Excavadora Kobelco SK170 Motor Hino

SERVICE MANUAL

SK170-9

47454079-DRAFT 06/11/2012 EN

Contents INTRODUCTION Engine....................................................................................... 10 Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202 Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.216 Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500

Hydraulic systems....................................................................... 35 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000 Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106 Charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.105 Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300 Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.322 Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.352 Hydraulic travel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.353 Hydraulic central joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.354 Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357 Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

Frames and ballasting ................................................................. 39 Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.100 Ballasts and supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.140

Tracks and track suspension ........................................................ 48 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.100 Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.130 Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.134 Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.138

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Cab climate control ..................................................................... 50 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200

Electrical systems ....................................................................... 55 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000 Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408 Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.512 Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.640 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

Booms, dippers, and buckets ....................................................... 84 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.100 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.910 Dipper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.912

Platform, cab, bodywork, and decals ............................................. 90 Machine shields and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.105 Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150

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INTRODUCTION

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Contents INTRODUCTION Personal safety and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Basic instructions – How to use the maintenance standard and precautions . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

Basic instructions – PREPARATION FOR PERFORMANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Basic instructions – Measuring Travel Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Basic instructions Measuring Swing Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

Basic instructions - MEASURING ATTACHMENT OPERATING PERFORMANCES . . . . . . . . 20 SK170-9 LA

Basic instructions Measuring Performances of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA

Basic instructions PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . 25 SK170-9 LA

Basic instructions INSTALLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SK170-9 LA

Basic instructions Floating seal precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SK170-9 LA

Basic instructions Electrical Equipment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SK170-9 LA

Basic instructions – Measurement of Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SK170-9 LA

Basic instructions – Measurement of Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SK170-9 LA

Basic instructions – Preparation for Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SK170-9 LA

Capacities FLUIDS AND LUBRICANTS SK170-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SK170-9 LA

General specification Performance inspection standard table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SK170-9 LA

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Personal safety and signal word definitions [50090504] SK170-9 LA

Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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Torque [45206476] SK170-9 LA

Bolt types Tighten nuts or bolts to torque specifications. There are two kinds of bolts; hexagon T bolts (1) and socket bolts (2). The two types of bolts are made from different materials. The correct type of bolt must be used when assembling the machine and/or components. RAPH12CEX1320AA

1

RAPH12CEX1321EA

2

Specified tightening torque chart Bolt diameter M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36

Wrench Size 13 17 19 22 24 27 30 32 36 41 46 50 55

Hexagon Wrench Size 6 8 10 12 14 14 17 17 19 19 22 24 27

T Bolt, Socket bolt 29.5 N·m 64 N·m 108 N·m 175 N·m 265 N·m 390 N·m 540 N·m 740 N·m 930 N·m 1370 N·m 1910 N·m 2550 N·m 3140 N·m

1. Apply lubricant (i.e., white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. 2. Torque tolerance is ± 10 % 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any.

Bolt tightening order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. A. Equally lighten upper and lower alternately. B. Tighten diagonally. C. Tighten from center and diagonally.

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Service recommendations for split flange 1. Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. 2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. when installing an O-ring into a groove, use grease to hold it in place.

RAPH12CEX1322AA

3

RAPH12CEX1323AA

4

RAPH12CEX1324AA

5

RAPH12CEX1325AA

6

RAPH12CEX1326AA

7

3. Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before the other bolts are tightened. This results in damage to the O-rings and/or uneven tightening of the bolts.

Nut and bolt lockings Lock plate NOTICE: Do not reuse lock plates. Do not try to bend the same point twice. Cotter pin NOTICE: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. Lock wire NOTICE: Apply wire to bolts in the bolt tightening direction, not in the bolt-loosening direction. A B C D E F

Wrong Right Bend along edge sharply Do not bend it round Tighten Loosen

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Piping joint Pipe thread connection / union joint tightening torque specifications Union joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to form a seal. Union joints are used to join small-diameter lines.

RAPH12CEX1327AA

1. Do not over tighten the union nut (3) . Excessive force will be applied to metal sealing surfaces (4) and (5), possibly crack the adaptor (1). Be sure to tighten the union nut to specifications (3). 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting. Type 37 °

Wrench size Union nut 19 22 27 36 41 50

Joint body 17 19 22 30, 32 36 46

Tightening Torque 29 N·m 39 N·m 78.5 N·m 157 N·m 205 N·m 323.6 N·m

NOTE: Tightening torque for the non union type 37 °

O-ring seal joint O-ring seats against the end face adaptor to form a seal. O-ring procedures: 1. Be sure to replace the O-ring with a new one when reconnecting 2. Before tightening the union nut, confirm that the O-ring is seated correctly in the O-ring groove. Tightening the union nut with the O-ring displaced will damage the O-ring, resulting in oil leakage. 3. Take care not the damage the O-ring groove or sealing face. Damage to the O-ring will cause leakage. 4. If the union nut is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace the O-ring with a new O-ring. Then tighten the union nut after confirming that the O-ring is securely seated in place. Wrench size Union nun 19 22 27 30 36 41 50

Joint body 17 19 22 27 30 36 46

Tightening Torque 29.4 N·m 68.6 N·m 93 N·m 137.3 N·m 175 N·m 205 N·m 320 N·m

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Screwed in connection NOTICE: Many types of screwed in connections are used for hose connections Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw in connection.

17,19 22 27 36,32 50 60

Male tapered thread Wrench Tightening torque Joint body 34 N·m 49 N·m 93 N·m 157 N·m 320 N·m 410 N·m

RAPH12CEX1516AA

A B

9

Male tapered thread Male straight thread

Seal tape application Seal tape is used to seal clearances between male and female threads to prevent any leakage between threads. Apply the seal tape to fill the thread clearances, do not over wrap. Application procedure • Confirm the thread surface is clean, and free of dirt or damage.

A B C

• Apply the seal tape around the threads as shown. Wrap the seal tape in the same direction as the threads.

RAPH12CEX1517AA

10

RAPH12CEX1518AA

11

Clearance Internal thread External thread

Leave one to two pitch threads uncovered

Low pressure hose clamp tightening torque Low pressure tightening torque vary depending on the type of clamp. f T-bolt type band clamp (1) tightening torque • 4.4 N·m (3.2 lb ft) Worm gear type band clamp (2) tightening torque • 5.9 - 6.9 N·m (4.4 - 5.1 lb ft)

RAPH12CEX1519AA

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Connecting hoses Only use genuine parts. Using hoses other than genuine hoses may cause oil leakage, hose rupture, or separation of the fitting, possible resulting in a fire on the machine. • DO NOT install hoses that are twisted. Application of high oil pressure, vibration, or an impact to a twisted hose may result in oil leakage, hose rupture or separation of the fitting. When installing the hoses, utilize the print marks on the hoses to prevent the hose from being installed twisted. RAPH12CEX1520AA

13

RAPH12CEX1522AA

14

RAPH12CEX1521AA

15

RAPH12CEX1523AA

16

• DO NOT allow hoses to rub against each other. Protect hoses from wear which will lead to hose rupture. • Take necessary measures to protect hoses from rubbing against each other. Properly use hose clamps.

• DO NOT allow hoses to come into contact with moving parts or sharp objects.

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Basic instructions – How to use the maintenance standard and precautions [49037636] SK170-9 LA

Application WHEN THE MACHINE IS NEW Confirm that the performances are in accordance with standard specifications as compared to the performance standards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY) Use the data for the criterion, for the purpose of correction, adjustment and replacement. WHEN PERFORMANCES ARE DETERIORATED Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations. WHEN MAIN COMPONENTS ARE REPLACED For example, use data to restore performances of pumps and others

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 corrections are performed, replace the parts immediately.

Cautions to be Exercised at Judgment EVALUATION OF MEASURED DATA Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values. DETERMINING CORRECTION, ADJUSTMENT OR REPLACEMENT Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels.

Other Cautions to be Exercised PARTS LIABLE TO DEGRADE Rubber products, such as, hydraulic hoses, O-rings, and oil seals deteriorate with time; replace them at regular intervals or at overhauls. 47454079-DRAFT 06/11/2012

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PARTS REQUIRING REGULAR REPLACEMENT Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly. INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.

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Basic instructions – PREPARATION FOR PERFORMANCE TESTS [49050352] SK170-9 LA

Observe the following rules in order to carry out performance tests accurately and safely.

The machine 1. Repair and defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

Test area 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 meters, and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. RAPH12CEX0329BA

1

RAPH12CEX0330BA

2

Precautions 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

Make precise measurements 1. Accurately calibrate test instruments in advance to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

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Basic instructions – Measuring Travel Performances [49094431] SK170-9 LA

Travel Speed PURPOSES Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system. CONDITIONS Hydraulic oil temperature 45 - 55 °C (113 - 131 °F); Crawler on the right and left sides are tensioned evenly. PREPARATION Attach the reflection panel with a magnet to the travel motor cover. Swing the swing frame through 90° as shown in Figure and make the crawler on one side take off the ground, using the attachment.

RAPH12CEX0331BA

1

RAPH12CEX0332BA

2

MEASUREMENT Engine revolution: Hi Idle 2–speed travel switch: 1st speed and 2nd speed Measuring points: right and left Method, example: Measure the revolutions per minute visually. SK170–9 Sprocket revolution Measurement item

Standard value

Reference value for remedy

Service limit

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

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Deviation of travel PURPOSE Measure the amount of deviation at 20 m (66 ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system. CONDITION Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution: Hi idle. PREPARATION RAPH12CEX0333BA

3

RAPH12CEX0334BA

4

1. Straight course more than 30 m (98 ft). 2. Travel position in which the bottom of the bucket is lifted by about 30 cm (12 in). MEASUREMENT 1. Measure the maximum. deviation distance of the circular arc in the 20 m (66 ft) length, excluding the preliminary run of 3 - 5 m (10 - 16 ft) 3~5m (10~16ft). 2. Operate the travel lever at the same time. Travel deviation Measuring position

Standard value

Reference value for remedy

Service limit

A

240 mm (9.45 in) or less

480 mm (18.9 in)

720 mm (28.3 in)

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Performances of parking brake PURPOSE Confirm that the parking brake holds a stopped condition of the machine in a no-load travel position and on a 15 degree slope. CONDITION A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position. 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.

RAPH12CEX0335BA

5

RAPH12CEX0336BA

6

MEASUREMENT Five minutes after the engine stops, measure the movement distance of the matching mark. Parking brake Measuring position

Standard value

C

0

Reference value for remedy 1 mm (0.04 in)

Service limit 2 mm (0.08 in)

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Drain rate of travel motor PURPOSE To measure the drain rate of the travel motor and to confirm the performances of the travel motor. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Engine revolution: Hi idle PREPARATION 1. Place a stopper under the RH and LH travel sprockets. 2. Stop the engine and release pressure from the hydraulic circuit.

RAPH12CEX0337AA

7

RAPH12CEX0338AA

8

3. Connect a hose with the drain port of the travel motor and take drain in a container. MEASUREMENT AT TRAVEL LOCK NOTICE: Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. 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. Drain rate of travel motor Measuring position

Standard value

Drain rate

5 l (1.3 US gal)

Reference value for Service limit remedy 13 l (3.4 US 15 l (4.0 US gal) gal)

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INTRODUCTION

Basic instructions Measuring Swing Performances [49117989] SK170-9 LA

Swing speed PARAGRAPH Measure the swing time and confirm the performances between the hydraulic pump and the swing motor of the swing drive system. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Firm, level ground Engine revolution: Hi idle PREPARATION Put the bucket empty and extend the boom, arm and bucket cylinder fully. And the machine becomes a position of minimum reach. MEASUREMENT AT TRAVEL LOCK Swing the machine by bringing the swing lever to its full stroke. Measure the time required to make two turns after one turn of preliminary run and calculate the time required for one turn. Measuring position

Standard value

Swing speed 3.7 - 4.9 s at min. reach

Reference value for remedy 4.6 - 6.2 s /rev

Service limit 6.4~ s

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RAPH12CEX0339BA

1

INTRODUCTION

Performance of swing brake PURPOSE Confirm the braking torque performances by the swing relief valve. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Firm, level ground Engine revolution: Hi idle PREPARATION

RAPH12CEX0340AA

1. Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin.

No.

2

Item Boom foot pin Arm top pin

1 2

2. Put a matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side. Place two poles (flags) on the front and back of the extended line of the matching mark. MEASUREMENT AT TRAVEL LOCK 1. When operating in regular swing speed, by shifting lever to neutral position at pole position the swing operation stops. 2. Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race: Swing drift angle = (Amount of deflection of matching marks [m (ft-in)] divided by circumferential length of swing race [m (ft-in)]) multiplied by 360. Swing brake performance Measuring position

Standard value

Swing 180°

75°

RAPH12CEX0341BA

Reference value for remedy 85°

No.

Service limit

1 2

90°

Item Matching marks on outer race Matching marks on inner race

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3

INTRODUCTION

Performance of swing parking brake PURPOSE To confirm the mechanical performances of the swing parking brake that is fitted to the inside of the swing motor. CONDITIONS On a slope of 15 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. PREPARATION Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Put a matching mark on the outer race side and on the inner race side.

RAPH12CEX0342BA

4

RAPH12CEX0341BA

5

MEASUREMENT AT TRAVEL LOCK When five minutes has passed after the engine stops, measure the length of the movement of the matching marks. Measuring position

Standard value

B

0

Reference value for remedy 1 mm (0.04 in) / 5 minutes

Service limit 2 mm (0.08 in) / 5 minutes

No. 1 2

Item Matching marks on outer race Matching marks on inner race

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INTRODUCTION

Drain rate of swing motor PURPOSE Measure the drain rate of the swing motor and confirm the performances of the swing motor. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Firm, level ground Engine revolution: Hi 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

RAPH12CEX0343BA

1. Start the engine and put the side faces of bucket against the inside of the right or left shoe plates. 2. Relieve the swing motor at full stroke of the swing motion. 3. Collect the amount of drained oil in a container for 30 seconds. Measuring position Drain rate

Reference value for remedy 5.2 l (1.37 2.1 l (0.55 US gal) / 30 US gal) / 30 seconds seconds Standard value

Service limit 6.2 l (1.64 US gal) / 30 seconds

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6

INTRODUCTION

Basic instructions - MEASURING ATTACHMENT OPERATING PERFORMANCES [49228069] SK170-9 LA

Operating time of cylinders PURPOSE Measure the operating time of the arm, positioning and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Engine revolution: Hi idle Operating time excluding the cushion stroke. PREPARATION Firm level ground with the bucket empty. MEASUREMENT Arm in and out, positioning in and out, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30cm (1ft) above ground, measure the full stroke operating time required with the arm, the positioning and bucket operating levers at full stroke. Measuring position

Standard value (Seconds)

1 2 7 8 9 10

3.5 - 4.1 s 2.1 - 2.7 s 3.6 - 4.2 s 2.4 - 3.0 s 3.0 - 3.6 s 4.9 - 5.5 s

Reference value for remedy (Seconds) 4.4 - 5.2 s 2.7 - 3.4 s 4.4 - 5.2 s 3.0 - 3.8 s 4.0 - 4.7 s 6.6 - 7.4 s

Service limit (Seconds) 5.4~ 3.5~ 5.6~ 4.0~ 4.9~ 7.8~

s s s s s s

RAPH12CEX0344CA

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1

INTRODUCTION

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

Standard value

Reference value for remedy 6 mm (0.24 8 mm (0.31 in) in) 10 mm (0.39 13 mm (0.51 in) in) – – 90 mm (3.54 150 mm (5.91 in) in)

Service limit

10 mm (0.39 in) 18 mm (0.71 in) – 225 mm (8.86 in)

MEASUREMENT Measure the items five minutes after the engine is turned off. Measuring position A B C D

Standard value

Reference value for remedy 6 mm (0.24 8 mm (0.31 in) in) 10 mm (0.39 13 mm (0.51 in) in) – – 90 mm (3.54 150 mm (5.91 in) in)

Service limit

10 mm (0.39 in) 18 mm (0.71 in) – 225 mm (8.86 in)

RAPH12CEX0345AA

No. Arm top pin 1 Boom foot pin 2

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Item

2

INTRODUCTION

Basic instructions Measuring Performances of Swing Bearing [49362376] SK170-9 LA

PURPOSE Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing. CONDITIONS Firm, level ground The swing bearing mounting bolts are not loosened. The swing bearing is lubricated well, not making abnormal sound during turning.

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INTRODUCTION

PREPARATION 1. Install a dial indicator to the magnetic base and fix it to the lower frame. 2. Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero. MEASUREMENT Measuring position 1 and 2 Measure the displacement of the outer race in the axial direction in position 1 [The arm at 90°~110° and the crawler front is lifted by attachment about 30cm (1ft)] and in position 2, using a dial indicator. No. 1 2 3 4

Axial play of swing bearing Measuring position A

RAPH12CEX0346BA

Service limit Reference value for remedy 0.8 - 1.8 mm 2.3 - 3.3 mm 3.6 mm (0.03 - 0.07 (0.09 - 0.13 (0.14 in) in) in) Standard value

Description Lower frame Dial indicator Swing bearing Location of bearing mounting bolts

No. Description Arm top pin 1 Boom foot pin 2

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1

RAPH12CEX0347BA

2

RAPH12CEX0340AA

3

INTRODUCTION

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

Service limit Reference value for remedy 30 - 50 mm 80 mm (3.15 120 mm (4.72 in) (1.18 - 1.97 in) in) Standard value

RAPH12CEX0340AA

No. Description Arm top pin 1 Boom foot pin 2

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4

INTRODUCTION

Basic instructions PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY [51294741] SK170-9 LA

PREPARATIONS FOR DISASSEMBLY - Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. - Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. - Check and record the items listed below to prevent problems from occurring in the future. 1. The machine model, machine serial number, and hour meter reading. 2. Reason for disassembly (symptoms, failed parts, and causes). 3. Clogging of filters and oil, water or air leaks, if any. 4. Capacities and condition of lubricants. 5. Loose or damaged parts. - Prepare the necessary tools to be used and the area for disassembling work. - Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. - 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. - Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work.

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT - 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.

DISASSEMBLING HYDRAULIC EQUIPMENT - Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited. - If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. - Make match mark on parts for reassembling. - Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not. - For parts which are required to use jig and tools, don’t fail to use the specified jig and tools. - For parts which can not be removed in the specified procedure, never force removal. First check for the cause. - Inspecting parts. Measure the wear of parts and clearance, and record the measured values. - If an abnormality is detected, repair or replace the parts. - The removed parts should be put in order and tagged so as to install on proper places without confusion. - For common parts, pay attention to the quantity and places.

REASSEMBLING HYDRAULIC EQUIPMENT - During the parts cleaning, ventilate the room. - Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. - Replace the removed O-ring, back-up rings and oil seal with new ones, and apply gear oil on them before assembling. - Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them. - Before assembling, remove rust preventives on new parts. - Use special tools to fit bearings, bushing and oil seal. - Assemble parts matching to the marks. - After completion, check that there is no omission of parts. 47454079-DRAFT 06/11/2012

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INTRODUCTION

Basic instructions INSTALLING HYDRAULIC EQUIPMENT [51298009] SK170-9 LA

Confirm level of hydraulic oil and lubrication oil Bleeding air from hydraulic system Air bleeding is required in the following cases: 1. When hydraulic oil is changed. 2. After replacement of parts on suction pipe side. 3. After removing and attaching hydraulic pump. 4. After removing and attaching swing motor. 5. After removing and attaching travel motor. 6. After removing and attaching a hydraulic cylinder. NOTICE: If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. - When air bleeding hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of air bleeding, tighten the plug securely. - When air bleeding travel motor and hydraulic cylinders, start the engine and operate it for 10 minutes or more at no-load and low speed. NOTICE: When operating cylinders during this procedure, do not move the rod to the stroke end at the beginning. - Air in the pilot circuit can be bled out only by operating the digging, swinging, and travelling motions thoroughly. - Check hydraulic oil level. Move attachments to hydraulic oil check position, as indicated in the figure below.

RAPH12CEX0378BA

1

- Open the hydraulic pump compartment door, then check the oil level on visual indicator (1) located on the hydraulic oil reservoir. If the indicator is within level marks, the oil quantity is acceptable.

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INTRODUCTION

RAPH12CEX0379BA

2

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INTRODUCTION

Basic instructions Floating seal precautions [51302493] SK170-9 LA

In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures: 1. Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. 2. Check the seal ring face (1) for scuffing, scoring, corrosion, deformation or uneven wear.

RAPH12CEX0380BA

1

3. Check O-Ring (2) for tears, breaks, deformation or hardening. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. 1. Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. 2. Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. 3. Check that the O-Ring is not twisted (2) , and that it is installed correctly (1)on the seal ring .

RAPH12CEX0381BA

2

4. After installing the floating seal, check that seal ring surface (3) is parallel with mating face (1) by measuring the distances (a) and (b), as illustrated. If these distances differ, correct the O-Ring (2) seating.

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INTRODUCTION

RAPH12CEX0382BA

3

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INTRODUCTION

Basic instructions Electrical Equipment Precautions [51309750] SK170-9 LA

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply could result in death or serious injury. W0111A

- The disassembly of electrical equipment is not allowed. - Handle equipment with care so as not to drop it or bump it. - Connector should be removed by unlocking while holding the connector. - Never stress in tension to the caulked section by pulling wire. - Check that connector is connected and locked completely. - Engine key off before removing and connecting connector. - Engine key off before touching terminals of starter and alternator. - Wash machine with care so as not to splash water on electrical equipment and connector. - When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting. - Remove battery grounding terminal before beginning work close to battery and battery relay with tools.

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INTRODUCTION

Basic instructions – Measurement of Engine Speed [60644565] SK170-9 LA

Warming up of engine Start engine to raise the coolant temperature of the engine to 60 - 90 °C (140 - 194 °F) at surface of radiator upper tank. The E/G coolant temperature gauge is used to measure this. The range in white shows the temperature of approximately 65 - 105 °C (149 - 221 °F) , so confirm that the pointer indicates the temperature is within this white range.

RAPH12CEX1229AA

1

RAPH12CEX1230AA

2

RAPH12CEX1231AA

3

Engine speed measured value through service diagnosis 1. Turn “ON” the starter switch with the buzzer stop switch (1) pressed. 2. A program No. and an actual engine revolution are displayed as the No. 2 item. 3. The screen advances like No. 2, No. 3...each time the “Wiper switch” on the gauge cluster is pushed. 4. The screen returns like No. 45, No. 44...each time the “Washer switch” is pushed. 5. The display does not disappear unless the starter switch is turned to “OFF”.

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INTRODUCTION

Basic instructions – Measurement of Hydraulic Pressure [60650951] SK170-9 LA

Preparing to measure hydraulic pressure HYDRAULIC EQUIPMENT 6.9 MPa (1001 psi) pressure gauge: 1 unit 49 MPa (7107 psi) pressure gauge: 2 units Pressure measuring equipment and instrument for analysis: 1 set MEASURING CLEANLINESS OF HYDRAULIC OIL NOTE: After releasing air in the hydraulic oil tank, open the cover and sample the oil inside the tank using an instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil.

Place to install pressure gauge RAPH12CEX1232AA

MAIN CIRCUIT After releasing the pressure in the hydraulic oil tank and system, replace plugs PF1/4 of main pump gauge ports A1 (1), and A2 (2), with plugs for pressure measurement. Then attach pressure gauge rated for 49 MPa (7107 psi). PILOT CIRCUIT Replace the pilot gauge plug A5 (3), with a plug PF1/4 for pressure measurement. Then attach a pressure gauge rated for 6.9 MPa (1001 psi).

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1

INTRODUCTION

Pressure adjustment position MAIN CONTROL VALVE Relief valve position on main control valve.

RAPH12CEX1233FA

2

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INTRODUCTION

RAPH12CEX1234FA

3

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INTRODUCTION

PILOT RELIEF VALVE The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

RAPH12CEX1235AA

4

RAPH12CEX1236AA

5

RAPH12CEX1237AA

6

SWING OVERLOAD RELIEF The swing motor is equipped with plugs PA, PB for pressure measurement, but the measurement is carried out using gauge ports A1 and A2.

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INTRODUCTION

Procedure for adjusting relief valve PILOT RELIEF VALVE Adjust it with adjust screw (311). No. of turns of adjusting screw 1 turn

Pressure change MPa (psi) Approximately 2.1 MPa (305 psi)

2–STAGE MAIN RELIEF VALVE (Common for travel and ATT sections) Start from the boosting side, first. Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustment on the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment. No. of turns of adjusting screw Boosting side 1 turn STD side 1 turn

RAPH12CEX1238AA

7

RAPH12CEX1239AA

8

RAPH12CEX1240AA

9

Pressure change MPa (psi) Approximately 17.6 MPa (2553 psi) Approximately 17.6 MPa (2553 psi)

OVERLOAD RELIEF VALVE (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjusting screw (2). No. of turns of adjusting screw 1 turn

Pressure change MPa (psi) Approximately 17.6 MPa (2553 psi)

OVERLOAD RELIEF VALVE (SWING) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap (2). No. of turns of adjusting screw 1 turn

Pressure change MPa (psi) Approximately 10 MPa (1451 psi) RAPH12CEX1241AA

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10

INTRODUCTION

OVERLOAD RELIEF VALVE (TRAVEL) This valve was adjusted by the valve manufacturer. When adjustment is required, loosen nut (1) and adjust the pressure with adjusting screw (2).

RAPH12CEX1242AA

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11

INTRODUCTION

Basic instructions – Preparation for Performance Tests [60724831] SK170-9 LA

Observe the following rules in order to carry out performance tests accurately and safely.

The machine 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

Test area 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 m, and to make a full swing with the front attachment extended. RAPH12CEX1271AA

1

RAPH12CEX1272AA

2

3. If required, rope off the test area and provide signboards to keep unauthorized personnel away.

Precautions 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

Make precise measurements 1. Accurately calibrate test instruments in advance to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

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INTRODUCTION

Capacities FLUIDS AND LUBRICANTS SK170-9 [50853068] SK170-9 LA

COMPONENT TO BE QUANTITY FILLED Engine 12 l (3.2 US gal)

Swing reduction unit 2.7 l (0.7 US gal) Travel reduction units 4 l (1.1 US gal) (each) Radiator 6.6 l (1.7 US gal)

Fuel tank DEF/ADBLUE® tank Hydraulic oil tank Swing gear Windshield washer Pressure gauge fittings

TUTELA

MANUFACTURER SPECIFICATIONS

TUTELA AUTO SUPREME™ ENGINE OIL SAE 10W-30 TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE

286 l (75.6 US gal) 79 l (20.9 US gal) + 90.7 l (24.0 US gal) 8.6 kg (19.0 lb) 1.5 l (0.4 US gal)

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INTERNATIONAL SPECIFICATIONS

INTRODUCTION

General specification Performance inspection standard table [60546611] SK170-9 LA

NOTE: Unless otherwise specified, measure it on “H” mode. Measuring Position Inspection Item

Position

Cleanliness of hydraulic oil Hydraulic oil temperature

Water temperature H mode Lo idle H mode Hi idle Engine Auto-Idle speed S mode Hi idle E mode Hi idle Pilot primary pressure circuit Main P1 ATT travel relief P2 valve P1 presPower boost P2 sure

Size

Port

NAS 9 or less (Class) 50 °C (122 °F) ± 5 °C Tank surface (41 °F) 75 °C (167 °F) ± 15 °C Radiator surface (59 °F) 1000 min-1 ± 50 2200 min-1 Measure the engine speed ± 50 at multi display on the gauge 1050 min-1 Adjustment cluster, or measure with diesel ± 50 not required speed meter 2000 min-1 ± 50 2000 min-1 ± 50 5.0 MPa G pump a5 PR1 +0.5/-0 a1 a2 a1 a2

a1 R

a1 R Main pump

LH

37.7 MPa +0/-5.9

37.7 MPa 37.7 MPa

a2 R

Travel

+0/-5.9

+0/-4.0

PF 1/4

Arm

RH

37.8 MPa +1.0/-0.5

39.7 MPa

H

Over load relief valve pressure

+0.7/-0.5

+0/-4.0

Bucket

Swing

34.3 MPa

39.7 MPa

Boom

H

Adjusting point

Hydraulic oil in tank

H

High pressure circuit

Standard value

+0/-4.0

39.7 MPa +0/-5.9

LH RH Forward Reverse Forward Reverse

a2

a1

a2

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29.0 MPa +4.0/-0

MR1

Measuring condition Sampling Atmospheric temp 50 °C (122 °F) ~ -10 °C (14 °F) Low throttle Full throttle (Hi idle) Perform all measurement with the air-conditioner "OFF" HI idle Boom up

MR1 OR3 OR4 OR1 OR2 OR7 OR8 OR5 OR6

Boom up Boom down Bucket digging Bucket dump Arm in Arm out Swing LH Swing RH

34.3 MPa +0.7/-0.5

34.3 MPa +0.7/-0.5

Simultaneous Operation of travel RH and LH

INTRODUCTION

Inspection Item Sprocket revolution (RH, LH)

1st speed

-

2nd speed

-

In Out Digging Dumping Up Down

Arm Operating time of Operating speeds cylinder

Bucket Positioner

Swing speed Travel speed

Performance

Measuring condition

Standard value

RH - LH 1st speed 2nd speed

Iron shoe Iron shoe

3.6 - 4.2 s 2.4 - 3.0 s 3.5 - 4.1 s 2.1 - 2.7 s 3.0 - 3.6 s 4.9 - 5.5 s 3.7 - 4.9 s per 1 revolution seconds per 3 revolutions

Amount of travel 2nd speed 0~240 mm / 20 m deviation Parking brake drift 15 ° Gradient 0 ° / 5 min Performance of Neutral position after 180 ° full speed 55 - 75 ° Swing brake swing Swing parking 0 mm 15° Gradient brake drift 90 mmper 5 min Tip of the bucket tooth Boom cylinder 6 mmper 5 min ATT amount of drift Arm cylinder 10 mmper 5 min Amount of horizontal play at the bucket tooth 30 - 50 mm

NOTE: Over load relief vales OR1~OR8 described in advance correspond to the following operations. 1. Bucket digging 2. Bucket dump 3. Boom up 4. Boom down 5. Swing left 6. Swing right 7. Arm in 8. Arm out RAPH12CEX1319AA

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1

(At no load)

At no load

CONSUMABLES INDEX Consumable Tutela Auto Supreme™ Engine oil SAE 10W-30 Tutela Hypoide EP Gear lube SAE 80W-90 CNH XHD Heavy Duty Coolant / Anti-freeze DEF/AdBlue®

Reference

PAGE

Capacities FLUIDS AND LUBRICANTS SK170-9

39


39


39


39

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SERVICE MANUAL Engine

SK170-9

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Contents Engine - 10

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 SK170-9

Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202 SK170-9

Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.216 SK170-9

Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254 SK170-9

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 SK170-9

Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500 SK170-9

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CONSUMABLES INDEX Consumable DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® Loctite® 262 Loctite® 262 DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue®

Reference Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Fuel tank - Install – Fuel Tank Radiator - Install Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve 47454079-DRAFT 06/11/2012

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PAGE 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.216 10.400 10.500 10.500 10.500 10.500 10.500 10.500 10.500

/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /

4 4 4 4 4 4 4 4 4 4 5 6 7 7 7 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 9 9 9 5 5 4 4 4 5 5 5 6

10.500 / 7 10.500 / 7 10.500 / 7 10.500 / 7 10.500 / 8 10.500 / 8

Consumable DEF/AdBlue® DEF/AdBlue® DEF/AdBlue®

Reference Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve

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PAGE 10.500 / 8 10.500 / 8 10.500 / 9

Engine - 10 Engine and crankcase - 001

SK170-9

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Contents Engine - 10 Engine and crankcase - 001

FUNCTIONAL DATA Engine Overview Selective Catalytic Reduction (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

SERVICE Engine Disconnect Preparation for removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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CONSUMABLES INDEX Consumable DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue®

Reference Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction Engine - Overview Selective Catalytic Reduction

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PAGE 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001

/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /

4 4 4 4 4 4 4 4 4 4 5 6 7 7 7 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 9 9 9

Engine - Engine and crankcase

Engine - Overview Selective Catalytic Reduction (SCR) [48866977] SK170-9 LA

Selective Catalytic Reduction (SCR) system is an after treatment method that cleans up emissions arising during the combustion process. A water based urea solution, and ammonium compound, is used as a reduction agent. The urea solution (marketed under the name DEF/ADBLUE® ) is injected into the exhaust flow entering the catalyst, which is integrated in the muffler. Diesel Exhaust Fluid DEF/ADBLUE® is a non-toxic aqueous urea solution (32.5%) with a slight ammonia odor used to chemically reduce NOx emissions from heavy duty diesel powered vehicles. DEF/ADBLUE® is neither explosive nor harmful to the environment and is classified under the minimum risk category of transportable fluids. When the process works as it should, the ammonium in the DEF/ADBLUE® solution reacts with the nitrogen oxides in the exhaust gases to form nitrogen and water. The engine can be optimized for fuel economy and the resulting NOx is cut by the catalyst. The DEF/ADBLUE® solution, which is highly corrosive, but otherwise fairly harmless, freezes at -11 Degrees Celsius. The tubes from the DEF/ADBLUE® tank to the catalyst are therefore double skinned to allow engine coolant to heat up the tubes as well as thaw the DEF/ADBLUE® tank if frozen. The main components of the SCR system include the SCR catalyst, the DEF/ADBLUE® injection unit, the DEF/ ADBLUE® tank, and the DEF/ADBLUE® dosing control unit. Exhaust System Specifications Max back pressure (after turbo) P10 at rated power with 16 kPa clean system Max exhaust gas temperature T10 at rated power 500 Deg C

RAPH12CEX0312FA

1

Exhaust System With SCR Layout

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RAPH12CEX0313GA

2

DEF/ADBLUE® Circuit Scheme

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DEF/ADBLUE® Tank

Supply Module

RAPH12CEX0314BA

3

Dosing Module

RAPH12CEX0315BA

4

RAPH12CEX0326BA

6

RAPH12CEX0328BA

8

Mixer Pipe

RAPH12CEX0325BA

5

NOx sensor ECU

NOx sensor

RAPH12CEX0327BA

7

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DEF/ADBLUE® Instrumentation Warning NOTE: The fuel system, exhaust after-treatment system, and engine on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only! Your machine is equipped with a warning system to inform the operator of the DEF/ADBLUE® level, system malfunctions, and engine power loss that may result from the SCR system for reducing exhaust emissions.

Warning symbols Engine power loss occurring

SCR failure

Engine stop

Low DEF/ADBLUE® level

DEF/ADBLUE®

Warning/Fault light

Stop engine light

DEF/AdBlue® level faults, failures and engine power loss levels Visual display Indicator light Indicator light Audible alarm Description warning status Active Active DEF/ADBLUE® level is less than 10 % of tank volume, refill DEF/ADBLUE® and reset the system by cycling the key switch OFF then ON. No engine power loss. Active Active DEF/ADBLUE® level is less than 5 % of tank volume, refill DEF/ADBLUE® immediately and reset the system by cycling the key switch OFF then ON. Up to 65 % torque reduction and 40 % engine speed reduction within 40 min of engine running time. Active Active DEF/ADBLUE® level has been empty for 60 min, refill DEF/ADBLUE® immediately and reset the system by cycling the key switch OFF then ON. Up to 80 % torque reduction and 40 % rated engine speed within 30 min of engine running time. Active Active Emergency re-start is active. No engine power loss. Engine will shutdown after 30 s of continued operation. Refill DEF/ADBLUE® immediately and reset the system by cycling the key switch OFF then ON.

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DEF/AdBlue® quality faults, failures and engine power loss levels Visual display Indicator light Indicator light Audible alarm Description warning status Active Active DEF/ADBLUE® quality/concentration is questionable. Drain DEF/ADBLUE® tank, clean and refill with approved DEF/ADBLUE® solution. No engine power loss. Active Active DEF/ADBLUE® quality/concentration is questionable 60 min after the initial warning. Drain DEF/ADBLUE® tank, clean and refill with approved DEF/ADBLUE® solution. Up to 65 % torque reduction and 40 % engine speed reduction within 40 min of engine running time. Active Active DEF/ADBLUE® quality/concentration is questionable 220 min after the initial warning. Drain DEF/ADBLUE® tank, clean and refill with approved DEF/ADBLUE® solution. Up to 80 % torque reduction within 30 min of engine running time. Active Active Emergency re-start is active. No engine power loss. Engine will shutdown after 30 s of continued operation. Contact you local authorized dealer for repair.

SCR system technical faults, failures and engine power loss levels Visual display Indicator light Indicator light Audible alarm Description warning status Active Active SCR fault/failure detected. Up to 25 % torque reduction within 25 min of engine running time. Contact your local authorized dealer for repair. Active

Active

Active

Active

Active

Active

SCR fault/failure detected 90 min after the initial warning Up to 65 % torque reduction and 40 % engine speed reduction within 40 min of engine running time. Contact your local authorized dealer for repair. SCR fault/failure detected 240 min after the initial warning. Up to 80 % torque reduction within 30 min of engine running time. Contact your local authorized dealer for repair. Emergency re-start is active. No engine power loss. Engine will shutdown after 30 s of continued operation. Contact you local authorized dealer for repair.

SCR system reset symbols and validation re-start counter Visual display Indicator light Indicator light Audible alarm Description warning status Active Active SCR system test in progress. Maintain current operating conditions. If all three validation re-starts have been used and the system has not been reset, the machine is limited to emergency re-starts only. See your local authorized dealer for repair.

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Resetting the Selective Catalytic Reduction (SCR) system After a failure or warning has been set, the SCR system must perform automatic tests to determine if failures or warnings have been resolved. The system must perform the following actions in order to recognize the resolved failures or warnings and reset itself. For DEF/ADBLUE® level warnings: • Key switch must be cycled OFF then ON. For poor DEF/ADBLUE® quality warnings: • Machine must be operated for approximately 20 minutes at a minimum of 50% load. For SCR system warnings, one of the following conditions must occur, depending on the exact cause of the warning: • Requires the machine to be operated for approximately 20 minutes at a minimum of 50% load to operate the SCR system. • Requires starting and running the engine, but does not require the SCR system to operate. • Requires the key switch to be cycled OFF then ON.

Validation Re-starts Validation re-starts allow operation of the machine for up to 30 minutes without power loss after a poor DEF/ADBLUE® quality or SCR system fault has been detected. Up to three re-starts are permitted. Re-starts are counted if either of the following conditions are met: • Engine speed exceeds 1000 RPM • Engine running time exceeds 5 minutes Normal operation will resume if a reset is detected within the 30 minute window. If a reset is not detected within a 30 minute window, power loss will occur as described in the table above. If all three validation re-starts have been used and the system has not been reset, the machine is limited to emergency re-starts only. See you local authorized dealer for repair.

Emergency Re-start NOTE: Emergency re-starts are only enabled after the allowable number of validation re-starts have expired. If full power loss is experienced, it may be impossible for the machine to move under its own power. Emergency re-starts are available to provide the capability to move the machine. • Allows 30 seconds of operation without power loss. • After 30 seconds, the engine shuts down automatically. • There is no limit to the number of emergency re-starts.

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Engine - Disconnect Preparation for removing [46306071] SK170-9 LA

1.

Remove battery ground.

2.

Remove bonnet and guard. Remove under cover.

3.

Remove air cleaner hose.

4.

Remove counterweight.

5.

Remove radiator hose and intercooler hose.

6.

Remove fuel hose and heater hose, and if necessary disconnect air conditioning hose.

7.

If necessary, remove pump, muffler and radiator.

8.

Remove harness connector. 1.

Remove E/G ground cable.

2.

Starter cable-Starter B terminal.

3.

Remove the connector that connects the upper harness with the engine and ECU harness.

4.

Upper harness P1 Alternator B terminal CN-160 E/G speed sensor CN-141, CN142 P1, P2 Pump proportional valve CN-139, CN-140 P1, P2 pump pressure sensor M-1 Starter motor C terminal

NOTE: Prepare a stand, which withstands the weight of the engine assembly and can place the removed engine firmly.

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RAPH12CEX0110GA

1

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Engine - Remove [46309064]

RAPH12CEX0111HA

1

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1.

Remove hose of engine oil filter. Place oil pan under the connection of filter (1) , and disconnect hoses (2) , (3) , at * positions

2.

Plug connector of filter side and hose.

3.

Remove hose of fuel injection pump. Place fuel pan under the connection of fuel injection pump (4) and disconnect hoses (5) .

ATTENTION: Pay attention during the disconnecting of the fuel hoses (fuel injection pump side) as the accidental fuel spillage can , going to contact with the hoses of the DEF/AdBlue® controller (supply module) and/or with the hoses of the DEF/AdBlue® shut off valve, could damage the hoses themselves causing leakages. To avoid the damage in case of disassembling, cover carefully the DEF/AdBlue® controller (supply module) and the hoses to it connected. 4.

5.

Loosen engine mounting bolt of frame. 1.

Loosen 4 nuts (6) M16

2.

Loosen 4 capscrews (7) M16.

3.

Remove 4 plates (8) and 4 covers (9) .

4.

Remove upper rubber mounts (10) and (11) 2 each.

Sling engine hooking wire to lifting lugs on the front and rear sides. Engine weight: Approximately 402 kg (886 lb) Lifting cable: 6 mm (0.24 in) x 1 m (3.3 ft) – 2 pieces.

ATTENTION: Prepare a stand, which withstands the weight of the engine assembly and can place the removed engine firmly. 6.

Position engine on the stand stably.

7.

Remove 4 rubber mounts (10) , (11) .

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Index Engine - 10 Engine and crankcase - 001 Engine - Disconnect Preparation for removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Engine - Overview Selective Catalytic Reduction (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - 10 Air cleaners and lines - 202

SK170-9

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Contents Engine - 10 Air cleaners and lines - 202

SERVICE Air cleaner Remove Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Install Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

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Engine - Air cleaners and lines

Air cleaner - Remove Air Cleaner [54408837] SK170-9 LA

Preparation for removal 1.

Open panel assembly (A) and (B).

2.

Open hood assembly (C).

Removal of air cleaner 1.

Unplug terminals on indicator wiring

2.

Loosen clips (1), (2) on both sides of hose (3).

3.

Pull out hose.

4.

Remove sems bolts (4) M10x25

5.

Remove air cleaner assembly (5) from bracket (6).

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Engine - Air cleaners and lines

Air cleaner - Install Air Cleaner [54408881] SK170-9 LA

Installation of the air cleaner 1.

Attach air cleaner using sems bolts (4) M10x25 to bracket (6).

2.

Tighten sems bolts to 39.2 N·m (29 lb ft).

3.

Attach hose (3) to the end of the air cleaner.

4.

Connect wire harness to indicator (7) on the air cleaner.

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Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Install Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Air cleaner - Remove Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Engine - 10 Fuel tanks - 216

SK170-9

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tank Remove – Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Install – Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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CONSUMABLES INDEX Consumable Loctite® 262

Reference Fuel tank - Install – Fuel Tank

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PAGE 10.216 / 5

Engine - Fuel tanks

Fuel tank - Remove – Fuel Tank [54310103] SK170-9 LA

1.


Unlock cap (1) with the ignition key and open it.

2.

Loosen valve (2) under the tank (3) and drain the fuel. Capacity of tank: 286 l (75.6 US gal)

3.

Loosen the machine screws (4) and remove the connector for the level sensor (5).

4.

Loosen the clip and pull out the hoses (6) and (7).

5.

Plug the ends of the hoses to prevent fuel leakage.

RAPH12CEX0580AA

1

RAPH12CEX0581AA

2

NOTE: Note location of shims before removing them in the next step. 2.

Removal of the fuel tank 1.

Remove capscrews (8) M16x40.

2.

Hook the lifting cable to the lifting eye on the fuel tank (3) and remove the fuel tank. Weight: 90.5 kg (199.5 lb)

3.

Remove shims (9).

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Engine - Fuel tanks

Fuel tank - Install – Fuel Tank [54310124] SK170-9 LA

NOTICE: If the gap between the tank mount and the frame exceeds 1 mm (0.04 in), adjust the gap with a shim (9) and tighten capscrews (8) to install the tank. 1.

Attach tank (3) to frame using the capscrews (8) M16x40, using LOCTITE® 262 on the threads.

RAPH12CEX0581AA

2.

Tightening torque: Item

Capscrew M16 Machine screw M5

Tightening torque Nm (lb ft) 196.4 - 235.6 N·m (144.9 - 173.8 lb ft) 1.76 - 2.16 N·m (1.3 - 1.6 lb ft)

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1

Index Engine - 10 Fuel tanks - 216 Fuel tank - Install – Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Fuel tank - Remove – Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

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Engine - 10 Intake and exhaust manifolds and muffler - 254

SK170-9

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Contents Engine - 10 Intake and exhaust manifolds and muffler - 254

SERVICE Exhaust muffler Remove Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Install Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

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Engine - Intake and exhaust manifolds and muffler

Exhaust muffler - Remove Muffler [55081113] SK170-9 LA


Remove hood assembly.

2.

Loosen capscrews (A) M12x25 and remove cover (B). Weight: 5 kg (11 lb)

RAPH12CEX0590AA

1

RAPH12CEX0591AA

2

Removal of muffler 1.

Remove two temperature sensor connectors (1).

2.

Remove NOx sensor connector (2).

3.

Remove clip (3).

4.

Remove sems bolts (4) M10x25.

5.

Separate two collars (5) from muffler (6).

6.

Remove muffler (6). Weight: 26.3 kg (58 lb)

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Engine - Intake and exhaust manifolds and muffler

Exhaust muffler - Install Muffler [55084163] SK170-9 LA

1.

Install muffler (6) by attaching two collars (5) around it.

2.

Secure two collars (5) using sems bolts (4) M10.25.

3.

Tighten clip (3) after inserting muffler inlet pipe into exhaust outlet pipe on engine.

4.

Insert NOx sensor connector into NOx sensor (2).

5.

Insert temperature sensor connectors into the temperature sensors (1).

RAPH12CEX0591AA

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1

Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust muffler - Install Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Exhaust muffler - Remove Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Engine - 10 Engine cooling system - 400

SK170-9

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Disconnect Preparation for removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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Reference Radiator - Install

PAGE 10.400 / 5

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Engine - Engine cooling system

Radiator - Disconnect Preparation for removal [46236268] SK170-9 LA

1.

Bleed air from the hydraulic oil tank and install the suction stopper.

2.

Remove bonnet assembly.

3.

Remove battery.

4.

Remove beam.

5.

Open panel assembly.

6.

Remove under cover installed on lower side of radiator.

7.

Drain the radiator. Put an 18 l (5 US gal) container under the drain valve to hold the drained coolant. Coolant capacity of the radiator: 6.6 l (1.7 US gal).

8.

Remove hose (1) from radiator sub tank (2) . Remove clip (3) of radiator cap side and disconnect hose (1).

9.

Disconnect hose (4).

ATTENTION: Do not loosen the joints of the hoses related to the air conditioner. Otherwise the refrigerant will leak.

10.

11.

RAPH12CEX0096BA

1

RAPH12CEX0097BA

2

Move air-conditioner condenser (5) and receiver tank (6) . 1.

Loosen 2 sems bolts (7) M8x25 and 2 semsbolts (8) M10x25.

2.

Move a set of air-conditioner condenser (5) and receiver tank (6) .

Disconnect connector of coolant level switch.

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Engine - Engine cooling system

Radiator - Install [46256992] SK170-9 LA

1.

Installing is done in the reverse order of removing. And removed clips of hose should be clamped at original position.

RAPH12CEX0103BA

2.

Install radiator assembly. Place a wire sling in the lifting eyes of the radiator and move it to original position temporally. And install hydraulic hose, radiator hose and hose of intercooler. Regarding inserting width of hose.

3.

Radiator attaching bolt. Apply LOCTITE® 262 on 4 sems bolts (30) M12X35.

4.

Adjust the clearance between the fan and the radiator shroud all around the circumference, as below: Back and forth: 20 to 25 mm (0.8 to 1 in)

5.

Clean the plastering area of the insulation thoroughly before plastering it.

6.

Mixing up hydraulic oil and LLC (Long Life Coolant). After completion of other installation, make up hydraulic oil and water.

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1

Index Engine - 10 Engine cooling system - 400 Radiator - Disconnect Preparation for removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

SK170-9

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Contents Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

SERVICE Diesel Exhaust Fluid (DEF)/AdBlue® tank Install – Installation of the tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Remove – Removal of the DEF/AdBlue® tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Coolant control valve Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

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CONSUMABLES INDEX Consumable DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue®

Reference Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve

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PAGE 10.500 10.500 10.500 10.500 10.500 10.500 10.500

/ / / / / / /

4 4 4 5 5 5 6

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Engine - Selective Catalytic Reduction (SCR) exhaust treatment

Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install – Installation of the tank [54228038] SK170-9 LA

1.

Tighten the plug (1) under the tank.

2.

Install the DEF/ADBLUE® tank and secure with bands (5), 2 screws (6) M10x16 and rubber washers (7).

3.

Install level sensor (3) and hose (4)

4.

Fill the DEF/ADBLUE® tank with 91 l (24 US gal) of the DEF/ADBLUE® fluid.

RAPH12CEX0579AA

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1


Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove – Removal of the DEF/AdBlue® tank [54227990] SK170-9 LA

1.

2.


Loosen plug (1) under the tank (2) and drain the DEF/ADBLUE® solution. Capacity of the tank: 91 l (24 US gal)

2.

Remove the connector for the level sensor (3).

3.

Pull out hose (4) and plug it with a plug that matches the hose bore.

Removal of the DEF/ADBLUE® tank. 1.

Remove the bands (5), screws (6) M10x16 and rubber bushings (7).

2.

Remove the DEF/ADBLUE® tank (2). Weight: 12.8 kg (28.2 lb) RAPH12CEX0579AA

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1


Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve [60451310] SK170-9 LA

1.

Loosen capscrews (1) M12x40 and remove under cover (2).

RAPH12CEX1115AA

1

RAPH12CEX1116AA

2

RAPH12CEX1117AA

3

Removal of the DEF/ADBLUE® supply module filter 1.

Use a suitable container to catch any fluid that is discharged during the hose and filter disassembly. Disconnect the supply line (3) by pressing the tabs on the fitting and pulling downward.

2.

Unscrew the supply module filter housing (4) using a 32mm wrench.

3.

Unscrew the supply module filter (5) from its housing (4). Discard the filter following local environmental and waste regulations.

4.

Inspect the filter housing and o-ring for damage. Clean the housing with a damp cloth.

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Removal of the DEF/ADBLUE® shut-off valve 1.

Remove the hoses (6) and (7).

2.

Loosen capscrews (8) M8x65

3.

Remove the DEF/ADBLUE® shut-off valve (9) from the supply module (10).

RAPH12CEX1118AA

4

RAPH12CEX1119AA

5

Removal of the DEF/ADBLUE® supply module 1.

Loosen capscrews (11) M8x25.

2.

Remove DEF/ADBLUE® supply module (10).

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Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve [60462982] SK170-9 LA

Installation of DEF/ADBLUE® supply module 1.

Install DEF/ADBLUE® supply module (10), tightening capscrews (11) M8x25.

RAPH12CEX1119AA

1

RAPH12CEX1118AA

2

Installation of the DEF/ADBLUE® shut-off valve 1.

Install DEF/ADBLUE® shut-off valve (9) onto the supply module (10), tightening capscrews (8) M8x65.

2.

Install hoses (6) and (7)

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Installation of the DEF/ADBLUE® supply module filter 1.

Install the new filter onto the filter housing by screwing it on manually.

2.

Install the filter onto the supply module using a 32 mm wrench. Torque to 20 N·m (14.75 lb ft).

3.

Connect the supply line (3).

4.

Start the engine and run at idle speed. Check for leaks.

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RAPH12CEX1117AA

3

RAPH12CEX1116AA

4

Index Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500 Coolant control valve - Install – DEF/AdBlue® Supply Module, Filter and Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Coolant control valve - Remove – Removal of DEF/AdBlue® Supply Module, Filter and Shut-Off Valve . . . . . . . . 6 SK170-9 LA

Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install – Installation of the tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove – Removal of the DEF/AdBlue® tank . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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CNH - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2012 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

KOBELCO policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your KOBELCO Dealer.

47454079-DRAFT 06/11/2012 EN

SERVICE MANUAL Hydraulic systems

SK170-9

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Contents Hydraulic systems - 35

Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000 SK170-9

Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106 SK170-9

Charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.105 SK170-9

Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300 SK170-9

Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.322 SK170-9

Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.352 SK170-9

Hydraulic travel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.353 SK170-9

Hydraulic central joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.354 SK170-9

Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357 SK170-9

Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359 SK170-9

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CONSUMABLES INDEX Consumable Loctite® 262 Loctite® 262 Permatex® Form-A-Gasket® No. 2 Sealant Tutela Hypoide EP Gear lube SAE 80W-90 Tutela Multi-purpose EP grease 251H, GR-9 Loctite® 515 Loctite® 515 Loctite® 515 Loctite® 262 Loctite® 243 Loctite® 242 Loctite® 242 Loctite® 277

Reference

PAGE

Variable displacement pump - Assemble Oil reservoir - Install Hydraulic Oil Tank Oil reservoir - Install Hydraulic Oil Tank

35.106 / 7 35.300 / 8 35.300 / 10

Hydraulic swing system - Overview Hydraulic Swing Motor and Reduction Unit Hydraulic swing system - Overview Hydraulic Swing Motor and Reduction Unit Swing reduction gear - Assemble Swing reduction gear - Assemble Swing reduction motor - Install Swing reduction motor - Install Hydraulic travel system - Assemble Travel Motor Hydraulic swivel - Assemble Hydraulic swivel - Assemble Pilot control manifold - Assemble Right and Left Pilot Valve

35.352 / 5

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35.352 / 5 35.352 35.352 35.352 35.352 35.353 35.354 35.354 35.357

/ / / / / / / /

26 30 32 32 69 19 19 14

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Hydraulic systems - 35 Hydraulic systems - 000

SK170-9

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Contents Hydraulic systems - 35 Hydraulic systems - 000

TECHNICAL DATA Hydraulic systems General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

FUNCTIONAL DATA Hydraulic systems Overview – Hydraulic Cylinders Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Hydraulic schematic frame 01 – Hydraulic Circuit Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic schematic frame 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

Hydraulic schematic frame 04 – 4. HOLDING VALVE FOR BOOM AND ARM (OPTION) . . . . . . . . . . . 19 SK170-9 LA

Hydraulic schematic frame 05 - PROPORTIONAL HAND CONTROL EXTRA HYDRAULIC CIRCUIT WITH PRESSURE UNLOAD (UNLOAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SK170-9 LA

Hydraulic schematic frame 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SK170-9 LA











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Overview Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SK170-9 LA

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Hydraulic systems - Hydraulic systems

Hydraulic systems - General specification [62558414] SK170-9 LA

Hydraulic Components Hydraulic Pump Item Pump Type Max. displacement capacity Revolution

Rated

Pressure

Rated ATT boost

cm³ RPM (Clockwise seen from shaft end) MPa (psi)

Max. flow

l/min (gpm)

Max. input power (at 2200 rpm) Max. input torque (at 1600 rpm)

kW (PS) N·m (lb ft) Model Control Function Others

Regulator

Mass

kg (lb)

Main pump Gear pump for pilot K5V80DTP1KBR-0E02-PV ZX10LGRZ2-07G Variable displacement plunger Fixed displacement type gear pump: regulator attached type pump 80 (4.88) x 2 10 (0.6) <—

2200

34.3 (4980) 5.0 (725) 37.8 (5480) 176 (46.5) x 2 at 7.8 MPa 22 (5.8) (1130 psi) 91.9 (125) 3.2 (4.3) 399 (295) 15 (11) KR38-0E02-V Electric flow control, positive flow control, total power control at emergency mode and power shift control With solenoid proportional reducing valve (KDRDE5K-31/ 30C50) 89.5 (197.3)

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump. Control Valve Item Model Max. flow rate Main relief valve set pressure Main relief valve set pressure when using power boost Over load relief valve set pressure: Boom H, Bucket H, Arm R Over load relief valve set pressure:Boom R, Bucket R, Arm H Item Model Over load relief valve set pressure: Positioner R Over load relief valve set pressure: Positioner H Mass

l/min (GPM) MPa (psi)

STD Valve KMX13YD/B44161 176 (46.5)x 2 34.3 (4970) at 60 x 2 L/min (15.9 x 2 gal/min)

MPa (psi)

37.8 (5480) at 55 x 2 L/min (14.5 x 2 gal/min)

MPa (psi)

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

MPa (psi)

37.8 (5480) at 30 L/min (8 gal/min) OPT Valve KADV22Y / 501103A

MPa (psi)

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

MPa (psi)

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

kg (lb)

11 ( 24.2)

Pilot Valve Item Model Primary pressure Secondary pressure Rated flow Mass

Attachment PV48K2058 5.0 MPa (725 psi) 0.6 ~ 3.2 MPa (87 ~ 464 psi) 20 L/min (5.3 gal/min) Approx. 2 kg (4.4 lb) 47454079-DRAFT 06/11/2012

35.000 / 4

Travel 6TH6NRZ 4.9 MPa (710.5 psi) 0.54 ~ 2.35 MPa (78.3 ~ 340.7 psi) 25 L/min (6.6 gal/min) Approx. 8 kg (17.6 lb)


Swing Motor Unit Model Type

M5X130CHB–10A–598/285-122 Swash-plate type, fixed-displacement plunger motor cm³ (in³) 121.6 (7.42) MPa (psi) 34.3 (4974) l/min (GPM) 143 (37.8) N·m (lb ft) 583–818 (430–603) MPa (psi) 2.3~5.0 (333~725) MPa (psi) 28 (4060) kg (lb) 47 (104) 2KAR6P72/240-712 kg (lb) 2.5 (5.5) kg (lb) 51.5 (114) Planetary 2-stage 15.378 Gear oil SAE90 (API class GL–4 grade) l (gal) 2.7 (0.7) Extreme pressure lithium base # 2 grease kg (lb) Approx. 0.7 (1.5) kg (lb) 134.5 (295) kg (lb) Approx. 181.5 (400)

Displacement Working pressure Hydraulic motor Max. flow Braking torque Release pressure Relief set pressure Mass Type Anti-reaction valve block Mass Hydraulic motor assembly mass Speed reduction type Reduction ratio Lubricate oil Lubricate oil volume Reduction Unit Grease Grease volume Mass Total mass Travel Device Item

SK170–9 Epicycloidal, two-stage planetary type 710 C3 K 1 : 63.1 Two speed, axial piston swash plate type 50.4 cm³ (3.1 in³) 87.3 cm³ (5.3 in³) 130.4 L/min (34.45 gal/min) 17368 Nm (12809 lbf·ft) 30087 Nm (22189 lbf·ft) 234 Nm (173 lbf·ft) 194 Nm (143 lbf·ft) 14 bar (207 psi) 311 bar (4593.4 psi) at 1.2 L/min (0.32 gal/min) 353 bar (5213.7 psi) at 40 L/min (10.6 gal/min) 245 kg (540 lbs)

Reduction gear unit Model Gearbox ratio Travel motor high speed low speed

Displacement Max. flow Max. gearbox outputtorque Parking brake torque

high speed low speed static dynamic

Min. pressure parking brake release Relief valve set pressure

cracking total flow

Mass Cylinders

Use

Boom Arm Bucket Positioning

Cylinder bore /Rod Dia. (mm (in)) Ø 110 / Ø 80 (4.33 / 3.15) Ø 125 / Ø 90 (4.92 / 3.54) Ø 105 / Ø 75 (4.13 / 2.95) Ø 135 / Ø 85 (5.31 / 3.35)

Stroke (mm (in)) 1170(46.06) 1290 (50.79) 1025 (40.35) 1012(39.84)

Center distanceof pinsFull extend B /Full retract A (mm (in)) 2840 / 1670 (111.81 / 65.75) 3060 / 1770 (120.47 / 69.68) 2565 / 1540 (100.98 / 60.63) 2555 / 1543 (100.59 / 60.75)

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Cushion

With cushion on rod side With cushion on both sides With cushionon rod side Without cushion

Mass (kg (lb)) 150 (331) 194 (428) 128 (282) 196 (432)


Hydraulic systems - Overview – Hydraulic Cylinders Construction [60825940] SK170-9 LA

General View

RAPH12CEX1274FA

1

Specifications Use Boom

Cylinder bore / Stroke Rod diameter 110 mm (4.33 in) 1170 mm (46.06 / 80 mm (3.15 in) in)

Arm

125 mm (4.92 in) 1290 mm (50.79 / 90 mm (3.54 in) in)

Bucket

105 mm (4.13 in) 1025 mm (40.35 / 75 mm (2.95 in) in)

Length A / Length B 2840 mm (111.81 in) / 1670 mm (65.75 in) 3060 mm (120.47 in) / 1770 mm (69.68 in) 2565 mm (100.98 in) / 1540 mm (60.63 in)

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Cushion

Dry weight

With cushion on rod side

150 kg (331 lb)

With cushion on both sides

194 kg (428 lb)

With cushion on rod side

128 kg (432 lb)


Construction – Boom Cylinder

RAPH12CEX1275GA

12345678-

Rod assembly Tube assembly Rod seals Head assembly Backup ring + o-ring Seal cushion Screw; M14x2 171 N·m (126 lb ft) Ring cushion

910111213141530-

2

Piston seals Piston Nut; M58x3 3790 N·m (2795 lb ft) Shim Screw; M12x1.75 46.2 - 67.6 N·m (34.1 - 49.9 lb ft) Steel ball Grease fitting; M10x1 Wiper

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Construction – Arm Cylinder

RAPH12CEX1276GA

12345678910-

Rod assembly Tube assembly Rod seals Head assembly Backup ring + O-ring Cushion seal Screw; M16x2 267 N·m (197 lb ft) Cushion ring Piston seals Piston; M65x3 8200 N·m (6048 lb ft)

121314151718192030-

3

Shim Screw; M12x1.75 46.2 - 67.6 N·m (34.1 - 49.9 lb ft) Steel ball Grease fitting Cushion ring Cushion seal Stopper Collar Seals kit

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Construction – Bucket Cylinder

RAPH12CEX1277GA

123456789-

Rod assembly Tube assembly Rod seals Head assembly Backup ring + O-ring Cushion seal Screw; M14x2.5 171 N·m (6048 lb ft) Cushion ring Piston seals

1011121314151630-

4

Piston Nut; M52x3 4810 N·m (3547 lb ft) Shim Screw; M12x1.75 46.2 - 67.6 N·m (34.1 - 49.9 lb ft) Steel ball Grease fitting M10x1 Grease fitting M10x1 Seals kit

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Hydraulic cylinder construction (for boom, arm and bucket cylinders) By construction the hydraulic cylinder consists mainly of cylinder tube assy (1) , piston rod assy (2) that takes out the motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide. Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts. In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube assy (1) and piston rod assy (2) ; buffer ring (6) , U ring (7) back-up ring (8) and wiper ring (9) are located between piston rod assy (2) and cylinder head (3) ; and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy (1) and cylinder head (3) .

Operation If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on the piston which in turn causes the piston rod (2) to extend and retract.

Operation of cylinder with cushion CUSHION ON ROD SIDE The cushion mechanism is provided to prevent the generation of shock when the moving speed of piston (15) is not reduced and strikes cylinder head (3) . An oil in chamber "A" returns to the tank by passing through paths "B" at a fixed flow rate in a intermediate stroke state of pressing bottom side.

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Next, in a state of just before stroke end, cushion ring (13) plunges into path "B". At this time, an oil in chamber "A" passes clearance "D" and mouth gap "C", an oil flow volume returning to tank suddenly drops and the piston part movement slows down.

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CUSHION ON HEAD SIDE This construction is similar to the one of cushion on rod side. In a state of intermediate stroke pressing rod side, an oil in chamber "A" returns to tank by passing through path "B" at a fixed flow rate. Next, in a state of just before stroke end, cushion bearing (23) plunges into path "B". At this time, an oil in chamber "A" path clearance "D" and cushion seal (24) are mouth gap "C", an oil flow volume returning to tank suddenly drops and the piston part movement slows down.

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7


Hydraulic systems - Hydraulic schematic frame 01 – Hydraulic Circuit Summary [60946259]

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Hydraulic systems - Hydraulic schematic frame 02 [60952940] SK170-9 LA

Hydraulic Diagram Reading Key Item Component name 1 Hydraulic pump assembly 2 Control valve (main) 3 Swing motor unit 4 Travel motor unit 5 Boom cylinder (RH&LH) 6 Arm cylinder 7 Bucket cylinder 8 Swivel joint 9 Pilot valve (ATT) 10 Pilot valve (travel) 11 Inline filter 12 Suction strainer 13 Solenoid valve assembly 14 Return filter 15 Air breather 16 Restrictor 17 Shuttle valve 18 Short-circuit valve 19 Low pressure sensor block

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Performance

Device Travel

Function • Travel straight

Features • Travel straight at combined operation

• Travel 2-speed change & • 1-2 travel speed change and low Auto 1st (low) speed return speed / high torque at heavy duty • Auto parking brake

• Automatic braking when parking

• Motor overrun protection

• Prevents overrunning of travel motor on the down hill slope

• Travel pilot operation Swing

Performance Mass handling capability

Attachment

• Swing priority circuit (simulta- • Easy operation of stable swing speed, neous operation of arm in and arm slanted leveling, swing press digswing motions) ging

Attachment

• Pilot safety lock system • Lock valve (boom / arm)

• Cut out of pilot circuit by safety lock lever.

Others

• • • • • • • •

• Boom up conflux circuit

• Speed up of boom up operation

• Arm conflux circuit

• Speed up of arm operation

• Bucket conflux circuit

• For speed up of bucket operation (digging & dump)

• Optimum operation by work mode select (H,S) • Efficient operation in all work modes Low fuel consumption

Protect boom and arm from unex• Holding valve for boom (Op- • pected drop (Natural fall) tion) Prevention of boom falling when boom • Emergency manual valve for • head side piping breaks lowering attachment

Easy operability and safety

Function Features • Electric flow controlled variable displace- • Pump delivery rate control by a current command to the solenoid proportional valve ment pump of the variable displacement pump • Positive flow rate control • Flow control by positive pilot control pres• Hydraulics backup control sure • Backup control by hydraulic when the electric flow controlled variable displacement pump fails.

• Prevents hunting by the built in travel shockless mechanism • Reverse rotation protective • Easy positioning to protect it from function swinging back when stops swinging

• Automatic swing parking • Swing parking brake when operating brake on a slope Hydraulic pilot control system • • Light action with operating lever

Device Pump

• For safety, this valve lowers risen attachment to the ground, if the machine stops with engine trouble, and the pressure in the cylinder of the attachment can be released. Pressurized hydraulic oil tank • To prevent hydraulic oil from entering dust and to promote self suction ability Suction strainer of pump Line filter; pilot circuit • Remove dust on suction side Return circuit oil filter • To prevent pilot operation circuit from Cooling hydraulic oil by oil malfunctioning cooler • To prevent hydraulic oil from contamiPressure draining circuit nation Main control valve with op- • To prevent hydraulic oil from deteriotional valve rating Switching of return line for • To release the main circuit pressure N&B machine in the cab (Op- for piping repair work tion) • Optional piping and additional work are easy • Switching of return line for N&B machine is able to change with a switch in the cab

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Micro Computer • Auto accel

• Reduce fuel consumption and noise by lowering engine speed when control lever is in neutral position


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Hydraulic systems - Hydraulic schematic frame 04 – 4. HOLDING VALVE FOR BOOM AND ARM (OPTION) [60985506] SK170-9 LA

HOLDING VALVE FOR BOOM The holding valve for boom prevents the boom from falling in case the head side of the cylinder piping breaks. HOLDING VALVE FOR ARM The holding valve for the arm prevents the arm from falling in case the rode side of the cylinder piping breaks. Item 54 55

Component name Holding valve for boom cylinders Holding valve for arm cylinder

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Hydraulic systems - Hydraulic schematic frame 05 PROPORTIONAL HAND CONTROL EXTRA HYDRAULIC CIRCUIT WITH PRESSURE UNLOAD (UNLOAD) [60995338] SK170-9 LA

EXTRA HYDRAULIC CIRCUIT READING KEY Item 57 58 59 60 61

Name of component Gear pump Control valve Solenoid valve Solenoid valve Shuttle valve

The extra hydraulic circuit with pressure unload is added to the standard hydraulic system.

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7. COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS Blue • Feed, drain circuit less than 0.44 MPa (64 psi) Green • Return, make up circuit, 0.44 - 0.59 MPa (64 - 86 psi) Purple • Secondary pilot pressure, (including proportional valve) 0.59 - 5 MPa (86 - 725 psi) Red • Primary pilot pressure, (including proportional valve) 5 MPa (725 psi) Orange • Main pump drive pressure, 5 - 34.3 MPa (725 - 4975 psi) Blue tone • At valve operation Red valve • When solenoid proportional valve (reducing) is operating Red solenoid • In active and exciting Displaying the flow circuit and standby circuit when operation. Regarding the electrical symbols in this manual refer to the electric circuit diagram.

8. NEUTRAL CIRCUIT This section describes the following: 8.1 Bypass cut valve and unload valve control 8.2 Safety lock lever and pilot circuit 8.3 Pump positive flow control 8.4 Pump P-Q (Pressure-Quantity) curve control

8.1 OPERATION OF BY-PASS CUT VALVE AND UNLOADING VALVE HOUSED IN CONTROL VALVE 1. Unloading valve On staring engine, like by-pass cut valve, the secondary pressures output by P1 and P2 unloading proportional valves (PSV-D, PSV-B) exert on PCb and PCa ports, consequently the P1 and P2 unloading valves are switched to OPEN side. 47454079-DRAFT 06/11/2012

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2. By-pass cut valve When machine is under normal conditions, bypass cut valve is closed normally. If pilot pressure sensor or unloading proportional valve is disconnected or malfunctioned, the unloading valve closes completely. Even if control valve is in neutral position, hydraulic oil is trapped. As a result, the pump relieves due to >pressure increase. In such the case, before the machine is repaired, open the by-pass cut valve manually. And the machine is operable by draining excess oil to hydraulic tank.

8.2 SAFETY LOCK LEVER AND PILOT CIRCUIT 1. Purpose: To protect attachment from unexpected movement for safety. 2. Principle: Cut pressure source of pilot valve for operation. 3. Operation: If the safety lock lever (red) is pushed forward after the engine starts, the limit switch (SW-11) is turned on. The timer relay is actuated one second later which causes the solenoid (SV-4) of the solenoid valve block (13) to be energized and makes the pilot operating circuit to stand by.

8.3 PUMP POSITIVE FLOW CONTROL 1. Type: Electric flow controlled variable displacement pump. 2. Principle: The current command I to the pump’s solenoid proportional valve controls the delivery rate of the pump. 3. Operation 1. Flow rate rise operation (Eg. P1 pump) By operating any of control levers, the operating secondary pressure of pilot valve rises, and the rising pressure is transformed to the rise of output voltage corresponding to the pressure input by the low pressure sensor. Mechatro controller signalprocesses this change of voltage, resulting in rise of command current value I to the pump proportional solenoid valve and consequently the pump flow rate rises. This is called "Positive Control System". As the pump command current value rises, the secondary pressure of proportional solenoid valve also rises. On the regulator attached on the pump, the spool (652) through piston (643) is pushed leftward, and stops at the position where being in proportion to the force of pilot spring (646). The tank port connected to the large bore of servo piston (532) opens, and the piston moves leftward by delivery pressure P1 of the small bore resulting in the increase of tilt angle. The servo piston (532) and spool (652) are connected to feedback lever (611). Therefore when servo piston moves leftward, the spool (652) also moves rightward by means of feedback lever. With this movement, the opening of spool sleeve closes gradually, and the servo piston stops at the position the opening closed completely. 2. Flow rate reduction operation As the current value I of mechtro controller reduces, the secondary pressure of solenoid proportional valve reduces, and spool (652) is moved rightward by the force of pilot spring (646). With the movement of spool, the delivery pressure P1 usually flows into the large bore of piston through the spool The delivery pressure P1 flows in the small bore of servo piston, but the servo piston moves rightward due to the difference of area, resulting in the reduction of tilt angle. Similarly, when the servo piston moves rightward, the spool (652) is moved leftward by the feedback lever. The operation is maintained until the opening of spool sleeve is closed.

8.4 PUMP P-Q CURVE CONTROL OPERATION 1. Type: Electrical flow control type variable pump. 2. Principle: Perform an operation of the value from pump high pressure sensor to P-Q curve control value, and send a command to the pump solenoid proportional valve. 3. Operation: The pump high pressure sensor converts the pressure to the output voltage corresponding to the pump delivery pressure. The mechatro controller converts the voltage output by the high pressure sensor to the P-Q curve control value. On the other hand, select the pump positive control command current value from the low pressure sensor in lower order, and the values are output to respective pump proportional valve as a command current. With this operation, the pump power is controlled so as not to be exceed the engine power, therefore engine dose not stall.

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NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unlocked position)

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9. TRAVEL CIRCUIT This section describes the following: 9.1 Travel forward pilot simultaneous operation circuit 9.2 2 speed travel solenoid command circuit and auto 1–speed return function Travel main circuit 9.4 Travel motor function

9.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT 1. Purpose: Light operating force and shockless operation. 2. Mechatronics: 1. If the travel lever with damping mechanism is operated for travel right, left and forward motions, the secondary pilot proportional pressure comes out of the 3, 1 ports of P/V (10). The higher of the pressures is selected, comes out of the 6, 5 ports and acts upon the low pressure sensors (SE-9) (SE-10). 2. The pilot secondary pressure flows to PAr and PAL ports of the control valve (2), moves the travel spool, and switches the main circuit. 3. The low pressure sensor output voltage is input into mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase of flow rate to P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2), and at the same time the command current is output to P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B). 4. The secondary pressures output by P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exert on pump regulator, actuating the pump on the delivery flow rate increase side. 5. The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is fed to PCb and PCa ports provided in control valve (2). The secondary pressure from proportional valve which has exerted on PCb and PCa ports switches the unloading spool in CLOSE side.

9.2 TWO–SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN FUNCTION 1. Purpose: Change travel motor speed with switch. 2. Principle: If the switch is turned, an electric signal is issued. It excites the 2-speed travel solenoid which in turn converts the primary pilot pressure and the self pressure to a tilting angle of the variable displacement motor. 3. Operation: If the rabbit marked switch on the gauge cluster is pressed, the solenoid (SV-3) of the proportional valve block (13) is excited and changes the proportional valve. Then the solenoid command pressure is issued from port A3, enters the Ps port of the travel motor (4), opens the oil passage to the 2nd speed select piston, and causes the motor to run in the 2nd speed tilting mode by its self pressure. However, when the main circuit pressure rises above 27.3 MPa (3960 psi), the motor’s self pressure pushes the 2nd speed select piston back to the 1st speed.

9.3 TRAVEL MAIN CIRCUIT 1. Operation: The delivery oil from Pump A1 and A2 ports by changing the travel spool with the operation of travel pilot flows into P1 port on the left side motor (4) and P2 port on the right side motor (4) through C,D ports of swivel joint (8) from AL, AR ports of C/V, and rotates the travel motor.

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9.4 TRAVEL MOTOR FUNCTION 1. Function 1. Prevents the motor from over running on a slope. 2. Check valve that prevents cavitation of the hydraulic motor. 3. Shockless relief valve and anti cavitation valve when inertia force stops. 4. High/Low 2 step speed change mechanism and auto 1st speed return at high load. 5. Travel parking brake.

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TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation

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10. BUCKET CIRCUIT This section describes the following: 10.1 Bucket digging pilot circuit 10.2 Auto accel operation 10.3 Flow control in the work mode 10.4 Bucket digging travel priority main circuit 10.5 Bucket spool stroke limiter

10.1 PILOT CIRCUIT FOR BUCKET DIGGING 1. Mechatronics 1. When the operation for bucket digging is performed, the pilot proportional secondary pressure is delivered through port 1 of the right pilot V (9), flows to PAc port, and acts on the low pressure sensor (SE-1), and at the same time the bucket spool is switched. 2. The voltage output by low pressure sensor (SE-1) inputs in mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase of pump flow rate to pump proportional valves (PSV-P1) and (PSV-P2) on the P1 and P2 pump sides, and at the same time the command current is output to P1 unloading valve (PSV-D), P2 unloading valve (PSV-B) and travel priority proportional valve (PSV-C). In the following pages, the relation of operation of low pressure sensor to both the increase of pump flow rate and unloading proportional valve is the same. Therefore the explanation is omitted. 3. The secondary pressure output by P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exerts on pump regulator, actuating the pump onto the delivery flow increase side. 4. The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is led to PCb and PCa ports provided in control valve (2). The secondary pressure from proportional valve which has exerted on PCb and PCa ports switches the unloading spool in CLOSE side. 5. The secondary pressure delivered in travel priority proportional valve (PSV-C) is led to PTb port provided in control valve (2) and shifts the travel priority valve one stage.

10.2 AUTO ACCELERATION OPERATION 1. Principle: Auto acceleration actuates according to signals from low pressure sensor. 2. Operation: 1. When lever is set to neutral position: In the event where the sensor does not receive signal for 4 seconds or more even though the acceleration dial is set to MAX position, the engine speed should be raised to 1000 rpm. 2. When lever is operated: When the pressure 0.6MPa (87psi) is input to low pressure sensor in STD specification (travel, bucket, swing, arm), proportional voltage from low pressure sensor inputs in mechatro controller, and then the engine speed returns to the dial set position corresponding to the lever operation.

10.4 BUCKET DIGGING AND TRAVEL PRIORITY CONFLUENCE (CONFLUX) MAIN CIRCUIT 1. Operation: 1. The oil delivered through A1 port of P1 pump goes into P1 port of C/V (2), opens load check valve LCc through parallel circuit and enters in bucket spool.

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2. On the other hand, the oil delivered through A2 port of P2 pump goes into P2 port of C/V (2), confluences with oil from P1 pump through travel priority valve, and goes into bucket spool. (Confluence of oil from 2 pumps) 3. With the function of pilot circuit, the oil flow is switched from bucket spool, and is fed into bucket cylinder head side through Ac port of C/V (2). On the other hand, the return oil from cylinder rod (R) side is throttled by bucket spool and returns to tank circuit from Bc port of C/V (2). 2. References: • In bucket dumping operation, the travel priority valve also switches like digging operation, resulting in confluence with travel straight. • When the bucket operation and other operation are simultaneously performed, the travel priority valve does not actuate, resulting in single flow of bucket circuit.

10.5 BUCKET SPOOL STROKE LIMITER 1. Purpose: To secure simultaneous operability of boom and arm and to prevent cavitations at low engine speed 2. Operation: On boosting up attachment pressure, pilot primary pressure exerts on PCc port of C/V(2) through attachment booster solenoid valve, operates stroke limiter of bucket spool, and throttle oil path of spool. As a result, P1 pump pressure increases, making the simultaneous operation of boom up and bucket digging possible. Even though the engine speed is low, similarly the cavitations can be prevented by actuating the stroke limiter.

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BUCKET CIRCUIT: Bucket digging (Travel priority conflux), Auto-accel and standby flow rate constant control

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11. Boom Circuit This section describes the boom raise conflux operation. 11.1 Boom up pilot circuit 11.2 Boom up 2 pumps conflux main circuit in C/V

11.1 Boom Raise Pilot Circuit 1. Operation: 1. If boom up operation is performed, the secondary pilot proportional pressure from the right pilot valve (9) gets out of port 4 and acts upon the low pressure sensor (SE3). At the same time, the pressure acts upon the PAb and PB1 ports. 2. The secondary pressure which enters the PAb port of C/V (2) shifts the boom spool. The secondary pressure which enters the PB1 port shifts the boom conflux spool.

11.2 Boom Up 2 Pumps Conflux Main Circuit In C/V 1. Purpose: Boom up speed up 2. Principle: Confluxing oil from 2 pumps 3. 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 LCb through parallel circuit and flows into boom spool. 2. Then the oil passes through boom spool, opens lock valve of boom lock valve CRb, 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 CCb 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.

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This section describes boom lower operation. 11.3 Boom down pilot circuit. 11.4 Prevention of natural fall by lock valve and actuation at lowering. 11.5 Constant recirculation function of boom down main circuit.

11.3 Boom Down Pilot Circuit Operation: 1. If the boom down operation is performed, the secondary pilot proportional pressure comes out of port 2 of the 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 proportional secondary pressure fed into C/V (2) PBb port and branches off in two lines and switches boom spool and releases boom lock valve.

11.4 Prevention of Natural Fall By Lock Valve and Actuation At Lowering 1. Purpose: Prevention of natural fall when the lever is neutral. 2. Principle: The oil is prevented from returning to the boom spool by the poppet seat of the boom lock valve. 3. Operation: In the boom down action, the selector valve is changed over by the secondary proportional pressure of PBb port. Then the poppet spring chamber of the lock valve CRb gets through the drain line (Dr) and makes the lock valve poppet open. 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.

11.5 Constant Recirculation Function Of Boom Down Main Circuit 1. Purpose: Prevention of cavitation during boom lowering motion. 2. Principle: The oil returning from the boom cylinder head (H) is recirculated to the rod (R). 3. Operation: When the oil is supplied to the boom cylinder rod (R) side during boom down operation, the boom moves faster than it should do in some cases by the self weight of the attachment. On that occasion, the circuit pressure on the rod (R) side is on the negative side. The oil supplied to the boom cylinder rod (R) flows into the A1 port of the P1 pump and the P1 port of C/V. The oil then passes through the boom spool and goes out of the Bb port. On that occasion, the oil returning from the head (H) goes through the recirculation path in the boom spool, pushes the check valve in the spool open, is recirculated to the Bb port and is supplied to the rod (R). When the (R) pressure is larger than the head (H) pressure, the check valve in spool closes. Thereupon, the recirculation is stopped.

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12. Swing Circuit This section describes the following operations: 12.1 Swing left pilot circuit 12.2 Swing auto parking brake 12.3 Swing main circuit 12.4 Swing motor circuit

12.1 Pilot Circuit For Left Swing 1. Operation: 1. When the left swing operation is performed, the pilot proportional secondary pressure is delivered through port (1) of left pilot V (9), and the secondary pressure acts on PBs port of C/V (2), and simultaneously flows out from Pss port of C/V and acts on low pressure sensor (SE-5). 2. The voltage output by the low pressure sensor is input in the mechatro controller, and is signal-processed. 3. Then, the secondary pressure led into PBs port of C/V (2) switches the swing spool.

12.2 Swing Auto Parking Brake 1. Purpose: Swing lock in neutral position and parking 2. Principle: Release mechanical brake only when required to operate swing arm in. 3. 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-5, 7). 3. The swing parking solenoid (SV-1) is excited five seconds after the pressure of the swing low pressure sensors (SE-5) 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.

12.3 Swing Main Circuit Operation: The oil delivered from the A2 port of the P2 pump enters the P2 port of C/V (2) and is branched off into the bypass line and the parallel circuit. However, since the bypass line is closed as the swing spool is shifted, the oil pushes the load check valve LCs open through the parallel circuit, enters the B port of the swing motor via the Bs port of C/V (2), and rotates the swing motor counterclockwise.

12.4 Swing Motor Circuit 1. Anti cavitation circuit at swing deceleration 2. Shockless relief valve that prevents the swing motor from being reverse.

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13. Arm Circuit This section describes the following operations: 13.1 Arm in, Light-load operation pilot circuit 13.2 Arm in, light-load variable normal recirculation main circuit / internal conflux circuit

13.1 Arm In, Light-Load Operation Pilot Circuit 1. Purpose: Speed-up and Anticavitation when the arm is at light load. 2. Principle: The oil returning from the arm cylinder rod (R) is recirculated variably to the head (H) at arm 2 spool in C/V. 3. 1. When the arm in operation is performed, the secondary pilot proportional pressure gets out of port 4 of the left pilot valve (9) and acts upon the low pressure sensor (SE-7). At the same time, the pressure is branched off in two flows, acts upon the PAa1 port and the PLc2 port, changes over the arm spool and the arm lock valve CRar releases. 2. The output voltage by the low pressure sensor is input into mechatro controller, and is pilot signal-processed, and is output to P1, P2 pump proportional valve (PSV-P1), (PSV-P2) and arm 2 inverse proportional valve (PSV-A). 3. The secondary pressure from pilot proportional valve, which is reduced by arm 2 inverse proportional valve (PSV-A) switches arm 2 spool.

13.2 Arm-In, Light-Load Variable Normal Recirculation, Internal Conflux Main Circuit 1. Operation: 1. The P2 pump delivery oil flows in travel left section through P2 port of C/V (2) and is branched off in by-pass circuit and parallel circuit, but because arm 1 spool is switched, the delivery oil which goes through parallel circuit opens load check valve LCa and is flowed into arm 1 spool. 2. On the other hand, P1 pump delivery oil flows in P1 port of C/V (2), and the flows in travel straight section and travel right tandem path. Then because arm 2 spool was switched, the delivery oil opens load check valve LCAT2, goes through arm 2 spool, and confluences with P2 pump delivery oil in the valve section, and then 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 passes through the Ba port because the arm lock valve CRar is open, and is flowed into arm 2 spool through arm 1 spool. 4. Because arm 2 spool is switched to normal recirculation position, causing restriction of passage to tank, the return oil from arm cylinder (R) side flows into arm cylinder (H) side. • Because, at light load, the pressure in cylinder rod (R) side is higher than that in the head (H) side, it opens the check valve housed-in arm 2 spool and is recirculated in the head (H) side, resulting in the speed up of arm-in operation at light load. 5. Cavitations prevention control in arm-in operation. Command current is output to arm 2 solenoid proportional valve by signal processing of E/G speed and arm-in pilot pressure, accordingly the arm 2 spool is switched to neutral (cavitations prevention) position, resulting in cavitations prevention. 6. Position of arm 2 spool

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RAPH12CEX1297AA

1

Reference: In light-load arm-in operation (normal recirculation, conflux), when the attachment to which the circuit in P1 pump side is applied is operated, the meter-in path of arm 2 spool is closed, resulting in single flow operation.

RAPH12CEX1298AA

2

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RAPH12CEX1291JA

3

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This section describes the following operations: 13.3 Arm in, heavy load operation pilot circuit (recirculation cut) 13.4 Arm in, Heavy load operating sequence confluxed main circuit

13.3 Arm In, Heavy Load Operating Pilot Circuit 1. Operation: 1. In arm-in operation, when the heavy loading is applied to arm and the P2 pump pressure increases to the set pressure, the voltage output by P2 pump pressure sensor (SE-23) is converted to signal (signal processing) by mechatro controller, consequently the current of arm 2 solenoid proportional valve is controlled according to the load pressure and the arm variable recirculation is cut. When the recirculation is cut, internal confluence is held similarly to that in light load operation. 2. Left pilot valve actuation due to arm-in operation is equivalent to that at light load operation.

13.4 Arm In, Heavy Load Operating Recirculation Cut Main Circuit 1. Purpose: Speed up for arm in operation 2. Principle: Cut the recirculation and reduce rod pressure. 3. 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 circuit and parallel circuit. Consequently the arm spool is switched and pushes and opens load check valve LCa through parallel circuit, and flows in the arm spool. 2. On the other hand, P1 pump delivery oil flows in P1 port of C/V (2), and flow in travel right tandem passage through travel straight section. Then because arm 2 spool was switched, the delivery oil opens load check valve LCAT2, and confluences with P2 pump delivery 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 CRar, but because the arm lock valve CRar is open, the return oil goes through arm lock valve CRar 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. 5. Position of arm 2 spool

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1

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RAPH12CEX1292JA

2

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This section describes the following operations: 13.5 Arm out pilot circuit 13.6 Arm out 2 pumps conflux main circuit 13.7 Natural fall protection with arm lock valve

13.5 Arm Out Pilot Circuit 1. Operation: 1. When the arm out operation is performed, the secondary pilot proportional pressure gets out of port 8 of the left pilot valve (9), and acts upon the low pressure sensor (SE- 8). At the same time, the oil is branched off in two flows and act upon the PBa1 and PBa2 ports of C/V (2). 2. The operating proportional secondary pressure flowed in PBa1 port of C/V (2) switches the arm 1 spool. 3. Then, the operating secondary pressure flowed in PBa2 port of C/V (2) switches the arm 2 spool valve.

13.6 Arm Out 2 Pumps Conflux Main Circuit 1. Purpose: Arm out operation speed up. 2. Principle: The oil delivered by the P1 pump is confluxed with that delivered by the P2 pump in C/V (2). 3. 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 CRar 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.

13.7 Natural Fall Portection With Arm Lock Valve 1. Purpose: To prevent the arm from falling naturally by the weight of the arm and bucket. 2. Principle: Complete seat of the return circuit against the arm spool of the arm cylinder (R) side circuit. 3. Operation: 1. When the secondary pressure for arm operation disappears and the arm cylinder stops, the pressure on the rod (R) side passes through the selector of the lock valve from the Ba port of C/V, acts the back pressure on the lock valve CRar and seats the lock valve. 2. Since the oil flow into the arm spool from the lock valve is shut off completely, natural fall of the arm due to oil leaks through the arm spool is prevented.

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RAPH12CEX1293JA

1

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14. Combined Circuit This section describes only the difference in combined operation. 14.1 Boom up / travel, pilot circuit 14.2 Boom up / travel, main circuit

14.1 Boom Up / Travel, Pilot Circuit 1. Operation: (Operation: different point of pilot circuit from independent operation) 1. The mechatro controller outputs command current to travel priority solenoid proportional valve after signal processing, and the solenoid proportional valve outputs secondary pressure and acts on PTb port of C/V (2). 2. Then the pressure of PTb port switches the travel priority valve.

14.2 Boom Up / Travel, Main Circuit 1. Purpose: To insure priority travel movement during travel operation even if the attachment is operated. 2. Principle: The travel action and the attachment action are actuated by quite different pump. 3. Operation: 1. P1 pump delivery oil flows through P1 port of C/V(2) and branches off in P1 parallel circuit and travel priority spool. P2 pump delivery oil flows through P2 port of C/V(2) and branches off in P2 tandem circuit and travel priority spool. 2. The delivery oil flowed into P1 parallel circuit of P1 pump opens check valve CT1 and LCb and flows in boom spool, which exerts on boom up operation. The delivery oil flowed into travel straight spool of P1 pump opens check valve CT2 because the travel straight spool is shifted, and flows in boom conflux spool and exerts on boom up operation with the internal oil conflux. (In travel priority 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 priority 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 priority operation, P2 pump delivery oil exerts on travel operation). 4. However, a portion of the flow is led to the travel priority spool notch restriction. The speed of attachments like travel, boom, etc. is adjusted by the circuit of restriction.

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RAPH12CEX1294JA

1

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In this section, the independent operation is omitted and describes difference in combined operation. 14.3 Swing / Arm in light load, pilot circuit 14.4 Swing / Arm in, swing priority main circuit

14.3 Swing / Arm In Light Load, Pilot Circuit 1. Operation: 1. On operating swing (left) and arm in motions simultaneously, mechatro controller outputs command current to travel priority solenoid proportional valve (PSV-C) and arm 2 solenoid inverse proportional valve according to signal processing, and this proportional valve outputs secondary pressure, which acts on PTb port and PAa2 port of C/V(2). 2. PTb port pressure switches the travel priority spool according to the secondary pilot pressure, and the PAa2 port pressure switches the arm 2 spool to the forced recirculation position.

14.4 Swing / Arm In, Swing Priority Main Circuit 1. Purpose: Stable swing speed. 2. Principle: Raise the oil pressure flowing to arm cylinder, and give a priority of the deliver of P2 pump to swing operation. 3. Operation: 1. The swing main circuit operates with P2 pump flow. But on P2 pump circuit side, the flow goes to the swing circuit and arm circuit simultaneously because the swing circuit and arm circuit are parallel. The arm 2 spool is switched to forced recirculation position and the opening of meter-out is not there, so the pressure of return oil is raised, causing the rise of circuit pressure on the arm cylinder head (H) side. 2. At the same time meter-in of arm 2 spool closes and arm in conflux is therefore cancelled, and delivery oil from P2 pump and P1 pump are combined in the parallel circuit on P2 pump side because the travel straight spool was switched. The conflux oil of P1 and P2 delivery oil in high pressure flows in swing side taking priority over all others. This operation is called "Swing Priority Circuit". 4. Position of arm 2 spool.

RAPH12CEX1300AA

1

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RAPH12CEX1295JA

2

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WARNING Crushing hazard! Before attempting any maintenance on the loader or tractor, always make sure the loader is in the down position and the bucket or attachment is resting on the ground. Failure to comply could result in death or serious injury. W0119A

15. Pressure Draining (Releasing) Circuit This section describes the following operations: 15.1 Pressure releasing pilot circuit 15.2 Pressure releasing main circuit

15.1 Pressure Releasing Pilot Circuit 1. Purpose: To release the pressure in the main circuit for piping repair works. 2. Principle: After the mode is switched to "Pressure Relief Mode" with switch on gauge cluster, mechatro controller outputs the following commands. 1. Minimum tilting command value to pump proportional valve (PSV-P1, PSV-P2). 2. Output “pressure relief control speed command value” at ECU. (Electric system). 3. Stand-by command value to P1, P2 unloading proportional valves. 3. How to switch to "Pressure release mode" 1. Select the service diagnosis mode 1. (Hold down the "BUZZER STOP SWITCH" on gauge cluster, turn the starter key switch on.) 2. Select the service Adjustment Mode 1. (Under the condition that "Screen No.1" of "Service diagnosis mode 1" is indicated, hold down the "BUZZER STOP SWITCH", press the "MENU SWITCH" 3 times. When "SERVICE MENU" is displayed, using "UP" switch or "DOWN" switch, select "SERVICE ADJUST 1". Press "NEXT" switch, to select "SERVICE ADJUST 1-2".) 3. Using "UP" switch or "DOWN" switch, and select "PRESS DRAIN". Then press "NEXT" switch, and cursor points to "OFF". 4. Press "UP" switch to display "ON", and press "MENU" switch. 5. Screen of gauge cluster changes to ordinary display, and "DRAINING HYD. PRESS." is appeared. 4. 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.

15.2 Pressure Releasing Main Circuit 1. Operation: When the operating lever is shifted to neutral during engine running, "DRAINING HYD. PRESS." is displayed on the gauge cluster while the mode switch is changed to pressure relieving mode. In this time the intermittent buzzer sounds continuously. When right and left operating levers are operated 4 or 5 times to their full stroke, pressure is relieved. After draining pressure is completed, turn off the starter key and buzzer sound stops. If the pump pressure is determined to be more than 1 MPa (145 psi) by the output value of the high pressure sensor (SE 22, SE 23) (or the high pressure sensors are broken) "FAIL DRAIN HYD. PRESS" is displayed and the buzzer sounds continuously. In that case, also the buzzer is not stopped unless the engine key is turned to OFF. Repeat the pressure releasing procedure once again. 47454079-DRAFT 06/11/2012

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2. Hydraulics: If the Unloading valves are turned to the pressure release position, the oil delivered by each pump is unloaded to the tank passage. If the spools are switched by pilot operation, the remaining pressure from the actuators may be relieved to the tank circuit, i.e. the main circuit pressure may be released.

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RAPH12CEX1296JA

1

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Hydraulic systems - Overview Hydraulic Cylinders [62557465] SK170-9 LA

Outline

RAPH12CEX0427FA

1

General view A. B. C.

Fully extended length Fully retracted length Part number and manufacturing number stamp position

Specifications Use

Boom Arm Bucket Positioning

Cylinder bore / rod diameter

Stroke

Ø 110 mm (4.33 in) / Ø 80 mm (3.15 in) Ø 125 mm (4.92 in) / Ø 90 mm (3.54 in) Ø 105 mm (4.13 in) / Ø 75 mm (2.95 in) Ø 135 mm (5.31 in) / Ø 85 mm (3.35 in)

1170 mm (46.06 in) 1290 mm (50.79 in) 1025 mm (40.35 in) 1012 mm (39.84 in)

Center distance of Pins Full extend A / Full retract B 2840 mm (111.81 in) / 1670 mm (65.75 in) 3060 mm (120.47 in) / 1770 mm (69.69 in) 2565 mm (100.98 in) / 1540 mm (60.63 in) 2555 mm (100.59 in) / 1543 mm (60.75 in)

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Cushion

With cushion on the rod side With cushion on both sides With cushion on the rod side Without cushion

Dry weight

150 kg (331 lb) 194 kg (428 lb) 128 kg (282 lb) 196 kg (432 lb)


Construction

2

RAPH12CEX0428GA

Boom cylinder 1 2 3 4 5 6 7 8

Rod assembly Tube assembly Rod seals Head assembly Backup ring and O-ring Cushion seal Screw; M14x2 171 N·m (126 lb ft); quantity 12 Cushion ring

9 10 11 12 13 14 15 30

Piston seals Piston Nut; M58x3 3790 N·m (2795 lb ft) Shim Screw; M12x1.75 56.9 N·m +/- 10.7 N·m ( 42.0 lb ft +/- 7.9 lb ft) Steel ball Grease fitting Wiper ring; quantity 4

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3

RAPH12CEX0429GA

Arm cylinder 1

Rod assembly

12 13

2

Tube assembly

3 4 5 6 7 8 9 10

Rod seals Head assembly Backup ring and O-ring Cushion seal Screw; M16x2 267 N·m (197 lb ft); quantity 12 Cushion ring Piston seals Piston

14 15 17 18 19 20 30

Shim Screw; M12x1.75 56.9 N·m +/- 10.7 N·m ( 42.0 lb ft +/- 7.9 lb ft) Steel ball Grease fitting Cushion ring Cushion seal Stopper Collar; quantity 2 Kit seals; quantity 4

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RAPH12CEX0430GA

4

Bucket cylinder 1 2 3

Rod assembly Tube assembly Rod seals

10 11 12 13

4

Head assembly

5 6 7 8 9

Backup ring and O-ring Cushion seal Screw; M14x2.5 171 N·m (126 lb ft); quantity 12 Cushion ring Piston seals

14 15 16 30

Piston Nut; M52x3 4810 N·m (3548 lb ft) Shim Screw; M12x1.75 56.9 N·m +/- 10.7 N·m ( 42.0 lb ft +/- 7.9 lb ft) Steel ball Grease fitting M10x1 Grease fitting M10x1 Kit seals; quantity 4

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RAPH12CEX0431GA

5

Positioning 1 2 3

Rod assembly Tube assembly Rod seals

10 11 12 13

4

Head assembly

5 7 9

14 Backup ring and O-ring Screw; M18x2.5 367 N·m (271 lb ft); quantity 12 15 Piston seals 30

Piston Nut; M70x3 6860 N·m (5060 lb ft) Shim Screw; M12x1.75 56.9 N·m +/- 10.7 N·m ( 42.0 lb ft +/- 7.9 lb ft) Steel ball Grease fitting M10x1 Kit seals; quantity 4

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Main components of the hydraulic cylinder (for boom, arm, and bucket cylinders) : • Cylinder tube assembly. • Piston rod assembly. This assembly takes out the motion of pistons reciprocating in the cylinder tube assembly • Cylinder head. The cylinder head’s function is to serve as both a lid and a guide. The cylinder tube assembly. This assembly is equipped with a pin mount (clevis) that connects the piston rod assembly (2) to other components. Additional components of the hydraulic cylinder : • Seal ring. This seal is located between the cylinder tube assembly and the piston rod assembly • Backup ring. This seal is located between the cylinder tube assembly and the piston rod assembly. • Buffer ring, U-ring, backup ring and wiper ring which are located between the piston rod assembly and the cylinder head. • An O-ring and a backup ring are placed between the cylinder tube assembly and the cylinder head.

Operation If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, a force acts on the piston which in turn caused the piston rod (F) to extend and retract.

Operation of cylinder with cushion Cushion on rod side The cushion mechanism provided prevents the generation of shock when the moving speed of the piston (A) is not reduced and srikes the cylinder head. (H) Oil in chamber (D) returns to the tank by passing through path (E) at a fixed flow rate in an intermediate stroke state of pressing the bottom side. Then, just before stroke end, the cushion ring (A) plunges into path (E).

RAPH12CEX0432AA

6

RAPH12CEX0435AA

7

Next, the oil in chamber (D) passes clearance (K) and mouth gap (L). There is a sudden drop in oil flow volume returning to the tank resulting in the slowing down of the piston movement.

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Hydraulic systems - Hydraulic schematic frame 01 – Hydraulic Circuit Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic systems - Hydraulic schematic frame 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

Hydraulic systems - Hydraulic schematic frame 04 – 4. HOLDING VALVE FOR BOOM AND ARM (OPTION) . 19 SK170-9 LA

Hydraulic systems - Hydraulic schematic frame 05 - PROPORTIONAL HAND CONTROL EXTRA HYDRAULIC CIRCUIT WITH PRESSURE UNLOAD (UNLOAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SK170-9 LA

Hydraulic systems - Hydraulic schematic frame 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SK170-9 LA












Hydraulic systems - Overview – Hydraulic Cylinders Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Hydraulic systems - Overview Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SK170-9 LA

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Hydraulic systems - 35 Variable displacement pump - 106

SK170-9

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Contents Hydraulic systems - 35 Variable displacement pump - 106

TECHNICAL DATA Variable displacement pump Dimension Maintenance Standard: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

SERVICE Variable displacement pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

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Reference Variable displacement pump - Assemble

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Hydraulic systems - Variable displacement pump

Variable displacement pump - Dimension Maintenance Standard: [45790312] SK170-9 LA

Part name and inspection item Clearance between piston and cylinder bore (D-d)

Standard Dimension 0.028(0.0011)

Recommended value for replacement 0.056(0.0022)

Remedy Replace piston or cylinder.

Gap between piston and caulked part 0 ~ 0.1(0 ~ 0.0039) of shoe (d)

0.3(0.0118)

Replace piston shoe assembly.

Thickness of shoe (t)

3.9(0.1536)

3.7(0.1457)

Replace piston shoe assembly.

Free height of cylinder spring (L)

31.3(1.2332)

30.2(1.1899)

Replace cylinder spring.

Combined height of retainer plate and spherical bushing (H-h)

10.5(0.4137)

9.8(0.3861)

Replace a set of spherical bushing or retainer plate.

Repair standards for cylinder, valve plate and swash plate (shoe plate face) Valve plate (sliding section) Swash plate (shoe plate face) Cylinder (sliding section) Roughness of each surface

Surface roughness requiring correction. Standard surface roughness (correction value)

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3-Z Less than 0.4 Z (lapping)


Variable displacement pump - Remove [45623805] SK170-9 LA

Park the machine on a firm, level surface. To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at pageT2-1-60. Cut off the engine. Press the valve located onthe hydraulic oil cap to release any residual pressure present in the tank itself. 1.

Remove all protection panels and doors to give access to the Hydraulic Pump Device.

2.

Disconnect all electrical connectors.

3.

Remove all hoses and collector from hydraulic pump device.

4.

Fasten the hydraulic pump device by means of hoist and lifting ropes.

NOTE: Hydraulic pump device weight- 89.5 kg (197 lbs). 5.

Remove the fixing bolts of hydraulic pump device and draw it from engine.

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Variable displacement pump - Install [45623825] SK170-9 LA

1.

Lift the hydraulic pump device by means of hoist and ropes.

NOTE: Hydraulic pump device weight- 89.5 kg (197 lbs). 2.

Install the hydraulic pump device to the engine by means of related bolts.

3.

Install all hoses and collector to the hydraulic pump device.

4.

Connect all electrical connectors.

5.

Install all protection panels and doors.

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Variable displacement pump - Assemble [45623845] SK170-9 LA

1.

2.

Assembly is the reverse order of disassembly, but notice the following: •

Repair scored parts at disassembly. Get replacements ready beforehand

•

Wash parts sufficiently in cleaning oil and dry them with jet air.

•

Do not forget to coat the sliding areas and bearings with clean hydraulic oil.

•

In principle, replace sealing parts such as O-rings and oil seals.

•

Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench.

Attach swash plate support (1) to pump casing (2) by tapping the swash plate support lightly with a plastic hammer.

RAPH12CEX0025BA

1

NOTE: When the servo piston, the tilting pin, the stoppers have been removed, install them to the pump casing before hand. When tightening servo piston and tilting pin, use a jig so as not to damage the head of the tilting pin and feedback pin. Coat the screwed part with LOCTITE® 262 . 3.

Install swash plate placing the pump casing with its mounting surface of the regulator facing down. Insert the tilting bushing of the swash plate into tilting pin, and fit swash plate (1) to swash plate support (2) properly.

RAPH12CEX0026BA

2

NOTE: Confirm by your both hands that swash plate moves smoothly. The shaft should install easily if grease is applied to the sliding parts of the swash plate and the swash plate support.

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4.

5.

Install shaft (1) fitted with bearing (2), bearing spacer (3) and snap ring, to swash plate support (4).

RAPH12CEX0027BA

3

RAPH12CEX0556AA

4

RAPH12CEX0557AA

5

Install seal cover (Front) (261) to pump casing (271) and fix it with socket bolts (406) .

NOTE: Coat the oil seal in seal cover with a thin film of grease. Handle the oil seal with sufficient care so it is not scored. 6.

Fit seal cover (Rear) (262) at the same way as above.

7.

Assemble the piston cylinder sub compound to the cylinder block (141) , piston (151) , shoe (152) , plate (153) , spherical bushing (156) and cylinder spring (157) . Align the spherical bushing with the cylinder spline and insert them into the pump casing.

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8.

Install valve plate (313) and (314) to valve block (312) by aligning pin.

RAPH12CEX0558AA

6

RAPH12CEX0559AA

7

NOTE: Do not mistake the suction and delivery sides of the valve plate. 9.

Install valve block (312) to pump casing (271) and fasten them together with socket bolts (401) .

NOTE: Work will be easier if assembly is started from the rear pump . Exercise care so as not to mistake the direction of the valve block (312) . Install it so the regulator comes up as seen from the front side and the suction flange comes on the right. Insert the 1st gear into the valve block beforehand and connect it with the spline of the shaft. 10.

Install regulator and PTO gear casing. Pinch feedback pin of tilting pin in feedback lever of the regulator and PTO gear casing, install the regulator and fasten socket bolt (415) and (435) .

RAPH12CEX0560AA

NOTE: Do not mistake the front regulator for the rear regulator.

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8


11.

Assembling the gear pump: 1.

Replace all of the O-rings with new ones.

2.

Install the plug, the adapter, the adjusting screw and the lock nut.

3.

Install the flange socket.

RAPH12CEX0561AA

9

NOTE: The setting of adjusting screw (311) must be performed according to group T4-3, after installation of pump device on the engine. 12.

Install drain port plugs (434) and (436) .

RAPH12CEX0562AA

13.

Refill with hydraulic oil the pump device till to the maximum allowed level.

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10


Variable displacement pump - Disassemble [45623865] SK170-9 LA

1.

Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from getting damaged.

2.

Clean the parts removing dust and rust, etc. on pump surface with wash oil.

3.

Drain out the oil in the pump casing by removing drain port plugs (1).

4.

5.

RAPH12CEX0013BA

1

RAPH12CEX0014BA

2

RAPH12CEX0015BA

3

Disassembly of Gear pump. a. Remove the flange socket (1) (Qty. 2). b. Remove the plug (2), the adapter (3),and if necessary, the adjusting screw (4) and the lock nut (5).

Remove regulator and PTO gear casing by loosening the related socket bolts.

NOTE: For disassembly and assembly of the regulator and PTO gear casing, refer to the related paragraphs.

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6.

7.

Loosen socket bolts (1) that fasten swash plate support, pump casing (2) and valve block (3).

RAPH12CEX0016BA

4

RAPH12CEX0017BA

5

Place the pump level on a work bench with its mounting surface of the regulator facing down. Then separate pump casing (1) and valve block (2).

NOTE: When facing the mounting surface of the regulator down, place a rubber board on a workbench so as not to score the mounting surface. When the pump casing has been separated from the valve block, draw out the 1st gear (116) at the same time. 8.

Draw out the cylinder block (1) out of pump casing (2) in parallel to shaft. At the same time draw out piston, plate, spherical bushing (3) and cylinder spring.

RAPH12CEX0018BA

6

NOTE: Use care so as not to score the sliding surface of the cylinder, spherical bushing, shoe and the swash plate.

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9.

Remove socket bolt (1) and seal cover (Front) (2).

RAPH12CEX0019BA

7

NOTE: The seal cover may be drawn out with ease if it is taken out by tightening bolts in the tapped holes of the seal cover. An oil seal is fitted to seal cover. Therefore, use care so as not to score the oil seal. 10.

Remove socket bolt and seal cover (Rear).

11.

Knock lightly on the mounting flange of swash plate support (1) from the pump casing (2) side and separate the swash plate support from the pump casing.

12.

RAPH12CEX0020BA

8

RAPH12CEX0021BA

9

Draw out shoe plate (1) and swash plate (2) from pump casing.

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13.

14.

15.

Tap lightly the shaft end by means of a plastic hammer and draw out the shaft from the swash plate support.

RAPH12CEX0022BA

10

RAPH12CEX0023BA

11

RAPH12CEX0024BA

12

Remove valve plate (1) from valve block (2).

If necessary, remove stoppers (1), servo piston (2) and tilting pin (3) from pump casing, and remove needle bearing (4)from valve block (5).

NOTE: When removing the tilting pin, use care so as not to score the head of the tilting pin, using a jig. It is hard to separate the tilting pin from the servo piston in some cases as Loctite is coated on the mating part between them. Use care so as not to score the servo piston by applying unreasonable force. Do not draw out needle bearings except when their service life has ended. Do not loosen hex nuts of valve block and swash plate support. A set flow rate changes.

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Index Hydraulic systems - 35 Variable displacement pump - 106 Variable displacement pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Variable displacement pump - Dimension Maintenance Standard: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Variable displacement pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Variable displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Variable displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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Hydraulic systems - 35 Charge pump - 105

SK170-9

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Contents Hydraulic systems - 35 Charge pump - 105

FUNCTIONAL DATA Charge pump Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

SERVICE Charge pump Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

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Hydraulic systems - Charge pump

Charge pump - Exploded view [45883191] SK170-9 LA

RAPH12CEX0047GA

Item 10 11 12 117 118 125 126 128 262

Description Idle shaft Gear casing Spring pin 2nd gear 3rd gear Ball bearing Roller bearing Bearing spacer Cover

1

Item 414 435 468 710 711 728 825 826 886

Description Socket bolt M10 x 20 Flange socket M10 x 20 VP plug PF3/4 O-Ring O-Ring O-Ring Snap ring Snap ring Pin

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Charge pump - Disassemble [45879891] SK170-9 LA

1.

Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from getting damaged.

2.

Remove dust, rust, etc, on pump surface with wash oil.

3.

Remove the socket bolts (1). Then remove the cover (2).

4.

RAPH12CEX0044BA

1

RAPH12CEX0045BA

2

RAPH12CEX0046BA

3

Remove snap ring and idle shaft (1). Then draw out 2nd gear (2), roller bearing and bearing spacer.

NOTE: Roller bearing can not be separated from 2nd gear. 5.

Remove snap ring and draw out 3rd gear (1) and ball bearing (2).

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NOTE: Ball bearing can not be separated from 3rd gear.

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Charge pump - Assemble [53975659] SK170-9 LA

Assembly is the reverse order of disassembly, but please note the following: •

Repair scored parts at disassembly. Get replacements ready beforehand.

•

Was parts sufficiently in cleaning oil and dry them with pressured air.

•

Do not forget to coat the sliding areas and bearings with clean hydraulic oil.

•

Replace all sealing parts such as O-rings and oil seals.

•

Tighten socket bolts and plugs to specified torques in this manual.

Maintenance standard In case of pitting (1 pit is more than 1 mm, while the area ratio is more than 5%) is seen on the gear tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive damage. 1.

Proceed with assembly operations in a clean place.

2.

Place ball bearing (125) and 3rd gear (118) into gear casing. Secure with snap ring (825).

3.

RAPH12CEX0046BA

1

RAPH12CEX0045BA

2

Install the 2nd gear (117) with roller bearing (126) and bearing spacer (128) into bottom of gear casing. Secure with the idle shaft (10) and spring pin (12).

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4.

Install cover (262) using socket bolts (414).

5.

Install VP plug (468) into gear casing.

RAPH12CEX0044BA

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3

Index Hydraulic systems - 35 Charge pump - 105 Charge pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Charge pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Charge pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Hydraulic systems - 35 Reservoir, cooler, and filters - 300

SK170-9

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Contents Hydraulic systems - 35 Reservoir, cooler, and filters - 300

SERVICE Oil reservoir Remove Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Install Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

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CONSUMABLES INDEX Consumable

Reference

Loctite® 262 Oil reservoir - Install Hydraulic Oil Tank Permatex® Form-A-Gasket® Oil reservoir - Install Hydraulic Oil Tank No. 2 Sealant

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PAGE 35.300 / 8 35.300 / 10

Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Remove Hydraulic tank [54318014] SK170-9 LA

CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A


2.

Remove hood assembly (A), panel assembly (B), guard (C) and other guards necessary to remove the hydraulic oil tank.

RAPH12CEX0582AA

1

RAPH12CEX0583AA

2

Release the internal pressure of the hydraulic tank. Remove cap (1) on air breather (2) and push valve (head of bolt) with your finger. Hold it in until the hissing stops.

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3.


4.

Remove cover (4).

5.

Remove suction strainer (5).

6.


7.

Remove cover (6).

8.

Remove filter element (7).

9.

Turn the handle of the element assembly (8) and disassemble the removed filter element. Disassemble parts: (8), (9), (10) x 2, (11), and (12).

10.

Place pump in tank and remove the hydraulic oil. Capacity of tank: 153.9 l (40.7 US gal) Level oil quantity: 90.7 l (24.0 US gal)

RAPH12CEX0584BA

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3


Removal of the hydraulic oil tank 1.

Remove two clamps (8) on the tank side of the suction hose (9). Pull the suction hose off of the side of the hydraulic tank.

2.

Remove sems bolts (10) M12x35 and remove the return hose.

3.

Remove drain hose (12) from the main hydraulic pump.

4.

Remove drain hose (13) from swing motor.

5.

RAPH12CEX0585AA

4

RAPH12CEX0586AA

5

RAPH12CEX0587AA

6

Disconnect the pilot return hoses (14), (15), and (16).

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6.

Remove drain hose (17) from pilot pump.

7.

Remove drain hose (18) from pilot pump.

8.

Remove capscrews (19) M16x40

9.

Use a steel cable attached to the lifting plate on top of the tank. Tank weight: approximately 118 kg (260 lb)

10.

Remove shims (20) after recording their location.

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RAPH12CEX0588AA

7

RAPH12CEX0589AA

8


Oil reservoir - Install Hydraulic Oil Tank [54318034] SK170-9 LA

Installation of the hydraulic oil tank 1.

Clean the hydraulic oil tank.

2.

Clean the suction hose.

3.

Clean the tank mounting.

4.

Installation is don in the reverse order of removing.

NOTICE: If the gap between the tank mount and the machine frame exceeds 1 mm (0.04 in), adjust the gap with shims (20) and tighten the capscrews (19) to install the tank. 5.

Install mounting capscrews (19) M16x40 with LOCTITE® 262. Torque the capscrews to 196.4 - 233.6 N·m (144.9 172.3 lb ft)

6.

Assemble the return element using a new o-ring (9) and new packing (11) .

7.

Install return element (7).

8.

Install suction strainer (5).

9.

Install the tank covers (4), (6). Use new O-rings for each cover. Tighten sems bolts (3) M10x25 that attach the tank covers. Torque the sems bolts to 41.2 - 51 N·m (30.4 - 37.6 lb ft)

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RAPH12CEX0589AA

1

RAPH12CEX0584BA

2


10.

11.

Connect the drain hoses (18) and (17) from pilot pump.

RAPH12CEX0588AA

3

RAPH12CEX0587AA

4

RAPH12CEX0586AA

5

Connect the pilot return hoses (14), (15) and (16) to the hydraulic tank.

12.

Connect the drain hose (13) from swing motor to hydraulic tank.

13.

Connect the drain hose (12) from the pump to the hydraulic tank.

14.

Attach the return hose (11) to the hydraulic tank using sems bolts (10) M12x35.

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15.

Connection of the suction hose (9). 1.

Apply PERMATEX® FORM-A-GASKET® NO. 2 SEALANT on the pipe side of the hose connection and insert it.

2.

Use hose clip (8) to secure the hose to the tank.

3.

Tighten hose clip to 4.89 - 5.89 N·m (3.61 - 4.34 lb ft)

RAPH12CEX0585AA

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6

Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil reservoir - Install Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Oil reservoir - Remove Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

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Hydraulic systems - 35 Regulated/Low pressure system - 322

SK170-9

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Contents Hydraulic systems - 35 Regulated/Low pressure system - 322

SERVICE Low pressure valve Priority/Regulator valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Priority/Regulator valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

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Hydraulic systems - Regulated/Low pressure system

Low pressure valve Priority/Regulator valve - Disassemble [45812069] SK170-9 LA

1.

Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging.

2.

Clean the parts removing dust and rust, etc. on regulator surface with wash oil.

3.

Remove regulator socket bolts and separate the regulator from the pump body.

RAPH12CEX0031BA

1

RAPH12CEX0033BA

2

NOTE: Exercise care so as not to lose O-Ring and check valve sub). 4.

Remove socket bolts (1) and remove valve casing (2) with solenoid proportional reducing valve.

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5.

6.

Remove socket bolt (1) and cover (2) .

RAPH12CEX0034BA

3

RAPH12CEX0035BA

4

RAPH12CEX0036BA

5

Draw out sleeve (1) and pilot piston from the regulator body.

7.

Remove fulcrum plug (1) and feed back lever (2).

8.

Draw out spool and sleeve from the sleeve hole of the regulator casing.

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9.

Draw out plunger (1). Then take out pilot spring and spring.

RAPH12CEX0037BA

6

RAPH12CEX0038BA

7

NOTE: The plunger comes off easily if an M4 bolt is used. 10.

The disassembly is complete when the check valve (1) has been drawn out.

NOTE: The check valves are placed in two places The mating surface of the pump casing and on the matching surface of the valve casing.

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Low pressure valve Priority/Regulator valve - Assemble [45855225] SK170-9 LA

1.

Assembly is the reverse order of disassembly. Do the work paying attention to the following: - Repair those parts that were damages during disassembly and prepare replacement parts beforehand. - Clean parts thoroughly in cleaning oil, blow them off with jet air and assemble parts in a clean place. - Always tighten screws and plugs to the specified torque. - Do not fail to coat the moving parts with clean hydraulic oil, before assembly. - Replace seals such as O-Ring.

2.

Fit the check valve to casing.

RAPH12CEX0038BA

1

NOTE: Assemble the check valve into the matching surface of the pump casing and the matching body of the valve casing. 3.

Place sleeve (1) and spool into the sleeve hole of casing.

RAPH12CEX0039BA

2

NOTE: Make sure that the spool and the sleeve slide smoothly in the casing without interference. Beware of the direction of the spool.

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4.

Insert pin (897) of feedback lever (611) into the pin hole of the sleeve and fix the feedback lever with fulcrum plug (614).

RAPH12CEX0040BA

3

NOTE: Operate the feedback lever and make sure that it does not have much looseness and that it operates without catching. 5.

6.

Place spring seat, pilot spring (1) and plunger into the hole in the sleeve.

RAPH12CEX0041BA

4

RAPH12CEX0042BA

5

Attach cover (1) to casing (2) and fasten them together with socket bolts (3).

NOTE: The cover is fitted with set screw and hex nut.

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7.

Assemble sleeve (1) and pilot piston (2) into casing.

RAPH12CEX0043BA

NOTE: Make sure that the pilot piston moves smoothly. 8.

Attach valve casing fitted with solenoid proportional reducing valve to casing and fasten them together with socket bolts.

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6

Index Hydraulic systems - 35 Regulated/Low pressure system - 322 Low pressure valve Priority/Regulator valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Low pressure valve Priority/Regulator valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Hydraulic systems - 35 Hydraulic swing system - 352

SK170-9

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Contents Hydraulic systems - 35 Hydraulic swing system - 352

FUNCTIONAL DATA Hydraulic swing system Overview Hydraulic Swing Motor and Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Swing reduction gear Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Dynamic description Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA

Swing reduction motor Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

Dynamic description Swing Motor Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

SERVICE Swing reduction gear Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SK170-9 LA

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SK170-9 LA

Swing reduction motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SK170-9 LA


Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SK170-9 LA

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CONSUMABLES INDEX Consumable Tutela Hypoide EP Gear lube SAE 80W-90 Tutela Multi-purpose EP grease 251H, GR-9 Loctite® 515 Loctite® 515 Loctite® 515 Loctite® 262

Reference Hydraulic swing system - Overview Hydraulic Swing Motor and Reduction Unit Hydraulic swing system - Overview Hydraulic Swing Motor and Reduction Unit Swing reduction gear - Assemble Swing reduction gear - Assemble Swing reduction motor - Install Swing reduction motor - Install

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PAGE 35.352 / 5 35.352 / 5 35.352 35.352 35.352 35.352

/ / / /

26 30 32 32

Hydraulic systems - Hydraulic swing system

Hydraulic swing system - Overview Hydraulic Swing Motor and Reduction Unit [52320334] SK170-9 LA

Outline General View

RAPH12CEX0420FA

Symbol A, B DB M PA, PB PG L IP 1 2 3

Name Main port Drain port Make-up port Pressure measuring port Parking brake release port Gear oil level gauge Gear oil filling port Relief valve (A port side) Relief valve (B port side) Threaded hole for eye bolt (M10 18mm deep) Qty. 2

1

Port size PF 3/4 PF 3/8 PF 3/4 PF 1/4

Tightening torque Nm (lb-ft) 167 N·m (123 lb ft) 74 N·m (55 lb ft) 167 N·m (123 lb ft) 36 N·m (27 lb ft)

PF 1/4

36 N·m (27 lb ft)

PF 1/2 PF 1/2 N/A N/A

65 N·m (48 lb ft) 98 N·m (72 lb ft) N/A N/A

N/A

N/A

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RAPH12CEX0424FA

No. 1 2

2

Description Swing Shockless Valve Grease Fitting

Specification Hydraulic Motor

Swing Shockless valve block Hydraulic motor assembly mass Reduction Unit

Model Type Displacement Working pressure Maximum flow Braking torque Release pressure Relief set pressure Mass Type Mass Speed reduction type Reduction ratio Lubricate oil Lubricate oil volume Grease Grease volume Mass

Total mass

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M5X130CHB–10A–598/285-122 Swash-plate type, fixed-displacement plunger motor 121.6 cm³ 34.3 MPa (4975 psi) 143 l/min (37.8 US gpm) 583 - 818 N·m (430 - 603 lb ft) 2.3 - 5.0 MPa (334 - 725 psi) 28 MPa (4061 psi) 47 kg (104 lb) 2KAR6P72/240-712 2.5 kg (5.5 lb) 51.5 kg (114 lb) Planetary 2-stage 15.378 Gear oil TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 2.7 l (0.7 US gal) TUTELA MULTI-PURPOSE EP GREASE 251H, GR-9 0.7 kg (1.5 lb) 134.5 kg (297 lb) 181.5 kg (400 lb)


Construction Swing motor Description

No.

Tightening Qty torque Nm (lb No. ft) 177 N·m (131 lb 400 2 ft) 2 400–1 1 400–2

Swing shockless valve; M22x1.5 O-ring; 1B P20 Backup ring

2 2

1

401

Socket bolt; M20×45

4

1 1 1

443 444 451

Roller bearing Roller bearing Pin

1 1 2

Qty

Description

2

051

Relief valve; M33x1.5

051–1 052

101 111 114

O-ring; 1B G30 Swing shockless valve Casing for swing shockless valve Drive shaft Cylinder Spring plate

121

Piston

9

469

ROMH plug; M30x1.5

2

122 123 124 131 151 161 162 163 171

Shoe Set place Shoe plate Valve plate Plug; PF1/4 O-ring; 1B P11 O-ring; 1B P12 O-ring; 1B P6 Socket bolt; M8×55

9 1 1 1 2 2 2 2 4

472 488 491 702 36 N·m (27 lb ft) 706 707 712 742 29 N·m (21 lb ft) 743

O-ring; W1516,WG40 O-ring; 1B P28 Oil seal Brake piston O-ring; W1516,WG38 O-ring; W1516,WG41 Brake spring Friction plate Separator plate

1 2 1 1 1 1 16 3 4

301

Casing

1

980

Plug; PF1/4

1

303

Valve casing

1

984

Plug; PF3/8

1

351

Plunger

2

985

Plug; PF3/4

3

355 390 391

Spring Name plate Rivet

2 1 2

993 994

Plug; PT1/2 Plug; PT3/4

1 1

100

No.

Description

Qty

1

16

3

#1 sun gear

1

17

3 4

#1 pinion #2 sun gear

3 1

18 19

5

#2 pinion

4

20

6 7

Ring gear Spider assy

1 1

21 22

8

Spider

1

23

9 10

Shaft Spherical bearing Spherical bearing

4 1

25 26

Needle bearing Needle bearing Washer Retaining ring Retaining ring Sleeve Spring pin Ø 8x25 Capscrew; M14X135 Tube L=112 Elbow

1

27

Plug

No.

Description

Qty

1

Pinion shaft

2

11

Tightening torque Nm (lb ft)

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Tightening torque (lb ft) 69 N·m (51 lb ft)

430 N·m (317 lb ft)

334 N·m (246 lb ft)

0.9 N·m (0.7 lb ft) 1.7 N·m (1 lb ft) 4.4 N·m (3.2 lb ft) 65 N·m (48 lb ft) 98 N·m (72 lb ft)

Tightening torque Nm (lb ft)

4 8 1 1 1 4 11

181 N·m (133 lb ft)

1 1 1

69.1 N·m (51 lb ft)


12

Oil seal

1

28

13 14

Housing Thrust washer Thrust washer

1 3

29 30

3

31

15

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Retaining ring Oil seal Grease fitting; PT 1/8 Relief fitting; PT 1/8

3 1 1 1


Hydraulic swing system - Overview [53512199] SK170-9 LA

Hydraulic motor Two speed hydraulic motor (axial piston swash plate type) containing: • Integrated counterbalance valve; • Crossover relief valve which contains a shock absorber to smooth acceleration and stopping; • Integrated flushing valve; • Negative multidisc parking brake built-in directly driven from the motor oil pressure (no additional hose is required); • Double speed function, allowing the motor to be set to a fast or slow speed.

Planetary gearbox Planetary gearbox, 3 stages, rotating housing type. The track drive is suitable to be used as track drive for crawled machines equipped with open loop hydraulic circuit.

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Ports

RAPH12CEX0541FA

Port P1 P2 T1 T2 Ps Pm1 Pm2

1

Size PF 3/4” PF 3/4” PF 1/2” PF 1/2” PF 1/4” PF 1/4” PF 1/4”

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Description Service ports Drain ports 2 speed control port Pressure gauge ports


Hydraulic circuit

RAPH12CEX0542FA

2

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Swing reduction gear - Sectional view [46087872] SK170-9 LA

Item 1 2 3 4 5 6 7 8 9 10

Description Pinion shaft #1 sun gear #1 pinion #2 sun gear #2 pinion Ring gear #1 spider assy #2 spider assy Shaft Spherical bearing

Item 11 12 13 15 16 17 18 19 20 21

Description Spherical bearing Oil seal Housing Thrust washer Needle bearing Needle bearing Thrust washer Snap ring Snap ring Sleeve

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Item 212 23 25 26 27 28 30 31 32

Description Spring pin Socket bolt Tube Elbow Plug Snap ring Oil seal Grease fitting Relief fitting


RAPH12CEX0061HA

1

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Swing reduction gear - Dynamic description Operation [53506400] SK170-9 LA

The swing reduction unit is used to reduce the rotating speed which is transmitted by the hydraulic motor and to convert it to the strong turning force (torque). This swing speed reduction unit is equipped with planetary speed reducing mechanism. The planetary mechanism is made up of sun gear, planetary pinion, planetary shaft, spider and ring gear. For the operation of the 1st stage planetary, the hydraulic motor rotates #1 sun gear (2) . Sun gear (2) is engaged with planetary pinion (3) and rotates, but since ring gear (6) is fixed, planetary pinion (3) revolves about sun gear (7) with the planetary shaft (9) and spider (7) .

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RAPH12CEX0539AA

1

RAPH12CEX0540BA

2


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Swing reduction motor - Sectional view [46184878] SK170-9 LA

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RAPH12CEX0086GA

1

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Swing reduction motor - Dynamic description Swing Motor Brake Section [53505171] SK170-9 LA

Operation The cylinder (111) is joined to the drive shaft (101) with a spline. the separator plate (743) is fixed in its circumferential direction by circular grooves provided in the casing (301). If the friction plate (742) splined to the outer circumference of the cylinder is pressed against casing (301) via separator plate (743) and brake piston (702) by the action of brake spring (712) , frictional force is created between friction plate (742) and casing (301) and between separator plate (743) and brake piston (702) . The frictional force bounds the drive shaft to brake the motor. In the meantime, when brake release pressure applied to the oil chamber formed between brake piston (702) and casing (301) overcomes the spring force, the brake is released as brake piston (702) moves till friction plate (742) is separated from casing (301) .

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RAPH12CEX0538AA

1


Swing reduction gear - Disassemble [46089213] SK170-9 LA

Before disassembly, clean thoroughly the swing reduction unit outer, checking for no damage or scratches. Drain out the gear oil from reduction unit. Remove the draining pipe. In order to case the reassembly, before disassembly put a matching mark (X) on the parts to be connected on the reduction casing. 1.

Place the reduction unit assembly on a stable workbench as shown in figure, remove plug (27), drain out oil put a matching mark on the matching surface of the figure on the right side.

2.

Loosen all socket bolt (23) (M14). Attach eyebolts (M10) in the lifting bolt holes in the top surface of the swing motor and lift the assembly by crane. If it is hard to remove the swing motor assembly from the reduction unit, float it by inserting a flat-blade screwdriver in the groove of the flange.

3.

Remove #1 sun gear (2) .

4.

The spider assembly (7) [consisting of thrust washers, #1 pinions, needle bearings and snap rings] can be removed from the spline easily if it is lifted up in that condition.

5.

RAPH12CEX0062BA

1

RAPH12CEX0063BA

2

RAPH12CEX0064BA

3

Attach eye bolts (M10) to the top surface of ring gear (6) and lift the ring gear lightly by a wire sling. Put a flat-blade screwdriver into the matching surface of ring gear (6) and housing (13) and remove ring gear (6) by lightly tapping the outer circumference of the ring gear with a plastic mallet.

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6.

Draw out #2 sun gear (4) and remove the #2 spider assembly (8).

RAPH12CEX0065BA

4

NOTE: Particularly if no failure is found, the further disassembly is not allowed. Check on parts for possible failure according to the inspection procedure shown in maintenance standards. It is recommended that the pinion shaft and housing assy are replaced together as one set. But if it is unavoidably necessary to replace a part of them, follow the procedure shown below.

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7.

Remove retaining ring (20) from pinion shaft (1).

8.

Pull pinion shaft (1), sleeve (21), oil seal (30)and spherical bearing (lower) (11) out by means of press while supporting housing (13)with special tool (B) (xxxxxxxxx).

NOTE: Spherical bearing (upper) and oil seal are left in the housing. 9.

Pull oil seal (30), sleeve (21) and spherical bearing (lower) (11) out by means of special tools (C) (xxxxxxxxx) and (D) (xxxxxxxxx) while supporting pinion shaft assembly as shown in the figure.

NOTE: Do not reuse the removed oil seal and bearing.

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RAPH12CEX0066BA

5

RAPH12CEX0067BA

6


10.

Set housing (13) as shown in the figure, insert special tool (E) (xxxxxxxxx) between bearing (10) and oil seal (12) and remove bearing (10) by striking from the upper side.

11.

Remove oil seal (12) from housing (13) .

NOTE: Do not reuse the removed oil seal and bearing.

RAPH12CEX0068BA

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7


12.

Disassemble #1 spider assembly performing the following operations. A.

Remove retaining rings (28) with pliers.

B.

Remove thrust washers (15) , pinions (3) and needle bearings (16) .

NOTE: Pinions (5) can not be replaced singly. Replace them in a set of four.

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RAPH12CEX0069BA

8

RAPH12CEX0070BA

9


Swing reduction gear - Assemble [46118523] SK170-9 LA

Sufficiently clean every part with wash oil and dry it with compressed air. Check on every part for failure. 1.

Attach oil seal (30) to sleeve (21) .

2.

Insert sleeve (30) and oils seal (21) assembly in pinion shaft (1).

3.

Apply gear oil to the perimeter of axis of pinion shaft (1) lightly to prevent seizure.

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RAPH12CEX0071BA

1

RAPH12CEX0072BA

2


4.

Seal sufficient grease in spherical bearing (lower) (11) and force it in pinion shaft (1).

NOTE: Since the bearing is formed with a partition at the center section, seal grease in it from both sides.

5.

RAPH12CEX0073BA

3

RAPH12CEX0074BA

4

Apply sufficient grease to the pinion shaft assembly. Use lithium extreme-pressure grease (SHELL Albania EP2 or equivalent)

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6.

Place housing (13) on level bench and attach eye bolt to screw (M10) at the axis end of pinion shaft assembly, and perpendicularly hang up pinion shaft assembly and place it in the housing.

NOTE: Horizontally orient the outer race of spherical bearing and insert it in by striking lightly. If the outer race is tilted, it is hard to insert even if striking. Then do not force to insert it in, but take it away once and horizontally orient the outer race twice and insert it in again.

7.

RAPH12CEX0075BA

5

RAPH12CEX0076BA

6

Set housing assembly so that the pinion directs downward and fit oil seal (12) in housing (13) .

NOTE: Apply LOCTITE® 515 to the perimeter of oil seal. Fill one third (1/3) of the space of the groove shaped section provided on the oil seal (12)lip with grease. Insert it horizontally giving attention to the lip of oil seal so as not be damaged.

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8.

9.

Press fit spherical bearing (upper) (10) in pinion shaft (1) and housing (13) at the same time

RAPH12CEX0077BA

7

RAPH12CEX0078BA

8

Attach retaining ring (20) .

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10.

Assemble #1 Spider assembly performing the following operations. A.

Coat the bore surface of pinion (3) with grease. Put pinion (3) on thrust washer (15) and assemble needle bearings (16) into the bore surface.

B.

Fit thrust washers (15), pinions (3) and fit snap rings (28) by means of pliers.

RAPH12CEX0079BA

11.

9

Assemble #2 Spider assembly performing the following operations. A.

Coat the bore surface of pinion (5) with grease. Put pinion (5) on thrust washer (18)and fit needle bearing (17) to the bore surface.

B.

Fit thrust washer (18) and pinion (5), insert shaft (9) into spider (8) and drive spring pin(22).

RAPH12CEX0080CA

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10


12.

13.

14.

Insert #2 spider assembly (8) in spline axis of pinion shaft.

RAPH12CEX0081BA

11

RAPH12CEX0082BA

12

RAPH12CEX0083BA

13

Install #2 sun gear (4) directing the spline upward.

Apply a thin film of sealant Loctite #515 to the matching surface of housing (13) and ring gear (6) and assemble them, aligning the gear teeth and according to the matching marks given.

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15.

Mesh the #1 spider assembly (7) with ring gear (6) and set them in place.

16.

Mesh #1 sun gear (2) with #1 pinions (3) and set them in place.

17.

Fit drain tube (25) and plug (27) .

18.

Fill in 2.7 L (0.7 gal) of gear oil.

19.

Attach eye bolts (M10) in the tapped holes of the swing motor and put a wire sling in them. Coat the matching surface of ring gear (6) with LOCTITE® 515 sealant. Insert the spline joint of the swing motor and match the matching marks. Coat socket bolts (23) with sealant Three-Bond 1360K and fasten them.

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RAPH12CEX0084BA

14

RAPH12CEX0085BA

15


Swing reduction motor - Remove [45896850] SK170-9 LA

1.

Remove hose (1) from the Tee in the make up port M.

2.

Remove the hoses (2) and (3) from the Tee in the drain port Dr.

3.

Remove the hoses (4) and (5) from the elbows of the A, B port.

4.

Remove the hose (6) from the elbow of the PG port.

5.

Put in plugs into the opened ports on the swing motor unit.

6.

Remove the swing motor unit by loosing the screws (1) (qty 13).

7.

Remove the plastic cap (2) M12 at the top of the swing motor and install the lifting eye bolt.

8.

Sling and remove the swing unit.

NOTE: Swing unit weight: about 181.5 kg (400 lbs).

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RAPH12CEX0049BA

1

RAPH12CEX0052BA

2


Swing reduction motor - Install [45933309] SK170-9 LA

1.

Clean mating surfaces of swing motor unit and upper frame.

2.

Apply LOCTITE® 515 on entire mounting surface of swing motor unit.

3.

Place the swing unit on the upper frame.

NOTE: Swing unit weight: about 181.5 kg (400 lbs). 4.

Remove the lifting eye bolts and inserts on the holes, the plastic caps (1) M12, previously removed.

5.

Fix the swing unit to the frame by tightening the screws (2) (qty 13). Apply LOCTITE® 262 .

6.

Install the hoses (4) and (5) on the elbows of port A and B.

7.

Install the hose (6) on the elbow of port PG.

8.

Install the hoses (2) and (3) on the tee in the drain port Dr.

9.

Install the hose (1) on the make up port M.

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RAPH12CEX0052BA

1

RAPH12CEX0049BA

2


Swing reduction motor - Disassemble [45984358] SK170-9 LA

–Hydraulic components are precision products and have small clearance. Therefore, assemble and disassemble in a less dusty clean place. Use clean tools and cleaning oil and handle components with full care. –If a component is removed from the main body, clean the area around the ports thoroughly and plug them up so no dust and water do not enter. When fitting them back to the body, do not remove the plugs till piping is completed. –Study the structural drawing before the work begins and prepare necessary parts according to your purpose and the scope of work. Seals and O-rings once removed can not be used again. –The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a matching mark on the piston and the cylinder block.

Disassembly 1.

Remove the drain plug and drain hydraulic oil from casing (18) .

2.

Fix the motor on a work bench so the drive shaft (5) end comes down. On that occasion, put a matching mark on the mating parts of casing (18) and valve casing (19). Handle the parts with care so as not to damage them.

3.

Loosen relief valve (1) and separate it from valve casing (19) .

4.

Loosen anti-reaction valve sub assembly (3) and remove from valve casing (19).

5.

Separate plugs (31) from valve casing (19) and draw out springs (21) and plungers (20) .

6.

Loosen socket bolts (27) and separate valve casing (19) from casing (18).

RAPH12CEX0053BA

1

RAPH12CEX0054BA

2

NOTE: If the socket bolt (27) are loosened, the valve casing (19) floats off casing (18) by the force of brake springs (38) . 7.

Separate valve plate (12) from valve casing (19). 47454079-DRAFT 06/11/2012

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8.

Draw out brake spring (38) from brake piston.

9.

Draw out the brake piston (35) with the special tool (A)

10.

Lay the motor on its side again and draw out cylinder block (6) from drive shaft (5) , draw out piston (8) , set spring (7) , plate (10) and shoe plate (11).

11.

Draw out friction plate (39) and separator plate (40) from casing.

12.

Draw out drive shaft (5) using a plastic mallet.

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RAPH12CEX0055BA

3

RAPH12CEX0056BA

4


13.

Perform the following operations as required: a. Drawing the inner race of roller bearing (28) from drive shaft (5) , using a press. b. Drawing out the outer race of roller bearing (28) from casing (18) , by lightly tapping the steel rod from the oil seal (34) housing side. c. Separate the outer race of roller bearing (42) from valve casing (19) , using a slide hammer bearing puller.

RAPH12CEX0057BA

ATTENTION: Do not reuse the bearing.

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5


Swing reduction motor - Assemble [46019908] SK170-9 LA

1.

2.

Place casing (18) on a proper bench facing upward. The following operations are necessary only when the roller bearings (28) and (42) are removed: A.

Shrinkage fit the inner race of roller bearing (28) into drive shaft (5) .

B.

Shrinkage fit the inner race of roller bearing (42) to drive shaft (5).

C.

Fit oil seal (34)to casing (18).

D.

Assemble the outer race of roller bearing (28)into casing (18), by lightly tapping the steel rod.

Attach drive shaft (5)to casing (18).

3.

Insert shoe plate (11).

4.

Set the set plate (10)and spring (7), then set piston sub (8) and (9)assembly.

5.

Assemble piston sub assembly (8)and (9)fixed in retainer plate (10)into cylinder (6), match it to the spline of drive shaft (5)and insert it in place.

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RAPH12CEX0058BA

1

RAPH12CEX0059BA

2


6.

7.

Place casing (18)with oil seal facing downward and assemble separator plate (40)and friction plate (39)into casing (18).

RAPH12CEX0060BA

3

RAPH12CEX0060BA

4

Fit O-rings (36) , (37) to casing (18) .

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8.

Assemble brake piston (35) into casing (18).

9.

Assemble brake spring (38) into brake piston (35) . Make sure that a spring is placed securely in the spot faced part of the brake piston.

NOTE: The following operation is necessary only where roller bearing (42) is removed. 10.

Insert the outer race of roller bearing (42) into valve casing (19) , while lightly tapping the steel rod using a hammer.

11.

Assemble valve plate (12) into valve casing (19) and fit O-ring (32) in it.

12.

Install valve casing (19) to casing (18) and fasten them with socket bolts (27) .

13.

Fit plunger (20) and spring (21) to valve casing (19) . Then tighten plug (31) fitted with O-ring (33) against valve casing (19) .

14.

Fit relief valve (1) to valve casing (19) .

15.

Fit anti-reaction sub assembly (3) to valve casing (19) .

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RAPH12CEX0053BA

5

RAPH12CEX0054BA

6

Index Hydraulic systems - 35 Hydraulic swing system - 352 Hydraulic swing system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Hydraulic swing system - Overview Hydraulic Swing Motor and Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Swing reduction gear - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SK170-9 LA

Swing reduction gear - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SK170-9 LA

Swing reduction gear - Dynamic description Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA

Swing reduction gear - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Swing reduction motor - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SK170-9 LA

Swing reduction motor - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 SK170-9 LA

Swing reduction motor - Dynamic description Swing Motor Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

Swing reduction motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SK170-9 LA

Swing reduction motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SK170-9 LA

Swing reduction motor - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

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Hydraulic systems - 35 Hydraulic travel system - 353

SK170-9

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Contents Hydraulic systems - 35 Hydraulic travel system - 353

FUNCTIONAL DATA Hydraulic travel system Overview Travel Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

SERVICE Hydraulic travel system Remove Hydraulic Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Install Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Disassemble Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Assemble Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SK170-9 LA

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Reference Hydraulic travel system - Assemble Travel Motor

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PAGE 35.353 / 69

Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Overview Travel Device [62556198] SK170-9 LA

Characteristics Item

SK170–9 Epicycloidal, three-stage planetary type 710 C3 K 1 : 63.1 Two speed, axial piston swash plate type MAG 85 VP 17 50.4 cm³/rev (3.1 in³/rev) 87.3 cm³/rev (5.3 in³/rev) 130.4 l/min (34.45 US gpm) 17368 N·m (12810 lb ft) 30087 N·m (22191 lb ft) 234 N·m (173 lb ft) 194 N·m (143 lb ft) 14 bar (203 psi) 311 bar (4510 psi) at 1.1 l/min (0.29 US gpm) 353 bar (5119 psi) at 37 l/min (9.77 US gpm) 245 kg (540 lb)

Reduction gear unit Model Gearbox ratio Travel Motor Model Displacement

high speed low speed

Maximum flow Maximum gearbox output torque

high speed low speed static Parking brake torque dynamic Minimum pressure parking brake release cracking Relief valve set pressure total flow Mass

Hydraulic motor Two speed hydraulic motor (axial piston swash plate type) containing: • An integrated counterbalance valve; • A crossover relief valve which contains a shock absorber to smooth acceleration and stopping; - Integrated flushing valve; • A negative multi-disc parking brake built-in directly driven from the motor oil pressure (no additional hose is required); • Double speed function, allowing the motor to be set to a fast or slow speed.

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Planetary gearbox The planetary gearbox is a 3 stage, rotating housing type. The track drive is suitable to be used as a track drive for crawler machines equipped with a open loop hydraulic circuit.

RAPH12CEX0418EA

1

Ports P1 P2 T1 T2 Ps Pm1 Pm2

PF PF PF PF PF PF PF

3/4 3/4 1/2 1/2 1/4 1/4 1/4

in in in in in in in

Service ports Drain ports 2 speed control port Pressure gauge ports

RAPH12CEX0419FA

2

Hydraulic circuit

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Construction

RAPH12CEX0421GA

3

Track drive 1

Socket screw M10x25 (Quantity 10) 75 N·m (55 lb ft) 12 Socket screw M20x100 (Quantity 4) 58 N·m (431 lb ft) 2 End cover 13 3rd reduction planet carrier 3 Plug M22x1.5 (Quantity 2) 65 N·m (48 lb ft) 14 Bush (quantity 4) 4 Washer 15 Screw (quantity 16) 5 O-ring 16 Washer (quantity 16) 6 Plug 17 Sprocket 7 1st stage sun gear 18 Gearbox housing 8 1st stage reduction assembly 19 Lifetime seal 9 2nd stage sun gear 20 Centering ring 10 2nd stage reduction assembly 21 Hydraulic motor 11 3rd stage sun gear

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RAPH12CEX0422GA

4

Hydraulic motor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Flanged hub O-ring Orifice O-ring (quantity 4) Seal ring Bearing Motor shaft Steel ball (quantity 2) Two speed control spring (quantity 2) Two speed control piston (quantity 2) Swash plate Piston (quantity 9) Retainer plate Spherical retainer plate holder Pin (quantity 3)

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

O-ring (quantity 2) Socket head screw M10x35 (quantity 4) Flanged plug Ball (quantity 2) Spring (quantity 2) O-ring (quantity 2) Plug Flanged plug (quantity 2) Relief valve (quantity 2) Backup ring (quantity 4) O-ring (quantity 2) Backup ring (quantity 4) O-ring (quantity 2) O-ring (quantity 2) O-ring (quantity 2)

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16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Cylinder block Spring holder Spring Collar washer Circlip Valve plate Bearing Brake disk Backup ring O-ring O-ring Backup ring Brake piston Pin (quantity 2) Spring (quantity 8) Pin (quantity 2) O-ring (quantity 2) Counterbalance valve spool Spring seat (quantity 2) Spring (quantity 2) Spring seat (quantity 2)

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

Two speed spool Spring Spring seat Spring seat O-ring (quantity 2) Plug Plug Backup ring O-ring Backup ring Backup ring Conical plug (quantity 11) Orifice (quantity 2) Orifice (quantity 2) Base plate Plug (quantity 3) O-ring (quantity 3) Orifice (quantity 2) O-ring (quantity 2) Plug (quantity 2) Socket head screw M14x40 (quantity 9)

Motor drain pressure Continuous running Max intermittent

Less than 2 bar (29 psi) Less than 5 bar (73 psi)

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Brake The track drive is supplied with a safety negative disc brake fitted into the hydraulic motor (parking brake). Parking brake release is automatically operated when high pressure oil is supplied to on of the two ports of the hydraulic motor. For this reason, there is no need for brake external pilot pressure. The brake technical data is shown on the track drive installation drawing.

Direction of rotation See the following diagram for proper direction of rotation when assembling the track drive on the machine and for when connecting the hoses.

RAPH12CEX0423FA

Oil inlet port P1 P2

5

Oil outlet port P2 P1

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Direction of rotation Clockwise Counterclockwise


Hydraulic travel system - Remove Hydraulic Motor Removal [59208687] SK170-9 LA

WARNING Escaping fluid! Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Make sure all components are in good condition and tighten all connections before pressurizing the system. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper. Failure to comply could result in death or serious injury. W1140A

WARNING Hot liquid under pressure! Service when cool. Failure to comply could result in death or serious injury. W1187A

DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Park the machine on a firm, level surface. Turn off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure from the hydraulic tank. The procedure starts on the premise that the track link has already been removed. 1.

Loosen bolts (7) M12 to remove cover (6). Disconnect hoses (2), (3), (4) and (5).

NOTE: Install caps on all disconnected hose and line ends. 2.

Attach the travel device to a crane using a steel cable. Remove any slack from the cable so the travel motor is secured when the mounting bolts are removed.

NOTE: Travel motor weight: 245 kg (540 lb) 3.

Remove the mounting bolts (1) M16. Remove the travel motor using the crane.

RAPH12CEX0920AA

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1


Hydraulic travel system - Install Travel Motor [59262411] SK170-9 LA

1.

Install the travel motor using bolts (1).

2.

Connect hoses (2), (3), (4) and (5)

3.

Install cover (6) and secure it with screws (7) and washers (8) and (9).

NOTE: After completing the travel motor installation, be sure to fill the travel motor with hydraulic oil. After filling with hydraulic oil, be sure to perform a drive test on the motors to prevent motor seizure. Test in the following way: 1. Run the engine with the engine throttle at idle. 2. Turn the travel speed mode switch to the slow speed position. 3. Test drive the machine back and forth for 0.5 - 1 m (1.6 - 3.3 ft) in each direction five times or more.

RAPH12CEX0920AA

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1


Hydraulic travel system - Disassemble Travel Motor [59270370] SK170-9 LA

Preliminary operations In the case that it was necessary to undergo a (partial or total) revision, it will be necessary to dismount the gear motor from the machine. As this is known as an out of the ordinary maintenance procedure, it is important that only personnel with specific skills and experience undertake it. It is also important that this procedure is undertaken in a workshop that is adequately tooled. As well as normal workshop tools it will be necessary to use special tools. In the following pages all the procedures for disassembling and reassembling the gear motor are given, it is important to strictly adhere to them. Proceed with these operations using all the necessary safety measures, like for example: 1.

Removing all of the hydraulic system connections on the gear motor to avoid the introduction of any foreign parts in the circuit and the gear motor.

2.

Making sure that the coupling surfaces are not damaged.

3.

Following the handling precautions so as to be sure that there are no risks to human safety and to guarantee the reliability of the gear motor.

4.

Making work area available that is in line with the health and work safety guidelines.

Initial inspection of the gears, can be made without disassembling the track and the track drive from the machine. Before track drive disassembling, make sure that the oil is discharged.

Gearbox disassembly 1.

Make sure that the hydraulic oil is discharged.

2.

Unscrew the socket bolts (1) which secure the end cover (2) to the gear box housing (3).

RAPH12CEX0729AA

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1


3.

4.

5.

Remove the end cover (2) by using screws (4) screwed into the oil plugs holes.

RAPH12CEX0730AA

2

RAPH12CEX0731AA

3

RAPH12CEX0915AA

4

Remove the o-ring seal (1) from the end cover (2).

Take out the 1st stage sun gear (2).

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6.

7.

8.

Remove the 1st reduction assembly (1).

RAPH12CEX0914AA

5

RAPH12CEX0913AA

6

RAPH12CEX0912AA

7

Take out the 2nd stage sun gear (4).

Remove the 2nd reduction assembly (3).

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9.

10.

11.

Take out the 3rd stage sun gear (2).

RAPH12CEX0911AA

8

RAPH12CEX0737AA

9

Unscrew the socket bolts (3), which secure the 3rd reduction assembly to the hydraulic motor.

Using a puller, remove the 3rd reduction planetary carrier (4) from the hydraulic motor (5).

RAPH12CEX0738AA

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10


12.

13.

14.

Using a puller (A), remove the bushings (1) from the reduction planetary carrier (2).

RAPH12CEX0739AA

11

RAPH12CEX0740AA

12

RAPH12CEX0741AA

13

Using a puller (A) remove the planetary gear assemblies of the 3rd reduction (2).

Lift the gear box housing (3) positioning it onto two spacers. by using a press and a metal stopper, remove the hydraulic motor (4) from the gear box housing (3) paying attention to the main bearing balls falling out of the housing.

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15.

16.

17.

Use a screwdriver to remove the 1st half-seal from the hydraulic motor (4).

RAPH12CEX0742AA

14

RAPH12CEX0743AA

15

RAPH12CEX0744AA

16

Use a screwdriver to remove the 2nd half-seal (1) from the gear box housing.

Use a puller to remove the bearing inner race remaining on the hydraulic motor (3).

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18.

Remove the bearing balls from the gear box housing (4).

RAPH12CEX0745AA

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17


Disassembly of the hydraulic motor DISASSEMBLY OF THE TWO SPEED CONTROL ASSEMBLY 1.

2.

3.

Unscrew the plug (1) from the base plate (2).

RAPH12CEX0746AA

18

RAPH12CEX0747AA

19

RAPH12CEX0748AA

20

Remove the o-ring seal from its seat in the plug (1).

Remove the o-ring seal (4)from its seat in the plug (2).

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4.

5.

6.

Take out the spring (1)

RAPH12CEX0749AA

21

RAPH12CEX0750AA

22

RAPH12CEX0751AA

23

Unscrew the plug (2) from the base plate.

Remove the o-ring seal (3) from its seat in the plug (2).

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7.

Take out the two speed spool (4).

RAPH12CEX0752AA

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24


DISASSEMBLY OF THE RELIEF VALVE. 1.

2.

3.

Unscrew the relief valve (1) from the base plate (2).

RAPH12CEX0753AA

25

RAPH12CEX0754AA

26

RAPH12CEX0755AA

27

Take out the free piston (3) from the relief valve (1).

Remove the o-ring seal (4) and the backup rings (5) from their seats in the free piston (3).

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4.

Remove the o-ring seal (6) from relief valve (1). Repeat the same steps for the 2nd relief valve disassembly (1).

RAPH12CEX0756AA

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28


DISASSEMBLY OF THE COUNTERBALANCE VALVE. 1.

2.

3.

Unscrew the socket bolts (1), of the 1st flanged plug assembly (2).

RAPH12CEX0757AA

29

RAPH12CEX0759AA

30

RAPH12CEX0760AA

31

Take out the 1st flanged plug (2) and the spring seat.

Remove the 1st spring (3).

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4.

5.

6.

Take out the 1st spring seat (4) from the counterbalance valve spool (5).

RAPH12CEX0761AA

32

RAPH12CEX0762AA

33

RAPH12CEX0763AA

34

Unscrew the socket bolts (1), of the 2nd flanged plug assembly.

Take out the 2nd flanged plug (2) and the spring seat.

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7.

8.

9.

Remove the 2nd spring (3).

RAPH12CEX0764AA

35

RAPH12CEX0765AA

36

RAPH12CEX0766AA

37

Take out the 2nd spring seat (1) from the counterbalance valve spool (2).

Take out the counterbalance valve spool (3).

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DISASSEMBLY OF FLANGED PLUG 1.

2.

3.

Remove the o-ring seal (2) from the flanged plug (4).

RAPH12CEX0767AA

38

RAPH12CEX0768AA

39

RAPH12CEX0769AA

40

Unscrew the plug (5) from the flanged plug (6).

Take out the spring (1) from the plug (2).

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4.

5.

Remove the o-ring seal (3) from the plug (2).

RAPH12CEX0770AA

41

RAPH12CEX0771AA

42

Take out the ball (4) from the flanged plug (5). Repeat the same steps for the 2nd flanged plug disassembly.

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DISASSEMBLY OF THE BASE PLATE 6.

7.

8.

Unscrew the plugs (1) from the base plate (2).

RAPH12CEX0772AA

43

RAPH12CEX0773AA

44

RAPH12CEX0774AA

45

Remove the o-ring seal (3) from the plug (4).

Unscrew the conical plugs from the base plate (2).

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9.

10.

11.

Unscrew the conical plugs (5) from the base plate (2).

RAPH12CEX0775AA

46

RAPH12CEX0776AA

47

RAPH12CEX0777AA

48

Unscrew the orifices (1) from the base plate.

Remove the caulking with a M5 tap before unscrewing the orifices (2).

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12.

13.

14.

Unscrew the orifices (2) from the base plate.

RAPH12CEX0778AA

49

RAPH12CEX0779AA

50

RAPH12CEX0780AA

51

Unscrew the plug (1) from the base plate.

Remove the o-ring seal (1) from its seat in the plug (2).

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15.

16.

17.

Unscrew the socket bolts (3), of the base plate.

RAPH12CEX0781AA

52

RAPH12CEX0782AA

53

RAPH12CEX0783AA

54

Remove carefully the base plate (4) until pins are completely out.

Remove the caulking in the brake pilot hole in the base plate (4) with a M5 tap.

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18.

19.

20.

Unscrew the orifice (1) from the base plate.

RAPH12CEX0784AA

55

RAPH12CEX0785AA

56

RAPH12CEX0786AA

57

Take out the pins (2).

Remove the valve plate (3).

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21.

Using a puller, remove the bearing (4) from the base plate (5) .

RAPH12CEX0787AA

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58


DISASSEMBLY OF MOTOR SHAFT AND CYLINDER BLOCK 1.

2.

3.

Remove the o-ring seal (1) from its seat in the flanged hub (2).

RAPH12CEX0788AA

59

RAPH12CEX0789AA

60

RAPH12CEX0790AA

61

Remove the o-ring seal (3) from its seat in the brake pilot hole in the flanged hub (2).

Remove the o-ring seals (3) from their seat in the two speed control holes in the flanged hub (2).

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4.

5.

6.

Remove the springs (4) from the brake piston.

RAPH12CEX0791AA

62

RAPH12CEX0792AA

63

RAPH12CEX0793AA

64

Mark the position of the brake piston (1) as a reference for the reassembling step.

Remove the brake piston (1).

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7.

8.

9.

Remove the o-ring seals (2) and the backup rings from their seats in the brake piston (1).

RAPH12CEX0794AA

65

RAPH12CEX0795AA

66

RAPH12CEX0796AA

67

Take out the brake disc (3).

Remove the cylinder block (1).

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10.

11.

12.

Take out the spherical retainer plate holder (2).

RAPH12CEX0797AA

68

RAPH12CEX0799AA

69

RAPH12CEX0822AA

70

Take out the pins (3) from their seats in the cylinder block (1).

Disassemble the pistons and the retainer plate (1).

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13.

14.

15.

Take out the pistons (2) from the retainer plate (3).

RAPH12CEX0823AA

71

RAPH12CEX0824AA

72

RAPH12CEX0825AA

73

Remove the swash plate (4) from the flanged hub (5).

Take out the steel balls (6) from their seats in the flanged hub (5).

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16.

17.

18.

Take out the two speed control pistons (1).

RAPH12CEX0826AA

74

RAPH12CEX0827AA

75

RAPH12CEX0828AA

76

Take out the two speed control springs (2).

Using a punch, take out the motor shaft and the bearing from the flanged hub.

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19.

20.

Using a puller, take out the bearing (3) from the motor shaft (4).

RAPH12CEX0829AA

77

RAPH12CEX0830AA

78

Using a screwdriver remove the seal ring (1) from its seat in the flanged hub.

NOTE: Disassemble the seal ring only when replacing it, as disassembling it will damage it.

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Hydraulic travel system - Assemble Travel Motor [59341772] SK170-9 LA

Prior operation: In the case of damaged gears, do not replace the damaged gear alone. Replace the entire reduction range for that gear. Prior operation: Always replace the o-rings and seals on the parts to be reassembled after having carefully cleaned the seats they are installed in. Be sure the grease the o-rings and seals along with the seats to ensure a proper assembly. Prior operation: Replace any worn or damaged parts with original spare parts.

Hydraulic motor assembly ASSEMBLY OF MOTOR SHAFT AND CYLINDER BLOCK 1.

2.

Place the seal ring (1) into its seat in the flanged hub (2).

RAPH12CEX0831AA

1

RAPH12CEX0832AA

2

Using tool (B) (380001077) and a rubber hammer, push the seal ring against the seat shoulder.

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3.

4.

5.

Place the bearing (1) on the motor shaft (2)

RAPH12CEX0833AA

3

RAPH12CEX0834AA

4

RAPH12CEX0835AA

5

Using a tool (C) (380001078) and a rubber hammer push the bearing (1) against the shaft shoulder (2).

Place the bearing-motor shaft unit (4) in the seat inside the flanged hub (5).

NOTE: Be sure to grease the shaft before inserting it into the motor seal.

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6.

7.

8.

Using a tool (D) (380001079) and a rubber hammer, push the bearing-motor shaft unit (4) against the flanged hub shoulder (5).

RAPH12CEX0836AA

6

RAPH12CEX0837AA

7

RAPH12CEX0838AA

8

Assemble the steel balls (1) into their seats (2) in the flanged hub.

Assemble the two speed springs (3) into their seats in the two speed pistons (4).

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9.

Assemble the two speed pistons (4) into their seats inside the flanged hub.

NOTE: Be sure that the pistons move freely into their seats.

RAPH12CEX0839AA

10.

11.

9

Insert the swash plate (5) inside the flanged hub being careful that the spherical housings (2) match with the steel balls (1).

RAPH12CEX0840AA

10

RAPH12CEX0841AA

11

Assemble the pins (1) in their seats in the cylinder block (2).

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12.

Assemble the spherical retainer holder (3) on the cylinder block (2).

NOTE: The two splines must be aligned together.

13.

14.

RAPH12CEX0842AA

12

RAPH12CEX0843AA

13

RAPH12CEX0844AA

14

Piston orifice (4) must be open and free of dust or dirt.

Assemble the pistons (4) correctly in the retainer plate (5).

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15.

16.

17.

Assemble the pistons-retainer plate unit (1) in the cylinder block.

RAPH12CEX0846AA

15

RAPH12CEX0847AA

16

RAPH12CEX0848AA

17

Assemble the cylinder block unit (2) into the flanged hub (3) on the motor shaft spline (4).

Insert the brake disc (5) in the cylinder block (2).

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18.

19.

Assemble the back up ring (6) into its seat in the brake piston (7).

RAPH12CEX0849AA

18

RAPH12CEX0850AA

19

RAPH12CEX0851AA

20

Assemble the o-rings seals (1) into their seats in the brake piston (2). Assemble the back up ring (3) into its seat as shown in the image at right.

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20.

21.

22.

Assemble the brake piston (2) respecting the markings set out previously and being careful not to damage the seals already fitted.

RAPH12CEX0852AA

21

RAPH12CEX0853AA

22

RAPH12CEX0854AA

23

Assemble the o-ring seal (4) into its seat in the flanged hub.

Assemble the o-ring seal (6) into the brake pilot hole of the flanged hub (5).

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23.

24.

Assemble the o-ring seals (1) into their seats in the two speed control holes in the flanged hub.

RAPH12CEX0855AA

24

RAPH12CEX0856AA

25

RAPH12CEX0857AA

26

Insert the springs (2) in their seats in the brake piston (3).

ASSEMBLY OF THE BASE PLATE 1.

Tighten the orifice (1) in the base plate (2).

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2.

3.

4.

Using a punch (3) and a hammer, deform the thread hole.

RAPH12CEX0858AA

27

RAPH12CEX0859AA

28

RAPH12CEX0860AA

29

Assemble the bearing (4) into its seat in the base plate (2).

By using a tool (E) (380001080) and a rubber hammer, push the bearing (4) against the base plate seat shoulder (2).

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5.

Place the valve plate (1) on the base plate (2).

NOTE: Bronze surface layer must be up.

6.

7.

RAPH12CEX0861AA

30

RAPH12CEX0862AA

31

RAPH12CEX0863AA

32

Insert the pins (2).

Place the base plate (3) on the flanged hub (4).

NOTE: The base plate is centered by two pins and the second speed oil passages must match each other.

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8.

9.

10.

Fix the base plate (2) to the flanged hub by using socket head bolts (5). Torque bolts to 195 - 215 N·m (143.8 - 158.6 lb ft)

RAPH12CEX0864AA

33

RAPH12CEX0865AA

34

RAPH12CEX0866AA

35

Using the tool (F) (380001065) assemble the o-ring seals (1) in their seats in the plugs (2).

Tighten the plugs to 34.3 - 39.3 N·m (25.3 - 29.0 lb ft).

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11.

12.

13.

Tighten the orifices (3) in the base plate. Torque to 2 - 3 N·m (1.48 - 2.21 lb ft).

RAPH12CEX0776AA

36

RAPH12CEX0775AA

37

RAPH12CEX0867AA

38

Seal the thread of the plugs (4) with sealing tape. Tighten the plugs in the base plate to 9 - 11 N·m (6.64 - 8.11 lb ft)

Tighten the orifices (1) in the base plate to 2 - 3 N·m (1.48 - 2.21 lb ft).

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14.

Using a punch and a hammer, deform the threaded hole.

RAPH12CEX0868AA

39

RAPH12CEX0869AA

40

RAPH12CEX0870AA

41

ASSEMBLY OF THE FLANGED PLUG 1.

2.

Insert ball (2) in the flanged plug (3).

Using tool (G) 380001066 assemble the o-ring (4) in its seat in the plug (5).

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3.

4.

5.

Insert the spring (1) into the plug (2).

RAPH12CEX0871AA

42

RAPH12CEX0872AA

43

RAPH12CEX0873AA

44

Tighten the plug (2). to 19.6 - 21.6 N·m (14.46 - 15.93 lb ft)

Assemble the o-ring (3) in its seat in the flanged plug (4).

ASSEMBLY OF THE COUNTERBALANCE VALVE

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1.

2.

3.

Insert the counterbalance valve spool (5) .

RAPH12CEX0874AA

45

RAPH12CEX0875AA

46

RAPH12CEX0876AA

47

Insert the 1st spring seat (1) on the counterbalance valve spool (2).

Insert the 1st spring (3) on the counterbalance valve spool (2).

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4.

5.

6.

Assemble the 1st flanged plug (1) with proper spring seat.

RAPH12CEX0877AA

48

RAPH12CEX0878AA

49

RAPH12CEX0879AA

50

Tighten the socket bolts (2), of the 1st flanged plug (1). Torque to 54 - 64 N·m (39.8 - 47.2 lb ft)

Insert the 2nd spring seat (3) on the counterbalance valve spool (4).

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7.

8.

9.

10.

Insert the 2nd spring (5) on the counterbalance valve spool (4)

RAPH12CEX0880AA

51

RAPH12CEX0759AA

52

RAPH12CEX0878AA

53

Assemble the 2nd flanged plug (1) with proper spring seat.

Tighten the socket bolts (2), of the 1st flanged plug (1). Torque to 54 - 64 N·m (39.8 - 47.2 lb ft)

ASSEMBLY OF THE RELIEF VALVE

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11.

12.

Using the tool (H) 380001067, assemble the o-ring seal (3) in its seat in the relief valve (4).

RAPH12CEX0883AA

54

RAPH12CEX0884AA

55

Assemble the 1st backup ring (1) into its seat in the free piston.

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13.

14.

Assemble the o-ring seal (3) into its seat in the free piston. After this step assemble the 2nd backup ring as shown at right.

RAPH12CEX0885AA

56

RAPH12CEX0886AA

57

RAPH12CEX0887AA

58

Insert the free piston (2) into the relief valve (4), checking that the groove side is toward the inside of the motor.

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15.

16.

Insert the relief valve (1) inside the base plate (2).

RAPH12CEX0888AA

59

RAPH12CEX0889AA

60

RAPH12CEX0890AA

61

Tighten the relief valve (1) to 353 - 393 N·m (260.4 289.9 lb ft)

17.

ASSEMBLY OF THE TWO SPEED CONTROL

18.

Using the tool (I) 380001068, assemble the o-ring (3) in its seat in the plug (4).

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19.

20.

Tighten the plug (4) to 115 - 125 N·m (84.8 - 92.2 lb ft)

RAPH12CEX0891AA

62

RAPH12CEX0892AA

63

RAPH12CEX0893AA

64

Insert the two speed spool (1) in the base plate (2).

NOTE: Two speed spool must move smoothly inside its seat in the base plate.

21.

Insert the sping (3) in the two speed spool (1).

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22.

23.

24.

Insert the spring seat (4) and the washer.

RAPH12CEX0748AA

65

RAPH12CEX0890AA

66

RAPH12CEX0895AA

67

Using the tool (I) 380001068, assemble the o-ring seal (1) in its seat in the plug (2).

Tighten the plug (3) to 115 - 125 N·m (84.8 - 92.2 lb ft)

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Gearbox assembly 1.

2.

3.

Get a new lifetime seal ready for installation. 1.

Carefully clean the seats (1) and (2) using, if necessary, metal brushes and solvent. Surfaces in contact with (3) or (6) must be perfectly clean and dry.

2.

Make sure that sealing surfaces (4) of metal rings (5) are free from scratches, dings or foreign substances. Metal ring surfaces must be perfectly clean and dry.

3.

Carefully clean the lapped surface (4) of metal rings (5) and remove dust or fingerprints. Then lubricate them with a thin oil film, taking care not to oil the other components. RAPH12CEX0896AA

68

RAPH12CEX0897AA

69

RAPH12CEX0898AA

70

Assemble a half seal (7) on the tool (J) 380001069.

Assemble a half seal (8) on the hydraulic motor.

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4.

5.

Carefully clean the metallic faces of the lifetime seal (1), and lube them with a thin film of oil.

RAPH12CEX0899AA

71

RAPH12CEX0900AA

72

Fit the lower ball row (d), into the gearbox housing (2) holding the innner raceway (c) with spacers (a) and the tube (F) 380001081.

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6.

Remove the spacer (a).

7.

Drop the upper ball row (e).

8.

Assemble the inner raceway (f).

9.

10.

RAPH12CEX0901AA

73

RAPH12CEX0902AA

74

RAPH12CEX0903AA

75

Using the tool (J) 380001069, assemble the half seal on the gearbox housing. Carefully clean the metal faces of the half-seals.

Using a hoist, position the hydraulic motor (2) inside the gearbox housing (1).

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11.

12.

13.

Using a press, and the tool (L) 380001082, push the hydraulic motor (2) against the shoulder of the gearbox housing (1) until assembly of the unit is complete.

RAPH12CEX0904AA

76

RAPH12CEX0905AA

77

RAPH12CEX0906AA

78

Screw the safety bushing (M) 380001083 in one of the four holes in the hydraulic motor by using the socket bolts (3), and turn the unit upside down. At the end of the above step, disassemble the safety bushing.

Place the bushings (1) into their seats in the hydraulic motor (2) and using a press, push them against the shoulder inside their seats until assembly is complete.

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14.

15.

16.

Place the planetary assemblies of the 3rd reduction (3) into their seats in the hydraulic motor (2). Using a press, push them against the shoulder until assembly is complete.

RAPH12CEX0907AA

79

RAPH12CEX0908AA

80

RAPH12CEX0909AA

81

Position the 3rd reduction planet carrier (4) on the hydraulic motor (2) and using a press, push it against the shoulder.

Apply LOCTITE® 243 on the socket bolts (5), and insert them in the threaded holes in the hydraulic motor.

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17.

18.

19.

Tighten the socket bolts (1) to 585 N·m (431 lb ft).

RAPH12CEX0910AA

82

RAPH12CEX0911AA

83

RAPH12CEX0912AA

84

Insert the 3rd stage sun gear (2).

Assemble the 2nd reduction assembly (3).

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20.

21.

22.

Insert the 2nd stage sun gear (4).

RAPH12CEX0913AA

85

RAPH12CEX0914AA

86

RAPH12CEX0915AA

87

Assemble the 1st reduction assembly (1).

Insert the 1st stage sun gear (2).

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23.

24.

25.

Assemble the o-ring seal (3) into its seat in the end cover (4) .

RAPH12CEX0916AA

88

RAPH12CEX0917AA

89

RAPH12CEX0918AA

90

Assemble the end cover (4) on the gearbox housing (5).

Secure the cover (1) to the gearbox housing (2) using socket bolts (3). Torque socket bolts to 75 N·m (55 lb ft).

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26.

Fill the gearbox with lubricant oil. Tighten the plugs (4) into the oil drain-filling holes of the end cover and torque them to 60 - 70 N·m (44.3 - 51.6 lb ft).

RAPH12CEX0919AA

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91

Index Hydraulic systems - 35 Hydraulic travel system - 353 Hydraulic travel system - Assemble Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SK170-9 LA

Hydraulic travel system - Disassemble Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Hydraulic travel system - Install Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Hydraulic travel system - Overview Travel Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Hydraulic travel system - Remove Hydraulic Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

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Hydraulic systems - 35 Hydraulic central joint - 354

SK170-9

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Contents Hydraulic systems - 35 Hydraulic central joint - 354

TECHNICAL DATA Hydraulic swivel Service limits Swivel Joint Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Hydraulic swivel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

SERVICE Hydraulic swivel Disconnect Disconnecting hoses of swivel joint lower side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Remove Swivel Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA


Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SK170-9 LA

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CONSUMABLES INDEX Consumable Loctite® 242 Loctite® 242

Reference Hydraulic swivel - Assemble Hydraulic swivel - Assemble

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PAGE 35.354 / 19 35.354 / 19

Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Service limits Swivel Joint Maintenance Standard [59535099]

Body, Stem

Item Sliding surface and sealed parts Sliding surface, no sealed parts Sliding surface ring

Cover

Sliding surface ring

Remedy

Allowable Limit Scored or damaged

Replace

Scored more than 0.1 mm (0.004 in) Scored less than 0.1 mm (0.004 in) Wear more than 0.5 mm (0.02 in) Wear less than 0.5 mm (0.02 in) Scored less than 0.5 mm (0.02 in) and able to repair. Wear more than 0.5 mm (0.02 in) Wear less than 0.5 mm (0.02 in) Scored less than 0.5 mm (0.02 in) and able to repair. 1. Protrudes excessively from the seal

Replace Repair with oil stone Replace Repair Repair Replace Repair Repair

Replace (with backup ring)

groove. 2. Slipper ring more than 1.5 mm (0.059 in) narrower than the seal groove, or narrower than the backup ring. Slipper ring


3. Worn unevenly more than 0.5 mm (0.02 in).


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Hydraulic swivel - Overview [52503716] SK170-9 LA

Outline

RAPH12CEX0425GA

1

General view Specifications High pressure ports A,B,C,D

Low pressure ports E Low pressure ports F Revolution speed Ports size

Working pressure Maximum impact pressure Rated flow Working pressure Rated flow Working pressure Rated flow A,B.C.D (body) A,B,C,D (stem E F

Length (height) Weight 47454079-DRAFT 06/11/2012

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34.3 MPa (4975.2 psi) 51.5 MPa (7470.1 psi) 255 l/min (67.4 US gpm) 0.49 MPa (71 psi) 50 l/min (13 US gpm) 5 MPa (725 psi) 30 l/min (8 US gpm) 15 RPM PF1 PF3/4 PF 1/2 PF 1/4 368 mm (14.5 in) 24.6 kg (54.2 lb)


Construction

RAPH12CEX0426GA

1 2 3 4 5 6

Body Stem Thrust plate Cover Seal (quantity 5) Seal

7 8 9 12 13

2

O-ring Capscrew; M8x20 (quantity 2) 30.4 N·m (22.4 lb ft) Capscrew; M8x20 (quantity 3) 30.4 N·m (22.4 lb ft) Plug O-ring

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Operation The swivel joint consists of: 1. a body (1) and a stem (2) that rotate simultaneously, 2. A thrust plate (3) that holds components together, 3. A cover (4) that closes one side of the body (1), 4. A seal (5) that partitions off the circuits and seal assembly (6) and, 5. an O-ring (7) that prevents external leaks. There are four ports for the travel main circuits on the body (1) and the stem (2) There are four oil passing grooves in the inner surface of the body (1) with a seal (5) fixed above and below the circumferential groove. The oil flowing in from the body (1) or the stem (2) keeps on flowing past the circumferential groove between the body (1) and the stem (2). The oil flow is never cut off because of the rotation. Also, there is an oil groove for lubrication that connects with the drain port which prevents the body (1) from seizing with the stem (2). This construction keeps the circuits connected between the swing bodies by a swivel joint.

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Hydraulic swivel - Disconnect Disconnecting hoses of swivel joint lower side [46313703] SK170-9 LA

1.

Disconnect the two hose (1) . (E Port: PF1/2)

2.

Disconnect the hose (2) and (3).

3.

Disconnect the hose (4) and (5) .

4.

Disconnect the two hose (6) .

RAPH12CEX0112GA

1

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RAPH12CEX0129GA

2

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Hydraulic swivel - Remove Swivel Joint [59446232] SK170-9 LA

WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

Park the machine on a firm, level surface. Turn off the engine. Actuate the control lever and pedal pilot valves to release any residual pressure from inside the hydraulic system. Press the valve on top of the hydraulic oil tank fill cap until no pressure resides in the hydraulic tank. 1.

Remove tube (5) and (6).

2.

Remove tubes (1) and (7).

3.


4.


RAPH12CEX0922FA

1

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5.

Remove drain hose (2).

6.

Remove hoses (4) and (6).

7.

Remove hoses (1) and (3).

8.

Remove hose (5).

9.

10.

RAPH12CEX0923BA

2

RAPH12CEX0924AA

3

RAPH12CEX0925AA

4

Loosen the stop nut (7) M20 of the swivel joint and remove the screw (8) M20x120.

Remove the two adapters (9) and (10).

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11.

Remove screws (2) M10x25.

12.

Remove clip (1).

13.

Remove seal (4).

14.

RAPH12CEX0926AA

5

RAPH12CEX0927AA

6

Attach an eye bolt (5), lift it up temporarily, and remove the screws (6) M12x35.

NOTE: Swivel joint weight: 31 kg (68.3 lb).

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Hydraulic swivel - Install [59453326] SK170-9 LA

1.

Attach an eye bolt (5), lift the swivel joint with a hoist, and install the screws (6) M12x35. Torque the bolts to 108 N·m (79.7 lb ft).

2.

Install seal (4).

3.

Tighten clip (1) onto seal (4). Torque to 6.8 N·m (5.0 lb ft).

4.

Attach ring (3) using screws (2) M10x25. Torque screws to 14.7 N·m (10.8 lb ft).

5.

RAPH12CEX0927AA

1

RAPH12CEX0926AA

2

RAPH12CEX0925AA

3

Install two adapters (9) and (10). Torque to 36 N·m (26.6 lb ft).

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6.

Install the stop nut (7) M20 and the screw (8) M20x120. Torque to 157 N·m (115.8 lb ft).

7.

Attach hose (5). Torque to 24.4 - 34.4 N·m (18.0 25.4 lb ft).

8.

Attach hose (1) and (3). Torque to 159 - 195 N·m (117.3 - 143.8 lb ft).

9.

Attach hoses (4) and (6). Torque to 159 - 195 N·m (117.3 - 143.8 lb ft).

10.

Attach drain hose (2). Torque to 73.5 - 83.5 N·m (54.2 - 61.6 lb ft).

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RAPH12CEX0924AA

4

RAPH12CEX0923BA

5


11.

Attach tubes (3) and (4). Torque to 24.4 - 34.4 N·m (18.0 - 25.4 lb ft).

12.

Attach tubes (2) and (8). Torque to 159 - 195 N·m (117.3 - 143.8 lb ft)

13.

Attach tubes (1) and (7). Torque to 159 - 195 N·m (117.3 - 143.8 lb ft)

14.

Attach tube (5) and (6). Torque to 73.5 - 83.5 N·m (54.2 - 61.6 lb ft).

RAPH12CEX0922FA

6

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Hydraulic swivel - Disassemble [59496697] SK170-9 LA

1.

Mark cover (4) and body (1) with matching marks for convenient reassembly.

2.

Place a ‘V’ block (A) on a work bench. Then place the swivel joint set on it and secure it to the block. Then loosen socket bolt (9). Alternatively, the swivel joint can be held fast by putting the stem (2) in a vise.

3.

4.

RAPH12CEX0928AA

1

RAPH12CEX0929AA

2

RAPH12CEX0930AA

3

Remove cover (4) from body (1) and draw out o-ring (7) from cover (4).

Loosen socket bolt (8) fastening thrust plate (3), in the same way cover was removed in the above step. When removing thrust plate (3) by holding the body (1) in a vise, support stem (2) so it won’t fall out.

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5.

6.

Place body (1) on a ‘V’ block (A). Put a wooden block (B) against the stem (2) that is big enough to cover at least half of the stem. Use a mallet to strike the block, forcing the stem out. When the stem is about halfway out, it can be pulled the rest of the way out by hand.

RAPH12CEX0931AA

4

RAPH12CEX0932AA

5

RAPH12CEX0933AA

6

Remove the back-up ring on the seal assemblies (5) and (6) by using a spatula (E).

NOTE: Be sure not to score the body (1) when using the spatula (E).

7.

Take off the slip ring (B) on the seal assemblies (5) and (6).and remove them from the o-ring grooves (D).

NOTE: Be sure not to score the body (1) when removing rings.

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Hydraulic swivel - Assemble [59508281] SK170-9 LA

Prior to assembly, clean each part (excluding the o-ring and slipper ring), and arrange in the sequence of assembly. 1.

Make sure that oil and grease have been completely removed from each piece.

2.

Apply grease to the groove where the o-ring (6) is seated.

3.

Apply a thin layer of hydraulic oil to o-ring (13) and insert it into the o-ring groove. Ensure the o-ring is not twisted.

4.

Slipper ring (B) is assembled, after first inserting the backup ring, by slightly distorting the shape as shown on right. After installation be sure all seals are completely in the seal groove.

5.

Assemble seal (5) using the same method as above after removing all traces of grease and oil from the seal groove. Seals (5) have no backup ring.

6.

RAPH12CEX0934AA

1

RAPH12CEX0935AA

2

Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease and slowly insert stem (2) into body.

NOTE: If stem is pressed in too fast, the seals may be damaged. Do it slowly. The clearance between the body (1) and the stem (2) is about 0.10 mm (0.004 in). Push stem straight along the shaft center.

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7.

While holding stem (2) and body , match the hole of the thrust plate (3) and the stem (2) hole.

8.

Next, after removing any oil from the thread of the socket bolt (8), coat it with LOCTITE® 242 and tighten to stem. Torque to 30.4 N·m (22.4 lb ft).

9.

After installing o-ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat the socket bolt (9) with LOCTITE® 242and tighten it which will then complete the assembly. Torque to 30.4 N·m (22.4 lb ft)

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RAPH12CEX0936AA

3

RAPH12CEX0928AA

4


Hydraulic swivel - Inspect [59542301] SK170-9 LA

INSPECTION AFTER ASSEMBLY 1.

High pressure port (A), (B), (C), (D) and (F). Install a directional valve (8) and pressure gauge (1) to the stem side port and body side port respectively, and while watching the pressure gauge (for high pressure) installed on the body side and also by regulating high pressure relief valve (7) , gradually increase the pressure. When the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) and lock in the hydraulic oil in the swivel. At this time, keep stop valve (6) on the low pressure relief valve side closed for, at least, 3 minutes and check for any distortions, breakages or loosening. During the first minute, check for oil leakages and, in case of pressure drop, this should be the 10% of the pressure trapped. This check should be performed on each circuit.

2.

Low pressure port (E). Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side. Open stop valve (6) on the side of low pressure relief valve (5). While watching the pressure gauge (for low pressure) connected to the body side and also by regulating low pressure relief valve gradually increase the pressure. Check for leakage with a color check at a pressure of 0.49 MPa (71 psi).

3.

Component Listing 1.

Pressure Gauge

2.

Swivel Joint

3.

Stop Valve

4.

Hydraulic source

5.

Relief Valve for low pressure

6.

Stop Valve

7.

Relief Valve for high pressure

8.

Directional Valve

9.

Piping, etc.

RAPH12CEX0943BA

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1

Index Hydraulic systems - 35 Hydraulic central joint - 354 Hydraulic swivel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

Hydraulic swivel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

Hydraulic swivel - Disconnect Disconnecting hoses of swivel joint lower side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Hydraulic swivel - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SK170-9 LA

Hydraulic swivel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

Hydraulic swivel - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Hydraulic swivel - Remove Swivel Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Hydraulic swivel - Service limits Swivel Joint Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Pilot system - 357

SK170-9

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Contents Hydraulic systems - 35 Pilot system - 357

FUNCTIONAL DATA Pilot control manifold Sectional view Right and Left Pilot Valve Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Exploded view Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

SERVICE Pilot control manifold Remove Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Disassemble Right and Left Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Assemble Right and Left Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Disassemble Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

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Reference Pilot control manifold - Assemble Right and Left Pilot Valve

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PAGE 35.357 / 14

Hydraulic systems - Pilot system

Pilot control manifold - Sectional view Right and Left Pilot Valve Cross-Sectional View [57253312] SK170-9 LA

RAPH12CEX0599FA

1. 2. 3. 4. 5. 6. 7. 8.

Adjusting nut M14 Boots Circular plate Joint M14 Plate Seal Plug O-ring

9. 10. 11. 12. 13. 14. 15. 17.

1

Push rod Spring Spring Spring seat 1 Spring seat 2 Spring seat 1 Spring Spring

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18. 19. 20. 21. 22. 23. 24.

Spring Washer 2 Spool Spool Casing 2 and 4 port 1 and 3 port


Pilot control manifold - Exploded view Travel Pilot Valve [58189311] SK170-9 LA

RAPH12CEX0680FA

1

NOTE: T = tightening torque Nm (lb ft) No. 5 6 6–d 6–f 6–g 6–l 7 7–h 7–I 7–j 7–k 8 10 11 12 12–o

Description Rubber boots Foot pedal (Switch plate) Switch plate Regulation screw M8x28 Set screw M5x8 Damping screw Retaining plate kit Plate Capscrew M10x20 Shaft Set screw M4x10 Flange kit Control spool Return spring Damper flange kit Damper plunger

Qty 2 2 2 4 4 4 1 1 2 2 2 4 4 4 4 4

No. 12–x 12–y 13 14 14–q 14–r 15 15–u 15–t 17 17–w 17–r 17–z 21 22

Description Seal 14x20x3 Wiper ring Damper spring Check valve kit Plug M8 Ball M6, 35 Orifice Plug M6 Orifice M6 Shuttle valve kit Shuttle valve & orifice Ball M6, 35 Orifice M5 Plug Valve body

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Qty 6 6 4 2 2 2 4 4 4 2 2 2 2 4 1


Pilot control manifold - Remove Travel Pilot Valve [57211815] CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

Park the machine on a firm, level surface. Drain the hydraulic pressure from the hydraulic system. Turn off the engine. Push in the relief valve located on top of the hydraulic oil tank fill cap. 1.

Loosen screws M12x30 and remove the cover under the cab. Weight: 5 kg (11 lb)

2.

Remove the floor mat in the cab.

3.

Remove the pedal removing securing screws (1) M8x25 then remove the levers, removing securing screws (2) M10x25.

4.

Disconnect pressure sensors (7) from body (8)

NOTE: Be sure to label each hydraulic hose before removal to aid in reassembly. 5.

Disconnect pipes from valve body (8).

NOTE: Attach a cap to the end of each disconnected hose. 6.

Remove body (8) removing securing screws (9) M10x30 complete with washers.

RAPH12CEX0598BA

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1


Pilot control manifold - Install Travel Pilot Valve [57211835] SK170-9 LA


1.

Install body (8) on the frame tightening securing screws (9) M10x30 complete with washers.

2.

Connect hydraulic hoses to body (8).

3.

Connect pressure sensors (7) to body (8).

4.

Install the levers tightening securing screws (2) M10x25 and the pedals tightening securing screws (1) M8x25.

5.

Install the cover under the cab tightening screws M12x30.

RAPH12CEX0598BA

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1


Pilot control manifold - Disassemble Right and Left Pilot Valve [57469024] SK170-9 LA

NOTE: Replace the O-rings during any disassembly of the pilot valve. 1.

Plug each port of pilot valve, and clean it with kerosene. P Port: PF 1/4” 1–4 port and T: PF 3/8”

2.

Fix pilot valve in a vise using protective plates, and remove boot (2).

3.

Remove adjusting nut (1) applying wrenches to adjusting nut (1) and circular plate (3).

4.

Remove circular plate (3).

5.

RAPH12CEX0176BA

1

RAPH12CEX0177BA

2

RAPH12CEX0178BA

3

Turn joint (4) in counterclockwise with jig (E) (380001055) to remove it. Be sure to push down on plate (5) with two fingers to keep it from popping off when the joint (4) is removed.

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6.

7.

Remove plate (5).

RAPH12CEX0179BA

4

RAPH12CEX0180BA

5

RAPH12CEX0181BA

6

Pull out plug (7) with a flat screw driver.

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8.

9.

Remove push rod (9), plug (7), pressure reducing valve assembly (spool) and the return springs (15) from casing (22).

RAPH12CEX0182BA

7

RAPH12CEX0183BA

8

RAPH12CEX0184BA

9

Push in springs (17) and (18) no more than 7 mm (0.276 in). This will allow just enough room to slide the seats (12) and (14) over to the side and off of the spools (20) and (21).

NOTE: Never push spring seat (12) in more than 7 mm (0.276 in) for ports 1 and 3. Never push spring seat (14) in more than 9.4 mm (0.370 in) for ports 2 and 4. Doing so will damage the springs.

10.

Remove spools (20) and (21), spring seats (12) and (14), springs (17) and (18) and washer.

11.

Remove spring (10) and (11), spring seat (13), from push rod (9).

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12.

Pull out push rod (9) from plug (7).

13.

Remove O-ring (8) from plug (7).

14.

RAPH12CEX0185BA

10

RAPH12CEX0186BA

11

Remove inside seal (6) from plug (7) with small driver.

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Pilot control manifold - Assemble Right and Left Pilot Valve [57469321] SK170-9 LA

Cleaning parts 1.

Clean parts and pilot valve completely with wash oil.

2.

Dry parts by using a clean rag.

3.

Apply rust preventative to parts.

Assembly of Right and Left Pilot Valve 1.

2.

Fit washer 2 (19), springs (17) and (18), spring seats (12) and (14) to spools (20) and (21).

RAPH12CEX0676AA

1

RAPH12CEX0183BA

2

Push spring (17) and (18) in just enough to allow spring seat to slide over and lock into place on the spool.

NOTE: Never push spring seat (12) in more than 7 mm (0.276 in) for ports 1 and 3. Never push spring seat (14) in more than 9.4 mm (0.370 in) for ports 2 and 4. Doing so will damage the springs.

3.

Place springs (15) into ports 1 and 3 of casing (22), and then install pressure reducing valve assembly in it.

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4.

5.

Place springs (15) into ports 1 and 3 of casing (22). Then install the pressure reducing valve assembly in it. Place spring (16) into ports 2 and 4 and then install the pressure reducing valve assembly in it.

RAPH12CEX0677AA

3

RAPH12CEX0679AA

4

RAPH12CEX0678AA

5

Fit o-ring (8) and seal (6) into plug (7). Apply hydraulic oil on the surface of the push rod (9).

6.

Insert push rod (9) in plug (7) and install spring (10) and spring seat (13) to push rod (9) on port 1 and 3 side. Insert push rod (9) in plug (7) and install spring (11) and spring seat (13) into push rod (9) on port 2 and 4 side.

7.

Fit plug (7) assembly into casing (22).

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8.

Install joint (4) in casing (22) with special tool (E) (380001055)

9.

Install circular plate (3) to joint (4).

NOTICE: Screw on the circular plate until it comes into contact with all four push rods (9) equally. Screwing in the plate further may cause the machine to malfunction. 10.

Screw adjusting nut (1), applying LOCTITE® 277 to the threads of the joint, until it touches the circular plate (3). Use a wrench to hold the circular plate while you tighten the adjusting nut.

11.

Apply a heat resistant grease (G) to joint (4) rotating section and the top of the push rods (9).

12.

Reinstall the rubber boot (2).

RAPH12CEX0176BA

13.

Spray rust preventatives through each port and install the plugs.

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6


Pilot control manifold - Disassemble Travel Pilot Valve [58233173] SK170-9 LA

1.

2.

3.

Boot removal/replacement 1.

Remove both faulty boots. (Using a flat head screwdriver if necessary)

2.

Replace both boots with new ones.

Boot reassembly 1.

First fit the lower part of the rubber boot (5) on the retaining plate (7h) between the two switch plates (6).

2.

Then put the lower part in the external groove of the retaining plate.

3.

Finish by fitting the upper part of the rubber boot on the switch plate.

Switch plate removal 1.

Remove the pilot control unit from the machine.

2.

Remove both rubber boots.

3.

Remove the screw (7k) locking the axis using a 2mm socket wrench.

4.

Fit a M3 screw on the switch plate axis (7j) in order to remove it (Using pliers if necessary).

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Index Hydraulic systems - 35 Pilot system - 357 Pilot control manifold - Assemble Right and Left Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Pilot control manifold - Disassemble Right and Left Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Pilot control manifold - Disassemble Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

Pilot control manifold - Exploded view Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Pilot control manifold - Install Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Pilot control manifold - Remove Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pilot control manifold - Sectional view Right and Left Pilot Valve Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

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Hydraulic systems - 35 Main control valve - 359

SK170-9

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Contents Hydraulic systems - 35 Main control valve - 359

FUNCTIONAL DATA Main control valve Component identification Control Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Overview Control Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

SERVICE Main control valve Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SK170-9 LA

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SK170-9 LA

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Hydraulic systems - Main control valve

Main control valve - Component identification Control Valve Ports [46348943] SK170-9 LA

RAPH12CEX0113HA

1

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RAPH12CEX0114GA

2

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Main control valve - Sectional view [46356315] SK170-9 LA

RAPH12CEX0115HA

1

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RAPH12CEX0116HA

2

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RAPH12CEX0117DA

3

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RAPH12CEX0118DA

4

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RAPH12CEX0119CA

5

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RAPH12CEX0120HA

6

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Main control valve - Overview Control Valve Operation [51884306] SK170-9 LA

In Neutral Position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system, because the by-pass cut valve (605) located on the downstream of center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel priority spool (306), and then flows though the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (605) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (605) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass cut valve (605) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation.

RAPH12CEX0406FA

1

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Actuation In Travel Operation A. In travel independent operation. On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (325) (327) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310). The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into A side of right travel motor through port AR. The hydraulic oil delivered by hydraulic pump P2 flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port AL similarly to the stream of hydraulic oil delivered by hydraulic pump P1. But in the meantime, the return oil from the B sides of left and right travel operations passes through between the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation.

RAPH12CEX0407FA

2

B. In travel priority operation. When actuator other than travel operation and the travel operation are operated simultaneously in the said item a) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward. With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel priority function) At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel priority spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel priority spool (307) closes and the pump line on the travel sides is independent from pump line on actuator.

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RAPH12CEX0408GA

3

Actuation In Bucket Operation A. In bucket digging operation. On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac). In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.

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RAPH12CEX0409FA

4

B. In bucket dumping operation. On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc). In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through low pressure circuit (D'), boost check valve (517) and returns to the hydraulic tank through tank port T1.

RAPH12CEX0410FA

5

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Boom A. In boom up operation. On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward against the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab). In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.

RAPH12CEX0411FA

6

B. In boom up conflux operation. The pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spools (310). The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side.

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RAPH12CEX0412GA

7

C. In boom down operation. On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (319) (320) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is connected to the drain circuit. The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb). In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function) 47454079-DRAFT 06/11/2012

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RAPH12CEX0413GA

8

Arm Operation A. In arm out operation. On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAP2 (515) and enters U-shaped passage, and pushes and opens load check valve LCAT2 (511) provided with orifice, and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R). In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing. The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing through boost check valve (517).

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RAPH12CEX0414FA

9

B. In arm in operation (At light load: arm recirculation function). On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves righrtward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is released. And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves rightward against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAP2 (515) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAT2 (511) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa). In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302). The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head side (H) again (Arm recirculation function). And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through tank port T1.

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RAPH12CEX0415HA

10

C. In arm in operation (In heavy load operation). The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) 47454079-DRAFT 06/11/2012

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The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (II), almost all the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1. The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.

RAPH12CEX0416FA

11

Swing Operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss. The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs). In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

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Spool Actuation for Operation in Option This spool is used to control the attachment in option like Nibbler (Crusher), etc. When the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (329) (330), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through U-shaped passage and is supplied to actuator for attachment through port (Ao). In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The operation where the pilot pressure acts on PBo port is the same as the above. * The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil passage is used as passage to connect to N&B selector valve.

Lock Valve Operation The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder. A. At boom spool neutral position (Arm spool makes the same operation.) When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed the lower side as shown in the figure and restricts the leaking to the minimum. B. In boom down operation (In arm in operation). Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the figure. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514). And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR through spring chamber (319). With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as shown in the figure is released. And since lock valve poppet (514) receives holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open. The said operation, in boom down operation, is performed before making the opening (meter out opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the operation has no effect on the operability of boom down operation. In case of arm-in operation, the operation is the same.

By-pass Cut Valve This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each center by-pass passage to low pressure passage (D). A. In normal operation. Adjusting screw (201) is tightened up to end in normal operation. Tapered end of adjusting screw (202) is seated on the seat of casing, and flow between center by-pass passage (52) and low pressure passage (D) is blocked. Consequently, in normal operation, center by-pass passage (52) is always blocked from low pressure passage (D). And the hydraulic oil delivered by pump P1 does not flow through center by-pass passage (52), but returns to hydraulic tank through P1 unload spool (309). B. At the time when failure occurred.

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When the electric system is failed, P1 unload spool (309) stops at neutral position. Hydraulic oil entered from P1 pump is blocked with P1 unload spool (309). And pump pressure rises to set pressure of main relief valve because oil flows through center by-pass passage (52) and it is blocked with by-pass cut valve (606). Hydraulic oil entered from P1 pump is blocked with P1 unload spool (309). And pump pressure rises to set pressure of main relief valve because oil flows through center by-pass passage (52) and it is blocked with by-pass cut valve (606). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position. And passage to low pressure passage (D) is blocked, but because center by-pass passage (52) is connected to low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.

Boost Check Valve, By-pass Check Valve A. Boost check valve. The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage. In normal operation. The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure generated by spring (527) is used as the boost pressure for the low pressure passage. B. By-pass check valve. Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage. When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2.

Emergency Manual Valve for Lowering Attachment Needle valve (Emergency manual valve for lowering attachment) is equipped internally between Ab port of boom cylinder head side and boom lock valve. For safety, this valve lowers risen attachment to the ground, if the machine stops with engine trouble. Only in case that the boom is lowering, the pressure in the cylinder of attachment can be released by operating arm or bucket control lever. NOTICE: Do not use excessive force at the end of the needle valve’s rotation. This could result in breaking the needle. Functional explanation. In normal cases, the needle valve was blocked completely to prevent pressure leak of boom circuit. 1. Lowering of boom. Loosen lock nut at first and loosen the needle valve to the end of contact. The oil of boom cylinder (1) head side (H) flows into drain passage (4) through orifice, and boom lowers slowly. The time of boom lowering to the ground takes about 4 to 8 minutes in accordance with machine position and holding pressure 2. Function of actuator. Oil pressure of XAb port is reduced by releasing holding pressure of boom cylinder head side to drain passage (4) through orifice. Operation of actuator with pilot control valve is possible by leading medium pressure via orifice from XAb port to shuttle valve (7). In this function, this leading of medium pressure ensures primary pressure of remote control (source of pressure). This function ensures that the cylinder movement of boom, arm, bucket and others can be actuated only downward by self weight. Consequently the releasing of pressure becomes possible. But after attachment is lowered to the ground by lowering boom, holding pressure disappears, and remote control, via pilot valve, becomes impossible. 3. Boom cylinder with holding valve. If the boom cylinder has holding valve, loosen above-mentioned needle valve together with port relief valve of holding valve, and boom cylinder starts boom lowering. Spool of holding valve moves to open side by back pressure of port relief valve, and holding pressure of boom cylinder is led to “Emergency manual valve for lowering attachment”, operation of actuator by pilot valve is possibile.

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Main control valve - Disassemble [43453162] SK170-9 LA

General Precautions 1.

As all the hydraulic components are precisely machined, it is essential to carry out disassembly and reassembly in an especially clean location.

2.

When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or sand.

3.

Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm that each cap is in place and then clean the exterior of the assembly.

4.

When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed spool, or the end cover. Handle the valve with care.

5.

Tests (for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after disassembly and reassembly require a hydraulic testing apparatus.

6.

Have ready beforehand: washing fluid, hydraulic oil, grease, etc..

Tools Prepare the following tools before disassembling the control valve. No. a b

Tools Vise Box end wrench

Qty 1 1 of each size

c

Allen wrench

1 of each size

d e f g h

Spanner Loctite #262 Spatula Pincers Adjustable wrench

1 1 1 1

Disassembly The figures in parentheses after part names in this manual represent those item numbers in the structural sectional drawing under Fig. “Section(1/6)” to Fig.”Section(6/6).

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Remarks 19mm, 24mm, 27mm, 32mm 5mm, 6mm, 10mm, 12mm, 14mm, 22mm


7.

8.

9.

Place the control valve on a work bench so as to orient the back pressure check valve upwards

1

RAPH12CEX0219BA

2

RAPH12CEX0220BA

3

Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for the P1 unload spool.

Pull out, from casing B (102), as an assembly of P1 unload spool (309), spring seat (331), springs (325), (328), stopper (336) and bolt (333).

ATTENTION: When pulling out the spool assembly, use care so as not to score case B (102). 10.

RAPH12CEX0218BA

Fix the P1 unload spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (325), (328) and stopper (336) from P1 unload spool.

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11.

12.

Loosen the socket bolts (273) and remove the spring cover (201) and the O-ring (261) for travel.

RAPH12CEX0221BA

4

RAPH12CEX0222BA

5

Draw out the assembly of travel spool (306), spring seat (331), springs (325), (327), stopper (339) and bolt (333) from casing A (101) or casing B (102).

NOTICE: When pulling out the spool assembly, take care so as not to score the casing A (101) or the casing B (102).

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13.

Fix the travel spool assembly with a vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (325), (327) and stopper (339) from travel spool (306).

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RAPH12CEX0223BA

6

RAPH12CEX0224BA

7


14.

Loosen socket bolts (273) and remove spring cover (202) for boom conflux and O-ring (261). Pull out the boom conflux assembly (305), spring seat (331), springs (321), (322), stopper (339) and bolt (333) from casing A (101).

NOTICE: When pulling out the spool assembly, use care so as not to score casing A (101) 15.

16.

Fix the boom conflux spool with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (339) from boom conflux spool (305).

RAPH12CEX0225BA

8

RAPH12CEX0226BA

9

Loosen socket bolts (273) and remove spring cover (203) for boom spool and O-ring (261), (266). Pull out boom spool assembly (301), spring seat (331), springs (319) (320), stopper (339) and bolt (333) from casing B (102).

NOTICE: When pulling out the spool assembly, take care so as not to score casing B (102).

RAPH12CEX0227BA

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10


17.

18.

Fix the boom spool assembly with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). then separate spring seat (331), springs (319), (320) and stopper (336) from boom spool (301) further unless there is a special reason.

RAPH12CEX0228BA

11

RAPH12CEX0229BA

12

RAPH12CEX0230BA

13

Loosen the socket bolts (273) and remove the spring cover sub (204) and the O-ring (261), (266) for swing. Do not disassemble spring cover sub (204) further unless there is special reason. Pull out the swing spool assembly (303), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing A (101).

NOTICE: When pulling out the spool assembly, use care so as not to score casing A (101). 19.

Fix the swing spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303).

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20.

21.

Loosen socket bolts (273) and remove bucket spring cover (201) and O-ring (261).

RAPH12CEX0231BA

14

RAPH12CEX0252BA

15

Pull out the bucket spool assembly (304), spring seat (331), springs (319), (320), stopper (339) and bolt (333) from casing B (102).

NOTICE: When pulling out the spool assembly, use care so as not to score casing B (102). 22.

Fix the bucket spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (319), (320) and stopper (339) from bucket spool (304).

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23.

Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 1 spool. Pull out the spool assembly, which consists of the arm 1 spool (302), spring seat (331), spring (321), (322), stopper (336) and bolt (333) from casing A (101)


Fix the arm 1 spool assembly in a vice via a protective plate (aluminum plate, etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 322) and stopper (336) from arm 1 spool (302).

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RAPH12CEX0232BA

16

RAPH12CEX0233BA

17


Disassembling arm 2 spool 25.

Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 2 spool. Pull out the spool assembly which consists of the arm 2 spool (308), spring seat (331), spring (325, 326), stopper (339) and bolt (333) from casing B.

NOTICE: When pulling out the spool assembly, use care so as not to score casing B. 26.

Fix the arm 2 spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then remove spring seat (331), spring (325, 326) and stopper (339) from arm 2 spool (308). Do not disassemble arm 2 spool (308) further unless there is a special reason.

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RAPH12CEX0234BA

18

RAPH12CEX0235BA

19


Disassembling option spool 27.

Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of option spool. Pull out the spool assembly which consists of the option spool (311), spring seat (331), spring (329, 330), stopper (337) and bolt (333) from casing A (101).


Fix the option spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then remove spring seat (331), spring (329, 330) and stopper (337 from option spool (311).

RAPH12CEX0236BA

20

RAPH12CEX0237BA

21

RAPH12CEX0238BA

22

Disassembling travel straight spool 29.

Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for travel straight. Pull out the spool assembly consisting of the travel straight spool (307), spring seat (331), springs (325), (328), stopper (336) and bolt (333) from casing B (102).

NOTICE: When pulling out the spool assembly, take care so as not to score the casing B (102).

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30.

Fix the travel straight spool assembly with a vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (325, 328) and stopper (336) from travel straight spool (307).

RAPH12CEX0239BA

23

Disassembling P2 unload spool 31.

Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261). Pull out the spool assembly which consists of the P2 unload spool (310), spring seat (331), spring (325, 328), stopper (336) and bolt (333) from casing A (101).

ATTENTION: When pulling out the spool assembly, use care so as not to score casing A (101). 32.

Fix the P2 unload spool assembly with a vise via a protective plate (aluminum plate, etc.) and remove bolt (333). then remove spring seat (3312), spring (325, 326) and stopper (336) from P2 unload spool (310).

Removing spool covers 33.

Travel, boom, bucket, arm 1, arm 2 and option: Loosen socket bolts (273) and remove spool cover (205) and O-ring (264). Swing: Loosen socket bolts (273) and remove spool cover (206) and O-ring (264), (266). Do not disassemble spool cover (206) further unless there is special reason.

Removing relief valve and plug assembly for relief valve hole 34.

Remove the main relief valve (601)and overload relief valve (602), (603) and relief hole plug (604) from the casing.

ATTENTION: –Use identifying tags to differentiate between the relief valves (602) and (606) to prevent them from being confused during reassembly, as they are the same in appearance and shap but differ in pressure setting. Do not disassemble the relief valves.

Removing by-pass cut valve 35.

Remove by-pass cut valve (605) from the casing.

ATTENTION: Remove the by-pass cut valve, giving particular attention to the poppet (606–201) and spring (605–202) which may remain inside the casing.

Removing lock valve selector valve sub 36.

Loosen socket bolt (211–171) and remove lock valve selector valve sub (211) from the casing. Further disassembly of the lock valve selector sub is not allowed. 47454079-DRAFT 06/11/2012

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Removing back pressure check valve 37.

Loosen socket bolt (278) and remove back pressure check valve (207) from the casing. Remove springs (527), (528), boost check valve poppet sub (517) and by-pass check valve poppet (518) from the casing. Further disassembly of the boost check valve poppet sub (517) is not allowed. Orient control valve so that the spool cover face is pointing downward.

ATTENTION: When replacing, take care so as not to score the spool cover.

Removing plate 38.

Loosen socket bolts (274), (275) and remove plates (212), (213). After removing plates, remove all O-rings (161), (164) remaining on the casing side.

Removing check valve 39.

Remove the plugs from the load check valve, conflux check valve, etc. and then remove poppet (511) and spring (521). Load check valve on the swing section: Remove plug (556) and then remove poppet (5110 and spring (524). Load check valve on arm 2 section: Remove plug (551) and then remove poppet (515) and spring (521).

ATTENTION: The plug and spring in use differ from the above. Do not mix the parts up when reassembling the valve. The poppet in use differs from the above. Do not mix the parts up when reassembling the valve. 40.

Lock valve: Remove plug (556) and then remove poppet (514) and spring (524). Main relief valve: Remove plug (556) and then remove poppet (512) and spring (522).

ATTENTION: The plugs, poppets, and springs differ from each other, do not mix the parts when reassembling the valve. NOTE: The plugs that are not included in the disassembly procedure are usually used to block auxiliary holes and holes created from casting. Do no disassemble further if unnecessary.

Disassembling casing 41.

Further disassembly of the casing is not allowed.

Inspection after disassembly 42.

Thoroughly clean all disassembled parts with wash oil, and dry them with pressurized air. Place each part on a clean sheet of paper or cloth for inspection.

Control valve 43.

Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.

44.

Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.

45.

If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.

46.

Confirm that the O-ring or the outer circumference of the sliding part of a manual spool is free from scratches, dents, and the like. Remove any small defects with an oil stone or lapping compound. 47454079-DRAFT 06/11/2012

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47.

Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are free from foreign matter.

48.

Replace any broken or deformed spring with a new one.

49.

If a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.

50.

Replace all O-rings with new ones.

ATTENTION: Take care not to leave lapping compound behind in the casing or block.

Relief valve 51.

Make sure that the poppet and the seat surface at the tip of the seat are not damaged and that the contact surface is even all over.

52.

Manually confirm that the main poppet slides smoothly onto and off the seat.

53.

Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from defects such as scratches.

54.

Confirm that each spring is free from breakage, deformation, and excessive wear.

55.

Confirm that the orifices of the main poppet and its seat are not clogged.

56.

Replace all O-rings with new ones. (Between casing and seal)

Reassembly 57.

Confirm that O-rings are free from defects caused by poor handling.

58.

Apply a thin coat of grease or hydraulic oil to O-rings and their mating parts.

59.

Do not stretch O-rings to the extent that they become permanently set.

60.

When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after installation, and can cause oil leaks.

61.

Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in “Maintenance Standards.”

Installing check valve 62.

Load check valve, conflux check valve, and so on: Attach poppet (511) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the specified torque. (8 places)

63.

Load check valve of swing section: Attach poppet (515) and spring (524) in place, place O-ring (561) in plug (556) and tighten them to the specified torque. (1 place)

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64.

Load check valve of arm 2 section: Attach poppet (515) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the specified torque. (1 place)

65.

Lock valve section: Attach poppet (514) and spring (524) in place, place O-ring (561) in plug (556) and tighten them to the specified torque. (2 places)

66.

Main relief valve section: Attach poppet (512) and spring (522) in place, place O-ring (561) in plug (556) and tighten them to the specified torque. (2 places)

ATTENTION: Take care to prevent mixing up of parts and assembling in the wrong position on the valve.

Assembling plate 67.

Place O-rings (162), (164) in casing.

68.

Attache plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.

69.

Replace control valve so that this plate faces directly downward.

Assembling back pressure check valve 70.

Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).

71.

Attach O-rings (267) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278) to the specified torque.

Assembling lock valve selector sub 72.

Attach lock valve selector sub (211) to the casing and tighten socket bolt (211–171) to the specified torque.

Assembling by-pass cut valve 73.

Attach by-pass cut valve (605) to casing and tighten it to the specified torque.

ATTENTION: Be sure to not drop poppet (605–201) and spring (605–202) when attaching the by-pass cut valve.

Assembling relief valve and relief valve hole plug assembly 74.

Tighten main relief valve (601), port relief valves (602), (606) and relief valve hole plug asembly (604) in respective place to the specified torque.

ATTENTION: Pay special attention to the labels attached when disassembling to prevent mistaking the port relief valves for each other. They are similar In shape.

Assembling p2 unload spool 75.

Hold the mid section of P2 unload spool (310) in a vise using a protective plate (aluminum plate, etc.). Attach the spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque..

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to damage P2 unload spool becaue of careless over clamping. 76.

Place P2 unload spool assembly in item (1) in casing A (101). 47454079-DRAFT 06/11/2012

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ATTENTION: Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place. 77.

Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten socket bolt (273) to the specified torque.

Assembling arm 2 spool 78.

Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (325), (326) and stopper (339) and tighten bolt (333) to the specified torque.

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform arm 2 spool as a result of over clamping. 79.

Place arm 2 spool assembly in option in item (1) casing B (102).

ATTENTION: Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place. 80.

Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten socket bolt (273) to the specified torque..

Assembling arm 1 spool 81.

Hold the mid section of arm 1 spool (302) with a vise using a protective plate (aluminum plate, etc.) and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform arm 1 spool (302) because of careless over clamping. 82.

Place arm 1 spool assembly in item (1) casing A (101).

ATTENTION: Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place. 83.

Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten socket bolt (273) to the specified torque.

Assembling bucket spool 84.

Hold the mid section of bucket spool (304) in a vise using a protection plate (aluminum plate, etc.), fit spring seat (331), springs (319), (320) and stopper (339) and tighten bolt (333) to the specified torque.

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform bucket spool (304) because of careless over clamping. 85.

Place bucket spool assembly in item (1) in casing B (102).

ATTENTION: Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place. 86.

Attach spring cover (201) with O-ring (261) attached to the spring side of bucket spool assembly and tighten socket bolt (273) to the specified torque.

Assembling swing spool 87.

Hold the mid section of swing spool (303) with a vise using a protective plate (aluminum plate, etc.), fit spring seat (331), springs (321) and stopper (336) and tighten bolt (333) to the specified torque. 47454079-DRAFT 06/11/2012

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ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform swing spool (303) because of careless over clamping. 88.

Place swing spool assembly in item (1) in casing A (101).

ATTENTION: Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place. 89.

Attache spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and tighten socket bolt (273) to the specified torque.

Assembling boom spool 90.

Hold the mid section of boom spool (301) with a vise using a protective plate (aluminum plate, etc.), fit spring seat (331), springs (319), (320) and stopper (339) and tighten bolt (333) to the specified torque.

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform boom spool (301) because of careless over clamping. 91.

Place boom spool in item (1) in casing B (102).

ATTENTION: Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place. 92.

Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and tighten socket bolt (273) to the specified torque.

Assembling boom conflux spool 93.

Hold the mid section of boom conflux spool (305) with a vise using a protective plate (aluminum plate, etc.), fit spring seat (331), springs (321)(322) and stopper (336) and tighten bolt (333) to the specified torque.

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform boom conflux spool (305) because of careless over clamping. 94.

Place boom conflux spool assembly in item (1) in casing A (101).

ATTENTION: Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place. 95.

Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and tighten socket bolt (273) to the specified torque.

Assembling travel spool (travel right and left) 96.

Hold the mid section of travel spool (306) with a vise using a protective plate (aluminum plate, etc.), fit spring seat (331), springs (325), (327) and stopper (339) and tighten bolt (333) to the specified torque.

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform travel spool (306) because of careless over clamping. 97.

Place travel spool assembly in item (1) in csing A (101) or casing B (102).

ATTENTION: Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze into place. 98.

Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten socket bolt (273) to the specified torque. 47454079-DRAFT 06/11/2012

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Assembling P1 unload spool 99.

Hold the mid section of P1 unload spool (309) with a vise using a protective plate (aluminum plate, etc.), fit spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque.

ATTENTION: Apply Loctite #262 when tightening bolt (333). Take care not to deform P1 unload spool (309) because of careless over clamping. 100. Place P1 unload spool assembly in item (1) in casing A (101). ATTENTION: Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place. 101. Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten socket bolt (273) to the specified torque.

Assembling spool covers 102. Travel, boom, bucket, arm 1, arm 2, option: Place O-ring (264) in spool cover (205) and tighten socket bolt (273 to the specified torque. 103. Swing: Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.

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Main control valve - Remove [46185993] SK170-9 LA

ATTENTION: Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load. Park the machine on a firm, level surface. To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page. T2-1-60. Cut off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself. 1.

Remove the panel protecting the control valve, removing the securing screws.

2.

Disconnect all hoses, pipes and connectors from the control valve (1) .

NOTE: Attach caps to hoses and pipes. Attach labels or tags to hoses and pipes, to aid in assembly. 3.

Remove 3 capscrews (2) M12x45.

RAPH12CEX0087BA

4.

Remove the control valve (1) by hoist.

NOTE: Control valve assembly weight: 155 kg (518lbs).

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1


Main control valve - Install [46345112] SK170-9 LA

1.

Install control valve (1) by tightening 3capscrews (2) M12x45.

RAPH12CEX0087BA

2.

1

Connect all hoses, pipes and connectors to the control valve.

Thread size PF 1/4 PF 3/8

PF 3/4 M10 M12

Ports Pss, PLc2, PL, PB1, PTb, PCa, PCb,PCc, PAL, PAr, XAb PAa1, PBa1, Pab, PBb, Pac, PBc, PBL,PBr, Pas, PBs, PAa2, PBa2, Pao, Pbo,DR MU1, MU2, T3, Ar, Br, AL, BL, As, Bs, Aa, Ba, Ac, Bc, Ab, Bb, Ao, Bo P1, P2 T1, T2

Connector / Bolt Tightening Opposing torque Nm Name flats (lbf ft)

ORS Joint

Sems bolt

3.

Check for oil leak and operation.

4.

Install the panel protecting the control valve using the relevant securing screws.

Opposing Tightening torque Nm (lbf ft) flats

19

36 (27)

19

29 (21)

22

74 (55)

22

49 (36)

36

162 (119)

36

118 (87)

17 17

62.2(45) 96 (70)

– –

– –

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Hose Nut

Index Hydraulic systems - 35 Main control valve - 359 Main control valve - Component identification Control Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Main control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SK170-9 LA

Main control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SK170-9 LA

Main control valve - Overview Control Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Main control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SK170-9 LA

Main control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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47454079-DRAFT 06/11/2012 EN

SERVICE MANUAL Frames and ballasting

SK170-9

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39

Contents Frames and ballasting - 39

Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.100 SK170-9

Ballasts and supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.140 SK170-9

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39

CONSUMABLES INDEX Consumable DEF/AdBlue® Loctite® 515 Loctite® 262 Loctite® 262

Reference Frame - External view Machine Main Component Locations Frame - Install Frame - Install Frame - Install

47454079-DRAFT 06/11/2012

39

PAGE 39.100 / 5 39.100 / 10 39.100 / 10 39.100 / 10

47454079-DRAFT 06/11/2012

39

Frames and ballasting - 39 Frame - 100

SK170-9

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Contents Frames and ballasting - 39 Frame - 100

FUNCTIONAL DATA Frame External view Machine Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

SERVICE Frame Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

Articulation frame pivot Remove Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

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CONSUMABLES INDEX Consumable DEF/AdBlue® Loctite® 515 Loctite® 262 Loctite® 262

Reference Frame - External view Machine Main Component Locations Frame - Install Frame - Install Frame - Install

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PAGE 39.100 / 5 39.100 / 10 39.100 / 10 39.100 / 10

Frames and ballasting - Frame

Frame - External view Machine Main Component Locations [50474954] SK170-9 LA

Machine Overview

RAPH12CEX0357GA

No. 1 2 3 4 5 6 7 8

Description Arm cylinder Boom Swivel joint Swing motor Fuel tank Hydraulic oil tank Control valve Hydraulic pumps

No. 10 11 12 13 14 15 16 17

Description Diesel engine Counterweight Radiators Travel motor Tracks Batteries Upper roller Lower roller

1

No. 19 20 21 22 23 24 25 26

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Description Track adjuster Track adjust wheel Track shoe Cab Boom cylinder Bucket Bucket cylinder Arm


9

Muffler

18

Air cleaner

27

Main components – Upper structure

RAPH12CEX0359GA

No. 1 2 3 4

Description Control cab Proportional solenoid valve block Radiators Engine

No. 5 6 7 8

2

Description Hydraulic pump Control valve Swing motor unit Center joint

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DEF/ADBLUE® tank


RAPH12CEX0358GA

No. 1 2 3

Description Right travel motor unit Left travel motor unit Center joint

No. 4 5

3

Description Swing gear Front idler assembly

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Frame - Remove [46453674] SK170-9 LA

NOTE: Approximate mass of upper frame: 1667 kg (3675 lb) 1.

Attach a chain block (1) , (of the type illustrated in the figure), to the boom foot side and the rear of the upper frame.

2.

Adjust chains lengths to level the frame.

ATTENTION: Make sure rear chains do not touch engine.

RAPH12CEX0131FA

Number 1 2 3 4 5 6

Item Master link L High coupling HC Chain Chain Grab hook H Hook

1

Quantity 1 9 1 2 1 2

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Type KITO HL050 KITO HC020 Ø 8x 4,4 m (14 ‘ 5”) Ø 8x 1,5 m (4 ‘ 11”) KITO HH020 KITO HJ050


3.

Put matching marks (M) on upper frame and swing bearing.

RAPH12CEX0133AA

4.

Remove 30 capscrews (5) M20x100 and a reamer bolt M20x105 used to install swing bearing and upper frame.

5.

Lift upper frame slightly from undercarriage. Level upper frame by adjusting the chain blocks.

6.

Remove upper frame.

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2


Frame - Install [46463639] SK170-9 LA

Approximate mass of upper frame: 1667 kg (3675 lb) Installing is done in the reverse order of removing. 1.

Clean mating surfaces of upper frame and swing bearing.

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2.

Apply LOCTITE® 515 to the inside of the capscrews on the contact surface (A) .

3.

Slinging upper frame. Match marks and install it with a reamer bolt (6) and a washer temporarily.

NOTE: Confirm the reamer bolt position (X) referring to figure at right. 4.

Apply LOCTITE® 262 onto thread of bolts (5) then, install bolts.

5.

Apply LOCTITE® 262 onto thread of reamer bolts (6) then, install reamer bolt.

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RAPH12CEX0134BA

1

RAPH12CEX0135BA

2

RAPH12CEX0136BA

3


Articulation frame pivot - Remove Swing bearing [45431441] SK170-9 LA

1.

Put alignment marks on (A) swing bearing (1)and track frame (2)

2.

Remove screws (3) (Q.ty 36) and the relevant washers (Qty. 36).

3.

Attach lifting tools (380001026), hoist swing bearing (4) and remove it.

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Index Frames and ballasting - 39 Frame - 100 Articulation frame pivot - Remove Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Frame - External view Machine Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Frame - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

Frame - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

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Frames and ballasting - 39 Ballasts and supports - 140

SK170-9

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Contents Frames and ballasting - 39 Ballasts and supports - 140

SERVICE Counterweight Remove Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Install Counterweight Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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Frames and ballasting - Ballasts and supports

Counterweight - Remove Counterweight Removal [46200694] SK170-9 LA

1.

Remove plugs (1) from the counterweight and attach two M36 eye bolts to the counterweight.

NOTE: Approximate mass of counterweight:- 3250 kg (7165 lb) for E175C- 3650 kg (8047 lb) for E195C.

2.

Attach wire rope (2) to eyebolts (3) using shackles. Take out slack of wire rope by applying tension slowly with a crane or hoist. Wire with hook: Length 1.5 m, diameter. more than 16 mm – (2 pc).

3.

Remove screws (4) M27x350. Lift counterweight using a crane or hoist.

4.

Remove shim (5), (6), (7) from the frame.

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RAPH12CEX0088BA

1

RAPH12CEX0089BA

2


5.

Lower the counterweight on proper stand.

RAPH12CEX0090BA

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3


Counterweight - Install Counterweight Install [46204939] SK170-9 LA

NOTE: Approximate weight of counterweight:- 3250 kg (7165 lb) for E175C- 3650 kg (8047 lb) for E195C. 1.

Attach lifting tools (2) to eyebolts (3) of counterweight.

2.

Install shim (5) , (6) , (7) onto the frame as it was.

3.

Lift counterweight and install it onto the frame.

4.

Install bolts (4) and washers to counterweight and tighten temporarily.

5.

Remove wire rope. Tighten the bolts (4) with a power wrench and torque wrench.

6.

Remove eyebolts (3) and install plugs (1) onto the counterweight.

RAPH12CEX0089BA

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1

Index Frames and ballasting - 39 Ballasts and supports - 140 Counterweight - Install Counterweight Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Counterweight - Remove Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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47454079-DRAFT 06/11/2012 EN

SERVICE MANUAL Tracks and track suspension

SK170-9

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48

Contents Tracks and track suspension - 48

Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.100 SK170-9

Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.130 SK170-9

Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.134 SK170-9

Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.138 SK170-9

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48

CONSUMABLES INDEX Consumable Tutela Unitek CJ-4 engine SAE 10W-40 Tutela Unitek CJ-4 engine SAE 10W-40 Loctite® 262 Loctite® 262 Loctite® 262 Molykote® G-N Metal assembly paste Tutela Unitek CJ-4 engine SAE 10W-40 Moly Lube Tutela Unitek CJ-4 engine SAE 10W-40

Reference

PAGE

oil Track frame roller - Service limits Lower Roller

48.138 / 4

oil Track support roller - Service limits

48.138 / 6

Track Track Track Track

rollers - Install Upper Roller rollers - Install Lower roller rollers - Install Lower roller frame roller - Assemble

48.138 48.138 48.138 48.138

/ / / /

10 14 14 19

oil Track frame roller - Assemble

48.138 / 21

Track support roller - Assemble Upper Roller oil Track support roller - Assemble Upper Roller

48.138 / 25 48.138 / 27

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48

Tracks and track suspension - 48 Tracks - 100

SK170-9

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Contents Tracks and track suspension - 48 Tracks - 100

TECHNICAL DATA Tracks Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

SERVICE Tracks Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

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Tracks and track suspension - Tracks

Tracks - Service limits [60026161] SK170-9 LA

Link Pin and Track Bushing • Measure the length of four links, as illustrated, with tension on the track. • Do not measure the track where the master pin is located.

RAPH12CEX1088EA

Ref. A

Standard 760 mm (29.92 in)

1

Allowable Limit 774 mm (30.47 in)

Remedy Replace

Master Pin

RAPH12CEX1089AA

Ref. A B

Standard 212 mm (8.35 in) 38 mm (1.496 in)

2

Allowable Limit 205 mm (8.07 in) 36.5 mm (1.437 in)

Master Bushing

RAPH12CEX1090EA

3

47454079-DRAFT 06/11/2012

48.100 / 3

Remedy Replace


Ref. A B C

Standard 129.2 mm (5.087 in) 38.7 mm (1.524 in) 59 mm (2.323 in)

Remedy

Allowable Limit – 40.2 mm (1.583 in) 54.4 mm (2.142 in)

Replace

Grouser Shoe

RAPH12CEX1091EA

Ref. A B C

Standard 220 mm (8.66 in) 95 mm (3.740 in) 25.5 mm (1.004 in)

4

Allowable Limit – – 15 mm (0.591 in)

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48.100 / 4

Remedy Replace


Tracks - Remove [59935873] SK170-9 LA

WARNING Pressurized fluid can penetrate the skin and cause severe injuries. The grease in the cylinder is under high pressure. Never loosen the grease fitting adaptor completely in order to speed up the flow of grease. Failure to comply could result in death or serious injury. W0261A

1.

2.

3.

Move the tracks so that the master pin (3) is positioned over the front idler (4). Put a wooden block under the track shoes (5), as shown.

RAPH12CEX1075AA

1

RAPH12CEX0967AA

2

RAPH12CEX1077AA

3

To loosen the track tension, slowly turn the valve (1) counterclockwise on turn; grease will escape from the grease outlet.

Remove the master pin (5) by using a special tool.

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4.

5.

6.

Special Tools A.

380001008

B.

380001009

C.

380001013

D.

380001012

E.

380001015

F.

380001019

RAPH12CEX1078AA

4

RAPH12CEX1079AA

5

RAPH12CEX1080AA

6

Slowly drive the machine in reverse until the whole length of the track being removed is on the ground.

Rotate the upper structure 90 degrees toward the removed track, perpendicular to the tracks. Operate the boom and arm so that the angle between them is 90 to 110 degrees. Lower the boom with the bucket rolled in to jack up the machine as illustrated.

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Tracks - Install [59937815] SK170-9 LA

1.

2.

3.

Jack up the machine and put the track under the lower rollers. Be sure to position the track in the correct direction, as illustrated. X: Sprocket side Y: Idler side

RAPH12CEX1081AA

1

RAPH12CEX1082AA

2

RAPH12CEX1083AA

3

Lift the track and place it on the sprocket (1).

Slowly turn the sprocket in a forward direction.

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4.

Turn sprocket (1) until the end of the track (4) comes onto the front idler (3). Lower the machine and put a wooden block under the track as shown.

RAPH12CEX1084AA

4

NOTE: Ensure that all hole surfaces, link holes, counter-bore surfaces, and bushing ends are free from dust and rust. 5.

Install master pin (5), using a hammer and special tool A.

380001008

B.

380001009

C.

380001013

D.

380001012

E.

380001015

F.

380001019

NOTE: Use rust preventative between the pin and bushing. RAPH12CEX1077AA

5

RAPH12CEX1078AA

6

NOTE: If any links have been removed from the track, be sure to apply grease between the pin and bushing when reconnecting the links. Also, apply a coat of grease to the ends of the bushing Grease Charging Method: – Stand the bushing on a flat plate. – Fill the bushing bore with the grease. – Insert the pin into the bushing while pushing the bushing onto the plate (so the bushing end stays on the plate). – Wipe off excess grease.

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6.

Supply grease to the tensioner grease cylinder through the grease fitting to adjust track tension. When proper track sag is obtained, turn valve clockwise and tighten. Torque to 70 N·m (51.6 lb ft). Track sag specifications (A): 320 - 350 mm (12.6 13.8 in).

NOTE: Check track sag after thoroughly removing soil and debris that art stuck on tracks.

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RAPH12CEX1087AA

7

RAPH12CEX1036AA

8

Index Tracks and track suspension - 48 Tracks - 100 Tracks - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Tracks - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Tracks - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Tracks and track suspension - 48 Track frame and driving wheels - 130

SK170-9

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Contents Tracks and track suspension - 48 Track frame and driving wheels - 130

TECHNICAL DATA Sprocket Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Tracks and track suspension - Track frame and driving wheels

Sprocket - Service limits [59442547] SK170-9 LA

RAPH12CEX0921FA

A B C D E

Standard mm (in) 68 mm (2.68 in) 584.7 mm (23.02 in) 644.6 mm (25.38 in) 659 mm (25.94 in) 190 mm (7.48 in)

1

Allowable Limit mm (in) 60 mm (2.36 in) 575 mm (22.64 in) — 648 mm (25.51 in) —

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Remedy

Repair or replace.

Index Tracks and track suspension - 48 Track frame and driving wheels - 130 Sprocket - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Tracks and track suspension - 48 Track tension units - 134

SK170-9

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Contents Tracks and track suspension - 48 Track tension units - 134

TECHNICAL DATA Idler wheel Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

SERVICE Track tension units Remove Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Track tensioner Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

Idler wheel Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

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Tracks and track suspension - Track tension units

Idler wheel - Service limits [59607924] SK170-9 LA

RAPH12CEX0965EA

A B C D E

Standard 84 mm (3.307 in) 159 mm (6.260 in) 500 mm (19.685 in) 540 mm (21.260 in) 20 mm (0.787 in)

1

Allowable 66 mm (2.598 in) — 482 mm (18.976 in) — —

Remedy

Repair or replace.

Shaft and Bushing Axle Bushing Bushing

Outside Diameter Inside Diameter Flange Thickness

Standard 75 mm (2.95 in) 75 mm (2.95 in) 2 mm (0.08 in)

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Allowable 74.2 mm (2.92 in) 76 mm (2.99 in) 1.2 mm (0.047 in)

Remedy Replace


Track tension units - Remove Track Adjuster [59554917] SK170-9 LA


Before removing the track adjuster, the tracks must be removed. In this section, the procedure starts on the premise that the tracks have already been removed. NOTE: Track adjuster assembly weight: 202 kg (445 lb). 1.

2.

Remove the front idler and track adjuster assembly from the track frame by prying it out. Use a pry bar as shown in the figure.

RAPH12CEX0944AA

1

RAPH12CEX0945AA

2

When idler assembly (1) has to be removed, loosen capscrew (3), and remove idler assembly (1) from adjuster assembly (2). Weight of idler assembly: 112 kg (247 lb) Weight of idler adjuster assembly: 90 kg (198 lb) The removed idler assembly (1) should be placed on square timbers.

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Track tension units - Install [59555155] SK170-9 LA


1.

As shown in figure, install the front idler and track adjuster assembly into the spring guide on track frame.

RAPH12CEX0946AA

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1


Track tensioner - Disassemble [59555762] SK170-9 LA

WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

Be sure to use special tool (A) 380001029 for assembly / disassembly of the track adjuster. 1.

2.

Place a jack on the bottom of the track spring holder assembly 380001029.

RAPH12CEX0947AA

1

RAPH12CEX0948AA

2

Loosen four nuts to remove the plate (A).

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3.

Pull out piston (9) from grease cylinder (1) of the idler adjuster assembly.

4.

Removing oil seal (7), o-ring (8) from grease cylinder (1).

5.

6.

RAPH12CEX0949AA

3

RAPH12CEX0950AA

4

RAPH12CEX0951AA

5

Connect the track adjuster to a hoist using a lifting strap. Set the idler adjuster assembly on the stand of the jig (A) 380001029, with its bracket side facing up. Remove the lifting strap.

Fit retainer plate (A) to bracket (4), tighten hold down nuts alternately, and secure idler adjuster assembly.

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7.

8.

9.

Remove spring pin (6), press spring (3) lifting it with jack so that nut (5) can be turned freely, and remove nut.

RAPH12CEX0952AA

6

RAPH12CEX0953AA

7

RAPH12CEX0954AA

8

Allow the hydraulic jack to retract slowly until the spring is extended to its free length. Remove the retainer plate and take off bracket (4) and cover (11).

Hook lifting eye nut (W) on grease cylinder (1) top end and hoist it. Then, remove the grease cylinder (1) and spring (3) using hoist. Remove spring (3), collar (2) and grease cylinder (1) in that order.

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Track tensioner - Assemble [59592637] SK170-9 LA

WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

1.

Insert grease cylinder (1) and collar (2) into spring (3) and attach lifting eye nut (W) to screw at the top of the grease cylinder. Lift the grease cylinder by crane and place it in the center of the jig stand upright 380001029.

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48.134 / 9

RAPH12CEX0949AA

1

RAPH12CEX0954AA

2


2.

Install bracket (4) and cover (11) on top of the spring (3). Center the rod of grease cylinder (1) and the holes in the bracket (4). Attach the retainer plate (13) and four hold down nuts (12). Fasten the nuts evenly all around and secure the idler adjuster assembly to the jig body 380001029.

3.

Extend the hydraulic jack, compress spring (3) to a set length and screw in nut (5) to the screwed part at the tip of the grease cylinder (1). Set length of the spring: 432 mm (17.0 in)

4.

Tighten nut (5) until the holes for locking spring pins (6) are aligned. Then insertspring pin (6).

5.

RAPH12CEX0955AA

3

RAPH12CEX0950AA

4

RAPH12CEX0956AA

5

Remove idler adjuster from jig 380001029.

NOTE: Track adjuster weight: 90 kg (198 lb)

6.

Apply grease on the oil seal (7) and o-ring (8) then fit them to grease cylinder (1).

7.

Fill up grease in cylinder (1), remove the grease nipple from piston (9) in order to discharge the inside air, and press the piston in by hand.

8.

Point the grease nipple hole downward to allow the air to escape easier.

9.

Tighten the grease nipple (X) to the piston (9). Torque to 70 N·m (51.6 lb ft)

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Idler wheel - Disassemble [59598094] SK170-9 LA

Remove plug (8) on the side of the collar (3) to drain oil. NOTE: Weight of front idler assembly with bracket: 112 kg (247 lb)

1.

2.

RAPH12CEX0957AA

1

RAPH12CEX0958AA

2

RAPH12CEX0959AA

3

To remove pin (5) apply pin push bar (A) 380001051to the top of the pin, and push out striking bar lightly with a hammer.

Put idler on repair stand. Aplly push-out jig on shaft (B) 380001052, push out shaft (6) with collar (3), then remove collar (3).

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3.

If removal of the collar (3) on the opposite side is required, turn over front idler and proceed with the procedure described in the pervious step.

4.

With the idler (1) mounted on the stand, tap bushing removal rod (C) 380001053 lightly with a hammer, while placing it on the end face of the bushing (2) evenly all around. Do this until the bushing comes free from the idler.

5.

Take out floating seals (4) from idler (1) and collar (3). If you intend to reuse the floating seals (4), confirm that there is no scoring or rust on the contact surface. Store the floating seals in pairs by placing cardboard between the sealing faces.

6.

Separate the o-ring from the shaft

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RAPH12CEX0960AA

4

RAPH12CEX0961AA

5


Idler wheel - Assemble [59602023] SK170-9 LA

1.

Align inner hole of the idler (1) and bushing (2) and press fit it vertically with press so that jig (D) 380001054 for bushing press fitting is inserted into bushings.

2.

Fit o-ring (7) to o-ring groove on shaft (6).

3.

Press fit the o-ring (7) installed side of shaft (6) into the collar (3), and drive in pin (5).

4.

Fit the half of the floating seal (4) on each side of the collar (3) and the idler (1).

5.

RAPH12CEX0961AA

1

RAPH12CEX0962AA

2

RAPH12CEX0963AA

3

Fit the half of the floating seal (4) on the other collar (3), press fit it in the shaft (6), and drive in pin (5) with a hammer.

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48.134 / 13


6.

Fit the other half of the floating seal (4) on the other collar (3), press fit in the shaft (6), and drive in pin (5) with a hammer.

RAPH12CEX0964AA

7.

Fill with 265 cm³ (16.17 in³) of oil through the plug hole in the collar (3), wind sealing tape around the plug and tighten.

NOTE: After installing the idler assembly to the idler adjuster assembly, make certain that no oil leaks from the floating seal and plug (8) and that the idler (1) rotates freely.

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4

Index Tracks and track suspension - 48 Track tension units - 134 Idler wheel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

Idler wheel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Idler wheel - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Track tension units - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Track tension units - Remove Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Track tensioner - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

Track tensioner - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

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Tracks and track suspension - 48 Track rollers - 138

SK170-9

47454079-DRAFT 06/11/2012

48.138 / 1

Contents Tracks and track suspension - 48 Track rollers - 138

TECHNICAL DATA Track frame roller Service limits Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Special tools – Dealer Made Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Track support roller Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Special tools – Dealer Made Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

SERVICE Track rollers Remove Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Install Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Remove Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Install Lower roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA


Track frame roller Disassemble Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SK170-9 LA

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SK170-9 LA

Track support roller Disassemble Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA

Assemble Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SK170-9 LA

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CONSUMABLES INDEX Consumable Tutela Unitek CJ-4 engine SAE 10W-40 Tutela Unitek CJ-4 engine SAE 10W-40 Loctite® 262 Loctite® 262 Loctite® 262 Molykote® G-N Metal assembly paste Tutela Unitek CJ-4 engine SAE 10W-40 Moly Lube Tutela Unitek CJ-4 engine SAE 10W-40

Reference

PAGE

oil Track frame roller - Service limits Lower Roller

48.138 / 4

oil Track support roller - Service limits

48.138 / 6

Track Track Track Track

rollers - Install Upper Roller rollers - Install Lower roller rollers - Install Lower roller frame roller - Assemble

48.138 48.138 48.138 48.138

/ / / /

10 14 14 19

oil Track frame roller - Assemble

48.138 / 21

Track support roller - Assemble Upper Roller oil Track support roller - Assemble Upper Roller

48.138 / 25 48.138 / 27

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Tracks and track suspension - Track rollers

Track frame roller - Service limits Lower Roller [59930253] SK170-9 LA

RAPH12CEX1069FA

No. A B C

D

E

ITEM Diameter of flange Tread diameter Flange width Clearance between shaft and bushing (Wrapped bushing) Interference between roller and bushing

1

REPAIRABLE LEVEL

STANDARD VALUE

SERVICE LIMIT

REMEDY

188 mm (7.40 in)

–

156 mm (6.14 in)

Repair or 149 mm (5.87 134 mm (5.28 replace in) in) – –

25.5 mm (1.004 in) Basic Tolerance dimension 60 mm (2.3622 in)

Shaft

64 mm (2.51969 in)

Hole

Fit 0.060 - 0.090 Clearance mm (0.0024 - 0.7 mm 0.0035 in) (0.0276 in) Interference 0.030 mm 0.01 mm (0.0012 in) (0.0004 in)

–

Fit Clearance 1 mm (0.0394 Replace in) bushing Clearance 0

Engine Oil TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40; Qty 219 cm³ (13.36 in³) Plug Perform air leak test at 0.2 MPa (29 psi) before tightening the plug. Roller rotation Rotates smoothly by hand Oil

Refill Reassembly

Track frame roller - Special tools – Dealer Made Tools [59930273] SK170-9 LA

47454079-DRAFT 06/11/2012

48.138 / 4


Ref. A

Name Support Jig

B

Shaft extruding jig

C

Bushing extruding jig

D

Bushing fixing jig

Drawing

RAPH12CEX1070AA

1

RAPH12CEX1071AA

2

RAPH12CEX1072AA

3

RAPH12CEX1073AA

4

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Track support roller - Service limits [59871824] SK170-9 LA

RAPH12CEX1049FA

ITEM No. A Diameter B C D D’ E

F

1

SERVICE LIMIT REMEDY 140 mm (5.51 in) 130 mm (5.12 Repair or replace in) Width 152 mm (5.98 in) 142 mm (5.59 in) Tread 120 mm (4.72 in) 110 mm (4.33 Diameter in) Tread Width 35 mm (1.38 in) 31 mm (1.22 in) Tread Width 33 mm (1.30 in) 29 mm (1.14 in) Replace Basic Tolerance Limit Clearance Standard bushing between shaft Dimension and bushing 45 mm (1.772 Shaft 0.025 mm (0.0010 in) Clearance Clearance in) 0.040 mm (0.0016 in) — 0.8 mm (0.0315 in) 49 mm (1.929 Hole + 0.030 mm (0.0012 Interference Clearance Interference – 0 in) between roller in) 0 and bushing Oil Engine oil: TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40 Refill Roller Rotates smoothly by hand Reassembly Rotation STANDARD VALUE

Track support roller - Special tools – Dealer Made Tools [59875513] SK170-9 LA

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Ref. A

Name Support Jig

B

Shaft extruding jig

C

Bushing extruding jig

D

Bushing fixing jig

Drawing

RAPH12CEX1050AA

1

RAPH12CEX1054AA

2

RAPH12CEX1055AA

3

RAPH12CEX1053AA

4

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Track rollers - Remove Upper Roller [59611903] SK170-9 LA


1.

Be sure that any packed gravel or mud between sprockets and tracks is removed before beginning.

2.

Loosen valve (1) to drain grease.

3.

RAPH12CEX0966AA

1

RAPH12CEX0967AA

2

RAPH12CEX0968AA

3

Lift the track chains (3) using a hydraulic jack with a rubber mat underneath it for grip. Raise the track chains (3) high enough to allow the removal of the track rollers (4).

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4.

Insert a wooden block between the tracks (3) and the track frame (5).

5.

Remove screws (2) M16x45 from the roller support (1).

6.

Remove the upper roller (1) from the track frame (3).

RAPH12CEX0969AA

4

RAPH12CEX0971AA

5

RAPH12CEX0972AA

6

NOTE: Upper roller weight: 16.5 kg (36.4 lb).

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Track rollers - Install Upper Roller [59611925] SK170-9 LA

1.

Before reassembling, check that upper roller rotates smooth manually and that there are no leaks.

2.

Apply LOCTITE® 262 on capscrew (2) M16x45, and tighten. Torque to 250 - 308 N·m (184.4 - 227.2 lb ft)

3.

RAPH12CEX1034AA

1

RAPH12CEX1035AA

2

Remove the wooden blocks and the hydraulic jack.

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4.

Tighten valve (1). Torque to 70 N·m (51.6 lb ft)

5.

Fill grease cylinder with grease to adjust the track tension using the grease nipple (2). Track sag specifications (A): 320 - 350 mm (12.60 13.78 in)

NOTE: Check track sag after thoroughly removing any soil stuck on the track area.

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RAPH12CEX0967AA

3

RAPH12CEX1036AA

4


Track rollers - Remove Lower Roller [59636716] SK170-9 LA


1.

Use the front attachment to lift the side of the lower frame up and off of the round. Stop the engine once the track frame is high enough off the ground.

2.

Place a wooden safety block under the track frame at the front and rear.

3.

RAPH12CEX1037AA

1

RAPH12CEX1038AA

2

Remove capscrews (1) M18x55 and remove the track guide (2). Weight of track guide: 29 kg (64 lb)

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4.

5.

Loosen valve (3) to drain grease enough to permit the roller removal.

RAPH12CEX0966AA

3

RAPH12CEX1039AA

4

RAPH12CEX1040AA

5

Remove the capscrews (5) M18x80 and remove the lower roller (6). Lower roller weight: 34.6 kg (76.3 lb)

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Track rollers - Install Lower roller [59636737] SK170-9 LA

1.

2.

Install lower roller (6). Coat mounting capscrews (5) M18x80 with LOCTITE® 262 and snug all four capscrews temporarily. Then torque them to 358 - 436 N·m (264 - 322 lb ft)

RAPH12CEX1040AA

1

RAPH12CEX1038AA

2

Install track guide (2). Coat mounting capscrews (1) M18x55 with LOCTITE® 262 and snug all four capscrews temporarily. Then torque them to 358 - 436 N·m (264 - 322 lb ft)

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3.

Tighten valve (3). Torque to 70 N·m (51.6 lb ft)

4.

Adjust track tension by filling grease cylinder with grease through the grease nipple (4). Track sag specifications (A) : 320 - 350 mm (12.60 13.78 in)

NOTE: Check track sag after thoroughly removing any soil or debris stuck on the track area.

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RAPH12CEX1039AA

3

RAPH12CEX1036AA

4


Track rollers - Disassemble [59826797] SK170-9 LA

1.

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Track frame roller - Disassemble Lower Roller [59913885] SK170-9 LA

1.

2.

Prepare an oil catch pan beforehand. Remove the plug (8) and drain out the oil (approximately 150 170 cm³ (9.15 - 10.37 in³)).

RAPH12CEX1068AA

1

RAPH12CEX1057AA

2

RAPH12CEX1058AA

3

Remove pins (6) from collars (3). Place both ends of the lower roller assembly on V-shaped blocks (KI). Then apply push-out bar (L) on the end of the pin (6) and push pin out by striking it with a mallet.

3.

Put the lower roller on a jig (A) for repair stand so that the shaft (2) is upright. Use the push-out jig (B) on the end of the shaft at the top. Push out the shaft with a press or by using a mallet until the o-ring (7) is separate from the collar. Remove the o-ring (7) from the shaft (2).

4.

Continue to push out the shaft (2) until free of the roller (1). Remove the other collar (3) and the o-ring (7).

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5.

6.

7.

Remove the floating seal (5) from the collar (3).

RAPH12CEX1059AA

4

RAPH12CEX1060AA

5

RAPH12CEX1061AA

6

Remove the floating seals (5) from the roller (1).

Remove bushing (4) from the roller. Since the bushing is so thin, you may need to remove it using a lathe. Remove it with extreme care so as not to damage the inner hole of the roller (1). When the bushing is not worn and therefore not as thin, you can remove it with a push-out jig (C). Use a repair stand (A) to hold the roller, then using a mallet, push out the bushing (4) with the push-out jig (C).

NOTE: Use caution when using the push-out jig (C). Hammer carefully around the circumference of the bushing little by little to remove it.

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Track frame roller - Assemble [59919617] SK170-9 LA

1.

Grease the o-ring (7) and install it onto the groove of the shaft (2).

NOTE: Always use a new o-ring when installing onto the shaft.

2.

RAPH12CEX1062AA

1

RAPH12CEX1063AA

2

RAPH12CEX1064AA

3

Fit bushing (4) into jig (D). Align the bushing and the inner hole of the roller and press fit it vertically into the roller. Use a press with a 4536 kg (5 ton) load.

NOTE: Apply MOLYKOTE® G-N METAL ASSEMBLY PASTE onto the press fit section of the bushing, and press fit it at room temperature.

3.

Install a floating seal (5) into collar (3), then press fit onto the shaft end with the o-ring (7) installed. Ensure proper alignment of the holes in collar and hole in shaft. Use a press with a capacity of 15422 kg (17 ton) or more.

NOTE: Care should be taken not to damage the o-ring (7) when press fitting the collar (3) onto shaft (2).

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4.

5.

Press fit pin (6) into pin holes of shaft (2) and collar (3).

RAPH12CEX1065AA

4

RAPH12CEX1066AA

5

RAPH12CEX1067AA

6

Install the floating seals (5) on both ends of the lower roller (1).

NOTE: Check that the floating seal is free of flaws, rust, debris, etc. before using. 6.

Insert shaft (2) into the roller

7.

Grease o-ring (7) and install it into the groove on the shaft (2).

8.

Press fit the collar (3) to the shaft (2). Ensure proper alignment of holes in collar to hole in shaft.

9.

Press fit pin (6) into collar (3) and shaft (2). 47454079-DRAFT 06/11/2012

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10.

Fill the roller with 219 cm³ (13.36 in³) of engine oil TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40.

11.

Before tightening plug (8), check roller for leakage by pressurizing it with 0.2 MPa (29 psi) of air pressure.

12.

Apply and oil resistant sealant on plug (8) and tighten it into the plug hole on the collar (3) face. Torque the plug to 9.8 - 19.6 N·m (7.2 - 14.5 lb ft).

NOTE: After assembling the lower roller, confirm that there is no oil leaking and that the roller rotates smoothly by hand.

RAPH12CEX1068AA

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7


Track support roller - Disassemble Upper Roller [59695666] SK170-9 LA

RAPH12CEX1041FA

1. 2. 3. 4. 5. 6. 7.

Roller Shaft Plug Bushing Bushing Floating seal Floating seal

8. 9. 10. 11. 12. 13.

1

Collar Cover Trust-washer O-ring Bolt Trust-washer bolt

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Removal 1.

Remove plug (3) and drain the oil.

2.

Mount the end face inside upper roller (1) on stand jib (A) and loosen bolts (12).

3.

Take off cover (9).

4.

Separate o-ring (11) from cover (9).

5.

Loosen two trust-washer bolts (13) and pull out trust washer (10) from roller (1).

6.

7.

RAPH12CEX1042AA

2

RAPH12CEX1043AA

3

RAPH12CEX1044AA

4

Put the extrusion jib (B) against the end of shaft (2) and push shaft with collar (8) to floating seals (6) and (7) using a press or a hammer.

Take out floating seals (6) and (7) from roller (1).

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8.

Remove the other floating seal (6) from the collar (8). It is located on the side from which shaft (2) was removed.

NOTE: Collar (8) is press fitted onto shaft (2), do not attempt to disassemble it.

9.

RAPH12CEX1045AA

5

RAPH12CEX1046BA

6

Since the bushings (4) and (5) are so thin, machine them down on a lathe or scrape them off. Use care so as not to damage the bore of the roller (1). If the bushings are not worn, mount upper roller (1) on jig (A), and push out the bushings (4) and (5) with a punch 380001053 and a hammer.

NOTE: Hammer the surface of the roller lightly so as not to damage the surface. Put the extrusion punch 380001053 uniformly over the circumference of the bushings and extrude them perpendicularly little by little.

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Track support roller - Assemble Upper Roller [59695724] SK170-9 LA

1.

Place the upper roller (1) on the top of the jig (A) with its floating seal side facing down.

2.

Confirm that the outer surface of bushing (5) is not seized and coat the outer surface of the inserting side of the bushing. Use MOLY LUBE.

3.

Put jig (C) into bushing (5) and press it in, using the bore of the bushing and the bore of the roller as guides.

NOTICE: If you fail the press in the bushing unevenly, the bushing will be distorted and unusable. In that case, do not re-use the bushing as it may cause the roller to malfunction.

RAPH12CEX1047BA

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1


4.

Two floating seal halves (6) make a pair. Attach one floating seal half to the retainer fixed in the shaft (2), and another to the inside of the upper roller (1). Then attach o-rings (7).

NOTE: Prior to installing floating seals (6), apply engine oil lightly to seal surface.

5.

RAPH12CEX1045AA

2

RAPH12CEX1044AA

3

RAPH12CEX1048BA

4

Coat shaft (2) with a thin film of oil and insert it into the upper roller (1).

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6.

Mount the upper roller (1) onto the stand jig (A) and attach the thrust-washer (10) to the end of the shaft (2) with bolts (13). Torque bolts to 114.7 N·m (84.6 lb ft)

7.

Apply grease to the o-ring and fit it (9) into the groove of the cover (11).

8.

Fit cover (9) to the upper roller (1) and secure it with bolts (12).

9.

Fill the roller with 0.2 kg (0.44 lb) of TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40 through the plug hole in the roller.

10.

Wind sealing tape around the plug (3) and screw it into the plug hole in the upper roller. Torque plug to 23 N·m (17 lb ft)

11.

After upper roller is assembled, confirm that no oil is leaking from it and that it rotates smoothly.

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RAPH12CEX1042AA

5

Index Tracks and track suspension - 48 Track rollers - 138 Track frame roller - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SK170-9 LA

Track frame roller - Disassemble Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SK170-9 LA

Track frame roller - Service limits Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Track frame roller - Special tools – Dealer Made Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Track rollers - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

Track rollers - Install Lower roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA

Track rollers - Install Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Track rollers - Remove Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

Track rollers - Remove Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Track support roller - Assemble Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SK170-9 LA

Track support roller - Disassemble Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA

Track support roller - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Track support roller - Special tools – Dealer Made Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

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47454079-DRAFT 06/11/2012 EN

SERVICE MANUAL Cab climate control

SK170-9

47454079-DRAFT 06/11/2012

50

Contents Cab climate control - 50

Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200 SK170-9

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Cab climate control - 50 Air conditioning - 200

SK170-9

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Contents Cab climate control - 50 Air conditioning - 200

TECHNICAL DATA Air conditioning General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

FUNCTIONAL DATA Air conditioning Overview – BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Overview – System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Component diagram Components and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Overview Function – Mechanism of cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

Overview – Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA

Wiring schema - Diagram and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SK170-9 LA

Component identification – Structure and Operation of Each Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SK170-9 LA

Component identification – Electrical Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SK170-9 LA

Overview – Self Diagnosis Function on Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SK170-9 LA

SERVICE Air conditioning Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SK170-9 LA

Service instruction – Charging Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SK170-9 LA

Charging Vacuum Making Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 SK170-9 LA

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SK170-9 LA

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Cab climate control - Air conditioning

Air conditioning - General specification [48679408] SK170-9 LA

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Air conditioning - Overview – BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) [47013953] SK170-9 LA

Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and internal / external air switching unit. And this unit changes hot air to cool air.

AIR CYCLE Heater Internal air or external air is taken in through inlet and the air is passing through filter and heat exchange is performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off fromgrille through duct. Cooler Internal air or external air is taken in through inlet 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 internal 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.

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Air conditioning - Overview – System Outline [47626446] SK170-9 LA

RAPH12CEX0255HA

1

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Air conditioning - Component diagram Components and Construction [47638301] SK170-9 LA

RAPH12CEX0256FA

1

Air Conditioner Group No. 27 27–1 27–2 27–3 27–4 30 32

Parts Air Conditioner Assy Air Conditioner Unit Hose Clamp Filter Panel Assy Compressor

Qty 1 1 2 2 1 1 1

No. 33 34 35 35–1 35–2 35–5 35–6

Parts Pulley Condenser Air Dryer Assy Receiver Dryer Bracket S hose: 24.5 D hose

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Qty 1 1 1 1 1 1 1

No. 35–7 35–8 35–9 35–10 39 40

Qty Parts L hose 1 L hose: 15.5 1 L Tube 1 S tube 1 Filter 1 Solar radiation sensor 1


RAPH12CEX0258GA

2

Air Conditioner Unit (1/2)

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RAPH12CEX0257GA

3

Air Conditioner Unit (2/2)

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

Description Heater core Case Intake Liner filter Packing intake Liner intake MAL Lever intake Damper intake assy Sun sensor Duct joint assy Case heater R Case heater L Case drain Clip ps harness Cover link Filter receiver assy Packing duct outlet A Packing duct outlet B Cooling hose

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1

No. 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Description Blower motor assy Motor actuator Harness assy Lever vent Lever face Lever foot Lever def Joint vent Joint foot Joint def Rod common Lever mode MAL Lever am main Lever am sub Link mode Main rod Damper mode assy A Damper mode assy B

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Qty 1 3 1 1 1 1 1 1 1 1 2 1 1 1 1 1 3 2

No. 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Description Damper air mix assy Relay Fan driver Evaporator assy Expansion valve Evaporator sensor Socket bolt M5x40 Harness holder Thermistor holder Tapping screw M5x14 Tapping screw M4x16 Bushing Rod holder Tapping screw M4x16 Insulation

Qty 1 2 1 1 1 1 2 1 1 3 36 4 2 1 2


RAPH12CEX0259HA

4

Air conditioner piping (1/2)

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RAPH12CEX0260HA

5

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No.

Tightening torque Nm (lbf ft)

3.9 ~ 5.9

1 2 3 4 5 6 7

20.7 ~ 25.3

8

20.7 ~ 25.3

9

41.9 ~ 51.1

10 11 12 13 14 15 16 17 18 19 20 21 22

20.7 ~ 25.3

23

3.92 ~ 4.9

24 25

Parts

Hose: L = 1200 Hose: L = 1700 Bracket V-belt Clip Hose: L = 1800 Sems bolt: M6x20 Sems bolt: M8x20 Capscrew: M8x100 Washer Lock washer Tube: L = 1100 Tube: L = 1700 Lock washer Lock washer Tube: L = 2800 Tube: L = 2100 Clamp Filter Tube: L = 1600 Bracket Sems bolt: M10x70 Sems bolt: M8x25 Washer Clip

Qty

1 1 2 1 6 1 2

Tightening torque Nm (lbf ft) 10~ 12

No.

Parts

Qty

26 27 30 32 33 34 35

Capscrew: M8x30 Conditioner Assy Panel Pulley assy Pulley ass Condenser Air dryer assy

4 1 1 1 1 1 1

37

Capscrew: M10x25

2

4

39

Filter

1

11 7 1 1 2 7 1 1 1 1 1 1 2

40 50 53 57 63 64 65 66 67 72

Solar radiation sensor Connector Washer Washer Capscrew: M10x30 Tube Capscrew: M10x60 Tube Clip Clip

1 1 10 2 5 1 1 1 1 1

41.9 ~ 51.1

5

20.7 ~ 25.3

16.7 ~ 18.6 41.9 ~ 51.1

2 4 13

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RAPH12CEX0261HA

6

Air dryer assembly

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No.

Tightening Torque Nm (lbf ft)

20 ~ 25 (14.8 ~ 18.4) 8 ~ 12 (5.9 ~ 8.9)

1 2 3 4 5 6 7 8 9 10

Parts Receiver dryer Bracket Capscrew Capscrew S hose D tube L tube L hose L tube S tube

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Qty 1 1 2 2 1 1 1 1 1 1


Air conditioning - Overview Function – Mechanism of cooling circuit [47766627] SK170-9 LA

Mechanism Of Cooling In the cooling process, the refrigerant that flows through the cooling circuit changes its phases from liquid to gas and vice versa during which process heat is transferred from the low temperature part (compartment) to the high temperature part (outside of the vehicle). Kind of Refrigerant Many kinds of refrigerants that change in that way are available, but the following requirements are needed for use in such applications: • Latent heat of vaporization (heat of vaporization) is large. • It is easy to liquefy (condense). It does not require very high pressure for condensation. • It is easy to gasify (evaporate). It evaporates sufficiently at not too low a pressure, i.e. cools down an object.

HFC—134a (R134a) Chemical formula CH2FCF3 Molecular weight 102.03 Boiling point –26.19 °C Critical temperature 101.14 °C Critical pressure 4.065 MPa Critical density 511 kg/m3 Density of saturated liquid 1206 kg/m3 (25 °C) Specific volume of 0.0310 m3/kg saturated vapor (25 °C) Latent heat of vaporization 197.5 kJ/kg (0 °C) Flammability Non flammable Ozone destruction 0 coefficient

• It has small specific heat. Since the refrigerant itself is cooled by the expansion valve, the loss resulting from it must be held down to a minimum. • It has a high critical temperature and a low solidification point. • It is stable chemically and does not corrode and permeate into the circuit parts. • It is free from toxicity, objectionable odor, flammability and explosiveness and excels in thermal conductivity and electric insulation. • It has small specific gravity. • It is easy to find leaks. Out of refrigerants meeting the above mentioned requirements, ones having characteristics that suit the intended cooling unit are chosen and used. If are refrigerant other that those designated is used, sufficient refrigeration will not be performed or the equipment in which the refrigerant is used may be broken. Therefore, always use a designated refrigerant for the cooling unit. Table shows the principal characteristics of theR134a refrigerant that is used in this machine.

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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 begins to condensate at a certain temperature to take a liquid state. The temperature at which condensation begins is unique to each substance (fluid) at a given pressure. The temperature determined by a given pressure is called saturation temperature.

RAPH12CEX0262GA

2. Inversely to 1. above, the pressure at which a gas condenses for a temperature is determined. This pressure is called saturation pressure. Figure below illustrates the relationships between the saturation temperature and the saturation pressure in the case of refrigerantR134a used in the air-conditioner. At the temperature and the pressure on the lower right hand side of the curve in above figure the refrigerant take a gaseous state, while at the temperature and the pressure on the upper left hand 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 compartment. In order to cool the inside of the compartment down to 25°C(77°F), the refrigerant must transform (evaporate) from a liquid to a gaseous state at a lower temperature. It can be seen from the above figure 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 it 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 35°C (95°F).Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 MPa (145psi), as seen from the above figure.

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1


Cooling circuit The figure illustrates the cooling circuit of the car air-conditioner. In this circuit diagram, the portion that cools the air of the compartment is the evaporator. The object air is cooled off by utilizing the fact that the refrigerant takes heat off the surrounding area as evaporation heat as it evaporates in the cooling circuit. Since the part at which vaporization of the refrigerant takes place is the evaporator, cooled air is constantly delivered to the circumference of the evaporator by the blower fan. In the meantime, liquid refrigerant (slightly wet vaporized refrigerant) is fed into the evaporator, when "cooling" effect is attained. For instance, in order to cool the air to 15°C (59°F), the refrigerant can not absorb evaporation heat from the air unless it evaporates at a temperature lower that15°C (59°F). For that purpose, it can be seen from the figure that the pressure of the refrigerant in the evaporator must be less than 0.51 MPa (74 psi). Furthermore, the cooling effect deteriorates unless the feed rate of the refrigerant is controlled so that all of the refrigerant supplied to the evaporator vaporizes and turns into dry vapor. Consequently, the cooling circuit is so constructed that the evaporator can cool down an object (air in this case) sufficiently (i.e. so as to decrease the pressure in the evaporator) and that an adequate amount of refrigerant can be fed to the evaporator. The feed rate of the refrigerant is controlled by the expansion valve, but the pressure in the evaporator is held low by the throttling action of the expansion valve and the suction action of the compressor. The compressor acts as a pump that allows the refrigerant to circulate. The compressive action of the compressor and the heat exchange (heat radiation) action of the condenser transform the refrigerant in a dry vapor state back to a liquid state.

RAPH12CEX0263HA

No. 1 2 3 4 5 6 7 8 9

Description Inside the cab compartment Evaporator Blower Compressor Cooling fan Inside of engine compartment Condenser Receiver dryer Expansion valve

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2


Air conditioning - Component identification [47931911] SK170-9 LA

EVAPORTATOR. The evaporator is an important heat exchanger that absorbs the heat of the compartment air (object) by the utilization of the latent vaporization heat of the low-temperature, low-pressure liquid-state refrigerant. Therefore, it is necessary that satisfactory heat transfer between the object and the refrigerant take place in the evaporator. To that end, the evaporator is equipped with fins on the air side in order to increase the heat transfer area of the air side and thereby perform excellent thermal transfer between the refrigerant and the air. The humidity in the air condenses as the air cools down and adheres to the outside of the evaporator as water drops. The cooling effect deteriorates if the water drops freeze. Therefore, how to discharge water is an important point. The amount of refrigerant supplied to the evaporator is controlled by the expansion valve which is described in the following. In order to attain proper control, it is necessary to reduce the pressure drop of the refrigerant of the evaporator. Accordingly, reducing the pressure drop is one element that makes the evaporator attain its full performances EXPANSION VALVE

RAPH12CEX0264BA

In order for the evaporator to fulfill its performances, a proper amount of low-pressure low-temperature liquid refrigerant must be fed to the evaporator. If the feed rate is too low, the refrigerant completes vaporization early in the evaporator which results in deterioration of the cooling effect. If the feed rate is too high, unvaporized liquid refrigerant returns to the compressor (liquid back). This not only deteriorates the cooling effect, but also damages the compressor valves. The expansion valve feeds the flowing high pressure high-temperature liquid refrigerant to the evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The expansion valve controls the feed rate of the refrigerant at the same time.

No. 1 2 3 4

Part Evaporator O-ring Expansion valve Socket bolt M5x40

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1


The figure beside shows how the block type expansion valve is constructed. The temperature sensing part is provided in the shaft of the expansion valve to directly detect the refrigerant temperature at the outlet of the evaporator. The diaphragm contains R134a in saturated state. The pressure in the diaphragm changes according to the temperature detected by the sensor. The change in the pressure causes the force acting upon the diaphragm to vary accordingly. The high-pressure high-temperature liquid refrigerant that is fed from the receiver side reduces the pressure abruptly as it passes through the valve (throttling action). On that occasion, part of the refrigerant evaporates by the very heat of the refrigerant and cooled off. The result is that low pressure low-temperature damp refrigerant vapor is fed to the evaporator. The opening of the valve is determined by the balance between the pressure (low) of the evaporator side, the action of the adjust spring and the pressing force of the diaphragm (the temperature of the refrigerant at the outlet of the evaporator to be sensed by the temperature sensor). The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly overheated (3 ~ 8 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.

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RAPH12CEX0265BA

2

RAPH12CEX0266BA

3


COMPRESSOR The compressor performs the following three functions in the cooling circuit: 1. Suction action 2. Pumping action 3. Compressive action 1. The suction action, as combined with the throttling action, works to decrease the refrigerant pressure in the evaporator. This permits the refrigerant to vaporize at low temperature in order to perform cooling effect. 2. The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This enables continuous cooling. 3. 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. For instance, it becomes possible to cool down the refrigerant by the use of an external air of 35°C (77°F) and liquefy it. 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. However, 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 near form of thermally insulated compression, so that the refrigerant discharged by the compressor turns into high-temperature high-pressure vapor and is delivered to the condenser.

RAPH12CEX0270BA

No. 1 Discharge Hose 2 Suction Hose 3 Compressor

4

Part

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.

RAPH12CEX0271BA

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5


RECEIVER DRYER 1. Receiver Tank On the air-conditioner, the revolution of the compressor varies greatly which causes the proper flow of refrigerant in the cooling circuit to vary. It is 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 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 the amount of water mixed in the refrigerant should be held below a concentration of 30ppm. The air-conditioner uses a molecular sieve as desiccant suited for the circuit, in order to absorb water content that intrudes into the circuit when the dryer is installed or when refrigerant is charged. 3. Sight Glass This is a inspection window with which the refrigerant level in the circuit is determined, the only 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 off the power supply to the compressor when high pressure increases abnormally high (more than 3.14 MPa (460 psi)). 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 (28 psi).

RAPH12CEX0272CA

No. 1 2 3 4 5 6 7 8

Part Refrigerant inlet Sight glass Refrigerant outlet Pressure switch Desiccant Suction pipe Filter Receiver tank

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6


Air conditioning - Overview – Operating Procedure [48289846] SK170-9 LA

Refrigerant charge into the air conditioner consists mainly of “vacuum making operation”, and “gas charge operation”. • The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water remains in the circuit, the small holes of the expansion valve are frozen during operation. This causes the circuit to clog up or rust, resulting in a variety of malfunctions. Therefore, before charging refrigerant in the circuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus eliminated. • The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not only depends upon the cooling performances of the air-conditioner, but also affects the service life of the component parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes the cooling performance to deteriorate. On the contrary, undercharge causes poor circulation of the lubricating oil of the compressor and causes seizure of the moving parts of the compressor. The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in this manual.

RAPH12CEX0286FA

1

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Air conditioning - Wiring schema - Diagram and Connectors [48595080] SK170-9 LA

RAPH12CEX0293GA

1/2 3 4 5 6 7 8 9

CCU (Operation Panel + Controller Air Inlet Sensor Evaporation Sensor Solar Radiation Sensor Motor Actuator (Air Mix) Motor Actuator (Mode) Motor Actuator ( Rec/Fresh) Compressor Relay

10 11 12 13 14 15 16 17

1

Connector Blower Off Relay Blower Motor Blower AMP Pressure Switch Compressor Main Key Switch Light Switch

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RAPH12CEX0294HA

2

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Air conditioning - Component identification – Structure and Operation of Each Part [48599848] SK170-9 LA

1. Control Panel The control unit is integrated into the control panel. It processes the signal input by each sensor and switch through the control panel with the function of the micro computer. The control unit also comprehensively controls each actuator (Air inlet / outlet mode select, air mix), blower motor and compressor on the output side. There is a self-diagnosis performance provided to facilitate the troubleshooting.

RAPH12CEX0295BA

1

2. Fan Driver The power transistor shifts the blower motor into variable speed with base current from the control unit. In normal operation: Disconnect the connector of blower amplifier. Check continuity between terminals on the blower amplifier side.

RAPH12CEX0296BA

Tester

Terminal No. 1 2 + + +

-

3 -

2

Continuity CONTINUED (4.7 kΏ ±5%) NOT CONTINUED CONTINUED (DIODE PARALLEL AND FORWARD DIRECTION FLOW)

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1. 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

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Air conditioning - Component identification – Electrical Equipment List [48611730] SK170-9 LA

Group (C) Controller

(D) Diode

(E) Electric Fittings

(L) Light

(M) Motor

Code C-1 C-2 C-3 D-4 D-5 D-6 D-9 D-10 D-12 D-13 D-14 D-15 D-16 D-17 D-18 D-19 D-20 D-21 D-22 D-23 D-25 E-1 E-3 E-5 E-6 E-8 E–9 E-10 E-11 E-12 E-22 E-23 E-46 E-63 L-1 L-2 L-5 L-6 M-1 M-3 M-4

Part Name Mechatro Controller Gauge Cluster AC Controller (including panel) Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Fuse and Relay box Hour meter Horn high Horn low Speaker left Speaker right Receiver dryer AC compressor Battery AC-DC converter 24V Socket Rear view camera AC-DC converter (camera) Boom work light (LH) Frame work light (RH) Room light Boom work light (RH) Starter motor Wiper motor Washer motor

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Part No. YN22E00425F1 YN59S00028F3 LQ20M01328P1 YN02D01001P1 Accessory of relay box ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ YN02D01001P1 ↑ ↑ ↑ ↑ ↑ ↑ YN24E00016F3 LQ58S00002P1 87357734 87565344 LQ54S00003S002 ↑ LQ54S00005P1 72203934 5199959 84130880 87524810 YN55S00009F1 YN77S00040P1 YN77S00040P1 87555081 LB80S00001F1 LQ02C00031S020 84377568 LQ53C00003S001 422702800


Group

Code PSV-A PSV-B

(P) Proportional solenoid valve

(R) Relay

(SE) Sensor

PSV-C PSV-D PSV-P1 PSV-P2 R-1 R-2 R-3 R-4 R-5 R-6 R-23 R-24 R-25 R-26 R-28 R-29 R-30 R-31 R-32 R-94 SE-1 SE-2 SE-3 SE-4 SE-5 SE-7 SE-8 SE-9 SE-10 SE-11 SE-13 SE-15 SE-16 SE-20 SE-22 SE-23

Part Name Arm 2 speed inverse prop. valve P2 unload prop. valve (YN35V00047F2) Solenoid valve assy Travel straight prop. valve P1 unload prop. valve P1 pump prop. valve (YN35V00052F2) Pump P2 pump prop. valve Battery relay Starter relay Glow relay Safety relay Horn relay Working light relay Auto idle stop relay 1 Auto idle stop relay 2 Engine emergency stop relay Lever lock relay Alternator relay Wiper motor relay (Normal rotation) Wiper motor relay (Reverse rotation) Wiper motor relay (Arc prevention) Washer motor relay Neutral stop relay Pressure sensor : Bucket digging Pressure sensor : Bucket dump Pressure sensor : Boom up Pressure sensor : Boom down Pressure sensor : Swing Pressure sensor : Arm in Pressure sensor : Arm out Pressure sensor : Travel RH Pressure sensor : Travel LH Pressure sensor : P2 OPT. E/G speed sensor Fuel sensor Accel potentiometer Pressure sensor : P1 OPT. Pressure sensor : Pump P1 Pressure sensor : Pump P2

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Part No. YN35V00049F1 YN35V00048F1 ↑ ↑ YN35V00052F2 ↑ YN24S00008F1 71403889 71451677 YN24S00010P1 ↑ ↑ YN24S00010P1 ↑ ↑ ↑ ↑ YN24S00012P2 ↑ ↑ ↑ YN24S00010P1 LC52S00019P1 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ 72213891 YN52S00045F1 LQ52S00025P1 LC52S00019P1 LS52S00015P1 ↑


Group

Code SV-1

(SV) Solenoid

SV-2 SV-3

(SW) Switch

SV-4 SW-1 SW-4 SW-8 SW-10 SW-11 SW-19 SW-20 SW-24 SW-55

Part name Swing parking brake (YN35V00047F2) Solenoid valve assy SOL Power boost SOL Two speed select SOL Safety lock lever SOL Key switch Swing parking brake release switch Air filter clogging switch Horn switch (LH) Safety lock lever switch Wiper interlock switch Power boost switch (RH) Coolant level switch Work light switch

NOTE: The part numbers may change, use them only for reference.

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Part No. YN35V00051F1 YN35V00050F1 ↑ ↑ YN50S00026F2 YN50S00047P1


Air conditioning - Overview – Self Diagnosis Function on Display Panel [60671056] SK170-9 LA

The failure of the motor actuator and each sensor can be identified on the display panel.

POSITION OF INDICATION OF FAILURE

RAPH12CEX1243EA

1

EXPLANATION OF INDICATION FOR FAILURE FAILURE OF MOTOR ACTUATOR 1. HL.Eis indicated on the 3 digit segment. Check harness or connector to motor actuator for the air mix damper for disconnection.

RAPH12CEX1244AA

2

2. MODE is flashing. Check harness or connector to motor actuator for the air outlet damper for disconnection

RAPH12CEX1245AA

3

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3. R/F is flashing. Check harness or connector to motor actuator for the inner and outer air damper for disconnection.

RAPH12CEX1246AA

4

NOTE: The above indication and flashing does not show if the harness and the connector were disconnected while the display panel is on. They will only show when the panel is turned on after the failure occurred. After the failure is corrected, the flashing will continue until the starter switch is turned OFF then back ON.

Failures of sensors 1. HL.* is indicated on the 3 digit display. Check the inner air sensor or the harness for a disconnection or short circuit, and also connectors for disconnection. (* is any of the numbers 0 to 9)

RAPH12CEX1247AA

5

2. **E and mark is shown on display. Check evaporator sensor or the harness for disconnection and short circuit, and also connectors for disconnection. (** is displayed leaving the present set temperature value.)

RAPH12CEX1248AA

6

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NOTE: The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition the panel ON/OFF switch is ON. And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is released.

Communication error of control amplifier and panel E is indicated on the only use segment of display. Check the harness of control amplifier and panel for disconnection, and connectors for poor connection.

RAPH12CEX1249AA

7

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EXPLANATION OF MONITOR MODE When error “failure of sensors” is displayed, the monitor mode is available to identify the sensor condition (disconnection, short circuit).

1. Position of monitor mode indication

RAPH12CEX1252EA

8

RAPH12CEX1253EA

9

2. Operation of monitor mode

1. Press inner and outer air flow select switch (A) and ON/OFF switch (D) simultaneously for 1 second. 2. Press AUTO switch (E). (After all segments are lit up for 1 second, the mode is switched into monitor mode.) 3. Any numbers from 0 to 9 or any letters from A to F are displayed on the 3rd digit and 2nd digit of the three digit segment. The 1st digit will show “H”. 4. Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing UP or DOWN of blower switch (B) or (C) , and the required sensor is selected from the list below. 0 is for INTAKE AIR SENSOR 1 is for EVAPORATOR SENSOR 2 is for SOLAR SENSOR

RAPH12CEX1254AA

10

5. The monitor display is terminated by pressing the inner and outer air flow select switch (A) and ON/OFF switch (D) for 1 second again, or turning off the main switch of the excavator.

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NOTE: The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for operation and setting until the monitor mode is cancelled.

3. Contents of monitor mode display Refer to the list of segment display exclusively used for monitor and the list of segments in three digits. 1. Example 1: When the segment exclusively used for monitor indicates 0 (displays the intake air sensor condition), since the segment indicates 3F, the sensor is in normal operating condition according to the list of 3 segments. --> The intake air sensor is in normal operating condition.

RAPH12CEX1254AA

11

2. Example 2: When the segment exclusively used for monitor indicates 1 (displays the evaporator sensor condition), since the segment indicates 00, the sensor is in disconnection condition according to the list of 3 segments. --> The evaporator sensor is in disconnection condition.

RAPH12CEX1255AA

12

3. Example 3: When the segment exclusively used for monitor indicates 2 (displays the solar sensor condition), since the segment indicates 0C, the sensor is in short-circuiting condition according to the list of 3 segments. -->The solar sensor is in short-circuiting condition.

RAPH12CEX1257AA

13

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4. List of 3 segments

RAPH12CEX1258EA

14

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Air conditioning - Disassemble [47990985] SK170-9 LA

Precautions to be exercised in operation 1.

Special Refrigerator Oil This air conditioner uses special refrigerator oil SP20 for use with new refrigerant R134a. Oils other than SP20 may not be used. Since SP20 tends to absorb moisture and may corrode paint and resin, the following points must be noted: – Do not keep open all pipe connections on a new compressor and the component parts of the installed refrigeration circuit (Remove valves and caps at the pipe openings of the compressor, just before connecting pipes. If you have removed a pipe joint for repair, put a cap to both ports immediately.) – Use care so SP20 does not adhere to the painted surface and resin parts. In case SP20 has adhered to such surfaces, wipe it off immediately.

2.

The receiver dryer is filled with desiccant to absorb moisture in the circuit. Therefore, remove the valve at the pipe port immediately before connecting pipes.

3.

Tightening Torque – Pipe Joints When connecting pipe joints, coat the O-ring with special oil (SP20) and fasten to the tightening torque indicated in the table, using a double spanner. – Screws and Bolts Fasten to the tightening torque indicated in the table

4.

Amount of oil for compressor The compressor SD7H (HD type) is filled with 135cc (8.2cu•in) of oil. If the oil volume is small, seizure at high revolution and shortening of service life will occur. If the oil volume is large, the cooling ability will be deteriorated. Once the air-conditioner is operated, part of the oil is dispersed in the refrigeration circuit. Therefore, when replacing the parts in right Table, adjust the oil level to that of table.

5.

Before performing operation, stop the engine and turn off all power supplies to the equipment related to the air-conditioner.

6.

After the operation is over, confirm that all faults have been repaired completely, by operating the air-conditioner.

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Pipe Fastening Part D hose and compressor (M8 bolt) D hose and condenser L hose and condenser L hose and receiver dyer (M6 bolt) L hose and air-conditioner unit S hose and air-conditioner unit Expansion valve

Tightening Torque Nm (lbf ft) 19.6~24.5 (14~18) 19.6~24.5 (14~18) 11.8~14.7 (8.7~11) 7.8~11.8 (5.8~8.7) 11.8~14.7 (8.7~11) 29.4~34.3 (22~25) 1.96~2.45 (1.4~1.8)

Screw Size N4, T4 machine screw, M4 N5, T5 machine screw, M5 M6 (mounting part of L hose joint) M6 (except mounting part of L hose joint) M8 (mounting part of S,D hose joints) M8 (mounting part of A/C unit) M8 (other than those mentioned above) M10

Tightening Torque 0.78~1.18 (0.58~0.87 1.96~2.45 (1.4~1.8) 7.85~11.8 (5.8~8.7) 9.8~11.8 (7.2~8.7) 19.6~24.5 (14~18) 9.8~11.8 (7.2~8.7) 11.8~15.7 (8.7~12) 39.2~53.9 (29~40)

Replaced Parts Evaporator Condenser Compressor Receiver Dryer Hoses

Amount of refrigerant to replace 40 cc (2.4cu·in) 40 cc (2.4cu·in) Drain out the volume of oil left in the compressor to be replaced, from the new compressor. 20 cc (1.2cu·in) 20 cc (1.2cu·in)

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1.

2.

Disassembly and assembly of blower motor 1.

Disconnect cooler hose (1) from A/C unit (2) .

2.

Loosen 3 tapping screws (3)

3.

Remove blower motor (4)

4.

Disconnect cooler hose (1) from blower motor (4) .

5.

Assemble the A/C unit in the reverse order of disassembly.

RAPH12CEX0275BA

1

RAPH12CEX0276BA

2

RAPH12CEX0277BA

3

Disassembly and assembly of internal/external actuator. 1.

Loosen 3 tapping screws (5) .

2.

Remove actuator (6) .

3.

Assemble the actuator in the reverse order of disassembly.

NOTE: Insert lever pin of actuator (7) into groove (8) of damper lever.

3.

Disassembly and assembly of relay. 1.

Loosen tapping screws (9).

2.

Remove relay (10).

3.

Assembly the relay in the reverse order of disassembly.

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4.

5.

6.

Disassembly and assembly of inner air sensor 1.

Pressing lock of connector (11) , remove the connector from inner air sensor (13).

2.

Pressing lock of sensor (12) remove inner air sensor (13).

3.

Remove cord sandwiched between components of unit slowly.

4.

Lift inner air filter (14) upwards and remove it.

5.

Pressing lock of connector (15) inwards and remove the connector.

6.

Assemble the inner air sensor in the reverse order of disassembly. RAPH12CEX0278BA

4

RAPH12CEX0279BA

5

RAPH12CEX0280BA

6

Disassembly and assembly of fan driver. 1.

Disconnect connector (16) from fan driver (18) .

2.


3.

Remove fan driver (18) .

4.

Assemble the fan driver in the reverse order of disassembly.

Disassembly and assembly of link cover. 1.


2.

Remove link cover (20) .

3.

Assemble the link cover in the reverse order of disassembly.

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7.

8.

Disassembly and assembly of mode actuator and air mix actuator. 1.


2.

Disconnect connector from 2 actuators.

3.

Turn rod latch (21) of mode actuator (22) in the direction of arrow as shown. Release link rod (23) .

4.

Twist link bar (24) of air mix actuator (25) in the direction of arrow as shown. Remove the link rod from damper lever.

5.

Loosen 3 tapping screws (26) fixing each actuator.

6.

Remove each actuator as shown.

7.

Assemble the actuators in the reverse order of disassembly.

RAPH12CEX0281BA

7

RAPH12CEX0282BA

8

Disassembly and assembly of heater core. 1.


2.

Disconnect connector (27) from air mix actuator (28) .

3.

Remove heater core (29)

4.

Assemble the heater core in the reverse order of disassembly.

NOTICE: Do not exert excessive load on piping.

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9.

Disassembly and assembly of evaporator. 1.

Turn HVAC unit (30) upside down.

2.


3.

Disconnect connector of evaporator sensor (32) .

4.

Pull out evaporator (33) .

5.

Assemble the evaporator in the reverse order of disassembly.

NOTICE: To avoid damage, pull out evaporator sensor cord from groove of HVAC unit carefully.

RAPH12CEX0283BA

10.

9

Disassembly and assembly of expansion valve. 1.

Loosen 2 socket bolts (34) .

2.

Remove expansion valve (35) .

NOTICE: Do not exert excessive load on piping. 3.

Assemble the expansion valve in the reverse order of disassembly.

4.

Prior to assembly, apply PAG oil to O-ring.

NOTICE: Damage to O-ring will cause a refrigerant leak. 11.

Disassembly and assembly of evaporator sensor (39) 1.

Remove the harness holder (36) and thermistor holder (37) from evaporator (38).

NOTICE: To avoid damage to sensor to not pull cord forcibly. 2.

Assemble the evaporator sensor in the reverse order of disassembly.

3.

Install the harness holder and thermistor holder as shown.

4.

Install the tip of sensor and thermistor holder as shown.

NOTICE: If the sensor cord is not properly secured, the cord will be damaged by the cab door.

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RAPH12CEX0546BA

10


Air conditioning - Service instruction – Charging Refrigerant [48243736] SK170-9 LA

WARNING Escaping refrigerant may cause frostbite! Always wear protective goggles when handling refrigerant. If you get refrigerant in your eye, immediately flush your eyes with water for 15 minutes. Seek medical assistance immediately. Failure to comply could result in death or serious injury. W0339A

Precautions to be exercised in operation 1.

Assign a person in charge of handling refrigerant. Refrigerant charge operation involves dangers as it handles high pressure gas. Assign a person familiar with how work is done for handling refrigerant.

2.

Storage and Transportation 1.

Keep the service can (hereinafter called can) less than 40 °C (104 °F).Since high pressure gas of R134a is filled in the can in a saturated liquified state, the pressure in the can increases sharply as temperature rises. The can may explode as a result. It is for this reason that the can temperature must be kept below 40 °C (104 °F).

2.

For storage, choose dark cold place not exposed to direct sunlight.

3.

If the can is placed near a fire, it is exposed to radiation heat and gets hot. This causes the inside pressure to rise and may cause the can to explode. Do not bring the can close to an open flame.

4.

The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temperature level. Do not bring the can into the compartment.

5.

Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.

6.

Do not drop or knock on the can. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.

7.

Keep can out of reach of children.

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3.

4.

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 40 °C (104 °F) 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 will explode.

2.

When charging refrigerant while running the engine, to avoid explosion, do not open the high pressure valve (HI) of the gauge manifold.

Others 1.

Reuse of service cans is prohibited by regulation, do not reuse them. Do not allow foreign matter 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 the entry of water and dust.

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Air conditioning - Charging Vacuum Making Operation [48290806] SK170-9 LA

1.

Close high pressure valve (3) and low pressure valve (1) on gauge manifold (2) .

2.

Connect the charging hoses [red (5) and blue (6) ] with the service valves (8) of the compressor. Red hose (5) : High pressure side (HI) of the gauge manifold -> high pressure side (DIS) of compressor. Blue hose (6) : Low pressure side (LO) of gauge manifold -> low pressure side (SUC) of compressor.

NOTICE: 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. Connect the quick release joint of the charging pipe with the service valve of the compressor. If the charging hose is connected in the opposite direction, mini-valve (9) of the compressor fails to open. 3.

Connect the center valve of the gauge manifold with charging hose (4) of the vacuum pump (7) .

RAPH12CEX0287BA

1

RAPH12CEX0288BA

2

NOTE: Some kinds of gauge manifolds are not equipped with an open/close valve in the center. 4.

Open high pressure valve (3) and low pressure valve (1) of gauge manifold.

5.

Turn on the switch of the vacuum pump and make vacuum for more than 30 minutes.

6.

When vacuum making for a specified duration is over (degree of vacuum : less than - 750 mmHg), close the high pressure valve (3) and the low pressure valve (1) of the gauge manifold (2) .

7.

Then turn off the vacuum pump.

8.

Close the high pressure valve (3) and the low pressure valve (1) of the gauge manifold (2), leave it as it is for more than five minutes and make sure that the gauge indication does not return toward 0.

NOTE: 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.

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Air conditioning - Charging [48372804] SK170-9 LA

1.

After making vacuum repeatedly, change the charging hose (yellow) (4) of the gauge manifold (2) , from the vacuum pump to the service can (9).

2.

Air purge. Close the high and low pressure valves of the gauge manifold. Open the service can valve (10). Then push the gas valve of the side service port on the low pressure side of the gauge manifold with a screw driver. This lets the air out of the charging hose. Remove the screw driver once a hissing sound is heard.

3.

Open the high pressure valve (3) of the gauge manifold and charge refrigerant. Charge with gaseous refrigerant to a gauge pressure of 0.1 MPa (14.5 psi). After charging, close high pressure valve (3) of the gauge manifold and service valve (10).

4.

RAPH12CEX0289BA

1

RAPH12CEX0290BA

2

RAPH12CEX0292BA

3

Check for gas leak in the cycle, using a gas leak detector (electric type). retighten and correct leaking points.

NOTE: Use the leak tester for R134a. Do not use one for flon gas service as it provides poor sensitivity. 5.

Make sure that high pressure valve (3) and low pressure valve (1) of the gauge manifold and service valve can (10) are closed.

6.

Start the engine and run the revolution from 1400 to 1600 rpm and close the cab door and the windows.

7.

Turn on the air conditioner switch, set the fan switch to Max and the temperature control switch to cool Max.

8.

When charging gas, set the discharge pressure of the compressor from 1.4 - 1.6 MPa (203 - 232 psi).

9.

Open low pressure valve (1) of the gauge manifold and service valve can (10) and fill with refrigerant until all air bubbles in sight window (12) of the dryer disappear. Total amount of gas to be charged: 850 - 950 g (30.0 - 33.5 oz)

10.

When refrigerant charge is completed, close low pressure valve (1) of the gauge manifold and the service valve can (10).

NOTICE: Do not open the high pressure valve of the gauge manifold. Do not turn over the service can. (The compressor valve may be damaged because the refrigerant is sucked in a liquid state.)

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11.

The level of refrigerant is correct only once the air conditioner is activated and through the inspection sight window, just a few air bubbles are seen and, afterward, a white color slightly milky is seen.

NOTE: When the air conditioner operates with an insufficient quantity of refrigerant, this has a negative effect on the compressor; on the contrary, when the refrigerant is charged with an excessive quantity, the cooling performance is lost. Also, the pressure of the system increases abnormally. 12.

Disassemble the manifold disconnecting the charging pipes from the compressor, as indicated here below. a) Press the quick release coupling of the charging pipe on the low pressure side against the service valve of the compressor so that the refrigerant does not escape leaking when loosening the connections. As soon as the nut has been removed, disconnect the charging pipe from the service valve. b) Wait for the pressure in the high pressure site to decrease, indicated on the pressure gauge, to a value of 1.0 MPa (145 psi). c) Disconnect the red charging pipe from the high pressure side, in the same manner as described for the low pressure.

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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SK170-9 LA

Air conditioning - Charging Vacuum Making Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 SK170-9 LA

Air conditioning - Component diagram Components and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Air conditioning - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

Air conditioning - Component identification – Electrical Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SK170-9 LA

Air conditioning - Component identification – Structure and Operation of Each Part . . . . . . . . . . . . . . . . . . . . . . . . 25 SK170-9 LA

Air conditioning - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SK170-9 LA

Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Air conditioning - Overview – BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) . . . . . . . . . . 4 SK170-9 LA

Air conditioning - Overview – Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA

Air conditioning - Overview – Self Diagnosis Function on Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SK170-9 LA

Air conditioning - Overview Function – Mechanism of cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

Air conditioning - Overview – System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Air conditioning - Service instruction – Charging Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SK170-9 LA

Air conditioning - Wiring schema - Diagram and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SK170-9 LA

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47454079-DRAFT 06/11/2012 EN

SERVICE MANUAL Electrical systems

SK170-9

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55

Contents Electrical systems - 55

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000 SK170-9

Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408 SK170-9

Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.512 SK170-9

Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.640 SK170-9

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC SK170-9

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CONSUMABLES INDEX Consumable Loctite® 277 DEF/AdBlue® DEF/AdBlue®

Reference Cab controls - Assemble – Right and Left Pilot Valve Assembly Electronic modules - Overview Electrical System Electronic modules - Overview Electrical System

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PAGE 55.512 / 15 55.640 / 40 55.640 / 42

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Electrical systems - 55 Electrical system - 000

SK170-9

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Contents Electrical systems - 55 Electrical system - 000

TECHNICAL DATA Electrical system General specification – Electrical Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

FUNCTIONAL DATA Electrical system Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

Electrical schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA














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Electrical systems - Electrical system

Electrical system - General specification – Electrical Equipment Specifications [60720589] SK170-9 LA

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RAPH12CEX1259HA

1

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RAPH12CEX1260HA

2

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RAPH12CEX1261HA

3

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RAPH12CEX1262HA

4

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RAPH12CEX1263HA

5

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RAPH12CEX1264HA

6

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RAPH12CEX1265HA

7

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RAPH12CEX1266HA

8

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RAPH12CEX1267HA

9

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RAPH12CEX1268HA

10

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RAPH12CEX1269HA

11

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RAPH12CEX1270GA

12

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Electrical system - Component identification [60760780] SK170-9 LA

Group (C) Controller

(D) Diode

(E) Electric fittings

(L) Light

(M) Motor

Code C-1 C-2 C-4 D-4 D-5 D-6 D-9 D - 10 D - 12 D - 13 D - 14 D - 15 D - 16 D - 17 D - 18 D - 19 D - 20 D - 21 D - 22 D - 23 D - 25 E-1 E-3 E-5 E-6 E-8 E-9 E - 10 E - 11 E - 12 E - 22 E - 23 E - 46 E - 63 L-1 L-2 L-5 L-6 M-1 M-3 M-4

Part Name Mechatro controller Gauge cluster Air-con controller (including panel) Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Fuse and Relay box Hour meter Horn high Horn low Speaker left Speaker right Receiver dryer Air-con compressor Battery DC-DC Converter 24V SOCKET Rearview camera DC-DC Converter (camera) Boom work light (LH) Frame work light (RH) Room light Boom work light (RH) Starter motor Wiper motor Washer motor

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Part No. YN22E00425F1 YN59S00028F3 LQ20M01328P1 YN02D01001P1 Accessory of relay box

YN02D01001P1

YN24E00016F3 LQ58S00002P1 87357734 87565344 LQ54S00003S002 LQ54S00005P1 72203934 5199959 84130880 87524810 YN55S00009F1 YN77S00040P1 87555081 LB80S00001F1 LQ02C00031S020 87555081 84377568 LQ53C00003S001 422702800


Group

(P) Proportional solenoid valve

(R) Relay

(SE) Sensor

(SV) Solenoid

(SW) Switch

Code PSV - A PSV - B PSV - C PSV - D PSV - P1 PSV - P2 R-1 R-2 R-3 R-4 R-5 R-6 R - 23 R - 24 R - 25 R - 26 R - 28 R - 29 R - 30 R - 31 R - 32 R - 94 SE - 1 SE - 2 SE - 3 SE - 4 SE - 5 SE - 7 SE - 8 SE - 9 SE - 10 SE - 11 SE - 13 SE - 15 SE - 16 SE - 20 SE - 22 SE - 23 SV - 1 SV - 2 SV - 3 SV - 4 SW - 1 SW - 4 SW - 8 SW - 10 SW - 11 SW - 19 SW - 20 SW - 24 SW - 55

Part Name Arm 2 speed inverse propo. valve P2 unload propo. valve Travel straight propo. valve (YN35V00047F2) Solenoid valve assy P1 unload propo. valve P1 pump propo. valve (YN35V00052F2) P2 pump propo. valve Pump Battery relay Starter relay Glow relay Safety relay Horn relay Working light relay Auto idle stop relay 1 Auto idle stop relay 2 Engine emergency stop relay Lever lock relay Alternator relay Wiper motor relay (Normal rotation) Wiper motor relay (Reverse rotation) Wiper motor relay (Arc prevention) Washer motor relay Neutral stop relay Pressure sensor : Bucket digging Pressure sensor : Bucket dump Pressure sensor : Boom up Pressure sensor : Boom down Pressure sensor : Swing Pressure sensor : Arm in Pressure sensor : Arm out Pressure sensor : Travel RH Pressure sensor : Travel LH Pressure sensor : P2 OPT. E/G speed sensor Fuel sensor Accel potentiometer Pressure sensor : P1 OPT. Pressure sensor : Pump P1 Pressure sensor : Pump P2 Swing parking brake SOL. Power boost SOL (YN35V00047F2) Solenoid valve assy Two speed select SOL Safety lock lever SOL Key switch Swing parking brake release switch Air filter clogging switch Horn switch (LH) Safety lock lever switch Wiper interlock switch Power boost switch (RH) Coolant level switch Work light switch

NOTE: Part numbers subject to change. Use them as a reference only.

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Part No. YN35V00049F1 YN35V00048F1

YN35V00052F2 YN24S00008F1 71403889 71451677 YN24S00010P1

YN24S00010P1

YN24S00012P2

YN24S00010P1 LC52S00019P1

72213891 YN52S00045F1 LQ52S00025P1 LC52S00019P1 LS52S00015P1 YN35V00051F1 YN35V00050F1

YN50S00026F2 YN50S00047P1


Electrical system - Electrical schematic frame 01 [] SK170-9 LA

Electrical System Diagram (no. 1)

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RAPH12CEX1299JA

1

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Item 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Description Mechatro Controller Fuel supply pump (automatic fuel stop) Rotary lamp switch (opt.) Cab rotary lamp light (opt.) Tank rotary lamp light (opt.) Cab rotary lamp light (opt.) DC - DC converter Nibbler open/close switch Nibbler open proportional solenoid valve (right slide) Nibbler close proportional solenoid valve (left slide) Power Boost right switch Extra (A1, A2) switch (left handle) Horn right switch Extra (A2) proportional solenoid valve (right slide) Extra (A1) proportional solenoid valve (left slide) Pressure switch (proportional) Seat heater Auto greasing switch (opt.) Auto greasing motor (opt.) Quick coupler operation solenoid valve Quick coupler operation switch Diode Diode Engine oil level sensor Indipendence travel switch Engine coolant level switch Pressure release switch Horn “high” Horn “low” Cab work lights switch Cab working light front 1 Cab working light front 2 Cab working light front 3 Cab working light front 4 Travel alarm switch Travel alarm Overload alarm select switch Overload alarm sensor Boom working light right Boom working light left Frame working light Working light switch Flasher relay (opt.) Swing flasher left and working light relay (opt.) Swing flasher right and working light relay (opt.) 9P Connector

Code C-1 M - 11 SW - 40 L - 20 L - 21 L - 22 E - 23 SW - 99 PSV - 6 PSV - 7 SW - 20 SW - 100 SW - 10 PSV - 8 PSV - 9 SW - 98 E - 26 SW - 60 M-8 SV - 14 SW - 64 D - 23 D - 22 SE - 12 SW - 37 SW - 24 SW - 96 E-5 E-6 SW - 26 L-7 L-8 L - 15 L - 16 SW - 13 E - 13 SW - 12 SE - 26 L-6 L-1 L-2 SW - 55 R - 19 L-3 L-4 -

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Electrical System Diagram (No. 2)

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RAPH12CEX1300JA

1

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Item 33 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Description Mechatro Controller Cluster gauge DC - DC converter (for camera) Rear camera Resistor CAN terminator Accel potentio pressure sensor Bucket digging sensor Bucket dump sensor Boom raising sensor Boom lowering sensor Arm in sensor Arm out sensor Swing sensor Travel right sensor Travel left sensor Pump P1 sensor Pump P2 sensor P1 option sensor (2PB) P2 option sensor (Hammer) Fuel level sensor Engine speed sensor Air filter restriction switch Operating lever lock solenoid valve Lever lock switch Heavy lift switch (opt.) Selector detect sensor (opt.) Selector solenoid (opt.) Air conditioner ampl. Swing parking release switch Swing parking brake solenoid valve Two-speed select solenoid valve Power boost solenoid valve P2 Unload proportional solenoid valve Travel priority proportional solenoid valve P1 Unload proportional solenoid valve Arm two-speed inverse proportional solenoid valve Proportional solenoid valve pump P1 Proportional solenoid valve pump P2 OPT. Relief adjustment proportional solenoid valve 1 OPT. Relief adjustment proportional solenoid valve 2 Control proportional solenoid valve Extra dis. Pressure solenoid valve (opt.) Extra dis. Pressure sensor (opt.) Wiper motor Washer motor Wiper interlock switch Receiver drier Air compressor clutch Radio Antenna Speaker left Speaker right DC – DC converter 12 V Socket Cigarette lighter

Code C-1 C-2 E - 63 E - 46 SE - 16 SE - 1 SE - 2 SE - 3 SE - 4 SE - 7 SE - 8 SE - 5 SE - 9 SE - 10 SE - 22 SE - 23 SE - 20 SE - 11 SE - 15 SE - 13 SW - 8 SV - 4 SW - 11 SW - 35 SE - 29 SV - 13 C-4 SW - 4 SV - 1 SV - 3 SV - 2 PSV - B PSV - C PSV - D PSV - A PSV - P1 PSV - P2 PSV - E PSV - I PSV - R SV - 11 SE - 28 M-3 M-4 SW - 19 E - 10 E - 11 E-7 E-8 E-9 E - 22 E - 23 E - 14

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135

Room light

L-5

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RAPH12CEX1301JA

1

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Item 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156

Description Fuse box Engine emergency stop relay Auto-Idle stop relay 1 Auto-Idle stop relay 2 Diode Diode Diode Diode Alternator relay Safety relay Lever lock relay Horn relay Revolution right nibbler relay Revolution left nibbler relay Nibbler open relay Nibbler close relay Diode Diode Diode Diode Diode

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Code E-1 R - 25 R - 23 R - 24 D-9 D - 12 D - 14 D - 13 R - 28 R-4 R - 26 R-5 R - 12 R - 13 R - 15 R - 16 D - 10 D - 16 D - 17 D-5 D-6



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RAPH12CEX1302JA

1

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Item 136 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179

Description Fuse box Grease (forward) relay Grease (reverse) relay Prevent spark relay Wiper motor relay Wiper motor reversing relay Window washer motor relay Diode Diode Diode Diode Diode Extra dis. pressure relay Bucket control relay Working light relay Cab working light relay 1 Cab working light relay 2 Travel alarm relay Cranking position relay NOx sensor relay Reserve relay Reserve relay Reserve relay Neutral stop relay

Code E-1 R - 27 R - 35 R - 31 R - 29 R - 30 R - 32 D - 22 D - 23 D - 20 D - 21 D - 15 R - 17 R - 10 R-6 R-9 R - 11 R-8 R - 41 R - 45 RE-R3 RE-R4 RE-R5 R - 94

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RAPH12CEX1303JA

1

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Electrical system - Electrical schematic frame 06 [62565948] SK170-9 LA

Cluster Gauge Wiring Harness Assembly Reading Key

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RAPH12CEX1304JA

1

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Cluster Gauge Wiring Harness Assembly

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RAPH12CEX1305JA

1

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Platform Wiring Harness Assembly Reading Key

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RAPH12CEX1306JA

1

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Platform Wiring Harness Assembly (No. 1)

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RAPH12CEX1307JA

1

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RAPH12CEX1308JA

1

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RAPH12CEX1309JA

1

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Upper Frame Wiring Harness Assembly

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RAPH12CEX1310JA

1

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Upper Frame Wiring Harness Assembly (No. 1)

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RAPH12CEX1311JA

1

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Upper Frame Wiring Harness Assembly (No. 3)

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RAPH12CEX1312JA

1

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Index Electrical systems - 55 Electrical system - 000 Electrical system - Electrical schematic frame 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SK170-9 LA

Electrical system - Electrical schematic frame 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SK170-9 LA








Electrical system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA






Electrical system - General specification – Electrical Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Electrical systems - 55 Warning indicators, alarms, and instruments - 408

SK170-9

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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

FUNCTIONAL DATA Instrument cluster Overview Summary of multi display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

SERVICE Instrument cluster Service instruction Self Diagnosis Function On Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Overview Summary of multi display [45266736] SK170-9 LA

Controls Electro-hydraulic information is displayed on the multi display of the gauge cluster.

RAPH12CEX0253CA

1

RAPH12CEX1102BA

2

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

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

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Screen selection by work mode select switch The mode after the engine starting is always the start from "S" mode. The work mode is switched in order of "S" to "E" to "H" to "S" each time the work mode select switch is pressed. Select proper work mode shown below according to the work condition and the purpose. For the selected work mode, refer to the upper left corner of display. • S mode: Suitable for standard digging and loading works and is in saving fuel consumption and is in good balance to the workload. • E mode (ECO): The mode focusing on better fuel economy, allowing for normal digging operation with lower fuel consumption than S mode. • H mode: Suitable for heavy duty digging work which gives priority to the workload at the high speed.

RAPH12CEX1103AA

3

RAPH12CEX1104AA

4

Screen selection by attachment mode switch This switch is used for switching the attachment mode. Press Digging mode switch (1) to select Digging mode from attachment modes. And selected Digging mode is indicated. Press Nibbler mode switch (2) to select Nibbler mode from attachment modes. And selected Nibbler mode is indicated. Press Breaker mode switch (3) to select Breaker mode from attachment modes. And selected Breaker mode is indicated. Depending on the attachment employed, select the applicable mode from "Digging", "Nibbler" and "Breaker". Before the working, confirm whether appropriate attachment had been selected. 1. Digging mode switch: Select when digging. 2. Nibbler mode switch: Select conflux flow when the attachment like a nibbler requires conflux flow circuit 3. Breaker mode switch: Select single flow when the attachment like a breaker requires single flow circuit

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Pump flow rate adjustment (Nibbler mode / Breaker mode) (Option) 1.

Screen Change Switch

2.

Buzzer Stop Switch

3.

Work Mode Select Switch

4.

Washer Switch

5.

Wiper Switch

6.

Travel Speed Select Switch

7.

Auto Accel Switch

8.

Menu Switch

9.

Attachment Mode Select Switch

10. Arrow Switch

RAPH12CEX0001HA

5

1. After turning starter key switch ON, the main screen (a) is appeared. 2. When the display is main screen (a), change the attachment mode from "DIGGING MODE" to "NIBBLER MODE" or "BREAKER MODE". The flow rate indication screen (b) appears. 3. When the display is flow rate indication screen (b), press "Menu Switch" to enter into "USER MENU" display (c). 4. Move cursor to "OPTION SETTING", and press "NEXT" to enter into "OPTION SETTING" display (e). 5. When the display is "OPTION SETTING" display (e), move cursor to desired flow rate. And press the menu switch to set target flow rate.

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

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Maintenance screen displays This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. This display shows the recommended replacement time of engine oil, time for next engine oil change and date of previous engine oil change. For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval Item

Default 500 Hr 500 Hr 1,000 Hr 5,000 Hr

Engine oil Fuel filter Hydraulic oil filter Hydraulic oil

This menu is available for confirmation of the following items. The maintenance screen changes each time the screen change switch is pressed. 1. Remaining time display to the engine oil change. This display shows the remaining time of "INTERVAL, REMAINING TIME, EXCHANGE DAY". 2. Remaining time display to the coming fuel filter replacement This display shows the remaining time of "INTERVAL REMAINING TIME, EXCHANGE DAY". 3. Remaining time display to the coming hydraulic oil filter replacement. This display shows the remaining time of "INTERVAL,REMAINING TIME, EXCHANGE DAY". 4. Remaining time display to the coming hydraulic oilchangeThis display shows the remaining time of "INTERVAL,REMAINING TIME, EXCHANGE DAY". NOTE: -For the setting procedure of maintenance time to be performed to the coming oil change in each type andfilter replacement, see the 3.5 SET PROCEDURE OF MAINTENANCE SCHEDULE.

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Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen.The display functions of multi display are explained below.

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Instrument cluster - Service instruction Self Diagnosis Function On Display Panel [48862238] SK170-9 LA

The failure of motor actuator and each sensor can be identified on the display panel. 1.

HL.E is indicated on the 3 digit segment.

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Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - Overview Summary of multi display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Instrument cluster - Service instruction Self Diagnosis Function On Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

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Electrical systems - 55 Cab controls - 512

SK170-9

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Contents Electrical systems - 55 Cab controls - 512

FUNCTIONAL DATA Cab controls Sectional view –Right and Left Pilot Valve Cross Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

SERVICE Cab controls Remove REMOVAL OF RIGHT AND LEFT PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Install Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Disassemble Right and Left Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Assemble – Right and Left Pilot Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

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Reference Cab controls - Assemble – Right and Left Pilot Valve Assembly

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PAGE 55.512 / 15

Electrical systems - Cab controls

Cab controls - Sectional view –Right and Left Pilot Valve Cross Sectional View [46525365] SK170-9 LA

RAPH12CEX0175GA

1 2 3 4 5 6 7 8

Adjusting nut M14 Boots Circular plate Joint M14 Plate Seal Plug O-Ring

9 10 11 12 13 14 15 17

1

Push rod Spring Spring Spring seat 1 Spring seat 2 Spring seat 2 Spring Spring

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18 19 20 21 22 23 24

Spring Washer 2 (shim) Spool Spool Casing 2 and 4 Port 1 and 3 Port


Cab controls - Exploded view [46805442] SK170-9 LA

Pilot Valve Travel

RAPH12CEX0216GA

1

T=tightening torque Nm (lbf ft) No. 5 6

6–g 6–l 7 7–h 7–I 7–j 7–k

Parts Rubber boots Foot pedal (Switch plate) Switch plate Regulation screw M828 Set screw M5x8 Damping screw Retaining plate kit Plate Capscrew M1020 Shaft Set screw M410

8

Flange kit

6–d 6–f

Qty 2 2

No. 12–x 12–y

Parts Seal ø14x20x3 Wiper ring

Qty 6 6

2 4

13 14

Damper spring Check valve kit

4 2

4 4 1 1 2 2 2

14–q 14–r 15 15–u 15–t 17 17–w

2 2 4 4 2 2 2

4

17–r

Plug M8 Ball M6, 35 Orifice Plug M6 Orifice M6, ø0.6 Shuttle valve kit Shuttle valve & orifice Ball M6, 35

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2


10 11 12 12–o

Control spool Return spring Damper flange kit Damper plunger ø14

4 4 4 4

17–z 21 22

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Orifice M5, ø0.8 Plug Valve body

2 4 1


Cab controls - Remove REMOVAL OF RIGHT AND LEFT PILOT VALVE [46498468] SK170-9 LA

ATTENTION: Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load. Park the machine on a firm, level surface. To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure”. Cut off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself. 1.

Press into (A) part of rubber boot (4) which is tucked into console and remove rubber boot from console.

2.

Remove side panels (2) and (3) removing securing screws.

3.

Remove the hand grip (1) removing locknut (5) disconnecting the relevant electric connection on the harness.

RAPH12CEX0172BA

ATTENTION: Attach an identification tag on each hose to aid in reassembly.

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1


4.

Disconnect hoses from port connector PF 3/8 (6) and PF 1/4 (7) of pilot valve body (8) .

NOTE: Attach a cap on each of disconnected hose ends. 5.

Remove pilot valve (8) removing securing screws (9) M6x25 complete with washers.

RAPH12CEX0173BA

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2


Cab controls - Install Travel Pilot Valve [46844732] SK170-9 LA

1.

Install body (8) on the frame tightening securing screws (9) M10x30 (Qty 4) complete with washers.

2.

Connect pipes (from (3) through (6) ) to body (8) .

3.

Connect pressure sensors (7) to body (8) .

4.

Install the levers tightening securing screws (2) M10x25 (Qty 4) and the pedals tightening securing screws (1) M8x25 (Qty 4).

5.

Install the cover under the cab tightening screws M12x30 (Qty 6).

RAPH12CEX0217CA

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1


Cab controls - Install [46501126] SK170-9 LA

1.

Install pilot valve (8) on the frame tightening securing screws (9) M6x25 complete with washers.

2.

Connect hoses to pilot valve body (8) .

RAPH12CEX0174AA

Right Side

Left Side 5 6 7 8 3.

Swing (L) Swing (R) Arm (H) Arm (R)

1

Gray Red Blue Green

1 2 3 4

Bucket (H) Bucket (R) Boom (H) Boom (R)

Red Blue Green Gray

Tighten the hand grip on the pilot valve, tighten locknut (5) and reconnect the electric connector.

RAPH12CEX0172BA

4.

Install side panels (2) and (3) tightening securing screws.

5.

Lock rubber boot (4) on side panel (2) .

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2


Cab controls - Disassemble Right and Left Pilot Valve [46530804] SK170-9 LA

Be sure to thoroughly read "Precautions for Disassembly and Assembly" on page W1-1-1before starting the disassembly work. NOTE: Replace O-rings every time valve is disassembled, as a rule. 1.

Plug each port of pilot valve, and clean it with kerosine.

2.

Fix pilot valve with vise, via a protective plate (Aluminum plate etc.), and remove boot (2) .

3.

Remove adjusting nut (1) applying spanners to adjusting nut (1) and circular plate (3) .

4.

Remove circular plate (3) .

5.

RAPH12CEX0177BA

1

RAPH12CEX0178BA

2

Turn joint (4) in counterclockwise with jig (E) 380001055 to remove it.

ATTENTION: When the force of return springs (15) is high, never loosen joint (4) . If loosened, it might result in jumping out of plate (5) plug (7) and push rod (9) . Remove joint (4) pressing plate (5) downward with two fingers.

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6.

Remove plate (5) .

NOTE: When the force of return spring (15) is high, press plate to let it come up slowly. When the force of return spring (15) is low, plug (7) is left in casing (22) due to sliding resistance of O-ring (8) .

7.

RAPH12CEX0179BA

3

RAPH12CEX0180BA

4

RAPH12CEX0181BA

5

Pull plug (7) out with a driver.

ATTENTION: To prevent personal injury, plug (7) must be removed slowly and evenly until the return spring (15) force is completely released.

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8.

Remove push rod (9) , plug (7) , pressure reducing valve assembly (spool) and the return springs (15) from casing (22) .

NOTE: Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.

9.

RAPH12CEX0182BA

6

RAPH12CEX0183BA

7

RAPH12CEX0184BA

8

Push springs (17) and (18) in the range of that the movement of spring seats (12) and (14) and shift the seats in a side direction, and remove spools (20) and (21) through the larger hole of seat.

ATTENTION: Never push down spring seat (12) in 7 mm (0.276 in) or more. (For port 1 and 3). Never push down spring seat (14) in 9.4 mm (0.370 in) or more. (For port 2 and 4).

10.

Remove spool (20) and (21) , spring seats (12) and (14) , springs (17) and (18) and washer (19) .

11.

Remove spring (10) and (11) , spring seat (13) , from push rod (9) .

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12.

Pull out push rod (9) from plug (7) .

13.

Remove O-ring (8) from plug (7) .

14.

Remove inside seal (6) from plug (7) with a small driver

RAPH12CEX0185BA

RAPH12CEX0186BA

Cleaning Parts 1.

Clean parts with wash oil roughly and the parts of pilot valve completely.

2.

Dry parts by swabbing with a clean rag.

3.

Apply rust preventatives to parts.

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9

10


Cab controls - Assemble – Right and Left Pilot Valve Assembly [46780378] SK170-9 LA

1.

Fit washer 2 (19) , springs (17) and (18) , spring seats (12) and (14) to spools (20) and (21) .

2.

Push spring (17)) and (18) in the range of that the movement of spring seats (12) (14) in a side direction, and install spools (20) through the larger hole of spring seat.

NOTICE: never push down spring seat (12) in 7mm (0.276 in) or more. (For port 1 and 3). Never push down spring seat (14) in 9,4 mm (0.370in) or more. (For port 2 and 4). 3.

Place springs (15) into ports 1,3 of casing (22) , and then install pressure reducing valve assembly in it. Place spring (16) into ports 2,4 and then install pressure reducing valve assembly in it.

NOTE: Install the removed assemblies into their respective holes. 4.

Fit O-ring (8) and seal (6) into plug (7) . Apply hydraulic oil on surface of push rod (9) .

5.

Insert push rod (9) in plug (7) and install spring (10) and spring seat (13) to push rod (9) on port1,3 side. Insert push rod (9) in plug (7) and install spring (11) and spring seat (13) to push rod (9) on port 2, 4 side.

6.

Fit plug (7) assembly to casing (22) .

NOTE: When the force of spring (15) is low, it stops at the position where it is pushed in by the sliding resistance of O-ring (8) . When the force of spring (15) is high, attach plate (5) and press 4 push rods by hand at the same time , and tighten joint (4) temporarily. Install spools (20) and (21) straight and evenly into the hole of casing (22) . Take care so that plugs (7) and plate (5) do not jump out of casing (22). 7.

Install joint (4) on casing (22) with special tool (E) 380001055 securely.

8.

Install circular plate (3) to joint (4) .

NOTICE: Screw it in until it comes in contact with 4 push rods (9) equally. The exceeding of screw in may cause malfunction of machine. 9.

Screw adjusting nut (1) , applying LOCTITE® 277 to the thread of joint, until it touches circular plate (3) , and tighten it applying spanner to stop circular plate returning.

10.

Apply heat-resisting grease (G) to joint (4) rotating section and the top of push rod (9) .

11.

Cover it with boots (2) .

12.

Spray rust preventives through each port and attach plug respectively.

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Index Electrical systems - 55 Cab controls - 512 Cab controls - Assemble – Right and Left Pilot Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

Cab controls - Disassemble Right and Left Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

Cab controls - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Cab controls - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SK170-9 LA

Cab controls - Install Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

Cab controls - Remove REMOVAL OF RIGHT AND LEFT PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

Cab controls - Sectional view –Right and Left Pilot Valve Cross Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

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Electrical systems - 55 Electronic modules - 640

SK170-9

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Contents Electrical systems - 55 Electronic modules - 640

FUNCTIONAL DATA Electronic modules Overview – Engine Control Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Overview Electrical System (Overall system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SK170-9 LA

SERVICE Electronic modules Adjust – ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) . . . . . . . . . . 47 SK170-9 LA

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CONSUMABLES INDEX Consumable DEF/AdBlue® DEF/AdBlue®

Reference Electronic modules - Overview Electrical System Electronic modules - Overview Electrical System

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PAGE 55.640 / 40 55.640 / 42

Electrical systems - Electronic modules

Electronic modules - Overview – Engine Control Input/Output [49422698] SK170-9 LA

RAPH12CEX0349FA

No. 1 2 3 4 5 6 7 8 9 10

1

Description Engine controller E-1: Fuse & relay box C-1: Mechatro controller Starter switch Accel potentiometer Pump proportional valve Engine speed sensor Injector C-2: Gauge cluster Engine

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Electronic modules - Overview [50969728] SK170-9 LA

This section explains the mechatro system and the function of the components related to the mechatro controller. Only the conditions related to the electro hydraulic conversion as mechatro control are described in this section. For the conditions before and after each conversion, refer to the hydraulic and electrical systems.

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Mechatro control system — general

RAPH12CEX0364HA

1

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RAPH12CEX0365HA

2

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RAPH12CEX0367HA

3

Unload valve control

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Unload valve control On starting any one operation: 1. The pilot secondary pressure signal enters the respective low pressure sensors. 2. The output voltage of the low pressure sensor is sent to the mechatro controller. 3. The mechatro controller processes the pilot signal The mechatro controller delivers a command dependent on the input voltage to each unload pressure proportional valve. 4. During this operation, the bleed opens based on lever movement which results in the pump pressure controlling/ operating the actuators.

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RAPH12CEX0367HA

4

Positive control & P-Q control

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Positive control & P-Q control Positive control 1. The pilot secondary pressure signal enters each of the low pressure sensors. 2. The output voltage of the low pressure sensor is sent to the mechatro controller. 3. The mechatro controller processes the pilot signal. The mechatro controller delivers a command dependent on the input voltage to each unload pressure proportional valves. 4. Each pump proportional valve delivers pilot secondary pressure based on the mechatro controller’s command. The pilot secondary pressure changes the tilting angle of each pump and controls the delivery rate. 5. The working speed is controlled by the delivery rate to the actuator. The delivery rate to the actuator is determined by lever movement.

RAPH12CEX0368AA

5

Positive control — pilot signal process A. Pilot pressure B. Pump proportional secondary pressure

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P-Q control 1. The output voltage of the high pressure sensor on each pump line is sent to the mechatro controller. 2. The mechatro controller processes the pilot signal and delivers its command based on the input voltage (load pressure). 3. The lower value between the calculated value of positive control and the operated value found by P-Q control (value found in items 1 and 2) is sent to each pump proportional valve. 4. Each pump proportional valve delivers pilot secondary pressure (value determined by the mechatro controller). The pilot secondary pressure changes the tilting angle of each pump and controls the delivery rate. 5. The working speed is controlled by the delivery rate to the actuator. The delivery rate to the actuator is determined by lever movement.

RAPH12CEX0369AA

6

P-Q control — pilot signal process A. Pump delivery pressure B. Pump proportional secondary pressure

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RAPH12CEX0370HA

7

Boom up conflux control

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Boom up conflux control Boom up operation 1. Boom up operating pilot pressure activates the boom main spool and the boom up conflux spool. The boom up operating pilot pressure signal is sent to the low pressure sensor. 2. The output voltage of the low pressure sensor is sent to the mechatro controller. The mechatro controller processes the pilot signal and delivers a command. The command is determined by the input voltage to the P1 and P2 proportional valves and the P1 and P2 unload proportional valves. 3. Each proportional valve delivers pilot proportional valve secondary pressure and changes the P1 and P2 pump delivery rate and activates the P1 and P2 unload pressure control valves. 4. Hydraulic pressure activates the boom main spool and the boom up conflux spool. The mechatro controller activates the P1 and P2 pumps as well as the P1 and P2 unload pressure control valves. This results in the delivery hydraulic oil on the P1 pump side to conflux (blend) with the delivery hydraulic oil on the P2 pump side during the boom up operation.

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RAPH12CEX0371HA

8

Arm in recirculation & conflux control

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Arm in recirculation & conflux control Recirculation and conflux (low loading) — Arm-in operation 1. The arm-in operating pilot secondary pressure signal is sent to the arm 1 spool, the arm 2 spool, and the low pressure sensor. 2. The output voltage of the low pressure sensor is sent to the mechatro controller. The mechatro controller processes the pilot signal and delivers a command based on the input voltage to the P1 and P2 proportional valves, the P1 and P2 unload proportional valves, and the reverse proportional valve from the arm-in 2 spool. 3. Primary pressure of the reverse proportional valve for the arm in 2 spool is also the arm-in pilot secondary pressure. The arm 2 spool is switched by the proportional secondary pressure. (the arm 2 spool controls the recirculation rate and the conflux rate) 4. The arm 1 spool is activated by the original oil pressure command. The mechatro controller’s command switches the P1,P2 pumps, the P1, P2 unload spools, and the arm 2 spool. Consequently, the return oil from the arm cylinder rod side of the arm is recirculated in the P1 and P2 pump’s delivery oil during arm operation. Recirculation cut The voltage output by the high pressure sensor on the P2 side is sent to the mechatro controller. When the load is increased during arm operation, the mechatro controller processes the pilot signal according to the pressure detected by the high pressure sensor. The mechatro controller sends out a command to cut recirculation to the reverse proportional valve for the arm-in 2 spool. The reverse proportional valve for the arm in 2 spool delivers pilot secondary pressure according to the mechatro controller’s command. The arm 2 spool is switched to the recirculation cut position resulting in the blocking of the recirculation passage.

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RAPH12CEX0372HA

9

Arm-in anti-cavitation control Arm-in operation 1. The arm-in operating pilot secondary pressure switches the arm 1 spool and a signal is sent to the low pressure sensor. 2. The accel potentiometer controls the engine speed command. The engine speed command is sent to the mechatro controller. 3. The low pressure sensor output voltage is sent to the mechatro controller. The mechatro controller processes the pilot signal and delivers a command based on the input voltage to the P2 pump proportional valve and the P2 unload proportional valve. 4. The mechatro controller also sends a signal (based on the input pressure by the accel potentiometer) to the reverse proportional valve for the arm 2 spool. 5. Each proportional valve delivers pilot secondary pressure according to each command output by the mechatro controller. The reverse proportional valve for the arm 2 spool is controlled to spool stroke based on the engine speed and changes the recirculation rate to prevent cavitation from occurring even if the pump delivery rate is low due to a low engine speed.

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RAPH12CEX0373HA

10

Arm-out conflux control

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Arm-out operation 1. The arm-out operating pilot pressure activates the arm 1 and arm 2 spool, and sends a signal to the low pressure sensor. 2. The output voltage of the low pressure sensor is sent to the mechatro controller. The mechatro controller processes the pilot signal and then outputs a command based on the input voltage to the P1, P2 proportional valves and the P1,P2 unload proportional valves. 3. Each proportional valve outputs pilot proportional valve secondary pressure (based on the mechatro controller output command) and changes the P1 and P2 pump delivery rate. The pilot proportional secondary pressure also activates the P1 and P2 unload pressure control valves. 4. The original hydraulic pressure command activates the arm 1 spool and the arm 2 spool. The mechatro controller sends a signal to the P1,P2 pumps and the P1,P2 unload valves. This results in the delivery oil on the P2 pump side to conflux (blend) with the delivery oil on the P1 side during arm-out operations.

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RAPH12CEX0374HA

11

Bucket digging (dump) conflux control

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Bucket digging (dump) operation 1. The bucket digging (dump) pilot pressure signal enters the low pressure sensor. 2. The output voltage of the low pressure sensor is sent to the mechatro controller. The mechatro controller processes the pilot signal and delivers a command based on the input voltage to the P1 and P2 proportional valves, the P1 and P2 unload proportional valves, and the travel straight proportional valve. 3. The mechatro controller sends a signal to each proportional valve. Each proportional valve sends pilot proportional valve secondary pressure which activates the P1 and P2 pump delivery rate, the P1, P2 unload valves and the travel straight valve of the control valve. 4. The tandem passage is connected to the P2 port for the following reason: The P1 pump delivery oil confluxes (blends) with the P2 pump delivery oil based on the movements of the travel straight valve and the P2 unload valve.

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RAPH12CEX0393HA

12

Bucket digging anti-cavitation control

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Bucket digging operation 1. Bucket digging operating pilot pressure signal enters the low pressure sensor. 2. The accel potentiometer sends the engine speed signal to the mechatro controller. 3. The output voltage of the low pressure sensor is sent to the mechatro controller. The mechatro controller processes the pilot signal and then outputs a command based on the input voltage to the P1 and P2 proportional valves, the P1 and P2 unload proportional valves, and the travel straight valve of the control valve. 4. Each proportional valve outputs pilot proportional valve secondary pressure (based on the mechatro controller output command) and changes the P1 and P2 pump delivery rate. The pilot proportional secondary pressure also changes the travel straight valve of the control valve. 5. The tandem passage is connected to the P2 port for the following reason: The P1 pump delivery oil confluxes (blends) with the P2 pump delivery oil based on the movements of the travel straight valve and the P2 unload valve. 6. The ATT boost solenoid switches the solenoid valve to the on position based on the engine speed. As a result, secondary pressure is delivered, the stroke limiter is actuated, and then the bucket spool is controlled. 7. When the P1 pump pressure is increased at the cylinder stroke end, the solenoid valve is closed based on the pump pressure. When the pump pressure is high, the boost solenoid does not operate the stroke limit of the bucket spool The control of the spool stroke prevents cavitation in low engine speed, low pump delivery rate conditions.

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RAPH12CEX0394GA

13

Swing priority control

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Swing priority control during arm-in operation 1. The arm operating pilot secondary pressure signal enters the low pressure sensor on starting swing operation (or arm-in operation during swing operation). The swing operation pilot secondary pressure signal enters the low pressure sensor. 2. The output voltage of the low pressure sensor is sent to the mechatro controller. The mechatro controller processes the pilot signal and then outputs a command based on the input voltage to the P1 and P2 proportional valves, the P1 and P2 unload proportional valves, the travel straight valve, and the reverse proportional valve for arm 2 spool. 3. Each proportional valve outputs pilot proportional valve secondary pressure which changes the P1 and P2 pump delivery rate. The pilot proportional valve secondary pressure also switches the P1 and P2 unload spool, the travel straight spool, and the arm 2 spool. 4. The original hydraulic pressure command activates the arm 1 spool and the swing spool. The mechatro controller sends a signal to the P1, P2 unload spools, the travel straight spool and the arm 2 spool enabling for two pump flow rates to be supplied to the arm cylinder head side. Consequently the return oil on the arm cylinder rod side is recirculated into the arm cylinder head side. 5. Since the return oil on the arm rod side is recirculated, the working pressure is raised. This results in the pump delivery rate being used for swing operation by priority. Using the recirculated oil results in a minimum speed drop for the arm-in operation.

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RAPH12CEX0395HA

14

Travel straight control

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Judgement travel straight 1. During right and left travel operation, the pilot pressure signal activates each travel spool and the signal enters the low pressure sensor. The signal from the low pressure sensor determines attachment system operation. 2. Based on the low pressure sensor signal combinations, described in the table below, the mechatro controller will turn the travel straight signal on. 3. The following commands are sent to each of the proportional valves when the travel straight signal is turned on. Operation of each proportional valve Attachment operation is actuated by the P1 pump and travel operation is actuated by the P2 pump in the travel straight condition. 1. The travel straight proportional valve delivers switching pressure based on the high priority select pressure in the attachment system operating pilot pressure during operation. 2. P1 unload proportional valve delivers switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation 3. P2 unload proportional valve delivers switching pressure according to the high priority select in the travel operating pilot pressure during operation. 4. P1 pump proportional valve delivers switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation. 5. P2 pump proportional valve delivers switching pressure according to the high priority select in the travel operating pilot pressure during operation. ATT operation In travel operation (P1) In travel operation (P2)

Boom

Arm

Bucket

O

Swing

Option

O

O

O O

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RAPH12CEX0396HA

15

Pressure release control

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1. To change the mechatro controller, select “Pressure Draining Mode” on the gauge cluster. Refer to “Pressure draining (releasing) circuit on Group 2 — Hydraulic Circuit. Once the mechatro controller is in pressure release mode: 1. The mechatro controller sends a minimum tilt angle signal to the P1,P2 pump proportional valves and fixes the P1,P2 pumps to the minimum tilt angle. 2. The mechatro controller sends a signal of pressure release and a signal of pressure release control to the ECU. As a result, the engine speed is fixed to the pressure release control speed. 3. The mechatro controller sends a maximum signal to the P1 and P2 unload valves and each pilot secondary pressure fixes the P1 and P2 unload valves to the maximum opening.

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RAPH12CEX0397GA

16

N&B switch control (option)

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Nibbler circuit 1. Select the nibbler mode on the cluster gauge. 2. The nibbler icon displays on the cluster gauge. 3. The return oil from the nibbler passes through the selector valve and the option spool and then travels to the tank line of the main control valve. 4. When the nibbler mode is selected through the switch on the cluster gauge, the breaker pressure sensor will not function. It is normal for the breaker pressure sensor not to output a signal when in the nibbler mode. An error message will display if the breaker pressure sensor does not function in any case other than described above. Breaker circuit 1. Select the breaker mode on the cluster gauge. 2. The breaker icon will display on the cluster gauge. 3. The return oil from the breaker passes through the selector valve and directly returns into the hydraulic tank. 4. When the breaker mode is selected through the switch on the cluster gauge, the breaker pressure sensor outputs a signal. It is normal for the breaker pressure sensor to output a signal when in the breaker mode. If there is no signal from the sensor in the breaker mode then an error message will display on the cluster gauge. NOTE: An error message will display on the cluster gauge when the breaker pressure does not output a signal in any case other than when the nibbler mode is selected.

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RAPH12CEX0398HA

17

Option conflux control (option)

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1. To adjust the flow rate, select the “Option Setting” display located on the “User Menu” screen. If the flow rate setting is larger than the one pump flow rate, the flow automatically becomes confluent (blended) flow. 2. The option operating pilot pressure signal enters the low pressure sensor. 3. The output voltage of the low pressure sensor is sent to the mechatro controller. The mechatro controller processes the pilot signal and outputs a signal based on the input voltage to the P1 and P2 pump proportional valves, the P1 and P2 unload pressure proportional valves, and the travel straight proportional valve. 4. Each proportional valve sends the pilot proportional valve pressure and changes the P1 and P2 delivery rate; switches the P1 and P2 unload valves, and travel straight valve of the control valve. 5. The parallel passage on the P2 side is connected to the P1 port for the following reason: The travel straight valve is activated and the P1 pump delivery oil confluxes (blends) with the P2 pump delivery oil.

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Electronic modules - Overview Electrical System (Overall system) [51353301] SK170-9 LA

RAPH12CEX0383HA

Description No. 1 Cab Control Mechatro Controller and Fuse & Relay box 2 Batteries, Batteries Relay, Fuse link 3

1

Description No. Hydraulic System Electrical Components 4 Engine Electrical Components 5 Light, Horn, etc. 6

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1. CAB CONTROL Electrical Components

RAPH12CEX0391GA

No. 1 2 3 4 5 6 7 8

Description Instrument cluster Power boost switch Starter switch Engine speed throttle Work lights switch Overload alarm switch (Optional) Cab work lights switch (Optional) Heavy Lift switch (Optional)

No. 9 10 11 12 13 14 15 16

2

Description Rotary lamp switch (Optional) Radio Pressure release switch Quick coupling switch (Optional) Climate controls panel 12V socket Parking brake release switch Horn

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Instrument Cluster

RAPH12CEX0385GA

No. 1 2 3 4 5 6 7 8 9

Description Engine coolant temperature meter Fuel level meter Urea level meter Screen change button Menu button Buzzer stop button Digging mode button Nibbler mode button Breaker mode button

No. 10 11 12 13 14 15 16 17 18

3

Description Work mode button Auto-Idle button Travel speed button Windshield washer button Windshield wiper button BACK button UP button NEXT button DOWN button

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Cluster gauge wiring harness

RAPH12CEX0392FA

No. 1 2 3 4 5 6 7 8

Description Cluster gauge (C-2) Hour meter (E-3) Wiper motor (M-3) Connector for DC-AC converter (E-22) Connector for flasher relay (R-19) Connector for roof wiper (Opt.) (CN-37F) Connector for wiper interlock switch (CN-60F) Connector for speaker (CN-611F)

No. 9 10 11 12 13 14 15

4

Description Connector for cab working light Connector for rotary light (CN-54F) Connector for platform harness (CN-574F) Connector for platform harness (CN-573F) Connector for air conditioner unit (CN-500F) Connector for camera AC-DC converter (CN-218F) Connector for rear camera (CN-234F)

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Platform wiring harness

RAPH12CEX0387FA

No. 1 2 3 4 5 6 7 8

Description Starter switch (SW-1) Engine speed throttle (SE-16) Work light switch (SW-55) Connector for cab work light (SW-26) Overload alarm select switch (SW-12) Heavy Lift switch (SW-35) (Opt.) Grease switch (SW-60) Starter switch (GND) (SW-1)

No. 9 10 11 12 13 14 15 16

5

Description Connector for lever lock (SW-11) Connector for horn (SW-10) Connector for extra function (Slider) (SW-100) Connector for Power Boost (SW-20) Rotary lamp switch (SW-40) Pressure release switch (SW-96) Connector for nibbler open/close (slider) (SW-99) Quick coupling switch (SW-64)

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2. Mechatro Controller, Engine Controller Unit, Fuses & Relay Box, DC-DC Converter

RAPH12CEX0388GA

Description

No. 1 2 3 4

6

Mechatro Controller Unit (C-1) Fuse & Relay box (E-1) DC-DC converter (E-22) Engine Controller Unit (C-8)

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2. Fuse & Relay box FUSES

RAPH12CEX0389EA

FUSE 11 (FS23) FUSE 12 (FS24) FUSE 13 (FS19) FUSE 14 (FS20) FUSE 15 (FS31) FUSE 16 (FS32)

Rating (A) 20 Cab work light 1 20 Cab work light 2 Instrument cluster \Rear camera 5 Windscreen wiper and washer 20 20 Optional 20 Flasher alarm, lifting magnet

FUSE 17 (FS25) FUSE 18 (FS26) FUSE 19 (FS16) FUSE 20 (FS2) FUSE 21 (FS7) FUSE 22 (FS8) FUSE 23 (FS9) FUSE 24 (FS12) FUSE 25 (FS11) FUSE 26 (FS15)

Air conditioner (main) Air conditioner (compressor) Option (Hand Control) Hour Meter Optional Horn DC-DC Converter Starter Key Switch Cab room lamp Optional

FUSE No.

Protected Circuit

15 5 5 5 10 10 10 20 5 10

7

FUSE No.

Protected Circuit

FUSE 36 (FS17) FUSE 37 (FS21) FUSE 38 (FS18) FUSE 39 (FS22) FUSE 40 (FS28) FUSE 41 (FS30)

Optional Bucket dump cut solenoid Air Conditioner Work Light Seat heater DEF/ADBLUE® supply module Optional Travel alarm Safety Lever Mechatro Controller Mechatro Controller Optional GPS system Mechatro controller Fuel transfer pump Mechatro lifting magnet backup

FUSE 42 (FS27) FUSE 43 (FS29) FUSE 44 (FS4) FUSE 45 (FS1) FUSE 46 (FS3) FUSE 47 (FS5) FUSE 48 (FS6) FUSE 49 (FS13) FUSE 50 (FS14) FUSE 51 (FS10)

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Rating (A) 10 10 5 20 10 5 15 20 10 5 20 15 15 5 15 5


RELAYS

RAPH12CEX0389EA

Relay No. 1 2 3 4 5 6 7 8 9 10 27 28 29 30 31

8

Relay No.

Description Window washer motor relay (RLY 32) Cab working light relay 1 (RLY 9) Cab working light relay 2 (RLY 11) Alternator relay (RLY 28) Auto-Idle stop relay 2 (RLY 24) Auto-Idle stop relay 1 (RLY 23) Engine emergency stop relay (RLY 25) Horn relay (RLY 5) Reserve relay (RE-RLY 1) Reserve relay (RE-RLY 2) Wiper motor reversing relay (RLY 30) Extra discharge pressure relay (RLY 17) Working light relay (RLY 6) Safety relay (RLY 4) Lever lock relay (RLY 26)

32 33 34 35 52 53 54 55 56 57 58 59 60 61

Description Nibbler open relay (RLY 15) Nibbler close relay (RLY 16) Reserve relay (RE-RLY 3) Reserve relay (RE-RLY 4) Prevent spark relay (RLY 31) Wiper motor relay (RLY 29) Grease (forward) relay (RLY 27) Grease (reverse) relay (RLY 35) Bucket control relay (RLY 10) Travel alarm relay (RLY 8) Revolution right relay (RLY 12) Revolution left relay (RLY 13) Reserve relay (RE-RLY 5) Reserve relay (RE-RLY 6)

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3. Batteries, Battery Relay, Fusible Links

RAPH12CEX0390FA

No. 1 2 3

Description Battery relay (R-1) Fuse link 1, 2, 3, 4 (E-25) Starter motor relay

No. 4 5 6

9

Description Fuel filter heater relay (R-40) Batteries (E-12) Pre-heater relay (R-3)

Fuses located in the radiator compartment Fuse No. FUSE 1 FUSE 2 FUSE 3 FUSE 4 FUSE 5 FUSE 6 FUSE 7

Protected circuit Fuses powering (1 - 6) Fuses powering (17 - 32) Alternator Starter relay, heated fuel filters, relay ECU Powering Fuses powering (10 - 15) DEF/ADBLUE® supply module

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Value (A) 60 60 100 60 30 60 20


4a. Hydraulic System Electrical Components

RAPH12CEX0402GA

No. Description 1 Pump P2 proportional solenoid valve (PSV-P2) 2 Pump P1 proportional solenoid valve (PSV-P1) 3 Lever lock solenoid valve (SV-4) 4 Power boost solenoid valve (SV-2) 5 P2 Unload proportional solenoid valve (PSV-B) 6 Travel priority prop. solenoid valve (PSV-C) 7 P1 Unload proportional solenoid valve (PSV-D) 8 Arm 2 inverse prop. solenoid valve (PSV-A) 9 Arm 2 inverse prop. solenoid valve (PSV-A) 10 Swing parking brake solenoid valve (SV-1)

10

No. Description 11 Control proportional solenoid valve (PSV-R) 12

Bucket digging sensor (SE-1)

13 14 15

Bucket dump sensor (SE-2) Boom raising sensor (SE-3) Boom lowering sensor (SE-4)

16 17

Arm in sensor (SE-7) Arm out sensor (SE-8)

18 19

Pump P1 sensor (SE-22) Pump P2 sensor (SE-23)

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4b. Hydraulic System Electrical Components

RAPH12CEX0403GA

No. 20 21 22 23 24 25

No. Extra valve selector press sensor (SE-29) (opt.) 26 Swing sensor (SE-5) 27 Extra dis-press solenoid valve (SV-11) (opt) 28 Extra dis-press sensor (SE-28) (opt) 29 P1 opt. sensor valve (SE-20) 30 Travel right sensor (SE-9) 31

11

Description

Description Travel left sensor (SE-10) P2 Opt. sensor valve (SE-11) Selector B&N solenoid valve (SV-13) Quick coupler solenoid valve (SV-14) (opt.) Relief adjustment prop. solenoid valve 1 (PSV-E) Relief adjustment prop. solenoid valve 2 (PSV-I)

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5. Engine Electrical Components

RAPH12CEX0404GA

No. 1 2 3 4 5 6

Description Air filter restriction switch (SW-8) Engine coolant level switch (SW-24) Receiver dryer (E-10) Starter motor assembly (M-1) Alternator assembly (E-2) Engine revolution sensor (SE-13)

No. 7 8 9 10 11 12

12

Description Air compressor (E-11) Cold start air heater (E-13) Fuel filter heater (E-20) Fuel sensor (SE-15) Water separator restriction switch (SW-36) DEF/AdBlue® supply module (C-9)

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6. Electrical Components (Lights, Horns)

RAPH12CEX0405GA

Description No. Frame Working light (L-2) 1 Boom Working light left (L-1) 2 Boom Working light right (L-6) 3

13

No. Horn high (E-5) 4 Horn low (E-6) 5

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Description


Electronic modules - Adjust – ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) [48745014] SK170-9 LA

Purpose of the adjustment There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to ensure performance of machine. 1.

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

2.

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

In cases where the adjustment of mechatro controller is required When the following parts are replaced or repaired, carry out the adjustment without fail: 1.

Mechatro controller

2.

Engine or engine controller

3.

Hydraulic pump or hydraulic pump proportional valve

4.

Unloading proportional valve, spool of unloading valve.

Preparation 1.

Raise the oil temperature to about 50°C (122°F) to warm up the engine.

2.

Turn the air-con OFF.

3.

Turn the starter key switch OFF to stop the engine. When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, 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. NOTE: For machines equipped with lifting magnet, turn the generator OFF.

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RAPH12CEX0350FA

No. 1 2 3 4 5 6

1

Description Multi Display Up Arrow Button Menu Button Down Arrow Button Buzzer Stop Button Work Mode Select Button

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Adjustment of pump (“B” Adjustment) 1.

Turn starter key switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

2.

Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selecting adjustment is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations.

3.

Press menu switch on gauge cluster to display "START ENG"."Engine SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PUMP" current (command value) are indicated.

4.

After engine starting, press the menu switch on gauge cluster, and "MEMORY PUMP" displayed. And the adjustment shifts to pump adjustment automatically. Then the speed shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PUMP" current (command value) are indicated.

5.

After detection of the engine rated speed, the adjustment of pump is automatically completed. And "FINISH PUMP" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.).

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RAPH12CEX0351CA

2

RAPH12CEX0352BA

3


ADJUSTMENT OF UNLOADING VALVE (“C” ADJUSTMENT) 1.

The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is displayed. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "UNLOAD" current (command value) are indicated.

2.

When the unloading valve operates to the specified value, the adjustment of unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiometer. The adjusting current value is indicated on the display of current of P1, P2 unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. stored.).

(The adjusted data is automatically

CORRECTIVE ACTION TAKEN WHEN THE ADJUSTMENT CAN BE NOT PERFORMED In cases where the adjustment of pump can not be performed; And "ERROR PUMP" is displayed. Judging condition 1: P1 and P2 average pump pressure at the time when the adjustment is completed is 25MPa or less. Judging condition 2: the adjustment does not complete although the pump proportional valve current reaches to the specified value. The P1 and P2 pump pressures usually increase to 33~38MPa. When the pressure does not increase: A. Identify the reason why the pressure does not increase, • Check that the relief valve operates normally. • Check that the hydraulic circuit is free from leak of pressure. • Check that the pressure sensor functions normally. And so on. B. Identify the reason why the actual flow rate does not increase, • Check that the pump proportional valve operates normally. • Check that the pump regulator operates normally. And so on.

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RAPH12CEX0353AA

4


In cases where unloading valve can not be performed; And "ERROR UNLOAD" is displayed. Judging condition 1: the pump pressure does not increase up to the pressure in the range of the specified adjustment. Or the increased pressure is held as it is. Judging condition 2: pressure sensor of either P1 pump or P2 pump is failed. Normally the pump pressures of P1 and p2 pumps gradually increase to 10~25MPa. (It may be affected by operating oil temperature.) When the pump pressure does not increase: Identify the reason why the pressure does not increase, •

Check that the relief valve operates normally.

•

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

•

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

Other Precautions 1.

In the event of a failure, there is case where the adjustment may not be performed normally. First serve the machine, and perform the adjustment work.

2.

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

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

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RAPH12CEX0354AA

5


WHEN THE ADJUSTMENT OF UNLOADING VALVE ONLY IS PERFORMED (“C” ADJUSTMENT) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only. PROCEDURE 1.

Turn starter switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

2.

Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selection of adjustment type is displayed. And "ADJUST" is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations.

3.

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

4.

Press menu switch on gauge cluster to display "START ENG". "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "UNLOAD" current (command value) are indicated.

RAPH12CEX0355CA

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6


5.

After starting engine, press menu switch on gauge cluster and "MEMORY UNLOAD" is indicated, the engine speed is automatically increased and the adjustment of unloading valve is performed. "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "UNLOAD" current (command value) are indicated.

6.

When the unloading proportional valve operates to the specified value, the adjustment of unloading proportional valve automatically completes. "FINISH UNLOAD" is indicated. The speed is shifted to the speed corresponding to acceleration potentiometer. The value of adjusting current is indicated on the display of current of P1 and P2 unloading proportional valves. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.)

RAPH12CEX0356BA

7

Operations in the event of a failure of equipment of mechatro controller PUMP EMERGENCY MODE In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to emergency mode, making the operation with the power shift control of pump and the constant power control by means of selfpressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor, the frequency of engine down is increased, and the engine stalls in LOW speed condition. NOTICE: The emergency mode should be used in only case of emergency. We recommend that the defective section is repaired by troubleshooting as early as possible.

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Index Electrical systems - 55 Electronic modules - 640 Electronic modules - Adjust – ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) 47 SK170-9 LA

Electronic modules - Overview – Engine Control Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Electronic modules - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

Electronic modules - Overview Electrical System (Overall system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SK170-9 LA

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Electrical systems - 55 FAULT CODES - DTC

SK170-9

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC A025-Pump proportional valve adjustment is missing or out of range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

A035-Unload valve adjustment is missing or out of range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

A215-ROM adjustment written data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

A225-Writing of ROM adjustment data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

A235-ROM hour meter written data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

A245-Writing of ROM hour meter data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA

A255-Proportional valve adjustment written data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

B012-Incorrect output of boom up pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

B013-Open-circuit of boom up pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

B014-Short-circuit of boom up pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SK170-9 LA

B022-Incorrect output of boom down pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA

B023-Open-circuit of Boom down pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SK170-9 LA

B024-Short-circuit of Boom down pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SK170-9 LA

B032-Incorrect output of arm out pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SK170-9 LA

B033-Open-circuit of arm out pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SK170-9 LA

B034-Short-circuit of arm out pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SK170-9 LA

B042-Incorrect output of arm in pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SK170-9 LA

B043-Open-circuit of arm in pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SK170-9 LA

B044-Short-circuit of arm in pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SK170-9 LA

B052-Incorrect output of bucket digging pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SK170-9 LA

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B053-Open-circuit of bucket digging pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SK170-9 LA

B054-Short-circuit of bucket digging pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 SK170-9 LA

B062-Incorrect output of bucket dump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 SK170-9 LA

B063-Open-circuit of bucket dump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 SK170-9 LA

B064-Short-circuit of bucket dump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 SK170-9 LA

B072-Incorrect output of swing pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 SK170-9 LA

B073-Open-circuit of swing pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 SK170-9 LA

B074-Short-circuit of swing pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 SK170-9 LA

B092-Incorrect output of travel right pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 SK170-9 LA

B093-Open-circuit of travel right pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 SK170-9 LA

B094-Short-circuit of travel right pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SK170-9 LA

B102-Incorrect output of travel left pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SK170-9 LA

B103-Open-circuit of travel left pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 SK170-9 LA

B104-Short-circuit of travel left pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 SK170-9 LA

B113-Open-circuit of pressure sensor of optional selector positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 SK170-9 LA

B114-Short-circuit of pressure sensor of optional selector positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 SK170-9 LA

B162-Incorrect output of P1 optional side pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 SK170-9 LA

B163-Open-circuit of P1 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 SK170-9 LA

B164-Short-circuit of P1 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 SK170-9 LA

B172-Incorrect output of P2 optional side pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 SK170-9 LA

B173-Open-circuit of P2 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 SK170-9 LA

B174-Short-circuit of P2 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 SK170-9 LA

C012-Incorrect output of P1 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 SK170-9 LA

C013-Open-circuit of P1 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SK170-9 LA

C014-Short-circuit of P1 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 SK170-9 LA

C022-Incorrect output of P2 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 SK170-9 LA

C023-Open-circuit of P2 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 SK170-9 LA

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C024-Short-circuit of P2 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 SK170-9 LA

C033-Open-circuit of boom head pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 SK170-9 LA

C034-Short-circuit of boom head pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 SK170-9 LA

C043-Open-circuit of boom rod pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 SK170-9 LA

C044-Short-circuit of boom rod pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 D012-Failure of output transistor ON at P1 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 SK170-9 LA

D013-Open-circuit of P1 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 SK170-9 LA

D022-Failure of output transistor ON at P2 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 SK170-9 LA

D023-Open-circuit of P2 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 SK170-9 LA

D033-Open-circuit of travel straight proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 SK170-9 LA

D062-Failure of output transistor ON at arm in high speed proportional valve. . . . . . . . . . . . . . . . . . . . . 112 SK170-9 LA

D063-Open-circuit of arm in high speed proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 SK170-9 LA

D153-Open-circuit of proportional bypass valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 SK170-9 LA

E012-Failure of output transistor ON at P1 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 SK170-9 LA

E013-Open-circuit of P1 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 SK170-9 LA

E022-Failure of output transistor ON at P2 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 SK170-9 LA

E023-Open-circuit of P2 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 SK170-9 LA

E032-Failure of output transistor ON at Optional relief adjusting proportional valve 1. . . . . . . . . . . . . . 126 SK170-9 LA

E033-Open-circuit of optional relief adjusting proportional valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 SK170-9 LA

E042-Failure of output transistor ON at Optional relief adjusting proportional valve 2. . . . . . . . . . . . . . 130 SK170-9 LA

E043-Open-circuit of optional relief adjusting proportional valve 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 SK170-9 LA

F011-Failure of output transistor OFF and GND short of attachment boost SOL valve. . . . . . . . . . . . . . 134 SK170-9 LA

F013-Failure of output transistor ON and open-circuit of attachment boost SOL valve. . . . . . . . . . . . . . 136 SK170-9 LA

F021-Failure of output transistor OFF and GND short of swing parking SOL valve. . . . . . . . . . . . . . . . . 138 SK170-9 LA

F023-Failure of output transistor ON and open-circuit of swing parking SOL valve. . . . . . . . . . . . . . . . . 140 SK170-9 LA

F031-Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve. . . . . . . . . . . . . . 142 SK170-9 LA

F033-Failure of output transistor ON and open-circuit of travel 1-2 speed SOL valve. . . . . . . . . . . . . . . 144 SK170-9 LA

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F041-Failure of output transistor OFF and GND short of optional selector SOL valve. . . . . . . . . . . . . . 146 SK170-9 LA

F043-Failure of output transistor ON and open-circuit of option selector SOL valve. . . . . . . . . . . . . . . . 148 SK170-9 LA

G032-Overrun of speed sensor of direct input Mechatro controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 SK170-9 LA

G033-Open-circuit of speed sensor of direct input Mechatro controller. . . . . . . . . . . . . . . . . . . . . . . . . . . 152 SK170-9 LA

G042-Overrun of speed sensor of direct input Mechatro controller and received data from E/G controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 SK170-9 LA

G043-Open-circuit of speed sensor of direct input Mechatro controller and received data from E/G controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 SK170-9 LA

H013-Open-circuit of acceleration potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 SK170-9 LA

H014-Short-circuit of acceleration potentiometer power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 SK170-9 LA

H023-Open-circuit of boom angle potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 SK170-9 LA

H024-Short-circuit of boom angle potentiometer power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 SK170-9 LA

H033-Open-circuit of arm angle potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 SK170-9 LA

H034-Short-circuit of arm angle potentiometer power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 SK170-9 LA

H091-Short-circuit of fuel sensor ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 SK170-9 LA

H093-Open-circuit of fuel sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 SK170-9 LA

I111-Receive error of CAN1 communication (passive error). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 SK170-9 LA

I113-Receive error of CAN1 communication (time-out). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 SK170-9 LA

I121-Transmission of CAN1 communication is abnormal (busoff). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 SK170-9 LA

I211-Reception of CAN1 communication is abnormal (passive error). . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 SK170-9 LA

I213-Reception of CAN2 communication is abnormal (time-out). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 SK170-9 LA

I221-Transmission of CAN2 communication is abnormal (busoff). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 SK170-9 LA

K014-Battery relay contact welded closed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 SK170-9 LA

R014-Failure of wiper motor arc prevention relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 SK170-9 LA

R024-Failure of wiper motor normal rotation relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 SK170-9 LA

R034-Failure of wiper motor reverse rotation relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 SK170-9 LA

R044-Failure of washer motor relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 SK170-9 LA

R134-Failure of swing flasher right relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 SK170-9 LA

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R144-Failure of swing flasher left relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 SK170-9 LA

R154-Failure of travel alarm relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 SK170-9 LA

R164-Failure of auto idling stop relay 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 SK170-9 LA

R174-Failure of engine forcible stop relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 SK170-9 LA

R184-Failure of lever lock relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 SK170-9 LA

R214-Failure of safety relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 SK170-9 LA

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Electrical systems - FAULT CODES

A025-Pump proportional valve adjustment is missing or out of range. [54335309] SK170-9 LA

Cause: 1. Pump proportional valve needs adjusting. 2. Connectors not mated, pins not seated in the connector, bent or broken pins \ wires at the connector. 3. Wiring or circuits shorted. 4. Faulty mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed go to step 2. B. If the fault code is not displayed return the unit to service. 2. Perform the pump adjustment procedure (B adjustment). A. For pump adjustment refer to Electronic modules - Adjust – Adjusting procedure (55.640). See Service Diagnosis screen number 6 for current pump parameters. B. If the fault code is still actively displayed after the pump adjustment procedure, continue with step 3. C. If the fault code is not displayed return the unit to service. 3. Verify the harness and connectors are not damaged. (1) Inspect the Mechatro controller connections CN-105, CN-1F, and CN-1M. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the Mechatro controller to the P1 and P2 proportional solenoids. Verify the harness is free of damage, corrosion, abrasion or not attached properly.

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RAIL12CEX0800FA

1

Schematic legend (1) (2)

PSV-P1: Pump P1 proportional solenoid PSV-P2: Pump P2 proportional solenoid

A. If the wiring is free of corrosion, damage, abrasion and properly connected go to step 4. B. If the wiring is not free of corrosion, damage, abrasion or not properly connected, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro Controller. A. Return to step 1 to confirm elimination of the fault.

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A035-Unload valve adjustment is missing or out of range. [54384177] SK170-9 LA

Cause: 1. Unload valve needs adjusting. 2. Connectors not mated, pins not seated in the connector, bent or broken pins \ wires at the connector. 3. Wiring or circuits shorted. 4. Faulty mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed go to step 2. B. If the fault code is not displayed return the unit to service. 2. Perform the unload valve adjustment procedure (C adjustment). A. For the valve adjustment refer to Electronic modules - Adjust – Adjusting procedure (55.640) . See Service Diagnosis screen number 7 for current valve parameters. B. If the fault code is still actively displayed after the valve adjustment procedure, continue with step 3. C. If the fault code is not displayed return the unit to service. 3. Verify the harness and connectors are not damaged. (1) Inspect the Mechatro controller connections CN-105, CN-1F, CN-118F, CN-120F, and CN-1M. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the Mechatro controller to the P1 and P2 unload proportional solenoids. Verify the harness is free of damage, corrosion, abrasion and attached properly.

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RAIL12CEX0800FA

1


PSV-D: P1 unload proportional solenoid PSV-B: P2 unload proportional solenoid

A. If the wiring is free of corrosion, damage, abrasion and properly connected go to step 4. B. If the wiring is not free of corrosion, damage, abrasion or not properly connected, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro Controller. A. Return to step 1 to confirm elimination of the fault.

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A215-ROM adjustment written data is incorrect. [54391534] SK170-9 LA

Cause: 1. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, view the adjustment data in the Trouble History log to see if it looks valid. Go to step 2. B. If the fault code is not displayed return the unit to service. 2. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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A225-Writing of ROM adjustment data is incorrect. [54393048] SK170-9 LA

Cause: 1. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, view the adjustment data in the Trouble History log to see if it looks valid. Go to step 2. B. If the fault code is not displayed return the unit to service. 2. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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A235-ROM hour meter written data is incorrect. [54393260] SK170-9 LA

Cause: 1. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, view the hour meter memory in the Trouble History log to see if it looks valid. Go to step 2. B. If the fault code is not displayed return the unit to service. 2. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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A245-Writing of ROM hour meter data is incorrect. [54393565] SK170-9 LA

Cause: 1. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, view the hour meter data in the Trouble History log to see if it looks valid. Verify that the hour meter does not read 0 h. Go to step 2. B. If the fault code is not displayed return the unit to service. 2. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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A255-Proportional valve adjustment written data is incorrect. [54393632] SK170-9 LA

Cause: 1. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, view the adjustment data in the Trouble History log to see if it looks valid. In the event of failure a fixed value will be used for control. Go to step 2. B. If the fault code is not displayed return the unit to service. 2. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B012-Incorrect output of boom up pressure sensor. [54394133] SK170-9 LA

Cause: Symptom: Raising the boom up becomes difficult. 1. Boom up (raising) pressure sensor SE-3 failure. 2. Faulty wiring or bad connection between the Boom up pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom up pressure sensor.

RAIL12CEX0801FA

1


Pressure sensor: Boom raising Mechatro controller

A. Measure the voltage from pin 3 to pin 1 on connector CN-126F and pin 3 to pin 1 on connector CN-101F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should

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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is not in this range, replace the Boom up pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom up pressure sensor SE-3 and the Mechatro controller. A. Check connectors CN-126F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B013-Open-circuit of boom up pressure sensor. [54396436] SK170-9 LA

Cause: Symptom: Boom up speed slows down. 1. Boom up (raising) pressure sensor SE-3 failure. 2. Faulty wiring or bad connection between the Boom up pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom up pressure sensor.

RAIL12CEX0801FA

1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B013 is triggered when this voltage is less than 0.1 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is less than 0.1 V , replace the Boom up pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom up pressure sensor SE-3 and the Mechatro controller. A. Check connectors CN-126F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom up independently, set the output of the P1 and P2 Unload proportional valves to 750 mA.

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B014-Short-circuit of boom up pressure sensor. [54397221] SK170-9 LA

Cause: Symptom: Boom up speed slows down. 1. Boom up (raising) pressure sensor SE-3 failure. 2. Faulty wiring or bad connection between the Boom up pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom up pressure sensor.

RAIL12CEX0801FA

1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B014 is triggered when this voltage is more than 4.7 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is higher than 4.7 V , replace the Boom up pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom up pressure sensor SE-3 and the Mechatro controller. A. Check connectors CN-126F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom up independently, set the output of the P1 and P2 Unload proportional valves to 750 mA.

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B022-Incorrect output of boom down pressure sensor. [54397356] SK170-9 LA

Cause: Symptom: The Boom down operation becomes difficult. 1. Boom down (lowering) pressure sensor SE-4 failure. 2. Faulty wiring or bad connection between the Boom down pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom down pressure sensor.

RAIL12CEX0801FA

1


Pressure sensor: Boom lowering Mechatro controller


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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is not in this range, replace the Boom down pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom down pressure sensor SE-4 and the Mechatro controller. A. Check connectors CN-127F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B023-Open-circuit of Boom down pressure sensor [54397495] SK170-9 LA


RAIL12CEX0801FA

1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B023 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 0.1 V or less, replace the Boom down pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom down pressure sensor SE-4 and the Mechatro controller. A. Check connectors CN-127F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 pump to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1 Unload proportional valve to 750 mA.

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B024-Short-circuit of Boom down pressure sensor. [54397564] SK170-9 LA


RAIL12CEX0801FA

1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B024 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 4.7 V or more, replace the Boom down pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom down pressure sensor SE-4 and the Mechatro controller. A. Check connectors CN-127F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1 Unload proportional valve to 750 mA.

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B032-Incorrect output of arm out pressure sensor. [54397651] SK170-9 LA

Cause: Symptom: Arm out operation becomes poor. 1. Arm out pressure sensor SE-8 failure. 2. Faulty wiring or bad connection between the Arm out pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Arm out pressure sensor.

RAIL12CEX0801FA

1


Pressure sensor: Arm out Mechatro controller

A. Measure the voltage from pin 3 to pin 1 on connector CN-131F and pin 10 to pin 12 on connector CN-101F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals

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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is not in this range, replace the Arm out pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm out pressure sensor SE-8 and the Mechatro controller. A. Check connectors CN-131F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B033-Open-circuit of arm out pressure sensor. [54397830] SK170-9 LA

Cause: Symptom: Shock when Arm out operation is stopped. 1. Arm out pressure sensor SE-8 failure. 2. Faulty wiring or bad connection between the Arm out pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Arm out pressure sensor.

RAIL12CEX0801FA

1




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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 11 to pin 12 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B033 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 0.1 V or less, replace the Arm out pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm out pressure sensor SE-8 and the Mechatro controller. A. Check connectors CN-131F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

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B034-Short-circuit of arm out pressure sensor. [54397889] SK170-9 LA

Cause: Symptom: Shock when stopping the Arm out operation. 1. Arm out pressure sensor SE-8 failure. 2. Faulty wiring or bad connection between the Arm out pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Arm out pressure sensor.

RAIL12CEX0801FA

1




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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 11 to pin 12 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B034 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 4.7 V or more, replace the Arm out pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm out pressure sensor SE-8 and the Mechatro controller. A. Check connectors CN-131F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

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B042-Incorrect output of arm in pressure sensor. [54397996] SK170-9 LA

Cause: Symptom: The Arm in operation becomes poor. 1. Arm in pressure sensor SE-7 failure. 2. Faulty wiring or bad connection between the Arm in pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Arm in pressure sensor.

RAIL12CEX0801FA

1


Pressure sensor: Arm in Mechatro controller


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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 8 to pin 7 on the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is not in this range, replace the Arm in pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm in pressure sensor SE-7 and the Mechatro controller. A. Check connectors CN-130F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B043-Open-circuit of arm in pressure sensor. [54398132] SK170-9 LA

Cause: Symptom: Cavitation occurs when independently operating Arm in. Difficulty pulling the arm in while in the horizontal position, and when the attachment is pulled in the arm will fall first. 1. Arm in pressure sensor SE-7 failure. 2. Faulty wiring or bad connection between the Arm in pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Arm in pressure sensor.

RAIL12CEX0801FA

1



A. Measure the voltage from pin 3 to pin 1 on connector CN-130F and pin 9 to pin 7 on connector CN-101F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should 47454079-DRAFT 06/11/2012

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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 8 to pin 7 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B043 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 0.1 V or less, replace the Arm in pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm in pressure sensor SE-7 and the Mechatro controller. A. Check connectors CN-130F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA. Set the output of arm 2 Arm in proportional valve to 200 mA.

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55.DTC / 37


B044-Short-circuit of arm in pressure sensor. [54399667] SK170-9 LA

Cause: Symptom: Cavitation occurs when independently operating Arm in. Difficulty pulling the arm in while in the horizontal position, and when the attachment is pulled in the arm will fall first. 1. Arm in pressure sensor SE-7 failure. 2. Faulty wiring or bad connection between the Arm in pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Arm in pressure sensor.

RAIL12CEX0801FA

1



A. Measure the voltage from pin 3 to pin 1 on connector CN-130F and pin 9 to pin 7 on connector CN-101F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should 47454079-DRAFT 06/11/2012

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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 8 to pin 7 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B044 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 4.7 V or more, replace the Arm in pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm in pressure sensor SE-7 and the Mechatro controller. A. Check connectors CN-130F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA. Set the output of arm 2 Arm in proportional valve to 200 mA.

47454079-DRAFT 06/11/2012

55.DTC / 39


B052-Incorrect output of bucket digging pressure sensor. [54399687] SK170-9 LA

Cause: Symptom: The bucket digging operability becomes poor. 1. Bucket digging pressure sensor SE-1 failure. 2. Faulty wiring or bad connection between the Bucket digging pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Bucket digging pressure sensor.

RAIL12CEX0801FA

1


Pressure sensor: Bucket digging Mechatro controller

A. Measure the voltage from pin 3 to pin 1 on connector CN-124F and pin 15 to pin 13 on connector CN-101F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals 47454079-DRAFT 06/11/2012

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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 14 to pin 13 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is not in this range, replace the Bucket digging pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Bucket digging pressure sensor SE-1 and the Mechatro controller. A. Check connectors CN-124F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 41


B053-Open-circuit of bucket digging pressure sensor. [54399647] SK170-9 LA

Cause: Symptom: The bucket digging speed slows down slightly. 1. Bucket digging pressure sensor SE-1 failure. 2. Faulty wiring or bad connection between the Bucket digging pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Bucket digging pressure sensor.

RAIL12CEX0801FA

1




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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 14 to pin 13 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B053 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 0.1 V or less, replace the Bucket digging pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Bucket digging pressure sensor SE-1 and the Mechatro controller. A. Check connectors CN-124F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

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B054-Short-circuit of bucket digging pressure sensor. [54399847] SK170-9 LA

Cause: Symptom: The Bucket digging speed slows down slightly. 1. Bucket digging pressure sensor SE-1 failure. 2. Faulty wiring or bad connection between the Bucket digging pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Bucket digging pressure sensor.

RAIL12CEX0801FA

1




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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 14 to pin 13 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B054 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 4.7 V or more, replace the Bucket digging pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Bucket digging pressure sensor SE-1 and the Mechatro controller. A. Check connectors CN-124F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

47454079-DRAFT 06/11/2012

55.DTC / 45


B062-Incorrect output of bucket dump pressure sensor. [54399867] SK170-9 LA

Cause: Symptom: The bucket dump operability becomes poor. 1. Bucket dump pressure sensor SE-2 failure. 2. Faulty wiring or bad connection between the Bucket dump pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Bucket dump pressure sensor.

RAIL12CEX0801FA

1


Pressure sensor: Bucket dump Mechatro controller


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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 17 to pin 18 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is not in this range, replace the Bucket dump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Bucket dump pressure sensor SE-2 and the Mechatro controller. A. Check connectors CN-125F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B063-Open-circuit of bucket dump pressure sensor. [54402614] SK170-9 LA

Cause: Symptom: The bucket dump speed slows down slightly. 1. Bucket dump pressure sensor SE-2 failure. 2. Faulty wiring or bad connection between the Bucket dump pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Bucket dump pressure sensor.

RAIL12CEX0801FA

1




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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 17 to pin 18 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B063 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 0.1 V or less, replace the Bucket dump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Bucket dump pressure sensor SE-2 and the Mechatro controller. A. Check connectors CN-125F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

47454079-DRAFT 06/11/2012

55.DTC / 49


B064-Short-circuit of bucket dump pressure sensor. [54402634] SK170-9 LA

Cause: Symptom: The bucket dump speed slows down slightly. 1. Bucket dump pressure sensor SE-2 failure. 2. Faulty wiring or bad connection between the Bucket dump pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Bucket dump pressure sensor.

RAIL12CEX0801FA

1




47454079-DRAFT 06/11/2012

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should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 17 to pin 18 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B064 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 5 for sensor voltage and pressure converted values. If the voltage is 4.7 V or more, replace the Bucket dump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Bucket dump pressure sensor SE-2 and the Mechatro controller. A. Check connectors CN-125F at the sensor and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

47454079-DRAFT 06/11/2012

55.DTC / 51


B072-Incorrect output of swing pressure sensor. [54402662] SK170-9 LA

Cause: Symptom: The Swing operability becomes poor. 1. Swing pressure sensor SE-5 failure. 2. Faulty wiring or bad connection between the Swing pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Swing pressure sensor.

RAIL12CEX0802FA

1


Pressure sensor: Swing Mechatro controller


47454079-DRAFT 06/11/2012

55.DTC / 52


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 2 to pin 1 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 6 for diagnostic readings.. If the voltage is not in this range, replace the Swing pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Swing pressure sensor SE-5 and the Mechatro controller. A. Check connectors CN-169F at the sensor, connector CN-1F\CN-1M, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 53


B073-Open-circuit of swing pressure sensor. [54402779] SK170-9 LA

Cause: Symptom: The swing operability becomes poor. 1. Swing pressure sensor SE-5 failure. 2. Faulty wiring or bad connection between the Swing pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Swing pressure sensor.

RAIL12CEX0802FA

1




47454079-DRAFT 06/11/2012

55.DTC / 54


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 2 to pin 1 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B073 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 0.1 V or less, replace the Swing pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Swing pressure sensor SE-5 and the Mechatro controller. A. Check connectors CN-169F at the sensor, connector CN -1F\CN-1M, and connector CN-101F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the swing arm independently, set the output of the P2 Unload proportional valve to 750 mA.

47454079-DRAFT 06/11/2012

55.DTC / 55


B074-Short-circuit of swing pressure sensor. [54402799] SK170-9 LA

Cause: Symptom: The Swing operability becomes poor. 1. Swing pressure sensor SE-5 failure. 2. Faulty wiring or bad connection between the Swing pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Swing pressure sensor.

RAIL12CEX0802FA

1




47454079-DRAFT 06/11/2012

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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 2 to pin 1 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B074 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 4.7 V or more, replace the Swing pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Swing pressure sensor SE-5 and the Mechatro controller. A. Check connectors CN-169F at the sensor, connector CN-1F\CN-1M, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Swing arm independently, set the output of the P2 Unload proportional valve to 750 mA.

47454079-DRAFT 06/11/2012

55.DTC / 57


B092-Incorrect output of travel right pressure sensor. [54402820] SK170-9 LA

Cause: Symptom: The Travel right operability becomes poor. 1. Travel right pressure sensor SE-9 failure. 2. Faulty wiring or bad connection between the Travel right pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Travel right pressure sensor.

RAIL12CEX0802FA

1


Pressure sensor: Travel right Mechatro controller


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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 2 to pin 1 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 6 for diagnostic readings.. If the voltage is not in this range, replace the Travel right pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Travel right pressure sensor SE-9 and the Mechatro controller. A. Check connectors CN-301F at the sensor, , and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B093-Open-circuit of travel right pressure sensor. [54402916] SK170-9 LA


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1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 2 to pin 1 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B093 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 0.1 V or less, replace the Travel right pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Travel right pressure sensor SE-9 and the Mechatro controller. A. Check connectors CN-301F at the sensor, , and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the boom up independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

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B094-Short-circuit of travel right pressure sensor. [54402938] SK170-9 LA


RAIL12CEX0802FA

1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 2 to pin 1 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B094 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 4.7 V or more, replace the Travel right pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Travel right pressure sensor SE-9 and the Mechatro controller. A. Check connectors CN-301F at the sensor, , and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom up independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

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55.DTC / 63


B102-Incorrect output of travel left pressure sensor. [54403195] SK170-9 LA

Cause: Symptom: The Travel left operability becomes poor. 1. Travel left pressure sensor SE-10 failure. 2. Faulty wiring or bad connection between the Travel left pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Travel left pressure sensor.

RAIL12CEX0802FA

1


Pressure sensor: Travel left Mechatro controller


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55.DTC / 64


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is not in this range, replace the Travel left pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Travel left pressure sensor SE-10 and the Mechatro controller. A. Check connectors CN-302F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B103-Open-circuit of travel left pressure sensor. [54403375] SK170-9 LA


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1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B103 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 0.1 V or less, replace the Travel left pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Travel left pressure sensor SE-10 and the Mechatro controller. A. Check connectors CN-302F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the boom up independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

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B104-Short-circuit of travel left pressure sensor. [54403398] SK170-9 LA


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1




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be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B104 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 4.7 V or more, replace the Travel left pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Travel left pressure sensor SE-10 and the Mechatro controller. A. Check connectors CN-302F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the Boom up independently, set the output of the P1, P2 Unload proportional valves to 750 mA.

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B113-Open-circuit of pressure sensor of optional selector positioning. [54403484] SK170-9 LA

Cause: Symptom: When Breaker mode is selected, the optional selector valve indicates an error. 1. Optional Selector detect sensor SE-29 failure. 2. Faulty wiring or bad connection between the optional Selector detect sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the optional Selector detect sensor.

RAIL12CEX0803EA

1

Schematic legend (1) (2) (3) (4)

Heavy lift switch Optional Selector detect sensor Optional Selector solenoid Mechatro controller

A. Measure the voltage from pin 3 to pin 1 on connector CN-181F and pin 21 to pin 19 on connector CN-104F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 20 to pin 19 at the Mechatro controller. This voltage is the sensor signal. Fault code B113 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 9 for diagnostic readings. If the voltage is 0.1 V or less, replace the optional Selector detect sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the optional Selector detect sensor SE-29 and the Mechatro controller.

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A. Check connectors CN-181F at the sensor, connector CN -1F\CN-1M, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B114-Short-circuit of pressure sensor of optional selector positioning. [54403504] SK170-9 LA

Cause: Symptom: When Breaker mode is selected, the optional selector valve indicates an error. 1. Optional selector detect pressure sensor SE-29 failure. 2. Faulty wiring or bad connection between the Optional selector detect pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Optional selector detect pressure sensor.

RAIL12CEX0803EA

1


Heavy lift switch Optional Selector detect sensor Optional Selector solenoid Mechatro controller

A. Measure the voltage from pin 3 to pin 1 on connector CN-181F and pin 21 to pin 19 on connector CN-104F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 20 to pin 19 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B114 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 9 for diagnostic readings. If the voltage is 4.7 V or more, replace the Optional selector detect pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Optional selector detect pressure sensor SE-29 and the Mechatro controller.

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A. Check connectors CN-181F at the sensor, connector CN-1F\CN1M, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B162-Incorrect output of P1 optional side pressure sensor. [54403524] SK170-9 LA

Cause: Symptom: The P1 side option operability becomes poor. 1. P1 side option pressure sensor SE-20 failure. 2. Faulty wiring or bad connection between the P1 side option pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P1 side option pressure sensor.

RAIL12CEX0804FA

1


Pressure sensor: P1 option Pressure sensor: P2 option Fuel sensor Engine revolution sensor 47454079-DRAFT 06/11/2012

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(5)

Mechatro controller

A. Measure the voltage from pin 3 to pin 1 on connector CN-304F and pin 10 to pin 12 on connector CN-102F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 11 to pin 12 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for diagnostic readings. If the voltage is not in this range, replace the P1 side option pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P1 side option pressure sensor SE-20 and the Mechatro controller. A. Check connectors CN-304F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B163-Open-circuit of P1 side optional pressure sensor. [54403587] SK170-9 LA

Cause: Symptom: The P1 side option does not work. 1. P1 side option pressure sensor SE-20 failure. 2. Faulty wiring or bad connection between the P1 side option pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P1 side option pressure sensor.

RAIL12CEX0804FA

1

Schematic legend (1) (2) (3) (4) (5)

Pressure sensor: P1 option Pressure sensor: P2 option Fuel sensor Engine revolution sensor Mechatro controller

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A. Measure the voltage from pin 3 to pin 1 on connector CN-304F and pin 10 to pin 12 on connector CN-102F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 11 to pin 12 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B163 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 5 for diagnostic readings. If the voltage is 0.1 V or less, replace the P1 side option pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P1 side option pressure sensor SE-20 and the Mechatro controller. A. Check connectors CN-304F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the boom up independently, set the output of the P1 Unload proportional valve to 750 mA. Normal control is possible when the left control pedal selection in ON.

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B164-Short-circuit of P1 side optional pressure sensor. [54403607] SK170-9 LA

Cause: Symptom: The P1 side option does not work. 1. P1 side option pressure sensor SE-20 failure. 2. Faulty wiring or bad connection between the P1 side option pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P1 side option pressure sensor.

RAIL12CEX0804FA

1



47454079-DRAFT 06/11/2012

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A. Measure the voltage from pin 3 to pin 1 on connector CN-304F and pin 10 to pin 12 on connector CN-102F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 11 to pin 12 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B164 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 5 for diagnostic readings. If the voltage is 4.7 V or more, replace the P1 side option pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P1 side option pressure sensor SE-20 and the Mechatro controller. A. Check connectors CN-304F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the boom up independently, set the output of the P1 Unload proportional valve to 750 mA. Normal control is possible when the left control pedal selection in ON.

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B172-Incorrect output of P2 optional side pressure sensor. [54403628] SK170-9 LA

Cause: Symptom: The P2 side option operability becomes poor. 1. P2 side option pressure sensor SE-11 failure. 2. Faulty wiring or bad connection between the P2 side option pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P2 side option pressure sensor.

RAIL12CEX0804FA

1


Pressure sensor: P1 option Pressure sensor: P2 option Fuel sensor Engine revolution sensor 47454079-DRAFT 06/11/2012

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(5)

Mechatro controller

A. Measure the voltage from pin 3 to pin 1 on connector CN-303F and pin 15 to pin 13 on connector CN-102F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 14 to pin 13 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 5 for diagnostic readings. If the voltage is not in this range, replace the P2 side option pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P2 side option pressure sensor SE-11 and the Mechatro controller. A. Check connectors CN-303F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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B173-Open-circuit of P2 side optional pressure sensor. [54404158] SK170-9 LA

Cause: Symptom: The selection of conflux does not work. 1. P2 side option pressure sensor SE-11 failure. 2. Faulty wiring or bad connection between the P2 side option pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P2 side option pressure sensor.

RAIL12CEX0804FA

1



47454079-DRAFT 06/11/2012

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A. Measure the voltage from pin 3 to pin 1 on connector CN-303F and pin 15 to pin 13 on connector CN-102F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 14 to pin 13 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B173 is triggered when this voltage is 0.1 V or less. See Service diagnosis screen number 5 for diagnostic readings. If the voltage is 0.1 V or less, replace the P2 side option pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P2 side option pressure sensor SE-11 and the Mechatro controller. A. Check connectors CN-303F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the boom up independently, set the output of the P2 Unload proportional valve to 750 mA.

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55.DTC / 83


B174-Short-circuit of P2 side optional pressure sensor. [54404205] SK170-9 LA

Cause: Symptom: The selection of conflux does not work. 1. P2 side option pressure sensor SE-11 failure. 2. Faulty wiring or bad connection between the P2 side option pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P2 side option pressure sensor.

RAIL12CEX0804FA

1



47454079-DRAFT 06/11/2012

55.DTC / 84


A. Measure the voltage from pin 3 to pin 1 on connector CN-303F and pin 15 to pin 13 on connector CN-102F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 14 to pin 13 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. Fault code B174 is triggered when this voltage is 4.7 V or more. See Service diagnosis screen number 5 for diagnostic readings. If the voltage is 4.7 V or more, replace the P2 side option pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P2 side option pressure sensor SE-11 and the Mechatro controller. A. Check connectors CN-303F at the sensor, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the proportional valve output rate of the P1 and P2 pumps to constant current. (Current when all operation is in neutral.) When operating the boom up independently, set the output of the P2 Unload proportional valve to 750 mA. Normal control is possible when the left control pedal selection in ON.

47454079-DRAFT 06/11/2012

55.DTC / 85


C012-Incorrect output of P1 pump pressure sensor. [54404249] SK170-9 LA

Cause: Symptom: The P1 pump operability becomes poor. 1. P1 pump pressure sensor SE-22 failure. 2. Faulty wiring or bad connection between the P1 pump pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P1 pump pressure sensor.

RAIL12CEX0802FA

1


Pressure sensor: Pump P1 Mechatro controller


47454079-DRAFT 06/11/2012

55.DTC / 86


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is not in this range, replace the P1 pump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P1 pump pressure sensor SE-22 and the Mechatro controller. A. Check connectors CN-139F at the sensor, connector CN-1F\CN-1M, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 87


C013-Open-circuit of P1 pump pressure sensor. [54404393] SK170-9 LA

Cause: Symptom: The ability to make fine adjustments to the P1 pump attachment becomes poor. 1. P1 pump pressure sensor SE-22 failure. 2. Faulty wiring or bad connection between the P1 pump pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P1 pump pressure sensor.

RAIL12CEX0802FA

1




47454079-DRAFT 06/11/2012

55.DTC / 88


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 0.1 V or less. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 0.1 V or less, replace the P1 pump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P1 pump pressure sensor SE-22 and the Mechatro controller. A. Check connectors CN-139F at the sensor, connector CN-1F\CN-1M, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the P1 pump pressure to 250 bar (3625.0 psi) and control the pump.

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55.DTC / 89


C014-Short-circuit of P1 pump pressure sensor. [54404413] SK170-9 LA


RAIL12CEX0802FA

1




47454079-DRAFT 06/11/2012

55.DTC / 90


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 5 to pin 6 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 4.7 V or more. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 4.7 V or more, replace the P1 pump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P1 pump pressure sensor SE-22 and the Mechatro controller. A. Check connectors CN-139F at the sensor, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the P1 pump pressure to 250 bar (3625.0 psi) and control the pump.

47454079-DRAFT 06/11/2012

55.DTC / 91


C022-Incorrect output of P2 pump pressure sensor. [54404439] SK170-9 LA

Cause: Symptom: The P2 pump operability becomes poor. 1. P2 pump pressure sensor SE-23 failure. 2. Faulty wiring or bad connection between the P2 pump pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the P2 pump pressure sensor.

RAIL12CEX0802FA

1




47454079-DRAFT 06/11/2012

55.DTC / 92


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and from pin 8 to pin 7 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is not in this range, replace the P2 pump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P2 pump pressure sensor SE-23 and the Mechatro controller. A. Check connectors CN-140F at the sensor, connector CN-1F\CN-1M, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 93


C023-Open-circuit of P2 pump pressure sensor. [54404581] SK170-9 LA


RAIL12CEX0802FA

1




47454079-DRAFT 06/11/2012

55.DTC / 94


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 8 to pin 7 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 0.1 V or less. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 0.1 V or less, replace the P2 pump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P2 pump pressure sensor SE-23 and the Mechatro controller. A. Check connectors CN-140F at the sensor, connector CN-1F\CN-1M, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the P2 pump pressure to 250 bar (3625.0 psi) and control the pump.

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55.DTC / 95


C024-Short-circuit of P2 pump pressure sensor. [54404603] SK170-9 LA


RAIL12CEX0802FA

1




47454079-DRAFT 06/11/2012

55.DTC / 96


be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the voltage from pin 2 to pin 1 at the sensor and pin 8 to pin 7 at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 4.7 V or more. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 4.7 V or more, replace the P2 pump pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the P2 pump pressure sensor SE-23 and the Mechatro controller. A. Check connectors CN-140F at the sensor, connector CN-1F\CN-1M, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: In the event of failure set the P2 pump pressure to 250 bar (3625.0 psi) and control the pump.

47454079-DRAFT 06/11/2012

55.DTC / 97


C033-Open-circuit of boom head pressure sensor. [54404684] SK170-9 LA

Cause: Symptom: Indication load value of High-reach crane becomes abnormal. 1. Boom head pressure sensor SE-24 failure. 2. Faulty wiring or bad connection between the Boom head pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom head pressure sensor. A. Measure the DC supply voltage on connector CN-706F and on connector CN-104F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the signal voltage at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 0.1 V or less. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 0.1 V or less, replace the Boom head pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom head pressure sensor SE-24 and the Mechatro controller. A. Check connectors CN-706F at the sensor, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: The Boom head pressure sensor is not supplied on North American units.

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C034-Short-circuit of boom head pressure sensor. [54404704] SK170-9 LA

Cause: Symptom: Indication load value of High-reach crane becomes abnormal. 1. Boom head pressure sensor SE-24 failure. 2. Faulty wiring or bad connection between the Boom head pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom head pressure sensor. A. Measure the DC supply voltage on connector CN-706F and on connector CN-104F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the signal voltage at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 4.7 V or more. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 4.7 V or more, replace the Boom head pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom head pressure sensor SE-24 and the Mechatro controller. A. Check connectors CN-706F at the sensor, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: The Boom head pressure sensor is not supplied on North American units..

47454079-DRAFT 06/11/2012

55.DTC / 99


C043-Open-circuit of boom rod pressure sensor. [54404778] SK170-9 LA

Cause: Symptom: Indication load value of High-reach crane becomes abnormal. 1. Boom rod pressure sensor SE-25 failure. 2. Faulty wiring or bad connection between the Boom rod pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom rod pressure sensor. A. Measure the DC supply voltage on connector CN-705F and on connector CN-104F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the signal voltage at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 0.1 V or less. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 0.1 V or less, replace the Boom rod pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom rod pressure sensor SE-25 and the Mechatro controller. A. Check connectors CN-705F at the sensor, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: The Boom rod pressure sensor is not supplied on North American units.

47454079-DRAFT 06/11/2012

55.DTC / 100


C044-Short-circuit of boom rod pressure sensor. [54404800] Cause: Symptom: Indication load value of High-reach crane becomes abnormal. 1. Boom rod pressure sensor SE-25 failure. 2. Faulty wiring or bad connection between the Boom rod pressure sensor and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check voltage to the Boom rod pressure sensor. A. Measure the DC supply voltage on connector CN-705F and on connector CN-104F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the sensor, measure the signal voltage at the sensor and at the Mechatro controller. This voltage is the sensor signal and should read between 1.4 - 4.7 V. This fault code is triggered when the voltage is 4.7 V or more. See Service diagnosis screen number 6 for diagnostic readings. If the voltage is 4.7 V or more, replace the Boom rod pressure sensor and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom rod pressure sensor SE-25 and the Mechatro controller. A. Check connectors CN-705F at the sensor, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault. NOTE: The Boom rod pressure sensor is not supplied on North American units..

47454079-DRAFT 06/11/2012

55.DTC / 101


D012-Failure of output transistor ON at P1 unload proportional valve. [54404834] SK170-9 LA

Cause: Symptom: Option conflux can not be done. Condition: The feed back value from the proportional valve is 1000 mA or more. 1. P1 unload proportional solenoid valve PSV-D failure. 2. Faulty wiring or bad connection between the P1 unload proportional solenoid valve and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, D-1 P1 Un-load (BP-CUT). Turn the key switch OFF and exchange the P1 unload proportional solenoid connector CN-120F with the P2 unload proportional solenoid connector CN-118F.

RAIL12CEX0800FA

1

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Schematic legend (1) (2) (3)

PSV-D: P1 unload proportional solenoid PSV-B: P2 unload proportional solenoid Mechatro controller

A. Turn the key switch back ON. If the D012 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace the P1 proportional valve and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D012 appears, continue with step 3. 3. Check the wiring and the connectors between the P1 unload proportional solenoid valve PSV-D and the Mechatro controller. A. Check connectors CN-120F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 103


D013-Open-circuit of P1 unload proportional valve. [54404993] SK170-9 LA

Cause: Symptom: Option conflux can not be done. Condition: The feed back value from the proportional valve is 100 mA or less. Note: Judging is not done if the output is 100 mA or less. 1. P1 unload proportional solenoid valve PSV-D failure. 2. Faulty wiring or bad connection between the P1 unload proportional solenoid valve and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, D-1 P1 Un-load (BP-CUT). Turn the key switch OFF and exchange the P1 unload proportional solenoid connector CN-120F with the P2 unload proportional solenoid connector CN-118F.

RAIL12CEX0800FA

1


PSV-D: P1 unload proportional solenoid PSV-B: P2 unload proportional solenoid 47454079-DRAFT 06/11/2012

55.DTC / 104


(3)

Mechatro controller

A. Turn the key switch back ON. If the D013 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace the P1 proportional valve and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D013 appears, continue with step 3. 3. Check the wiring and the connectors between the P1 unload proportional solenoid valve PSV-D and the Mechatro controller. A. Check connectors CN-120F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 105


D022-Failure of output transistor ON at P2 unload proportional valve. [54405024] SK170-9 LA

Cause: Symptom: Independent operations of Boom up and Bucket digging\dump become slow. Condition: The feed back value from the proportional valve is 1000 mA or more. 1. P2 unload proportional solenoid valve PSV-B failure. 2. Faulty wiring or bad connection between the P2 unload proportional solenoid valve and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, D-2 P2 Un-load (BP-CUT). Turn the key switch OFF and exchange the P2 unload proportional solenoid connector CN-118F with the P1 unload proportional solenoid connector CN-120F.

RAIL12CEX0800FA

1

47454079-DRAFT 06/11/2012

55.DTC / 106



PSV-D: P1 unload proportional solenoid PSV-B: P2 unload proportional solenoid Mechatro controller

A. Turn the key switch back ON. If the D022 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace the P2 proportional valve and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D022 still appears, continue with step 3. 3. Check the wiring and the connectors between the P2 unload proportional solenoid valve PSV-B and the Mechatro controller. A. Check connectors CN-118F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 107


D023-Open-circuit of P2 unload proportional valve. [54405158] SK170-9 LA

Cause: Symptom: Independent operations of Boom up and Bucket digging\dump become slow. Condition: The feed back value from the proportional valve is 100 mA or less. Note: Judging is not done if the output is 100 mA or less. 1. P2 unload proportional solenoid valve PSV-B failure. 2. Faulty wiring or bad connection between the P2 unload proportional solenoid valve and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, D-2 P2 Un-load (BP-CUT). Turn the key switch OFF and exchange the P2 unload proportional solenoid connector CN-118F with the P1 unload proportional solenoid connector CN-120F.

RAIL12CEX0800FA

1


PSV-D: P1 unload proportional solenoid PSV-B: P2 unload proportional solenoid 47454079-DRAFT 06/11/2012

55.DTC / 108


(3)

Mechatro controller

A. Turn the key switch back ON. If the D023 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace the P2 proportional valve and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D023 still appears, continue with step 3. 3. Check the wiring and the connectors between the P2 unload proportional solenoid valve PSV-B and the Mechatro controller. A. Check connectors CN-118F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 109


D033-Open-circuit of travel straight proportional valve. [54405297] SK170-9 LA

Cause: Symptom: Travel deviation occurs when operating both travel and attachment operations. Condition: The feed back value from the proportional valve is 100 mA or less. Note: Judging is not done if the output is 100 mA or less. 1. Travel priority (straight) proportional solenoid valve PSV-C failure. 2. Faulty wiring or bad connection between the Travel priority (straight) proportional solenoid valve and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, D-3 S-Travel. Turn the key switch OFF and exchange the Travel priority (straight) proportional solenoid connector CN-119F with another proportional solenoid connector.

RAIL12CEX0800FA

1

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PSV-C: Travel priority (straight) proportional solenoid Mechatro controller

A. Turn the key switch back ON. If the D033 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace the Travel priority (straight) valve and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D033 still appears, continue with step 3. 3. Check the wiring and the connectors between the Travel priority (straight) proportional solenoid valve and the Mechatro controller. A. Check connectors CN-119F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 111


D062-Failure of output transistor ON at arm in high speed proportional valve. [54405326] SK170-9 LA

Cause: Symptom: Operability of combined operation with arm in becomes poor. Condition: The feed back value from the proportional valve is 1000 mA or more. 1. Arm two-speed inverse proportional solenoid valve PSV-A failure. 2. Faulty wiring or bad connection between PSV-A and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, D-6 Arm in - 2-speed. Turn the key switch OFF and exchange PSV-A, CN-121F with another proportional solenoid valve.

RAIL12CEX0800FA

1


PSV-A: Arm two-speed inverse proportional solenoid Mechatro controller

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A. Turn the key switch back ON. If the D062 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-A and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D062 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-A and the Mechatro controller. A. Check connectors CN-121F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 113


D063-Open-circuit of arm in high speed proportional valve. [54405662] SK170-9 LA

Cause: Symptom: Operability of combined operation with arm in becomes poor. Condition: The feed back value from the proportional valve is 100 mA or less. Note: If the output is 100 mA or less, judging is not done. 1. Arm two-speed inverse proportional solenoid valve PSV-A failure. 2. Faulty wiring or bad connection between PSV-A and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, D-6 Arm in - 2-speed. Turn the key switch OFF and exchange PSV-A, CN-121F with another proportional solenoid valve.

RAIL12CEX0800FA

1

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PSV-A: Arm two-speed inverse proportional solenoid Mechatro controller

A. Turn the key switch back ON. If the D063 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-A and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D063 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-A and the Mechatro controller. A. Check connectors CN-121F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 115


D153-Open-circuit of proportional bypass valve. [54405800] SK170-9 LA

Cause: Symptom: Operability of combined operation with travel becomes poor. Condition: The feed back value from the proportional valve is 100 mA or less. Note: If the output is 100 mA or less, judging is not done. 1. Proportional bypass solenoid valve PSV-R failure. 2. Faulty wiring or bad connection between PSV-R and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 12, D-15. Turn the key switch OFF and exchange PSV-R, CN-250F with another proportional solenoid valve.

RAIL12CEX0805FA

1


PSV-R: Control proportional (bypass) solenoid Mechatro controller

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A. Turn the key switch back ON. If the D153 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-R and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code D153 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-R and the Mechatro controller. A. Check connectors CN-250F at the solenoid, and connector CN-106F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

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E012-Failure of output transistor ON at P1 pump proportional valve. [54405824] SK170-9 LA

Cause: Symptom: The ability to make fine adjustments to the P2 pump attachment becomes poor. Condition: The feed back value from the proportional valve is 1000 mA or more. 1. P1 pump proportional solenoid valve PSV-P1 failure. 2. Faulty wiring or bad connection between PSV-P1 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 6, E-1 Pump P1. Turn the key switch OFF and exchange PSV-P1, CN-141F with another proportional solenoid valve.

RAIL12CEX0800FA

1


PSV-P1: P1 pump proportional solenoid Mechatro controller

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A. Turn the key switch back ON. If the E012 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-P1 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code E012 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-P1 and the Mechatro controller. A. Check connectors CN-141F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 119


E013-Open-circuit of P1 pump proportional valve. [54405920] SK170-9 LA

Cause: Symptom: The ability to make fine adjustments to the P2 pump attachment becomes poor. Condition: The feed back value from the proportional valve is 100 mA or less. Note: If the output is 100 mA or less, judging is not done. 1. P1 pump proportional solenoid valve PSV-P1 failure. 2. Faulty wiring or bad connection between PSV-P1 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 6, E-1 Pump P1. Turn the key switch OFF and exchange PSV-P1, CN-141F with another proportional solenoid valve.

RAIL12CEX0800FA

1



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47454079-DRAFT 06/11/2012

55.DTC / 121


E022-Failure of output transistor ON at P2 pump proportional valve. [54405944] SK170-9 LA

Cause: Symptom: The ability to make fine adjustments to the P2 pump attachment becomes poor. Condition: The feed back value from the proportional valve is 1000 mA or more. 1. P2 pump proportional solenoid valve PSV-P2 failure. 2. Faulty wiring or bad connection between PSV-P2 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 6, E-2 Pump P2. Turn the key switch OFF and exchange PSV-P2, CN-142F with another proportional solenoid valve.

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1



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47454079-DRAFT 06/11/2012

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E023-Open-circuit of P2 pump proportional valve. [54406230] SK170-9 LA

Cause: Symptom: The ability to make fine adjustments to the P2 pump attachment becomes poor. Condition: The feed back value from the proportional valve is 100 mA or less. Note: If the output is 100 mA or less, judging is not done. 1. P2 pump proportional solenoid valve PSV-P2 failure. 2. Faulty wiring or bad connection between PSV-P2 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 6, E-2 Pump P2. Turn the key switch OFF and exchange PSV-P2, CN-142F with another proportional solenoid valve.

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1



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47454079-DRAFT 06/11/2012

55.DTC / 125


E032-Failure of output transistor ON at Optional relief adjusting proportional valve 1. [54406262] SK170-9 LA

Cause: Symptom: Valve does not relieve at pressure setting. Condition: The feed back value from the proportional valve is 1000 mA or more. 1. Optional relief adjusting proportional solenoid valve 1 PSV-E failure. 2. Faulty wiring or bad connection between PSV-E and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, E-3 Optional relief 1. Turn the key switch OFF and exchange PSV-E, CN-148F with another proportional solenoid valve.

RAIL12CEX0805FA

1


PSV-E: Optional relief adjusting proportional solenoid 1 Mechatro controller

47454079-DRAFT 06/11/2012

55.DTC / 126


A. Turn the key switch back ON. If the E032 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-E and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code E032 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-E and the Mechatro controller. A. Check connectors CN-148F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

55.DTC / 127


E033-Open-circuit of optional relief adjusting proportional valve 1. [54406913] SK170-9 LA

Cause: Symptom: Valve does not relieve at pressure setting. Condition: The feed back value from the proportional valve is 100 mA or less. Note: If the output is 100 mA or less, judging is not done. 1. Optional relief adjusting proportional solenoid valve 1 PSV-E failure. 2. Faulty wiring or bad connection between PSV-E and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, E-3 Optional relief 1. Turn the key switch OFF and exchange PSV-E, CN-148F with another proportional solenoid valve.

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PSV-E: Optional relief adjusting proportional solenoid 1 Mechatro controller

A. Turn the key switch back ON. If the E033 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-E and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code E033 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-E and the Mechatro controller. A. Check connectors CN-148F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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E042-Failure of output transistor ON at Optional relief adjusting proportional valve 2. [54406937] SK170-9 LA

Cause: Symptom: Valve does not relieve at pressure setting. Condition: The feed back value from the proportional valve is 1000 mA or more. 1. Optional relief adjusting proportional solenoid valve 2 PSV-I failure. 2. Faulty wiring or bad connection between PSV-I and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, E-4 Optional relief 2. Turn the key switch OFF and exchange PSV-I, CN-183F with another proportional solenoid valve.

RAIL12CEX0805FA

1


PSV-I: Optional relief adjusting proportional solenoid 2 Mechatro controller

47454079-DRAFT 06/11/2012

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A. Turn the key switch back ON. If the E042 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-I and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code E042 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-I and the Mechatro controller. A. Check connectors CN-183F at the solenoid, connector CN-1F\CN-1M, and connector CN-106F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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E043-Open-circuit of optional relief adjusting proportional valve 2. [54407716] SK170-9 LA

Cause: Symptom: Valve does not relieve at pressure setting. Condition: The feed back value from the proportional valve is 100 mA or less. Note: If the output is 100 mA or less, judging is not done. 1. Optional relief adjusting proportional solenoid valve 2 PSV-I failure. 2. Faulty wiring or bad connection between PSV-I and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, E-4 Optional relief 2. Turn the key switch OFF and exchange PSV-I, CN-183F with another proportional solenoid valve.

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1

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PSV-I: Optional relief adjusting proportional solenoid 2 Mechatro controller

A. Turn the key switch back ON. If the E043 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace PSV-I and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code E043 still appears, continue with step 3. 3. Check the wiring and the connectors between PSV-I and the Mechatro controller. A. Check connectors CN-183F at the solenoid, connector CN-1F\CN-1M, and connector CN-106F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 133


F011-Failure of output transistor OFF and GND short of attachment boost SOL valve. [54408111] SK170-9 LA

Cause: Symptom: Power (ATT-attachment) boost is not available. Condition: The feed back signal is at grounding level when the output is energized. The feed back signal should be 24 V when the output is energized. 1. Power (ATT) boost solenoid valve SV-2 failure. 2. Faulty wiring or bad connection between SV-2 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 3, F-1 power boost. Turn the key switch OFF and exchange SV-2, CN-117F with another solenoid valve.

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1

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SV-2: Power boost solenoid SV-3: Two speed select solenoid Mechatro controller

A. Turn the key switch back ON. If the F011 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-2 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F011 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-2 and the Mechatro controller. A. Check connectors CN-117F at the solenoid, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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F013-Failure of output transistor ON and open-circuit of attachment boost SOL valve. [54408009] SK170-9 LA

Cause: Symptom: Power (ATT-attachment) boost is not available or is leaving available status. Condition: The feed back signal is at 24 V when the output is not energized. The feed back signal should be at grounding level when the output is not energized. 1. Power (ATT) boost solenoid valve SV-2 failure. 2. Faulty wiring or bad connection between SV-2 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 3, F-1 power boost. Turn the key switch OFF and exchange SV-2, CN-117F with another solenoid valve.

RAIL12CEX0800FA

1

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A. Turn the key switch back ON. If the F013 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-2 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F013 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-2 and the Mechatro controller. A. Check connectors CN-117F at the solenoid, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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F021-Failure of output transistor OFF and GND short of swing parking SOL valve. [54408493] SK170-9 LA

Cause: Symptom: Swing parking is not available. Condition: The feed back signal is at grounding level when the output is energized. The feed back signal should be 24 V when the output is energized. 1. Swing parking brake solenoid valve SV-1 failure. 2. Faulty wiring or bad connection between SV-1 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 3, F-2 Swing brake. Turn the key switch OFF and exchange SV-1, CN-123F with another solenoid valve.

RAIL12CEX0806EA

1


SV-1: Swing parking brake solenoid SW-4: Swing parking release switch Mechatro controller

A. Turn the key switch back ON. If the F021 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-1 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F021 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-1 and the Mechatro controller. A. Check connectors CN-123F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F\CN-108F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. Also verify wiring through the Swing parking release switch SW-4 when switch is in both positions. If the connections test is good continue with step 4.

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B. If the wiring, switch, or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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F023-Failure of output transistor ON and open-circuit of swing parking SOL valve. [54408473] SK170-9 LA

Cause: Symptom: Swing parking is not available, or is leaving available status.. Condition: The feed back signal is at 24 V when the output is not energized. The feed back signal should be grounding level when the output is not energized. 1. Swing parking brake solenoid valve SV-1 failure. 2. Faulty wiring or bad connection between SV-1 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 3, F-2 Swing brake. Turn the key switch OFF and exchange SV-1, CN-123F with another solenoid valve.

RAIL12CEX0806EA

1


SV-1: Swing parking brake solenoid SW-4: Swing parking release switch Mechatro controller

A. Turn the key switch back ON. If the F023 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-1 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F023 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-1 and the Mechatro controller. A. Check connectors CN-123F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F\CN-108F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. Also verify wiring through the Swing parking release switch SW-4 when switch is in both positions. If the connections test is good continue with step 4.

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F031-Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve. [54408666] SK170-9 LA

Cause: Symptom: Travel 2 speed is not obtainable. Condition: The feed back signal is at grounding level when the output is energized. The feed back signal should be 24 V when the output is energized. 1. Two speed select solenoid valve SV-3 failure. 2. Faulty wiring or bad connection between SV-3 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 3, F-3 1/2-Travel. Turn the key switch OFF and exchange SV-3, CN-122F with another solenoid valve.

RAIL12CEX0800FA

1

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A. Turn the key switch back ON. If the F031 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-3 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F031 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-3 and the Mechatro controller. A. Check connectors CN-122F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring, switch, or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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F033-Failure of output transistor ON and open-circuit of travel 1-2 speed SOL valve. [54408645] SK170-9 LA

Cause: Symptom: Travel 2 speed is not obtainable, or is keeping 1 speed. Condition: The feed back signal is at 24 V when the output is not energized. The feed back signal should be at grounding level when the output is not energized. 1. Two speed select solenoid valve SV-3 failure. 2. Faulty wiring or bad connection between SV-3 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 3, F-3 1/2-Travel. Turn the key switch OFF and exchange SV-3, CN-122F with another solenoid valve.

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1

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A. Turn the key switch back ON. If the F033 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-3 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F033 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-3 and the Mechatro controller. A. Check connectors CN-122F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring, switch, or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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F041-Failure of output transistor OFF and GND short of optional selector SOL valve. [54408856] SK170-9 LA

Cause: Symptom: Option selector valve does not change to the breaker side. Condition: The feed back signal is at grounding level when the output is energized. The feed back signal should be 24 V when the output is energized. 1. Option selector solenoid valve SV-13 failure. 2. Faulty wiring or bad connection between SV-13 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, F-4 Opt select. Turn the key switch OFF and exchange SV-13, CN-251F with another solenoid valve.

RAIL12CEX0803EA

1


SV-35: Heavy lift switch SE-29: Option selector detect sensor SV-13: Option selector solenoid Mechatro controller

A. Turn the key switch back ON. If the F041 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-13 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F041 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-13 and the Mechatro controller. A. Check connectors CN-251F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4.

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F043-Failure of output transistor ON and open-circuit of option selector SOL valve. [54408817] SK170-9 LA

Cause: Symptom: Option selector valve does not change to the breaker side, or it does not change from breaker to nibbler. Condition: The feed back signal is at 24 V when the output is not energized. The feed back signal should be at grounding level when the output is not energized. 1. Option selector solenoid valve SV-13 failure. 2. Faulty wiring or bad connection between SV-13 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current valve conditions using the service diagnosis screen number 7, F-4 Opt select. Turn the key switch OFF and exchange SV-13, CN-251F with another solenoid valve.

RAIL12CEX0803EA

1


SV-35: Heavy lift switch SE-29: Option selector detect sensor SV-13: Option selector solenoid Mechatro controller

A. Turn the key switch back ON. If the F043 fault clears and a different fault is displayed, check the solenoid valve for any possible damage. If it cannot be repaired, replace SV-13 and go to step 1 to confirm elimination of the fault. Remember to reinstall the connectors back to their original solenoids. B. If fault code F043 still appears, continue with step 3. 3. Check the wiring and the connectors between SV-13 and the Mechatro controller. A. Check connectors CN-251F at the solenoid, connector CN-1F\CN-1M, and connector CN-105F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4.

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55.DTC / 148



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G032-Overrun of speed sensor of direct input Mechatro controller. [54409009] SK170-9 LA

Cause: Symptom: No noticeable problems. Engine rpm (rotations per minute) input is received from the engine controller in the event of failure. Condition: Engine rpm input is 3000 RPM or more. (Only trouble history). 1. Engine speed sensor SE-13 failure. 2. Faulty wiring or bad connection between SE-13 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current sensor conditions using the service diagnosis screen number 2, G-3 MEAS 1(signal from Mechatro controller), and G-3 MEAS 2 (signal from the engine controller).

RAIL12CEX0804FA

1

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SE-20: Pressure sensor P1 option SE-11: Pressure sensor P2 option SE-15: Fuel sensor SE-13: Engine revolution sensor Mechatro controller

A. If the Engine revolution sensor SE-13 displays more than 3000 RPM, unplug connector CN-106 and measure the resistance across terminals CN-106F-20 and CN-106F-21. The resistance should read between 1.6 - 2.0K Ω . If the resistance is good proceed to step 3. B. If the resistance does not fall within the limits replace the Engine revolution sensor SE-13. Go to step 1 to confirm elimination of the fault. 3. Verify engine controller speed sensor is functioning properly from the service diagnosis screen G-3 MEAS 2 (signal from the engine controller). A. If engine controller speed sensor is good proceed to step 4. B. If the Engine controller speed sensor does not fall within the limits replace the sensor. See engine controller for details. Go to step 1 to confirm elimination of the fault. 4. Check the wiring and the connectors between SE-13 and the Mechatro controller. A. Check connectors CN-160F at the sensor, connector CN-2F\CN-2M, and connector CN-106F on the Mechatro controller. Note: for models SK-350–9 and SK-485–9 the connector at the sensor is CN-136F. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. Especially check for open circuits and unwanted noise on the wires. Verify the shielding wire SH1 is good if noise levels are high. If the connections test is good continue with step 5. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 5. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 151


G033-Open-circuit of speed sensor of direct input Mechatro controller. [54409042] SK170-9 LA

Cause: Symptom: No noticeable problems. Engine rpm (rotations per minute) input is received from the engine controller in the event of failure. Condition: Voltage from the alternator is 12 V or more, and the speed sensor indicates excess low engine rpm. 1. Engine speed sensor SE-13 failure. 2. Faulty wiring or bad connection between SE-13 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current sensor conditions using the service diagnosis screen number 2, G-3 MEAS 1(signal from Mechatro controller), and G-3 MEAS 2 (signal from the engine controller).

RAIL12CEX0804FA

1

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A. If the Engine revolution sensor SE-13 indicates a low engine rpm, unplug connector CN-106 and measure the resistance across terminals CN-106F-20 and CN-106F-21. The resistance should read between 1.6 - 2.0K Ω . If the resistance is good proceed to step 3. B. If the resistance does not fall within the limits replace the Engine revolution sensor SE-13. Go to step 1 to confirm elimination of the fault. 3. Verify the Engine controller speed sensor is functioning properly from the service diagnosis screen G-3 MEAS 2 (signal from the engine controller). A. If engine controller speed sensor is good proceed to step 4. B. If the Engine controller speed sensor does not fall within the limits replace the sensor. See engine controller for details. Go to step 1 to confirm elimination of the fault. 4. Check the wiring and the connectors between SE-13 and the Mechatro controller. A. Check connectors CN-160F at the sensor, connector CN-2F\CN-2M, and connector CN-106F on the Mechatro controller. Note: for models SK-350–9 and SK-485–9 the connector at the sensor is CN-136F. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. Especially check for open circuits and unwanted noise on the wires. Verify the shielding wire SH1 is good if noise levels are high. If the connections test is good continue with step 5. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 5. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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G042-Overrun of speed sensor of direct input Mechatro controller and received data from E/G controller. [54409202] SK170-9 LA

Cause: Symptom: No noticeable problems. Engine rpm (rotations per minute) input is received from the engine controller in the event of failure. Condition: Engine rpm input is 3000 RPM or more. (Only trouble history). 1. Engine speed sensor SE-13 failure. 2. Faulty wiring or bad connection between SE-13 and the Mechatro controller. 3. Faulty wiring or bad connection on engine speed sensor, pressure sensor, or poor communications between Mechatro controller and Engine controller. (CAN bus) 4. Faulty Mechatro controller. 5. Faulty Engine controller (ECU). Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current sensor conditions using the service diagnosis screen number 2, G-3 MEAS 1(signal from Mechatro controller), and G-3 MEAS 2 (signal from the engine controller).

RAIL12CEX0804FA

1

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A. If the Engine revolution sensor SE-13 displays more than 3000 RPM, unplug connector CN-106 and measure the resistance across terminals CN-106F-20 and CN-106F-21. The resistance should read between 1.6 - 2.0K Ω . If the resistance is good proceed to step 3. B. If the resistance does not fall within the limits replace the Engine revolution sensor SE-13. Go to step 1 to confirm elimination of the fault. 3. Verify engine controller speed sensor is functioning properly from the service diagnosis screen G-3 MEAS 2 (signal from the engine controller). A. If engine controller speed sensor is good proceed to step 4. B. If the Engine controller speed sensor does not fall within the limits replace the sensor. See engine controller for details. Go to step 1 to confirm elimination of the fault. 4. Check the wiring and the connectors between SE-13 and the Mechatro controller. A. Check connectors CN-160F at the sensor, connector CN-2F\CN-2M, and connector CN-106F on the Mechatro controller. Note: for models SK-350–9 and SK-485–9 the connector at the sensor is CN-136F. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. Especially check for open circuits and unwanted noise on the wires. Verify the shielding wire SH1 is good if noise levels are high. If the connections test is good continue with step 5. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 5. Check the wiring between the engine speed sensor and the Engine control unit (ECU). See engine control for details. Also verify communication between ECU and Mechatro controller.

RAIL12CEX0808EA

2

Model SK 170-9, SK 210-9, SK 260-9, and SK 295-9.

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RAIL12CEX0809EA

3

RAIL12CEX0810EA

4

Model SK 350-9

Model SK 485-9 Schematic legend (1) (2) (3) (4)

Mechatro controller Engine controller (ECU) Engine harness Dosing diagnostic connector

A. Check the CAN_L1 and CAN_L2 lines using the appropriate wiring diagram above. If the wiring tests good, continue with step 6. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 6. Replace the Mechatro controller. A. After replacing the controller, return to step 1 to confirm elimination of the fault. B. If the fault code remains, continue with step 7. 7. Replace the Engine controller (ECU). A. Return to step 1 to confirm elimination of the fault.

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G043-Open-circuit of speed sensor of direct input Mechatro controller and received data from E/G controller. [54409222] SK170-9 LA

Cause: Symptom: Abrupt loading may cause reduced engine rpms (rotations per minute) and additional crank time. Condition: Voltage from the alternator is 24 V or more, and the data received from the engine controller indicates excess low engine rpm. For control in the event of failure enter 0 RPM for the engine speed, and 0 for the ESS (engine speed sensing) power shift command. 1. Engine speed sensor SE-13 failure. 2. Faulty wiring or bad connection between SE-13 and the Mechatro controller. 3. Faulty wiring or bad connection on engine speed sensor, pressure sensor, or poor communications between Mechatro controller and Engine controller. (CAN bus) 4. Faulty Mechatro controller. 5. Faulty Engine controller (ECU). Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify the current sensor conditions using the service diagnosis screen number 2, G-3 MEAS 1(signal from Mechatro controller), and G-3 MEAS 2 (signal from the engine controller).

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RAIL12CEX0804FA

1



A. If the Engine revolution sensor SE-13 displays low rpms, unplug connector CN-106 and measure the resistance across terminals CN-106F-20 and CN-106F-21. The resistance should read between 1.6 - 2.0K Ω . If the resistance is good proceed to step 3. B. If the resistance does not fall within the limits replace the Engine revolution sensor SE-13. Go to step 1 to confirm elimination of the fault. 3. Verify engine controller speed sensor is functioning properly from the service diagnosis screen G-3 MEAS 2 (signal from the engine controller). A. If engine controller speed sensor is good proceed to step 4. B. If the Engine controller speed sensor does not fall within the limits replace the sensor. See engine controller for details. Go to step 1 to confirm elimination of the fault. 4. Check the wiring and the connectors between SE-13 and the Mechatro controller. A. Check connectors CN-160F at the sensor, connector CN-2F\CN-2M, and connector CN-106F on the Mechatro controller. Note: for models SK-350–9 and SK-485–9 the connector at the sensor is CN-136F. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. Especially check for open circuits and unwanted noise on the wires. Verify the shielding wire SH1 is good if noise levels are high. If the connections test is good continue with step 5. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault.

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5. Check the wiring between the engine speed sensor and the Engine control unit (ECU). See engine control for details. Also verify communication between the ECU and Mechatro controllers.

RAIL12CEX0808EA

2


RAIL12CEX0809EA

3

RAIL12CEX0810EA

4

Model SK 350-9



A. Check the CAN_L1 and CAN_L2 lines using the appropriate wiring diagram above. If the wiring tests good, continue with step 6. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 47454079-DRAFT 06/11/2012

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6. Replace the Mechatro controller. A. After replacing the controller, return to step 1 to confirm elimination of the fault. B. If the fault code remains, continue with step 7. 7. Replace the Engine controller (ECU). A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 160


H013-Open-circuit of acceleration potentiometer. [54409316] SK170-9 LA

Cause: Symptom: LOW idling is fixed. Condition: The input voltage from the Accel potentiometer is 0.1 V or less. 1. Accel potentiometer SE-16 failure. 2. Faulty wiring or bad connection between SE-16 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Measure the resistance between terminals of the Accel potentiometer.

RAIL12CEX0801FA

1


SE-16: Accel potentiometer Mechatro controller


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should be the same at the potentiometer and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the potentiometer, measure the resistance from pin 2 to pin 1 at the potentiometer and pin 8 to pin 7 at the Mechatro controller. This resistance should read between 1.6 - 2.0K Ω. Turning the potentiometer should vary the resistance within this range. The fault code is triggered when the voltage on these pins is 0.1 V or less. See Service diagnosis screen number 2, H-1 Accel volt for voltage readings from the controller. If the voltage is 0.1 V or less, replace the Accel potentiometer and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Accel potentiometer SE-16 and the Mechatro controller. A. Check connectors CN-402F at the potentiometer, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 162


H014-Short-circuit of acceleration potentiometer power. [54409339] SK170-9 LA

Cause: Symptom: LOW idling is fixed. Condition: The input voltage from the Accel potentiometer is 4.7 V or more. 1. Accel potentiometer SE-16 failure. 2. Faulty wiring or bad connection between SE-16 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Measure the resistance between terminals of the Accel potentiometer.

RAIL12CEX0801FA

1


SE-16: Accel potentiometer Mechatro controller


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should be the same at the potentiometer and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the potentiometer, measure the resistance from pin 2 to pin 1 at the potentiometer and pin 8 to pin 7 at the Mechatro controller. This resistance should read between 1.6 - 2.0K Ω. Turning the potentiometer should vary the resistance within this range. The fault code is triggered when the voltage on these pins is 4.7 V or more. See Service diagnosis screen number 2, H-1 Accel volt for voltage readings from the controller. If the voltage is 4.7 V or more, replace the Accel potentiometer and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Accel potentiometer SE-16 and the Mechatro controller. A. Check connectors CN-402F at the potentiometer, and connector CN-102F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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55.DTC / 164


H023-Open-circuit of boom angle potentiometer. [54409509] SK170-9 LA

Cause: Symptom: Indications of rating load and working radius of High-reach crane become abnormal. Condition: The input voltage from the Boom angle potentiometer is 0.1 V or less. 1. Boom angle potentiometer SE-17 failure. 2. Faulty wiring or bad connection between SE-17 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Measure the resistance between terminals of the Boom angle potentiometer. A. Measure the voltage from pin 3 to pin 1 on connector CN-702F and on connector CN-103F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the sensor and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the potentiometer, measure the resistance from pin 2 to pin 1 at the potentiometer and at the Mechatro controller. This resistance should read between 0 - 6.0K Ω. Turning the potentiometer should vary the resistance within this range. The fault code is triggered when the voltage on these pins is 0.1 V or less. See Service diagnosis screen number 10, H-2 Boom for voltage readings from the controller. If the voltage is 0.1 V or less, replace the Boom angle potentiometer and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom angle potentiometer SE-17 and the Mechatro controller. A. Check connectors CN-702F at the sensor, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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H024-Short-circuit of boom angle potentiometer power. [54409529] SK170-9 LA

Cause: Symptom: Indications of rating load and working radius of the High-reach crane become abnormal. Condition: The input voltage from the Boom angle potentiometer is 4.7 V or more. 1. Boom angle potentiometer SE-17 failure. 2. Faulty wiring or bad connection between SE-17 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Measure the resistance between terminals of the Boom angle potentiometer. A. Measure the voltage from pin 3 to pin 1 on connector CN-702F and on connector CN-103F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the potentiometer and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the potentiometer, measure the resistance from pin 2 to pin 1 at the potentiometer and at the Mechatro controller. This resistance should read between 0 - 6.0K Ω. Turning the potentiometer should vary the resistance within this range. The fault code is triggered when the voltage on these pins is 4.7 V or more. See Service diagnosis screen number 10, H-2 Boom for voltage readings from the controller. If the voltage is 4.7 V or more, replace the Boom angle potentiometer and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Boom angle potentiometer SE-17 and the Mechatro controller. A. Check connectors CN-702F at the potentiometer, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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H033-Open-circuit of arm angle potentiometer. [54409657] SK170-9 LA

Cause: Symptom: Indications of rating load and working radius of the High-reach crane become abnormal. Condition: The input voltage from the Arm angle potentiometer is 0.1 V or less. 1. Arm angle potentiometer SE-19 failure. 2. Faulty wiring or bad connection between SE-19 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Measure the resistance between terminals of the Arm angle potentiometer. A. Measure the voltage from pin 3 to pin 1 on connector CN-703F and on connector CN-103F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the potentiometer and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the potentiometer, measure the resistance from pin 2 to pin 1 at the potentiometer and at the Mechatro controller. This resistance should read between 0 - 6.0K Ω. Turning the potentiometer should vary the resistance within this range. The fault code is triggered when the voltage on these pins is 0.1 V or less. See Service diagnosis screen number 10, H-3 Arm for voltage readings from the controller. If the voltage is 0.1 V or less, replace the Arm angle potentiometer and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm angle potentiometer SE-19 and the Mechatro controller. A. Check connectors CN-703F at the potentiometer, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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H034-Short-circuit of arm angle potentiometer power. [54409699] SK170-9 LA

Cause: Symptom: Indications of rating load and working radius of the High-reach crane become abnormal. Condition: The input voltage from the Arm angle potentiometer is 4.7 V or more. 1. Arm angle potentiometer SE-19 failure. 2. Faulty wiring or bad connection between SE-19 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Measure the resistance between terminals of the Arm angle potentiometer. A. Measure the voltage from pin 3 to pin 1 on connector CN-703F and on connector CN-103F. There should be approximately 5 V. If necessary, install a breakout tee to access these points. Voltage signals should be the same at the potentiometer and the Mechatro controller connectors. If they are different, repair or replace the wires and go to step 1 to confirm elimination of the fault. If you do not read 5 V go to step 3. B. If you read 5 V at the potentiometer, measure the resistance from pin 2 to pin 1 at the potentiometer and at the Mechatro controller. This resistance should read between 0 - 6.0K Ω. Turning the potentiometer should vary the resistance within this range. The fault code is triggered when the voltage on these pins is 4.7 V or more. See Service diagnosis screen number 10, H-3 Arm for voltage readings from the controller. If the voltage is 4.7 V or more, replace the Arm angle potentiometer and go to step 1 to confirm elimination of the fault. If the voltage is within the range continue with step 3. 3. Check the wiring and the connectors between the Arm angle potentiometer SE-19 and the Mechatro controller. A. Check connectors CN-703F at the potentiometer, and connector CN-103F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

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H091-Short-circuit of fuel sensor ground. [54410016] SK170-9 LA

Cause: Symptom: Warning for low fuel level is indicated. Condition: The input voltage from the fuel sensor is 0.1 V or less. 1. Fuel sensor potentiometer SE-15 failure. 2. Faulty wiring or bad connection between the Fuel sensor potentiometer and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check resistance at the Fuel sensor.

RAIL12CEX0804FA

1


SE-20: Pressure sensor P1 option SE-11: Pressure sensor P2 option SE-15: Fuel sensor SE-13: Engine revolution sensor Mechatro controller 47454079-DRAFT 06/11/2012

55.DTC / 169


A. Verify the Fuel sensor reading using the service diagnosis screen 8, H-9 Fuel level. Remove connector CN-152F and measure the resistance on the Fuel sensor potentiometer SE-15. When the tank is empty you should read 95 Ω, and when the tank is full you should read 5 Ω . If the resistance is not correct, or falls outside of this range replace the Fuel sensor and go to step 1 to confirm elimination of the fault. If the resistance is within the range, continue with step 3. 3. Check the wiring and the connectors between the Fuel sensor SE-15 and the Mechatro controller. A. Check connectors CN-152F at the sensor, connector CN-1F\CN-1M, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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H093-Open-circuit of fuel sensor. [54409996] SK170-9 LA

Cause: Symptom: Warning for low fuel level is indicated. Condition: The input voltage from the fuel sensor is 4.7 V or more. 1. Fuel sensor potentiometer SE-15 failure. 2. Faulty wiring or bad connection between the Fuel sensor potentiometer and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check resistance at the Fuel sensor.

RAIL12CEX0804FA

1


SE-20: Pressure sensor P1 option SE-11: Pressure sensor P2 option SE-15: Fuel sensor SE-13: Engine revolution sensor Mechatro controller 47454079-DRAFT 06/11/2012

55.DTC / 171


A. Verify the Fuel sensor reading using the service diagnosis screen 8, H-9 Fuel level. Remove connector CN-152F and measure the resistance on the Fuel sensor potentiometer SE-15. When the tank is empty you should read 95 Ω, and when the tank is full you should read 5 Ω . If the resistance is not correct, or falls outside of this range replace the Fuel sensor and go to step 1 to confirm elimination of the fault. If the resistance is within the range, continue with step 3. 3. Check the wiring and the connectors between the Fuel sensor SE-15 and the Mechatro controller. A. Check connectors CN-152F at the sensor, connector CN-1F\CN-1M, and connector CN-104F on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 4. B. If the wiring or connectors are damaged, repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

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I111-Receive error of CAN1 communication (passive error). [54409362] SK170-9 LA

Cause: Symptom: No noticeable problems. Condition: Reception from the engine controller is not received correctly. 1. Faulty wiring or bad communications between Mechatro controller and Engine controller (ECU) on CAN bus. 2. Faulty Mechatro controller. 3. Faulty Engine controller (ECU). Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify wiring and communication between Engine controller (ECU) and Mechatro controller.

RAIL12CEX0808EA

1


RAIL12CEX0809EA

2

Model SK 350-9

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RAIL12CEX0810EA

3



A. Check the CAN_L1 and CAN_L2 lines using the appropriate wiring diagram for your model above. Note: There is a possibility of a false open-circuit reading. If the wiring tests good, continue with step 3. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 3. Replace the Mechatro controller. A. After replacing the controller, return to step 1 to confirm elimination of the fault. B. If the fault code remains, continue with step 4. 4. Replace the Engine controller (ECU). A. Return to step 1 to confirm elimination of the fault.

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I113-Receive error of CAN1 communication (time-out). [54409552] SK170-9 LA

Cause: Symptom: No noticeable problems. Condition: Reception from the gauge cluster is not received correctly. 1. Faulty wiring or bad communications between the Cluster gauge, Mechatro controller, or Engine controller (ECU) on CAN bus. 2. Faulty Mechatro controller. 3. Faulty Cluster gauge. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify wiring and communication between the Cluster gauge, Engine controller (ECU), and Mechatro controller.

RAIL12CEX0808EA

1


RAIL12CEX0809EA

2

Model SK 350-9

47454079-DRAFT 06/11/2012

55.DTC / 175


RAIL12CEX0810EA

3

RAIL12CEX0811FA

4




C2: Cluster gauge E-63: DC-DC converter (for camera) E-46: Rear camera CAN bus wiring from fuse and relay box

A. Check the CAN_L1 and CAN_L2 lines using the appropriate wiring diagram for your model above. Note: There is a possibility of a false open-circuit reading. Check service diagnosis screen 2, G-5 Water temp to verify communication. If the wiring tests good, continue with step 3.

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B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 3. Replace the Mechatro controller. A. After replacing the controller, return to step 1 to confirm elimination of the fault. B. If the fault code remains, continue with step 4. 4. Replace the Cluster gauge. A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

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I121-Transmission of CAN1 communication is abnormal (busoff). [54409722] SK170-9 LA

Cause: Symptom: No noticeable problems. Condition: Reception from the Mechatro controller is not received correctly. 1. Faulty wiring or bad communications between the Mechatro controller and the Engine controller (ECU) on the CAN bus. 2. Faulty Mechatro controller. 3. Faulty Engine controller (ECU). Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify wiring and communication between the Engine controller (ECU) and Mechatro controller.

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1


RAIL12CEX0809EA

2

Model SK 350-9

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55.DTC / 178


RAIL12CEX0810EA

3



A. Check the CAN_L1 and CAN_L2 lines using the appropriate wiring diagram for your model above. Note: There is a possibility of a false open-circuit reading. If the wiring tests good, continue with step 3. B. If the wiring or connectors are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 3. Replace the Mechatro controller. A. After replacing the controller, return to step 1 to confirm elimination of the fault. B. If the fault code remains, continue with step 4. 4. Replace the Engine controller (ECU). A. Return to step 1 to confirm elimination of the fault.

47454079-DRAFT 06/11/2012

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I211-Reception of CAN1 communication is abnormal (passive error). [54410040] SK170-9 LA

Cause: Symptom: Switch operation of the gauge cluster can not receive correctly. Condition: Reception from the gauge cluster is not received correctly. 1. Faulty wiring or bad communications between the Cluster gauge, Mechatro controller, or Engine controller (ECU) on CAN bus. 2. Faulty Mechatro controller. 3. Faulty Cluster gauge. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify wiring and communication between the Cluster gauge, Engine controller (ECU), and Mechatro controller.

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1


RAIL12CEX0809EA

2

Model SK 350-9

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RAIL12CEX0810EA

3

RAIL12CEX0811FA

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A. Check the CAN_L1 and CAN_L2 lines using the appropriate wiring diagram for your model above. Note: There is a possibility of a false open-circuit reading. If the wiring tests good, continue with step 3.

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I213-Reception of CAN2 communication is abnormal (time-out). [54410196] SK170-9 LA

Cause: Symptom: Switch operation of the gauge cluster can not be done. Condition: Reception from the gauge cluster is not received correctly. 1. Faulty wiring or bad communications between the Cluster gauge, Mechatro controller, or Engine controller (ECU) on CAN bus. 2. Faulty Mechatro controller. 3. Faulty Cluster gauge. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify wiring and communication between the Cluster gauge, Engine controller (ECU), and Mechatro controller.

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Model SK 350-9

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I221-Transmission of CAN2 communication is abnormal (busoff). [54410347] SK170-9 LA

Cause: Symptom: No noticeable problems. Condition: Transmission from the Mechatro controller can not receive correctly. 1. Faulty wiring or bad communications between the Cluster gauge, Mechatro controller, or Engine controller (ECU) on CAN bus. 2. Faulty Mechatro controller. 3. Faulty Cluster gauge. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Verify wiring and communication between the Cluster gauge, Engine controller (ECU), and Mechatro controller.

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1


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2

Model SK 350-9

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K014-Battery relay contact welded closed. [54409576] SK170-9 LA

Cause: Symptom: The power on the secondary side of the Battery relay does not turn OFF, even if the key switch is turned OFF. Condition: 24 V is continuously supplied to the controller for 40 s or more while the key switch ON signal is turned OFF. 1. Battery relay R-1 failure. 2. Auto idle stop relay 2 R-24 failure. 3. Alternator relay R-28 failure. 4. Faulty wiring or bad connection between R-24, R-28, and the Mechatro controller. 5. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check Battery relay contacts.

RAIL12CEX0814FA

1

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Schematic legend (1) (2) (3) (4) (5) (6) (7)

R-1: Battery Relay Fuse 6 – 60 A Battery C-9: To fuse 20 A E1: To fuse and relay box (10–15 fuse) R-24: Auto idle stop RY 2 E-1: from fuse and relay box (auto idle stop RY:1)

A. Verify the current conditions using the service diagnosis screen number 4, K-1 AIS relay 2, and K-3 Key switch OFF. Turn the key switch OFF and disconnect CN-256F, on the battery relay coil. Check for 24 V on the battery relay secondary side, terminals 1, 2, and 3. If voltage is not present, go to step 3. B. If voltage is present on the secondary side, the relay contacts are welded closed. Replace the relay and go to step 1to confirm elimination of the fault. 3. Check Auto stop relay 2 R-24 and Alternator relay R-28 . A. Verify power supply to Battery relay coil is working properly by removing Auto stop relay 2 or Alternator relay. If Battery relay coil is energized with both relays removed from E-1 fuse and relay box, go to step 4. B. Reinstall Auto stop relay 2 and Alternator relay one at a time or swap relay with a known good relay. Battery relay operation will return to normal once the bad relay has been replaced. Go to step 1 to confirm elimination of the fault. 4. Check the wiring and the connectors between the Auto stop relay \ Alternator relay and the Mechatro controller.

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RAIL12CEX0813GA

2

Schematic legend: (1) (2) (3) (4) (5) (6)

RLY RLY RLY RLY RLY RLY E-1:

25: Engine emergency stop relay 23: Auto idle stop relay 1 24: Auto idle stop relay 2 28: Alternator relay 4: Safety relay 26: Lever lock relay Fuse and relay box

A. Check connectors CN2, CN4 on the fuse and relay box, and connector CN-109F-11 on the Mechatro controller. The wiring and connector pins should be free of corrosion, damage, abrasion, and properly connected. If the connections test is good continue with step 5. B. If the wiring, connectors, or fuse \ relay box are damaged, repair or replace as required. Go to step 1 to confirm elimination of the fault. 5. Replace the Mechatro controller.

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A. Return to step 1 to confirm elimination of the fault.

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R014-Failure of wiper motor arc prevention relay. [54409744] SK170-9 LA

Cause: Symptom: Wiper does not move. Condition: The Mechatro controller output to the wiper motor arc prevention relay is short-circuited with the power source. 1. Failure of the Wiper motor arc prevention relay R-31 . 2. Faulty wiring or bad connection between R-31 and the Mechatro controller. 3. Faulty Fuse and relay box. 4. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Wiper motor arc prevention relay. R-31.

RAIL12CEX0815FA

1


RLY-31: Prevent spark relay (arc prevention) RLY-29: Wiper motor relay

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(3) (4) (5)

RLY-30: Wiper motor reversing relay RLY-32: Window washer motor relay E-1 Fuse and relay box

RAIL12CEX0818AA

2

A. Verify the current conditions using the service diagnosis screen number 19, Prevent arc. Turn the key switch OFF and remove relay R-31 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-31 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Wiper motor arc prevention relay and the Mechatro controller. A. If error code R014 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–1–3. If no voltage is found go to step 4. B. Replace the fuse and relay box. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R024-Failure of wiper motor normal rotation relay. [54410063] SK170-9 LA

Cause: Symptom: Wiper does not move. Condition: The Mechatro controller output to the wiper motor forward rotation relay is short-circuited with the power source. 1. Failure of the Wiper motor forward rotation relay R-29 . 2. Faulty wiring or bad connection between R-29 and the Mechatro controller. 3. Faulty Fuse and relay box. 4. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Wiper motor forward rotation relay. R-29.

RAIL12CEX0815FA

1


RLY-31: Prevent spark relay (arc prevention) RLY-29: Wiper motor relay (forward rotation)

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(3) (4) (5)


RAIL12CEX0818AA

2

A. Verify the current conditions using the service diagnosis screen number 19, CW motor rly. Turn the key switch OFF and remove relay R-29 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-29 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Wiper motor forward rotation relay and the Mechatro controller. A. If error code R024 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–1–14. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay coil, replace the fuse and relay box. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R034-Failure of wiper motor reverse rotation relay. [54410219] SK170-9 LA

Cause: Symptom: Wiper does not move after forward rotation. Condition: The Mechatro controller output to the wiper motor reverse rotation relay is short-circuited with the power source. 1. Failure of the Wiper motor reverse rotation relay R-30 . 2. Faulty wiring or bad connection between R-30 and the Mechatro controller. 3. Faulty Fuse and relay box. 4. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Wiper motor reverse rotation relay. R-30.

RAIL12CEX0815FA

1


RLY-31: Prevent spark relay (arc prevention) RLY-29: Wiper motor relay (forward rotation)

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(3) (4) (5)


RAIL12CEX0818AA

2

A. Verify the current conditions using the service diagnosis screen number 19, CCW motor rly. Turn the key switch OFF and remove relay R-30 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-30 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Wiper motor reverse rotation relay and the Mechatro controller. A. If error code R034 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–1–16. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay coil, replace the fuse and relay box. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R044-Failure of washer motor relay. [54410369] SK170-9 LA

Cause: Symptom: Washer motor does not move. Condition: The Mechatro controller output to the Washer motor relay is short-circuited with the power source. 1. Failure of the Washer motor relay R-32 . 2. Faulty wiring or bad connection between R-32 and the Mechatro controller. 3. Faulty Fuse and relay box. 4. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Washer motor relay. R-32.

RAIL12CEX0815FA

1


RLY-31: Prevent spark relay (arc prevention) RLY-29: Wiper motor relay (forward rotation) RLY-30: Wiper motor reversing relay

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(4) (5)

RLY-32: Window washer motor relay E-1 Fuse and relay box

RAIL12CEX0818AA

2

A. Verify the current conditions using the service diagnosis screen number 19, Motor relay. Turn the key switch OFF and remove relay R-32 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-32 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Washer motor relay and the Mechatro controller. A. If error code R044 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–1–2. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay coil, replace the fuse and relay box. Go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R134-Failure of swing flasher right relay. [54410467] SK170-9 LA

Cause: Symptom: Right swing flasher does not light. Condition: The Mechatro controller output to the Swing flasher right relay is short-circuited with the power source. 1. Failure of the Swing flasher right relay R-19 . 2. Faulty wiring or bad connection between R-19 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Swing flasher right relay. R-19.

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RAIL12CEX0816GA

1


R-19: Flasher relay L-3: Swing flasher left and working light unit L-4: Swing flasher right and working light unit Mechatro controller

A. Verify the current conditions using the service diagnosis screen number 16, D13. Turn the key switch OFF and remove connector CN-74F from the Flasher relay. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-19 between pin H and C, and pin H and B. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Swing flasher right relay and the Mechatro controller. A. If error code R134 is still displayed with the relay removed, check for 24 V on the relay (-) line CN–74F–5. If no voltage is found go to step 4. 47454079-DRAFT 06/11/2012

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B. If voltage is found on the (-) side of the relay coil, replace the faulty wiring and go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R144-Failure of swing flasher left relay. [54410518] SK170-9 LA

Cause: Symptom: Left swing flasher does not light. Condition: The Mechatro controller output to the Swing flasher left relay is short-circuited with the power source. 1. Failure of the Swing flasher left relay R-19 . 2. Faulty wiring or bad connection between R-19 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Swing flasher left relay. R-19.

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RAIL12CEX0816GA

1


R-19: Flasher relay L-3: Swing flasher left and working light unit L-4: Swing flasher right and working light unit Mechatro controller

A. Verify the current conditions using the service diagnosis screen number 17, D14. Turn the key switch OFF and remove connector CN-74F from the Flasher relay. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-19 between pin H and C, and pin H and B. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Swing flasher left relay and the Mechatro controller. A. If error code R144 is still displayed with the relay removed, check for 24 V on the relay (-) line CN–74F–5. If no voltage is found go to step 4. 47454079-DRAFT 06/11/2012

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B. If voltage is found on the (-) side of the relay coil, replace the faulty wiring and go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R154-Failure of travel alarm relay. [54410614] SK170-9 LA

Cause: Symptom: Travel alarm does not actuate. Condition: The Mechatro controller output to the Travel alarm relay is short-circuited with the power source. 1. Failure of the Travel alarm relay R-8 . 2. Faulty wiring or bad connection between R-8 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Travel alarm relay. R-8.

RAIL12CEX0817EA

1

RAIL12CEX0818AA

2


R-8: Travel alarm relay E-1: Fuse and relay box

A. Verify the current conditions using the service diagnosis screen number 17, D15 . Turn the key switch OFF and remove relay R-8 from the fuse box. Turn the key switch on and check if the error condition still exists. If

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the error has cleared, check for resistance on R-8 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Travel alarm relay and the Mechatro controller. A. If error code R154 is still displayed with the relay removed, check for 24 V on the relay socket (-) line CN2–2–2. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay socket, replace the fuse box and go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R164-Failure of auto idling stop relay 2. [54410694] SK170-9 LA

Cause: Symptom: Auto idle stop relay 2 does not actuate. Condition: The Mechatro controller output to the Auto idle stop relay 2 is short-circuited with the power source. 1. Failure of the Auto idle stop relay 2 R-24 . 2. Faulty wiring or bad connection between R-24 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Auto idle stop relay 2. R-24.

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RAIL12CEX0813GA

1




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RAIL12CEX0818AA

2

A. Verify the current conditions using the service diagnosis screen number 4, K-1 AIS relay 2. Turn the key switch OFF and remove relay R-24 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-24 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Auto idle stop relay 2 and the Mechatro controller. A. If error code R164 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–2–6. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay socket, replace the fuse box and go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R174-Failure of engine forcible stop relay. [54410744] SK170-9 LA

Cause: Symptom: Engine auto idle stop function does not actuate. When turning the key switch OFF the engine does not stop. Condition: The Mechatro controller output to the Engine emergency stop relay is short-circuited with the power source. 1. Failure of the Engine emergency stop relay R-25 . 2. Faulty wiring or bad connection between R-25 and the Mechatro controller. 3. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Engine emergency stop relay R-25.

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RAIL12CEX0813GA

1




A. Verify the current conditions using the service diagnosis screen number 4, K-3 ENG STOP. Turn the key switch OFF and remove relay R-25 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-25 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Engine emergency stop relay and the Mechatro controller. 47454079-DRAFT 06/11/2012

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A. If error code R174 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–2–5. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay socket, replace the fuse box and go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R184-Failure of lever lock relay. [54410778] SK170-9 LA

Cause: Symptom: Safety lock lever timer does not actuate. Condition: The Mechatro controller output to the Lever lock relay is short-circuited with the power source. 1. Failure of the Lever lock relay R-26 . 2. Faulty wiring or bad connection between R-26 and the Mechatro controller. 3. Faulty Fuse and relay box. 4. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Lever lock relay R-26.

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RAIL12CEX0813GA

1




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RAIL12CEX0818AA

2

A. Verify the current conditions using the service diagnosis screen number 4, K-4 Lock lever. Turn the key switch OFF and remove relay R-26 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-26 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Lever lock relay and the Mechatro controller. A. If error code R184 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–2–19. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay socket, replace the fuse box and go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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R214-Failure of safety relay. [54410884] SK170-9 LA

Cause: Symptom: Safety relay does not actuate. Condition: The Mechatro controller output to the Safety relay is short-circuited with the power source. 1. Failure of the Safety relay R-4 . 2. Faulty wiring or bad connection between R-4 and the Mechatro controller. 3. Faulty Fuse and relay box. 4. Faulty Mechatro controller. Solution: 1. Verify the fault code is still active on the Gauge Cluster Display. Refer to the Trouble History section in the Service Diagnosis screen if the fault is not currently active. To access the Service Diagnosis screen hold down the buzzer stop switch and turn the key switch ON. Hold down the menu switch and press the buzzer stop switch 3 times to access the Service Menu. Use the UP and DOWN keys to highlight Trouble History and press the NEXT key. A. If the fault code is still actively displayed, turn the key switch OFF and back ON. If the fault code is still active go to step 2. B. If the fault code is not displayed return the unit to service. 2. Check the Safety relay R-4.

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RAIL12CEX0813GA

1




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RAIL12CEX0818AA

2

A. Verify the current conditions using the service diagnosis screen number 4, K-2 Safety rly. Turn the key switch OFF and remove relay R-4 from the fuse and relay box. Turn the key switch on and check if the error condition still exists. If the error has cleared, check for resistance on R-4 between pin 1 and 2. If the resistance reads less than 10 Ω go to step 3. B. If the resistance reads higher than 10 Ω or an open circuit, replace the relay and go to step 1 to confirm elimination of the fault. 3. Check the wiring between the Safety relay and the Mechatro controller. A. If error code R214 is still displayed with the relay removed, check for 24 V on the relay (-) line CN2–2–20. If no voltage is found go to step 4. B. If voltage is found on the (-) side of the relay socket, replace the fuse box and go to step 1 to confirm elimination of the fault. 4. Replace the Mechatro controller. A. Return to step 1 to confirm elimination of the fault.

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Index Electrical systems - 55 FAULT CODES - DTC A025-Pump proportional valve adjustment is missing or out of range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SK170-9 LA

A035-Unload valve adjustment is missing or out of range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SK170-9 LA

A215-ROM adjustment written data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA

A225-Writing of ROM adjustment data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA

A235-ROM hour meter written data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

A245-Writing of ROM hour meter data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA

A255-Proportional valve adjustment written data is incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SK170-9 LA

B012-Incorrect output of boom up pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA

B013-Open-circuit of boom up pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SK170-9 LA

B014-Short-circuit of boom up pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SK170-9 LA

B022-Incorrect output of boom down pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA

B023-Open-circuit of Boom down pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SK170-9 LA

B024-Short-circuit of Boom down pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SK170-9 LA

B032-Incorrect output of arm out pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SK170-9 LA

B033-Open-circuit of arm out pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SK170-9 LA

B034-Short-circuit of arm out pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SK170-9 LA

B042-Incorrect output of arm in pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SK170-9 LA

B043-Open-circuit of arm in pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SK170-9 LA

B044-Short-circuit of arm in pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SK170-9 LA

B052-Incorrect output of bucket digging pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SK170-9 LA

B053-Open-circuit of bucket digging pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SK170-9 LA

B054-Short-circuit of bucket digging pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 SK170-9 LA

B062-Incorrect output of bucket dump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 SK170-9 LA

B063-Open-circuit of bucket dump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 SK170-9 LA

B064-Short-circuit of bucket dump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 SK170-9 LA

B072-Incorrect output of swing pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 SK170-9 LA

B073-Open-circuit of swing pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 SK170-9 LA

B074-Short-circuit of swing pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 SK170-9 LA

B092-Incorrect output of travel right pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 SK170-9 LA

B093-Open-circuit of travel right pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 SK170-9 LA

B094-Short-circuit of travel right pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SK170-9 LA

B102-Incorrect output of travel left pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SK170-9 LA

B103-Open-circuit of travel left pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 SK170-9 LA

B104-Short-circuit of travel left pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 SK170-9 LA

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B113-Open-circuit of pressure sensor of optional selector positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 SK170-9 LA

B114-Short-circuit of pressure sensor of optional selector positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 SK170-9 LA

B162-Incorrect output of P1 optional side pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 SK170-9 LA

B163-Open-circuit of P1 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 SK170-9 LA

B164-Short-circuit of P1 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 SK170-9 LA

B172-Incorrect output of P2 optional side pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 SK170-9 LA

B173-Open-circuit of P2 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 SK170-9 LA

B174-Short-circuit of P2 side optional pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 SK170-9 LA

C012-Incorrect output of P1 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 SK170-9 LA

C013-Open-circuit of P1 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SK170-9 LA

C014-Short-circuit of P1 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 SK170-9 LA

C022-Incorrect output of P2 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 SK170-9 LA

C023-Open-circuit of P2 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 SK170-9 LA

C024-Short-circuit of P2 pump pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 SK170-9 LA

C033-Open-circuit of boom head pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 SK170-9 LA

C034-Short-circuit of boom head pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 SK170-9 LA

C043-Open-circuit of boom rod pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 SK170-9 LA

C044-Short-circuit of boom rod pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 D012-Failure of output transistor ON at P1 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 SK170-9 LA

D013-Open-circuit of P1 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 SK170-9 LA

D022-Failure of output transistor ON at P2 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 SK170-9 LA

D023-Open-circuit of P2 unload proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 SK170-9 LA

D033-Open-circuit of travel straight proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 SK170-9 LA

D062-Failure of output transistor ON at arm in high speed proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 SK170-9 LA

D063-Open-circuit of arm in high speed proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 SK170-9 LA

D153-Open-circuit of proportional bypass valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 SK170-9 LA

E012-Failure of output transistor ON at P1 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 SK170-9 LA

E013-Open-circuit of P1 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 SK170-9 LA

E022-Failure of output transistor ON at P2 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 SK170-9 LA

E023-Open-circuit of P2 pump proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 SK170-9 LA

E032-Failure of output transistor ON at Optional relief adjusting proportional valve 1. . . . . . . . . . . . . . . . . . . . . . 126 SK170-9 LA

E033-Open-circuit of optional relief adjusting proportional valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 SK170-9 LA

E042-Failure of output transistor ON at Optional relief adjusting proportional valve 2. . . . . . . . . . . . . . . . . . . . . . 130 SK170-9 LA

E043-Open-circuit of optional relief adjusting proportional valve 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 SK170-9 LA

F011-Failure of output transistor OFF and GND short of attachment boost SOL valve. . . . . . . . . . . . . . . . . . . . . . 134 SK170-9 LA

F013-Failure of output transistor ON and open-circuit of attachment boost SOL valve. . . . . . . . . . . . . . . . . . . . . . 136 SK170-9 LA

F021-Failure of output transistor OFF and GND short of swing parking SOL valve. . . . . . . . . . . . . . . . . . . . . . . . . 138 SK170-9 LA

F023-Failure of output transistor ON and open-circuit of swing parking SOL valve. . . . . . . . . . . . . . . . . . . . . . . . . 140 SK170-9 LA

F031-Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve. . . . . . . . . . . . . . . . . . . . . . 142 SK170-9 LA

F033-Failure of output transistor ON and open-circuit of travel 1-2 speed SOL valve. . . . . . . . . . . . . . . . . . . . . . . 144 SK170-9 LA

F041-Failure of output transistor OFF and GND short of optional selector SOL valve. . . . . . . . . . . . . . . . . . . . . . 146 SK170-9 LA

F043-Failure of output transistor ON and open-circuit of option selector SOL valve. . . . . . . . . . . . . . . . . . . . . . . . 148 SK170-9 LA 47454079-DRAFT 06/11/2012

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G032-Overrun of speed sensor of direct input Mechatro controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 SK170-9 LA

G033-Open-circuit of speed sensor of direct input Mechatro controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 SK170-9 LA

G042-Overrun of speed sensor of direct input Mechatro controller and received data from E/G controller. . . . . 154 SK170-9 LA

G043-Open-circuit of speed sensor of direct input Mechatro controller and received data from E/G controller. 157 SK170-9 LA

H013-Open-circuit of acceleration potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 SK170-9 LA

H014-Short-circuit of acceleration potentiometer power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 SK170-9 LA

H023-Open-circuit of boom angle potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 SK170-9 LA

H024-Short-circuit of boom angle potentiometer power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 SK170-9 LA

H033-Open-circuit of arm angle potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 SK170-9 LA

H034-Short-circuit of arm angle potentiometer power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 SK170-9 LA

H091-Short-circuit of fuel sensor ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 SK170-9 LA

H093-Open-circuit of fuel sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 SK170-9 LA

I111-Receive error of CAN1 communication (passive error). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 SK170-9 LA

I113-Receive error of CAN1 communication (time-out). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 SK170-9 LA

I121-Transmission of CAN1 communication is abnormal (busoff). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 SK170-9 LA

I211-Reception of CAN1 communication is abnormal (passive error). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 SK170-9 LA

I213-Reception of CAN2 communication is abnormal (time-out). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 SK170-9 LA

I221-Transmission of CAN2 communication is abnormal (busoff). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 SK170-9 LA

K014-Battery relay contact welded closed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 SK170-9 LA

R014-Failure of wiper motor arc prevention relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 SK170-9 LA

R024-Failure of wiper motor normal rotation relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 SK170-9 LA

R034-Failure of wiper motor reverse rotation relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 SK170-9 LA

R044-Failure of washer motor relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 SK170-9 LA

R134-Failure of swing flasher right relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 SK170-9 LA

R144-Failure of swing flasher left relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 SK170-9 LA

R154-Failure of travel alarm relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 SK170-9 LA

R164-Failure of auto idling stop relay 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 SK170-9 LA

R174-Failure of engine forcible stop relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 SK170-9 LA

R184-Failure of lever lock relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 SK170-9 LA

R214-Failure of safety relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 SK170-9 LA

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47454079-DRAFT 06/11/2012 EN

SERVICE MANUAL Booms, dippers, and buckets

SK170-9

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84

Contents Booms, dippers, and buckets - 84

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.100 SK170-9

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.910 SK170-9

Dipper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.912 SK170-9

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Booms, dippers, and buckets - 84 Bucket - 100

SK170-9

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Contents Booms, dippers, and buckets - 84 Bucket - 100

SERVICE Bucket Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Bucket teeth Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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Booms, dippers, and buckets - Bucket

Bucket - Remove [60264758] SK170-9 LA

Removing the bucket •

Place the machine on a firm and flat surface and rest the bucket on the ground in a stable position.

•

Place o-rings (1) out of the relevant seats. Remove the pins and the retaining rings of the pins.

•

Remove pin (E) and pin (B); then remove the bucket.

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RAPH12CEX1094AA

1

RAPH12CEX1095AA

2


Bucket - Install [60264782] SK170-9 LA

1.

Using a suitable hoist, place the bucket on the same level as the tracks.

2.

Place o-rings (1) outside their seats.

3.

Using the arm cylinder control and boom cylinder control, make small vertical and horizontal movements to insert the pivot pin (B) connecting the bucket to the arm into the hole (A).

4.

Use the bucket cylinder control to align the connecting rod (C) to hole (D) and insert pivot pin (E).

5.

Secure pivot pins using lock pins and retaining rings and reposition the o-rings into their seats.

RAPH12CEX1094AA

1

RAPH12CEX1095AA

2

RAPH12CEX1096AA

3

Adjusting bucket play Bucket play (g) is adjusted by changing the total shims installed. NOTE: Bucket play (g) should be 0.5 - 1.5 mm (0.02 - 0.06 in) If bucket play (g) exceeds the specified value, increase the adjusting shims as follows: •

Loosen the three bolts (2) taking care to retrieve the washers. Slide out the ring (1).

•

Add adjusting shims (3) until the bucket play is within the acceptable measurement.

•

Install the ring (1), and tighten the securing bolts (2).

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Bucket teeth - Replace [60280846] SK170-9 LA

WARNING Eye injury hazard! Avoid eye injury when using a drill, hammer, saw, or other tools that may cause chips to fly. Always wear safety glasses when working. Failure to comply could result in death or serious injury. W0174A

1.

Ensure the machine is parked on a level surface.

2.

Rest the bucket on the ground.

3.

Switch off the Auto-Idle, fully turn the engine speed manual control counter-clockwise, stop the engine, remove the ignition key and move the safety lever in the locked position.

4.

Use a hammer and punch to push lock pin (1) out of its seat and remove the tip of the bucket tooth (2).

NOTE: To push lock pin (1) out of its seat, strike it with a punch on its upper side. 5.

Install a new rubber insert (3) inside the lock pin (1).

6.

Clean the surface of the bucket tooth (4) and insert a new tip.

7.

Insert the lock pin (1) into its seat using a punch and hammer, until it is fully mounted.

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RAPH12CEX1097AA

1

Index Booms, dippers, and buckets - 84 Bucket - 100 Bucket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Bucket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Bucket teeth - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SK170-9 LA

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Booms, dippers, and buckets - 84 Boom - 910

SK170-9

47454079-DRAFT 06/11/2012

84.910 / 1

Contents Booms, dippers, and buckets - 84 Boom - 910

TECHNICAL DATA Boom Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

SERVICE Boom Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

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Booms, dippers, and buckets - Boom

Boom - Service limits [60213231] SK170-9 LA

RAPH12CEX1092EA

Ref. A B

C

D E

F

G

H

I J K

Part Name Pin Bushing Pin Boss (Main Frame) Bushing (Boom Cylinder) Pin Bushing (Boom Cylinder) Boss (Boom) Pin Bushing Pin Boss (Arm) Bushing (Arm Cylinder) Pin Boss (Arm) Bushing (Arm Cylinder) Pin Boss (Arm) Bushing (Arm Cylinder) Pin Bushing Bushing (Bucket Cylinder) Pin Bushing Pin Bushing Pin Bushing

85 85 85 85 85 80 80 80 80 80 70 70 70 70 65 80 80

1

Standard 85 mm (3.35 in) mm (3.35 in) 85 mm (3.35 in) mm (3.35 in) mm (3.35 in) 85 mm (3.35 in) mm (3.35 in) mm (3.35 in) 80 mm (3.15 in) mm (3.15 in) 80 mm (3.15 in) mm (3.15 in) mm (3.15 in) 80 mm (3.15 in) mm (3.15 in) mm (3.15 in) 70 mm (2.76 in) mm (2.76 in) mm (2.76 in) 70 mm (2.76 in) mm (2.76 in) mm (2.76 in) 65 mm (2.56 in) mm (2.56 in) 80 mm (3.15 in) mm (3.15 in) 80 mm (3.15 in) mm (3.15 in)

NOTICE: Be sure to install front attachment bushing using a press.

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Allowable Limit 84 mm (3.31 in) 86.5 mm (3.41 in) 84 mm (3.31 in) 86.5 mm (3.41 in) 86.5 mm (3.41 in) 84 mm (3.31 in) 86.5 mm (3.41 in) 86.5 mm (3.41 in) 79 mm (3.11 in) 85.5 mm (3.37 in) 79 mm (3.11 in) 81.5 mm (3.21 in) 81.5 mm (3.21 in) 79 mm (3.11 in) 81.5 mm (3.21 in) 81.5 mm (3.21 in) 69 mm (2.72 in) 71.5 mm (2.81 in) 71.5 mm (2.81 in) 69 mm (2.72 in) 71.5 mm (2.81 in) 71.5 mm (2.81 in) 64 mm (2.52 in) 66.5 mm (2.62 in) 79 mm (3.11 in) 81.5 mm (3.21 in) 79 mm (3.11 in) 81.5 mm (3.21 in)

Remedy

Replace


Boom - Remove [60165026] SK170-9 LA


CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B

1.

Park the machine on firm, level ground. Position the front attachment as illustrated and lower the bucket to the ground.

2.

Disconnect lubrication hoses (1) from the boom cylinder rod end.

3.

Loosen lock nuts (2), remove bolt (3) and stopper (4) from boom cylinder rod end. Carry our the same procedure for the other boom cylinder.

4.

Attach each boom cylinder to a crane. Remove cylinder rod end pin (5) and shims (6) using a hammer and bar.

NOTE: Boom cylinder weight: 150 kg (331 lb) 5.

Slowly lower the boom cylinder onto a wooden block using the crane.

6.

Press the valve located on the hydraulic oil tank fill cap. This will bleed the residual pressure inside the tank itself. Complete the bleeding of the tank by holding in the valve until the hissing stops.

7.

Disconnect hoses (7) and (8) of the bucket cylinder and the arm cylinder. Attach plugs to the disconnected hoses to prevent contamination.

NOTE: If the machine is equipped with a hammer, nibblerbreaker, or lock valves variants, disconnect the relevant hoses (9), (10) and (11). 8.

Disconnect centralized lubrication hoses (12) located between the boom cylinders.

9.

Disconnect the electrical connection for the lights.

10.

Sling the boom to a hoist. Slightly lift the boom.

NOTE: Approximate mass of the front equipment: 2700 kg (5952 lb) 11.

Loosen lock nuts (16) and remove bolt (17). 47454079-DRAFT 06/11/2012

84.910 / 4


12.

Pull out the boom lower pivot pin (18) to the frame using the appropriate puller.

13.

Lift the front attachment. Move the machine away from the front attachment and the hoist.

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Boom - Install [60202171] SK170-9 LA

1.

Lift the front attachment.

NOTE: Approximate mass of the front equipment: 3200 kg (7055 lb) 2.

Install dust seals to boom foot. Align the boom foot boss with the main frame boss. insert a thrust plate to both the right and the left sides of the boom foot boss to take out clearance between the boom foot boss and the main frame boss.

3.

Install boom foot pin (18) using a hammer and bar.

4.

Install bolt (17) and tighten lock nuts (16). Torque nuts (16) to 200 N·m (147.5 lb ft)

5.

Connect hoses (7) and (8) of the bucket and arm cylinder. Hose torque specifications:

6.

•

Bucket (7) and arm (8) cylinder hoses: 159 - 195 N·m (117.3 - 143.8 lb ft)

•

Hammer/Crusher hoses (9): 159 - 195 N·m (117.3 - 143.8 lb ft)

•

Bucket rotation hoses (10): 73 - 83 N·m (53.8 - 61.2 lb ft)

•

Anti-drop valve hoses (11): 44 - 54 N·m (32.5 - 39.8 lb ft)

Attach the boom cylinder to a crane. Lift the boom cylinder and align the boom cylinder rod with the pin hole on the boom.

NOTE: Boom cylinder weight: 150 kg (331 lb) . For easy alignment, start the engine and use the boom control lever. 7.

Install shims (6) and insert pin (5).

8.

Install stopper (4), tighten bolts (3) and lock nuts (2). Torque to 147 N·m (108 lb ft)

9.

Connect lubrication hoses (1) to boom cylinder rod. Torque to 20 N·m (14.8 lb ft)

10.

Connect the centralized lubrication hoses (12) located between the boom cylinders. Torque to 20 N·m (14.8 lb ft).

11.

Using a grease gun, inject grease via grease nipple (16)(boom) and (17)(boom cylinders).

NOTE: Fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at idle. Check the hose connections for any oil leakage. NOTICE: Be sure to bleed air from the hydraulic circuit. 12.

Connect the electrical connector for the boom lights (13) .

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Index Booms, dippers, and buckets - 84 Boom - 910 Boom - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SK170-9 LA

Boom - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Boom - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Booms, dippers, and buckets - 84 Dipper arm - 912

SK170-9

47454079-DRAFT 06/11/2012

84.912 / 1

Contents Booms, dippers, and buckets - 84 Dipper arm - 912

TECHNICAL DATA Dipper arm General specification – Standard Dimensions for Arm and Bucket Connection . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Booms, dippers, and buckets - Dipper arm

Dipper arm - General specification – Standard Dimensions for Arm and Bucket Connection [60217854] SK170-9 LA

RAPH12CEX1093EA

1

Dimension

Ref. a(*) a(**) b(*) b(**) c d e f g h I j k l m n o p q

329 mm (12.95 in) 330 mm (12.99 in) 50 mm (1.97 in) 42 mm (1.65 in) 580 mm (22.83 in) 525 mm (20.67 in) 400.1 mm (15.75 in) 1373 mm (54.06 in) 427 mm (16.81 in) 320 mm (12.60 in) 70 mm (2.76 in) 399 mm (15.71 in) 30 mm (1.18 in) 427 mm (16.81 in) 301 mm (11.85 in) 70 mm (2.76 in) 45 ° 0° 445 mm (17.52 in)

(*) Arm : 2200 mm (86.6 in) (**) Arm : 2600 mm (102.4 in) / 3100 mm (122.0 in)

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Index Booms, dippers, and buckets - 84 Dipper arm - 912 Dipper arm - General specification – Standard Dimensions for Arm and Bucket Connection . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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47454079-DRAFT 06/11/2012 EN

SERVICE MANUAL Platform, cab, bodywork, and decals

SK170-9

47454079-DRAFT 06/11/2012

90

Contents Platform, cab, bodywork, and decals - 90

Machine shields and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.105 SK170-9

Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124 SK170-9

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150 SK170-9

47454079-DRAFT 06/11/2012

90

Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

SK170-9

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90.105 / 1

Contents Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

SERVICE Side shields Remove Removal of the guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Install Installation of the guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Lower guard Remove Removal of under covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

Install Installation of under covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA

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Platform, cab, bodywork, and decals - Machine shields and guards

Side shields - Remove Removal of the guards [50447299] SK170-9 LA


Remove the guard in the following order: (1) –> (5) –> (7) –> (8)–> (18) –> (19) –> (26) –> (28) –> (29) –> (30).

2.

If any of the covers are locked, open them with the ignition key.

RAPH12CEX0565AA

1

RAPH12CEX0566AA

2

RAPH12CEX0567AA

3

Guard removal 1.

2.

Remove the hood assembly (1). 1.

Unlock catch (2), unlatch catches (2) and (3) and open hood (1).

2.

Remove 4 nuts (4) M12.

3.

Remove hood (1). Weight: 38 kg (84 lb)

Remove guard (5). 1.

Remove 6 sems bolts (6) M12x25.

2.

Remove guard (5). Weight: 14 kg (31 lb)

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3.

4.

5.

Remove guard (7) and guard (8). 1.

Remove 6 bolts (6) M12x25.

2.

Remove guard (7). Weight: 8.4 kg (19 lb)

3.


4.

Remove guard (8). Weight: 9.4 kg (21 lb)

RAPH12CEX0568AA

4

RAPH12CEX0569AA

5

RAPH12CEX0570AA

6

Remove stay (19). 1.


2.


3.

Remove clamp (12) and (13).

4.

Remove a sems bolt (14) M12x65.

5.

Remove a sems bolt (15) M10x55.

6.

Remove clamp (16), and bracket (17) and stay (9). Wight: 12 kg (26 lb)

Remove guard assembly (18) and covers (19), and (20). 1.

Unlock and open guard assembly (18).

2.

Loosen 4 sems bolts (21) M10x60 and remove guard assembly (18). Weight: 10.6 kg (23.4 lb)

3.

Remove 4 sems bolts (22) M12x30 and 1 sems bolt (23) M12x25.

4.

Remove plate (24). Weight: 1.5 kg (3 lb)

5.

Remove cover (19). Weight: 3.8 kg (8.4 lb)

6.


7.

Remove cover (20). Weight: 9 kg (20 lb)

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6.

7.

8.

Remove panel assembly (26). 1.

Unlock panel assembly (26).

2.


3.

Remove panel assembly (26). Weight: 14 kg (31 lb)

RAPH12CEX0571AA

7

RAPH12CEX0572AA

8

RAPH12CEX0573AA

9



2.

Remove panel assembly (28). Weight: 8.2 kg (18.1 lb)


Unlock and open panel assembly (29).

2.


3.

Remove panel assembly (29). Weight: 14.9 kg (32.8 lb)

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NOTE: Remove battery relay box before removing the pillar (31) below. 9.

10.

11.

Remove beam (30) and pillar (31), (32). 1.

Loosen 6 sems bolts (6) M12x25.

2.

Remove beam (30). Weight: 9.3 kg (20.5 lb)

3.

Loosen 2 capscrews (33) M12x40 and one capscrew M12x35 and remove pillar (31). Weight: 10.3 kg (22.7 lb)

4.

Loosen 2 sems bolts (33) M12x30 and remove pillar (32). Weight: 4.8 kg (10.6 lb)

RAPH12CEX0577AA

10

RAPH12CEX0574AA

11

RAPH12CEX0575AA

12

Remove guard assembly (35), (36), and (37). 1.


2.

Loosen 4 sems bolts (6) M12x25, 2 sems bolts (22)M12x30 and remove guard assembly (36). Weight: 18.6 kg (41.0 lb)

3.


Remove guard assembly (38). 1.


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12.

Remove pillar (39). 1.

Loosen 3 sems bolts (33) M12x30 and remove pillar (39). Weight: 11.2 kg (24.7 lb)

RAPH12CEX0576AA

13.

Remove other brackets, as required.

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13


Side shields - Install Installation of the guards [54100258] SK170-9 LA

1.

Installation is the reverse of removing.

2.

Tightening torque: NUT

SIZE M8 M10 M12 M16

46.5 N·m (34.3 lb ft)

SEMS BOLTS 20.7 - 25.3 N·m (15.3 - 18.7 lb ft) 58.5 - 71.5 N·m (43.1 - 52.7 lb ft) 72 - 88 N·m (53.1 - 64.9 lb ft) 172 - 210 N·m (126.9 - 154.9 lb ft)

Installation 1.

Install pillar (39). 1.

2.

Tighten the sems bolts (33) M12x30

RAPH12CEX0576AA

1

RAPH12CEX0575AA

2

Install guard assembly (38). 1.

Attach the guard assembly. Tighten the sems bolts (6)M12x25.

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3.

4.

5.

Install guard assembly (35), (36), and (37). 1.

Attach guard assembly (37). Tighten the sems bolts (6) M12x25.

2.

Attach guard assembly (36). Tighten the sems bolts (6) M12x25, and the other sems bolts (22) M12x30.

3.

Attach guard assembly (35). Tighten the sems bolts (6) M12x25.

RAPH12CEX0574AA

3

RAPH12CEX0577AA

4

RAPH12CEX0573AA

5

Install beam (30) and pillar (31), (32). 1.

Attach pillar (32). Tighten the sems bolts (33) M12x30.

2.

Attach pillar (31). Tighten the capscrews (33) M12x40 and capscrew (34) M12x35

3.

Attach beam (30). Tighten the sems bolts (6) M12x25.

Install panel assembly (29). 1.

Attach panel assembly (29).

2.

Tighten nuts (27) M10.

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6.

7.

8.



2.


RAPH12CEX0572AA

6

RAPH12CEX0571AA

7

RAPH12CEX0570AA

8



2.


Install guard assembly (18) and covers (19), (20). 1.

Attach cover (20).

2.

Tighten the sems bolts (25) M12x25.

3.

Attach cover (19).

4.

Attach plate (24).

5.

Tighten the sems bolts (22) M12x30 and sems bolt (23) M12x25.

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9.

Install stay (9) 1.

Install clamp (16), bracket (17) and stay (9).

2.

Tighten sems bolt (15) M10x55.

3.

Tighten sems bolt (14) M12x65.

4.

Install clamp (12) and plate (13).

5.

Tighten sems bolts (11) M12x30.

6.


RAPH12CEX0569AA

10.

11.

9

Install guard (7) and guard (8). 1.

Attach guard (8).

2.


3.


RAPH12CEX0568AA

10

RAPH12CEX0567AA

11

Install guard (5). 1.

Attach guard (5).

2.

Tighten sems bolts (6)M12x25.

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12.

Install hood assembly (1). 1.

Attach hood (1).

2.


RAPH12CEX0566AA

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12


Lower guard - Remove Removal of under covers [54223332] SK170-9 LA

1.

Remove attaching sems bolts (11) M12x30 and (12) M12x40.

2.

Remove under covers (1), (2), (3), (4), (5), (6), (7) and (8).

RAPH12CEX0578FA

1

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Lower guard - Install Installation of under covers [54223354] SK170-9 LA

1.

Install under cover (1), (2), (3), (4), (5), (6), (7) and (8) tightening sems bolts (11) M12x30 and (12) M12x40.

2.

Torque sems bolts to 80 N·m (59 lb ft).

RAPH12CEX0578FA

1

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Index Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105 Lower guard - Install Installation of under covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SK170-9 LA

Lower guard - Remove Removal of under covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SK170-9 LA

Side shields - Install Installation of the guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SK170-9 LA

Side shields - Remove Removal of the guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124

SK170-9

47454079-DRAFT 06/11/2012

90.124 / 1

Contents Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124

SERVICE Pneumatically-adjusted operator seat Remove Removal of the operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

Install Installation of operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Remove Removal of the operator seat [53770583] SK170-9 LA

1.

Remove the head rest (2) of the operator’s seat (1) ease handling.

2.

Move the whole control stand to its foremost position.

3.

Move the operator’s seat to its forward end.

4.

Incline the reclining seat as forward as possible.

5.

Remove two capscrews (3) M8x20 from the upper rail. Then move the control stand to its rearmost end and remove two capscrews (3) M8x20.

6.

Remove the operator’s seat.

NOTE: Weight of mechanical seat: about 28 kg (62 lb). Weight of the pneumatic heated seat: about 38 kg (84 lb) Carry out the following operations as required. 7.

Remove seat belt (4), bracket (5), removing screws (6) M8x18 and (11) M8x20.

8.

Remove bracket assembly (12) and rail (13).

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Install Installation of operator seat [53770603] SK170-9 LA

1.

Install the bracket assembly (12) and the rail (13).

2.

Install armrest (8) and (9), using screw (10) M8x18 and (11) M8x18.

3.

Install bracket (5), seat belt (4), using screws (6) M10x20 and (7).

4.

Install the operators seat (1).

5.

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Index Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124 Pneumatically-adjusted operator seat - Install Installation of operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA

Pneumatically-adjusted operator seat - Remove Removal of the operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Platform, cab, bodywork, and decals - 90 Cab - 150

SK170-9

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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Platform, cab, bodywork, and decals - Cab

Cab - Remove [56146464] SK170-9 LA

Removal of the cab 1.

Remove the floor mat.

2.

Remove cover assembly (1). 1.

Remove cover (2) and loosen sems bolts (3) M6x20.

2.

Disconnect harness connector of power socket and remove cover assembly (1)

RAPH12CEX0592BA

3.

4.

5.

6.


Remove cover (5) and loosen sems bolts (3) M6x20.

2.

Remove cover assembly (4).

Remove the harness connector. 1.

Disconnect connectors of cab harness at rear right of cab.

2.

Disconnect antenna cable of radio located at rear left of cab.

3.

Disconnect harness for cab light located at rear right of cab.


Loosen sems bolts (3) M6x20.

2.

Disconnect harness connector for the hour meter and remove cover assembly (6).

Remove the plastic tube for the window washer from the rear left of the cab.

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1

Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA

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SCHEMAS INDEX Reference Electrical system - Electrical schematic frame 01 Electrical system - Electrical schematic frame 02 Electrical system - Electrical schematic frame 03 Electrical system - Electrical schematic frame 04 Electrical system - Electrical schematic frame 05 Electrical system - Electrical schematic frame 06 Electrical system - Electrical schematic frame 07 Electrical system - Electrical schematic frame 08 Electrical system - Electrical schematic frame 09 Electrical system - Electrical schematic frame 10 Electrical system - Electrical schematic frame 11 Electrical system - Electrical schematic frame 12 Electrical system - Electrical schematic frame 13 Electrical system - Electrical schematic frame 14 Hydraulic systems - Hydraulic schematic frame 01 – Hydraulic Circuit Summary Hydraulic systems - Hydraulic schematic frame 02 Hydraulic systems - Hydraulic schematic frame 04 – 4. HOLDING VALVE FOR BOOM AND ARM Hydraulic systems - Hydraulic schematic frame 05 - PROPORTIONAL HAND CONTROL EXTRA HYDRAULIC CIRCUIT WITH PRESSURE UNLOAD Hydraulic systems - Hydraulic schematic frame 06 Hydraulic systems - Hydraulic schematic frame 07 Hydraulic systems - Hydraulic schematic frame 08 Hydraulic systems - Hydraulic schematic frame 09 Hydraulic systems - Hydraulic schematic frame 10 Hydraulic systems - Hydraulic schematic frame 11 Hydraulic systems - Hydraulic schematic frame 12 Hydraulic systems - Hydraulic schematic frame 13 Hydraulic systems - Hydraulic schematic frame 14 Hydraulic systems - Hydraulic schematic frame 15 Hydraulic systems - Hydraulic schematic frame 16 Hydraulic systems - Hydraulic schematic frame 17

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PAGE 55.000 55.000 55.000 55.000 55.000 55.000 55.000 55.000 55.000 55.000 55.000 55.000 55.000 55.000 35.000 35.000 35.000

/ / / / / / / / / / / / / / / / /

18 22 27 32 36 38 40 42 44 46 48 50 52 54 12 13 19

35.000 / 23 35.000 35.000 35.000 35.000 35.000 35.000 35.000 35.000 35.000 35.000 35.000 35.000

/ / / / / / / / / / / /

27 33 39 45 49 53 57 61 65 69 73 77

SPECIAL TOOL INDEX Genuine 380001055 [Pilot Valve Joint Disassembling Tool] 380001055 [Pilot Valve Joint Disassembling Tool]

Reference

PAGE

Cab controls - Disassemble Right and Left Pilot Valve

55.512 / 11

Cab controls - Assemble – Right and Left Pilot Valve Assembly

55.512 / 15

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Excavadora Kobelco SK170 Motor Hino

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