New Holland E265B E265BLC HS Engine Hydraulic Excavator Service Manual (87731202) - PDF Download

E265B model E265BLC (HS Engine)

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. 87731202 0-1

GENERAL SAFETY INFORMATION

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:

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 our Distributor for a replacement. If you have any questions, please consult an authorized our Distributor.

(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 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.

(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 of 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 either word of "DANGER", "WARNING" and "CAUTION". 1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

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

0-2

SAFETY PRECAUTIONS

stands, capable of supporting the machine, before performing any disassembly.

The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.

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.

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.

(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.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section ; SPECIFICATIONS.

(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 to 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.

The following is a list of basic precautions that must always be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine.

(9) To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) 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.

(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 machinery.

(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.

(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.

(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.

(5) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack

0-3

(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.

(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.

(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.

(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 type of metal being welded and select 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 line 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 or paper 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.

0-4

E265B E265BLC

NHK Russia

MAINTENANCE SPECIFICATIONS

Book Code No. Distribution Year–Month

SYSTEM

S5YN0118E01 2007-9 S5LQ0221E01 2007-9 S5LQ0318E01 2007-9 S5LQ1114E01 2007-9 S5LQ1218E01 2007-9 S5LQ1314E01 2007-9 S5LQ2118E01 2007-9 S5LQ2218E01 2007-9 S5LQ2321E01 2007-9 S5LQ2418E01 2007-9 S5LQ2514E01 2007-9

Title

Index No.

OUTLINE

1

SPECIFICATIONS

2

ATTACHMENT DIMENSIONS

3

TOOLS

11

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

12 13 21

HYDRAULIC SYSTEM

22

ELECTRIC SYSTEM

23

COMPONENTS SYSTEM

24

AIR-CONDITIONER SYSTEM

25

DISASSEMBLING & ASSEMBLING

31

ATTACHMENT

32

UPPER STRUCTURE

33

TRAVEL SYSTEM

34

BY ERROR CODES

46

BY TROUBLE

47

TROUBLE DIAGNOSIS MODE

48

ENGINE

51

_

E /G TROUBLESHOOTING

DISASSEMBLING

S5YN3118E01 2007-9 S5LQ3214E01 2007-9 S5LQ3318E01 2007-9 S5LQ3418E01 2007-9 S5YN4618E02 2007-9 S5YN4718E01 2007-9 S5YN4818E01 2007-9 _

S5LQ5121E01 2007-9 _ _ _

LQ12-06001~ LL12-05001~

APPLICABLE MACHINES

0-5

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

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

The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are contained. Therefore, the order must be placed with respective formal number with due confirmation on the Parts Manual for 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 assembly mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment.

•

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

•

The Chapter "Engine" describes the engines 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.

0-6

1

1. OUTLINE TABLE OF CONTENTS 1.1

GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3

1.1.1

PREPARATION BEFORE DISASSEMBLING ..........................................................1-3

1.1.2

SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3

1.1.3

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3

1.1.4

ELECTRICAL EQUIPMENT .....................................................................................1-4

1.1.5

HYDRAULIC PARTS ................................................................................................1-5

1.1.6

WELD REPAIR .........................................................................................................1-5

1.1.7

ENVIRONMENTAL ISSUES.....................................................................................1-5

1.2

INTERNATIONAL UNIT SYSTEM .....................................................................................1-6

Book Code No. S5YN0118E01 1-1

1. OUTLINE Issue

Date of Issue

First edition

July, 2006

SK330-8 : LC10-07001~ SK350LC-8 : YC10-03501~

n

August, 2006

SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~

n

October, 2006

SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~

n

Applicable Machines

Remarks S5YN0118E01 (ASIA, OCE) n (ASIA, OCE) n (ASIA, OCE) n

December, 2006 SK850LC: LY01-00101~

n

February, 2007

E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~

n

n

SK235SRLC-2 : YU05-02001~

n

March, 2007

n

April, 2007

n

n

SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~

n

May, 2007

SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~

n

June, 2007

E225BSR : YB05-03001~ E225BSRLC : LA05-02001~

n

n

SK215SRLC : LA05-02001~

n

July, 2007

E135BSR : YY05-12001~ E135BSRLC : YH05-07001~

n

n

SK225SR : YB05-03001~ SK225SRLC : LA05-02001~

n

n

SK460-8: LS10-02001~ SK480LC–8 : YS10-01501~

n

n

E215B : YN11-45001~ E215BLC : YQ11-06001~

n

n

E265B : LQ12-06001~ E265BLC : LL12-05001~

n

n

n

n

n

n

n

August, 2007

E385B : LC10-07001~ E385BLC : YC10-03501~

n

September, 2007

E265B : LQ12-06001~ E265BLC : LL12-05001~

E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~

n E215B : YN11-45001~ E215BLC : YQ11-06001~ n

1-2

n (NHK) n (North America) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (ASIA, OCE) n (NHK Middle East) n (NHK Russia) n (NHK Middle East) n (NHK Russia) HS Engine n

K K K K K K K K K K K K K K K K K K K K

(NHK Middle East) HS Engine

n (NHK Middle East) n NHK Russia (HS Engine)

K K

1. OUTLINE

1.1

GENERAL PRECAUTIONS FOR MAKING REPAIRS

1.1.1

PREPARATION BEFORE DISASSEMBLING

2) Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work. 3) Before starting inspection and maintenance stop the engine. 4) Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire.

Read Operator's Manual before disassembling

(1) Knowledge of operating procedure Read Operator’s Manual carefully to understand the operating procedure.

5) Choose a hard, lever and safe place, and put attachment on the ground without fail. 6) Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).

(2) Cleaning machines Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the service shop, causes making less efficient work and damage of parts.

7) Use proper tools, and change or repair defective tools. 8) Machine and attachment required to work in the lifting condition should be supported with supports or blocks securely.

(3) Inspecting machines Confirm the disassembling section before starting work, determine the disassembly procedure taking the conditions in work shop into account, and request to procure necessary parts in advance.

1.1.3

(4) Recording Record the following items to keep contact and prevent malfunction from recurring.

(1) Removing hydraulic equipment assy 1) Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter.

1) Inspecting date, place 2) Model name, Serial number and Record on hour meter

2) Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.

3) Trouble condition, place, cause

3) Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.

4) Visible oil leak, water leak and damage 5) Clogging of filters, oil level, oil quality, oil contamination and looseness.

4) Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working bench.

6) Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter.

(2) Disassembling hydraulic equipment

(5) Arrangement and cleaning in service shop

1) Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited.

1) Tools required for repair work. 2) Prepare the places to put the disassembled parts. 3) Prepare oil pans for leaking oil, etc. 1.1.2

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

SAFETY WHEN DISASSEMBLING AND ASSEMBLING

2) If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. 3) Make match mark on parts for reassembling.

WARNING

(1) Safety

4) Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not.

1) Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.

5) For parts which are required to use jig and tools, don’t fail to use the specified jig and tools.

1-3

1. OUTLINE 6) For parts which can not be removed in the specified procedure, never force removal. First check for the cause.

If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged.

7) The removed parts should be put in order and tagged so as to install on proper places without confusion.

3) For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely.

8) For common parts, pay attention to the quantity and places. (3) Inspecting parts 1) Check that the disassembled parts are free from adherence, interference and uneven working face.

4) For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed.

2) Measure the wear of parts and clearance, and record the measured values. 3) If an abnormality is detected, repair or replace the parts.

For cylinder, don’t move it to the stroke end at beginning.

(4) Reassembling hydraulic equipment 1) During the parts cleaning, ventilate the room. 2) Before assembly, clean parts roughly first, and then completely.

5) Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions thoroughly.

3) Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them.

6) Check hydraulic oil level. Move attachments to hydraulic oil check position, and check hydraulic oil level of tank. Refill oil if the oil level is lower than the specified level. How to check oil level of hydraulic oil tank

4) Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on them before assembling. 5) Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them.

LEVEL GAUGE

6) Before assembling, remove rust preventives on new parts.

Oil level of hydraulic oil tank. If the indicator is within level marks, the oil quantity is acceptable.

7) Use special tools to fit bearings, bushing and oil seal. 8) Assemble parts matching to the marks.

1.1.4

ELECTRICAL EQUIPMENT

9) After completion, check that there is no omission of parts. (5) Installing hydraulic equipment

(1) The disassembly of electrical equipment is not allowed.

1) Confirm hydraulic oil and lubrication oil. 2) Air release is required in the following cases ;

(2) Handle equipment with care so as not to drop it or bump it.

1. Change of hydraulic oil 2. Replacement of parts on suction pipe side

(3) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire.

3. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. Removing and attaching travel motor

(4) Check that connector is connected and locked completely.

6. Removing and attaching hydraulic cylinder

(5) Engine key off before removing and connecting connector.

1-4

1. OUTLINE (2) Flexible hose (F hose)

(6) Engine key off before touching terminals of starter and alternator. (7) Remove battery grounding terminal before beginning work close to battery and battery relay with tools.

•

Even if the connector and length of hose are the same, the parts differ according to the withstanding pressure. Use proper parts.

•

Tighten it to the specified torque, and check that it is free from twist, over tension, interference, and oil leak.

(8) Wash machine with care so as not to splash water on electrical equipment and connector. (9) When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting.

1.1.6

(1) The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the grounding cable of battery. If the grounding cable is not disconnected, the electrical equipment may be damaged. (2) Remove parts which may cause fire due to the entry of spark beforehand.

Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. • •

•

• •

(3) Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don’t fail to cover the section with flame-proof clothes. 1.1.7

When it has adhered on skin ; Wash with soap and water.

(2) Waste disposal The following parts follows the regulation. Waste oil, waste container and battery

When it has spilled out in large quantity ; Use sodium bicarbonate to neutralize, or wash away with water.

(3) Precautions for handling hydraulic oil Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes on handling it.

When it was swallowed ; Drink milk or water. When it has adhered on clothes ; Wash it immediately.

•

When it has got in eyes ; Wash eyes with water until the stimulus is gone.

•

When it was swallowed ; Don’t force him to vomit it, but immediately receive medical treatment.

•

When it has adhered on skin ; Wash with soap and water.

HYDRAULIC PARTS

(4) Others For spare parts, grease and oil, use KOBELCO genuine ones.

(1) O-ring •

Check that O-ring is free from flaw and has elasticity before fitting.

•

Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated. So, choose proper O-ring.

•

Fit O-ring so as to be free from distortion and bend.

•

Floating seal should be put in pairs.

ENVIRONMENTAL ISSUES

(1) Engine should be started and operated in the place where air can be sufficiently ventilated.

When it has got in eyes ; Wash in water for 10 minutes or more immediately.

1.1.5

WELD REPAIR

1-5

1. OUTLINE

1.2

INTERNATIONAL UNIT SYSTEM

(4) Derived Units bearing Peculiar Designations Table1-4

Introduction Although this manual uses the SI units system. Outline of SI units system is described here. Given hereinunder are an excerpt of the units that are related to this manual :

QUANTITY

SI unit system

SI units

Derived units

Derived units bearing peculiar designations Table 1-4

DESIGNATION

SIGN

Meter Kilogram Second Ampere Kelvin

m kg s A K

kg • m/s 2

Pa

N/m2

J

N•m

watt

W

J/s

coulomb

C

A•s

Electric potential difference, Voltage, and volt Electromotive force

V

W/A

Quantity of static electricity farad and Electric capacitance

F

C/V

Mol Candela

mol cd

DESIGNATION Radian Steradian

Illuminance

Square meter Cubic meter Meter per second Meter per second / second Kilogram per cubic meter

V/A

C

(t+273.15)K

lx

l m/m2

°

lux

(5) Prefixes of SI Table1-5 PREFIX

POWER

DESIGNATION

SIGN

Giga

G

109

Mega

M

106

SIGN

Kilo

k

103

rad sr

Hecto

h

102

Deca

da

10

Deci

d

10–1

Centi

c

10–2

Milli

m

10–3

SIGN

Micro

P

10–6

m2 m3 m/s m/s2 kg/m3

Nano

n

10–9

Pico

p

10–12

Table1-3 DESIGNATION

ohm

celcius Celcius degree or temperature degree

(3) Derived Units of Basic Units

Area Volume Velocity Acceleration Density

N

Electric resistance

Table1-2

QUANTITIES

newton

Quantity of electricity

Derived units of base units Table 1-3

(2) Supplementary Units

Plain angle Solid angle

1Hz=1/s

Power

Table1-1

QUANTITIES

Hz

Energy, Work and Quantity of joule heat

(1) Basic Units

Length Mass Time Current Thermodynamic temperature Gram molecule Luminous intensity

hertz

Pressure and pascal Stress

Prefixes of SI (n-th power of 10, where n is an integer) Table 1- 5

QUANTITIES

FORMULA

Force

2. Construction of SI Unit System

Supplemen tary units Table 1-2

SYMBOL

Frequency

1. Etymology of SI Units English : International System of units

Base units Table 1-1

UNIT

1-6

1. OUTLINE (6) Unit Conversion Table QUANTITIES

JIS

SI

Mass

kg

kg

Force

kgf

N

1kgf=9.807N

Torque

kgf•m

N•m

1kgf•m=9.807N•m

Pressure

kgf/cm

MPa

1kgf/cm2=0.098MPa

Motive power

PS

kW

1PS=0.7355kW

Revolution

r.p.m

min–1

1r.p.m=1min–1

2

REMARKS

1-7

1. OUTLINE

[MEMO]

1-8

2

2. SPECIFICATIONS TABLE OF CONTENTS 2.1

NAME OF COMPONENTS................................................................................................2-3

2.2

GENERAL DIMENSIONS ..................................................................................................2-4

2.2.1

E265B/E265BLC [6.02m (19ft-9in) Boom+2.98m (9ft-9in) Standard Arm+1.0m3 (1.3cu•yd) Bucket Shoe] .......2-4

2.2.2

E265B/E265BLC [6.02m (19ft-9in)+2.5m (8ft-2in) Short Arm+1.2m3 (1.57cu•yd) Bucket Shoe] ..........2-4

2.2.3

E265B/E265BLC [6.02m (19ft-9in) Boom+3.66m (12ft-0in) Long Arm+0.81m3 (1.06cu•yd) Bucket Shoe] ........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 SPECIFICATIONS ..............................................................................................2-14

2.9.1

SPECIFICATIONS....................................................................................................2-14

2.9.2

ENGINE CHARACTERISTIC CURVE (HINO J05E-TB) ..........................................2-15

Book Code No. S5LQ0221E01 2-1

2. SPECIFICATIONS Issue

Date of Issue

First edition

September, 2007

Applicable Machines E265B : LQ12-06001~ E265BLC : LL12-05001~

2-2

Remarks S5LQ0221E01 NHK Russia (HS Engine)

K

2. SPECIFICATIONS

2.1

NAME OF COMPONENTS ARM CYLINDER

ARM

BOOM BUCKET CYLINDER

BOOM CYLINDER CAB SWIVEL JOINT

IDLER LINK

SLEWING BEARING SLEWING MOTOR FUEL TANK CONTROL VALVE

BUCKET LINK

HYDRAULIC TANK MUFFLER GUARD HYDRAULIC PUMP

BUCKET

MONITOR PANEL

SHOE AND TRACK LINK FRONT IDLER IDLER ADJUST

ENGINE

UPPER ROLLER COUNTER WEIGHT AIR CLEANER TRACK GUIDE LOWER ROLLER TRAVEL MOTOR

2-3

RADIATOR AND OIL COOLER BATTERY

2. SPECIFICATIONS

GENERAL DIMENSIONS

2.2.1

E265B/E265BLC [6.02m (19ft-9in) Boom+2.98m (9ft-9in) Standard Arm+1.0m3 (1.3cu•yd) Bucket Shoe] 1,195 (3'11") 1,195 (3'11") [1,295 (4'13") ] [1,295 (4'13")]

2.2

2,950 (9'8")

Unit : mm (ft-in)

3,0

20

(9'

11

10,120 (33'2")

")

Lower roller Q'ty : 8 pcs or [9 pcs ]

4,260 (13'12") [4,640 (15'3")] 5,090 (16'8") [5,280 (17'4")]

460 (18.1")

1,090 (3'7") 3,060 (10'1")

3,200 (10'6")

2,970 (9'9")

600 (23.6") 2,990 (9'10") [3,190 (10'6")]

Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications. 2.2.2

E265B/E265BLC [6.02m (19ft-9in)+2.5m (8ft-2in) Short Arm+1.2m3 (1.57cu•yd) Bucket Shoe] 10,170 (33'4") 4,120 (13'6")

1,090 (3'7")

3,380 (11'1")

2,970 (9'9")

Lower roller Q'ty : 8 pcs. or [9 pcs.]

4,260 (13'12") [4,640 (15'3")] 5,090 (16'8") [5,280 (17'4")]

2-4

2. SPECIFICATIONS 2.2.3

E265B/E265BLC [6.02m (19ft-9in) Boom+3.66m (12ft-0in) Long Arm+0.81m3 (1.06cu•yd) Bucket Shoe] Unit : mm (ft-in) 10,130 (33'3") 4,120 (13'6")

1,090 (3'6")

3,360 (11'3")

2,970 (9'9")

Lower roller Q'ty : 8 pcs. or [9 pcs.]

4,260 (13'12") [4,640 (15'3")] 5,090 (16'8") [5,280 (17'4")]

Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications.

2-5

2. SPECIFICATIONS

2.3

WEIGHT OF COMPONENTS Unit ; kg (lb) Model E265B

E265BLC

Machine complete

24,400 (53,800)

24,900 (54,900)

1. Upper frame assy (Assembly of following :)

11,380 (25,100)

m

1.1 Upper frame

2,200 (4,850)

m

1.2 Counter weight (Semi-weighted)

5,820 (12,830)

m

Item

270 (595)

m

*520 (1,150)

m

1.5 Hydraulic oil tank

*170 (375)

m

1.6 Fuel tank

*160 (350)

m

1.7 Slewing motor (including reduction unit)

*280 (620)

m

1.8 Control valve

*240 (530)

m

1.9 Boom cylinder

*240 (530) u 2

m

1.10 Pin (for mounting boom)

130 (290)

m

1.11 Pump

*120 (260)

m

1.12 Radiator (including intercooler)

*90 (200)

m

2. Lower frame assy (Assembly of following :)

7,900 (17,420)

8,400 (18,520)

2.1 Lower frame

2,880 (6,350)

3,100 (6,840)

1.3 Cab 1.4 Engine

400 (880)

m

520 (1,150) u 2

m

2.4 Upper roller

50 (110) u 2

m

2.5 Lower roller

30 (66) u 16

30 (66) u 18

2.6 Front idler

250 (550) u 2

m

2.7 Idler adjuster

150 (330) u 2

m

50 (110) u 2

m

*25 (55)

m

1,370 (3,020) u 2 1,500 (3,310) u 2 1,630 (3,590) u 2

1,490 (3,290) u 2 1,630 (3,590) u 2 1,770 (3,900) u 2

520 (1,150) u 2

570 (1,260) u 2

5,120 (11,300)

m

2.2 Slewing bearing 2.3 Travel motor (including reduction unit)

2.8 Sprocket 2.9 Swivel joint 2.10 Track link with 600mm (23.6in) shoes assy Track link with 700mm (27.6in) shoes assy Track link with 800mm (31.5in) shoes assy 2.10.1 Track link assy 3. Attachment (Assembly of following / STD :) {6.02m(19ft-9in) Boom + 2.98m(9ft-9in) Arm + 1.0m (1.3cu•yd) Bucket} 3

810 (1,790)

m

1,360 (2,999)

m

3.2.1 STD Arm

920 (2,030)

m

3.2.2 Bucket cylinder

*190 (419)

m

3.1 Bucket assy (STD) 3.2 STD Arm assy (Assembly of following :)

60 (132) u 2

m

3.2.4 Bucket link

100 (220)

m

3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket)

90 (200)

m

3.3 Boom assy (Assembly of following :)

2,460 (5,420)

m

3.3.1 Boom

1,890 (4,170)

m

*330 (728)

m

60 (132)

m

3.2.3 Idler link

3.3.2 Arm cylinder 3.3.3 Pin (Mounting arm • Mounting arm cylinder)

2-6

2. SPECIFICATIONS Unit ; kg (lb) Model Item 4. Lubricant and water (Assembly of following :) 4.1 Hydraulic oil 4.2 Engine oil 4.3 Fuel 4.4 Water

Marks * show dry weight.

2-7

E265B

E265BLC

590 (1,300)

m

160 (350)

m

20 (44)

m

380 (840)

m

30 (66)

m

2. SPECIFICATIONS

2.4

TRANSPOTATION

2.4.1

OVERALL DIMENSIONS OF MACHINE ON A TRAILER

(1) 6.02m (19ft-9in) Boom+2.98m (9ft-9in) Arm+1.00m3 (1.3cu•yd) Bucket Model E265B

E265BLC

2,990 (9ft-10in)

3,190 (10ft-6in)

24,700kg (54,460 lbs)

25,200kg (55,570 lbs)

Item Width 600mm (23.6in) shoes Weight

Unit : mm (ft-in)

A

220 (8.66") [ 370 (14.6")]

A

330 (13")

10

")

94

3. 0(

SECTION A-A

* marks indicate LC specifications.

2-8

600 1,080 (3'7") (23.6") 3,200 (10'6") 3,800 (12'6")

2,300 (7'7") [ 2,450 (8'1")]

38(1.5")

10,120 (33'2")

2. SPECIFICATIONS 2.4.2

DIMENSIONS OF ATTACHMENT

(1) BOOM Type 6.02m (19ft-9in) Boom

Item LengthuHeightuWidth m (ft-in) LuHuW Weight

kg (lbs)

6.25 u 1.71 u 0.75 (20'6"u 5'7"u 29.5") 2,140 (4,720)

(2) ARM AND BUCKET Type Item LengthuHeightuWidth m (ft-in) LuHuW Weight

kg (lbs)

2.5m (8ft-2in) Arm + 1.2m 3(1.57cu•yd) Bucket

2.98m (9ft-9in) Arm + 1.0m 3 (1.3cu•yd) Bucket

3.66m (12ft) Arm + 0.81m 3 (1.06cu•yd) Bucket

5.00 u 1.00 u 1.44 (16'5"u3'3"u4'9")

5.47 u 1.03 u1.27 (17'11"u3'5"u4'2")

6.14 u 1.0 u 1.06 (20'2"u3'3"u3'6")

2,100 (4,630)

2,170 (4,790)

2,240 (4,940)

2.5 m (8ft-2in) Arm

2.98 m (9ft-9in) Arm

3.66 m (12ft-0in) Arm

3.59 u 0.89 u 0.55 (11'9"u35"u22")

4.06 u 0.90 u 0.55 (13'4"u35.4"u22")

4.73 u 090 u 0.55 (15'6"u35.4"u22")

1,240 (2,735)

1,340 (2,955)

1,520 (3,350)

(3) Arm Type Item LengthuHeightuWidth m (ft-in) LuHuW Weight

kg (lbs)

2-9

2. SPECIFICATIONS (4) Bucket Type

Hoe bucket m (ft-in

1.48 u 1.34u 1.06 (4'10"u4'5"u3'6")

Weight

kg (lbs)

700 (2,955)

810 (1,790)

850 (1,870)

Bucket capacity

m3 cu•yd

0.81 (1.06)

STD 1.0 (1.3)

1.2 (1.57)

LengthuHeightuWidth LuHuW

Type

Hoe bucket

LengthuHeightuWidth LuHuW

m (ft-in

1.47u1.34u1.27 (4'10"u4'5"u4'2")

Weight

kg (lbs)

930 (2,050)

Bucket capacity

m cu•yd

1.0 (1.3) HD

3

Hoe bucket

2-10

1.47 u 1.34u 1.27 (4'10"u4'5"u4'2")

1.47 u 1.34u 1.44 (4'10"u4'5"u4'9")

2. SPECIFICATIONS

2.5

SPECIFICATIONS AND PERFORMANCE

2.5.1

SPEED AND CLIMBING CAPABILITY Area & Model

E265B

Item Swing speed

min-1 {rpm}

Travel speed (1-speed/2speed)

km/h (mile/h)

Gradeability

% (degree)

2.5.2

E265BLC 11.0 {11.0} 3.6 / 5.8 (2.2 / 3.6) 70 (35)

ENGINE

Engine model

HINO J05E-TH Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger

Type

4 -ø112 mm u 130 mm (4.41 in u 5.12 in)

Number of cylinders—BoreuStroke Total displacement

5.123 L (312.61 cu•in)

Rated output / Engine speed

131 kW (178 PS) / 2,100 min-1

Maximum torque / Engine speed

654 N•m (482 lbf•ft)/ 1,600 min-1

Starter

24 V / 5.0kW

Alternator

24 V / 1.2kW

2.5.3

HYDRAULIC COMPONENTS

Hydraulic pump

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

Hydraulic motor (swing)

Axial piston motor u 1

Hydraulic motor (travel)

Variable displacement axial piston motor u 2 (with counterbalance valve) 8-spool control valve u 1

Control valve Cylinder (Boom, Arm, Bucket)

Double action cylinder

Oil cooler 2.5.4

Air-cooled type WEIGHT Unit : kg (lbs)

Fully equipped weight

24,400 (53,800)

24,900 (54,900)

Upper structure

11,380 (25,100)

m

Lower machinery (600mm grouser shoe)

7,900 (17,420)

8,400 (18,520)

5,120 (11,300)

m

Attachment 6.02m (19 ft-9in) Boom+2.98m (9ft-9in) Arm +1.0m3 (1.3cu•yd) Bucket

2-11

2. SPECIFICATIONS

2.6

TYPE OF CRAWLER Shape

Overall width of crawler mm (ft-in)

Shoe width mm (in)

600 (23.6)

Grouser shoe

700 (27.6)

800 (31.5)

Ground pressure kPa (psi)

STD

2,790 (9'10")

53 (7.69)

LC

3,190 (10'6")

49 (7.11)

STD

3,090 (10'2")

46 (6.67)

LC

3,290 (10'9")

43 (6.24)

STD

3,190 (10'6")

41 (5.95)

LC

3,390 (11'2")

38 (5.51)

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

Hoe bucket

Heaped capacity m3(cu•yd)

Outer width mm (ft-in) Struck

Availability Weight of face kg (lbs) shovel

Number

W or W/O side cutter

4

W

YES

700 (1,540)

m3(cu•yd)

With side cutter

Without side of tooth cutter

0.81 (1.06)

0.59 (0.77)

1,060 (3'5")

1.0 (1.31)

0.76 (0.99)

1,270 (4'2") 1,180 (3'10")

5

W

YES

810 (1,790)

1.20 (1.57)

0.84 (1.1)

1,440 (4'9")

1,340 (4'5")

5

W

YES

850 (1,870)

1.40 (1.83)

1.00 (1.31)

—

1,510 (4'11")

6

W/O

YES

890 (1,960)

960 (3'2")

2-12

2. SPECIFICATIONS

2.8

COMBINATIONS OF ATTACHMENT Bucket

Available Arm

Heaped capacity m3 (cu•yd)

Struck m (cu•yd)

0.81 (1.06)

0.59 (0.77)

1.00 (1.3)

0.76 (0.99)

1.2 (1.57)

0.84 (1.1)

1.40 (1.83) Side pin type

1.00 (1.31)

Breaker

—

—

Nibbler

—

—

Type

Hoe bucket

3

2.98m (9ft-9in) Arm (STD)

3.66m (12ft) Arm (Long)

2.5m (8ft-2in) Arm (Short)

Standard combination General operation : Excavation or loading of sand, gravel, and clay Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel) Prohibited combination : There are problems from the view points of strength and stability. •

Use the attachments recommended by NEW HOLLAND KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibility

If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and bucket may occur.

2-13

2. SPECIFICATIONS

2.9

ENGINE SPECIFICATIONS

2.9.1

SPECIFICATIONS

Applicable machine

E265B, E265BLC

Engine model

HINO J05E-TH Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger

Type Number of cylinderuBoreuStroke Total displacement

mm (in)

4 u 112 u 130 (4.41 u 5.12)

cc (cu•in)

5,123 (313)

Compression ratio Rated output

18.0 kW (PS) at min

131 (178) at 2,100

N•m (lb•ft) at min-1

654 (482) at 1,600

High idling

min-1

2,300 ± 30

Low idling

min

800 ± 30

Maximum torque

Injection starting pressure Thermostat action

-1

-1

MPa (psi)

3.2 (464)

Start/Full open K (°F)

350 (170) / 363 (194)

Firing order Compression pressure

1-3-4-2 MPa (psi) at min-1

3.4~3.7 (493~537) at 280

Fuel injection timing

Valve clearance

Starter capacity Generator capacity (Alternator)

0° Valve clearance

Open

Close

Intake valve

0.3 mm at cool

14°before top dead point

30°after bottom dead point

Exhaust valve

0.45 mm at cool

54°before bottom 13°after top dead dead point point

V u kW

24 u 5.0

VuA

24 u 50 ø650 (25.6") u suction type 7 fans, V-belt drive, pulley ratio Crank / Fan= 0.93

Cooling fan drive method

Engine oil quantity

L (gal)

Full level 18.0 (4.76) Low level 15.0 (3.96) Total 20.5 (5.42)

Dry weight

kg (lbs)

580 (1,280)

g/kW•h (g/ps•h)

211 (156)

Fuel consumption ratio Allowable inclination (Limited by E/G lubrication) Dimension (LuWuH)

Front / Rear and Right / Left : 35° 1,063 u 737 u 1,045 (3ft-5.86in u 29.0in u 3ft-5in)

mm (in)

Rotating direction

Counterclockwise seeing from flywheel side

2-14

2. SPECIFICATIONS 2.9.2

ENGINE CHARACTERISTIC CURVE (HINO J05E-TH)

FUEL CONSUMPTION RATE

SHAFT OUTPUT

SHAFT TORQUE

Condition to be measured: The net value is indicated, measuring with cooling fan ; ø650 (25.6")usuction type, pulley ratio Crank / Fan=0.93 marks show the rated point

ENGINE SPEED (min-1) Fuel consumption volume Fuel consumption rate X kW X Load factor ( ) 0.835 X 1000 211g/kW.h X 131kW X 0.835 X 1000 33.1

. L/h

2-15

: Standard load factor (0.70~0.80) Fuel consumption in regular operation (load factor 0.70~0.80) 23.2 L/h~26.5 L/h

2. SPECIFICATIONS

[MEMO]

2-16

3. ATTACHMENT DIMENSIONS TABLE OF CONTENTS 3.1

BOOM ................................................................................................................................3-3

3.1.1

BOOM DIMENSIONAL DRAWING...........................................................................3-3

3.1.2

BOOM MAINTENANCE STANDARD .......................................................................3-4

3.2

ARM ...................................................................................................................................3-6

3.2.1

ARM DIMENSIONAL DRAWING..............................................................................3-6

3.2.2

ARM MAINTENANCE STANDARD ..........................................................................3-7

3.3

BUCKET ............................................................................................................................3-10

3.3.1

BUCKET DIMENSIONAL DRAWING .......................................................................3-10

3.3.2

BUCKET DIMENSIONAL TABLE .............................................................................3-10

3.3.3

LUG SECTION DIMENSIONAL DRAWING .............................................................3-11

3.3.4

BOSS SECTION DIMENSIONAL DRAWING...........................................................3-12

Book Code No. S5LQ0318E01 3-1

3

3. ATTACHMENT DIMENSIONS Issue

Date of Issue

Applicable Machines

First edition

July, 2007

n

n

n

n

September, 2007

n

E265B : LQ12-06001~ E265BLC : LL12-05001~

3-2

Remarks S5LQ0318E01 (NHK Russia) n (NHK Middle East) n NHK Russia (HS Engine)

K K K

3. ATTACHMENT DIMENSIONS

3.1

BOOM

3.1.1

BOOM DIMENSIONAL DRAWING

Fig. 3-1 Boom dimensional drawing Unit : mm (ft-in) 6.02M (19ft-9in) BOOM No

STD

—

LQ02B00251F1

—

NAME

A

Boom length

B

DIMENSION 6,020 (19'9")

—

Boom foot width

752 (29.6")

—

C

Boom end inner width

380 (15.0")

—

D

Boom end outer width

528 (20.8")

—

E

Height of boom cylinder rod pin

1,063 (3'6")

—

F

Height of arm cylinder (head side) pin

1,305 (4'3")

—

G

Distance between pins of boss

H

Distance between pins of bracket

R2,437 (7'12")

—

R3,009.5 (9'10")

—

I

Arm cylinder (head side) inner width

136 (5.35")

—

J

Outer width of bracket on the arm cylinder (rod side) mounting

522 (20.6")

—

ø 100 (3.94")

—

d1

Boom foot pin dia.

d2

Boom cylinder (rod side) pin dia.

ø 90(3.54")

—

d3

Pin dia. of boom end.

ø 90 (3.54")

—

d4

Arm cylinder (head side) pin dia.

ø 90(3.54")

—

3-3

3. ATTACHMENT DIMENSIONS 3.1.2

BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section

D

A C

B

Fig. 3-2 Clearance of pin and bushing on boom section Unit : mm (in) Standard value Symbol

Item

Pin part No.

A

Boom foot

LQ02B01395P1

B

Boom cylinder (Head side)

LQ02B01390P2

C

Boom cylinder (Rod side)

LQ02B01373P1

D

Arm cylinder (Head side)

Pin dia.

Pin dia. tolerance

Standard value

RepairService Remedy able limit level

+ 0.233 + 0.213 (+0.0084) (+0.0092) + 0.045 + 0.065 (+0.0026) (+0.0018)

ø 100 (3.9370)

ø 90 (3.5433)

Bushing i.d. tolerance

Clearance

+ 0.020 (+0.0008) - 0.020 (-0.0008)

+ 0.238 (+0.094) + 0.077 (+0.003)

+ 0.258 (0.0102) + 0.057 (+0.0022)

+ 0.270 + 0.25 (+0.0098) (+0.0106) + 0.030 + 0.05 (+0.0020) (+0.0012)

LQ02B01380P1

3-4

More than 2.0 (0.08)

2.5 (0.1)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom cylinder installation section

D

D

C C

A A

B B

SECTION C-C SECTION D-D

SECTION A-A

SECTION B-B Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section Unit : mm (in) Basic size Sec.

Item No. Boom

A-A Boom foot

Boom cylinder B-B (Head side)

C-C

Boom cylinder (Rod side)

Arm cylinder D-D (Head side)

L1

Size 752 (29.6)

Upper frame

758 (29.8)

Boom cylinder

120 (4.7)

L2 Upper frame Boom cylinder Boom

L3

120 (4.7)

L3'

522 (20.6)

Arm cylinder L4 Boom

126 (5.0)

130 (5.12) 136 (5.35)

Clearance X adjusted with shim (total of both sides) Standard value

Repairable level

Service limit

0.5 (0.02) or less 2.0 (0.08)

Pin length Remedy No. Length

PL1

921 (36.3)

PL2

284 (11.2)

2.5 (0.10)

0.6~1.0 (0.02~0.04)

0.6~2.0 (0.02~0.08)

3.0 (0.12)

4.0 (0.16)

PL3

810 (31.9)

0.6~1.0 (0.02~0.04)

2.0 (0.08)

2.5 (0.10)

PL4

274 (10.8)

3-5

Shim adjust ment

3. ATTACHMENT DIMENSIONS

3.2

ARM

3.2.1

ARM DIMENSIONAL DRAWING

VIEW J SECTION X-X

SECTION Z-Z

SECTION Y-Y

Fig. 3-4 ARM DIMENSIONAL DRAWING

2.98m (9ft-9in) ARM LQ12B00530F1 (01) Code

NAME

Unit : mm (ft-in) DIMENSION

Code

2,980 (9'9")

N

Arm cyl. rod inner width

136 (5.35")

R930.5 (36.6")

O

Bracket cyl. head inner width

113 (4.45")

D1 I.D of boss

ø120 (4.72")

P

Idler link dimension

695 (27.4")

D2 I.D of boss

ø85 (3.35")

Q

Bucket link dimension

636 (25.0")

D4 I.D of boss

ø105 (4.13")

R

Height between pins of boss and center

37 (1.46")

C

Arm length

D

Distance between pins of boss and bracket

NAME

DIMENSION

E

Distance between pins of boss and bracket

R2,394 (7'10")

d1

Pin dia.

ø90 (3.54")

F

Distance between pins of boss and boss

R450 (17.7")

d2

Pin dia.

ø70 (2.76")

G

Height between pins of boss and bracket

684 (26.9")

d3

Pin dia.

ø90 (3.54")

H

Height between pins of boss and bracket

312 (12.3")

d4

Pin dia.

ø90 (3.54")

K

Arm top end boss width

325 (12.8")

d5

Pin dia.

ø80 (3.15")

L

Arm link section boss width

332 (13.1")

M

Boss width

375 (14.8")

3-6

3. ATTACHMENT DIMENSIONS 3.2.2

ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing

E

F

D, D'

B A

C

G

Fig. 3-5 Clearance of pin and bushing on arm section Unit : mm (in) Standard dimensions No.

A

Item

Pin part No.

Pin dia.

Arm point LQ12B01439P1

ø90 (3.5433)

B

Bucket link (Bucket side)

C

Idler link (Connected part LQ12B01440P1 of arm)

ø70 (2.7559)

D

Bucket link (Idler link side) LQ12B01441P1

D'

Bucket cylinder (Rod side)

E

Bucket cylinder LQ12B01563P1 (Head side)

F

Arm cylinder (Rod side)

G

Arm foot (Connected part LQ12B01487P1 of boom)

Pin dia. tolerance

–0.020 (-0.0008) –0.080 (-0.0031)

0 (0) –0.040 (-0.0016)

Standard value

+0.252 (+0.0099) +0.077 (+0.0030)

+0.312 (+0.0123) +0.097 (+0.0038)

+0.282 (+0.0111) +0.154 (+0.0061)

+0.342 (+0.0135) +0.194 (+0.0076)

+0.241 (+0.0095) +0.175 (+0.0069)

+0.281 (+0.0111) +0.175 (+0.0069)

+0.228 (+0.0090) +0.158 (+0.0062)

+0.268 (+0.0106) +0.158 (+0.0062)

ø80 (3.1496) +0.250 (+0.0098) +0.050 (+0.0020)

LQ02B01380P1 ø90 (3.5433)

+0.020 (+0.0008) –0.020 (-0.0008)

3-7

Clearance

Bushing i.d. tolerance

+0.278 (+0.0109) +0.148 (+0.0058)

+0.290 (+0.0114) +0.050 (+0.0020) +0.270 (+0.0106) +0.030 (+0.0012) +0.298 (+0.0117) +0.128 (+0.0050)

Repairable level

Service limit

2.0 (0.08)

2.5 (0.01)

Remedy

Replace bushing or pin

3. ATTACHMENT DIMENSIONS (2) Clearance of arm and cylinder installing sections in thrust direction

E D, D'

B C

B A

A

D, D'

F G

C X1

L1

X

L3 X

PL1 SECTION A-A X2

L2

F

E

G

PL5 L5

X

PL3 SECTION C-C X

SECTION E-E

PL7 X7

L4

L6

PL6 SECTION F-F

L7

X4' L4' PL2 SECTION B-B

PL4 SECTION D-D

SECTION G-G

Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction

3-8

3. ATTACHMENT DIMENSIONS Unit : mm (in) Basic size Sec.

Item No. Arm

A-A Arm point

L1 Bucket Link side

B-B Bucket link

L2 Bucket

C-C

Idler link (Arm connection)

Bucket link D-D (Idler link connection)

D’-D’

E-E

Bucket link (Rod side)

Bucket cylinder (Head side)

Arm cylinder F-F (Rod side)

Arm

L3

Link side

325 (12.79)

332 (13.07)

L4’

332 (13.07) 107 (4.21)

Link side

113 (4.45)

Head side

107 (4.21)

L5 Arm

113 (4.45)

Rod side

130 (5.12)

L6 Arm

136 (5.35)

Arm

375 (14.76)

L7 Boom

RepairService limit No. able level

2.0 (0.08)

Remedy Length

PL1 472 (18.6)

—

—

0.5 (0.02)

1.0 (0.04)

327 (12.87)

Pin length

PL2

2.5 (0.10)

PL3

L4

Rod side

G-G Arm foot

Standard value

325 (12.79) 1.0 (0.04) or less 326 (12.83)

-

Rod side Link side

Size

Clearance X adjusted with shim (total of both sides)

380 (14.96)

0.6~1.0 (0.024~0.04)

0.6~2.0 (0.024~0.08)

0.5 (0.02)

3-9

454 (17.9)

2.0 (0.08)

3.0 (0.12)

1.0 (0.04)

PL4

PL5

247 (9.72)

PL6

274 (10.8)

PL7

552 (21.7)

4.0 (0.16)

2.5 (0.10)

Shim adjust -ment

3. ATTACHMENT DIMENSIONS

3.3

BUCKET

3.3.1

BUCKET DIMENSIONAL DRAWING

(1) Hoe bucket

Fig. 3-7 Bucket dimensional drawing No. A

NAME

No.

NAME

Distance between pin and bracket

G

Inner width of bucket bottom

B

Distance between bucket pin and tooth end

H

Bucket outer width of front side

C

Inner width of bucket top end

I

Pitch between teeth

D

Inner width of lug

Io

Pitch between teeth

E

Inner width of bracket

d1

Outer dia. of bushing

F

Outer width of side cutter

d2

Pin dia.

3.3.2

BUCKET DIMENSIONAL TABLE Unit : mm (ft-in)

Type

Hoe bucket

Capacity

0.81 m3 (1.06 cu•yd) Side pin type

[STD] 1.00 m3 (1.31 cu•yd))

1.20 m3 (1.57 cu•yd))

1.40 m3 (1.83 cu•yd))

Part No.

LQ61B00170F1

LQ61B00186F1

LQ61B00125F1

LQ61B00166F1

A

R500 (19.7")

m

m

m

B

R1,515 (4'12")

m

m

m

C

896 (35.3")

1,115 (3'8")

1,276 (4'2")

1,443 (4'9")

D

399 (15.7")

m

m

m

E

327 (12.9")

m

m

m

F

959 (37.8")

1,274 (4'2")

1,339 (4'5")

1,505 (4'11")

G

746 (29.4")

965 (38")

1,126 (3'8")

1,293 (4'3")

H

896 (35.3")

1,178 (3'10")

1,276 (4'2")

1,443 (4'9")

I

256 (10.1")

247 (9.7")

287 (11.3")

263 (10.4")

IO

256 (10.1")

247 (9.7")

287 (11.3")

263 (10.4")

d1

ø 105 (4.13")

m

m

m

d2

ø 90 (3.54")

m

m

m

3-10

3. ATTACHMENT DIMENSIONS 3.3.3

LUG SECTION DIMENSIONAL DRAWING

B

X

J

A X 28 (1.10)

Apply rust prevention oil

19 (0.748)

N

BOSS 2416P26834

M

3-G B

F

D

E

H SHIM

1

Five shims are installed at shipping

Insert this pin flush with surface

BOSS LQ61B01016P1

SECTION X-X

DETAIL B

Fig. 3-8 Dimension of lug section

Hoe bucket

0.81 (1.06)

LQ61B00170F1

[STD] 1.00 (1.31)

LQ61B00186F1

1.20 (1.57)

LQ61B00125F1

1.40 (1.83)

LQ61B00166F1

Spring pin dia.

Boss outer dia.

Screw dia.

Boss width.

Boss outer dia.

Boss width.

Screw hole P.C.D

Part No. of bucket

Hole dia.

Capacity of bucket m3 (cu.yd)

Lug plate thickness

Type of bucket

Pin hole dia.

Unit : mm (ft-in)

A

B

D

E

F

G

H

J

M

N

90 25 105 13 190 (3.45") (0.984") (4.13") (0.512") (7.48")

3-11

M16

25 180 36 150 (0.984") (7.09") (1.42") (5.91")

3. ATTACHMENT DIMENSIONS 3.3.4

BOSS SECTION DIMENSIONAL DRAWING A

H

5 (0.197")

oD

oC

oB

oA

oG

15 (0.591")

E F

Fig. 3-9 Dimension of boss section Unit : mm (ft-in) Type

Capacity of

of

bucket

bucket

m3 (cu•yd) 0.81 (1.06)

Part No. of

Part No.

bucket

of boss

øA

øB

øC

øD

E

F

øG

H

I

LQ61B00170F1

[STD] Hoe

1.00 (1.31)

LQ61B00186F1

bucket

1.20 (1.57)

LQ61B00125F1

1.40 (1.83)

LQ61B00166F1

LQ61B01016P1

2418P26834

127

94

118.5

124.5

15

30

17

13

3.0

(5.00")

(3.7")

(4.67")

(4.9")

(0.59")

(1.18")

(0.669")

(0.512")

(0.12")

n

n

n

n

n

n

n

3-12

19

34

(0.75")

(1.34")

11. TOOLS

11

TABLE OF CONTENTS 11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ............................................11-3 11.2 SCREW SIZE...................................................................................................................11-5 11.2.1

CAPSCREW (BOLT) ..............................................................................................11-5

11.2.2

CAPSCREW (SOCKET BOLT) ..............................................................................11-5

11.2.3

SOCKET SET SCREW...........................................................................................11-5

11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-6 11.3.1

JOINT (O-RING TYPE)...........................................................................................11-6

11.3.2

HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6

11.3.3

JOINT (ORS TYPE) ................................................................................................11-6

11.3.4

SPLIT FLANGE ......................................................................................................11-6

11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-7 11.5 PLUG ...............................................................................................................................11-8 11.5.1

PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8

11.5.2

PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9

11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11 11.7 SPECIAL TOOLS.............................................................................................................11-12 11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......11-14 11.9 SUCTION STOPPER.......................................................................................................11-15 11.9.1

COMPONENTS ......................................................................................................11-15

11.9.2

DIMENSION ...........................................................................................................11-15

11.9.3

APPLICABLE MODEL ............................................................................................11-15

11.10 COUNTER WEIGHT LIFTING JIG ..................................................................................11-16 11.11 UPPER FRAME LIFTING JIG..........................................................................................11-17 11.12 ENGINE MOUNTING PEDESTAL ...................................................................................11-18 11.13 TRACK SPRING SET JIG ...............................................................................................11-19

Book Code No. S5LQ1114E01 11-1

11. TOOLS Issue

Date of Issue

Applicable Machines

First edition

October, 2006

n

May, 2007

n

July, 2007

n

n

n

n

September, 2007

n

SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~ n E265B : LQ12-06001~ E265BLC : LL12-05001~

11-2

Remarks S5LQ1114E01 (ASIA, OCE) n ASIA (HS Engine) n (NHK Russia) n (NHK Middle East) n NHK Russia (HS Engine)

K K K K K

11. TOOLS

11.1

TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables Table11-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given. Overtightening of bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques. Table11-1 Tightening torque for metric coarse threads (not plated) Unit : N•m (lbf•ft) Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M6

P=1

4.4±0.5 (3.2±0.4)

3.7±0.4 (2.7±0.3)

9.6±1.0 (7.1±0.7)

8.1±0.8 (6.0±0.6)

17.4±1.8 (12.8±1.3)

14.7±1.5 (10.8±1.1)

M8

P=1.25

10.7±1.1 (7.9±0.8)

9.0±0.9 (6.6±0.7)

23.5±2.0 (17.3±1.5)

19.6±2.0 (14.5±1.5)

42.2±3.9 (31.1±2.9)

35.3±3.9 (26.0±2.9)

M10

P=1.5

21.6±2.0 (15.9±1.4)

17.9±1.8 (13.2±1.3)

46.1±4.9 (34.0±3.6)

39.2±3.9 (28.9±2.9)

83.4±8.8 (61.5±6.5)

70.6±6.9 (52.1±5.1)

M12

P=1.75

36.3±3.9 (26.8±2.9)

31.4±2.9 (23.2±2.1)

79.4±7.8 (58.6±5.8)

66.7±6.9 (49.2±5.1)

143±15 (105±11)

121±12 (89.2±8.9)

M14

P=2

57.9±5.9 (42.7±4.4)

49.0±4.9 (36.1±3.6)

126±13 (92.9±9.6)

106±10 (78.2±7.4)

226±20 (167±15)

191±19 (141±14)

M16

P=2

88.3±8.8 (65.1±6.5)

74.5±6.9 (55.0±5.1)

191±20 (141±15)

161±16 (119±12)

343±39 (253±29)

284±29 (209±21)

M18

P=2.5

122±12 (90.0±8.9)

103±10 (75.8±7.2)

265±29 (195±21)

226±20 (167±15)

481±49 (355±36)

402±39 (297±29)

M20

P=2.5

172±17 (127±13)

144±14 (106±10)

373±39 (275±29)

314±29 (232±21)

667±69 (492±51)

559±59 (412±44)

M22

P=2.5

226±20 (167±15)

192±20 (142±15)

500±49 (369±36)

422±39 (311±29)

902±88 (665±65)

755±78 (557±58)

M24

P=3

294±29 (217±21)

235±29 (173±21)

637±69 (470±51)

520±49 (383±36)

1160±118 (856±87)

941±98 (694±72)

M27

P=3

431±39 (318±29)

353±39 (260±29)

941±98 (694±72)

765±78 (564±58)

1700±167 (1250±123)

1370±137 (1010±101)

M30

P=3.5

588±59 (434±44)

490±49 (361±36)

1285±127 (948±94)

1079±108 (796±80)

2300±235 (1700±173)

1940±196 (1430±145)

M33

P=3.5

794±78 (586±58)

667±69 (492±51)

1726±177 (1270±131)

1451±147 (1070±108)

3110±314 (2290±232)

2610±265 (1930±195)

M36

P=4

1030±98 (760±72)

863±88 (637±65)

2226±226 (1640±167)

1863±186 (1370±137)

4010±402 (2960±297)

3360±333 (2480±246)

11-3

11. TOOLS Table11-2 Tightening torques for metric fine threads (not plated) Torque value Unit : N•m (lbf•ft) Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M8

P=1.0

11.3±1.1 (8.3±0.8)

9.5±1.0 (7.0±0.7)

24.5±2.0 (18.1±1.5)

20.6±2.0 (15.2±1.5)

44.1±3.9 (32.5±2.9)

37.3±3.9 (27.5±2.9)

M10

P=1.25

22.6±2.0 (16.7±1.5)

18.7±1.9 (13.8±1.4)

48.1±4.9 (35.5±3.6)

41.2±3.9 (30.3±2.9)

87.3±8.8 (64.4±6.5)

73.5±6.9 (54.2±5.1)

M12

P=1.25

39.2±3.9 (28.9±2.9)

33.3±2.9 (24.6±2.1)

85.3±8.8 (62.9±6.5)

71.6±6.9 (52.8±5.1)

154±16 (114±12)

129±13 (95.2±9.6)

M16

P=1.5

92.2±8.8 (68.0±6.5)

77.5±7.8 (57.2±5.8)

196±20 (145±15)

169±17 (125±13)

363±39 (268±29)

304±29 (224±21)

M20

P=1.5

186±19 (137±14)

155±16 (114±12)

402±39 (297±29)

333±29 (246±21)

726±69 (535±51)

608±59 (448±44)

M24

P=2

314±29 (232±21)

265±29 (195±21)

686±69 (506±51)

569±59 (420±44)

1240±118 (915±87)

1030±98 (760±72)

M30

P=2

637±59 (470±44)

530±49 (391±36)

1390±137 (1030±101)

1157±118 (853±87)

2500±255 (1840±188)

2080±206 (1530±152)

M33

P=2

853±88 (629±65)

706±70 (521±52)

1860±186 (1370±137)

1550±155 (1140±114)

3350±334 (2470±246)

2790±275 (2060±203)

M36

P=3

1070±108 (789±80)

892±88 (658±65)

2330±226 (1720±167)

1940±196 (1430±145)

4200±422 (3100±311)

3500±353 (2580±260)

11-4

11. TOOLS

11.2

SCREW SIZE

11.2.1

CAPSCREW (BOLT)

Nominal screw size (d) M6

B mm Tool size 10

Nominal screw size (d)

B mm Tool size

M36

55

M8

13

M42

65

M10

17

M45

70

M12

19

M48

75

(M14)

22

M56

85

M16

27

(M60)

90

(M18)

27

M64

95

M20

30

(M68)

100

(M22)

32

M72

105

M24

36

M76

110

(M27)

41

M80

115

M30

46

11.2.2

B

CAPSCREW (SOCKET BOLT)

Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm Tool size

(M3)

2.5

M20

17

(M4)

3

(M22)

17

(M5)

5

M24

19

M6

5

(M27)

19

M8

6

M30

22

M10

8

M36

27

M12

10

M42

32

M14

12

(M45)

32

M16

14

M48

36

(M18)

14

M52

36

11.2.3

d

SOCKET SET SCREW

Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm

d

Tool size

M2.5

1.27

M8

4

M3

1.5

M10

5

M4

2

M12

6

M5

2.5

M16

8

M6

3

M20

10

B

11-5

11. TOOLS

11.3

TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1

JOINT (O-RING TYPE)

11.3.2

Size (PF)

Wrench (mm)

Tightening torque N•m (lbf•ft)

1/8

14

17±2 (13±1.5)

1/4

19

36±2 (27±1.5)

3/8

22

74±5 (55±4)

1/2

27

108±9.8 (80.0±7)

3/4

36

162±9.8 (119±7)

1

41

255±9.8 (188±7)

HYDRAULIC HOSE (30° FLARE TYPE) Size (PF)

Wrench(mm)

Tightening torque N•m (lbf•ft)

1/8

17

15±2.0 (11±1.5)

1/4

19

29±4.9 (21±3.6)

3/8

22

49±4.9 (36±3.6)

1/2

27

78±4.9 (58±3.6)

3/4

36

118±9.8 (87±7.2)

1

41

137±15 (101±11)

Unified screw size

Opposing flats

Tightening Torque N•m (lbf•ft)

1-14 UNS

30, 32

137±14 (101±10)

36

177±18 (131±13)

41

206±26 (152±15)

41

206±26 (152±15)

46

206±26 (152±15)

11.3.3

UNION NUT

JOINT (ORS TYPE)

1 3 / 16-12 UN 1 7/ 16-12 UN 11.3.4

SPLIT FLANGE Tightening torque N•m (lbf•ft) Standard pressure series 20.6 MPa

Bolt size

Hi pressure series 41.2 MPa

Bolt size

3/4

33.9±5.6 (25±4)

M10

39.5±5.6 (29±4)

M10

Size

1

42.4±5.6 (31±4)

M10

62.2±5.6 (46±4)

M12

11/4

55.1±7.1 (41±5)

M10

93.3±8.4 (69±6)

M14

11/2

70.6±8.4 (52±6)

M12

169±11 (125±8)

M16

2

81.9±8.4 (60±6)

M12

282±11 (208±8)

M20

11-6

CONNECTOR

O-RING

NUT

FITTING

11. TOOLS

11.4

TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table11-3 indicates standard tightening torques applicable to cases where no particular note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections. Always tighten nuts and sleeves to proper torques. Table11-3

Manufacturer's name

Nippon A.M.C.

Ihara Koatu

Opposing flats (HEX) mm

Tightening torque N•m (lbf•ft)

ø10u1.5 (0.394u0.059)

19

49.0±9.8 (36±7.2)

ø15u2.0 (0.591u0.079)

27

118±12 (87±8.7)

ø18u2.5 (0.709u0.098)

32

147±15 (110±11)

ø22u3.0 (0.866u0.118)

36

216±22 (160±16)

ø28u4.0 (1.10u0.157)

41

275±27 (200±20)

ø35u5.0 (1.38u0.197)

55

441±44 (330±33)

Tube size OD u thickness mm (in)

Working pressure MPa (psi)

29.4 (4270)

29.4 (4270)

SLEEVE

NUT B

d

d

Parts No.

Parts No.

Tube size ød

Ihara Koatu

Nippon A.M.C.

Tube size ød

Opposing flats (HEX) mm

Ihara Koatu

Nippon A.M.C.

6

ZF93S06000

—

6

14

ZF93N06000

—

8

ZF93S08000

—

8

17

ZF93N08000

—

10

ZF93S10000

ZA93S10000

10

19

ZF93N10000

ZA93N10000

12

ZF93S12000

—

12

22

ZF93N12000

—

15

ZF93S15000

ZA93S15000

15

27

ZF93N15000

ZA93N15000

18

ZF93S18000

ZA93S18000

18

32

ZF93N18000

ZA93N18000

22

ZF93S22000

ZA93S22000

22

36

ZF93N22000

ZA93N22000

28

ZF93S28000

ZA93S28000

28

41

ZF93N28000

ZA93N28000

32

ZF93S32000

—

32

50

ZF93N32000

—

35

ZF93S35000

ZA93S35000

35

55

ZF93N35000

ZA93N35000

38

ZF93S38000

—

38

60

ZF93N38000

—

11-7

11. TOOLS

11.5

PLUG

11.5.1

PLUG FOR HYDRAULIC PIPE JOINT

A

(1) Cap nut (Joint plug)

H1

H

T screw

Applicable tube O. D : A 6 8 10 12 15 18 22 28

Opposing flats

Cap nut parts No.

T screw

ZF83H06000 ZF83H08000 ZF83H10000 ZF83H12000 ZF83H15000 ZF83H18000 ZF83H22000 ZF83H28000

M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5

Applicable tube O. D : A

Plug parts No.

6 8 10 12 15 18 22 28

ZF83P06000 ZF83P08000 ZF83P10000 ZF83P12000 ZF83P15000 ZF83P18000 ZF83P22000 ZF83P28000

H1 14 17 17 19 24 27 32 38

H 14 17 19 22 27 32 36 41

A

(2) Plug (Tube plug)

Sleeve Type joint body

Nut

d screw

A

(3) Nut

Applicable tube O. D : A 6 8 10 12 15 18 22 28 32 35 38

11-8

Nut parts No.

d screw

Opposing flats

ZF93N06000 ZF93N08000 ZF93N10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000

M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5 M42 X 1.5 M45 X 1.5 M48 X 1.5

14 17 19 22 27 32 36 41 50 55 60

11. TOOLS 11.5.2

PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw

O-ring

B PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring 19 PF1/4 ZE72X04000 ZD12P01100 1B P11 22 PF3/8 ZE72X06000 ZD12P01400 1B P14 27 PF1/2 ZE72X08000 ZD12P01800 1B P18 36 PF3/4 ZE72X12000 ZD12P02400 1B P24 41 PF1 ZE72X16000 ZD12P02900 1B P29

PF screw (2) PT screw

PT screw

B PT screw Plug parts No. ZE82T02000 PT1/8 ZE82T04000 PT1/4 ZE82T06000 PT3/8 ZE82T08000 PT1/2 ZE82T12000 PT3/4 ZE82T16000 PT1 ZE82T20000 PT1 1/4 ZE82T24000 PT1 1/2

B mm 5 6 8 10 14 17 22 22

(3) Plug for (F) flare hose

PF screw

60

PF screw Plug parts No. 2444Z2728D1 PF1/4 2444Z2728D2 PF3/8 2444Z2728D3 PF1/2 2444Z2728D4 PF3/4 2444Z2728D5 PF1

60

Opposing flats B

PF screw PF1/4 PF3/8 PF1/2 PF3/4 PF1 PF1 1/4

PF screw

Opposing flats F

Opposing flats E

11-9

Plug parts No. 2444Z2729D1 2444Z2729D2 2444Z2729D3 2444Z2729D4 2444Z2729D5 2444Z2729D6

E mm 14 17 23 27 36 40

B mm 14 17 22 27 36

F mm 19 22 27 36 41 50

11. TOOLS (4) Plug for ORS joints Male

Female

(5) Plug for half clamp 4-oH

For standard pressure : 20.6 MPa (2990 psi) Size

Plug part No.

C mm D mm

1/2 ZE12Q08000 38.10

C

3/4 ZE12Q12000 47.63 1 D

ZE12Q16000 52.37

1 1/4 ZE12Q20000 58.72

G mm

25.53~ 25.40 31.88~ 22.23 31.75 39.75~ 26.19 39.62 44.58~ 30.18 44.45 17.48

H mm

O-ring part No.

9

45Z91D2

11

ZD12P02600

11

ZD12P03400

11

ZD12P03800

H mm

O-ring part No.

9

2445Z831D1

11

ZD12P02600

13

ZD12P03400

15

ZD12P03800

For high pressure : 41.2 MPa (5970 psi) G

Size

Plug part No.

C mm D mm

1/2 ZE13Q08000 40.49 3/4 ZE13Q12000 50.80 1

ZE13Q16000 57.15

1 1/4 ZE13Q20000 66.68

11-10

G mm

25.53~ 25.40 31.88~ 23.80 31.75 39.75~ 27.76 39.62 44.58~ 31.75 44.45 18.24

11. TOOLS

11.6

SPECIAL SPANNER FOR TUBE

Applicable tube diameter mm (in)

Part No.

HEX (mm)

Drawing of a special spanner mm (in)

70(2.76)

15 (0.591)

2421T160

16 (0.630)

27

22 (0.866)

(0.315)

12.7

40(1.57)

(0.500

)

70(2.76) 42(1.65)

18 (0.709)

2421T138

22 (0.866)

19 (0.748)

32

22(0.866)

48(1.89)

22 (0.866)

2421T130

12.7

22 (0.866) 12.7

60(2.36)

28 (1.10)

2421T115

2421T231

46

32 (1.26)

2421T232

50

35 (1.38)

2421T314

55

11-11

)

22 (0.866) 12.7

28 (1.10)

(0.500

109(4.29) 14.5(0.571)

29 (1.142)

41

)

70(2.76) 11.5(0.453)

23 (0.906)

36

(0.500

(0.500

)

11. TOOLS

11.7

SPECIAL TOOLS Table11-4

No.

Tools name

1

Allen wrench Nominal B : 10, C : 11.3

Tools No.

Shape

Applicable

ZT22A10000

Pump suction Commercial tool length (L1) - cut length = Required length

40 (1.57") - 10 (0.39") = 30 (1.18")

2

Spanner or socket Nominal B : 17

Pump install

General tools CUT

3

Spanner Nominal S : 36

ZT12A36000

Swing motor A,B port Commercial tool outer width (D) - cut length = Required length

81 (3.19") - 16 (0.63") = 65 (2.56")

4

Plug PF1

Additional M10 X 22 threading for M10 eye bolt

ZE72X16000

PF1

For slinging the swing motor

O-ring M12 Eye bolt

For slinging the swing motor & Flare hose

ZS91C01200 or commercial equivalent 22

5

Eye bolt M12u22

M12

M8 Eye bolt

6

Plug (Nominal tube dia. 22) Reference Eye bolt Nut

ZF83P22000 Reference nut

ZS91C00800 ZF93N22000

M8 X 18 Addtional threading for M8 Eye bolt

11-12

Flare hose

11. TOOLS Table11-4 M8 Eye bolt

7

Plug Nominal 1-14UNS

YN01H01001P1

Eye bolt

ZS91C00800

M8 X 18 Additional threading HEX 27

Flare hose

1-14UNS

M8 Eye bolt

Plug 8

YN01H01002P1

M8 X 18 Additional threading

Nominal 1 3/16-12UN Eye bolt

HEX 36

Flare hose

ZS91C00800 1 3/16-12UN

M12 Eye nut

9

Plug PF1/2

ZE25F08000 Weld

Coupling half

For slinging the swivel joint

Coupling half PF 1/2

10

TORX driver (with tamper proof) T30 (For M6)

5.49

—

Point shape

11-13

For instrument panel cover (RH)

11. TOOLS

11.8

APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND

(1) For general use Manufacturer

Service

Screw locking compound

Sealing compound

Features

Loctite

Three-Bond

#242

1360K

Low strength

#262

1374

Middle strength

#271

1305

High strength

#515

1215

Sealing

(2) For specific location No.

Use

Manufacturer

Name

Equivalent

Applicable

(Manufacturer ; Loctite) Three-Bond

1

Sealing Loctite compound & adhesive Loctite

# 1901

Anti-seizure

Cylinder

# 1215 gray

# 5699

Swing motor

# 1211 white

# 5301J

Swing motor

# 1303B

# 211

Main pump

(Manufacturer ; ThreeBond) # 222 # 277

# 1344N

Main pump

# 1307N

Pilot valve

(Manufacturer ; ThreeBond) Parmatex 98D

# 1121

Sumitomo Chemical Co., Cyano Bond PO-1 Ltd. Shell petroleum

Shell Alvania EP2

Hydraulic oil tank : Hose

New Molyknock Grease 2

11-14

Swing bearing grease bath

11. TOOLS

11.9

SUCTION STOPPER

11.9.1

COMPONENTS

No.

NAME

PARTS No.

Q'TY

SUCTION STOPPER ASSY 24100P978F2

1

ROD

2420T4660D1

1

2

NUT

ZN16C08007

1

3

COVER

2414T2123D2

1

4

O-RING

45Z91D6

1

1 Rod

2 Nut 3 Cover 4 O-ring

Fig. 11-1 Components of suction stopper 11.9.2

DIMENSION

50 (1.97")

R8

O113 (4.45") 2

(0.787") 20

O8 (1.315")

600 (23.6")

M8 NUT

O100 +0.5 0 (3.94 +0.0197 ) 0

M8

O108 (4.25") COVER

ROD Fig. 11-2 Dimension of suction stopper

24100P978F2

11-15

SK250-8

SK200-8

SK200-6ES

SK200-6E

SK200-6

SK235SR

SK135SR

SK115SR

SK120-3

SK100-3

SK120-2

Part No.

SK100-2

Applicable model

SK120

APPLICABLE MODEL

SK100

11.9.3

11. TOOLS

11.10

COUNTER WEIGHT LIFTING JIG

(1) Standard eye bolt

Size Part No. d L M8 15 ZS91C00800

80 (176)

M10 18 ZS91C01000

150 (331)

M12 22 ZS91C01200

220 (485)

M16 27 ZS91C01600

450 (992)

Vertical lifting load kg (lbs)

L

M20 30 ZS91C02000 630 (1390) M24 38 ZS91C02400 950 (2090)

d

M30 45 ZS91C03000 1500 (3310) M36 55 ZS91C03600 2300 (5070) M42 65 ZS91C04200 3400 (7490) M48 70 ZS91C04800 4500 (9920) Fig. 11-3 Eye bolt

11-16

11. TOOLS

11.11

UPPER FRAME LIFTING JIG

No.

NAME

Q'TY

TYPE

1 MASTER LINK L

1

KITO HL050

2 HIGH COUPLING HC

9

KITO HC020

3 CHAIN

1

8 4.4m(14' 5")

4 CHAIN

2

8 1.5m(4' 11")

5 GRAB HOOK H

1

KITO HH020

6 HOOK

2

KITO HJ050

Fig. 11-4 Upper frame lifting jig

11-17

11. TOOLS

11.12

ENGINE MOUNTING PEDESTAL Material : Wood Unit ; mm (inch)

245 (9.65)

6

744 (29.3)

2 750 (29.5)

375 (14.8)

400 (15.7) 175(6.89)

240 (9.45)

120 120 (4.72) (4.72)

175(6.89)

3

375 (14.8)

1

6

6 100 (3.94)

945 (37.2)

5 6

6

2 X 1 piece

4 X 1 piece

400 (15.7)

352 (13.9)

200(7.87)

213(8.39) 250(9.84)

0 R5 .0) (2 t 24 (0.95)

t 24 (0.95)

5 X 1 piece

3 X 1 piece

670 (26.4)

400 (15.7)

120 (4.72)

945 (37.2)

6 X 5 pieces t 24 (0.95)

R5 (2. 0 0)

10(0.39)

100(3.94)

t50 (2.0)

Fig. 11-5 Engine stand

11-18

10(0.39) 190 (7.48)

t 24 (0.95)

90 (3.5)

(2.2)

145 (5.71)

352 (13.9)

200 (7.87) 55

352 (13.9)

50(2.0)

25 (0.98)120 (4.72) 5(0.2)

t 50 (2.0)

1 X 1 piece

670 (26.4) 430 (16.9)

200 (7.9) 55 (2.2)

300 (11.8)

750 (29.5)

275 (10.8)

11. TOOLS

TRACK SPRING SET JIG M30

Retainer nut

Retainer plate )

.6"

(27.6")

(12

Stand (15.0")

11.13

Hydraulic jack

Base Fig. 11-6 Track spring set jig

11-19

11. TOOLS

[MEMO]

11-20

12. STANDARD MAINTENANCE TIME TABLE TABLE OF CONTENTS 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4 12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) ................................................................................................12-15 12.2.1

MEASURING METHOD .........................................................................................12-15

12.2.2

WORKING CONDITION .........................................................................................12-15

12.2.3

STANDARD TIME CONSTITUENT ........................................................................12-15

12.2.4

MEANING OF WORDS IN USE .............................................................................12-17

Book Code No. S5LQ1218E01 12-1

12

12. STANDARD MAINTENANCE TIME TABLE Issue

Date of Issue

Applicable Machines

First edition

July, 2007

n

n

n

n

September, 2007

n

E265B : LQ12-06001~ E265BLC : LL12-05001~

12-2

Remarks S5LQ1218E01 (NHK Russia) n (NHK Middle East) n NHK Russia (HS Engine)

K K K

12. STANDARD MAINTENANCE TIME TABLE PREFACE (1) Working Conditions 1) Workers : More than one worker shall be 1st class service technician (having five years or more of field experience and having received training in the operation). 2) Equipment : Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for specific self inspection activities. 3) Place : A flat land where work may be performed and to which a service car or a truck crane is accessible. (2) Range of standard maintenance time 1) Standard maintenance time=Direct maintenance timeuPreparation time 2) Direct maintenance time : Net time actually spent for maintenance 3) Spare time : Time needed to move machines for service, prepare safety operations, discuss work, and process the needs of the body. (3) Extra time (not included in the standard service time) 1) Repair time : Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting. 2) Items excluded from service time because of uncertainty in time : Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults, diagnosis, and inspection. 3) Indirect time : Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time because of user’s convenience in the field, paper work after returning to shop, and preparation of bills. 4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately. 5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks. (4) Applicable machine for estimation of standard maintenance time 1) Standard machine 2) A well maintained and controlled machine with a standard combination of attachments which is used in a general environment.

12-3

12. STANDARD MAINTENANCE TIME TABLE

12.1

STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR

(1) Standard maintenance time table 1) Units of working time : 6 minutes = 0.1 hour 2) Calculating method of standard maintenance time : Maintenance time=Working timeuNumber of workers (Working time=Maintenance timeyNumber of workers) 3) When more than one operation is going on : Add each standard service time. A pure time (readily started) is given except covers easily removed by hand. Assy works include the following works marked with black dot •. 4) O/H : The removing and attaching time is not included. 5) Abbreviations in the table. A/C

: Air conditioner

C/V

: Control valve

O/H

: Over haul

ASSY

: Assembly

Cyl

: Cylinder

SOL

: Solenoid

ATT

: Attachment

E/G

: Engine

SW

: Switch

BRG

: Bearing

F hose

: Flexible hose

V

: Valve

(2) Classification of working code No.

Group

Remarks

01

Attachment

Indicates installing, removing, replacement and overhaul.

02

Cab & Guard

03

Swing frame

04

Travel system

06

Electric equipments

Indicates the installing, removing and replacement of single items.

09

E/G relation

Indicates overhaul of the single engine. (Materials prepared by manufacturer )

(3) Conditions for standard service time of the engine 1) Tools designated by E/G maker are used 2) Genuine parts are changed 3) Correct working procedures are observed. •

The time required for works specified in this Chapter shows the total time for maintenance.

12-4

12. STANDARD MAINTENANCE TIME TABLE

01 Attachment

Group

Location

Work to be done

Unit

Remarks

Unit : Hour

00

Bucket relation

01

Bucket ASSY

Detach/attach

1 pc.

02

•

Preparation

1 pc.

03

• Bucket attaching pin

Detach/attach

1

04

• Bucket drive pin

Detach/attach

1

0.1

05

• Bucket sling and movement

Preparation

1 pc.

0.2

06

Bucket (single)

O/H

1 pc.

07

• Tooth

Replace

1 pc.

0.6

08

• Side cutter

Replace

1 pc.

1.2

09

• Bushing

Replace

1 pc.

0.6

10

Arm relation

11

Arm ASSY

Detach/attach

1 pc.

1.2

12

• Bucket cylinder attaching and detaching position and piping

Preparation

1 pc.

0.4

13

• Bucket cylinder rod pin

Detach/attach

1 pc.

Include stopper pin

0.1

14

• Bucket cylinder head pin

Detach/attach

1 pc.

Include stopper pin

0.1

15

• Bucket cylinder assy

Detach/attach

1 pc.

16

• Arm cylinder rod pin

Detach/attach

1 pc.

Include stopper pin

0.1

17

• Boom top pin

Detach/attach

1 pc.

Include wire stop pin.

0.1

18

• Arm sling and movement

Detach/attach

1 pc.

30

Boom relation

Bucket attaching and detaching position

See 32.1.2 Include adjustment.

0.6 0.1

Include stopper pin.

Not include attaching and detaching

0.1

2.4

See 32.1.3

0.1

0.2 See 32.1.4

31

Boom ASSY

Detach/attach

1 pc.

1.4

32

• Boom attaching and detaching position Preparation

1 pc.

0.1

33

• Boom cylinder temporary slinging

Preparation

2 pcs.

0.2

34

• Boom cylinder rod pin

Detach/attach

2

35

• Boom cylinder piping

Detach/attach

2 pc.

0.2

36

• Arm & bucket piping

Detach/attach

1 pc.

0.2

37

• Boom assy temporary slinging

Detach/attach

1 pc.

0.1

38

• Boom foot pin

Detach/attach

1

39

• Boom assy slinging

Detach/attach

1 pc.

0.2

40

Arm cylinder attaching and detaching Detach/attach

1 pc.

0.4

41

• Arm cylinder piping

Detach/attach

1 pc.

0.2

42

• Arm cylinder head pin

Detach/attach

1 pc.

43

• Arm cylinder slinging

Detach/attach

1 pc.

0.1

50

Boom cylinder attaching and detaching

Detach/attach

2 pcs.

0.7

51

• Boom cylinder piping

Detach/attach

2

0.3

52

• Boom cylinder head pin

Detach/attach

2 pcs.

0.2

53

• Boom cylinder slinging

Detach/attach

2

0.2

60

Bucket cylinder

O/H

1

3.6

61

• Pin bushing

Replace

1

70

Arm cylinder

O/H

1

12-5

Include two stopper pins.

Include stopper pin.

Include stopper pin.

Include seal.

0.2

0.2

0.1

1.2 3.6

12. STANDARD MAINTENANCE TIME TABLE

Group

02 Cab & Guard

01

71

Location • Pin bushing

Work to be done

Unit

Replace

1 set

Remarks

Unit : Hour

Include seal.

1.2

Include seal.

1.2

80

Boom cylinder

O/H

2

81

• Pin bushing

Replace

1 set

7.0

10

Cab relation

11

Cab ASSY

Detach/attach

12

• Front lower glass, floor mat

Detach/attach 1 pc. each

0.1

13

• Seat rear cover top, bottom

Detach/attach

4 places

0.2

14

• Seat rear cover top, bottom

Detach/attach 1 pc. each

0.2

15

• Right side panel (include A/C duct) Detach/attach

3

0.3

16

• Cable and harness (electric)

Detach/attach

6

0.2

17

• Cab mounting bolt

Detach/attach

8 pcs.

0.2

18

• Cab slinging

Detach/attach

3 places

0.2

20

Guard relation

21

Bonnet assy (31)

Detach/attach

1 pc.

0.2

22

Guard (5)

Detach/attach

1 pc.

0.2

23

Guard (6)

Detach/attach

1 pc.

0.2

24

Guard assy (3)

Detach/attach

1 pc.

0.2

25

Stay (7)

Detach/attach

1 pc.

0.2

26

Guard (2)

Detach/attach

1 pc.

0.2

27

Panel assy (21)

Detach/attach

1 pc.

0.2

28

Panel assy (23)

Detach/attach

1 pc.

0.2

29

Panel assy (22)

Detach/attach

1 pc.

0.2

30

Guard assy (16)

Detach/attach

1 pc.

0.2

31

Guard (14)

Detach/attach

1 pc.

0.2

32

Guard (15)

Detach/attach

1 pc.

0.2

34

Pillar (11)

Detach/attach

1 pc.

0.2

35

Beam (4)

Detach/attach

1 pc.

0.2

36

Pillar (10)

Detach/attach

1 pc.

0.2

37

Pillar (12)

Detach/attach

1 pc.

0.2

38

Guard assy (17)

Detach/attach

1 pc.

0.2

39

Guard assy (13)

Detach/attach

1 pc.

0.2

40

Guard (19)

Detach/attach

1 pc.

0.2

41

Cover (1)

Detach/attach

1 pc.

0.2

42

Guard assy (2)

Detach/attach

1 pc.

0.2

43

Guard assy (3)

Detach/attach

1 pc.

0.2

44

Plate (19)

Detach/attach

1 pc.

0.2

45

Cover assy (1)

Detach/attach

1 pc.

0.2

See 33.1.2 1 pc.

1.4

See 33.1.4

33

Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.

12-6

12. STANDARD MAINTENANCE TIME TABLE

03 Swing frame

02 Cab & Guard

Group

Location

Work to be done

Unit

Remarks

Unit : Hour

50

Under cover relation

See 33.1.5

51

Cover (1)

Detach/attach

1 pc.

0.1

52

Cover (2)

Detach/attach

1 pc.

0.1

53

Cover (3)

Detach/attach

1 pc.

0.1

54

Cover (4)

Detach/attach

1 pc.

0.1

55

Cover (5)

Detach/attach

1 pc.

0.1

56

Cover (6)

Detach/attach

1 pc.

0.1

57

Cover (7)

Detach/attach

1 pc.

0.1

58

Cover (8)

Detach/attach

1 pc.

0.1

60

Counterweight relation

61

Counterweight ASSY

Detach/attach

1 pc.

0.6

62

• Counterweight lifting eye bolt

Detach/attach

1 set

0.1

63

• Counterweight temporary slinging

Preparation

1 pc.

0.2

64

• Counterweight mounting bolt

Detach/attach

1 pc.

0.2

65

• Counterweight slinging

Detach/attach

1 pc.

0.1

10

Intake relation

11

Air cleaner ASSY

Detach/attach

1 pc.

0.4

12

• Hose (3)

Detach/attach

1

0.1

13

• Air cleaner mounting bolt

Detach/attach

1 set

0.2

14

• Element

Replace

1

0.1

20

Exhaust relation

21

Muffler ASSY

Detach/attach

1 pc.

0.4

22

• U bolt

Detach/attach

1 pc.

0.2

23

• Clamp ASSY

Detach/attach

1 pc.

0.2

30

Radiator relation

31

Radiator ASSY

32

• Coolant (LLC)

33

See 33.1.11

See 33.1.9

See 33.1.10

See 33.1.12 Detach/attach

1 pc.

4.0

Replace

1 pc.

0.3

• • Concentration of coolant

Measuring

1 pc.

0.2

34

• A/C condenser

Detach/attach

1 pc.

0.3

35

• Stay

Detach/attach

1 pc.

0.1

36

• Bracket

Detach/attach

1

0.3

37

• Sub tank hose

Detach/attach

1 pc.

0.1

38

• Fan guard

Detach/attach

1 pc.

0.3

39

• Water hose (radiator ~ E/G)

Detach/attach

2

0.5

40

• Radiator mounting bolts removing

Detach/attach

1 set

0.2

41

• Under cover

Detach/attach

1 pc.

0.1

42

• Hydraulic oil tank suction stopper

Detach/attach

1 pc.

0.2

43

• Hydraulic oil piping

Detach/attach

1 pc.

0.6

Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.

12-7

12. STANDARD MAINTENANCE TIME TABLE

03 Swing frame

Group

Location

Work to be done

Unit

Remarks

Unit : Hour

44

• Inter cooler hose & tube (E/G to inter cooler)

Detach/attach

2 pcs.

0.5

45

• Radiator lifting or hoisting

Detach/attach

1 pc.

0.2

46

• Radiator inter cooler core & oil cooler

Cleaning

1 pc.

1.0

50

Fuel relation

51

Fuel tank ASSY

52

• Fuel

53

See 33.1.6 Detach/attach

1 pc.

1.8

Replace

1 pc.

0.3

• Hose (water separator side)

Detach/attach

2

0.1

54

• Water separator

Detach/attach

1 pc.

0.1

55

• Tube (tank side)

Detach/attach

1

0.1

57

• Fuel tank installing bolts

Detach/attach

1 pc.

0.3

58

• Tank slinging

Detach/attach

1 pc.

0.3

Other necessary works

Detach/attach

1 pc.

Removing and installing guard

0.4

60

Hydraulic oil tank relation

61

Hydraulic oil tank ASSY

Detach/attach

65

• Cover

Detach/attach

1 pc.

0.2

66

• Hydraulic oil

Replace

1 pc.

0.5

68

• Pilot drain hose

Detach/attach

1 pc.

0.2

69

• Pump suction hose

Detach/attach

1 pc.

0.5

70

• Mounting bolt

Detach/attach

1 pc.

0.2

71

• Hydraulic oil tank slinging

Detach/attach

1 pc.

0.3

72

• Return filter

Replace

1

0.2

73

• Suction filter

Cleaning

1

0.2

80

Pump relation

81

Pump ASSY

Detach/attach

1 pc.

3.2

82

• Hydraulic oil tank cover

Detach/attach

1 pc.

0.2

83

• Strainer & stopper

Detach/attach

1 pc.

0.3

84

• Piping

Detach/attach

1 set

1.0

85

• Guard

Detach/attach

5 pcs.

1.0

86

•

Detach/attach

1 pc.

0.5

87

• Cleaning

Cleaning

1 pc.

0.1

88

• Vent air

Adjust

1 pc.

0.1

89

Pump ASSY

O/H

1 pc.

4.0

90

Swing motor unit relation

91

Swing motor ASSY

Detach/attach

1 pc.

2.4

92

• Piping

Detach/attach

1 set

1.0

93

• Mounting bolt

Detach/attach

1 pc.

0.7

94

• Unit slinging

Detach/attach

1 pc.

0.5

95

• Cleaning and sealant

Cleaning

1 set

0.2

Pump slinging

See 33.1.7 1 pc.

3.0

See 33.1.8

See 33.1.18

12-8

12. STANDARD MAINTENANCE TIME TABLE

Group

Location

Work to be done

Unit

Unit : Hour

96

Swing motor

O/H

1 pc.

3.6

97

Swing reduction gear

O/H

1 pc.

4.2

100 Swivel joint relation

See 33.1.19

101 Swivel joint ASSY

Detach/attach

1

2.6

102 • Piping (Top part only)

Detach/attach

1 set

0.5

103 • Whirl stop bolt

Detach/attach

1

0.2

104 • Cover

Detach/attach

1

0.4

105 • Joint & elbow

Detach/attach

1 set

0.4

106 • Mounting bolt

Detach/attach

1 set

0.4

107 • Swivel joint slinging

Detach/attach

1

0.4

108 • Cleaning

Cleaning

1 set

0.3

109 Swivel joint

O/H

1 set

Removing and installing guard

3.6

Detach/attach

1 set

Lower piping

0.6

Other necessary works

03 Swing frame

Remarks

120 Main control valve

See 33.1.15

121 Main control valve ASSY

Detach/attach

1 pc.

2.5

122 • Attach tag to port name of pipe

Preparation

1 pc.

0.6

123 • Piping

Detach/attach

1 set

1.7

124 • Bracket mounting bolt

Detach/attach

1 pc.

0.1

125 •

Valve slinging

Detach/attach

1 pc.

0.1

126 Main control valve ASSY

Detach/attach

1 set

6.0

Detach/attach

1 set

131 Solenoid valve ASSY

Detach/attach

1

1.0

132 • Attach tag to port name of pipe

Preparation

1

0.2

133 • Piping

Detach/attach

1 set

0.5

134 • Mounting bolt

Detach/attach

1

0.3

Other necessary works

Guard

0.4

130 Valve relation

140 Engine (E/G) mounting relation

See 33.1.13

141 Engine ASSY

Detach/attach

1 pc.

142 • Harness connector & grounding & cable connection

Detach/attach

1 pc.

0.3

143 • Fuel hose

Detach/attach

1 pc.

0.1

144 • Others

Detach/attach

1 set

0.5

145 • Mounting bolt

Detach/attach

1 pc.

0.5

146 • Engine slinging

Detach/attach

1 set

0.2

Cleaning

1 pc.

0.3

O/H

1 set

147 • Cleaning 148 Engine

12-9

After removing pump & radiator

Reference for engine (Chapter 51)

1.8

12. STANDARD MAINTENANCE TIME TABLE

Location

Work to be done

Unit

Other necessary works

Detach/attach

1 set

Removing and installing guard

0.6

Detach/attach

1 set

Removing and installing Counterweight

0.6

Detach/attach

1 set

Removing and installing pump

3.2

Detach/attach

1 set

Removing and installing air cleaner 0.4

Detach/attach

1 set

Removing and installing muffler

0.4

Detach/attach

1 set

Removing and installing radiator

4.0

03 Swing frame

Group

150 Upper frame

Unit : Hour

See 33.1.20

151 Upper frame ASSY

Detach/attach

1 pc.

152 • Mounting bolt

Detach/attach

1 set

0.4

153 • Upper frame slinging

Detach/attach

1 pc.

0.4

154 • Cleaning

Cleaning

1 pc.

0.3

155 • Sealant

Apply

1 pc.

0.2

Detach/attach

1 set

Cab

1.4

Detach/attach

1 set

Guard

0.4

Detach/attach

1 set

Counterweight

0.6

Detach/attach

1 set

Boom

1.4

Other necessary works

04 Travel system

Remarks

After removing swivel joint

1.3

00

Travel relation

01

Track link ASSY

Detach/attach

02

•

Preparation One side

0.1

03

• Master pin

Detach/attach

One side

0.5

04

• Track link extending and winding

Detach/attach

One side

0.5

05

Shoe plate

Replace

1 pc.

0.4

10

Upper roller relation

11

Upper roller ASSY

12

Upper roller

20

Lower roller relation

21

Lower roller ASSY

22

Lower roller

30

Front idler relation

31

Front idler ASSY

Detach/attach

One side After removing track link

0.6

32

Front idler ASSY slinging

Detach/attach

One side

0.3

33

Front idler ASSY

Detaching One side

0.3

34

Idler ASSY

O/H

One side

1.0

35

Idler adjuster ASSY

O/H

One side Replace spring

2.4

36

• Grease cylinder

O/H

One side

0.6

40

Sprocket

41

Sprocket

Track link attaching and detaching position

See 34.1.2 One side Include adjustment of tension

1.5

See 34.1.3 Detach/attach

1

O/H

1

After removing track link

0.2 1.0

See 34.1.4 Detach/attach

1

0.2

O/H

1

1.5 See 34.1.5

See 34.1.6 Replace

12-10

One side After removing track link

0.6

12. STANDARD MAINTENANCE TIME TABLE

04 Travel system

Group

Location

Work to be done

Unit

Remarks

Unit : Hour

50

Travel motor relation

See 34.1.7

51

Travel motor ASSY

Detach/attach

One side After removing track link

1.7

52

• Motor cover

Detach/attach

One side

0.1

53

• Hydraulic piping

Detach/attach

One side

0.9

54

• Motor mounting bolt

Detach/attach

One side

0.5

55

• Motor slinging

Detach/attach

One side

0.1

56

Motor cleaning

Cleaning

One side

0.1

57

Travel motor

O/H

One side

3.6

58

Travel reduction gear

O/H

One side

3.6

60

Swivel joint relation

61

Pipe on swivel joint travel side

Detach/attach

1 pc.

Include bonnet assy removing and installing.

0.6

62

Swivel joint

O/H

1 pc.

See 33.2.6

3.6

70

Swing bearing

71

Swing bearing ASSY

Detach/attach

1 pc.

72

Swing bearing mounting bolt

Detach/attach

1 pc.

0.5

73

Swing bearing slinging

Detach/attach

1 pc.

0.3

C-1 Controller (KPSS)

Replace

1

0.5

C-2 Gauge cluster

Replace

1

1.0

C-4 Air conditioner Amplifier

Replace

1

2.0

D-4 Diode

Replace

1

0.3

D-5 Diode

Replace

1

0.3

D-6 Diode

Replace

1

0.3

D-9 Diode

Replace

1

0.3

D-10 Diode

Replace

1

0.3

D-12 Diode

Replace

1

0.3

D-13 Diode

Replace

1

0.3

D-14 Diode

Replace

1

0.3

D-15 Diode

Replace

1

0.3

D-16 Diode

Replace

1

0.3

D-17 Diode

Replace

1

0.3

D-18 Diode

Replace

1

0.3

D-19 Diode

Replace

1

0.3

D-20 Diode

Replace

1

0.3

D-25 Diode

Replace

1

0.3

See 34.1.8 After removing upper frame

0.7

Controller

06 Electric equipments

Diode

12-11

12. STANDARD MAINTENANCE TIME TABLE Unit : Hour

Work to be done

Unit

E-1 Fuse & relay box

Replace

1

0.3

E-2 Alternator

Replace

1

1.0

E-3 Hour meter

Replace

1

0.3

E-5 Horn (High)

Replace

1

0.3

E-6 Horn (Low)

Replace

1

0.3

E-7 Tuner

Replace

1

0.3

E-8 Speaker left

Replace

1

0.3

E-9 Speaker right

Replace

1

0.3

E-10 Receiver dryer

Replace

1

Include gas sealing.

1.0

E-11 Air compressor

Replace

1

Include Counterweight removing and installing.

1.0

E-12 Battery

Replace

2

0.4

E-13 Travel alarm (Middle East)

Replace

1

0.3

E-14 Cigarette lighter

Replace

1

0.3

E-15 Fusible link

Replace

1

0.2

E-22 DC-DC converter

Replace

1

0.3

E-23 12V socket

Replace

1

0.3

E-27 Accel emergency mode volume

Replace

1pair

0.5

L-1 Boom work light left

Replace

1

L-2 Work light right

Replace

1

0.2

L-5 Room light

Replace

1

0.2

L-6 Boom cylinder work light (right)

Replace

1

0.2

L-7 Cab work light

Replace

1

0.2

M-1 Starter motor

Replace

1

M-3 Wiper motor

Replace

1

0.5

M-4 Washer motor

Replace

1

0.5

M-8 Grease motor (OPT)

Replace

1

0.5

M-9 Skylight wiper motor (OPT)

Replace

1

0.5

Replace

1

0.5

Group

Location

Remarks

06 Electric equipments

Electric equipments

Light Bulb

0.2

Motor Include Counterweight removing and installing.

1.0

Proportional valve PSV-A Arm variable recirculation proportional valve PSV-B

P2 bypass cut proportional valve

Replace

1

PSV-C

Travel straight proportional valve

Replace

1

0.5

PSV-D

P1 bypass cut proportional valve

Replace

1

0.5

12-12

Include proportional valve block removing and installing.

0.5

12. STANDARD MAINTENANCE TIME TABLE

Group

Location

Work to be done

Unit

Remarks

Unit : Hour

PSV-P1

P1 pump proportional valve

Replace

1

0.5

PSV-P2

P2 pump proportional valve

Replace

1

0.5

R-1 Battery relay

Replace

1

0.3

R-2 Starter relay

Replace

1

0.3

R-3 Glow relay

Replace

1

0.3

R-4 Safety relay

Replace

1

0.1

R-5 Horn relay

Replace

1

0.1

R-6 Work light relay

Replace

1

0.1

R-8 Travel alarm relay (Middle East)

Replace

1

0.1

R-23 Auto idle stop relay 1

Replace

1

0.1

R-24 Auto idle stop relay 2

Replace

1

0.1

R-25 E/G emergency stop relay

Replace

1

0.1

R-26 Safety lock lever relay

Replace

1

0.1

R-28 Alternator relay

Replace

1

0.1

R-29 Wiper motor relay (Normal rotation)

Replace

1

0.1

R-30 Wiper motor relay (Reverse rotation)

Replace

1

0.1

R-31 Wiper motor relay arc prevention relay

Replace

1

0.1

R-32 Washer motor relay

Replace

1

0.1

SE-1 Pressure sensor : Bucket digging

Replace

1

0.3

SE-2 Pressure sensor : Bucket dump

Replace

1

0.3

SE-3 Pressure sensor : Boom up

Replace

1

0.3

SE-4 Pressure sensor : Boom down

Replace

1

0.3

SE-5 Pressure sensor : Swing

Replace

1

0.3

SE-7 Pressure sensor : Arm in

Replace

1

0.3

SE-8 Pressure sensor : Arm out

Replace

1

0.3

SE-9 Pressure sensor : Travel right

Replace

1

Include under cover removing and installing

0.5

SE-10 Pressure sensor : Travel left

Replace

1

Include under cover removing and installing

0.5

SE-11 Pressure sensor : P2 side OPT.

Replace

1

Include under cover removing and installing

0.5

SE-13 Engine speed sensor

Replace

1

Include under cover removing and installing

0.5

SE-15 Engine water temperature sensor

Replace

1

Include guard removing and installing

0.5

SE-16 Accel potentio

Replace

1

SE-20 Pressure sensor : P1 side : P1 side (OPT.)

Replace

1

SE-22 Pressure sensor : P1 pump

Replace

1

0.5

SE-23 Pressure sensor : P2 pump

Replace

1

0.5

SV-1 Swing parking SOL

Replace

1

Include proportional valve block removing and installing.

0.5

SV-2 Attachment boost pressure SOL

Replace

1

Include proportional valve block removing and installing.

0.5

06 Electric equipments

Relay

Sensor

0.5 Include under cover removing and installing

0.5

Solenoid

12-13

12. STANDARD MAINTENANCE TIME TABLE Work to be done

Unit

SV-3 2-speed travel SOL

Replace

1

Include proportional valve block removing and installing.

0.5

SV-4 Safety lever lock SOL

Replace

1

Include proportional valve block removing and installing.

0.5

SW-1 Key switch

Replace

1

0.3

SW-4 Swing parking release switch

Replace

1

0.3

SW-7 Engine oil pressure switch

Replace

1

0.3

SW-8 Clogged air filter switch

Replace

1

0.3

SW-10

Horn switch (left)

Replace

1

0.3

SW-11

Safety lever lock switch

Replace

1

0.3

SW-13

Travel alarm switch (For Middle East)

Replace

1

0.3

SW-19

Wiper interlock switch

Replace

1

0.3

SW-20

Attachment power boost switch (right)

Replace

1

0.3

SW-26

Cab work light switch

Replace

1

0.3

SW-27

Engine cooling coolant level switch

Replace

1

0.3

SW-55

Boom work light switch

Replace

1

0.3

06 Electric equipments

Group

Location

Remarks

Unit : Hour

Switch

12-14

12. STANDARD MAINTENANCE TIME TABLE

12.2

ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION)

Preface This standard working time is based on the work time required for service of engine like disassembly, check, adjustment and assembly and so on under a following condition. This standard working time is provided under the following conditions. 12.2.1

MEASURING METHOD

(1) The time from the worker beginning working at the regular position of machine to the returning to the regular position after completion of the work is counted as working time. (2) The measuring unit is in 0.1 minute, and then round up the fractions. (3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted as the working time. But light work which can be carried out easily by a person and the efficient is higher is counted as a workman. 12.2.2 12.2.2.1

WORKING CONDITION TOOLS, INSTRUMENT

(1) Hand tool ; Tools which are commercially available and each workman usually carries (2) Common tool ; Tools which are commercially available and each workman do not usually carry but the storing place is specified (3) Special tool ; Tools especially prepared by HINO Motor’s Ltd. and the storing place is specified (4) Machine tool ; When measuring equipment and instrument are used, the time required to move parts to the specified place is included but the time waiting for tool is not included as a general rule 12.2.2.2

WORKING PROCEDURE

The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor’s Ltd. Service Technical Dept. Training Group. 12.2.2.3

STANDARD WORKMAN QUALIFICATION

Workmen shall basically acquire 2~3 years of maintenance experience of HINO 12.2.3 12.2.3.1

STANDARD TIME CONSTITUENT STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD ALLOWANCE TIME

(1) Net working time The time workman works actually and the time required for measurement, cleaning, and so on is included, but the time required for troubleshooting is not included (2) Standard time Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts and so on, and for the work site clean-up. (3) Standard allowance time Calculate the allowance time directly required for workmen from the following equation. Net standard time u HINO allowance rate Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position and so on.

12-15

12. STANDARD MAINTENANCE TIME TABLE 12.2.3.2 12.2.3.2.1

ALLOWANCE RATE, STANDARD PREPARATION TIME HINO allowance rate (0.15~0.75)

(1) Basic rate : 0.10 (2) Working posture allowance (Fatigue coefficient) : Take any one of the followings according to the work contents. Standing work : 0.05 Work in bent posture : 0.10 Work while lying : 0.15 (3) Difficult work allowance : 0.30 (4) Seized rusted section (For new vehicle) : 0.50 Take any one of above (3) and (4). Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.05 = 0.15 Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75 12.2.3.2.2

STANDARD WORKING TIME

(1) Working standard time : 3 minutes (One time for a set of works) (2) Special tool standard time : 3 minutes (One time for a set of works) (3) Standard time of non-portable machine : 3 minutes (For single work) (4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more) (One time for a set of works) (5) Test : 15 minutes (One time for a set of works) (6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes (One time for a set of works) (7) General cleaning : 2 minutes (One time for a set of works) (8) Safety treatment like wheel stopper, and so on : 3 minutes (9) Visual checks : 2 minutes The preparation time is classified into as described above, and only items required for the every work are selected, calculated and counted as preparation time of the work.

12-16

12. STANDARD MAINTENANCE TIME TABLE 12.2.4

MEANING OF WORDS IN USE

• Completed machine : When detaching, replacing and adjusting the specified parts, it means the time which is determined by addition of the preparation time, net working time and standard allowance time of the work. • Single unit : When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed machine". • Removal and installation : The work to remove specified parts from machine and to attach the parts, and then to perform necessary adjustment • Simultaneous replacement : The work to remove specified parts in 2 types or more from machine and to attach the spare parts, and then to perform necessary adjustment • Adjustment : The work to carry out necessary adjustment with the specified parts removed or attached : • Overhaul : The work to remove specified assembled parts from machine, disassemble and check them, and then to attach the spare parts to machine and to perform necessary adjustment • Include : Explains the contents of work to make the specified work range clear • Exclude : Shows the work which is not included in the specified primary work • Unit : Time is shown by hour.

12-17

12. STANDARD MAINTENANCE TIME TABLE SK330-8

SK200-8, SK250-8

Work No.

Work

Work unit

Q'ty

Works 1

1

00101

Engine adjustment A set

2

00103

Engine adjustment B set

3

00111

Compression measuring

8

99012

9

99013

Replacing cylinder, block, piston, ring and liner simultaneously Replacing crank shaft, piston, ring and liner simultaneously

Completed Timing adjustment machine Valve clearance adjustment

Adding hour

1

by 1 each

by 1 each

2.3

2.5

—

—

3.4

4.3

Single unit From engine is removed condition

27.4

31.6

Single unit From engine is removed condition

20.8

25.8

24.4

30

Completed machine Completed machine

A set and nozzle adjustment

Adding hour

Include; Engine warm-up, valve clearance adjustment, removing air cleaner element and battery specific gravity measurement

From engine is removed condition

Replacing cylinder block

Single unit

Include; Valve clearance adjustment Exclude; Installing expansion plug knock pin

11

00126

Replacing crank shaft

Single unit From engine is removed condition

18.4

22.8

12

00127

Replacing crank shaft main bearing

Single unit From engine is removed condition

18.4

22.8

38.5

44.3

2.3

3.1

From engine is removed condition Include; Adjustment of water pump, oil pump, valve clearance, valve lapping and

15

00151

Engine overhaul

Single unit measurement/cleaning Exclude; Replacing of injection pump, electrical equipment, water pressure test, clutch overhaul and valve guide

16

00152

Compression measuring

Single unit

From piston & connecting rod are re-

17

00153

Replacing piston

Single unit

18

00154

Replacing piston ring

Single unit

19

00155

Replacing cylinder liner

Single unit

20

00157

Replacing connecting rod

Single unit

21

00158

Replacing piston pin bushing

Single unit condition

moved conditions From piston & connecting rod are removed conditions From piston & connecting rod are removed conditions From piston & connecting rod are removed conditions

0.5

0.5

0.5

0.5

0.2

0.2

0.2

0.2

0.4

0.4

0.4

0.4

0.3

0.3

0.3

0.3

0.4

0.4

0.4

0.4

0.4

0.4

0.4

0.4

From connecting rod is a single unit Include; Reaming 26

00165

Replacing expansion plug

41

00302

Valve clearance adjustment

42

00305

43

00306

44

00304

45

00312

46

00313

Replacing rocker arm

47

00314

Replacing rocker arm support

48

00315

Replacing rocker arm shaft

50

00322

Removal and installing cylinder head

51

00323

Replacing cylinder head

Replacing rocker chamber cover upper Replacing rocker chamber cover lower Replacing rocker chamber cover gasket Removal and installing rocker arm and support

Single unit Completed

1.7

2.0

One set

1.3

1.4

One set Include; Removal and installing upper

—

4.3

One set

1.3

1.4

2.6

3.3

2.6

3.4

2.6

3.4

2.6

3.4

8.2

10.4

11.5

16.9

machine

Completed machine Completed machine Completed machine Completed machine Completed Excluding; Removal and installing of nozzle machine

holder or injector and injector sub harness

Completed Include; Valve lapping machine

Exclude; Replacing of valve guide

12-18

12. STANDARD MAINTENANCE TIME TABLE SK330-8

SK200-8, SK250-8

Work No.

Work

Work unit

Q'ty

Works 1

Adding hour

1

by 1 each

Adding hour by 1 each

Include; Valve lapping 52

00324

Overhaul of cylinder head

Completed Exclude; Replacing of valve guide, machine

water pressure test and replacing

13.3

18.8

8.2

10.4

10.2

15.6

4.9

8.8

5.3

9.4

valve seat 53

00325

Replacing cylinder head gasket

54

00326

Replacing valve

55

00327

Replacing valve spring

57

00328

Replacing valve stem seal

61

00376

62

00377

Removal and installing camshaft housing plug

Completed machine Completed machine

Include; Valve lapping

Completed Exclude; Removal and installing of machine

cylinder head

Completed Exclude; Removal and installing of machine

cylinder head

One set

1.2

Removal and installing camshaft (with Completed machine camshaft gear)

0.2

1.6

2.6

3.4

6.1

6.5

0.2

With manifold and nozzle holder Include; Valve lapping

Replacing cylinder head 63

00352

(one piece and one set require same Single unit hour)

Excluding; Removal and installing of cylinder head, replacing valve guide, water pressure test and replacing valve seat

66

00355

Replacing valve guide

72

00361

Replacing expansion plug Replacing rocker arm

73

00371

(one piece and one set require same hour) Replacing rocker arm support

74

00372

(one piece and one set require same hour)

75

00373

Replacing rocker arm bushing

76

00374

Replacing valve

Unit of 1 cylinder Single unit

Unit of 1 cylinder Unit of 1 cylinder Unit of 1 cylinder Unit of 1 cylinder

1.0

0.8

1.0

0.8

0.4

0.4

0.4

0.4

0.1

0.1

0.1

0.1

0.3

0.1

0.3

0.1

0.5

0.5

0.5

0.5

0.2

0.2

0.2

0.2

0.3

0.3

0.3

0.3

From cylinder head is removed condition Include; Valve lapping

Unit of 1 From cylinder head is removed condi-

77

00375

Replacing valve spring

78

00330

Replacing valve stem seal

81

00406

Removal and installing supply pump

2.3

2.3

84

00411

Tightening oil pan

Single unit From engine is removed condition

0.5

0.5

85

00412

Removal and installing oil pan

Single unit From engine is removed condition

0.5

0.5

86

00413

Replacing oil pan

Single unit From engine is removed condition

0.7

0.7

87

00414

Replacing oil pan gasket

Single unit From engine is removed condition

0.7

0.7

88

00421

Replacing oil pan drain cock

Single unit From engine is removed condition

0.5

0.5

89

00422

Replacing oil pan drain cock gasket

Single unit From engine is removed condition

0.5

92

00443

Replacing breather hose

Single unit From engine is removed condition

0.3

93

00444

Replacing oil level gauge

Single unit From engine is removed condition

0.1

0.1

94

00445

Replacing oil level gauge guide

Single unit From engine is removed condition

0.2

0.2

cylinder tion Unit of 1 From cylinder head is removed condicylinder tion One set Include; Function check

0.5 0.2

0.3

95

00446

Replacing oil level gauge bracket

Single unit From engine is removed condition

0.2

0.2

102

00512

Replacing fly wheel housing

Single unit From engine is removed condition

3.4

3.4

103

00541

Replacing fly wheel housing gasket

Single unit From engine is removed condition

5.4

5.4

104

00542

Replacing rear end plate

Single unit From engine is removed condition

5.4

5.4

105

00543

Replacing rear end plate gasket

Single unit From engine is removed condition

5.4

5.4

106

00515

Replacing crank shaft rear oil seal

Single unit From engine is removed condition

5.4

5.4

12-19

0.2

12. STANDARD MAINTENANCE TIME TABLE SK330-8

SK200-8, SK250-8

Work No.

Work

Work unit

Q'ty

Works 1

119

00552

Replacing crank shaft rear oil seal

Single unit From fly wheel is removed condition

Adding hour

1

by 1 each

by 1 each

0.2

0.2

131

00613

Replacing intake manifold

One set Include; Applying liquid gasket

2.0

2.3

132

00614

Replacing intake manifold gasket

One set Include; Applying liquid gasket

2.0

2.3

One set

1.3

1.6

One set

1.3

1.6

Removal and installing intake pipe

Adding hour

133

00636

134

00637

Replacing intake pipe (manifold side)

135

00622

Replacing air intake hose

One set

0.4

0.2

0.4

0.2

136

00623

Replacing air intake pipe

One set

0.4

0.2

0.4

0.2

137

00626

Replacing air intake pipe

One set Turbo charger to inter cooler

0.4

138

00627

Replacing air intake pipe

One set Air cleaner to turbo charger

0.4

0.2

0.4

0.2

0.3

0.2

0.3

0.2

(manifold side)

Completed

139

00675

Replacing silencer body

142

00641

Tightening exhaust manifold

143

00643

Removal and installing exhaust mani- Completed With insulator and stud bolt machine fold

144

00644

Replacing exhaust manifold

145

00645

Replacing exhaust manifold gasket

146

00646

Replacing exhaust heat insulator

machine Completed machine

Completed Include; Replacing stud bolt with new machine

one and insulator (TI system)

Completed machine One side of completed machine

Removal and installing of turbo charger

0.4

0.9

1.3

2.8

3.2

3.0

3.4

2.8

3.2

2.4

2.6

147

00651

Replacing exhaust pipe

One set

0.8

0.8

148

00653

Replacing exhaust pipe gasket

One set

0.6

0.6

164

00686

Removal and installing turbo charger

One set

2.9

2.5

165

00687

Replacing turbo charger

One set Include; Replacing stud bolt

2.6

2.5

0.9

0.9

0.4

0.4

5.4

5.4

5.4

5.4

0.7

0.7

1.0

1.0

1.0

1.0

0.2

0.2

0.1

0.1

0.2

0.2

0.1

0.1

0.4

0.4

0.4

0.4

167

00689

174

00624

188

00701

Replacing turbo charger oil return pipe Replacing air intake pipe upper (cooler to manifold)

One set

From engine is removed condition Single unit Include; Removal and installing of cyl-

inder head

(fly wheel housing) 189

00711

190

00712

191

00713

192

00714

Replacing timing gear cover (fly wheel housing) Replacing timing gear cover gasket (fly wheel housing) Replacing timing gear cover plate (rear end plate)

From engine is removed condition Single unit Include; Removal and installing of cyl-

inder head Single unit

Single unit

Replacing timing gear cover plate gasket

lower insulator

One set

Removal and installing engine and timing gear cover

Include; Removal and installing of

Single unit

(rear end plate gasket) 193

00725

Replacing idler gear (main)

Single unit

194

00736

Replacing idler gear (sub)

Single unit

195

00726

Replacing idler gear shaft (main)

196

00737

Replacing idler gear shaft (sub)

Single unit

197

00724

Replacing crank shaft gear rear

Single unit

201

00738

Replacing cam idle gear

Single unit

Single unit

From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition

12-20

12. STANDARD MAINTENANCE TIME TABLE SK330-8

SK200-8, SK250-8

Work No.

Work

Work unit

Q'ty

Works 1 From timing gear cover is removed

Adding hour

1

by 1 each

by 1 each

202

00739

Replacing cam idle gear shaft

Single unit

203

00731

Replacing camshaft

Single unit

204

00732

Replacing camshaft gear

Single unit

205

00751

Replacing crank pulley

One set

1.9

1.9

206

00754

Replacing crank dumper

One set

2.8

2.8

207

00755

Replacing crank shaft front oil seal

One set

2.2

2.2

One set

2.8

2.8

One set

2.8

2.8

0.3

0.3

Replacing crank shaft front oil seal re-

condition From timing gear cover is removed condition From timing gear cover is removed condition

0.4

0.4

0.8

0.8

0.8

0.8

208

00757

209

00758

211

00801

Checking injection timing

226

00834

Replacing priming pump

One set

0.4

0.4

227

00835

Cleaning fuel feed pump strainer

One set

0.4

0.4

228

00836

Replacing through feed valve

One set

0.4

230

00838

Replacing fuel injection pipe

One set

2.5

236

00851

Replacing fuel filter assembly

One set

0.5

0.5

237

00857

Replacing fuel filter cartridge

One set

0.3

0.3

253

00875

Replacing fuel hose

One set

0.8

0.8

254

00876

Replacing fuel leakage pipe

One set

0.8

0.8

276

00912

Replacing oil filter cartridge

One set

0.4

0.4

One set

0.3

0.3

One set

0.3

0.3

tainer Replacing crank shaft front oil seal retainer gasket

Replacing oil filter relief valve (oil filter

Completed machine

0.4 0.1

2.5

277

00907

278

00908

279

00909

Replacing oil filter safety valve

One set

0.3

0.3

280

00910

Replacing oil filter safety valve spring

One set

0.3

0.3

Single unit From engine is removed condition

6.1

6.1

regulator valve) Replacing oil filter relief valve spring (oil filter regulator valve)

Adding hour

0.1

00961(tim Removal and installing fly wheel 294

ing gear housing cover)

(timing gear cover)

295

00942

Replacing oil pump

Single unit From engine is removed condition

6.3

6.3

296

00944

Replacing oil pump gear

Single unit From engine is removed condition

6.5

6.5

297

00943

Overhaul of oil pump

Single unit From engine is removed condition

6.5

6.5

298

00946

Replacing suction strainer

One set

0.1

0.1

299

00947

Replacing suction strainer O-ring

One set

0.1

0.1

301

00951

Replacing oil pipe

One set

0.4

0.4

0.4

0.4

302

00954

Replacing oil hose

One set

0.4

0.4

0.4

0.4

303

00971

Replacing cooling oil jet

0.2

0.2

0.2

0.2

327

01028

Removal and installing water pump

328

01029

Replacing water pump

329

01030

Overhaul of water pump

Single unit

330

01031

Replacing water pump pulley

Single unit

0.6

0.6

331

01032

Replacing water pump casing gasket

One set Liquid gasket

4.0

4.0

332

01036

Replacing cooling fan

One set

0.9

0.9

333

01037

Replacing fluid fan coupling

One set

0.9

0.9

334

01044

Replacing thermostat casing

One set Include; Filling engine coolant up

1.3

1.3

336

01046

Replacing thermostat casing cover

One set Include; Filling engine coolant up

1.0

1.0

337

01047

One set Include; Filling engine coolant up

1.0

1.0

338

01048

1.0

1.0

Replacing thermostat casing cover gasket Replacing thermostat

1 One set Include; Filling engine coolant up

4.0

4.0

One set Include; Filling engine coolant up

4.0

4.0

0.8

0.8

One set

Include; Checking for temperature at valve start opening

12-21

12. STANDARD MAINTENANCE TIME TABLE SK330-8

SK200-8, SK250-8

Work No.

Work

Work unit

Q'ty

Works 1

339

01049

Checking thermostat

One set

Include; Checking for temperature at valve start opening

Adding hour

1

by 1 each

1.0

Adding hour by 1 each

1.0

341

01053

Replacing coolant hose

One set

0.3

0.2

0.3

0.2

342

01054

Replacing radiator hose

One set

0.3

0.2

0.3

0.2

343

01071

Replacing fluid fan coupling

1

0.3

0.3

344

01072

Replacing cooling fan

1

0.3

0.3

345

01073

Replacing water pump

1

1.7

1.7

346

01074

Overhaul of water pump

1

0.8

0.8

402

01401

Removal and installing alternator

One set

0.8

0.8

403

01402

Replacing alternator

One set

0.9

0.9

From cooling fan is removed condition

404

01406

Replacing alternator support bracket

One set

1.0

1.0

405

01408

Replacing V-belt

One set

0.3

0.3

438

01801

Removal and installing supply pump

One set Include; Function check

3.0

3.0

439

01802

Replacing supply pump

One set Include; Function check

3.0

3.0

One set Include; Function check

3.8

3.8

(with pressure sensor, pressure limit- One set Include; Function check

3.8

3.8

2.9

3.5

3.4

4.0

Removal and installing common rail 440

01830

assembly (with pressure sensor, pressure limiter) Replacing common rail assembly

441

01804

er) 442

01805

443

01806

444

01807

445

01808

446

01809

447

01810

Removal and installing injector assembly Replacing injector assembly Removal and installing injector assembly Replacing injector assembly Removal and installing injector sub harness assembly Replace injector sub harness assembly

Completed machine

Include; Function check

Completed Include; Function check and repromachine

gramming

One set Include; Function check One set

Include; Function check and reprogramming

1.9

0.2

1.9

0.2

2.4

0.2

2.4

0.2

One set Include; Function check

1.9

1.9

One set Include; Function check

1.9

1.9

448

01811

Removal and installing flow dumper

One set Include; Function check

1.2

0.3

1.2

0.3

449

01812

Replacing flow dumper

One set Include; Function check

1.2

0.3

1.2

0.3

450

01813

One set Include; Function check

1.2

1.2

451

01814

One set Include; Function check

1.2

1.2

One set Include; Function check

1.2

1.2

452

01815

Removal and installing pressure limiter Replacing pressure limiter Replacing common rail pressure sensor

453

01816

Replacing main engine speed sensor

One set Include; Function check

1.2

1.2

454

01817

Replacing sub engine speed sensor

One set Include; Function check

1.2

1.2

455

01818

One set Include; Function check

1.2

1.2

456

01819

Replacing fuel temperature sensor

One set Include; Function check

1.2

1.2

457

01820

Replacing accel sensor

One set Include; Function check

1.5

1.5

460

01823

461

01824

463

01826

464

01827

Replacing coolant temperature sensor

Removal and installing pressure sensor Removal and installing pressure limiter Replacing injection pipe Replacing fuel pipe (common rail to supply pump)

1

Include; Function check

0.3

0.3

1

Include; Function check

0.3

0.3

One set Include; Function check

1.2

0.1

1.2

0.1

One set Include; Function check

1.2

0.1

1.2

0.1

465

01828

Replacing fuel leakage pipe

One set Include; Function check

1.7

1.7

469

01840

Checking leakage of pressurized fuel

One set Include; Function check

1.2

1.2

12-22

12. STANDARD MAINTENANCE TIME TABLE SK330-8

SK200-8, SK250-8

Work No.

Work

Work unit

Q'ty

Works 1

471

01901

472

01902

Adding hour

1

by 1 each

by 1 each

Replacing main engine speed sensor

One set Include; Function check

1.2

1.2

Replacing sub engine speed sensor

One set Include; Function check

1.2

1.2

One set Include; Function check

1.2

1.2

Replacing coolant temperature sen-

473

01903

474

01904

Replacing accel sensor

One set Include; Function check

1.5

1.5

475

01908

Removal and installing EGR valve

One set Include; Function check

2.1

2.5

sor

476

01909

Replacing EGR valve

One set Include; Function check

2.1

2.5

479

01916

Removal and installing EGR cooler

One set

1.8

1.8

480

01917

Replacing EGR cooler

One set

1.8

1.8

One set

0.3

0.3

One set

0.3

0.3

481

01918

482

01919

Removal and installing closed ventilator Replacing closed ventilator

12-23

Adding hour

12. STANDARD MAINTENANCE TIME TABLE

[MEMO]

12-24

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13

TABLE OF CONTENTS 13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE .....................................................13-4 13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6 13.3.1

MEASUREMENT OF ENGINE SPEED ..................................................................13-6

13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7 13.4.1

PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7

13.4.2

PLACE TO INSTALL PRESSURE GAUGE............................................................13-7

13.4.3

PRESSURE ADJUSTMENT POSITION.................................................................13-8

13.4.4

PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10

13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12 13.5.1

TRAVEL SPEED.....................................................................................................13-12

13.5.2

DEVIATION OF TRAVEL .......................................................................................13-12

13.5.3

PERFORMANCES OF PARKING BRAKE .............................................................13-13

13.5.4

DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14

13.6 MEASURING SWING PERFORMANCES.......................................................................13-15 13.6.1

SWING SPEED ......................................................................................................13-15

13.6.2

PERFORMANCE OF SWING BRAKE ...................................................................13-15

13.6.3

PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16

13.6.4

DRAIN RATE OF SWING MOTOR ........................................................................13-17

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18 13.7.1

OPERATING TIME OF CYLINDERS .....................................................................13-18

13.7.2

OIL TIGHTNESS OF CYLINDERS .........................................................................13-19

13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20 13.9 MECHATRO CONTROLLER...........................................................................................13-21 13.9.1

ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21

13.9.2

ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)..........13-21

13.9.3

OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER ...13-27

Book Code No. S5LQ1314E01 13-1

13. MAINTENANCE STANDARD AND TEST PROCEDURE Issue

Date of Issue

Applicable Machines

First edition

October, 2006

n

May, 2007

n

July, 2007

n

n

n

n

September, 2007

n

SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~ n E265B : LQ12-06001~ E265BLC : LL12-05001~

13-2

Remarks S5LQ1314E01 (ASIA, OCE) n ASIA (HS Engine) n (NHK Russia) n (NHK Middle East) n NHK Russia (HS Engine)

K K K K K

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1

HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED

(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. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2

PERFORMANCE INSPECTION STANDARD TABLE

The mode is already "S" mode when power is thrown. Unless otherwise specified, measure it on "H" mode. Table13-1 Size

Port

or less

Unit

Hi

Lo

—

— - 5 (23)

Adjusting Point

Measuring condition

—

Sampling

—

Atmospheric temp

Hydraulic oil temperature

Tank surface

50 (122)

+ 5 (41)

Water temperature

Radiator surface

75 (167)

+ 15 (59)

H mode Lo idle

1000

+ 30

- 30

H mode Hi idle

2100

+ 30

- 30

2100

+ 30

- 30

2100

+ 30

- 30

1050

+ 30

- 30

1900

+ 30

- 30

5.0 (725)

+ 0.5 (+73)

0

34.3 (4970) + 0.7 (+100)

- 0.5 (-73)

MR1 Boom up

37.8 (5480) + 1.0 (+145)

- 0.5 (-73)

MR1

A mode Hi idle Decel

ATT Boost

Arm Bucket Swing

Travel

Over load relief valve pressure

Boom

RH LH

G pump

a4

P1

a1

P2

a2

P1

a1

P2

a2

R

a1

H R H R H RH LH FW RV FW RV

Main pump

valve pressure

Main relief

Pilot primary pressure circuit

PF1/4

a2 a1 a2

°C

- 15 (5) (°F)

50°C~-10°C

—

(122°F~14°F)

LOW throttle

min-1

Adjustment not required

B mode Hi idle

Measure the engine speed at multi display on the gauge cluster.

S mode Hi idle

High pressure circuit

value NAS 9

Cleanliness of hydraulic oil Hydraulic oil in tank

Engine speed

Standard Measuring condition

Position

Tolerance

Standard

Class

Measuring Position

Inspection Item

Full throttle (HI idle)

PR1

HI idle

Perform all measurement with the air-conditioner "OFF".

37.8 (5480)

0

- 4.0 (-580)

OR4

Boom down

39.7 (5760)

0

- 5.9 (-855)

OR3

Boom up

39.7 (5760)

0

- 5.9 (-855)

OR8

Arm out

37.8 (5480)

0

- 4.0 (-580) MPa

OR7

Arm in

37.8 (5480)

0

- 4.5 (-650) (psi)

OR2

Bucket dump

39.7 (5760)

0

- 5.9 (-855)

OR1

Bucket digging

28.5 (4130) + 4.0 (+580) + 1.0 (+145)

OR6

Swing RH

28.5 (4130) + 4.0 (+580) + 1.0 (+145)

OR5

Swing LH

a1

34.3 (4970) + 0.7 (+100)

- 0.5 (-73)

a2

34.3 (4970) + 0.7 (+100)

- 0.5 (-73)

13-4

— — — —

Simultaneous operation of travel RH and LH

13. MAINTENANCE STANDARD AND TEST PROCEDURE Standard value

Inspection item Sprocket revolution (RH,LH)

1st speed

32.7 ~ 29.5

2nd speed

52.9 ~ 47.9

Up

2.8 ~ 3.4

Down

2.3 ~ 2.9

In

3.2 ~ 3.8

Out

2.6 ~ 3.2

Digging

2.5 ~ 3.1

Dumping

2.0 ~ 2.6

Operating speed

Boom Operating time of cylinder

Arm Bucket

Swing speed

RH LH 1st speed

Iron shoe 19.5 ~ 21.5

2nd speed

Iron shoe 12.3 ~ 13.5

Travel speed Amount of travel deviation

Performance

Parking brake drift

ATT amount of drift

min-1

sec

sec / 20 m

0 ~ 240

mm / 20 m

15 degree gradient

0

mm / 5 min

55 ~ 75

degree

15 degree gradient

0

mm

Tip of the bucket tooth

95

Boom cylinder

7

Arm cylinder

6

Amount of horizontal play at the bucket tooth

30 ~ 50

(At no load)

sec / 1 rev

2nd speed

Performance of Swing Neutral position after 180° full speed swing brake Performance of Swing parking brake

5.0 ~ 6.2

Unit

mm / 5min (At no load) mm

The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in advance. (1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down (5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out

13-5

13. MAINTENANCE STANDARD AND TEST PROCEDURE

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 90째C (140 to 194째F) at surface of radiator upper tank. The E/G coolant tem-perature gauge is used to measure. The range in white color shows the temperature of approx. 65 to 105째C (149 to 221째F), so confirm that the pointer indicates the temperature within the white range.

(2) Engine speed measured value through service diagnosis (See Fig. 13-2) 1) Turn "ON" the starter switch with the buzzer stop switch pressed. 2) A program No. and an actual engine revolution are displayed as the No.2 Item. 3) The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is pushed. 4) The screen returns like No.45, No.44....each time the "Washer switch" is pushed. 5) The display does not disappear unless the starter switch is turned to"OFF". Fig. 13-1 Switch for E/G speed indication NO.2 ENG G-3 SPEED SET MEAS 1 MEAS 2 G-5 ENG OIL PRS. WATER TEMP. F MODE H-1 ACCEL. VOLT. POS ECU OUTPUT

2205 2201 2201 LIVE 100 OF HM 4.2V 100% 0.5V

Fig. 13-2 Service diagnosis for E/G speed measuring (Example)

13-6

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4

MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1

PREPARING TO MEASURE HYDRAULIC PRESSURE

(1) Hydraulic equipment 6.9 MPa (1000psi) pressure gauge : 1unit 49 MPa (7100psi) pressure gauge : 2 units Pressure measuring equipment and instrument for analysis : 1 set

a5

A3

A2 (A1)

PSV2 (PSV1)

(2) Measuring cleanliness of hydraulic oil

Dr3 B3

After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil.

13.4.2

PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit After releasing the pressure in hydraulic oil tank and system, replace plugs PF1/4 of main pump gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa (7100 psi). (2) Pilot circuit Replace pilot gauge plug (a5) with plug PF1/4 for pressure measurement, and attach pressure gauge 6.9 MPa (1000 psi).

13-7

B1 a1

a2

Fig. 13-3 Gauge port on main pump

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.3

PRESSURE ADJUSTMENT POSITION

(1) Main control valve

OR8 : ARM (R)

PLUG FOR OPTIONAL RELIEF

MACHINE FRONT

MR1 : MAIN RELIEF (ATT & TRAVEL)

OR3 : BOOM (H)

OR2 : BUCKET (R)

VIEW FROM THE TOP OF THE MACHINE

OR4 : BOOM (R)

OR1 : BUCKET (H)

MACHINE FRONT

OR7 : ARM (H)

PLUG FOR OPTIONAL RELIEF

VIEW FROM THE BOTTOM OF THE MACHINE Fig. 13-4 Relief valve position on main control valve

13-8

13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pilot relief valve The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

A3

a5

Dr3 B3

PR1 ADJUST SCREW FOR PILOT RELIEF

Fig. 13-5 Pilot relief valve position (3) Swing over load relief The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is carried out using gauge ports (a1) and (a2). (See Fig. 13-3)

Fig. 13-6 Swing over load relief position

13-9

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.4

PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve Adjust it with adjust screw (311). : 24 mm, Tightening torque : 29.4 N•m (22 lbf•ft) : 6 mm

No. of turns of adjust screw Pressure change MPa (psi) 1 turn

Approx. 2.1 (305)

(2) 2-stage main relief valve (Commom for travel and ATT sections) Start from the boosting side, first. Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustment on the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment.

Fig. 13-7 Pilot relief valve

Fig. 13-8 Main relief valve (Travel section, ATT common section)

: 32 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft) : 22 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft) : 19 mm, Adjust screw : 6 mm

No. of turns of adjust screw Pressure change MPa (psi) Boosting side 1 turn STD side 1 turn

Approx. 17.6 (2560) Approx. 17.6 (2560)

(3) Over load relief valve (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw (2). : 22 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft) : 6 mm Fig. 13-9 Over load relief valve (Boom, bucket, arm sections)

No. of turns of adjust screw Pressure change MPa (psi) 1 turn

Approx. 17.7 (2560)

13-10

13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Over load relief valve (Swing) This valve was adjusted by valve maker. If adjustment is required, adjust with shim thickness. When you cannot perform a check of setting pressure, do not adjust pressure by any means. Pressure change [by SIMM 0.1 mm] : about 0.5 MPa (73 psi) Fig. 13-10 Swing over load relief valve : 14 mm Tightening torque : 157 N•m (116 lbf•ft) (5) Travel over load relief valve The adjustment is done by manufacturer before shipment. When adjustment is required, loosen nut (1) and adjust the pressure with adjusting screw (2). : 19 mm : 6 mm Fig. 13-11 Travel over load relief valve

13-11

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5

MEASURING TRAVEL PERFORMANCES

13.5.1

TRAVEL SPEED

(1) Purposes Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system. (2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Crawler on the right and left sides are tensioned evenly. (3) Preparation Attach the reflection panel with a magnet to the travel motor cover. Swing the swing frame through 90°as shown in Fig. 13-12 and make the crawler on one side take off the ground, using the attachment. (4) Measurement Engine revolution; Hi idle 2-speed travel switch; 1st speed and 2nd speed Measuring points ; Right and left Method, example 1 ; Measure revolution with a stroboscope Method, example 2 ; Measure the revolutions per minute visually.

Fig. 13-12 One side lifted position

Fig. 13-13 Adhering position of reflection panel

Measurement item RH H mode 1st speed & LH H mode 2nd speed

13.5.2

Unit

Sprocket revolution Standard value

Reference value for remedy

min-1

Service limit

32.7~29.5 25.5~23.0 20.8 or less 52.9~47.9 41.3~37.4 33.8 or less

DEVIATION OF TRAVEL

(1) Purpose Measure the amount of deviation at 20m (66ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system. (2) Condition Hydraulic oil temperature ; 45~55°C (113~131°F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution; Hi idle

BOOM FOOT PIN

ARM TOP PIN

Fig. 13-14 Travel position

13-12

13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Preparation 1) Straight course more than 30m (108ft) 2) Travel position in which the bottom of the bucket is lifted by about 30cm (1ft).

A 20m (66ft)

(4) Measurement 1) Measure the max. deviation distance of the circular arc in the 20m (66ft) length, excluding the preliminary run of 3~5m (10~16ft).

Fig. 13-15 Measuring method Travel deviation

2) Operate the travel lever at the same time.

13.5.3

Unit : mm (in) / 20m (66ft)

Measuring position

Standard value

A

240 (9.45) or less

Reference value Service limit for remedy

480 (18.9)

720 (28.4)

PERFORMANCES OF PARKING BRAKE

(1) Purpose Confirm that the parking brake holds a stopped condition of the machine in a no-load travel position and on a 15 degree slope. (2) Condition A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position (3) Preparation Place an angle meter on the shoe plate and confirm that it makes an angle more than 15 degree. Hang a perpendicular in parallel with the guide frame rib on the track frame and put a mark (matching mark) on the shoe plate.

Fig. 13-16 Parking brake operating position

(4) Measurement Five minutes after the engine stops, measure the movement distance of the matching mark.

C

GUIDE FRAME

Fig. 13-17 Method of measurement Parking brake Measuring position

C

13-13

Unit : mm(in)/5min Reference value Standard value Service limit for remedy

0

1 (0.04)

2 (0.08)

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5.4

DRAIN RATE OF TRAVEL MOTOR

(1) Purpose To measure the drain rate of the travel motor and to confirm the performances of the travel motor. (2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Engine revolution; Hi idle

90 o 10 (3.54") (0.394")

FORWARD

o 22 PIPE (0.866") RIB "A"

150 (5.91")

STOPPER "B"

(3) Preparation

ROTARY DIRECTION

1) Place a stopper under the RH and LH travel sprockets.

40 (1.57")

o 80 (3.15")

Fig. 13-18 Location of stopper applied to travel sprocket

2) Stop the engine and release pressure from the hydraulic circuit. 3) Connect a hose with the drain port of the travel motor and take drain in a container. (4) Measurement ; at Travel Lock

Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. (See Fig. 13-18) 1) Start the engine and relieve pressure at the full stroke of the travel lever. 2) Measure the drain rate for 30 seconds of relieving.

Fig. 13-19 Method of measuring the drain rate of travel motor Travel deviation Measuring position

Drain rate

13-14

Unit : L(gal)/30sec

Reference value Standard value Service limit for remedy

7 (1.8)

14 (3.7)

21 (5.5)

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6

MEASURING SWING PERFORMANCES

13.6.1

SWING SPEED

(1) Purpose Measure the swing time and confirm the performances between the hydraulic pump and the swing motor of the swing drive system. (2) Conditions Hydraulic oil temperature ; 45~55째C (113~131째F) Firm, level ground Engine revolution; Hi idle (3) Preparation Put the bucket empty and extend the boom, arm and bucket cylinder fully. And the machine becomes a position of minimum reach.

Fig. 13-20 Swing speed measuring position (at the min. reach)

(4) Measurement Swing the machine by bringing the swing lever to its full stroke. Measure the time required to make two turns after one turn of preliminary run and calculate the time required for one turn. 13.6.2

PERFORMANCE OF SWING BRAKE

(1) Purpose Confirm the braking torque performances by the swing relief valve.

Swing speed

Unit : sec/rev

Measuring Reference value Service limit Standard value position for remedy Swing speed at 5.0~6.2 8.4~ 6.4~7.9 min. reach

(2) Conditions Hydraulic oil temperature ; 45~55째C (113~131째F) Firm, level ground Engine revolution; Hi idle

ARM TOP PIN

BOOM FOOT PIN

(3) Preparation 1) Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. 2) Put a matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side. Place two poles (flags) on the front and back of the extended line of the matching mark.

Fig. 13-21 Swing brake performance measuring position

13-15

13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Measurement 1) When operating in regular swing speed, by shifting lever to neutral position at pole position the swing operation stops.

MEASURING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE

2) Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race :

MATCHING MARKS ON INNER RACE

Fig. 13-22 Measuring position of swing brake performances Swing brake performance Measuring position

Swing 180

13.6.3

Unit : degree

Reference value Standard value Service limit for remedy

75

85

90

PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose To confirm the mechanical performances of the swing parking brake that is fitted to the inside of the swing motor. (2) Conditions On a slope of 15 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. Fig. 13-23 Swing parking brake performance measuring position (3) Preparation Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Put a matching mark on the outer race side and on the inner race side.

MEASUREING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE

(4) Measurement When five minutes has passed after the engine stops, measure the length of the movement of the matching marks.

MATCHING MARKS ON INNER RACE

Fig. 13-24 Measuring position of swing parking brake performances Performance of swing parking brake Measuring position

C

13-16

Unit : mm(in)/5min

Reference value Standard value Service limit for remedy

0

1 (0.04)

2 (0.08)

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.6.4

DRAIN RATE OF SWING MOTOR

(1) Purpose Measure the drain rate of the swing motor and confirm the performances of the swing motor. (2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground Engine revolution; Hi idle (3) Preparation 1) Stop the engine. 2) Release pressure from inside the hydraulic circuit. 3) Disconnect the swing motor drain hose from its end returning to the hydraulic oil tank and take oil in a container. 4) Put a plug to the tank side. (4) Measurement ; at Swing Lock

Fig. 13-25

1) Start the engine and put the side faces of bucket against the inside of the right or left shoe plates. 2) Relieve the swing motor at full stroke of the swing motion.

Travel deviation Measuring position

Drain rate

3) Collect the amount of drained oil in a container for 30 seconds.

13-17

Unit : L(gal)/30sec

Reference value Standard value Service limit for remedy

1.5 (0.4)

3.0 (0.8)

4.2 (1.1)

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7

MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1

OPERATING TIME OF CYLINDERS

(1) Purpose Measure the operating time of the boom, arm and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system. (2) Condition Hydraulic oil temperature ; 45~55°C (113~131°F) Engine revolution; Hi idle Operating time excluding the cushion stroke

Fig. 13-26 Measuring position for bucket digging and dump

(3) Preparation Firm level ground with the bucket empty (4) Measurement 1 ; Boom up and down With the boom operating lever at full stroke, measure the required operating time of the bucket between the ground surface and its highest position. Fig. 13-27 Measuring position for boom up and down motions When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ; never put the bucket against concrete or other solid material. Measurement 2 ; Arm in and out, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30cm (1ft) above ground, measure the full stroke operating time required with the arm and bucket operating levers at full stroke.

13-18

30cm (1ft)

Fig. 13-28 Measuring position for arm in and out motions Cylinder Operating time Measuring position

Unit : sec

Reference value Service limit Standard value for remedy

2.5~3.1

3.2~4.0

4.2~

2.0~2.6

2.6~3.3

3.5~

2.8~3.4

3.6~4.4

4.7~

2.3~2.9

2.9~3.7

3.9~

3.2~3.8

4.1~4.9

5.3~

2.6~3.2

3.3~4.1

4.4~

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.7.2

OIL TIGHTNESS OF CYLINDERS

(1) Purpose Confirm that the cylinder oil tight by checking the moving length of the cylinder rods. (2) Condition Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness. Retract the arm cylinder rod 50mm (2in) from stroke end so that the piston does not match a same range of the cushioning mechanism. (3) Preparation Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position. And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin. (4) Measurement Measure the items five minutes after the engine is turned off.

13-19

Fig. 13-29 Oil tightness of cylinder Measuring position

Unit : mm(in)/5min

Reference value Standard value Service limit for remedy

A

7 (0.28)

9 (0.35)

12 (0.47)

B

6 (0.24)

7 (0.28)

9 (0.35)

C

-

-

-

D

95 (3.7)

120 (4.7)

160 (6.3)

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.8

MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing.

LOCATION OF BEARING MOUNTING BOLTS

SWING BEARING

(2) Condition Firm, level ground The swing bearing mounting bolts are not loosened. The swing bearing is lubricated well, not making abnormal sound during turning.

A

DIAL INDICATOR LOWER FLAME

Fig. 13-30 How to measure the axial play of swing bearing (3) Preparation 1) Install a dial indicator to the magnetic base and fix it to the lower frame. 2) Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero.

Fig. 13-31 Measuring position 1

(4) Measurement 1 (Measuring position 1 and 2) 1) Measure the displacement of the outer race in the axial direction in position 1 [The arm at 90°~110° and the crawler front is lifted by attachment about 30cm (1ft)] and in position 2, using a dial indicator.

BOOM FOOT PIN

ARM TOP PIN

Fig. 13-32 Measuring position 2 Axial play of swing bearing Measuring position

A

Unit : mm (in)

Reference value Standard value Service limit for remedy

0.8~1.8 (0.03~0.07)

2.3~3.3 (0.09~0.13)

3.6~ (0.14)

(5) Measurement 2 (Measuring position 3) 1) Retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. Then swing the bucket right and left by man power. But in this case, the gap of the attachment is included.

BOOM FOOT PIN

ARM TOP PIN

Fig. 13-33 Measuring position 3 Right and left movement of the tip of bucket Measuring position

Bucket

13-20

Unit : mm (in)

Reference value Standard value Service limit for remedy

30~50 (1.18~1.97)

80 (3.15)

120 (4.72)

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9

MECHATRO CONTROLLER

13.9.1

ENGINE CONTROL INPUT / OUTPUT

E-27: EMERGENCY ACCEL

C-8: ENGINE CONTROLLER

INJECTOR E-1: FUSE&RELAY BOX

C-2: GAUGE CLUSTER

ENGINE SPEED SENSOR

STARTER SWITCH

C-1: MECHATRO CONTROLLER

ACCEL POTENTIO METER

ENGINE

PUMP PROPORTIONAL VALVE

Fig. 13-34 INPUT / OUTPUT 13.9.2 13.9.2.1

ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) PURPOSE OF THE ADJUSTMENT

There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to ensure performance of machine. (1) Adjustment of engine ("A" adjustment) This adjustment is performed to set the relation between the acceleration command voltage output from mechatro controller to engine controller and the engine speed. (2) Adjustment of pump ("B" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output. (3) Adjustment of unloading valve ("C" adjustment) This adjustment is performed to correct the open variation of unloading valve to improve the operability further. 13.9.2.2

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. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.3

PREPARATION

(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine. (2) Turn the air-con OFF. (3) Turn the starter key switch OFF to stop the engine. When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, A015, A025, A035 As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List.

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

13-22

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.4

ADJUSTING PROCEDURE

MULTI DISPLAY

WORK MODE SELECT SWITCH

BUZZER STOP SWITCH

WASHER SWITCH WIPER SWITCH

SELECT SWITCH

Fig. 13-35 Gauge cluster (1) Adjustment of engine ("A" adjustment) Procedure 1) Turn starter key switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for 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 selector switch on gauge cluster to display "START ENG". "Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.

4) After starting engine, press selector switch on gauge cluster, and "MEMORY ENG" is displayed, the engine speed is automatically increased, and the adjustment of engine is performed. (When trying to limit engine speed, press selector switch on gauge cluster at the speed as it is, and the adjustment of engine is terminated. The torque adjustment and unloading adjustment required later are not performed, and default value is written.) 5) When normal HIGH idling speed is detected, the adjustment is completed. And "FINISH ENG" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared, and the adjustment of engine is completed. The torque adjustment and unloading adjustment required later are not performed, and default value is written.)

13-23

FINISH ENG ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 STEP 400

2.0M

13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Adjustment of pump ("B" adjustment) Procedure 1) The adjustment automatically shifts from engine to pump, the speed shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump "PROPO-VALVE" current (command value) are indicated. 2) After detection of the engine rated speed, the adjustment of pump is automatically completed. And "FINISH PUMP" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.)

FINISH PUMP ENGINE SPEED 2000rpm PUMP PRESSURE C-1 35.0M C-2 PROPO-VALVE E-1 300mA E-2

35.0M 300mA

(3) 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 "PROPOVALVE" voltage (command value) are indicated. 2) When the unloading valve operates to the specified value, the adjustment of unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiometer. The adjusting current value is indicated on the display of current of P1, P2 unloading proportional valves. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.) (4) Corrective actions taken when the adjustment can not be performed; 1) In cases where the adjustment of engine can not be performed; And ERROR ENG" is displayed. Judging condition: The read engine speed is 50rpm lower than the last value. It is conceived that the error is caused by the speed read error, pump load applied to the engine and unusual acceleration command voltage applied to the engine controller in the course of adjustment. a. Checking speed sensor: Check that it is free from wrong reading of speed due to engine vibration. b. Checking load applied to pump: Check that it is free from abnormal increase of pump pressure during adjustment of engine through adjustment screen. c. Checking acceleration command voltage: Measure the acceleration command voltage output from mechatro controller to engine controller. Check that signal is regularly input to the engine controller by actual measurement of voltage or with failure diagnosis tool of engine controller.

13-24

MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA

13. MAINTENANCE STANDARD AND TEST PROCEDURE 2) 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. 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.

3) 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 10~25MPa. (It may be affected by operating oil temperature.) When the pump pressure does not increase; a. Identify the reason why the pressure does not increase, •

Check that the relief valve operates normally.

•

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

•

Check that the pressure sensor functions normally. And so on.

(5) 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.

13-25

13. MAINTENANCE STANDARD AND TEST PROCEDURE (6) When the adjustment of unloading valve only is performed; ("C" adjustment) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only. Procedure 1) Turn starter switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selection of adjustment type is displayed. And "ADJUST" 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 washer switch ( ) and wiper switch ( ), and select "ADJUST UNLOAD". (See Fig. 13-35) Like the output adjustment, when adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. 4) Press selector switch on gauge cluster to display "START ENG". "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.

5) After starting engine, press selector 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 "PROPO-VALVE" (acceleration command current) 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 520~635mA. Stop the engine. (The adjusted data is automatically stored.)

13-26

MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA

13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.3

OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER

(1) Engine emergency mode When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating emergency acceleration (E-27) provided on the seat rear side. (See Fig. 13-34) Operating procedure: 1) Set the emergency acceleration to NORMAL position. 2) Start engine. 3) Turn the emergency acceleration to HI side and control the engine speed. 4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping. Never increase the engine speed immediately after starting engine. It is dangerous. To avoid this danger, repeat the above procedure, or the engine speed does not increase. When the machine does not operate, set the emergency acceleration to NORMAL position. (2) Pump emergency mode In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to emergency 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.

13-27

13. MAINTENANCE STANDARD AND TEST PROCEDURE

[MEMO]

13-28

21. MECHATRO CONTROL SYSTEM 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 ...............................................................21-7

21.1.4

BOOM UP CONFLUX CONTROL ..........................................................................21-9

21.1.5

ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-10

21.1.6

ARM-IN ANTI-CAVITATION CONTROL ................................................................21-12

21.1.7

ARM-OUT CONFLUX CONTROL ..........................................................................21-13

21.1.8

BUCKET DIGGING (DUMP) CONFLUX CONTROL ..............................................21-14

21.1.9

BUCKET DIGGING ANTI-CAVITATION CONTROL ..............................................21-15

21.1.10 SWING PRIORITY CONTROL ...............................................................................21-17 21.1.11 TRAVEL STRAIGHT CONTROL ............................................................................21-18 21.1.12 PRESSURE RELEASE CONTROL ........................................................................21-20 21.1.13 N&B SWITCH CONTROL (OPTION) .....................................................................21-21 21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................................21-22 21.2 MECHATRO CONTROLLER...........................................................................................21-23 21.2.1

SUMMARY OF MULTI DISPLAY ...........................................................................21-23

21.2.2

SELF DIAGNOSIS DISPLAY..................................................................................21-28

21.2.3

SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-30

21.2.4

TROUBLE HISTORY DIAGNOSIS .........................................................................21-40

21.2.5

TROUBLE DIAGNOSIS MODE ..............................................................................21-41

21.2.6

SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-42

21.2.7

ADJUSTING PROCEDURE OF DISPLAY .............................................................21-43

21.2.8

MECHATRO CONTROL EQUIPMENT ..................................................................21-47

Book Code No. S5LQ2118E01 21-1

21

21. MECHATRO CONTROL SYSTEM Issue

Date of Issue

Applicable Machines

First edition

July, 2007

n

n

n

n

September, 2007

n

E265B : LQ12-06001~ E265BLC : LL12-05001~

21-2

Remarks S5LQ2118E01 (NHK Russia) n (NHK Middle East) n NHK Russia (HS Engine)

K K K

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

21-3

21. MECHATRO CONTROL SYSTEM

21.1

SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1

MECHATRO CONTROL SYSTEM IN GENERAL

21-4

21. MECHATRO CONTROL SYSTEM

L1

MAIN CONTROL VALVE SE-29

UP

REVERSE

L2 L3

(5)

(7)

SV-13 N&B SELECTOR VALVE

(8)

OPTION

(6)

BOOM UP CONFLUX

TRAVEL LEFT

PL1 ATTACHMENT BOOST

REVERSE

LEFT ARM OUT

ARM 1 SPEED

(3)

P1 P2

(3)

P2 UNLOAD

FORWARD

(4)

SWING

(1)

DIGGING

DOWN FORWARD

TRAVEL P1 UNLOAD STRAIGHT

BUCKET

ARM 2 SPEED

(2)

TRAVEL RIGHT

DUMP

(8)

BOOM LOW SPEED

ARM OUT

SOL

RIGHT ARM IN

SOLENOID VALVE

L4 SWING MOTOR PARKING RELEASE

PSV -A

PSV PSV PSV -D -C -B

SV -2

SV -3

SV -1

BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX

SAFETY LOCK LEVER

SWING PARKING BRAKE

TRAVEL 1,2 SPEED

ATTACHMENT BOOST

P2 UNLOAD

TRAVEL STRAIGHT

P1 UNLOAD

L5

ARM IN 2 SPEED

TRAVEL MOTOR 1,2 SPEED SELECT

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. MECHATRO CONTROL SYSTEM

P2

(LEFT)

(RIGHT)

OPTIONAL PILOT VALVE

PILOT VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

UNLOAD VALVE CONTROL

OPTION

21.1.2

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 respective low pressure sensors. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. (3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by mechatro controller and switches each unload spools. (4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.

21-6

21. MECHATRO CONTROL SYSTEM

P2

SE-23

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

OPTIONAL PILOT VALVE

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

POSITIVE CONTROL & P-Q CONTROL

OPTION

21.1.3

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

21-7

21. MECHATRO CONTROL SYSTEM (1) Positive control 1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. 3) Each pump proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes the 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 according to the lever manipulated movement will be obtained. (2) P-Q control 1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and the mechatro controller processes pilot signal and operates the command according to the input voltage (load pressure). 2) The lower value between command 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 mechatro controller and changes 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 actuator and consequently 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

PUMP DELIVERY PRESSURE

21-8

21. MECHATRO CONTROL SYSTEM

P2

PILOT VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

BOOM UP CONFLUX CONTROL

OPTION

21.1.4

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

(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux spool and is input to low pressure sensor. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves. (3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve. (4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.

21-9

21. MECHATRO CONTROL SYSTEM

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

ARM PILOT SECONDARY PRESSURE

P2 PUMP PRESSURE

REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL

MECHATRO CONTROLLER

21-10

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

ARM IN RECIRCULATION & CONFLUX CONTROL

OPTION

21.1.5

21. MECHATRO CONTROL SYSTEM (1) Recirculation and conflux (Low loading) 1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the arm-in independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for armin 2 spool. 3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional valves output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve. 4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm operation. (2) Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool. The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked.

21-11

21. MECHATRO CONTROL SYSTEM

P2

LOW PRESSURE SENSOR SE-7

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL STRAIGHT

PILOT VALVE

P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

BOOM UP CONFLUX

ARM-IN ANTI-CAVITATION CONTROL

OPTION

21.1.6

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 arm 1 spool and is input to low pressure sensor. (2) The engine speed command output by accel potentiometer is input to mechatro controller. (3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2 unload proportional valve. (4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool. (5) Each proportional valves output pilot secondary pressure according to each command output by mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump delivery rate is low due to low engine speed.

21-12

21. MECHATRO CONTROL SYSTEM

PILOT VALVE

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

ARM-OUT CONFLUX CONTROL

OPTION

21.1.7

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

(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is input to low pressure sensor. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves. (3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valves. (4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.

21-13

21. MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

BOOM UP CONFLUX

TRAVEL LEFT

TRAVEL STRAIGHT

PILOT VALVE

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

BUCKET DIGGING (DUMP) CONFLUX CONTROL

OPTION

21.1.8

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

(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket spool and is input to low pressure sensor. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve. (3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve. (4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.

21-14

21. MECHATRO CONTROL SYSTEM

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

21-15

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

BUCKET DIGGING ANTI-CAVITATION CONTROL

OPTION

21.1.9

21. MECHATRO CONTROL SYSTEM (1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and is input to low pressure sensor. (2) The engine speed command output by accel potentiometer is input to mechatro controller. (3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve. (4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of control valve. (5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched. (6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary pressure, and actuate stroke limiter and then controls the stroke of bucket spool. The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump delivery rate is low. (7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the stroke limit of bucket spool.

21-16

21. MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

BOOM UP CONFLUX

TRAVEL LEFT

SOLENOID

P2 UNLOAD

N&B SELECTOR VALVE

SWING

PILOT VALVE

ARM 1 SPEED

SWING PRIORITY CONTROL

OPTION

21.1.10

P1

LOW PRESSURE SENSOR pi

ARM IN PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

PILOT SIGNAL PROCESS

pi

pi

SWING PILOT SECONDARY PRESSURE

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

ARM IN PILOT SECONDARY PRESSURE

SWING PILOT SECONDARY PRESSURE

P2 PUMP PROPORTIONAL VALVE PSV-P2

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

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot secondary pressure switches swing spool and is input to low pressure sensor. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool. (3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight spool, arm 2 spool. (4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil on arm cylinder rod side is recirculated into arm cylinder head side. (5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible.

21-17

21. MECHATRO CONTROL SYSTEM

(RIGHT)

PILOT VALVE FOR TRAVEL

SE-10

SE-9

SE-11

PILOT VALVE

P2

P1

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

21-18

P1 UNLOAD PROPORTIONAL VALVE PSV-D

MECHATRO CONTROLLER

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

BOOM UP CONFLUX

PILOT VALVE

TRAVEL STRAIGHT

(LEFT)

TRAVEL LEFT

SOLENOID

P2 UNLOAD

N&B SELECTOR VALVE

SWING

OPTIONAL PILOT VALVE

ARM 1 SPEED

TRAVEL STRAIGHT CONTROL

OPTION

21.1.11

21. MECHATRO CONTROL SYSTEM (1) Judgment travel straight 1) During travel operation (right and left), pilot pressure switches each spool and is input to low pressure sensor on carrying out attachment system operation. 2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on. 3) On turning 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 P1 pump and travel operation is actuated by 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, 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.

21-19

21. MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

TRAVEL STRAIGHT

GAUGE CLUSTER

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

PRESSURE RELEASE CONTROL

OPTION

21.1.12

P1

SE-23

SE-22

ENGINE

PRESSURE RELEASE CONTROL

ENGINE SPEED CONTROL

pi

pi

pi

pi

PILOT SIGNAL PROCESS

PILOT SIGNAL PROCESS

PILOT SIGNAL PROCESS

PILOT SIGNAL PROCESS MECHATRO CONTROLLER

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster. For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1. (2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot, accel potentiometer, etc.) the mechatro controller; 1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum tilt angle. 2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes engine speed to pressure release control speed. 3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and P2 unload valves to the maximum opening. (3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster. (4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool with the unload valve opened.

21-20

21. MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

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

ARM 1 SPEED

N&B SWITCH CONTROL (OPTION)

OPTION

21.1.13

P1

A MODE

B MODE GAUGE CLUSTER

pi

B MODE SWITCH

MECHATRO CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

(1) Nibbler circuit 1) Select A mode through gauge cluster. 2) Nibbler display appears on gauge cluster. 3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main control valve. 4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output. It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display is output to gauge cluster. (2) Breaker circuit 1) Select B mode through gauge cluster. 2) Breaker display appears on gauge cluster. 3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank. 4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal. It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display is output to gauge cluster.

21-21

21. MECHATRO CONTROL SYSTEM

P2

LOW PRESSURE SENSOR

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

BOOM UP CONFLUX

TRAVEL LEFT

SOLENOID

P2 UNLOAD

PILOT VALVE

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

OPTION CONFLUX CONTROL (OPTION)

OPTION

21.1.14

P1

SINGLE / CONFLUX SWITCH

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

(1) Select the Conflux with the aid of Conflux/Single switch. (2) On starting option operation, option operating pilot pressure switches option spool and is input to low pressure sensor. (3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve. (4) Each proportional valves output pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve. (5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.

21-22

21. MECHATRO CONTROL SYSTEM

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 EMERGECY ACCEL DIAL GAUGE CLUSTER

SWING PARKING BRAKE RELEASE SWITCH

SAFETY LOCK LEVER RIGHT CONTROL LEVER WITH ATT BOOST SW. FUSE & RELAY BOX

STARTER SWITCH ACCEL DIAL

A (2) Gauge cluster No. 11

22:00 H 1

2 3 10 4

9

8

5

7

6

Name

1

Engine coolant temperature gauge

2

Fuel level gauge

3

Screen change switch

4

Buzzer stop switch

5

Work mode select switch

6

Washer switch

7

Wiper switch

8

Travel high speed, low speed select switch

9

Auto accel switch

10

Select switch

11

Multi display (LCD)

21-23

DETAIL A

21. MECHATRO CONTROL SYSTEM (3) Screen selection by work mode select switch After starting engine, "S" mode is usually set. The work modes "S","H","B" and "A" are selected in order every time ( ) is pressed. Select efficient work mode according to the working condition and the purpose from the following table. The selected mode is displayed on the left lower corner on multi display. • S mode: For standard digging work • H mode: For heavy duty digging work • B mode: For works with breaker

10:25

• A mode: For works with crusher (nibbler)

H

Work mode

Display

Contents

S mode

10:25

H mode

10:25

B mode

10:25

For the work with breaker, select "B mode" without fail.

A mode

10:25

For the work with crusher (nibbler), select "A mode".

"S mode"is suitable for standard digging and loading works and is in fuel saving and is maintained well-balanced relations with workload.

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

21-24

21. MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode) No.

1

Switches

1

Screen change switch

2

Buzzer stop switch

3

KPSS work mode select switch

4

Washer switch

5

Wiper switch

6

Travel speed select switch

7

Auto accel switch

8

Select switch

2

8

3

7

4

5

6 Fig. 21-1

According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate in accordance with the procedure mentioned below. In this machine, last set flow rate has been stored and the initial flow rate is 246L/min. The adjustment (increase or decrease) of flow rate is changeable by 10L/min step.

Main screen

Attachment mode (A mode)

10:25

Flow rate

H

Flow rate

246 L/m

Enter

A

(a)

Flow rate

100 L/m

(b)

(d)

100 L/m

A

Increase/Decrease

In Breaker mode (B mode) Flow rate

246

L/m

Flow rate

Enter

B Screen in Attachment/Breaker mode A mode Flow rate

(c)

(d)

A

Flow rate

L/m

100 L/m

B

Increase/Decrease When the conflux switch is tuned on, the double flow rate is displayed.

B mode 246

Flow rate

100 L/m

246

L/m

B (b)

(c)

1. Turn starter key switch on and display main screen (a). 2. The display on the left lower corner of screen is changed in order of "S" o "H" o "B" o "A" each time the "MODE" switch (3) is pressed under the condition where main screen (a) is displayed. 3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed. 4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and the screen (d) is displayed. In this condition, press FEED decreases.

(4)/

(5) and the flow rate value increases or

5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.

21-25

21. MECHATRO CONTROL SYSTEM (4) MAINTENANCE SCREEN DISPLAYS This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/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 Hydraulic oil

1,000 Hr Middle East

2,000 Hr

Russia

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. 1. Remaining time display to the engine oil change This display shows the remaining time to the coming engine oil change.

492Hr

ENGINE OIL

H

2. Remaining time display to the coming fuel filter replacement This display shows the remaining time to the coming engine fuel filter replacement.

492Hr

FUEL FILTER

H

3. Remaining time display to the coming hydraulic oil filter replacement This display shows the remaining time to the coming hydraulic oil filter replacement.

992Hr

HYD. FILTER

H

4. Remaining time display to the coming hydraulic oil change This display shows the remaining time to the coming hydraulic oil change.

1992Hr HYD. OIL

H

•

The display automatically changes to the main screen, if switch is not operated for 30 seconds.

•

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

21-26

21. MECHATRO CONTROL SYSTEM (5) Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The display functions of multi display are explained below. CLOCK DISPLAY SELF DIAGNOSIS / WARNING MACHINE CONDITION

H MULTI DISPLAY INDICATIONS

1) Display function for operator ......... Screen usually displayed during operation 1.1 Clock display function ......... Current time is displayed. 1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays error code. 1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning contents with the symbol and statement. (For warning contents, see items shown below.) 1.4 Machine condition display ......... Displays machine operating condition. 2) Display function for maintenance ......... Displays remaining time up to replacement/change of following items. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil 3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence. 4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment, etc. 5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve command, etc. output by mechatro controller 6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are not detected by self diagnosis and displays the results.

. Warning CAUTION ATTACHMENT

These descriptions indicate error codes. LOW ENG OIL PRESS.

W005

PREHEAT

HIGH ENG WATER TEMP.

W006

CHARGE ERROR

POWER BOOST ON

LOW ENG WATER W004 LEVEL

LOW FUEL LEVEL

WARM FINISH WARM-UP

DRAIN WATER SEPA W010

WARM AUTO WARMING UP

CLOGGED AIR FLTR W008

CHANGE ENG OIL

AUTO IDLE STOP

DATA

CPU COMMUNICATION ERROR

SWING BRAKE DISENGAGED

W009

W011

ENGINE STOP

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

21-27

21. MECHATRO CONTROL SYSTEM 21.2.2

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 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. (2) I/O configuration

(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.

21-28

21. MECHATRO CONTROL SYSTEM

Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.

21-29

21. MECHATRO CONTROL SYSTEM 21.2.3

SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes 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.

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~No.30

•

Mode No.2 : Screen No.1, Screen No.31~No.40

•

Mode No.3 : Screen No.1, Screen No.41~No.50

3) The screen changes each time each switch is pressed from now on. Washer switch: Screen gains by 1 in order. (No.2oNo.3oNo.4o...) Wiper switch: Screen loses by 1 in order. (No.24oNo.23oNo.22o...) Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1. (No.1oNo.2oNo.3oNo.1o...) Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3. (No.3oNo.2oNo.1oNo.3o...) 4) Turn key switch OFF and the display of service diagnosis mode is closed.

21-30

21. MECHATRO CONTROL SYSTEM (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

2

3

NO.2 ENG G-3 SPEED SET 2205 MEAS1 2201 MEAS2 2201 G-5 ENG PRS. LIVE WATER TEMP 100 OFF MODE HM 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. 4

P/No. indication

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

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

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

Displays

Contents

NO.4 RELAY

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

NO.6 PRESS.SENSOR 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 B-18 DOZER 1 3.5V 2.6M B-19 DOZER 2 3.5V 2.6M

21-31

Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch

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 Sensor voltage / Pressure converted value

21. MECHATRO CONTROL SYSTEM

7

8

9

10

11

NO.7 P.SENSOR PROPO-V C-1 PUMP P1 3.5V 32.6M C-2 PUMP P2 3.5V 32.6M C-3 BOOM-HEAD 3.5V 32.6M C-4 BOOM-ROD 3.5V 32.6M PROPO-VALVE E-3 OPT RELIEF 1 COMP. 600mA 14.5M MEAS. 600mA 14.5M E-4 OPT RELIEF 2 COMP. 600mA 14.5M NO.8 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

NO.9 PROPO-VALVE 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.10 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 LIVE NO.11 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

12

NO.12 POTENTIO. H-2 BOOM 3.5V 137 H-3 ARM 3.5V 137

16 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

NO.16 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-20 3.5V 12.6M

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

18 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

19 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

20 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

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

22 Sent value from sensor / Converted value from angle Sent value from sensor / Converted value from angle

NO.18 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

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.19 DIGITAL INPUT DI15 OFF DI16 OFF DI17 OFF DI18 OFF DI19 OFF DI20 OFF DI21 OFF DI22 OFF DI23 OFF DI24 OFF DI25 OFF DI26 OFF DI27 OFF DI28 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

NO.20 DIGITAL INPUT DI29 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

NO.21 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

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.22 DIGITAL OUTPUT 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 DO14 COMP. OFF MEAS. OFF

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

21-32

See Mechatro controller connector

21. MECHATRO CONTROL SYSTEM

No. 23

24

25

Displays

Contents

NO.23 DIGITAL OUTPUT 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

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.24 DIGITAL OUTPUT 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 DO27 COMP. OFF MEAS. OFF DO28 COMP. OFF MEAS. OFF

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.25 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

No. 27

Displays

Contents

NO.27 MERIT SYSTEM COMMUNICATION

OFF 4

Status of communication in MERIT controller

0412051200

28

NO.28 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

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 Engine oil pressure Glow output from ECU Engine stop command from ECU Calculated torque of ECU

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

2) Service diagnosis mode No.2 No. 1

31

32

Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00

Contents

No. 33

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

SERVICE DIAG 2

Service diagnosis mode

NO.31 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.32 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

34

35

Displays

Contents

NO.33 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.34 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.35 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

21-33

21. MECHATRO CONTROL SYSTEM 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

41

NO.41 ADJUSTMENT 1 ENG HI-IDLE 2205 PUMP ACT I 515mA 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

Contents

No. 43

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

44 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

Displays NO.43 MACHINE-INFORM. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200

Contents 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

NO.44 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

21-34

21. MECHATRO CONTROL SYSTEM (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 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.32 ARM, SWING

No.32 ARM, SWING

C-1

P1-PRES

0.2~1.5 M

C-1

P1-PRES

0.2~1.5 M

C-2

P2-PRES

0.2~1.5 M

C-2

P2-PRES

0.2~1.5 M

E-1

P1-PSV

350 mA

E-1

P1-PSV

350 mA

E-2

P2-PSV

350 mA

E-2

P2-PSV

350 mA

D-1

P1-UL(BPC)

750 mA

D-1

P1-UL(BPC)

750 mA

D-2

P2-UL(BPC)

750 mA

D-2

P2-UL(BPC)

750 mA

D-3

S-TRAVEL

350 mA

D-3

S-TRAVEL

350 mA

D-6

ARM-IN-2

750 mA

D-6

ARM-IN-2

750 mA

B-3

ARM OUT

0.0 M

B-3

ARM OUT

0.0 M

B-4

ARM IN

0.0 M

B-4

ARM IN

0.0 M

B-1

BOOM RAISE

0.0 M

B-1

BOOM RAISE

0.0 M

B-7

SWING

0.0 M

B-7

SWING

0.0 M

G-3

ENG SPEED

G-3

ENG SPEED

POWER SHIFT

2070~2130 0 mA

POWER SHIFT

1870~1930 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

No.31 BOOM

No.31 BOOM

H mode Hi idle

C-1

P1-PRES

33.0~35.8 M

C-1

P1-PRES

12.0~17.0 M

C-2

P2-PRES

33.0~35.8 M

C-2

P2-PRES

12.0~17.0 M

E-1

P1-PSV

415~525 mA

E-1

P1-PSV

560~750 mA

E-2

P2-PSV

415~525 mA

E-2

P2-PSV

560~750 mA

D-1

P1-UL(BPC)

360 mA

D-1

P1-UL(BPC)

360 mA

D-2

P2-UL(BPC)

360 mA

D-2

P2-UL(BPC)

360 mA

B-1

BOOM RAISE

3.0 M

B-1

BOOM RAISE

3.0 M

B-2

BOOM LOWER

0.0 M

B-2

BOOM LOWER

0.0 M

G-3

ENG SPEED

G-3

ENG SPEED

POWER SHIFT

2100~2190 0 mA

POWER SHIFT

21-35

2100~2190 0 mA

21. MECHATRO CONTROL SYSTEM

Operation No.5 : Boom down in full lever operation & in operation H mode Hi idle

No.31 BOOM C-1

P1-PRES

10.5~14.0 M

C-2

P2-PRES

0.7~2.0 M

E-1

P1-PSV

585~605 mA

E-2

P2-PSV

350 mA

D-1

P1-UL(BPC)

435~485 mA

D-2

P2-UL(BPC)

750 mA

B-1

BOOM RAISE

0.0 M

B-2

BOOM LOWER

3.0 M

G-3

ENG SPEED POWER SHIFT

2070~2160 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.32 ARM, SWING

No.32 ARM, SWING

C-1

P1-PRES

33.0~35.8 M

C-1

P1-PRES

12.5~16.5 M

C-2

P2-PRES

33.0~35.8 M

C-2

P2-PRES

12.5~16.5 M

E-1

P1-PSV

415~525 mA

E-1

P1-PSV

550~750 mA

E-2

P2-PSV

415~525 mA

E-2

P2-PSV

550~750 mA

D-1

P1-UL(BPC)

360 mA

D-1

P1-UL(BPC)

360 mA

D-2

P2-UL(BPC)

360 mA

D-2

P2-UL(BPC)

360 mA

D-3

S-TRAVEL

350 mA

D-3

S-TRAVEL

350 mA

D-6

ARM-IN-2

200 mA

D-6

ARM-IN-2

400 mA

B-3

ARM OUT

0.0 M

B-3

ARM OUT

0.0 M

B-4

ARM IN

3.0 M

B-4

ARM IN

3.0 M

B-1

BOOM RAISE

0.0 M

B-1

BOOM RAISE

0.0 M

B-7

SWING

0.0 M

B-7

SWING

0.0 M

G-3

ENG SPEED

G-3

ENG SPEED

POWER SHIFT

2100~2190 0 mA

POWER SHIFT

21-36

2100~2190 0 mA

21. MECHATRO CONTROL SYSTEM

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.32 ARM, SWING

No.32 ARM, SWING

C-1

P1-PRES

33.0~35.8 M

C-1

P1-PRES

15.0~22.0 M

C-2

P2-PRES

33.0~35.8 M

C-2

P2-PRES

15.0~22.0 M

E-1

P1-PSV

415~525 mA

E-1

P1-PSV

488~677 mA

E-2

P2-PSV

415~525 mA

E-2

P2-PSV

488~677 mA

D-1

P1-UL(BPC)

360 mA

D-1

P1-UL(BPC)

360 mA

D-2

P2-UL(BPC)

360 mA

D-2

P2-UL(BPC)

360 mA

D-3

S-TRAVEL

350 mA

D-3

S-TRAVEL

350 mA

D-6

ARM-IN-2

750 mA

D-6

ARM-IN-2

750 mA

B-3

ARM OUT

3.0 M

B-3

ARM OUT

3.0 M

B-4

ARM IN

0.0 M

B-4

ARM IN

0.0 M

B-1

BOOM RAISE

0.0 M

B-1

BOOM RAISE

0.0 M

B-7

SWING

0.0 M

B-7

SWING

0.0 M

G-3

ENG SPEED

G-3

ENG SPEED

2100~2190

POWER SHIFT

0 mA

2100~2190

POWER SHIFT

0 mA

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

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

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.32 ARM, SWING

No.32 ARM, SWING

C-1

P1-PRES

0.5~1.8 M

C-1

P1-PRES

0.5~1.8 M

C-2

P2-PRES

28.0~35.8 M

C-2

P2-PRES

10.0~15.0 M

E-1

P1-PSV

350 mA

E-1

P1-PSV

350 mA

E-2

P2-PSV

557~660 mA

E-2

P2-PSV

660 mA

D-1

P1-UL(BPC)

750 mA

D-1

P1-UL(BPC)

750 mA

D-2

P2-UL(BPC)

360 mA

D-2

P2-UL(BPC)

360 mA

D-3