In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power control section of regulator on each pump through pump inside passage and shifts respective control to the same power set value.

In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is automatically reduced; consequently the input torque is controlled to the constant value or less. (When the speed is constant, the input power is also constant.)

This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in the condition where the power is controlled, the overloading of engine is automatically prevented regardless of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power control is not worked.

With this mechanism, it is possible to obtain proper power for the working condition.

This regulator is made up of the above two kinds of control systems, but when both controls are actuated together, the low tilt angle (low delivery rate) command precedes on mechanical operation described later.

24-12

24. COMPONENTS SYSTEM

1. Flow rate electrical control The pump delivery rate is controlled according to the command current value corresponding to the movement of control devices. This relation is shown in the right figure.

Delivery flow rate Q

(3) Explanation of operation

Command current I

a. Flow rate increase (See right Fig.) As the command current value I rises, the secondary pressure P2 of electromagnetic proportional pressurereducing valve rises, and by pressing pilot piston (643) in (A) direction it stops at the position the secondary pressure P2 balances the pilot spring force (646). The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (B) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (C) fulcrum in the same arrow direction as (B).

Consequently the spool (652) connected to feedback lever moves towards (D). When the spool moves towards (D), the port CL connected to tank port is open and the pressure in the servo piston large bore diameter chamber is released, consequently the servo piston (532) moves towards (E) according to delivery pressure Pd1 in small bore diameter piston chamber, resulting in the rise of flow rate. Since the feed back lever is connected to the servo piston and spool, the feed back lever rotates at (F) fulcrums with the movement of the servo piston towards (E), consequently the spool is returned to the original position. With this movement, the opening of the spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

CL port : Connect with large diameter chamber of servo piston

652 B 876

D

646 613 F 897

875 611 643

A C 532

E (KDRDE5K)

Psv A

Pd1

CL port a3

Hydraulic circuit diagram B

24

24-13

24. COMPONENTS SYSTEM b. Flow rate decrease (See right Fig.) As the command current value I is reduced, the secondary pressure P2 of electromagnetic proportional pressurereducing valve is reduced, and by pressing pilot piston (643) in (G) direction it stops at the position the pilot spring force (646) balances the secondary pressure P2. The movement of the pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (H) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (I) fulcrum in the same arrow direction as (H). Consequently the spool (652) connected to the feedback lever moves towards (J). When the spool moves towards (J), the delivery pressure Pd1 is led in the servo piston large bore diameter chamber through the spool and port CL. The servo piston small bore diameter chamber constantly receives delivery of the pressure Pd1, consequently the servo piston moves towards (K) according to the difference of area resulting in the reduction of tilt angle, and finally the flow rate is reduced. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (L) fulcrum with the movement of servo piston towards (K), consequently the spool is returned to the original position. With this movement, the opening of the spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

613 CL port : Connect with large diameter chamber of servo piston 652

G 646 H 876

J

875 611 643

I K

532 (KDRDE5K)

Psv A

Pd1 CL port a3

Hydraulic circuit daigram

2. Power control (In emergency mode) When the load pressure rises, the pump tilt angle is reduced preventing the overloading of engine as shown in right Fig. The operation of power control is the same as the flow rate control, and is explained below.

Delivery flow rate Q

B

Delivery output (Pd1)

24-14

L 897

24. COMPONENTS SYSTEM a. Overload prevention operation (See right Fig.) Because the delivery pressure Pd1 acts on the compensating rod stepped section with the rise of self pump delivery pressure Pd1; the compensating rod (623) is pushed towards (M), and moves to the position the delivery pressure Pd1 balances the spring force of outer spring (625) and inner spring (626). The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (N) fulcrum in arrow direction.

Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (O) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected with feedback lever moves towards (P). When the spool moves towards (P), the delivery pressure Pd1 is led in the servo piston large bore diameter chamber through the spool and CL port. Since the delivery pressure Pd1 is constantly led to servo piston large bore diameter chamber, the servo piston moves towards (Q) according to the difference of area, resulting in the reduction of tilt angle, consequently the flow rate is also reduced. Since the feed back lever is connected with the servo piston and spool, the feed back lever rotates at (R) fulcrum with the movement of the servo piston towards (Q), consequently the spool is returned to the original position. With this movement, the opening of the spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

b. Flow rate recovery operation (See right Fig.) Because the compensating rod (623) is pushed towards (S) with the force of outer spring (625) and inner spring (626) with reduction of self pump delivery pressure Pd1, and moves to the position the spring force of outer spring (625) and inner spring (626) balances the delivery pressure Pd1. The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (T) fulcrum in arrow direction.

Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (T) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected to feedback lever moves towards (V).

As the spool moves towards (V), CL port is open and connected to tank port, the pressure of the servo piston large bore diameter chamber is released and the servo piston (532) moves towards (W) with delivery pressure Pd1 in the small bore diameter chamber, and consequently the flow rate is raised. Since the feed back lever is connected to the servo piston and spool, the feed back lever rotates at (X) fulcrum with the movement of the servo piston towards (W), consequently the spool is returned to the original position.

With this movement, the opening of the spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.

625 897 896 626 R N 612

CL port : Connect with large diameter chamber of servo piston

G

652 H P

M

621 O Q 532 Psv A

(KDRDE5K)

Pd1 CL port a3

Hydraulic circuit daigram B

625 897 876 612 626 X T

S

CL port : Connect with large diameter chamber of servo piston

G

652 H J 875

V

623 611

621 U W 532 (KDRDE5K)

Psv A

24 Pd1 CL port a3

Hydraulic circuit daigram B

24-15

646

875 623 611

24. COMPONENTS SYSTEM 3. Priority mechanism of low tilt angle (low flow rate) command As the said explanation, the tilting commands of flow rate control and power control are transferred to feedback lever (611) and spool (652) through the large bore section of lever 1 (612) and lever 2 (613), but because the pin (dia 5) is extruded in large bore (dia 9), pin (897) on the side where making tilt angle smaller contacts with it, consequently the bore (dia 9) of lever on the side where the larger tilt angle command is given is free without contact with pin (897). In this mechanical selecting manner, the command on the side of the low tilt angle of the flow rate control and power control has priority.

Delivery flow rate Q

4. Power shift control As shown in right Fig., the pump set power is controlled according to the movement of control by power shift pressure Pf. As power pressure Pf rises, the compensating rod (623) moves rightward through pin (898) and compensating piston (621). Consequently like the overloading prevention operation of power control, the pump tilt angle becomes smaller and the power setting value is reduced.

Conversely, if the power shift pressure Pf is reduced, the power set value is raised.

Delivery pressure (Pd1) The power shift pressure Pf of this pump is ordinarily set to 0MPa, but in emergency mode, the power shift pressure Pf is raised to 4.9 MPa. 24.1.1.3.3 ADJUSTING THE REGULATOR The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency mode control) control characteristics, flow control characteristics using the adjust screw.

Adjust screw no.

954

No. of turns for tightening

1/4

Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min (gal/min)

Delivery flow rate Q

(1) Adjusting the maximum flow (See construction Fig.) Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it). Tightening set screw (954) decreases the delivery rate, as indicated in right Fig..

Only the maximum flow varies, but other control characteristics remain unchanged.

No change 5.8 (1.5)

Input current I (Pilot pressure Pi)

Adjusting the max. delivery flow

24-16

24. COMPONENTS SYSTEM

Adjust screw no.

953

No. of turns for tightening

1/4

Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min (gal/min)

Delivery flow rate Q

(2) Adjusting the minimum flow (See construction Fig.) Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or loosening it). Tightening socket screw increases the delivery rate, as indicated in right Fig..

Other control characteristics remain unchanged in the same way as maximum flow adjustment, care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action).

No change 4.6 (1.2)

Input current I (Pilot pressure Pi)

Adjusting the min. delivery flow

(3) Adjusting the input horsepower (At emergency mode) Since the regulator is of total horsepower control type, turn the adjust screws of both the front (No.1) and rear (No.2) pumps when changing horsepower set values. Adjust the horsepower settings of both pumps to a same level. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values will by halved when only one pump is loaded.

Adjust screw no.

628

No. of turns for tightening

1/4

Delivery flow rate Q

1. Adjusting the Outer Spring (See constuction Fig.) (At emergency mode) Adjust it by loosening lock nut (630) and by tightening adjust screw (628) (or loosening it). Tightening the adjust screw shifts the control chart to the right and increases the input horsepower, as indicated in right Fig..

Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626), return the adjust screw C (627) by NX1.48 turns at first.

Increase delivery pressure MPa (psi) 2.06 (299) Increase in input torque N.m (lbf.ft)

50 (36.9)

Delivery pressure (Pd1)

Adjusting the input horsepower (1)

24

24-17

24. COMPONENTS SYSTEM

Adjust screw no.

627

No. of turns for tightening

1/4

Increase inflow L/min (gal/min)

Delivery flow rate Q

2) Adjusting the Inner Spring (See construction Fig.) (At emergency mode) Adjust it by loosening nut (802) and by adjust screw (C) (627) (or loosening it). Tightening the adjust screw increases the flow and then the input horsepower, as indicated in right Fig.. And the input torque raises.

12 (3.2)

Increase in input torque N.m (lbf.ft) 58.7 (43.3)

Delivery pressre (Pd1)

Adjusting the input horsepower (2)

Adjust screw no.

924

No. of turns for tightening

1/4

Increase Pilot pressure MPa (psi)

0.18 (26)

Decrease in delivery flow L/min (gal/min)

18.5 (4.9)

Delivery flow rate Q

(4) Adjusting the flow control characteristics (See construction Fig.) Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the control chart to move to the right as shown in right Fig..

Input current I (Pilot pressure Pi)

Adjusting the flow control characteristics

24-18

24. COMPONENTS SYSTEM 24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter YN33-II" (1) When the engine is overloaded, Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start checking from para. 3).

1. Check that the power shift command current I is normal 2. The power shift pressure is low.

-Check the dither of amp.

-Replace solenoid proportional reducing valve.

3. Stick of compensating piston (621) and compensating rod (623) -Disassemble and clean it.

4. Stick of pin (898) -Disassemble and clean it.

(2) The max. flow rate is not delivered.

1. Check that pilot differential pressure Pi is normal.

2. Stick of pilot piston (643) -Disassemble and clean it.

3. Stick of spool (652) -Disassemble and clean it.

4. Stick of pin (898) -Disassemble and clean it.

Note: When the damage of part is severe, replace the part with new one.

24

24-19

24. COMPONENTS SYSTEM 24.1.1.4 CONTROL CURVE OF PUMP 250

Q

[1] 99kW H mode at traveling or optional working [2] 83kW H mode at operating attachment [3] 75kW S mode at operating attachment

2000min-1: (H mode) 1800min-1: (S mode)

200

[2]

Input revolution ;2000 min-1 Input horse power ;114 kW Input torque ;544 N.m

Reference value in ( )

[1]

Delivery flow rate Q [ L/min ]

Two pumps are loaded at the same time

150 [3]

100

50 Min.Flow(at 2000min-1)

0

5

10

15 20 Delivery pressure Pd

250

25

30

35

40 [MPa]

[4] 91kW : At emergency mode

Input revolution ;2000 min-1 Input horse power ;114 kW Input torque ;544 N.m

718mA 220L

Q 2000min-1 300mA 200

Reference value in ( )

Delivery flow rate Q [ L/min ]

Two pumps are loaded at the same time Pf:Power shift pressure (Reference value) [4]

150

(P At f=4 em .9M er Pa ge ) nc y

100

1471

m

981

od

e

I-Q Curve Pd=7.8MPa at Qmax 490 Input torque Tin N.m

50 Min.Flow(at 2000min-1) 400mA 30L

Tin 0

5

10

0

1

2

15 20 Delivery pressure Pd 3 4 [MPa] Pilot pressure Pi

24-20

25

30

35

40 [MPa]

24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24

24-21

24. COMPONENTS SYSTEM 24.1.2 CONTROL VALVE 24.1.2.1 SPECIFICATIONS 24.1.2.1.1 OUTSIDE VIEW PTb

PBL

CT2

P2

CP2

(P6) CT1

(P5) P1

PAL

Pcb

(P6)

(P6)

(P5)

CT1 T2

P1 unload

PTb

Travel straight PBr PAb

PL CMR1 CMR2 Br CP1 Bb

Ac (HEAD)

PAa2

PAL

PCb

PCb

PAL

CT2

Travel left

AL

DR Ab (HEAD)

Travel right

LCb CRb Bc

Boom Bucket

PBb PBb PCc

Arm 2

PB1

Boom conflux

CCb

PBs

Arm 1

PBa2

PBa2

PAo PAo

Option

CRa

PLc2

(HEAD)

PAa1

LCa

(ROD)

PBo

Bo

Ao

PBa2

Aa

LCs Ba

MU

P2 unload PAs

Pss PBa1

Bs

As

Swing

PBa1 Pss

PBc

(ROD)

LCc PCAP2 LCAT2

PB1 PBs

PC

PCa

CP2

PAr

PAr

PBL

BL

Ar

(ROD)

PAc

T1

LCo

PAo

PAa2

Arm 2

Option PBo PAc

Bucket PAb

PAa1

Arm 1 PAa

Swing

Boom Travel right

PBr

PTb

Travel straight

PCa

P2 unload (T3) PBL

PBo PAa2

A

(P6)

(P5)

VIEW A Outside view

24-22

Travel left

24. COMPONENTS SYSTEM 24.1.2.1.2 PORTS Port size

Tightening torque

Ports

Description

PF3/4

150 to 180 N-m (111 to 133 lbf-ft)

MU (T3) (P5) (P6)

Pluged Pluged Pluged

PF3/8

69 to 78 N-m (51 to 58 lbf-ft)

PAa1 PBa1 PAb PBb PAc PBc PBL PBr PAs PBs PAa2 PBa2 PAo PBo DR

Arm 1 (in) pilot port Arm 1 (out) pilot port Boom (up) pilot port Boom (down) pilot port Bucket (digging) pilot port Bucket (dump) pilot port Travel left (reverse) pilot port Travel right (reverse) pilot port Swing (right) pilot port Swing (left) pilot port Arm 2 (in) pilot port Arm 2 (out) pilot port Option pilot port Option pilot port Drain port

PF1/4

34 to 39 N-m (25 to 29 lbf-ft)

Pss PLc2 PAr PAL PBp1 PBp2 PL PB1 PTb PCa PCb PCc

Swing pilot high pressure select port Lock valve select pilot port Travel right (forward) pilot port Travel left (forward) pilot port Bypass cut valve (P1 side) pilot port Bypass cut valve (P2 side) pilot port Attachment boost port Boom (up) conflux pilot port Travel straight pilot port Unload valve (P2 side) pilot port Unload valve (P1 side) pilot port Bucket (digging) stroke limiter pilot port

M12

83 to 110 N-m (61 to 81 lbf-ft)

P1 P2 T1 T2

Pump port (P1 side) Pump port (P2 side) Tank port 1 Tank port 2

M10

49 to 65 N-m (36 to 48 lbf-ft)

Ar Br AL BL As Bs Ab Bb Aa Ba Ac Bc Ao Bo

Right travel motor port (forward) Right travel motor port (reverse) Left travel motor port (forward) Left travel motor port (reverse) Swing motor port (right) Swing motor port (left) Boom cylinder head side port (up) Boom cylinder rod side port (down) Arm cylinder head side port (in) Arm cylinder rod side port (out) Bucket cylinder head side port (digging) Bucket cylinder rod side port (dump) Optional pilot port Optional pilot port

24-23

24

24. COMPONENTS SYSTEM 24.1.2.1.3 SPECIFICATIONS Item

Specifications

Model

KMX15YD/B44102

Maximum flow rate [L/min (gal/min)]

220 (58)X2

Maximum set pressure [MPa (psi)]

37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)

Main relief valve set pressure [MPa (psi)] When power boost pressure

Std 34.3 (4970) [at 70X2L/min (18.5X2gal/min)] 37.8 (5480) [at 60X2L/min (15.9X2gal/min)]

Overload relief valve set pressure (Boom head, Bucket head, Arm rod) [MPa (psi)]

39.7 (5760) [at 30L/min (8gal/min)]

Overload relief valve set pressure (Boom rod, Bucket rod, Arm head) [MPa (psi)]

37.8 (5480) [at 30L/min (8gal/min)]

24-24

24. COMPONENTS SYSTEM 24.1.2.2 CONSTRUCTION AND OPERATION 24.1.2.2.1 CONSTRUCTION (1) Control valve J 154

164

(P5)

T2

PAL

101 P2

T1

PBL

J

PB1

PCa

PBs

PAs Pss

PBa1

PAa1

PAo

PBo

(P4)

163

162 163

162

SECTION A-A 154

164 P1

102 973

973

PTb

PCb

973

973 PBr

PAr

973 PAb

PBb

973 PBc

PAc

973

PCc PBc

974

973

PAa2

PBa2

974

162

162

163

SECTION B-B Section (1/6)

24-25

162

24

24. COMPONENTS SYSTEM

A (P6)

H

B

T2

273x10

273x10

PAL

PCb

P1 unload

H

Travel left

(Travel straight) C

C

977

PAr

PB1

Travel right D

Boom conflux (P2 unload)

978x2

D PBs

Boom

Swing

E

E

PBb

PCc

Pss

PBa1

Bucket

Arm 1

F

F PAo PA

PBa2

Arm 2

Option

MU

G

G K

K

B

A PBa2 PBa2

PAo

274x4

275x4 213

212

PBo

273x10 273x10 PAa2

Section (2/6)

24-26

24. COMPONENTS SYSTEM

P1 unload

202 333 331 336 329 327

Travel left

PCb

202 333 331

PAL

336 MR

601 331 261 309

324 323

PL

AL

159

511 521

512 CP2

522

551 164 162

CMR2

552 562 562 552 522 512

CMR1

BL

163

307 261 331 327 329 336 331 333 202 202 333 331 336 324 323

264 205

PBL

SECTION C-C Travel straight PTb

Travel right

Boom conflux

PAr

202 333 331

PB1

339 326 325 331 261

331 261 306 161 163 511 521

331 261 306 163 162

CCb

511 521 551 164 305

Ar

CP1

551 164

551 164 163

Br

161

310

(T3)

264

PBr

205 SECTION D-D

PCa

P2 unload

Section (3/6)

24-27

164 154 261 331 327 329 336 331 333 202

24

24. COMPONENTS SYSTEM Swing

L

556 164 511 521

204

PBs

203 333 331 336 322 321 603 331 211 261 266 160 160 514 524

Boom PBb

333

Pss

331 336 AbR

322 321

266

As

CRb Ab

LCs

LCb

331 261 303 161 162 163 511 523 556 164

551 164 Bb Bs

162 161

301 264 602

266 264 206

PAb

205

160

BbR

164 551 209 216 333 331 336 322 321 602

PAs

SECTION E-E Bucket

PCc

201 333 331 336 322 321 603 331 261 211

Arm 1 PBa1 PBc

BaR BcR

331 261 304

160 514 524 CRa Bc Ba

511 521 551 164

LCc

556 164 511 521

LCa

551 164 Ac

162

Aa

161 264 603 205

PAc AcR

302 264

PAa1

SECTION F-F

Section (4/6)

24-28

AaR

205 605

24. COMPONENTS SYSTEM 201 333 331 340 328 321

Arm 2

Option

PBa2

201 333

PAo

331 336

331 261

324 AoR

323 604 331

MU

308

261 311

162 162 162 511 521 551 164 515 521

Ao

511 521

LCAT2

LCo

551 164

LCAP2

551 164 Bo

162 161

604 264

BoR

264

Q

Q

PBo

205

210 SECTION G-G

T2

161 P1 T1

511 521

163 CT1

551 164

163 162 P2

511 521 CT2

551 164

SECTION H-H

Section (5/6)

24-29

24

24. COMPONENTS SYSTEM

207 606

160 278x5

266

264

264

527

528

606

163

T1

517

518

SECTION J-J SECTION K-K

563 564

SECTION L-L

SECTION Q-Q

Section (6/6)

24-30

24. COMPONENTS SYSTEM

Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

220-250 (162-184) 20-24 (15-18)

101 102 154 159

Casing A Casing B Plug PF3/4 Plug PT1/4 MEC (Pre-coat bolt)

1 1 3 1

322 323 324 325

Spring Spring Spring Spring

4 3 3 1

7.8-9.8 (5.8-7.2)

160

5

326

Spring

1

161 162 163

Plug PT1/16 MEC (Pre-coat bolt) O-ring O-ring O-ring

7 15 11

327 328 329

Spring Spring Spring

3 1 3

164 201

O-ring Cover

19 3

331 333

Spring seat Spacer bolt

24 12

202 203

Cover Cover

6 1

336 339

Stopper Stopper

10 1

204 205 206 207

Sub cover Cover Cover Back pressure check valve cover

1 6 1 1

340 511 512 514

Stopper Poppet Poppet Poppet

1 11 2 2

209 210 211

1 1 2

515 517 518

Poppet Poppet Poppet

1 1 1

212

Cover Cover Lock valve selector sub Plate

1

521

Spring

11

213 216 261 264 266

Plate Piston O-ring O-ring O-ring

1 1 12 10 4

522 523 524 527 528

Spring Spring Spring Spring Spring

2 1 2 1 1

273 274 275 278 301

Socket bolt Socket bolt Socket bolt Socket bolt Boom spool sub

40 4 4 5 1

13-17 (9.6-12.5)

551 552 556 562 563

Plug Plug Plug O-ring Plug

13 2 3 2 1

302 303 304 305 306

Arm 1 spool Swing spool Bucket spool Boom conflux spool Travel spool

1 1 1 1 2

69-78 (51-58) 69-78 (51-58) 69-78 (51-58) 69-78 (51-58)

564 601 602 603 604

O-ring Main relief valve Port relief valve Port relief valve Relief valve plug assy

1 1 2 3 2

307 308 309 310 311

Travel straight spool Arm 2 spool sub P1 unload spool P2 unload spool Option spool

1 1 1 1 1

605 606 973 974 977

Overload relief valve Bypass cut valve Socket bolt Socket bolt Name plate

1 2 8 2 1

321

Spring

5

978

Rivet

2

9.8-14 (7.2-10.3)

25-34 (18-25) 98-120 (72-89) 98-120 (72-89) 25-34 (18-25)

16-18 (11.8-13.3) Loctite #262

230-260 (170-192) 130-150 (96-111) 230-260 (170-192)

69-78 (51-58) 98-120 (72-89) 140-180 (103-133) 140-180 (103-133)

24-31

24

24. COMPONENTS SYSTEM (2) Main relief valve (Two step relief) (601)

Main relief valve (Two step relief) Tightening torque N-m (lbf-ft) 69 to 78 (51 to 58)

No.

NAME

103 104 121 122 123

Plug; M27 Adjust screw C-ring Spacer C-ring

124 125 163 512 521 541 561

Q'TY

Tightening torque N-m (lbf-ft)

No.

NAME

1 1 1 1 1

562 611 613 614 621

Back up ring Poppet Stopper Piston Spring

1 1 1 1 1

Filter stopper Filter O-ring Plunger Spring

1 1 1 1 1

28 to 31 (21 to 23)

652 661 663 664 671

Adjust screw O-ring O-ring O-ring Lock nut; M14

1 1 1 1 1

Seat O-ring

1 1

46 to 52 (34 to 38)

673

Lock nut; M24

1

24-32

Q'TY

24. COMPONENTS SYSTEM (3) Over load relief valve (602,603,605)

Over load relief valve Tightening torque N-m (lbf-ft) 69 to 78 (51 to 58) 69 to 78 (51 to 58)

No.

NAME

Q'TY

Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

101 102 161 162 123

Body; M27 Plug; M27 O-ring O-ring C-ring

1 1 1 1 1

541 561 562 563 564

Seat O-ring Backup ring O-ring Backup ring

1 1 1 1 1

124 125 301 511 521

Filter stopper Filter Piston Plunger Spring

1 1 1 1 1

611 612 621 651 661

Poppet Spring seat Spring Adjust screw O-ring

1 1 1 1 1

522

Spring

1

671

Lock nut; M14

1

28 to 31 (21 to 23)

24

24-33

24. COMPONENTS SYSTEM (4) Arm 2 spool (308)

351

371

361

308

340 319

317

340

361

371

350

Arm 2 spool Tightening torque N-m (lbf-ft)

No. 308 317 319 340

NAME Spool Plunger Plunger Spring

Q'TY 1 1 1 2

Tightening torque N-m (lbf-ft)

No.

16 to 18 (33 to 35) Loctite #638 16 to 18 (33 to 35) Loctite #638

350 351 361 371

NAME Plug Plug O-ring Buckup ring

Q'TY 1 1 2 2

(5) Boom spool (301)

301

317

340

361 371 350

Boom spool Tightening torque N-m (lbf-ft)

No. 301 317 340

NAME Spool Plunger Spring

Q'TY 1 1 1

Tightening torque N-m (lbf-ft) 16 to 18 (12 to 13) Loctite #638

24-34

No. 350 361 371

NAME Plug O-ring Buckup ring

Q'TY 1 1 1

24. COMPONENTS SYSTEM (6) Lock valve selector (211)

101 164

171

201

321 PLc

A

166

B

Dr

541 167 511

Lock valve selector

Tightening torque N-m (lbf-ft)

No. 101 161 164 166 167

NAME Casing O-ring O-ring O-ring O-ring

Q'TY 1 4 1 1 1

161

Tightening torque N-m (lbf-ft) 10 to 14 (7.4 to 10.3) 49 to 59 (36 to 44)

No.

NAME

171 201 321 511 541

Socket bolt Plug Spring Spool Sleeve

Q'TY 3 1 1 1 1

24

24-35

24. COMPONENTS SYSTEM (7) Bypass cut valve (606) 202

301

P

T

Dr

102

101

201

Bypass cut valve Tightening torque N-m (lbf-ft) 98 to 120 (72 to 89) 25 to 29 (18 to 21)

No.

NAME

Q'TY

Tightening torque N-m (lbf-ft)

101 102 201

Plug O-ring Adjusting screw

1 1 1

25 to 29 (18 to 21)

24-36

No. 202 301

NAME O-ring Lock nut

Q'TY 1 1

24. COMPONENTS SYSTEM (8) Swing shuttle valve cover (204)

Swing shuttle valve cover Tightening torque N-m (lbf-ft)

No. 166 202 541

NAME O-ring Cover Steel ball

Tightening torque N-m (lbf-ft)

Q'TY 1 1 1

25 to 29 (18 to 21) 7.9 to 9.8 (5.9 to 7.2)

No. 542 554 555

NAME Seat Plug Plug

Q'TY 1 1 1

24

24-37

24. COMPONENTS SYSTEM (9) Boost check valve (517)

104

107 102

101

Boost check valve Tightening torque N-m (lbf-ft)

No. 101 102

NAME Poppet Poppet

Q'TY 1 1

Tightening torque N-m (lbf-ft) 20 to 29 (15 to 21) Loctite #262

24-38

No. 104 107

NAME Plug Spring

Q'TY 1 1

24. COMPONENTS SYSTEM 24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM (P6)

P1

PL PTb

(P5)

T1

T2

P2

CT1

CMR1

CMR2 PBL

Travel straight PCb

PAL

P1 unload CT2

CP2

(T3)

Travel right

PAr

PCa CP1

Br Ar PBr

Boom conflux P2 unload

PB1 CCb PBs

Dr LCs

LCb

Boom

Travel left

AL BL

Pss

PAb

PAs

Swing

As Bs (ROD) Bb

PBa1 CRb

LCa

(HEAD) Ab PAa1

Arm 1

PBb Aa (HEAD)

LCc

Bucket

PAc

CRa PLc2

(ROD) Bc (HEAD) Ac

Ba (ROD)

PCc PBc

LCAT2 LCo

LCAP2

Arm 2

PAa2

PAo

Option

Ao Bo PBo

PBa2 MU

Hydraulic circuit diagram

24

24-39

24. COMPONENTS SYSTEM 24.1.2.2.3 OPERATION (1) In neutral position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to failure of the electric control system, because the by-pass cut valve (606) located on the downstream of the center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though the center by-pass passage (52) which passes through the travel right, boom, bucket and arm 2 and the by-pass cut valve (606) on the P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (606) located on the downstream of the center by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port passes through the main passage, and then flows though the center by-pass passage (55), which passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into the low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

! "! #! "# $ # % # &

In neutral position

24-40

24. COMPONENTS SYSTEM (2) Actuation in travel operation 1. In travel independent operation On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into the travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into the travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (323) and (324), and the secondary pressure of the solenoid proportional valves [X1] and [X2] act on ports PCb and PCa and switch the unloading spools (309) and (310).

The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into the main circuit, and flows between the perimeter of the right travel spool (306) and casing and is fed into the A side of the right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2 flows through the perimeter of the left travel spool (306) and casing and is fed into the A side of the left travel motor through port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump P1.

But in the meantime, the return oil from the B sides of left and right travel operations passes through the perimeter of the right and left travel spools (306) and casing through ports Br and BL and flows into the low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. When reverse traveling (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation.

In left reverse travel (at PBL is pressurized)

24

24-41

24. COMPONENTS SYSTEM 2. In travel straight operation When actuating other operations than the travel operation and the travel operation and other operation are operated simultaneously in the said item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward.

With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into the main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel straight spool (307) closes and the pump line on the travel side is independent from pump line on actuator.

Movement of travel straight spool

24-42

24. COMPONENTS SYSTEM (3) Actuation in bucket operation 1. In bucket digging operation On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309).

The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).

In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.

And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is low, the pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation, the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may occur on bucket cylinder head side (H). (Stroke limiter ON) 53 216

PAc

PCc

PBc

Bc 321 322

Ac

LCc

(D) 304

511

(R)

(H)

In bucket digging operation (Stroke limiter ON)

24

24-43

24. COMPONENTS SYSTEM 2. In bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and the bucket spool (304) moves rightward from the force of springs (321) and (322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through a U-shaped passage, and is supplied to the bucket cylinder rod side (R) through port (Bc).

In the meantime, the return oil from the bucket cylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through the low pressure circuit (D), and returns to the hydraulic tank through tank port T1. The return oil does not pass through boost check valve (517). Downstream of boost check valve.

! " #"

In bucket dumping operation

24-44

24. COMPONENTS SYSTEM (4) Boom 1. In boom up operation On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward against the force of springs (321) and (322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCa and switches unloading spool (309).

And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spools (310).

The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through a U-shaped passage, and is supplied to the bucket cylinder head side (H) through port (Ab).

In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of boom spool (301) and casing, flows through the low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.

In boom up operation (Boom spool)

24

24-45

24. COMPONENTS SYSTEM 2. In boom up conflux operation The hydraulic oil delivered by hydraulic pump P2 passes through the travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of a U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and receives the hydraulic oil from the hydraulic pump P1 side.

In boom up conflux operation (Boom conflux spool)

24-46

24. COMPONENTS SYSTEM 3. In boom down operation On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (321) and (322) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches the unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of the lock valve poppet CRb (514) is connected to the drain circuit.

The hydraulic oil delivered by hydraulic pump P1 flows into the parallel passage (53), and pushes and opens the load check valve LCb (511), and flows through between the perimeter of the boom spool (301) and casing through a U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).

In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab).

Because the retention of the lock valve poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters the BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows through the low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. A part of the return oil flows into the inside of boom spool (301) through the circular notch of the boom spool (301). Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through the inside passage of the boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then is supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)

In boom down operation

24

24-47

24. COMPONENTS SYSTEM (5) Arm operation 1. In arm out operation On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves rightward against the force of springs (321) and (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).

And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321) and (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309).

The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into AR chamber between the perimeter of arm 1 spool (302) and the casing through a U-shaped passage.

In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters the U-shaped passage, and pushes and opens load check valve LCAP2 (515) provided with an orifice, and flows into the U-shaped passage. And then the hydraulic oil flows between the perimeter of arm 2 spool (308) and the casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side.

The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R).

In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D') and casing inside passage (HH) and then flows into the low pressure circuit (D') between the perimeter of arm 2 spool (308) and the casing.

The return oil in the low pressure circuit (D') returns to the hydraulic tank through tank port T1 without passing through boost check valve (517).

)

'

(

'(

In arm out operation

24-48

! "

!#" $ %$ & "&

24. COMPONENTS SYSTEM 2. In arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves leftward against the force of springs (321) and (322), and simultaneously the secondary pressure of the solenoid proportional valve [X2] acts on port PCa and switches the unloading spool (310). At the same time, since the spool in the lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is released.

And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm 2 spool (308) moves leftward against the force of springs (321) and (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I).

The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into port (Aa) between the perimeter of arm 1 spool (302) and the casing through Ushaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through the center bypass passage (52) and pushes and opens load check valve LCAT2 (511) and enters the U-shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2 (515) provided with an orifice and flows into the U-shaped passage. And then the hydraulic oil flows between the perimeter of arm 2 spool (308) and the casing from the U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side.

The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).

In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).

Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302).

The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and the casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into the casing inside passage (HH) and is supplied to arm cylinder head side (H) again. (Arm recirculation function) And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through tank port T1.

(R) AR 322 321 chamber 514 211 CRar 511 LCa Ba

(H)

302

Aa

56 PBa1

PAa1

P1 (D') (D)

Arm 1

LCAT2

(D') (D)

RR 52

RH

LCAP2 P1 PBa2 Dr

PAa2 Dr

HH

Arm 2 (a) PAa2 [XR]

PBa2 53 MU

328 321

To arm 1 spool Aa (HEAD) Ba (ROD) To pilot cut valve

Circuit (I) 317 515

308319(D)511 LCAT2 LCAP2

In arm in operation (At light load: arm recirculation function)

24-49

24

24. COMPONENTS SYSTEM 3. In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (aU), almost all the return oil passes through between the perimeter of arm 2 spool (308) and the casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1.

The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and the casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.

(R) AR 322 321 chamber 514 211 CRar 511 LCa Ba

(H)

302

Aa

56 PBa1

PAa1

P1 (D') (D)

Arm 1

LCAT2

(D') (D) RR 52

Arm 2

RH

LCAP2 P1 PBa2 Dr

PAa2 Dr

HH

(a) PAa2 [XR] Ba

PBa2

To arm 1 spool Aa (HEAD)

(ROD)

53

To pilot cut valve

MU 328 321

Circuit (II)

308 (D) 319 511 LCAT2 LCAP2

515

317

In arm in operation (In heavy load operation)

24-50

24. COMPONENTS SYSTEM (6) Swing operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) and (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).

At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss. The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through the U-shaped passage and is supplied to the swing motor A side or B side through port (As) or (Bs).

In the meantime, the return oil from the swing motor A side or B side passes through between the perimeter of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

Swing operation

24

24-51

24. COMPONENTS SYSTEM (7) Spool actuation for operation in option This spool is used to control the attachment in option like Nibbler (Crusher), etc.

Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (323) and (324), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).

The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and the casing through the U-shaped passage and is supplied to the actuator for attachment through port (Ao).

In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option spool (311) and the casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

The operation where the pilot pressure acts on PBo port is the same as the above. * The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil passage is used as passage to connect to the N&B selector valve.

Spool actuation for operation in option

24-52

24. COMPONENTS SYSTEM (8) Lock valve operation The lock valve is housed in between each port of the control valve connected to the arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder.

1. At boom spool neutral position (Arm spool makes the same operation.)

When the boom spool (301) is set to the neutral position, spool (511) in lock valve selector is held on the left side as shown in the figure. At this position, passages Sa and Sb are connected to each other at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed to the lower side as shown in the below Fig. and restricts the leaking to a minimum.

% & ' ( ) ) * '&+ , +

!"# $

Lock valve operation (At boom spool neutral position)

24

24-53

24. COMPONENTS SYSTEM 2. In boom down operation (In arm in operation) Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the below Fig. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked; therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).

And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR through spring chamber (321).

With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as shown in the below Fig. is released. And since lock valve poppet (514) receives holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open.

The said operation, in boom down operation, is performed before making the opening (meter out opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the operation has no effect on the operability of boom down operation.

In case of arm-in operation, the operation is the same.

Return oil from boom cylinder head

RH CHAMBER 514

Lock valve selector BH CHAMBER

511

541

Sb CRb

PLc Dr

Ab

(a) A

(b)

PLc Sa Sb

A

321 Dr

SECTION A-A Sa

321

322

PBb

(D) 301 Dr

Lock valve selector operation (At boom down operation)

24-54

24. COMPONENTS SYSTEM (9) By-pass cut valve This by-pass cut valve is located on the most downstream of P1 side center by-pass passage (52) and P2 side center by-pass passage (55). This by-pass cut valve controls the flow of hydraulic oil from each center by-pass passage to low pressure passage (D).

1. In normal operation Adjusting screw (201) is tightened up to end in normal operation. Tapered end of adjusting screw (202) is seated on the seat of casing, and flow between center by-pass passage (52) and low pressure passage (D) is blocked.

Consequently, in normal operation, center by-pass passage (52) is always blocked from low pressure passage (D). And the hydraulic oil delivered by pump P1 does not flow through center by-pass passage (52), but returns to hydraulic tank through P1 unload spool (309).

201

Dr

(D)

52

By-pass cut valve (In normal operation)

24

24-55

24. COMPONENTS SYSTEM 2. At the time when failure occurred When the electric system is failed, P1 unload spool (309) stops at neutral position. Hydraulic oil entered from the P1 pump is blocked with the P1 unload spool (309). And pump pressure rises to the set pressure of the main relief valve because oil flows through the center by-pass passage (52) and it is blocked with the by-pass cut valve (606).

Meanwhile, the hydraulic oil flows from the center by-pass passage (52) low pressure passage (D) through bypas cut valve (606).

Therefore when the electric system is failed, the P1 unloading spool (309) is shifted to the neutral position. And the low pressure passage (D) is blocked, but because the center by-pass passage (52) is connected to the low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.

201 301

Dr

(D)

52

By-pass cut valve (In condition of failure)

24-56

24. COMPONENTS SYSTEM (10)Boost check valve, By-pass check valve 1. Boost check valve The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage. a. In normal operation The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure generated by spring (527) is used as the boost pressure for the low pressure passage.

But the return oil used for the arm out and bucket dumping operation does not pass through boost check valve (517), but returns from low pressure passage (D) to hydraulic tank through tank port T1. b. In make up operation When supplying to make up the flow rate through low pressure passage (D) after the swing operation is suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic oil is made up from the hydraulic tank into low pressure passage (D).

When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving section in the ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make up the deficient flow rate.

Boost check valve operation

24-57

24

24. COMPONENTS SYSTEM 2. By-pass check valve Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage.

When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2.

527

528 (D')

T2

518 T1

102

517

(D)

By-pass check valve operation

24-58

24. COMPONENTS SYSTEM 24.1.3 PILOT VALVE (ATT)

24

24-59

24. COMPONENTS SYSTEM

24-60

24. COMPONENTS SYSTEM

24

24-61

24. COMPONENTS SYSTEM

24-62

24. COMPONENTS SYSTEM 24.1.4 PILOT VALVE (TRAVEL)

24

24-63

24. COMPONENTS SYSTEM

24-64

24. COMPONENTS SYSTEM 24.1.5 SWING MOTOR UNIT 24.1.5.1 SPECIFICATION (1) General view

Port name

Symbol

Port size

Tightening torque N.m (lbf.ft)

A,B

Main port

PF3/4

167 (123)

DB

Drain port

PF3/8

74 (55)

M

Make-up port

PF3/4

167 (123)

PA,PB Pressure measuring port PF1/4 PG

36 (27)

Parking brake release port PF1/4

36 (27)

L

Gear oil level gauge

PT1/2

65 (48)

IP

Gear oil filling port

PT3/4

98 (72)

M

PB

L

THREAD FOR EYE BOLT 2-M12 DEPTH 24 RELIEF VALVE (B PORT SIDE)

B

(SH)

IP PR RELIEF VALVE (A PORT SIDE)

A

DB PA

PB A,(B)

PR PR

PA ANTI-REACTION VALVE BLOCK M DB

IP FILLING PORT PT3/4

DB

M

PA

PB

A

Grease fitting

B

Hydraulic diagram

24

24-65

24. COMPONENTS SYSTEM (2) Specifications Swing motor unit part No. Hydraulic motor

YN15V00054F1 Type

M5X130CHB-10A-89B/295

Part No.

Anti-reaction valve block

Displacement Working pressure

MPa (psi)

Max. flow

L/min (gal/min)

220 (58)

Braking torque

N-m (lbf-ft)

655 (483)

Release pressure

MPa (psi)

2.5~5.0 (362~725)

Relief set pressure

MPa (psi)

29 (4205)

Weight

kg (lbs)

49 (108)

(in3)

Type Weight

Hydraulic motor assy weight Reduction unit

YN15V00055F1 cm3

32.4 (4700)

2KAR6P72/240-712 kg (lbs)

2.5 (5.5)

kg (lbs)

51.5 (114)

Part No.

YN32W00025F1

Speed reduction type

Planetary 2-stage

Reduction ratio

15.378

Lubicate oil Lubicate oil volume

Gear oil SAE90 (API class GL-4 grade) L (gal)

Grease

Total weight

129.2 (7.88)

2.7 (0.7) Extreme pressure lithum base #2 grease

Grease volume

kg (lbs)

Approx. 0.7 (1.5)

Weight

kg (lbs)

134 (295)

kg (lbs)

Approx. 185.5 (409)

24-66

24. COMPONENTS SYSTEM 24.1.5.2 CONSTRUCTION (1) Swing motor 993 VALVE CASING SECTION

702 712

ANTI CAVITATION PLUNGER

Arrangement of brake spring

351 355

051 RELIEF VALVE

469 051-1 488 401

ANTI-REACTION VALVE BLOCK

052 162

303

151 171 161 163 A

A

985

444

984

131

451 390 391

985

VIEW I

712 472 702 707 100 980 743 706 742 400-1 400-2

111

052

400 121

994

123 114 122

124

443 491

101

24-67

301

SECTION A-A

24

24. COMPONENTS SYSTEM

Tightening torque N-m (lbf-ft)

No.

177 (130)

051

36 (27)

29 (21)

Q'TY

Tightening torque N-m (lbf-ft)

No.

Relief valve; M33-P1.5

2

69 (51)

400

051-1 O-ring; 1B G30 052 Anti-reaction valve sub 100 Casing for anti-reaction valve 101 Drive shaft

2 1 1

NAME

431 (318)

NAME

Anti-reaction valve; M22-P1.5 400-1 O-ring; 1B P20 400-2 Backup ring 401 Socket bolt; M20X45

Q'TY 2 2 2 4

1

443

Roller bearing

1

444 451 469 472 488

Roller bearing Pin ROMH plug; M30-P1.5 O-ring; W1516,WG40 O-ring; 1B P28

1 2 2 1 2

111 114 121 122 123

Cylinder Spring plate Piston Shoe Set plate

1 1 9 9 1

124 131 151 161 162

Shoe plate Valve plate Plug; PF1/4 O-ring; 1B P11 O-ring; 1B P12

1 1 2 2 2

491 702 706 707 712

Oil seal Brake piston O-ring; W1516,WG38 O-ring; W1516,WG41 Brake spring

1 1 1 1 18

163 171 301 303 351

O-ring; 1B P6 Socket bolt; M8X55 Casing Valve casing Plunger

2 4 1 1 2

0.9 (0.66) 1.7 (1.2) 4.4 (3.2)

742 743 980 984 985

Friction plate Separator plate Plug; PF1/4 Plug; PF3/8 Plug; PF3/4

3 4 1 1 3

355 390 391

Spring Name plate Rivet

2 1 2

65 (48) 98 (72)

993 994

Plug; PT1/2 Plug; PT3/4

1 1

334 (246)

24-68

24. COMPONENTS SYSTEM (2) Swing reduction unit TAKE CARE OF INSTALLING DIRECTION OF RING RETAINING APPLY THREE BOND #1211

PAINT THIS PLANE.

APPLY LOCTITE #515 APPLY LOCTITE #515

TIGHTENING TORQUE 181N.m (134 lbf.ft) APPLYING THREE BOND 1360K.

12

10 20

8 4

7 6

23 OIL FILLING PORT PT3/4

A

2 LEVEL PORT PT1/2

A II 1

9 22 18 17 5

21 29 11

18 14 3 16 15 28

19 TAKE CARE OF INSTALLING DIRECTION OF RING RETAINING

INSERT 1mm DEEP FROM THE SURFCE OF ITEM 8 (SPIDER).

LUBRICATE GREASE

13

27

26

25

TIGHTENING TORQUE 69.1N.m (51.0 lbf.ft) USE SEAL TAPE OR APPLY LOCTITE #577

30 31

WRAP THE SEAL TAPE OR APPLY THE LOCTITE #577 AROUND THE SCREW.

INSTALL NIPPLE GRASE TO WARD TO MOTOR SIDE. PUNCH HERE 2 PORTIONS NEAR HOLE, TO PREVENT ITEM 22 (PIN, SPRING) COMING OUT.

TAKE CARE OF INSTALLING DIRECTION OF PIN, SPRING

VIEW II 4PLACES

24

SECTION AA

24-69

24. COMPONENTS SYSTEM

Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

Tightening torque N-m (lbf-ft)

No.

NAME

Q'TY

1

Pinion shaft

1

16

Needle bearing

102

2

#1 sungear

1

17

Needle bearing

4

3

#1 pinion

3

18

Washer

8

4

#2 sungear

1

19

Retaining ring

1

5

#2 pinion

4

20

Retaining ring

1

6

Ring gear

1

21

Sleeve

1

7

Spider assy

1

22

Spring pin

4

8

Spider

1

23

Capscrew; M14X130

11

9

Shaft

4

25

Tube L=130

1

10

Spherical bearing

1

26

Elbow

1

11

Spherical bearing

1

27

Plug

1

12

Oil seal

1

28

Retaining ring

3

13

Housing

1

29

Oil seal

1

14

Thrust Washer

3

30

Grease fitting

1

15

Thrust Washer

3

31

Plug

1

24-70

181 (134)

69.1 (51)

24. COMPONENTS SYSTEM 24.1.5.3 OPERATION 24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR If the high pressure oil flows into the cylinder through the inlet port (a) of valve plate (131), as shown on the figure on the right, the hydraulic pressure acts upon piston (121) and creates force F in the axial direction.

The force F may be divided into force F1 vertical to shoe plate (124) via shoe (122) and force F2 at right angles with the shaft.

The force F2 is transmitted to cylinder block (111) via pistons (121) and causes drive shaft to turn so as to produce a rotating moment.

The cylinder block (111) has nine pistons equally arranged. Rotating torque is transmitted to drive shaft by turns by pistons connected to inlet port of high pressure oil.

If the oil supply and discharge directions are reversed, the drive shaft rotates in the opposite direction.

Theoretical output torque T can be given by the following equation.

Cylinder block (111)

F2 F1 F

Drive shaft (101)

Valve plate Shoe

Shoe

Piston

plate

(122)

(121)

(124)

T=

P X q P ; Effective differential pressure MPa 2X q ; Displacement per revolution cc/rev

Low pressure oil

OUTLET

(131)

High pressure oil

INLET

(a)

Operation of hydraulic motor

24

24-71

24. COMPONENTS SYSTEM 24.1.5.3.2 VALVE CASING SECTION (1) Operation of anti-cavitation check plunger Since the system using this type of motor is not equipped with a valve having a counterbalance function, the motor is rotated beyond the oil feed rate in some cases.

The system has check plunger (351) and sucks in deficient oil, in order to prevent cavitation from occurring due to oil deficiency.

351

M port

(Make-up port)

DIRECTIONAL VALVE Operation of anti-cavitation check plunger (2) Operation of relief valve 1. Consider where the relief valve is pressurized.

The pressure at the P and R ports is equal to the tank pressure at the beginning, as shown in below Fig. The relief valve begins to operate when the hydraulic pressure that is determined by the product of the pressurereceiving area A1 of plunger (301) and the pressure P balances the hydraulic pressure that is determined by the product of the pressure-receiving area A2 of the plunger (301) and the pressure Pg of chamber g.

Thereafter, the pressure of chamber g rises and the piston 1 (302) begins to stroke. The load to spring (321) increases by this movement of the piston.

As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1 till Ps. This process is explained in the following in the relationships between the movements of the components shown in (2) to (4) in below Fig. and the relief pressure:

Orifice m

Spring (321)

Chamber h Piston I (302)

Orifice m

P

Spring (321)

Chamber h Pin (303) Piston I (302)

P

Pressure R receiving Plunger(301) area A1

Chamber g

A3 A2 Orifice n

R

A4

Plunger(301)

Functional explanation of relief valve (1)

Orifice n Chamber g

Functional explanation of relief valve (2)

a. Condition shown in above Fig. If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor m of plunger (301).

The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of spring (321), the relief valve performs relieving action by the pressure P1.

This relationship is expressed as: P1XA1=FSP1+Pg1XA2 where FSP1: primary set load value of spring (321)

24-72

24. COMPONENTS SYSTEM b. Condition shown in below Fig. The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the left.

On this occasion, since the machine turns to the left while discharging the oil of chamber h arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston 1 (302), chamber h serves as a dumping chamber.

The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief pressure P rises smoothly.

Orifice m

Spring (321)

Orifice m

Chamber h Pin (303) Piston I (302)

P

Spring (321)

Pin (303) Piston I (302)

P R

Plunger(301)

Orifice n

R

Plunger(301)

Chamber g

Functional explanation of relief valve (3)

Orifice n Chamber g

Functional explanation of relief valve (4)

c. Condition shown in above Fig. The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust plug (401).

Therefore, the relief valve keeps its normal relieving action whereby the relief pressure is held at P2. In the processes 1 to 3 above, the relief pressure changes as shown in above Fig.

(4)

PS (3) (2)

P1 (1)

t1 Condition 2. Function when the relief valve pressure is reduced Let us consider the pressure of the P port is reduced.

When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank pressure level. The result is that the plunger (301) which is now open moves to the left and is seated on seat (341). At the same time, the piston 1 (302) moves to the right by the action of spring (321) and returns to the condition of above Fig.

24

24-73

24. COMPONENTS SYSTEM (3) Operation of anti-reaction valve

Hydraulic circuit diagram for anti-reaction valve.

1. Neutral condition: Above Fig. illustrates the relationship between the neutral condition of the anti-reaction valve and the hydraulic circuits. Now, let us consider a braking condition in which brake pressure generates on the AM port side.

L

k 322

321

313

311

Neutral condition 2. When brake pressure occurs: If pressure (P) generates at the AM port, it passes through the passage L, the hole on the shaft of seat (313) and the passage m of plunger (311) and is led to the n chamber.

When the pressure P rises above a value (Ps) set by spring (321), plunger (311) compresses spring (321) and shifts it to the left.

Seat (313) compresses weak spring (322) as pushed by plunger (311) and moves to the left.

m

n

P=PS L

322

313

321

When brake pressure occurs

24-74

311

24. COMPONENTS SYSTEM 3. At anti-reaction action When inertia load stops moving (point Y below Fig.), brake pressure (P) tries to fall.

When P<Ps, plunger (311) moves toward the right return side by the action of spring (321). Seat (313) tries to move to the right by the action of spring (322), but since chamber p provides damping action by orifice g, the return of the seat makes a time delay with regard to the return of the plunger.

Consequently, seat t opens. This makes a passage connecting the AM port and BM ports or both ports of the hydraulic motor by way of L-->t-->r-->k. The result is that the pressures at the AM and BM ports become equal (Pb), falling into the condition at point Z in below Fig..

This prevents the hydraulic motor from swing shock by the closing pressure of the AM port. p

t

P

Y

PS P<PS PB

L

X Z T

k 322 313

g

r

321

Pressure change diagram of anti-reaction operation

311

At anti-reaction action 24.1.5.3.3 OPERATION OF BRAKE SECTION The cylinder (111) is jointed by drive shaft (101) and a spline. Separator plate (743) is fixed in its circumferential direction by circular grooves provided in casing (301).

Now, if the friction plate (742) splined to the outer circumference of the cylinder is pressed against casing (301) via separator plate (743) and brake piston (702) by the action of brake spring (712), frictional force is created between friction plate (742) and casing (301) and between separator plate (743) and brake piston (702). The frictional force bounds the drive shaft to brake the motor.

In the meantime, when brake release pressure applied to the oil chamber formed between brake piston (702) and casing (301) overcomes the spring force, the brake is released as brake piston (702) moves till friction plate (742) is separated from casing (301).

712

702 712

743

702

742

111

301

743

742

301

101

Operation of swing brake

24

24-75

24. COMPONENTS SYSTEM 24.1.5.3.4 SWING REDUCTION UNIT The swing reduction unit is used to reduce the rotating speed which is transmitted by the hydraulic motor and to convert it to the strong turning force (torque).

This swing speed reduction unit is equipped with planetary speed reducing mechanism.

The planetary mechanism is made up of sun gear, planetary pinion, planetary shaft, spider and ring gear, as shown in right Fig.

Ring gear (Fixed)

Planetary shaft

Spider

Sun gear

Planetary pinion

Planetary mechanism For the operation of the 1st stage planetary, the hydraulic motor rotates #1 sun gear (2). Sun gear (2) is engaged with planetary pinion (3) and rotates, but since ring gear (6) is fixed, planetary pinion (3) revolves about sun gear (2) with the planetary shaft and spider (7).

The role of spider is to hold the planetary pinion and planetary shaft and transmits the power from the planetary pinion to the spider through the planetary shaft.

The #1 spider (7) is linked with #2 sun gear (4) by the involute spline, and transmits the power to the 2nd stage planetary mechanism.

For the operation of the 2nd stage planetary, the power is transmitted to sun gear (4)-->planetary pinion (5)->spider (8) similarly to the 1st stage. The #2 spider (8) is linked with pinion shaft (1) by the involute spline, and pinion shaft (1) is engaged with the swing gear fixed on the undercarriage (lower frame) and rotates.

Swing motor 3

2

7 4 8 13 5

10

11

1 Function of reduction unit

24-76

6

24. COMPONENTS SYSTEM 24.1.6 TRAVEL MOTOR

24

24-77

24. COMPONENTS SYSTEM

24-78

24. COMPONENTS SYSTEM

24

24-79

24. COMPONENTS SYSTEM

24-80

24. COMPONENTS SYSTEM

24

24-81

24. COMPONENTS SYSTEM

24-82

24. COMPONENTS SYSTEM

24

24-83

24. COMPONENTS SYSTEM

24-84

24. COMPONENTS SYSTEM

24

24-85

24. COMPONENTS SYSTEM

24-86

24. COMPONENTS SYSTEM

24

24-87

24. COMPONENTS SYSTEM

24-88

24. COMPONENTS SYSTEM

24

24-89

24. COMPONENTS SYSTEM 24.1.7 SWIVEL JOINT

24-90

24. COMPONENTS SYSTEM

24

24-91

24. COMPONENTS SYSTEM 24.1.8 CYLINDER

24-92

24. COMPONENTS SYSTEM

24

24-93

24. COMPONENTS SYSTEM

24-94

24. COMPONENTS SYSTEM

24

24-95

24. COMPONENTS SYSTEM

24.2

ELECTRICAL EQUIPMENT

24.2.1 ELECTRICAL EQUIPMENT LIST Group

Code

Part Name

Part No.

-

Mechatro controller

YN22E00425F1

-

Gauge cluster

YN59S00028F3

-

Fuse and Relay box

YN24E00016F3

-

Hour meter

LQ58S00002P1

-

Tuner AM / FM

LQ54S00003S004

-

Speaker left

LQ54S00003S002

-

Speaker right

-

Socket

YN81S01002P1

-

Accel redundant volume

YN52S00052P1

(M) Motor

-

Wiper motor

LQ53C00003S001

(P) Proportional solenoid valve

-

P1 pump propo. valve

-

P2 pump propo. valve

-

Safety relay

-

Horn relay

↑

-

Working light relay

↑

-

Flasher relay

YY24S00001P2

-

Auto idle stop relay 1

YN24S00010P1

-

Auto idle stop relay 2

↑

-

Engine emergency stop relay

↑

-

Lever lock relay

↑

-

Alternator relay

↑

-

Wiper motor relay (Normal rotation)

-

Wiper motor relay (Reverse rotation)

↑

-

Washer motor relay

↑

-

Pressure sensor

LC52S00019P1

-

Accel potentiometer

LQ52S00025P1

-

Key switch

YN50S00026F1

-

Swing parking brake release switch

YN50S00047P1

-

Work light switch

YN50S00040D1

-

Heavy lift switch

YN50S00040D5

-

Independent travel switch

YN50S00040DB

(C) Controller

(E) Electric fittings

(R) Reray

(SE) Sensor

(SW) Switch

↑

(YN10V00036F2) Pump

YN35V00052F2 ↑ YN24S00010P1

The part number may be changed for modification, use part numbers for reference only.

24-96

YN24S00012P2

24. COMPONENTS SYSTEM 24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT Code No. Parts Name Parts No. Use Applicable Machine -

Specifications

Maker

Sinko Electric Co. Ltd

Rated voltage Controller

Description

DC24V

Weight

4.0 kg (8.8 lbs)

Maker

Nippon seiki Co., Ltd

YN22E00425F1 Mechatro controller YN13 -

-

Rated voltage Controller

Insulation

DC24V More than 3M at 500V megger

YN59S00028F3 Gauge cluster YN13 -

-

Fuse capacity and circuit

Fuse & Relay box

24

YN24E00016F3 Fuse & Relay YN13 -

Front side of machine

24-97

24. COMPONENTS SYSTEM Code No. Parts Name Parts No. Use Applicable Machine Hour meter

Specifications

Movement Operating voltage

Description

Quarts 9~64VC

LQ58S00002P1 Service meter YN13 -

Tuner

TERMINALS TO ACCEPT GM TERMINAL 2962447 AND GM CONNECTOR 2962447 EQUIVALENT

Maker Part name

PRESS KOGYO CO., LTD. AM/FM radio

Maker Part name

PRESS KOGYO CO., LTD. Speaker

Model

347-0385-00010

TERMINAL

TERMINAL ENABLE TERMINAL

LQ54S00003S004 Radio (AM & FM) YN13 -

Speaker (L/R) LQ54S00003S002 Radio YN13 -

-

Rated voltage Socket

Max. current

DC 12V 10A COVER SOCKET

YN81S01002P1 TERMINAL, ERATH

Cigarette lighter

PLUS TERMINAL

YN13 -

WELD DEPOSIT

SOCKET ASSY

WELD DEPOSIT

OPERATING DIRECTION CASE

24-98

24. COMPONENTS SYSTEM Code No. Parts Name Parts No. Use Applicable Machine Accel redundant volume

Specifications

Rated voltage

Description

Resistance 2

DC 5V

Resistance 2 TOCOS RA30YME20FB202

Parts E-27

YN52S00052P1

After soldering, insulate this part with heat shrinkable tube

Accel redundant volume

Clip Adhesive

YN13 Fix this resistance with tape PVC tube (Black)

Dial

-

Maker Part name

HOUSING : 172131-5 TERMINAL : 170340-1

VIEW I

PRESS KOGYO CO., LTD. Wiper motor

Motor LQ53C00003S001 Wiper motor YN13 -

-

Maker

Tyco Electronics

Maker's p/No. Relay YN24S00010P1

V23074-A2002-A403

Type

Micro relay A

Rated voltage Contact

Safety relay Horn realy Work light relay Auto idle stop relay 1, 2 Engine emergency stop relay Lever lock relay Alternator relay

DC 24V 1C

* Accessory of relay box

Pin assignment

YN13 -

24 Terminal arrangement

24-99

24. COMPONENTS SYSTEM Code No. Parts Name Parts No. Use Applicable Machine

Specifications

Description

UPPER

Relay YY24S00001P2 Flasher relay YN13 TERMINAL NUMBER

-

Maker's P/No.

V23134-A0053-C643

Parts name Relay YN24S00012P2

Relay

Rated voltage

DV 24V

Contact

1C

* Accessory of relay box Wiper motor relay Washer motor relay

Pin assignment

YN13 -

Pressure sensor (Low pressure)

Pressure range

0~3MPa (435 psi)

Rated voltage

5+0.5V DC

Insulation resistance

50M or more /DC50V megger

LC52S00019P1 Swing

YN13 -

TERMINAL No. CONNECTION

1

COM

2

OUTPUT(+)

3

POWER(+)

HEX 19

O-RING 1B P11

-

PF1/4

Total resistance value Effective electric angle

Potentio meter

AMP MQS TYPE CONNECTOR 3P (B TYPE) OPPOSITE CONNECTOR (FEMALE) HOUSING : 2-967642-1 TERMINAL : 965906-5 (GOLD PLATED) HARNESS SEAL : 967067-1

113

LQ52S00025P1 A

Accel dial YN13 -

BLACK RED

YELLOW CONNECTOR (AMP) CAP HOUSING : 174359-2 TAB : 171661-1 RUBBER PLUG : 172888-2 DOUBLE LOCK PLATE : 1-174360-1

24-100

VIEW A

24. COMPONENTS SYSTEM Code No. Parts Name Parts No. Use Applicable Machine Solenoid YN35V00052F2 Pump P1, P2 proportional valve YN13 -

Specifications

Description

KDRDE-5K 13.7MPa (1987 psi) Max. feed press 5.0MPa (725 psi) Rated feed press 1MPa (145 psi) Allowable back press Control pressure range 0~2.7MPa (392 psi) DC 24V Rated voltage Type

AMP MARK II HOUSING : 174354-2 TERMINAL : 173706-1

Retaining ring Spool

Spring

HEX 10 T=7.4N.m (5.5lbf.ft)

O-ring Sleeve

O-ring O-ring

O-ring Solenoid 1B P20

Seal nut

Auto return

Connection Switch

Terminal Position

Auto return

YN50S00026F1 Starter switch

VIEW A

Terminal arrangement

YN13 -

Switch

Type

ST110D

Rated

DC30V, 10A

Insulation tape R B W

Insulation resistance

YN50S00047P1 Swing parking brake release YN13 -

Vinyl tube T No. Contact construction : Position Swing parking release

Red (2)

YAZAKI 7122-2237 7114-2020

Normal White (3)

Switch

Rated voltage

DC 24V

Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger

YN50S00040D1 Work light switch

Terminal connector Connector

YN13 -

Blue (1)

Position

24-101

24 UP

24. COMPONENTS SYSTEM Code No. Parts Name Parts No. Use Applicable Machine Switch

Specifications

Rated voltage

Description

DC 24V

Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger

YN50S00040D5 Heavy lift switch YN13 -

Switch

Terminal connector Connector Position

Rated voltage

DC 24V

Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger

YN50S00040DB Independent travel switch YN13 -

UP

Terminal connector Connector Position

24-102

UP

24. COMPONENTS SYSTEM

24.3

SELECTIVE CATALYTIC REDUCTION (SCR)

Selective Catalytic Reduction (SCR) system is an after-treatment method that cleans up emissions arising during the combustion process. A water-based urea solution, an ammonium compound, is used as reduction agent.

The urea solution (marketed under the name DEF/AdBlue®) is injected into the exhaust flow entering the catalyst, which is integrated in the muffler.

Diesel Exhaust Fluid (DEF)/AdBlue® is a non-toxic aqueous urea solution (32.5%) with a slight ammonia odor used to chemically reduce NOx emissions from heavy-duty diesel powered vehicles. DEF/AdBlue® is neither explosive nor harmful to the environment and is classified under the minimum-risk category of transportable fluids.

When the process works as it should, the ammonium in the DEF/AdBlue® solution reacts with the nitrogen oxides in the exhaust gases to form nitrogen and water. The engine can be optimized for fuel economy and the resulting NOx is cut by the catalyst.

The DEF/AdBlue® solution, which is highly corrosive, but otherwise fairly harmless, freezes at -11°C. The tubes from the DEF/AdBlue® tank to the catalyst are therefore double-skinned to allow engine coolant to heat up the tubes as well as thaw the DEF/AdBlue® tank if frozen.

The main components of the SCR system include the SCR catalyst, the DEF/AdBlue® injection unit, the DEF/ AdBlue® tank, and the DEF/AdBlue® dosing control unit.

24.3.1 EXHAUST SYSTEM SPECIFICATIONS Max back pressure (after turbo) P10 at rated power with clean system

16 kPa

Max exhaust gas temperature T10 at rated power

500°C

24.3.2 EXHAUST SYSTEM WITH SCR LAYOUT

24

P10 T10 SMC0565

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24. COMPONENTS SYSTEM 24.3.3 DEF/AdBlue® CIRCUIT SCHEME

SMC0566

24.3.4 DEF/AdBlue® CIRCUIT COMPONENTS DEF/AdBlue® Tank

Supply Module

SMC0568 SMC0567

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24. COMPONENTS SYSTEM

Dosing Module

Mixer Pipe

SMC0569 SMC0570

NOx sensor ECU

NOx sensor

SMC0572 SMC0571

24.3.5 DEF/AdBlue® INSTRUMENTATION WARNING

ATTENTION: The fuel system, exhaust after-treatment system, and engine on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only!

Your KOBELCO CONSTRUCTION machine is equipped with a warning system to inform the operator of low levels of DEF/AdBlue® solution, system malfunctions, and engine power loss that may result from the SCR exhaust emissions system.

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24. COMPONENTS SYSTEM 24.3.6 Warning symbols Engine power loss occurring

SCR failure

Engine stop

Low DEF/AdBlue® level

DEF/AdBlue®

Warning/Fault light

Stop engine light

24.3.7 DEF/AdBlue® level faults, failures and engine power loss levels Visual display warning

Indicator light

Indicator light status

Audible alarm

Description

Active

Active

DEF/AdBlue® level is less than 10 % of tank volume, refill DEF/AdBlue® and reset the system by cycling the key switch OFF then ON. No engine power loss.

Active

Active

DEF/AdBlue® level is less than 5 % of tank volume, refill DEF/AdBlue® immediately and reset the system by cycling the key switch OFF then ON. Up to 65 % torque reduction and 40 % engine speed reduction within 40 min of engine running time.

Active

Active

DEF/AdBlue® level has been empty for 60 min, refill DEF/AdBlue® immediately and reset the system by cycling the key switch OFF then ON. Up to 80 % torque reduction and 40 % rated engine speed within 30 min of engine running time.

Active

Active

Emergency re-start is active.

No engine power loss. Engine will shutdown after 30 s of continued operation. Refill DEF/AdBlue® immediately and reset the system by cycling the key switch OFF then ON.

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24. COMPONENTS SYSTEM 24.3.8 DEF/AdBlue® quality faults, failures and engine power loss levels Visual display warning

Indicator light

Indicator light status

Audible alarm

Description

Active

Active

DEF/AdBlue® quality/concentration is questionable.

Drain DEF/AdBlue® tank, clean and refill with approved DEF/AdBlue® solution.

No engine power loss.

Active

Active

DEF/AdBlue® quality/concentration is questionable 60 min after the initial warning. Drain DEF/AdBlue® tank, clean and refill with approved DEF/AdBlue® solution.

Up to 65 % torque reduction and 40 % engine speed reduction within 40 min of engine running time.

Active

Active

DEF/AdBlue® quality/concentration is questionable 220 min after the initial warning. Drain DEF/AdBlue® tank, clean and refill with approved DEF/AdBlue® solution.

Up to 80 % torque reduction within 30 min of engine running time.

Active

Active

Emergency re-start is active.

No engine power loss. Engine will shutdown after 30 s of continued operation. Contact your local authorized dealer for repair.

24.3.9 SCR system technical faults, failures and engine power loss levels Visual display warning

Indicator light

Indicator light status

Audible alarm

Description

Active

Active

SCR fault/failure detected.

Up to 25 % torque reduction within 25 min of engine running time. Contact your local authorized dealer for repair.

Active

Active

SCR fault/failure detected 90 min after the initial warning Up to 65 % torque reduction and 40 % engine speed reduction within 40 min of engine running time.

Contact your local authorized dealer for repair.

Active

Active

SCR fault/failure detected 240 min after the initial warning.

Up to 80 % torque reduction within 30 min of engine running time. Contact your local authorized dealer for repair.

Active

Active

Emergency re-start is active.

No engine power loss. Engine will shutdown after 30 s of continued operation. Contact your local authorized dealer for repair.

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24. COMPONENTS SYSTEM 24.3.10 SCR system reset symbols and validation re-start counter Visual display warning

Indicator light

Indicator light status

Audible alarm

Description

Active

Active

SCR system test in progress.

Maintain current operating conditions.

If all three validation re-starts have been used and the system has not been reset, the machine is limited to emergency re-starts only. See your local authorized dealer for repair.

24.3.11 Resetting the Selective Catalytic Reduction (SCR) system After a failure or warning has been set, the SCR system must perform automatic tests to determine if failures or warnings have been resolved. The system must perform the following actions in order to recognize the resolved failures or warnings and reset itself.

-

For DEF/AdBlue® level warnings: •

-

Key switch must be cycled OFF then ON.

For poor DEF/AdBlue® quality warnings: •

Machine must be operated for approximately 20 min at a minimum of 50% load.

- For SCR system warnings, one of the following conditions must occur, depending on the exact cause of the warning: •

Requires the machine to be operated for approximately 20 min at a minimum of 50% load to operate the SCR system.

•

Requires starting and running the engine, but does not require the SCR system to operate.

•

Requires the key switch to be cycled OFF then ON.

24.3.12 Validation re-starts Validation re-starts allow operation of the machine for up to 30 min without power loss after a poor DEF/AdBlue® quality or SCR system fault has been detected. Up to three re-starts are permitted. Re-starts are counted if either of the following conditions are met: -

Engine speed exceeds 1000 RPM

-

Engine running time exceeds 5 min

Normal operation will resume if a reset is detected within the 30 min window.

If a reset is not detected within 30 min, power loss will occur as described in the table above.

If all three validation re-starts have been used and the system has not been reset, the machine is limited to emergency re-starts only. See your local authorized dealer for repair.

24.3.13 Emergency re-start NOTE: Emergency re-starts are only enabled after the allowable number of validation re-starts have expired.

If full power loss is experienced, it may be impossible for the machine to move under its own power. Emergency restarts are available to provide the capability to move the machine.

-

Allows 30 seconds of operation without power loss.

-

After 30 seconds, the engine shuts down automatically.

-

There is no limit to the number of emergency re-starts.

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