Kobelco SK 200 10 Manual
Kobelco SK 200 10 Manual
Kobelco SK 200 10 Manual
MAINTENANCE SPECIFICATIONS
SHOP SK200-10
MANUAL model SK210LC-10
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
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GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in mi-
nor or moderate injury. It may also be used to
alert against possible damage to the machine
Do not operate or perform any maintenance on this and its components and is represented as fol-
machine until all instructions found in the OPERA- lows:
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine (4) It is very difficult to forecast every danger that may
may cause accidents and could result in serious in- occur during operation. However, safety can be en-
jury or death. sured by fully understanding proper operating pro-
Always keep the manual in storage. cedures for this machine according to methods
If it is missing or damaged, place an order with an recommended by Manufacturer.
authorized our Distributor for a replacement.
(5) While operating the machine, be sure to perform
If you have any questions, please consult an autho-
work with great care, so as not to damage the ma-
rized our Distributor.
chine, or allow accidents to occur.
(1) Most accidents, which occur during operation, are (6) Continue studying the manual until all Safety, Oper-
due to neglect of precautionary measures and safe- ation and Maintenance procedures are completely
ty rules. Sufficient care should be taken to avoid understood by all persons working with the ma-
these accidents. Erroneous operation, lubrication chine.
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:
0-2
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SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
0-3
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(13)Always use the proper tools that are in good condi- (19)Loose or damaged fuel, lubricant and hydraulic
tion and that are suited for the job at hand. Be sure lines, tubes and hoses can cause fires. Do not bend
you understand how to use them before performing or strike high pressure lines or install ones which
any service work. have been bent or damaged. Inspect lines, tubes
(14)Reinstall all fasteners with the same part number. and hoses carefully. Do not check for leaks with
Do not use a lesser quality fastener if replacements your hands. Very small (pinhole) leaks can result in
are necessary. a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
(15)Repairs which require welding should be per-
cause personal injury. Use card-board or paper to
formed only with the benefit of the appropriate ref-
locate pinhole leaks.
erence information and by personnel adequately
trained and knowledgeable in welding procedures. (20)Tighten connections to the correct torque. Make
Determine type of metal being welded and select sure that all heat shields, clamps and guards are in-
correct welding procedure and electrodes, rods or stalled correctly to avoid excessive heat, vibration
wire to provide a weld metal strength equivalent at or rubbing against other parts during operation.
least to that of the parent metal. Make sure to dis- Shields that protect against oil spray onto hot ex-
connect battery before any welding procedures are haust components in event of a line, tube or seal
attempted. failure must be installed correctly.
(16)Do not damage wiring during removal operations. (21)Do not operate a machine if any rotating part is
Reinstall the wiring so it is not damaged nor will be damaged or contacts any other part during opera-
damaged in operation of the machine by contacting tion. Any high speed rotating component that has
sharp corners, or by rubbing against some object or been damaged or altered should be checked for
hot surface. Do not connect wiring to a line contain- balance before reusing.
ing fluid. (22)Be careful when servicing or separating the tracks
(17)Be sure all protective devices including guards and (crawlers). Chips can fly when removing or install-
shields are properly installed and functioning cor- ing a track (crawlers) pin. Wear safety glasses and
rectly before starting a repair. If a guard or shield long sleeve protective clothing. Tracks (crawlers)
must be removed to perform the repair work, use can unroll very quickly when separated. Keep away
extra caution and replace the guard or shield after from front and rear of machine. The machine can
repair is completed. move unexpectedly when both tracks (crawlers)
are disengaged from the sprockets. Block the ma-
(18)The maintenance and repair work while holding the
chine to prevent it from moving.
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
The copyright of this manual belongs to KOBELCO CONSTRUCTION MACHINERY CO., LTD.
Copy, reproduction, distribution, and delivery (including these actions on the Internet) of all or part of this
manual are prohibited without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD.
This manual is intended to provide instructions for repair, maintenance, and adjustment of the machine, sold
directly or indirectly by KOBELCO CONSTRUCTION MACHINERY CO., LTD. or KOBELCO authorized dealer,
and any use other than that purpose will not be allowed.
Also, all or part of this manual cannot be transferred, sold, or lent to a third person without permission of
KOBELCO CONSTRUCTION MACHINERY CO., LTD.
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C area in SE Asia (TKCM) INDEX SK200-10
SK210LC-10
Index
Distribution Year–Month Title 1
No. 17 9
MAINTENANCE SPECIFICATIONS
2015-11 OUTLINE 1
2015-11 SPECIFICATIONS 2
DISASSEMBLING 13 5
DISASSEMBLING
2015-11 12
& ASSEMBLING
2015-11 ATTACHMENT 13
2015-11 BY TROUBLE 17
_
15 7
_
2015-11 ENGINE 18
_
16 8
_
0-5
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NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
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[1. OUTLINE]
1. OUTLINE
1.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................1-3
1.2 GENERAL PRECAUTIONS FOR MAKING REPAIRS .................................................................1-4
1.2.1 PREPARATION BEFORE DISASSEMBLING ..........................................................................1-4
1.2.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING .........................................................1-4
1.2.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .........................................1-5
1.2.4 ELECTRICAL EQUIPMENT....................................................................................................1-7
1.2.5 HYDRAULIC PARTS..............................................................................................................1-7
1.2.6 WELD REPAIR ......................................................................................................................1-8
1.2.7 ENVIRONMENTAL ISSUES ...................................................................................................1-8
1.3 INTERNATIONAL UNIT SYSTEM ..............................................................................................1-9
1-1
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[1. OUTLINE]
1-2
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[1. OUTLINE]
1-3
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[1. OUTLINE]
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.
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.
Recording
Record the following items to keep contact and prevent malfunction from recurring.
• Inspecting date, place
• Model name, Serial number and Record on hour meter
• Trouble condition, place, cause
• Visible oil leak, water leak and damage
• Clogging of filters, oil level, oil quality, oil contamination and looseness.
• Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour
meter.
WARNING
Safety
• Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
• Attach "Don't operate" tag to control lever, and begin a meeting before starting the work.
• Before starting inspection and maintenance stop the engine.
• 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.
• Choose a hard, level and safe place, and put attachment on the ground without fail.
• Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
• Use proper tools, and change or repair defective tools.
• Machine and attachment required to work in the lifting condition should be supported with supports or blocks
securely.
1-4
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[1. OUTLINE]
1
Removing hydraulic equipment assy
• 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.
• Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
• Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
• Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before
putting them on working bench.
Inspecting parts
• Check that the disassembled parts are free from adherence, interference and uneven working face.
• Measure the wear of parts and clearance, and record the measured values.
• If an abnormality is detected, repair or replace the parts.
1-5
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[1. OUTLINE]
Im p o r t a n t im fo r m a t io n
LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within
level marks, the oil quantity
is acceptable.
1-6
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[1. OUTLINE]
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.
1-7
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[1. OUTLINE]
1-8
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[1. OUTLINE]
1-9
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[1. OUTLINE]
1-10
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[2. SPECIFICATIONS]
2. SPECIFICATIONS
2.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................2-3
2.2 BASIC COMPONENTS OF THE MACHINE................................................................................2-4
2
2.3 GENERAL DIMENSIONS..........................................................................................................2-6
2.3.1 SK200-10[5.65m(18ft-6in) Boom + 2.94m(9ft-8in) Standard Arm + 0.8m3(1.05cu·yd)
Bucket]............................................................................................................2-6
2.3.2 SK210LC-10[5.65m(18ft-6in) Boom + 2.94m(9ft-8in) Standard Arm + 0.8m3(1.05cu·yd)
Bucket]............................................................................................................2-7
2.4 WEIGHT OF COMPONENTS.....................................................................................................2-8
2.5 SPECIFICATIONS FOR TRANSPORTATION .............................................................................2-9
2.5.1 DIMENSIONS AND WEIGHT OF ATTACHMENT/EQUIPMENT ................................................2-9
2.6 GENERAL SPECIFICATIONS ................................................................................................. 2-11
2.6.1 SPEED AND CLIMBING CAPABILITY .................................................................................. 2-11
2.6.2 ENGINE .............................................................................................................................. 2-11
2.6.3 HYDRAULIC COMPONENTS ............................................................................................... 2-11
2.6.4 WEIGHT .............................................................................................................................. 2-11
2.7 TYPE OF CRAWLER ..............................................................................................................2-12
2.7.1 SK200-10 TYPE OF SHOE ...................................................................................................2-12
2.7.2 SK210LC-10 TYPE OF SHOE...............................................................................................2-12
2.8 TYPE OF BUCKET .................................................................................................................2-13
2.9 COMBINATIONS OF ATTACHMENT .......................................................................................2-14
2.10 ENGINE SPECIFICATION .....................................................................................................2-15
2.10.1 SPECIFICATIONS..............................................................................................................2-15
2-1
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[2. SPECIFICATIONS]
2-2
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[2. SPECIFICATIONS]
2-3
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[2. SPECIFICATIONS]
29 28
30
27
15
32
26
3 4
13 16
33
19
20
18
21
5
7 1
22 17
8 24
23 34
35 6 12
14
Inside the left side door 10 9 11
25
2-4
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[2. SPECIFICATIONS]
2-5
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[2. SPECIFICATIONS]
45 (1.77”)
0 R
9 4 ”) (9 2 9 1
R 1 6 ’4 ’7 ” 0
)
(
9600 (31’6”) 2710 (8’1 1”)
2900 (9’6”) 1390 1320
(4’7”) (4’4”)
3010 (9’11”)
2980 (9’9”)
2740 (8’12”)
1060* (3’6”)
450*
(17.7”)
4170 (13’8”) 600
(23.6”)
4990 (16’4”) 2800 (9’2”)
2-6
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[2. SPECIFICATIONS]
45 (1.77”)
2
0 R
9 4 ”) (9 2 9 1
1
R 6’ 4 ’7 ” 0
( )
9600 (31’6”) 2710 (8’1 1”)
2900 (9’6”) 1390 1320
(4’7”) (4’4”)
3010 (9’11”)
2980 (9’9”)
2740 (8’12”)
1060* (3’6”)
450*
(17.7”)
4450 (14’7”) 600
(23.6”)
5130 (16’10”) 2990 (9’10”)
2-7
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[2. SPECIFICATIONS]
2-8
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[2. SPECIFICATIONS]
2.5.1.3 ARM
Item / Type 2.94m (9ft-8in) arm
2-9
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[2. SPECIFICATIONS]
2.5.1.4 BUCKET
Type Hoe bucket
Length X Height X Width 1.38 x 1.24 x 1.16 1.38 x 1.24 x 1.30 1.37 x 1.26 x 1.46
L X H X W: m (ft-in) (4'6" x 4'1" x 3'10") (4'6" x 4'1" x 4'3") (4'6" x 4'2" x 4'9")
Bucket capacity: m3 (cu·yd) 0.80 (1.05) STD 0.93 (1.22) 1.0 (1.31)
Õ Hoe bucket
2-10
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[2. SPECIFICATIONS]
Rated output / Engine speed 114kW (153 hp) / 2,000 min-1 (rpm) (ISO 9249 : With fan)
Maximum torque / Engine speed 596 N·m (420 lbf·ft) / 1,600 min-1(rpm) (ISO 9249 : With fan)
Starter 24 V / 5.0kW
Alternator 24 V / 60A
2.6.4 WEIGHT
Fully equipped weight kg (lbs) 20,500 (45,200) 20,900 (46,080)
Travel system
kg (lbs) 6,900 (15,210) 7,270 (16,030)
(600 mm {23.6in} grouser shoe)
Attachment
4,120 (9,080) ←
5.65m (18ft-6in) Boom + 2.94m kg (lbs)
0.8 m3 (1.05cu·yd) Bucket 0.8 m3 (1.05cu·yd) Bucket
(9ft-8in) Arm + Bucket
2-11
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[2. SPECIFICATIONS]
Use 600mm (23.6in) 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.)
46 LINKS
46 LINKS
2-12
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[2. SPECIFICATIONS]
2-13
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[2. SPECIFICATIONS]
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
STD
0.59 (0.77) ◎
0.80 (1.05)
Hoe bucket
0.93 (1.22) 0.67 (0.88) ○
Breaker ― ― ○
Nibbler ― ― ○
2-14
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[2. SPECIFICATIONS]
Maximum torque (ISO 9249: With fan) 596 N·m (420 lbf·ft) at 1,600 min-1 (rpm)
Thermostat action Start 344 K (160F degrees) / Full open 358 K (185F degrees)
Firing order 1 -3 -4 -2
Specific fuel consumption (at rated power) 208 g / kw·h (155 g / hp·h)
2-15
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[2. SPECIFICATIONS]
2-16
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[3. ATTACHMENT DIMENSIONS]
3. ATTACHMENT DIMENSIONS
3.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................3-3
3.2 BOOM......................................................................................................................................3-4
3.2.1 BOOM DIMENSIONAL DRAWING..........................................................................................3-4
3.2.2 BOOM MAINTENANCE STANDARD ......................................................................................3-5
3.3 ARM ........................................................................................................................................3-8
3.3.1 ARM DIMENSIONAL DRAWING.............................................................................................3-8
3.3.2 ARM MAINTENANCE STANDARD .......................................................................................3-10 3
3.4 BUCKET ................................................................................................................................3-13
3.4.1 BUCKET DIMENSIONAL DRAWING ....................................................................................3-13
3.4.2 BUCKET DIMENSIONAL TABLE..........................................................................................3-13
3.4.3 LUG SECTION DIMENSIONAL DRAWING ...........................................................................3-14
3.4.4 BOSS SECTION DIMENSIONAL DRAWING .........................................................................3-15
3-1
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[3. ATTACHMENT DIMENSIONS]
3-2
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[3. ATTACHMENT DIMENSIONS]
3-3
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[3. ATTACHMENT DIMENSIONS]
3.2 BOOM
3.2.1 BOOM DIMENSIONAL DRAWING
d2
J
SECTION X-X
3-4
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[3. ATTACHMENT DIMENSIONS]
A
C
B
3
Unit:mm (in)
+ 0.250 + 0.290
Boom 0
ø 85 (+0.0098) (+0.0114)
B cylinder YN02B02457P1 - 0.040
(3.3465) + 0.050 + 0.050
(Head side) (-0.0016) Replace
(+0.0020) (+0.0020) 2.0 2.5
bushing
+ 0.020 + 0.250 + 0.270 (0.08) (0.1)
Boom or pin
ø 85 (+0.0008) (+0.0098) (+0.0106)
C cylinder YN02B01721P1
(3.3465) - 0.020 + 0.050 + 0.030
(Rod side)
(-0.0008) (+0.0020) (+0.0012)
3-5
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[3. ATTACHMENT DIMENSIONS]
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
3-6
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[3. ATTACHMENT DIMENSIONS]
Unit:mm (in)
3-7
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[3. ATTACHMENT DIMENSIONS]
3.3 ARM
3.3.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
3-8
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[3. ATTACHMENT DIMENSIONS]
Dimension Dimension
Code Part Name Code Part Name
mm (ft-in) mm (ft-in)
L Arm link section boss width 323 (12.7") d5 Pin dia. ø80 (3.15")
3-9
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[3. ATTACHMENT DIMENSIONS]
C
G
Unit:mm (in)
+ 0.231 + 0.291
Bucket link
(+0.0091) (+0.0115)
D (Idler link
+ 0.020 + 0.161 + 0.161
connection) Replace
ø80 (+0.0008) (+0.0063) (+0.0063) 2.0 2.5
YN12B11520P1 bushing
(3.1496) - 0.040 + 0.250 + 0.290 (0.08) (0.01)
Bucket or pin
(-0.0016) (+0.0098) (+0.0114)
D' cylinder
+ 0.050 - 0.030
(Rod side)
(+0.0020) (-0.0012)
3-10
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[3. ATTACHMENT DIMENSIONS]
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X3 L3 PL5
X6 L6
X5 L5
PL1 PL3
3
PL6
SECTION A-A SECTION C-C SECTION E-E SECTION F-F
PL7
X2 L2 X7 L7
X4 L4
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D SECTION G-G
3-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[3. ATTACHMENT DIMENSIONS]
Unit:mm (in)
105
Head side
Bucket cylinder (4.13) 227
E-E L5 PL5
(Head side) 11 1 (8.9)
Arm
(4.37) 0.6 to 2.0 3.0 4.0
120 (0.02 to 0.08) (0.12) (0.16)
Rod side
Arm cylinder (4.72) 252
F-F L6 PL6
(Rod side) 126 (9.9)
Arm
(4.96")
342
Arm
(13.46) 0.5 1.0 2.5 508
G-G Arm foot L7 PL7
347 (0.02) (0.04) (0.10) (20.0)
Boom
(13.66)
3-12
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[3. ATTACHMENT DIMENSIONS]
3.4 BUCKET
3.4.1 BUCKET DIMENSIONAL DRAWING
Hoe bucket
B Distance between bucket pin and tooth end H Bucket outer width of front side
A R430 (16.9") ←
B R1,440 (4'9") ←
D 399 (15.7") ←
E 327 (12.9") ←
d1 ø95 (3.74") ←
d2 ø80 (3.15") ←
3-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[3. ATTACHMENT DIMENSIONS]
X B
J
A
bb
F
N
D E
Unit:mm (ft-in)
3-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[3. ATTACHMENT DIMENSIONS]
H 5
(0.197" )
- G
I
m 0 .2 0 8 "
.0 0 . x
(0 R a
R 0 .0
ax
08 2
m
(
")
.0 .5
- A - B - C- D
(0 -C 0
")
)
20
30r
2
15 (0.591")
3
DETAIL bb
E
Unit:mm (ft-in)
øA 114.3 (4.50") ←
øB 84 (3.31") ←
øC 105.5 (4.15") ←
øD 111.5 (4.39") ←
E 23 (0.91") ←
F 38 (1.50") ←
øG 17 (0.669") ←
H 13 (0.512") ←
I 2.5 (0.098") ←
3-15
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[3. ATTACHMENT DIMENSIONS]
3-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[4. TOOLS]
4. TOOLS
4.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................4-3
4.2 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ..........................................................4-4
4.3 SCREW SIZE AND NOMINAL SIZE OF TOOL ...........................................................................4-6
4.3.1 CAPSCREW (HEX HEAD BOLT) ............................................................................................4-6
4.3.2 CAPSCREW (HEX HEAD SOCKET BOLT) .............................................................................4-6
4.3.3 SET SCREW (HEX HEAD SOCKET SET SCREW) ..................................................................4-6
4.4 TIGHTENING TORQUE FOR HOSE AND FITTING ....................................................................4-7
4.4.1 JOINT (O-RING TYPE)...........................................................................................................4-7
4.4.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ..........................................................................4-7
4.4.3 ORS FITTNIG ........................................................................................................................4-7
4.4.4 SPLIT FLANGE .....................................................................................................................4-7
4.5 TIGHTENING TORQUES FOR NUTS AND SLEEVES ................................................................4-8
4.6 PLUG.......................................................................................................................................4-9 4
4.6.1 PLUG FOR BYTE TYPE TUBE FITTING .................................................................................4-9
4.6.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................................4-10
4.7 SPECIAL SPANNER FOR TUBE .............................................................................................4-12
4.8 SPECIAL TOOLS....................................................................................................................4-13
4.9 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND....................4-15
4.10 SUCTION STOPPER ............................................................................................................4-16
4.10.1 COMPONENTS..................................................................................................................4-16
4.10.2 DIMENSION.......................................................................................................................4-16
4.11 COUNTER WEIGHT LIFTING JIG..........................................................................................4-17
4.12 ENGINE MOUNTING PEDESTAL ..........................................................................................4-18
4.13 TRACK SPRING SET JIG .....................................................................................................4-19
4-1
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[4. TOOLS]
4-2
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[4. TOOLS]
4-3
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[4. TOOLS]
Strength
4.8T 7T 10.9T
classification
Size
Use No Oil No Oil No Oil
classification lubrication lubrication lubrication lubrication lubrication lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
4-4
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[4. TOOLS]
Strength
4.8T 7T 10.9T
classification
Size
Use No Oil No Oil No Oil
classification lubrication lubrication lubrication lubrication lubrication lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
4-5
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[4. TOOLS]
M6 10 M36 55
M8 13 M42 65
M10 17 M45 70
d
M12 19 M48 75
(M14) 22 M56 85
M16 24 (M60) 90
(M18) 27 M64 95 B
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
M6 5 (M27) 19
M8 6 M30 22
B
M10 8 M36 27
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
4-6
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[4. TOOLS]
3/4 36 162±9.8(119±7)
1 41 255±9.8(188±7)
1 41 137±15 (101±11)
36 177±18 (131±13)
1 3 / 16-12 UN
41 206±21 (152±15)
41 206±21 (152±15)
1 7/ 16-12 UN NUT
46 206±21 (152±15)
4-7
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[4. TOOLS]
Nippon A.M.C. 29.4 (4270) ø18 X 2.5 (0.709 X 0.098) 32 147±15 (110±11)
Ihara Science 29.4 (4270) ø35 X 5.0 (1.38 X 0.197) 55 441±44 (330±33)
SLEEVE NUT
B
d
d
6 ZF96S06000 — 6 14 ZF96N06000 —
8 ZF96S08000 — 8 17 ZF96N08000 —
10 ZF96S10000 ZA93S10000 10 19 ZF96N10000 ZA93N10000
12 ZF96S12000 — 12 22 ZF96N12000 —
15 ZF96S15000 ZA93S15000 15 27 ZF96N15000 ZA93N15000
18 ZF96S18000 ZA93S18000 18 32 ZF96N18000 ZA93N18000
22 ZF96S22000 ZA93S22000 22 36 ZF96N22000 ZA93N22000
28 ZF96S28000 ZA93S28000 28 41 ZF96N28000 ZA93N28000
32 ZF96S32000 — 32 50 ZF96N32000 —
35 ZF96S35000 ZA93S35000 35 55 ZF96N35000 ZA93N35000
38 ZF96S38000 — 38 60 ZF96N38000 —
4-8
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[4. TOOLS]
4.6 PLUG
4.6.1 PLUG FOR BYTE TYPE TUBE FITTING
Cap nut (Joint plug)
Applicable Opposing
tube Cap nut parts No. T screw flats
O.D:A H1 H
6 ZF83H06000 M12 X 1.5 14 14
A
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
H1 T s cre w H
Applicable
tube Plug parts No.
O.D:A 4
6 ZF83P06000
8 ZF83P08000
A
10 ZF83P10000
12 ZF83P12000
15 ZF83P15000
18 ZF83P18000 S le e ve Nut
Type
22 ZF83P22000
joint body
28 ZF83P28000
Nut
Applicable
Opposing
tube Nut parts No. d screw
flats
O.D:A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
A
d s cre w
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
4-9
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[4. TOOLS]
PF
Plug parts No. B mm O-ring parts No. Nominal O-ring B
screw O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PT screw
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
PF3/4 2444Z2729D4 27 36
PF1 2444Z2729D5 36 41
Opposing Oppos ing
PF1 1/4 2444Z2729D6 40 50 flats F flats E
4-10
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[4. TOOLS]
Male
Opposing
Screw Applicable O-ring Nominal
Plug parts No. flats
size A hose O.D parts No. O-ring
(HEX)
Female
Applicable Opposing
Screw size A Plug parts No.
hose O.D flats (HEX)
25.53 to
1/2 ZE12Q08000 38.10 17.48 9 45Z91D2
25.40
31.88 to
3/4 ZE12Q12000 47.63 22.23 11 ZD12P02600
31.75 C
39.75 to
1 ZE12Q16000 52.37 26.19 11 ZD12P03400
39.62
44.58 to
1 1/4 ZE12Q20000 58.72 30.18 11 ZD12P03800 D
44.45
25.53 to
1/2 ZE13Q08000 40.49 18.24 9 2445Z831D1
25.40 G
31.88 to
3/4 ZE13Q12000 50.80 23.80 11 ZD12P02600
31.75
39.75 to
1 ZE13Q16000 57.15 27.76 13 ZD12P03400
39.62
44.58 to
1 1/4 ZE13Q20000 66.68 31.75 15 ZD12P03800
44.45
4-11
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[4. TOOLS]
70(2 .76)
16 8 PART-No. 22
15 (0.591) 2421T160 27 (0.3 15)
(0.6 30) (0.8 66)
HEX27
40(1 .57) 12.7
(0.500 )
70(2 .76)
42(1 .65)
70(2 .76)
11.5 (0.453)
HEX50
HEX55
4-12
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[4. TOOLS]
Allen wrench
ZT22A10000 Pump
1 Nominal
suction
B:10, C:11.3
Spanner or socket
2 General tools Pump install
Nominal size:17
CUT
Com merc ia l tool oute r width (D) - cut le ngth = Re quire d le ngth
81 (3.19") - 16 (0.63") = 65 (2.56")
Additiona l M10 X 22
ta pping
4
for M10 e ye bolt
For slinging
Plug ZE72X12000
4 the swing
PF3/4
motor
PF3/4 O-ring
M12
M8 Eye bolt
Plug ZF83P22000
(Nominal size 22)
6 Reference Re fe re nce nut Flare hose
Eye bolt ZS91C00800
Nut ZF93N22000
M8 X 18
Addtiona l ta pping
4-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[4. TOOLS]
M8 Eye bolt
M8 X 18
Additional
threading
Plug YN01H01001P1
Nominal 1-14UNS
7 HEX 27 Flare hose
Eye bolt ZS91C00800
1-14UNS
M8 X 18 M8 Eye bolt
Additional
threading
Plug
YN01H01002P1
Nominal 1 3/16-
8 12UN HEX 36 Flare hose
ZS91C00800
Eye bolt
1 3/16-12UN
Plug ZE25F08000
PF1/2 We ld For slinging
9
Coupling the swivel joint
half Coupling ha lf
PF 1/2
5.49
TORX driver
For instrument
(with tamper proof) Point shape
10 — panel cover
T30
(RH)
(For M6)
4-14
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[4. TOOLS]
High
#271 1305
strength
(Manufacturer ; Loctite)
Sumitomo
Chemical Co., Cyano Bond P0-1 Swing bearing and seal
Ltd.
Shell petroleum Shell Alvania EP2 New Molyknock Grease 2 Grease bath of swing bearing
4-15
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[4. TOOLS]
2
3
4.10.2 DIMENSION
50
(1.97")
R
(1 8 O113 (4.45")
.3
15" 2
) M8 NUT (0.08")
O8 (1.315")
600 (23.6")
+0.5
M8 O100 0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
4-16
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[4. TOOLS]
M8 15 ZS91C00800 80 (176)
L
M30 45 ZS91C03000 1500 (3310) dd
4-17
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[4. TOOLS]
6 1
175(6.89)
375 (14.8)
2
400 (15.7)
240 (9.45)
(4.72) (4.72)
750 (29.5)
120 120
375 (14.8)
175(6.89)
6 6
744 (29.3) 100
(3.94)
945 (37.2)
6 6
275 300
(10.8) (11.8)
352 (13.9)
250(9.84)
0
213(8.39)
750 (29.5)
R5 .0)
200(7.87)
t 50 (2
(2.0) 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)
200 (7.87) 945 (37.2)
55 145
352 (13.9)
(2.2) (5.71)
6 X 5 pieces
R5
352 (13.9)
100(3.94)
(2. 0
(3.5)
10(0.39)
90
t 24 (0.95) 0)
t 24
10(0.39)
(7.48)
(0.95)
190
t50
(2.0)
Engine stand
4-18
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[4. TOOLS]
Retainer plate
)
.6"
(12
(27.6")
Stand
(15.0")
Hydraulic jack
Base 4
Track spring set jig
4-19
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[4. TOOLS]
4-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
5-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
5-2
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
5-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
5.2 PREFACE
Working Conditions
• 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).
• 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.
• Place:
A flat land where work may be performed and to which a service car or a truck crane is accessible.
5-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
The time required for works specified in this Chapter shows the total time for maintenance.
5-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
5.3.1 Attachment(01)
Group Work to Unit:
Location Unit Remarks
No. be done Hour
See Paragraph "BUCKET" in Chapter
00 Bucket related parts
"ATTACHMETNTS"
Detach/
01 Bucket assy 1 pc. Include adjustment 0.6
attach
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
Detach/
03 • Bucket attaching pin 1 Include stopper pin. 0.1
attach
Detach/
04 • Bucket drive pin 1 0.1
attach
05 • Bucket sling and movement Preparation 1 pc. 0.2
06 • Bucket (single) O/H 1 pc. Not include attaching and detaching 2.4
Detach/
13 • Bucket cylinder rod pin 1 pc. Include stopper pin. 0.1
attach
Detach/
14 • Bucket cylinder head pin 1 pc. Include stopper pin. 0.1
attach
Detach/
15 • Bucket cylinder assy 1 pc. 0.1
attach
Detach/
16 • Arm cylinder rod pin 1 pc. Include stopper pin. 0.1
attach
Detach/
17 • Boom top pin 1 pc. Include wire stop pin 0.1
attach
Detach/
18 • Arm sling and movement 1 pc. 0.2
attach
See Paragraph "BOOM" in Chapter
30 Boom related parts
"ATTACHMETNTS"
Detach/
31 • Boom assy 1 pc. 1.4
attach
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
5-6
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[5. STANDARD MAINTENANCE TIME TABLE]
5-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
5-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
Cover (7)
Detach/
1 pc.
5
47 0.1
attach
5-9
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[5. STANDARD MAINTENANCE TIME TABLE]
5-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
5-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
109 Swivel joint O/H 1 set Removing and installing guard 3.6
Detach/
Other necessary works 1 set Lower piping 0.6
attach
See Paragraph "CONTROL VALVE"
110 Main control valve in Chapter "UPPER SLEWING
STRUCTURE"
Detach/
111 Main control valve assy 1 pc. 2.5
attach
112 • Attach tag to port name of pipe Preparation 1 pc. 0.6
Detach/
113 • Piping 1 set 1.7
attach
5-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
Detach/
Other necessary works 1 set Removing and installing guard 0.6
attach
Detach/ Removing and installing
1 set 0.6
attach Counterweight
Detach/
1 set Removing and installing pump 3.2
attach
Detach/
1 set Removing and installing air cleaner 0.4
attach
Detach/
1 set Removing and installing muffler 0.4
attach
Detach/
1 set Removing and installing radiator 4.0
attach
See Paragraph "UPPER FRAME" in
140 Upper frame Chapter "UPPER SLEWING
STRUCTURE"
Detach/
141 Upper frame assy 1 pc. After removing swivel joint 1.3
attach
5-13
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[5. STANDARD MAINTENANCE TIME TABLE]
5-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[5. STANDARD MAINTENANCE TIME TABLE]
Detach/
11 Upper roller assy 1 After removing track link 0.2
attach
12 Upper roller O/H 1 1.0
See Paragraph "REMOVING AND
20 Lower roller related parts INSTALLING LOWER ROLLER" in
Chapter "TRAVEL SYSTEM"
Detach/
21 Lower roller assy 1 0.2
attach
22 Lower roller O/H 1 1.0
See Paragraph "REMOVING AND
Front idler related parts
INSTALLING FRONT IDLER 5
30
ASSEMBLY" in Chapter "TRAVEL
SYSTEM"
Detach/ One
31 Front idler assy After removing track link 0.6
attach side
Detach/ One
32 Front idler assy slinging 0.3
attach side
One
33 Front idler assy Detaching 0.3
side
One
34 Idler assy O/H 1.0
side
One
35 Idler adjuster assy O/H Replace spring 2.4
side
One
36 • Grease cylinder O/H 0.6
side
See Paragraph "REMOVING AND
40 Sprocket INSTALLING SPROCKET" in
Chapter "TRAVEL SYSTEM"
One
41 Sprocket Replace After removing track link 0.6
side
See Paragraph "REMOVING AND
50 Travel motor related parts INSTALLING TRAVEL MOTOR" in
Chapter "TRAVEL SYSTEM"
5-15
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[5. STANDARD MAINTENANCE TIME TABLE]
Detach/
71 Swing bearing assy 1 pc. After removing upper frame 0.7 0.7
attach
Detach/
72 Swing bearing mounting bolt 1 pc. 0.5
attach
Detach/
73 Swing bearing slinging 1 pc. 0.3
attach
5-16
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[5. STANDARD MAINTENANCE TIME TABLE]
5-17
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[5. STANDARD MAINTENANCE TIME TABLE]
5-18
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[5. STANDARD MAINTENANCE TIME TABLE]
Solenoid
Include removing and installing
SV-1 Swing parking sol. Replace 1 0.5
proportional valve block.
5-19
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[5. STANDARD MAINTENANCE TIME TABLE]
5-20
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-1
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-2
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-3
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Terminology
• 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).
• 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.
• 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.
6-4
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When turning on the power, the work mode is the "S" mode. Unless otherwise specified, measure the inspection
items by the "H" mode.
FULL throttle
H mode Hi idle 2170 + 30 - 30
Adjustment (HI idle)
See measured value from min-1
Decel 1200 + 30 - 30 not required
gauge cluster
Perform all measurement
S mode Hi idle 1950 + 30 - 30 with air conditioner "OFF".
ECO mode Hi idle 1950 + 30 - 30
Pilot primary pressure circuit G pump a3 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
P1 a1
valve pressure
P2 a2
P1 a1
Power boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1
P2 a2
R 37.8 (5480) + 0.5 (+73) - 0.5 (-73) OR4 Boom down
Boom a1
H 39.7 (5760) + 0.5 (+73) - 0.5 (-73) OR3 Boom up
High pressure circuit
Main pump
Overload relief valve pressure
6-5
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Swing brake performance 180 degrees full speed swing 106 to 126 degree
Swing parking 0
15 degrees slope mm (inch)
brake performance (0)
Tip of bucket tooth 96 (3.8)
mm / 5 min
ATT lowering amount Boom cylinder 7.2 (0.28) (No load)
(inch / 5 min)
Arm cylinder 5.4 (0.21)
30 to 50
Amount of horizontal play at bucket tooth mm (inch)
(1.18 to 1.97)
Note
The port re lie f va lve s No.OR1 to OR8 on the control s e ction a re a djus te d to the following ope ra tion numbe rs .
(1) Bucke t digging, (2) Bucke t dumping, (3) Boom up, (4) Boom down,
(5) S wing le ft, (6) S wing right, (7) Arm in, (8) Arm out
Left Right
Control levers
6-6
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-7
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OFF
F
MODE HM
ATT MODE BRK
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
6-8
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
a1
6-9
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
MACHINE
FRONT
MACHINE
FRONT
6-10
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
A3
a3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
PB
PA
6-11
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
2 1
H E X 2 2
6-12
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-13
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature: 45 to 55 degrees C (113 to
131 degrees F)
The crawlers on the right and left sides are tensed
evenly.
Preparation
Attach the reflection panel with a magnet to the travel
motor cover. REFLECTION
PANEL
Swing the swing frame through 90C degrees as shown
in Fig. "One side lifted position" and make the crawler on
one side take off the ground, using the attachment.
Measurement
Number of sprocket rotations Unit: min -1
Engine speed: High idle
Measurement item Standard value Reference value for remedy Service limit
2-speed travel switch: 1st speed and 2nd speed
Measuring points: Right and left H mode 1st speed 33.1 to 29.9 25.8 to 23.3 21.1 or less
RH & LH
Method, example 1: H mode 2nd speed 54.4 to 49.6 42.4 to 38.7 34.8 or less
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.
6-14
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Measuring Method
Measurement
Tra ve l de via tion Unit : mm (in) / 20m (66ft)
1. Measure the max. deviation distance of the circular Measuring
Standard value
Reference value
Service limit
position for remedy
arc in the 20 m (66 ft) length, excluding the
A 240 (9.45) or less 480 (18.9) 720 (28.4)
preliminary run of 3 to 5 m (10 to 16 ft).
2. Operate the travel lever at the same time.
6-15
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
15 degree slope
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.
C ANGLE
GUIDE FRAME METER
Measuring Method
Measurement
Parking brake Unit : mm(in)/5min
Five minutes after the engine stops, measure the Measuring
Standard value
Reference value
Service limit
position for remedy
movement distance of the matching mark.
C 0 1 (0.04) 2 (0.08) or more
6-16
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Preparation
1. Place a stopper under the RH and LH travel
sprockets.
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.
Measurement: At Travel Lock Drain rate of travel motor Unit : L(gal )/30sec
Measuring Reference value
position Standard value for remedy Service limit
Drain rate 9 (2.4) 16 (4.2) 23 (6.1) or more
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.
Perform measurement on each side at the forward rotation for three times and the average value of the results
is the measurement value.
6-17
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature: 45 to 55 degrees C (113 to
131 degrees F)
Firm, level ground
Engine speed: High idle
Preparation
Make the bucket empty and extend the boom, arm and
bucket cylinders fully. (Minimum reach) Swing speed measuring position (at the min.
reach)
6-18
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature: 45 to 55 degrees C (113 to 131 degrees F)
Firm, level ground, no load bucket
Engine speed: High idle
Preparation
• Make the bucket empty, retract the arm cylinder fully ARM TOP
BOOM FOOT
and extend the bucket cylinder fully. And move the PIN
PIN
boom so that the arm top pin is positioned at same
height with the boom foot pin.
• 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.
Amount of deflection of
Swing drift matching marks [m (ft-in)]
angle (degrees) = Circumferential length of X 360
degrees
swing race [m (ft-in)]
6
Swing brake performance Unit: degrees
Measurement item Standard value Reference value for remedy Service limit
Swing 180 Within 126 117 to 139 151 or more
6-19
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Make
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.
MATCHING MARKS
ON INNER RACE
6-20
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature: 45 to 55 degrees C (113 to
131 degrees F)
Engine speed: High idle
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.
Measurement: At Swing Lock
Drain rate of swing motor Unit : L(gal)/30sec
1. Start the engine and put the side faces of bucket Measuring
Standard value
Reference value
Service limit
position for remedy
against the inside of the right or left shoe plates.
Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 ( 1.6 ) or more
2. Relieve the swing motor at full stroke of the swing
motion.
3. Collect the amount of drained oil in a container for 30 seconds.
6-21
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Condition
3 0 c m (1 ft)
Hydraulic oil temperature: 45 to 55 degrees C (113 to
131 degrees F)
Measuring position for bucket digging and dump
Engine speed: High idle
Operating time excluding cushion stroke
Preparation C o n d itio n :
A r m c y lin d e r m o s t r e tr a c te d
Firm level ground with the bucket empty B u c k e t c y lin d e r m o s t e x te n d e d
6-22
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-23
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Condition
Firm, level ground
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making abnormal sound during turning.
Preparation
LOCATION OF BEARING
1. Install a dial indicator to the magnetic base and fix it MOUNTING BOLTS
to the lower frame.
2. Direct the upper swing body and the lower frame SWING BEARING
toward the travel direction, bring the probe of the A
dial indicator in contact with the bottom surface of
the outer race on the swing body side and set the
reading at zero. DIAL INDICATOR
3 0 c m (1 ft)
Measuring position I
ARM TOP
PIN BOOM FOOT
PIN
Measuring position II
6-24
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-25
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
C-8:
ENGINE
C-2: CONTROLLER
GAUGE CLUSTER
PUMP
PROPO RTIONAL
VALVE
S TARTER E-1:
SWITCH FUSE&REL AY BOX EMERGENCY E-27:
ACCEL
ACCEL DIAL ENGINE THROTTLE FOR
POTENTIO METER REDUNDANT MODE
INPUT / OUTPUT
6-26
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
2 4
Gauge cluster
Preparation
• Raise the oil temperature to approximately 50 degrees C (122 degrees F) to warm up the engine.
• Turn the air-con OFF.
• 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.
6
1. For machines equipped with lifting magnet, turn the generator OFF.
2. For the adjustment items not included in the specifications, "- - -" is displayed.
1. Turn starter key switch ON keeping the work mode MULTI DISPLAY
select switch on the gauge cluster pressed, and hold (EXAMPLE)
it for 5 to 10 seconds, and then release it. (If the S 12:15
6-27
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
ADJUST 0 CRANE
READY
READY
STEP
0
P1 PUMP 350
P2 PUMP 350
P1 UNLOAD 200
P2 UNLOAD 200
P1 PRESSURE 0
P2 PRESSURE 0
STEP
0
P1 PUMP 350
(To restrict the engine speed, press the menu switch P2 PUMP 350
P2 UNLOAD 200
is obtained. Then adjustment of the engine is P1 PRESSURE 0
STEP
0
P1 PUMP 350
and unload adjustment are not performed, and the P2 PUMP 350
P2 UNLOAD 200
P1 PRESSURE 0
P2 PRESSURE 0
6-28
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
STEP
0
P1 PUMP 350
the load on the pump. P2 PUMP 350
P2 UNLOAD 200
PRESSURE", and the current (command value) of P1 PRESSURE 0
displayed.
2. After detection of the engine rated speed, the
adjustment of pump is automatically completed. FINISH
PUMP
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the adjustment is ENGINE
STEP
0
P1 PUMP 350
is not performed, and the default value is written.) P2 PUMP 350
P1 UNLOAD 200
P2 UNLOAD 200
P1 PRESSURE 0
P2 PRESSURE 0
STEP
0
P1 PUMP 350
PRESSURE", and the current (command value) of P2 PUMP 350
P2 UNLOAD 200
valves are displayed. P1 PRESSURE 0
P2 PRESSURE 0
STEP 0
P1 PUMP 350
acceleration potentiometer. P2 PUMP 350
P2 UNLOAD 200
display of current of P1, P2 unloading proportional P1 PRESSURE 0
mA.
Stop the engine. (The adjusted data is automatically
stored.)
6-29
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
ADJUST LMN
---
---
ADJUST UNLOAD
FIN
FIN
STEP
2040
P1 PUMP 350
P2 PUMP 350
P1 UNLOAD 750
P2 UNLOAD 750
P1 PRESSURE 250
P2 PRESSURE 11
P1 PUMP 390
and "PROPO-VALVE" (acceleration command P2 PUMP 390
P2 UNLOAD 360
P1 PRESSURE 341
P2 PRESSURE 340
6-30
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
P1 UNLOAD 750
display of current of P1 and P2 unloading P2 UNLOAD 750
P2 PRESSURE 11
520 to 635 mA.
Stop the engine. (The adjusted data is automatically
stored.)
6-31
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
P1 PUMP 350
pump load during adjustment and an error of the P2 PUMP 350
P2 UNLOAD
200
200
P2 PRESSURE 0
1) Check of rotation sensor: Check for abnormal
reading of the engine speed caused by engine
vibration.
2) Check of pump load: Check for abnormal rise of the pump pressure during engine adjustment in the
adjustment screen.
3) Check of acceleration command voltage: Measure the acceleration command voltage that is output from the
mechatro controller and input to the engine controller. Measure the voltage actually or use the failure
diagnosis tool of the engine controller to check that the signal is input to the engine controller correctly.
2. When adjustment of pump is impossible
Judging condition 1: P1 and P2 average pump
pressure at the time when the adjustment is ERROR
PUMP
completed is less than 25 MPa (3625 psi).
Judging condition 2: The adjustment does not ENGINE
STEP
0
P1 PUMP 350
current reaches to the specified value. P2 PUMP 350
P2 UNLOAD 200
33 to 38 MPa (4785 to 5510 psi). P1 PRESSURE 0
STEP
0
P1 PUMP 350
gradually increase to 10 to 25 MPa (1450 to 3625 P2 PUMP 350
P2 UNLOAD 200
temperature.) P1 PRESSURE 0
6-32
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
• In the event of a failure, the adjustment may not be performed normally. First service the machine, and perform
the adjustment work.
• In the condition where a large load is constantly applied to the engine, the adjustment could not be performed
normally.
For machines equipped with the lifting magnet, turn the generator OFF.
6
The hydraulic emergency mode should be used in only case of emergency. Repair the failure part by
troubleshooting as early as possible.
6-33
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-34
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[7. MECHATRO CONTROLLER]
7. MECHATRO CONTROLLER
7.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................7-3
7.2 FOREWORD ............................................................................................................................7-4
7.3 SUMMARY OF MECHATRO CONTROL SYSTEM......................................................................7-6
7.3.1 MECHATRO CONTROL SYSTEM IN GENERAL .....................................................................7-6
7.3.2 UNLOAD VALVE CONTROL ..................................................................................................7-8
7.3.3 POSITIVE CONTROL AND P-Q CONTROL ..........................................................................7-10
7.3.4 BOOM UP CONFLUX CONTROL .........................................................................................7-12
7.3.5 CONTROL OF ARM-IN RECIRCULATION AND CONFLUX ...................................................7-14
7.3.6 ARM-IN ANTI-CAVITATION CONTROL.................................................................................7-16
7.3.7 ARM-OUT CONFLUX CONTROL .........................................................................................7-17
7.3.8 BOOM DOWN AND ARM-OUT CONTROL............................................................................7-20
7.3.9 BUCKET DIGGING AND ANTI-CAVITATION CONTROL .......................................................7-22
7.3.10 SWING PRIORITY CONTROL ............................................................................................7-24
7.3.11 TRAVEL STRAIGHT CONTROL .........................................................................................7-26
7.3.12 PRESSURE RELEASE CONTROL .....................................................................................7-28
7.3.13 WARNING OF RETURN FILTER CLOGGING ......................................................................7-30
7.4 MECHATRO CONTROLLER ...................................................................................................7-32
7.4.1 SUMMARY OF MULTI-DISPLAY...........................................................................................7-32
7.4.2 SELF DIAGNOSIS DISPLAY FUNCTION ..............................................................................7-39
7.4.3 SERVICE DIAGNOSIS DISPLAY FUNCTION ........................................................................7-43
7.4.4 TROUBLE HISTORY DISPLAY FUNCTION...........................................................................7-52
7.4.5 CHANGE PROCEDURES OF REPLACEMENT INTERVAL....................................................7-53
7.4.6 VARIOUS ADJUSTMENT FUNCTION (USER MENU)............................................................7-55
7.4.7 VARIOUS ADJUSTMENT FUNCTION (SERVICE MENU) ......................................................7-63
7.4.8 MECHATRO CONTROL DEVICES .......................................................................................7-74
7-1
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[7. MECHATRO CONTROLLER]
7-2
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[7. MECHATRO CONTROLLER]
7-3
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[7. MECHATRO CONTROLLER]
7.2 FOREWORD
This chapter explains the control related to hydraulic to electric power conversion or vice versa as mechatro control
and explains only the summary of the mechatro system and mechatro controller related devices and functions.
Regarding the conditions before and after each conversion, refer to Chapters "HYDRAULIC SYSTEM" and
"ELECTRICAL SYSTEM".
7-4
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[7. MECHATRO CONTROLLER]
7-5
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[7. MECHATRO CONTROLLER]
LH RH LH RH
SE-9 NOTE:
SE-10 FOR NOR TH AMERICA:
WITH BHL MULTI SELECT OR VALVE
NOTE FOR EUROPE:
WITHOUT MULTI SELECT OR VALVE
GAUGE CLUSTER
LOW PRESSURE SENSOR
LCD FOR SELECITION SE-4
AND DISPLAY (4)
FUEL LEVEL METER SE-3
COOLANT TEMP.
(3)
GAUGE SE-2 L2
(2) L3
LOWER SW.
SCREEN CHANGE SW. SE-1
(1)
BUZZER STOP SW.
WORK MODE SELECT SE-8
S W. (H, S, AND ECO) (8)
WASHER SW. SE-7
(7)
WIPER SW. L4
OUTPUT VOLTAGE
ENGINE
THROTTLE
SE-16
SE-23
PROP. VOLTAGE
HIGH PRESSURE
SENSOR SE-22
L5
C-1
MECHATRO CONTROLLER A1 A2 A3
ENGINE
INJECT OR SPEED SENSOR
SE-13
PSV-P1
SE-21
P1 PUMP PROPOR TIONAL VALVE
: HIGH PRESSURE SENSOR
(P1, P2, BOOM HEAD, AND BOOM ROD) PSV-P2
P2 PUMP PROPOR TIONAL VALVE
: INJECT OR
CAN COMMUNICATION
: E/G SPEED SENSOR C-8
ENGINE CONTROLLER L6
ENGINE SPEED
: LOW PRESSURE SENSOR COMMAND CURRENT
(ATT: 6 PCS., SWING: 2PCS. AND TRAVEL: 2 PCS.) VOLTAGE OF 24V
PROP . COMMAND CURRENT L7
: ENGINE THROTTLE POTENTIOMETER E-27
ENGINE THROTTLE FOR REDUNDANT MODE
7-6
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[7. MECHATRO CONTROLLER]
P1 UNLOAD
CONFLUX
BOOM 2
BOOM UP
BOOM METER IN CUT
PL1(POWER BOOST)
ARM-IN SPEED 2
ARM-IN SPEED 1
TRAVEL RIGHT
TRAVEL LEFT
BUCKET
P2 UNLOAD
STRAIGHT
BOOM 3
SWING
BOOM
TRAVEL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM-IN
L2
L3
L4
2-SPEED SELECTION OF
TRAVEL MOTOR
TRAVEL 2-SPEED SELECTION
BOOM CYLINDER
BOOM UP CONFLUX
SWING PARKING BRAKE
SE-24
BOOM METER IN CUT
L5
TRAVEL STRAIGHT
ARM-IN SPEED 2
POWER BOOST
LEVER LOCK
P2 UNLOAD
P1 UNLOAD
BOOM 2
BOOM 3
SE-25
ARM CYLINDER
ARM-OUT CONFLUX
ARM-IN CONFLUX RECIRCULATION
7
PSV PSV PSV PSV PSV S V PSV S V SV SV SV
-A -23 -24 -B -C -1 -D -4 -105 -3 -2
(7)
L6 ARM-IN BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
SE-60
CLOGGING SENSOR
SOLENOID OPERA TED DIRECTIONAL
CONTROL VALVE AND PROP. SOLENOID VALVE ) BLOCK
7-7
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 2 SPEED
ARM 1 SPEED
BUCKET
SWING
BOOM
STRAIGHT
TRAVEL
P2 P1
BOOM CYLINDER
PILOT PILOT
(LEFT) (RIGHT) OPTIONAL VALVE VALVE
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1 | 4 SE-40,41,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
MECHATRO pi :
PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
OF PROPORTIONAL VALVE
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in each low
pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to each unload proportional valve according to the
input voltage.
3. Each unload proportional valve outputs the pilot secondary pressure according to the command output by the
mechatro controller and switches each unload spool.
4. With this operation, the bleed opening is obtained according to the lever displacement, and the pump pressure
which actuates each actuator is delivered, so that each actuator starts working.
7-8
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[7. MECHATRO CONTROLLER]
7-9
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
STRAIGHT
TRAVEL
BOOM 3
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
BOOM CYLINDER
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1 | 4 SE-40,41,7,8
pi
PILOT SIGNAL
PROCESS COMMAND TO P2 PUMP
P2 PUMP PROP. PROP. VALVE
VALVE PSV-P2
pi
pi
COMMAND TO P1 PUMP
P1 PUMP PROP. PROP. VALVE
PILOT SIGNAL VALVE PSV-P1
PROCESS pi :
MECHATRO SECONDARY PRESSURE
PILOT SECONDARY PRESSURE
CONTROLLER OF PROPORTIONAL VALVE
Positive control
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in each low
pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs command values to each pump proportional valve according to the input
voltage.
3. Each pump proportional valve outputs the pilot secondary pressure according to the command value output by
the mechatro controller and changes the swash plate angle of each pump to control the delivery rate.
7-10
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[7. MECHATRO CONTROLLER]
4. With this operation, the delivery rate is supplied to the actuator according to the lever displacement, and the
working speed changes according to the lever displacement.
P−Q control
1. The output voltage of the high pressure sensor at each pump line is input to the mechatro controller and the
mechatro controller processes pilot signals and calculates the command value according to the input voltage
(load pressure).
2. A lower value between the command value calculated by positive control and command value (1) calculated by
P-Q control (calculated value in 1.) is selected and is output to each pump proportional valve as the command
value.
3. Each pump proportional valve outputs the pilot secondary pressure according to the command value output by
the mechatro controller and changes the swash plate angle of each pump to control the delivery rate of
pressure oil.
4. With this operation, the actuator load becomes high and even when the pump load becomes high, the machine
can keep working without engine stall.
POSITIVE CONTROL P-Q CONTROL
7-11
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
SWING
BOOM
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
BOOM CYLINDER
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
1. On starting boom up operation, the pilot pressure or boom up operation switches the boom spool and the boom
up conflux spool and is input to the low pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves and the
P1 and P2 unload proportional valves according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure of the proportional valve according to the
command value output by the mechatro controller and changes the P1 and P2 pump delivery rates and
switches the P1 and P2 unload valves.
7-12
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[7. MECHATRO CONTROLLER]
4. The boom main spool and the boom up conflux spool are switched by the original hydraulic pressure
command, and also the P1 and P2 pumps and the P1 and P2 unload valves are switched by the command of
the mechatro controller, and the delivery oil of the P1 pump joins the delivery oil of the P2 pump during boom
up operation.
7-13
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
STRAIGHT
BOOM 3
TRAVEL
PILOT
VALVE
P2 P1
BOOM CYLINDER
LOW
PRESSURE LOW PRESSURE
SENSOR SENSOR
SE-1 | 4,40,41 SE-7
CONTROL PROCESS
OF 2-SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
P1 PUMP
PROP. VALVE
PSV-P1
P1 UNLOAD
PROP. VALVE
pi PSV-D
pi
CONTROL PROCESS ARM-IN SPEED 2
OF ARM-IN SPEED 2 INVERSE PROP.
INVERSE PROP. VALVE PSV-A
VALVE
PILOT SECONDARY
PRESSURE OF ARM
7-14
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[7. MECHATRO CONTROLLER]
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, and the arm-in speed 2 inverse proportional valve according to the input
voltage.
In case of combined operation, the pilot pressure of other than arm-in operation is input to the low pressure
sensor and the output voltage is input to the mechatro controller. And the mechatro controller processes the
pilot signals according to the combined operation and outputs the command values to the P1 pump
proportional valve, the P1 unload proportional valve, and the arm-in speed 2 inverse proportional valve,
differently from arm-in independent operation.
3. The primary pressure of the arm-in speed 2 inverse proportional valve is the pilot secondary pressure of arm-in
operation and the arm 2 spool is switched by the secondary pressure of the proportional valve according to the
command value. (The arm 2 spool controls recirculation rate and conflux rate.)
The other proportional valves output the secondary pressure of the proportional valve according to the
command value of the mechatro controller, change the delivery rate of the P1 and P2 pumps, and switch the
P1 and P2 unload spools.
4. The arm speed 1 spool is switched by the original hydraulic pressure command, and the P1 and P2 pumps, the
P1 and P2 unload spools, and the arm speed 2 spool are switched by the command of the mechatro controller
to recirculate the return oil from the arm cylinder rod side and mix it with the delivery oil from the P1 and P2
pumps during arm operation.
Recirculation cut
The voltage output value from the high pressure sensor at the P2 side is input to the mechatro controller, and when
load becomes high during arm-in operation, the mechatro controller processes the pilot signals according to the
pressure detected by the high pressure sensor and outputs the command value to the arm-in speed 2 inverse
proportional valve to command recirculation cut on the arm-in speed 2 function.
The arm-in speed 2 inverse proportional valve outputs the pilot secondary pressure according to the command
value of the mechatro controller and switches the arm 2 spool to the recirculation cut position to block the
recirculation passage.
7-15
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
TRAVEL
PILOT
VALVE
P2 P1
BOOM CYLINDER
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
pi :
ENGINE SPEED (COMMAND VALUE) MECHATRO
SECONDARY PRESSURE
CONTROLLER
OF PROPORTIONAL VALVE
1. On starting arm-in operation, the pilot secondary pressure of arm-in operation switches the arm speed 1 spool
and is input to the low pressure sensor.
2. The engine speed command output by the engine throttle potentiometer is input to the mechatro controller.
3. The output voltage of the low pressure sensor is input to the mechatro controller, and the mechatro controller
processes the pilot signals and outputs the command value to the P2 pump proportional valve and the P2
unload proportional valve according to the input voltage.
4. And also the mechatro controller outputs the command value to the arm-in speed 2 inverse proportional valve
according to the input voltage from the engine throttle potentiometer.
5. Each proportional valve outputs the pilot secondary pressure according to the command value of the mechatro
controller, and spool stroke of the arm-in speed 2 inverse proportional valve is controlled according to the
engine speed. By changing the recirculation rate, cavitation can be prevented even when a pump delivery rate
is low due to a low engine speed.
7-16
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 2 SPEED
ARM 1 SPEED
BUCKET
BOOM
SWING
STRAIGHT
BOOM 3
TRAVEL
PILOT
P2 P1
VALVE
BOOM CYLINDER
LOW PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
7-17
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[7. MECHATRO CONTROLLER]
4. The arm speed 1 and 2 spools are switched by the original hydraulic pressure command, and also the P1 and
P2 pumps and the P1 and P2 unload valves are switched by the command of the mechatro controller, and the
delivery oil of the P1 pump joins the delivery oil of the P2 pump during arm-out operation.
7-18
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[7. MECHATRO CONTROLLER]
7-19
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
TRAVEL LEFT
ARM 1 SPEED
BUCKET
BOOM
SWING
TRAVEL
P2 P1
BOOM CYLINDER
LOW
PRESSURE
SENSOR LOW PRESSURE
SE-4
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1
pi
BOOM 2 PSV-23
BOOM DOWN AND
ARM-OUT PROCESS
BOOM 3 PSV-24
7-20
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[7. MECHATRO CONTROLLER]
1. When arm-out operation is performed during boom down operation (or boom down operation is performed
during arm-out operation), the pilot secondary pressure of the boom down operation switches the boom spool
and is input to the low pressure sensor and also that of arm-out operation switches the arm spool and is input
to the low pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, the boom 2 and 3 proportional valves, and the boom meter in cut solenoid
valve according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure according to the command value output by the
mechatro controller and changes the P1 and P2 pump flow rates and switches the P1 and P2 unload spools,
the boom 2 and 3 spools, and the meter in cut valve.
4. The boom spool, and the arm speed 1 and 2 spools are switched by the original hydraulic pressure command,
and also the P1 and P2 unload spools, the boom 2 and 3 spools, and the boom meter in cut valve are switched
by the command of the mechatro controller. With this operation, the return oil from the boom head can be
supplied to the arm-out side.
7-21
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
PILOT
VALVE P2 P1
BOOM CYLINDER
LOW
PRESSURE
SENSOR
SE-1(2) pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
pi :
MECHATRO SECONDARY PRESSURE
P1 PUMP PRESSURE CONTROLLER OF PROPORTIONAL VALVE
1. On starting bucket digging operation, the pilot pressure of bucket digging operation switches the bucket spool
and is input to the low pressure sensor.
7-22
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[7. MECHATRO CONTROLLER]
2. The engine speed command output by the engine throttle potentiometer is input to the mechatro controller.
3. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, and the travel straight proportional valve according to the input voltage.
4. Each proportional valve outputs the pilot secondary pressure of the proportional valve according to the
command value output by the mechatro controller and changes the P1 and P2 pump delivery rates and
switches the P1 and P2 unload valves and the travel straight valve in the control valve.
5. The tandem passage at the P1 side communicates with the P2 port due to the switched travel straight valve
and the P1 pump delivery oil and P2 pump delivery oil join together because of the switched P2 unload valve.
6. The power boost solenoid valve turns the solenoid valve on according to the engine speed, outputs the
secondary pressure, actuates the stroke limiter, and limits stroke of the bucket spool.
By limiting the spool stroke, cavitation can be prevented even when a pump delivery rate is low due to a low
engine speed.
7. When the P1 pump pressure is increased due to cylinder stroke end, etc., the solenoid valve turns OFF
according to the pump pressure, and when the pump pressure is high, the power boost solenoid valve does not
limit stroke of the bucket spool.
7-23
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
PILOT
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
VALVE
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
P2 P1
LOW
PRESSURE BOOM CYLINDER
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
P1 PUMP
PILOT SECONDARY PRESSURE OF ARM-IN PROP. VALVE
pi PSV-P1
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
P1 UNLOAD
PROP. VALVE
PILOT SECONDARY PRESSURE OF ARM-IN PSV-D
pi
COMMAND TO TRAVEL TRAVEL STRAIGHT
STRAIGHT PROP. PROP. VALVE
VALVE PSV-C
pi :
PILOT SECONDARY PRESSURE OF SWING MECHATRO SECONDARY PRESSURE
CONTROLLER OF PROPORTIONAL VALVE
1. When swing operation is performed during arm-in operation (or arm-in operation is performed during swing
operation), the pilot secondary pressure of arm operation switches the arm spool and is input to the low
pressure sensor and also the pilot secondary pressure of swing operation switches the swing spool and is
input to the low pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, the travel straight proportional valve, and the arm-in speed 2 inverse
proportional valve according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure according to the command value output by the
mechatro controller and changes the P1 and P2 pump delivery rates and switches the P1 and P2 unload
spools, the travel straight spool, and the arm speed 2 spool.
4. The arm speed 1 spool and the swing spool are switched by the original hydraulic pressure command, and the
P1 and P2 unload spools, the travel straight spool, and the arm speed 2 spool are switched by the command of
the mechatro controller to supply the flow rates of two pumps to the arm cylinder head side and recirculate the
return oil from the arm cylinder rod side to the arm cylinder head side.
7-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[7. MECHATRO CONTROLLER]
5. The return oil from the arm rod side is recirculated and it makes the working pressure increase and the pump
delivery rate be used for swing operation preferentially. The arm is operated by the recirculated oil and
because of this, the operation at a speed decreased by a minimum range becomes possible.
7-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
OPTIONAL
PILOT VALVE
TRAVEL
(LEFT) (RIGHT)
BOOM
CYLINDER P2 P1
PILOT VALVE
FOR TRAVEL
PILOT PILOT
VALVE VALVE
SE-11 LOW
SE-10 SE-9 PRESSURE
SENSOR
S E-1~4,
7,8,40,41
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROP. VALVE
PSV-C
7-26
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[7. MECHATRO CONTROLLER]
7-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
PILOT
BOOM 3
TRAVEL
VALVE
GAUGE CLUSTER
P2 P1
SE-23 SE-22
BOOM
CYLINDER ENGINE
PRESSURE
RELEASE ENGINE SPEED
CONTROL CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROP. VALVE
PSV-D
MECHATRO pi : SECONDARY PRESSURE
CONTROLLER OF PROPORTIONAL VALVE
1. Change the mechatro controller to the pressure release mode by operating switches on the gauge cluster.
For details of mode switching method, refer to "How to switch to 'Pressure release mode'" in Chapter
"HYDRAULIC SYSTEM".
2. Once the mechatro controller judges the operation as pressure release control, regardless of each input signal
(operation pilot and engine throttle potentiometer, etc.), the mechatro controller;
1) Outputs the command value of the minimum swash plate angle to the P1 and P2 pump proportional valves
and fixes the swash plate angle of the P1 and P2 pumps at the minimum.
2) Outputs the command value of pressure release to the ECU and fixes the engine speed to a pressure
release control speed.
3) Outputs the maximum command value to the P1 and P2 unload proportional valves and each pilot
secondary pressure fixes the P1 and P2 unload valves at the maximum opening.
7-28
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[7. MECHATRO CONTROLLER]
3. The mechatro controller senses the output voltage from the high pressure sensor of the main pump, judges the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on the gauge cluster.
4. By operating each control lever and switching spools with the unload valve opened, each pump delivery oil is
unloaded to the tank passage enabling the remained pressure (trapped pressure) of each actuator to be
released.
7-29
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[7. MECHATRO CONTROLLER]
SUCTION
CHAMBER SIDE
M4 NUT
TIGHTENING TORQUE:
0.49 N .m (0.36 lbf .ft) OR LESS
HYD. OIL TEMP.SENSOR(SE-21)
WARNING DISPLAY
(0.64 inch)
16.2
COM NC
7-30
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[7. MECHATRO CONTROLLER]
Pressure sensor
• This is a normal close, voltage detection type sensor.
• At 0 MPa (0 psi), it turns OFF (close), and at 0.1 MPa (14.5 psi) or more, it turns ON (open).
Detection mode
During normal operation, even when the pressure sensor turns ON, it does not affect detection.
When the operation under the condition that the oil temperature is 30 degrees C (86 degrees F) or more and the
engine speed is 1600 min–1 or more is performed for total 60 seconds or more, the pump flow rate increases to the
maximum automatically for approximately 3 seconds while each control lever, pedal, and switch are at the neutral
position to detect ON/OFF of the pressure sensor.
Count
When the pressure switch turns ON during the detection mode, if the starter switch is turned off with that condition,
ON is counted as 1 time. If ON is counted for three times continuously, the return filter is judged as being clogged.
But, even if ON of the pressure sensor is detected during the detection mode, if OFF is detected at the next
detection mode during a continuous operation, ON of the previous time can be cancelled. In other words, ON just
before turning off the starter switch is only applied for count.
Warning display
When the return filter is judged as being clogged due to the third count at the time of starter switch OFF, "CHANGE
HYD. OIL FLTR" appears on the gauge cluster at the time of the next starter switch ON.
Furthermore, the warning display for filter replacement appears not only when clogging occurs but also when the
remaining time for maintenance set from the gauge cluster becomes zero.
Canceling warning
When the return filter is clogged or the replacement interval of the return filter has been reached, replace the filter.
At that time, the warning can be cancelled by either of the following method.
1. Reset the maintenance interval of the return filter from the gauge cluster. (Default value: 1,000 hours)
2. Set the machine in the detection mode to make the pressure sensor OFF, and then turn the starter switch off.
7-31
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[7. MECHATRO CONTROLLER]
7.4.1.1 CONTROLS
5 12
11
3 2
1
6
8
10
4
9
DETAILA
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[7. MECHATRO CONTROLLER]
(10)Menu switch 10
6
11 30
9
MIN
25 20 15 10 5
11
0
0
(12)Nibbler switch
(13)Breaker switch 8 7
5 13
(14)Up arrow switch 4 16
(15)Down arrow switch 10
(16)Right arrow switch
(17)Left arrow switch
17 3 14 15 12
(18)Multi-display (LCD)
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[7. MECHATRO CONTROLLER]
The work mode after engine start always starts from the "S" mode.
S
K
S: S mode The "S mode" is suitable for a standard digging work and loading
(for standard digging operations. It provides good fuel consumption and is well-balanced
work) with a workload.
E
K
E: ECO mode
(for digging work with The "ECO mode" focuses on a low fuel consumption operation.
low fuel consumption)
H
K
H: H mode
The "H mode" is suitable for a heavy duty digging work with high
(for heavy duty digging
speed, which gives priority to a workload.
work)
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[7. MECHATRO CONTROLLER]
S
K
S
K
S
K
If you perform work with "nibbler mode" selected, it may lead to damage of the components.
Do not use "nibbler mode".
7
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[7. MECHATRO CONTROLLER]
After turning the starter switch "ON" or starting the S INTERVAL REMAINDER
EXCHANGE
DAY
engine, press "menu switch" (8) to enter user menu K
USER MENU ENGINE OIL 500Hr 500Hr 14/12/12
K
screen (b). Move the cursor to "MAINTENANCE" and MAINTENANCE FUEL FILTER 500Hr -100Hr 14/12/12
interval of the engine oil, fuel filter, hydraulic oil filter, and
EXCHANGE
hydraulic oil, the remaining time until the next ENGINE OIL
INTERVAL REMAINDER
500Hr 500Hr
DAY
14/12/12
replacement interval, and the date of the previous BACK
HOME
UP
DOWN
NEXT
FUEL FILTER 500Hr -100Hr 14/12/12
EXCHANGE EXCHANGE
INTERVAL REMAINDER INTERVAL REMAINDER
DAY DAY
ENGINE OIL 500Hr 500Hr 14/12/12 ENGINE OIL 500Hr 500Hr 14/12/12
FUEL FILTER 500Hr -100Hr 14/12/12 FUEL FILTER 500Hr -100Hr 14/12/12
HYD. FILTER 1000Hr 500Hr 14/12/12 HYD. FILTER 1000Hr 500Hr 14/12/12
HYD. OIL 3000Hr 3000Hr 14/12/12 HYD. OIL 3000Hr 3000Hr 14/12/12
Item Default
Engine oil 250 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
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[7. MECHATRO CONTROLLER]
(1)Clock display
(2)Self diagnosis display 1
4
(3)Warning display S
K
(4)Machine condition display
2,3
• W001, W004, W005, W006, W008, W009, and W011 are error codes.
• Error codes are stored as trouble history, and displayed on the multi-display by the trouble history display
function.
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
CONTROL
Pressure sensor, Engine controller CAN COMMUNICATION
INPUT Proportional valve, Battery relay Gauge cluster
Selector valve (SOL) (Buzzer sound)
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[7. MECHATRO CONTROLLER]
Dozer down
Travel rear
left
Adjustment CAN
data sector 1 communication Safety relay
Adjustment CAN
data sector 2 communication
Hour meter
sector 1
Hour meter
sector 2
Proportional valve
adjustment data
Cluster
communication
Expansion
controller
communication
Last 1
digit
Larger than Larger than
normal range normal range Abnormal
S e e Cha pte r "ENGINE".
Transistor
OFF failure
/GND short GND short CAN error
Abnormal Abnormal Transistor Transistor
output output ON failure ON failure Overrun
Transistor
ON failure
Disconnection Disconnection Disconnection Disconnection /disconnection Disconnection Disconnection Time out
Contact point
Power short Power short Power short adhesion due Power short
circuit circuit circuit to melting circuit
Failure value
*H11 Temperature sensor for clogging of hydraulic oil
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[7. MECHATRO CONTROLLER]
Error Code Possible cause of failure Error Code Possible cause of failure
Injector common 1 ground
P0217 Engine overheat P1211
short
Atmospheric pressure sensor Injector related Injector common 2 ground
P2228 P1214
circuit low input errors short
Atmospheric pressure sensor Injector common 1 power
P2229 P1212
circuit high input source line short
Common rail pressure sensor Injector common 2 power
P0192 P1215
circuit low input source line short
Common rail pressure sensor Injector common 1 open
P0193 P1212
circuit high input circuit
Common rail pressure sensor Injector common 2 open
Sensor related P0191 P1215
malfunction circuit
errors &
related dialogs Boost pressure sensor circuit Injector circuit malfunction
P0237 P0201
low input -cylinder 1
Emergency accelerator
P1133 P0605 Flash ROM error
sensor malfunction high input ECU body
Engine speed main and sub related errors CPU malfunction (Hard
P0335 P0606
sensor circuit malfunction detection) 7
Abnormal engine main Monitoring IC malfunction
Rotation P0336 P0607
rotation sensor pulse count in CPU
sensor related
errors Engine speed sub sensor
P0340 P1601 QR code failure
circuit malfunction
Abnormal engine auxiliary
P0341 P0540 Preheat circuit malfunction
rotation sensor pulse count
Machine
Supply pump SCV related errors
Supply pump
P0629 malfunction (Power source P0686 Main relay malfunction
related errors
line short)
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[7. MECHATRO CONTROLLER]
Error Code Possible cause of failure Error Code Possible cause of failure
Supply pump SCV
P0628 malfunction (Full discharge P0219 Engine overrun
mode)
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[7. MECHATRO CONTROLLER]
2. After the logo mark appears, the screen enters service diagnosis mode. The service diagnosis screen "Mode
No.1", and "Screen No.1" are displayed first. The service diagnosis is classified into two modes, 1, and 2, and
the present mode is displayed on "Screen No.1".
The screen numbers on the screen differ according to each mode. The screen numbers displayed at each
mode are as follows.
• Mode No.1: Screen No.1 to 22
• Mode No.2: Screen No.1, Screen No.23 to 30
3. After that, the screen is switched every time you press each switch.
Up arrow switch
The screen changes to the next number.
(No.2→No.3→No.4→...)
4. Turn the key switch "OFF" and the display of service diagnosis mode is closed.
To switch the service diagnosis mode to No. 3, turn the swing parking brake release switch ON for 1 second or
more with the service diagnosis screen No.1 displayed and then turn OFF that switch.
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[7. MECHATRO CONTROLLER]
2 NO.2 ENG
7 NO.6 SENSOR PROPO-V
HOUR METER 35.3h HOUR METER 35.3h
G-3 SPEED SET 2205 No load set speed C-1 P1 PUMP
MEAS.1 2201 Actual speed 1 3.5V 2.6M Sensor voltage/pressure converted value
MEAS.2 2201 Actual speed 2 (engine controller) C-2 P2 PUMP
G-5 ENG PRS LIVE Engine oil pressure 3.5V 2.6M Sensor voltage/pressure converted value
W ATER TEMP 100¥¥ OFF Coolant temperature sensor E-1 P1 PUMP
MODE H Work mode COMP . 600mA 4.5M Command value/pressure converted value
ATT MODE BRK Attachment mode MEAS. 600mA 4.5M Measured value/pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage POWER SHIFT 100mA Amount of horse power reduction
POS. 100% Volta ge % dis pla y FLOW RA TE 100L P1 pump flow rate
ECU OUTPUT 0.5V Acceleration output voltage to engine controller E-2 P2 PUMP
FIN. ACCEL POS. 100% Final acceleration openin COMP . 600mA 4.5M Command value/pressure converted valu e
CAN COMMAND ENG SPEED Final target speed MEAS. 600mA 4.5M Measured value/pressure converted value
2500 POWER SHIFT 100mA Amount of horse power reduction
ACCEL SENSOR 1 VOL. 5.0V Acceleration voltage FLOW RA TE 100L P2 pump flow rate
COMP . FUEL CONS. Final injection quantity
500mm /VV W .cyl.
3
COMP . FUEL CONS. Final injection quantity
H-10 HYD. OIL TEMP 100 ¥ Hydraulic oil temperature 500mm 3 /VV W .cyl.
PERCENT TORQUE 100% Percent torque
ENG SPEED 2350 Input speed from ECU
BOOST PRESS. 400 Intake air pressure
ENG RAIL PRESS. 200.0M Common rail pressure
EGR V ALVE P OS . 100.0% EGR valve actual opening
SCV CURRENT 900mA SCV drive current
VNT POS. 100.0% VNT opening
EXHAUST TEMP 100 ¥ Exhaust gas temperature
TURB SPEED 50000 Turbo s pe e d
INTAKE AIR 500k J /h Intake air amount
100 ¥ Intake air temperature
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
29
NO.28 ENG S TART CHECK
HOUR METER 35.3h
WATER TEMP 100 ¥ Coolant temperature
OIL TEMP 100 ¥ Hydraulic oil temperature
E-1 P1 PUMP P1 pump proportional valve
COMP . 700mA 25.0M Command value/pressure converted value
MEAS. 700mA 25.0M Measured value/pressure converted value
E-2 P2 PUMP P2 pump proportional valve
COMP . 700mA 25.0M Command value/pressure converted value
MEAS. 700mA 25.0M Measured value/pressure converted value
ECU OUTPUT 4.8V Acceleration voltage to ECU
ENG SPEED 2350 Input speed from ECU
COMP. FUEL CONS. Final injection quantity
500mm 3 /st .cyl.
ENG RAIL PRESS 200.0M Actual common rail pressure
FIN. ACCEL POS. 100% Final acceleration opening
BAROMETRIC P . --- Atmospheric pressure
S TARTER S W --- Starter switch of ECU side
KEY SWITCH ECU --- Key switch of ECU side
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
Operation No.5 :
Boom down in full lever operation & in operation
H mode Hi idle
No.23 BOOM
C-1 P1-PRES 12.5 to 16.0 M
C-2 P2-PRES 0.2 to 1.5 M
E-1 P1-PSV 600 to 617 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427 to 477 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 1770 to 1860
POWER SHIFT
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
4. The trouble history data (one or many) and the hour DOWN
All the stored trouble history items are deleted and cannot be deleted partially.
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[7. MECHATRO CONTROLLER]
• When the remaining time to engine oil replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 250 hrs. has been reached, the warning appears
but the buzzer does not sound.
• When the remaining time to fuel filter replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 500 hrs. has been reached, the warning appears
but the buzzer does not sound.
• When the remaining time to hydraulic oil filter replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 1000 hrs. has been reached, the warning appears
but the buzzer does not sound.
• When the remaining time to hydraulic oil replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 2000 hrs. has been reached, the warning appears
but the buzzer does not sound.
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[7. MECHATRO CONTROLLER]
EXCHANGE EXCHANGE
S INTERVAL REMAINDER DAY INTERVAL REMAINDER DAY
12h
USER MENU ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12
MAINTENANCE
FUEL FILTER 500Hr -100Hr 08/12/12 FUEL FILTER 500Hr -100Hr 08/12/12
SWITCH ST ATUS HYD. FILTER 1000Hr 1000Hr 08/12/12 HYD. FILTER 1000Hr 1000Hr 08/12/12
OPTION SETTING HYD. OIL 5000Hr 5000Hr 08/12/12 HYD. OIL 5000Hr 5000Hr 08/12/12
CONSUMPTION
SCREEN SETTING
CLOCK SETTING
EXCHANGE
INTERVAL REMAINDER DAY
EXCHANGE EXCHANGE
INTERVAL REMAINDER DAY INTERVAL REMAINDER DAY
ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12
FUEL FILTER 500Hr -100Hr 09/01/12 FUEL FILTER 500Hr 500Hr 09/01/12
HYD. FILTER 1000Hr 500Hr 08/12/12 HYD. FILTER 1000Hr 1000Hr 08/12/12
HYD. OIL 5000Hr 3000Hr 08/12/12 HYD. OIL 5000Hr 5000Hr 08/12/12
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "MAINTENANCE". Press the right arrow switch to enter
the maintenance information setting.
3. Using the up or down arrow switch, move the cursor to one of the items from "ENGINE OIL", "FUEL FILTER",
"HYD.FILTER" or "HYD.OIL".
4. Press the right arrow switch. The background color of "REMAINDER" turns blue.
5. Press "menu switch" (8) to reset the remaining time.
To set "REMAINDER" to a desired value, press the up or down arrow switch to set the desired value between
the recommended replacement time and zero.
At this time, "EXCHANGE DAY" is updated.
6. Press the right arrow switch to store the value.
At this time, "REMAINDER" turns black.
7. Press "screen change switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU SWITCH ST ATUS SWITCH ST ATUS
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the Up or Down arrow switch, move the cursor to "SWITCH STATUS". Press the Right arrow switch to
enter the switch setting.
3. Using the Up or Down arrow switch, move the cursor to "AUTO IDLING STOP".
4. Press the Right arrow switch to enter display (f). The background color of "OFF" turns blue.
7
5. Using the Up or Down arrow switch, select "ON".
6. Press "Menu Switch" (8) to set the status.
At this time, the background color of "ON" turns black.
7. Turn "OFF" the starter key switch once to store the status.
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU CLOCK CLOCK
SETTING SETTING
MAINTENANCE MAINTENANCE YEAR 10 YEAR 10
SWITCH ST ATUS SWITCH ST ATUS MONTH 01 MONTH 01
OPTION SETTING OPTION SETTING DATE 01 DATE 01
CONSUMPTION CONSUMPTION HOUR 13 HOUR 13
SCREEN SETTING SCREEN SETTING MINUTE 25 MINUTE 25
CLOCK SETTING CLOCK SETTING
CLOCK CLOCK
SETTING SETTING
YEAR 11 YEAR 11
MONTH 01 MONTH 01
DATE 01 DATE 01
HOUR 13 HOUR 13
MINUTE 25 MINUTE 25
(g) (f)
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the Up or Down arrow switch, move the cursor to "CLOCK SETTING". Press the Right arrow switch to
enter the clock setting.
3. Using the Up and Down arrow switches, select any of "YEAR/MONTH/DAY/HOUR/MINUTE" as display (d).
4. Press the Right arrow switch to enter display (e). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired value.
6. Press menu switch (8) to set the desired value.
At this time, the background color of the value turns black.
7. Press "Screen Change Switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH ST ATUS SWITCH ST ATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 50 Brightness(night) 50
CONSUMPTION CONSUMPTION
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
SCREEN SCREEN
SETTING SETTING
CONTRAST 6 CONTRAST 6
Brightness(day) 100 Brightness(day) 100
Brightness(night) 50 Brightness(night) 50
(g) (f)
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the Up or Down arrow switch, move the cursor to "SCREEN SETTING". Press the Right arrow switch to
enter the screen setting.
3. Using the Up or Down arrow switch, move the cursor to "CONTRAST".
4. Press the Right arrow switch to enter display (e). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired values. 7
The adjustable range is from 1 (Faint) to 10 (Clear).
* The default value is 5.
6. Press menu switch (8) to set the desired value.
At this time, the background color of the value turns black.
7. Press "Screen Change Switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH ST ATUS SWITCH ST ATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 50 Brightness(night) 50
CONSUMPTION CONSUMPTION
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the Up or Down arrow switch, move the cursor to "SCREEN SETTING". Press the Right arrow switch to
enter the screen setting.
3. Using the up and down arrow switches, move the cursor to "Brightness (day)" as display (e).
4. Press the Right arrow switch to enter display (f). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired values.
Adjustable Range: 1 (Dark) to 100 (Bright)
* The default value is 100.
6. Press menu switch (8) to set the desired value.
At this time, the background color of the value turns black.
7. Press "Screen Change Switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH ST ATUS SWITCH ST ATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 50 Brightness(night) 50
CONSUMPTION CONSUMPTION
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the Up or Down arrow switch, move the cursor to "SCREEN SETTING". Press the Right arrow switch to
enter the screen setting.
3. Using the up and down arrow switches, move the cursor to "Brightness (night)" as display (e).
4. Press the Right arrow switch to enter display (f). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired values. 7
Adjustable Range: 1 (Dark) to 100 (Bright)
* The default value is 5.
6. Press menu switch (8) to set the desired value.
At this time, the background color of the value turns black.
7. Press "Screen Change Switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
7.4.6.6 CONSUMPTION
S
12h
USER MENU USER MENU CONSUMPTION CONSUMPTION
L/h L/h
MAINTENANCE MAINTENANCE 50 50
40 40
SWITCH ST ATUS SWITCH ST ATUS 30 30
20 20
OPTION SETTING OPTION SETTING
10 10
CONSUMPTION CONSUMPTION 0 0
30 25 20 15 10 5 0 30 25 20 15 10 5 0
MIN MIN
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
WORKTIME 100 HOURS WORKTIME 0 HOURS
CONSUMPTION 100 L CONSUMPTION 0L
AVERAGE 24.4 L/h AVERAGE 0 L/h
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up and down arrow switches, move the cursor to "CONSUMPTION" as display (c). Press the Right
arrow switch to enter the fuel efficiency setting.
3. The graph indicates the average fuel consumption by 2 hours for this 12 hours. The values of the operating
time, fuel consumption and average fuel consumption are also displayed.
4. To reset these values, press the down arrow switch.
5. Press "Screen Change Switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
7.4.6.7 PUMP FLOW RATE SETTING (NIBBLER MODE/BREAKER MODE) AND SELECTION OF
OPTION RELIEF PRESSURE
If there is no switch operation for 20 seconds, the display returns to the main screen.
In nibbler mode
S S
12h 12h
USER MENU USER MENU NIBBLER
SETTING
FLOW RATE 780 L/min MAINTENANCE MAINTENANCE SET1 440
MPa
30
SET8 176
MPa
15 SET9 154
MPa
SET10 132
0 MPa
30 25 20 15 10 5 0
MIN BACK UP NEXT BACK UP NEXT BACK UP
AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME DOWN OK
In breaker mode
S
12h
USER MENU USER MENU BREAKER
SETTING
FLOW RATE 480 L/min MAINTENANCE MAINTENANCE SET1 220
MPa
30
SET8 66
MPa
15 SET9 44
MPa
SET10 30
0 MPa
30 25 20 15 10 5 0
MIN BACK UP NEXT BACK UP NEXT BACK
AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME OK
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[7. MECHATRO CONTROLLER]
5. When the display is option setting screen (e), move the cursor to a desired flow rate. Press menu switch (8) to
set the desired flow rate value.
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[7. MECHATRO CONTROLLER]
Item Contents
Language Language selection
Idle stop Adjustment of time (sec) until auto idle stop function starts.
P1 side option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 side option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Selection of using left pedal for rotation or not. (Unload valve does not actuate because
Left pedal for rotation
P4 pump is equipped. Europe specification.)
Optional flow rate limitation, relief pressure limitation, adjustment for combination of
Option adjustment setting
return selector.
Engine speed display ON/OFF of engine speed display
Rise-up wiper Switching wiper control(Changed when cab is changed to new demolition cab )
Flow rate setting of breaker Pump flow rate setting for using breaker
Fuel consumption gauge display ON/OFF of fuel consumption gauge (eco mark) display
Pump difference study Clearance and restudy of ECU difference study contents
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[7. MECHATRO CONTROLLER]
1 7
2
8 5 6
According to the attachment to be installed, the flow rate of the service circuit needs to be reduced.
Regarding the flow rate of the nibbler service circuit, there are 10 patterns of setting.
SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10
Nibbler Flow
L/min 440 396 352 308 264 220 176 132 98 30
(crusher) rate
Flow
Breaker L/min 220 198 176 154 132 110 88 66 49 15
rate
The flow rate of the nibbler service circuit is set at "SET6" of the above table as a factory-set value when the
machine is shipped from a factory.
The flow rate of the breaker service circuit is set at "SET1" of the above table as a factory-set value when the
machine is shipped from a factory.
Refer to the following procedure when setting the flow rate. Set values of above-mentioned adjustment can be
selected from the user menu of "the pump flow rate at the nibbler or breaker mode".
2-VRE 00.00 TROUBLE HIST ORY START MODE X SET2 443 SET2 443
L/min L/min
SER VICE DIAG 1 LANGUAGE & LOGO SETTING CANCEL LOW TEMP ON SET3 394L/min
SET3 394
L/min
CLUSTER GAUGE P/N SER VICE ADJUST 1 CANCEL MODE SET4 344L/min
SET4 344
L/min
YN59S00033F1 SER VICE ADJUST 2 CHECK INJECT OR SET5 295 SET5 295
PROGRAM VERSION L/min L/min
1. Turn the starter switch "ON". Press nibbler switch (3) to select the nibbler mode, then turn the starter switch
"OFF".
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[7. MECHATRO CONTROLLER]
2. With holding down buzzer stop switch (1), turn the starter switch "ON". Service diagnosis screen (a) is
displayed.
3. Start the engine.
4. With holding down buzzer stop switch (1), press menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using up arrow switch (5) or down arrow switch (6), point the cursor to "SERVICE ADJUST 1" of screen (b).
Press right arrow switch (7), and the "SERVICE ADJUST 1-1" screen is displayed. Then press down arrow
switch (6) several times and "SERVICE ADJUST 1-2" screen (c) is displayed.
6. Using up arrow switch (5) or down arrow switch (6), point the cursor to "NIBBLER SETTING" of screen (d).
Press right arrow switch (7), and "NIBBLER SETTING" screen (e) is displayed.
7. There are 10 step settings from "SET 1" to "SET 10". Using up arrow switch (5) or down arrow switch (6),
select a desired set number. To set the desired set number, press right arrow switch (7).
8. Using up arrow switch (5) or down arrow switch (6), select a desired flow rate and press menu switch (2) and
confirm it.
9. After that, press left arrow switch (8) to return to "SERVICE ADJUST 1-2" screen (c).
2-VRE 00.00 TROUBLE HIST ORY START MODE X SET2 221 SET2 221
L/min L/min
SER VICE DIAG 1 LANGUAGE & LOGO SETTING CANCEL LOW TEMP ON SET3 197
L/min
SET3 197
L/min
CLUSTER GAUGE P/N SER VICE ADJUST 1 CANCEL MODE SET4 172
L/min
SET4 172
L/min
YN59S00033F1 SER VICE ADJUST 2 CHECK INJECT OR SET5 148 SET5 148
PROGRAM VERSION L/min L/min
1. Turn the starter switch "ON". After pressing breaker switch (4) to select the breaker mode, turn the starter
switch "OFF".
2. With holding down buzzer stop switch (1), turn the starter switch "ON". Service diagnosis screen (a) is
displayed.
3. Start the engine.
4. With holding down buzzer stop switch (1), press menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using up arrow switch (5) or down arrow switch (6), point the cursor to "SERVICE ADJUST 1" of screen (b).
Press right arrow switch (7), and the "SERVICE ADJUST 1-1" screen is displayed. Then press down arrow
switch (6) several times and "SERVICE ADJUST 1-2" screen (c) is displayed.
6. Using up arrow switch (5) or down arrow switch (6), point the cursor to "BREAKER SETTING" of screen (d). 7
Press right arrow switch (7), and "BREAKER SETTING" screen (e) is displayed.
7. There are 10 step settings from "SET 1" to "SET 10". Using up arrow switch (5) or down arrow switch (6),
select a desired set number. To set the desired set number, press right arrow switch (7).
8. Using up arrow switch (5) or down arrow switch (6), select a desired flow rate and press menu switch (2) and
confirm it.
9. After that, press left arrow switch (8) to return to "SERVICE ADJUST 1-2" screen (c).
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[7. MECHATRO CONTROLLER]
(f)
CYLINDER BALANCING(FCCB)
HOUR METER 99999.4h
OK
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. With holding down buzzer stop switch (2), press menu switch (8) 3 times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Start the engine and using the up or down arrow switch, point the cursor to "CHECK INJECTOR" of screen (e).
Press the right arrow switch, and the "CYLINDER BALANCING (FCCB)" screen is displayed and inter-cylinder
calibration starts.
5. The engine speed is fixed at approximately 800 rpm.
6. When the value of [mm3/st.cyl] for each cylinder becomes stabled, the inter-cylinder calibration is completed.
Press menu switch (8) to return to the service adjust screen.
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[7. MECHATRO CONTROLLER]
RISE-UP WIPER ON
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP NEXT
DOWN DOWN DOWN DOWN
STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER
HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h
STOP CYLINDER No. 4 STOP CYLINDER No. 3 STOP CYLINDER No. 2 STOP CYLINDER No. 1 1 STOP CYLINDER No. +
ENG SPEED 1134 ENG SPEED 1127 ENG SPEED 1134 ENG SPEED 1129 ENG SPEED 1149
COMP. FUEL CONS. 24mm3/s t .cyl. COMP. FUEL CONS. 20mm3/s t .cyl. COMP. FUEL CONS. 24mm3/s t .cyl. COMP. FUEL CONS. 20mm3/s t .cyl. COMP. FUEL CONS. 16mm3/s t .cyl.
ENG RAIL PRESS 57.0M ENG RAIL PRESS 57.0M ENG RAIL PRESS 57.0M ENG RAIL PRESS 56.0M ENG RAIL PRESS 53.0M
BOOST PRESS 104 BOOST PRESS 104 BOOST PRESS 104 BOOST PRESS 104 1 BOOST PRESS 102
EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0%
EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0%
SCV CURRENT 1020mA SCV CURRENT 1040mA SCV CURRENT 1120mA SCV CURRENT 1920mA SCV CURRENT 1020mA
INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h
INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥
PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.1%
P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M
P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M
P1-PSV 338mA P1-PSV 339mA P1-PSV 339mA P1-PSV 338mA P1-PSV 339mA
P2-PSV 341mA P2-PSV 341mA P2-PSV 341mA P2-PSV 340mA P2-PSV 340mA
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
4 OK 4 OK 4 OK 4 OK 4 OK
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. During pressing buzzer stop switch (2), press menu switch (8) three times. "SERVICE MENU" screen (b) 7
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Using the up or down arrow switch, point the cursor to "STOP CYLINDER" of screen (e).
Start the engine and press the right arrow switch to display the "STOP ENG CYLINDER" screen.
5. Referring to the display, select the number of a desired cylinder (1 to 4) to be stopped. The selected cylinder is
stopped.
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[7. MECHATRO CONTROLLER]
6. At the time of the cylinder stop, check the value of COMP.FUEL CONS. (If the command injection quantity has
been changed significantly or has not been changed from the command injection quantity of when stopping the
cylinder under a normal machine condition, the stopped injector can be failed.)
7. Press the switch of the same number of the stopped engine cylinder and then the stopped cylinder works
again.
8. Press menu switch (8) to finish the "STOP ENG CYLINDER" screen and return to the "SERVICE ADJUST
SCREEN 1-3" screen.
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[7. MECHATRO CONTROLLER]
• Even if "READ INJECTOR CODE" is not performed, the injector codes can be input but in this case, "F" is input
to all of the boxes of each "injector no." first and it takes a lot of times to rewrite them.
• If a wrong value of the injector code is input, "WRITING FAILED" is displayed.
In this case, the input injector code is not stored. Input the injector code again.
• When replacing the ECU, display the injector code by following the procedure 10. and write the injector code
down, and then input that code. Otherwise, input the code displayed on the tag attached to the injector body.
• When replacing the injector, perform the procedures of 1. to 5. to allow the injector to read the code.
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[7. MECHATRO CONTROLLER]
RISE-UP WIPER ON
BACK NEXT BACK NEXT BACK NEXT BACK NEXT
Example:
When is input (h) (g) (f)
INPUT CODE INJECT OR No.1 INPUT CODE INJECT OR No.1 INPUT CODE INJECT OR No. SELECT INJECT OR SELECT INJECT OR
5.7h 5.6h 5.6h 5.6h 5.7h
A 1 0 0 0 0 E 4 2 1 0 0 0 0 E 4 2 1 0 0 0 0 E 4
INJECT OR No.1 INJECT OR No.1
1 2 3 4
5 6 7 8
9 A B C
BACK NEXT D E F 0 BACK NEXT BACK BACK
OK OK OK OK
or
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. With holding down buzzer stop switch (2), press menu switch (8) 3 times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Using the up or down arrow switch, point the cursor to "INPUT INJECTOR CODE" of screen (e). Press the right
arrow switch, and the "SELECT INJECTOR" screen is displayed.
5. Using the up or down arrow switch, point the cursor to "READ INJECTOR CODE" of screen (f) and press menu
switch (8). The injector code is read from the ECU and the value is read by each "injector no. n" (n is an
arbitrary number).
6. Using the up or down arrow switch, point the cursor to a desired "injector no. n" of screen (g). Press menu
switch (8) to display "INPUT CODE INJECTOR No. n" (h).
7. Using the up or down arrow switch, point the cursor to a desired box of screen (h). Press the right arrow switch,
and input a desired code referring to the screen of the gauge cluster.
8. After inputting the code, the cursor is moved to the next right box. Input a code again following the same
procedure of 7.
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[7. MECHATRO CONTROLLER]
9. After inputting the codes to the all boxes, press menu switch (8) to register the input codes. At this time, the
screen returns to "SELECT INJECTOR".
10. Finally, perform "READ INJECTOR CODE" once again and display "INPUT CODE INJECTOR No. n" to check
that the injector codes are input correctly.
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[7. MECHATRO CONTROLLER]
By pressing menu switch (8) under any condition of "CLEARED" or "DONE" in the procedure of 7., the screen shifts
to screen (k) and each condition information is stored.
RISE-UP WIPER ON
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP NEXT
DOWN DOWN DOWN DOWN
BACK
OK OK OK OK OK
(k)
STUDY PUMP DIFFERENCE
3.1h
CONDITION DONE
BACK
OK
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[7. MECHATRO CONTROLLER]
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. With holding down buzzer stop switch (2), press menu switch (8) 3 times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Using the up or down arrow switch, point the cursor to "STUDY PUMP DIFFERENCE" of screen (e). Press the
right arrow switch, and the "STUDY PUMP DIFFERENCE" screen is displayed.
5. Confirm that "STUDY PUMP DIFFERENCE CONDITION" is "CLEARED" by screen (f). If it is "DONE", press
menu switch (8) to change it to "CLEARED".
6. Start the engine and press menu switch (8) to start pump difference study.
7. The contents of "CONDITION FLAG" shifts through "CLEARED", "LEARNING 2", "LEARNING 1", and
"DONE". When it becomes "DONE", the pump difference study is completed.
8. By pressing menu switch (8), the study result is stored and shifts to screen (k).
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[7. MECHATRO CONTROLLER]
CIRCUIT NUMBER
List of connectors
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
BREAKER
SWITCH
CN-600
MULTI
DISPLAY(LCD) 1 2 3 4
5 6 7 8
HARNESS SIDE
DIGGING SWIHCH AMP 040 (8P)
HOUSING : 174044-2
TERMINAL : 173681-2
WORK MODE
SELECT SWIHCH
BUZZER STOP
SWITCH
LEFT ARROW
SWITCH RIGHT ARROW SWITCH
MENU SWITCH CN-601
SCREEN CHANGE HARNESS SIDE
DOWN ARROW SWITCH 1 2 3 4 5 6 AMP 040 (12P)
SWITCH
UP ARROW SWITCH 7 8 9 10 1112 HOUSING : 174045-2
TERMINAL : 173681-2
Function
• Signals from communication between the gauge cluster and the mechatro controller are processed and they are
displayed by the lamps, LCD and sound the buzzer.
• Coolant temperature signals, fuel level signals and panel switch signals are output to the mechatro controller
through the communication ports.
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[7. MECHATRO CONTROLLER]
9 Nibbler switch
10 Breaker switch
11 Up arrow switch
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[7. MECHATRO CONTROLLER]
Detail of label
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[7. MECHATRO CONTROLLER]
Circuit schematic
No. Name Device name
diagram No.
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[7. MECHATRO CONTROLLER]
Circuit schematic
No. Name Device name
diagram No.
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
O-RING P14
JIS B2401 CLASS1B
PF 3/8
Tighte ning torgue
73.5N .m (54.2lbf .ft)
VIEW A
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[8. HYDRAULIC SYSTEM]
8. HYDRAULIC SYSTEM
8.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................8-3
8.2 SUMMARY ...............................................................................................................................8-4
8.3 HYDRAULIC CIRCUITS AND COMPONENTS ...........................................................................8-5
8.3.1 PART NUMBER OF HYDRAULIC COMPONENT.....................................................................8-5
8.3.2 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS ...................................................8-5
8.3.3 STANDARD SPECIFICATION ............................................................................................... 8–7
8.3.4 N&B (FOOT) SPECIFICATION .............................................................................................. 8–8
8.4 NEUTRAL CIRCUIT................................................................................................................8-10
8.4.1 OPERATION OF UNLOAD VALVE AND BY-PASS CUT VALVE HOUSED IN CONTROL
VALVE ...........................................................................................................8-10
8.4.2 SAFETY LOCK LEVER AND PILOT CIRCUIT .......................................................................8-10
8.4.3 PUMP POSITIVE FLOW CONTROL .....................................................................................8-10
8.4.4 PUMP P-Q CURVE CONTROL OPERATION.........................................................................8-10
8.5 TRAVEL CIRCUIT...................................................................................................................8-12
8.5.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT....................................8-12
8.5.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION.....................................................................................................8-12
8.5.3 TRAVEL MAIN CIRCUIT ......................................................................................................8-12
8.5.4 TRAVEL MOTOR FUNCTION ...............................................................................................8-12
8.6 BUCKET CIRCUIT..................................................................................................................8-14
8.6.1 PILOT CIRCUIT FOR BUCKET DIGGING .............................................................................8-14
8.6.2 AUTO ACCELERATION OPERATION ..................................................................................8-14
8.6.3 STAND-BY CURRENT CONSTANT CONTROL.....................................................................8-14
8.6.4 BUCKET DIGGING AND TRAVEL STRAIGHT CONFLUENCE (CONFLUX) MAIN
CIRCUIT ........................................................................................................8-14
8.6.5 BUCKET SPOOL STROKE LIMITER ....................................................................................8-14
8.7 BOOM CIRCUIT .....................................................................................................................8-16
8.7.1 BOOM UP PILOT CIRCUIT ..................................................................................................8-16
8.7.2 BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT IN C/V .........................................................8-16
8.7.3 BOOM DOWN PILOT CIRCUIT.............................................................................................8-18
8.7.4 PREVENTION OF NATURAL FALL BY LOCK VALVE AND ACTUATION AT
LOWERING....................................................................................................8-18
8.7.5 BOOM DOWN MAIN CIRCUIT..............................................................................................8-18
8.8 SWING CIRCUIT ....................................................................................................................8-20
8.8.1 PILOT CIRCUIT FOR LEFT SWING ......................................................................................8-20
8.8.2 SWING AUTO PARKING BRAKE .........................................................................................8-20
8.8.3 SWING MAIN CIRCUIT ........................................................................................................8-20 8
8.8.4 SWING MOTOR FUNCTION.................................................................................................8-20
8.9 ARM CIRCUIT ........................................................................................................................8-22
8.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT CIRCUIT ............................................................8-22
8-1
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[8. HYDRAULIC SYSTEM]
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[8. HYDRAULIC SYSTEM]
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[8. HYDRAULIC SYSTEM]
8.2 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability,
safety, mass volume handling and low fuel consumption.
• Reverse rotation protective function • Easy positioning to protect it from swinging back when stops
swinging.
• Swing priority circuit (simultaneous
Swing operation of arm in and swing motions) • Easy operation of stable swing speed, arm slanted leveling,
swing press digging
• Automatic swing parking brake
• Swing parking brake when operating at on a slope
• Pressurized hydraulic oil tank • To prevent hydraulic oil from entering dust and to promote self
suction ability of pump
• Line filter ; pilot circuit • To prevent pilot operating circuit from malfunctioning
Others • Return circuit • To prevent hydraulic oil from contamination
• Cooling hydraulic oil by oil cooler • To prevent hydraulic oil from being deteriorated.
• Pressure draining circuit • To release the main circuit pressure for piping repair work.
• Switching of return line for N&B • Switching of return line for N&B machine is possible from
machine from inside cab inside cab
• Electric flow controlled variable • Pump delivery rate control by a current command to the
Pump displacement pump solenoid proportional valve of the variable displacement pump
• Positive flow rate control • Flow control by positive pilot control pressure
Micro • Auto accel • Reduce fuel consumption and noise by lowering engine speed
computer when control lever is in neutral position.
8-4
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[8. HYDRAULIC SYSTEM]
6 Arm cylinder mm (ft-in) YN01V00175F4 95 (3.74") dia. x 135 (5.32") dia. x 1558 (5'1")
7 Bucket cylinder mm (ft-in) YN01V00153F2 80 (3.15") dia. x 120 (4.72") dia. x 1080 (3'7")
The part numbers may be changed due to modification, so use the table above only as references.
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[8. HYDRAULIC SYSTEM]
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
8–7
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[8. HYDRAULIC SYSTEM]
61
62
60
LQ01Z00094P1 01
8–8
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[8. HYDRAULIC SYSTEM]
8–9
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[8. HYDRAULIC SYSTEM]
8.4 NEUTRAL CIRCUIT 8.4.3 PUMP POSITIVE FLOW 8.4.4 PUMP P-Q CURVE CONTROL
CONTROL OPERATION
This section describes the following functions.
• Bypass cut valve and unload valve control Type: Type:
• Safety lock lever and pilot circuit Electrical flow control type variable pump Electrical flow control type variable pump
• Pump positive flow control
Principle: Principle:
• Pump positive flow control
The current command I to the pump's solenoid proportional Perform an operation of the value from pump high pressure
valve controls the delivery rate of the pump. sensor to P-Q curve control value, and send a command to
8.4.1 OPERATION OF UNLOAD the pump solenoid proportional valve.
VALVE AND BY-PASS CUT Operation:
VALVE HOUSED IN CONTROL • Flow rate rise operation (Eg. P1 pump)
Operation:
VALVE By operating any of control levers, the operating The pump high pressure sensor converts the pressure to
secondary pressure of pilot valve rises, and the rising the output voltage corresponding to the pump delivery
• Unloading valve
pressure is transformed to the rise of output voltage pressure.
On starting engine, like by-pass cut valve, the secondary
corresponding to the pressure input by the low pressure The mechatro controller converts the voltage output by the
pressures output by P1 and P2 unloading proportional
sensor. Mechatro controller signal-processes this high pressure sensor to the P-Q curve control value. On the
valves (PSV-D, PSV-B) exert on PCb and PCa ports,
change of voltage, resulting in rise of command current other hand, select the pump positive control command
consequently the P1 and P2 unloading valves are
value I to the pump proportional solenoid valve and current value from the low pressure sensor in lower order,
switched to OPEN side.
consequently the pump flow rate rises. This is called and the values are output to respective pump proportional
• By-pass cut valve "Positive Control System". As the pump command valve as a command current.
When machine is under normal conditions, by-pass cut current value rises, the secondary pressure of With this operation, the pump power is controlled so as not
valve is closed normally. If pilot pressure sensor or proportional solenoid valve also rises. On the regulator to be exceed the engine power, therefore engine dose not
unloading proportional valve is disconnected or attached on the pump, the spool (652) through piston stall.
malfunctioned, the unloading valve closes completely. (643) is pushed rightward, and stops at the position
Even if control valve is in neutral position, hydraulic oil is where being in proportion to the force of pilot spring
trapped. As a result, the pump relieves due to pressure (646).
increase. The tank port connected to the large bore of servo
In such the case, before the machine is repaired, open piston (532) opens, and the piston moves leftward by
the by-pass cut valve manually. And the machine is delivery pressure P1 of the small bore resulting in the
operable by draining excess oil to hydraulic tank. increase of tilt angle (α). The servo piston and spool
(652) are connected to feedback lever (611). Therefore
8.4.2 SAFETY LOCK LEVER AND when servo piston moves leftward, the spool (652) also
PILOT CIRCUIT moves rightward by means of feedback lever." With this
movement, the opening of spool sleeve closes gradually,
Purpose: and the servo piston stops at the position the opening
To protect attachment from unexpected movement for closed completely.
safety. • Operation to decrease current flow rate
As the current value I of mechatro controller reduces, the
Principle: secondary pressure of solenoid proportional valve
Cut pressure source of pilot valve for operation. reduces, and spool (652) is moved leftward by the force
of pilot spring (646). With the movement of spool, the
Operation: delivery pressure P1 usually flows into the large bore of
piston through the spool.
If the safety lock lever (red) is pushed forward after the
The delivery pressure P1 flows in the small bore of servo
engine starts, the limit switch (SW-11) is turned on. The
piston, but the servo piston moves rightward due to the
timer relay is actuated one second later which causes the
difference of area, resulting in the reduction of tilt angle.
solenoid (SV-4) of the solenoid valve block (14) to be
Similarly, when the servo piston moves rightward, the
energized and makes the pilot operating circuit to stand by.
spool (652) is moved leftward by the feedback lever.
The operation is maintained until the opening of spool
sleeve is closed.
8-10
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
8-11
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[8. HYDRAULIC SYSTEM]
8.5.1 TRAVEL FORWARD PILOT It excites the 2-speed travel solenoid which in turn converts
the primary pilot pressure and the self pressure to a tilting
SIMULTANEOUS OPERATION
angle of the variable displacement motor.
CIRCUIT
Operation:
Purpose:
If the rabbit marked switch on the gauge cluster is pressed,
Light operating force and shockless operation
the solenoid (SV-3) of the proportional valve block (14) is
Operation: excited and changes the proportional valve. Then the
solenoid command pressure is issued from port A3, enters
1. If the travel lever with damping mechanism is operated the P port of the travel motor (4), opens the oil passage to
for travel right, left and forward motions, the secondary the 2nd speed select piston, and causes the motor to run in
pilot proportional pressure comes out of the 3, 1 ports the 2nd speed tilting mode by its self pressure. However,
of P/V (10). The higher of the pressures is selected, when the main circuit pressure rises above 28 MPa (4060
comes out of the 6, 5 ports and acts upon the low psi), the motor's self pressure pushes the 2nd speed select
pressure sensors (SE9) (SE-10). piston back to the 1st speed.
2. The pilot secondary pressure flows to PAr and PAL
ports of the control valve (2), moves the travel spool, 8.5.3 TRAVEL MAIN CIRCUIT
and switches the main circuit.
3. The low pressure sensor output voltage is input into Operation:
mechatro controller. The mechatro controller performs The delivery oil from Pump A1 and A2 ports by changing
signal processing, and outputs flow rate increase the travel spool with the operation of travel pilot flows in
current to P1 pump proportional valve (PSV-P1) and each P1 port on the left side of travel motor (4) and P2 port
P2 pump proportional valve (PSV-P2). At the same on the right side of travel motor (4) through C,D ports of
time, it outputs command current to P1 unloading swivel joint (8) from AL, AR ports of C/V, and rotates the
proportional valve (PSV-D) and P2 unloading travel motor.
proportional valve (PSV-B).
4. The secondary pressures output by P1 pump 8.5.4 TRAVEL MOTOR FUNCTION
proportional valve (PSV-P1) and P2 pump proportional
valve (PSV-P2) exert on pump regulator, actuating the Function:
pump on the delivery flow rate increase side. • Prevents the motor from over running on a slope.
5. The secondary pressure delivered in P1 unloading • Check valve that prevents cavitation of the hydraulic
valve (PSV-D) and P2 unloading valve (PSV-B) is fed motor.
to Pcb and PCa ports provided in control valve (2).
• Shockless relief valve and anti cavitation valve when
The secondary pressure from proportional valve which
inertia force stops.
has exerted on PCb and PCa ports switches the
unloading spool in CLOSE side. • High/Low 2 step speed change mechanism and auto 1st
speed return at high load.
• Travel parking brake.
8-12
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
8-13
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[8. HYDRAULIC SYSTEM]
8.6 BUCKET CIRCUIT 8.6.2 AUTO ACCELERATION 8.6.4 BUCKET DIGGING AND
OPERATION TRAVEL STRAIGHT
This section describes the following functions.
CONFLUENCE (CONFLUX)
• Bucket digging pilot circuit Principle:
MAIN CIRCUIT
• Auto acceleration operation Auto acceleration actuates according to signals from low
• Stand-by current constant control pressure sensor. Operation:
• Bucket digging and travel straight confluence (conflux) 1. The oil delivered through A1 port of P1 pump goes into
Operation:
main circuit P1 port of C/V (2), opens load check valve LCc through
• When lever is set to neutral position parallel circuit and enters in bucket spool.
• Bucket spool stroke limiter
In the event where the sensor does not receive signal for
2. On the other hand, the oil delivered through P2 port of
4 seconds or more even though the acceleration dial is
P2 pump goes into P2 port of C/V (2), confluences with
8.6.1 PILOT CIRCUIT FOR BUCKET set to MAX position, the engine speed should be raised
oil from P1 pump through travel straight valve, and
DIGGING to 1000 rpm.
goes into bucket spool. (Confluence of oil from 2
• When lever is operated pumps)
Operation:
When the pressure 0.6 MPa (87 psi) is input to low
3. With the function of pilot circuit, the oil flow is switched
1. When the operation for bucket digging is performed, pressure sensor in STD specification (travel, bucket,
from bucket spool, and is fed into bucket cylinder head
the pilot proportional secondary pressure is delivered swing, arm), proportional voltage from low pressure
(H) side through AC port of C/V (2). On the other hand,
through port 1 of the right pilot V (9), flows to PAc port, sensor inputs in mechatro controller, and then the engine
the return oil from cylinder rod (R) side is throttled by
and acts on the low pressure sensor (SE-1), and at the speed returns to the dial set position corresponding to
bucket spool and returns to tank circuit from BC port of
same time the bucket spool is switched. the lever operation.
C/V (2).
2. The low pressure sensor output voltage is input into
mechatro controller. The mechatro controller performs 8.6.3 STAND-BY CURRENT Reference:
signal processing, and outputs command current of CONSTANT CONTROL • In bucket dumping operation, the travel straight valve
pump flow rate increase to the electromagnetic
also switches like digging operation, resulting in
proportional valves (PSV-P1) and (PSV-P2) on the P1 Principle:
confluence with travel straight.
and P2 pump sides. At the same time, it outputs
When the engine speed is intermediate speed or lower, • When the bucket operation and other operation are
command current to P1 unloading proportional valve
command current value to have the pump delivery rate simultaneously performed, the travel straight valve does
(PSV-D), P2 unloading proportional valve (PSV-B) and
constant is output. not actuate, resulting in single flow of bucket circuit.
travel straight proportional valve (PSV-C).
In the following pages, the relation of operation of low Operation:
pressure sensor to both the increase of pump flow rate 8.6.5 BUCKET SPOOL STROKE
Even if the engine speed specified by acceleration
and unloading proportional valve is the same.
potentiometer is low speed, as the delivery rate
LIMITER
Therefore the explanation is omitted."
corresponds to the intermediate speed, the actuator moves Purpose:
3. The secondary pressure output by P1 pump earlier than the movement equivalent to the control lever
proportional valve (PSV-P1) and P2 pump proportional angle rate in light load operation. To secure simultaneous operability of boom and arm and to
valve (PSV-P2) exerts on pump regulator, actuating the prevent cavitations at low engine speed.
pump onto the delivery flow increase side.
Operation:
4. The secondary pressure delivered in P1 unloading
valve (PSV-D) and P2 unloading valve (PSV-B) is led On boosting up attachment pressure, pilot primary pressure
to PCb and PCa ports provided in control valve (2). exerts on PCc port of C/V(2) through attachment booster
The secondary pressure from proportional valve which solenoid valve, operates stroke limiter of bucket spool, and
has exerted on PCb and PCa ports switches the throttle oil path of spool. As a result, P1 pump pressure
unloading spool in CLOSE side. increases, making the simultaneous operation of boom up
5. The secondary pressure delivered in travel straight and bucket digging possible.
proportional valve (PSV-C) is led to PTb port provided Even though the engine speed is low, similarly the
in control valve (2) and shifts the travel straight valve. cavitations can be prevented by actuating the stroke limiter.
8-14
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
BUCKET CIRCUIT : Bucket digging (travel straight conflux), auto-acceleration and standby flow rate constant control function
8-15
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[8. HYDRAULIC SYSTEM]
Principle:
Confluxing oil from 2 pumps
Operation:
1. The oil delivered through A1 port of P1 pump flows into
C/V (2) P1 port, and branches into bypass circuit and
parallel circuit. Since P1 unloading valve is closed, the
boom spool is moved and bypass circuit is closed, the
oil opens load check valve LCb1 through parallel circuit
and flows into boom spool.
2. Then the oil passes through boom spool, opens lock
valve of boom lock valve CRb1, and is led into H side
of boom cylinder through C/V (2) Ab port.
3. Meanwhile, the oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and due to shut off
the P2 unloading valve, the oil then passes through the
parallel circuit and via the restrictor on the
circumference of the boom conflux spool, pushes the
load check valve CRb2 open from the boom conflux
circuit, and combines the oil delivered by the P1 pump
internally.
4. The return oil from boom cylinder R side flows into tank
circuit through boom spool from C/V (2) Bb port.
8-16
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
8-17
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[8. HYDRAULIC SYSTEM]
This section describes boom lower operation. 8.7.5 BOOM DOWN MAIN CIRCUIT
• Boom down pilot circuit
Operation:
• Prevention of natural fall by lock valve and actuation at
lowering During boom down operation, the hydraulic oil delivered
from hydraulic pump P1 is supplied to the boom cylinder
• Constant recirculation function of boom down main
rod (R) side through port (Bb).
circuit
On the other hand, the oil returned from the boom cylinder
head (H) side enters the C/V through port (Ab). The lock
8.7.3 BOOM DOWN PILOT CIRCUIT valve poppet is pushed and opened because holding of the
lock valve poppet is released.
Operation:
Then the return oil flows the boost check valve and returns
1. If the boom down operation is performed, the to the hydraulic oil tank through tank port T1.
secondary pilot proportional pressure comes out of
port (4) of right pilot valve (9) and acts upon the low
pressure sensor (SE-4). At the same time, the
pressure acts upon the PBb port of C/V (2).
2. The voltage output of the low pressure sensor (SE-4)
enters the mechatro controller and processed in it.
3. Then, the proportionl secondary pressure fed into C/V
(2) PBb port and branches off in two lines and switches
boom spool and releases boom lock valve.
Principle:
The oil is prevented from returning to the boom spool by the
poppet seat of the boom lock valve.
Operation:
In the boom down action, the selector valve is changed
over by the secondary proportional pressure of PBb port.
Then the poppet spring chamber of the lock valve CRb1
gets through the drain line (Dr) and makes the lock valve
poppet open. When the boom lever is at neutral, the drain
line on the lock valve CRb1 poppet spring chamber is
closed which causes the poppet closed.The result is that
the oil returning from the boom cylinder head (H) to the
boom spool is held and makes the leak from the boom
spool zero.Thus the boom cylinder is prevented from
making a natural fall.
8-18
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
BOOM CIRCUIT : Boom down operation & prevention of natural boom falling by boom lock valve
8-19
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[8. HYDRAULIC SYSTEM]
Principle:
Release mechanical brake only when required to operate
swing and arm in.
Operation:
1. The swing parking system excites the swing parking
SOL (SV-1) usually if the key switch is turned on and
works by the action of the mechanical brake.
2. The mechanical brake is released if the swing parking
solenoid is de-excited only when the secondary
operating pressure in the swing and arm in actions acts
upon any of the low pressure sensors (SE-7, 41).
3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low pressure
sensors (SE-41) is reduced to zero. In the case of arm
in operation, the swing parking solenoid (SV-1) is
excited the moment the pressure of the arm in low
pressure sensor (SE-7) is reduced to zero. This causes
the mechanical brake to operate.
8-20
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
8-21
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[8. HYDRAULIC SYSTEM]
8.9 ARM CIRCUIT 8.9.2 ARM-IN, LIGHT-LOAD applied is operated, the meter-in path of arm 2 spool is
VARIABLE NORMAL closed, resulting in single flow operation.
This section describes the following operations.
RECIRCULATION, INTERNAL Spool position at arm in,
• Arm in, light-load operating pilot circuit
CONFLUX MAIN CIRCUIT light load and combined operation
• Arm-in, light-load variable normal recirculation, internal (This position is not shown in hydraulic diagram)
Reference:
In light-load arm-in operation (normal recirculation, conflux),
when the attachment to which the circuit in P1 pump side is
8-22
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
ARM CIRCUIT : Arm in (light load) operation, arm recirculation, conflux & anti cavitation function
8-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[8. HYDRAULIC SYSTEM]
This section describes the following operations. 8.9.4 ARM IN, HEAVY LOAD
• Arm in, heavy load operating pilot circuit (recirculation OPERATING RECIRCULATION
cut) CUT MAIN CIRCUIT
• Arm in, heavy load operating recirculation cut main
circuit Purpose:
Power up for arm in operation
8.9.3 ARM IN, HEAVY LOAD
Principle:
OPERATING PILOT CIRCUIT
Cut the recirculation and reduce rod pressure.
Operation:
Operation:
1. Left pilot valve actuation due to arm-in operation is
equivalent to that at light load operation. 1. P2 pump delivery oil flows in the travel left section
through P2 port of C/V (2) and branched off in by-pass
2. In arm-in operation, when the heavy loading is applied
circuit and parallel circuit. Consequently the arm spool
to arm and the P2 pump pressure increases to the set
is switched and pushes and opens load check valve
pressure, the voltage output by P2 pump pressure
LCa through parallel circuit, and flows in the arm spool.
sensor (SE-23) is converted to signal (signal
processing) by mechatro controller, consequently the 2. On the other hand, P1 pump delivery oil flows in P1
current of arm 2 solenoid proportional valve is port of C/V (2), and flow in travel right tandem passage
controlled according to the load pressure and the arm through travel straight section. Then because arm 2
variable recirculation is cut. spool was switched, the delivery oil opens load check
When the recirculation is cut, internal confluence is valve LCAT2, and confluences with P2 pump delivery
held similarly to that in light load operation. oil in the valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3. The return oil from arm cylinder (R) side flows in Ba
port of C/V(2) and is flowed to arm lock valve CRa, but
because the arm lock valve CRa is open, the return oil
goes through arm lock valve CRa and flows in arm 2
spool.
4. The return oil returns directly into tank circuit because
arm 2 spool is switched to recirculation cut position.
8-24
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
ARM CIRCUIT : Arm in (heavy load) operation, arm conflux & recirculation cut function
8-25
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[8. HYDRAULIC SYSTEM]
This section describes the following operations. 8.9.7 NATURAL FALL PROTECTION
• Arm out pilot circuit WITH ARM LOCK VALVE
• Arm out 2 pumps conflux main circuit
Purpose:
• Natural fall protection with arm lock valve
To prevent the arm from falling naturally by the weight of the
arm and bucket.
8.9.5 ARM OUT PILOT CIRCUIT
Principle:
Operation:
Complete seat of the return circuit against the arm spool of
1. When the arm out operation is performed, the
the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out of port 8
of the left pilot valve (9), and acts upon the low Operation:
pressure sensor (SE-8). At the same time, the oil is
1. When the secondary pressure for arm operation
branched off in two flows and act upon the PBa1 and
disappears and the arm cylinder stops, the pressure on
PBa2 ports of C/V (2).
the rod (R) side passes through the selector of the lock
2. The operating proportional secondary pressure flowed valve from the Ba port of C/V, acts the back pressure
in Pba1 port of C/V (2) switches the arm 1 spool. on the lock valve CRa and seats the lock valve.
3. Then, the operating secondary pressure flowed in 2. Since the oil flow into the arm spool from the lock valve
PBa2 port of C/V (2) switches the arm 2 spool valve. is shut off completely, natural fall of the arm due to oil
leaks through the arm spool is prevented.
8.9.6 ARM OUT 2 PUMPS CONFLUX
MAIN CIRCUIT
Purpose:
Arm out operation speed up.
Principle:
The oil delivered by the P1 pump is confluxed with that
delivered by the P2 pump in C/V (2).
Operation:
1. P1 pump delivery oil opens load check valve (LCAT2)
by switching arm 2 spool and confluxes with P2 pump
delivery oil just short of the arm lock valve.
2. And, P2 pump delivery oil flows through arm 1 spool
and confluences with P1 delivery oil, opens lock valve
of arm lock valve CRa with free flow and is flowed into
arm cylinder rod (R) side through Ba port of C/V(2).
3. On the other hand, the return oil from arm cylinder (H)
side flows in Aa port, and returns into tank circuit
through arm 1 spool and arm 2 spool.
The return line which does not pass through boost
check valve is used for this return circuit to reduce the
pressure loss.
8-26
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
8-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[8. HYDRAULIC SYSTEM]
Principle:
8.10.1 BOOM UP / TRAVEL, PILOT
CIRCUIT The travel action and the attachment action are actuated by
separate pumps.
Operation:
Operation:
• Different point of pilot circuit from independent operation
1. P1 pump delivery oil flows through P1 port of C/V(2)
1. The mechatro controller outputs command current to and branches off in P1 parallel circuit and travel
travel straight solenoid proportional valve after signal straight spool.
processing, and the solenoid valve outputs secondary P2 pump delivery oil flows through P2 port of C/V(2)
pressure and acts on PTb port of C/V (2). and branches off in P2 tandem circuit and travel
2. Then the pressure of PTb port switches the travel straight spool.
straight valve. 2. The delivery oil flowed into P1 parallel circuit of P1
pump opens check valve LCb1 and flows in boom
spool, which exerts on boom up operation.
The delivery oil flowed into travel straight spool of P1
pump opens check valve LCb2 because the travel
straight spool is shifted, and flows in boom conflux
spool and exerts on boom up operation with the
internal oil conflux.
(In travel straight operation, P1 pump delivery oil exerts
on swing operation of attachment.)
3. The delivery oil flowed into P2 tandem circuit of P2
pump flows in left travel spool to travel leftward.
The delivery oil flowed into travel straight spool of P2
pump flows in right travel spool because the travel
straight spool is shifted and exerts on the right travel
operation.
(In travel straight operation, P2 pump delivery oil exerts
on travel operation.)
4. However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted by the
circuit of restriction.
8-28
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
COMBINED CIRCUIT : Boom up & travel forward (RH & LH) 1st speed operation, travel straight function.
8-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[8. HYDRAULIC SYSTEM]
This section describes only the difference in combined 8.10.4 SWING / ARM IN, SWING
operation. PRIORITY MAIN CIRCUIT
• Swing / arm in light load, pilot circuit
Purpose:
• Swing / arm in, swing priority main circuit
Stable swing speed.
8.10.3 SWING / ARM IN LIGHT LOAD, Principle:
PILOT CIRCUIT
Raise the oil pressure flowing to arm cylinder, and give a
Operation: priority of the delivery of P2 pump to swing operation.
8-30
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
COMBINED CIRCUIT : Swing left / arm in (light load) operation, swing priority function
8-31
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[8. HYDRAULIC SYSTEM]
Operation:
1. Pump proportional valve reduces the pump flow rate to
the minimum.
2. Unloading proportional valves (PSV-D, PSV-B) output
secondary pressure and the secondary pressure flows
in PCb, PCa ports of C/V(2) and switches the P1, P2
unloading valves to OPEN position.
8-32
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[8. HYDRAULIC SYSTEM]
YN01Z00266P1 02
8-33
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[8. HYDRAULIC SYSTEM]
8-34
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[9. ELECTRICAL SYSTEM]
9. ELECTRICAL SYSTEM
9.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................9-3
9.2 ELECTRICAL EQUIPMENT LIST ..............................................................................................9-4
9.3 ELECTRICAL DIAGRAM ......................................................................................................... 9–9
9.4 HARNESS............................................................................................................................. 9–17
9.4.1 HARNESS LIST .................................................................................................................. 9–17
9.4.2 INSTRUMENT PANEL ASSY............................................................................................... 9–18
9.4.3 CONTROLLER & RELAY BOX ASSY INSTALLATION ......................................................... 9–20
9.4.4 OPERATORS CONTROLS .................................................................................................. 9–22
9.4.5 SWITCH INSTALLATION (CAB WORKING LIGHT) .............................................................. 9–23
9.4.6 UPPER ELEC ASSY ........................................................................................................... 9–24
9.4.7 UPPER HARNESS ASSY.................................................................................................... 9–27
9.4.8 UPPER HARNESS ASSY (FLOOR PLATE).......................................................................... 9–44
9.4.9 WASHER TANK ASSY ........................................................................................................ 9–49
9.4.10 CAB HARNESS ASSY ...................................................................................................... 9–50
9.4.11 CAB HARNESS ASSY (BOOM CYLINDER LIGHT) ............................................................ 9–65
9.4.12 IT KIT HARNESS ASSY .................................................................................................... 9–69
9.4.13 BOOM HARNESS ASSY ................................................................................................... 9–73
9.4.14 BOOM HARNESS ASSY (BOOM CYLINDER LIGHT) ......................................................... 9–74
9.4.15 BOOM LIGHT INSTALLATION .......................................................................................... 9–75
9.4.16 BOOM CYLINDER LIGHT INSTALLATION......................................................................... 9–76
9.4.17 UPPER LIGHT INSTALLATION ......................................................................................... 9–77
9.4.18 CAB 1 LIGHT INSTALLATION ........................................................................................... 9–78
9-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9-2
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(D) DIODE
D-13 DIODE ↑
D-14 DIODE ↑
D-20 DIODE ↑
D-21 DIODE ↑
D-22 DIODE ↑
D-23 DIODE ↑
D-24 DIODE ↑
9-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(L) LIGHT
(M) MOTOR
9-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(R) RELAY
9-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(SE) SENSOR
(SV) SOLENOID
(SW) SWITCH
9-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(1/8)
YN03Z00104P1 03
9–9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(2/8)
YN03Z00104P1 03
9–10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(3/8)
YN03Z00104P1 03
9–11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(4/8)
YN03Z00104P1 03
9–12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(5/8)
YN03Z00104P1 03
9–13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(6/8)
YN03Z00104P1 03
9–14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(7/8)
YN03Z00104P1 03
9–15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(8/8)
YN03Z00104P1 03
9–16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9.4 HARNESS
9.4.1 HARNESS LIST
9
DRAWING No. HARNESS
REMARKS
NAME ASSEMBLY No. CODE No. NAME PART No.
UPPER FRAME
INSTRUMENT PANEL ASSY YN17M00179F1
CONTROLLER & RELAY BOX ASSY CONTROLLER INSTALLATION YN22E00670F1
INSTALLATION
CONTROLLER INSTALLATION YN22E00667F1 MECHATRO CONTROLLER
CONTROLLER INSTALLATION YN22E00669F1
RELAY BOX ASSY YN24E00040F1
OPERATORS CONTROLS CONTROL BOX ASSY YN03M00504F1
GRIP ASSY YN03M02496F1
SWITCH INSTALLATION SWITCH INSTALLATION LQ50E00011F1 CAB WORKING LIGHT SWITCH
(CAB WORKING LIGHT)
BOOM
BOOM HARNESS ASSY YN15E00066F1 1 HARNESS YN15E01088P1 1 LIGHT
BOOM HARNESS ASSY (BOOM CYLINDER LIGHT) YN15E00067F1 1 HARNESS YN15E01018D1 1 LIGHT
LIGHT
BOOM LIGHT INSTALLATION YN80E00011F2
BOOM CYLINDER LIGHT INSTALLATION YN80E00081F1
UPPER LIGHT INSTALLATION LQ80E00014F1
CAB 1 LIGHT INSTALLATION LQ80E00035F1 1-2 HARNESS LQ80E01019P2 1 LIGHT
NOTE : Use the above part numbers for reference only, as they may be subject to improvement or modification.
9–17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(2.14 lbf.ft)
(7.15 lbf.ft)
9–20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
2-2-3
2-1-3
2 P LACES
NUT
CAPSCREW CAPSCREW TIGHTENING TORQUE
TIGHTENING TORQUE TIGHTENING TORQUE 41.2 N.m (30.4 lbf.ft)
2.7 N.m (1.99 lbf.ft) 2.7 N.m (1.99 lbf.ft)
1-5
SECTION AA
L/H R/H
LOCK WASHER
CAPSCREW
FORWARD (MAKER RECOMMENDED VALUE)
TIGHTENING TORQUE
0.4 N.m (0.3 lbf.ft)
ISOMETRIC DRAWING
OPERATORS CONTROLS
9–22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
GROUND 9
9–25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
410 (16.1”)
15
60-8
AV60s qfB TERMINAL
CORRUGATED TUBE TO BE
INS TALLED.
CAP TERMINAL
YAZAKI 7134-2201(BLACK) YAZAKI 7306-2107-02
OR
TAP ED IN TWO TURNS
HERO ELECTRIC DVCP -B (BLACK)
9–26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
XXXIV
FIX WHITE TAP ING
POSITION
CLIP
TO FRAME WORKING S TARTER CABLE UPP HARNESS CLIP FIX WHITE TAP ING
LIGHT RIGHT FIX WHITE TAP ING P OS ITION P OS ITION
SE-2 5:
CLIP NOTE 5
FIX A HARNES S PART OF P RES S . S ENS OR:BOOM ROD
COULGATED TO P RES S CONNECT "S E-25" TAG
SENSOR BY A CLIP OF CONNECTOR
9–27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
VIEW VII
SE-41:
PRESS SENSOR:
SWING LEFT.
CONNECT "SE-41" TAG FIX WHITE TAP ING P OS ITION
OF CONNECT OR BUNDLE AND FAS TEN
CLIP A RES T S OL.S IDE HARNES S
FIX A HARNES S TO S V-2: TO THE CONNECTOR BY A CLIP
THE MOUS E P IECE P OWER BOOS T S OL. CLIP
OF HOS E BY A CLIP A1 A2 A3
CONNECT "S V-2" TAG
FOR WARD OF CONNECTOR TO
"A3" S OL.
S V-3:
VIEW V TWO-S P EED S ELECT S OL.
CONNECT "S V-3" TAG
VIEW VI OF CONNECTOR TO
"A2" S OL.
FIX WHITE TAP ING P OS ITION S V-105:
TO THE HOS E BOOM METER IN CUT S OL.
CLIP CONNECT "S V-105" TAG
UPP HARNESS OF CONNECTOR TO
"A1" S OL.
VIEW VIII
UPP HARNESS
FIX HARNESS TO
SE-15:FUEL SENSOR THE HOSE
CONNECT A HARNES S
CLIP
WITH IN A CAP.
FIX WHITE TAP ING P OS ITION
CLIP
FORWARD
L-2:
FOR WARD FRAME WORKING
LIGHT RIGHT
FOR WARD
FIX WHITE TAP ING P OS ITION
CLIP
CLIP
CLIP UPP HARNESS FIX WHITE TAP ING P OS ITION
FIX A CONNECTORS PART
TO FUEL S ENS OR CLIP THERE IS RES T HARNES S FOR
FIX WHITE TAP ING P OS ITION LIGHT S IDE HARNES S
CLIP IT BUNDLES AND FIXES HERE.
SET THE WHITE TAP ING
POSITI ON TO THE CLIP VIEW II
FOR HO SE AND FIX BY A CLIP
VIEW IX VIEW XXXIII
9–28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
CLIP
FIX WHITE TAP ING P OS ITION S WING FLAS HER RIGHT
XV CLIP
FIX WHITE TAP ING P OS ITION
FIX WHITE TAP ING P OS ITION FIX WHITE TAP ING P OS ITION CLIP
CLIP CLIP
CLIP
TO ENGINE
FORWARD
SEMS-BOL T
CLIP PLATE
FIX WHITE CLIP FIX WHITE TAP ING P OS ITION
TAP ING P OS ITION FIX WHITE TAP ING P OS ITION CLIP
UPP HARNESS
FORWARD
CLIP
XIII FOR WARD
INSULATION
STICK THE INSULATION CLIP
FIX WHITE TAP ING P OS ITION
AFTER COA TING
COMPLETELY CLEAN & TO TRAVEL ALARM AND
TO HYD.FLUID FILTER
REMOVE DUSTS,F ATS & S WING FLAS HER RIGHT
FOR WARD RESTRICTION SENSOR
OILS AND WATER FROM
THE STICKING F ACE, VIEW XIV
THEN STICK IT VIEW XV VIEW XVI
VIEW XIII
CLIP
FIX WHITE TAP ING P OS ITION
9–29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
E-10:
NOTE 6 RECEI VER DRIER
CLIP ITEM 1 HARNESS HARNES S OF
CLIP ATTACHED ENG.
UNDER BRACKET
DIRECTION CLIP OF ATTACHED
OF MACHINE SEMS-BOL T CONNECT OR
HOSE ENG.HARNES S
US E THE CLIP OF
ATTACHED ENGINE
XXIII
S W-27: CLIP FIX A CONNECTOR
CLIP TO THE BRACKET
RADIATOR COOLANT
FIX HARNESS TOGETHER HOS E BY A CLIP
LEVEL SW.
FIX HARNESS TOGETHER HOS E 16P
12P 14P
FIX WHITE TAP ING P OS ITION BY HOS E S IDE CLIP BRACKET
CLIP FIX WHITE TAP ING
P OS ITION
FOR WARD CLIP FIX WHITE TAP ING P OS ITION
CLIP
FAS TEN UP P HARNES S
AND S TARTER CABLE
CLIP
SET THE WHITE TAP ING P OS ITION CLIP SEMS-BOL T
TO AIR FILTER FIX HARNES S TOGETHER HOS E SEMS-BOL T
RES TRICTION S W. TO THE CLIP FOR HOS E
AND FIX BY A CLIP
FIX HARNESS TOGETHER HOS E
BY HOS E S IDE CLIP
TO RECEIVER DRIER VIEW XXI
S TARTER CABLE
FIX WHITE TAP ING P OS ITION
HOSE
UPP HARNESS E-10:
TO CONNECTOR UPP HARNESS
CLIP
RECEI VER DRIER
VIEW XXII
FORWARD
9–30
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
ENG.EAR TH CABLE
SEMS-BOL T
TIGHTENING TORQUE
S PACER 51.9N.m(3 8.3 lbf.ft)
S W-7: ALTERNATOR
ENG. OIL PRESS SW . TIGHTENING TORQUE 25.5N.m(18.8 lbf .ft)
SEMS-BOL T VIEW XXVII
BRACKET DETAIL OF ALTERNATOR
CLIP
FIX A HARNES BY A CLIP
TO THE BRACKET OF
ENG.ACCESSOR Y
XXVII
FOR WARD
UPP HARNESS
CLIP
SEMS-BOL T SEMS-BOL T
FIX WHITE TAP ING P OS ITION BRACKET
TIGHTENING TORQUE TIGHTENING TORQUE 25.5N.m(1 8.8 lbf.ft)
23.0N.m(1 7.0 lbf.ft)
VIEW XXVI GLOW NUT CLIP
CLIP SE-1 3: FIX WHITE TAP ING P OS ITION
ENG.REVOLUTION S ENS OR
FIX A CONNECTOR ON BRACKET FIX A HARNES S PART OF
FIX A WHITE TAP ING P OS ITION COULGATED TO P LATE WITH A CLIP
FORWARD
OF HARNES S TO
THE BRACKET WITH CLIP
TO GLOW
DETAIL OF ENGINE REVOLUTION SENSOR INST
WAS HER
COLLAR
9–31
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
R-3: NOTES
CONNECT TO 2P CONNECTOR 1. TIGHTENING TORQUE OF BATTERY TERMINAL 6N.m(4 .43 lbf.ft)
GLOW RELAY F TERMINAL TIGHTENING TORQUE43N.m(2 .53 lbf.ft)
FOR HARNESS OF ATTACHED
USE NUT OF ATTACHED 2. TIGHTEN TO TORQUE AT EARTH: 10.7N.m(7 .89 lbf.ft)
GLOW RELAY S TERMINAL GLOW RELAY
3. TIGHTEN TO TORQUE
CONNECT WHITE TAP ING HARNES S
M8 : 23N.m(1 7.0 lbf.ft)
FAS TEN GLOW RELAY S TERMINAL
AND CONNECT OR HARNESS M10 : 46.5N.m(3 4.3 lbf.ft)
CLIP CONNECT RED TAP ING HARNES S . 4. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS MADE INTO THE FOLLOWING.
DETAIL aa
VIEW XXXI
9–32
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
YN13E01884P5
CORRUGA TE TUBE
CAP TO BE INS TALLED 7034-1280
SECTION AA
WHITE TAP ING
CLIP
HARNESS
CLIP
CLIP
CLIP
TAP ING
WHITE TAP ING WHITE TAP ING WHITE TAP ING WHITE TAP ING
403A-403B-403C 401A-401B-401C
SPL ICE SPL ICE
WHITE TAP ING 402A-402B-402C
YELLOW TAP ING SPL ICE
A A
CLIP
CLIP WHITE TAP ING WHITE TAP ING WHITE TAP ING
CLIP
CAP
TO BE INS TALLED CAP
CLIP
(1/10) YN13E01884P5
9–33
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TAP ING
SH1 SHIELD
UN-CONNECTED
WHITE TAP ING WHITE TAP ING WHITE TAP ING WHITE TAP ING WHITE TAP ING
CLAMP
WHITE TAP ING
(2/10) YN13E01884P5
9–34
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
7034-1280
CAP TO BE INSTALLED
9
7034-1279
CAP TO BE INSTALLED
TAPING
64A-64B-64C
SPLICE
157A-157B-157C
SPLICE
(3/10) YN13E01884P5
9–35
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TO CAB HARNES S
P2 UN-LOAD
PROPOR TIONAL SOL.
ARM TWO-SPEED INVERSE
PROPOR TIONAL SOL.
(4/10) YN13E01884P5
9–36
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
SUPPL Y WITH
TO BE INS TALLED
YN13E01322P1 CAP . HORN HIGH
PRESS. SENSOR:
SWING P ARKING PUMP P2
BRAKE SOL. SEALING PLUG TO BE
INSER TED INTO ALL
PRESS. SENSOR:
ARM OUT
FUEL SENSOR
TRAVEL ALARM
HORN LOW
PUMP P1
PROPOR TIONAL SOL.
PRESS. SENSOR: RECEIVER DRIER
BOOM RAISING
(5/10) YN13E01884P5
9–37
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
DIODE
YAZAKI 7321-9822
SUPPLY WITH DIODE
ADAPT CONNECTOR 7123-7144
STARTER RELAY BATTERY RELAY ADAPT TERMINAL 7116-1181
HORN LOW GLOW
DIODE
SUPPLY WITH
SUPPLY WITH
ARM CUSHION
PROPORTIONAL SOL.
SEALING PLUG TO BE
INSERTED INTO ALL
GLOW RELAY
(6/10) YN13E01884P5
9–38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
SUPPL Y WITH
SUPPL Y WITH
BOOM 3
PRESS. SENSOR: PROPOR TIONAL SOL.
HYD. FLUID FILTER BOOM HEAD
RESTRICTION SENSOR
SEALING PLUG TO BE
INSER TED INTO ALL
SEALING PLUG TO BE
INSER TED INTO ALL
TO CAB HARNES S
TO BOOM/
TO S WING FLAS HER RIGHT SRM POTENTIO.
BOOM 2
PROPOR TIONAL SOL.
TO CAB HARNES S
TO CAB HARNES S
PRESS. SENSOR:
BOOM ROD
TO CAB HARNES S
PRESS. SENSOR:
SWING LEFT
TO CAB HARNES S
BOOM METER IN CUT SOL.
(7/10) YN13E01884P5
9–39
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
SUPPL Y WITH
TO CAB HARNES S
AIR FILTER
RESTRICTION SW .
(8/10) YN13E01884P5
9–40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TO EARTH TO EARTH
FRAME GND OF UNDER CHASSIS GND
FLOOR
TO EARTH
TO EARTH
CHASSIS GND
TO EARTH
TO EARTH
(9/10) YN13E01884P5
9–41
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(10/10) YN13E01884P5
9–42
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
100
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
9–43
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
S W-21:
P OWER BOOS T S W. LEFT
I (YELLOW TAP ING)
FIX A P OWER
LEVER ROCK SW . S W-10:
SIDE HARNESS TO HOS E HORN S W. LEFT (BLUE TAP ING)
CLIP
CLIP
BUNDLE TO HORN S W.LEFT S IDE HARNES S AND
LEVER ROCK S IDE HARNES S .
CLIP CLIP
FIX TO A HALL OF P LATE.
1 SET WHITE TAP ING P OS ITION
AND FIX TO A S LIT OF P LATE.
CLIP CLIP
SET WHITE TAP ING P OS ITION
CAB HARNESS
CONNECT TO
S W-12: PILOT HOSE CAB HARNESS
OVER ROAD ALARM S ELECT S W.
(OVER L TAG)
M-4:
WAS HER MOTOR DETAIL OF LEFT CONSOLE
III
S W-26:
CAB WORKING LIGHT S W. S W-26:
FIX POWER BOOST SW. TO (CAB LIGHT TAG) CAB WORKING LIGHT S W.
RIGHT OF FLOOR HARNESS (CAB LIGHT TAG)
VIEW III S W-12:
OVER ROAD ALARM S ELECT S W.
(OVER L TAG) FRONT
S W-12:
INSULATION
FIX WITH TILTED
LEVER OVER ROAD ALARM SELECT SW. (OVER L TAG)
AT THE FRONT FLOOR HARN ESS
CLIP
BUNDLE POWER BOOST SW.
FIX WHITE TAP ING P OTIS ION FRONT DETAIL OF bb
SIDE HARNESS AT THE BACK OF
FLOOR HARNESS FIX TO A HALL OF P LATE. TO THE MOUS E P ICE OF HOS E CLIP
BY A CLIP.
CLIP FIX WHITE TAP ING P OTIS ION.
II CLIP
S W-20:
POWER BOOST SW. RIGHT FIX TO THE P ILOT HOS E. PILOT HOSE
(YELLOW TAP ING)
TRIM
CLIP
9–44
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
NOTE 2
1. ATTACHMENT OF CLIP IS MADE INTO THE FOLLOWING.
TO S ENS OR
CLIP
SE-1 1:
NOTE 1
PRESS SENSOR:P2 OPT .
FIX WHITE TAP ING P OTIS ION.
BUNDLE THE REMAINDER OF HARNESS
AND FIX IN THIS POSITION FIX TO A HOS E
CLIP FIX WHITE TAP ING P OTIS ION.
CLIP CLIP
FIX WHITE TAP ING P OTIS ION. TO THE FRONT S IDE OF CLIP FIX WHITE TAP ING P OTIS ION.
SE-2: FIX WHITE TAP ING P OTIS ION.
FLOOR P LATE.
PRESS SENSOR: CAB HARNESS
BUCKET DIGGING
FIX TO A HOS E
FIX WITH HOSE SIDE BY CLIP
VIEW FROM THE BACK SIDE OF FLOOR PLA TE.
SE-1:
FOR FIXATION IS POSSIBLE.
PRESS SENSOR:
CLIP BUCKET DIGGING
NOTE 1 SE-4 0:
FIX WHITE TAP ING P OTIS ION. P RES S S ENS OR: SE-7 :
SE-40: BUNDLE THE REMAINDER OF HARNESS P RES S S ENS OR:
S WING RIGHT
PRESS SENSOR: AND FIX IN THIS POSITION ARM IN NOTE 1
SWING RIGHT CLIP
CLIP SE-7 : SE-2 :
SE-1 :
P RES S S ENS OR: P RES S S ENS OR:
SE-7: SE-2 : NOTE 1 P RES S S ENS OR:
ARM IN BUCKET DUMP
TO THE BACK S IDE OF PRESS SENSOR: SE-4 0: P RES S S ENS OR: CLIP BUCKET DIGGING FRONT
FLOOR PLA TE. ARM IN P RES S S ENS OR: BUCKET DUMP
S WING RIGHT
SE-2: SE-1:
PRESS SENSOR: PRES S S ENS OR:
DETAIL OF aa : CASE OF SENSOR BLOCK SK330-10 BUCKET DIGGING BUCKET DIGGING
FRONT
SE-1:
FIX TO A HOS E PRESS SENSOR:
FIX WITH HOSE SIDE BY CLIP BUCKET DIGGING
FOR FIXATION IS POSSIBLE.
CLIP
SE-40: CLIP FIX TO A HOS E CLIP
CLIP PRESS SENSOR: NOTE 1
FIX TO A HOS E
SWING RIGHT FIX WHITE TAP ING P OTIS ION.
CLIP BUNDLE THE REMAINDER OF
SE-7: NOTE 1 HARNES S AND FIX IN THIS
PRESS SENSOR: FIX WHITE TAP ING P OTIS ION. P OS ITION
TO THE BACK S IDE OF BUNDLE THE REMAINDER OF HARNES S
ARM IN
FLOOR PLA TE. AND FIX IN THIS P OS ITION
9–45
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TAP ING
TAP ING
HARNESS INSULATION
TAP ING
9–46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
PRESS. SENSOR:
BUCKET DUMP
9–47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
100
1PAF
YAZAKI
9–48
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
(0.43")
(11)
5 8 8 (2
3 .5 ")
(5.91")
150
(3.74")
95
FOR WARD
TIGHTENING TORQUE
23N .m (17.0 lbf .ft) CAB CLIP FIXED THAT.
SEMS-BOL T CLIP CUT A LENGTH OF CAB HOS E,
THAT ADJ US TMENT.
335 (13.19") SECTION AA
675 (26.58")
VIEW I
1
BRACKET
SEMS-BOL T
TIGHTENING TORQUE I
9.7N .m (7.15 lbf .ft)
III
HARNESS FIXED THAT.
VIEW II MUST LAYOUT THE HOS E MUST NOT BE CRUSHING
ALONG THE HARNESS. OF THE HOSE.
CLIP
FOR WARD
TUBE
11 0 (4 .3
3 ")
1
(3 . 0 0
100 (3.94")
94
")
RUBBER
A
7”)
50
(1.9
CLIP
HARNESS FIXED THAT. 360
)
.7 9 ”
(1 4
20)
OF THE HOSE.
(0 . 3
A II
WHITE TAP E P OS ITION
S TARTING S TICK P OS ITION OF FOR HARNESS.
RUBBER (END OF R)
CLIP
VIEW III HARNESS FIXED THAT AT THE
RUBBER INST ALLATION WHITE TAP E P OS ITION. TUBE LAYOUT UNDER FLOOR PLA TE
MUST NOT BE CRUSHING
OF THE HOSE.
9–49
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
UPP HARNESS
DETAIL aa
C-2: IV V
II FIX TO BEACKET
CLUSTER GAUGE CLIP
VIEW V
VIII
cc
1
III
I aa 31 PIN CONNECT OR
34 PIN CONNECT OR 32 PIN
CONNECT OR
35 PIN CONNECT OR
35 PIN CONNECT OR CONNECT TO
WIPER RELA Y
M-3: VIEW IV VIEW III
WIPER MOT OR
9–50
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
C-1:
E-1 : E-7 : E-6 5: MECHATORO
FUS E&RELAY BOX TUNER 24V S OCKET CONTOROLLER
9
bb
CLIP
VI
FIX WHITE
TAP ING P OTIS ION.
DETAIL bb
CLIP CLIP
FIX WHITE TAP ING P OTIS ION. CLIP FLOOR HARNESS FIX THE CLIP TO THE BRACKET. dd FIX THE CLIP TO THE BRACKET.
CONNECT TO FIX WHITE TAP ING P OTIS ION.
FLOOR HARNES S . FIX WHITE TAP ING P OTIS ION.
VIEW I
TIGHTENING TORQUE
CONNECT TO
TUNER S IDE HARNES S 4.4N.m(3 .25 lbf.ft)
TIGHTEN AFTER CHECKING NO PAINT.
TIGHTEN WITH TWO EYELET TERMINALS .
GND
P-2 CAB HARNESS GROUND
SEMS-BOL T SPLICE
ROTARY LIGHT
FLASHER RELA Y
A A DC-DC CONVER TER(12/24V SOCKET)
CAB WORKING LIGHT FRONT 1
CAB WORKING LIGHT
ENG. CONTROLLER CHECK CONNECT OR
RELEASE SW .(KPSS)
KEY SW. GROUND
WIPER MOT OR
CLUSTER GAUGE
P-13 CAB HARNESS GROUND
GND P-19 CAB HARNESS GROUND
CONNECTO TO RELEAS E S W. FUEL SUPPL Y P UMP SEMS-BOL T
CLIP (KPSS)SI DE HARNES S FROM UPPER HARNESS
CLIP P-80 CAB HARNESS GROUND TIGHTENING TORQUE
S W-22: IT CONTROLLER 4.4N.m(3 .25 lbf.ft)
FIX WHITE TAP ING P OTIS ION. RELEASE SW .(KPSS) TIGHTEN AFTER CHECKING
FUSE & RELAY BOX NO PAINT.
TUNER AM&FM TIGHTEN WITH TWO EYELET
VIEW VI TERMINALS .
FUEL DISCRIMINANT SENSOR
BOOM,DECK WORKING LIGHT SW.
DETAIL bb WIPER INTERLOCK SW .
NEUTRAL ST OP RELAY SECTION AA
9–51
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
FIX THE CONNECTOR TO HARNES S CONNECT DOUBLE S P LICE OF RED YELLOW WIRE
CONNECT 6P CONNECTOR OF CAB HARNES S TO RED YELLOW WIRE
BUNDLE A RES T CAB S IDE CLIP OF CAB HARNES S TO DC-DC OF CAB S IDE HARNES S .
OF S P EAKER HARNES S CONVERTER FOR CAMERA(OP T) CONNECT WITH CAB WORK LIGHT FRONT.
BY A CLIP CLIP
B SE-9 9:
BUNDLE AND FAS TEN
FIX TO THE HARNES S R-19: P RES S S ENS OR:
OF AIR CONDITIONER UNIT. FLAS HER RELAY S WING S P EED S ENS OR CLIP A RES T CAB S IDE OF
CLIP CAB WORK LIGHT
FRONT HARNES S
C-8: BY A CLIP
ENG
CONTOROLLER
B E-6 3:
FIX WHITE TAP ING P OTIS ION. DC-DC CONVERTER
(FOR CAMERA)
(OP T)
FIX TO THE HARNES S CONNECT
OF AIR CONDITIONER UNIT. WITH S P EAKER.
CLIP CLIP
FIX WHITE TAP ING
P OTIS ION.
CLIP
DIVERGRS HARNES S
CLIP
TO FUS E&RELAY BOX.
C-5:
RADIATOR COOLANT
ee LEVEL CONTOROLLER
FIX WHITE
TAP ING P OTIS ION.
2 P OINTS
CLIP
PLATE
SEMS-BOL T
TIGHTENING TORQUE FIX WHITE
9.7N.m(7 .15 lbf.ft) CLIP TAP ING P OTIS ION.
FLOOR
HARNESS CLIP CONNECT WITH WIP ER CLIP
THREW CLIP TO S LIT OF BRACKET. INTALOCK S W. FIX THE CLIP
FIX HARNESS TO CENTER OF FIX HARNES S TOGETHER CAB S IDE
GROMMET TO THE BRACKET. WITH THE CAB S IDE RADIO RADIO CABLE
INSULATION BY THE LOCATED OF GROMMET.
CABLE BY A CLIP.
FIX WITH FLOOR HARNESS. CONNECT WITH
DETAIL cc CAB WORK LIGHT.
CONNECT DOUBLE S P LICE OF RED YELLOW WIRE
VIEW II
OF CAB HARNES S TO RED YELLOW WIRE
OF CAB S IDE HARNES S .
CONNECT DOUBLE S P LICE OF BLACK WIRE
OF CAB HARNES S TO BLACK WIRE OF CAB S IDE HARNES S .
CLIP
CONNECT WITH
CONNECT TO NAME TAG OF "PARKING".
ACCEL P OTENTIO.
9–52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9
CONNECT THE CONNECTOR(1P ) OF
CAB HARNES S TO ROOM LIGHT CABLE.
VIEW VIII
GSM ORBCOMM
ASSEMBLY
GSM ORBCOMM
TEST
GSM ORBCOMM
SHIPMENT
DETAIL ee
9–53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TAP ING
E38-991 TAP ING TAP ING WHITE
SPLICE TAP ING
SH8-E17 770C-770D
SPLICE SPLICE
TAP ING
SUPPL Y WITH
9–54
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
60B-60C-60D
SPLICE
9
TAP ING
52A-52B
SPLICE
62D-62E-62C
SPLICE
UN-CONNECTED
TAP ING SH2
INSULATION
TAP ING
WHITE TAP ING BLUE TAP ING
UN-CONNECTED
SH11
SPLICE RED TAP ING
TAP ING
9–55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
RESIST OR
TO FUS E & RELAY BOX
RELEASE SW .(KPSS)
9–56
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
24V SOCKET
TO FUEL S UP P LY P UMP
TO UP P HARNES S
9–57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
CAN RESIST OR 2
DT04-3P-P006
CAN RESIST OR
DEUTSCH CONNECT OR ACCEL POTENTIO.
RADIATOR COOLANT TO REAR CAMERA CABLE
LEVEL CONTROLLER
BOOM,DECK WORKING
LIGHT SW.
TUNER AM&FM
CAN RESIST OR 1
9–58
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TO S P EAKER
TO UP P HARNES S
TO IT HARNES S
TO UP P HARNES S
CLUSTER GAUGE
TO DC-DC CONVERTER
TO UP P HARNES S
TO UP P HARNES S
TO ROTARY LIGHT
9–59
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TO KEY S W. EARTH
FUEL DISCRIMINANT
TO FUS E & RELAY BOX TO FUS E & RELAY BOX TO FUS E & RELAY BOX
TO UP P HARNES S
TO UP P HARNES S
9–60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TO CAB EARTH
TO CAB WORKING
TO CAB WORKING LIGHT FR ONT
LIGHT FR ONT
TO CAB EARTH
9–61
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–62
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–63
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–64
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
CLIP
FIX TO UP P HARNES S
2
CLIP
FIX TO UP P HARNES S
E-45:
BOO M CYLINDER WORK LIGHT RELAY
CAB HARNESS
II
III
3
IV SEMS-BOL T
E-4 5:
BOOM CYLINDER
WORK LIGHT RELAY
TIGHTENING TORQUE
9.7N.m(7.15 lbf.ft)
CLIP CLIP
FIX TO CAB HARNES S SET THE WHITE TAP ING PART TO
THE WHITE TAP ING PART OF CAB HARNES S
AND FIX TO CAB HARNES S BY A CLIP.
VIEW II
VIEW I
9–65
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
VIEW IV
CONNECT CONN ECTOR WHTH
TAG OF "CN8" FOR ITEM 2 HARNES S
FLOOR HARNESS
CAB HARNESS
ITEM 1 HARNESS]
THROUGH TOO HOLE OF GROMMET.
VIEW V
SECTION AA
9–66
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9
SUPPL Y
WITH
RESER VE CONNECT OR
TO FUS E & RELAY BOX
TAP ING
CAB WORKING LIGHT SW.
TAP ING
TO FLOOR HARNES S
9–67
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–68
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
CLIP
2. IT KIT HARNESS ASSY (CONNECTOR ASSY) LQ11E00076F1 (03) HARNES S IS CLAMP ED US ING
THE HOLES OF CONTROLLER.
ITEM PART NAME PART No. Q'TY REMARKS
2-3 CONNECT OR ASSY LQ11E01092F1 1 (02)
CLIP
TO ATTACH BUNDLED ORBCOMM AND
GP S ANTENNA WIRES .
TIGHTENING TORQUE
5.0 N.m(3.69 lbf .ft) ORBCOMM & GPS ANTENNA WIRE IS
SEMS-BOL T CLAMPED WITH CAB HARNESS. DETAIL bb
bb 1-1 CLIP
ANTENNA
aa ORBCOMM ANTENNA
DETAIL aa
THE ST ATE AT THE TIME OF
DELIVERY OF CAB
VIEW I
9–69
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–70
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–71
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–72
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–73
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
CONNECT TO CONNECT TO UP P
LIGHT HARNES S
CB 104 CA 104
aa
CLIP
VIEW I
II
CONNECT TO LIGHT
DETAIL aa VIEW II
9–74
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TO CENTER OF BUCKET
BRACKET
LOCK WASHER
REMOVE LOCK W ASHER ATTACHED TO LIGHT
CAPSCREW
LOCK WASHER
TIGHTENING TORQUE: 46.1N.m(34.0 lbf .ft)
SECTION AA
9–75
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
TIGHTENING TORQUE
31.5N .m(23.2 lbf .ft)
APP LY LOCTITE #242.
CAPSCREW
A BAND LOCK WASHER
BAND
CAPSCREW
LOCK WASHER
TIGHTENING TORQUE
31.5N .m(23.2 lbf .ft)
APP LY LOCTITE #242.
1 TIGHTENING TORQUE(M12)
18.6N .m(13.7 lbf .ft)
BOOM CYL.L.H. SECTION AA
BOOM CYL.R.H.
9–76
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
A
1
NUT
(SUPPLIED WITH LIGHT )
GROMMET
BRACKET
VIEW I
SEMS-BOLT
LIGHT HARNESS TIGHTENING TORQUE
46.1N .m(34.0lbf .ft)
SECTION AA
NOTE
1. TIGHTENING TORQUE OF ITEM 1 TO BE 18.6 N.m (13.7lbf .ft)
9–77
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–78
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
9–79
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[9. ELECTRICAL SYSTEM]
170 (6.69”)
70 (2.76”)
9–80
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-2
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
a4
a5 A1 A2
(Dr) Psv
VIEW
MAX. FLOW RATE MIN. FLOW RATE
ADJUSTING SCREW ADJUSTING SCREW
2 2-1 EYE BOLT (M10) 2-1
2
a4 a5
Psv
3 Psv
(Dr)
B3 B3
B1
A3
a1 a2
(Dr) a3 a3
P H1 P H2 P H2
A1 A2
Hydraulic ports
No. Parts Q'TY No. Ports name Size
1 Main pump assy 1 A1,A2 Delivery port SAE 6000psi 1"
2 Regulator assy 2 B1 Suction port SAE 2500psi 2 1/2 "
2-1 Solenoid proportional reducing valve 2 Dr Drain port PF3/4-20
3 Gear pump assy (for pilot) 1 Psv Servo assist port PF3/8-17
PH1,2 pressure sensor port PF3/8-17
a1,a2 gauge port PF1/4-15
a3 gauge port PF1/4-14
a4,a5 gauge port PF1/4-15
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
10-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(FRONT) (REAR)
(KDRDE5K) (KR7G-0E1K-V) a 1 A1 P H1 P s v P H2 A2 a 2 (KR7G-0E1K-V) (KDRDE5K) Solenoid
Solenoid
proportional proportional
reducing reducing
valve (PSV -P1) valve (PSV -P2)
a4 a5
Regulator
10
Regulator
Main pump
Dr A3
B1 B3 a3
Specifications
Item Main pump Gear pump
Revolu- min-1
Rated 2000 ←
tion (Clockwaise seen from shaft end)
10-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Main pump
953 806 537 789 732 532 532 548 531 214 808 901 954 792 702 534 717 981 983 151 152
211
490
251
C C
886
B B 04
127
111
A A
774
261 113
710 272
123 824 271 212 153 466 156 157 468 313 124 711 116 312 724 885 314 401 141
406 723 726
414
326
Tighte ning torque
Item Tighte ning torque
number Thread size
N.m (lbf.ft)
401 M20 430 (317)
406 M8 29 (21) (537) 953 806 419
414 M10 57 (42)
419 M16 240 (177) 544 724
466 PF 1/4 36 (27)
468 PF 3/4 170 (125) 723
545
490 M7X0.75 18 (13)
806 M16 130 (96)
808 M20 240 (177) 541
VIEW C SECTION B-B SECTION A-A
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Va lve pla te & L) 1 717 O-ring 2
113 Drive shaft (R) 1 326 Cover 1 723 O-ring 14
116 Gear #1 1 401 Socket bolt;M20X210 4 724 O-ring 10
123 Roller bearing 2 406 Socket bolt;M8X16 4 726 O-ring 4
124 Needle bearing 2 414 Socket bolt;M10X20 4 732 O-ring 2
127 Bearing spacer 4 419 Socket bolt;M16X35 4 774 Oil seal 1
141 Cylinder block 2 466 ROH plug PF1/4 2 789 Back-up ring P18 2
151 Piston 18 468 ROH plug PF3/4 4 792 Back-up ring G35 2
152 Shoe 18 490 Plug;M7X0.75 18 806 Nut ; M16 2
153 Set plate 2 531 Tilting pin 2 808 Nut ; M20 2
156 Spherlcal bush 2 532 Servo piston 2 824 Stop ring 2
157 Cylinder spring 18 534 Stopper (L) 2 885 Pin 4
211 Shoe plate 2 535 Stopper (S) 2 886 Pin 2
212 Swash plate 2 537 Servo cover 2 901 Eye bolt ; M10 2
214 Tilting bus h 2 541 Seat 4 953 Socket screw 2
251 Swash plate support 2 544 Stopper 1 4 954 Set screw ; M20 2
261 Seal cover (F) 1 545 Steel ball 4 981 Name plate 1
271 Pump casing (F) 1 548 Feed back pin 2 983 Pin 2
272 Pump casing (R) 1 702 O-ring 2 04 Gear pump 1
312 Va lve block B 1 710 O-ring 1
313 Va lve pla te & R) 1 711 O-ring 1
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
10-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Z
X
10
B3
434
X
311 A3
X
312
a3 850
732 355
Z
435 361 353 307 310 308 309 434 466
SECTION ZZ 725
Delivery port : PF1/2
Tightening torque : 53N .m (39.1 lbf .ft)
10-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10.2.1.3 OPERATION
The pump assy is equipped with two pumps arranged on
the same axis that are connected with gear (116) and
distribute the rotating power to the gear trains on a
REGULATOR
different axis. Thus the engine rotation is transmitted to
front shaft (111) that drives the two pumps and, at the
same time, drives the auxiliary pump (OPT) arranged on
another shaft.
116
The pump assy consists largely of the rotary group, the
main part of the pump that makes rotary on; the swash
plate group that changes the delivery rate; the valve 111
block group that selects between oil suction and delivery
and the PTO group (OPT) that transmits the drive power
to the auxiliary pump.
Rotary group
The rotary group consists of shaft(111), cylinder block PTO GEAR CASE
(OPT)
(141), piston (151), shoe (152), plate (153), spherical
AUXILIARY PUMP
bushing (156), and cylinder spring (157). The shaft is (OPT)
supported by bearings (123) and (124) at its both ends.
The shoe, which is caulked to the piston, forms a
Construction of hydraulic pump
spherical joint and relieves it of thrust force that is
generated by load pressure. Further, the piston is
provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance.
The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and
the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder block (141) is also pressed
against valve plate (313) by the action of cylinder spring (157).
3 1 3
1 2 4
3 1 2
1 1 1
1 1 6
1 2 4
3 1 4
1 4 1
1 5 7
1 5 6
1 5. 1 1 5 3
1 5 2
2 1 1
Rotary group
10-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
728
a
641
924
755 801
758 656
708 402
A
887
468 658
726 755
VIEW B
614 466
Tighte ning torque
10-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
The item having the number marked with * is an adjusting screw. Do not touch the adjusting screw as much as
possible.
10-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Control function
Control function :
• Positive flow control
Summary
Regulator KR7G-0E2K-V for the swash plate type axial piston pump K7V series consists of the following control
mechanisms.
• Control of current flow rate, Positive flow control
The pump swash plate angle (delivery flow rate) is controlled in accordance with a controlled command current
value of the proportional pressure reducing solenoid valve equipped with this regulator. This regulator is
operated by a positive control, which increases a delivery flow rate as command current value I increases. With
this mechanism, when a current is input in accordance with the working status, the pump delivers only a required
flow rate and do not use an extra power.
Operation
• Control of current flow rate
The delivery flow rate of the pump is controlled in
accordance with command current value I as shown
De live ry flow ra te Q
in the right figure.
• Operation to increase current flow rate
When command current value I increases, the second
pressure of the proportional pressure reducing
solenoid valve increases and spool (642) moves
through pilot piston (898) and stops at the position
where the hydraulic pressure to the right direction and
the power of pilot spring (646) balance each other. Command current I
If spool (642) moves, pilot sleeve/spool pressure
adjusting part (C1) opens and the pressure at the large-diameter part of servo piston (532) is released. Then,
servo piston (532) moves right due to delivery pressure P1 of the small-diameter part to increase the swash
plate angle.
Feedback lever (611) is linked with the servo piston and sleeve (643) and if the servo piston moves right, the
feedback lever rotates around the supporting point and the sleeve moves right. Opening part (C1) of the spool
and the sleeve starts to close gradually and at its fully-closed position, the servo piston stops and stabilizes.
• Operation to decrease current flow rate
If command current value I decreases, the secondary pressure of the proportional pressure reducing solenoid
valve decreases and spool (642) moves left.
After the spool moves, pilot sleeve/spool pressure adjusting part (C2) opens and delivery pressure P1 is led to
the large-diameter chamber of the servo piston. Delivery pressure P1 is always led to the small-diameter
chamber of the servo piston and the servo piston moves left due to the difference of the areas to decrease the
swash plate angle. If the servo piston moves left, the feedback lever rotates around the supporting point and the
sleeve moves left. It moves until the opening part of the spool and the sleeve closes and it stops at the closed
position.
10-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
898 Pd1
P2
532
C1 C2 10
924
Pd1 Pcl
030
801
Pcl
656
954
953
Left Right 808
806 (Flew reducing) (Flew reducing)
10-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
300
(79)
250
(66)
Q d (Up side)
699mA 220 L/min (58 ga l/min)
737mA
200 3.92
Flow ra te Q d [L/min (ga l/min)]
(53) (568)
3.43
(497)
150 2.94
100 1.96
(26) (284)
1.47
(213)
0.92 MPa (133 ps i)
400mA
50 0.98
(13) (142)
0 0
200 300 400 500 600 700 800
Input electric current (mA)
10-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
OUTSIDE VIEW
P Tb
PBL
P2
CT2
10
CP 2
Pc
(P6 ) (P5 )
Dr2
P1
P Cb PAL
P Tb CT1 T2 T1
CT2
Travel Dr1 P1 P Cb PAL
P AL
Travel left
PCb P BL
straight CMR1 CMR2
PL unload CP 2 BL
MR AL
Ar
P Ca
Travel PAr PB1 Boom
PBr right PAr PB1
Br
CP L Ab
AbR conflux LCb2 P2 unload
PAb XAb Prb
Bb PBb Pra Boom 2 CAb
Pc PBb Pra
Dr2 CRbL
Boom CRb2 CRa CBb Boom 3
P Lc1
PAc Bucket PBs
Ac Bc BcR PBs Swing As Bs P Aa
LCc LCs
PBc P Cc P Cc P Aa 1
Arm 2 CBa PBa 1 P Lc2 CRa
PBa 2 Arm 1 Aa
PAa 2 PBa 2 PBa 1
Ta LCAP 2 LCAT2 MU Ba LCa
MU Ba R
PBa 2 PBa 1
Dr2 BbR
Boom PAb
Boom 3
Pc Prb
VIEW A
A
Outside view
10-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
PORTS
Tightening
Port size Ports Description
torque
10-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
SPECIFICATIONS
Item Specifications
Model KMX15YF/B44004
Maximum flow rate [L/min (gal/min)] 220 (58) X 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (P port)/39.7 (5760) (A,B port)
Main relief valve set pressure [MPa (psi)] When power boost Std 34.3 (4970) [at 70 X 2 L/min (18.5 X 2 gal/min)]
pressure High 37.8 (5480) [at 60 X 2 L/min (15.9 X 2 gal/min)]
10-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Control Valve
J
J
154 164 101
P2
T2
PAL P BL
J
P B1 P Ca
Pra Prb
P Bs PAs
PBa 1 PAa 1
154 164
P1 102
974
973
P Tb P Cb
974
973
P Br PAr
973
PAb P Bb
973 973
PAc
973 P Cc
P Bc
PAa 2 PBa 2
973 973
SECTION B-B
Section (1/6)
10-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
T2
H 273x1 0 H
P1 unload P Cb PAL Travel left
C 273x10 C
PAr P B1 977 10
Travel right Boom conflux
D D
978x2
Boom P Bb Pra
Boom 2
E
E
P Bs
Bucket Swing
F F
P Cc
PBa 2 PBa 1
Arm 2
Arm 1
G G
MU
K K
B A
PBa 2 PBa1
274x 4 274x4
Dr2
Pc
213 213
PAa 1
PAa 2
Section (2/6)
10-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
331 331
261 MR 261
309
601
PL 306
AL 163
511
512
521
522 CP2
CMR2 551
552 164
562
CMR1 162
BL
552
522 163
Dr1
512
307
261
331 PBL 264
327 205
329
336
331 SECTION C-C
333
202 PTb
Travel straight
331 331
261 261
306
305
161
Ar
511 511
521 521
CP1 LCb2
551
551
164 164
163 Br
310
161
(T3)
164
264 154
PBr
261
205 331
327
SECTION D-D
329
336
PCa 331
P 2 unload 333
202
Section (3/6)
10-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
203 202
333 Boom Boom 2 333
331 331
336 P Bb Pra 336
319 322
321 320
603 331
AbR 261
L 331 L 212
163
211 M N N
M 261 161
266 159
159 PLc1 312
514 CAb
551
524
CRb1
521
164
10
556 CRb2 511
164
556
Dr2 164
529
Pc 513
CRe 164
208 551
520 521
Bb 516
162
163
CBb 313
551
301 164
264 521
162 511
PAb
161 261
602 BbR 331
SECTION E-E 320
205 322
336
Prb 331
Boom 3 333
202
209
216 P Cc Swing 201
333 333
PBs
331 331
336 P Bc
336
322 322
321 321
602 BcR
331 331
261
261
304
Bc
162 As
511 511
521 523
LCc
LCs
551
556
164
164
163 Ac
Bs
162
162
162
264 303
PAc
264
603 PAs
205 SECTION F-F 205
AcR
Section (4/6)
10-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
201
201 333
333 Arm 2 Arm 1 331
331 PBa2 PBa1 336
340 322
328 321
321
BaR 603
331
331
550 211
261 562
525 L L
CBa 261
519 159
MU
308
PLc2 514
162
162 524
CRa
162 556
511
164
521
551 LCAT2 511
164 521
515 LCa
521 551
LCAP2
551 164
164 302
162
162 Ta Aa
163
162
510
526 CTa 604
167 264
557 PAa1
P P
264 205
210 PAa2 AaR
SECTION G-G
T2
161
P1
T1
163
CT1
551
163
164
162
P2
CT2
551
164
SECTION H-H
Section (5/6)
10-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
207
606 606 563
160
278x 5 564
266
264 264
10
SECTION N-N SECTION L-L
SECTION J -J SECTION K-K
Section (6/6)
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
16 to 20
159 Plug ; M7X0.75 4 329 Spring 3
(12 to 15)
7.8 to 9.8
160 Plug ; R-1/16MEC 1 331 Spring seat 26
(5.8 to 7.2)
16 to 18
161 O-ring 5 (12 to 13) 333 Spacer bolt 13
Loctite #262
162 O-ring 21 336 Stopper 11
10-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
9.8 to 14
212 Lock valve selector sub 1 520 Sub logic valve 1
(7.2 to 10.3)
98 to 120
274 Socket bolt 8 527 Spring 1
(72 to 89)
25 to 34
278 Socket bolt 5 528 Spring 1
(18 to 25)
230 to 260
303 Swing spool 1 551 Plug 13
(170 to 192)
130 to 150
304 Bucket spool 1 552 Plug 2
(96 to 111)
230 to 260
305 Boom conflux spool 1 556 Plug 4
(170 to 192)
49 to 59
306 Travel spool 2 557 Plug 1
(36 to 44)
69 to 78
312 Boom 2 spool sub 1 602 Port relief valve 2
(51 to 58)
69 to 78
313 Boom 3 spool sub 1 603 Port relief valve 3
(51 to 58)
69 to 78
319 Spring 1 604 Port relief valve 1
(51 to 58)
69 to 78
320 Spring 2 606 Bypass cut valve 2
(51 to 58)
140 to 180
321 Spring 5 973 Socket bolt 8
(103 to 133)
140 to 180
322 Spring 5 974 Socket bolt 2
(103 to 133)
10-26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
325 Spring 1
10
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
69 to 78
103 Plug 1 562 Back up ring 1
(51 to 58)
561 O-ring 1
10-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
69 to 78
101 Body 1 541 Seat 1
(51 to 58)
69 to 78
102 Plug 1 561 O-ring 1
(51 to 58)
10-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Arm 2 spool
10
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
16 to 18 (12 to 13)
308 Spool 1 350 Plug 1
Loctite #638
16 to 18 (12 to 13)
317 Plunger 1 351 Plug 1
Loctite #638
319 Plunger 1 361 O-ring 2
Boom spool
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
10-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Boom 3 spool
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
351 361
371 312
Boom 2 spool
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
10-30
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
101 10
164
171
201
321
PLc A B Dr
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
10 to 14
101 Casing 1 171 Socket bolt 3
(7.4 to 10.3)
49 to 59
161 O-ring 4 201 Plug 1
(36 to 44)
10-31
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
101
164
171x3
201
321
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
10 to 14
101 Casing 1 171 Socket bolt 3
(7.4 to 10.3)
49 to 59
161 O-ring 4 201 Plug 1
(36 to 44)
10-32
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
102
106x4
103
10
104
101 105
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
6 to 8
101 Casing 1 104 Adjust screw 1
(4.4 to 5.9)
20 to 24
102 O-ring 1 (14.8 to 105 Lock nut 1
17.7)
102 101
110
114
112 113 103
120x4
Logic valve
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
13 to 17
110 Plug 1
(10 to 13)
10-33
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
106
104
107
102
101
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
24.5 to 29.5
101 Logic poppet 1 (18.1 to 104 Plug 1
21.8)
10-34
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
202 301
10
T Dr
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
69 to 78
101 Plug 1 202 O-ring 1
(51 to 58)
25 to 29
102 O-ring 1 301 Lock nut 1
(18 to 21)
25 to 29
201 Adjust screw 1
(18 to 21)
104
107
102
101
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
20 to 29 (15 to 21)
101 Poppet 1 104 Plug 1
Loctite #262
102 Poppet 1 107 Spring 1
10-35
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Travel
straight
Boom conflux
Boom 3
Boom
Boom 2
Swing
Bucket
Arm 1
Arm 2
10-36
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
606
52
517
307
T1
P2
P1
309
606
55 310
(D)
Connected to low
pressure circuit of
P2 side casing
At neutral
10-37
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
A B
AL BL
306 CP2
323
324
PAL PBL
10-38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
C M R 2 C M R 2
B P 2 B P 2
C M R 1 C M R 1
P 1 P 1
A A
3 0 7 3 0 7
3 2 7 3 2 7
3 2 9 3 2 9
P T b P T b
P 2 P 1 P 2 P 1
P T b P T b
D r D r D r D r
B A A
T o e a c h a c tu a to r B T o e a c h a c tu a to r
T o tr a v e l r ig h t T o tr a v e l r ig h t
C ir c u it ( I) C ir c u it ( II)
10-39
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
216
PAc
PCc PBc
321
322 (D) Bc LCc Ac
304 511
(R) (H)
10-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
PAc
PCc PBc
322
321
Bc Ac
LCc
304
511
(R) (H)
10-41
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(R) (R)
(H) (H)
520 514
Pc Dr2 321 319
Ab BH chamber
301 (D) 53
CRb1
Bb
PAb
PBb
10-42
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
P B1
326 10
325
305
Conflux passage
To Ab port of P1 casing
511
LCb2
56
10-43
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(R) (R)
(H) (H)
520 514
P c Dr2 321 319
Ab BH Cha mbe r
301 CRb1
Bb
PAb
PBb
BH Cha mbe r
Prb Pra
P Lc1
CBb CRe CRb2 CAb
56
322 320 313 516 513 511 312 320 322
10-44
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(R) (R)
(H) (H)
520 514
P c Dr2 321
Ab BH Cha mbe r 319
301 CRb1
Bb
10
PAb
PBb
BH Cha mbe r
Prb Pra
P Lc1
CBb CRe CRb2 CAb
56
320 320
322 313 516 513 511 312 322
10-45
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
ARM 1
P1
RR RH HH (D'') PAa2 PBa2
52 53 Dr Dr
ARM 2 CBa
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
(ROD)
To bypass cut valve
MU CTa
LCAT2 LCAP2 Ta
328 321 308 (D) 511 515
10-46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
RR RH HH PAa2 PBa2
(D) 52 53 Dr Dr
Arm 2 CBa
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
(ROD)
Ta
(D) LCAT2 LCAP2
328 321 308 511 515
10-47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
PAa2 PBa2
RR RH HH Dr Dr
(D) 52 53
Arm 2 CBa
To arm 1 spool
Aa (HEAD)
PBa2 PAa2 Ba
(ROD)
10-48
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
PBs
PAs
303
Bs As 321 322
LCs
(D) 56 511
B A
Swing motor
Swing operation
10-49
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
A A P Lc
(a ) S a Sb (b) Dr
RH S ECTION A-A
chambe r
P Bb
301
Dr
10-50
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
A A
P Lc (a ) S a S b (b) Dr
RH cha mbe r
S ECTION A-A
P Bb
301
Dr
10-51
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
208-104
(b)
520-102
520-101 (a)
(e)
(d)
(c)
10-52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
[Normally]
The adjusting screw (201) of the bypass cut valve (606) is tightened normally and apical tapered portion of the
adjusting screw (201) is pushed to the seating portion of casing. Then, the center bypass (52) and the low-pressure
passage (D) are blocked.
As a result, in the normal operation, the center bypass (52) are always blocked from the low-pressure passage (D),
the working fluid discharged from the hydraulic pump P1 at neutral does not pass the center bypass (52), but
returns to the working fluid tank through the P1 unloading spool (309). 10
201
(D)
52
10-53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
[At Failure]
When the electric control system is failed, the P1 unloading spool (309) remains at the neutral position. Because
the working fluid discharged from the hydraulic pump P1 is blocked by the P1 unloading spool (309) and the center
bypass (52) is blocked from the low-pressure passage (D) by the bypass cut valve (606), the pressure of pump P1
rise to the main relief setting pressure. However, the working fluid passed through the center bypass (52) passes to
the low-pressure passage (D) through the bypass cut valve (606) by loosing the lock nut and the adjusting screw
(201) of the bypass cut valve (606).
Thus, when the electric control system has failed, the P1 unloading spool is positioned at neutral to block the
passage to the low-pressure passage (D), but the center bypass (52) instead is communicated with the low-
pressure passage (D) through the bypass cut valve (606) to prevent the pump pressure from rising abnormally by
loosing the adjusting screw (201) of the bypass cut valve (606).
201
(D)
52
10-54
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[10. COMPONENTS SYSTEM]
5 2 7
5 2 8
( D ')
T 2 5 1 8
T 1
1 0 2
5 1 7 (D ) 5 2 7 5 2 8
T 2 5 1 8
In n o r m a l o p e r a tio n 1 0 2 T 1
5 1 7
(D )
In m a k e u p o p e r a tio n
10-55
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[10. COMPONENTS SYSTEM]
527
528
(D') T2
518
T1
102
517
(D)
10-56
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[10. COMPONENTS SYSTEM]
Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
POR T 1, 3 POR T 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)
S e conda ry pre s s ure [MP a (ps i)]
S e conda ry pre s s ure [MP a (ps i)]
0 5 10 15 19 0 5 10 15 20 25
1 3 2 4
HYDRAULIC SYMBOL
10-57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
312
M14
Apply Loctite #262 68.6±4.9 N .m
Application part (hatched area) (50.6±3.61 lbf .ft)
302
501 301
Apply grease on
Apply grease rotating and sliding sections.
on top section 246-1 Be careful the
212 assembling direction
246-2 213 M14
151 47.1±2.9 N .m
(34.7±2.14 lbf .ft)
218
211
214
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
10-58
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[10. COMPONENTS SYSTEM]
Lever in neutral
216-2
201-2
POR T (2,4) POR T (1,3)
10-59
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[10. COMPONENTS SYSTEM]
Lever held
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (241–2) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4) rises
above a set value, ports (2,4) and the P port close while
ports (2,4) and the T port open. When the pressure at
ports (2,4) falls below a set value, ports (2,4) and the P 241-2
port open while ports (2,4) and the T port close. Thus the
secondary pressure is kept constant.
T P ORT
Operation in the area where the tilting angle of the
P P ORT
lever is large. (varies with the model)
If the lever is inclined beyond a certain angle on certain
models, the top end of the spool contacts the bottom of POR T (2,4) POR T (1,3)
the bore of the push rod. This keeps the output pressure
connected with the P port pressure. When the lever is held
Furthermore, on a model in which a spring seat and a
spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever is turned
beyond a certain angle. This causes the secondary pressure gradient to change by the spring action. Thereafter,
the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure
connected with the P port.
10-60
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[10. COMPONENTS SYSTEM]
Outside view
10
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
Specifications
P T
Item Specifications
Part No. YN30V00105F2
Type 6TH6NRZ
Primary pressure 5.0MPa (725psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
10-61
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[10. COMPONENTS SYSTEM]
Performance characteristics
Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30'~ 11 30'~ Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
10-62
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[10. COMPONENTS SYSTEM]
5
3
8 10
3
11 12
4
10
9
9
7 6
2
10-63
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[10. COMPONENTS SYSTEM]
Tightening
Port
Symbol Port name torque
size N.m (lbf.ft)
A,B Main port PF3/4 167 (123)
DB Drain port PF3/8 74 (54.6) B
B PB
M DB
M Make-up port PF3/4 167 (123)
PR DB
PA,PB Pressure meaduring port PF1/4 36 (27.0)
A
PA
PR Parking break release port PF1/4 36 (27.0) A
Gear oil filler port
IP,L,AR serving also as level gauge PT3/4 98 (72.3)
and air breather port PB
PA
Lifting bolt 2-M12 IP, L, AR
Thread depth 24 (0.94")
Lifting capacity M
2160N (486 lbf)
A, B
PR
PR
DB
PA PB
Grease nipple
A B
Hydraulic diagram
10-64
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[10. COMPONENTS SYSTEM]
Specifications
Swing motor unit part No. YN15V00078F1
Type M5X130CHB-10A-4RA/295
10-65
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[10. COMPONENTS SYSTEM]
Swing motor
993
390 391
VIEW I
351
355
051
(051-1)
469
702
488
401 712
151
171 161 163 985 444 984 131
052
A A
I Arrangement of brake spring
162
451
303
985
472
707 712
702
980
706 743
100
111
742
121
400-1
123 994
052
400-2
122 400
124 443 491 101 114 301 SECTION A-A
10-66
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[10. COMPONENTS SYSTEM]
Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N・・m (lbf・・ft) N・・m (lbf・・ft)
0.9
301 Casing 1 980 Plug ; PF1/4 1
(0.7)
1.7
303 Valve casing 1 984 Plug ; PF3/8 1
(1.3)
4.4
351 Plunger 2 985 Plug ; PF3/4 3
(3.2)
65
355 Spring 2 993 Plug ; PT1/2 1
(48)
98
390 Name plate 1 994 Plug ; PT3/4 1
(72)
391 Rivet 2
10-67
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[10. COMPONENTS SYSTEM]
Apply Three
Bond #1211. Apply Loctite #515.
Paint this machined surface. Apply Loctite #515.
Tightening torque
181 N .m (134 lbf .ft)
12 10 20 8 4 7 6 23 Apply Three Bond 1360K
OIL FILLING POR T P T3/4
A
2
LEVEL
POR T P T1/2
A
II
1 9 22 18 17 5 18 14 3 16 15 28 19
21 29 11
Be careful about
Insert 1mm(0.04") deep from installation direction
Lubricate grease.
the surface of Item 8 (spider). of retaining ring.
13 27 26 25
Wind seal tape around plug and
install it (tightening torque Wind seal tape around tube and install elbow to tube
10N .m (7 lbf .ft)) to item 26 elbow with tightening torque 30N .m (22 lbf .ft) and then make
until its surface becomes direction of elbow as shown in drawing by retightening.
the same surface of elbow end.
Wind the seal tape or
Install grease nipple apply the Locktite #577
as facing to motor side. 30 31 around the screw.
Tightening torque
10.8N .m (8.0 lbf .ft)
Leave installation angle as it is.
Punch here 2 portions to deform holes in order to
prevent spring pin (22) from coming out.
VIEW II
4 places
SECTION AA
10-68
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[10. COMPONENTS SYSTEM]
Tightening Tightening
torque N・・m No. Parts Q'ty torque N・・m No. Parts Q'ty
(lbf・・ft) (lbf・・ft)
10-69
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[10. COMPONENTS SYSTEM]
10-70
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[10. COMPONENTS SYSTEM]
DIRECTIONAL VALVE
10-71
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[10. COMPONENTS SYSTEM]
R
Plunger (301) Orifice n Chamber g
Condition
10-72
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[10. COMPONENTS SYSTEM]
10
1. Neutral condition
Above Fig. illustrates the relationship between the
neutral condition of the anti-reaction valve and the
hydraulic circuits. L
Now, let us consider a braking condition in which
brake pressure generates on the AM port side.
k
322 313 321 311
Neutral condition
p t
P<PS
k
322 313 g r 321 311
10-73
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[10. COMPONENTS SYSTEM]
3. At anti-reaction action P Y
When inertia load stops moving (point Y below Fig.),
PS
brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the right
return side by the action of spring (321). Seat (313) PB
X
tries to move to the right by the action of spring Z
(322), but since chamber p provides damping action T
by orifice g, the return of the seat makes a time
delay with regard to the return of the plunger. Pressure change diagram of anti-reaction
Consequently, seat t opens. This makes a passage operation
connecting the AM port and BM ports or both ports
of the hydraulic motor by way of L→t→r→k. The result is that the pressures at the AM and BM ports become
equal (Pb), falling into the condition at point Z in below Fig.. This prevents the hydraulic motor from swing
shock by the closing pressure of the AM port.
10-74
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[10. COMPONENTS SYSTEM]
10
P la ne ta ry pinion
Planetary mechanism
For the operation of the 1st stage planetary, the hydraulic Swing motort
motor rotates #1 sun gear (2). Sun gear (2) is engaged
with planetary pinion (3) and rotates, but since ring gear 3 2
(7) is fixed, planetary pinion (3) revolves about sun gear 7
(2) with the planetary shaft and spider (28).
The role of spider is to hold the planetary pinion and 28
planetary shaft and transmits the power from the 5
planetary pinion to the spider through the planetary
shaft. 29
The #1 spider (28) is linked with #2 sun gear (5) by the
involute spline, and transmits the power to the 2nd stage 30
planetary mechanism. For the operation of the 2nd stage 6
planetary, the power is transmitted to sun gear 12
(5)→planetary pinion (6)→spider (29) similarly to the 1st
stage.
The #2 spider (29) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with the
swing gear fixed on the undercarriage (lower frame) and 11 1
rotates.
10-75
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[10. COMPONENTS SYSTEM]
Outside view
SPROCKET
INSTALLING FACE
Pm1 P1
T
Pm2
A
Tin
P2
Pp
Ps
LUBRICATION PORT
Specifications
Parts No. YN15V00051F5
Item
Type MAG-170VP-3800G-K10
Reduction ratio 1/43.246
Reduction unit Lube oil Gear oil SAE #90 GL4
Oil level L (gal) 5.0 (1.3)
10-76
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[10. COMPONENTS SYSTEM]
10
10-77
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[10. COMPONENTS SYSTEM]
Z3 Z3
17 22 23 19,20 21 24 26 23 25 17
X1 X1
28
S ECTION Z6-Z6
(1P LACE)
29
11 13 12 7 6 5 4 3 67 30 8 9 10 S ECTION Z5-Z5
(3P LACES )
65 66
Z6
Z4 Z4
Z6
33 34 15 14 14 15 34 33
18
S ECTION Z4-Z4 S ECTION X1-X1
10-78
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[10. COMPONENTS SYSTEM]
18 18 18
Z5 Z5
Z5
Z5
Z5 Z5
41 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96
10
52 87
60 90
51 91
69 92
62 88
89
93
32
31
50
68 94
95
59
56 97
98
64
83
60
84
57 63 58 55 54 1 36 46 70 47 49 53 71 99 77 78 79 80 81 82
10-79
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[10. COMPONENTS SYSTEM]
Tight- Tight-
width width
ening ening
across across
torque No. Name Q'TY torque No. Name Q'TY
flats flats
N・・m N・・m
mm mm
(lbf・・ft) (lbf・・ft)
205
1 FLANGE 1 12 52 CAPSCREW; M14X35 10
(151)
OIL SEAL;
2 BASE PLATE 1 53 1
TCZ50X72X9
(SPOOL)
3 1 54 DISK PLATE 3
PLUNGER
4 CHECK VALVE 2 55 FRICTION PLATE 2
5 SPRING 2 56 BRAKE PISTON 1
137*
14 6 PLUG; M24,P=1.5 2 57 O-RING 1
(101)
539* Torques
26 WASHER 1 76 BOLT; M20X70 8
(398) T90
2.45
2.5 28 ORIFICE; M5X0.8 1 77 THRUST PLATE 4
(1.81)
2.45
2.5 29 ORIFICE; M5X0.8 3 78 INNER RACE 4
(1.81)
2.45
2.5 30 ORIFICE; M5X0.8 2 79 NEEDLE BEARING 4
(1.81)
10-80
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[10. COMPONENTS SYSTEM]
Tight- Tight-
width width
ening ening
across across
torque No. Name Q'TY torque No. Name Q'TY
flats flats
N・・m N・・m
mm mm
(lbf・・ft) (lbf・・ft)
36.8
6 31 PLUG; PF1/4 4 80 PLANETARY GEAR C 4
(27.1)
47 BALL 2 95 COVER 1
73.4
48 PISTON ASSY 2 8 96 BOLT; M10X16 16
(54.1)
157
49 BALL BEARING 1 12 97 PLUG; PF3/4 3
(116)
10-81
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[10. COMPONENTS SYSTEM]
10-82
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[10. COMPONENTS SYSTEM]
27
29
28
53
37 C
10-83
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Functions
The function of double counter balance valve is described below.
• Overrun prevention function to control the speed of piston motor to the speed corresponding to the supply flow
rate when the piston motor speed is higher than the speed decided by the supply flow rate (hereinafter called
pumping action) due to the outer load.
• Braking function to gradually stop the piston motor revolution by forming the brake circuit by the use of crossover
relief valve and giving the braking force to the piston motor revolution.
• Shuttle valve function for high pressure selection to release the parking brake with the aid of self pressure.
Operation
1. Stop condition
(See Fig. “Construction of double counter balance valve (stop condition)”.)
When the control valve is at the neutral position (motor is stopped), M1 and M2 ports are locked by plunger (3)
and check valve (4) (hydraulic lock) and the motor stops rotating because the pressure does not flow through
P1 and P2 ports.
OIL PASSAGE B
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1
ORIFICE D3
3
4
10-84
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[10. COMPONENTS SYSTEM]
OIL PASSAGE B
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1 ORIFICE D3
SPRING CHAMBER 2
SPRING CHAMBER 1
8 21
21 4
5 4 3
10-85
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[10. COMPONENTS SYSTEM]
11-2
11
OIL PASSAGE B
11-5
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1
ORIFICE D3
Double counter balance valve and relief valve when piston motor is braked.
10-86
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
OIL PASSAGE D
OIL PASSAGE D
ORIFICE 50 47
10-87
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[10. COMPONENTS SYSTEM]
P RES S URE
10-88
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[10. COMPONENTS SYSTEM]
T1 T2
13,14
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
39
39 FACE B
2-SPEED FACE C M1 M2
CONTROL
PISTON THRUST (29)
PISTON
THRUST
SPRING
THRUST (34)
37
38 FACE A
1 38
10-89
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[10. COMPONENTS SYSTEM]
2. When switching the motor capacity to large capacity (low speed mode)
(See Fig. “When fixed to low speed (large capacity)”.)
When switching the motor capacity to large capacity (low speed mode), (See below Fig..) With turning the
speed control switch to low speed, by returning the pilot pressure oil acting on Ps port into the tank, 2-speed
control valves (13,14) is moved rightward by the spring (15) force until it comes into contact with plug (16).
Therefore M1 and M2 ports of the motor close, and oil passages A1 and A2 led to the 2-speed control piston
chamber F is led into motor case drain oil passages T1 and T2. And pressure oil in the 2-speed control piston
chamber F is led into the motor case drain, and the face C is pushed by the thrust of piston (29) and spring (34)
until the face B of swash plate (37) comes in contact with flange holder (1), consequently the tilt angle of swash
plate (37) becomes larger and the piston motor speed switches to low speed.
PS (PILOT PRESSURE)
16
T1 T2
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
39
FACE B
39
FACE C M1 M2
PISTON THRUST (29)
SPRING
THRUST (34)
37
38 FACE A
1 38
10-90
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
OIL
PILOT PRESSURE PASSAGE A MOTOR LOAD PRESSURE CHAMBER
OIL CHAMBER
T1 OIL T2
PASSAGE
B
Pin
M2 M1
10-91
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[10. COMPONENTS SYSTEM]
4. Low speed (large capacity) position (See Fig. “Low speed (large capacity) in Auto 2-speed”.)
The motor low speed condition at auto 2-speed position is shown in Fig. “Low speed (large capacity) in Auto 2-
speed”. When load pressure Pin to the motor is raised higher than the auto 1st speed return pressure, the
motor capacity control valve moves rightward, and is switched to the motor low speed (large capacity) mode,
that is, the motor low speed operation.
PS (PILOT PRESSURE)
T1 OIL T2
PASSAGE
B
Pin
M2 M1
10-92
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[10. COMPONENTS SYSTEM]
50 47 CYLINDER CHAMBER E
10-93
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-94
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[10. COMPONENTS SYSTEM]
D
F E A
C
10
D
VIEW Y
C
VIEW Z
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF1
Ports size
E PF1/2
F PF1/4
Length: L 371 mm (14.6 inch)
10-95
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[10. COMPONENTS SYSTEM]
VIEW Y
5
5 places
7 3 places
Tighte ning torque
3 30.4 N .m (22.4 lbf .ft)
10 Apply Loctite #242
4
11 2 places
Tighte ning torque
30.4 N .m (22.4 lbf .ft)
Apply Loctite #242
10.2.10.4 FUNCTION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove. The body
(1) and the stem (2) rotate mutually.
The oil flowing in from body (1) or stem (2) keeps on flowing to stem (2) or body (1) past the circumferential groove
between body (1) and stem (2) ; the oil flow is never shut off because of rotation. Further, an oil groove for
lubrication that connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem
(2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
10-96
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
General view
(-)
Type of conne ctor: e quiva le nt to AMP ECONOS EAL J s e rie s conne ctors
MARK II(+) cap hausing
(+)
Cap housing 174354-2 or equivalent 10
ELECTRICAL CIRCUIT Te rmina l 173706-1 or e quiva le nt
t1 P t2
LCo
BoR AoR
PAo P Bo
T
Dr
Ps
PBo
Bo Ao PL
HYDRAULIC CIRCUIT
LCo
Item Specification
10-97
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
701x2
901
B B
P Bo LCo
Bo
Ao
BoR
C C
D 271x2
PAo
AoR
703x4
271x2
201 321 161 302 SECTION BB
207
162
PL Ps Dr 163
PBo PAo
t1 P t2
602
BoR
AoR
PBo PAo
202
334
204 262 101 301 261 337 333 324 323 337
SECTION CC
10-98
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Tightening torque
Item Size Note
N・・m (lbf・・ft)
10-99
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
2-M10x1.5 VIEW B
Thread depth15
Item Specification
2.35 ( 341)
Effort to ope ra te
0 0 2 4 6 8 10 12 [de g]
Operating angle
Hydraulic circuit Control diagram
10-100
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10
10-101
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
1
2
29 5
20
8 9
11
32 12
22
16 18
28
26
3
25
Tightening
Item Size torque Note
N・・m (lbf・・ft)
18 - 24.5 (18.1)
21 M8 14.7 (10.8)
10-102
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
1 Shim 2 16 Body 2
2 Shim 2 18 Plug 1
3 Seat 1 19 Capscrew 1
5 Sleeve 2 20 Bolt 2
6 Cover 1 21 Setscrew 2
7 Piston 2 22 Washer 2
8 Spring 1 24 Pin 2
Spring
10
9 2 25 Ball 1
11 Shim 2 26 Ball 3
12 Shim 1 27 O-ring 2
13 Cam 1 28 O-ring 1
14 Boot 1 29 O-ring 2
10-103
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10.2.13 CYLINDER
10.2.13.1 SPECIFICATIONS OF CYLINDER
General View
B A
n gth ngth
ed le ed le
nd act
exte r etr
l l y ll y
Fu Fu
Specifications
Center distance of pins
Cylinder bore / Stroke Dry
Part No. of Full extend B / Full Cushion
Use Rod Dia. Unit: mm weight
cylinder assy retract A mm (inch)
Unit: mm (ft-in) (ft-in) [kg (lbs)]
Unit: mm (ft-in)
With cushion
Dia. 120 / Dia. 85 1,355 3,199 / 1,844 166
Boom YN01V00151F2 on rod side
(4.72”/3.34”) (4’5”) (10’6”/6’11”) (370)
R-50 (1.97”)
With cushion
135 dia./ 95 dia. 1,558 3,637 / 2,079 on both sides 255
Arm YN01V00175F4
(5.32"/3.74") (5’1”) (11’11”/6’10”) H-40 (1.57”), (562)
R-60 (2.36”)
Rod side
Dia. 120 / Dia. 80 1,080 2,675 / 1,595 143
Bucket YN01V00153F2 on rod side
(4.72”/3.15”) (3’7”) (8’9”/5’3”) (315)
R-50 (1.97”)
10-104
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
4-M10x1.5
[Effective thread depth: 18mm (0.71 inch) ]
4-M12x1.75
[Effective thread depth: 21mm (0.83 inch) ]
(-0.02")
(4.13")-0.5
105 0
22 23 23 22
PS1/8
PT1/4
10 20
9 8 7 6 3 4 5 12 11 2 1 13 14 16 17 24 19 15 21
[At installation,
pay attention to
orientation of slit.]
10-105
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
P/No: YN01V00151F2
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty
30
30 27 27
P/No: YN01V00175F4
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty
10-106
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
4-M12×1.75
[Effective thread depth: 21mm (0.83 inch)]
(-0.02")
(-0.02")
(4.13") -0.5
(4.13")-0.5
105 0
105 0
10
25 22 22 25
PS1/8
PS1/8
10 19
9 8 7 6 3 4 5 12 11 24 23 13 15 16 17 18 14 20
P/No: YN01V00153F2
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty
10-107
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Clearance "D"
Mouth gap C
10-108
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(D) DIODE
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 20 Diode ↑
D - 21 Diode ↑
D - 22 Diode ↑
D - 23 Diode ↑
D - 24 Diode ↑
E - 12 Battery YN72S00018F1
E - 15 Fusible link YB73S00001P1
E - 27 Accel redundant volume YN52S00106P1
E - 35 Glow ENG. ACCESSORY PARTS
E - 38 Resistor LC22E01001D1
E - 65 24V power socket LQ81S01001P1
E - 101 CAN resistor 1 PY26E01001P1
10-109
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(L) LIGHT
(M) Motor
(R) Relay
10-110
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
R - 28 Alternator relay ↑
10
R - 29 Wiper motor normal rotation relay YN24S00012P2
(SE) Sensor
SE - 102 Engine coolant temperature sensor (for ECU) ENG. ACCESSORY PARTS
10-111
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
(SV) Solenoid
(SW) SWITCH
10-112
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
C-1
Maker Sinko Electric Co., Ltd.
Controller
YN22E00488F1
Rated voltage DC24V 10
We ight 4.2 kg (9.3 lbs)
Mechatro controller
LQ16C10001–
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
C-2
Controller Maker Nippon seiki Co., Ltd.
Rated voltage DC24V
YN59S00039F1
Cluster gauge
YN15T17101–
YQ15–T3101–
C-4
Controller Maker SANDEN Co., Ltd.
Rated voltage DC24V
LQ20M00088F1
Rated imput power 215W
Air conditioner amplifier
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-113
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
D - 4, 25
Diode Maker's part No. 7321-9822
Repetitive peak voltage 400V
YN02D01001P1 (4P)
Mean output current 3A
Glow, Switch etc. Surge current 200A
YN15T17101–
YQ15–T3101–
10-114
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
E-1
Fuse capacity and circuit
Fuse & relay box
YN24E00036F2
Fuse & relay 10
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-115
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 10
Receiver dryer Maker SANDEN Co., Ltd.
Model 51440-A1300
LQ54S00005P1
IN SIDE
Air-conditioner
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001- OUT SIDE
YN15C10001-
PRESSURE SW .
YN15H10001-
APPLICABLE HOUSING MAKER’S P ART No.
YQ15C10001-
SUMITOMO WIRING SYSTEMS L TD. No. 6189-0094
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
E - 11
Maker's part No. 7360-6000
Air compressor
Rated voltage DC24V
YX91V00001F1
Max. revolution 4000rpm
Air-conditioner V belt Type B
YN12-56001- Refregerant R-134a
YQ12-08001- Oil SP-20:135cc(8.24cu .in)
LQ13-07001-
Cover (Clutch)
LL13-06001-
YF06-02501-
YU06-03001-
YF07-03001-
YU07-04001-
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-116
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 12
Battery Type N120
Volta ge 12V
YN72S00018P1
Capacity (5HR) 96Ah
Power Weight (Incl. fluid) Approx. 33.0kg (72.8 lbs)
YN15T17101– 502 (19.76") 10
YQ15–T3101–
180 (7.09")
E - 15
Fusible link Type Slow blow fuse
Allowable current 100A
YB73S00001P1
Fuse
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-117
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 27
Accel redundant volume Rated voltage DC 5V
Parts Volume TOCOS RV24YN
YN52S00106P1
Engine redundant device
Furukawa Denko equivalent
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
HOUSING : 172131-5
Fix resistor with the harness tape TERMINAL : 170340-1
after fixing the PVC tube.
NUT
VIEW I
SPRING W ASHER
PLAIN WASHER
E - 38
Resistor Maker Nihon Te ikouki.Co.Ltd.
Rated voltage 40W
LC22E01001D1
Insulation resistance DC500V /
Resistor 20M or more
LQ16C10001- Dielectric strength AC1500V .1Minute
LQ16H10001-
LL16C10001- CONNECTOR YAZAKI
LL16H10001- HOUSING
YN15C10001- TERMINAL
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-118
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 65
Type 433092-0002
24V power socket
Rated voltage DC 24V
LQ81S01001P1 Maximum current 5A
Socket Insulation resistance 1M or more / DC 500V megger
YN15T17101– Thermal fuse Fusing temperature180 to 210 degrees C 10
YQ15–T3101– ″ +″ te rmina l
Ground te rmina l
E - 101, 102
Resistance
Maker DEUTSCH JAP AN LIMIITED
Maker's part No. DT04-3P-P006
PY26E01001P1
CAN resistor 1,2
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-119
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
L-1
Light (Halogen) Va lve 24V,70W
YN80S00012F1
Boom working light left
YN15T17101–
CA104
YQ15–T3101–
M14 1.5
L - 2, 7, 8, 9, 15, 16
Type BL84-200
Light (Halogen)
Bulb DC 24V,70W
YT80S00002F2 Effe ctive a re a of le ns 69.2cm 2
Boom cylinder working
light
Deck working light (RH)
Cab working light front 1,
front 2,
front 3, front 4
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
L-5
Volta ge 24V
Light
Type RL-8700 Body
Lens
LQ02C00031S020
Room light Room light BATT
LQ16C10001- OFF ON
LQ16H10001- DR S W
ON
LL16C10001- 24V (Door)
LL16H10001- 10W (Connector) OFF
YN15C10001- DR
YN15H10001- Bulb
Circuit
YQ15C10001-
YQ15H10001-
YQ15–20001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-120
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
M-3
Motor Type 191-1 1H0-D
LQ53C00003S001
Wiper motor 10
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
M-4
Rated voltage DC 24V
Motor (Tank)
Injection flow 1.2L (0.32 gal) / min or more
YT54C00003F1 Capacity 1.5L(0.4 gal)
Washer motor Time ra te d Max. continuous 60 sec.
LQ16C10001- Injection nozzle 1 X 2 pcs.
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
PUMP
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-121
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
PSV - A, B, C, D, 23, 24
YN35V00048F2
Proportional solenoid YN35V00049F1 YN35V00051F1 YN35V00061F1
valve assy YN35V00048F2
Hydraulic symbol
Le ve r lock
Arm 2nd s pe e d
Boom2
Boom3
P 2 unloa d
S wing pa rking
10-122
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
R-1
At start 24V2000A(0.1 sec) VIEW A
Te rmina l A
Relay Ra te d volta ge / curre nt
At charge 28V120A(Continuous)
YN24S00008F1 Exciting current 0.4A or less / 24V Lock section
R - 4, 5, 6, 9, 11, 23-26,
28, 94 Maker TYCO ELECTRONIC AMP Co,.Ltd.
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-123
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
EN24S00008P1
Boom cylinder working
light relay (+ SIDE) (- SIDE)
Key ON holding relay
CIRCUIT DIAGRAM
YN15T17101–
Specification
YQ15–T3101–
Rated voltage: DC24
Insulation resistance: 1M or more by DC500V
insulation resistance tester
10-124
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Float
VIEW A
10-125
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 16
Tota l re s is ta nce
Accel potentio CONNECT OR (AMP)
Effe ctive e le ctrica l a ngle CAP HOUSING : 174359-2
LQ52S00025P1 TAB : 171661-1
RUBBER PLUG : 172888-2
Accel dial DOUBLE LOCK PLATE : 1-174360-1
M4×0.7 -5.9
m )
SE - 22, 23
Pressure range 0~50MPa(7250psi)
Pressure sensor (High
pressure) Ma x.a llowa ble pre s s . 120MPa(17400psi)
Operating source voltage 5+0.5V DC
YN52S00103P1
Insulation resistance 100M or more/DC50V megger
P1 PUMP (Between casing and terminal)
P2 PUMP
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-126
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
PF TIGHTENING TORQUE
73.5N .m(54.2ft-in)
SE - 60
Sensor Fluid Mineral hydraulic oil(ISO VG32,46,68)
Pro of pre s s ure 7.0MPa (1015psi)
YN52S00107P1
Range of oil temp -30 ~ 120 (-22~248 F)
Hyd. oil filter clogging
Port size JIS B2351 G1/2
sensor
Setting pressure 0.1±15 MPa (15±15 psi)
LQ16C10001-
Electric rating DC30V
LQ16H10001-
LL16C10001- Contact rating 100mA (Resistance load)
LL16H10001-
YN15C10001-
YN15H10001-
(1.06inch)
YQ15C10001-
27mm
YQ15H10001- G1/2
YQ15–20001-
LL16–10001-
YN15T17101– High pressure
YQ15–T3101–
10-127
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 99
Swing speed sensor Type TAG 209
LQ52S00032P1
Sensor
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001- HOUSING 7122-2830(Y AZAKI)
YN15C10001- CONTACT 7114-2630(Y AZAKI)
Electrical wire for automobiles AVS 0.5s q
YN15H10001-
A
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
A
YN15T17101–
YQ15–T3101–
Te rmina l function
10-128
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
SV - 1, 4
Rated pressure 5.0MPa(725psi)
Solenoid valve
(8sectional) Solenoid operated directional control valve Rated voltage:DC24V
P1,P2,T ,A1,A8Port PF3/8
Selector valve assy
Electromagnetic proportional valve
Dither current 100Hz,200mA
9Coil resistance 17.5Ω (at20
P-P
(68 F))
A2~A7Port
AMPmarkII
PF1/4 10
Hydraulic symbol
AMP mark II
See A1-A3
Conne ctor s pe cifica tion HOUSING Part No 174354-2 equivalent
TERMINAL PartNo 173706-1 equivqlent
YN35V00051F1
YN35V00061F1
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
SV - 2, 3, 105
Rated pressure 5.0MPa(725psi)
Solenoid valve
(3sectional) Solenoid operated directional control valve Rated voltage:DC24V
Selector valve assy
Hydraulic symbol
See A1-A3
(LQ35V00007F1)
16068–10100
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001- A3 A2 A1
YQ15–20001- SOL3 SOL2 SOL1
LL16–10001-
YN15T17101– T1 T2
YQ15–T3101–
PAC P
Circuit diagram A3 A2 A1 T
T
P
PAC
10-129
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
SW - 1
OFF AC
Switch C
Connection
ON
YN52S00026F1 Terminal
Position
Starter switch
S TA
Auto return
LQ16C10001-
RT
LQ16H10001- VIEW A
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
Te rmina l
YQ15C10001- arrangement
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
SW - 4
Switch Rated voltage DC 24V
Type Single-pole,single-throw type(alternate)
YN50S00040D7
Insulation resistance 1M or more/DC500Vmegger
Swing parking release
switch
LQ16C10001-
Connection
LQ16H10001-
LL16C10001- Term ina l
Positi on
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YN15T17101–
YQ15–T3101–
SW - 8
Switch
2450R163S1 RED BLACK
Air filter restriction switch JIS-D5403-104(CA)
YN15T17101–
YQ15–T3101–
JIS-D5403-104(CB)
PT1/8
10-130
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 10, 20
Type Incorporated in grip S W-10 : Incorporated in left grip
Switch Le ft a nd right s witch a s s e mblie s
Switch assembly YN50E00017P1
YN03M02619F2 a re s a me
Rated voltage, current 125V 3A AC
(right grip)
YN03M02619F1 Insulation resistance 100M or more / DC 500V megger
(left grip) 10
Horn, ATT power boost
YN15T17101–
YQ15–T3101– SUMITOMO WIRING SYSTEMS L TD. Housing : 6090-1031 (2P male)
SUMITOMO WIRING SYSTEMS L TD. Te rmina l : 8230-4282
Lead wire (ROBOT OP DP 3)
SW - 11
Switch Type Panasonic coporation:ABV19440F
YN50S00058P1
Lever lock switch
LQ16C10001-
LQ16H10001-
BLACK
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001- WHITE RED
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-131
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[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 22 SUMITOMO
HOUSING : 6098-0258
Switch
TERMINAL : 8230-4282
YX50S00004F1
Release switch (KPSS)
YQ15–20001-
LL16–10001- VIEW I
YN15T17101– ON 1 SIDE
( NORMAL)
YQ15–T3101–
ON 2 SIDE
(KPSS RELEASE)
UNIT SHAPE OF SWITCH
Specifications
CHARACTERISTICS OF CIRCUIT NUMBER OF
1.Rating : AC 125V 10A AC 250V 7A
CONTACY POSITION CIRCUIT DIAGRAM TERMINALS
DC30V 10A
2.Initinal contact resistance
CENTER
: 20m or less at DC2~4V 1A
3.Insulation resistance
ONqq NONE ONrr
:The valve between insulated terminals
18
and between terminal frames to be 100 M
or more at DC500V megger .
4.Dielectric strength
:Insulations between insulated terminals and
between terminal frame must be endured against
AC2000V for one minutes.
SW - 26
Switch Rated voltage DC 24V
Single pole single throw
YN50S00040D4 Type (alternate)
More than 1M /
Cab working light switch Insulation resistance DC500V megger UP
YQ15–20001-
LL16–10001- Te rmina l conne ctor
Connector
YN15T17101– Position
YQ15–T3101–
SW - 27
Purpose Coolant level detection
Switch
Working te mpe ra ture -40 ~130 (-40~266 F)
S8346-01510 Type of conne ctor
Engine cooling coolant Hino P/No. : S82580-7170
Sumitomo P/No. : 6188-01 10
level switch Electrode side
(To controlle r)
YQ15–20001-
LL16–10001-
YN15T17101– Housing side CONNECT OR
YQ15–T3101– (To ground)
Mating connector
Hino P/No. : S82580-7180
Sumitomo P/No. : 6189-0189
10-132
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 55
Switch Rated voltage DC 24V
Single pole single throw
YN50S00040D1 Type (alternate)
More than 1M /
Boom work light switch Insulation resistance DC500V megger UP
LL16C10001- 10
LL16H10001- Te rmina l conne ctor
Connector
YN15C10001- Position
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-133
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[10. COMPONENTS SYSTEM]
10-134
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
11-1
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[11. AIR-CONDITIONER SYSTEM]
11-2
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[11. AIR-CONDITIONER SYSTEM]
11
11-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air blows
off from grille through duct.
Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows in
the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation
is controlled by air mixing damper on the air-con unit.
11-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
25. 0 COMPRESSOR
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
11-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
41-2
42-2
41-1-1-15
41-1-1
42-1
41-3
41-1-3
41-1-2
42-4
42-4-2
42-3 42-4-1
42-4-7
42-4-8
42-4-6
42-4-3
42-1 Compressor 1
11-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
16
33 48 23 22 26 35 11
49
50 25 47 20 36
31
34 32 10
20 47
35
30 24
47 29 27 36
1 28 29
14
35
47 11
15 47 39
51
47
38 4
45
47 37
44
40
17
51
42
7 41
6
3 5
47
8 2 12
47 43
20 13
47
18
21 46
19
11-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
11-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
3
4
5
11
6
Receiver dryer
1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
3 DESICCANT 1
4 SUCTION PIPE 1
5 FILTER 1
6 RECEIVER TANK 1
11-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
AC UNIT
A
6 PLACES 24
TIGHTENING TORQUE
16.7~18.6N ~ m
(12.3~13.7 lbf .ft)
LENGTH OF
INSER T HOS E
28
(1.18”)
(1.18”)
14 VIEW XIV
13 VIEW FROM
THE TOP FLOOR
PLATE
A
A CLIP FOR
DRAIN HOS E
(42-4-6)
H S-H OS E
(0.59”)
(0.79”)
32 (42-4-3)
VIEW II HOSE LAYOUT UNDER FLOO R P LATE
11-10
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[11. AIR-CONDITIONER SYSTEM]
DIMENS ION TO
INS TALL RECEIVER
(3.15”)
F
39
VIEW XIII
BOLT FOR L-HOS E CONNECTION
K TIGHTENING TORQUE 7.8~11.8N~ m
30
D-HOSE G (5.90~8.70 lbf .ft) P ROVIDE CLEARANCE BETWEEN
25 THE RADIATOR HOS E AND D-HOS E.
TIGHTENING TORQUE
30 (1 .1 8”)
TIGHTENING TORQUE
23N~ m
(17.0 lbf .ft) 30
CLAMP THREE HOS ES
(S-H OS E · D-HOS E ·
HEATER HOS E).
11
/ ~ N 25 9
(17.0 lbf .ft)
(6.42”)
10
k
j 30
F
VIEW V
L L-HOS E (42-4-6)
N FOR RECEIVER INST BKT
CONNECT THE COMP RES S OR 31
HARNES S WITH THE ENGINE
M RECEIVER HARNES S .
TIGHTENING
TORQUE
23N~ m 25
(17.0 lbf .ft) TIGHTENING TORQUE 4.9N~ m
44 2 P LACES (3.61 lbf .ft)
2 P LACES
11-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
30 h
27
45 g
CLAMP USING THE HIGH
NUT OF UPP FRAME.
30
CLAMP USING
TIGHTENING TORQUE THE CLIP OF fCENTER OF
THE R-CLIP
/ ~ N UPP FRAME.
(34.3 lbf .ft) 30
32
30
CLAMP THREE HOS ES 27 TIGHTENING 30 46
SECTION AA (S-HOS E·D-HOS E·
HEATER HOS E).
45 TORQUE / ~ N
(34.3 lbf .ft)
40
30
(3.35”)
VIEW VII
(1.18”)
25 TIGHTENING TORQUE
.
23N~ m
12
(17.0 lbf ft)
29 INS TALLATION P ROCEDURE
FOR COMP RES S OR BKT:
TIGHTEN ITEM 25 AND THEN
27 TIGHTENING TORQUE LENGTH OF ITEM 26.
46.5N~~ m
LENGTH OF
INSER T HOS E
33 (34.3 TIGHTENING
lbf .ft) TORQUE 37 INSER T HOS E
23N~~ m
(17.0 lbf .ft)
38
22
29 D
(1.18”)
(1 .1 8”)
28
LENGTH OF INS ERT HOS E
15 11 8
ADJ US TMENT OF BELT
TENS ION (AT INITIAL BELT)
TENSION PULLEY ”) IT ADJ US TS S O THAT R MAY
98
(0 .
LOCKING NUT BE P US HED BY THE LOAD
TIGHTENING OF 28N(6.29 lbf) AND IT
TORQUE E MAY BEND 7 to 8mm(0.28 to 0.31”).
46.5N~~ m
(34.3 lbf .ft) (2 .5 (0 .6 28
6 ”) 1 ”)
23
APPLY THREEBOND
1110B ON THREADS .
TIGHTENING TORQUE
69.1N~ m
(51.0 lbf .ft)
CLAMP USING THE HIGH
NUT OF GUARD.
VIEW IV
11-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
32 (42-4-2) (42-4-3)
14 L-HOSE I 14
H S-HOSE (42-4-2)
S-HOSE H
13
13
(42-4-3)
L-HOSE I 14
I L-HOSE 30
30 (42-4-3) 30
SECTION DD
SECTION CC 30 S-HOSE H 13
14 (42-4-3) 14 (42-4-2)
(42-4-3)
L-HOSE 30 L-HOSE I
I S-HOSE H 13 SECTION FF
(42-4-2) 13 (42-4-2)
S-HOSE H
13
45 47
(42-4-1)
SECTION EE SECTION GG D-HOSE G
30
H S-HOSE
13 13
30 32 46
(42-4-2) 11
30
(42-4-1) D-HOSE G
D-HOSE G H S-HOSE (42-4-1) H
(42-4-2) S-HOSE
(42-4-2)
SECTION JJ SECTION KK
SECTION HH
(42-4-2)
S-HOSE H 30
30
(42-4-1) 30
G G D-HOSE
D-HOSE 13
32 32 (42-4-1)
G D-HOSE L-HOSE I
(42-4-1) (42-4-3)
I L-HOSE
(42-4-3)
SECTION LL
I L-HOSE
SECTION MM G (42-4-3)
D-HOSE
30
(42-4-1)
SECTION NN No. Na me Q'ty
SECTION PP
A Air-conditione r a s s y 1
30 (42-4-1) B P a ne l 1
D-HOSE
(42-4-2) G C Filte r 1
13
H D Air-compre s s or 1
S-HOSE
E P ully a s s y 1
FUEL F Conde ns e r 1
HOSE
D
COMPRESSOR L G Hos e a s s y 1
FUEL L-HOSE F
HOSE (42-4-6) CONDENSER H Hos e a s s y 1
I Hos e a s s y 1
I
L-HOSE J Ca ps cre w 2
(42-4-3) K Ca ps cre w 2
A L Hos e a s s y 1
A/C UNIT
H M Re ce ive r drye r 1
S-HOSE
SECTION QQ (42-4-2) A/C CIRCUIT DIAGRAM N Bra cke t 1
11-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
FOR WARD
CLIP A
CONNECT WITH
VIEW X ITEM B HARNESS. CONNECTOR FOR P OWER
S UP P LY OF A/C UNIT IS
B CONNECTED WITH
MAIN HARNES S .
A CLIP
FOR WARD
VIEW III
LAYOUT OF A/C HARNES S C ATTACH TO OUTS IDE AIR DUCT.
US E AND CLAMP
USE AND CLAMP THE L THE HOLE OF THE
CHARACTER CL IP OF 31 RELAY BOX
THE RELAY BOX BRACKET.
BRACKET. 31
HEATER-HOS E
11-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
S-HOSE : (42-4-2)
(10’7”)
(5’1”)
(29.1”)
(3’9”)
(18.5”)
(35.0”)
(17.7”)
(12.2”)
(0.94”)
(1.18”)
31 18 31
(2.80”) (0.39”) (10’2”) (0.39”)
D-HOSE : (42-4-1)
(8’10”)
(33.5”) 11
(20.1”)
(36.6”) (13.8”)
(26.0”)
(1.26”) (6.30”) (1.26”)
(0.75”)
(0.94”)
31 31
19
(1.02”) (0.39”) (8’6”) (0.39”)
L-HOSE : (42-4-3)
(8’11”)
(5’1”)
(3’8”)
(34.3”)
(18.1”) (35.0”)
(0.94”)
31
19 31
(2.76”) (0.39”)
(8’6”) (0.39”)
L-HOSE : (42-4-6)
(13.4”)
(1.18”) (1.18”)
31 20 31
(1.18”) (0.39”) (9.84”) (0.39”)
11-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
(0.83”)
(1.06”)
31 31
16
(7.87”) (0.39”) (9’8”) (0.39”)
(1.97”)
(0.83”)
(1.06”)
31 31
17
(0.39”) (6’7”) (0.39”)
(9.84”) (1.97”)
15
(0.94”)
(1.18”)
31 21
31 (0.39”)
(3.94”) (0.39”) (11.8”)
(1.97”)
11-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
8 V-belt 1 28 Clip 4
9 Bracket 1 29 Clip 2
10 Bracket 1 30 Clip 22
11 Bracket 1 31 Clip 18
12 Bracket 1 32 Clip 5
11-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
7
3
4 Capscrew: M8×25 2
5 Capscrew: M6×25 2
11-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
Flammability Nonflammable
Ozone destruction coefficient 0
*1 : 1MPa (mega pascal) equals 10.1972 kgf/cm2 (145psi)
11-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
Characteristics of Refrigerant
In general, the fluid (general term of gas and liquid) has the following qualities:
1. As a gas under certain pressure is cooled down, it
PRESSURE
begins to condensate at a certain temperature to MPa(psi)
take a liquid state. The temperature at which R134a
4(580)
condensation begins is unique to each substance
(fluid) at a given pressure. The temperature 3(435)
determined by a given pressure is called saturation LIQUID
temperature. 2(290)
1(145) GAS
0.5(75)
TEMPERATURE
[ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2. Inversely to 1) above, the pressure at which a gas condenses is determined by a given temperature. This
pressure is called saturation pressure. The graph in the figure “Pressure-temperature characteristics of R134a”
shows the relationships between the saturation temperature and the saturation pressure in the case of
refrigerant R134a used in the air-conditioner. At the temperature and the pressure on the lower righthand side
of the curve in the figure “Pressure-temperature characteristics of R134a” the refrigerant take a gaseous state,
while at the temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid
state.
Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant
evaporates, it absorbs evaporation heat from the air of the operator’s station. In order to cool the inside of the
operator’s station down to 25C degrees (77F degrees), the refrigerant must transform (evaporate) from a liquid
to a gaseous state at a temperature lower than that. It can be seen from the figure “Pressure-temperature
characteristics of R134a” that R134a under a pressure above the atmospheric pressure is capable of cooling
the inside of the compartment sufficiently. (If a refrigerant that requires a pressure below the atmospheric
pressure to cool the air to a required temperature is used, air is mixed into the circuits, thereby deteriorating the
performance of the cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state,
the refrigerant is cooled and condensed by the outer air exceeding 35C degrees (95F degrees). Therefore the
refrigerant is capable of condensing at the pressure of 1 MPa (145psi) or more, as seen from the figure
“Pressure-temperature characteristics of R134a”.
11-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
11-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
11-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly
overheated (3 to 8C degrees ) and goes out of the evaporator. This action is carried out by sensing the
refrigerant temperature at the outlet of the evaporator as against the inlet pressure of the evaporator and
consequently controlling the feed rate of the refrigerant.
This means that if the refrigerant pressure drop in
the evaporator is excessive, it is difficult to control
the overheating or the feed rate of the refrigerant.
For this reason, the smaller the pressure drop of the
evaporator, the better.
The expansion valve senses the pressure and the
temperature at the outlet of the evaporator and
controls the overheating of the refrigerant and the
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block
type expansion valve. Expansion valve outside view
Compressor
The compressor performs the following three functions in the cooling circuit: 11
1. Suction action
The suction action, as combined with the throttling D HOSE
action, works to decrease the refrigerant pressure in
the evaporator. This permits the refrigerant to
vaporize at low temperature in order to perform
S HOSE
cooling effect.
Compressor
2. Pumping action
The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This enables
continuous cooling.
3. Compressive action
The compressive action, as combined with the action of the condenser which is mentioned hereunder,
transforms vaporized refrigerant back to a liquid state again.
The saturation temperature gets higher as the pressure increases. Because of this, for instance, cooling down
the refrigerant by the use of external air of 35C degrees (77F degrees) to liquefy the refrigerant become
possible. The compressive action of the compressor works to turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then serves to cool down the refrigerant. Moreover, since the
compressive action takes place only for a short period, the refrigerant hardly exchanges heat with external air.
That is to say, it takes a form of close to adiabatic compression, so that the refrigerant discharged by the
compressor is high-temperature high-pressure vapor and is delivered to the condenser.
11-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
Condenser
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by the
use of external air and condenses the refrigerant. The
direction in which heat moves is from the refrigerant to
air, the opposite to the case of the evaporator. Fins are
equipped on the external air side to improve thermal
transfer. If the refrigerant is not cooled well by the
condenser, the air in the compartment can not be cooled
sufficiently by the evaporator. For that purpose, it is
necessary to secure ventilation required for the cooling
of the refrigerant.
Condenser
11-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
Receiver dryer
1. Receiver Tank
REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the INLET
compressor varies greatly which causes the proper
flow of refrigerant in the cooling circuit to vary. It is REFRIGERANT
OUTLET
the receiver tank that receives the variations. When
the cooling circuit does not need much refrigerant,
the receiver tank stores extra refrigerant temporarily
and supplies it when the cooling circuit needs much
refrigerant. The receiver tank also stores an extra
amount of refrigerant to be used for filling balance
and supplement small amounts of leakage of the
PRESSURE SWITCH
refrigerant through penetration into rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it deteriorates
the compressor valves and oil, corrodes the metallic
parts of the circuit or clogs the circuit as the water
freezes in the expansion valve. It is desirable that 11
the amount of water mixed in the refrigerant should
be held below a concentration of 30 ppm. The air-
conditioner uses a molecular sieve as desiccant DESICCANT
suited for the circuit, in order to absorb water
content that intrudes into the circuit when the dryer SUCTION
is installed or when refrigerant is charged. PIPE
3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the only FILTER
means of confirming the inside of the circuit visually.
4. Filter
5. Pressure Switch
This machine employs pressure switches of high/
low pressure type.
The pressure switch protects the circuit by cutting RECEIVER
off the power supply to the compressor when high TANK
pressure increases abnormally high [more than 3.14
MPa (460psi) ]. The pressure switch also detects
the leakage of refrigerant by cutting the power
supply to the compressor when the pressure of the
circuit falls below 0.2 MPa (28psi).
Receiver dryer
11-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
11-26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
2) Assembly
11
• Assemble the A/C unit in the reverse order of disassembly.
2. Disassembly and assembly of internal/external actuator
1) Disassembly HVAC Unit
• Remove the connector. Groove of
damper lever
• Loosen 3 tapping screws.
Lever pin
• Remove actuator as shown. Actuator
Ta pping s cre w
Conne ctor
2) Assembly
• Assemble the actuator in the reverse order of disassembly.
11-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
2) Assembly
• Assemble the relay in the reverse order of disassembly.
When performing the above-mentioned relay installation, put the cable of the inner air sensor in the position in the
following figure.
Inner sen s or A
SECTION AA
Con ne ctor 1
Connector 2
2) Assembly
• Assemble the inner air sensor in the reverse order of disassembly.
11-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
When performing the above-mentioned relay installation, put the cable of the inner air sensor in the position in the
following figure.
Inner sen s or A
SECTION AA
11
5. Disassembly and assembly of fan driver
1) Disassembly
• Disconnect connector from fan driver. Connector
• Loosen 2 tapping screws.
HVAC Unit
• Remove fan driver as shown.
2) Assembly
• Assemble the fan driver in the reverse order of disassembly.
6. Disassembly and assembly of link cover
1) Disassembly
• Loosen 4 tapping screws.
• Remove link cover as shown.
Link cover
HVAC Unit
Tapping screw
2) Assembly
• Assemble the link cover in the reverse order of disassembly.
11-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[11. AIR-CONDITIONER SYSTEM]
M o d e a c tu a to r
Mode actuator
HVAC Unit Tapping screw
2) Assembly
• Assemble the actuators in the reverse order of disassembly.
8. Disassembly and assembly of heater core
1) Disassembly
• Remove link cover. HVAC Unit
See the paragraph of “Disassembly and assembly Connector
of link cover”
• Disconnect connector from air mix actuator.
Air mix actuator
• Remove heater core as shown.
Heater core
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[11. AIR-CONDITIONER SYSTEM]
2) Assembly
• Assemble the heater core in the reverse order of disassembly.
11
HVAC Unit
Connection area of
evaporator sensor connector
2) Assembly
• Assemble the inner air sensor in the reverse order of disassembly.
To avoid damage, pull out evaporator sensor cord from groove of HVAC unit carefully.
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[11. AIR-CONDITIONER SYSTEM]
Thermistor holder
73mm
(2.87 inch)
Stay
Harness holder
Evaporator sensor
O-ring 1/2
O-ring 5/8
Expansion valve
Socket bolt
20mm
(0.79 inch)
Enlarged illustration of sensor
and thermistor holder
2) Assembly
• Assemble the expansion valve in the reverse order of disassembly.
• Prior to assembly, apply PAG oil to O-ring.
2) Assembly
• Assemble the evaporator sensor in the reverse order of disassembly.
• Install the harness holder and thermistor holder as shown.
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
HANDLING OF REFRIGERANT
Charging
1. When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low
pressure valve of the gauge manifold and warm the can in warm water of 40C degrees (104F degrees) or
below. If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply,
thereby the can explodes.
2. When charging refrigerant while running the engine, to avoid explosion, do not open the high pressure valve
(HI) of the gauge manifold.
If the high pressure valve is open, it is very dangerous because a high pressure gas flows in the reverse
direction, causing the service can and the charging hose to explode.
Others
• Reuse of service cans is prohibited by the regulation, so never reuse them.
• Do not allow foreign materials to enter the air conditioner circuit.
• Air, water, and dust are detrimental to the refrigeration cycle. Install the components of the air conditioner
correctly and speedily. Pay full attention to prevent water and dust from entering the refrigerant cycle.
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
Operation Chart
More tha n Le a ve it a s it is ,
30 min. for five minute s .
Be gin va cuum S top va cuum Che ck Cha rge Che ck for Cha rge
ma king ma king air-tightness re frige ra nt ga s le a k re frige ra nt
Lowe r tha n
-750mmHg Ga uge indica te s
a bnorma lity
Cha rge re frige ra nt ga s to a ga uge
Che ck a nd corre ct joints pre s s ure of 0.098 MP a (14.2 ps i)
Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1 23.5mm
(0.93 inch) side
Gauge
1 1
manifold
For service
5 T joint 1
can valve
Red :
high pressure
side
Blue :
Charging Service can For service
2 3 low pressure 6 2
hose valve can
side
Yellow :
vacuum pump
side
Vacuum
For vacuum
3 Quick joint 1 7 pump 1
27.5mm pump
(1.08 inch) adapter
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[11. AIR-CONDITIONER SYSTEM]
CHARGING
HOSE
(GAS VALVE)
• Do not mistake the high pressure hose for the low pressure hose in any circumstances when connecting them.
Put the hose in firmly till a clicking sound is heard.
• Some kinds of gauge manifolds are not equipped with an open/close valve in the center.
2. Vacuum making
LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes.
GAUGE MANIFOLD
3) When vacuum making for a specified duration is
over (degree of vacuum : less than - 750 mmHg),
close the high pressure valve and the low
pressure valve of the gauge manifold.
4) Then turn off the vacuum pump. DIS
SUC
3. Air-tightness Check
Close the high pressure valve and the low pressure valve of the gauge manifold, leave it as it is for more than
five minutes and make sure that the gauge indication does not return toward 0.
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[11. AIR-CONDITIONER SYSTEM]
If the gauge indication goes toward 0, there is somewhere that is leaking. Retighten pipe joints, make vacuum again
and make sure of no leakage.
BLUE RED
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge
manifold.) LOW PRESSURE HIGH PRESSURE VALVE
Then push the gas valve of the side service port VALVE(CLOSE) (OPEN) (CLOSE)
on the low pressure side of the gauge manifold, RED FILL IN 1~1.5 CANS
using a screw driver, in order to let out the air in BLUE OF REFRIGERANT
the charging hose by the pressure of the
DIS
refrigerant. YELLOW
(The operation ends when a hissing sound is SERVICE CAN
VALVE
heard.) (OPEN) (CLOSE)
CHARGE
SUC
3) Open the high pressure valve of the gauge manifold and charge in refrigerant. [Charge in gaseous
refrigerant to a gauge pressure of 0.098 MPa (14.2 psi).]
After charging, close the high pressure valve of the gauge manifold and the service and valve.
Use the leak tester for R134a. (Do not use one for flon gas service as it provides poor sensitivity.)
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[11. AIR-CONDITIONER SYSTEM]
2) Start the engine and run the revolution from 1400 to 1600rpm and close the cab door and the windows.
3) Turn on the air-conditioner switch, set the fan switch to Max and the temperature control switch to cool Max.
4) When charging gas, set the discharge pressure of the compressor from 1.37 to 1.57 MPa (199 to 228psi).
5) Open the low pressure valve of the gauge SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver disappear.
[Total amount of gas to be charged: 800 to 900g
(1.76 to 1.98 lbs)]
RECEIVER DRYER
Receiver dryer
6) When refrigerant charge is completed, close the low pressure valve of the gauge manifold and the service
can valve.
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[11. AIR-CONDITIONER SYSTEM]
HANDLING OF REFRIGERANT
• If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
• If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated. Moreover, the
circuit pressure gets abnormally high:
Always keep a proper level.
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
2 3
Blower controller
Relay
Four-electrode relay is used for the blower OFF relay
and compressor relay.
1. Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2. Compressor relay
The relay ON-OFF is switched by the control
amplifier and electronic thermostat control.
3. Relay specification and inspection
1) Coil resistance: 320Ω
2) Specified voltage: DC20V to 30 V
3) Be careful about the coil polarity of relay.
4) Inspection: Inspect the continuity between terminals 3 and 4 as follows.
20 to 30 V applied between terminals 1-2: Continued
20 to 30 V not applied between terminals 1-2: Not continued
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[11. AIR-CONDITIONER SYSTEM]
Motor actuator
Air mix actuator is located in at the center of air-con unit,
and opens and closes air mix damper through the link
motion.
The air mix actuator incorporates potentiometer which is
switched by linked shaft with actuator.
When the target air mix door position is determined Control panel Motor actuator
through the temperature control switch, the control unit
M
reads the level of potentiometer of the actuator. And it
determines the rotating direction of motor in either
normal rotation or reverse rotation. And the motor
rotates, the contact point is moved, and when the
contact point is detached or the output signal of control
unit turns OFF, the motor stops. Both motor actuators
(+ a t (6 ) a n d - a t (4 ))
O u tp u t v o lta g e
C ir c u it b o a r d c h a r a c te r is tic
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[11. AIR-CONDITIONER SYSTEM]
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[11. AIR-CONDITIONER SYSTEM]
A s now ma rk ( ) on A s now ma rk ( )
the panel is flashing. on panel is flashing. Check and correct or replace parts.
NO YES
11
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporator sensor are
disconnected or shorted.
See paragraph of monitor mode. . Controller failed.
A
NO YES
NO YES
NO YES
M/A stops halfway . Inspect and correct
ON/OFF and power circuit
of compressor clutch. Controller is faulty Check duct or
or inner air sensor eliminate cause for
is faulty. cool air intrusion.
Refer to troubleshooting
for refrigeration cycle.
Check and replace.
NO YES
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[11. AIR-CONDITIONER SYSTEM]
NO YES
NO YES
Check and replace.
Replace.
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[11. AIR-CONDITIONER SYSTEM]
NO YES
NO YES
Battery voltage is applied on between
white/green wire of blower motor relay
and ground wire. Eliminate cause Check and
of failure and then repair harness.
NO YES replace blower amplifier .
Note 1)
In the connector connected condition, measure the voltage.
Note 2)
When connecting the wires directly , turn of f the air conditioner , starter switch,
and light switches for safety .
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[11. AIR-CONDITIONER SYSTEM]
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 to 9.
NO YES
No Ye s
Re fe r to trouble s hooting
for re frige ra tion cycle .
Che ck clutch Check air conditioner
fus e s . harness for possible failure.
No Ye s
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
NO YES sight glass. is low.
Cooling does not work Oil comes out from
if refrigeration circuit is piping and parts.
operated at high speed. Compre s s or cylinde r Compressor cylinder
NO YES doe s not ge t hot. gets extremely hot.
NO YES
Expansion valve Expansion valve Natural Gas leaks
is clogged. is frozen or leak from from pipe
intruded by water. hose. joints and Expansion valve is Compressor does
parts. maladjusted. not discharge well.
Replace After performing (too much open)
expansion valve. air purge by Charge gas. Retighten
vacuum, refill or replace
refrigerant and parts. Replace Replace compressor
replace receiver. expansion valve.
High pressure
is low.
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[11. AIR-CONDITIONER SYSTEM]
Recirculation and
Recirculation and fresh air display is flashing
fresh air selection
Failure part of
Display of failures
sensor
18 degrees C: LO.E
·“E” is indicated on first decimal
Evaporator sensor 25 degrees C: 25.E
place of temperature indication
32 degrees C: HO.E
Detection of each sensor error by monitor mode function (for obtaining failure control status from the
control panel)
• When the air conditioner is in operating condition, press the internal and external air selector switch and main
power switch for one second or more simultaneously. And the display of monitor mode begins. To return the
display to previous display, perform the same operation.
• Normal condition, disconnection and short circuit of inner air sensor, evaporator sensor and solar sensor are
indicated in segment of display.
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[11. AIR-CONDITIONER SYSTEM]
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[12. DISASSEMBLING AND ASSEMBLING]
12
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[12. DISASSEMBLING AND ASSEMBLING]
12-2
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[12. DISASSEMBLING AND ASSEMBLING]
12
12-3
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[12. DISASSEMBLING AND ASSEMBLING]
ATTACHMENTS
1. Removing and Installing
2. Disassembling and Assembling
1) Cylinder
UPPER STRUCTURE
1. Removing and Installing
2. Disassembling and Assembling
1) Hydraulic Pump
2) Control Valve
3) Pilot Valve (ATT)
4) Pilot Valve (Travel)
5) Slewing Motor
6) Swivel Joint
TRAVEL SYSTEM
1. Removing and Installing
2. Disassembling and Assembling
1) Travel Motor
12-4
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[13. ATTACHMENTS]
13. ATTACHMENTS
13.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.............................................................13-3
13.2 PREFACE ............................................................................................................................13-4
13.3 REMOVING AND INSTALLING ATTACHMENT ......................................................................13-5
13.3.1 ATTACHMENT ASSEMBLY AND NAME .............................................................................13-5
13.3.2 BUCKET............................................................................................................................13-6
13.3.3 ARM..................................................................................................................................13-9
13.3.4 BOOM ............................................................................................................................. 13-13
13.4 DISASSEMBLING AND ASSEMBLING ............................................................................... 13-18
13.4.1 CYLINDER ...................................................................................................................... 13-18
13
13-1
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[13. ATTACHMENTS]
13-2
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[13. ATTACHMENTS]
13
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[13. ATTACHMENTS]
13.2 PREFACE
• This Manual describes all the procedures from removing to attaching, arranging them by item.
• This Manual consists of mainly 2 sections of "REMOVING AND INSTALLING ATTACHMENT" and
"DISASSEMBLING AND ASSEMBLING".
• The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
• The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
• Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
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[13. ATTACHMENTS]
(D) (C)
(A)
1
4
(F)
(E)
(J) 2
5
(G)
3
8 6
7 (K) (B)
(I)
(H)
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[13. ATTACHMENTS]
13.3.2 BUCKET
13.3.2.1 REMOVING BUCKET
1. Put the machine in position to remove bucket.
SECTION OF BOSS
13-6
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[13. ATTACHMENTS]
13
Attaching bucket
• When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
• Check the seals for damaged and replace as necessary.
• When inserting the pin, coat the shaft with grease.
13-7
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[13. ATTACHMENTS]
• When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
• Remove shims (9), push out bushing (7) rightwards by means of three capscrews (11) and adjust clearance (B)
so it settles within the standard value evenly all round.
13-8
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[13. ATTACHMENTS]
13.3.3 ARM
13.3.3.1 REMOVING ARM
1. Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket cylinder
and bring the arm down on the ground.
OIL PAN
13-9
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[13. ATTACHMENTS]
DETAIL bb
H 7
DUST SEAL
cc Apply Molybdenum
SHIM added grease
SHIM Install resin shim DUST SEAL
in the inner surface.
to bucket link side.
SECTION DD
DETAIL cc
G
Apply
Molybdenum
added grease
in the inner surface. 3
SECTION AA DETAIL aa
13-10
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[13. ATTACHMENTS]
aa 2
E
SHIM
SHIM SHIM
Tota l cle a ra nce of
3 Install resin shim
both side to be to cylinder side.
0.6~2.0mm (0.02~0.08in)
after adjusting by shims.
SECTION BB DETAIL aa
aa
SHIM
Tota l cle a ra nce of both s ide
to be 0.5mm (0.02in) or less
after adjusting by shims.
F
SECTION AA
13-11
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[13. ATTACHMENTS]
(0.02")
CLEARANCE
147 (108)
M16
Metric threads 279 (206)
13-12
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[13. ATTACHMENTS]
13.3.4 BOOM
PREPARATION
When removing and attaching the boom in the position shown in the figure "Position to remove boom", to remove
and install boom foot pin (A), removing and attaching of the cab and the guard on the upper structure are required.
BLOCK
STAND 13
13-13
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[13. ATTACHMENTS]
A A
7. Removing boom foot pin (A) Tota l cle a ra nce of both s ide s to be
0.5mm (0.02in) after adjusting by shims.
1) Remove capscrew (4) M20×40 and plate (3). SHIM
Tools: Spanner: 30mm
13-14
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[13. ATTACHMENTS]
D
D
SHIM
Tota l cle a ra nce of
both side to be
0.6~1.0mm
(0.02~0.04in)
after adjusting by shims. SECTION DD
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[13. ATTACHMENTS]
4) Removing boom cylinder foot pin (B) Tota l cle a ra nce of both s ide to be
(See the figures "Removing and installing boom 0.6~1.0mm (0.02~0.04in)
after adjusting by shims.
cylinder head pin (B)" and "Installing boom foot SHIM
pin (A)".) 5 SHIM
Remove nut (6) and capscrew (5) M16×150 and
B
pull out pin (B). SHIM
6 aa
Tools: Spanner: 24mm Install resin
shim to
5) Sling boom cylinder (2) and remove it. Apply Molybdenum cylinder side.
Weight of boom cylinder: 166kg (366 lbs) added grease
in the inner surface. DETAIL aa
5
6) Remove another boom cylinder the same way. Apply Molybdenum added
grease in the inner surface. B
6
SECTION AA
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[13. ATTACHMENTS]
13
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[13. ATTACHMENTS]
WORK AREA
The following working area is required for disassembly:
1. Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this
reason, the first condition is that the working area is long enough for the work. In terms of width, it is also
necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the
work can be performed.
2. Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and
plastic materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt,
and in particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is
assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube
inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and
welding operation should not be performed in the neighborhood of the working area to keep it clean.
APPARATUS
The following equipment are required for disassembly:
1. Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
2. Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in
its most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder
head and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently
large.
3. Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to
prevent damage of seals.
4. Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil
leak tests after completion of assembly.
5. Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
6. Cleaning bath, cleaning oil and detergent
7. Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
8. Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
13-18
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[13. ATTACHMENTS]
NECESSARY TOOLS
The tools and jigs to be used depend on the cylinder to work with. Prepare necessary tools referring to the table
below as a rough guideline.
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place of a
gimlet.
Chisel Flat chisel Special jig 1. For removing and press-fitting bushing. (A),
(D), (C)
2. For press-fitting wiper ring. (D)
• For the details of special tools and jigs, refer to the back pages of this manual.
EXTERNAL CLEANING 13
The cylinder taken off the excavator has dust and foreign
matter, and grease is usually adhered to the clevis part.
For this reason, remove external soil and contamination
from the cylinder with water and steam before bringing it
into the workshop. Cylinder gauge
• The following describes the construction of boom
cylinder. When disassembling and servicing the cylinder, confirm the construction of cylinder referring to Parts
Manual.
13-19
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[13. ATTACHMENTS]
DISCHARGING OIL
Place a wooden-block on the work bench and place the WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time,
V BLOCK
connect a suitable hose to each port so that the hydraulic
oil may not gush out. PORT A
AIR
OIL PAN
Preparation
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[13. ATTACHMENTS]
PS1/8
PT1/4
SLIT 15
ONE HOLE
DETAILA DETAIL B
DETAIL C
Piston with piston nut type
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23
C
A
13
In case of piston with piston nut type, the parts with * are not used.
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[13. ATTACHMENTS]
13.4.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder, check the construction and the availability of service parts as
well as necessary tools and jigs on separate Parts Manual.
• The figures in parentheses after part names correspond to those in Fig. "Construction of general cylinder"
• The following explanation and quantities are for a general use cylinder which has separated piston and piston
nut. In case that piston and piston nut are combined, the construction differs from separated type, refer to the
sentence in parenthesis.
Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside
piping as a locking means.
3. Loosen and remove socket bolts (12) of the rod cover in sequence.
Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged during operation.
4. Strike the corner of the rod cover flange by means of ALLEN WRENCH 12
a plastic mallet till rod cover (3) comes off.
Turn counterclockwise
3
Cover here with cloths
2
• At this time, the weight of piston rod (2) is loaded on KNOCK THIS EDGE
rod cover (3). Therefore, lift the top end of the piston WITH A PLASTIC MALLET.
LIFT HERE.
rod with a hoist to the extent that only the rod weight
may be held.
3
2
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[13. ATTACHMENTS]
5. Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
HORIZONTALLY
OIL PAN
Since the piston rod assy is heavy in this case, lift the tip of the piston rod (2) with a hoist and draw it out. However,
when piston rod (2) has been drawing out to approximately two thirds of its length, lift it in its center to draw it
completely. However, since the plated surface of piston rod (2) is lifted, do not use a wire rope which may score the
surface, but use a strong cloth belt or a rope.
WOODEN V-BLOCK
(PLACE CLOTHS)
19
18
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[13. ATTACHMENTS]
WOODEN V-BLOCK
(PLACE CLOTHS)
• Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston
(15), though the rod diameter is the same.
• It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is used, put cloths
or something over the rod to prevent it from damage.
21
23
TURN COUNTER
CLOCKWISE.
15
EYE WRENCH
21
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[13. ATTACHMENTS]
• Since piston nut (21) and piston (15) is tightened by a strong torque, use an eye wrench of proper size for the
outside diameter of piston nut (21) and "piston (15) hexagonal part" and use a power wrench using a hydraulic
jack or hydraulic cylinder.
• In case that piston and piston nut are combined, apply the eye wrench to hexagonal part of piston and loosen the
piston directly.
4 15
In case that piston and piston nut are combined, the shim (20) is not used.
3 4 6 8,7 9 2
Take care so rod bushing (4) and the lip of packings (6,7,8,9) may not be damaged by thread of the piston rod (2).
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[13. ATTACHMENTS]
Cut the seal ring (16) by tapping it with a screwdriver or a chisel. Take care not to strike it too hard, otherwise the
groove may be damaged.
11
2. Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(8). Each seal is fixed in the groove on the bore and
removing in flawless is impossible. Stab each seal
with a gimlet and pull it out of the groove. 8
3 7
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[13. ATTACHMENTS]
3. Remove wiper ring (9). When taking out wiper ring HAMMER SCREW- 3
(9), fix rod cover (3) in a vise. DRIVER
WOOD PIECE
WOOD PIECE
VISE
BLOCK TOOL C
13
24 BASE
2. Push out pin bushing (24) press fitted in cylinder tube (1) and piston rod (2) with press.
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[13. ATTACHMENTS]
13.4.1.4 CLEANING
1. After disassembly the cylinder, wash all parts with commercial detergent.
Never use benzene (gasoline, thinner, etc.) because it may be damage the rubber, etc.
2. Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after inspection.
3. After cleaning, dry all parts by compressed air, and put them on the working bench taking care not to damage
them.
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[13. ATTACHMENTS]
2. Press fit wiper ring (25) in the upper and lower sides of cylinder tube (1) and piston rod (2) respectively with
press.
• Before press fitting, apply grease on wiper ring and boss hole.
• Before press fitting the pin bushing, align the position of oil hole.
13
ASSEMBLING OF PISTON ASSY
1. The fitting of seal ring (16) requires special tool as PRESS HERE METAL (G)
shown in right Fig. Seal ring (16) is pushed in by
PRESS JIG (E)
press, etc. with pushing in tool as shown in the
figure. (The O-ring of seal ring (16) and back-up ring
(17) on one side should be installed beforehand.) SLIDE JIG (F)
15
16 O-RING
17
Heat them, and they may be soften. But never heat them over 100C degrees (212.0F degrees) or more.
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[13. ATTACHMENTS]
2. Fit back-up ring (17) on the other side. After fitting it, PRESS HERE
correct seal ring (16) immediately by correctional jig 16 17
(H) as shown in the figure "Correcting seal ring (16)"
to prevent it from remaining in an expanded CORRECTIONAL
condition. JIG (H)
• For piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully.
• After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston (15) is inserted
in cylinder tube (1).
• Fit slide rings (18) (19) at the same time when piston (15) is inserted in cylinder tube (1).
The snap ring (5) can not be fitted when the bushing (4) is not press-fitted fully to the stop end.
2. Apply grease to wiper ring (9), and fit wiper ring (9), PRESS HERE. (STRAIGHT DOWN)
directing the lip side toward the groove of retainer
tool (D). And set retainer tool (D) on rod cover (3) RETAINER TOOL (D)
and press fit wiper ring (9) with press.
U-RING GROOVE
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[13. ATTACHMENTS]
3. Fit buffer ring (6), back-up ring (8) and U-ring (7) in PUSH BAR (WOOD OR PLASTIC)
their grooves in that order. Before setting packings, 10
coat them with hydraulic oil (or vaseline if not
11
available). If you forget the coating, the packings Tube side
may be scored. 3
When attaching seals, deform them in a heart shape
as illustrated.
7
8
9
13
• U-ring (7) is harder than other packing and it would be difficult to deform them in a heart shape. In such a case,
put a U-ring in the groove obliquely by hand as deep as possible and push in the last part with a push bar till it is
set with a click.
• Buffer ring (6) should be fitted taking care of the fitting direction. The reverse fitting may cause deformation,
damage, etc. of the piston due to high pressure generated between the buffer ring and U-ring.
• If U-ring (7) is set upside down, the lip may be damaged. Check the correct orientation of U-ring (7) shown in the
figure "How to fit U-ring (7)"
• Attach back-up ring (11) on the open air side of O-ring (10).
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[13. ATTACHMENTS]
2. Install rod cover (3) on piston rod (2) by using inserting guide jig (I) as shown in the figure "Inserting rod cover
(3)" paying attention for the lip sections of the wiper ring and the U-ring not to be caught on the stepped
section.
• For the rod the outer diameter of piston installing section is small, insert spacer on the faucet section of rod first,
and attach inserting guide jig.
• Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the insertion smooth.
2. When cushion is installed on the retraction side, fit Direct slit toward
cushion bearing (13) and cushion seal (14) by the thread side
following procedure. THREADED PART
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[13. ATTACHMENTS]
• Cushion seal and cushion bearing should be fitted taking care of the fitting direction.
If they are fitted in reverse directions, the cushion does not effective.
• After installing cushion, be sure that the cushion bearing moves up and down, and right and left.
• In case that piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to hexagonal
part of piston and loosen the piston directly.
• Always correct the threads in piston nut (21) or [piston (15)] before fixing piston nut, using a tapping.
• Insufficient tightening torque causes an inner leak and a damage of thread. And over tightening torque causes a
bulge of cushion bearing and a deformation of piston contacted surface.
• Clean and decrease (with solvent) the parts of piston assembly, and dry it, then tighten this piston assembly.
13
4. Put steel ball (23) into hole and tighten setscrew ANTI-LOOSENING
(22). 22 CAULKING 20
2
Tools: Allen wrench: 6mm 23
After tightening the setscrew to a specified torque,
caulk the two places of the thread of the piston nut
side to secure the setscrew. See "TIGHTENING
TORQUE" described later for the tightening torque.
V-BLOCK
21
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[13. ATTACHMENTS]
21 V-BLOCK
OVERALL ASSEMBLY
1. Place a V-block on a work bench (A wooden V-
1
block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar LIFT
through the clevis pin hole to lock the assy.
STRAIGHT
PREVENT TURNING
WITH WOODEN BAR.
2. Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy with a hoist. In
this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube mouth and the circumference of
the piston. Align the center of the piston rod assy with the center of the cylinder tube assy and put it in straight
forward.
When inserting, make sure that slide rings (18), (19) on the perimeter of the piston is not out of the groove.
3. Tighten socket bolt (12).
12
Match the bolt holes of the rod cover flange to the
threaded holes in the cylinder assy, and screw in PLACE CLOTH
socket bolts (12) one by one. Tighten the bolts to a
specified torque, taking care so the bolts may not be
tightened unevenly. See "TIGHTENING TORQUE"
described later for the tightening torque.
Tools: Allen wrench: 14mm
ALLEN WRENCH
TURN CLOCKWISE
Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod surface with cloth is
recommended to prevent damage to it.
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[13. ATTACHMENTS]
H R
HYDRAULIC CYLINDER
• Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) for the cylinder of the
machine.
• Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest the cylinder in
such a case.
LEAK TEST
1. Apply a test pressure to the retracting and extending
sides of the cylinder for 3 minutes independently to MEASURE THE
check the rod part, the welded part and others for INTERNAL LEAK. 13
external leakage and permanent deformation.
Furthermore, regarding an internal leak test,
perform it by connecting the cylinder with a test unit
as shown in the figure "Internal leak test".
2. After completing the test, apply a plug to each port
and store the cylinder. (See the figure "Cylinder FROM DIRECTIONAL VALVE
storing method".)
Internal leak test
PLUG PLUG
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[13. ATTACHMENTS]
Inspection Item
REPAIR METHOD
Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores on the
piston rod, observe the following procedure:
1. Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2. In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone. If
the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1 mm (0.004 in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
LIMIT OF SERVICEABILITY
Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod that have no
such damage as may degrade the sealing effect.
1. Clearance between piston rod and rod bushing
Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm (0.01in).
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[13. ATTACHMENTS]
Even if the bend is within the above limit, the cylinder may not operate smoothly because of localized bend. Beware
of it during function test after assembly. Replace the rod if the cylinder makes a squeaking noise or dose not
operate smoothly.
TIGHTENING TORQUE
B A C A B C
Cylinder Piston nut or
Socket bolt Setscrew
[Piston]
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[13. ATTACHMENTS]
13.4.1.8 TROUBLESHOOTING
Trouble Failed Parts Cause Remedy
Oil leak through sliding Back-up ring Foreign matter is trapped in the Remove foreign matter.
surface of piston rod. Oil ring bore of back-up ring.
is formed on piston rod, and
Lips on outer and inner diameter Replace back-up ring.
the ring grows up to oil drops,
surfaces of back-up ring are
and they drip.
scored.
Other back-up ring are failed. Replace back-up ring.
OIL LEAKS FROM HERE U-ring Foreign matter is trapped in the Remove foreign matter.
bore of U-ring.
Piston rod Score is present on the sliding Smooth out the sliding surface with an
surface of piston rod. oilstone. If leakage occurs even if the sliding
surface is finished below 1.6S, rod packings
may be scored. Disassemble and inspect it
and replace rod packings as required. If leak
will not stop by that treatment, replace piston
rod.
Hard chromium plating has Replate.
peeled off.
Oil leaks from welds. Cylinder tube Welds of cylinder are broken. Replace cylinder tube.
WELDS
Cylinder falls by it-self. Piston seal Foreign matter is trapped in the Remove foreign matter.
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the
Score is present on the sliding Replace seal ring.
maximum working pressure
surface of seal ring.
multiplied by the area of the
cylinder bore, the maximum Slide ring Sliding surface of slide rings is Replace slide ring.
movement of the piston is scored.
more than 0.5mm (0.02") in
Piston rod Piston rod and piston are Replace piston rod.
ten minutes.]
elongated. (Loose nut)
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[13. ATTACHMENTS]
Application Shape
A D
D
For press fitting wiper ring
E H
F
I
For inserting rod cover 13
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[13. ATTACHMENTS]
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[13. ATTACHMENTS]
12-S
5(0.20 ") Unit : mm (inch)
C2(0.08 ") R2(0.08 ") R0.2 (0.008 ")
10 12-S d D Cylinder Used
-0.008"
-0.4 -0.016"
-0.158"
-0.020"
-1 -0.040"
-0.118"
D -0.2
D -0.5
D -3-4
Unit : mm (inch)
B Cylinder Used
13
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[13. ATTACHMENTS]
4 5 (0.197")
(CHUCK)
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[13. ATTACHMENTS]
A L L E N W R E N C H
A
13
3. Attaching tools for retainer
Put retainer on the press bench directing the wiper
ring fitting section of rod cover upward, then put D
retainer tool (D) on the rod cover.
FLANGE
• Fit retainer tool as shown in the right figure directing
large diameter section (flange section) upward.
• Clean the surface of press bench, and take care for
the tool bottom face not to be damaged by foreign
matter like dust, chip, etc.
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[13. ATTACHMENTS]
CHUCKING JIG A
D
15 (0.59") 15 (0.59")
d 10
10
Unit : mm (inch)
Class
d D h
(Nominal size)
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[13. ATTACHMENTS]
6. Removing of bushing
1) Move block (C) and rod cover (3) with tool under
the press.
2) Press the upper part of retainer tool (D) slowly
until bushing (4) is take out from rod cover (3)
D
(until there is a sound that the chuck tool (A)
drops on the work bench)
The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32 to 52 mm
(1.26 in to 2.04 in).
(But it varies according to the difference of
dimension of cylinder head.)
• Press it with retainer tool (D)
When the block and rod cover assy are not
aligned, interrupt the work and align the block
and rod cover assy.
13
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[13. ATTACHMENTS]
8. Removing of bushing
1) Place chuck tool (A) with bushing (4) sideways,
and loosen adjuster bolt with allen wrench and
lever.
A D J U S T E R B O L T
C H U C K
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[13. ATTACHMENTS]
13
3
ADJUSTER BOLT
WEDGE
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[13. ATTACHMENTS]
S T E P O F W E D G E
RETAINER(D)
CHUCK(A)
BUSHING(4)
BUSHING PRESS-
FITTING PART
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[13. ATTACHMENTS]
5. Press-fitting of bushing
Push the head of retainer (D) with press, and press
fit bushing (4) to the specified position of rod cover
(3) slowly.
• The pressing force should be held 5 tons (11025 lbs)
or less, keeping the required force for the press-fitting. STEP OF WEDGE
• Raise the pressure gradually adjusting the force by
means of pressure adjusting valve of press unit.
• Be sure that the end face of bushing is located on the
interior of the groove for snap ring. When it is located
on near place, press fit and adjust the location again.
LIFTING THREAD
ADJUSTER BOLT
WEDGE
13
CHUCK TOOL ASSY (A)
CHUCK
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[13. ATTACHMENTS]
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[14. UPPER SLEWING STRUCTURE]
14-1
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[14. UPPER SLEWING STRUCTURE]
14-2
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[14. UPPER SLEWING STRUCTURE]
14
14-3
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[14. UPPER SLEWING STRUCTURE]
14.2 FOREWORD
1. This manual describes all the procedures from removing to attaching, arranging them by item.
2. This chapter consists of the first half, "REMOVING AND INSTALLING ASSEMBLY", and the second half,
"DISASSEMBLING AND ASSEMBLING COMPONENT".
3. The removing and installing can be performed in the order specified in TABLE OF CONTENTS, but in view of
actual repairing or time saving, some processes can be omitted.
4. The removing and installing procedures of assembly parts do not completely cover all possible situations
because of differences of field condition and defective section, and limitation of editing. We hope for your
understanding about this.
5. Recognize well that a service man must decide a work procedure before proceeding to repair.
When removing, installing, disassembling, or assembling procedure is required, choose an item that is needed,
familiarize yourself with the contents of the work and itemize the work procedure, before starting work.
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove head rest (A1-1) of operator's seat (A1) for easy handling.
• Move the whole control stand to its foremost position.
• Move the whole control stand to its foremost position.
• Incline the reclining seat as forward as possible.
Rail displacement
Upper rail.....Fixed at the lower surface of the seat (forward direction: 80 mm (3.15 inch) and rear direction: 80 mm
(3.15 inch))
Lower rail.....Fixed at the seat stand (forward direction: 60 mm (2.36 inch) and rear direction: 60 mm (2.36 inch))
Adjustment amount of seat height: (upper: 23 mm (0.91 inch) and lower: 37 mm (1.46 inch))
B2
14
Tightening torque
Name
N·m (lbf·ft)
14-5
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[14. UPPER SLEWING STRUCTURE]
14.3.2 CAB
14.3.2.1 REMOVING CAB
1. Remove the floor mat. A48
2. Removing cover assembly (A36)
FOR WARD
14-6
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[14. UPPER SLEWING STRUCTURE]
FOR WARD
1) Remove five sems bolts (D5) and (D6) M6 x 16. Removing mechatro controller and relay box
assembly (C2)
Tools: Socket: 10 mm
14
FOR WARD
14-7
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[14. UPPER SLEWING STRUCTURE]
E1
E1
F3
F3
Slinging cab
14-8
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[14. UPPER SLEWING STRUCTURE]
14
14-9
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[14. UPPER SLEWING STRUCTURE]
Follow the procedures for removing and installing the battery cable.
Disconnect the battery cable at the ground side first but when connecting the battery cable, connect it to the ground
side last. If these procedures are not followed, it may cause a short circuit resulting in spark.
B1 B2
B6 B3
C1
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[14. UPPER SLEWING STRUCTURE]
1) Install cable (A3) last. Check carefully that the grounding face of the machine body is free from painting and
rust, etc.
Tools: Wrench: 13 mm
14
14-11
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[14. UPPER SLEWING STRUCTURE]
14.3.4 GUARD
14.3.4.1 REMOVING GUARDS
1. Release all the locks with the starter key.
B2 E1
2. Removing bonnet assembly (B1) and cover C5 D2 C1
assembly (B3)
D1
1) Release the lock of bonnet (B1) and open bonnet
(B1).
E E
B
B14
B11 VIEW II
SECTION BB
B11 9 B14
SECTION EE
B14
II B3
SECTION DD
B14 VIEW I
Removing and installing bonnet assembly (B1) and cover assembly (B3)
14-12
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[14. UPPER SLEWING STRUCTURE]
C3
C13
SECTION BB
D2
B5 B1 14
A
B
14-13
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[14. UPPER SLEWING STRUCTURE]
To open and fix the bonnet, hook up stay (B5) at the A position of cover (D2) and even if cover (D2) is removed, by
hooking up stay (B5) to the second holder (B position), bonnet (B1) can be kept open.
The second holder (B position) is located at the front of the counterweight. Use this as required such as when
maintaining the area around the muffler.
C12
C5
FOR WARD
14-14
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[14. UPPER SLEWING STRUCTURE]
FOR WARD
C12 C6
SECTION BB
FOR WARD
C8
C12
C12 C7
SECTION AA
14
C12
C4
DETAIL aa
14-15
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[14. UPPER SLEWING STRUCTURE]
D15
FOR WARD
D3 D4 D5
D15 D15
D13
SECTION AA
14-16
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[14. UPPER SLEWING STRUCTURE]
D9
D16 D10
A12
VIEWéé
VIEWèè
14-17
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[14. UPPER SLEWING STRUCTURE]
F1
FOR WARD F3
F3
E1 E5 E4 E6
14-18
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[14. UPPER SLEWING STRUCTURE]
9
9
11
9 FOR WARD
14
14-19
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the guards and the components which need to be removed to remove the fuel tank. (See Paragraphs
"REMOVING AND INSTALLING GUARDS", "REMOVING AND INSTALLING AIR CLEANER", and "REMOVING
AND INSTALLING RADIATOR AND OIL COOLER".)
1. Draining fuel
B1
A6
A3,A4,A5
A7,A8
A9
A1
14-20
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[14. UPPER SLEWING STRUCTURE]
If the clearance (gap) between the tank mounting base and the frame is 1 mm (0.04 inch) or more, adjust the
clearance with shim (A3) and then tighten the bolts.
• At installation, use the reverse order of removal with the tightening torques in the tightening torque table.
Tank mounting bolt (A1) M20 x 50
Tools: Socket: 24 mm, apply Loctite #262
Tightening torque
Tightening torque
Item Name
N·m (lbf·ft)
14
14-21
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[14. UPPER SLEWING STRUCTURE]
C1
Removing guards
Air breather
Element No.
YN57V00010S002
14-22
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[14. UPPER SLEWING STRUCTURE]
14
A14
A13 A3
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[14. UPPER SLEWING STRUCTURE]
14-24
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[14. UPPER SLEWING STRUCTURE]
B4
D2
14
D1
14-25
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Clean the hydraulic oil tank.
• Clean the suction hose.
• Clean the tank mounting base in the upper frame.
1. Install four mounting cap screws (D1) M20 x 45.
(See the figure "Removing and installing hydraulic oil tank".)
Tools: Socket: 30 mm, apply Loctite #262
Tightening torque: 370N·m (273 lbf·ft)
If the clearance (gap) between the tank mounting base and the frame is 1 mm (0.04 inch) or more, adjust the
clearance with shims (D3), (D4), and (D5) and then tighten the bolts.
Replace the O-ring at the back side of the tank cover with a new one.
14-26
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[14. UPPER SLEWING STRUCTURE]
2
B2
B1
14-27
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[14. UPPER SLEWING STRUCTURE]
Hose Tool
Port Remarks
No. (mm)
PSV -P2:
P2 pump
CLIP proportional
SEMS BOL T solenoid valve
Tighte ning torque SE-21:
25.5N .m (18.8 lbf .ft) Hydraulic oil
CLIP
Fix white taping part. Fix harness to temperature sensor
pipe fitting with Tighte n a cce s s ory nut
CLIP cable tie. of hydraulic oil
Fix harness to lifting temperature sensor .
eye with cable tie. Tighte ning torque of M4 s cre w is
0.49N m (0.36 lbf .ft) or less and
.
no spinning is allowed at mold part.
CLIP
CLIP
Fix corrugated part of harness SE-23:
to pressure sensor with cable tie. Pressure sensor: P2 pump
14-28
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[14. UPPER SLEWING STRUCTURE]
6) Remove four capscrews (2-5) M18 x 55 mounting insert MAs (2-3) from the engine side flywheel and
remove insert MAs (2-3), as required. Furthermore, remove spring pins (2-7) from insert MAs (2-3). Tools:
Allen wrench: 14mm
Tools: Allen wrench: 14mm
14
14-29
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[14. UPPER SLEWING STRUCTURE]
14-30
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[14. UPPER SLEWING STRUCTURE]
Dimension between
4
10. Install suction hose (A3) with each two clips (A13) hub end surface and
spline end surface
d 1
and (A14). (See the figure "Removing and installing Coupling hub
can be assembled VIEW I
delivery and suction hoses".) DETAIL aa reversely .
Tools: Flat-head screwdriver
Tightening torque: 5.39 N·m (3.98 lbf·ft)
Installing hydraulic pump
11. Install hose (3) with two clips (11). (See the figure
"Removing and installing other hoses")
Tools: Flat-head screwdriver
Tightening torque: 5.39 N·m (3.98 lbf·ft)
12. Install the hydraulic pipes by referring to Chapter "HYDRAULIC SYSTEM".
13. Installing each hose (See the figure "Removing and installing other hoses")
Tightening
Tightening Hose Tool
torque
position No. (mm)
N·m (lbf·ft)
14
Cap nut Psv 1.3 22 49 (36)
14. Install the connectors of the pressure sensors and the proportional valves.
15. Remove the suction stopper.
16. Install the suction strainer.
When replacing the pump, be sure to supply the hydraulic oil of 1 L (0.26 gal) or more form drain port (Dr).
14-31
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[14. UPPER SLEWING STRUCTURE]
14-32
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the guards which need to be removed to remove the air cleaner.
FOR WARD
FOR WARD 6 2
6
I 3
11
1
III
5
aa 1
II
HOSE INSERTION CLIP
ALLOWANCE INSTALLATION
INSTALL POSITION HOSE INSERTION 9
THE CLIP ALLOWANCE TIGHTENING
TORQUE
IN THE 6 46.5N .m
4 0 7 ”)
CLIP
5
SHOWN IN 5 INSTALLATION 7
(1 .
(0 .
57
THE FIGURE.
20
THE FIGURE. 5
23
VIEW I CLEANER,
INSTALL
AIR ACCESSORIES
THE CLIP TIGHTENING TORQUE CLIP
IN THE 3.9N .m(2.88 lbf .ft)
VIEW II INSTALLATION
ORIENTATION 7
INSTALL THE CLIP POSITION
SHOWN IN TO BE INSERTED IN
THE FIGURE. IN THE O RIENTATION VIEW III
SHO WN IN THE FIGURE. THE INSULATION.
14
Removing and installing air cleaner
14-33
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[14. UPPER SLEWING STRUCTURE]
Tightening Torque
Tightening torque
Item Name
N·m (lbf·ft)
39.2 (28.9)
9 Sems bolt
(Apply Loctite #262.)
4 1
14-34
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[14. UPPER SLEWING STRUCTURE]
14.3.10 MUFFLER
14.3.10.1 REMOVING MUFFLER
Preparation
• Remove the guards which need to be removed to remove the muffler.
9 9
3
6 9
10
9
8 5
A 11
A
2
14
14-35
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[14. UPPER SLEWING STRUCTURE]
1) Remove two capscrews (7) M10 × 35, and then clamp assembly (3).
2. Removing muffler (1)
14-36
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[14. UPPER SLEWING STRUCTURE]
C
MOUNTING P ROCEDURE
FOR THE CLAMP ASSEMBLY
UPP ER
9 SIDE
(UPPER
SIDE)
(LOWER
9 SIDE) LOWER
SIDE
AFTER MOUNTING THE THE MOUNTING SURFACE OF
ATTACHED GASKET, COMPLETELY CLAMP SHOULD NOT
TIGHTEN THE BOLT. OVERLAP THE SLIT.
TO BE 10 +0 FROM
MUFFLER SLIT.
AFTER FIXING THE MUFFLER
(0.39 + 0 )
THE END OF
0.20
WITH THE U BOLT, MOUNT
5
THE SEAL CLAMP.
SEE THE MOUNTING PROCEDURE
FOR THE CLAMP ASSEMBLY.
3
7
MUFFLER
MOUNT THE WASHERS SIDE
ON THE NUT SIDE.
TIGHTENING TORQUE
68. 6|| 98N .m
(50.6|| 72 lbf.ft) ENGINE
COMPLETELY SIDE
TIGHTEN THEM.
Tightening Torque
Tightening torque
14
Item Name
N·m (lbf·ft)
108 (80)
5 Sems bolt
(Apply Loctite #262.)
108 (80)
6 Capscrew
(Apply Loctite #262.)
14-37
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[14. UPPER SLEWING STRUCTURE]
Lifting counterweight
1) Remove four cap screws (A1) M33 x 350. A3, A4, A5, A6
Tools: Socket: 50 mm 10 (0.39”)
Adjus t cle a ra nce be twe e n Adjus t cle a ra nce with
counte rwe ight a nd de ck from 1 to 2 s hims .
to 10mm (0.39 inch).
2) Remove shims (A3), (A4), (A5), and (A6).
A1, A2
(Selection)
14-38
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[14. UPPER SLEWING STRUCTURE]
14
14-39
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[14. UPPER SLEWING STRUCTURE]
1
29 FOR WARD
DETAIL aa
Do not loosen or remove the connecting parts of the hoses related to the air conditioner. It will cause leakage of
coolant.
14-40
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[14. UPPER SLEWING STRUCTURE]
FOR WARD
14
14-41
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[14. UPPER SLEWING STRUCTURE]
4 9
24
20 6
FOR WARD
FOR WARD
14-42
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[14. UPPER SLEWING STRUCTURE]
(2).
FOR WARD
10. Removing radiator assembly (See the figure
"Removing and installing radiator stays".)
8
1) Remove four sems bolts (A4) M12 x 25.
Tools: Wrench: 19 mm
Tools: Socket: 19mm
8
2
C/V T1-
O/C IN
14
14-43
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[14. UPPER SLEWING STRUCTURE]
II
FOR WARD
IV aa
FORWARD
III
bb
ALLOWANCE
40
3
(1 . 5
HOS E INSER TION INSTALL THE CLIP 38
”)
IN THE ORIENT ATION
ALLOWANCE SHOWN IN THE FIGURE.
(0.63”)
CLIP 22 24
16
VIEW I 40
(1.57”) 5
HOS E INSER TION
ALLOWANCE
TIGHTENING TORQUE 10
39.2N .m(28.9 l bf.ft) 3
APPLY LOCTITE #262. 5 INSTALL THE CLIP VIEW II
3 SO THAT THE RUBBER
21 31 CABLE COVER IS NOT
CAUGHT.
TIGHTENING TORQUE
. .
21 39.2N m(28.9 lbf ft)
APPLY LOCTITE #262.
32
INSTALL THE CLIP SO THAT
THE RUBBER CABLE COVER
IS NOT CAUGHT.
DETAIL bb
14-44
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[14. UPPER SLEWING STRUCTURE]
(1 .7 7 ”)
INSTALL THE CLIP IN
45
THE ORIENT ATION (1 40 6
SHOWN IN THE FIGURE. . 57 INSTALL THE
”) CLIP IN THE
TO BE INSTALLED
HOS E INSER TION 23
SO THAT THE WHITE
PAINT COMES ON
22 ORIENTATION
SHOWN IN ALLOWANCE INSTALL THE CLIP
THE TOP OF THE FIGURE. IN THE ORIENTATION
(1 .7 7 ”)
ENGINE SIDE. 2
1 5 (0
45
TO BE INSTALLED SO THAT SHOWN IN THE FIGURE.
THE WHITE P AINT COMES
.5
ON THE TOP OF ENGINE SIDE.
9 ”)
23
(1.57”)
(1.77”)
THE ORIE NTATION
HOS E INSER TION VIEW III
45
SHOWN IN THE FIGURE.
ALLOWANCE HOS E INSER TION
(0.63”)
ALLOWANCE TIGHTENING
16
TORQUE
CLIP TIGHTENING 10. 8N.m
TORQUE .
INSTALLATION
POSITION 2.2N.m 16 (8.0 lbf ft) 15
23 INSTALL THE CLIP IN (1.62 lbf.ft)
THE ORIENT ATION 16
VIEW IV SHOWN IN THE FIGURE. 17
TO I/C 12 9 11
19 TIGHTENING
TORQUE
19.6N .m
(14.5 lbf.ft)
APPLY LOCTITE
#262.
FROM
THE ENGINE
TURBO
15
TIGHTENING 20 17
TORQUE 17
39.2N .m TIGHTENING 19
TIGHTENING
(28.9 l bf.ft) TORQUE
TORQUE
2.2N.m
16 16 TIGHTENING
TORQUE
APPLY 19.6N .m
LOCTITE #262. (1.62 lbf.ft) 2.2N.m (1.62 lbf.ft)
(14.5 l bf.ft) 16
APPLY LOCTITE TIGHTENING 16 TIGHTENING
#262. TORQUE TORQUE
10. 8N.m 10. 8N.m (8.0 lbf.ft)
(8.0 lbf.ft) ' ( 7 $ , / D D
14-45
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[14. UPPER SLEWING STRUCTURE]
5. Refilling hydraulic oil and LLC (Long Life Coolant) ADJUST THE CLEARANCE BETWEEN
THE FAN AND THE RADIATOR
After finishing the other installation works, refill 9
SHROUD IS TO 9±5 mm (0.35±0.20").
(0.35”)
hydraulic oil and coolant.
Amount of coolant in engine body: 9 L (2 gal)
Amount of radiator coolant: 5.5 L (1.5 gal)
Amount of hydraulic oil in oil cooler: 2.4 L (0.6 gal) I
VIEW I
14-46
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[14. UPPER SLEWING STRUCTURE]
14.3.12.3 REMOVING AND INSTALLING RADIATOR, INTERCOOLER CORE, AND OIL COOLER
Preparation
• Remove one under cover under the radiator.
• Wait until the engine coolant temperature goes down 4
Forward
to a temperature that will not cause burns, then
remove the radiator cap, open the drain cock at the
lower rear side, drain the coolant, and receive it with a
container. 13
Tighte ning torque
* When only the intercooler is to be pulled out, the 23.5 ±2.0N .m
(17.3 ±1.5 lbf .ft)
above work is unnecessary. 10
9
1. Removal
9) Separating hose for hydraulic oil cooler Removing and installing radiator and intercooler
core
Separate hoses (1) and (2) at the upper and
lower sections of the cooler and drain the
hydraulic oil. (See the figure "Separating hydraulic oil hoses (1) and (2)".)
10) Sling the cooler by using the flange on the upper part of the cooler and lift the cooler temporarily.
14-47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[14. UPPER SLEWING STRUCTURE]
There is no specified removal order among the radiator core, the intercooler core, and the oil cooler, so that remove
those components as required.
2. Installation
Installation should be done in the reverse order of removal.
14-48
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[14. UPPER SLEWING STRUCTURE]
14.3.13 ENGINE
14.3.13.1 REMOVING ENGINE
Preparation
• Remove the battery ground cable (See Paragraph "BATTERY").
• Remove the bonnet and the guards (See Paragraph "GUARD") and remove the under cover (See Paragraph
"UNDER COVER").
• Remove the air cleaner hose (See Paragraph "AIR CLEANER").
• Remove the counterweight (See Paragraph "COUNTERWEIGHT").
• Remove the radiator hoses and the intercooler hoses (See Paragraph "RADIATOR AND OIL COOLER").
• Remove the fuel hose and the heater hose, and remove the air conditioner hose as required
• Remove the pump, the muffler, and the radiator as required.
• Remove the harnesses and the connectors. (See Chapter "ELECTRIC SYSTEM".)
– Engine ground cable
– Starter cable of starter B terminal
– Connectors of ECU harness and engine accessory harness
– Upper harness
P5-Alternator B terminal
CN-136F-Engine speed sensor
CN-141F and CN142F-Pump proportional valve
CN-139F and CN-140F-P1 and P2 pump pressure sensors
CN-212F-Glow
P3-C terminal of starter motor
Prepare a cradle which can support the weight of the engine and keep the removed engine at a stable condition.
(See Chapter "TOOLS".)
14
14-49
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[14. UPPER SLEWING STRUCTURE]
THERMOST AT
OIL FILTER
ELEMENT
ALTERNATOR
FUEL FILTER
S TARTER ELEMENT
Appearance of engine
14-50
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[14. UPPER SLEWING STRUCTURE]
RADIATOR S IDE
III BUNDLE THE
bb FOR WARD HARNESSES
50 WITH CLIP.
INSTALL THE FAN AS
THE PROJECTION TURNED 32
aa TO RADIATOR S IDE.
DETAIL hh
51
PROJECTION 6 PLACES
hh
32
I
34 ee 33
cc FIX ITEM 24, 25,
AND 26 HOS ES .
dd
44, 47
6 44, 47
20
43, 46 19
33 4 P LACES
33
II
17 20
VIEW I 19
15
39
28 VIEW II 19
37
OUT
25 47
2, 3 45
DETAIL ee DETAIL cc
3, 29
IN
24 HOS E INS ERTION ALLOWANCE
42 CLIP INS TALLATION P OS ITION
14
1 40
(0.91”)
(0.12”)
8
23
48 5 27
DETAIL aa 32
7
26 5
4
2 P LACES
VIEW V
38 21
14
IV
35 13 AFFIX THE LABEL
IN THE ORIENTATION
VIEW VI
P UMP S IDE
S HOWN IN THE FIGURE.
23
32
31
21 22
48 P OS ITION S LIT OUTS IDE
22 5
49
4 P OS ITION
41 FAN S IDE S LIT OUTS IDE
14-51
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[14. UPPER SLEWING STRUCTURE]
FOR WARD
ff
DETAIL OF MTG.
BREATHER 7 ENGINE MOUNT (FR)
HOSE
(2.8”)
(70)
A
4 P LACES
43, 46 A 6
44, 47
18
20
19
VI 19 11
47 12
45
DETAIL gg
39 16
19 PIN (ITEM6) IS Hydraulic hose
STRICKEN TO
Thread Tighte ning torque
THE PIN HOSE OF 6 diameter N.m(lbf.ft)
F/W HOUSING.
AND INSER T P INS PF1 137 ±15 (101±1 1)
IN ENGINE SIDE. PF1/4 29 ±4.9 (21±3.6)
47
M12 26.5 ±2.6 (19.5±1.9)
45
DETAIL ff Tighte ning torque
SECTION AA for engine remote
oil filter piping
14-52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[14. UPPER SLEWING STRUCTURE]
Prepare a cradle which can support the weight of the engine and keep the removed engine at a stable condition.
(See Chapter "TOOLS".)
1) Put a wire with hook to the lifting eyes at the front and rear of the engine.
Weight: Approx. 515 kg (136 lbs)
Wire: 6 mm (0.24 inch) diameter x 1 m (3feet-3inch), 2pcs.
5. Place the engine on the engine cradle in a stable condition.
Tightening torque
Tightening
Item Name torque Remarks
N·m (lbf·ft)
Tightening torque
N·m (lbf·ft)
Thread
O-ring fitting Hydraulic hose
diameter
PF1 205 (151) 137 (101)
PF1/4 - 29 (21)
14-53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[14. UPPER SLEWING STRUCTURE]
1-20
Tighte ning torque
5.0N .m (3.69 lbf .ft)
1-10
1-20
Tighte ning torque
5.0N .m (3.69 lbf .ft)
Tightening torque
Item Name
N·m (lbf·ft)
1-18
Sems bolt M6 5.0 (3.69)
1-20
14-54
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[14. UPPER SLEWING STRUCTURE]
14
14-55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[14. UPPER SLEWING STRUCTURE]
Function Port name Upper side (base machine) port Port name Function
Tra ve l le ft (re a rwa rd) pilot PBL PBb Boom (down) pilot
Tra ve l le ft (forwa rd) pilot PAL PAr Tra ve l right (forwa rd) pilot
P 1 P1 pump
P 2 P2 pump
Emergency manual valve drain XAb Bb Boom cylinder rod side (boom down)
Boom cylinder head side (boom up) Ab Br Right travel motor (rearward)
Power boost PL
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[14. UPPER SLEWING STRUCTURE]
Function Port name Left side (base machine) port Port name Function
T1 Return to tank
Unload valve (P2 side) pilot PCa PBr Tra ve l right (re a rwa rd) pilot
Arm 1 (arm in) pilot PAa 1 PAa 2 Arm 2 (arm in) pilot
Aa R
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[14. UPPER SLEWING STRUCTURE]
Tightening torque
Size Port name
N·m (lbf·ft)
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Lower the attachment to the ground, stop the engine, and release the pressure in the hydraulic oil tank.
• Remove left console covers (1-8) and (1-9) according to Paragraph "REMOVING AND INSTALLING CONSOLE
COVER".
• Attach tags to the hoses to make the assembly work secure and easier.
1. Disconnect the connector for the horn harness.
2. Remove each hose in order from the nearest hose to the farthest hose.
Tools: Wrench: 19 mm and 22 mm
3. Move boot (3) upward and loosen nut (6). (See the
figure "Removing and installing boot and lever".)
Tools: Wrench: 22 mm
3
4. Turn lever (1-2) and remove the lever parts as a set.
(See the figure "Removing and installing boot and
6
lever".) 1-2
"F" stamp
PF3/8
PF1/4
P port conne ctor
Hose side (with filter)
1 to 4 and 5 to 6 T port conne ctor
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[14. UPPER SLEWING STRUCTURE]
As the pilot valve is made of aluminum, use caution with the tightening torque.
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Release the internal pressure of the hydraulic oil tank
(Refer to Paragraph "REMOVING AND INSTALLING
HYDRAULIC OIL TANK").
• Release under cover (1) (Refer to Paragraph
"REMOVING AND INSTALLING UNDER COVER"). A1
A9
A2 A8
A5
A8
A6
B1
A9
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[14. UPPER SLEWING STRUCTURE]
1. Remove floor mat (B1). T: Tighte ning torque N.m (lbf.ft) A13 A10
2. Separate the wires for two pressure sensors SE-9 A1
(A10) and SE-10 (A10) and then remove two SE-9
pressure sensors (A10) form the pilot valve. 6
Tools: Wrench: 19 mm T=30 (22)
A10 5 T
T=30 (22)
3. Put tags to hoses (A1), (A2), (A3), (A4), and (A5)
P A1
and separate the hoses and the connectors.
Tools: Wrench: 19 mm
3 A5
SE-10 PT
(T port, P port, and 1 to 4 ports) A2 PT T
C/V P
T=30 (22) 4
PAr
4. Plug each hose. 1 A3
Plug PF1/4
2
C/V BLOCK
B5
5. Remove four sems bolts (A9) M8 x 25 and then PAL
A4
remove left and right pedals (A5) and (A6). BLOCK
Width across flats 19mm B6
Tools: Wrench: 13 mm A3
PF1/4 PF1/4
6. Remove four sems bolts (A8) M10 x 25 and then
remove left and right levers (A1) and (A2).
Tools: Socket: 17 mm Va lve s ide Hose side
7. Remove four sems bolts (A13) M10 x 30. Va lve s ide T port conne ctor
Tools: Wrench: 17 mm PF3/8
8. Pull up the pilot valve and remove it. Width across flats 19mm
Va lve s ide Hos e s ide
PF1/4
9. Attach plugs PF 1/4.
P F3/8 P F1/4
Hose side
P port conne ctor
1 to 4 port connector (with filter)
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Park the machine on a level and firm ground and place the attachment on the ground.
• Remove the guards which need to be removed to remove the swing motor unit. (See Paragraph "REMOVING
AND INSTALLING GUARDS".)
• Operate the switch on the gauge cluster and change the machine to the pressure release mode and operate the
control lever to release the pressure inside the circuit. (See Section "PRESSURE DRAINING" in Chapter
"HYDRAULIC SYSTEM".)
• Release the internal pressure of the hydraulic oil tank and put a tag on which a port name is written to each
hose.
1. Removing hoses 4
1) Remove hose (3) from the connector of make-up S/J HYD. TANK
port M. E
B
4) Remove two hoses (A1) and (A2) from the
connector of ports A and B.
Tools: Wrench: 32 mm PR
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14
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[14. UPPER SLEWING STRUCTURE]
A B
C D
(Tra ve l motor) (Tra ve l motor)
P2(Lower)Rearward P1(Lower)Rearward
(Left side) A,B,C,D-PF1 (Right side)
P1(Upper)Forward P2(Upper)Forward
E-PF1/2
F-PF1/4
A2
Swivel joint
D A4
B
A7
F
A1 B2
F
C
E A16
A
B2
A16 A7
A3
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[14. UPPER SLEWING STRUCTURE]
A5
B25
B5
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[14. UPPER SLEWING STRUCTURE]
B1
C1
Swivel joint
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[14. UPPER SLEWING STRUCTURE]
Tightening torque
Thread N·m (lbf·ft)
Tool
diameter
mm O-ring type Hydraulic
PF
connector hose
1/4 19 36 (27) 29 (21)
2. Check the swivel joint for oil leakage and hydraulic oil level.
3. Check the swivel joint for operation.
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the attachment/equipment
(See Chapter "ATTACHMENT").
• Remove the cab (See Paragraph "REMOVING AND INSTALLING CAB").
• Remove the guards (See Paragraph "REMOVING AND INSTALLING GUARDS").
• Remove the counterweight
(See Paragraph "REMOVING AND INSTALLING COUNTERWEIGHT").
• Remove the swivel joint
(See Paragraph "REMOVING AND INSTALLING SWIVEL JOINT").
1. Sling the upper frame temporarily.
Match mark
2. Attaching match mark to swing bearing
Make match marks on the upper frame and the
swing bearing.
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[14. UPPER SLEWING STRUCTURE]
*Mark 1 place
7 8
Apply Loctite #262. Apply Loctite #262.
Tightening torque Tightening torque
392N .m (289 lbf .ft) 392N .m (289 lbf .ft)
Detail of bearing mounting section
14
Make sure the position of the reamer bolt by the figure "Reamer bolt position (*) and apply Loctite on hatched area".
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[14. UPPER SLEWING STRUCTURE]
Main pump
534
792
702
983 532
981 548
886 214
530
490
732
789
535
537 808
806 954
251
953 901
490
726
419 468
272
531
212
406
261
774
710
111
123
723 724 127
824
490
141
313
724 271
013
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[14. UPPER SLEWING STRUCTURE]
The marks (W), (X), (Y), and (Z) in Fig. "Structural exploded view of regulator" show the position where regulator is
installed.
111 Drive shaft (F) 1 414 Socket bolt; M10 X 20 4 *806 Nut; M16 2
113 Drive shaft (R) 1 419 Socket bolt; M16 X 35 4 *808 Nut; M20 2
127 Bearing spacer 2 531 Tilting pin 2 901 Eye bolt; M10 2
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[14. UPPER SLEWING STRUCTURE]
TOOL
The tools necessary to disassemble/reassemble K7V
pump are shown in the following list.. B
The size of bolts and plugs depend on the pump type.
○: Necessary
Tool name and size Tool Part name
Pump model
ROH plug
Hexagon socket Hexagon socket
Names B K7V125 VP plug
head cap screw head set screw
(Parallel thread)
2 ― ― M4
2.5 ― ― M5
3 ― ― M6
4 M5 ― M8
5 M6 ― M10
6 ○ M8 PF1/4 M12, M14
19 M24, M27 ― ―
21 ― ― ―
22 M30 ― ―
Adjustable angle wrench ― ○ Medium size 1set
Disassembling Procedures
1. Selection of a place for disassembling
• Select a clean place.
• Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Cleaning
Remove dust, and rust, etc., from the pump surfaces with cleaning oil or so on.
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[14. UPPER SLEWING STRUCTURE]
3. Draining oil
Remove drain port plugs (468) and let the oil out
from pump casings (271) and (272).
Tools: Spanner: 36 mm
• Drain the oil from each plug opening of the front and
rear pumps.
4. Removing regulator
Remove socket bolts (414) (See Figures "Structural exploded view of main pump" and "Structural exploded
view of regulator") and remove the regulator.
Tools: Allen wrench: 8 mm
• Refer to Paragraph "REGULATOR" for dissembling the regulator.
5. Removing PTO unit and PTO cover (326)
Place the pump horizontally on a workbench with its
regulator-fitting surface down, and remove the PTO
unit by removing flange socket (435).
• Before bringing the regulator-fitting surface down,
spread a rubber sheet on the workbench to avoid
damaging the fitting surface.
• Check the PTO unit maintenance manual for
disassembling or assembling the PTO unit.
14
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14
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[14. UPPER SLEWING STRUCTURE]
Assembling Procedures
1. Precautions of assembling
Perform assembling procedures in the reverse order of disassembling procedures by taking care of the
following items.
• Be sure to repair the parts damaged during disassembling, and repair replacement parts in advance.
• Clean each part fully with cleaning oil and dry it with compressed air.
• Be sure to apply clean hydraulic oil to the sliding portions and the bearings, etc. before assembling them.
• Always replace the sealing parts, such as the O-ring and the oil seal, in general.
• Prepare a torque wrench for mounting socket bolts or plugs at each part and tighten them with the specified
torques shown in "Tightening torque for hydraulic pump".
• In case of a tandem pump is used, take care not to mix up parts of the front pump with those of the rear pump.
2. Installing swash plate supports (251)
Install swash plate support (251) to positioning pin
(886) of the casing (271) and (272). 14
• If the servo piston, stopper (L), stopper(S), and servo
cover are removed, fit them to pump casing in
advance for reassembling.
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14
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[14. UPPER SLEWING STRUCTURE]
Installing regulator
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[14. UPPER SLEWING STRUCTURE]
Recommended
Standard
replacement
Part name and inspection dimension Countermeasures
value
mm (inch)
mm (inch)
Play between piston and shoe-caulking 0 to 0.1 0.3 Replace assembly of piston &
(δ)
section (0 to 0.0039) (0.0118) shoe.
5.0 4.8 Replace assembly of piston &
Thickness of shoe (t)
(0.197) (0.189) shoe.
41.8 41.0
Free height of cylinder spring (L) Replace cylinder spring.
(1.65) (1.61)
Combined height of set plate and 25.0 24.0 Replace set plate or spherical
(H-h)
spherical bushing. (0.98) (0.94) bush.
d D
(L)
H
h
t
P la y be twe e n pis ton $ shoe caul king pa rt ( ) Combi ned hei ght of set pl ate $
Thickne s s of s hoe (t) Spheri cal bushi ng (H-h)
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[14. UPPER SLEWING STRUCTURE]
Tightening B
Part name Size torque dimension Tool
N·m (lbf·ft) mm (inch)
14
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[14. UPPER SLEWING STRUCTURE]
14.4.1.1.5 TROUBLESHOOTING
Troubleshooting
1. Overload of engine
The torque setting of the regulator is Adjust the regulator. See the instruction manual of the
higher than specified value. regulator.
Seizure or damage of a part inside the Replace the damaged part. Check the filter and drain oil for abnormal
pump. worn metal particles.
2. Extreme Decrease of Pump Oil Level or Delivery Pressure Does Not Increase.
Seizure or damage of a part inside the Replace the damaged parts. Check the filters and drain oil.
pump.
Failure of the attached pump. Replace the damaged parts. Remove the attached pump and check
the shaft coupling.
Failure of the accessory valve. Replace the accessory valves. See the instruction manual of the
(Especially, check the poppets, seats accessory valves.
and springs.)
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[14. UPPER SLEWING STRUCTURE]
Hunting of the regulator. Repair the regulator. See the instruction manual of the
regulator.
14
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[14. UPPER SLEWING STRUCTURE]
14.4.1.2 REGULATOR
(874)
876
611
642
643
898
728
418
641
079
412 467
466
412 728
755 801
412 924
402
497
466 656
755 728
497 645
646
644
726
601
658 414 614
729
468 874
497
887
497
758
755
758
708
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[14. UPPER SLEWING STRUCTURE]
The marks (W), (X), (Y), and (Z) in the figure above show the pump casing mounting position. (See Fig. "Structural
exploded view of main pump".)
418 Socket bolt; M5 X 12 2 644 Spring seat (Q) 1 801 Nut; M10 1
466 ROH plug; PF1/4 2 645 Adjusting stem (Q) 1 874 Pivot Pin 1
NOMINAL
Tightening torque
No. DESIGNATION OF
N·m (lbf·ft)
SCREW THREAD
402 M6 12 (9)
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[14. UPPER SLEWING STRUCTURE]
Tools
Tool and dimension Part name
Required tool
(Marked with ○) Socket bolt ROH plug Hex head socket
Name B
(Flange bolt) (PF screw) set screw
2 - - M4
2.5 - - M5
3 ○ - - M6
4 ○ M5 - M8
5 ○ M6 ROH-1/8 M10
6 ○ M8 ROH-1/4 M12, M14
Allen wrench
8 M10 ROH-3/8 M16, M18
10 ○ M12 ROH-1/2 M20
12 M14 - -
14 M16, M18 ROH-3/4 -
19 M24, M27 - -
22 ○ - VP-3/8 -
24 M16 - -
27 ○ M18 VP-1/2 -
Eye wrench 30 M20 - -
Socket wrench
36 - VP-3/4 -
Double (single) end
wrench 41 - VP-1 -
46 M30 - -
50 - VP-1 1/4 -
55 - VP-1 1/2 -
Adjustable wrench - ○ Middle-sized, 1 pc.
Disassembling procedure
1. Selection of a place for disassembling
• Select a clean place.
• Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Cleaning
Remove dust, and rust, etc. from surfaces of the regulator with clean oil.
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[14. UPPER SLEWING STRUCTURE]
3. Removing regulators
Remove socket bolts (412) and (414), and remove the regulator from the pump.
Tools: Allen wrench: 6mm
• When disassembling the pump body, check the maintenance manual for K7V series axialpiston pump.
• Take care not to lose O-rings while removing the regulator.
4. Removing proportional pressure reducing solenoid valve (079)
Remove hexagon socket head cap screws (418) and remove the proportional pressure reducing solenoid
valve (079).
• When removing the proportional pressure reducing solenoid valve, do not damage the connector of it.
5. Loosen pilot plug (641).
• Do not remove the pilot plug (641). If it is removed,
the pilot spring (646) and the sprig seat (Q) (644) will
fall from the casing.
• Be careful about falling down of the workpiece while
loosening pilot plug (641) because it was tightened
with a high torque.
• Do not damage the regulator mating surface while
using a vise.
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[14. UPPER SLEWING STRUCTURE]
14
Removing restrictor (658)
Since component parts are small, take care not to lose them.
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[14. UPPER SLEWING STRUCTURE]
ASSEMBLING PROCEDURES
Perform assembling procedures in the reverse order of disassembling procedures by taking care of the following
items.
• Be sure to repair the parts damaged during disassembling, and repair replacement parts in advance.
• If foreign materials enter the regulator, it will cause malfunction. Clean each part fully with cleaning oil, dry it with
air blow, and then perform work at a clean place.
• Prepare a torque wrench for mounting bolts or plugs at each part and tighten them with the specified torques
shown in " Tightening torque of bolt, plug, and nut ".
• Be sure to apply clean hydraulic oil to the sliding portions before assembling them.
• Always replace the sealing parts such as the O-ring etc., in general.
1. Selection of a place for assembling
• Select a clean place.
• Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Installing restrictor (658)
Fully wash out casing (601) and restrictor (658).
Remove oil from the restrictor (658) completely.
Then, apply a drop of *adhesive to only the thread
part of the restrictor (658), and tighten it into the
casing.
Tools: Allen wrench: 5mm
Tightening torque: 6.9N·m (5.1 lbf·ft) (466)
• Do not operate this pump for approximately three
hours after installing the restrictor (658). (The
hydraulic oil will wash out the adhesive before it is
hardened and it may cause the restrictor to lose its
effect.)
• If adhesive is adhered to other parts, wipe off the
adhesive at once.
*adhesive
Product name: Loctite#241
Maker: Henkel Japan Ltd.
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
14
Installing spring seat (Q) (644) and pilot spring
(646)
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[14. UPPER SLEWING STRUCTURE]
T2
PAL P BL
J
P B1 P Ca
Pra Prb
P Bs PAs
PBa 1 PAa 1
154 164
P1 102
974
973
P Tb P Cb
974
973
P Br PAr
14
973
PAb P Bb
973 973
PAc
973 P Cc
P Bc
PAa 2 PBa 2
973 973
SECTION B-B
Section (1/6)
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[14. UPPER SLEWING STRUCTURE]
T2
H 273x1 0 H
P1 unload P Cb PAL Travel left
C 273x10 C
PAr P B1 977
Travel right Boom conflux
D D
978x2
Boom P Bb Pra
Boom 2
E
E
P Bs
Bucket Swing
F F
P Cc
PBa 2 PBa 1
Arm 2
Arm 1
G G
MU
K K
B A
PBa 2 PBa1
274x 4 274x4
Dr2
Pc
213 213
PAa 1
PAa 2
Section (2/6)
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[14. UPPER SLEWING STRUCTURE]
331 331
261 MR 261
309
601
PL 306
AL 163
511
512
521
522 CP2
CMR2 551
552 164
562
CMR1 162
BL
552
522 163
Dr1
512
307
261
331 PBL 264
327 205
329
336
331 SECTION C-C
333
202 PTb
Travel straight
331 331
261 261
306
305
161
Ar
511
521
511
521 14
CP1 LCb2
551
551
164 164
163 Br
310
161
(T3)
164
264 154
PBr
261
205 331
327
SECTION D-D 329
336
PCa 331
P 2 unload 333
202
Section (3/6)
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203 202
333 Boom Boom 2 333
331 331
336 P Bb Pra 336
319 322
321 320
603 331
279x3 AbR 261
211
L 331 L 212
163
215 M N N
M 261 161
266 159
159 PLc1 312
514 CAb
551
524 521
CRb1 164
556 CRb2 511
164
556
Dr2 164
529
Pc 513
CRe 164
208 551
520 521
Bb 516
162
163
CBb 313
551
301 164
264 521
162 511
PAb
161 261
602 BbR 331
SECTION E-E 320
205 322
336
Prb 331
Boom 3 333
202
209
216 P Cc Swing 201
333 333
PBs
331 P Bc 331
336 336
322 322
321 321
602 BcR
331 331
261
261
304
Bc
162 As
511 511
521 523
LCc
LCs
551
556
164
164
163 Ac
Bs
162
162
162
264 303
PAc
264
603 PAs
205 SECTION F-F 205
AcR
Section (4/6)
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201
201 333
333 Arm 2 Arm 1 331
331 PBa2 PBa1 336
340 322
328 321
321
BaR 603
331
331
550 211
261 562
525 L L
CBa 261
519 159
MU
308
PLc2 514
162
162 524
CRa
162 556
511
164
521
551 LCAT2 511
164 521
515 LCa
521 551
LCAP2
551 164
164 302
162
162 Ta Aa
163
162
510
526 CTa 604
167 264
557 PAa1
P P
264 205
210 PAa2 AaR
SECTION G-G
T2
161
511
P1
T1
14
521
163
CT1
551
163
164
162
P2
CT2
551
164
Section (5/6)
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527 528
SECTION P-P
T2 T1
517
518
SECTION M-M
SECTION K-K
SECTION J -J
SECTION N-N SECTION L-L
Section (6/6)
Tightening Tightening
torque Item Part Name Q'ty torque Item Part Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
16 to 20
159 PLUG M7*0.75 4 328 SPRING 1
(12 to 15)
7.8 to 9.8
160 PLUG R-1/16 MECH 1 329 SPRING 3
(5.8 to 7.2)
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Tightening Tightening
torque Item Part Name Q'ty torque Item Part Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
98 to 120
274 SOCKET BOLT 8 527 SPRING 1
(72 to 89)
25 to 34
278 SOCKET BOLT 5 528 SPRING 1
(18 to 25)
9.8 to 14
279 SOCKET BOLT 3 529 SPRING 1
(7.2 to 10.3)
230 to 260
302 ARM 1 SPOOL 1 551 PLUG 13
(170 to 192)
130 to 150
303 SWING SPOOL 1 552 PLUG 2
(96 to 111)
230 to 260
304 BUCKET SPOOL 1 556 PLUG 4
(170 to 192)
49 to 59
305 BOOM CONFLUX SPOOL 1 557 PLUG 1
(36 to 44)
69 to 78
310 P2 UNLOADING SPOOL 1 602 PORT RELIEF VALVE 2
(51 to 58)
69 to 78
319 SPRING 1 606 BYPASS CUT VALVE 2
(51 to 58)
140 to 180
320 SPRING 2 973 SOCKET BOLT 8
(103 to 133)
140 to 180
321 SPRING 5 974 SOCKET BOLT 2
(103 to 133)
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Tightening Tightening
torque Item Part Name Q'ty torque Item Part Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
General Precautions
• The hydraulic components are all precision-machined, so a particularly clean place needs to be selected for
disassembling and assembling.
• Thoroughly be careful in handling the control valve also to prevent dust, dirt and sand from entering inside.
• In removing the control valve from the machine, apply a cap to each of the ports, confirm thorough application of
the caps prior to disassembling, and then cleanse the assembly outside. Besides, use an appropriate work
bench for working by spreading a clean sheet of paper or a rubber mat on it.
• In carrying and moving the control valve, politely handle it by supporting it at the body portion, but never the
lever, exposed spool, or end cover portions.
• Besides, conducting various tests (such as the relief valve characteristics, leakage test, overload valve setting,
and flow rate resistance, etc.) is desired after disassembling and assembling, but a hydraulic test device is
needed for these. Therefore, do not disassemble components unable to be tested or adjusted even though
disassembling is technically possible. In addition, prepare clean washing oil, hydraulic oil, and grease, etc. in
advance.
Tools
Prior to disassembling of the control valve, prepare the following tools.
d Wrench 1 24 mm, 32 mm
e Loctite #262 1
f Scraper 1
g Tweezers 1
h Adjustable wrench 1
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Perform disassembling in a clean place, and avoid damaging flange faces and plate faces.
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When removing the spool assembly, be careful not to damage casing B (102).
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When removing the spool assembly, be careful not to damage casing A (101) or casing B (102).
2) Remove boom conflux spool (305), spring seat (331), springs (325) and (326), stopper (339), and bolt (333)
in an assembled condition out of casing A (101).
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When removing the spool assembly, be careful not to damage casing A (101).
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When removing the spool assembly, be careful not to damage casing B (102).
3) Fix the boom 2 spool assembly to the vise applying a protection plate (aluminum plate and the like) in
between them, remove bolt (333), and then disassemble spring seat (331), springs (320) and (322), and
stopper (336) from boom 2 spool (312). Do not disassemble boom 2 spool (312) any further.
6. Disassembling boom spool
1) Loosen socket bolts (273), and remove spring
cover (203) and O-rings (261) and (266) of the
boom spool.
2) Remove boom spool (301), spring seat (331), springs (319) and (321), stopper (336), and bolt (333) in an
assembled condition out of casing B (102).
When removing the spool assembly, be careful not to damage casing B (102).
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2) Remove swing spool (303), spring seat (331), springs (321) and (322), stopper (336), and bolt (333) in an
assembled condition out of casing A (101).
When removing the spool assembly, be careful not to damage casing A (101).
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When removing the spool assembly, be careful not to damage casing B (102).
4) In case disassembling of spring cover (209) of the bucket spool is necessary, loosen plug (551) with the
condition that the cover is installed to casing B (102). After removing spring cover (209) from casing B (102),
removes plug (551), and take out piston (216).
14
9. Disassembling arm 1 spool
1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of the arm 1 spool.
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2) Remove arm 1 spool (302), spring seat (331), springs (321) and (322), stopper (336), and bolt (333) in an
assembled condition out of casing A (101).
When removing the spool assembly, be careful not to damage casing A (101).
2) Remove arm 2 spool (308), spring seat (331), springs (321) and (328), stopper (340), and bolt (333) in an
assembled condition out of casing B (102).
When removing the spool assembly, be careful not to damage casing B (102).
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2) Remove travel straight spool (307), spring seat (331), springs (327) and (329), stopper (336), and bolt (333)
in an assembled condition out of casing B (102).
When removing the spool assembly, be careful not to damage casing B (102). 14
3) Fix the travel straight spool assembly to the vise
applying a protection plate (aluminum plate and
the like) in between them, remove bolt (333), and
then disassemble spring seat (331), springs
(327) and (329), and stopper (336) from travel
straight spool (307).
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2) Remove P2 unload spool (310), spring seat (331), springs (327) and (329), stopper (336), and bolt (333) in
an assembled condition out of casing A (101).
When removing the spool assembly, be careful not to damage casing A (101).
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When removing the spool assembly, be careful not to damage casing A (101).
3) Fix the boom 3 spool assembly to the vise applying a protection plate (aluminum plate and the like) in
between them, remove bolt (333), and then disassemble spring seat (331), springs (320) and (322), and
stopper (336) from boom 3 spool (313).
14. Removing spool covers
1) Travel, boom, bucket, swing, and arm 1
Loosen socket bolts (273), and remove spool
covers (205) and O-rings (264).
14
Removing spool covers (205) and (210)
2) Arm 2
Loosen socket bolts (273), and remove spool cover (210) and O-ring (264).
Do not disassemble spool cover (210) any further.
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• Port relief valves (602), (603) and (604) have the same external shape with different pressure settings, so put
identification tags to them for avoiding mistake at reassembling.
• Do not disassemble the relief valve themselves.
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14
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When placing the control valve, be careful not to damage the spool cover surface.
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2) After removing the plate, remove all of O-rings (162) remaining in the casing.
22. Removing check valve
1) Load check valve and conflux check valve
Remove plugs (551), and then poppets (511) and
springs (521).
• Be careful not to mistake the plugs and springs of (3) for those of (1) when reassembling them because they are
different from those of above-mentioned (1).
• Be careful not to mistake the poppet of (4) for that of (1) when reassembling them because it is different from
above-mentioned (1).
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• Be careful not to mistake the poppet of (5) for that of (1) when reassembling them because it is different from that
of above-mentioned (1).
• Be careful not to mistake the parts of (6), (7), and (8) for those of (1) when reassembling them because all of
them are different kinds from those of above-mentioned (1).
• Be careful not to mistake the poppet and spring of (9) for those of (8) when reassembling them because they are
different from those of above-mentioned (8).
• Be careful not to mistake the parts of (10) for the above-mentioned parts when reassembling them because the
all parts of (10) are different kinds from the above-mentioned parts.
The plugs not described in the disassembling procedure above are those for plugging unnecessary holes and
casting holes, so do not disassemble them unless it is required specifically.
23. Disassembling casing
Do not disassemble the casing any further.
24. Inspection after disassembling
Thoroughly cleanse all the disassembled parts with clean mineral oil, dry them with compressed air, and put
the parts on a clean sheet of paper or cloth for inspection.
Control valve
• Inspect all the surfaces of the parts for burrs, scratches, carved damage, or other defects.
• Check that the faces of the O-ring grooves of the casing and the covers are smooth without dusts, dents, and
rust.
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• In case dents or scratches are found on the check valve seat surface of the casing, remove them by lapping.
• Check the periphery of the sliding portion of the spool for scratches and dents and if small ones are found,
remove them using an oil stone or cloth applied lapping agent.
• Check the sliding and fitting parts for easy movement by hand and all the grooves and passages for foreign
materials.
• In case springs are broken or deformed, replace them with new ones.
• In case the relief valve does not work properly, replace it with a new one.
• Replace all the O-rings with new ones.
Relief valve
• Check that the main plunger and the seat face of the seat tip have uniform contact faces with no defects.
• Check the main plunger and the seat for easy and smooth movement by hand.
• Check the main plunger orifice for clogging by foreign materials. (Main relief valve)
• In case minor scratches are found in the inspections above, remove them by lapping.
• In case a failure part or relief valve malfunction is found, replace them with a new one.
• Replace the O-rings with new ones. (Sealing portions with the casing)
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The parts of (1) — (10) have similar shapes, so be careful not to assemble wrong parts and not to assemble parts in
wrong places.
2. Assembling plate
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• Then, place the control valve so that the plate mounting surface faces downward.
3. Assembling boost check valve and bypass check valve
1) Assemble boost check valve poppet sub-assembly (517), bypass check valve poppet (518), and springs
(527) and (528).
2) Attach O-rings (264) and (266) to boost check valve cover (207), assemble them to casing A (101), and
tighten socket bolt (278) to the specified tightening torque.
4. Assembling lock valve selector sub-assembly
Install lock valve selector sub-assemblies (211) and (212) to the casing, and tighten socket bolts (211-171) and
(212-171) to the specified torque.
5. Assembling manual emergency lowering valve and lock valve selector sub-assembly
Put lock valve selector sub-assembly (211) on manual emergency lowering valve (215) and install them to the
casing, and tighten socket bolts (279) to the specified torque.
6. Assembling logic valve poppet and logic control valve
1) Assemble logic valve poppet (520) to the casing.
2) Assemble logic control valve (208) to the casing holding the spring seat of logic valve poppet (520-103) and
tighten socket bolts (208-120) to the specified torque.
In assembling logic control valve (208) to the casing, be careful not to let spring (520-106) and spring seat (520-
103) of the logic valve poppet to fall off.
14
Port relief valves (602), (603) and (604) have the same external appearance, so be careful not to choose a wrong
part by seeing the identification tags attached at the time of disassembling.
Assemble the boom 3 spool assembly into the casing A (101) carefully and slowly and never push it in forcefully.
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3) Install spring cover (202) with O-ring (261) installed to the spring side of the boom 3 spool assembly, and
tighten socket bolt (273) to the specified torque.
10. Assembling P2 unload spool
1) Fix the central portion of P2 unload spool (310) to the vise applying a protection plate (aluminum plate and
the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and tighten
bolt (333) to the specified torque.
Assemble the P2 unload spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the P2 unload spool assembly, and
tighten socket bolt (273) to the specified torque.
11. Assembling travel straight spool
1) Fix the central portion of travel straight spool (307) to the vise applying a protection plate (aluminum plate
and the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and
tighten bolt (333) to the specified torque.
2) Assemble the travel straight spool assembly described in 1) into casing B (102).
Assemble the travel straight spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed it to the spring side of the travel straight spool
assembly, and tighten socket bolt (273) to the specified torque.
12. Assembling arm 2 spool
1) Fix the central portion of arm 2 spool (308) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (328), and stopper (340), and tighten bolt
(333) to the specified torque.
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Assemble the arm 2 spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the arm 2 spool assembly, and
tighten socket bolt (273) to the specified torque.
13. Assembling arm 1 spool
1) Fix the central portion of arm 1 spool (302) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the arm 1 spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the arm 1 spool assembly, and
tighten socket bolt (273) to the specified torque.
14. Assembling bucket spool
1) Fix the central portion of bucket spool (304) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the bucket spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (209) with O-ring (261) installed to the spring side of the bucket spool assembly, and
tighten socket bolt (273) to the specified torque.
4) Assemble piston (216) into spring cover (209), attach O-ring (164) to plug (551), and then tighten it with the
specified tightening torque.
15. Assembling swing spool
1) Fix the central portion of swing spool (303) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
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Assemble the swing spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the swing spool assembly, and
tighten socket bolt (273) to the specified torque.
16. Assembling boom spool
1) Fix the central portion of boom spool (301) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (319) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the boom spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (203) with O-rings (261) and (266) installed to the spring side of the boom spool
assembly, and tighten socket bolt (273) to the specified torque.
17. Assembling boom 2 spool
1) Fix the central portion of boom 2 spool (312) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (320) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the boom 2 spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the boom 2 spool assembly, and
tighten socket bolt (273) to the specified torque.
18. Assembling boom conflux spool
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1) Fix the central portion of boom conflux spool (305) to the vise applying a protection plate (aluminum plate
and the like) in between them, attach spring seat (331), springs (325) and (326), and stopper (339), and
tighten bolt (333) to the specified torque.
2) Assemble the boom conflux spool assembly described in 1) into casing A (101).
Assemble the boom conflux spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the boom conflux spool assembly,
and tighten socket bolt (273) to the specified torque.
19. Assembling travel spools (travel left and right spools)
1) Fix the central portion of travel spool (306) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (323) and (324), and stopper (336), and tighten bolt
(333) to the specified torque.
2) Assemble the travel spool assembly described in 1) into casing A (101) or casing B (102).
Assemble the travelspool assembly into casing A (101) or casing B (102) carefully and slowly and never push it in
forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the travel spool assembly, and
tighten socket bolt (273) to the specified torque.
14
20. Assembling P1 unload spool
1) Fix the central portion of P1 unload spool (309) to the vise applying a protection plate (aluminum plate and
the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and tighten
bolt (333) to the specified torque.
Assemble the P1 unload spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
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3) Attach spring cover (202) with O-ring (261) installed to the spring side of the P1 unload spool assembly, and
tighten socket bolt (273) to the specified torque.
21. Assembling spool covers
1) Travel, boom, bucket, swing, and arm 1
Attach O-ring (264) to spool cover (205), and tighten socket bolt (273) to the specified torque.
2) Arm 2
Attach O-ring (264) to spool cover (210), and tighten socket bolt (273) to the specified torque.
Part Inspection
Part Name Inspection Item Criterion and Measures
Casing Existence of scratches, rust, or corrosion In case damage occurs at portions below,
correct them or replace casing.
• Sliding portion of casing hole and spool, in
particular, land where holding pressure is
applied
• Sealing portions contacting with O-rings
• Sealing portions and seats of main and port
relief valves
• Seats and sliding portions of poppets
• Sealing portions of plugs
• Other damages likely to cause malfunctions
Spool Existence of scratches, galling, rust, or In case scratches are felt by your nails at
corrosion peripheral sliding portion (in particular, portions
contacting seals), replace spool.
Insert spool into casing hole, and rotate it to In case spool movement is not smooth, correct
confirm smooth stroke. or replace it.
Insert poppet into casing, and operate it. Poppet is normal if it moves lightly and
smoothly without sticking.
Spring and related parts Rust, corrosion, deformation, and breakage of Replace severely damaged parts
spring, spring seat, stopper, spacer bolt, and
cover
Main relief valve External rust and breakage Replace if required
Port relief valve
Valve seat contact face Replace if damage is found
Bypass cut valve
O-ring Replace in principle
(Sealing portion contacting with casing)
Troubleshooting
• In case an abnormal phenomenon has been found, check if it is a failure of the control valve itself or a matter of
the pump body or the circuit. To check this, measurement of the pilot pressure, pump delivery pressure, and load
pressure, etc. is necessary. In case disassembled inspection is made even partially, follow the disassembling
and assembling procedures described above.
• Dust is very harmful to the hydraulic components, so be very careful about dust prevention. In case even a part
of the component is disassembled, perform it by taking dust prevention measures.
• Handle movable parts carefully. If they are damaged even slightly, correct the damage with an oil stone or
something.
• Work carefully not to damage the gasket surfaces of the O-rings. These damages are sure to cause oil leakage.
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[14. UPPER SLEWING STRUCTURE]
Control Valve
Travel or swing Malfunction of main relief valve Pressure measurement of main relief valve
operations cannot be • Foreign materials between main poppet and • Disassembling, cleansing, and replacement
made. seat of assembly if damage is severe
Slow operation
• Foreign materials between poppet and seat • Same as above
(insufficient power) or
slow response • Sticking of main poppet • Replacement of assembly
• Breakage or permanent set in fatigue of • Replacement of assembly
spring
• Clogging of main poppet orifice • Replacement of assembly
• Loosening of adjusting screw • Readjustment and tightening of lock nut to
specified torque
Bypass cut valve seat failure Tightening of adjusting screw of bypass cut
(When electric control system is normal) valve
Simultaneous operation Malfunction of travel straight spool Measurement of pilot secondary pressure
of travel and other • Sticking of spool • Correction of sticking portion by oil stone or
attachments causes replacement of spool
travel deviation
• Breakage or permanent set in fatigue of • Replacement of spring
spring
• Excessive clearance between casing and • Replacement of spool
spool
Bypass cut valve seat failure Tightening of adjusting screw of bypass cut
(When electric control system is normal) valve
Cylinder falls significantly Excessive clearance between casing and Replacement of spool
by its own weight with spool
spool in neutral position
Incomplete return of spool to neutral Measurement of pilot secondary pressure
• Foreign materials or sticking between • Disassembling, cleansing, correction by oil
casing and spool stone, or replacement of spool
• Breakage or permanent set in fatigue of • Replacement of spool
spring
• Clogging of pilot circuit • Removing of foreign materials
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[14. UPPER SLEWING STRUCTURE]
Bucket, boom, and arm, Malfunction of main spool Measurement of pilot secondary pressure
and swing operations are • Excessive clearance between casing and • Replacement of spool
impossible spool
Slow operation
• Foreign materials between casing and spool • Disassembling and cleansing
(insufficient power) or
slow response • Sticking of spool • Correction of sticking by oil stone or
replacement of spool
• Breakage or permanent set in fatigue of • Replacement of spring
return spring
• Clogging of pilot circuit • Removing of foreign materials
Bypass cut valve seat failure Tightening of adjusting screw of bypass cut
(When electric control system is normal) valve
Boom conflux operation is Malfunction of conflux spool Measurement of pilot secondary pressure
impossible. • Excessive clearance between casing and • Replacement of spool
spool
• Sticking of spool • Correction of sticking by oil stone or
replacement of spool
• Breakage or permanent set in fatigue of • Replacement of spring
return spring
• Sticking of conflux check valve poppet • Correction of sticking by oil stone or
replacement of poppet
Relief Valve
Pressure does not rise at Relief valve remains open due to sticking of Checking for catching foreign materials
all main plunger or pilot poppet, or foreign Main plunger and seat must slide smoothly
materials at valve seat Replacement of assembly if failure is found
Unstable pressure Damaged seat of pilot poppet of relief valve Replacement of assembly
Sticking of main plunger and seat due to dust Checking for scratches or foreign materials
Replacement of assembly if failure is found
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[14. UPPER SLEWING STRUCTURE]
312
M14
Apply Loctite #262 68.6±4.9 N .m
Application part (hatched area) (50.6±3.61 lbf .ft)
302
501 301
Apply grease on
Apply grease rotating and sliding sections.
on top section 246-1 Be careful the
212 assembling direction
246-2 213 M14
151 47.1±2.9 N .m
(34.7±2.14 lbf .ft)
218
211
214
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
Tightening Tightening
torque torque
No NAME Q'TY No NAME Q'TY
N・・m N・・m
(lbf・・ft) (lbf・・ft) 14
101 Casing 1 218 Seat 4
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[14. UPPER SLEWING STRUCTURE]
302
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[14. UPPER SLEWING STRUCTURE]
Installing Jig A
JI G A
301
14
When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out
of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with two fingers.
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[14. UPPER SLEWING STRUCTURE]
211
To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is
completely released.
211
221
101
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[14. UPPER SLEWING STRUCTURE]
Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.
201-1
or 201-2
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
217
201-1
or 201-2
14
Disassembling pressure reducing valve
212
211
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[14. UPPER SLEWING STRUCTURE]
212
213
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[14. UPPER SLEWING STRUCTURE]
217
201-1
or 201-2
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
101
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[14. UPPER SLEWING STRUCTURE]
‚n -RING (214)
PUSH ROD
(212) Apply hydraulic oil
211
214 213
246-1
212 211 246-2 218
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[14. UPPER SLEWING STRUCTURE]
101 211
151
• Install spool (201) straight and evenly into the hole of casing (101).
• Take care so that plug (211) and plate (151) do not jump out of casing (101).
7. Install joint (301) on casing (101) with jig A securely.
Jig (A): See Paragraph "JIG FOR PILOT VALVE
(ATT)".
Tightening torque : 47.1N·m (34.7 lbf·ft) 14
101
JI G A
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[14. UPPER SLEWING STRUCTURE]
312
302
9. Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular
plate returning.
Tools: Spanner: 32 mm
Tools: Socket: 22 mm
• Apply Loctite #277 to threads of joint.
Tightening torque: 68.6N·m (51 lbf·ft)
301
212
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[14. UPPER SLEWING STRUCTURE]
Push rod When the wear of top is 1 mm (0.04 inch) or more, replace it with new one.
Secondary pressure springs (241) are broken or fatigued. Replace with new ones.
Secondary pressure Clearance between spool (201) and cas-ing (101) is Replace spool (201).
does not rise. abnormally large.
Secondary pressure is Tank line pressure varies. Bring pressure directly to oil tank.
unstable.
Air has mixed into pipeline. Bleed air by operating it several
times.
Secondary pressure is Tank line pressure is high. Bring pressure directly to oil tank.
high. Sliding parts are caught. Correct.
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[14. UPPER SLEWING STRUCTURE]
(1.14”)
(1)
Material ; SCM415 (N)
(1.04”) Carburizing and Quenching
(0.93”) (2) BUSHING
Material ; S45C (0.51”)
SECTION AA
(0.75”)
(2.72”)
(2.13”)
(1.97”)
(1.81”)
(0.98”)
A A
(0.67”)
(0.91”)
(1.06”)
(1.22”)
(0.26”)
(0.61”)
(0
.
23
(0 .
”)
18 (0.02”)
”)
(0.49”)
(0.37”)
(0.02”)
Material ; SCM415 (N)
(0.46”) Carburizing and Quenching
Q'ty ; 2
Detail of bushing
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[14. UPPER SLEWING STRUCTURE]
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3 (2.2)
g
14
q 11
T=5 r 15
(3.7)
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3-5 (2.2-3.7)
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
Boot replacement
The pilot control unit does not need to be removed from the machine to perform this operation.
R e ta in in g p la te
Boot replacement
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[14. UPPER SLEWING STRUCTURE]
1 L o c k in g s c r e w
3 A x is h o le
S w itc h p la te
a x is
4 5
2. Remove the screw locking the axis using a 2mm socket wrench. (See No. 1 of Fig. "Switch plate removal")
Reassembly:
1) Apply a droplet of Loctite #262 on the locking screw thread.
2) Tightening torque: 1.2N·m (0.9 lbf·ft)
3. Fit a M3 screw on the switch plate axis in order to remove it
(Using pliers if necessary). (See No. 2 of Fig. " Switch plate removal")
Reassembly:
Position the axis so that the hole is aligned with the locking screw as shown on the picture (See No. 3 of Fig. "
Switch plate removal")
4. Mark out the position of the switch plate before removing it.
5. Repeat the operation for the second switch plate.
6. Reassemble parts in reverse order.
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[14. UPPER SLEWING STRUCTURE]
Do not misadjust the two damping screws. (See Fig. "Switch plate (seeing from backside)")
14
Regulation Damping screws
screws to already adjusted
adjust and glued
SWITCH PLATE
The figure is shown
from the backside.
5. Repeat the operation for the second switch plate making sure both switch plates are parallel.
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[14. UPPER SLEWING STRUCTURE]
2. Unscrew simultaneously both screws holding the retaining plate using a 8mm socket wrench.
(See Fig. "Retaining plate removal")
Reassembly:
1) Apply a droplet of Loctite #262 on the screw thread.
2) Tightening torque: 30N·m (22 lbf·ft)
3. Lift the retaining plate to remove it. (See Fig.
"Condition with retaining plate removed")
Reassembly :
Use the retaining plate to insert the 4 guides into the
body simultaneously and perpendicularly. (See Fig.
"Condition with retaining plate removed")
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[14. UPPER SLEWING STRUCTURE]
D A M P IN G P L U N G E R
T H 6 N R B O D Y
D A M P IN G S P R IN G
Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly positionned.
3 4 B O D Y
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[14. UPPER SLEWING STRUCTURE]
5 6
7 8
2) Insert the seal within the groove with your fingers (lip in bottom position). (See No. 6 and 7 of Fig. "Damping
plunger seals replacement")
3) Push the seal against the side using the round head of a small socket wrench. (See No. 8 of Fig. "Damping
plunger seals replacement")
5. Repeat the operation for the other 3 assemblies.
6. Extract the damping springs from the body (using flat nose pliers).
7. Inspect the damping springs. If defects are detected, replace the 4 springs.
8. Reassemble parts in reverse order.
During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage nor twist it.
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[14. UPPER SLEWING STRUCTURE]
2. Guide/plunger replacement
Insert the end of a thin screwdriver between the guide and the body, carefully lift the guide to remove it from the
body.
3. Remove the guide / plunger assembly.
14
4. Repeat the operation for the other 3 sub-assemblies.
5. Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-
assemblies.
Hold the guides with the other hand during the extraction operation to limit the effect of the return spring.
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[14. UPPER SLEWING STRUCTURE]
14-154
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[14. UPPER SLEWING STRUCTURE]
SCREW
THROTTLE
2. Unscrew the screw using a 3mm socket wrench. (See Fig. "Throttle kit replacement")
Reassembly:
1) Apply a droplet of Loctite #262 on the screw thread.
2) Screw on until it sets just above the body. (See Fig. "Throttle kit replacement")
3. Unscrew the throttle using a 3mm socket wrench.
Reassembly:
Tightening torque: 4N·m (3 lbf·ft)
4. Repeat the operation for the other 3 assemblies.
5. Replace with new screws and new throttles.
6. Reassemble parts in reverse order.
14
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[14. UPPER SLEWING STRUCTURE]
The pilot control unit does not need to be disassembled to perform this operation.
2. Unscrew the shuttle valve using a 4mm socket wrench. (See Fig. "Shuttle valve kit removal")
Reassembly:
1) Thoroughly clean the body to remove any trace of loctite.
2) Apply a droplet of Loctite #242 on the shuttle valve thread.
Tightening torque: 4N·m (3 lbf·ft)
Wait for 8 hours before using the machine to let the Loctite #242 dry completely.
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[14. UPPER SLEWING STRUCTURE]
14
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[14. UPPER SLEWING STRUCTURE]
The pilot control unit does not need to be disassembled to perform this operation.
C H E C K V A L V E
P L U G
B A L L
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[14. UPPER SLEWING STRUCTURE]
14
14-159
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[14. UPPER SLEWING STRUCTURE]
Swing motor
993
390 391
VIEW I
351
355
051
(051-1)
469
702
488
401 712
151
171 161 163 985 444 984 131
052
A A
I Arrangement of brake spring
162
451
303
985
472
707 712
702
980
706 743
100
111
742
121
400-1
123 994
052
400-2
122 400
124 443 491 101 114 301 SECTION A-A
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[14. UPPER SLEWING STRUCTURE]
Tightening Tightening
torque torque
No. Parts Q'ty No. Parts Q'ty
N·m N·m
(lbf·ft) (lbf·ft)
0.9
301 Casing 1 980 Plug ; PF1/4 1
(0.7)
1.7
303 Valve casing 1 984 Plug ; PF3/8 1
(1.3)
4.4
351 Plunger 2
(3.2)
985 Plug ; PF3/4 3
14
65
355 Spring 2 993 Plug ; PT1/2 1
(48)
98
390 Name plate 1 994 Plug ; PT3/4 1
(72)
391 Rivet 2
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[14. UPPER SLEWING STRUCTURE]
Apply Three
Bond #1211. Apply Loctite #515.
Paint this machined surface. Apply Loctite #515.
Tightening torque
181 N .m (134 lbf .ft)
12 10 20 8 4 7 6 23 Apply Three Bond 1360K
OIL FILLING POR T P T3/4
A
2
LEVEL
POR T P T1/2
A
II
1 9 22 18 17 5 18 14 3 16 15 28 19
21 29 11
Be careful about
Insert 1mm(0.04") deep from installation direction
Lubricate grease.
the surface of Item 8 (spider). of retaining ring.
13 27 26 25
Wind seal tape around plug and
install it (tightening torque Wind seal tape around tube and install elbow to tube
10N .m (7 lbf .ft)) to item 26 elbow with tightening torque 30N .m (22 lbf .ft) and then make
until its surface becomes direction of elbow as shown in drawing by retightening.
the same surface of elbow end.
Wind the seal tape or
Install grease nipple apply the Locktite #577
as facing to motor side. 30 31 around the screw.
Tightening torque
10.8N .m (8.0 lbf .ft)
Leave installation angle as it is.
Punch here 2 portions to deform holes in order to
prevent spring pin (22) from coming out.
VIEW II
4 places
SECTION AA
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[14. UPPER SLEWING STRUCTURE]
Tightening Tightening
torque torque
No. Parts Q'ty No. Parts Q'ty
N·m N·m
(lbf·ft) (lbf·ft)
Tightening torque
Thread size Name Item No. of applicable part
N·m (lbf·ft)
When parts are different from the above-mentioned parts with item No., see the sectional assembly drawing.
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[14. UPPER SLEWING STRUCTURE]
Wrenches
Item No. of
Name Size Size Tool
applicable part
When plugs and bolts are different from the above-mentioned plugs and bolts, see the sectional assembly drawing.
Tool Size
Screw driver Middle-sized flat-head screwdriver, 2pcs.
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[14. UPPER SLEWING STRUCTURE]
14
(0.55”)
85 (3.35”)
75 (2.95”)
30 (1.18”)
15
(0.59”)
35 (1.38”)
2 .5 )
R1 49”
0 .
(
M16
Through
100 (3.94”)
30 (1.18”)
(0.55”)
44 (1.73”)
14
8 (0.31”)
M16
(0.16”)
BRAKE PISTON
4
DRAWING TOOL
o8
(0.31”) BRAKE PISTON
CASING
14
Tools
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[14. UPPER SLEWING STRUCTURE]
General precautions
• The hydraulic components are precise components and have small internal clearances between the parts, so
that perform disassembling and assembling works at a place where the amount of dust is small and clean. Use
each kind of tools and wash oil that are clean and be very careful about handling them.
• After removing the swing motor from the machine body, take sufficient care not to allow dust and water to enter
the inside, so clean the area around the ports carefully and plug them. In case of installing the swing motor to the
machine body, do not remove plugs until starting a piping work.
• Before starting work, consider the construction drawing and prepare required parts according to your objective
and a range of the work. Disassembled seals and O-rings are impossible to reuse.
Furthermore, some parts cannot be available as a single part, so that it needs to be replaced as a part of sub
assembly. Refer to the parts catalog and prepare the replacement part or sub assembly beforehand.
• The pistons and the cylinder block are already assembled in a new machine, so that if the pistons are to be
reused, make match marks when removing the pistons from the cylinder block.
Disassembling procedures
In case of disassembling the swing motor, disassemble it following the order below. The numbers inside the
parentheses ( ) following the part names show item numbers in the construction drawing of "Swing motor".
1. Wind a wire rope around the motor periphery, lift it by a crane, and wash it with kerosene. After washing it, dry it
with compressed air.
Mask each port by a tape, etc. to prevent foreign materials from entering inside the motor, and then wash adhered
soil and dust.
2. Drain the oil inside casing (301) from the drain port.
3. Place drive shaft (101) with the shaft end facing
downward on a workbench that is proper for easy
disassembling, and fix it to the workbench. At this
time, make match marks on the mating portions of
casing (301) and valve casing (303).
Select a clean place. Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
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[14. UPPER SLEWING STRUCTURE]
If necessary, remove anti-reaction valves (400) from casing of anti-reaction valve (100).
Be sure to replace the O-rings of the relief valves because they are damaged when loosening the relief valves.
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[14. UPPER SLEWING STRUCTURE]
Be careful not to allow the valve plate to fall off from the valve casing. (The valve plate may be attached to the
cylinder side.) When prying the mating surfaces with a screw driver, be careful not to damage the mating surfaces.
Hook the tip end of the jig to the groove of the brake piston and pull it up straight.
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[14. UPPER SLEWING STRUCTURE]
Be careful not to damage the sliding surfaces of the cylinder and the shoes. In case the shoe plate does not come
off, remove it in procedure 12.
11. Pull out friction plate (742) and separator plate (743)
from casing (301).
14
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[14. UPPER SLEWING STRUCTURE]
12. Pull out drive shaft (101) and shoe plate (124).
When pulling out the drive shaft, the spline will damage the oil seal, so that wind a vinyl tape, etc. around the spline
of the drive shaft.
Drive s ha ft
P la ce inne r ra ce
on pre s s s ta nd.
You can tap the inner race of the roller bearing by the hammer through the steel rod, but tap it evenly taking care
not to damage the bearing.
Do not reuse the removed bearing.
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[14. UPPER SLEWING STRUCTURE]
2) Tap the outer race of roller bearing (443) slightly from the housing side of oil seal (491) by the hammer
though the steel rod and then remove it from casing (301).
3) Remove roller bearing (444) from valve casing
(303) by using the slide hammer bearing puller.
That is all of the disassembling work. Inspect each part carefully for possible failure.
14
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[14. UPPER SLEWING STRUCTURE]
General precautions
Assembling is performed in the reverse order of the disassembling. Perform it taking care of the following items.
• Be sure to repair parts damaged during the disassembling work and prepare replacement parts beforehand.
• Wash each part by cleaning solvent sufficiently and dry it with compressed air.
• Be sure to apply clean hydraulic oil to the sliding portions and the bearings before assembling them.
• Always replace the sealing parts such as the O-ring and the oil seal, etc. in general.
• Tighten the mounting bolts and the plugs of each part using the torque wrench with the tightening torque shown
in the table.
Assembling procedures
Assembling procedures are described as follows. The numbers inside the parentheses ( ) following the part
names show item numbers in the construction drawing of "Swing motor".
1. Place casing (301) on a proper workbench with valve casing (303) side facing upward.
2. (This procedure is required only if the roller bearing is removed.)
Shrink-fit the inner race of roller bearing (443) onto drive shaft (101).
OUTP UT S IDE
Be careful about the orientation of the oil seal. (See the sectional assembly drawing.)
Apply a thin coat of grease to the lip of the oil seal. Tap the jig evenly, taking care not to damage the periphery
portion.
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[14. UPPER SLEWING STRUCTURE]
Be careful not to damage the lip of the oil seal when inserting the drive shaft. Protect the oil seal by winding a vinyl
tape, etc. around the spline portion of the drive shaft.
14
Install the shoe plate with its larger chamfer side facing the casing side. Apply a thin coat of grease to the mating
surfaces to prevent the shoe plate from falling off.
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
14
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[14. UPPER SLEWING STRUCTURE]
Tap the periphery of the outer race evenly until the outer race stops moving completely at the stepped portion of the
valve casing.
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[14. UPPER SLEWING STRUCTURE]
Apply a thin coat of grease to the mating surface of the valve plate. (falling off protection)
14
• Be careful about the orientation of the valve casing at installation. (See "ASSEMBLY DRAWING OF SWING
MOTOR UNIT")
• Be careful not to allow the valve plate to come off.
• Be careful not to allow the brake springs to fall down.
• Tighten the socket bolts evenly.
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[14. UPPER SLEWING STRUCTURE]
In case anti-reaction valves (400) are removed from casing of anti-reaction valve (100) at the time of
disassembling, install anti-reaction valves (400).
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[14. UPPER SLEWING STRUCTURE]
230 (9.1”)
a Stand
Material:
P.C.D 140
(5.5”) VIEW X
X
100 (4”)
removing jig (II)
SS400
Oil seal (15)
9
e 125 (4.9”)
installing jig
Material:
(0.35”)
132 (5.2”)
SS400
9
Material:
(2.4”)
(2.0”)
60
50
SS400
Spherical bearing (12) 91
h
press-fit jig (3.6”)
158
(6.2”)
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[14. UPPER SLEWING STRUCTURE]
Tools
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[14. UPPER SLEWING STRUCTURE]
13
13
14
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[14. UPPER SLEWING STRUCTURE]
13
11
29
21
J IG (a )
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[14. UPPER SLEWING STRUCTURE]
21
29
11
13
12
10 14
JIG (d)
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[14. UPPER SLEWING STRUCTURE]
14
• The shaft attached to spider assembly (7) is caulked. When replacing it, replace as the set of spider assembly.
• Pinions (3) cannot be replaced singly. Replace them it in a set of three.
29
21
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[14. UPPER SLEWING STRUCTURE]
2. Inserting sleeve
Insert sleeve (21) and oils seal (29) assembly in
pinion shaft (1).
29
21
11
14
Fitting spherical bearing (lower)
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[14. UPPER SLEWING STRUCTURE]
Applying grease
4. Fit oil seal (12) in housing (13) by using jig (g). JIG (g)
• Apply Three Bond #1211 to the periphery of the oil
seal.
• Fill one third (1/3) of the space of the groove-shaped
section on the oil seal lip with grease.
• Insert it horizontally taking care not to damage the oil 12
seal lip.
13
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[14. UPPER SLEWING STRUCTURE]
10
13
20
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[14. UPPER SLEWING STRUCTURE]
15
14
7
28 3
Attach the retaining ring with the sharp edge facing the motor side (upper side in the position of the figure
"Attaching retaining ring".
8 5
17
18
22
9
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[14. UPPER SLEWING STRUCTURE]
2) Fit thrust washer (18) and pinion (5) as in the figure, insert shaft (9) into spider (8), and then insert spring
pin (22).
Insert shaft (9) into spider (8) so that the holes for spring pin (22) are aligned with each other.
13
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[14. UPPER SLEWING STRUCTURE]
install it.
6
2. Engage #1 sun gear (2) with #1 pinion (3) to install
it. 3
Filling lubricant 13
Fill approx. 2.7 L (0.71 gal) of gear oil #90 (API Service
Classification GL-4 grade) in the swing reduction unit.
Installing #1 spider assembly
Installing swing motor assembly
1. Attach lifting eyes (M12) in the tapped holes for
lifting eye on the swing motor and put a wire sling to
them.
2. Apply sealant (Loctite #515) to the mating surfaces M14 130
of ring gear (6), insert the spline of the swing motor, 23
aligning the match marks.
3. Apply screw locking agent (Three Bond #1360K) to
socket bolts (23) and tighten them.
Tools: Allen wrench: 12 mm Match mark
Tightening torque: 181N·m (134 lbf·ft)
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[14. UPPER SLEWING STRUCTURE]
Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (inch)
mm (inch)
0.027 0.052
Replace piston or cylinder.
(0.00160) (0.00205)
0.3
0 Replace piston and shoe assy.
(0.0112)
5.5 5.3
Replace piston and shoe assy.
(0.217) (0.209)
t
14
Thickness of friction plate (t)
2.0 1.8
Replace.
(0.0787) (0.0709)
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[14. UPPER SLEWING STRUCTURE]
• Lap each sliding surface to the level that the surface roughness is equal or lower than the standard of surface
roughness.
• If the sliding ball surfaces of the spring plate and the cylinder are rough, replace these parts together.
Inspection at disassembly
1. Spacers and thrust washers
1) Inspect that the parts are not seized or worn abnormally or unevenly.
2) Inspect and measure the parts to see that the wear does not exceed the allowable values.
2. Gears
1) Inspect that the gear tooth surfaces do not show pitting and seizure.
2) Inspect the bottom of the teeth that it does not show cracks by dye penetrant test.
3. Bearings
Turn the bearings and check that they do not generate abnormal sound, catching and other faults.
Do not reuse the removed spherical bearings.
4. Oil seals
Do not reuse the removed oil seals. Be sure to replace the O-rings with new ones at assembly.
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[14. UPPER SLEWING STRUCTURE]
Maintenance standard
A D
G
H Lubrica nt le ve l C
B
14
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[14. UPPER SLEWING STRUCTURE]
Unit: mm (inch)
0
2.0
E Thickness of thrust washer –0.2 1.7 (0.067) Replace
(0.08) (-0.0079)
Wear of shaft 0
95 dia.
F (Diameter of section contacting -0.089 94.9 dia. (3.736) Replace
(3.740) (-0.0035)
with oil seal)
Gear oil # 90
H Lubricant (API Service 2.7 L (0.71 gal) Refill or replace
Classification GL-4 grade)
Pressure does Safety valve in circuit is not correctly. Set valve to correct value.
not increase.
Relief valve does not function well.
1. Sticking of plunger 1. Repair or replace stuck section.
Seat of plunger does not function well. Check seat section and replace it if damaged.
Brake is not applied with release pressure. Check and repair circuit.
Friction plate is seized. Disassemble and check it. Replace seized one.
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[14. UPPER SLEWING STRUCTURE]
Motor rotates Motor is assembled to rotate reversely. Check Fig. "ASSEMBLY DRAWING OF SWING
reversely. MOTOR UNIT" and reassemble it correctly.
Speed does Oil flow rate is insufficient. Check pump delivery rate and circuit to motor.
not reach set
Oil temp. is high and oil leaks abnormally. Reduce oil temp.
value.
Sliding parts are worn or damaged. Replace damaged parts.
Brake torque is Friction plate is worn. Disassemble and check it. Replace it, if it is worn
insufficient. more than criterion.
Brake piston sticks. Disassemble and check it.
Spline of friction plate is damaged. Disassemble and check it. Replace it if damaged.
When external Relief valve does not function well. Replace it.
driving torque
Same as item "Hydraulic motor does not rotate.". Same as item "Hydraulic motor does not rotate.".
is applied to
motor, it slips Seat of plunger does not function well. Replace it.
too much.
Oil leakage 14
Oil leaks from oil seal.
Oil leaks from Lip catches foreign materials and is damaged. Replace oil seal.
oil seal.
Shaft is scratched or worn. Shift lip and shaft contact position or replace them.
Lip of oil seal is turned up due to abnormally If drain piping is clogged, repair it.
increased internal pressure of casing.
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[14. UPPER SLEWING STRUCTURE]
Oil leaks O-ring is unintentionally omitted. Install it correctly and carry out reassembling.
through mating
O-ring is scratched. Replace it.
surfaces.
Seal surface is scratched. Disassemble and repair it.
Bolts are loose or damaged. Tighten them with specified torque or replace them.
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[14. UPPER SLEWING STRUCTURE]
2) Oil leakage
Disassemble and apply
Oil leaks through mating surfaces. Liquid packing is not applied. liquid packing.
3) Temperature is high.
Check oil level and fill oil
Temperature of reduction unit casing is high. No gear oil or oil level is low. up to specified level.
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[14. UPPER SLEWING STRUCTURE]
VIEW Y
5
5 places
7 3 places
Tighte ning torque
3 30.4 N .m (22.4 lbf .ft)
10 Apply Loctite #242
4
11 2 places
Tighte ning torque
30.4 N .m (22.4 lbf .ft)
Apply Loctite #242
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[14. UPPER SLEWING STRUCTURE]
Tools
Item Part name Used for Remarks
Steel hammer
a Hammer
Wooden or plastic mallet
Spatula
Disassembly and Approx. 120 mm (4.72 inch)
f
assembly
Disassembly and
g Vise Vise with movable range of 150 mm (6 inch) or more
assembly
h Loctite - #242
i Lubricant - Hydraulic oil or vasaline
j Wash oil - -
Facility
1. Hoist or crane
Prepare lifting devices that are capable of lifting the swivel joint in an assembly condition.
2. Workbench
14
A workbench with the size of approx. 1.2 m X 1.5 m (4ft X 5ft) is required.
3. Others
Waste clothes, wooden blocks, and containers for drain oil are required.
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[14. UPPER SLEWING STRUCTURE]
ALLEN WRENCH
EXTENTION BAR
When removing thrust plate (3) by fixing body (1), support stem (2) to prevent it from falling off.
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[14. UPPER SLEWING STRUCTURE]
Be careful not to damage body (1) by the tip of the spatula. Also, do not hit the spatula.
O -R IN G
G R O O V E
S E A L (6 ) P IN (e ) S E A L G R O O V E
A S S Y
O IL G R O O V E
S E A L (5 ) S E A L G R O O V E
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[14. UPPER SLEWING STRUCTURE]
Enclose grease in the seal grooves of seal (6) and O-rings (8).
1. Installing sealing parts
1) Apply a thin coat of petroleum jelly (or hydraulic
oil) to O-rings (8) and then attach them in the O-
ring grooves.
After attaching them, check the O-rings for twist.
2) Attach the slipper ring of seal assembly (6) by
deforming it little bit as shown in the right figure
after inserting the backup ring. Then, after all
sealing parts are inserted, securely put them into
the seal grooves by using the spatula.
3) Assemble seal (5) by the same procedure above.
Remove petroleum jelly, hydraulic oil and grease from the seal groove completely before installing seal (5).
Seal (5) does not have a backup ring.
2. Assembling stem
Apply a thin coat of grease or petroleum jelly to the
Press in by applying your weight by your hands
periphery of stem (2) or the inside of body (1) and
then insert stem (2) slowly into body (1).
1
6
Work bench
• Insert stem (2) slowly because if it is pressed in too fast, the seal could be damaged.
• The clearance between body (1) and stem (2) is approx. 0.1 mm (0.0039 inch) so that push in the stem straight
along with the axial center.
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[14. UPPER SLEWING STRUCTURE]
4. Assembling cover
1) After installing O-ring (7) to cover (4), align the
1
match marks of cover (4) and body (1) with each MATCH MARK
other.
2) Apply Loctite #242 to socket bolts (10), and then 10
install and tighten them. That is all of the
assembling work. 4
Tools: Allen wrench: 6 mm
Tightening torque: 30.4N·m (22.4 lbf·ft)
ALLEN WRENCH
EXTENTION BAR
Protection seal
Replace O-ring if any oil leakage is
14
2,000hr for oil leakage Check oil leakage outside
found.
outside
Replace all sealing parts.
4,000hr Seal assembly
In principle, All sealing parts - (slipper ring, and backup ring)
disassemble and Seal
check swivel joint O-ring
regardless of
occurrence of oil Check abnormal wear, scoring, or
Repair or replace according to service
leakage All sliding parts corrosion caused by foreign materials or
limit.
seizure.
When
Check seizure, foreign materials, Repair or replace according to service
disassembly is
All parts abnormal wear, and deformation or limit. All O-rings and seals should be
performed due to
damage of seals. replaced.
failure
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[14. UPPER SLEWING STRUCTURE]
Protrusion
Replace
(with backup ring)
Backup ring
Slipper ring
Replace
(with backup ring)
1.5 mm(0.06 inch)
(Ma x.)
Backup ring
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[14. UPPER SLEWING STRUCTURE]
3 Stop valve
6 Stop valve
Set pressure:
High pressure relief
7 (Working pressure X
valve
1.5)
8 Selector valve
9 Pipe, etc.
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[14. UPPER SLEWING STRUCTURE]
TROUBLESHOOTING
External leakage of hydraulic oil Defective O-ring & seal Replace all sealing parts.
Internal leakage of hydraulic oil Defective slipper ring Replace all sealing parts.
Seizure of swivel stem Seizure of stem and body Perform grinding and honing.
Replace assembly, if stem and body
are too loose and causing oil
leakage.
Looseness of swivel stem and cover Insufficient tightening of socket bolt Retighten bolt with specified torque.
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[15. TRAVEL SYSTEM]
15
15-1
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[15. TRAVEL SYSTEM]
15-2
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[15. TRAVEL SYSTEM]
15
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[15. TRAVEL SYSTEM]
15.2 FOREWORD
1. This Manual describes all the procedures from removing to attaching, arranging them by item.
2. This Manual consists of the first half, "REMOVING AND INSTALLING ASSEMBLY", and the second half,
"REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT".
3. The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
4. The removing and attaching procedure does not completely cover all possible situations because of
differences of field condition and defective section.
5. Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
15-4
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[15. TRAVEL SYSTEM]
10
6 9
8
7 3
2
5
4
15
15-5
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[15. TRAVEL SYSTEM]
• When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
• Where grease does not come out well, move the machine back and forth. The over loosening of grease nipple
may cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple.
R e m o v in g / fix in g
p o s itio n o f m a s te r p in
When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by
flying objects.
15-6
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[15. TRAVEL SYSTEM]
4) Removing crawler R e m o v in g
Put attachment on ground so that weight is not m a s te r p in
loaded to the lower frame, and remove track link
assy rotating sprocket.
Removing crawler
Crawler end section may fall on the ground just before extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
15
15-7
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[15. TRAVEL SYSTEM]
2. Installing crawler
• Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
1) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm (0.39 to 0.79 inch) above
the ground level by holding it by hand so the
machine body weight is not exerted on the shoe.
Retract the sprocket to help push the back
winding of the crawler.
3. Preparation for press fitting master pin
Winding crawler
1) Put square wood under the shoe plate.
(Refer to the figure "Removing/fixing position of master pin").
• When using a big hammer, exercise care so you are not injured by flying objects the same way as when pushing
out the master pin.
• Coat the master pin with molybdenum disulfide grease, before pressing it in.
15-8
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[15. TRAVEL SYSTEM]
15
15-9
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[15. TRAVEL SYSTEM]
1-6
1-1
1-8
1-4
1-3 2
1-8
1-7
3
1-1
4
1-7 1-5
1-2 1-2
LC SPECIFICATION
15-10
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[15. TRAVEL SYSTEM]
MAINTENANCE STANDARD
F E
D D G
B
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Link pitch 190 ±0.13 (7.4803 ± 0.0051) 194 (7.64) 198 (7.80)
Replace the
+0.1 (+0.0039) link assy if the
B O.D. of bushing 59.41 dia. (2.3390) 56 dia. (2.20) 55 dia. (2.17)
0 service limit is
exceeded
C Height of link 110 ±0.25 (4.3307 ± 0.0098) 104 (4.09) 104 (4.02)
Basic
Interference Tolerance Fit Fit
dimension
D between bushing
and link 59.41 dia. +0.1 (+0.0039) Interference Interference
Shaft
(2.3390) 0 0.05 (0.0020) 0 Replace
Interference
38.19 dia. +0.2 (+0.0079) Interference Interference
E between track pin Shaft
(1.5035) -0.1 (-0.0039) 0.05 (0.0020) 0
and link
Interference
37.8 dia. Interference Interference
F between master Shaft ±0.04 (±0.0016) Replace Link
(1.4882) 0.05 (0.0020) 0
pin and link
Tightening torque
H 853 N·m (629 lbf·ft) Retightening
of shoe bolt
15
TOOLS AND JIGS
TIGHTENING TOOLS
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 30
15-11
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[15. TRAVEL SYSTEM]
JIGS
Name Shape
15-12
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[15. TRAVEL SYSTEM]
3 NUT 4
4 WASHER 8
Preparation
Remove the crawler (by the above-mentioned procedures).
• Removing upper roller (1)
15
15-13
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[15. TRAVEL SYSTEM]
Inspection
Before reassembling, check it that it rotates smoothly by hand and for leak.
1. Install cap screws (2) by installing the nuts on the
position shown in VIEW I and II. MACHINE FRONT MACHINE FRONT
S TAMP
2. Insert the roller until the collar comes in contact with 2 3
the support. 4 4 4 4
3. Fit it directing the stamp on the shaft end upward. 3 2
S TAMP
4. Apply Loctite #262 on capscrew M20X120, and
tighten it to the specified torque. VIEWéé (LEFT SIDE) VIEWèè (RIGHT SIDE)
Tools: Socket: 30 mm
Tightening torque: 539 N·m (398 lbf·ft)
1
è è
é é
15-14
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[15. TRAVEL SYSTEM]
2 Shaft 1 7 Bushing 1
15
15-15
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[15. TRAVEL SYSTEM]
Collar (3) is press-fitted into shaft (2). Therefore do not disassemble it.
15-16
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[15. TRAVEL SYSTEM]
15
15-17
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[15. TRAVEL SYSTEM]
Pushing in bushing
If you fail in this operation by press-fitting the bushing unevenly, the bushing is distorted and gets unserviceable. In
that case, do not re-use the bushing as it may develop malfunctioning after assembly.
3 1
Inserting shaft
15-18
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[15. TRAVEL SYSTEM]
9. Refilling oil
Refill 62 to 68cc (3.78 to 4.15 cu·in) of engine oil
API grade CD #30 through the plug hole of cover 10
(5). 5
1
10. Installing plug (10) 4
Wind seal tape around plug (10) and screw it into
9
the plug hole of cover (5).
Tools: Allen wrench: 6mm
Tightening torque: 21.6 to 24.5N·m (15.9 to 18.1
lbf·ft)
• After assembling the lower roller, confirm that oil f
is not leaking from the lower roller unit and that
the roller rotates smoothly by hand.
Refilling oil
15
15-19
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[15. TRAVEL SYSTEM]
E
F
D D
B
G
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. 140 dia.(5.51) - -
Basic
Clearance Tolerance Fit Fit
dimension
E between shaft and
bushing 45 dia. +0.086 (+0.0034) Clearance Clearance
Shaft Replace
(1.772) -0.066 (–0.0026) 0.7 (0.028) 1.0 (0.039)
bushing
Interference
49 dia. +0.210 (+0.0083) Interference Clearance
F between roller and Hole
(1.929) -0.186 (-0.0073) 0 0.01 (0.0004)
bushing
Tightening torque
G 115 N·m (85 lbf·ft)
of socket bolt
Oil Engine oil API grade CD #30, 62 to 68cc (3.78 to 4.15cu·in) Refilling
TIGHTENING TOOLS
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 30
Allen wrench 6, 10
15-20
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[15. TRAVEL SYSTEM]
JIGS
Unit : mm (inch)
120 (4.72)
90 (3.54)
160 (6.30)
f Cradle jig
52.5(2.07)
g
(0 .7 0 9 )
Shaft push-out jig
18
48(1.89)
+0 . 1
+0 . 1
0
0
4 4 .6
4 8 .5
Bushing press-fitting
i
1 . 7 5 6 +00 .0 0 4
1 . 9 0 9 +00 .0 0 4
jig (1.26)32
(1.46)37 50(1.97)
87(3.43)
15
15-21
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[15. TRAVEL SYSTEM]
2 1 B2
Apply Loctite #262
T=455N .m (336 lbf .ft)
ROLLER LC LQ64D00066F1
Assembly NLC LQ64D00025F1
No. NAME Q'TY REMARKS
LQ64D00063F1
1 Lower Roller 16
(LC)
YN64D00058F1
1 Lower Roller 16
(NLC)
2 Capscrew 64 M18×80(P=1.5)
15-22
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[15. TRAVEL SYSTEM]
HD YN01F00048F1
Lower Roller
STD YN01F00047F1
No. NAME Q'TY
B2 TRACK GUIDE : YN63D00006P2 2 4
B5 CAPSCREW : M18X40(P=1.5) 8 16
15-23
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[15. TRAVEL SYSTEM]
6 9 1 2 4 53 7
LC YN64D00058F1
Lower Roller
NLC LQ64D00063F1
No. NAME Q'TY REMARKS
1 ROLLER 1
2 SHAFT 1
3 COLLAR 1
4 BUSHING 2
5 FLOATING SEAL 2
6 PIN 2
7 O-RING 2 1A G60
8 PLUG 1 PT1/4
9 COLLAR 1
15-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
The shaft (2) pushing-out operation may cause the remaining lube oil to flow out. Prepare an oil container
beforehand.
1
15
15-25
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[15. TRAVEL SYSTEM]
JIG M
Strike the inside surface of the roller lightly with a mallet so as not to damage the surface. Put push-out jig (N)
securely over the circumference of bushing (4) and push-out it perpendicularly little by little.
15-26
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[15. TRAVEL SYSTEM]
9
7
15-27
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[15. TRAVEL SYSTEM]
2
9
7
After assembling the lower roller, confirm that oil is not leaking from the lower roller unit and that the roller rotates
smoothly by hand.
15-28
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[15. TRAVEL SYSTEM]
D
E
A
Lower roller
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange 185 dia.(7.28) - -
Build up repair or
B Tread dia. 150 dia.(5.91) 134 dia.(5.28) 128 dia.(5.04)
replacement.
C Flange width 33.5 (1.32) 18 (0.71) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
D shaft and bushing -0.060
(Wrapped bushing) 65 dia. (-0.0024) Clearance Clearance
Shaft
(2.56) -0.090 0.7 (0.28) 1.0 (0.39) Replacement of
(-0.0035) bushing
+0.030
Interference between 69 dia. (+0.0012) Interference Clearance
E Hole
roller and bushing (2.71) -0.020 0 0.01 (0.0004)
(-0.0008)
F Oil Engine oil API grade CD #30, 150 to 170cc (9.2 to 10.4cu·in) Refilling
Plug (8) : LC Execute air leak test at 0.245MPa (35.5psi) before tightening the plug.
H
Plug (8) : NLC Execute air leak test at 0.2Mpa(29psi) before tightening the plug.
TIGHTENING TOOLS 15
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 19 and 27
Allen wrench 6
15-29
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[15. TRAVEL SYSTEM]
JIGS
Unit : mm (inch)
K V-block
100(3.94)
Pin (5)
(0 .5 5 1 )
L
14
push-out rod
1 6 (0 .6 3 0 )
200(7.87)
Bushing
N
push-out rod
290(11.4)
1 6 0 (6 . 3 0 )
M Cradle jig
(4 .9 2 )
125
270(10.6)
Shaft
P
(2 .5 2 )
push-out jig
64
(1 . 1 8 )
30
86(3.39)
9 4 . 5 (3 . 7 2 )
6 4 . 5 (2 . 5 4 )
Bushing
Q
press-fitting jig
+0.1
64.6 0
(2.543 +0.004
0 )
15-30
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[15. TRAVEL SYSTEM]
BAR
15
15-31
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[15. TRAVEL SYSTEM]
3
4
15-32
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[15. TRAVEL SYSTEM]
1
2
3
7
8
6
5
4
Idler assembly
15
Removing pin (5)
15-33
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[15. TRAVEL SYSTEM]
U
3
15-34
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[15. TRAVEL SYSTEM]
15-35
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[15. TRAVEL SYSTEM]
2 Bracket 1
3 Nut 1
4 Spring pin 1 8 dia.X80
5 Spring 1
6 Piston 1
7 Collar 1
8 O-ring 1 1B G80
9 U-packing 1
10 Pin 2
Preparation
• Spring set special jig
Before disassembling and assembling the idler
M30
adjuster assembly, prepare track spring set jig (V). HOLDING-DOWN NUT
(See "TRACK SPRING SET JIG" in Chapter
"TOOLS") RETAINER PLATE
Hydraulic jack capacity : 20 ton (44,100 lbs) or more
Tools: Wrench: 46 mm
S TAND
HYDRAULIC JACK
BASE
Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.
15-36
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[15. TRAVEL SYSTEM]
1. Place a hydraulic jack between the jig base and the stand. Loosen the holding-down nuts of the jig and draw
out the retainer plate upward.
Tools: Wrench: 46 mm
2. Drawing out piston (6)
(See Fig. "Idler adjuster assembly".)
Draw out piston (6) from grease cylinder (1) of the idler adjuster assembly.
3. Removing U-packing (9), and O-ring (8)
(See Fig. "Idler adjuster assembly".)
Take out U-packing (9) and O-ring (8) from grease cylinder (1).
4. Slinging idler adjuster assembly
Set the idler adjuster assembly with the above-
2
mentioned parts removed on the stand of the jig,
with its bracket (2) side facing up.
S TAND
RETAINER PLATE
4
15-37
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[15. TRAVEL SYSTEM]
15-38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
15
15-39
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[15. TRAVEL SYSTEM]
15-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
D
E
A
Idler assembly
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection 535 dia. (21.1) - -
B Tread dia. 497 dia. (19.6) 490 dia. (19.3) 487 dia. (19.2) Replacement
Basic
Tolerance Fit Fit
dimension
Clearance between -0.03
D
shaft and bushing 75 dia. (-0.0012) Clearance Clearance
Shaft Replacement of
(2.9528) -0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.0024)
+0.035
Interference between 83 dia. Interference Clearance
E Hole (+0.0014)
idler and bushing (3.2677) 0 0.01 (0.0004)
0
F Oil Engine oil API CD class # 30, 200 cc (12.2cu·in) Refilling
15
15-41
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[15. TRAVEL SYSTEM]
X aa
A, B
INSTALLA HELICAL S P LING, WHOS E S TARTING P OINT
D AT ITEM 2 BRACKET S IDE TO BE 35 DEGREES
EES
5 DEGR
3
DETAIL aa
SECTION XX
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 24
Allen wrench 5
Unit : mm (inch)
(1 . 1 8 )
15
30
15-42
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Unit : mm (inch)
340 (13.4)
(2 . 9 1 )
S Shaft push-out jig
74
(0 .6 3 0 )
16
300(11.8)
U Cradle jig
(0 .7 8 7 )
105(4.13)
20
9 0 (3 . 5 4 )
Bushing press-fitting
7 0 (2 . 7 6 )
V
jig
+0. 1
74.6 0
(2.937 +0.
0
004
)
103(4.06)
15
15-43
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
• Removing sprocket
Loosen 30 sprocket mounting capscrews (5)
M16X55, and remove sprocket (4).
Weight of sprocket: 50 kg (110 lbs)
Tools: Socket: 24mm
Removing sprocket
15-44
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[15. TRAVEL SYSTEM]
UNIT: mm (inch)
B
190 (7.480")
C
Sprocket
Unit: mm (inch)
STANDARD VALUE
REPAIRABLE SERVICE
No. NAME Basic REMEDY
Tolerance LEVEL LIMIT
dimension
658 dia. Build up repair or
A O.D. of sprocket ±2 (±0.079) 650 dia.(25.6) 648 dia.(25.5)
(25.90) replacement.
Width of sprocket
B 66 (2.520) ±2 (±0.079) 60 (2.36) 58 (2.28) Replacement
teeth
I.D. of sprocket +2 (+0.079) Build up repair or
C 585 dia.(23.1) 577 dia.(22.7) 575 dia.(22.6)
bottom –1 (–0.039) replacement.
TIGHTENING TOOLS
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 24
15
15-45
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[15. TRAVEL SYSTEM]
15-46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
2
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N .m(206 lbf .ft)
6
1
15-47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
3. Removing sprocket
Remove 30 (one side) capscrews (5) M16X55.
Tools: Socket: 24 mm
4. Loosening travel motor mounting bolts (2) REMOVE PIPES (CUT OIL COMMUNICATION)
Apply match marks on the travel motor and the
crawler frame, and remove 27 (one side) capscrews
(2) M16X55.
Tools: Socket: 24 mm
15-48
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Tightening torque
TIGHTENING
TOOLS
NAME SIZE NO. TORQUE REMARKS
HEX
N·m (lbf·ft)
15
15-49
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
FRONT
A A
2 SECTION AA
Matchmarks
15-50
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
GREASE BATH
temporarily.
Tools: Socket: 30 mm A A
15-51
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
2
4
3
15-52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
1
PUSH-OUT ROD 6
2
3
5
WOOD BLOCK
EYE BOLT
HOOK ROD
WOOD BLOCK
To insert ball (3) and retainer (4), use a push rod or hook rod etc., to protect persons from injury from inserting
fingers into the plug hole.
15
4. Install plug (8) to outer race (1) while checking the orientation and position of the taper pin hole.
5. Apply the adhesive (Cyano Bond PX-3000 or equivalent) to the groove for seal (6) and attach the seal to the
groove of outer race (1) all the way around. And connect both ends of seal (6) with the adhesive (Cyano Bond
PO-X or equivalent).
6. After completion of assembly, caulk the hole portion of taper pin (7) by punching.
7. Check that grease nipple (9) is in proper condition, and fill it with the grease (extreme pressure heavy duty).
Then, check the swing bearing for smooth rotation and the seal lip portion for flaws.
• Shell Albania EP#2; 160 cc (9.8 cu·in)
15-53
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[15. TRAVEL SYSTEM]
Z3 Z3
17 22 23 19,20 21 24 26 23 25 17
X1 X1
28
S ECTION Z6-Z6
(1P LACE)
29
11 13 12 7 6 5 4 3 67 30 8 9 10 S ECTION Z5-Z5
(3P LACES )
65 66
Z6
Z4 Z4
Z6
33 34 15 14 14 15 34 33
18
S ECTION Z4-Z4 S ECTION X1-X1
15-54
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
18 18 18
Z5 Z5
Z5
Z5
Z5 Z5
41 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96
52 87
60 90
51 91
69 92
62 88
89
93
32
31
50
68 94
95
59
56 97
98
64
83
60
84
57 63 58 55 54 1 36 46 70 47 49 53 71 99 77 78 79 80 81 82
15-55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
9.8 PLUG;
2.5 18 8 68 PLUG; PT1/2 1
(7.2) METALPLUG M5
SPOOL A :
19 2-SPEED 1 69 PLUG; PT1/4 1
CHANGE OVER
20 SPOOL C 1 70 FLOATING SEAL 2
ANGULAR
21 SPRING 1 71 2
BEARING
118 HOUSING
10 22 PLUG; PF1/2 1 72 1
(87) (RING GEAR)
539* Torques
26 WASHER 1 76 BOLT; M20X70 8
(398) T90
2.45
2.5 28 ORIFICE; M5X5 1 77 THRUST PLATE 4
(1.81)
2.45
2.5 29 ORIFICE; M5X5 3 78 INNER RACE 4
(1.81)
2.45 NEEDLE
2.5 30 ORIFICE; M5X5 2 79 4
(1.81) BEARING
15-56
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
47 BALL 2 95 COVER 1
73.4
48 PISTON ASSY 2 8 96 BOLT; M10X16 16
(54.1)
157
49 BALL BEARING 1 12 97 PLUG; PF3/4 3
(116)
15
15-57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
15.4.1.2 TOOLS
Standard tools
Application Application
Tools name Type・・size Tools name Type・・size
Item (No.) Item (No.)
Hex bit for Opposing flats 8 96 Minus driver 6X100 2, 62, 68, 70
socket wrench Opposing flats 10 13, 22 Plastic hammer Nominal #3
Opposing flats 12 52, 97 For M20
Eye bolt
Opposing flats 14 6,15 For M12 2
Materials
Application Application
Materials name Description Materials name Description
Item (No.) Item (No.)
15-58
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[15. TRAVEL SYSTEM]
Special tools
Application Application
Special tools name Description Special tools name Description
Item (No.) Item (No.)
Measuring instrument
Measuring Application
Description
instrument name Item (No.)
15
15-59
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Cap (11) is pressed out by spring(9). Therefore, do the work, taking care of the following.
• Loosen socket bolts (13) evenly all round.
• Loosen socket bolts (13), holding down cap (11).
Plunger (3) and base plate (2) have a very tight fit. Therefore, do the work, paying attention to the following.
• In case plunger (3) gets stuck halfway and does not come out, do not try to force it out. If it is pulled out by force,
the bore surface of base plate (2) and the outer surface of plunger (3) are scored.
In case the plunger gets stuck halfway, do as follows:
Put plunger (3) back into base plate (2) by lightly tapping the end face of it with a plastic mallet. Then make sure
that the plunger (3) moves smoothly and draw out the plunger (3) once again, turning it by hand.
• Do not disassemble plunger (3) unless it is necessary; the outer surface of it may be scored at disassembly.
15-60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
17-6 2
17-16
17-15
17
Relief valve assy (17) is set at certain pressure. The set pressure of it determines the starting power and the
braking power of the motor.
For this reason, do not do the following.
• Do not loosen nut (17-16) and tamper with set screw (17-15). If the set screw is turned, the set pressure of the
relief valve changes, making the motor unable to attain required performances.
• Do not disassemble the relief valve assy. Otherwise, the set pressure changes and the motor is unable to attain
required performances.
17-3
15-61
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
2
19
22
Spool (19) and base plate (2) are combined to a very small fit. For this reason, execute the work, paying attention to
the following.
• Do not disassemble spool (19) unless necessary.
• In case the spool gets stuck halfway, do not force it out. If the spool is forced out, the bore surface of base plate
(2) and the outer surface of spool (19) are scored.
If it gets stuck, do as below.
Put spool (19) into base plate (2) once again by lightly tapping the end face of spool (19) with a plastic mallet.
Then, make certain that spool (19) moves smoothly and draw it out, turning spool (19) by hand.
52
2
59
15-62
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[15. TRAVEL SYSTEM]
60
When removing base plate (2), do the work, taking care of the following.
• Base plate (2) is pushed up by the action of spring (59). Therefore, loosen the cap screws evenly all round.
• A positioning knock pin (60) is placed between base plate (2) and the main body. When removing base plate (2),
do it upright toward the motor shaft center so knock pin (60) is not wrenched. In case it is wrenched, bring knock
pin (60) back in place by lightly tapping base plate (2) with a plastic mallet and remove the knock pin.
• When removing base plate (2), valve plate (62) comes with base plate (2). Since the moving surface of valve
plate (62) tends to be scored, use care so valve plate (62) does not fall.
15
When removing valve plate (62), take care of the following.
• The moving surface of valve plate (62) tends to be scored. If the surface is scored, desired performances are not
available; use care so as not to score it.
15-63
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
60
63
64
56
56
57
58
54
55
54
55
54
15-64
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
37
When drawing out cylinder block (37), use care of the following :
• Hold cylinder block (37) by both hands and take it out slowly, while turning it both ways lightly.
• Exercise care so as not to score the moving surface of cylinder block (37) in contact with valve plate (62). If the
surface is scored, desired performances will not be attained.
• Exercise care so as not to score the moving surface of the shoe of piston assy (38). Desired performances will
not be attained if the surface is scored.
37 15
38
39
15-65
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
39
38
45
37
40
37
When removing snap ring (41), take care as below, so as not to injure yourself.
• If snap ring (41) is tight to remove with snap ring pliers, you may injure yourself when the snap ring comes off
from the pliers. Always use the removing jig to remove the snap ring and make certain that the claw of the pliers
is set in the hole of the snap ring.
15-66
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
43
42
37
46
15-67
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
36
49
97 97
15-68
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[15. TRAVEL SYSTEM]
72
95
91
94
15
93
15-69
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
1 s t s ta g e h o ld e r a s s y
Use care of the following when removing the 1st stage holder assy :
• Take care so you do not pinch your fingers at removing.
15-70
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
83
78
80 77
81
82
76
99
15-71
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
99
72
72
70
15-72
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[15. TRAVEL SYSTEM]
15
15-73
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
1
70
Make certain that there is no dust on the surface of flange (1) in contact with floating seal (70).
• Thoroughly degrease the surface where floating seal (70) of flange (1) is located.
• Make sure that no dust is there on the O-ring of floating seal (70).
• Thoroughly degrease the surface of the O-ring in floating seal (70).
71
72
71
Angular bearing fixing jig
15-74
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Floa ting s e a l
fixing jig
70
72
Make certain that there is no dust and foreign matter on the surface on which floating seal (70) in housing (72) is
located.
• Thoroughly degrease the surface where floating seal (70) in housing (72) is located.
• Make sure that there is no dust and foreign matter on the O-ring of floating seal (70).
• Thoroughly degrease the surface of the O-ring in floating seal (70).
72
Make certain that there is no foreign matter on the moving surface of the seal ring located in floating seal (70).
• Apply lubricating oil for the reduction unit or hydraulic oil to all sliding surface of seal ring located in floating seal 15
(70).
• When assembling housing (72) into flange (1), make sure that the shaft centers are aligned with each other.
15-75
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
h
Press load : 3,000kgf (6,600 lbf)
J IG
H
71
2) In that case, measure the step H between the end face of the inner race of angular bearing (71) and the end
face of flange (1).
3) Measure the step h at holder (74).
4) Select and combine the repair kit [T=0.05mm (0.002inch), 0.1mm (0.004inch), 0.3mm (0.012inch), 0.5mm
(0.020inch), 1.0mm (0.039inch)] of shims (73) so as to attain shim thickness that matches (H-h).
15-76
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
73
74
99
75
76
75
Be wa re of the a s s e mbling
dire ction of wa s he r (75).
Look a t the dire ction on
the figure on the right.
80 77 79 78
Place the draft on
the holder (74) side.
74 Assembling direction of
15
thrust plate (77)
15-77
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Assemble thrust plate (77) to planetary gear C (80) so the draft of the thrust plate (77) is located on holder C (74)
side.
• When the planetary gears C (80) are installed finally to the holder C (74), mesh the inner gear of housing (72)
with gear of planetary gear C (80).
• Use care of the assembling direction of planetary gear C (80).
81
Use care of the attaching direction of thrust plate (81). If the neck of the bolt is damaged, it breaks down.
• Clean the screw threads of bolt (82) thoroughly, degrease it and coat it with Locktite.
• Clean the screw threads in the tapped hole of holder C (74) thoroughly and degrease it thoroughly.
15-78
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
84 83
Engage the teeth of planetary gear C (80) with those of sun gear C (83) and assemble them together.
83
85
15
15-79
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
89
85
87
88
P la ce the dra ft on 89 86 88 87
the holde r (85) s ide .
85
Attach thrust plate (86) to planetary gear B (89) so the draft side (by press) of thrust plate (86) is located on the
holder B side (85).
• Finally, when assembling planetary gear B (89) to holder B (85), engage the inner gear teeth of housing (72) with
the teeth of planetary gear B (89)
• Be careful of the assembling direction of planetary gear B (89).
15-80
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
72
Measure the step T.
91
94
Unit : mm (inch)
Step Shim
Thrust plate code
dimension (T) thickness (t)
1.20 to 0.67
20941 - 62306 2.3 (0.09)
(0.0472 to 0.0264)
0.66 to 0.04
20941 - 62307 2.8 (0.11)
(0.0260 to 0.0016)
0.03 to -0.16
20941 - 62308 3.0 (0.12)
(0.00122 to -0.0063)
-0.174 to -0.41
20941 - 62309 3.2 (0.13)
(-0.00685 to -0.0161)
-0.42 to -0.80
B0841 - 23017 3.6 (0.14)
(-0.0165 to -0.0315)
15
Align the hole in the center of thrust plate (94) with the convex part of drive gear (93) and assemble them together.
15-81
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Motor
1. Fitting oil seal (53)
Make sure that flange (1) is equipped with oil seal
(53). If not, press oil seal (53) into flange (1), using
the oil seal fixing jig.
Oil s e a l
fixing jig
53
15-82
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Before attaching oil seal (53), apply grease to the bore surface of flange (1) and outer diameter surface of oil seal
(53).
• Coat the lip of the bore of oil seal (53) with grease and put it in.
• Push the oil seal upright. If it is tilted, the outer diameter of oil seal (53) will be scored.
• Be careful so as not to score the lip of the bore of oil seal (53) when fixing it. If the lip is scored, oil leakage may
occur and break the inside of the reduction gear while the motor is running.
47 15
15-83
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Before fixing steel balls (47), apply hydraulic oil to the bore surface in the spherical part of flange (1) and steel balls
(47).
15-84
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Assemble swash plate (46) by matching the holes in the rear spherical surface of the swash plate (46) to steel balls
(47).
• After coating steel balls (47) with hydraulic oil and assemble swash plate (46).
• After assembling swash plate (46), make sure that the swash plate moves smoothly.
37
J IG
15
If snap ring (41) is tight, the snap ring pliers come off from the snap ring and you are injured by it, in some cases.
When fixing the snap ring, always use a jig and make sure that the claw of the snap ring pliers is engaged in the
hole of the snap ring
• If it is difficult to narrow the snap ring, use snap ring pliers one size larger.
• To press in collar (44), align the center of the cylinder block with that of the press.
15-85
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
37
Before placing cylinder block (37) on a work bench, make certain that there is nothing on the work bench.
• Use care so as not to score the sliding surface of valve plate (62) in cylinder block (37). If the surface is scored,
the motor performances are deteriorated which leads to a failure of the motor in an early stage.
• Before fixing pins (45), coat the pin holes with grease.
37
40
39
38
15-86
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
37
38
Coat the piston holes (9pcs.) in cylinder block (37) with hydraulic oil, before installing piston assy (38)
• Coat the spherical surface of retainer holder (40) with hydraulic oil, before assembling it.
At assy, use care so piston assy (38), retainer plate (39) and retainer holder (40) do not come off from cylinder block
(37).
• Before assy, coat the surface of swash plate (46) and the sliding surface of piston assy (38) with hydraulic oil.
15
15-87
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
57
58
Positioning jig
56
15-88
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
59
Place valve plate (62) with the copper alloy side facing upward.
• Coat the matching face between base plate (2) and valve plate (62) with grease to prevent the valve plate from
falling off.
• Use care so as not to score the copper alloy surface of valve plate (62).
15-89
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Assemble spool A (19) into base plate (2) so that the pipe port surface of base plate (2) comes toward yourself and
that the side of spool A (19) on which spring (21) is placed comes on the right. If the spool is assembled inversely,
spool change may get out of order and other trouble may occur in some cases.
• Coat the outer surface of spool (19) with hydraulic oil, before assembling it.
• After spool (19) is placed, make certain that it moves smoothly.
15-90
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
17-17,18 2
17-3
17-7
17
15
Assemble the plunger (3) to the base plate, while turning the plunger.
• Install plunger (3) straight.
• In case plunger (3) gets stuck, do not force it in, but tap it lightly with a plastic mallet.
• Coat the outer surface of plunger (3) with hydraulic oil before assmble.
15-91
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
15-92
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Piston assy (38) Sliding surface of shoe The roughness is 0.8a or the Lap the moving surface of shoe
surface is roughened or the (#1000).
scratch is deeper than 0.02mm If the scratch does not
(0.0008inch). disappear, replace cylinder
block assy.
O.D. of piston The roughness is 1.2a or the Replace cylinder block assy.
surface is roughened or the
scratch is deeper than 0.02mm
(0.0008inch).
Cylinder block (37) Sliding surface of The roughness is 0.8a or the Lap the sliding surface (#1000).
valve plate surface is roughened or the If the scratch does not
scratch is deeper than 0.02mm disappear, replace cylinder
(0.0008inch). block assy.
Bore diameter The roughness is 1.6a or the Replace cylinder block assy.
surface is roughened or the
scratch is deeper than 0.02mm
(0.0008inch).
Spline at the joint of The pin that measures the Replace cylinder block assy.
shaft (36) between dia. 38.749mm
(1.52732inch) measures 3.333
dia.mm (0.13122inch) (V1=2.80)
or is broken.
Valve plate (62) Sliding surface A scratch deeper than 0.02mm Lap the moving surface.
(0.0008inch) is there on the 0.8a (#1000) If the scratch does not
roughness moving surface or a disappear, replace the valve
seizure is seen on the surface. plate.
The moving surface shows
abnormal wear.
Retainer plate (39) Sliding surface The sliding surface of 0.8a Replace retainer plate and
Retainer holder (40) roughness shows a scratch retainer holder.
deeper than 0.02mm
(0.0008inch) or shows a seizure.
Swash plate (46) Sliding surface The sliding surface of 0.8a Lap the sliding surface. (#1000)
roughness shows abnormal If the scratch does not
wear or a scratch deeper than disappear, replace the valve
0.02mm (0.0008inch). plate. 15
Spherical hole in which a The spherical surface of 1.6a Replace swash plate.
steel ball is placed roughness shows a scratch
deeper than 0.02mm
(0.0008inch) or is roughened.
15-93
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Shaft (36) O.D. of oil seal sliding surface The sliding surface shows a Replace shaft.
scratch deeper than 0.02mm
(0.0008inch) or is roughened,
except the oil seal lip moving
marks on the 1.6a roughness.
Spline at the joint of cylinder The pin that measures the over-
block (37) pin dia. 47.380mm
(1.86535inch) measures 3.00
dia.mm (0.11811inch) or is
broken.
Spline at the joint of drive The pin that measures the
gear between dia. 30.498mm
(1.20071inch) measures 3.33
dia.mm (0.13122inch) or is
broken.
Brake piston (56) Appearance and dimension Height : Replace brake piston.
38.2mm (1.504inch)
Disk plate (54) Appearance and dimension Thickness : Replace disk plate.
3.2mm (0.126inch)
Ball bearing (49) Rolling surface Flaking or impressed marks are Replace ball bearing.
Ball bearing (50) seen.
Function Rotation is abnormal.
(abnormal sound and uneven
rotation)
Piston assy (48) Sliding surface of shoe The roughness is 1.6a or the Lap the sliding surface of shoe.
surface is roughened or the (#1000)
scratch is deeper than 0.02mm In case the scratch does not
(0.0008inch). disappear, replace the flange
holder kit.
O.D. of piston The roughness is 1.2a or the Replace flange holder kit.
surface is roughened or the
scratch is deeper than 0.02mm
(0.0008inch).
Plunger (3) O.D. of plunger The roughness is 0.8a or the Replace base plate kit.
surface shows a scratch deeper
than 0.02mm (0.0008inch) or is
roughened.
15-94
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Base plate (2) Hole in which plunger (3) is The surface has a roughness Replace base plate kit.
placed more than 0.8a or shows a
scratch deeper than 0.02mm
(0.0008inch) or is roughened.
Spool A (19) O.D. of spool The surface has a roughness Replace base plate kit.
more than 0.8a or a scratch
deeper than 0.02mm
(0.0008inch) or is roughened.
Free piston (17-9) Sliding surface and seat The surface has a scratch Replace relief valve assy.
surface of base plate deeper than 0.02mm
(0.0008inch) or is roughened.
Housing (17-1) Moving surface (O.D.) of free The surface has a scratch
piston deeper than 0.02mm
(0.0008inch) or is roughened.
O-rings and oil seals At disassy Replace O-rings and oil seals.
15-95
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Planetary gear A (89) Tooth thickness Bridged dimension of 6 teeth : Replace planetary gear.
66.649mm (2.62397inch)
Inner race (87) Outer diameter surface Flaking is seen on the surface.
Drive gear (93) Tooth thickness Bridged dimension of 3 teeth: Replace drive gear.
29.908mm (1.17748inch)
Inner race (78) Outer diameter surface Flaking is seen on the surface.
Housing (72) Tooth thickness The pin that measures the Replace housing.
between dia. 330.449mm
(13.00978inch) measures 7.00
dia.mm (0.27559inch).
Flange (1) Bore dia. of the hole in 2- Clearance : Replace flange kit.
speed piston and the O.D. of 0.040 mm (0.00157inch)
piston assy
15-96
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Thrust plate (94) Thickness The plate thickness is either Replace thrust plate.
3.3mm (0.130inch), 2.5mm
(0.098inch), 2.9mm (0.114inch),
2.0mm (0.079inch), 2.7mm
(0.106inch) or the moving
surface has a deep scratch.
Angular bearing (71) Rolling surface of ball Flaking is seen. Replace angular bearing
Floating seal (70) Sliding surface A deep scratch that develops oil Replace floating seal.
leaks is on the surface.
O-ring The surface has developed Do not disassemble any further
cracks. as oil leakage may occur if the
sliding marks on the seal ring
do not match the surface at
disassembly.
15
15-97
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Motor does not turn. Devices other than piston motor and Check that pressure is at the inlet of the
reduction gear have trouble. motor. Then check for the cause, inspect
and repair.
The motor itself has a problem; the Disassemble, clean, eliminate foreign
operating part is stuck with dirt. matter and reassemble. In case parts are
scored by foreign matter, replace parts.
Motor inlet pressure is low. Increase the set pressure by operating the
main relief valve of the circuit.
The moving surface of piston motor is Disassemble and replace such parts that
abnormally worn and oil pressure is are worn abnormally.
escaping. Eliminate scratches and burrs from the
surface, clean parts and reassemble.
The main parts of piston motor are broken. Disassemble and replace those parts that
In that case, piston motor makes an are broken.
abnormal sound. After cleaning, reassemble parts.
Relief valve is operating as piston motor is Check the loaded condition and adjust the
loaded too much. load to a level that matches the set pressure
of relief valve.
Rotating speed of motor is low. Because of some trouble of hydraulic Check that a required flow is supplied to the
pump, pressure regulating valve, flow inlet of piston motor.
control valve and the like, the piston motor Then check for the cause of the trouble,
does not receive a required flow. This is the inspect and repair.
cause of low revolution.
Since the moving surface of piston motor is Disassemble, check the worn condition of
worn, hydraulic pressure escapes from the the moving surface of piston motor, and
high to low sides. (Volumetric efficiency is repair or replace according the maintenance
low.) manual.
This is why the revolution is deficient.
Motor revolution varies much Since the moving surface of piston motor is Disassemble and check the worn condition
and motor makes a big sound. worn, high pressure oil runs out of the drain of the moving surface.
port. Then repair or replace according to the
This causes the revolution to decrease maintenance procedure.
extremely and changes the revolution.
When machine goes downhill, double Disassemble and check the worn condition
counterbalance valve develops hunting of double counterbalance valve.
and causes the motor revolution to vary. Then repair or replace according to the
maintenance procedure.
Operating sound is large. Poor alignment causes the driven part to Align the centers correctly.
interfere with other part and make a sound.
Piston motor bearing is worn or broken, or Disassemble and replace broken parts such
spring is broken. as bearing and spring.
This causes the motor to make a sound. Clean parts and reassemble.
15-98
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Oil leak Bolts in matching surface get slack. Retighten fastening bolts to a specified
This developed oil leakage. torque.
Oil is leaking as oil seal, O-ring and Disassemble and replace seals.
packing are broken. Confirm the temperature of hydraulic oil. In
case the operating oil temperature has risen
above 80C degrees (176F degrees),
examine the cooler and hold down the
hydraulic oil temperature below 80C
degrees (176F degrees).
Since the sliding surface of piston motor is Disassemble and check the worn condition
worn, the drain rate increased. of sliding surface.
This caused the oil seal to break and Repair or replace according to the shop
developed an oil leak. manual. Review oil seals.
Clean parts and reassemble.
Drain pressure rose as drain pipe was Disassemble and replace oil seals.
stuck with foreign matter or drain pipe is too Clean drain pipe and eliminate foreign
small or long. This caused oil seal to break matter. Review piping system so as to
and developed an oil leak. decrease the line resistance.
Abnormal sound and revolution Hydraulic oil level in hydraulic tank fell, Confirm the hydraulic oil level in hydraulic
and pressure fluctuations occur entrapped air and developed aeration. oil tank and resupply hydraulic oil according
due to cavitation. to the instructions of the machine proper.
Motor is installed improperly or the location Confirm the motor orientation and if it is
of hydraulic oil tank is improper. wrong, correct it to the correct orientation.
Therefore, hydraulic oil is discharged from Check that the oil level in the hydraulic oil
motor piping and motor circuits while the tank is above the motor level and if not,
hydraulic device is not running. change it higher than the motor level.
The motor developed aeration immediately Before running, place a self supply circuit so
after motor was driven. hydraulic oil is filled up in motor circuit and
piping.
When motor makes pumping action, motor Disassemble and repair or replace double
inlet pressure becomes negative due to counterbalance valve according to the shop
malfunctioning double counterbalance manual.
valve. This causes the motor to develop
cavitation.
Motor stopped while running Engine stalled because of too much load. Review load condition and change it to a
suitable level.
Motor stalled as the sliding surface of Check the spec (flow and motor revolution
piston motor was seized. in particular). if the motor revolution
exceeds a limit value, decrease the flow.
Replace motor as insides of motor are
broken beyond reuse.
15
15-99
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Parking brake
Trouble Probable cause Remedy
If motor is rested under external Parking brake torque is low as disk is worn. Disassemble and replace parking brake
load, motor rotates. disk. Clean parts and reassemble.
Disk face deteriorated due to poor contact. Disassemble and replace disk.
This decreased the parking brake torque. Correct the surface in contact with the disk
and reassemble.
Spring is distorted or broken. Disassemble and replace spring.
This decreased the parking brake torque. Clean parts and reassemble.
Since external load is too large, power of Review the external load and change it to a
the parking brake is deficient. suitable level.
Motor does not produce Since O-ring is broken and pressure Disassemble and replace O-ring.
required drive force. escapes, the parking brake is not released. Clean parts and reassemble.
Motor generates abnormal heat.
Orifice in parking brake release oil passage Disassemble and remove foreign matter
is stuck with foreign matter. Therefore, from orifice. Then clean parts and
pressure does not reach parking brake reassemble. Flush the inside of pipes.
cylinder chamber. Thus parking brake is
not released.
Since drain pipe is stuck with foreign Clean drain pipe.
matter, drain pipe is small or long, drain Also, review piping system to decrease the
pressure rises. line resistance.
This prevents parking brake from being
released.
15-100
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[15. TRAVEL SYSTEM]
Relief valve
Trouble Probable cause Remedy
Motor does not turn or revolution Foreign matter is included between poppet Disassemble and remove foreign matter.
is low. seat and poppet of relief valve. Clean parts and reassemble.
This developed poor seating, and high
pressure oil is leaking toward the low
pressure side.
Spring of relief valve is broken and the high Replace relief valve.
pressure oil is leaking toward the low Disassemble motor, clean parts and
pressure side. reassemble.
Foreign matter is included between free Remove relief valve and eliminate foreign
piston of relief valve and seat in contact matter.
with base plate.
This causes the set pressure to fall.
Foreign matter gets stuck in orifice located Remove relief valve and eliminate foreign
in poppet of relief valve. This causes set matter.
pressure to fall. Remove relief valve and
eliminate foreign matter.
Motor does not stop or motor Since foreign matter is included between Disassemble and eliminate foreign matter.
stops late. poppet seat and poppet of relief valve, poor Clean parts and reassemble.
seating occurs.
Relief valve does not close.
Spring of relief valve is broken, and relief Replace relief valve.
valve does not close. Disassemble motor, clean parts and
reassemble.
Since spring of relief valve is fatigued, set Replace relief valve.
pressure falls and the braking power drops.
Since foreign matter is included between Remove relief valve and eliminate foreign
free piston of relief valve and seat in matter.
contact with base plate, set pressure falls
and the braking force decreases.
Since foreign matter is included in orifice Remove relief valve and eliminate foreign
located in poppet of relief valve, set matter.
pressure falls and the braking power falls.
Shocks are large at stop. Since foreign matter is included in the Replace relief valve.
moving surface of poppet, poppet does not
operate.
Free piston does not operate as it is stuck Remove relief valve and remove foreign
with foreign matter. matter. Then reassemble.
15-101
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[15. TRAVEL SYSTEM]
Counterbalance valve
Trouble Probable cause Remedy
If motor makes pumping action Plunger does not operate smoothly as Disassemble and remove the
as external load acts on it, motor foreign matter is included in plunger. contamination.
revolution changes. Then clean the plunger and reassemble it.
Wrong orifice size is used in pilot oil Replace with a correct orifice.
passage.
If motor makes pumping action Foreign matter is included in plunger. Disassemble and eliminate foreign matter.
as external load acts on motor , Plunger movement is bad and motor does Check the extent of damage according to
motor develops cavitation and not display counterbalance functions. the shop manual and reassemble if it is still
makes an abnormal sound. serviceable.
In case plunger is not serviceable, replace
base plate kit.
15-102
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[15. TRAVEL SYSTEM]
High-speed rotation can not be Pilot pressure is not at Ps port. Check that pilot pressure is at Ps port,
selected check for the cause, inspect and repair.
Foreign matter is included between spool Disassemble, remove foreign matter, and
and base plate, and spool does not change check the extent of scratch according to the
over. maintenance manual.
If spool is reusable, reassemble.
If it can not be reused, replace base plate
kit.
2-speed control piston develops abnormal Disassemble and replace flange holder kit.
wear and pressure is leaking into casing.
Orifice in 2-speed oil passage is clogged Disassemble, eliminate foreign matter and
with foreign matter. Therefore, pressure reassemble.
does not reach 2-speed control piston.
Motor changes over to high 2-speed control piston is worn abnormally, Disassemble and replace flange holder kit.
speed, but changes to low and pressure is leaking into casing.
speed as the temperature of
hydraulic oil rises.
Motor does not select low Pressure at Ps port does not go down even Check that pressure at Ps port is below
speed. if speed control switch is set at low speed. 0.5MPa (72.5psi) and review piping system.
Spring in 2-speed control valve is broken. Disassemble, remove foreign matter and
replace spring.
Motor does not change over to Orifice in 2-speed passage is clogged with Disassemble, remove foreign matter and
low speed. foreign matter, and pressure does not go reassemble.
out of 2-speed control piston chamber.
Motor changes to low speed, but Pilot piping is clogged with foreign matter Clean the inside of piping and remove
changes to high speed while and oil leaks from 2-speed control valve. foreign matter.
running. As the result, pilot pressure rises to a Also review the piping system.
changeover level.
15
15-103
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[15. TRAVEL SYSTEM]
Reduction unit
Trouble Probable cause Remedy
Reduction unit does not rotate. Devices other than piston motor and Check that pressure is there at the motor
reduction unit have trouble. inlet, check for the cause, inspect and
repair.
Load exceeding motor output torque is Check load condition and get rid of load
acting on it. acting upon motor.
Parts are interfering with each other Disassemble and confirm the broken
because the sliding surface in reduction condition. If something broken is
unit is broken. discovered, replace reduction unit.
If no part is broken, replace worn parts,
clean them and reassemble.
Reduction unit is generating Lube oil in reduction unit is deficient. Confirm that there is no oil leakage.
abnormal heat. Disassemble and make sure of the
damaged condition in reduction unit.
If something is found broken, replace
reduction unit.
Fill lube oil to a specified level.
Too much lube oil is filled in reduction unit. Adjust lube oil volume to a specified level.
Abnormal thrust load is acting in reduction Disassemble and confirm the damaged
unit because of wrong selection of thrust condition of the inside.
plate. If something broken is confirmed, replace
reduction unit.
If not, replace thrust place with one of
proper thickness.
15-104
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[15. TRAVEL SYSTEM]
Oil leakage occurs. Reduction unit cover is slack and oil is Remove cover, reapply liquid packing and
leaking. tighten cover to a specified torque. Then fill
in lube oil to a specified level.
Oil is leaking from leaked plugs in oil inlet, Retighten plugs to specified torque. After
outlet, and check ports of reduction unit tightening, fill in lube oil to a specified level.
cover.
Oil is leaking as O-rings in oil inlet, outlet Replace O-rings in plugs. After
and check ports of reduction unit cover are replacement, fasten plugs to a specified
aged. torque and fill in lube oil to a specified level.
Oil is leaking as foreign matter is included Disassemble reduction unit, remove foreign
in the sliding surface of floating seal. matter from floating seal and reassemble.
Oil is leaking as the sliding surface of Disassemble reduction unit and replace
floating seal is corroded. floating seal.
15
15-105
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[15. TRAVEL SYSTEM]
15-106
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16
16-1
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16-2
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16
16-3
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16.2 PREFACE
Troubleshooting provides process locating for the cause
of trouble in the order that trouble occurred. This manual
describes how to solve the specific phenomenon
systematically as early as possible. For troubleshooting
concerning the inside of equipment, refer to
troubleshooting for each manual of equipment.
16-4
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
When error code of self diagnosis is displayed on gauge Carry out troubleshooting according to the error code.
A
cluster.
When no failure is detected currently but error code after When it is hard to recreate the failure situation, cancel the
self diagnosis is remained in trouble history. data in the history and reproduce the failed situation or
B
suppose the cause according to the troubleshooting by
error code, and then repair it.
When error code of self diagnosis is not displayed or is Carry out troubleshooting according to instructions in
C
not remained in history. "TROUBLESHOOTING (BY TROUBLE)".
16-6
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16
16-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
A025 Pump proportional valve adjustment (B adjustment) is not adjusted yet or is failed.
16-8
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
B114 Power short circuit of option selector position detect pressure sensor
16-9
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
F013 Failure of output transistor ON and disconnection of power boost SOL valve
F021 Failure of output transistor OFF and GND short circuit of swing parking SOL valve
F023 Failure of output transistor ON and disconnection of swing parking SOL valve
F031 Failure of output transistor OFF and GND short circuit of travel 1-2 speed SOL valve
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
F041 Failure of output transistor OFF and GND short circuit of option selector SOL valve
F043 Failure of output transistor ON and disconnection of option selector SOL valve
F071 Failure of output transistor OFF and GND short circuit of boom M/I cut SOL valve
F073 Failure of output transistor ON and disconnection of boom M/I cut SOL valve
G042 Overrun of received data from Mechatro-controller direct input speed sensor and engine controller
G043 Disconnection of received data from Mechatro-controller direct input speed sensor and engine controller
16-10
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16
16-11
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging Engine adjustment is not adjusted yet. Or the value cannot be set in the adjustment range during
condition adjustment.
Symptom Deviated from the command engine speed, but no problem in normal operations.
Symptom Deviated from the pump output, but no problem in normal operations.
16-12
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Symptom Deviated from the unload valve output, but no problem in normal operations.
Judging Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom Becomes not normal output, but no problem in normal operation.
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
16
16-13
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging Check adjustment data, and judge the data is correct or not.
condition
Symptom No effect
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
16-14
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom The hour meter reading can become 0.
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
Judging Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom Becomes not normal output, but no problem in normal operation.
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
16
16-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the boom up
condition pressure sensor is from 1.4V or more to less than 4.7V.
1 • Boom up pressure sensor When B012 is cancelled and another error occurs by turning the starter switch on
SE-3 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom up When B012 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-126F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-1 BOOM RAISE
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B013 is cancelled and another error occurs by turning the starter switch on
SE-3 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom up When B013 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-126F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-1 BOOM RAISE
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B014 is cancelled and another error occurs by turning the starter switch on
SE-3 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom up When B014 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-126F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the boom
condition down pressure sensor is from 1.4V or more to less than 4.7V.
1 • Boom down pressure sensor When B022 is cancelled and another error occurs by turning the starter switch on
SE-4 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom down When B022 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-127F to the wiring checking procedures and repair it if necessary. 16
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from boom down pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-2 BOOM LOWER
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and another error occurs by turning the starter switch on
SE-4 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom down When B023 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-127F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-2 BOOM LOWER
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and another error occurs by turning the starter switch on
SE-4 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom down When B024 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-127F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the arm-out
condition pressure sensor is from 1.4V or more to less than 4.7V.
1 • Arm out pressure sensor When B032 is cancelled and another error occurs by turning the starter switch on
SE-8 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between arm-out When B032 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-131F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from arm-out pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-3 ARM OUT
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Arm out pressure sensor When B033 is cancelled and another error occurs by turning the starter switch on
SE-8 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between arm-out When B033 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-131F to the wiring checking procedures and repair it if necessary. 16
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-3 ARM OUT
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Arm out pressure sensor When B034 is cancelled and another error occurs by turning starter switch on after
SE-8 replacing the connector with that of another sensor, check sensor unit for possible
failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check wiring for possible failure according to
CN-131F the wiring checking procedure and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the arm-in
condition pressure sensor is from 1.4V or more to less than 4.7V.
1 • Arm in pressure sensor When B042 is cancelled and another error occurs by turning the starter switch on
SE-7 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between arm-in When B042 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-130F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-20
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from arm-in pressure sensor is less than 0.1V.
condition
Symptom Cavitation occurs during independent arm-in operation. Speed of all operations slows down.
1 • Arm in pressure sensor When B043 is cancelled and another error occurs by turning the starter switch on
SE-7 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between arm-in When B043 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-130F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Symptom Cavitation occurs during independent arm-in operation. Speed of all operations slows down.
1 • Arm in pressure sensor When B044 is cancelled and another error occurs by turning the starter switch on
SE-7 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between arm-in When B044 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-130F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the bucket
condition digging pressure sensor is from 1.4V or more to less than 4.7V.
1 • Bucket digging pressure When B052 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-1 possible failure and replace it if necessary.
2 • Wiring between bucket When B052 is displayed by turning the starter switch on after replacing the
digging pressure sensor and connector with that of another sensor, check the wiring for possible failure according
controller to the wiring checking procedures and repair it if necessary.
CN-124F
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from bucket digging pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-5 BUCKET DIG
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure When B053 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-1 possible failure and replace it if necessary.
2 • Wiring between bucket When B053 is displayed by turning the starter switch on after replacing the
digging pressure sensor and connector with that of another sensor, check the wiring for possible failure according 16
controller to the wiring checking procedures and repair it if necessary.
CN-124F
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-5 BUCKET DIG
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure When B054 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-1 possible failure and replace it if necessary.
2 • Wiring between bucket When B054 is displayed by turning the starter switch on after replacing the
digging pressure sensor and connector with that of another sensor, check the wiring for possible failure according
controller to the wiring checking procedures and repair it if necessary.
CN-124F
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the bucket
condition dump pressure sensor is from 1.4V or more to less than 4.7V.
1 • Bucket dump pressure sensor When B062 is cancelled and another error occurs by turning the starter switch on
SE-2 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between bucket dump When B062 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-125F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from bucket dump pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-6 BUCKET DUMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Bucket dump pressure sensor When B063 is cancelled and another error occurs by turning the starter switch on
SE-2 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between bucket dump When B063 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-125F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-6 BUCKET DUMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Bucket dump pressure sensor When B064 is cancelled and another error occurs by turning the starter switch on
SE-2 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between bucket dump When B064 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-125F to the wiring checking procedures and repair it if necessary. 16
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing
condition right pressure sensor is from 1.4 V or more to less than 4.7 V.
1 • Swing right pressure sensor When B072 is cancelled and another error occurs by turning the starter switch on
SE-40 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between swing right When B072 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-315F to the wiring checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from swing right pressure sensor is less than 0.1 V.
condition
Symptom The swing operability becomes poor.
1 • Swing right pressure sensor When B073 is cancelled and another error occurs by turning the starter switch on
SE-40 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between swing right When B073 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-315F to the wiring checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from swing right pressure sensor is 4.7 V or more.
condition
Symptom The swing operability becomes poor.
1 • Swing right pressure sensor When B074 is cancelled and another error occurs by turning the starter switch on
SE-40 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between swing right When B074 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-315F to the wiring checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing left
condition pressure sensor is from 1.4 V or more to less than 4.7 V.
1 • Swing left pressure sensor When B082 is cancelled and another error occurs by turning the starter switch on
SE-41 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between swing left When B082 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-316F to the wiring checking procedures and repair it if necessary. 16
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from swing left pressure sensor is less than 0.1 V.
condition
Symptom The swing operability becomes poor.
1 • Swing left pressure sensor When B083 is cancelled and another error occurs by turning the starter switch on
SE-41 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between swing left When B083 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-316F to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from swing left pressure sensor is 4.7 V or more.
condition
Symptom The swing operability becomes poor.
1 • Swing left pressure sensor When B084 is cancelled and another error occurs by turning the starter switch on
SE-41 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between swing left When B084 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-316F to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing
condition right pressure sensor is from 1.4V or more to less than 4.7V.
1 • Travel right pressure sensor When B092 is cancelled and another error occurs by turning the starter switch on
SE-9 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between travel right When B092 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-301F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from travel right pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-9 TRAVEL (R)
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and another error occurs by turning the starter switch on
SE-9 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between travel right When B093 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-301F to the wiring checking procedures and repair it if necessary. 16
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from travel right pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-9 TRAVEL (R)
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and another error occurs by turning the starter switch on
SE-9 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between travel right When B094 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-301F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the travel left
condition pressure sensor is from 1.4V or more to less than 4.7V.
1 • Travel left pressure sensor When B102 is cancelled and another error occurs by turning starter switch on after
SE-10 replacing the connector with that of another sensor, check sensor unit for possible
failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-302F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-30
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from travel left pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-10 TRAVEL (L)
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and another error occurs by turning the starter switch on
SE-10 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between travel left When B103 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-302F to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from travel left pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-10 TRAVEL (L)
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and another error occurs by turning the starter switch on
SE-10 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between travel left When B104 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-302F to the wiring checking procedures and repair it if necessary. 16
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-31
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from option selector position detect pressure sensor is less than 0.1V.
condition
Symptom The switched position of the selector valve cannot be detected.
1 • Option selector position detect When B113 is cancelled and another error occurs by turning the starter switch on
pressure sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-29 possible failure and replace it if necessary.
2 • Option selector position detect When B113 is displayed by turning the starter switch on after replacing the
pressure sensor connector with that of another sensor, check the wiring for possible failure according
CN-1031F to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from option selector position detect pressure sensor is 4.7V or more.
condition
Symptom The switched position of the selector valve cannot be detected.
1 • Option selector position detect When B114 is cancelled and another error occurs by turning the starter switch on
pressure sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-29 possible failure and replace it if necessary.
2 • Option selector position detect When B114 is displayed by turning the starter switch on after replacing the
pressure sensor connector with that of another sensor, check the wiring for possible failure according
CN-1031F to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-32
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P1side
condition option pressure sensor is from 1.4V or more to less than 4.7V.
1 • P1 side option pressure When B162 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-20 possible failure and replace it if necessary.
2 • Wiring between P1 side option When B162 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-304F to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from P1 side option pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure But normal control is done when the left control pedal selection is ON.
1 • P1 side option pressure When B163 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-20 possible failure and replace it if necessary.
2 • Wiring between P1 side option When B163 is displayed by turning the starter switch on after replacing the
connector with that of another sensor, check the wiring for possible failure according
pressure sensor and controller
CN-304F to the wiring checking procedures and repair it if necessary. 16
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-33
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure But normal control is done when the left control pedal selection is ON.
1 • P1 side option pressure When B164 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-20 possible failure and replace it if necessary.
2 • Wiring between P1 side option When B164 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-304F to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P2 side
condition option pressure sensor is from 1.4V or more to less than 4.7V.
1 • P2 side option pressure When B172 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-11 possible failure and replace it if necessary.
2 • Wiring between P2 side option When B172 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-303F to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-34
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from P2 side option pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 5 B-17 P2 OPT.
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • P2 side option pressure When B173 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-11 possible failure and replace it if necessary.
2 • Wiring between P2 side option When B173 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-303F to the wiring checking procedures and repair it if necessary
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure But normal control is done when the left control pedal selection is ON.
1 • P2 side option pressure When B174 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-11 possible failure and replace it if necessary.
2 • Wiring between P2 side option When B174 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-303F to the wiring checking procedures and repair it if necessary. 16
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-35
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P1 pump
condition pressure sensor is from 1.4V or more to less than 4.7V.
Symptom Speed of all operations slows down. Engine speed goes down significantly.
1 • P1 pump pressure sensor When C012 is cancelled and another error occurs by turning the starter switch on
SE-22 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between P1 pump When C012 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-139F to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from P1 pump pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
1 • P1 pump pressure sensor When C012 is cancelled and another error occurs by turning the starter switch on
SE-22 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between P1 pump When C012 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-139F to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-36
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
1 • P1 pump pressure sensor When C014 is cancelled and another error occurs by turning the starter switch on
SE-22 after replacing the connector with that of another sensor, check sensor unit for
possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-139F to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P2 pump
condition pressure sensor is from 1.4V or more to less than 4.7V.
Symptom Speed of all operations slows down. Engine speed goes down significantly.
1 • P2 pump pressure sensor When C022 is cancelled and another error occurs by turning the starter switch on
SE-23 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between P2 pump When C022 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-140F to the wiring checking procedures and repair it if necessary. 16
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-37
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from P2 pump pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
1 • P2 pump pressure sensor When C023 is cancelled and another error occurs by turning the starter switch on
SE-23 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between P2 pump When C023 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-140F to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
1 • P2 pump pressure sensor When C024 is cancelled and another error occurs by turning the starter switch on
SE-23 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between P2 pump When C024 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-140F to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from boom head pressure sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
1 • Boom head pressure sensor When C033 is cancelled and another error occurs after replacing the connector with
SE-24 that of another sensor, check the sensor unit for possible failure and replace it if
necessary.
2 • Wiring between boom head When C033 is displayed after replacing the connector with that of another sensor,
pressure sensor and controller check the wiring for possible failure according to the wiring checking procedures
CN-706F and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Not affect machine movement.
1 • Boom head pressure sensor When C034 is cancelled and another error occurs by turning the starter switch on
SE-24 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom head When C034 is displayed after replacing the connector with that of another sensor,
pressure sensor and controller check the wiring for possible failure according to the wiring checking procedures
CN-706F and repair it if necessary. 16
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-39
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from boom rod pressure sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
1 • Boom rod pressure sensor When C043 is cancelled and another error occurs after replacing the connector with
SE-25 that of another sensor, check the sensor unit for possible failure and replace it if
necessary.
2 • Wiring between boom rod When C043 is displayed after replacing the connector with that of another sensor,
pressure sensor and controller check the wiring for possible failure according to the wiring checking procedures
CN-705F and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Not affect machine movement.
1 • Boom rod pressure sensor When C044 is cancelled and another error occurs after replacing the connector with
SE-25 that of another sensor, check the sensor unit for possible failure and replace it if
necessary.
2 • Wiring between boom rod When C044 is displayed after replacing the connector with that of another sensor,
pressure sensor and controller check the wiring for possible failure according to the wiring checking procedures
CN-705F and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Arm out/option conflux operation is impossible. Travel right operation is impossible.
1 • P1 unload proportional sol. When D012 is cancelled and another error occurs after replacing the connector with
PSV-D that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between P1 unload When D012 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-120F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
1 • P1 unload proportional sol. When D013 is cancelled and another error occurs after replacing the connector with
PSV-D that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between P1 unload When D013 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring 16
controller checking procedures and repair it if necessary.
CN-120F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-41
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up, bucket digging, and bucket dump become slow. Travel left operation
is impossible.
1 • P2 unload proportional valve When D022 is cancelled and another error occurs after replacing the connector with
PSV-B that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between P2 unload When D022 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary
CN-118F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-42
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
1 • P2 unload proportional valve When D023 is cancelled and another error occurs after replacing the connector with
PSV-B that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between P2 unload When D023 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-118F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of traveling and attachment.
1 • Travel straight proportional When D032 is cancelled and another error occurs after replacing the connector with
valve that of another proportional valve, check the proportional valve unit for possible
PSV-C failure and replace it if necessary.
2 • Wiring between Travel straight When D032 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring 16
controller checking procedures and repair it if necessary.
CN-119F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-43
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
Symptom Travel deviation occurs by combined operation of traveling and attachment. Speed of all operations slows
down.
Control in the Normal control
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 7 D-3 S-TRAVEL
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Travel straight proportional When D033 is cancelled and another error occurs after replacing the connector with
valve that of another proportional valve, check the proportional valve unit for possible
PSV-C failure and replace it if necessary.
2 • Wiring between Travel straight When D033 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-119F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-44
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 • Arm-in spool 2 proportional When D062 is cancelled and another error occurs after replacing the connector with
valve that of another proportional valve, check the proportional valve unit for possible
PSV-A failure and replace it if necessary.
2 • Wiring between Arm-in spool When D062 is displayed after replacing the connector with that of another
2 proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-121F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-45
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
Symptom Cavitation occurs during independent arm-in operation. Operability of combined operation including arm-
in becomes poor.
1 • Arm-in spool 2 proportional When D063 is cancelled and another error occurs after replacing the connector with
valve that of another proportional valve, check the proportional valve unit for possible
PSV-A failure and replace it if necessary.
2 • Wiring between Arm-in spool When D063 is displayed after replacing the connector with that of another
2 proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-121F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Not affect machine movement.
1 • Boom 2 proportional valve When D172 is cancelled and another error occurs after replacing the connector with
PSV-23 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between boom 2 When D172 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-799F
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
1 • Boom 2 proportional valve When D173 is cancelled and another error occurs after replacing the connector with
PSV-23 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between boom 2 When D173 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring 16
controller checking procedures and repair it if necessary.
CN-799F
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Not affect machine movement.
1 • Boom 3 proportional valve When D182 is cancelled and another error occurs after replacing the connector with
PSV-24 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between boom 3 When D182 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-823F
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-48
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
1 • Boom 3 proportional valve When D183 is cancelled and another error occurs after replacing the connector with
PSV-24 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between boom 3 When D183 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-823F
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-49
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P1 pump proportional valve When E012 is cancelled and another error occurs after replacing the connector with
PSV-P1 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
3 • Wiring between P1 pump When E012 is displayed after replacing the connector with that of another
proportional valve, KPSS proportional valve, check the wiring for possible failure according to the wiring
release switch, and controller checking procedures and repair it if necessary.
CN-141F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-50
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is 150mA or less, judging is
condition not done.)
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P1 pump proportional valve When E013 is cancelled and another error occurs after replacing the connector with
PSV-P1 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
3 • Wiring between P1 pump When E013 is displayed after replacing the connector with that of another
proportional valve, KPSS proportional valve, check the wiring for possible failure according to the wiring
release switch, and controller checking procedures and repair it if necessary.
CN-141F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-51
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P2 pump proportional valve When E022 is cancelled and another error occurs after replacing the connector with
PSV-P2 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
3 • Wiring between P2 pump When E022 is displayed after replacing the connector with that of another
proportional valve, KPSS proportional valve, check the wiring for possible failure according to the wiring
release switch, and controller checking procedures and repair it if necessary.
CN-142F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P2 pump proportional valve When E023 is cancelled and another error occurs after replacing the connector with
PSV-P2 that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
3 • Wiring between P2 pump When E023 is displayed after replacing the connector with that of another
proportional valve, KPSS proportional valve, check the wiring for possible failure according to the wiring
release switch, and controller checking procedures and repair it if necessary
CN-142F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is grounding level while exciting command is output.
condition
Symptom Not switch to power boost operation.
1 • ATT boost solenoid valve When F011 is cancelled and another error occurs after replacing the connector with
SV-2 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Wiring between ATT boost When F011 is displayed after replacing the connector with that of another solenoid
solenoid valve and controller valve, check the wiring for possible failure according to the wiring checking
CN-117F procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-54
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Not switch to power boost operation. Or not switch from power boost operation.
1 • ATT boost solenoid valve When F013 is cancelled and another error occurs after replacing the connector with
SV-2 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Wiring between ATT boost When F013 is displayed after replacing the connector with that of another solenoid
solenoid valve and controller valve, check the wiring for possible failure according to the wiring checking
CN-117F procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking brake does not change. (The brake does not work.)
1 • Swing parking solenoid valve When F021 is cancelled and another error occurs after replacing the connector with
SV-1 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Swing PB release switch Set swing PB release switch to the release side and check that connector (CN-63F)
SW-4 is switched.
If failure is found, replace it.
3 • Wiring between swing parking When F021 is displayed after replacing the connector with that of another solenoid
solenoid valve, swing PB valve, check the wiring for possible failure according to the wiring checking
release switch, and controller procedures and repair it if necessary.
CN-123F
CN-63F
CN-104F
CN-102F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-56
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking brake does not change. (Stays in braking condition or the brake does not work.)
1 • Swing parking solenoid valve When F023 is cancelled and another error occurs after replacing the connector with
SV-1 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Swing PB release switch Set swing PB release switch to the release side and check that connector (CN-63F)
SW-4 is switched.
If failure is found, replace it.
3 • Wiring between swing parking When F023 is displayed after replacing the connector with that of another solenoid
solenoid valve, swing PB valve, check the wiring for possible failure according to the wiring checking
release switch, and controller procedures and repair it if necessary.
CN-123F
CN-63F
CN-104F
CN-102F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is grounding level while exciting command is output.
condition
Symptom The speed does not switch to the travel 2 speed.
1 • Travel 1, 2speed solenoid When F031 is cancelled and another error occurs after replacing the connector with
valve that of another solenoid valve, check the solenoid valve unit for possible failure and
SV-3 replace it if necessary.
2 • Wiring between travel 1, When F031 is displayed after replacing the connector with that of another solenoid
2speed solenoid valve and valve, check the wiring for possible failure according to the wiring checking
controller procedures and repair it if necessary.
CN-122F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-58
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is 24V level while exciting command is not output.
condition
Symptom The speed does not switch to the travel 2nd speed. Or it does not switch to the travel 1st speed from the
travel 2nd speed.
1 • Travel 1, 2speed solenoid When F033 is cancelled and another error occurs after replacing the connector with
valve that of another solenoid valve, check the solenoid valve unit for possible failure and
SV-3 replace it if necessary.
2 • Wiring between travel 1, When F033 is displayed after replacing the connector with that of another solenoid
2speed solenoid valve and valve, check the wiring for possible failure according to the wiring checking
controller procedures and repair it if necessary.
CN-122F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-59
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is grounding level while exciting command is output.
condition
Symptom The option selector solenoid valve does not change.
1 • Option selector solenoid valve When F041 is cancelled and another error occurs after replacing the connector with
SV-13 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary
2 • Wiring between option When F041 is displayed after replacing the connector with that of another solenoid
selector solenoid valve and valve, check the wiring for possible failure according to the wiring checking
controller procedures and repair it if necessary.
CN-1031F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is 24V level while exciting command is not output.
condition
Symptom The option selector solenoid valve does not change. Or stays in the changed condition.
1 • Option selector solenoid valve When F043 is cancelled and another error occurs after replacing the connector with
SV-13 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Wiring between option When F043 is displayed after replacing the connector with that of another solenoid
selector solenoid valve and valve, check the wiring for possible failure according to the wiring checking
controller procedures and repair it if necessary.
CN-1031F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The feed-back signal is grounding level while exciting command is output.
condition
Symptom Not affect machine movement.
1 • Boom cut solenoid valve When F071 is cancelled and another error occurs after replacing the connector with
SV-105 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Wiring between boom When F071 is displayed after replacing the connector with that of another solenoid
solenoid valve and controller valve, check the wiring for possible failure according to the wiring checking
procedures and repair it if necessary.
16
CN-800F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-61
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Not affect machine movement.
1 • Boom cut solenoid valve When F073 is cancelled and another error occurs after replacing the connector with
SV-105 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Wiring between boom When F073 is displayed after replacing the connector with that of another solenoid
solenoid valve and controller valve, check the wiring for possible failure according to the wiring checking
CN-800F procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Control in the Receives rpm from the engine controller to perform control.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 2 G-3 MEAS 1 (for mechatro controller)
No.
Service
Screen 2 G-3 MEAS 2 (receives from engine controller)
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
(The controller is broken only when power voltage is applied to the signal GND
side.)
16-62
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The voltage of the alternator is 12 V or more and the speed sensor indicates the extreme low speed or
condition less.
Symptom Operates without problem.
Control in the Receives rpm from the engine controller to perform control.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 2 G-3 MEAS 1 (for mechatro controller)
No.
Service
Screen 2 G-3 MEAS 2 (receives from engine controller)
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
(The controller is broken only when power voltage is applied to the signal GND
side.)
16
16-63
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-103F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and
speed sensor, pressure repair it if necessary.
sensor and controller Especially check wiring for false disconnection and noise included.
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
(The controller is broken only when power voltage is applied to the signal GND
side.)
5 • Engine controller Check that the error is corrected after replacement of the controller.
16-64
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The voltage of the alternator is 12 V or more and the received data from the speed sensor and the engine
condition controller is the extreme low speed or less.
Symptom Abrupt load application may cause the engine speed to go down significantly.
Control in the Engine speed input becomes 0 rpm. And ESS horse power reduction command becomes 0.
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 2 G-3 MEAS 1 (for mechatro controller)
No.
Service
Screen 2 G-3 MEAS 2 (receives from engine controller)
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F
CN-103F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and
speed sensor, pressure repair it if necessary.
sensor and controller
4 Mechatro controller Check that the error is corrected after replacement of the controller.
• (The controller is broken only when power voltage is applied to the signal GND
side.)
5 Engine controller Check that the error is corrected after replacement of the controller.
•
16
16-65
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from accel potentiometer is less than 0.1V.
condition
Symptom LOW idling is fixed.
1 • Acceleration potentiometer Measure the resistance between terminals of the acceleration potentiometer.
SE-16 Normal value: 1.6 to 2.4 kΩ
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between acceleration Check wiring for possible failure according to the wiring checking procedure and
potentiometer and controller repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-66
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 • Acceleration potentiometer Measure the resistance between terminals of the acceleration potentiometer.
SE-16 Normal value: 1.6 to 2.4 kΩ
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between acceleration Check wiring for possible failure according to the wiring checking procedure and
potentiometer and controller repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
1 • Fuel sensor Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 Ω to FULL 5 Ω
2 • Wiring between fuel sensor Check wiring for possible failure according to the wiring checking procedure and
and controller repair it if necessary.
CN-152F
CN-103F 16
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-67
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 Ω to FULL 5 Ω
2 • Wiring between fuel sensor Check wiring for possible failure according to the wiring checking procedure and
and controller repair it if necessary.
CN-152F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from the sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
1 • Hydraulic oil temperature Measure the resistance between terminals of the hydraulic oil temperature sensor
sensor by changing the temperature of the sensor.
SE-21 0 degrees C (32 degrees F): 1150 Ω to 50 degrees C (122 degrees F): 98.2 Ω
2 • Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking procedure and
temperature sensor and repair it if necessary.
controller
CN-59F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-68
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Control in the Hydraulic oil temperature is regarded as 0 degrees C (32 degrees F).
event of failure
Return in normal It returns automatically in normal condition.
condition
Screen 8 H-10 HYD. OIL TEMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Hydraulic oil temperature Measure the resistance between terminals of the hydraulic oil temperature sensor
sensor by changing the temperature of the sensor.
SE-21 0 degrees C (32 degrees F): 1150 Ω to 50 degrees C (122 degrees F): 98.2 Ω
2 • Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking procedure and
temperature sensor and repair it if necessary.
controller
CN-59F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging The input voltage from swing speed sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
1 • Wiring between swing speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-798F
CN-105F
2 • Swing speed sensor Check that the error is corrected after replacement of the sensor. 16
SE-99
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-69
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The input voltage from swing speed sensor is 4.7V or more.
condition
Symptom Not affect machine movement.
1 • Wiring between swing speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-798F
CN-105F
2 • Swing speed sensor Check that the error is corrected after replacement of the sensor.
SE-99
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging Data from the engine controller cannot be received correctly. (Only trouble history)
condition
Symptom Affects operation very little.
1 • Wiring between ECU and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-1F (There is a possibility of false disconnection.)
CN-3F
CN-5F
CN-104F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-70
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Control in the Operates as the coolant temperature is 20 degrees C (68 degrees F). Output of the P1 and P2 pump
event of failure proportional valves becomes 350 mA.
1 • Wiring between ECU and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-1F (There is a possibility of false disconnection.)
CN-3F
CN-5F
CN-104F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
1 • Wiring between ECU and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-1F (There is a possibility of false disconnection.)
CN-3F
CN-5F
CN-104F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-71
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging Data from the gauge cluster cannot be received correctly. (Only trouble history)
condition
Symptom Switches of gauge cluster can not be used.
1 • Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-102F
CN-33F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
1 • Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-102F
CN-33F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-72
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 • Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-102F
CN-33F
2 Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-73
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch ON
condition signal turned OFF
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery relay
R-1 coil. If 24V power lives on battery relay secondary side, check on battery relay for
CN-256F failure and replace it if failed.
2 • Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the battery relay
R-24 coil side. If power of battery relay on secondary side falls, remove either auto idle
stop relay 2 or alternator relay.
• Alternator relay
The failure may be occurred in case where the power falls after the relay was
R-28
removed, and therefore check on the relay unit and replace it with new one if failed.
3 • Wiring between auto idle stop When R024 is left displayed with the relay removed, check that 24V is produced on
relay/alternator relay and relay (-) line according to the wiring checking procedure and repair it.
controller
CN2-1,CN-102F, and CN-
104F When no failure is found after checking on wiring and K014 is left displayed, replace
fuse/relay box.
• Fuse & relay box
E-1
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-74
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power
condition source.
Symptom Wiper does not move.
1 • Wiper motor arc prevention When error is cancelled after removing wiper motor arc prevention relay, check
relay relay unit for failure, replace it with new one if falied.
R-31 When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between wiper motor When R014 is left displayed with the relay removed, check that 24V is produced on
arc prevention relay and relay (-) line according to the wiring checking procedure and repair it.
controller
CN-101F,CN2-1
When no failure is found after checking on wiring and R014 is left displayed, replace
• Fuse & relay box
fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-75
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to wiper motor normal rotation relay is short-circuited with the power
condition source.
Symptom Wiper does not move.
1 • Wiper motor normal rotation When error is cancelled after removing wiper motor normal rotation relay, check
relay relay unit for failure, replace it with new one if failed.
R-29 When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed, check that 24V is produced on
normal rotation relay and relay (-) line according to the wiring checking procedure and repair it.
controler
CN-101F,CN2-1 When no failure is found after checking on wiring and R024 is left displayed, replace
fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-76
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power
condition source.
Symptom Wiper does not move after forward rotation.
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay, check
relay relay unit for failure, replace it with new one if failed.
R-30 When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed, check that 24V is produced on
forward rotation relay and relay (-) line according to the wiring checking procedure and repair it.
controller
CN-101F,CN2-1 When no failure is found after checking on wiring and R034 is left displayed, replace
fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-77
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
1 • WASHER MOTOR RELAY When error is cancelled after removing washer motor relay, check relay unit for
R-32 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between washer motor When R044 is left displayed with the relay removed, check that 24V is produced on
relay and controllerWASHER relay (-) line according to the wiring checking procedure and repair it.
MOTOR RELAY
CN-105F, CN2-1 When no failure is found after checking on wiring and R044 is left displayed, replace
fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-78
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to the swing flasher relay is short-circuited with the power source.
condition
Symptom Swing flasher right relay does not work.
1 • Swing flasher relay When the error is cancelled after removing the swing flasher relay, check the relay
R-19 unit for failure, replace it with a new one if failed.
When the resistance between relay terminals H and D shown in the right figure is 0
2 • Wiring between flasher relay When R134 is left displayed with the relay removed, check that 24V is produced on
and controller relay (-) line (C, shown in the upper figure) according to the wiring checking
CN-104F procedure and repair it.
CN-74F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-79
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to the swing flasher relay is short-circuited with the power source.
condition
Symptom Swing flasher right relay does not work.
1 • Swing flasher relay When the error is cancelled after removing the swing flasher relay, check the relay
R-19 unit for failure, replace it with a new one if failed.
When the resistance between relay terminals H and D shown in the right figure is 0
2 • Wiring between flasher relay When R144 is left displayed with the relay removed, check that 24V is produced on
and controller relay (-) line according to the wiring checking procedure and repair it.
CN-104F
CN-74F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-80
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
1 • Travel alarm relay When error is cancelled after removing travel alarm relay, check relay unit for
R8 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Travel alarm switch Remove connector (CN-521F) and check that if conduction/non-conduction is
SW-13 switched by switch ON/OFF or not. If failure is found, replace it.
3 • Wiring between travel alarm When R154 is left displayed with the relay removed, check that 24V is produced on
relay, travel alarm switch, and relay (-) line according to the wiring checking procedure and repair it.
controller
CN-105F, CN2–1 When no failure is found after checking on wiring and R154 is left displayed, replace
CN-521F fuse/relay box.
• Fuse & relay box
E-1
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-81
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
condition
Power source for mechatro controller often turns off.
Symptom
Auto idle stop function does not actuate.
1 • Auto idle stop relay 2 When error is cancelled after removing of auto idle stop relay 2, check relay unit for
R-24 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between auto idle stop When R164 is left displayed with the relay removed, check that 24V is produced on
relay 2 and controller relay (-) line according to the wiring checking procedure and repair it.
CN-102F, CN2-1
When no failure is found after checking on wiring and R164 is left displayed, replace
• Fuse & relay box
fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-82
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to engine emergency stop is short-circuited with the power source.
condition
When key switch is turned off, engine does not stop.
Symptom
Auto idle stop function does not actuate.
1 • Engine emergency stop relay When error is cancelled after removing of engine emergency stop relay, check relay
R-25 unit for failure, replace it with new one if failed
When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between engine When R174 is left displayed with the relay removed, check that 24V is produced on
emergency stop relay and relay (-) line according to the wiring checking procedure and repair it.
controller When no failure is found after checking on wiring and R174 is left displayed, replace
CN-102F, CN2-1 fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-83
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to lever lock relay is short-cricuited with the power source.
condition
Symptom Lever lock timer does not actuate.
1 • Lever lock relay When error R184 is cancelled after removing of lever lock relay, check relay unit for
R-26 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between lever lock When R184 is left displayed with the relay removed, check that 24V is produced on
relay and controller relay (-) line according to the wiring checking procedure and repair it.
CN-102F, CN2-1 When no failure is found after checking on wiring and R184 is left displayed, replace
fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-84
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to safty relay is short-cricuited with the power source.
condition
Symptom Safty relay does not actuate.
1 • Safety relay When error R214 is cancelled after removing of safty relay, check relay unit for
R-4 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between safty relay When R214 is left displayed with the relay removed, check that 24V is produced on
and controller relay (-) line according to the wiring checking procedure and repair it.
CN-105F, CN2-1 When no failure is found after checking on wiring and R214 is left displayed, replace
fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-85
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16-86
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[17. TROUBLESHOOTING(BY TROUBLE)]
17
17. TROUBLESHOOTING(BY
TROUBLE)
17.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.............................................................17-3
17.2 HYDRAULIC SYSTEM ..........................................................................................................17-4
17.3 ELECTRIC SYSTEMS......................................................................................................... 17-31
17.3.1 WIRING CHECKING PROCEDURE .................................................................................. 17-31
17.3.2 TROUBLE ....................................................................................................................... 17-33
17.4 FAILURE DIAGNOSIS TABLE FOR ENGINE RELATED PARTS ........................................... 17-36
17-1
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-2
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-3
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-4
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[17. TROUBLESHOOTING(BY TROUBLE)]
5 Pilot pressure • Stop engine and turn on key. Check 5V power of controller
sensor All pilot low pressure sensors are for possible failure.
0MPa to 0.1MPa (0 to 15psi).
6 Solenoid valve for Measure pressure About 0MPa (0psi) by pushing lock lever Replace solenoid valve.
lever lock of A1 port of 8 up, and 4MPa (580psi) or more by
section solenoid pushing it down.
block
7 Pilot line filter Disassemble and Check filter for clogging. Clean filter.
check it visually
8 Pilot gear pump Measure pilot Check that it is 4MPa (580psi) or more at Check gear pump and its relief
primary pressure high idle. valve for possible failure.
at gear pump
9 Multi control valve Switched position Since all are blocked if switching is failed,
(in case that travel check that lever is set to proper select
is operable) pattern position.
10 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD(BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.3: Boom up in full lever
operation & relief.
11 Secondary Measure Check that both P1/P2 unload valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressures are from 0.5 to
unload proportional secondary 1.2MPa (73 to 174psi) in boom up full
valves pressures directly lever operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
12 Actually measured Carry out service • No.6 E-1 P1 PUMP In case where command value
current values of diagnosis. E-2 P2 PUMP is largely differed from the
P1/P2 pump actually measured value,
• See Service Diagnosis Data List for
proportional valves check proportional valve and
Operation No.18: Travel right in full
controller for possible failure.
lever operation and travel idling, and
Operation No.19: Travel left in full
lever operation and travel idling.
17-5
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[17. TROUBLESHOOTING(BY TROUBLE)]
14 Main relief Carry out service • See Service Diagnosis Data List for Measure actual relief pressure
pressure diagnosis Operation No.3: Boom up in full lever
operation & relief.
15 Main relief Check set Check that P1/P2 pump pressures are Reset or replace
pressure pressure 32MPa (4640psi) in boom up full lever
operation at high idle and H mode.
16 Pump regulator Visual check When removing pump regulator, it is free Replace
from abnormal resistance against sliding.
External appearance is free from
abnormal damage.
Spring is free from breakage.
17 Pump body Visual check When removing pump body, inside parts Replace
(cylinder block, piston, valve plate, and
shaft, etc.) are free from abnormal
resistance against sliding, and abnormal
damage, etc.
Engine down/stalle
No. Sections Contents/normal value Corrective action, others
1 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.1: No.operation.
2 Secondary Measure the pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
pump proportional secondary are from 0.5 to 1.0MPa (73 to 145psi) in
valves pressures directly control lever neutral position at high idle.
(a4 and a5 ports)
3 Pressure sensors Check pressure • See Service Diagnosis Data List for Check pressure sensor and
of P1/P2 pumps values Operation No.1: No operation, and replace it if necessary.
No.3: Boom up in full lever operation
& relief.
4 Pump regulator Visual check When removing pump regulator, it is free Replace
from abnormal resistance against sliding.
External appearance is free from
abnormal damage.
Spring is free from breakage.
5 Pump body Visual check When removing pump body, inside parts Replace
(cylinder block, piston, valve plate, and
shaft, etc.) are free from abnormal
resistance against sliding, and abnormal
damage.
17-6
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[17. TROUBLESHOOTING(BY TROUBLE)]
3 Main spool Check target spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage.
4 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from abnormal damage.
5 Lock valve poppet Check target Seat is it is free from abnormal damage. Replace
(for boom, boom 2 poppet visually
and arm)
6 Lock valve selector Exchange lock Check that the phenomenon is reversed. Replace
(for boom, boom 2 valve selector of
and arm) boom with that of
arm, and vice
versa.
7 Holding valve spool Check smooth Check that holding valve spool for boom Replace
for boom sliding of spool in is free from abnormal resistance against Do not pull spool out of sleeve
sleeve sliding. forcibly.
8 Relief valve in Check target relief Check that filter part is free from Replace
holding valve for valve visually abnormal contamination.
boom
9 Cylinder Check target Check that seals, etc. are normal at Replace cylinders or seals.
cylinder visually inspection after disassembly.
17-7
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[17. TROUBLESHOOTING(BY TROUBLE)]
2 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.1: No operation.
3 Secondary Measure Check that both P1/P2 unload Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
unload proportional secondary are from 2.7MPa (392psi) or more in
valves pressures directly control lever neutral position at high idle.
at A2 and A5 ports
of 8 section
solenoid block
4 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.1: No operation.
5 Secondary Measure pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures Check regulator.
pump proportional secondary are from 0.5 to 1.0MPa (73 to 145psi) in
valves pressures directly. control lever neutral position at high idle.
(a4 and a5 ports)
6 Slow return check Visual check Check that the slow return check valve Clean and replace
valve of pilot line installed on the pilot line is free from
(for boom up, or foreign materials caught in valve.
arm in or out)
17-8
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[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in boom up full lever operation at When equipped with multi
pressure of boom high idle. control valve, check it while
up changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.4: Boom up in full lever between P1/P2 pump
P2 pump operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current value of P1/ diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valve proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.3: Boom up in full lever
operaion & relief.
5 Secondary Measure Check that both P1/P2 unload valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressures are from 0.5 to
unload proportional secondary 1.2MPa (73 to 174psi) in boom up full
valves pressures directly lever operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 E-1 P1 PUMP In case where command value
current values of diagnosis E-2 P2 PUMP is largely differed from actually
P1/P2 pump measured value, check
• See Service Diagnosis Data List for
proportional valves proportional valve and
Operation No.4: Boom up in full lever
controller for possible failure.
operation & in operation.
7 Secondary Measure the pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valves pressures are from
pump proportional secondary 2.1 to 3.0MPa (305 to 435psi) in boom
valves pressures directly up full lever operation at high idle.
(a4 and a5 ports)
8 P2 by-pass cut Visual check Check main poppet for sliding ability and Clean and replace
valve orifice for contamination.
<Trouble> Check internal piston for sliding ability.
Only P2 pressure is
low.
9 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
10 Lock valve poppet Visual check When removing lock valve, it is free from Replace
<Trouble> abnormal resistance against sliding. (Check casing for damage.)
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
11 Conflux check Visual check When removing conflux check valve, it is Replace
valve free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
Only P2 pressure is External appearance is free from
high. abnormal damage.
17-9
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[17. TROUBLESHOOTING(BY TROUBLE)]
13 Boom spool Visual check When removing boom spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Only P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
14 Boom spool Inspection after Boom spool is free from abnormal Replace spool assembly.
<Trouble> disassembly resistance against sliding.
Only P1 pressure is Spring is free from breakage.
low.
15 Conflux spool Visual check When removing conflux spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Only P2 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
16 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
17 Port relief valve Visual check Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> (Head side) boom up full lever operation at high idle. boom up is low, replace port
Relief pressure is Free from foreign material caught in port relief valve.
low. relief valve.
Seat is free from abnormal damage.
17-10
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[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure remote Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure control pressure of or more in boom down full lever When equipped with multi
boom down operation at high idle. control valve, check it while
directly changing lever pattern.
3 Actually measured Carry out service P1 unload valve In case where command value
current values of diagnosis • See Service Diagnosis Data List for is largely differed from actually
P1 unload Operation No.5: Boom down in full measured value, check
proportional valve lever operation & in operation. proportional valve and
controller for possible failure.
4 Secondary Measure Check that P1 unload valve secondary Replace proportional valve.
pressure of P1 proportional valve pressure is from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in boom down full lever operation
valve pressures directly at high idle.
at the A2 port of 8
section solenoid
block.
5 Actually measured Carry out service • No.6 E-1 P1 PUMP In case where command value
current values of diagnosis is largely differed from actually
• See Service Diagnosis Data List for
P1 pump measured value, check
Operation No.5: Boom down in full
proportional valve proportional valve and
lever operation & in operation.
controller for possible failure.
6 Secondary Measure pump Check that P1 pump proportional valve Replace proportional valve.
pressure of P1 proportional valve secondary pressure is from 2.0 to
pump proportional secondary 2.6MPa (290 to 377psi) in boom down
valve pressures directly full lever operation at high idle.
(a4 port)
7 Actually measured Carry out service Check that value is not changed • Check pressure sensor of
current values of diagnosis regardless of operation. travel
travel straight • See Service Diagnosis Data List for • In case where command
proportional valve Operation No.1: No operation, value is largely differed from
Operation No.18: Travel right in full actually measured value,
lever operation & travel idle, and check proportional valve
Operation No.19: Travel left in full and controller for possible
lever operation & travel idle. failure.
8 Travel straight Measure directly Secondary pressure is 0.8MPa (116psi) Replace proportional valve.
proportional valve travel straight or less at high idle regardless of in
secondary proportional valve neutral position / operation.
pressure secondary
pressure.
9 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
10 Lock valve Visual check When removing lock valve poppet, it is Replace
poppet boom 1 free from abnormal resistance against (Check casing for damage.)
and boom 2 sliding.
<Trouble> External appearance is free from
Boom down is abnormal damage.
slow.
17-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
13 Boom spool Inspection after Check that boom spool is free from Replace spool assembly
<Trouble> disassembly abnormal resistance against sliding.
Machine can not be Spring is free from breakage.
lifted by supporting
with boom.
14 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
15 Port relief valve Visual check Check that port relief valve is free from Replace
<Trouble> foreign materials caught in valve.
Machine can not be Seat is free from failure.
lifted by supporting
with boom.
16 Boom 3 Visual check Outside surface is free from abnormal Replace proportional valve.
proportional valve damage.
17 Boom 3 spool Visual check When removing boom 3 spool, it is free Replace
from abnormal resistance against sliding. (Check casing for damage)
Outside surface is free from abnormal
damage.
Spring is free from breakage.
18 Boom meter in cut Visual check Outside surface is free from abnormal Replace solenoid
solenoid damage.
19 Boom meter in cut Visual check Outside surface is free from abnormal Replace boom meter in cut
valve damage. valve
17-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in arm-in full lever operation at When equipped with multi
pressure of arm in high idle. control valve, check it while
changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.7: Arm-in in full lever between P1/P2 pump
P2 pump operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.6: Arm-in in full lever
operation & relief.
5 Secondary Measure the Check that both P1/P2 unload valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressures are from 0.5 to
unload proportional secondary 1.2MPa (73 to 174psi) in arm-in full lever
valves pressures directly operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block.
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.7: Arm-in in full lever
operation & in operation.
7 Secondary Measure the pump Check that both P1/P2 pump proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures are 2.0MPa
pump proportional secondary (290psi) or more in arm-in full lever
valves pressures directly. operation at high idle. (Secondary
(a4 and a5 ports) pressure is affected by oil temperature
and attachment weight)
8 Actually measured Carry out service • See Service Diagnosis Data List for In case where command value
current value of diagnosis Operation No.1: No operation, is largely differed from actually
arm in 2-speed Operation No.6: Arm-in in full lever measured value, check
proportional valve operation & relief, and proportional valve and
Operation No.7: Arm-in in full lever controller for possible failure.
operation & in operation.
9 Secondary Measure directly Check that proportional valve secondary Replace proportional valve.
pressure of arm in proportional valve pressure at high idle is within the range of
2-speed secondary following.
proportional valve pressure at A8 Lever neutral: 0MPa (0psi)
port (arm 2-speed) Operation in the air: 1.7 to 2.2MPa (247
of 8 section to 319psi)
solenoid block. Arm in relief: 2.5MPa (363psi) or more
17-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
13 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
14 Port relief valve Visual check Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> (Head side) arm-in relief operation. arm in is low, replace valve.
P1/P2 pressures Check that port relief valve is free from
are low. foreign materials caught in valve.
Seat is free from abnormal damage.
15 Port relief valve Visual check (Rod Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> side) arm-out relief operation. arm out is low, replace valve.
P1/P2pressures Check that port relief valve is free from
are low. foreign materials caught in valve.
Seat is free from abnormal damage.
16 Arm 1 spool Visual check When removing arm 1 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P1/P2 pressures External appearance is free from
are high. abnormal damage.
Spring is free from breakage.
17 Arm 2 spool Visual check When removing arm 2 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P1/P2 pressures External appearance is free from
are high or low. abnormal damage.
Spring is free from breakage.
18 Recirculation check Inspection after Check that check valve is free from Replace spool assembly
valve of arm 2 disassembly. abnormal resistance against sliding.
spool Spring is free from breakage.
<Trouble>
Arm in speed is
slow.
19 Lock valve poppet Visual check When removing lock valve poppet, it is Replace
<Trouble> free from abnormal resistance against (Check casing for damage.)
Both P1/P2 sliding.
pressures are high. External appearance is free from
abnormal damage.
17-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in arm out full lever operation at When equipped with multi
pressure of arm high idle. control valve, check it while
out changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.9: Arm-out in full lever between P1/P2 pump
P2 pump operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.8: Arm-out in full lever
operation & relief.
5 Secondary Measure Check that P1/P2 unload secondary Replace proportional valve.
pressures of P1/P2 proportional valve pressures are from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in arm out full lever operation
valves pressures directly and high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.9: Arm-out in full lever
operation & in operation.
7 Secondary Measure pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
pump proportional secondary are from 1.7 to 2.9MPa (247 to 421psi) in
valves pressures directly arm out full lever operation at high idle.
(a4 and a5 ports) (Secondary pressure is affected by oil
temperature and attachment weight.)
8 Actually measured Carry out service Check that value is not changed • Check pressure sensor of
current value of diagnosis regardless of operation. travel.
travel straight • See Service Diagnosis Data List for • In case where command
proportional valve Operation No.1: No operation, value is largely differed from
Operation No.18: Travel right in full actually measured value,
lever operation & travel idling, and check proportional valve
Operation No.19: Travel left in full and controller for possible
lever operation & travel idling failure.
9 Secondary Measure directly 0.8MPa (116psi) or less at high idle Replace proportional valve.
pressure of travel proportional valve regardless of in neutral lever position/
straight secondary operation.
proportional valve pressure at A4
port (travel
straight) of 8
section solenoid
block
17-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
11 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
12 Port relief valve Visual check (Rod Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> side) arm out relief operation. arm out is low, replace valve.
P1/P2 pressures Free from dust entered in port relief
are low. valve.
Seat is free from abnormal damage.
13 Arm 1 spool Visual check When removing arm 1 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P2 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
14 Arm 2 spool Visual check When removing arm 2 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
15 Recirculation check Inspection after Check that check valve is free from Replace spool assembly.
valve of arm 2 disassembly. abnormal resistance against sliding.
spool (spring side) Spring is free from breakage.
<Trouble>
Both P1/P2
pressures are low.
16 Lock valve poppet Visual check When removing lock valve poppet, it is Replace
<Trouble> free from abnormal resistance against (Check casing for damage.)
Both P1/P2 sliding.
pressures are high. External appearance is free from
abnormal damage.
17-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in bucket digging full lever When equipped with multi
pressure of bucket operation at high idle. control valve, check it while
digging changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.13: Bucket digging in between P1/P2 pump
P2 pump full lever operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.12: Bucket digging in
full lever operation & relief.
5 Secondary Measure Check that both P1/P2 unload secondary Replace proportional valve.
pressures of P1/P2 proportional valve pressures are from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in bucket digging full lever
valves pressures directly operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.13: Bucket digging in
full lever operation & in operation.
7 Secondary Measure pump Check that secondary pressure of P1/P2 Replace proportional valve.
pressures of P1/P2 proportional valve pump proportional valve in bucket
pump proportional secondary digging full lever operation at high idle is
valves pressures directly as follows.
(a4 and a5 ports) P1 pump proportional valve: 2.5MPa
(363psi) or more
P2 pump proportional valve: 1.5 to 2.1
Mpa (218 to 305psi)
8 Power boost Carry out service No.3 F-1 POWER BOOST Check harness.
solenoid command diagnosis In bucket digging operation, COMP. Replace solenoid valve.
OFF, and MEAS. OFF.
9 Power boost Measure switching Check that pressure is 0MPa (0psi) in Replace solenoid valve.
solenoid secondary valve secondary bucket digging full lever operation at high
pressure pressure at A3 idle.
port of 3 section
solenoid block
10 Actually measured Carry out service • See Service Diagnosis Data List for In case where command value
current values of diagnosis Operation No.12: Bucket digging in is largely differed from actually
travel straight full lever operation & relief. measured value, check
proportional valve proportional valve and
controller for possible failure.
17-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
12 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
13 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
pressure Operation No.3: Boom up in full lever
operation & relief.
14 Bucket spool Visual check When removing bucket spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
Spring is free from breakage.
15 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from abnormal damage.
17-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa Check remote control valve.
pressure remote control (435psi) or more in bucket dump full When equipped with multi
pressure of bucket lever operation at high idle. control valve, check it while
dump changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.15: Bucket dump in full between P1/P2 pump
P2 pump lever operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.14: Bucket dump in full
lever operation & relief.
5 Secondary Measure Check that both P1/P2 unload secondary Replace proportional valve.
pressures of P1/P2 proportional valve pressures are from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in bucket dump full lever
valves pressures directly operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves. proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.15: Bucket dump in full
lever operation & in operation.
7 Secondary Measure pump Check that the secondary pressures of Replace proportional valve.
pressures of P1/P2 proportional valve P1/P2 pump proportional valves in
pump proportional secondary bucket dump full lever operation and high
valves pressures directly idle is as follows.
(a3 port) P1 pump proportional valve: 2.7MPa
(392psi) or more
P2 pump proportional valve: 1.0MPa
(145psi) or more
8 Actually measured Carry out service • See Service Diagnosis Data List for In case where command value
current value of diagnosis Operation No.14: Bucket dump in full is largely differed from actually
travel straight lever operation & relief. measured value, check
proportional valve proportional valve and
controller for possible failure.
9 Secondary Measure directly Check that travel straight proportional Replace proportional valve.
pressure of travel proportional valve valve secondary pressure is 2.7MPa
straight secondary (392psi) or more in bucket dump full
proportional valve pressure at A4 lever operation at high idle.
port (travel
straight) of 8
section solenoid
block
17-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
12 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
13 Bucket spool Visual check When removing bucket spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
Spring is free from breakage.
14 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from abnormal damage.
17-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressures are 3.0MPa Check remote control valve.
pressures remote control (435psi) or more in boom up full lever When equipped with multi
pressures of left operation at high idle. control valve, check it while
and right swing changing lever pattern.
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor.
brake solenoid diagnosis Swing parking lever neutral: COMP. ON, Check harness.
and MEAS. ON
Swing: COMP. OFF, and MEAS. OFF
4 Swing parking Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve.
brake solenoid at A3 port of 8 In operation: 4MPa (580psi) or more
section solenoid
block
5 Pump pressure Carry out service • See Service Diagnosis Data List for Check high pressure sensor.
sensor diagnosis for P2 Operation No.11: Swing in full lever
pump pressures in operation & in operation.
operation
6 Actually measured Carry out service • No.7 D-2 P2 UN-LOAD (BP-CUT) In case where command value
current value of P2 diagnosis is largely differed from actually
• See Service Diagnosis Data List for
unload proportional measured value, check
Operation No.11: Swing in full lever
valve proportional valve and
operation & in operation.
controller for possible failure.
9 Secondary Measure pump Check that P2 pump proportional valve Replace proportional valve.
pressure of P2 proportional valve secondary pressure is 2.7MPa (392psi)
pump proportional secondary or more in swing full lever operation at
valve pressure directly high idle.
(a5 port)
10 Actually measured Carry out service Check that value is not changed • Check pressure sensor of
current value of diagnosis regardless of operation. travel.
travel straight • See Service Diagnosis Data List for • In case where command
proportional valve Operation No.1: No operation, value is largely differed from
(Check this by only Operation No.18: Travel right in full actually measured value,
swing operation) lever operation & travel idling, and check proportional valve
Operation No.19: Travel left in full and controller for possible
lever operation & travel idling. failure.
17-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
13 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
P2 pressure is low. External appearance is free from
abnormal damage.
Spring is free from breakage.
14 Swing spool Visual check When removing swing spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P2 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
15 Swing relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.10: Swing in full lever
Relief pressure is operation & relief.
low.
16 Swing motor Visual check When removing swing motor, inner parts Replace
(cylinder block, piston, and valve plate,
etc.) are free from abnormal resistance
against sliding.
External appearance (brake disk, etc.) is
free from abnormal damage.
17 Swing reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from swing powder. reduction unit.
reduction unit
drain
18 Swing reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
4 By-pass check Visual check When removing by-pass check valve, it is Replace
valve free from abnormal resistance against
(Sound of sliding.
cavitation at Spring is free from breakage.
stopping)
5 Swing motor Visual check Disassemble and inspect swing motor for Replace
(Brake disk/friction abnormal wear and scuffing.
plate)
6 Swing motor piston Visual check When removing swing motor piston, it is Replace
free from abnormal resistance against
sliding.
Spring is free from breakage.
7 Swing reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from swing powder. reduction unit.
reduction unit
drain.
8 Swing reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check and replace pressure
brake solenoid diagnosis Lever neutral: COMP. ON, and MEAS. sensor.
ON Check harness.
Swing: COMP. OFF, and MEAS. OFF Check parking brake release
switch.
4 Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve.
at A3 port of 8 In operation: 4MPa (580psi) or more
section solenoid
block
5 Swing motor Visual check Disassemble and inspect swing motor for Replace
(Brake disk/friction abnormal wear and scuffing
plate)
6 Parking brake Visual check When removing parking brake, piston Replace
and friction plate are free from abnormal
resistance against sliding. Spring is free
from breakage.
2 Swing relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.10: Swing in full lever
Relief pressure is operation & relief.
low.
3 Anti-reaction valve Visual check Check that anti-reaction valve is free Clean or replace
from foreign materials caught in valve.
Sliding part should be free from foreign
materials caught in there, abnormal
damage, and wear.
4 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
5 Swing motor Visual check When removing swing motor, inner parts Replace
(cylinder block, piston, and valve plate,
etc.) are free from abnormal resistance
against sliding.
External appearance (brake disk, etc.) is
free from abnormal damage.
17-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 2.1MPa (305psi) Check remote control valve.
valve remote control or more in travel right (left), forward
pressures of travel (reverse) full lever operation at high idle.
right and left
3 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
4 Secondary Measure Check that P1/P2 unload proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures in travel
unload proportional secondary idling, travel right (left), and forward
valves pressures directly (reverse) full lever operation at high idle
at A2 and A5 ports are as follows.
of 8 section Travel right (P1 unload): 0.5 to 1.2MPa
solenoid block (73 to 174psi)
Travel left (P2 unload): 0.5 to 1.2MPa
(73 to 174psi)
5 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
6 Secondary Measure pump Check that P1/P2 pump proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures in travel
pump proportional secondary idling, travel right (left), and forward
valves pressures directly (reverse) full lever operation at high idle
(a4 and a5 ports) are as follows.
Travel right (P1 pump): 2.7MPa (392psi)
or more
Travel left (P2 pump): 2.7MPa (392psi)
or more
7 Actually measured Carry out service Check that value is not changed • Check voltage of low
current value of diagnosis regardless of operation. pressure sensor other than
travel straight • See Service Diagnosis Data List for sensor for travel.
proportional valve Operation No.1: No operation, • In case where command
Operation No.18: Travel right in full value is largely differed from
lever operation & travel idling, and actually measured value,
Operation No.19: Travel left in full check proportional valve
lever operation & travel idling. and controller for possible
failure.
17-25
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[17. TROUBLESHOOTING(BY TROUBLE)]
9 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
Check shuttle valve for sealing ability
and orifice for foreign materials caught in
it.
10 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
11 Travel spool Visual check of When removing travel spool, it is free Replace
<Trouble> target spool from abnormal resistance against sliding. (Check casing for damage.)
Pump pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
12 Travel motor relief Check set Check P1/P2 pump pressures are When P1 pressure or P2 relief
valve pressure 32MPa (4640psi) or more in right and left valve pressure of right travel
travel levers full lever operation (relief motor is low, check and
operation at locked crawler belt) at high replace relief valve of left travel
idle. motor.
13 Travel motor Visual check When removing travel motor, inner parts Replace
(piston, cylinder block, valve plate, and
brake valve spool, etc.) are free from
abnormal resistance against sliding.
External appearance is free from
abnormal damage.
14 Parking brake in Visual check When removing parking brake, it is free Replace
travel motor from abnormal resistance against sliding.
No sticking on friction plate and
separator.
15 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
unit oil from travel metal powder. reduction unit.
reduction unit
drain
16 Travel reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17-26
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[17. TROUBLESHOOTING(BY TROUBLE)]
Travel deviation
No. Sections Contents/normal value Corrective action, others
1 Travel right and left Carry out service Check and replace pressure
pressure sensor diagnosis
• See Service Diagnosis Data List for
Operation No.18: Travel right in full sensor. 17
lever operation and travel idling, and Check remote control valve.
Operation No.19: Travel left in full
lever operation and travel idling.
2 Remote control Measure directly Check that pressure in travel idling, Check remote control valve.
valve remote control travel right (left), and forward (reverse)
pressure of travel full lever operation at high idle is 2.1 MPa
right and left (305psi) or more.
3 Actually measured Carry out service Check that value is not changed • Check voltage of low
current value of diagnosis regardless of operation. pressure sensor other than
travel straight • See Service Diagnosis Data List for sensor for travel
proportional valve Operation No.1: No operation, • In case where command
Operation No.18: Travel right in full value is largely differed from
lever operation & travel idling, and actually measured value,
Operation No.19: Travel left in full check proportional valve
lever operation & travel idling. and controller for possible
failure.
4 Secondary Measure directly 0.8MPa (116psi) or less at high idle Replace proportional valve.
pressure of travel travel straight regardless of in neutral lever position/
straight proportional valve operation.
proportional valve secondary
pressure
5 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
6 Secondary Measure Check that P1/P2 unload proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures in travel
unload proportional secondary idling, travel right (left), and forward
valves pressures directly (reverse) full lever operation at high idle
at A2 and A5 ports are as follows.
of 8 section Travel right (P1 unload): 0.5 to 1.2MPa
solenoid block (73 to 174psi)
Travel left (P2 unload): 0.5 to 1.2MPa
(73 to 174psi)
7 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
17-27
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[17. TROUBLESHOOTING(BY TROUBLE)]
11 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
12 Travel spool Visual check of When removing travel spool, it is free Replace
<Trouble> targeted spool from abnormal resistance against sliding. (Check casing for damage.)
Pump pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
13 Travel motor relief Check set Check P1/P2 pump pressures are When P1 pressure or P2 relief
valve pressure 32MPa (4640psi) or more in right and left valve pressure of right travel
travel levers full lever operation (relief motor is low, check and
operation at locked crawler belt) at high replace relief valve of left travel
idle. motor.
14 Travel motor Visual check When removing travel motor, inner parts Replace
(piston, cylinder block, valve plate, and
brake valve spool, etc.) are free from
abnormal resistance against sliding.
External appearance is free from
abnormal damage.
15 Travel reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from travel powder. reduction unit.
reduction unit
drain
16 Travel reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17 Pump regulator Visual check When removing pump regulator, it is free Replace
from abnormal resistance against sliding.
External appearance is free from
abnormal damage.
Spring is free from breakage.
18 Pump body Visual check When removing pump body, inside parts Replace
(cylinder block, piston, valve plate, and
shaft, etc.) are free from abnormal
resistance against sliding, and abnormal
damage.
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[17. TROUBLESHOOTING(BY TROUBLE)]
4 1/2 speed Visual check Check that orifice is free from foreign Remove dust or replace
switching orifice in materials caught in it.
travel motor
5 Tilting piston in Visual check Check that tilting piston and seal are free Replace
travel motor from abnormal wear. (Check casing for damage.)
2 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
3 Parking brake in Visual check When removing parking brake, it is free Replace
travel motor from abnormal resistance against sliding.
Spring is free from breakage.
4 Orifice of passage Visual check Check that orifice is free from foreign Remove dust or replace
for parking brake in materials caught in it.
travel motor
17-29
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[17. TROUBLESHOOTING(BY TROUBLE)]
Machine does not travel straight in simultaneous operation of traveling left and right and attachment
No. Sections Contents/normal value Corrective action, others
1 Actually measured Carry out service Check that current value in travelling left • Check voltage of low
current values of diagnosis and right and boom up full lever pressure sensor other than
travel straight operation at high idle is as follows. travel sensor.
proportional valve No.7 D-3 S-TRAVEL
• In case where command
COMP. 590 mA and MEAS. 560 to 620
value is largely differed
mA
from actually measured
value, check proportional
valve and controller for
possible failure.
2 Secondary Measure travel Check secondary pressure is from 2.0 to Replace proportional valve.
pressure of travel straight 2.4 MPa (290 to 348psi) in travelling left
straight proportional valve and right and boom up full lever
proportional valve secondary operation at high idle.
pressure directly
at A4 port of 8
section solenoid
block
3 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
sliding.
External appearance is free from
abnormal damage.
Spring is free from breakage.
17-30
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[17. TROUBLESHOOTING(BY TROUBLE)]
Do not insert the male terminal the thickness differs. It may cause loose connection.
17-31
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[17. TROUBLESHOOTING(BY TROUBLE)]
Since the voltage may vary between with connector connected and with connector not connected. Measure the
voltage with each connector connected whenever possible.
Checking the general view of connector CRIMPED
PART
• Check the terminal crimped condition
Pull one electric cable with the about 3 kg (7 lbs)
RUBBER
force, and make sure that the cable does not come PLUG
RECEPTACLE.
out of the terminal. CONTACT
When came out, replace the terminal and crimp it PLUG
again. SEALING
(is housed in plug)
• Check connector for imperfect insertion DOUBLE LOCK
Check that all top ends form a line on the same PLATE FOR PLUG
DETAIL aa
17-32
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[17. TROUBLESHOOTING(BY TROUBLE)]
17.3.2 TROUBLE
• Engine does not stop.
• "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
17
• Auto accel does not actuate. (The engine speed does not automatically slow down.)
• Auto accel does not actuate. (The engine speed does not automatically speed up.)
• Wiper does not function.
2 Key ON holding Measure voltage of When starter switch is OFF, voltage is Check key ON holding relay for
relay wire between 62E OFF. possible failure.
wire, which is
between key ON
holding relay and
engine controller, and
machine ground
2 Wiring 770A and 582A wires See "WIRING CHECKING Repair wiring
in transceiver circuit PROCEDURE".
of mechatro controller
and gauge cluster
3 Mechatro controller Check control of Engine speed varies according to Check mechatro controller and
mechatro controller accel potentiometer operation. replace as necessary.
such as acceleration (Perform remote control lever
control operation because auto accel function
can be working.)
17-33
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[17. TROUBLESHOOTING(BY TROUBLE)]
Auto acceleration does not actuate (engine speed does not automatically slow down).
No. Sections Contents/normal value Corrective action, others
1 Cluster gauge Indication of auto Auto acceleration mark appears/ Replace gauge cluster
acceleration disappears according to operation of
auto acceleration switch on gauge
cluster.
2 Engine coolant Check engine coolant When “No.2 G-5 WATER TEMP” Replace engine coolant
temperature temperature by shows temperature of less than -15 temperature sensor.
carrying out service degrees C (5 degrees F), auto
diagnosis. acceleration does not work. Perform
warming-up operation to raise water
temperature to -15 degrees C (5
degrees F) or more.
3 Low pressure Carry out service When remote control lever operation Check low pressure sensor.
sensor diagnosis is performed, each control pressure of
No.5 and 6 rises and does not fall.
Auto acceleration does not actuate (engine speed does not automatically rise).
No. Sections Contents/normal value Corrective action, others
1 Low pressure Carry out service When control lever is in neutral Check low pressure sensor.
sensor diagnosis position, each control pressure of No.
5 and 6 is from 0 to 0.1 MPa (0 to 15
psi).
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
17-34
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[17. TROUBLESHOOTING(BY TROUBLE)]
No. S e ctions Conte nts /norma l va lue Corre ctive a ction, othe rs
1 Fus e Che ck fus e No.20 Re pla ce fus e .
2 S W-19: S e rvice dia gnos is No.14 DI4 Che ck wipe r inte rlock s witch
Wiper interlock switch Wipe r s witch dis pla y (DI4) is OFF with front window clos e d. a nd re pa ir it if ne ce s s a ry. 17
Che ck it a ccording to "WIRING
CHECKING P ROCEDURE" a nd
re pa ir it if ne ce ssa ry.
3 Ris e up limit s witch built- Service diagnosis No.19 Wiper sys te m Che ck a nd re pa ir s witch
in wipe r motor a ccording to "WIRING
Re ve rs e limit s witch CHECKING P ROCEDURE" .
S witch a ction in ope ra tion
Norma l condition
Rise up limit switch
Wiper motor (RIS EUP S W) ON OFF OFF
Re ve rs e limit s witch
Wiper motor (REVERSE SW ) ON ON OFF
Che ck tha t the re la y is worke d a s s hown in the ta ble . Che ck tha t the re la y is e xcite d.
* Whe n the limit s witch doe s not cha nge in OFF a fte r 4 s e conds Che ck re la y & fus e box a nd re pla ce it
from the wipe r s ta rtup, turn OFF a ll re la y's outputs . if ne ce s s a ry.
17-35
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[17. TROUBLESHOOTING(BY TROUBLE)]
Muffler clogged
Engine oil leak
Coolant level
Trouble
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[17. TROUBLESHOOTING(BY TROUBLE)]
17
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble
17-37
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[17. TROUBLESHOOTING(BY TROUBLE)]
Intake and
Fuel system exhaust Lubrication Cooling
system system system
Factors
Da ma ge of wa te r pump
Fa ilure of s upply pump
Trouble
17-38
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[17. TROUBLESHOOTING(BY TROUBLE)]
Engine body
Factors
Damage of dumper
Trouble
17-39
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-40
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[18. ENGINE]
18. ENGINE
18.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.............................................................18-5
18.2 GENERAL ............................................................................................................................18-6
18
18.2.1 Warning ............................................................................................................................18-6
18.2.2 How to read this manual ...................................................................................................18-7
18.2.3 Precautions for work ...................................................................................................... 18-11
18.2.4 Tightening of engine bolts and nuts ............................................................................... 18-14
18.2.5 Tightening of chassis bolts and nuts .............................................................................. 18-17
18.2.6 Tightening of flare nuts and hoses ................................................................................. 18-19
18.2.7 Taper thread sealant for piping ....................................................................................... 18-20
18.2.8 Assembly of joints and gaskets for piping ...................................................................... 18-21
18.2.9 Handling of liquid gasket ................................................................................................ 18-23
18.2.10 Failure diagnosis table for each problem ...................................................................... 18-24
18.2.11 Failure diagnosis using HinoDX.................................................................................... 18-25
18.2.12 Connection method of HinoDX...................................................................................... 18-30
18.2.13 Chassis number and engine number ............................................................................ 18-30
18.3 STANDARD VALUE ............................................................................................................ 18-31
18.3.1 Engine Body ................................................................................................................... 18-31
18.3.2 Fuel System .................................................................................................................... 18-31
18.3.3 Electrical......................................................................................................................... 18-32
18.3.4 Intake.............................................................................................................................. 18-32
18.3.5 Engine Mechanical ......................................................................................................... 18-33
18.3.6 Exhaust .......................................................................................................................... 18-40
18.3.7 Cooling ........................................................................................................................... 18-40
18.3.8 Lubrication ..................................................................................................................... 18-41
18.3.9 Starting and Charging..................................................................................................... 18-43
18.3.10 Turbocharger ................................................................................................................ 18-45
18.4 PARTS TO BE PREPARED ................................................................................................. 18-46
18.4.1 Engine Body ................................................................................................................... 18-46
18.4.2 Fuel System .................................................................................................................... 18-46
18.4.3 Electrical......................................................................................................................... 18-46
18.4.4 Engine Mechanical ......................................................................................................... 18-47
18.4.5 Lubrication ..................................................................................................................... 18-50
18.4.6 Starting and Charging..................................................................................................... 18-51
18.4.7 Turbocharger .................................................................................................................. 18-52
18.4.8 Engine Failure Diagnosis................................................................................................ 18-53
18.5 ENGINE MOUNTING/DISMOUNTING.................................................................................. 18-55
18.5.1 Inspection Before Service............................................................................................... 18-55
18.5.2 Engine Body ................................................................................................................... 18-57
18-1
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[18. ENGINE]
18-2
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[18. ENGINE]
PREFACE
This manual describes the engine unit. Please note that this shop manual uses the service manual of Hino Motors,
Ltd.
18
18-3
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[18. ENGINE]
18-4
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[18. ENGINE]
18-5
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[18. ENGINE]
18.2 GENERAL
18.2.1 Warning
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
18-6
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[18. ENGINE]
Standard value
1. Standard value, limit, action and tightening torque described in the text are summarized in tables.
Items to be prepared
1. Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list section
of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually equipped in general
service shop are omitted.
The part layouts in this manual are inserted based on illustrations and part numbers of the parts catalog CD-ROM
issued in April, 2007. (Some areas do not show exploded view. They will be additionally issued when the parts
catalog CD is revised.) Be sure to use the parts catalog for confirmation of illustrations and part numbers and for
ordering parts.
18-7
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[18. ENGINE]
2. Pre-inspection
18-8
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[18. ENGINE]
Example
S AP H041170900182
I:It is the ID number for parts to prepare electronic data. It is not required for repair work.
18-9
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[18. ENGINE]
Definition of terms
Terms in this manual are defined as follows :
1. Direction
1) Individual unit
Front/back direction
The power input side is front and the output side is back.
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is left
rotation.
Vertical direction
With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction is
lower.
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
2) Standard value....Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined.
3) Repair limit..........It is the value requiring repair. Symbol of + or - with the value means increase or decrease
to the standard value.
4) Service limit........It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
5) Warning..............It is an item that may result in risk of human life or serious injury by incorrect handling.
6) Caution...............It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
7) Reference...........It is supplementary explanation in work.
Unit
1. SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
2. This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
Conversion value*1 Conversion value*1
Conven- Conven-
SI unit (1[Conventional unit] = SI unit (1[Conventional unit] =
tional unit tional unit
X [SI unit]) X [SI unit])
Spring 1kgf/mm=9.80665N/
Force N kgf 1kgf=9.80665N N/mm kgf/mm
constant mm
1kgf·cm=
Torque*2 N·m kgf·cm Volume L cc 1cc=1mL
0.0980665N·m
1kgf/cm2=98.0665kPa
kgf/cm2 Efficiency W PS 1PS=0.735499kW
=0.0980665MPa
Pressure Pa
Calorific
mmHg 1mmHg=0.133322kPa W·h cal 1kcal=1.163W·h
value
r/min 1rpm=1r/min Fuel
Rotational
rpm consump- g/W·h g/PS·h 1g/PS·h=1.3596g/kW·h
speed min-1 1rpm=1min-1 tion rate
*1 : X means the value when 1 [Conventional unit] is converted to the SI unit.
It is used as the conversion factor from the conventional unit to the SI unit.
*2 : The conversion value of the torque may vary depending on the unit.
18-10
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[18. ENGINE]
18-11
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[18. ENGINE]
4. Handling of connector
1) When a connector is removed, hold the
connector (as shown by the arrow in the left) and
pull it out. Do not pull the wire harness.
2) Unlock the locking connector before pulling.
3) Insert the locking connector completely until it
clicks.
4) To insert a test lead into the connector, insert it
from the back of the connector.
5) If it is difficult to insert a test lead from the back of
the connector, prepare a harness for inspection.
18-12
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[18. ENGINE]
18-13
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[18. ENGINE]
Unit : N·m{kgf·cm}
Remark Bolt with number “7” on the head Bolt with number “9” on the head
Unit : N·m{kgf·cm}
18-14
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[18. ENGINE]
Precoated bolt
Precoated bolt is the bolt with an application of a seal
lock agent at the thread.
1. When re-application of lock agent is required
1) When precoated bolts are removed
2) When precoated bolts are moved due to
tightening check (for loosening or tightening) Seal Lock Agent
18
• Check torque with the lower limit of the tightening torque allowable value. If movement is found, tighten the bolt
according to the procedure below.
2. Parts tightened
One turn by 90° Tighten it 45°
Cylinder head bolt, crankshaft main bearing cap One turn by 45° (Second time)
bolt, connecting rod bearing cap bolt, etc.
Tighten it 90°
(First time)
• Measure the overall length of the bolt before assembly and replace the bolt if the length exceeds the service
limit.
Apply engine oil to bolt seating and bolt thread in assembly.
18-15
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[18. ENGINE]
3. Tightening method after tightening to seating torque Two turns by 90° Tighten it 90°
Tightening of 90°, 135°(90°once and 45°once) and (Second time)
18-16
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[18. ENGINE]
Hexagonal nut
Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below :
Formula
18-17
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[18. ENGINE]
Unit : N·m{kgf·cm}
Strength
zone
Bolt 4T 7T 9T
diameter
(mm)
4.5±1.8{50±20}
(Cab)
M6 9.0±1.8{90±20} 11.5±2.0{117±23}
5.5±1.1{60±10}
(Chassis)
14.0±3.5{140±40}
(Cab)
M8 22.0±4.0{220±40} *2 29.0±5.5{300±60} *2
17.0±3.0{170±30}
(Chassis)
43.0±8.5{440±90} *2 57.0±11.0{580±110} *2
(Cab) (Cab)
M10 27.0±5.0{276±55}
51.5±10.0{530±100} 68.5±13.5{700±140}
(Chassis) (Chassis)
• Use the tightening torque value for seating A with flange except for *2 in the table larger by 10% than the
tightening torque value in the table.
• Use the tightening torque value for seating B with flange of *2 in the table larger by 20% than the tightening
torque value in the table.
The tightening torque value of M8 for seating B with flange remaines unchanged.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in pairs. Use the standard
seating for the tightening torque value.
18-18
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[18. ENGINE]
Unit : N·m{kgf·cm}
Pipe outer
diameter ø4.76 ø6.35 ø8 ø10 ø12 ø15
Material
Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80}
21.5±1.5{215±15}
Air hose Only meter gauge 41.5±2.5{425±25} —
10{100}
Packing
Brake hose — —
51.5±7.5{525±75}
Unit : N·m{kgf·cm}
Screw nominal
M12 M16 M20 M27
size
Tightening
15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}
torque
18-19
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[18. ENGINE]
• If your eye or skin comes in contact with sealant, wash it off immediately with water.
Unit : N·m{kgf·cm}
Screw diameter
1/4 3/8 1/2
Material
Steel 49±10{500±100} 64±15{650±150}
Aluminum,
25±5{250±50} 34±5{350±50} 44±5{450±50}
brass
2) When a sealing tape is replaced with sealant, remove the tape completely first as in (1).
3) If air leak is found after assembly with application of sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and (2).
18-20
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[18. ENGINE]
Unit : N·m{kgf·cm}
M8 13{130}
M24 69{700}
M28 *127{1300}
18-21
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[18. ENGINE]
Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint
Gasket
with sleeve Gasket Sealing surface
Gasket : 5 places Sealing surface: 5 places
Sealing surface
: 8 places Connector nipple
Joint pipe
Bracket
Sealing surface
: 3 places
Joint bolt
Joint bolt
Joint pipe
18-22
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[18. ENGINE]
Winding tool
Application gun
For a tube, desired application width may be obtained from the cut position at the nozzle end.
Nozzle of tube
18-23
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[18. ENGINE]
Engine m echanical Causes and actions are described for each item.
JP03Z01020601001
18-24
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[18. ENGINE]
• HinoDX is used for inspection and adjustment of the system in addition to failure diagnosis.
HinoDX
1. With HinoDX, failure of the common rail fuel
injection system can be diagnosed. The interface 18
box (Hino-Bowie) and the special cable are required
for connection to the vehicle.
Hino Diagnostic
• Install the software included in the
eXplorer —
Hino Diagnostic eXplorer (Hino-DX)
(Hino-DX)
into the computer. For the
installation method, refer to the
instruction manual included with the
CD.
18-25
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[18. ENGINE]
Part name Part No. External shape General description and function
• Computer interface
Cable bundled
to the Hino-Bowie
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
18-26
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[18. ENGINE]
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
18
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
7
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i — — — — — —
1.0.9 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN OK OK OK OK OK OK
Bowie w/o CAN OK OK — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
XP
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
DST-i OK OK — — — —
1.0.9 Bowie w/ CAN OK OK — — — —
Bowie w/o CAN OK OK — — — —
18-27
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[18. ENGINE]
Unit harness
Signal check harness
Test lead
2) Connect the signal check harness to the machine harness and the ECU.
Signal check harness
(for common rail fuel injection system)
Part No.
09843-E9020
18-28
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[18. ENGINE]
3) Terminal No.
For the signal check harness connector, the ECU terminal number in the text is treated as follows :
ECU unit
18
Signal check
harness
18-29
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[18. ENGINE]
Failure diagnosis
connector
2) Set the starter key to "ON" and start HinoDX. Failure diagnosis connector
Hino-Bowie
Stamp position
18-30
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[18. ENGINE]
18-31
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[18. ENGINE]
18.3.3 Electrical
Standard value
Tightening torque
18.3.4 Intake
Tightening torque
18-32
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Unit : mm {in.}
IN 0.30 {0.0118} — —
Valve clearance (cold)
EX 0.45 {0.0177} — —
0.01 - 0.08
Cylinder liner protrusion — —
{0.003 - 0.003}
18
Cylinder liner flange width 8 {0.314} — —
117 - 117.008
A — —
{4.6063 - 4.6066}
117.014 - 117.022
C — —
{4.6068 - 4.6072}
116.982 - 116.99
A — —
{4.6056 - 4.6059}
116.996 - 117.004
C — —
{4.6061 - 4.6064}
112.15 Cylinder
Cylinder liner inner diameter 112 {4.4094} —
{4.4154} Replace liner
Cylinder
0.088 - 0.112
Piston clearance — — Liner
{0.0035 - 0.0044}
Replace piston
18-33
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[18. ENGINE]
2.5 –0.1
Top —
{0.0984} {–0.0039}
4 –0.1
Oil —
{0.1574} {–0.0039}
2.5 +0.2
Top —
{0.0984} {+0.0079}
4 +0.1
Oil —
{0.1574} {+0.0039}
0.09 - 0.13
Top — —
Clearance {0.0035 - 0.0051}
between
0.04 - 0.08 Replace piston ring or
piston ring Second — —
{0.00016 - 0.0031} piston.
and piston
Piston
ring groove 0.02 - 0.06
Oil — —
{0.0008 - 0.0024}
37 –0.04
Piston pin outer diameter — Replace piston pin
{1.4567} {–0.0015}
37 +0.05
Piston boss inner diameter — Replace piston
{1.4567} {+0.0020}
–0.002T - 0.025
{0.0000 - 0.0010}L
Clearance between piston 0.05 Replace piston pin or
(T : Tightening —
pin and piston boss {0.0020} piston
allowance,
L : Clearance)
18-34
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[18. ENGINE]
79.3
Crank 18
Crank journal outer diameter 80 {3.1496} — Replace shaft
{3.1221}
(Note 1)
+1.00
Center journal width 36 {1.4173} — Replace crankshaft.
{+0.039}
+0.8
Crank pin width 34 {13.386} — Replace crankshaft
{+0.0315}
Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or more.
Replace crankshaft for wear of 0.7 or more.
Note 2 : Under-size bearing values are 0.25 and 0.50.
18-35
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[18. ENGINE]
0.04 0.1
Camshaft runout — Replace camshaft
{0.0016} {0.039}
–0.08
Rocker shaft outer diameter 22 {0.8661} — Replace rocker shaft
{–0.0031}
IN 7 {0.2756} — —
Valve stem outer diameter Replace valve
EX 7 {0.2756} — —
IN 7 {0.2756} — —
Valve guide inner diameter Replace valve guide
EX 7 {0.2756} — —
0.023 - 0.058
IN — —
Oil clearance between valve {0.0009 - 0.0020} Replace valve or valve
guide and valve stem 0.050 - 0.083 guide
EX — —
{0.0020 - 0.0033}
18-36
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[18. ENGINE]
Inner –3.0
Free length 64.6 {2.5433} — Replace spring
{–0.3543}
2.0
Squareness — — Replace spring
Valve {0.0787}
spring Set length 46.8 {1.8252} — —
2.0
Squareness — — Replace spring
{0.0787}
Bushing inner
Timing 57 {2.2441} — —
diameter
gear
Clearance between 0.030 - 0.090 0.20 Replace shaft or
—
Main shaft and bushing {0.0012 - 0.0084} {0.0079} bushing
idle
Gear width 44 {1.7322} — —
Bushing inner
50 {1.9685} — —
diameter
Clearance between 0.025 - 0.075 0.20 Replace shaft or
—
Sub- shaft and bushing {0.0010 - 0.0030} {0.0079} bushing
idle
Gear width 22 {0.8661} — —
18-37
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[18. ENGINE]
0.016 - 0.22
End play — —
{0.0006 - 0.0087}
Longitudinal
direction 0.06 Grinding is inhibited
Flatness under cylinder head {0.0024} 0.2 because backlash
—
Flatness above cylinder block Square direction {0.0079} between cam idle- sub-
0.03 idle gears is changed.
{0.0012}
0.15
Surface runout of flywheel — —
{0.0060}
68.0
Connecting rod bolt — — Replacement
{2.6772}
187.5
long — — Replacement
{7.3819}
156.5
Head bolt middle — — Replacement
{6.1614}
126.5
short — — Replacement
{49.8031}
18-38
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[18. ENGINE]
Valve timing
Tightening torque
Rocker arm and crosshead adjusting screw lock nut 25 {250, 18}
Main bearing cap mounting bolt 69 {700, 51}+90°+45° Refer to the main text.
Connecting rod cap mounting bolt 69 {700, 51}+90°+45°
Air compressor idle gear shaft mounting bolt 108 {1,100, 80}
18-39
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[18. ENGINE]
18.3.6 Exhaust
Tightening torque
18.3.7 Cooling
Standard value
18-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18.3.8 Lubrication
Standard value
Unit : mm {in.}
Repair Service
Inspection item Standard value Action
limit limit
39kPa
Hydraulic alarm switch operation pressure — —
{0.4kgf/cm2, 5.66lbf/in.2}
Clearance between drive gear and 0.100 - 0.202 0.30 Replace drive gear
—
cylinder block {0.0039 - 0.0080} {0.0118} or oil pump
18-41
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Tightening torque
18-42
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[18. ENGINE]
Standard Repair
Inspection item Service limit Action
value limit
Resistance between stator coil terminals
0.247 - 0.273Ω — — Replacement
(for 2 phases)
Resistance between stator coil core and coil 1MΩ or more — — Replacement
Resistance between feed coil core and coil 1MΩ or more — — Replacement 18
25mm 24.98mm
Front —
Shaft outer diameter of rotor {0.9843 in.} {0.9835 in.}
Replacement
assembly 17mm 16.98mm
Rear —
{0.6693 in.} {0.6685 in.}
Forward
Approx. 10Ω — —
Resistance between diode and resistance value
Replacement
rectifier holder Reverse
Infinite — —
resistance value
Forward
Approx. 10Ω — —
Resistance between regulator resistance value
Replacement
terminals F - E Reverse
Infinite — —
resistance value
Feed coil mounting bolt 3.9 - 4.9 {40 - 49, 2.9 - 3.6}
Inside B terminal mounting nut 3.9 - 4.9 {40 - 49, 2.9 - 3.6}
18-43
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[18. ENGINE]
Unit : mm {in.}
Resistance between
1MΩ or more 1kΩ or less
commutator and core
Commutator outer diameter 36 {1.4173} 34 {1.1458} or less Replace armature
Armature assembly
assembly Shaft outer diameter A 12 {0.4724} 11.98 {0.4717} or less
Clutch assembly inner sleeve outer diameter 25 {0.9843} 24.90 {0.9803} or more Replacement
Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush
Metal bushing inner diameter of center bracket 26 {1.02362} 26.2 {1.0315} Replace center bracket
Metal bushing inner diameter of shaft assembly 9 {0.3543} 9.2 {0.3622} Replace shaft assembly
Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13}
Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}
18-44
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[18. ENGINE]
18.3.10 Turbocharger
Standard value
Unit : mm {in.}
Tightening torque
18
Unit : N·m{kgf·cm, lbf·ft}
18-45
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
S0949–11010
Wire rope For engine lifting
(09491–1010)
S0955–21030
Compression gauge adapter
(09552–1030)
S0955–21060
Compression gauge adapter
(09552–1060)
S0955–21110
Compression gauge adapter
(09552–1110)
18.4.3 Electrical
Special tool
Shape Part No. Name Remark
S0944–41210
Compression gauge For V-belt tension adjustment
(09444–1210)
95506–00090
Belt tension gauge For V-belt tension adjustment
(Denso part No.)
18-46
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[18. ENGINE]
18
S0940–71030 For crankshaft front oil seal
Oil seal press
(09407–1030) press-fit
S0947–11520
Guide For valve guide press-fit
(09471–1520)
S0947–21210
Bar For nozzle seat clamping
(09472–1210)
S0943–11020
Valve lapping tool For valve adjustment
(09431–1020)
S0947–22100
Bar For valve stem seal mounting
(09472–2100)
18-47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
For assembly/disassembly of
S0940–21530
Press sub-assembly connecting rod small end
(09402–1530)
bushing
For assembly/disassembly of
connecting rod small end
SL271–01036
Wing nut bushing
(9233–10360)
(together with S0940-21530
(09402-1530))
For assembly/disassembly of
connecting rod small end
S0948–11130
Guide bushing
(09481–1130)
(together with (S0940-21530
(09402-1530))
For assembly/disassembly of
S0940–21540
Spindle connecting rod small end
(09402–1540)
bushing
S0944–11370
Piston ring holder For piston mounting
(09441–1370)
18-48
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[18. ENGINE]
S0947–11490
Guide For insertion of cylinder liner
(09471–1490)
S0947–21620
Tool For cooling jet repair
(09472–1620)
18-49
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Instruments
Name Remark
Micrometer For measurement of part outer diameter
Lubricant, etc.
Name Remark
Liquid gasket (Threebond TB1207B or equivalent : Black) For sealing of parts
18.4.5 Lubrication
Special tool
Shape Part No. Name Remark
S0950–31110
Oil filter wrench
(09503–1110)
Lubricant, etc.
Name Remark
Liquid gasket
(Threebond
TB1211 (white) or equivalent
For sealing of parts
TB1207B (black) or equivalent
TB1207D (silver) or equivalent
TB1207G (gray) or equivalent)
18-50
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
f 23{20.827} f 25{0.984}
1C{0.039}
35{1.378} 18
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 f 50{1.969}
+0.5{0.0196} {0.394 - 0.787}
f 19{0.748}
0
f 30{1.181}
Jig C Jig D
f 34{1.339} f 41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
f 54{2.126} f 64{2.520}
f 60{2.362} f 70{2.756}
18-51
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Instruments
Alternator
Name Remark
Circuit tester For measurement of parts
Starter
Name Remark
Circuit tester For measurement of parts
Lubricant, etc.
Name Remark
Kyodo Yushi Multemp AC-N For lubrication of parts
18.4.7 Turbocharger
Special tool
Shape Part No. Name Remark
S0944-41800
End play gauge
(09444-1800)
18-52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Hino Diagnostic
• Install the software included in the
eXplorer —
Hino Diagnostic eXplorer (Hino-DX)
(Hino-DX)
into the computer. For the
installation method, refer to the
instruction manual included with the
CD.
• Computer interface
Cable bundled
to the Hino-Bowie
18-53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Part name Part No. External shape General description and function
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
18-54
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
• Measure the compression pressure before disassembly of the engine and record the result. Regular
measurement of the compression pressure can tell the engine status. 18
1. Preparation before measurement
1) Charge the battery completely.
2) Check the valve clearance and adjust it when exceeding the standard value.
3) Warm the engine and set the water temperature to 80℃{176℉}.
4) Remove the air cleaner.
5) Remove the head cover.
6) Remove all injectors.
7) To prevent spread of engine oil, attach a jig which cuts a head cover in half. (Cut it so that the camshaft may
be covered.
2. Measurement
1) Attach a special tool to the nozzle sheet of the
cylinder where the compression pressure is
measured with nozzle clamp and clamp fixing
bolts.
Special
tool
Engine
18-55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Compression pressure:
Unit MPa {kgf/cm2,lbf/in.2}
Difference between
0.3{3, 44} or less
cylinders
4) If the compression pressure is the service limit or less or if the difference between cylinders is over the
standard value, overhaul the engine.
5) After measurement, reassemble the removed parts.
18-56
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
2) Drain engine oil from the oil pan drain plug as required.
Cylinder head
Cover
• Close the opening of the intake manifold with a packing tape to prevent entry of dirt inside the engine.
18-57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Clip
18-58
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
• Work carefully so that the engine may not come in contact with the frame and others.
18
18-59
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18.5.2.2 Installation
1. Connection of fuel hose
1) Insert a fuel hose and fix it with a hose band.
Filler cap
bleeding bolt.
2) Loosen the main fuel filter air bleeding bolt.
3) Operate the priming pump.
4) Operate the priming pump until fuel without
bubble comes out.
5) Tighten the main fuel filter air bleeding bolt.
Tightening torque:
9 - 11 N·m {91.8 - 112 kgf·cm, 6.7 - 8.1 lbf·ft}
6) Operate the main fuel filter priming pump again until it becomes hard.
• After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel leak.
18-60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
Injector
Common rail
18
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Supply pump
Fuel tank
*There are models which
are not equipped with it.
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Tightening torque
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18
Tightening torque
23711 M14 : 44N·m {450 kgf·cm, 33 lbf·ft} 23713 M14 : 44N·m {450 kgf·cm, 33 lbf·ft}
M16 : 54N·m {550 kgf·cm, 40 lbf·ft} M16 : 54N·m {550 kgf·cm, 40 lbf·ft}
23712 M14 : 44N·m {450 kgf·cm, 33 lbf·ft} 23714 M14 : 44N·m {450 kgf·cm, 33 lbf·ft}
M16 : 54N·m {550 kgf·cm, 40 lbf·ft} M16 : 54N·m {550 kgf·cm, 40 lbf·ft}
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[18. ENGINE]
Pre filter
Tightening torque
Tightening torque
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18
Tightening torque
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[18. ENGINE]
• After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel leak.
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[18. ENGINE]
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
• Take care that no dirt or water gets into the system during the work.
18
2. Prepare a container under the pre fuel filter drain Main fuel filter
valve. air bleeding bolt
3. Loosen the main fuel filter air bleeding bolt and the pre fuel filter drain valve. Discharge water at the bottom of
the pre fuel filter case.
• Since discharged water contains fuel, observe the local disposal procedure for disposal.
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[18. ENGINE]
• Make sure that the main fuel filter air bleeding bolt has been loosened.
• The main fuel filter air bleeding bolt has a slit (groove) as shown in the figure. As air will bleed out even when the
bolt is not removed completely, perform priming work with the bolt loosened to an intermediate position in order
to prevent the entry of foreign matter to the fuel system.
• After work, wipe off spilled water or fuel. After start of the engine, make sure that there is no fuel leak.
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[18. ENGINE]
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
• Take care that no dirt or water gets into the system during the work.
2. Prepare a container under the final fuel filter drain Main fuel filter
valve. air bleeding bolt 18
3. Loosen the main fuel filter air bleeding bolt and the final fuel filter drain valve. Discharge water at the bottom of
the final fuel filter case.
• Since discharged water contains fuel, observe the local disposal procedure for disposal.
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[18. ENGINE]
• Make sure that the main fuel filter air bleeding bolt has been loosened.
• The main fuel filter air bleeding bolt has a slit (groove) as shown in the figure. As air will bleed out even when the
bolt is not removed completely, perform priming work with the bolt loosened to an intermediate position in order
to prevent the entry of foreign matter to the fuel system.
• After work, wipe off spilled water or fuel. After start of the engine, make sure that there is no fuel leak.
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[18. ENGINE]
A
18
B
5) Set a socket with a width across flats of 27 mm to the hexagonal part (C) at the bottom of the case (4), and
then turn it with a ratchet wrench to remove the case.
Tightening torque:
30±2 N·m {306±20 kgf·cm, 23±1.4 lbf·ft}
6) Prepare a new filter element (5) and a gasket (6).
Install the gasket in the case after applying a thin
layer of oil.
7
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[18. ENGINE]
7) Remove dirt and foreign matter from the inside of the cover (7).
8) Set a socket with a width across flats of 27 mm to the hexagonal part (C) at the bottom of the case, and then
turn it with a ratchet wrench to securely install it to the case.
9) Tighten the air venting plug (2) and the drain plug (3).
10) Set the cock (1) to the position "Open".
11) Refer to "Air venting" for venting air.
12) Start the engine, let it idle for several minutes, and then confirm that no fuel is leaking from the filter
mounting parts.
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[18. ENGINE]
• The frequency for water draining and replacement of the main fuel filter cartridge differs according to the fuel
situation in the use region.
Replace the main fuel filter cartridge every 500 hours or when the engine output decreases, whichever occurs
first.
• Inspection of the main fuel filter cartridge should be performed before each start of operation. 18
• Always use HINO genuine parts fuel filter cartridge.
• Complete the work for removal and installation quickly to prevent entry of foreign matter to the fuel system.
• Before assembly, make sure that there is no dirt on the seating surface of the parts.
• Always do air bleeding after replacing an element.
• Completely remove any dust around the main fuel filter cartridge and case.
• Completely remove any dust around the main fuel filter head and especially around the air bleeding bolt.
• Since the filter contains diesel oil, prepare a tray.
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[18. ENGINE]
1) The soiling and the foreign material of the clamp face are removed.
2) Install the main fuel filter cartridge with tightening angle 3/4 turn after the O-ring of the main fuel filter
cartridge comes into contact with the main fuel filter head.
• As the O-ring is included in the cartridge kit, do not use an O-ring again after it has been removed once.
• Install the O-ring after applying fuel to the surface of the O-ring.
• Do not use a tool, but tighten by hand.
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[18. ENGINE]
• Completely remove any dust around the main fuel filter cartridge and case.
• Install the O-ring after applying fuel to the surface of the O-ring.
• Do not reuse the fuel filter element.
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[18. ENGINE]
• The clearance between the cap and case should be even around the entire circumference to the cap and case.
• Just before the marks of the case and nut align, the turning difficulty of the fastener nut will increase.
Use a screwdriver and a lever to turn the fastener nut.
6) Measure the distance between the marks on the cap and case, and the clearance between the cap and
case.
Standard clearance (A):
1.0 mm {0.039 in.} or more
Standard clearance (B):
1.0 mm {0.039 in.} or less
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[18. ENGINE]
18
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[18. ENGINE]
• Take care that no dirt or water gets into the system during the work.
Flywheel housing
cover
2) Turn the crankshaft counterclockwise when
viewed from the flywheel. Set the timing mark in
the flywheel housing inspection window to "1".
Flywheel
1
Flywheel housing
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[18. ENGINE]
With
gap
18
Contact surface
• If the special tool is not seated, it will contact parts other than the coupling flange stopper key; therefore, do not
push too hard.
• If the special tool is not touch the flange, No.1 cylinder is not setting to the Compression Top Dead Center.
Remove the special tool, and rotate the engine and then check again.
• When you rotate the crankshaft, always remove the special tool.
• Do not rotate the crankshaft with the special tool inserted.
• Prepare a container and a waste cloth because fuel spills when removing the pressure feed pipes.
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[18. ENGINE]
Pipe A
• Take care that no dirt or water gets into the system during the work.
Bolt
2) Secure the supply pump, install the injection
pump drive gear on the shaft, and use a vice or
similar to prevent turning while tightening the nut.
Tightening torque: 63.7 N·m {650 kgf·cm, 47
lbf·ft}
• Do not use the guide pin for stopper key of the shaft.
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[18. ENGINE]
• Take care that no dirt or water get into the system during the work.
• Before assembly, make sure that there is no dirt on the seating surface of the parts.
• Always do air bleeding after replacing an element.
1) Match the match mark of the bearing holder case with the missing tooth of the injection pump drive gear.
2) Install a new O-ring and mount the air
Supply pump O-ring
compressor and supply pump assembly on the
flywheel housing.
Tightening torque: 28.5 N·m {290 kgf·cm, 21
lbf·ft}
• Adjust the gear so that the compression top dead center alignment of the No.1 cylinder may not be changed.
• Be sure to remove the guide pin in cranking the engine.
• After assembly, be sure to remove the guide pin and install the inspection window plug.
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[18. ENGINE]
• If learning value is not updated, correct common rail pressure is not controlled, resulting in engine stall or high
common rail pressure. Therefore, when the supply pump is replaced, be sure to update the learning value.
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[18. ENGINE]
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[18. ENGINE]
• Take care that no dirt or water gets into the system during the work.
Leakage
pipe
Part of connector
Injector Cylinder
harness head
• Removal becomes easier when the connector part of the camshaft housing is disconnected last.
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[18. ENGINE]
18
View A
Injection pipe
oil seal
Injector clamp
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[18. ENGINE]
Injector
• When the injector is replaced, it is necessary to enter the injector correction value (QR code) described on the
new injector to the engine ECU. Incorrect entry of the correction value may result in faulty engine.
• Available entry methods of the injector correction value are the PC tool and the QR code reader.
• The flow of work is described in the following.
If you want details regarding any procedure, however, refer to the PC Tools instruction manual.
1) Read the injector QR code with the scanner of the QR code reader and prepare the correction data file.
2) Enter the injector correction value directly from the PC tools to the engine ECU.
PC
QR Code reader
Hino-Bowie
Engine-use code
QR code
Connector
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[18. ENGINE]
• Before connecting the connector, confirm that the terminal shows no signs of sparking.
Part of connector
18
Injector Cylinder
harness head
• Installation becomes easier when the connector part of the camshaft housing is connected first.
Leakage
pipe
Leakage
pipe
• It is noted that the union bolt of the injector and the union bolt of the camshaft housing are different bolt pitch.
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[18. ENGINE]
• There is the "X" mark at the union bolt of the camshaft housing.
Injection pipe
Nozzle clamp
holder
Injection pipe
oil seal
O-ring
• Take care that no dirt or water gets into the system during the work.
• Before assembly, make sure that there is no dirt the seating surface of the parts.
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
1) Attach a new O-ring to the groove of the cylinder head and insert the injector.
• Apply engine oil to the O-ring and be careful to prevent pinching of the O-ring.
2) Install the nozzle clamp holder and tighten the injector temporarily.
• Do not fix the nozzle holder until the injection pipe is tightened.
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[18. ENGINE]
• Install the injection pipe oil seal to prevent undue force to the injection nozzle. (Offset position between the
injection pipe oil seal and the injection nozzle may cause oil leak or poor assembly of the injection pipe.)
4) Assemble the injection pipe temporarily and tighten the fixing bolt of the nozzle clamp holder.
Tightening torque: 25 N·m {250 kgf·cm, 1.8 lbf·ft}
5) Tighten the injection pipe. 18
Tightening torque: 44 N·m {450 kgf·cm, 33 lbf·ft}
Terminal cap
(lower)
Injector harness
and rubber seal
Upper body
Standard value
1000MΩ or more
(normal temperature)
4) If the resistance value in (2) and (3) exceeds the standard value, replace the injector assembly.
2. Cleaning of injector
1) Remove sludge at or around the terminal, if any.
• In removing sludge, do not use a cleaning agent. Wipe it off with a rag. Use of a cleaning agent may result in
electric failure due to penetration of the agent.
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[18. ENGINE]
Y X
X
Coolant pipe bracket Z
Injection pipe
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[18. ENGINE]
Y X 18
X
Z
Coolant pipe bracket
Injection pipe
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[18. ENGINE]
• Take care that no dirt or water get into the system during the work.
• Pull out the female connector from the male connector during pushing the spring lock at the female connector.
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[18. ENGINE]
18
View A
• Always follow the procedure exactly, because a fuel leakage can be the result when the injection pipe is not
installed correctly.
• Fuel leakage causes engine damage.
• Pressure feed pipe and injection pipes are not reusable.
• Install so that the markings of the tightening nuts for the flared parts of the injection pipes are arranged in the
indicated order.
• This figure is the common rail with flow damper.
• The work method is same the common rail without flow damper and the common rail with flow damper.
Mark:2 Mark:4
Mark:1 Mark:3
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[18. ENGINE]
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[18. ENGINE]
18
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[18. ENGINE]
18.7 ELECTRICAL
18.7.1 Electrical System
18.7.1.1 Part layout
83420 Water temperature sender gauge 89410 Engine sub revolution sensor
83530 Oil pressure warning switch 89411 Engine main revolution sensor
Tightening torque
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[18. ENGINE]
18
Tightening torque
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[18. ENGINE]
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[18. ENGINE]
18
18-99
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[18. ENGINE]
Engine main
revolution sensor
Boost pressure sensor Suction control valve (SCV) Fuel temperature sensor
Upper view
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[18. ENGINE]
18
Front view
18-101
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[18. ENGINE]
conductivity below 39.2 kPa or when there is {0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
conductivity above 58.8 kPa. 2.9kPa{0.3kgf/cm ,
2
4.7lbf/in }
Within
OFF Toward pressure increase
C
B
Between A and C
Temperature 75 100
(℃{℉}) {167} {212}
Resistance 35.5 -
79 - 92
value (Ω) 42.5
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[18. ENGINE]
Standard value
Resistance value :
Ω(Normal temperature 20℃ 2.59-3.29
{68℉})
6. Inspection of injector
1) For inspection and replacement of the injector, refer to the chapter of "J05E FUEL SYSTEM".
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[18. ENGINE]
O-ring
• Since this sensor is a flange type, gap does not have to be adjusted.
18-104
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[18. ENGINE]
Alternator 18
Pulley
Crankshaft
Pulley
8 - 10mm 10 - 12mm
Deflection {0.3152 - {0.394 -
0.394in.} 0.472in.}
• If the V-belt is replaced with a new one, it becomes loose due to initial fitting. Run the engine for three to five
minutes and adjust the tension of the belt again.
• At the time of inspection, the new V-belt has reached the value after complete initial stretching. A new V-belt
completes initial stretching after running the engine for approximately two hours.
18-105
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[18. ENGINE]
18.8 INTAKE
18.8.1 Intake Manifold
18.8.1.1 Part layout
Tightening torque
9068-08320 28.5N·m {290kgf·cm, 21 lbf·ft} 9240-08087 28.5N·m {290kgf·cm, 21 lbf·ft}
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[18. ENGINE]
18
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[18. ENGINE]
18.8.1.2 Replacement
1. Removal of intake manifold
1) Remove bolts and nuts and remove the intake manifold.
2. Installation of intake manifold
1) Clean inside of the intake manifold and the
cylinder head.
2) Assemble a new gasket.
Protrusion
• Install the gasket so that the protrusion may come at the rear end stud bolt of the cylinder head.
• Apply it continuously.
• Apply the liquid gasket at the width of 1.5 to 2.5 mm {0.0591 to 0.09843 in.}
• Install the oil cooler within 20 minutes after application of the liquid gasket.
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[18. ENGINE]
18
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[18. ENGINE]
Tightening torque
18-110
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[18. ENGINE]
• If it is difficult to remove the cylinder head, insert a chisel between the cylinder head and the cylinder block, and
move the chisel vertically so that the contact surface may not be damaged. Then, separate the cylinder head.
Underhead length
short 126.5{4.9803}
long 187.5{7.3819}
18-111
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[18. ENGINE]
• Remove dirt, water or oil from the mounting surfaces of the cylinder head and the cylinder block before work.
• Never reuse the gasket. Otherwise, it may damage the engine.
• The water hole seal ring of the cylinder head gasket is susceptible to damage. Avoid contact with hand or object.
• Before installation of the cylinder head gasket, make sure that there is no fall of or damage to the seal ring.
Application area of
liquid gasket
Liquid gasket
Cylinder head
Too small
Clearance Clearance
• Apply the liquid gasket so that the surface of the liquid gasket may be raised on the cylinder head gasket.
• Install the oil cooler within 20 minutes after application of the liquid gasket.
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[18. ENGINE]
• Before mounting the cylinder head, make sure that there is no foreign matter in the cylinder.
• When the cylinder head is mounted, be careful for engagement between the cam idle gear and the sub-idle gear.
(Contact of gear teeth with undue force may cause impact mark or chipping, resulting in abnormal noise or
missing tooth.)
18
• Mounting of the cylinder head with guide bolt can prevent displacement of the liquid gasket.
5) After tightening, tighten head bolts 1 to 18 again from the center to the outside.
Tightening torque : 59 N·m {600 kgf·cm, 44 lbf·ft}
6) Mark the head parts of head bolts (M12) 1 to 18 with paint in the same direction.
7) Tighten head bolts (M12) 1 to 18 in tightening order for another 90°. (First time)
8) Tighten head bolts (M12) 1 to 18 according to the
same procedure by the angles shown in the
table. (Second time)
135° 4, 5, 12, 13
9) Make sure the head bolts that have the same Paint mark
tightening angle markings have the same
orientation.
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[18. ENGINE]
10) Tighten the remaining bolts (M10) 1 to 3 in the This just 3 tighten
order shown in the figure.
Tightening torque : 59 N·m {600 kgf·cm, 44 lbf·ft}
18.9.1.3 Liquid gasket application procedure for semicircular plug (only when semicircular plug is
removed)
1. Remove liquid gasket from the cylinder plug and the
Semicircular plug
camshaft housing.
Liquid gasket
application region
2. Coat the semicircular plugs at the front and rear of the cylinder head with liquid gasket (Three Bond TB 1207B-
Black or equivalent), and install the semicircular plugs.
3. Temporarily install the cylinder head cover with the gasket attached, and execute a parallel adjustment of the
semicircular plugs.
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[18. ENGINE]
18
Silent Cylinder Head
Block Cover Gasket
• Install the oil cooler within 20 minutes after application of the liquid gasket.
Cylinder
Head cover
gasket Cylinder Head
cover lower
surface
Cylinder head
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[18. ENGINE]
Injector harness
connector
2) Remove the O-ring from the injector harness
O-ring
connector.
3) Replace the O-ring with new one and fit it to the injector harness connector.
4) Mount the injector harness connector to the
cylinder head with 2 bolts.
Injector harness
connector
• To remove carbon or other deposit, do not damage the lower surface of the cylinder head.
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[18. ENGINE]
18
• In press fit, be careful not to damage the valve stem at the upper/lower ends of the guide.
• In press fit, be sure to apply engine oil to the circumference of the valve guide.
Electric welding
Valve
Cut three areas
from here.
• The valve seat replacement procedure below may damage the cylinder head depending on the case. It is
recommended that a request for replacement be made to a machining vendor.
1) If the valve seat is replaced, use an out-of-use valve. After cutting three pieces from the valve
circumference, weld them to the valve seat.
• Apply grease to protect the cylinder head lower surface from welding spatter before work.
2) Put a backup metal (e.g. brass bar) at the valve stem head and pull out the valve seat using a press.
3) Remove welding spatter or dirt on the valve seat surface.
4) Heat the cylinder head to approx. 80 to 100 ℃
and strike the cooled valve seat into the mounting
area of the cylinder head.
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[18. ENGINE]
6) Strike gently while turning the valve using a special tool for adjustment.
Special tool : S0943–11020 (09431–1020) Valve lapping tool
5. Replacement of nozzle seat
1) Tap the nozzle seat from the cylinder head lower
part. Then, put an appropriate bolt inside.
2) Hit the bolt head using a hammer and pull out the
nozzle seat toward the the cylinder head upper
part.
3) Remove the O-ring from the cylinder head.
• After pulling out the nozzle seat, be sure to remove deposit such as remaining liquid gasket or dirt.
4) After attaching a new O-ring into the nozzle seat Cylinder head
hole of the cylinder head, apply the liquid gasket
[Threebond TB1211 (white) or equivalent] at the O-ring
lower part of a new nozzle seat and assemble it
on the cylinder head.
Nozzle sheet
• Be sure to replace the O-ring with a new part. Reuse may cause water leak or gas leak, resulting in overheat or
crack of the cylinder head.
5) Clamp the nozzle seat using a special tool. Bar Nozzle seat
Special tool : S0947–21210 (09472–1210) Bar
SN441–00610 (9800–06100) Steel ball
Cylinder
Head
Steel ball
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18
Longitudinal direction
0.06{0.0024}
0.2{0.0079}
Square direction
0.03{0.0012}
• Repair of the lower surface by grinding can change backlash of the timing gear. Do not grind it.
18-119
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[18. ENGINE]
2 Cooling jet
Tightening torque
18-120
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[18. ENGINE]
18.9.2.2 Overhaul
1. Replacement of cylinder liner
1) Put match marks on the flange surfaces of the
cylinder block and the cylinder liner using a oil
based marker.
Match mark
18
• Be careful for handling of the cylinder liner. Do not reuse the cylinder liner which has been dropped.
• Do not touch the cooling jet during work.
4) Align the match mark of the cylinder liner with that of the cylinder block. Install the cylinder liner using a
special tool.
Special tool : S0947–11490 (09471–1490) Guide
Liner identification mark Engine type
Block front
Front of engine
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[18. ENGINE]
Cylinder liner
A, B and C marking
position
• When a new cylinder liner is installed, install the cylinder liner with the same identification mark (A, B, C)
stamped on the cylinder block.
0.01 - 0.08
Standard value (mm{in.})
{0.0004 - 0.0031}
Check bolt
2) Connect the injection test oil hose from the lower
part of the cylinder block to the special tool check
bolt.
Check bolt
Oil hose
18-122
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[18. ENGINE]
Cylinder liner
Cooling jet
Air hose
5) When the injection center hits within the specified Injection Gauge target circle
line of the gauge, it is considered normal.
• Oil is susceptible to combustion due to spread. Do not use fire near around.
• Work at well ventilated place.
6) Make sure that the jet position check gauge hole at the tool assembly end may not interfere with the cooling
jet pipe.
7) If injection does not hit the target circle, correct it
with a special tool.
Special tool : S0947–21620 (09472–1620) Tool
18-123
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[18. ENGINE]
Longitudinal direction
0.06{0.0024}
0.2{0.0079}
Square direction
0.03{0.0012}
• Repair of the upper surface by grinding can change backlash of the timing gear. Do not grind it.
18-124
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[18. ENGINE]
18
Tightening torque
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[18. ENGINE]
• Remove bolts fixing the flywheel housing from the cylinder block.
• Apply it continuously.
• Apply the liquid gasket at the width of 1.5 to 2.5 mm{0.0591 to 0.0984 in.}.
• Install the oil cooler within 20 minutes after application of the liquid gasket.
• Tighten bolts fixing the flywheel housing from the cylinder block.
18-126
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[18. ENGINE]
18
2. Installation of end plate
1) Install the end plate and a new gasket with bolts.
• Make sure that there is no dirt or foreign matter on the installation surface of the cylinder block and the screw
holes.
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[18. ENGINE]
Boplt x 4
Plate
2) Hook the special tool oil seal puller with the tab of
the front oil seal and install the hook on the plate
of the special tool oil seal puller with
accompanying bolts.
4) Attach the accompanying center bolt to the special tool oil seal puller and tighten it. Pull out the front oil seal.
18-128
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[18. ENGINE]
1) Insert a new oil seal into the guide of the oil seal
press.
Special tool : S0940–71030 (09407–1030) Oil
seal press
Oil seal
18
• Be careful for front/rear directions of the front oil seal. (The felt surface is at the crankshaft damper side.)
2) Checking that there is no dent or dirt in the oil Check that there are
seal insertion part of the front oil seal retainer and no hit marks or
crankshaft. scratchings.
Bolt
4) Appying the small amount of engine oil to the fitting area (crankshaft and oil seal retainer side) of a new
crankshaft front oil seal.
5) Remove contamination from the joint surface of
the front oil seal and the cylinder block.
6) Apply small amount of engine oil to the fitting area (crankshaft and oil seal retainer side) of the front oil seal.
7) Install the oil seal press guide inserting a new front oil seal with accompanying guide bolts on the
crankshaft.
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[18. ENGINE]
8) Align the oil seal press hole to the guide bolt and
insert the oil seal press.
9) Attach the accompanying center bolt to the oil seal press and tighten it until stop. Press fit the front oil seal.
18-130
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[18. ENGINE]
18
• Align the large hole of the plate with the collar dowel of the crankshaft.
2) Hook the oil seal puller with the tab of the rear oil
seal and install the hook on the plate of the oil
seal puller with accompanying bolts.
3) Remove two bolts which installed the plate of the oil seal puller on the crankshaft.
4) Attach the accompanying center bolt to the oil
seal puller and tighten it. Pull out the rear oil seal.
• Be careful for front/rear directions of the rear oil seal. (The felt surface is at the flywheel side.)
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[18. ENGINE]
3) Apply small amount of engine oil to the fitting area (crankshaft and flywheel housing side) of the rear oil seal.
4) Install the oil seal press guide inserting a new rear oil seal with accompanying guide bolts on the crankshaft.
• Align the large hole of the guide with the collar dowel of the crankshaft.
5) Align the oil seal press hole to the guide bolt and
insert the oil seal press.
18-132
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[18. ENGINE]
18
Tightening torque
18-133
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[18. ENGINE]
• Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent
turning of the crankshaft.
• Store removed connecting rod cap for each cylinder number so that combinations of the connecting rod and the
connecting rod cap may not be changed.
Cooling jet
18-134
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[18. ENGINE]
• In removing the piston, rotate the connecting rod as shown in the figure. Do not bend the cooling jet.
• Store removed pistons and connecting rods for each cylinder number.
• Be careful not to touch the cooling jet. 18
Match mark
stamp
18-135
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[18. ENGINE]
Lower surface
• The identification print is present only on the secondary ring and the top and bottom of the top ring and the oil
ring are not identified.
Connecting rod
• Make sure that the oil hole of the connecting rod bearing is aligned with the oil hole of the connecting rod.
18-136
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[18. ENGINE]
18
• Make sure that there is no deformation or damage to the special tool piston ring holder.
• Face the "0" mark on the piston toward the exhaust side for insertion.
• Set the crankshaft of the cylinder as the top dead center for assembly.
• Do not damage the cylinder liner, crankshaft and cooling jet during work.
Bearing
• Do not change the combination between the connecting rod and the connecting rod cap.
18-137
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[18. ENGINE]
Underhead length
8) Apply engine oil to the connecting rod bolt thread and the seat and install it on the connecting rod.
9) Tighten the connecting rod bolt and mark the bolt Paint mark
head in the same direction with paint.
Tightening torque : 69 N·m {700 kgf·cm, 51 lbf·ft} Connecting rod cap
45°
90°
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[18. ENGINE]
18
Standard value (mm{in.}) Service limit (mm{in.})
112{4.4095} 112.15{4.4153}
Standard value
111.9±0.008{4.4055±0.0003}
(mm{in.})
• The measuring position is 23 mm{0.9055 in.} above the piston lower end and square to the pin hole.
3) Calculate the difference between the inner diameter of the cylinder liner and the outer diameter of the
piston. If it is beyond the standard value, replace the cylinder liner and the piston.
Standard value
0.088 - 0.112{0.0035 - 0.0044}}
(mm{in.})
18-139
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[18. ENGINE]
Top ring
2.5{0.0984} 2.70{0.1063}
groove
Second ring
2{0.0787} 2.20{0.0866}
groove
Piston Ring
0.3 - 0.40
Top ring 1.5{0.0591}
{0.0118 - 0.0157}
0.75 - 0.90
Second ring 1.5{0.0591}
{0.0295 - 0.0354}
0.15 - 0.30
Oil ring 1.2{0.0472}
{0.0059 - 0.0118}
Standard value
Service limit (mm{in.}
(mm{in.})
37 {1.4567} 36.96{1.4551}
18-140
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[18. ENGINE]
Standard value
Service limit (mm{in.}
(mm{in.})
37 {1.4567} 37.05{1.4587}
3) Calculate the difference between the outer diameter of the piston pin contact area with the piston boss and
the inner diameter of the piston boss. If it is out of the service limit, replace the piston pin or piston. 18
Standard value
Service limit (mm{in.}
(mm{in.})
–0.002T-0.025L 0.05{0.0020}
T : Tightening allowance
L : Clearance
37 {1.4567} 37.1{1.4606}
5) Calculate the difference between the inner diameter of the connecting rod small end and the outer diameter
of the piston pin, and if it is beyond the service limit, replace the connecting rod or the bush.
0.015L-0.036L
0.08{0.0031}
{0.0005L-0.0014L}
L: clearance
18-141
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[18. ENGINE]
Press
Sub-assembly
• Align the press sub-assembly groove with the special tool spindle groove for installation.
5) Check the small end of the connecting rod with the bush removed, and see if there is deformation to the
inner diameter or scratches or dents on the inner surface.
18-142
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[18. ENGINE]
• The presence of deformation, scratches or dents indicates that the bush was not properly installed.
18
• Align grooves of the special tool guide and the special tool spindle for installation.
• Make sure that the edge of the special tool spindle and the special tool guide is in close contact.
• Using dry ice to cool the bush to -10℃ (14℉) before assembling it will improve the quality of the assembled bush.
Also, work quickly so that the bush does not warm up during assembling work.
18-143
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[18. ENGINE]
• Place the connecting rod so that the chamfer side of the connecting rod small end inner diameter may be the
bushing side
• Apply engine oil to the inner diameter surface of the connecting rod.
• After press-fitting the bush, make sure there are no machine burrs on the bush.
18-144
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[18. ENGINE]
18
2. Installation of crankshaft
1) Face the groove side (front) of the thrust bearing
toward the crankarm and the part number side
(back) toward the main bearing cap or the
cylinder block. Install it on the cylinder block and
the main bearing cap.
• To prevent falling in assembly, apply engine oil or grease to the back of the thrust bearing.
2) Install the main bearing on the cylinder block and each bearing cap.
• Assemble the bearing with oil hole on the cylinder block and assemble the bearing without oil hole on the cap.
• Apply new engine oil to the sliding surfaces of each bearing.
18-145
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[18. ENGINE]
• The pentagon mark on the main bearing cap should face the front of the vehicle. Align in the order of 1, 2, 3, 4, 5,
6 and 7 from the front.
• Check the stamp number of each main bearing cap with the stamp number of the cylinder block.
Underhead length
1 3 5
7 9
7) Tighten the bearing cap bolt according to the sequence in the figure.
Tightening torque : 69 N·m {700 kgf·cm, 51 lbf·ft}
8) Loosen the bearing cap fixing the thrust bearing and hit the crankshaft gently at the front/rear end using a
plastic hammer.
9) Loosen all bearing cap bolts.
10) Tighten the bearing cap bolt as in (7).
Tightening torque : 69 N·m {700 kgf·cm, 51 lbf·ft}
11) Mark bearing cap bolt heads in the same direction with paint.
12) Tighten 90 deg (1/4 turn) with the same order as in (7).
13) Retighten 45 deg (1/8 turn) as in (7). Paint mark
45
90
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[18. ENGINE]
14) Make sure that all paint marks are in the same direction.
15) After tightening, hit the front/rear ends of the crankshaft gently with a plastic hammer for initial fit.
18
• Make sure that the crankshaft turns smoothly.
• Measure the end play of the crankshaft and make sure that it is within the standard value.
0.050 - 0.219
0.50{0.0197} 1.219{0.0480}
{0.0020 - 0.0086}}
18-147
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[18. ENGINE]
0.050 - 0.219
{0.0020 - 0.50{0.0197} 1.219{0.0480}
0.0086}}
Wear of 0.20{0.0079}
Regrind
or more
Wear of 0.7{0.0276} Replace the crankshaft.
18-148
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[18. ENGINE]
36{1.4173} 37.0{1.4567} 18
4. Inspection of crankshaft oil clearance
1) Measure the outer diameter of the crankshaft
journal using a micrometer. 90
0.051 - 0.102
0.2{0.0079}
{0.0020 - 0.0040}
18-149
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[18. ENGINE]
Wear of 0.20{0.0079}
Regrind
or more
Wear of 0.7{0.0276} Replace the crankshaft.
18-150
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[18. ENGINE]
18
• Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent
turning of the crankshaft.
• Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent
turning of the crankshaft.
18-151
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[18. ENGINE]
• Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent
turning of the crankshaft.
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
18-152
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[18. ENGINE]
18
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
4. Installation of flywheel
1) Make sure that there is no burr or dirt on the joint
surface of the crankshaft and the flywheel and
the screw hole.
2) Install the special tool into the bolt hole of the
crankshaft.
Special tool : S0948–11340 (09481–1340) Guide
18-153
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[18. ENGINE]
• Install one special tool on the collar dowel and the other at the opposite side of the collar dowel.
3) Insert the flywheel until it comes in contact with the collar dowel of the crankshaft and adjust the position.
5) Apply engine oil to the bolt seat and the bolt thread of the flywheel mounting bolt.
6) Tighten 6 bolts by 2 to 3 threads temporarily with
hand in the bolt holes without installation of the
special tool.
lbf·ft} 3 4
7 6
2
• Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent
turning of the crankshaft.
18-154
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[18. ENGINE]
18
Tightening torque
18-155
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[18. ENGINE]
• Removal without turning the adjusting screw may bend the rocker shaft.
• Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.
18-156
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[18. ENGINE]
18
Standard value Service limit
(mm{in.}) (mm{in.})
IN 8.067{0.3176} (7.987{0.3144})
Cam lift
EX 10.104{0.3978} (10.024{0.3946})
0.04{0.0016} 0.1{0.0039}
40{1.5748} 39.85{1.5689}
40{1.5748} 40.15{1.5807}
3) Calculate the difference of the camshaft journal bearing inner diameter. If it is beyond the standard value,
replace the camshaft or the camshaft bearing.
0.020 - 0.063
Standard value (mm{in.})
{0.0008 - 0.0025}
18-157
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[18. ENGINE]
Underhead length
3. Set the dowel pin to the camshaft and the camshaft gear and tighten the camshaft gear mounting bolt.
Tightening torque : 59 N·m {600 kgf·cm, 44 lbf·ft}
4. Retighten 90 deg (1/4 turn).
18-158
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[18. ENGINE]
18
Ruler or etc
Misconnection prevention drill hole
• Place a transparent plastic ruler or an edged ruler on the upper surface of the camshaft housing and the side of
the camshaft gear. Make sure that the position of the foolproof drilled hole is above the ruler.
making sure the five-sided mark on the cap
points forward.
Engine Foreword
• To make sure the crosshead is correctly in place, move it to the left and right by hand and make sure it clicks
against the valves.
• If the crosshead is not sitting properly on the valves, it will push the upper seat and cause the valve to drop out.
4) Make sure the rocker arm is correctly assembled on the rocker arm shaft.
5) Fully unscrew the adjust screw on the end of the rocker arm.
• Securing the rocker arm and nozzle clamp together with a string will facilitate installation work.
18-159
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[18. ENGINE]
• After the bolts are tightened, make sure the rocker arm moves smoothly.
18-160
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[18. ENGINE]
18
• Turning over the engine vertically or turn it onto the side during work. This prevents workers from dropping parts
in the flywheel housing.
18-161
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[18. ENGINE]
Standard value
(mm{in.})
2) Calculate the difference between the idle gear bushing inner diameter and the idle gear shaft outer
diameter. If it is beyond the service limit, replace the idle gear shaft and the idle gear bushing.
18-162
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[18. ENGINE]
Lubricating
hole
Cylinder
Block
3) Face the lubricating hole of the idle gear shaft Sub-idle gear
toward the oil pan (downward). Install A in the
figure by adjusting the timing of the crankshaft
gear and the main idle gear as in the detailed
drawing.
Oil pump
gear
A
Main idle gear
Crankshaft gear
18-163
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[18. ENGINE]
18-164
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[18. ENGINE]
18-165
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[18. ENGINE]
3) Calculate the clearance. If it is beyond the standard value, replace the shaft and the bushing.
0.025 - 0.075
Standard value (mm{in.})
{0.0010 - 0.030}
18-166
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[18. ENGINE]
18
2) Measure backlash between the camshaft gear
and the cam idle gear using a dial gauge. If it is
beyond the service limit, replace each gear.
0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.011}
0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}
18-167
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[18. ENGINE]
• If the magnet stand is not stable, provide a steel plate for measurement using bolt holes of the cylinder block.
0.032 - 0.096
0.10{0.0039}
{0.0013 - 0.0038}
4. Inspection of backlash between idle gear at bearing case and supply pump drive gear
1) Remove the supply pump drive.
"Reference : Replacement, Supply pump"
2) Remove the bearing case assembly.
3) Fix the supply pump drive with a vice and install
Work example
the bearing case assembly.
4) Measure backlash between the idle gear and the supply pump drive gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.
0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
18-168
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[18. ENGINE]
0.030 - 0.131
0.30{0.0118}
{0.0012 - 0.0005}
0.114 - 0.160
Main idle gear 0.30{0.0118}
{0.0045 - 0.0063}
0.040 - 0.095
Sub-idle gear 0.30{0.0118}
{0.0016 - 0.0037}
18-169
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[18. ENGINE]
0.050 - 0.218
0.30{0.0118}
{0.0020 - 0.0086}
18-170
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[18. ENGINE]
18
13709 Adjusting screw (rocker arm) 13787 Adjusting screw (cross head)
Tightening torque
18-171
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[18. ENGINE]
22{0.8661} 21.92{0.8630}
2) Measure the rocker arm bushing inner diameter using a cylinder gauge.
22{0.8661} 20.08{0.7905}
3) Calculate the difference between the outer diameter of the rocker shaft and the inner diameter of the rocker
arm bushing. If it is beyond the standard value, replace the rocker shaft or the rocker arm bushing.
0.03 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}
• Attach a tag with the applicable cylinder number to the valve so that combinations of the valve and the cylinder
head may not be mixed.
18-172
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[18. ENGINE]
18
Oil application
Rubber
• After assembly of the valve stem seal, make sure that there is no deformation, crack or inclination of the rubber.
+0.1{0.0039in.}
22.9mm{0.9022in.}
-0.4{0.0157in.}
22.5 - 23.0
Standard value (mm{in.})
{0.8858 - 0.9055}
18-173
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[18. ENGINE]
• Apply engine oil to the contact surface of each part before assembly.
• Be sure to assemble each valve at the original cylinder position.
• When the valve spring is compressed, avoid contact of the valve spring upper seat with the valve stem seal.
• Since the valve spring has equal spacing, vertical direction is not specified for assembly.
• Check for scratch on the valve stem seal when the valve is reused.
Outer valve
(75.7{2.9803}) 72.7{2.8622}
spring
18-174
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[18. ENGINE]
3) Calculate the difference between the valve stem outer diameter and the valve guide inner diameter. If it is
beyond the standard value, replace the valve or the valve guide.
0.023 - 0.058
Intake valve oil clearance
{0.0009 - 0.0023}
18-175
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[18. ENGINE]
• Before adjustment, make sure that bolts of the cylinder head, rocker arm support, nozzle clamp, camshaft
housing and camshaft bearing cap are tightened to the specified torque.
Clearance
Close contact
Lock Nut
• Provide the adjusting screw protrusion of 10 mm or more from the top surface of the crosshead. If the adjusting
screw is not completely separated from the valve stem, correct adjustment is not allowed.
Close contact
Crosshead
18-176
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[18. ENGINE]
(Appropriate
contact)
18
• If it becomes lighter, make adjustments again from the beginning.
Close contact
Close contact
• Do not over-loosen the adjusting screw. Over-loosening of the adjusting screw reproduces the original status.
Although feel on the thickness gauge is appropriate, there is clearance between the adjusting screw and the
valve of the crosshead. Correct adjustment is not allowed.
18-177
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[18. ENGINE]
18.10 EXHAUST
18.10.1 Exhaust Manifold
18.10.1.1 Part layout
Tightening torque
9209A 53N·m {540kgf·cm, 401 lbf·ft}
18-178
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[18. ENGINE]
18
18-179
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[18. ENGINE]
18.10.1.2 Replacement
1. Removal of exhaust manifold
1) Remove nuts and remove the exhaust manifold.
2. Replacement of stud bolt
1) Remove dirt (e.g. sealant) at the female thread of the cylinder head and clean the thread again with tap
(M10 x 1.5).
2) Use the Torx wrench to tighten a new stud bolt.
Tightening torque : 30 N·m {300 kgf·cm, 22 lbf·ft}
• Excessive tightening with over torque may cause crack in the cylinder head.
Black side
• Since a gasket has front and back, install the black side on the exhaust manifold.
2) Tighten the mounting nut of the exhaust manifold When a new exhaust manifold is used
according to the order in the figure. 12 11 10 9 8 7 6 5
Tightening torque : 53 N·m {540 kgf·cm, 40 lbf·ft}
1 2 3 4
8 9 2 3 5 6 11 12
7 1 4 10
Spacer
• When nuts are tightened, prevent each spacer from riding on the counterbore area of the manifold flange.
• The tightening sequence of the exhaust manifold varies between use of a new part and reuse.
18-180
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[18. ENGINE]
3) Tighten the same nuts again according to the order in the figure.
Tightening torque : 53 N·m {540 kgf·cm, 40 lbf·ft}
18
18-181
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[18. ENGINE]
18.11 COOLING
18.11.1 Cooling System
18.11.1.1 Cooling system drawing
Reservoir
Water temperature
Air compressor
Radiator
Thermostat
Cylinder block
Turbo charger
Car
heater
Drain cock
Drain cock
18-182
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[18. ENGINE]
18
18-183
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[18. ENGINE]
bolt1
scraper.
2) Apply liquid gasket [Threebond TB1207B(black)
or equivalent] to the thermostat case as shown in
the figure.
• Apply it continuously.
• Apply the liquid gasket at the width of 1.5 to 2.5 mm{0.0591 to 0.0984 in.}.
• Install the oil cooler within 20 minutes after application of the liquid gasket.
bolt1
4) Put the thermostat case mounting bolt through the thermostat case in advance.
5) Align the thermostat case at the mounting position and tighten mounting bolt 1 temporarily to the cylinder
head.
6) Tighten mounting bolt 2 temporarily to the coolant pump.
7) Tighten bolts in the order mounting bolt 1 to the cylinder head and mounting bolt 2 to the coolant pump.
18-184
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[18. ENGINE]
Coolant pipe A
Thermostat case
18
2. Installing of the thermostat Thermostat
1) Replace the gasket with new ones, and install the
thermostat and the coolant pipe to the thermostat Gasket
case.
Coolant pipe A
Thermostat case
Flange
Thermostat
Gasket
• As a wrong gasket installation can cause water leakage, make sure during assembly that it is clamped to the
flange part of the thermostat.
TOP
Jiggle valve
18-185
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[18. ENGINE]
• Support the thermostat in the center to prevent approach to the heat source.
• Stir the water well so that water temperature in the container may be uniform.
• The thermostat valve opening temperature (T1) is stamped on the thermostat seat.
L1 At cold open
L2 :Temperature at (T2)°C{°F}
L : Valve lift
L
L 1
L 2
4) Put the full open thermostat valve in water at normal temperature. Make sure that the thermostat valve
closes completely within 5 minutes.
5) If faulty item is found with the inspection above, replace the thermostat.
18-186
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[18. ENGINE]
18
2. Installation of coolant pump
1) Remove contamination on the joint surface between the coolant pump and the cylinder block using a
scraper and degrease the surface.
2) Apply the liquid gasket [Threebond TB1207B Liquid gasket
(black) or equivalent] to the coolant pump as
shown in the figure.
• Apply it continuously.
• Apply the liquid gasket at the width of 2 to 3mm{0.0787 to 0.1181in.}.
• Install the oil cooler within 20 minutes after application of the liquid gasket.
• Fill the groove on the water pump flange with the liquid gasket.
• When the coolant pump is installed using a guide bolt, displacement of the liquid gasket does not occur.
18-187
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[18. ENGINE]
18.12 LUBRICATION
18.12.1 Oil Cooler, Oil Filter and Oil Pump
18.12.1.1 System drawing
Roller pin
Cam Roller
Adjusting Rocker
Valve Crosshead Rocker arm arm
screw shaft
Camshaft
Oil pan
Cam idle
gear shaft
Sub-idle
gear shaft
Turbocharger
Strainer
Supply
pump
drive
Main idle
gear shaft
: Lubrication
: Return
18-188
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[18. ENGINE]
18
Tightening torque
9068-08160 28.5 N·m {290 kgf·cm, 21lbf·ft} 9068-08750 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
9068-08250 31 N·m {320 kgf·cm, 23lbf·ft} 9068-08900 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
9068-08320 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft} 9068-58100 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
18-189
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[18. ENGINE]
Tightening torque
15662 44.5±4.9 N·m {450±50 kgf·cm, 33±41 lbf·ft} 9201-10080 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
18-190
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[18. ENGINE]
18
2) If it is difficult to remove the oil cooler due to liquid
Figure is an
gasket sticking to the cylinder block, put a flat tip example of work.
screwdriver at the protrusion in the figure for
removal.
Flat area
• Apply it continuously.
• Apply the liquid gasket at the width of 1.5 to 2.5 mm{0.0590 to 0.0984 in.}.
• Install the oil cooler within 20 minutes after application of the liquid gasket.
18-191
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[18. ENGINE]
Guide bolts
5) After temporary tightening with bolts, remove the positioning stud and tighten bolts.
Tightening torque :
24.5±4.9 N·m {250±50 kgf·cm, 18±4 lbf·ft}
• If a new part is used, tighten it to 58.8±4.9N·m {600±50kgf·cm, 43±4lbf·ft} and loosen it.
• Then, tighten it again to the torque above.
18-192
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[18. ENGINE]
18
2. Inspection of oil cooler element
1) Wash water and oil channels with kerosene oil or washing fluid.
2) Check for crack or deformation on the stud bolt mounting area and element visually.
3) Blow air of approx. 0.5kgf/cm2 into the oil channel to check for leak from parts. If crack, leak or deformation
is found, replace it with a new part.
3. Disassembly of oil cooler case
• Disassembly immediately after stop of the engine may cause blowout of engine oil.
1) Remove valve spring plugs and safety valves using a hexagonal wrench.
2) Remove the oil pressure warning switch.
18-193
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[18. ENGINE]
3) Install the soft washer in (2) and the oil pressure warning switch.
7. Installation of oil cooler element
1) Assemble new gasket and new O-ring and
assemble the oil cooler element with nuts.
Tightening torque :
24.5±4.9 N·m {250±50 kgf·cm, 18±4 lbf·ft}
• In handling the oil cooler element, be careful not to give damage to it.
18-194
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[18. ENGINE]
• Without application of engine oil, poor oil suction may occur at the initial start, resulting in seizure or abnormal
wear.
Gasket
Oil pump
• Assembly with offset gasket may cause faulty sealing. Oil in the oil pump may be completely discharged when
the engine stops. Faulty sealing may cause insufficient suction of oil at initial revolution of engine restart,
resulting in seizure or abnormal wear.
18-195
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[18. ENGINE]
• If the tightening order is not observed, the oil pump may be damaged.
• After tightening, make sure that the gear can be turned with hand.
18-196
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[18. ENGINE]
• When the cotter pin is removed, seat 2 and the relief valve spring may eject out.
Standard value
Measuring area
(mm{in.})
0.100 - 0.202
0.30 {0.0118}
{0.0039 -0.0080} (reference)
18-197
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[18. ENGINE]
Standard value
Measuring area
(mm{in.})
0.047 - 0.137
0.15 {0.0059}
{0.00186 - 0.00539} (reference)
Standard value
Measuring area
(mm{in.})
18-198
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[18. ENGINE]
Standard value
(mm{in.})
0.040 - 0.099
{0.0016 - 0.0039}
18
6. Inspection of clearance betweeen outer diameter of
driven gear shaft and inner diameter of driven gear
bushing
1) Measure the outer diameter of the driven gear
shaft using a micrometer and measure the inner
diameter of the driven gear bushing using a
cylinder gauge.
Standard value
Measuring area
(mm{in.})
18-199
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[18. ENGINE]
Standard value
Measuring area
(mm{in.})
0.040 - 0.083
0.15 {0.0059}
{0.0016 - 0.0033}
0.073 - 0.207
0.30 {0.0118}
{0.0029 - 0.0081}
18-200
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[18. ENGINE]
18
2. Installation of oil strainer
1) Replace the O-ring with new ones and install the oil strainer.
Tightening torque : 31 N·m {320 kgf·cm, 23 lbf·ft}
18-201
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[18. ENGINE]
Tightening torque
12149 30 N·m {300 kgf·cm, 22 lbf·ft} 9068-08800 30N·m {300 kgf·cm, 22 lbf·ft}
18-202
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[18. ENGINE]
18.12.2.2 Replacement
1. Installation of oil pan Gasket
Cylinder block Reae end plate
1) Cut the gasket of the rear end plate to be flush to
the cylinder block lower surface using a scraper.
Flywheel housing
Scraper cutting
Cylinder block
Applying all around
the bolt mounting hole
Protrusion
Bolt tightening
attaching direction
4) Position the oil pan gasket protrusion at the intake side and the flywheel housing (printed seal surface at
cylinder block). Align the new oil pan gasket and oil pan to the cylinder block lower surface and tighten bolts
in the arrow order of the figure.
Tightening torque :
19.6 - 24.5 N·m {200 - 250 kgf·cm, 14 - 18 lbf·ft}
5) Remove positioning stud bolts and install the correct bolts.
6) Tighten bolts in the arrow order of the figure.
Tightening torque : 30 N·m {300 kgf·cm, 22 lbf·ft}
18-203
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[18. ENGINE]
• To prevent spread of engine oil, attach a jig which cuts a head cover in half. Cut it to the degree that the
camshaft is covered.
• If time until lubrication is long or if lubrication is not performed,the oil pressure may be low or the oil channel may
be clogged. Seizure,abnormal wear or abnormal noise may occur due to insufficient lubrication.
18-204
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[18. ENGINE]
18
18-205
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[18. ENGINE]
Tightening torque
18-206
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[18. ENGINE]
18.13.1.2 Disassembly
Commutator end
frame
• Hold the M lead wire and remove the commutator end frame by lifting.
18-207
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[18. ENGINE]
Spring
Brush
Brush lead
Clamp
Center bracket
assembly
• Do not hold the M lead wire and hold the yoke assembly outer diameter for removal.
Packing Packing
18-208
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[18. ENGINE]
18
Center bracket
assembly
• When the armature assembly is removed, the washer at the end of the gear may be dropped and lost. Be careful
for handling.
Puller
18-209
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[18. ENGINE]
Carrier pin
Internal gear
Center bracket
Pinion stopper
Pinion
18-210
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[18. ENGINE]
• Push upward or pull out the chipped part of the clip mouth.
Pinion
18
Holder
Lever assembly
Lever assembly
18-211
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[18. ENGINE]
Brake plate
Shaft assembly
• Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of the washers.
Packing
18-212
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[18. ENGINE]
Yoke assembly
18-213
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[18. ENGINE]
Commutator
18-214
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[18. ENGINE]
Undercut length:
0.5 to 0.8 mm
Segment {0.0197 - 0.0315}
Insulating material
11.98{0.4717}
Area A 12{0.4724}
or less
Area B 9{0.3543} 8.98{0.3535} or less
18-215
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[18. ENGINE]
Brush
25.90{1.0197}
Area A 26{1.0236}
or less
12.04{0.4740} or
Area B 12.1{0.4764}
less
6. Inspection of bearing
1) Measure the bearing metal inner diameter (1 in
the figure) of the pinion case using a cylinder
gauge. If it is beyond the service limit, replace the 1
bushing.
18-216
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[18. ENGINE]
26{1.0236} 26.2{1.0315}
18
Standard value (mm{in.}) Service limit (mm{in.})
9{0.3543} 9.2{3.6220}
4) Measure the bearing housing inner diameter (4 in the figure) of the commutator end frame using a cylinder
gauge. If it is beyond the service limit, replace the commutator end frame.
B terminal
18-217
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[18. ENGINE]
18-218
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[18. ENGINE]
18.13.1.4 Assembly
1. Installation of packing
1) Install a new packing on the center bracket
assembly.
Packing
18
2. Installation of shaft assembly
Washer
1) Turn the center bracket assembly upside down
and hold the carrier plate. Lubricate parts (refer
to the lubrication point drawing and the
lubrication list) and install the shaft assembly.
Shaft assembly
• Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of the washers.
Brake plate
5. Installation of lever
1) Lubricate parts (refer to the lubrication point
drawing and the lubrication list). Turn and install
the lever assembly using the clutch as the axis.
Lever assembly
18-219
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[18. ENGINE]
7. Installation of pinion
Pinion stopper
1) Lubricate parts (refer to the lubrication point
drawing and the lubrication list) and install the
Pinion
pinion and the pinion stopper.
Retainer clip
Pinion stopper
Pinion
Internal gear
Center bracket
18-220
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[18. ENGINE]
Center bracket
assembly
• When the armature assembly is installed, the washer at the end of the gear may be dropped and lost. Be careful
for handling.
Packing Packing
18-221
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[18. ENGINE]
Center bracket
assembly
Spring
Brush
Brush lead
Clamp
• Hold the M lead wire and remove the commutator end frame by lifting.
18-222
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[18. ENGINE]
19. Lubrication
Refer to the following figure and table for lubricant to be applied. 18
18-223
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[18. ENGINE]
Table of lubricant
Lubricant
Code Lubricating point Lubricant used Amount (g{oz}) Remark
manufacturer
Pinion case metal and 0.8 - 1.5
1 Multemp AC-N Kyodo Yushi
grease reservoir {0.03 - 0.05}
0.3 - 0.6
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
{0.01 - 0.02}
0.5 - 1
9 Helical spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
1-2
12 Planetary gear metal Multemp AC-N Kyodo Yushi
{0.04 - 0.07}
0.4 - 0.8
13 Lever holder Multemp AC-N Kyodo Yushi
{0.01 - 0.03}
18-224
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[18. ENGINE]
A
B
D 18
F
E
G
18-225
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[18. ENGINE]
Tightening torque
A 3.2-4.4N·m E 3.9-4.9N·m
{33-44kgf·cm, 2.4-3.2lbf·ft} {40-49kgf·cm, 2.9-3.6lbf·ft}
Capacitor
Diode
Fuse Load
L Lamp 1.4 to 3W
R
Starter switch
P
Feed coil
N
Regulator
Battery 24V
Stator coil
Alternator
18-226
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[18. ENGINE]
18.13.2.3 Disassembly
18
• Press the tabs of the cover for removal. Be careful not to break the tab with excessive force.
2. Disassembly of front
1) Remove nuts and remove the pulley, fan and
collar.
18-227
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[18. ENGINE]
• Tie around a general V -belt in the pulley groove and fix the pulley with a vice.
18-228
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[18. ENGINE]
3. Disassembly of rear
1) Remove solder of the lead wire connecting the
stator coil and the diode using a soldering bit and
suction line or a solder suction device
18
• At solder of the stator coil and the diode, the end of the diode is clamped. Do not damage the diode by prying.
Deformed diode must not be reused.
• Perform soldering in a short time (within 5 seconds).
Terminal
Lead wire
Regulator assembly
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[18. ENGINE]
• Remove the lead wire of the field coil by raising the terminal of the regulator.
• Perform soldering in a short time (within 5 seconds).
• Loosen the nut to some extent and do not remove it from the B terminal.
• Screw lock is used. Since torque is high until bolt is removed, be careful not to damage the groove of the bolt
head.
• When the rear bracket is reused, clean the screw hole.
18-230
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[18. ENGINE]
18
• Removed bearing must not be reused.
18-231
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[18. ENGINE]
18-232
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[18. ENGINE]
Standard value
Forward resistance value Approx. 10 Ω
18-233
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[18. ENGINE]
3) Inspection of regulator
Measure the resistance between regulator
terminals F and E using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
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[18. ENGINE]
18.13.2.5 Assembly
1. Assembly of front
1) Press fit a new ball bearing into the front bracket Jig C
using a press and jig C.
18
0 0
0 0
• Be sure to support the inner race of the bearing for press fit of the rotor.
• Do not damage the shaft.
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[18. ENGINE]
• Tie around a general V -belt in the pulley groove and fix the pulley with a vice.
2. Assembly of rear
1) Press fit a new roller bearing into the rear bracket Jig A
using a press, jig A and jig B.
Roller bearing
Jig B
• Press fit until jig A comes in contact with the rear bracket.
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[18. ENGINE]
18
• Apply screw lock to the ends of the heat sink mounting bolt and the regulator mounting bolt.
Terminal
Lead wire
Regulator assembly
18-237
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[18. ENGINE]
• After installation of the alternator, connect the wire and tighten the outside nut
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[18. ENGINE]
1. Inspection of rotation
1) Turn the pulley with hand to check if there is no
interference with internal parts and if rotation is
smooth.
18
B E Approx. 20Ω
E B Infinite
P E Approx. 7Ω
E P Infinite
R L
N P
E
Connector details
18-239
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[18. ENGINE]
18.14 TURBOCHARGER
18.14.1 Turbocharger Assembly
18.14.1.1 Part layout
Tightening torque
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[18. ENGINE]
18.14.1.2 Inspection
1. Inspection of turbine shaft axial play
1) Inspect play of the turbine shaft at the exhaust
side using a special tool.
Special tool : S0944-41800 (09444-1800) End
play gauge
2) If the measurement value is beyond the standard
value, ask the manufacturer to overhaul the unit.
• Since the assembly is replaced, disassembly and inspection are not allowed.
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[18. ENGINE]
18.14.1.3 Replacement
Removal
1. Remove the boost pipe and U-turn pipe.
2. Disconnect all pipes connected to the turbocharger.
• Loosen union bolt of the coolant pipe, drain coolant and remove the pipe. Disconnect the lower pipe similarly and
remove the oil pipe.
• After removing pipes, be sure to seal oil holes, water holes and cylinder block holes to prevent entry of dirt.
3. Remove the bolts fixing the exhaust pipe and the turbocharger and remove the turbocharger.
• After removal, seal holes both at the exhaust manifold and the exhaust pipe to prevent entry of foreign matter.
• If a stud bolt is sticking, remove and replace the stud bolt using a commercially available stud remover.
Installation
1. Install the turbocharger in the reverse order of disassembly. When the turbocharger is installed on the engine
or after installation, observe the following precautions for work. Pay special attention to entry of foreign matter
inside the turbocharger.
Tightening torque :
56 N·m {570 kgf·cm, 41 lbf·ft}
(Turbocharger to exhaust manifold)
2. Lubrication and cooling system
1) Before installation on the engine, pour new engine oil from the oil inlet and turn the turbocharger with hand
to lubricate the journal bearing and the thrust bearing.
2) Clean the oil pipe, oil hose, coolant pipe and hose. Check for pipe deformation, hose crack or dirt or foreign
matter in the pipe or hose.
3) Do not use sealant at the installation surface of the oil pipe and the coolant pipe or joint between the coolant
hose and the coolant pipe to prevent failures such as damage due to clogging or loosening of tightened
areas.
4) Be sure to use new soft washers, O-rings and gaskets.
5) Be sure to install the oil pipe, oil hose, coolant pipe and coolant hose correctly to prevent leak of oil or water
from connections.
3. Air intake system
1) Make sure that there is no dirt or foreign matter in the air intake system.
2) Do not use sealant at the inlet/outlet of air to prevent failures such as damage due to clogging or loosening
of tightened areas.
3) Be sure to install the air feed pipe and the air hose correctly to prevent air leak from connections.
4. Exhaust system
1) Make sure that there is no dirt or foreign matter in the exhaust piping system.
2) Since heat resistant steel is used for bolts and nuts, do not mix them with normal bolts for installation.
18-242
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[18. ENGINE]
Large engine oil consumption Wear of piston ring and cylinder liner Replace piston ring and cylinder liner
(piston, cylinder liner and piston ring)
Damage to piston ring Replace piston ring and cylinder liner
Faulty fixing of piston ring Replace piston ring and cylinder liner
Faulty assembly of piston ring Replace piston ring and cylinder liner
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide)
Wear of valve guide Replace valve guide
Piston seizure Sudden stop of engine Perform warm-up before stop of engine
(in operation)
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[18. ENGINE]
Insufficient engine power Clogging of air cleaner element Clean or replace air cleaner element
(air cleaner)
Insufficient engine power Piston, cylinder liner and piston ring Refer to Large engine oil consumption.
Faulty engine start Clogging of air cleaner element Clean or replace air cleaner element
(air cleaner)
Faulty engine start Insufficient fuel Replenish fuel and bleed air from fuel
(fuel unit) system
Faulty engine start Excessive viscosity of engine oil Replace with engine oil with correct
(lubrication unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and cylinder
liner
Bearing seizure Replace bearing and crankshaft
18-244
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[18. ENGINE]
Faulty contact of valve seat Adjust or replace valve and valve seat.
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Gas leak (cylinder liner Crack of cylinder liner Replace cylinder liner.
18-245
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[18. ENGINE]
18.15.1.2 Alternator
Status Cause Action
Lamp is ON.→Charge current does not Faulty regulator (open PTr) Replace regulator.
run (alternator).
Faulty stator coil (disconnection, rare Replace stator coil.
shorting)
Lamp is ON.→Charge current does not Disconnection of wire (fuse) Replace wire (fuse).
run (wiring).
Lamp is ON.→Voltmeter indicates 29V Faulty regulator (shorting of PTr) Replace regulator.
or more (alternator).
Faulty tightening of voltage detection Repair, replace voltage detection circuit
circuit (e.g. support) or replace regulator.
Lamp is OFF.→Charge current is Faulty stator coil (disconnection of 1 Replace stator coil.
always limited.→Battery goes flat phase, rare shorting)
(alternator).
Faulty diode (open, shorting) Replace rectifier.
Lamp is OFF.→Charge current is Operation load is large (Load balance is Reduce load
always limited.→Battery goes flat poor).
(operation load).
Lamp is OFF.→Charge current is Battery is close to the service life. Replace battery.
always large.→Battery fluid runs short
in a short period of time (battery).
Others→Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
18-246
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[18. ENGINE]
18.15.1.3 Starter
Status Cause Action
Starter does not turn. Turning is low. Faulty connection of starter key Repair connecting area.
Faulty contact of start magnet switch Replace start magnet switch assembly 18
assembly.
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[18. ENGINE]
18.15.1.4 Turbocharger
Status Cause Action
Exhaust smoke is black (insufficient Clogging of air cleaner element Clean or replace air cleaner element.
intake air).
Air intake inlet is closed. Recover normal status.
Leak from connection of air intake Check and repair.
system
Exhaust smoke is black Oil impurities are deposited at the Replace engine oil and disassemble the
(Turbocharger is not operating). sealing part of the turbine and revolution turbocharger for cleaning.
of the turbine shaft is heavy.
Seizure of bearing (insufficient Check the oil system of the engine and
lubrication or clogging of oil pipe) repair faulty areas. Also, replace engine
oil.
Seizure of bearing (Oil temperature is Check the oil system of the engine and
too high.) repair faulty areas. Also, replace engine
oil.
Seizure of bearing (Balance of revolving Replace or clean revolving part.
body is poor.)
Exhaust smoke is black Exhaust gas is leaking before the Check and repair mounting area.
(due to exhaust gas resistance). turbocharger. Revolution is not
increased.
Since pipe of the exhaust system is Recover normal status.
deformed or clogged, revolution of the
turbocharger is not increased.
18-248
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[18. ENGINE]
Negative pressure at the back of the Check and replace the pipe. Replace or
blower impeller is increased and engine clean the air cleaner element.
oil runs out to the blower.
Seal ring is excessively worn or Disassemble and repair turbocharger.
damaged due to excessive wear of the
bearing.
Entry of water into the cylinder Exchange or repair of the parts where
18
water has entered
Oil is quickly reduced. Seal ring is excessively worn or Disassemble and repair turbocharger.
damaged due to excessive wear of the
bearing.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Low engine output Gas leak from exhaust system parts Check and repair faulty areas.
Air leak from blower outlet Check and repair faulty areas.
Acceleration (follow-up of Carbon deposit at the turbine (disc Replace engine oil and clean
turbocharger) is poor (slow). sealing area) makes revolution of the turbocharger.
turbine heavy.
Air and gas leak from intake/exhaust Check and repair faulty areas.
system parts
Air and gas leak from intake/exhaust Check and repair faulty areas.
system parts
Vibration Loosening between turbocharger and Check the turbocharger mounting status
intake/exhaust pipe and between oil and repair faulty areas.
pipe and mounting area.
18-249
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[18. ENGINE]
18-250
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[18. ENGINE]
ACT Relay
Fuse
Each Sensor Power
Main relay
Key switch signal Fuse
Starter signal
- + Battery
Diagnosis switch
Diagnosis tool 18
Accelerator sensor for operation
I/F
PC Diagnosis tool
OUTP UT
CAN 250K
Mechatro controller
Glow relay
INP UT
T
Othe rs
Common rail T
G
N Engine
P
18-251
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[18. ENGINE]
18.16.1.3 Inspection
Pre-inspection
1. If an error occurs on the system, The DTC code is indicated in the console panel.
2. Reading of failure code
1) Connection of Hino-DX
Remove the left side cover at the rear of the
driver's seat and connect the failure diagnosis Engine ECU
connector with a PC which installed Hino-DX
through the interface box.
Failure diagnosis
connector
Hino-Bowie
Connecting cable
Connect to the failure diagnosis
connector at the vehicle side.
18-252
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[18. ENGINE]
• For the system status by indication of DTC code in the table, refer to "1. Pre-inspection, Inspection, Engine
ECU".
"Reference : Inspection, Engine ECU, Engine diagnosis code"
a. Low output (LOW idle 800rpm fixing) P2120 Accelerator sensor 1 and 2 malfunction
b. DTC code indication.
a. Low output P0217 Engine overheat
b. DTC code indication.
P0335 Engine speed main and sub sensor circuit malfunction
18-253
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[18. ENGINE]
18-254
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[18. ENGINE]
• When measuring terminal of the engine ECU, connect the signal check harness to prevent damage to the
connector. Place the tester rod on the contact box of the signal check harness for measurement.
18
• Terminal numbers in the text and the illustrations correspond as shown below in the "Computer pin
arrangement".
18-255
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[18. ENGINE]
Test lead
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[18. ENGINE]
18
18-257
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
harness.
OK
Normal
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
D1 D E4 E E5 harness.
OK
Normal
18-259
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[18. ENGINE]
18.16.1.9 Engine speed main sensor circuit malfunction (DTC code P0335)
1. Set the starter key to "OFF" and connect the signal check
B6 B B7 harness.
OK
S ta n d a rd : No d ia g n o s tic c o d e
OK
Normal
OK
18-260
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[18. ENGINE]
18.16.1.10 Abnormal engine speed main sensor pulse count (DTC code P0336)
1. Set the starter key to "OFF" and connect the signal check
B6 B7
harness.
1 rotation
56 peaks (pulse)
0V
OK
• Th e c o n n e c to r o f th e e n g in e s p e e d m a in
s e n s o r is s h o wn fro m th e e n g a g e m e n t s id e .
18-261
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[18. ENGINE]
• Th e c o n n e c to r o f th e e n g in e s p e e d m a in
s e n s o r is s h own fro m th e e n g ag e m e n t s id e .
S ta n d a rd va lu e : 2Ω o r le s s
NG Defective harness
OK
• Th e c o n n e c to r o f th e e n g in e s p e e d m a in
s e n s o r is s h own fro m th e e n g ag e m e n t s id e .
S ta n d a rd : 56 p u ls e s fro m m is s in g to o th to m is s in g
to o th
1 rotation
56 peaks (pulse)
0V
OK
18-262
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[18. ENGINE]
18.16.1.11 Engine speed sub sensor circuit malfunction (DTC code P0340)
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the engine speed sub sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the engine speed sub 18
sensor connector (at machine harness side).
S ta n d a rd va lu e : 5.0 ± 0.5 V
OK
OK
Harness failure
18-263
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the connector of the
D engine speed sub sensor.
D19
D30
2. Start the engine and keep idling status.
S ta n d a rd : P u ls e wave fo rm o f 0 ↔ 5V
OK
! CAUTION • Th e c o n n e c to r o f th e e n g in e s p e e d s u b
s e n s o r in th e fig u re is viewe d fro m th e fittin g
s u rfa c e .
S ta n d a rd va lu e : 2 Ω o r le s s
NG Harness failure
OK
18-264
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[18. ENGINE]
18.16.1.12 Abnormal engine speed sub sensor pulse count (DTC code P0341)
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the engine speed sub sensor.
3. Set the starter key to "ON" and measure the voltage between
the +5 V terminal of the engine speed sub sensor connector 18
(unit harness side) and the GND terminal.
S ta n d a rd va lu e : 5.0 ± 0.5 V
OK
1. Set the starter key to "OFF" and connect the connector of the
SIG engine speed sub sensor.
D19
2. Measure the resistance between terminal SIG of the engine
speed sub sensor connector (unit harness side) and terminal
D19 of the signal check harness.
! CAUTION • Th e c o n n e c to r o f th e e n g in e s p e e d s u b
s e n s o r is s h o wn fro m th e e n g a g e m e n t s id e .
S ta n d a rd va lu e : 2 Ω o r le s s
NG Defective harness
OK
18-265
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the conector of the
engine speed sub sensor.
D19
D30
2. Start the engine.
5V
0V
OK
18-266
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[18. ENGINE]
5V
0V
OK
18-267
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[18. ENGINE]
18.16.1.13 Engine speed main and sub sensor circuit malfunction (DTC code P0335)
1. Inspection item
1) Take actions of (DTC code P0335) and (DTC code P0340).
"Reference : Engine speed main sensor circuit malfunction (DTC code P0335), Engine ECU, Engine
diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction (DTC code P0340), Engine ECU, Engine
diagnosis code"
18-268
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
D E harness.
E19 18
D34 2. Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminal E19
and terminal D34.
S ta n d a rd va lu e (Me a s u re e ith e r o n e p o in t o f th e
fo llowin g .)
: 2.45 kΩ (Co o la n t te m p e ra tu re a t 20 °C{68 °F})
: 1.15 kΩ (Co o la n t te m p e ra tu re a t 40 °C{104 °F})
: 584 Ω (Co o la n t te m p e ra tu re a t 60 °C{140 °F})
: 318 Ω (Co o la n t te m p e ra tu re a t 80 °C{176 °F})
OK
S ta n d a rd va lu e (Me a s u re e ith e r o n e p o in t o f th e
fo llowin g .)
: 2.45 kΩ (Co o la n t te m p e ra tu re a t 20 °C{68 °F})
: 1.15 kΩ (Co o la n t te m p e ra tu re a t 40 °C{104 °F})
: 584 Ω (Co o la n t te m p e ra tu re a t 60 °C{140 °F})
: 318 Ω (Co o la n t te m p e ra tu re a t 80 °C{176 °F})
OK
18-269
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[18. ENGINE]
S ta n d a rd va lu e (Me a s u re e ith e r o n e p o in t o f th e
fo llo win g .)
: 2.45kΩ (Co o la n t te m p e ra tu re a t 20 °C{68 °F})
: 1.15kΩ (Co o la n t te m p e ra tu re a t 40 °C{104 °F})
: 584Ω (Co o la n t te m p e ra tu re a t 60 °C{140 °F})
: 318Ω (Co o la n t te m p e ra tu re a t 80 °C{176 °F})
NOTICE • Th is c o d e is d is p laye d wh e n th e c o o la n t
te m p e ra tu re s e n s o r is n o rm a l a n d th e c o o la n t
te m p e ra tu re is 108 °C{226 °F} o r m o re .
• Wh ile th is fa ilu re c o d e is d e te c te d , th e
m a xim u m in je c tio n vo lu m e is re s tric te d .
Wh e n th e c o o la n t te m p e ra tu re is 80 °C{176°F}
o r le s s , n o rm a l c o n tro l is re s u m e d .
OK
18-270
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[18. ENGINE]
• The objective of this failure code is not to detect overrun due to failure of this system, but to memorize high
revolution of the engine.
• Engine speed may be incorrectly recognized with noise on the speed sensor signal due to harness failure or 18
modification, resulting in detection of overrun.
18-271
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
D34 E27 harness.
S ta n d a rd va lu e (Me a s u re e ith e r o n e p o in t o f th e
fo llowin g .)
Te m p e ra tu re in
Re s is ta n c e (kΩ )
m e a s u re m e n t (°C{°F})
-20 {-4} 15.04 (+01.29, -1.20)
20 {68} 2.45 (+0.14, -0.13)
80 {140} 0.318 (+0.008, -0.008)
110 {230} 0.1417 (+0.0018, -0.0018)
OK
18-272
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[18. ENGINE]
S ta n d a rd va lu e (Me a s u re e ith e r o n e p o in t o f th e
fo llo win g .)
Te m p e ra tu re in
Re s is ta n c e (kΩ )
m e a s u re m e n t (°C{°F}) 18
-20 {-4} 15.04 (+01.29, -1.20)
20 {68} 2.45 (+0.14, -0.13)
80 {140} 0.318 (+0.008, -0.008)
110 {230} 0.1417 (+0.0018, -0.0018)
OK
18-273
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the boost pressure sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the boost pressure
sensor connector (at machine harness side).
S ta n d a rd va lu e : 5 ± 0.5 V
OK
OK
Harness failure
18-274
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[18. ENGINE]
1. Set the starter key to "OFF" and connect the connector of the
D boost pressure sensor.
D27
2. Set the starter key to "ON" and measure the voltage between
terminal D27 and terminal D33 of the signal check harness.
D33
S ta n d a rd va lu e : 0.2 to 4.8 V
OK
OK
Harness failure
18-275
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
18-276
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33 of the signal check
harness.
S ta n d a rd va lu e : 3.6 to 4.7 V
18
NG Engine ECU failure or harness/connector contact
failure
OK
18-277
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18.16.1.21 Excessive common rail pressure, supply pump excess forced feed (DTC code P0088)
1. Set the starter key to "OFF" and connect the signal check
D20 harness.
D31 2. Start and warm-up the engine until the coolant temperature
D33 gauge moves.
S ta n d a rd va lu e : 1.56 V o r le s s
OK
2. Check the fuel injection timing of the supply pump. If the timing
is not set 0° for the top dead center, set it correctly.
3. When there is no error after the check above, delete the past
failure using the PC diagnosis tool and start the engine.
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with failure diagnosis
tool (HinoDX) using PC.
18-278
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33.
S ta n d a rd va lu e : 0.9 to 1.1 V
18
NG Engine ECU failure or harness/connector contact
failure
OK
OK
18-279
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18.16.1.23 Common rail pressure sensor malfunction (DTC code P0192, P0193)
1. Set the starter key to "OFF" and connect the signal check
D33 D harness.
D20
D31 2. Set the starter key to "ON" and measure the voltage between
terminals D20/D31 and terminal D33 of the signal check
harness.
S ta n d a rd va lu e : 0.7 to 4.7 V
OK
2. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at machine harness side).
S ta n d a rd va lu e : 5 ± 0.5 V
OK
18-280
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
D
D20
D31 2. Measure the resistance between terminals D20/D31 of the
signal check harness and the SIG terminal of the common rail
pressure sensor connector (at machine harness side).
SIG
S ta n d a rd va lu e : 2 Ω o r le s s
18
NG Harness failure
OK
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
S ta n d a rd va lu e : 2 Ω o r le s s
NG Harness failure
D33
OK
18-281
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
harness.
2. Set the starter key to "ON" and measure the voltage between
terminal A21 and terminal B20 of the signal check harness.
B20
A21 S ta n d a rd va lu e : 0.7 - 1.5V (id le s ta tu s )
OK
S ta n d a rd va lu e
OK
Harness failure
18-282
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Ab n o rm a l va lu e
: 0.3 V o r le s s
18
: 4.85 V o r m o re
OK
18-283
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
harness.
A22
B21
2. Set the starter key to "ON" and measure the voltage between
terminal A22 and terminal B21 of the signal check harness.
OK
En g in e revo lu tio n
Me as u ring ite m Vo lta g e (V)
(r/m in )
Low id le 1,000 Ap p rox.1.4
Hig h id le 2,000 Ap p rox.3.3
OK
Harness failure
18-284
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Ab n o rm a l va lu e
: 0.3 V o r le s s
18
: 4.85 V o r m o re
OK
18-285
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1 Inspection item
18-286
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
OK
S ta n d a rd va lu e : 5.0 ± 0.5 V
OK
Harness failure
18-287
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
OK
OK
Harness failure
18-288
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229) is output. 18
S ta n d a rd : No rm a l
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
18-289
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[18. ENGINE]
18.16.1.29 Injector common 1 ground short (DTC code P1211), Injector common 2 ground short (DTC
code P1214)
1. Set the starter key to "OFF" and connect the signal check
harness.
S ta n d a rd va lu e : ∞ Ω
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
18-290
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[18. ENGINE]
Te rm in a l to m e a s u re re s is ta n c e
18
DTC c o d e
+ s id e – s id e
ECU c a s e
P 1211 3, 7, 8, 11
g ro u n d
ECU c a s e
P 1214 2, 5, 6, 10
g ro u n d
S ta n d a rd va lu e : ∞ Ω
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
18-291
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18.16.1.30 Injector common 1 power source line short (DTC code P1212), Injector common 2 power
source line short (DTC code P1215)
1. Set the starter key to "OFF" and connect the signal check
D5 D D6 harness.
ECU case ground
(ECU mounting bolt)
2. Disconnect the ECU side connector of the signal check
harness and set the starter key to "ON".
E6 E E7
3. Measure the voltage between each terminal of the signal check
harness and the ECU case ground.
! CAUTION • Neve r s ta rt th e e n g in e b e c a u s e it m ay c a u s e
fa ilu re o f th e u n it o r e le c tric s h o ck.
Te rm in a l to m e a s u re vo lta g e
DTC c o d e
+ s id e – s id e
ECU c a s e
P 1212 D5, D6
g ro u n d
ECU c a s e
P 1215 E6, E7
g ro u n d
S ta n d a rd va lu e : 14 V o r le s s
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
18-292
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
! CAUTION • Neve r s ta rt th e e n g in e b e c a u s e it m ay c a u s e 18
fa ilu re o f th e u n it o r e le c tric s h o ck.
Te rm in a l to m e a s u re vo ltag e
DTC c o d e
+ s id e – s id e
ECU c a s e
1212 7, 8
g ro u n d
ECU c a s e
1215 5, 6
g ro u n d
S ta n d a rd va lu e : 14 V o r le s s
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
18-293
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
harness.
Te rm in a l to
Fa ilu re a re a
E1 DTC c o d e m e a s u re
E2 E7
(in je c to r)
E6 re s is ta n c e
P 0201 #1 D2 ↔ D5
P 0202 #2 E2 ↔ E6
P 0203 #3 E1 ↔ E7
P 0204 #4 D3 ↔ D6
S ta n d a rd va lu e : 2 Ω o r le s s
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
18-294
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
S ta n d a rd va lu e : 2 Ω o r le s s
OK
Machine harness disconnection (Check the harness between the ECU and the injector clustered connector.)
S ta n d a rd va lu e : 0.45 ± 0.1 Ω
OK
18-295
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
S ta n d a rd va lu e : 10 MΩ o r m o re
OK
18-296
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18.16.1.32 Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269, P0272)
4. If the same DTC is displayed again after erasing it, replace the
common rail.
18-297
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18-298
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
DTC P0629 Supply pump SCV malfunction (Power source line short)
OK
1. Set the starter key to "OFF", connect the signal check harness
and disconnect the ECU side connector.
S ta n d a rd va lu e : 1 Ω o r le s s
OK
18-299
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
OK
18-300
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
18.16.1.34 Supply pump SCV sticking (DTC code P2635), Supply pump abnormal pressure record (DTC
code P2635)
OK
2. When there is no error after the check above, delete the past
failure and operate the engine.
If the same code is output again, possible failures are the
supply pump and engine ECU. Perform more detailed
diagnosis with failure diagnosis tool (HinoDX) - Hino–DX
[Inspection Menu], using PC.
18-301
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
C2 harness.
C1 C D1 D E4 E E5
S ta n d a rd va lu e : 25 ± 2.5 Ω
OK
S ta n d a rd va lu e : 24.8 ± 0.5 Ω
OK
18-302
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1 Inspection of QR code
1. Read the QR code data with the failure diagnosis tool (HinoDX)
using PC.
Re fe re n c e va lu e : Th is s h a ll c o in c id e with th e QR c o d e
m a n ag e d b y th e m a c h in e m a n u fa c tu re r.
OK
18-303
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
2. After deleting the past failure, check if the same code (DTC
code P0605, P0606, P0607) is output again.
S ta n d a rd : No rm a l
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
18-304
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1 Check of ECU
2. After deleting the past failure, check if the same code (DTC
18
code P0611, P0200) is output again.
S ta n d a rd : No rm a l
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
18-305
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
A6
A5 A A7 harness.
S ta n d a rd va lu e : 0 V
NG Defective harness
OK
18-306
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
[18. ENGINE]
1. Set the starter key to "OFF" and connect the signal check
B B14 C C4
harness.
S ta n d a rd va lu e
: 0 V (wh e n s ta rte r key is a t "OFF")
: 24 V (wh e n s ta rte r key is a t "S TART")
NG Harness failure
OK
18-307
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]