Kobelco SK330-8 Shop Manual
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Kobelco SK330-8 Shop Manual

Kobelco SK330-8 Shop Manual

Hydraulic excavator
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SHOP
MANUAL
INDEX
1
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Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]
HYDRAULIC EXCAVATOR
model
SPECIFICATIONS SECTION
MAINTENANCE SECTION
SYSTEM SECTION
DISASSEMBLY SECTION
TROUBLESHOOTING
ENGINE SECTION
PROCEDURE OF INSTALLING
OPTIONS SECTION
0-1
SK330
-
8
SK350
LC
S5LC0011E04
Book Code No.
-
8

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Summary of Contents for Kobelco SK330-8

  • Page 1 HYDRAULIC EXCAVATOR SHOP SK330 SK350 MANUAL model INDEX SPECIFICATIONS SECTION MAINTENANCE SECTION SYSTEM SECTION DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION PROCEDURE OF INSTALLING OPTIONS SECTION S5LC0011E04 Book Code No. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 2: General Safety Information

    2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows: Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 3: Safety Precautions

    (5) Do not work on any machine that is supported only can be hot. by lift, jacks or a hoist. Always use blocks or jack Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 4 Shields that protect against oil spray onto hot ex- haust components in event of a line, tube or seal failure must be installed correctly. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 5 UPPER STRUCTURE 2007-02 S5LC3411E02 TRAVEL SYSTEM 2007-02 S5YN4618E03 BY ERROR CODES 2008-10 S5LC4711E02 BY TROUBLE 2007-02 S5YN4818E01 TROUBLE DIAGNOSIS MODE 2006-07 S5LC5111E04 ENGINE 2010-07 LC10-07001~ APPLICABLE MACHINES YC10-03501~ Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 6 The Chapter "Engine" describes the engines mak- ing use of the "Maintenance Manual" provided by the suppliers. • The Chapter "Installation Procedures for Optional Attachment" describes the supplements added on request as required. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 7 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......1-3 1.1.4 ELECTRICAL EQUIPMENT ..................1-4 1.1.5 HYDRAULIC PARTS ....................1-5 1.1.6 WELD REPAIR ......................1-5 1.1.7 ENVIRONMENTAL ISSUES..................1-5 INTERNATIONAL UNIT SYSTEM ..................1-6 Book Code No. S5YN0118E01 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 8 ↑ SK250-8: LQ12-06001~ ↑ October, 2006 SK260LC–8 : LL12-05001~ (ASIA, OCE) ↑ ↑ December, 2006 SK850LC: LY01-00101~ ↑ E235BSR : YF05-02001~ ↑ February, 2007 E235BSR(N)LC : YU05-02001~ (NHK) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 9 Instruction in advance, and determine if the 1) Wear appropriate clothing, safety shoes, safety disassembly and assembly are permitted or helmet, goggles, and clothes with long sleeves. not. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 10: Electrical Equipment

    4. Removing and attaching swing motor completely. 5. Removing and attaching travel motor (5) Engine key off before removing and connecting 6. Removing and attaching hydraulic cylinder connector. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 11: Hydraulic Parts

    So, choose proper O-ring. • Fit O-ring so as to be free from distortion and bend. • Floating seal should be put in pairs. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 12 Micro –6 Area Square meter Nano Volume Cubic meter –9 Velocity Meter per second Pico –12 Acceleration Meter per second / second Density Kilogram per cubic meter kg/m Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 13 1. OUTLINE (6) Unit Conversion Table QUANTITIES REMARKS Mass Force 1kgf=9.807N Torque kgf•m N•m 1kgf•m=9.807N•m Pressure kgf/cm 1kgf/cm =0.098MPa Motive power 1PS=0.7355kW Revolution r.p.m 1r.p.m=1min –1 –1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 14 1. OUTLINE [MEMO] Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 15 2.6.1 SK330-8........................2-12 2.6.2 SK350LC-8 .......................2-12 TYPE OF BUCKET ......................2-13 COMBINATIONS OF ATTACHMENT................2-14 ENGINE SPECIFICATIONS ....................2-15 2.9.1 SPECIFICATIONS....................2-15 2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-TM) ..........2-16 Book Code No. S5LC0211E01 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 16: Specifications

    2. SPECIFICATIONS Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC0211E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 17: Name Of Components

    HYDRAULIC TANK HYDRAULIC PUMP BUCKET GUARD MONITOR PANEL SHOE FRONT IDLER IDLER ADJUST ENGINE UPPER ROLLER AIR CLEANER COUNTER WEIGHT LOWER ROLLER RADIATOR AND OIL COOLER BATTERY TRAVEL MOTOR Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 18: General Dimensions

    Q'TY OF LOWER ROLLER:7SETS[9SETS] (23.6") 600 4650 (15'3") [4980(16'4")] 3200(10'6") 5830 (19'2") [5990(19'8")] Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 19 11230(36'10") 4750(15'7") 3500(11'6") Q'TY OF LOWER ROLLER:7SETS[9SETS] 4650(15'3") [4980(16'4")) 5830(19'2") [5990(19'8")] Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 20: Weight Of Components

    3.3 Boom assy (Assembly of following :) 3,610 (7,960) ← 3.3.1 Boom 2,670 (5,890) ← 3.3.2 Arm cylinder *539 (1,190) ← 3.3.3 Pin (Mounting arm • Mounting arm cylinder) 75 (165) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 21 862 (1,900) ← 4.1 Hydraulic oil 310 (684) ← 4.2 Engine oil 28 (62) ← 4.3 Fuel 484 (1,070) ← 4.4 Water 44 (97) Marks * show dry weight. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 22 (1) 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm+1.40m (1.83cu•yd) Bucket Model SK330-8 SK350LC-8 Item Width 600mm (23.6in) shoes 3,200 (10ft-6in) 3,200 (10ft-6in) Weight 33,800kg (74,500 lbs) 34,200kg (75,400 lbs) SECTION AA 11218(36'10") 1800(5'11") (21") Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 23 3.82 × 1.09 × 0.62 4.48 × 0.97 × 0.62 5.35 × 0.99 × 0.63 Length×Height×Width m (ft-in) (12'6"×3'7"×2'2") (14'8"×3'2"×2'2") (17'7"×3'3"×2'1") L×H×W Weight kg (lbs) 1,660 (3,660) 1,830 (4,040) — Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 24 (5'4"×4'8"×5'2") (5'6"×4'9"×5'6") Weight kg (lbs) 930 (2,050) 1070 (2,360) 1140 (2,510) 1170 (2,580) Bucket capacity 1.2 (1.57) 1.40 (1.83) STD 1.60 (2.09) 1.80 (2.35) (cu•yd) HOE BUCKET 2-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 25: Specifications And Performance

    33,800 (74,500) 34,600 (76,300) ← Upper structure 15,800 (34,840) Lower machinery 11,300 (24,900) 12,000 (26,460) Attachment ← 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm 6,590 (14,530) +1.40m (1.83cu•yd) Bucket 2-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 26 Use 600mm (23.6in) grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.) 2-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 27 1.00 1,070 1,420 (4'8") 1,300 (4'3") (1.31) (2,360) 1.20 1,140 1.60 (2.09) 1,565 (5'2") 1,450 (4'9") (1.57) (2,510) 1.40 1,170 1.80 (2.35) — 1,670 (5'6") (1.83) (2,580) 2-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 28 The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibility If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and bucket may occur. 2-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 29: Engine Specifications

    (Limited by E/G lubrication) 1,294 × 868 × 987 (4ft-2.95in × 34.2in × 38.9in) Dimension (L×W×H) {without fan} mm (in) Rotating direction Counterclockwise seeing from flywheel side 2-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 30: Engine Speed

    225g/kW . h X 209kW X 0.835 X 1000 : Standard load factor (0.70~0.80) . L/h 56.3 Fuel consumption in regular operation (load factor 0.70~0.80) 39.4 L/h~45.1 L/h 2-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 31 ARM MAINTENANCE STANDARD ................3-8 BUCKET ..........................3-12 3.3.1 BUCKET DIMENSIONAL DRAWING ...............3-12 3.3.2 BUCKET DIMENSIONAL TABLE ................3-12 3.3.3 LUG SECTION DIMENSIONAL DRAWING .............3-13 3.3.4 BOSS SECTION DIMENSIONAL DRAWING............3-14 Book Code No. S5LC0311E02 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 32 3. ATTACHMENT DIMENSION Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC0311E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC0311E02 ↑ Revision February, 2007 (ASIA, OCE) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 33 ø 125 (4.92") Boom cylinder (rod side) pin dia. ø 110 (4.33") Pin dia. of boom end. ø 110 (4.33") Arm cylinder (head side) pin dia. ø 110 (4.33") Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 34 ø 110 (+0.0041) (+0.0033) (4.331) + 0.030 + 0.250 + 0.280 Arm cylinder (+0.0012) (+0.0098) (+0.0110) LC02B01444P1 (Head side) - 0.030 + 0.050 + 0.020 (-0.0012) (+0.0020) (+0.0008) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 35 + 0.020 (+0.0041) (+0.0033) ø 110 (+0.0008) (4.331) - 0.020 + 0.226 + 0.246 Arm cylinder (-0.0008) (+0.0089) (+0.0097) LC02B01337P1 (Head side) + 0.098 + 0.078 (+0.0039) (+0.00031) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 36 Boom cylinder (5.12) Boom cylinder 0.6~2.0 (Rod side) (0.02~0.08) (0.12) (0.16) (34.5) Boom (22.2) Arm cylinder (5.51) Arm cylinder 0.6~1.0 (Head side) (0.02~0.04) (0.08) (0.10) (12.2) Boom (5.75) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 37 Pin dia. ø110 (4.33") bracket Arm top end boss width 368 (14.5") d5 Pin dia. ø90 (3.54") Arm link section boss width 390 (15.4") Boss width 400 (15.75") Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 38 Arm cylinder LC02B01444P1 (+0.0008) (-0.0012) (Rod side) ø110 +0.020 +0.288 +0.308 Arm foot (4.331) (+0.0008) (+0.0113) (+0.0121) (Connected part LC12B01468P1 +0.190 +0.170 –0.020 of boom) (+0.0075) (+0.0067) (-0.0008) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 39 (+0.0089) (+0.0097) LC02B01337P1 (Rod side) –0.020 +0.098 +0.078 (+0.0039) (+0.0031) ø110 (-0.0008) (4.331) +0.200 +0.220 Arm foot (+0.0079) (+0.0087) (Connected part LC12B01468P1 +0.099 +0.079 of boom) (+0.0039) (+0.0031) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 40 D, D' SECTION E-E SECTION A-A SECTION C-C SECTION F-F SECTION B-B SECTION D-D,D'-D' SECTION G-G Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction 3-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 41 (5.35) 0.6~2.0 (0.12) (0.16) (0.024~0.08) Rod side (5.51) Arm cylinder (Rod side) (12.2) (5.75) With in (15.75) G-G Arm foot (0.04) (0.10) (22.7) 405.8 (0.02) Boom (15.98) 3-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 42 280.5 (11") 316 (12.4") 318 (12.5") 377 (14.8") 280.5 (11") 315 (12.4") 318 (12.5") 376 (14.8") ← ← ← ø 105 (4.13") ← ← ← ø 90 (3.54") 3-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 43 (cu . yd) 1.40 (1.83) LC61B00115F1 1.20 (1.57) LC61B00052F1 GD bucket (3.54") (1.10") (4.13") (0.63") (4.13") (0.748") (7.48") (0.472") (5.91") 1.60 (2.09) LC61B00118F1 1.80 (2.35) LC61B00057F1 3-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 44 (cu•yd) 1.40 (1.83) LC61B00115F1 1.20 (1.57) 139.8 103.8 LC61B00052F1 GD bucket LS12B01054P1 (5.50") (4.09") (0.591") (1.58") (0.827") 1.60 (2.09) LC61B00118F1 1.80 (2.35) LC61B00057F1 3-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 45 SEALING COMPOUND ....................11-14 11.9 SUCTION STOPPER.......................11-15 11.9.1 COMPONENTS ......................11-15 11.9.2 DIMENSION ......................11-15 11.9.3 APPLICABLE MODEL ....................11-15 11.10 UPPER FRAME LIFTING JIG..................11-16 11.11 ENGINE MOUNTING PEDESTAL...................11-17 Book Code No. S5LC1111E01 11-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 46 11. TOOLS Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC1111E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) 11-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 47 (1700±173) (1430±145) 794±78 667±69 1726±177 1451±147 3110±314 2610±265 P=3.5 (586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195) 1030±98 863±88 2226±226 1863±186 4010±402 3360±333 (760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246) 11-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 48 (853±87) (1840±188) (1530±152) 853±88 706±70 1860±186 1550±155 3350±334 2790±275 (629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203) 1070±108 892±88 2330±226 1940±196 4200±422 3500±353 (789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260) 11-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 49 (M3) (M4) (M22) (M5) (M27) (M45) (M18) 11.2.3 SOCKET SET SCREW Nominal B mm Nominal B mm screw size screw size Tool size Tool size M2.5 1.27 11-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 50 33.9±5.6 (25±4) 39.5±5.6 (29±4) 42.4±5.6 (31±4) 62.2±5.6 (46±4) 1 1 / 4 55.1±7.1 (41±5) 93.3±8.4 (69±6) 1 1 / 2 70.6±8.4 (52±6) 169±11 (125±8) 81.9±8.4 (60±6) 282±11 (208±8) 11-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 51 ZA93S15000 ZF93N15000 ZA93N15000 ZF93S18000 ZA93S18000 ZF93N18000 ZA93N18000 ZF93S22000 ZA93S22000 ZF93N22000 ZA93N22000 ZF93S28000 ZA93S28000 ZF93N28000 ZA93N28000 ZF93S32000 — ZF93N32000 — ZF93S35000 ZA93S35000 ZF93N35000 ZA93N35000 ZF93S38000 — ZF93N38000 — 11-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 52 (3) Nut Applicable d screw tube Opposing flats Nut parts No. d screw O. D : A ZF93N06000 ZF93N08000 ZF93N10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000 11-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 53 PF screw Plug parts No. E mm F mm 2444Z2729D1 PF1/4 screw 2444Z2729D2 PF3/8 2444Z2729D3 PF1/2 2444Z2729D4 PF3/4 Opposing 2444Z2729D5 Opposing flats F 2444Z2729D6 PF1 1/4 flats E 11-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 54 No. 25.53~ ZE13Q08000 2445Z831D1 40.49 18.24 25.40 31.88~ ZE13Q12000 ZD12P02600 50.80 23.80 31.75 39.75~ ZE13Q16000 ZD12P03400 57.15 27.76 39.62 44.58~ ZE13Q20000 ZD12P03800 1 1/4 66.68 31.75 44.45 11-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 55 09(4.29) 80(3. 5) 6.5(0.649) PART-No. 32 (1.26) 2421T232 ( .30) ( .38) 9.05 (0.750 HEX50 81(3.19) 90(3.54) 20.5(0.807) ART-No. 35 (1.38) 2421T314 (1.77) (1.61) 19.05 (0.750 HEX55 11-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 56: Special Tools

    M8 X 18 Addtional threading for M8 Eye bolt M8 Eye bolt M8 X 18 Additional Plug YN01H01001P1 threading Nominal 1-14UNS Flare hose HEX 27 ZS91C00800 Eye bolt 1-14UNS 11-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 57 For slinging the Weld Coupling swivel joint half Coupling half PF 1/2 TORX driver 5.49 (with tamper For instrument proof) — Point shape panel cover (RH) (For M6) 11-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 58 # 1121 Hydraulic oil tank : Sumitomo Chemical Co., Cyano Bond PO-1 Hose Ltd. Shell Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease bath petroleum 11-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 59 O113 (4.45") M8 NUT (0.08") O8 (1.315") +0.5 O100 +0.0197 (3.94 O108 (4.25") COVER Fig. 11-2 Dimension of suction stopper 11.9.3 APPLICABLE MODEL Applicable model Part No. 24100P978F2 11-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 60 HIGH COUPLING HC KITO HC020 CHAIN 8 4.4m(14' 5") CHAIN 8 1.5m(4' 11") GRAB HOOK H KITO HH020 HOOK KITO HJ050 Fig. 11-3 Upper frame lifting jig 11-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 61 11. TOOLS 11.11 ENGINE MOUNTING PEDESTAL Material : Wood Unit : mm(inch) 1X1 set 5X1 set 4X1 set 2X1 set 3X1 set 6X5 sets Fig. 11-4 Engine stand 11-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 62 11. TOOLS [MEMO] 11-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 63 (TEMPORARY EDITION) ....................12-15 12.2.1 MEASURING METHOD ..................12-15 12.2.2 WORKING CONDITION ..................12-15 12.2.3 STANDARD TIME CONSTITUENT ................12-15 12.2.4 MEANING OF WORDS IN USE ................12-17 Book Code No. S5LC1211E01 12-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 64 12. STANDARD MAINTENANCE TIME TABLE Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC1211E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) 12-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 65 (4) Applicable machine for estimation of standard maintenance time 1) Standard machine 2) A well maintained and controlled machine with a standard combination of attachments which is used in a general environment. 12-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 66 2) Genuine parts are changed 3) Correct working procedures are observed. • The time required for works specified in this Chapter shows the total time for maintenance. 12-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 67 52 • Boom cylinder head pin 2 pcs. Detach/attach 53 • Boom cylinder slinging Detach/attach 60 Bucket cylinder 61 • Pin bushing Replace Include seal. 70 Arm cylinder 12-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 68 1 pc. Detach/attach 46 Cover assy (1) 1 pc. Detach/attach Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure. 12-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 69 1 pc. Detach/attach 43 • Hydraulic oil piping 1 pc. Detach/attach Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure. 12-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 70 92 • Piping 1 set Detach/attach 93 • Mounting bolt 1 pc. Detach/attach 94 • Unit slinging 1 pc. Detach/attach 95 • Cleaning and sealant Cleaning 1 set 12-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 71 1 pc. After removing pump & radiator Detach/attach 142 • Harness connector & grounding & Detach/attach 1 pc. cable connection 143 • Fuel hose 1 pc. Detach/attach 12-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 72 One side After removing track link Detach/attach 32 Front idler ASSY slinging One side Detach/attach 33 Front idler ASSY Detaching One side 34 Idler ASSY One side 12-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 73 D-14 Diode Replace D-15 Diode Replace D-16 Diode Replace D-17 Diode Replace Electric equipments E-1 Fuse & relay box Replace E-2 Alternator Replace E-3 Hour meter Replace 12-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 74 PSV-P2 Relay R-1 Battery relay Replace R-2 Starter relay Replace R-3 Glow relay Replace R-4 Safety relay Replace R-5 Horn relay Replace R-6 Work light relay Replace 12-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 75 SW-7 Engine oil pressure switch Replace SW-8 Clogged air filter switch Replace Horn switch (left) Replace SW-10 Safety lever lock switch Replace SW-11 Wiper interlock switch Replace SW-19 12-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 76 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour Attachment power boost switch (right) Replace SW-20 Engine cooling coolant level switch Replace SW-27 12-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 77 Net standard time × HINO allowance rate Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position and so on. 12-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 78 The preparation time is classified into as described above, and only items required for the every work are selected, calculated and counted as preparation time of the work. 12-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 79 Explains the contents of work to make the specified work range clear • Exclude : Shows the work which is not included in the specified primary work • Unit : Time is shown by hour. 12-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 80 Removal and installing cylinder head 10.4 machine holder or injector and injector sub harness Include; Valve lapping Completed 00323 Replacing cylinder head 11.5 16.9 machine Exclude; Replacing of valve guide 12-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 81 00543 Replacing rear end plate gasket From engine is removed condition Single unit 00515 Replacing crank shaft rear oil seal From engine is removed condition Single unit 12-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 82 Replacing idler gear shaft (sub) Single unit condition 00724 Replacing crank shaft gear rear Single unit From timing gear cover is removed 00738 Replacing cam idle gear Single unit condition 12-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 83 One set Include; Filling engine coolant up Replacing thermostat casing cover 01047 One set Include; Filling engine coolant up gasket Include; Checking for temperature at 01048 Replacing thermostat One set valve start opening 12-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 84 One set Include; Function check (common rail to supply pump) 01828 Replacing fuel leakage pipe One set Include; Function check 01840 Checking leakage of pressurized fuel One set Include; Function check 12-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 85 Removal and installing EGR cooler One set 01917 Replacing EGR cooler One set Removal and installing closed 01918 One set ventilator 01919 Replacing closed ventilator One set 12-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 86 12. STANDARD MAINTENANCE TIME TABLE [MEMO] 12-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 87 13.9.2 ..13-21 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) 13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER .......................13-27 Book Code No. S5LC1311E02 13-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 88 Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC1311E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC1311E02 ↑ Revision February, 2007 (ASIA, OCE) 13-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 89 In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well. 13-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 90 29.0 (4205) + 6.0 (+870) OR5 Swing LH — 35.8 (5190) 0 - 2.0 (-290) Simultaneous — operation of travel — RH and LH 35.8 (5190) 0 - 2.0 (-290) — 13-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 91 (1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down (5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out ONTROL LEVER 13-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 92 2201 MEAS 2 2201 ENG OIL PRS. LIVE WATER TEMP. MODE ACCEL. VOLT. 4.2V 100% ECU OUTPUT 0.5V Fig. 13-2 Service diagnosis for E/G speed measuring (Example) 13-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 93 49 MPa (7100 psi). (2) Pilot circuit Replace pilot gauge plug (a5) with plug PF1/4 for pressure measurement, and attach pressure gauge 6.9 MPa (1000 psi). 13-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 94 OR1 : BUCKET (H) MACHINE FRONT PLUG FOR OPTIONAL RELIEF OR7 : ARM (H) VIEW FROM THE BOTTOM OF THE MACHINE Fig. 13-4 Relief valve position on main control valve 13-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 95 (a1) and (a2). (See Fig. 13-3) PLUGS F R PRESSURE MEASUREMENT 2-PT1/4 SWING LEFT SWING RIGHT VERL AD RELIEF VERL AD RELIEF Fig. 13-6 Swing over load relief position 13-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 96 : 6 mm Fig. 13-9 Over load relief valve (Boom, bucket, arm sections) No. of turns of adjust screw Pressure change MPa (psi) 1 turn Approx. 17.7 (2560) 13-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 97 (5) Travel over load relief valve This valve was adjusted by valve maker. Do not replace any inner parts except for O-ring. Fig. 13-11 Travel over load relief valve 13-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 98: Travel Speed

    Hydraulic oil temperature ; 45~55 C (113~131 ° ° RH and LH crawler are tensioned evenly. Fig. 13-14 Travel position Firm, level ground Engine revolution; Hi idle 13-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 99 GUIDE FRAME Fig. 13-17 Method of measurement Parking brake Unit : mm(in)/5min Measuring Reference value Service limit Standard value position for remedy 2 (0.08) 1 (0.04) 13-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 100 Travel deviation Unit : L/30sec Measuring Reference value Service limit Standard value position for remedy 7.0 (1.8 gal) 21.0 (5.5 gal) Drain rate 14.0 (3.7 gal) 13-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 101 Place two poles (flags) on the front and back of the extended line of the matching mark. 13-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 102 Fig. 13-24 Measuring position of swing parking brake performances Performance of swing parking brake Unit : mm(in)/5min Measuring Reference value Service limit Standard value position for remedy 1 (0.04) 2 (0.08) 13-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 103 2) Relieve the swing motor at full stroke of the Drain rate 2.1 (0.55 gal) 5.2 (1.4 gal) 6.2 (1.6 gal) swing motion. 3) Collect the amount of drained oil in a container for 30 seconds. 13-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 104 3.5~4.2 4.5~ 2.7~3.3 3.3~ 1.9~2.5 2.4~3.2 3.5~4.2 4.5~ 2.7~3.3 3.6~ 2.1~2.7 2.7~3.5 4.4~5.1 5.6~ 3.4~4.0 4.8~ 2.9~3.5 3.7~4.5 13-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 105 (4) Measurement Measure the items five minutes after the engine is turned off. 13-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 106 Right and left movement of the tip of bucket Unit : mm (in) Measuring Reference value Service limit Standard value position for remedy Bucket 30~50 (1.18~1.97) 100 (3.94) 120 (4.72) 13-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 107 When the following parts are replaced or repaired, carry out the adjustment without fail. (1) Mechatro controller (2) Engine or engine controller (3) Hydraulic pump or hydraulic pump proportional valve (4) Unloading proportional valve, spool of unloading valve 13-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 108 As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List. For machines equipped with lifting magnet, turn the generator OFF. 13-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 109: Adjusting Procedure

    PUMP PRESSURE 2.0M 2.0M STEP and the adjustment of engine is completed. The torque adjustment and unloading adjustment required later are not performed, and default value is written.) 13-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 110 Check that signal is regularly input to the engine controller by actual measurement of voltage or with failure diagnosis tool of engine controller. 13-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 111 2) In the condition where large load is constantly applied to engine, the adjustment could not be performed normally. For machines equipped with lifting magnet, turn the generator OFF. 13-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 112 The value of adjusting current is indicated on the display of current of P1 and P2 unloading proportional valves. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.) 13-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 113 LOW speed condition. The emergency mode should be used in only case of emergency. We recommend that the defective section is repaired by troubleshooting as early as possible. 13-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 114 13. MAINTENANCE STANDARD AND TEST PROCEDURE [MEMO] 13-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 115 21.2.5 TROUBLE DIAGNOSIS MODE ................21-41 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE ...........21-42 21.2.7 ADJUSTING PROCEDURE OF DISPLAY .............21-43 21.2.8 MECHATRO CONTROL EQUIPMENT ..............21-47 Book Code No. S5LC2111E03 21-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 116 SK330–8 : LC10-07001~ S5LC2111E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC2111E02 ↑ Revision February, 2007 (ASIA, OCE) S5LC2111E03 ↑ ↑ October, 2008 (ASIA, OCE) 21-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 117 Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system. 21-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 118 : LOW PRE URE EN OR ENGINE PEED (ATT : 7pcs, TRAVEL : 2pcs) COMMAND CURRENT VOLTAGE 24V : ACCEL DIAL POTENTIOMETER PROPORTIONAL COMMAND CURRENT E-27 EMERGENCY MODE ACCEL DIAL 21-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 119: Proportional Valve

    BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX ARM IN BUCKET CYLINDER DIGGING / DUMP CONFLUX PROPORTIONAL VALVE BLOCK SOLENOID VALVE 21-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 120 (4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating. 21-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 121 PILOT SECONDARY PRESSURE P1 PUMP P1 PUMP PROPORTIONAL PROPORTIONAL PILOT SIGNAL VALVE PSV-P1 VALVE COMMAND PROCESS MECHATRO PILOT SECONDARY PRESSURE pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE 21-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 122 4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and consequently working speed will be obtained according to lever movement. POSITIVE CONTROL P-Q CONTROL PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS PILOT PRESSURE PUMP DELIVERY PRESSURE 21-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 123 P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation. 21-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 124 VALVE CONTROL VALVE FOR ARM PROCESS FOR ARM 2 SPOOL PSV-A 2 SPOOL ARM PILOT SECONDARY PRESSURE P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE 21-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 125 The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked. 21-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 126 2 spool is controlled to spool stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump delivery rate is low due to low engine speed. 21-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 127 P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation. 21-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 128 (4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched. 21-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 129 BUCKET DIGGING PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS BUCKET ATT BOOST ANTI-CAVITATION SOLENOID VALVE PROCESS SV-2 ENGINE SPEED (COMMAND VALUE) MECHATRO CONTROLLER pi : PROPORTIONAL VALVE P1 PUMP PRESSURE SECONDARY PRESSURE 21-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 130 (7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the stroke limit of bucket spool. 21-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 131 (5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible. 21-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 132 P2 UNLOAD PROPORTIONAL VALVE PSV-B PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS P1 UNLOAD PROPORTIONAL VALVE PSV-D MECHATRO pi : PROPORTIONAL VALVE CONTROLLER PILOT SECONDARY PRESSURE SECONDARY PRESSURE 21-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 133 Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. ATT operation ucket Swing Option In travel operation (P1) In travel operation (P2) 21-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 134 (4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool with the unload valve opened. 21-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 135 It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display is output to gauge cluster. 21-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 136 (5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched. 21-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 137 Buzzer stop switch Work mode select switch Washer switch Wiper switch Travel high speed, low speed select switch Auto accel switch 10 Select switch Multi display (LCD) 21-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 138 For the work with breaker, select "B mode" without fail. The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and breaker. 21-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 139 (5) and the flow rate value increases or decreases. 5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value. 21-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 140 For the setting procedure of maintenance time to be performed to the coming oil change in each type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE. 21-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 141 CHANGE ENG OIL COMMUNICATION W008 ERROR SWING BRAKE ENGINE STOP DISENGAGED Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function. 21-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 142: Self-Diagnosis Display

    Transistor ON Disconnection failure / Disconnection Power source Power source Power source Power source Contact point is short circuit short circuit short circuit melted and adhered short circuit 21-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 143 21. MECHATRO CONTROL SYSTEM Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine. 21-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 144 Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3. (No.3→No.2→No.1→No.3→...) 4) Turn key switch OFF and the display of service diagnosis mode is closed. 21-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 145 MEAS. Measured value B-18 DOZER 1 SWITCH Switch 3.5V 2.6M Sensor voltage / Pressure converted value B-19 DOZER 2 3.5V 2.6M Sensor voltage / Pressure converted value 21-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 146 Set value in computer MEAS. OFF Measured value DO13 COMP. OFF Set value in computer MEAS. OFF Measured value DO14 COMP. OFF Set value in computer MEAS. OFF Measured value 21-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 147 Conflux/ Single selector switch G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current 21-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 148 Angle adjustment LEVEL3 Total / In the last 10 hours OFFSET 137 137 Angle adjustment LEVEL4 Total / In the last 10 hours INTER-B 137 137 Angle adjustment 21-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 149 3.0 M BOOM RAISE 3.0 M BOOM LOWER 0.0 M BOOM LOWER 0.0 M ENG SPEED 2050~2200 ENG SPEED 2050~2200 POWER SHIFT 0 mA POWER SHIFT 0 mA 21-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 150 BOOM RAISE 0.0 M BOOM RAISE 0.0 M SWING 0.0 M SWING 0.0 M ENG SPEED 2050~2200 ENG SPEED 2050~2200 POWER SHIFT 0 mA POWER SHIFT 0 mA 21-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 151 BOOM RAISE 0.0 M BOOM RAISE 0.0 M SWING 3.0 M SWING 3.0 M ENG SPEED 2050~2200 ENG SPEED 2050~2200 POWER SHIFT 0 mA POWER SHIFT 0 mA 21-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 152 0.0 M BUCKET DIG 0.0 M BUCKET DUMP 3.0 M BUCKET DUMP 3.0 M ENG SPEED 2050~2200 ENG SPEED 2050~2200 POWER SHIFT 0 mA POWER SHIFT 0 mA 21-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 153 2.0~2.5 M Pi-P1 0.0 M Pi-P1 0.0 M Pi-P2 0.0 M Pi-P2 0.0 M ENG SPEED 2050~2200 ENG SPEED 2050~2200 POWER SHIFT 0 mA POWER SHIFT 0 mA 21-39 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 154 3) When "NO ERROR" is displayed, the deletion is completed. 4) Turn starter switch off. All the stored items are erased. It is impossible to erase data partially. 21-40 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 155 For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE". 21-41 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 156 2 to 5. 2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound. 21-42 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 157 6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display. 7. Turn starter key switch off once and store the auto idling stop setting as a memory. 21-43 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 158 5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is completed, and then the screen returns to main screen (a). 21-44 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 159 6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to main screen (a). 21-45 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 160 Change of starter mode Change of start mode Low temperature mode forcible Low temperature mode release release Cylinders calibration Injection adjust mode of engine Pressure release For pressure release 21-46 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 161 DO 21 Spare Output DO 22 EARTH/OPEN Rotary light (yellow) Output EARTH/OPEN DO 23 Rotary light (green) Output DO 24 EARTH/OPEN Heavy lift Input EARTH/OPEN DI 36 21-47 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 162 Input 0.5~4.5V P2 pump Input 0.5~4.5V +5VA Power output 5V +5VA Power output 5V Boom angle Input 0.5~4.5V Arm angle Input 0.5~4.5V +5VA Power output 5V Reserved 21-48 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 163 P2 pump Output +0~800mA -0~800mA Cab slow stop valve Output +0~800mA -0~800mA Boom cushion Output +0~800mA -0~800mA Arm cushion Output -0~800mA +0~800mA +24V Battery direct connection 20~32V 21-49 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 164 Input EARTH / OPEN DI 39 Extra pressure Input EARTH / OPEN DI 40 Spare Input EARTH / OPEN DI 41 Spare Input EARTH / OPEN Reserved 21-50 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 165 IT controller TXD2 RS232C communication Tranmission RXD2 Reception RS232C communication Spare RS232C communication Spare RS232C communication SHG2 Shiled GND DO 10 24V/OPEN Cab up and down switching valve 21-51 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 166 LCD dot 120×168 Gauge display (Coolant temp., Fuel level) Stepping motor — Buzzer Piezo-electricity type Screen change switch Buzzer stop switch Work mode select switch Back light 21-52 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 167 CN13 CN2-3 CN10 CN10 LOCATION OF CONNECTORS (Seen from backside) LOCATION OF RELAY & FUSE LABEL OF RELAY & FUSE BOX No. CODE IN CIRCUIT PARTS NAME 21-53 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 168 21. MECHATRO CONTROL SYSTEM 2) Circuit diagram 21-54 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 169 21. MECHATRO CONTROL SYSTEM 21-55 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 170 21. MECHATRO CONTROL SYSTEM 21-56 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 171 PRESSURE RANGE : 0 3.0 MPa (0 448 psi) RATED VOLTAGE : 5.0+0.5V DC INSURANCE RESISTANCE : 100M OR MORE (BETWEEN BODY AND EACH TERMINAL AT 50V DC MEGGER) 21-57 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 172 21. MECHATRO CONTROL SYSTEM [MEMO] 21-58 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 173: Hydraulic System

    22.6 BUCKET CIRCUIT......................22-12 22.7 BOOM CIRCUIT ......................22-14 22.8 SWING CIRCUIT ......................22-18 22.9 ARM CIRCUIT .........................22-20 22.10 COMBINED CIRCUIT ......................22-26 22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ....................22-30 Book Code No. S5LC2211E02 22-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 174 Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC2211E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC2211E02 ↑ Revision February, 2007 (ASIA, OCE) 22-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 175 Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes Auto accel Reduce fuel consumption and noise by lowering engine speed when control lever is in neutral position. 22-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 176 Multi control valve (with lever) YN30V00117F1 New zealand : STD 17 Restrictor YN21V00005F1 07381-00000 The part numbers may be changed due to modification, so use only the numbers for references. 22-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 177 LEFT TRAVEL FORWARD TRAVEL PBp1 LEFT TRAVEL REVERSE P1 BYPASS P2 BYPASS PRIORITY PBp2 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 22-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 178 4. ADJUST OVERLOAD RELIEF VALVE OF OPTIONAL PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE. LEFT NIBBLER NOTE 4 HYD.TANK RIGHT BREAKER OPTION NIBBLER & BREAKER PILOT VALVE 24.5MPa 24.5MPa C2 A SOL/V BLOCK LEVER LOCK SE-11 SV-13 SE-29 YN01Z00162P1 01 22-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 179 22. HYDRAULIC SYSTEM This page is blank for editing convenience. 22-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 180 The delivery pressure P1 flows in the small bore of servo piston, but the servo piston moves rightward due to the difference of area, 22-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 181 P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position) 22-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 182 The secondary pressure from proportional valve which has exerted on PCb and PCa ports switches the unloading spool in CLOSE side. 22-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 183 PBp2 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation. 22-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 184 PCb and PCa ports travel straight valve, and goes into bucket switches the unloading spool in CLOSE side. spool. (Confluence of oil from 2 pumps) 22-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 185 (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control 22-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 186 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. 22-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 187 P2 BYPASS PRIORITY PBp2 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function. 22-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 188 (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. 22-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 189 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling. 22-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 190 22.8.4 SWING MOTOR CIRCUIT (1) Anti cavitation circuit at swing deceleration (2) Shockless relief valve that prevents the swing motor from being reversed. 22-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 191 P1 BYPASS P2 BYPASS PRIORITY PBp2 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-6 SWING CIRCUIT : Swing operation (LH) 22-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 192 Then because arm 2 spool was switched, the delivery oil opens load check valve LCAT2, Normal recirculation opsition goes through arm 2 spool, and confluences Arm 2 spool 22-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 193 (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function 22-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 194 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. 22-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 195 (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function 22-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 196 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. 22-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 197 P2 BYPASS PRIORITY PBp2 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function 22-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 198 4) However, a portion of the flow is led to the travel straight spool notch restriction. The speed of attachments like travel, boom, etc. is adjusted by the circuit of restriction. 22-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 199 (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function. 22-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 200 Position of arm 2 spool Position of forced recirculation Meter-in passage Neutral position (Close) From From arm 2 inverse arm out proportional valve Normal recirculation opsition Arm 2 spool 22-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 201 PBp2 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function 22-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 202 Press "Selector Switch" and highlight "OFF", circuit, i.e. the main circuit pressure may be and press [ ] switch to change to "DRAIN released. HYD. ON", and then press "Selector Switch" again. 22-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 203 P2 BYPASS PRIORITY PBp2 PSV-C P1UNLOAD (T3b) (T3a) (T4a) (Dr4) PSV-D (P3) (P4) ARM2 PSV-A LC01Z00070P1 03 Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode. 22-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 204 22. HYDRAULIC SYSTEM [MEMO] 22-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 205 23.3.10 BOOM HARNESS ASSY..................23-36 23.3.11 INSTALLING BOOM LIGHT ...................23-36 23.3.12 INSTALLING UPPER LIGHT..................23-37 23.3.13 CAB LIGHT INSTALL .....................23-37 23.3.14 FLASHER LAMP INSTALL..................23-38 23.3.15 ALARM ASSY......................23-38 Book Code No. S5LC2311E02 23-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 206: Electric System

    Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC2311E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC2311E02 ↑ Revision February, 2007 (ASIA, OCE) 23-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 207 OUT SOURCE : (PSV, SOL. MOTOR) R-28 : ALTERNATOR RELAY CONTROL : (SENSOR POWER SOURCE, CPU) WATCH IC TO 2/4 SW-28 : (1/4) WATER SEPARATOR SW. LC03Z00036P1 02 23-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 208 SW-20 : POWER BOOST SW. RIGHT SE-13 : ENG. SPEED SENSOR SHIELD SHIELD MODE DISPLAY BUZZER WASHER SELECT SW. STOP ENTER DECEL TRAVEL WIPER TO 3/4 2-SPEED (2/4) LC03Z00036P1 02 23-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 209 TERMINAL SE-26 : PRESS. SENSOR : BOOM HEAD FM / AM EU(FOR OVER LOAD ALARM) E-9 : SPEAKER RIGHT (BACK-UP) ROOF WIPER TO 4/4 (3/4) LC03Z00036P1 02 23-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 210 SWING FLASHER RIGHT & WORKING LIGHT SWING FLASHER & WORKING LIGHT SW-59 : SW-37 : QUICK COUPLER TRAVEL INDEPENDENT SW. OPERATION SW. EU OPT. QUICK COUPLER DOWNLOAD (4/4) LC03Z00036P1 03 23-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 211 R-32 WASHER MOTOR RELAY NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 02 23-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 212 FLASHER LAMP INSTALL LC80E00011F1 YN53E00015F1 ALARM 3.15 ALARM ASSY The parts number may be changed due to the improvement of machine, so use the number for reference only. 23-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 213 5.0N . m (3.7lbf . ft) SECTION CC TIGHTENING TORQUE VIEW SEMS BOLT 5.2N . m (3.8lbf . ft) TIGHTENING TORQUE INSTALL TAPPING SCREW 5.0N . m (3.7lbf . ft) TO A/C 23-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 214 CLIP PUT SURPLUS CABLE INTO CAB CLAMP CABLE WITH HARNESS INSIDE TOGETHER CABLE ARRANGEMENT PASS CABLE THROUGH THE HOLE CONNECT CABLE WITH FOR HARNESS CAB SIDE ANTENNA 23-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 215 POWER SOURCE WIRING FRONT SIDE TIGHTENING TORQUE 11.7N . m (8.6lbf . ft) (BLACK) (BLACK) (GREEN ORANGE) (GREEN ORANGE) SECTION BB (BATTERY RELAY BOX) VIEW (COVER INSTALL) VIEW VIEW 23-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 216 M10 : 46.1N . m (34.0lbf . ft) CLIP M12 : 79.4N . m (58.6lbf . ft) (5) PLACE THE SLIT OF CORRUGATED TUBE SECTION AA DOWNWARD AND INSTALL IT. 23-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 217 PUMP P1 VIEW (PUMP P1, P2 PROPORTIONAL SOL. INSTALL) TO SWING FLASHER (PRESS SENSOR : PUMP P1, P2 INSTALL) TO WATER SEPARATOR SW VIEW BATTERY RELAY VIEW 23-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 218 P - 13 UPPER HARNESS GROUND BATTERY RELAY (COIL) CAB HARNESS (GROUND) FUSE & RELAY BOX DIODE (GLOW RELAY) FLASHER RELAY GLOW RELAY (COIL) FUSE & RELAY BOX CONNECTION 23-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 219 FIX WHITE TAPING POSITION BATTERY RELAY BOX BATTERY RELAY CABLE CLIP FIX A HARNESS OF UPPER HARNESS CLIP ON GUARD STARTER CABLE VIEW AIR FILTER CLOGGING SW. INST VIEW 23-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 220 SUB HARNESS UPP HARNESS CLIP FIX A WHITE TAPING VIEW OF HARNESS BY CLIP ON BRACKET UPPER HARNESS DETAIL OF E DETAIL OF ENGINE SPEED SENSOR INSTALLATION 23-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 221 UPPER HARNESS CLIP ECU HARNESS AND FIX WHITE TAPING POSITION CAB SUB HARNESS FLOOR HARNESS ECU HARNESS DETAIL B (DETAIL OF PSV BLOCK) TO UNDER FLOOR VIEW 23-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 222 SEALING PLUG TO BE SEALING PLUG TO BE SEALING PLUG TO BE INSERTED IN TO ALL INSERTED IN TO ALL INSERTED IN TO ALL INSERTED IN TO ALL 23-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 223 ROTARY LIGHT SUPPLY SUPPLY WITH WITH SEALING PLUG TO BE SEALING PLUG TO BE SW-16 : INSERTED IN TO ALL INSERTED IN TO ALL ENGINE ROOM LIGHT 23-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 224 TAPING TAPING WHITE TAPING WIRE WIRE DOUBLE DOUBLE WIRE SIZE FROM CONNECTION COLOR SPLICE SPLICE DOUBLE SPLICE TO AIR-CONDITIONER SUB HARNESS E-1 : FUSE & RELAY BOX 23-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 225 WIRE SIZE FROM CONNECTION WIRE SIZE FROM CONNECTION COLOR COLOR COLOR CONNECTORS SELECTION TABLE PART. NUMBER CONNECTOR NAME MANUFUC, HOUSING TERMINAL (PIN NUM,) SHIELDED CABLE (2 CORE) 23-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 226 BUNDLED BY TAPING, CAP TO BE INSTALLED DETAIL A TERMINAL TERMINAL TAPED IN TWO TURNS 23.3.6.4 BATTERY GROUNDING CABLE : LC13E01245P1 440 (17.3") 40 (1.57") TERMINAL TERMINAL TAPED IN TWO TURNS 23-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 227 SUMITOMO 6409-0073 TO HARNESS (FLOOR) TAPING SUPPLY WITH SUMITOMO 6409-0603 TAPING SUPPLY WITH SUMITOMO 6409-0072 TAPING WHITE TAPING SH8 SHIELD UN-CONNECTED WHITE TAPING C-6 : ENGINE CONTROLLER 23-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 228 PART. NUMBER PART. NUMBER CONNECTOR CONNECTOR LE-SS NAME MANUFUC, NAME MANUFUC, SHIELDED CABLE HOUSING TERMINAL HOUSING TERMINAL (PIN NUM,) (PIN NUM,) (2 CORE) LE-SS SHIELDED CABLE (2 CORE) 23-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 229 25.5N . m (18.8lbf . ft) E-2 : ALTERNATOR (FOR PLATE FIX) SW-7 : VIEW TIGHTENING TORQUE ENGINE OIL PRESS SW 25.5N . m (18.8lbf . ft) DETAIL OF ALTERNATOR 23-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 230 THERMO SENSOR (FOR ECU) WHITE TAPING PART. NUMBER CONNECTOR NAME MANUFUC, (PIN NUM,) HOUSING TERMINAL SEALING PLUG WHITE TAPING TO UPP HARNESS E-2 : ALTERNATOR E-2 : ALTERNATOR SEALING PLUG 23-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 231 FIX WHITE TAPING OF SEAT SIDE THROUGH THE HARNESS POSITION AT SEAT SIDE OF BRACKET CLIP TO THE FRONT SIDE OF FLOOR PLATE FIX WHITE TAPING POSITION 23-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 232 "ITEM 4 HARNESS" FLOOR HARNESS FIX TO THE LOWER PART OF PLATE WITH CLIP 34P CONNECTOR 22P CONNECTOR 28P CONNECTOR 22P CONNECTOR TO UNDER FLOOR VIEW SECTION AA 23-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 233 PRESS SENSOR : PRESS SENSOR : FUSE & RELAY BOX BUCKET DUMP ARM IN SE-4 : SE-3 : PRESS SENSOR : PRESS SENSOR : BOOM LOWERING BOOM RAISING 23-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 234 S -34 : SPLICE REVOLUTION LEFT S . DOUBLE SPLICE E-22 : SPLICE E17 AND SH8 DC-DC CONVERTER HITE TAPING DOUBLE SPLICE TAPING UN-CONNECTED SH11 TO IT HARNESS 23-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 235 23. ELECTRIC SYSTEM 23.3.8-1 FLOOR HARNESS (3/3) : YN13E01449P3 23-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 236 CAB SUB-HARNESS : LC13E01186P1 TO HARNESS (UPPER) E-1 : FUSE & RELAY BOX TO CAB HARNESS 23.3.8-9 FLOOR GROUNDING CABLE : LE13E01005P1 100 (3.94") 1PAF YAZAKI 7123-3010 23-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 237 CONDITIONER UNIT FIX TO THE BRACKET FIX WHITE TAPING CLIP POSITION TIE UP FLOOR HARNESS WITH CLIP CAB HARNESS USING CLIP DETAIL B DETAIL OF HOUR METER 23-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 238 TO HARNESS (UPP) SPLICE WORKING LIGHT SW. SW-26 : CAB WORK LIGHT DOUBLE SPLICE WHITE TAPING TAPING AFTER TAPING AFTER TAPING BUNDLED BUNDLED TAPING TO CAB HARNESS 23-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 239 23. ELECTRIC SYSTEM 23.3.9-1 CAB HARNESS (2/2) : YN14E01102P3 23-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 240 TIGHTENING TORQUE 18.6N . m (13.7lbf . ft) SECTION AA YAZAKI YAZAKI CAP : 7120-1010 HOUSING : 7122-2810 TERMINAL : 7115-1050 BRANCH WITH SPLICE TERMINAL : 7114-2020 23-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 241 GROMMET SEMS-BOLT PAINT PANGIN SEAL TIGHTENING TORQUE FROM SURFACE 46.1N . m (34lbf . ft) DETAIL aa DETAIL bb HOW TO INSTALL LIGHT AT RIGHT SIDE DECK 23-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 242 NOTE : TIGHTENING TORQUE OF ITEM 1 AND 2 TO BE UNDER 3~3.9N . m (2.2~2.9lbf . ft) DETAIL OF FUSE & RELAY BOX RIGHT CONSOLE BOX 23-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 243 SWING MOTOR UNIT....................24-65 24.1.6 TRAVEL MOTOR ....................24-75 24.1.7 SWIVEL JOINT.......................24-89 24.1.8 CYLINDER......................24-91 24.2 ELECTRIC EQUIPMENT....................24-97 24.2.1 ELECTRIC EQUIPMENT LIST ................24-97 24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS...........24-100 Book Code No. S5LC2411E02 24-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 244: Components System

    Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC2411E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC2411E02 ↑ Revision February, 2007 (ASIA, OCE) 24-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 245: Hydraulic Components

    Gauge port PF1/4-14 Delivery port of gear pump PF1/2-19 Suction port of gear pump PF3/4-20.5 Drain port of gear pump PF3/8-15 Fig. 24-1 Hydraulic pump • regulator 24-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 246 Electric flow control, positive flow control, Control function total power control at emergency mode and power shift control Others With solenoid proportional reducing valve (KDRDE5K-31/30C50) Weight kg (lb) 141 (310) 143 (315) 24-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 247: Hydraulic Pump

    O-ring ; 1B G145 Valve plate (R) The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. Fig. 24-3 24-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 248 351 Gear case 710 O-ring ; 1B G95 353 Drive gear 725 O-ring ; 1B P11 354 Driven gear 732 O-ring ; 1B P16 355 Filter 850 Locking ring 24-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 249 728 O-ring ; 1B P24 128 Bearing spacer 825 Snap ring 262 Cover 826 Snap ring 326 Gear case 885 Sprig pin 414 Capscrew ; M10×20 886 Pin 24-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 250: Auxiliary Pump

    The cylinder block (141) is also pressed against valve plate (313) by the action of cylinder spring (157). 151 . Fig. 24-5 Rotary group 24-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 251 2nd gear (117) and the 3rd gear (118), in that order, to drive the gear pump that is linked to the 3rd gear. 24-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 252 At normal 29 (21) 412,413 12 (8.9) 438,439 6.9 (5.1) 36 (27) PF 1/4 8.8 (6.5) NPTF1/16 160 (118) M30X1.5 16 (12) SECTION D-D 19 (14) Fig. 24-9 24-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 253 Solenoid proportional reducing valve Adjusting stem (C) O-ring ; 1B P22 The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. 24-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 254 The pump delivery rate is controlled according to the command current value corresponding to the movement of control devices. This relation is shown in right figure. Command current I Fig. 24-10 24-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 255 With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely. 24-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 256 Fig. 24-13. The operation of power control is the same as the flow rate control, and is explained below. Delivery output (Pd1) Fig. 24-13 24-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 257 With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely. 24-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 258 (897). In this mechanical selecting manner, the command on the side of low tilt angle of the flow rate control and power control has a priority. 24-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 259: Adjusting The Regulator

    Fig. 24-18 Adjusting the min. delivery flow No. of turns for tightening Pilot pressure Pi (Input current I) No change 4.6 (1.2) Min. increase in delivery flow L/min (gal/min) 24-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 260 Increase Pilot pressure MPa (psi) 0.18 (26) Input current I (Pilot pressure Pi) 18.5 (4.9) Decrease in delivery flow L/min (gal/min) Fig. 24-21 Adjusting the flow control characteristics 24-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 261 Disassemble and clean it. 4) Stick of pin (898) • Disassemble and clean it. Note : When the damage of part is severe, replace the part with new one. 24-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 262 38.0MPa (5510psi) (13) (22gal) Min.Flow(at 2100min 400mA (8gal) Delivery 40[MPa] pressure (725) (1450) (2175) (2900) (3625) (4350) (5075) (5800)(psi) 4 [MPa] Pilot pressure (580)(ps) (145) (290) (435) 24-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 263: Control Valve

    PAa1 Arm 1 Bucket (P4) (P4) (P3) (P3) Swing Boom Travel right P2 unload (T3) (T3) Travel left Travel straight PAa2 VIEW A Fig. 24-22 Outside view 24-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 264 Boom cylinder rod side port (down) Arm cylinder head side port (in) Arm cylinder rod side port (out) Bucket cylinder head side port (digging) Bucket cylinder rod side port (dump) 24-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 265 (Boom head, Bucket head, Arm rod) [MPa (psi)] Overload relief valve set pressure 37.8 (5481) [at 30 L/min (at 8 gal/min)] (Boom rod, Bucket rod, Arm head) [MPa (psi)] 24-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 266: Construction And Operation

    24.1.2.2 CONSTRUCTION AND OPERATION 24.1.2.2.1 CONSTRUCTION (1) Control valve PBa1 PAa1 (P4) 162 163 169 155 SECTION A-A PAa2 PBa2 (P3) SECTION B-B Fig. 24-23 Section (1/6) 24-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 267 Arm 2 Option PBp1 PBp1 PBp2 PBp2 (P3) (P3) PBa2 PBa2 PBp1 PBp1 PBp2 PBp2 274x4 275x4 (P4) (P4) (P3) (P3) PAa2 273x10 273x10 Fig. 24-24 Section (2/6) 24-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 268 24. COMPONENTS SYSTEM P1 unload Travel left CMR2 CMR1 ECTION C-C Travel straight Travel right Boom conflux (T3) ECTION D-D P2 unload Fig. 24-25 Section (3/6) 24-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 269 24. COMPONENTS SYSTEM Swing Boom SECTION E-E 164 551 Bucket Arm 1 PBa1 CRar PAa1 SECTION F-F Fig. 24-26 Section (4/6) 24-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 270 24. COMPONENTS SYSTEM Arm 2 Option PBa2 LCAT2 LCAP2 PAa2 SECTION G-G SECTION H-H Fig. 24-27 Section (5/6) 24-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 271 24. COMPONENTS SYSTEM PBp1 PBp2 278x5 SECTION J-J SECTION K-K Fig. 24-28 Section (6/6) 24-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 272 308 Arm 2 spool sub 974 Socket bolt ; M14×140 140~180 (103~133) 309 P1 unload spool 977 Name plate 310 P2 unload spool 978 Rivet 311 Option spool 24-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 273 163 O-ring 663 O-ring 512 Plunger 664 O-ring 521 Spring 28~31 (21~23) 671 Lock nut ; M14 541 Seat 46~52 (34~38) 673 Lock nut ; M24 561 O-ring 24-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 274 125 Filter 612 Spring seat 301 Piston 621 Spring 511 Plunger 651 Adjust screw 521 Spring 661 O-ring 522 Spring 28~31 (21~23) 671 Lock nut ; M14 24-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 275 Fig. 24-33 Travel straight spool Tightening torque Tightening torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 307 Spool 361 O-ring 16~18 (12~13) Loctite #638 350 Plug 371 Backup ring 24-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 276 N•m (lbf•ft) 101 Casing 10~14 (7.4~10.3) 171 Socket bolt 161 O-ring 49~59 (36~44) 201 Plug 164 O-ring 321 Spring 166 O-ring 511 Spool 167 O-ring 541 Sleeve 24-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 277 Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 98~120 (72~89) 101 Plug 301 Plunger 102 O-ring 302 Spring 201 Poppet 69~78 (51~58) 401 Plug 202 Spring 402 O-ring 24-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 278 Tightening torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 166 O-ring 542 Seat 202 Cover 25~29 (18~21) 554 Plug 541 Steel ball 7.9~9.8 (5.9~7.2) 555 Plug 24-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 279 Fig. 24-37 Boost check valve Tightening torque Tightening torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 101 Poppet 20~29 (15~21) Loctite #262 104 Plug 102 Poppet 107 Spring 24-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 280: Hydraulic Circuit Diagram

    Aa (H LC c Bucket PLc2 (ROD) B (HEA D) Ac Ba (ROD) LCAT2 LCAP2 Option Arm 2 PAa2 PBa2 PBp1 (P3) (P4) Fig. 24-38 Hydraulic circuit diagram 24-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 281: Operation

    (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. YP 1 YS 1 YB G1 Connected to low pressure circuit of P2 side casing Fig. 24-39 In neutral position 24-39 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 282 (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. Left travel motor Fig. 24-40 In left reverse travel (at PBL is pressurized) 24-40 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 283 CMR2 CMR2 CMR1 CMR1 To each actuator To each actuator To travel right To travel right Circuit (I) Circuit (II) Fig. 24-41 Movement of travel straight spool 24-41 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 284 (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may be occurred on bucket cylinder head side (H). (Stroke limiter ON) Fig. 24-42 In bucket digging operation (Stroke limiter ON) 24-42 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 285 T1. The return oil does not pass through boost check valve (517). Downstream of boost check valve (D') Downstream of boost check valve Fig. 24-43 In bucket dumping operation 24-43 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 286 (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. BH chamber Fig. 24-44 In boom up operation (Boom spool) 24-44 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 287 CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side. onflux passage To Ab port of P1 casing Fig. 24-45 In boom up conflux operation (Boom conflux spool) 24-45 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 288 (R) side again through port Bb. (Boom recirculation function) BH chamber Fig. 24-46 In boom down operation 24-46 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 289 (D') PBa2 PAa2 (D') Arm 2 To arm 1 spoo Aa (HEAD) PAa2 PBa2 (ROD) To pilot cut valve LCAT2 LCAP2 Fig. 24-47 In arm out operation 24-47 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 290 To arm 1 spool Aa (HEAD) PAa2 PBa2 [XR] (ROD) To pilot cut valve Circuit (I) LCAT2 LCAP2 Fig. 24-48 In arm in operation (At light load: arm recirculation function) 24-48 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 291 PBa2 To arm 1 spool [XR] Aa (HEAD) (ROD) To pilot cut valve Circuit (II) LCAT2 LCAP2 Fig. 24-49 In arm in operation (In heavy load operation) 24-49 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 292 (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. 321 322 Swing motor Fig. 24-50 Swing operation 24-50 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 293 N&B selector valve. 324 323 Oil passage to N&B valve. Fig. 24-51 Spool actuation for operation in option 24-51 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 294 Return oil from boom cylinder head Lock valve selector BH HAMBER PLc Sa Sb SE TION A-A Fig. 24-52 Lock valve operation (At boom spool neutral position) 24-52 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 295 RH CHAMBER Return oil from boom cylinder head Lock valve selector BH CHAMBER PLc Sa Sb SECTION A-A Fig. 24-53 Lock valve selector operation (At boom down operation) 24-53 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 296 (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309). [X1] PBp1 Fig. 24-54 By-pass cut valve (In normal operation) 24-54 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 297 (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented. PBp1 Fig. 24-55 By-pass cut valve (In condition of failure) 24-55 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 298 (D) to make up the deficient flow rate. (D') In normal operation In make up operation Fig. 24-56 Boost check valve operation 24-56 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 299 (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2. (D') Fig. 24-57 By-pass check valve operation 24-57 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 300 24. COMPONENTS SYSTEM This page is blank for editing convenience. 24-58 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 301 SECONDARY PRESSURE SECONDARY PRESSURE (145)1.0 1.0(0.74) (145)1.0 1.0(0.74) 0.94(0.69) 0.94(0.69) (87)0.6 (87)0.6 PUSH ROD STROKE (mm) PUSH ROD STROKE (mm) Operating angle (deg.) Operating angle (deg.) HYDRAULIC SYMBOL 24-59 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 302 216-1 Spring seat 68.6 (50.6) Adjust nut : M14 216-2 Spring seat Boots Washer 2 (Shim) Note) The parts marked * may not be equipped depending on valve type. 24-60 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 303: Operation

    (2,4) and the P port open while ports (2,4) and the T port close. Thus the secondary pressure is kept constant. P POR POR (2,4) POR (1,3) Fig. 24-61 When the lever is held 24-61 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 304 Thereafter, the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure connected with the P port. 24-62 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 305 6.4 + 0.64 7.7 + 0.77 (5.7 + 0.6) 12.7 + 1.27 (9.4 + 0.9) Operating Operating torque torque Control diagram [N . m (lbf . ft)] 24-63 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 306 (1) position and control spring (3). control ports 2-4 control ports 1-3 P line T line 24-64 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 307: Relief Valve

    Air breather port or PT3/4 98 (72) IP,L,AR Gear oil filling port IP, L, AR 12- 22 Through THREAD FOR EYE BOLT 2-M12 RELIEF VALVE PB PA Hydraulic diagram 24-65 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 308 7.4 L (1.96 gal) Grease Extreme pressure lithum base #2 grease Grease volume kg (lbs) Approx. 1.7 (3.7) Weight kg (lbs) 371 (818) Total weight kg (lbs) 446 (983) 24-66 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 309 24. COMPONENTS SYSTEM 24.1.5.2 CONSTRUCTION (1) Swing motor 702 712 ARRENGEMENT OF BRAKE SPRING 051-1 163 985 391 390 444 400-1 400-2 SECTION A-A 491 101 24-67 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 310 5.6 (4.1) 985 Plug ; PF1 351 Plunger 0.9 (0.66) 986 Plug ; PF1/4 355 Spring 98 (72) 994 Plug ; PT3/4 390 Name plate 391 Rivet 24-68 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 311 Shim ; t=0.3 Plate Shim ; t=0.5 Plate *1 : Apply Three Bond #1360K. *2 : Apply seal tape or Loctite #577. *3 : Apply Loctite #515. 24-69 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 312 The system has check plunger(351) and sucks in deficient oil, in order to prevent cavitation from M port occurring due to oil deficiency. (Make-up port) DIRECTIONAL VALVE Fig. 24-63 Operation of anti-cavitation check plunger 24-70 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 313 The load of the spring increases slowly till Fig. 24-68 Pressure boost characteristics piston 1 reaches the end of the adjust plug. The relief pressure P rises smoothly. 24-71 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 314 (321) and shifts it to the left. Seat (313) compresses weak spring (322) as Fig. 24-71 When brake pressure occurs pushed by plunger (311) and moves to the left. 24-72 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 315 (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). 24-73 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 316 (9) is linked with pinion shaft (2) by the involute spline, and pinion (1) is engaged with the swing gear fixed on the undercarriage (lower frame) and rotates. Bearing Fig. 24-76 Function of reduction unit 24-74 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 317 36 (26.6) Pilot (2 speed changeover) port Left (counter clockwise) D1, D2 PF1/2 98.1 (72.4) Drain port VA, VB 255 (188) Motor drive port MA, MB PF1/4 29.4 (21.7) Pressure measurement 24-75 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 318 Less than 1.54 (223) Working 0.2 (29) Allowable drain pressure MPa (psi) Surge 0.98 (142) Weight kg (lb) — Unit weight (with oil) kg (lb) 399 (880) 24-76 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 319: Travel Motor

    58 Coupling 19 Separating plate 39 O-ring 1B P11 59 Retaining ring C-type 40 20 Friction plate 40 Restrictor (brake valve) 60 G1/2 plug 61 O-ring 1B P18 24-77 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 320: Reduction Unit

    17 Planetary gear 1 27 O-ring 1B P24 Support ring 18 Thrust washer 1 Carrier 2 19 Needle bearing FBNP-406040 10 Planetary gear 2 20 Carrier pin 1 24-78 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 321 O RING 1B P7 CONNECTING PISTON 7-11 BACKUP RING 7-12 PLUG O RING 1B G2 PILOT BODY 7-13 BACKUP RING PISTON Fig. 24-80 Construction of overload relief valve 24-79 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 322 Spool control pressure : 0.59~0.95 MPa (86~138 psi) heck valve cracking pressure : 0.015 MPa (2.2 psi) HE K VALVE Fig. 24-81 Brake valve portion 24-80 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 323 (20) and separating plates (19) towards casing (1) and generates the friction force which brakes the rotation of cylinder block (13) and hence the shaft (9). Fig. 24-83 Parking brake portion 24-81 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 324 When PB goes down, the spool (31) moves to the right and the speed become high. TO COUNTERBALANCE VALVE (BRAKE VALVE) HIGH SPEED PILOT LINE (EXTERNAL PILOT) LOAD APPLICATION POINT Fig. 24-84 Capacity control Mechanism 24-82 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 325 (57-5) PORT B (57-4) AL E SEAT (57-3) PORT A ADJUSTING SPRING PISTON AL E (57-9) (57-7) (57-2) SMALL HOLE Fig. 24-85 Function of overload relief valve 24-83 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 326 (26), operates to avoid the cavitation and opens the passage from VA to MA or from VB to MB. Then the oil equivalent to the leakage is sucked from the tank line to the closed circuit. SPRING SPRING Fig. 24-86 Holding Operation 24-84 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 327 CHECK VALVE CHECK VALVE WITH RE TRICTOR WITH RE TRICTOR PILOT CHAMBER PILOT CHAMBER PRING PRING Fig. 24-87 Accelerating Operation 24-85 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 328 Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and the motor is mechanically stopped. ILOT CHAMBER ILOT CHAMBER S RING S RING Fig. 24-88 Stopping operation 24-86 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 329 The parking brake is released during pressure adjusting action of the spool (26). CHECK VALVE CHECK VALVE WITH RESTRICTOR WITH RESTRICTOR PILOT CHAMBER PILOT CHAMBER SPRING SPRING Fig. 24-89 Counterbalance operation 24-87 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 330: Function Of Reduction Gear

    This time, because carrier K2 is fixed to frame, gear d drives ring gear a and then ring gear a rotates to drive sprocket. Fig. 24-91 Two stages reduction gear 24-88 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 331: General View

    (15 rpm) A, B, C, D (Body) A, B, C, D (Stem) PF3/4 Ports size PF1/2 PF1/4 Length : L 368 mm (14.5") Weight 25 kg (245 lbs) 24-89 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 332 Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem (2). This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint. 24-90 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 333 SE.Asia LC01V00055F2 ø150 / ø100 1,193 3,005 / 1,812 With cushion on Bucket 265 (584) (5.91" / 3.94") (3'11") (9'10" / 5'11") rod side Oceania LC01V00055F1 24-91 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 334: Construction And Function

    23 Wiper ring Buffer ring 15 Piston 24 Pin bushing U-ring 16 Seal ring 25 Wiper ring Buckup ring 17 Buckup ring Wiper ring 18 Slide ring 24-92 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 335 U-ring 17 Buckup ring 27 Snap ring Buckup ring 18 Slide ring 28 Pin bushing Wiper ring 19 Slide ring 29 Wiper ring 10 O-ring 20 Shim 24-93 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 336 13 Cushion bearing 21 Set screw; M14×2 Buffer ring 14 Piston 22 Steel ball U-ring 15 Seal ring 23 Pin bushing Buckup ring 16 Buckup ring 24 Wiper ring 24-94 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 337 Mouth gap (23). So the returning oil volume drops suddenly and the piston movement slows down. ushion seal (23) Fig. 24-100 Cushion mechanism on the head side 24-95 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 338 24. COMPONENTS SYSTEM This page is blank for editing convenience. 24-96 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 339: Electric Equipment

    YT80S00001P1 L - 6 Boom work light (RH) YW80S00001F1 L - 7 Cab work light (for SE.Asia) YT80S00002F2 L - 9 Boom cyl. light (for SE.Asia) YT80S00002F1 24-97 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 340 ↑ R - 31 Wiper motor relay (Arc prevention) ↑ R - 32 Washer motor relay R - 45 Boom cyl. working light relay (for SE.Asia) YN24S00010P1 24-98 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 341 YN50S00040D4 SW - 26 Coolant level switch VHS834601510A SW - 27 Water separator switch VHS233002800A SW - 28 Boom, deck work light switch YN50S00040D1 SW - 55 24-99 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 342 DC 20~30V YN20M01468P1 Controller and panel are all in one. Air-con Controller YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ 24-100 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 343 16~32V (DC) Operating voltage LC10 - 07001 ~ 9~32V (DC) (at starter ON) Back-up source YC10 - 03501 ~ 5mA MAX (BAT=24V) (reference value) Connector 167 pins Male 24-101 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 344 GM terminal : 2962447 YT58S00006P1 GM connector : 2962448 Service meter YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ 24-102 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 345 YQ11 - 06001 ~ adsorption capability (Include initial absorption 2%) LC10 - 07001 ~ Refrigerant HFC-134a YC10 - 03501 ~ /300g 578cm Inner volume/Desiccant Inlet (From condenser) 24-103 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 346 Approx. 6.7 L (1.77 gal) YQ11 - 06001 ~ Negative Positive LC10 - 07001 ~ terminal terminal YC10 - 03501 ~ 17.9 19.5 (0.705") (0.768") 502 (19.76") 180 (7.09") 24-104 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 347 YQ11 - 06001 ~ LC10 - 07001 ~ Fix this resistance with tape HOUSING : 172131-5 YC10 - 03501 ~ TERMINAL : 170340-1 PVC tube (Black) Dial VIEW I 24-105 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 348 YM80S00001F2 VIEW I Flasher lamp (RH) Rear work light YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ SECTION A-A 24-106 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 349 1.5L (0.4 gal) Window washer Injection pressure 88.3 kPa (12.8 psi) or more YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ 24-107 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 350: Specification

    LC10 - 07001 ~ YC10 - 03501 ~ Black Blue Vynil tube (Red) Terminal C Terminal B Electric diagram E (AVX 0.85mm Black) E (AVX 0.85mm Blue) Tape 24-108 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 351 Wiper motor relay Washer motor relay Boom cyl. working light relay YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ Terminal arrangement 24-109 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 352: Terminal Number

    LC10 - 07001 ~ YC10 - 03501 ~ M16 x 1 Hex. : 17 Hex. : 22 Tightening torque : 47N . m (34.7 lbf . ft) 24-110 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 353 Tightening torque Econo seal J series O ring P14 : 73.5 N . m (Mark II (+) Common (+) JIS B2401 (54.2 lbf . ft) 3 pole 24-111 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 354 AMP MARK II (YN35V00047F1) HOUSING 174354-2 Connector specification TERMINAL 173706-1 YN35V00050F1 YN35V00051F1 YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ 24-112 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 355 YN11 - 45001 ~ Color : Black Hino P/No. : 82580-6830 YQ11 - 06001 ~ Yazaki P/No. : 7383-1114 LC10 - 07001 ~ YC10 - 03501 ~ 24-113 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 356 Conflux / single flow Insulation resistance DC500V megger switching (OPT) YN11 - 45001 ~ Terminal connector YQ11 - 06001 ~ Connector Position LC10 - 07001 ~ YC10 - 03501 ~ 24-114 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 357 YQ11 - 06001 ~ LC10 - 07001 ~ CONNECTOR YC10 - 03501 ~ Housing side (To ground) Mating connector M18, P=1.5 Hino P/No. : 82580-71808 Sumitomo P/No. : 6189-0189 24-115 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 358 Insulation resistance DC500V megger Boom work light switch YN11 - 45001 ~ YQ11 - 06001 ~ Terminal connector Connector LC10 - 07001 ~ Position YC10 - 03501 ~ 24-116 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 359 25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..........25-44 25.9.1 POSITION OF INDICATION FOR FAILURE............25-44 25.9.2 EXPLANATION OF INDICATION FOR FAILURE..........25-44 25.9.3 EXPLANATION OF MONITOR MODE..............25-46 Book Code No. S5LC2511E02 25-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 360: Air-Conditioner System

    Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC2511E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC2511E02 ↑ Revision February, 2007 (ASIA, OCE) 25-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 361: Air Cycle

    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. 25-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 362 EVAPORATION SENSOR INNER AIR AND OUTER AIR SWITCHING SIGNAL OUTER AIR INTAKE MOTOR ACTUATOR VENT INNER AIR MOTOR ACTUATOR AIR CONDITIONER UNIT FACE MOTOR BLOWER FOOT ACTUATOR CONTROLLER 25-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 363 27–4 Filter 35–2 Bracket 35–11 D tube : Ø 12 30 Panel assy 35–5 S hose : Ø 24.5 Filter 32 Compressor 35–6 D hose Solar radiation sensor 25-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 364 25. AIR-CONDITIONER SYSTEM 25.2.2 CONSTRUCTION (1) Air conditioner unit Fig. 25-2 Air conditioner unit (1/2) 25-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 365 25. AIR-CONDITIONER SYSTEM Fig. 25-3 Air conditioner unit (2/2) 25-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 366 43 Foot joint lever (2) Receiver dryer REFRIGERANT INLET REFRIGERANT OUTLET 2-M6 NAME Q'TY PRESSURE SWITCH SIGHT GLASS DESICCANT SUCTION PIPE FILTER RECEIVER TANK Fig. 25-4 Receiver dryer 25-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 367: Air Conditioner

    1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings. 2. Refrigerant volume : 900±50 g (2±0.1 lbs) 3. Tightening torque : T=N•m (lbf•ft) 25-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 368 L HOSE (8) L HOSE (7) 34 CONDENSER Note : RECEIVER DRYER MOUNTING BRACKET 35 RECEIVER DRYER Numbers in ( ) shows the number in Fig. 25-6. 25-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 369 N•m (lbf•ft) Receiver dryer L hose Bracket L hose Capscrew : M8×25 S tube Capscrew : M6×25 10 L tube S hose 11 D tube D hose 25-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 370 Therefore, always use a designated refrigerant for the cooling unit. Table shows the principal characteristics of the R134a refrigerant that is used in this machine. 25-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 371 35 C (95 ° ° Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 MPa (145psi), as seen from Fig. 25-7. 25-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 372: Cooling Circuit

    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. 25-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 373: Component Parts

    (damp vapor of low dryness). The expansion valve controls the feed rate of the refrigerant at the same time. 25-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 374 Fig. 25-11 Expansion valve outside view securely. The air-conditioner of this machine adopts a block type expansion valve. 25-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 375 For that purpose, it is necessary to secure ventilation required for the cooling of the refrigerant. Fig. 25-13 Condenser 25-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 376 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 0.2MPa (28psi). 25-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 377: Disassembly And Assembly

    (6) After the operation is over, confirm that all faults have been repaired completely, by operating the air-conditioner. 25-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 378 UPPER UNIT be caught by the casing. CASING AIR MIX ROD SUB AIR MIX ROD SUB LOWER UNIT CASING Fig. 25-17 25-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 379 3) Insert the sensor holder into the new evaporator 105mm at the position shown in Fig. 25-20 and install the (4.1 inch) evaporator sensor again. 11TH ROWS OF FIN EVAPORATION SENSOR Fig. 25-20 25-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 380 Remove the MA lever air MIX from the removed motor actuator, and install it on new motor actuator by the reverse procedure of AIR MIX ACTUATOR removal. PLUS SCREW 3PCS. Fig. 25-23 25-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 381 NNER AND OUTER A R SW TCH NG ACTUATOR Fig. 25-24 25-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 382: Charging Refrigerant

    Pay full attention to the entry of water and dust. • Be careful about overcharge of gas. • Fasten pipes to a specified torque. 25-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 383: Operating Procedure

    Blue : For service can hose low pressure side valve Yellow : vacuum pump side Vacuum High pressure For vacuum 3 Quick joint pump side pump adapter 25-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 384 GAS VALVE) Fig. 25-26 Connecting gauge manifold Some kinds of gauge manifolds are not equipped with an open/close valve in the center. 25-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 385 Fig. 25-27 Vacuum making operation If the gauge indication swings toward 0, there is somewhere that is leaking. Retighten pipe joints, make vacuum again and make sure of no leakage. 25-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 386 (electric type). Retighten and correct leaking points. • Always use the leak tester for R134a. (Do not use one for flon gas service as it provides poor sensitivity.) 25-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 387 Fig. 25-31 Receiver dryer • Never place the service can upside down. (The compressor valve may be scored because the refrigerant is sucked in a liquid state.) 25-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 388 [below 1MPa (140psi)]. 3. Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure side. 25-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 389 25. AIR-CONDITIONER SYSTEM This page is blank for editing convenience. 25-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 390: Electric Circuit

    2. The connector colors indicate the cord colors seen from the connecting part. Br Lg O LIGHT PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE Fig. 25-32 Electric diagram (1/2) 25-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 391 (FOR MODE) BLOWER OFF RELAY BLOWER MOTOR BLOWER AMP MOTOR ACTUATER (REC/FRESH) COMPRESSOR RELAY AIR CONDITIONER SIDE IN THE CAB WIRING (PARTS) Fig. 25-33 Electric diagram (2/2) 25-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 392 1. Disconnect the connector of blower amplifier. 2. Check continuity between terminals on the blower amplifier side. Fig. 25-35 * The installing position is provided on the left side of air-con unit. 25-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 393 OFF, the motor stops Fig. 25-37 rotating. 25-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 394 Inspection : Check for the continuity between Fig. 25-41 terminals. 25-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 395: Troubleshooting

    Inspect and replace. M/A failed or controller Inspect, correct or replace is out of order. M/A lever link. After cleaning lever link, apply grease. Replace. 25-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 396 Inspect and replace. Inspect, correct or M/A failed or controller replace M/A lever link. is out of order. Clean lever link and apply grease. Replace. 25-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 397 Inspect and correct harness or replace controller. Note 1) Measure with connector set. Note 2) Always turn off air-conditioner, starter key switch and light switch before work. 25-39 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 398 Is door or front window open? See CASE (1). The limiting or control operation See CASE (1). is actuated by door switch or front window switch. 25-40 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 399 M/A is disconnected or in poor or is broken. contact. Or M/A failed or main harness failed. Remove foreign matter M/A failed and replace parts. Inspect or replace. Replace 25-41 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 400 M/A or controller is out of order. foreign matter or is broken Erroneous motion occurs due to Replace. dirty grease. Remove foreign matter or replace parts. Clean cam and apply new grease. 25-42 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 401 Remove Clean clogging or condenser. Air is mixed. replace parts. Make vacuum and refill refrigerant. 25-43 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 402 ON, it functions. After correction of failure, if the main switch is not switched from OFF to ON the error indication and flickering are not released. 25-44 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 403 (3) Communication error of control amplifier and panel 1) E is indicated on the only use segment of display. heck the harness of control amplifier and panel for disconnection, and connectors for poor connection. 25-45 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 404 2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized. Therefore turn on ON/OFF switch again, and the error display is disappeared. 25-46 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 405 SOLAR RADIATION SHORT-CIRCUITING (0CH INDICATED) EACH SENSOR IS NORMAL SOLAR SENSOR 5V SIDE SHORT-CIRCUITING (C7H INDICATED) INNER AIR SENSOR SHORT-CIRCUITING (F6H INDICATED) EVAPORATOR SENSOR SHORT-CIRCUITING (F6H INDICATED) 25-47 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 406 25. AIR-CONDITIONER SYSTEM [MEMO] 25-48 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 407 31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY......31-3 31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ........31-3 31.1.2 INDICATION OF TIGHTENING TORQUE .............31-3 Book Code No. S5YN3118E01 31-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 408 SK210LC–8 : YQ11-06001~ SK250-8: LQ12-06001~ ↑ ↑ October, 2006 SK260LC–8 : LL12-05001~ ↑ ↑ December, 2006 SK850LC: LY01-00101~ ↑ E235BSR : YF05-02001~ ↑ February, 2007 E235BSR(N)LC : YU05-02001~ (NHK) 31-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 409: Indication Of Tightening Torque

    Tightening torque is indicated as follows, for example ; T=98N•m(72 lbf•ft) Tolerance is ±10% unless otherwise specified. • Refer to "Chapter 11 TOOLS" for standard tightening torque. 31-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 410 31. DISASSEMBLING AND ASSEMBLING [MEMO] 31-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 411 TABLE OF CONTENTS 32.1 REMOVING AND INSTALLING..................32-3 32.1.1 ATTACHMENT ASSY.....................32-3 32.1.2 BUCKET .........................32-3 32.1.3 ARM........................32-6 32.1.4 BOOM........................32-9 32.2 DISASSEMBLING AND ASSEMBLING................32-15 32.2.1 CYLINDER......................32-15 Book Code No. S5LC3211E01 32-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 412 (5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working. 32-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 413: Removing And Installing

    Fig. 32-2 Position to remove bucket (2) Removing capscrew (1) Loosen the double nut (2) and pull out the capscrew (1). O-RING SECTION A-A Fig. 32-3 Removing capscrew (1) 32-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 414 • Check the seals for damaged and replace as necessary. • When inserting the pin, coat the shaft with grease. Fig. 32-6 Attaching bucket 32-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 415 Remove shims (10), push out bushing (12) rightwards by means of three capscrews (7) and adjust clearance (B) so it settles within the standard value evenly all round. 32-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 416 (G). : 30mm SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in). SECTION A-A Fig. 32-11 Detail of bucket cylinder head pin (G) 32-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 417 Insert pin (F) into the original hole. Apply Loctite #242 After adjustment of shim, the total gap should be within 0.5mm (0.02in). SECTION A-A Fig. 32-14 Detail of boom top pin (F) 32-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 418 7) Tightening torque Tightening torque Classfication Size lbf . ft N . m Metric threads (BOOM TOP) 16.7 12.3 1/8" PF,PT threads 36.3 26.8 1/4" 32-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 419 (See Fig. 32- SHIM SHIM Apply grease to inner wall of bushing SECTION A-A Fig. 32-18 Detail of boom cylinder rod pin (C) 32-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 420 Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded. Weight of single boom : 2,670 kg (5,890 lbs) Boom assy temporary lift up procedure 32-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 421 Fig. 32-20 Details of boom foot pin (A) section (8) Hoisting boom assy Hoist and remove boom assy. Weight of single boom : 2,670 kg (5,890 lbs) Boom assy hoisting procedure 32-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 422 1) Disconnect hose (C2) at the position B and plug both end. Plug both end of disconnected pipes. Plug : Tools section 11.5.2-(4) Tools section 11.5.2-(5) : 41mm Fig. 32-22 Removing and installing boom cylinder 32-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 423 7) Tightening torque Tightening torque Classfication Size lbf . ft N . m Metric threads 1/8" 16.7 12.3 PF,PT threads 1/4" 36.3 26.8 3/8" 73.5 54.2 32-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 424 32. ATTACHMENT This page is blank for editing convenience. 32-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 425: Disassembling And Assembling

    An oil reservoir is required to collect oil spilt on the floor and waste oil. (8) Others Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary. 32-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 426: Necessary Tools

    At this time, V BLOCK connect a suitable hose to each port so that the hydraulic oil may not gush out. PORT A OIL PAN Fig. 32-26 Preparation 32-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 427 Back-up ring 17 Back-up ring Wiper ring 18 Slide ring Note : In case of piston with piston nut type, the parts with * are not used. 32-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 428 (4) Strike the corner of the rod cover flange by means of a plastic mallet till rod cover (3) comes off. Turn counterclockwise Cover here with cloths Fig. 32-29 32-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 429 (7) Remove slide ring (18) and (19) from piston (15). Remove slide ring by widening the slit toward the arrow Fig. 32-33 Remove slide ring (18) and (19) 32-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 430 (15) with hoist. In case that piston and piston nut are combined, the shim (20) is not used. Fig. 32-37 Removing piston (15) 32-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 431 BACK-UP RING SEAL RING USE CARE NOT O-RING TO DAMAGE THE GROOVE. Fig. 32-39 Removing seal ring (16) and back-up ring (17) 32-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 432 BUSHING See para 32.2.1.9.3 (1) for removing. BLOCK TOOL C Fig. 32-43 Removing rod bushing (4) 32-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 433 Before press fitting, apply grease on wiper ring and boss hole. OIL HOLE LOCATION • Before press fitting the pin bushing, align the Fig. 32-45 Press fitting of pin bushing (24) position of oil hole. 32-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 434 (D). And set retainer tool (D) on rod cover (3) RETAINER TOOL (D) and press fit wiper ring (9) with press. U-RING GROOVE Fig. 32-48 Press fitting of bushing (4) 32-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 435 • Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the insertion smooth. 32-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 436 If they are fitted in reverse directions, the cushion does not effective. After installing cushion, be sure that the cushion bearing moves up and down, and right and left. 32-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 437 Set the slide rings about 180 degrees apart with each other so that the slits may not point to the same direction. 32-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 438: Overall Assembly

    Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod surface with cloth is recommended to prevent damage to it. 32-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 439 • For storage, place the cylinder on wooden V- PLUG PLUG blocks and bring the cylinder to the most Fig. 32-61 How to store the cylinder retracted condition. 32-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 440 • Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in). • In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the surface. 32-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 441: Tightening Torque

    Volume of Internal Oil Leak Boom 1.0cc (0.06 cu•in) or below / 3min 1.0cc (0.06 cu•in) or below / 3min Bucket 1.0cc (0.06 cu•in) or below / 3min 32-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 442: Troubleshooting

    3. Piston rod 1. Elongation.Piston rod and piston 1. Replace piston rod. more than 0.5mm (0.02") in are elongated. (Loose nut) ten minutes.] 32-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 443 CORRECTING JIG For inserting rod cover 32.2.1.5.4 For above jigs, contact our dealer. (The Jig No. List provided by cylinder maker is shown in the following page.) 32-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 444 125 (4.92") 3012J-51001 inserting & correcting 130 (5.12") 3013J-01001 135 (5.32") 3013J-51001 140 (5.51") 3014J-01001 145 (5.71") 3014J-51001 150 (5.91") 3015J-01001 160 (6.30") 3016J-01001 170 (6.69") 3017J-01001 32-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 445 (2) Wrench for piston nut or [piston] Unit : mm (inch) Cylinder Used 115 (4.53") Boom, Bucket 135 (5.32") Fig. 32-64 Wrench for piston nut or [piston] 32-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 446 • Move rod cover onto the working bench holding tool attached. A EN WRENCH • Be careful not to drop it on foots, etc. 32-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 447 Set the pressing force to 2~3 tons (4410~6615 lbs). After completion of pressing, tighten adjuster bolt again by hand. • Press it with retainer tool (D). CHUCKING JIG A 32-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 448 • Press it with retainer tool (D). When the block and rod cover assy are not aligned, interrupt the work and align the block and rod cover assy. 32-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 449 Remove the wedge from the edge of chuck. • Clean the surface of work bench, and be careful for the tool not to be damaged by foreign matters like dust, chips, etc. 32-39 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 450 • This special tool differs according to the corresponding piston rod diameter. • The chuck edge is an important portion. Take care of handling and storage. CHUCK 32-40 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 451 • Be sure that the adjuster bolt is tightened to the extent that there is no gap between adjuster of chuck assy (A) and wedge. DJUSTER BOLT WEDGE 32-41 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 452 • Adjust it so that the press ram is centered to RETAINER(D) the tool. CHUCK(A) BUSHING(4) BUSHING PRESS- FITTING PART 32-42 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 453 LIFTING THREAD RETAINER JIG (D) ADJUSTER BOLT WEDGE CHUCK TOOL ASSY (A) CHUCK BLOCK TOOL (C) Bushing removing and press fitting jig (For reference only) 32-43 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 454 32. ATTACHMENT [MEMO] 32-44 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 455 HYDRAULIC PUMP • REGULATOR ..............33-54 33.2.2 CONTROL VALVE....................33-80 33.2.3 PILOT VALVE (ATT)....................33-111 33.2.4 PILOT VALVE (FOR TRAVEL)................33-121 33.2.5 SWING MOTOR UNIT....................33-130 33.2.6 SWIVEL JOINT.......................33-157 Book Code No. S5LC3311E02 33-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 456: Upper Structure

    (6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component and wiring are performed. (7) The explanatory note and figure of this manual may differ from the actual machine by the difference in specification. 33-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 457: Removing And Installing

    Lower rail …… Fixed on seat stand. [Forward 60mm (0.19in), backward 60mm (0.19in)] Amount of adjustment of seat height Fig. 33-2 Disassembling and Assembling armrest [Up; 23mm (0.07in), down; 37mm (0.16in)] 33-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 458 M6×40 one each, and remove front panel (A5-2) with air conditioner duct. : Plus driver A5-2 Fig. 33-4 Disassembly and assembly of right panels (A4-2), (A3) and (A5-2) 33-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 459 191 (140) Capscrew (A1)(A3) 79.4 (60) Torx driver 8.5 (6.3) Sems bolt M6 (A39)(A40) (T30) Plus driver 5.0 (3.7) Sems bolt M6 (A22)(A23) Fig. 33-7 Slinging cab 33-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 460 1) Loosen 2 capscrews (A4) M10×235. Fig. 33-9 Removing and installing battery cable : 17 mm 2) Remove plate (A3). 3) Remove battery (B1). Fig. 33-10 Removing and installing battery 33-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 461 (2) Installing grounding cable Install grounding cable (C4) last. Especially care must be taken that the grounding face is free from painting, rust, etc. : 13 mm 33-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 462: Preparation For Removal

    2) Remove 4 sems bolts (39) M12×25 on the side. 3) Remove guard (7) : 19 mm Weight : 11kg (24 lbs) Fig. 33-13 Removing guard (7) 33-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 463 1) Unlock panel assy (21). 2) Remove 4 nuts (4) M10. 3) Remove panel assy (21). : 17 mm Weight : 17kg (37 lbs) Fig. 33-17 Removing panel assy (21) 33-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 464 (15) : 6.5kg (14 lbs) guard (16) : 3.5kg (7.7 lbs) guard assy (17) : 2kg (4.4 lbs) !& !& Fig. 33-20 Removing guard assy (17) and guard (15), (16). 33-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 465 Fig. 33-23 Removing and installing of plate (49) (Refer to Fig. 33-22) 4) Loosen 5 sems bolts (5) M12×30. : 19 mm 5) Remove guard assy (13) Weight : 17kg (37 lbs) 33-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 466 (15)Remove plate (18) Loosen 3 sems bolts (39) M12×30, and remove plate (18). : 19 mm Weight : 2.9kg (6.4 lbs) Fig. 33-26 Removing and installing of plate (18) 33-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 467 (1) Installing is done in the reverse order of removing. (2) Tightening torque Unit : N . m (lbf . ft) Size Sems bolt 23.5 (17.3) 46.1 (34.0) 46.1 (34.0) 79.4 (58.6) 33-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 468: Under Cover

    Under cover (8) 4 pcs. 4.4kg ( .7 lbs) Fig. 33-28 Under cover assy 33.1.5.2 INSTALLATION (1) Install under cover (1,2,3,4,5,6,7,8) : 19 mm Tightening torque : 79.4 N•m (60 lbf•ft) 33-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 469 (2) Hook the wire to the lifting eye on the fuel tank assy (C1) and remove the fuel tank. Weight : 203kg (448 lbs) (3) Remove shim (A3). Record the shim locations. Fig. 33-30 Removing fuel tank 33-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 470 (A1) to install the tank. (2) Tightening torque Tightening torque Name Q'ty N . m (lbf . ft) 191 (140) Capscrew 1.96 (1.4) Machine screw 34 (25) Stop valve 33-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 471: Hydraulic Tank

    (6) Draining hydraulic oil Hyd.tank Place pump in tank and draw up hydraulic oil. Capacity of tank : 186 L (49gal) Fig. 33-33 Remove cover (C2), (C3) 33-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 472 3) Remove pilot hose (A14). : 22 mm Fig. 33-36 Remove pilot return hose (4) Remove drain hose (2) of pilot pump : 22 mm Fig. 33-37 Removing pump drain hose 33-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 473 Tightening torque : 373 N•m (275 lbf•ft) If the gap (looseness) between tank mount and frame exceeds 1mm (0.04inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank. 33-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 474 (9) Tighten sems bolts (C5) M10×25 that attach tank covers (C2), (C3). M10 Tightening torque : 46.1 N•m (34.0 lbf•ft) Replace O-ring fitted on the back side of tank cover with new one. 33-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 475 3) Remove those parts that are required to remove the hydraulic pump such as the fuel filter assy. 4) Remove drain hose at the bottom of the muffler. Fig. 33-41 Removing guards 33-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 476 S/V P1- PUMP B3 PUMP Psv1 2) Attach tags to hoses to identify. 3) Put a plug in the hoses and the pump. Fig. 33-43 Removing other hoses 33-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 477 Then remove and spring pin (2-8) from insert NA (2-3). : 17 mm 7) Removing bracket (1) Loosen 4 capscrews (3) M20×55, and remove bracket (1) from pump (0). 33-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 478 (2- : 17 mm Tightening torque : 465 N•m (343 lbf•ft) (See Fig. 33-45 about above mentioned (1) ~ (5).) 33-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 479 (20)Install guards (See Fig. 33-41,Fig. 33-20) ightening torque ightening position N m (lbf ft) Sems bolt M12 79.4 (59) Fig. 33-47 Bleed air port (Dr) in pump 33-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 480: Filter Element

    (LC11P00018S003) (LC11P00018S002) Tightening torque N . m (lbf . ft) Name O-RING (1-6) (EB11P00001S003) Indicator 3.9 (2.9) Sems bolt 39.2 (29) (Apply Loctite #262) Clip 5.9 (4.4) 33-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 481 Tightening torque: 68.6~98 N . m (5 ~72lbf . ft) Tighten nut ( ) till the no gap is here between plates of clamp. Installing clamp side (5) Fig. 33-51 Removing and installing the muffler 33-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 482 Tightening torque N . m (lbf . ft) Name Sems bolt 108 (80) (Apply Loctite #262) Capscrew 85 (63) 69 (51) (4) Replacing parts Name Part No. Muffler (1) LC12P00014P1 33-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 483 : 55 mm A1,A2 Tightening torque : 2,940 N•m (2,170 lbf•ft) Fig. 33-54 Fastening the counterweight attaching (5) Remove slinging tools, and install bonnet assy (11). capscrew 33-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 484: Radiator & Oil Cooler

    Fig. 33-56 Removing hose of sub tank (1) receiver tank. (10)Disconnect connector of coolant level switch (B5). (See Fig. 33-58) Fig. 33-57 Moving condensers and receiver tank 33-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 485 Fig. 33-59 Removing hose for radiator/inter-cooler (4) Remove guard (15), (16) (See Fig. 33-56) 1) Remove 5 sems bolts (27) M10×20. 2) Remove guard (15), (16). : 17 mm 33-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 486 Place a wire sling in the lifting eyes of the radiator assy and remove the assy by crane. Weight : 142kg (313 lbs) Fig. 33-60 Removing hydraulic oil hose (1), (2) 33-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 487 Coolant volume of engine body : 13 L (3.4gal) Coolant capacity of radiator : 11 L (2.9gal) Hydraulic oil capacity of oil cooler : 12 L (3.2gal) Fig. 33-62 Back-and-forth adjusting position of radiator 33-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 488: Drain Valve

    9) Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler. Confirm the missing of rubber bushing (14) under the inter-cooler. VIEW A Fig. 33-63 Removing radiator and inter-cooler 33-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 489 Removing these components can be done as necessary. (3) Installing Installing is done in the reverse order of removing. 33-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 490 ASSY FUEL FILTER OIL FILTER ELEMENT ELEMENT V BELT (2 PIECES) ALTERNATOR V BELT (COMPRESSOR) STARTER ENGINE V BELT (3 PIECES) Fig. 33-64 Outside view of engine 33-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 491 33. UPPER STRUCTURE 33.1.13.2 REMOVAL Fig. 33-65 Dismantling and mounting engine 33-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 492 Bolt 26.5 (20) Sems bolt 46.1 (34) Apply Loctite Sems bolt 46.1 (34) #262 Apply Loctite Sems bolt 115 (85) #262 Apply Loctite Capscrew 226 (167) #271 33-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 493 Tightening torque N . m (lbf . ft) Item Bolts Sems bolt M6 16~16C 8.5 (6.3) Sems bolt M6 23.5 (17.3) Fig. 33-68 Removing left armrest 33-39 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 494 (3) Tightening torque Fig. 33-71 Removing hoses between main C/V and ightening torque ightening position N . m (lbf . ft) multi C/V Sems bolt (B9) 70.6 (52.1) 33-40 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 495 PBs,PAa2,PBa2,Pao,Pbo,DR PF3/4 165 (122) 118 (87) Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 42.4 (31) Ab,Bb 57 (42) Sems bolt P1,P2 62.2 (45) T1,T2 96 (70) (2) Check for oil leak and operation. 33-41 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 496: Upper Side

    Bucket dump Bucket (H) stroke limit Bucket digging Boom up Boom down Drain Travel right reverse Travel right forward ATT power boost Fig. 33-73 Control valve ports (1/2) 33-42 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 497: Left Side

    Boom up Arm (H) relief valve Boom (R) relief valve Arm in Bucket (H) relief valve Option Bucket digging Arm 2 in Fig. 33-74 Control valve ports (2/2) 33-43 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 498 (Red) because pilot valve is made of aluminum. Arm (H) (Blue) Boom (H) (Green) LEFT SIDE RIGHT SIDE Fig. 33-77 Pilot valve port position (from upper side) 33-44 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 499 (7) Remove pilot valve lifting it upward. PF1/4 PF1/4 PF1/4 (8) Stop up holes with plugs PF1/4. HOSE SIDE PORT P PORT CONNECTOR CONNECTOR (With filter) Fig. 33-79 Installing and Removing pilot valve 33-45 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 500 : 17 mm T = 46.1 N•m (34.0 lbf•ft) Sems bolt (A8) : 13 mm T = 23.5 N•m (17.3 lbf•ft) Pressure sensor : 24 mm T = 16.7 N•m (12.3 lbf•ft) 33-46 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 501 : 8 mm Fig. 33-80 Removing swing unit piping Put in plugs half clamp, PF1, PF3/4, PF1/2, and PF1/4 into the removed ports. Fig. 33-81 Removing swing unit 33-47 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 502: Level Gauge

    Amount of oil : 7.4L (2.0gal) (2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leak and noise. 33-48 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 503: Swivel Joint

    T : Tightening torque of connector N . m (lbf . ft) SWIVEL JOINT T=36.3 (26.8) T=255 (188) T=255 (188) T=108 (79.7) T=108 (79.7) Fig. 33-83 Removing piping (lower side) 33-49 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 504 (B4), apply adhesive to the 2) Remove clip (B9). adhering surface of S/J and the upper frame. : Flat-blade screwdriver Fig. 33-86 Removing seal (B4) 3) Remove plate (B5), seal (B4). 33-50 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 505: Lower Frame

    78 (58) 162 (120) 118 (87) 255 (180) 137 (100) 1-3/16-12UN 177 (130) (2) Check for oil leak and the hydraulic oil level. (3) Check for operating. 33-51 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 506: Upper Frame

    Sling according to Fig. 33-88, and remove upper frame and put it on a stand. Weight : Approx. 5ton (11,000lbs) Fig. 33-90 Removing upper frame attaching bolts 33-52 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 507 Install 34 capscrews (10) M24×135. : 36 mm Apply Loctite #262 Tightening torque : 932 N•m 687lbf•ft) Fig. 33-92 Reamer bolt position (*) Apply Loctite to shaded area 33-53 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 508 33.2.1 HYDRAULIC PUMP • REGULATOR 33.2.1.1 HYDRAULIC PUMP 33.2.1.1.1 Structural exploded view (1) Main pump 531 . 151 . Fig. 33-93 Structural exploded view of main pump 33-54 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 509 12 (8.9) 57 (42) 36 (27) PF 1/4 74 (55) PF 3/8 170 (125) PF 3/4 8.8 (6.5) NPTF1/16 240 (177) 531,532 M24X2 130 (95) 240 (177) 33-55 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 510 351 Gear case 710 O-ring ; 1B G95 353 Drive gear 725 O-ring ; 1B P11 354 Driven gear 732 O-ring ; 1B P16 355 Filter 850 Snap ring 33-56 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 511 6) Remove socket bolt (401) Loosen socket bolts (401) that fasten swash plate support (251), pump casing (271) and valve block (312). : 17 mm Fig. 33-95 Remove socket bolt (401) 33-57 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 512 An oil seal is fitted to seal cover (F). Therefore, use care so as not to score the oil seal. Fig. 33-98 Removing seal cover F (261) 33-58 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 513 Tap lightly the shaft end (111, 113) by means of a plastic hammer and draw out the shaft from the swash plate support. ! Fig. 33-101 Drawing out the shaft (111), (113) 33-59 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 514 • Do not loosen hex nuts (806),(808) of valve block (312) and swash plate support (251). A set flow rate changes. Fig. 33-103 Removing other parts 33-60 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 515 • Do not damage the sliding surface of shoe plate. Fig. 33-105 Installing swash plate (212) 33-61 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 516 (312) by aligning pin. • Do not mistake the suction and delivery sides of the valve plate. (313 : Opposite Side) Fig. 33-109 Installing valve plates (313), (314) 33-62 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 517 The work is complete when drain port VP plugs (466), (468) have been set. : 19 mm, 36 mm Tightening torque ; 36 N•m (27 lbf•ft) Tightening torque ; 170 N•m (125 lbf•ft) 33-63 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 518 Height=H-h cylinder bore : D-d Gap between piston and shoe : Free height cylinder spring : L thickness of shoe : t 33-64 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 519 4. Attached valve is out of order. 4) Check attached valve. 4) Refer to Manual for Attached Valve. Particularly poppet, seat and spring. 5. Regulator is piped incorrectly. 5) Pipe correctly. 33-65 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 520 5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual. 6. Relief valve in attached valve is 6) Repair attached valve. 6) See the Manual for Attached Valve. hunting. 33-66 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 521 33. UPPER STRUCTURE This page is blank for editing convenience. 33-67 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 522 33. UPPER STRUCTURE 33.2.1.2 REGULATOR 33.2.1.2.1 Structural exploded view 8-724 Fig. 33-112 Structural exploded view of regulator 33-68 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 523 N . m (lbf . ft) 29 (21) 412,413 12 (8.9) 438,439 6.9 (5) 36 (26) PF 1/4 8.8 (6.5) NPTF1/16 160 (118) M30X1.5 16 (12) 19 (14) 33-69 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 524 (801) and set screw (924). Do not loosen those screws and nuts. If they are loosened, 629( 628 ) preadjusted set pressure and flow values change. 630 924 Fig. 33-114 Removing cover (C) (629) 33-70 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 525 (614) and adjust plug (615). • Fulcrum plug (614) and adjust plug (615) come off easily if a M6 bolt is used. " Fig. 33-118 Removing adjust plug (615) 33-71 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 526 1 (612). Fig. 33-121 Removing feedback lever (611) [1] Fig. 33-122 Removing feedback lever (611) [2] 33-72 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 527 Remove VP plug (466) from pilot cover (641), and draw out spool (642) and spring (662). This completes disassembly. " " " Fig. 33-124 Part of exploded view of regulator 33-73 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 528 (612) SODE • Take care so as not to mistake the direction of the feedback lever. Fig. 33-127 Assembling feedback lever (611) 33-74 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 529 Assemble return spring (654) and spring seat (653) into the spool hole and fit snap ring (814). #" Fig. 33-131 Installing return spring (654) and spring seat (653) 33-75 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 530 14) Installing block cover (See Fig. 33-113) Attach block cover (656). : 5 mm Tightening torque ; 12 N•m (8.7 lbf•ft) Fig. 33-135 Installing cover (C) (629) This completes assembly. 33-76 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 531 728 O-ring ; 1B P24 128 Bearing spacer 825 Snap ring 262 Cover 826 Snap ring 326 Gear casing 885 Spring pin 33 (25) 414 Socket bolt ; M10×20 886 Pin 33-77 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 532 : 8 mm COVER PTO GEAR CASING COVER Fig. 33-136 Removing gear pump HOLE FOR FLANGE (435) SOCKET GEAR CASING Fig. 33-137 Removing PTO gear casing 33-78 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 533 In case a pitching (1 pit is more than 1mm (0.039in), 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. 33-79 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 534: Sectional View

    33. UPPER STRUCTURE 33.2.2 CONTROL VALVE 33.2.2.1 SECTIONAL VIEW PBa1 PAa1 (P4) 162 163 169 155 SECTION A-A PAa2 PBa2 (P3) SECTION B-B Fig. 33-140 Section (1/6) 33-80 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 535 Arm 2 Option PBp1 PBp1 PBp2 PBp2 (P3) (P3) PBa2 PBa2 PBp1 PBp1 PBp2 PBp2 274x4 275x4 (P4) (P4) (P3) (P3) PAa2 273x10 273x10 Fig. 33-141 Section (2/6) 33-81 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 536 33. UPPER STRUCTURE P1 unload Travel left CMR2 CMR1 ECTION C-C Travel straight Travel right Boom conflux (T3) ECTION D-D P2 unload Fig. 33-142 Section (3/6) 33-82 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 537 33. UPPER STRUCTURE Swing Boom SECTION E-E 164 551 Bucket Arm 1 PBa1 CRar PAa1 SECTION F-F Fig. 33-143 Section (4/6) 33-83 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 538 33. UPPER STRUCTURE Arm 2 Option PBa2 LCAT2 LCAP2 PAa2 SECTION G-G SECTION H-H Fig. 33-144 Section (5/6) 33-84 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 539 33. UPPER STRUCTURE PBp1 PBp2 278x5 SECTION J-J SECTION K-K Fig. 33-145 Section (6/6) 33-85 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 540 140~180(103~133) 308 Arm 2 spool sub 974 Socket bolt 140~180(103~133) 309 P1 unload spool 977 Name plate 310 P2 unload spool 978 Pakerrizing rivet 311 Option spool 33-86 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 541: Preparation For Disassembly

    Disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate mounting surfaces. Fig. 33-146 Preparation for disassembly 33-87 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 542 (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (327), (329) and stopper (336) from P1 unload spool (309). Fig. 33-149 Disassembling P1 unload spool assy (309) 33-88 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 543 (331), springs (323), (324) and stopper (336) from travel spool (306). Fig. 33-152 Removing right travel spring cover (201) Fig. 33-153 Disassembling travel spool (306) assy 33-89 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 544 (333) from casing B (102). When drawing out the spool assy, take care so as not to score casing B (102). Fig. 33-156 Removing spring cover (203) 33-90 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 545 (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303). Fig. 33-159 Drawing out swing spool (303) assy 33-91 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 546 (551) with casing B (102) installed. After removed cover (209) from casing B (102), remove plug (551) and then take out piston (216). Fig. 33-162 Disassembling bucket spring cover (209) 33-92 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 547 (340) from arm 2 spool (308). Do not disassemble arm 2 spool (308) further unless there is special reason. Fig. 33-166 Disassembling arm 2 spool (308) assy 33-93 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 548 (3) Fix the travel straight spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (327, 329) and stopper (336) from travel straight spool (307). 33-94 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 549 Loosen socket bolts (273) and remove spool cover Fig. 33-172 Removing spool cover (205),(206) (206) and O-ring (264). Do not disassemble spool cover (208) further unless there is special reason. 33-95 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 550 Regarding the disassembly of the relief valves themselves, do not disassemble it. Fig. 33-174 Removing overload relief valve (602) and (603) Fig. 33-175 Removing plug assy (604) for relief valve hole 33-96 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 551 Removing back pressure check valve (1) Loosen socket bolt (278) and remove back pressure check valve (207) from the casing. Fig. 33-178 Removing back pressure check valve cover (207) 33-97 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 552 (1) Loosen socket bolts (274), (275) and remove plates (212), (213). (2) After removing plates, remove all O-rings (162), (163) remained on the casing side. Fig. 33-180 Removing plate (212),(213) 33-98 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 553 Do not disassemble further if unnecessary. 33.2.2.3.19 Disassembling casing Further disassembly of the casing is not allowed. 33-99 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 554 4) 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. 5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance Standards." 33-100 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 555 (1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque. Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve. 33-101 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 556 (3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and tighten socket bolt (273) to the specified torque. 33-102 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 557 (3) 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. 33-103 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 558 (3) Attach 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. 33-104 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 559 Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place. (3) 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. 33-105 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 560 Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque. (3) Boom Place O-ring (264) in spool cover (208) and tighten socket bolt (273) to the specified torque. 33-106 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 561: Maintenance Standards

    2) Inspect the contact face of the valve seat. 2) If damaged, replace. 3) Inspect the O-ring, backup ring, and seal. 3) As a general rule, replace all parts with new ones. (Between casing and seal) 33-107 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 562: Troubleshooting

    • Broken or deformed spring. • Remove foreign matter. and attachment. • Clogged small hole in spool. 2) Malfunctioning main relief valve. 2) Remove main relief valve. 33-108 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 563 (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2)) 3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure. to item 1. 1) above. (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2)) 33-109 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 564 2) Sticking component due to foreign matter. 2) Confirm that there are no scratches, scores, or foreign matter present before reassembling. If failure is found, replace it an assembly. 33-110 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 565: Cross-Sectional View

    312 Adjust nut : M14 68.6 (51) 216-2 Spring seat 501 Boots 217 Washer 2 (Shim) Note) The parts marked * might not be equipped depending on valve type. 33-111 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 566 : 22mm, 32mm Fig. 33-185 Removing adjusting nut (312) (4) Remove circular plate (302) : 32mm Fig. 33-186 Removing circular plate (302) Fig. 33-187 Circular plate is removed 33-112 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 567 Pull plug (211) out with a driver. To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is completely released. Fig. 33-191 Removing plug (211) 33-113 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 568 2) from push rod (212). *218-1 *218-1 *246 *246 *218-2 *218-2 The parts marked * might not be equipped depending on valve type. Fig. 33-195 Disassembling push rod 33-114 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 569: Cleaning Parts

    (1) Fit washer 2 (217), springs (241-1), (241-2), spring 201-1 201-1 241-1 241-1 216-1 216-1 seats (216-1), (216-2) to spool (201-1), (201-2). 216-2 216-2 201-2 201-2 241-2 241-2 Fig. 33-198 Assembling pressure reducing valve 33-115 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 570 And install spring seat (*218-2) to push rod on port 2,4 side. The parts marked * might not be equipped depending on valve type. 218-1 218-1 Fig. 33-202 Assembling push rod, spring (246) and seat (218) 33-116 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 571 (7) Install joint (301) on casing (101) with jig A securely. Jig A : See 33-120. Tightening torque : 47.1 N•m (35±2.2 lbf•ft) Fig. 33-205 Installing joint (301) 33-117 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 572 (212). GREASE GREASE (11)Cover it with boots. (12)Spray rust preventives through each port and attach plug respectively. Fig. 33-207 Applying grease to joint section and push rod 33-118 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 573 3) Bleed air by operating it several times. 1) Tank line pressure is high. 1) Bring pressure directly to oil tank. Secondary pressure is high 2) Sliding parts are caught. 2) Correct. 33-119 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 574 Installing condition on joint * (1) and (2) are tight fitted Sectional drawing of jig Material ; SCM415 (N) Carburizing and Quenching Q'ty ; 2 Detail of bushing 33-120 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 575 17-w’ Shuttle valve & orifice 10 Control spool 17-r Ball M6, 35 Return spring 17-z Orifice M5, ø0.8 12 Damper flange kit 21 Plug 12-o Damper plunger ø14 33-121 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 576 4) Mark out the position of the switch plate before removing it. Fig. 33-210 5) Repeat the operation for the second switch plate. 6) Reassemble parts in reverse order. 33-122 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 577: Switch Plate

    8mm socket wrench. (See Fig. 33-213) * Reassembly : • Apply a droplet of Loctite #262 on the screw thread. • Torque :30 N•m (22 lbf•ft) Fig. 33-213 33-123 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 578 4) Using a needle, remove the seal placed inside usingneedle the body (See Fig. 33-217 No.3, 4) * Reassembly : • Replace with a new seal and grease it. BODY Fig. 33-217 33-124 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 579 4) Repeat the operation for the other 3 sub- assemblies. 5) Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-assemblies. Fig. 33-219 33-125 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 580 Both rubber boots (See 33.2.4.2 (1)) • Both switch plates (See 33.2.4.2 (2)) • The retaining plate (See 33.2.4.2 (4)) • The damping plungers and springs (See 33.2.4.2 (5)) Fig. 33-222 33-126 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 581 Apply a droplet of Loctite #242 on the shuttle valve thread. • Torque :4 N•m (3 lbf•ft) Wait for 8 hours before using the machine to let the Loctite #242 dry completely. Fig. 33-225 33-127 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 582: Shuttle Valve

    5) Inspect the check valve plugs, O-rings and balls. If defects are detected, replace all the assemblies. (See Fig. 33-229) 6) Reassemble parts in reverse order. HE K VALVE PLUG BALL Fig. 33-229 33-128 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 583 (6) Operate gently the pedal until the bubbles disappear. (7) Tighten the check valve plug. • Torque : 5 N•m (3.7 lbf•ft) (8) Repeat the operation for the other check valve plug. Fig. 33-230 33-129 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 584 33.2.5.1 CONSTRUCTION (1) Swing motor 702 712 ARRENGEMENT OF BRAKE SPRING 051-1 163 985 391 390 444 400-1 400-2 SECTION A-A 491 101 Fig. 33-231 Swing motor 33-130 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 585 984 Plug ; PF1/2 351 Plunger 5.6 (4.1) 985 Plug ; PF1 355 Spring 0.9 (0.65) 986 Plug ; PF1/4 390 Name plate 98 (72) 994 Plug ; PT3/4 33-131 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 586 16 Oil seal 36 Shim ; t=0.1 17 Sleeve 37 Shim ; t=0.2 18 Sleeve 38 Shim ; t=0.3 19 Plate 39 Shim ; t=0.5 20 Plate 33-132 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 587 Slide hammer bearing puller 14 (0.551") 85 (3.35") 75 (2.95") 30 (1.18") 15 (0.591") Through Brake piston drawing tool BRAKE PISTON DRAWING TOOL BRAKE PISTON o 8 (0.315") CASING 33-133 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 588 Choose a clean place, and lay with a rubber sheet or a cloth on a work bench. Handle the valve casing with care so parts do not have dents. Fig. 33-233 Removing valve casing (303) 33-134 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 589 Handle the parts with care so as not to score the sliding surfaces of cylinder block (111) and shoe (122). Fig. 33-236 Drawing cylider block (111), piston sub assy, friction plate (742) and separator plate 33-135 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 590 (303), using a slide hammer bearing puller. Put the inner race on the press bench. Fig. 33-238 Removing inner race of roller bearing (443) 33-136 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 591 (301), by lightly tapping the steel rod. 5) Attach drive shaft (101) to casing (301). Fig. 33-240 Fitting oil seal (491), outer race of roller bearing (443), and drive shaft (101) 33-137 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 592 Assemble four slits in the four claws of separator plate Position of (743) in the position of Fig. 33-243. separator plate (743) PG PORT Fig. 33-243 Installing of separator plate (743), friction plate (742). 33-138 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 593 Tightening torque : 177 N•m (130 lbf•ft) 18) Fit anti-reaction sub assy (052) to valve casing (303). : 6 mm, Tightening torque : 29 N•m (22 lbf•ft) 33-139 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 594 Plastic hammer (Wooden mallet) Press 30 ton (66150 lb) class Flat-bladed screw driver General tools Allen wrench, Steel bar Thread sealant Three Bond #1360K Sealant Loctite #515 33-140 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 595 (25)] can be removed from the spline easily if it is lifted up in that condition. Fig. 33-246 Removing #1 sun gear and #1 spider assy 33-141 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 596 (20). Attach eyebolt (M8) to pinion (1) and hoist pinion (1). : 24mm • When oil seal (16) is separated from housing (15), oil seal (16) and is pinion (1) are removed together. Fig. 33-250 33-142 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 597 JIG (b) Press force : 30t • Do not use the removed bearing. Fig. 33-253 Removing spherical bearing (lower) (11) 33-143 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 598 (23), pinion (7) and needle bearing (11). Fig. 33-256 Disassembling #2 spider assy Pinions (7) can not be replaced singly. Replace them it in a set of four. 33-144 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 599 Press force : 4~5t • Since the bearing is formed with a partition at the center section, seal grease in it from both sides. Fig. 33-258 Fitting spherical bearing (lower) 33-145 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 600 Fig. 33-260 Placing pinion shaft assy in 3) Assembling plate (19) Place plate (19) and attach ring into groove of housing, and fix plate. 19 21 Fig. 33-261 Assembling plate (19) 33-146 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 601 (2) and housing (15) at the same time by means JIG (g) of jig (g). In this case insert sleeve (17) in advance. Fig. 33-264 Spherical bearing (upper) Press-fitting 33-147 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 602 Fig. 33-267 Assembling #2 spider assy (5) Installing #2 spider assy #2 SPIDER ASSY Insert #2 spider assy in spline axis of shaft (2). Fig. 33-268 Assembling #2 spider assy 33-148 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 603 Coat socket bolts (27) with sealant Three-Bond ACHING 1360K and fasten them. ARKS : 17 mm, Tightening torque : 539 N•m (398 lbf•ft) Fig. 33-272 Installing swing motor assy 33-149 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 604: Swing Motor

    ( ) Replace piston and shoe assy. (0.0112) Thickness of shoe (t) Replace piston and shoe assy. (0.236) (0.228) Thickness of friction plate Replace. (0.157) (0.142) 33-150 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 605 Lap each sliding surface to a standard roughness level or finer. • If the spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts in pairs. 33-151 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 606: Swing Reduction Gear

    Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish gear oil SAE90 (API Service Grade GL-4). 33-152 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 607 Socket bolt tightening torque M20— 539 N•m (398 lbf•ft) tighten to specified torque. Gear oil SAE90 Lube oil 7.4 L (2.0 gal) Replenish or replace. (API Service Grade GL-4) 33-153 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 608 2. Oil leaks are excessive due to high 2. Lower oil temperature. temperature. 3. Sliding surfaces are worn or damaged. 3. Replace. 33-154 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 609 2. O-ring has a scratch. 2. Replace. 3. Seal surface has a scratch. 3. Disassemble and correct. 4. Bolt is loose or damaged. 4. Tighten to specified torque or replace. 33-155 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 610 The amount of grease is small. Fill up grease. Replace reduction unit. Gear and bearing are damaged. 33-156 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 611 Part name Q’ty Part name Q’ty Body O-ring (G95 1A) Stem Socket bolt (M8×20) Thrust plate Socket bolt (M8×30) Cover 12 Plug Seal 13 O-ring (P80) Seal assy 33-157 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 612 33.2.6.2.3 Cleaning outside Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil. • Keep all ports plugged up while cleaning. 33-158 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 613 By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand. Stem weight : 10.5 kg (23 lbs) ORK BENCH V-BLOCK Fig. 33-277 Drawing out stem (2) 33-159 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 614 (6) and O-ring (13). (1) Assembling seals to body 1) Apply hydraulic oil to O-ring (13) thinly and insert it in O-ring groove. Check the twist of O-ring 33-160 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 615: Work Bench

    (8), coat it with Loctite #242 and tighten to stem (2). : 6 mm, Tightening torque : 30.4 N•m (22 lbf•ft) Fig. 33-282 Tightening socket bolt (8) 33-161 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 616 (9) with Loctite #242 and tighten it which will then complete assembly. : 6 mm, Tightening torque : 30.4 N•m (22 lbf•ft) ALLEN WRENCH PIPE Fig. 33-283 Tightening socket bolt (9) 33-162 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 617 2) Worn less than 0.5mm (0.02in). Smooth Sliding surface with thrust Cover plate 3) Damage due to seizure or contamination Smooth repairable within wear limit 0.5mm (0.02in). 33-163 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 618 Replace Slipper ring (With back-up ring) 1.5mm (0.02in) (max.) BACKUP RING 3) Worn unevenly more than 0.5mm (0.02in) .5mm ( . 2in) Replace (max.) (With back-up ring) 33-164 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 619 2) Inappropriate swivel stopper bracket 2) Reinstall Secure 2~3mm (0.08~0.12in) allowance for bolt stopper. 4. Loose swivel stem and cover Socket bolt tightened insufficiently. Retighten. 33-165 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 620 33. UPPER STRUCTURE [MEMO] 33-166 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 621 TRAVEL MOTOR ASSEMBLY ................34-46 34.2.5 TRAVEL MOTOR ....................34-51 34.2.6 TRAVEL MOTOR TROUBLESHOOTING ..............34-54 34.2.7 REDUCTION UNIT DISASSEMBLY...............34-56 34.2.8 ASSEMBLING ......................34-62 34.2.9 MAINTENANCE STANDARD.................34-68 Book Code No. S5LC3411E02 34-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 622: Travel System

    (5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working. 34-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 623 Fig. 34-3 Removing / fixing position of master pin • When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by flying objects. 34-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 624 Apply press fitting jig on master pin, and strike it on master pin with a mallet to press fit. Fig. 34-7 Press fitting of master pin (5) Set the stopper pin. 34-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 625 1–10 ••Seal 2–10 ••Seal 1–11 ••Pin 2–11 ••Pin •Shoe 600mm — •Shoe 600mm — •Shoe 800mm — •Shoe 800mm — •Bolt LC60D01001P1 •Bolt LC60D01001P1 •Nut 2420Z1414 •Nut 2420Z1414 34-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 626 34.1.2.5 TOOLS AND JIGS (1) Tightening tools Unit : mm Name Opposing flats 19, 32 Socket (2) Jig Name Shape Master pin fixing jig for iron crawler 34-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 627 3) Apply Loctite #262 on capscrew M20×150, and tighten it to the specified torque. : 30 mm Tightening torque : 539 N•m (400 lbf•ft) Fig. 34-12 Installing upper roller 34-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 628: Disassembly And Assembly

    Put the extrusion jig (h) against the end face of shaft (2) and push shaft (2) with collar (3) for floating seal (13), using a press or hammer. Fig. 34-15 Extruding shaft 34-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 629 In that case, do not re-use the bushing as it may develop malfunctioning after assembly. Fig. 34-19 Fixing floating seal 34-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 630 Tightening torque : 23N•m (17 lbf•ft) • After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by hand. Fig. 34-22 Filling oil 34-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 631: Maintenance Standard

    Tightening torque of socket 114.7 N•m (85 lbf•ft) Apply loctite #262 bolt Engine oil API grade CD #30, 100cc (6.1cu•in) Refill or replace Roller rotation Roller rotates smoothly by hand. 34-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 632 Allen wrench (2) Jigs Unit : mm (in) Name Shape 160 (6.30") 120 (4.72") Stand jig 50 (1.97") For extruding shaft Bushing fixing 65 (2.56") (0.787") (3.35") 34-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 633 Tightening torque : 932N•m (690 lbf•ft) (3) Adjusting tension of crawler. Tighten grease nipple and fill it with grease. : 19 mm, Tightening torque : 59N•m (43 lbf•ft) 34-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 634 The shaft (3) extrusion operation may cause the Jig M remaining lube oil to flow out. Prepare an oil container beforehand. Fig. 34-28 Removing shaft (3), collar (2) 34-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 635 Put the extrusion jig (N) uniformly over the circumference of bushing (4) and extrude it Fig. 34-31 Extruding bushing (4) perpendicularly little by little. 34-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 636 6) Inserting roller (1) Insert roller (1) from the side where collar (2) is not press-fitted to the shaft (3). Fig. 34-35 Inserting roller (1) 34-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 637 Fig. 34-37 Installing filling oil plug (8) Tightening torque : 23 N•m (17 lbf•ft) After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by hand. 34-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 638 Engine oil API grade CD #30, 430cc (26.14cu•in) Refill Execute air leak test at 0.2MPa (28psi) before tightening the Plug (8) plug. Roller rotation Rotates smoothly by hand. Reassembly 34-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 639 Pin (5) extrusion rod 300 (11.8") Bushing extrusion rod 400 (15.7") Stand jig 400 (15.7") Shaft extrusion jig 104 (4.09") Bushing fixing jig +0.1 74.6 +0.004 (2.94" 34-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 640 Weight of idler adjuster assy :186 kg (410 lb) • The separated idler assy (1) should be placed on square timbers. Fig. 34-41 Separating idler assy (1) from idler adjuster 34-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 641 If removal of collar (2) on the opposite side is required, turn over front idler and proceed with the procedure described in Par. 3). Fig. 34-45 Removing collar (2) 34-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 642 (3). 6) Installing floating seal (6) Fit floating seal (6) on the other side of idler (1). Fig. 34-49 Inserting idler (9) and installing floating seal (6) 34-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 643 • After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly. 34-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 644 Interference between idler and ø 89 (+0.0014) Clearance 0.01 bushing (3.504) (0.0004) Engine oil API grade CD#30, 350cc (21.4cu•in) Refill Idler rotation Rotates smoothly by hand. Reassemble 34-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 645 Applox 200 (8") Applox 800 (32") Stand Applox 500 (20") 2 Piece 115 (4.53") Bushing Press fitting +0.1 84.6 +0.004 (3.33" 120 (4.72") W Collar Press fitting jig 34-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 646 Free length of spring (27.0in) Stroke 53mm (2.09in) Set length 797mm (31.4in) Nor scoring and Outside view of piston rusting Tightening torque of 59N•m (43 lbf•ft) grease nipple A, B 34-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 647 Remove the wooden blocks under the truck frame, bring the machine down on the ground and tighten the sprocket. : 30 mm Tightening torque : 539 N•m (400 lbf•ft) Fig. 34-55 Securing sprocket temporarily 34-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 648 O.D. of sprocket bottom ø 664.05 (26.1) ø 656 (25.8) ø 654 (25.7) repair or replace. 34.1.6.4 TOOLS AND JIGS (1) Tightening tools Unit : mm Name Opposing flats Socket 34-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 649 34. TRAVEL SYSTEM (2) Sprocket tooth profile gauge : W Fig. 34-57 Tooth profile gauge (Full scale) 34-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 650 Fig. 34-60 Removing and installing hydraulic pipe : 19mm, 27mm, 32mm, 41mm Refer to hydraulic pipe plug 5-1 (Refer to LC11 Tools). plug for flare hose 5-2 (3) (Refer to LC11 Tools) 34-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 651 At starts the machine, run the motor slowly at 162 (120) 255 (188) engine low idling for several minutes, and check oil leakage and abnormal sound from motor. 34-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 652 Attach eyebolt on swing bearing and sling it. EYE BOLT Weight of swing bearing : 540kg (1,190 lb) GREASE BATH Fig. 34-66 Removing and installing swing bearing 34-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 653 3) Draw out plug (8), utilizing an pull bolt inserted in the screwed hole (M10) in the center of the plug Fig. 34-70 Removing swing bearing and using a puller. 34-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 654 MAINTENANCE STANDARD Maintenance standard concerning wear of swing bearing is described in the section 13.6, "Maintenance Standard and Test Procedure" MEASURING SWING PERFORMANCES in the separate volume. 34-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 655 58 Coupling 19 Separating plate 39 O-ring 1B P11 59 Retaining ring C-type 40 20 Friction plate 40 Restrictor (brake valve) 60 G1/2 plug 61 O-ring 1B P18 34-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 656 57–10 O-ring 1B P7 57–4 Coupling piston 57–11 Backup ring T2 P7 57–5 57–12 O-ring 1B G25 57–6 Pilot body 57–13 Backup ring T2 G25 57–7 Piston 34-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 657 17 Planetary gear 1 27 O-ring 1B P24 Support ring 18 Thrust washer 1 Carrier 2 19 Needle bearing FBNP-406040 10 Planetary gear 2 20 Carrier pin 1 34-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 658 10 - Plain washer 18 120 (4.72") 2-M18X50 (1.97") Jig for inserting brake piston o 67.5 (2.66") o 90 (3.54") (0.12") Jig for inserting oil seal Jig for inserting rear bearing 34-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 659: Disassembly Procedures

    However, you cannot disassemble the motor without removing overload relief valve (57). There is dread of the burn, disassemble motor after cooling it to ambient temperature. 34-39 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 660 5) Remove pilot valve plug (35) and then, remove O-ring (36), pilot valve spring (34), spring holder (33), pilot valve spool (31) and pin (32). 6) Remove coupling (58). 34-40 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 661 (51) comes out. (See Fig. 34-78) 7) Put two fingers of gear (bearing) puller under the inner race of rear bearing (51) and remove the race. Fig. 34-78 Removing rear bearing 34-41 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 662 The situation is rather easier for with reduction gears because the shaft is rather restricted by a gear to move. 34-42 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 663 • Never detach oil seal (3) only for the purpose of inspecting it. If disassembled, remove retaining ring IRTW68 (4) first and remove oil seal (3).Never fail to replace oil seal (3) with new one. 34-43 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 664 As a rule, overload relief valve (57) should be handled as one service part. If there are any trouble on overload relief valve (57) , replace as an assembly. Fig. 34-84 Disassembling overload relief valve 34-44 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 665 (57-3) easily comes off, so take great care not to lose. When assembling overload relief valve (57) to rear cover (24), apply grease sufficiently on engagement part not to drop valve seat (57-3). Fig. 34-85 Engagement part 34-45 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 666: Assembling Procedures

    (7) Apply grease sufficiently on three spherical recess of swash plate (12) and assemble it in casing (1). Fig. 34-87 Assembling swash plate 34-46 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 667 Otherwise, it may be scraped off by the edge of the hole of casing (1). Jig for inserting rear bearing Jig for inserting brake piston 10 - Plain washer 18 Fig. 34-89 Inserting brake piston 34-47 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 668 When removing outer race of rear bearing (51), install shim (52) without fail. Confirm that O-rings (47), (49), (50) are installed to rear cover (24). (15)Assemble coupling (58). 34-48 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 669 (27) and spring (28). Spool assy (26) is unsymmetry. Insert spool assy (26) in an appropriate direction. (20)Assemble M42 plug (29) with O-ring (30). Tightening torque : 441~461N•m (325~329 lbf•ft) 34-49 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 670 Bleed air in motor casing from un-piping port (upper side). (2) Initial Pre-conditioning operation Operate motor 5 minutes at low speed mode and low-idle, check if there are abnormal noise or leak of oil. 34-50 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 671 = d min min. inner dia. = D min max. inner dia. = D max In exchanging pistons, replace all of nine pistons at the same time 34-51 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 672 Criteria: 33.04 mm (1.30") (Dimension in the drawing) standard of replacing friction and Allowable Thickness : 31.5 mm (1.24") separating plate If it is impossible to disassemble traveling unit, refer to the right value. 34-52 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 673 Plug G1/4 29.4 (21.7) (42) Plug G1/8 14.7 (10.8) (56) Hex. socket head bolt 324±32.4 (239±23.9) (57) Overload relief valve 98.1~118 (72.4~87.0) (60) Plug G1/2 98.1 (72.4) 34-53 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 674: General Instructions

    2. Relief valve catches small particles 2. Wash relief valve, check or replace seat of it 3. Seizure of sliding portion 3. Check, repair or replace sliding portion 34-54 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 675 • Stick between spool and body • Restrictor is not seated completely Interference with parking brake Repair or replace • Permanent set or broken spring 34-55 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 676 Put a matching mark on the outside of each matching surface so it may be installed where it was. • The numbers in the parentheses after part names correspond to those in the assembly drawing on Fig. 34- 34-56 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 677 2) As the cover (24) is adhered to ring gear (3), remove cover (24) by lightly hammering slantwise upward by wooden bar aiming at projection of cover (24). Fig. 34-94 Removing bolts Fig. 34-95 Removing cover 34-57 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 678 Fig. 34-98 Removing support ring 2) Take off lock washers (7) by tapping on screw driver or on similar tool placed at parting surface of them. Fig. 34-99 Removing lock washer 34-58 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 679 (1). Don't remove the bearings (2) unless otherwise their exchange is needed. In case bearings (2) removed, don't re-use them. New bearings (2) should be used and shim (6) adjusting be required. 34-59 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 680 When carrier pin 1 (20) or planetary gear 1 (17) is needed to be exchanged, three pins or three gears should be all exchanged. Fig. 34-104 Disassembling carrier 1 assy 34-60 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 681 Fig. 34-105 Disassembling carrier 2 assy When carrier pin 2 (13) or planetary gear 2 (10) is needed to be exchanged, three pins or three gears should be all exchanged. 34-61 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 682 (Sink spring pins of 1 - 2 mm (0.04"~0.08")from Fig. 34-108 Caulking the spring pin surface) 4) Calk carrier 1 (16) on diagonally position to prevent spring pin 6×36 (21) from coming out. 34-62 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 683 (1) and motor casing after assembled. (See Fig. 34- Fig. 34-112 How to apply Loctite #242 110) • It is recommended to use jig to install floating seal. 34-63 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 684 "S", the clearance "X" can be calculated as follows : X=(B+C)-(A+D+S) 7) Select a shim (6) so as the clearance X to come to -0.08 mm (interference)~ +0.02 mm (clearance) (-0.0031"~0.0008") on this unit. 34-64 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 685 3) While pressing inner lace of bearing (2), install lock washers (7) into groove. Fig. 34-115 Installing lock washer 4) Install support ring (8) over outside of lock washers (7). Fig. 34-116 Installing support ring 34-65 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 686 3) Place thrust plate (23) on carrier 1 (16). SHARP EDGE THRUST PLATE Face sharp edged side to cover (24). (See Fig. 34-119) COVER Fig. 34-119 Assembling carrier 1 assy 34-66 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 687 1) Fill gear oil (SAE #90 API class GL-4 or GL-5, 9.5 litters (2.5 gal)) from two G3/4 ports. 2) Tighten taper screw plugs (26). : 14mm Tightening torque : 147.1N•m (108 lbf•ft) 34-67 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 688 Replace (11) (0.21"~0.22") of wear 4.5±0.16mm 0.15 mm (0.006") Thickness of thrust plate (23) Replace (0.171"~0.183") of wear Lubrication oil 2,000 working hours (engine hour meter) Replace 34-68 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 689 Put the unit on the test stand and rotate with no load and check if there are abnormal noise or leak of oil. Take care not to overspeed the motor. Rotate within specified flow rate. 34-69 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 690 34. TRAVEL SYSTEM [MEMO] 34-70 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 691 46.1 JUDGMENT OF ACTUAL THING AT SITE ..............46-3 46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING ........46-4 46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ............46-4 46.4 TROUBLESHOOTING BY ERROR CODE..............46-4 Book Code No. S5YN4618E03 46-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 692: Trouble Shooting (By Error Codes)

    ↑ ASIA (HS Engine) SK250-8 : LQ12-06001~ S5YN4618E02 ↑ October, 2008 SK260LC-8 : LL12-05001~ (ASIA, OCE) SK330-8 : LC10-07001~ S5YN4618E03 ↑ ↑ SK350LC-8 : YC10-03501~ (ASIA, OCE) 46-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 693 And also use care not to flaw and damage those Fig. 46-4 Diagnosing fail by means surfaces. troubleshooting. 46-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 694: Troubleshooting By Error Code

    Short-circuit of boom up pressure sensor 46-12 B022 Incorrect output of boom down pressure sensor 46-12 B023 Disconnection of boom down pressure sensor 46-13 B024 Short-circuit of boom down pressure sensor 46-13 46-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 695 Failure of output transistor ON at arm in high speed proportional valve 46-36 D063 Disconnection of arm in high speed proportional valve 46-37 E012 Failure of output transistor ON at P1 pump proportional valve 46-37 46-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 696 Failure of auto idling stop relay 2 46-57 R174 Failure of engine forcible stop relay 46-58 R184 Failure of lever lock relay 46-59 R214 Failure of safety relay 46-59 46-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 697: Speed Set

    When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed" 2 • Mechatro controller Check that the error is corrected after replacement of controller. 46-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 698 Screen No. diagnosis Screen No. checking screen Screen No. Checking object Checking contents and remedy 1 Mechatro controller Check that the error is corrected after replacement of controller. 46-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 699 Screen No. diagnosis Screen No. checking screen Screen No. Checking object Checking contents and remedy 1 Mechatro controller Check that the error is corrected after replacement of controller. 46-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 700 Screen No. diagnosis Screen No. checking screen Screen No. Checking object Checking contents and remedy 1 Mechatro controller Check that the error is corrected after replacement of controller. 46-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 701 Check wiring for possible failure according to the wiring checking procedure CN-126F and repair it if necessary. CN-101F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 702 Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 703 Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 704 Check wiring for possible failure according to the wiring checking procedure CN-131F and repair it if necessary. CN-101F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 705 Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 706 Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 707 Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 708 Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 709 Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 710 Check wiring for possible failure according to the wiring checking procedure CN-103F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 711 Check wiring for possible failure according to the wiring checking procedure CN-102F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 712 Check wiring for possible failure according to the wiring checking procedure CN-102F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 713 Check wiring for possible failure according to the wiring checking procedure CN-102F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 714 Check wiring for possible failure according to the wiring checking procedure CN-162F and repair it if necessary. CN-104F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 715 Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 716 Check wiring for possible failure according to the wiring checking procedure CN-102F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 717 Check wiring for possible failure according to the wiring checking procedure CN-102F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 718 Check wiring for possible failure according to the wiring checking procedure CN-103F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 719 Check wiring for possible failure according to the wiring checking procedure CN-103F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 720 Check wiring for possible failure according to the wiring checking procedure CN-103F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 721 Check wiring for possible failure according to the wiring checking procedure CN-104F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 722 Check wiring for possible failure according to the wiring checking procedure CN-104F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 723 Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 724 Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 725 Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 726 Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 727 When replacing of connector is executed, turn off power source once. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-37 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 728 When replacing of connector is executed, turn off power source once. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-38 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 729: Power Boost

    Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-39 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 730: Swing-Brake

    Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-40 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 731 Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-41 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 732 Check wiring for possible failure according to the wiring checking procedure CN-105F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-42 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 733 Especially check wiring for false disconnection and noise included. CN-106F 3 • Mechatro controller Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.) 46-43 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 734 4 • Mechatro controller (Controller is broken by only applying power to grounding of signal.) 5 • Engine controller Check that the error is corrected after replacement of controller. 46-44 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 735 4 • Mechatro controller (Controller is broken by only applying power to grounding of signal.) 5 • Engine controller Check that the error is corrected after replacement of controller. 46-45 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 736 Check wiring for possible failure according to the wiring checking procedure potentiometer and controller and repair it if necessary. CN-402F CN-102F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-46 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 737 Check wiring for possible failure according to the wiring checking procedure potentiometer and controller and repair it if necessary. CN-702F CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-47 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 738 Check wiring for possible failure according to the wiring checking procedure potentiometer and controller and repair it if necessary. CN-703F CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-48 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 739: Fuel Level

    Check wiring for possible failure according to the wiring checking procedure sensor and controller and repair it if necessary. CN-152F CN-104F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-49 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 740: Water Temp

    Check wiring for possible failure according to the wiring checking procedure and controller and repair it if necessary. CN-3F CN-101F 2 • Mechatro controller Check that the error is corrected after replacement of controller. 46-50 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 741 When no failure found after checking on wiring and K014 is left displayed • Fuse& relay box Replace fuse/relay box. 4 • Mechatro controller Check that the error is corrected after replacement of controller. 46-51 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 742 When no failure found after checking on wiring and R014 is left displayed Replace fuse/relay box. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-52 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 743 When no failure found after checking on wiring and R024 is left displayed •Fuse & relay box Replace fuse/relay box. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-53 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 744 When no failure found after checking on wiring and R034 is left displayed •Fuse & relay box Replace fuse/relay box. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-54 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 745: Motor Relay

    C) according to the wiring checking procedure and replace it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-55 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 746 When no failure found after checking on wiring and R154 is left displayed. Replace fuse/relay box. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-56 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 747 When no failure found after checking on wiring and R164 is left displayed. Replace fuse/relay box. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-57 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 748 When no failure found after checking on wiring and R174 is left displayed. • Fuse & relay box Replace fuse/relay box. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-58 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 749: Lock Lever

    When no failure found after checking on wiring and R214 is left displayed. Replace fuse/relay box. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 46-59 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 750 46. TROUBLE SHOOTING (BY ERROR CODES) [MEMO] 46-60 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 751 TABLE OF CONTENTS 47.1 HYDRAULIC SYSTEM ....................47-3 47.2 ELECTRIC SYSTEMS .....................47-27 47.2.1 WIRING CHECKING PROCEDURE ..............47-27 47.2.2 TROUBLE.......................47-30 47.3 ENGINE RELATED TROUBLESHOOTING ..............47-33 Book Code No. S5LC4711E02 47-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 752 Issue Date of Issue Applicable Machines Remarks SK330–8 : LC10-07001~ S5LC4711E01 First edition July, 2006 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC4711E02 ↑ Revision February, 2007 (ASIA, OCE) 47-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 753 (19)Travel does not run straightly when both crawlers and attachment operated simultaneously. (20)Slow breaker (crusher) operation, weak power (21)Option selector valve malfunction: not switched to breaker circuit (22)Option selector valve malfunction: not switched to nibbler circuit 47-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 754 (left) travel full lever and high idling operation directly in idling operation. (Ports a3, Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve 47-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 755 4 Over load relief valve Check targeted spool Free from dust entered in port relief Replace visually valve. Seat is free from abnormality 47-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 756 Check that slow return check valve Clean and replace of pilot line installed on pilot line is free from dust (in case of boom up or entered arm out) 47-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 757 (poppet) resistance against sliding (Check on the casing side for <Trouble> Free from abnormal damage, etc on damage) Both P1 and P2 outside surface pressures are high. 47-7 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 758: Table Of Contents

    1.9 to valve secondary pressure 2.5MPa in boom down full lever and directly (Ports a3, a4) high idling operation 47-8 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 759: Check Boom Spool And Recirculation

    Check remote control valve pressure control pressure of arm in arm in full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern 47-9 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 760 0.8MPa or less in high idling operation Replace proportional valve travel straight proportional valve regardless of neutral/operation proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block 47-10 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 761: Over Load Relief Valve

    •See Service Diagnosis Data List proportional valve and controller valve Operation No.8 Arm out full lever & for possible failure. relief 47-11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 762 (Check on the casing side for <Trouble> P1 pressure is high. Free from abnormal damage, etc on damage) outside surface Spring is free from breakage. 47-12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 763 9 Attachment boost Measure switching Check that pressure is 0MPa in bucket Replace solenoid valve solenoid secondary valve secondary digging full lever and high idling pressure pressure operation 47-13 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 764 P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump lever and in operation pump pressures in pressures, check high pressure operation. sensor 47-14 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 765: Actual Measuring

    (Check on the casing side for Both P1, P2 pressures Free from abnormal damage, etc on damage) are high. outside surface Spring is free from breakage. 47-15 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...

  • Page 766: Carry Out Service Diagnosis

    Operation No.18 Travel right full lever actually measured value, check only swing operation) & idling proportional valve and Operation No.19 Travel left full lever & controller for possible failure. idling 47-16 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 767 Replace (Brake valve/friction wear and scuffing plate) 6 Swing motor piston Visual check When removing, free from abnormal Replace resistance against sliding Spring is free from breakage. 47-17 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 768 Inner parts (cylinder block, piston, Replace valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc) 47-18 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 769 Check that spool is free from abnormal Replace control valve damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice 47-19 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 770 4 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve travel straight proportional valve regardless of neutral/operation proportional valve secondary pressure 47-20 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 771 (relief operation at If P2 is low, left travel motorÅfs locked crawler belt) and high idling relief valve is failed. Replace as necessary 47-21 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 772 Check remote control valve 2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage 47-22 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 773 & relief optional attachment valve •In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure. 47-23 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 774 4 N&B selector pressure Carry out service •No.16 B-11 Check pressure sensor sensor diagnosis Data List Check harness 3.0MPa at B mode and 0.0MPa at A mode 47-24 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 775 2 N&B selector solenoid Carry out service •No.11 F-4 Option selector is A mode Check solenoid valve diagnosis COMP OFF, MEAS OFF Check harness Spool position NIB Selector switch NIB 47-25 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 776 FAILURE" 10 Stopping — — — — — — — — — — — — — — — — — — — — — — — — 47-26 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 777 (3) Checking for presence or absence of short-circuit between wirings. Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1M or more, it is in normal condition. TESTER 47-27 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 778 Pull out the connector and check that the inside is free from intruding of water. When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly. 47-28 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 779 Block of grounding is located under floor plate of cab. 47-29 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 780 (3) Auto accel does not actuate. (The engine speed does not automatically slow down.) (4) Auto accel does not actuate. (The engine speed does not automatically speed up.) (5) Wiper does not function. 47-30 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 781 Contents/normal value Corrective action, others 1 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor No.6 is raised with control lever operated. 47-31 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 782 * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it from the wiper startup, turn OFF all relay's outputs. if necessary. 47-32 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 783 Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration 47-33 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 784 Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration 47-34 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 785 Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration 47-35 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 786 Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased. (Intruding of water and fuel) Vibration 47-36 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 787 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) TABLE OF CONTENTS 48.1 TROUBLE DIAGNOSIS MODE ..................48-3 Book Code No. S5YN4818E01 48-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 788 ↑ August, 2006 SK210LC–8 : YQ11-06001~ SK250-8 : LQ12-06001~ ↑ ↑ October, 2006 SK260LC-8 : LL12-05001~ ↑ E235BSR : YF05-02001~ ↑ February, 2007 E235BSR(N)LC : YU05-02001~ (NHK) 48-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 789 4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history. 48-3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 790 Is normal pressure generated in the condition that the unload valve is in emergency position, 12 3 P2 PUMP and P2 side flow rate is maximum? 48-4 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 791 Secondary pressure is excessive high against the command Check P2 pump proportional valve P2 PUMP PSV NG and replace it if necessary Secondary pressure is excessive low against the command 48-5 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 792 Check engine and replace it if ENGINE NG Output is lowered necessary Check engine speed sensor and E/G R SENSOR NG Characteristics is misaligned replace it if necessary 48-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 793 This service manual explains the single engine. Note that this manual is edited without modification by based on the service manual of HINO MOTOR. Book Code No. S5LC5111E04 51-1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 794 (NHK Middle East) ↑ ↑ ↑ April, 2008 (NHK Russia) SK330–8 : LC10-07001~ S5LC5111E03 ↑ October, 2008 SK350LC–8 : YC10-03501~ (ASIA, OCE) S5LC5111E04 ↑ ↑ July, 2010 (ASIA, OCE) 51-2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 795 HINO DIESEL ENGINE WORKSHOP MANUAL J08E-TM (Shovel) KSS-SMJ8-E003E 2010.7 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 796 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 797 GENERAL STANDARD VALUE PARTS TO BE PREPARED ENGINE ASSEMBLY/DISASSEMBLY FUEL SYSTEM EMISSION CONTROL ELECTRICAL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION STARTING AND CHARGING TURBOCHARGER FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ENGINE DIAGNOSIS CODE [S5LC0011E04] [0713CsCshWbYs]...
  • Page 798 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 799 GENERAL 1–1 ENGINE 1 GENERAL General General information Warning..............1-2 How to read this manual ........1-3 Precautions for work ..........1-7 Tightening of engine bolts and nuts ...... 1-11 Tightening of flare nuts and hoses......1-13 Taper thread sealant for piping ......1-14 Assembly of joints and gaskets for piping .....
  • Page 800 1–2 GENERAL Warning JP30002010102001 Observe the following precautions to work safely and to prevent damage to customers' vehicles. This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who perform service with the way not specified in this manual may not only damage the vehicle, but also put service engineers and surrounding people in danger.
  • Page 801 GENERAL 1–3 How to read this manual JP30002010102002 Scope of repair work Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement, assembly⋅disassembly and inspection⋅adjustment" and "Final inspection". This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement, assembly⋅disassembly and inspection⋅adjustment"...
  • Page 802 1–4 GENERAL How to read troubleshooting Failure diagnosis in this manual describes Step 2 and Step 3 below : Hear from customers for conditions and environments of (1) Question "Step 1" failures and check the fact. Perform diagnosis inspection, status inspection, (2) Pre-inspection function inspection and basic inspection.
  • Page 803 GENERAL 1–5 How to read explanation details Part layout Example ENGINE MECHANICAL [J08E] 9–17 Timing Gear Cover and Flywheel Housing Part layout JP04117090402003 Part name code Part catalog Fig. No. SAPH041170900182 11308 Flywheel housing 11390 End plate Description of 11309 Oil seal retainer 9828A Front oil seal*...
  • Page 804 1–6 GENERAL Definition of terms Terms in this manual are defined as follows : Direction Individual unit Front/back direction The power input side is front and the output side is back. Rotating direction When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is left rotation.
  • Page 805 GENERAL 1–7 Unit SI unit is used in this manual. SI unit is the international unit to unify the conventional different international units into one unit per quantity and to promote smooth technical communications. This manual shows both the SI unit and conventional units. The conventional units are shown in { }. Convent Conversion value Convent...
  • Page 806 1–8 GENERAL Precautions for service work Pay attention to the following points before service work Preparation before disassembly Prepare general tools, special tools and gauges before work. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected to ease assembly.
  • Page 807 GENERAL 1–9 Handling of wire harness Mark clamps and clips to prevent interference of a wire harness with body edge, sharp edge and bolts. Be sure to reassemble it to the original position. When parts are assembled, be careful not to pinch a wire harness.
  • Page 808 1–10 GENERAL Precautions for electric welding Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding circuit, resulting in damage to electric and electronic parts. Observe the following items for electric welding. Turn "OFF" the starter switch. Make sure that switches are "OFF".
  • Page 809 GENERAL 1–11 Tightening of engine bolts and nuts JP30002010102003 Tightening torque of general standard bolts For bolts with seatings Unit : N⋅m{kgf⋅cm} Screw diameter x Pitch M8 x 1.25 (Coarse thread) 28.5{290} 36{370} M10 x 1.25 (Fine thread) 60{610} 74.5{760} M10 x 1.5 (Coarse thread) 55{560} 68.5{700}...
  • Page 810 1–12 GENERAL Precoated bolt Precoated bolt is the bolt with application of seal lock agent at the thread. When re-application of lock agent is required When precoated bolts are removed When precoated bolts are moved due to tightening check (for loosening or tightening) Seal Lock Agent •...
  • Page 811 GENERAL 1–13 Tightening of flare nuts and hoses JP30002010102004 Tightening torque of pipe flare nut Unit : N⋅m{kgf⋅cm} Pipe outer φ4.76 φ6.35 φ8 φ10 φ12 φ15 diameter Material Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80} Tightening torque of hoses Unit : N⋅m{kgf⋅cm} Hose outer diameter Hose outer diameter...
  • Page 812 1–14 GENERAL Taper thread sealant for piping JP30002010102005 The taper thread of the air pipe joint has application of sealant [Loctite # 575 (by Japan Loctite)]. Follow the procedures below for connection or disconnection of pipes. For disconnection Removal of joint (Example: Use of magnetic valve) The sealant ( # Loctite 575) has strong sealing feature.
  • Page 813 GENERAL 1–15 Assembly of joints and gaskets for piping JP30002010102006 Tightening torque of joints Unit : N⋅m{kgf⋅cm} Metal sealing method Sealing method (Flare pipe type, nipple connector type) Gasket sealing method (Aluminum + Rubber or Copper) Tightening screw Type A Type B size 13{130}...
  • Page 814 1–16 GENERAL Examples of joint methods in various pipes Metal sealing method Gasket sealing method Type A Type B (Flare pipe type) (Nipple connector type) Joint bolt Flare pipe Sealing surface: 3 places Connector Gasket Flare nut Connector nipple Joint bolt Sealing surface : 4 places Flare connector...
  • Page 815 GENERAL 1–17 Handling of liquid gasket JP30002010102007 Application of liquid gasket and part assembly procedure Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent deposit of oil, moisture, dirt, etc. Be sure to overlap parts at the beginning and at the end of application.
  • Page 816 1–18 GENERAL Failure diagnosis table for each problem JP30002010301001 Causes and actions are described for each item. Engine mechanical JP03Z01020601001 Status Cause Action Engine overheat (coolant) Insufficient coolant Replenish coolant Faulty thermostat Replace thermostat Water leak from cooling system Correction Faulty coolant pump Repair or replace Faulty head gasket...
  • Page 817 GENERAL 1–19 Failure diagnosis procedures JP30002010301002 Display of failure code If the system has an error, the failure code is displayed on the multiple display of gauge cluster . SAPH300020100027 Deletion method of past failure To delete past failures of the engine ECU, use HINO–DX on the PC.
  • Page 818 1–20 GENERAL How to read troubleshooting for each diagnosis monitor code "Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be started from the code list.
  • Page 819 GENERAL 1–21 Failure diagnosis using Hino-DX JP30002010301003 • Hino-DX is used for inspection and ! CAUTION adjustment of the system in addition to failure diagnosis. Hino-DX With Hino-DX, failure of the common rail fuel injection system can be diagnosed. The interface box (Hino- Bowie) and the special cable are required for connection to the vehicle.
  • Page 820 1–22 GENERAL Connection of signal check harness To prevent damage to the ECU connector and to improve accessibility, connect the signal check harness and put a testing rod on the signal check connector of the signal check harness for meaurement. Disconnect the connector from the ECU.
  • Page 821 GENERAL 1–23 Terminal No. For the signal check harness connector, the ECU terminal number in the text is treated as follows : ECU unit Signal check harness ECU side Vehicle side SAPH300020100037 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 822 1–24 GENERAL Connection method of Hino-DX JP30002010301004 Removal of the maintenance cover Remove the maintenance cover (A) on the rear cover Maintenance Cover (A) behind the operator seat by pushing down the tab at the top (at one location). • The engine fault diagnosis connector (16 P) is NOTICE on the inside.
  • Page 823 STANDARD VALUE 2–1 ENGINE 2 STANDARD VALUE Specification (performance) System drawing Engine Body..............2-2 Standard value............2-2 Tightening torque............ 2-2 Fuel System ..............2-2 Tightening torque............ 2-2 Emission Control............2-3 Tightening torque............ 2-3 Electrical..............2-3 Standard value............2-3 Tightening torque............ 2-3 Intake ................
  • Page 824 2–2 STANDARD VALUE Engine Body Standard value JP30002020205001 Unit : MPa {kgf/cm , lbf/in. Inspection item Standard value Repair limit Service limit Action 3.4-3.7MPa 2.7MPa Compression pressure {35-38kgf/cm {28kgf/ — (Engine revolution per cylinder: 150 r/min) 493-237lbf/ ,392lbf/ Tightening torque JP30002020205002 Unit:N⋅m{kgf⋅cm, lbf⋅ft} Tightening area...
  • Page 825 STANDARD VALUE 2–3 Emission Control Tightening torque JP30002020205004 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark EGR pipe mounting bolt 57±11 {582±116, 42±8} EGR valve mounting bolt 68.5 {700, 51} EGR cooler mounting bolt 37 {377, 27} EGR cooler - Exhaust manifold 68.5 {700, 51} Intake pipe - intake manifold 55 {560, 41}...
  • Page 826 2–4 STANDARD VALUE Tightening area Tightening torque Remark Outside B terminal mounting nut 3.2 - 4.4{33 - 45, 2 - 3} Through bolt 7.8 - 9.8{80 - 99, 6 - 7} Intake Tightening torque JP30002020205005 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Intake manifold mounting bolt...
  • Page 827 STANDARD VALUE 2–5 Inspection item Standard value Repair limit Service limit Action Cylinder 0.088 - 0.112 Liner Piston clearance — — {0.0035 - 0.0044} Replace piston Approx. 11.5 — — {0.4528} Free joint clearance Approx. 14 Second — — {0.4921} 0.3 - 0.40 —...
  • Page 828 2–6 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Replace 0.015 - 0.036 0.08 piston pin or Connecting rod bushing oil clearance — {0.0006 - 0.0014} {0.0031} connecting rod bushing Replace the 64.3 Crank pin outer diameter 65 {2.5590} —...
  • Page 829 STANDARD VALUE 2–7 Inspection item Standard value Repair limit Service limit Action Replace 0.20 - 0.52 connecting Connecting rod end play — 1.0 {0.0394} {0.0079 - 0.0205} rod or crankshaft Camshaft journal outer –0.15 Replace 40 {1.5748} — diameter {–0.0059} camshaft Camshaft bearing inner +0.15...
  • Page 830 2–8 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action 30° Allowable angle 30° - 30°35' Valve seat angle 45° Allowable angle 45° - 30°30' Correction 30° Allowable angle 29°30 - 45° Valve face angle 45° Allowable angle 44°30 - 45° Set length 44.8 {1.764} —...
  • Page 831 STANDARD VALUE 2–9 Inspection item Standard value Repair limit Service limit Action 0.030 - 0.167 0.30 Crank - Main idle — {0.0012 - 0.0066} {0.0012} Main idle - Pump drive 0.032 - 0.096 0.10 — idle {0.0013 - 0.0038} {0.00393} Pump drive idle - 0.020 - 0.083 0.10...
  • Page 832 2–10 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Shaft outer diameter 34 {1.3386} — — Bushing inner 34 {1.3386} — — diameter Clearance between 0.025 - 0.075 0.20 Replace shaft — shaft and bushing {0.0002 - 0.0030} {0.0079} or bushing idle...
  • Page 833 STANDARD VALUE 2–11 Tightening torque JP30002020205007 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Crankshaft pulley mounting bolt 118 {1,203, 87} Head cover mounting bolt 28.5 {290, 21} Camshaft bearing cap mounting bolt 28.5 {290, 21} Union bolt of leakage pipe 13.5 {135, 10} Injector harness mounting nut 28 {290, 21}...
  • Page 834 2–12 STANDARD VALUE Exhaust Tightening torque JP30002020205008 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Exhaust manifold mounting stud bolt 30 {300, 22} Exhaust manifold mounting nut 53 {540, 40} Cooling Standard value JP30002020205009 Standard Repair Service Inspection item Action value limit...
  • Page 835 STANDARD VALUE 2–13 Lubrication Standard value JP30002020205010 Unit : mm {in.} Repair Service Inspection item Standard value Action limit limit 39kPa Hydraulic alarm switch operation pressure {0.4kgf/cm — — 5.66lbf/in. Outer diameter of drive gear 54 {2.1260} — — Cylinder block side 54 {2.1260} —...
  • Page 836 2–14 STANDARD VALUE Tightening area Tightening torque Remark 24.5±4.9 {250±50, 18±4} 24.5±4.9 {250±50, 18±4} Oil circuit spring plug Oil cooler 29.4±4.9 {300±50, 22±4} 34.3±4.9 {350±50, 25±4} Coolant drain plug 44.1±4.9 {450±50, 33±4} Oil cooler case assembly mounting bolt 24.5±4.9 {250±50, 18±4} Starting and Charging Standard value (alternator 60A) JP30002020205012...
  • Page 837 STANDARD VALUE 2–15 Tightening area Tightening torque Remark Heat sink mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} Screw lock is used Regulator mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} Inside B terminal mounting nut 4.9 - 5.9 {50 - 60, 4 - 4} Front side - Rear side mounting bolt 7.8 - 9.8 {80 - 99, 6 - 7}...
  • Page 838 2–16 STANDARD VALUE Standard Inspection item Service limit Action value Between C terminal and M Start 0.12 - 0.15Ω — Replace start terminal (P coil) magnet magnet switch switch Between C terminal and body assembly 1.13 - 1.25Ω — assembly (H coil) [S5LC0011E04] [0713CsCshWbYs]...
  • Page 839 STANDARD VALUE 2–17 Tightening torque (starter) JP30002020205015 Unit : N⋅m{kgf⋅cm, lbf⋅tt} Tightening area Tightening torque Remark C lead wire mounting bolt 2 - 3 {19 - 25, 1 - 2} M lead wire mounting nut 12.3 - 15.2 {126 - 154, 9 - 11} Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13} Brush holder set bolts of commutator end frame...
  • Page 840 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 841 PARTS TO BE PREPARED 3–1 ENGINE 3 PARTS TO BE PREPARED Special tool (SST) Special tool Engine Body..............3-2 Special tool ............. 3-2 Fuel System ..............3-2 Lubricant, etc............3-2 Electrical..............3-2 Special tool ............. 3-2 Engine Mechanical ............. 3-3 Special tool .............
  • Page 842 3–2 PARTS TO BE PREPARED Engine Body Special tool JP30002030901001 Shape Part No. Description Remark 09491–1010 Wire rope For engine lifting 09552–1030 Compression gauge adapter 09552–1060 Compression gauge adapter 09552–1110 Compression gauge adapter Fuel System Lubricant, etc. JP30002030901002 Name Remark Guide bolt (9069-08180) For supply pump positioning Electrical...
  • Page 843 PARTS TO BE PREPARED 3–3 Engine Mechanical Special tool JP30002030901004 Shape Part No. Name Remark For crankshaft front oil seal 09420–1731 Oil seal puller removal For crankshaft front oil seal 09407–1030 Oil seal press press-fit For assembly/disassembly 09433–1070 Eye bolt of cylinder head For assembly/disassembly 09470–1170...
  • Page 844 3–4 PARTS TO BE PREPARED Shape Part No. Name Remark For valve stem seal 09472–2100 mounting For removal and inspection 09420–2100 Cylinder liner puller of cylinder liner For assembly/disassembly 09442–1011 Piston ring expander of piston ring For mounting of connecting rod small end bushing 9191–08252 Bolt...
  • Page 845 PARTS TO BE PREPARED 3–5 Shape Part No. Name Remark 09441–1370 Piston ring holder For piston mounting For assembly/disassembly 09481–1340 Guide of flywheel For crankshaft rear oil seal 09420–1742 Oil seal puller removal 09420–1100 For main/sub idle gear Sliding hammer assembly and cam idle gear 09420–1442 shaft removal...
  • Page 846 3–6 PARTS TO BE PREPARED Shape Part No. Name Remark For cooling jet inspection 09470–1280 Tool assembly and adjustment Instruments JP30002030901005 Name Remark Micrometer For measurement of part outer diameter Cylinder gauge For measurement of part inner diameter Thickness gauge For measurement of each clearance Dial gauge For measurement of parts...
  • Page 847 PARTS TO BE PREPARED 3–7 Lubrication Special tool JP30002030901008 Shape Part No. Name Remark 09503–1110 Oil filter wrench Lubricant, etc. JP30002030901009 Name Remark Liquid gasket (Threebond TB1207D or equivalent : For sealing of parts Silver) Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts Starting and Charging Jig (reference dimensional drawing for manufacture) JP30002030901010...
  • Page 848 3–8 PARTS TO BE PREPARED Instruments JP30002030901011 Alternator Name Remark Circuit tester For measurement of parts Micrometer For measurement of parts Regulator checker (G&M Machinery ICD-101D or For inspection of regulator equivalent) Starter Name Remark Circuit tester For measurement of parts Micrometer For measurement of part outer diameter Growler tester...
  • Page 849 PARTS TO BE PREPARED 3–9 Engine Failure Diagnosis Special tool JP30002030901014 Shape Part No. Name Remark • Operating system(OS):Windows95, Windows98(IE5.0 or later), Windows2000(SP3, IE5.0 or later), WindowsXP(SP1a, IE6.0 – Personal computer (DOS-V) or later) • CPU and memory: Conditions that assure operation of the above operating system •...
  • Page 850 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 851 ENGINE ASSEMBLY/DISASSEMBLY 4–1 ENGINE 4 ENGINE ASSEMBLY/DISASSEMBLY Service procedure Overhaul item Inspection Before Service ......... 4-2 Measurement of compression pressure ....4-2 Engine Body..............4-4 Removal..............4-4 Installation............... 4-6 Work after installation ..........4-6 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 852 4–2 ENGINE ASSEMBLY/DISASSEMBLY Inspection Before Service Measurement of compression pressure JP30002040702001 • Measure the compression pressure before NOTICE disassembly of the engine and record the result. Regular measurement of the compression pressure can tell the engine status. Preparation before measurement Charge the battery completely.
  • Page 853 ENGINE ASSEMBLY/DISASSEMBLY 4–3 Measure the compression pressure of each cylinder continuously. Engine revolution 150r/min {rpm} Compression pressure: Unit MPa {kgf/cm ,lbf/in. Standard value 3.4 - 3.7 {35 - 38 ,493 - 537} Service limit 2.7 {28, 392} Difference between 0.3{3, 44} or less cylinders If the compression pressure is the service limit or less or if the difference between cylinders is over the standard...
  • Page 854 4–4 ENGINE ASSEMBLY/DISASSEMBLY Engine Body Removal JP30002040702002 Preliminary work before removal of engine Place the vehicle on a level ground. Block tires with scotch. Remove the battery cable from the battery minus terminal. Drain of coolant and engine oil Right side of engine Drain coolant from the radiator drain cock and the oil cooler drain plug.
  • Page 855 ENGINE ASSEMBLY/DISASSEMBLY 4–5 Disconnection of fuel hose Remove the fuel hoses (feed side and return side). Wrap the removed hose with a plastic sheet with its end facing upward to prevent spill of fuel. • Wipe spilled fuel with a rag. ! CAUTION SAPH300020400006 Disconnection of water, engine oil pipes, etc.
  • Page 856 4–6 ENGINE ASSEMBLY/DISASSEMBLY Installation JP30002040702003 Connection of fuel hose Insert a fuel hose and fix it with a hose band. Work after installation JP30002040702004 Inspection of engine oil Make sure that the drain cock is closed. Pour engine oil. Check the amount of oil with an oil level gauge. Engine oil amount (L{us gal}) Oil pan Oil filter and etc...

  • Page 857: Fuel System

    FUEL SYSTEM 5–1 ENGINE 5 FUEL SYSTEM Setup layout Layout Fuel System ..............5-2 Fuel system diagram..........5-2 Part layout............... 5-3 Fuel filter drain (With water cup) ......5-6 Replacement of fuel filter element (With water cup)............5-7 Replacement of fuel filter element (Without water cup)..........
  • Page 858 5–2 FUEL SYSTEM Fuel System Fuel system diagram JP30002050402001 Feed pipe Injection pipe Flow damper Injector Common rail Leakage pipe Pressure limiter Through feed pipe Overflow pipe Supply pump Fuel tank Fuel filter SAPH300020500001 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 859 FUEL SYSTEM 5–3 Part layout JP30002050402002 SAPH300020500002 13691 Bearing holder case 23716 Injection pipe 22610 Coupling 22730 Supply pump 22611 Coupling flange 23766 Through feed pipe 22760 Common rail assembly 23766A Through feed pipe 23083 Through feed pipe 23781 Fuel pipe 23711 Injection pipe 23783...
  • Page 860 5–4 FUEL SYSTEM Fuel filter element (With water cup) SAPH300020500003 23300 Fuel filter assembly S2330 Fuel filter head 23390 Fuel filter element S2330A Water cup Tightening torque 23390 Refer to the main text. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 861 FUEL SYSTEM 5–5 Fuel filter element (Without water cup) SAPH300020500004 S2330 Fuel filter head 23300 Fuel filter assembly 23390 Fuel filter element S2284 O-ring* *Parts not to be reused. Tightening torque 23390 Refer to the main text. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 862 5–6 FUEL SYSTEM Service procedure Replacement procedure item Fuel filter drain (With water cup) JP30002050704001 Prepare a water container under the drain pipe. Air bleeding bolt Priming pump Loosen the fuel filter air bleeding bolt and the drain valve. Discharge water at the bottom of the fuel filter case. •...
  • Page 863 FUEL SYSTEM 5–7 Replacement of fuel filter element (With water cup) JP31002050704002 • The frequency for water draining and replacement of the fuel filter element differs ! CAUTION according to the fuel situation in the use region. Replace the fuel filter element every 500 hours or when the engine output decreases, whichever occurs first.
  • Page 864 5–8 FUEL SYSTEM Installation of fuel filter element • Fuel filter element is not reused. ! CAUTION The soiling and the foreign material of the clamp face are removed. Install the fuel filter element with according to tightening angle in the table below of a turn after the O-ring of the fuel filter element comes into contact with the fuel filter head.
  • Page 865 FUEL SYSTEM 5–9 Installation of water cup • Fuel filter element is not reused. ! CAUTION • Install the O-ring after applying fuel to the surface of the O-ring. • Do not use a tool, but tighten by hand. Fuel filter element Tightening angle (Image with the fuel filter seen from below) O-ring...
  • Page 866 5–10 FUEL SYSTEM Replacement of fuel filter element (Without water cup) JP31119050704003 • Replace the fuel filter element every 500 hours or when the engine output decreases, ! CAUTION whichever occurs first. • Inspection of the fuel filter element and draining of water should be performed before each start of operation.
  • Page 867 FUEL SYSTEM 5–11 Bleeding air from the fuel system Loosen the fuel filter air bleeding bolt. Operate the priming pump and bleed the air from the system. Priming pump Air bleeding bolt SAPH300020500012 • Make sure that the fuel filter air bleeding bolt has been loosened. ! CAUTION •...
  • Page 868 5–12 FUEL SYSTEM Replacement of supply pump JP30002050704003 Compression upper dead center setting of No.1 cylinder Turn the crankshaft counterclockwise when viewed from the flywheel. Set the timing mark in the flywheel housing inspection window to "1". Flywheel Flywheel housing SAPH300020500013 Remove the inspection window plug in the bearing holder case of the supply pump.
  • Page 869 FUEL SYSTEM 5–13 Fix the coupling flange with a vice to prevent turning and Bearing holder case remove the coupling flange. Remove the bearing holder case from the supply pump. Shaft Coupling flange SAPH300020500017 Assembly of supply pump and bearing holder case Fit a new O-ring to the supply pump and install the bearing holder case.
  • Page 870 5–14 FUEL SYSTEM Put the guide bolt 9069-08180 into the bearing holder Bearing holder case case to come in contact with the stopper key hole of the coupling flange. Shaft • Do not tighten the guide bolt by contact not ! CAUTION with the stopper key hole of the coupling or Guide bolt...
  • Page 871 FUEL SYSTEM 5–15 Inspection of supply pump JP30002050704004 Inspection of suction control valve and fuel temperature sensor Fuel temperature sensor Measure the resistance of the suction control valve Suction control valve terminals and the fuel temperature sensor terminals using a circuit tester. If it is beyond the standard, remove the supply pump assembly and request for replacement at the Denso service shop.
  • Page 872 5–16 FUEL SYSTEM Assemble the injection pipe temporarily and tighten the fixing bolt of the nozzle clamp holder. Tightening torque : 25 N⋅m {250 kgf⋅cm, 1.8 lbf⋅ft} Entry of injector correction value to the engine ECU (entry using Hino field support system and QR code reader) QR code •...
  • Page 873 FUEL SYSTEM 5–17 Inspection of injector JP30002050704006 Inspection of injector insulation Remove the injector plastic terminal cap (upper). <Cross-section view of injector head> Measure the insulation resistance between the injector upper body and one terminal (no polarity) of two terminals for the injector harness.
  • Page 874 5–18 FUEL SYSTEM Inspection of common rail JP30002050704008 Inspection of common rail pressure sensor Measure the resistance value between terminals using a circuit tester. If it exceeds the standard value, replace the common rail assembly Between 1 and 2 Between 2 and 3 Standard value SAPH300020500031 (kΩ...

  • Page 875: Emission Control

    EMISSION CONTROL 6–1 ENGINE 6 EMISSION CONTROL Setup layout Layout EGR................6-2 Part layout............... 6-2 Overhaul of EGR valve and EGR cooler....6-3 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 876 6–2 EMISSION CONTROL Part layout JP30002060402001 SAPH300020600001 11104 Coolant pipe 17173 Gasket* 11104A Coolant pipe 17308 EGR pipe 16305 Coolant pipe 17309 EGR cooler assembly 16691 Coolant pipe 17350 EGR valve 16691A Coolant pipe 900234A Coolant hose 17104A Gasket* 900234B Coolant hose 17104B Gasket*...
  • Page 877 EMISSION CONTROL 6–3 Overhaul of EGR valve and EGR cooler JP30002060704001 Removal of EGR valve • Since burn may occur, replace the part after ! CAUTION cooling. (Leave it standing for 30 minutes or more after the starter key is turned OFF.) Remove the connector from the EGR solenoid valve.
  • Page 878 6–4 EMISSION CONTROL Installation of EGR valve Replace the EGR valve gasket with a new one and install the EGR valve on the intake air pipe paying attention to the direction Tightening torque : 68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft} Apply liquid gasket (Threebod TB1207B: Black) to the intake air pipe and connect it to the intake manifold.
  • Page 879 EMISSION CONTROL 6–5 Remove the EGR cooler. SAPH300020600008 Installation of EGR cooler Replace the gasket with a new one and tighten the EGR pipe and the EGR cooler temporarily. SAPH300020600009 Install the EGR cooler. Tightening torque : 37 N⋅m {377 kgf⋅cm, 27 lbf⋅ft} SAPH300020600010 Tighten the EGR pipe and the EGR cooler with bolts.
  • Page 880 6–6 EMISSION CONTROL Connect the EGR pipe. Tightening torque : 68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft} Connect hoses and pipes to the EGR cooler. SAPH300020600011 SAPH300020600012 Inspection of EGR cooler Check visually for crack or clogging of the unit gas channel and the sub-coolant pipe.
  • Page 881 ELECTRICAL 7–1 ENGINE 7 ELECTRICAL Setup layout Layout Electrical System............7-2 Part layout............... 7-2 Layout of components..........7-4 Inspection of components ........7-7 Installation of component ........7-9 Installation of starter ..........7-9 Removal and installation of the alternator..... 7-10 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 882 7–2 ELECTRICAL Electrical System Part layout JP30002070402001 SAPH300020700001 82030 Injector harness 89390 Boost pressure sensor 83420 Water temperature sender gauge 89410 Engine sub-revolution sensor 83530 Oil pressure warning switch 89411 Engine main revolution sensor [S5LC0011E04] [0713CsCshWbYs]...
  • Page 883 ELECTRICAL 7–3 SAPH300020700002 12511 Alternator bracket 28100 Starter assembly 27040 Alternator 900145 V –belt Tightening torque 9011-64401 83 N⋅m {850 kgf⋅cm, 61 lbf⋅ft} 9241-10107 51 N⋅m {520 kgf⋅cm, 37 lbf⋅ft} 9069D 154 N⋅m {1, 570 kgf⋅cm, 114 lbf⋅ft} 9241-14147 154 N⋅m {1,570 kgf⋅cm, 114 lbf⋅ft} [S5LC0011E04] [0713CsCshWbYs]...
  • Page 884 7–4 ELECTRICAL Layout of components JP30002070402002 Boost pressure sensor Engine sub-revolution sensor Suction control valve (SCV) Fuel temperature sensor Left side view SAPH300020700004 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 885 ELECTRICAL 7–5 Oil pressure warning switch Right side view SAPH300020700005 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 886 7–6 ELECTRICAL Water temperature sender gauge Engine main revolution sensor Common rail pressure sensor Upper view SAPH300020700003 Service procedure Overhaul item [S5LC0011E04] [0713CsCshWbYs]...
  • Page 887 ELECTRICAL 7–7 Inspection of components JP30002070702001 Inspection of oil pressure warning switch (Laid out on the oil filter) Apply pressure with air or oil and check continuity between terminals using a circuit tester. If it is faulty, replace it. At no load or less than 39 kPa With continuity {0.4 kgf/cm ,5.6565 lbf/in.
  • Page 888 7–8 ELECTRICAL Inspection of glow plug Measure continuity between the body and the terminal using a circuit tester. If it is faulty, replace the glow plug. Standard value Resistance value : Ω (Normal temperature 2.59 - 3.29 20°C{68°F}) SAPH300020700009 Inspection of suction control valve SCV and fuel temperature sensor Fuel temperature sensor For inspection and replacement of the suction control...
  • Page 889 ELECTRICAL 7–9 Installation of component JP30002070702002 Installation of engine revolution sensor Make sure that the sensor has the O-ring. Install the O-ring sensor on the flywheel housing and the cam housing. • Since this sensor is a flange type, gap does NOTICE not have to be adjusted.
  • Page 890 7–10 ELECTRICAL Removal and installation of the alternator JP30002070702004 Removal of alternator. Fixing nut(s) on the Adjustment bolt Brace side of the brace Remove the adjustment bolt. Remove the fixing nut(s) on the side of the brace. Remove the through bolt while supporting the alternator, and remove the alternator.
  • Page 891 ELECTRICAL 7–11 After the adjustment, tighten all nuts and bolts securely. Tightening torque : 83 N⋅m {850 kgf⋅cm, 61 lbf⋅ft} (Through bolt) 51 N⋅m {520 kgf⋅cm, 38 lbf⋅ft} (Fixing nuts at brace) 5.9 N⋅m {60 kgf⋅cm, 4 lbf⋅ft} (Adjustment bolt) •...
  • Page 892 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 893 INTAKE 8–1 ENGINE 8 INTAKE Setup layout Layout Intake Manifold ............8-2 Part layout............... 8-2 Replacement............8-3 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 894 8–2 INTAKE Intake Manifold Part layout JP30002080402001 SAPH300020800001 17031 Intake pipe 17113 Intake pipe 17111 Intake manifold 17171 Gasket* *Parts not to be reused. Tightening torque 9068-08000 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} 9240-08087 28 N⋅m {290 kgf⋅cm, 21lbf⋅ft} 9068-08550 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} Service procedure Replacement procedure item [S5LC0011E04] [0713CsCshWbYs]...
  • Page 895 INTAKE 8–3 Replacement JP30002080704001 Removal of intake manifold Remove bolts and nuts and remove the intake manifold. Installation of intake manifold Clean inside of the intake manifold and the cylinder head. Assemble a new gasket. • Install the gasket so that the protrusion may ! CAUTION come at the rear end stud bolt of the cylinder head.
  • Page 896 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 897 ENGINE MECHANICAL 9–1 ENGINE 9 ENGINE MECHANICAL Setup layout Layout Cylinder Head ............. 9-2 Part layout............... 9-2 Replacement of cylinder head ........ 9-4 Replacement of camshaft housing ......9-6 Liquid gasket application procedure for cylinder plug (only when cylinder plug is removed)...... 9-7 Replacement of head cover ........
  • Page 898 9–2 ENGINE MECHANICAL Cylinder Head Part layout JP30002090402001 SAPH300020900001 11101 Cylinder head assembly 11135 Exhaust valve seat 11122 Valve guide 11176 Nozzle seat 11131 Intake valve seat 900115 Gasket* *Parts not to be reused. [S5LC0011E04] [0713CsCshWbYs]...
  • Page 899 ENGINE MECHANICAL 9–3 SAPH300020900002 11101 Cylinder head assembly 11188A Cylinder plug 11103 Camshaft housing 11201 Cylinder head cover 11115 Cylinder head gasket 11213 Head cover gasket 11118 Camshaft housing gasket 12108 Oil filler cap 11188 Cylinder plug 23745 Pipe oil seal *Parts not to be reused.
  • Page 900 9–4 ENGINE MECHANICAL Replacement of cylinder head JP30002090704001 Removal of cylinder head and head gasket Loosen the head bolts from outside to inside gradually (1/ 4 turn for each) as shown in the order of the figure and remove them. SAPH300020900003 Remove the cylinder head using a special tool and hoist.
  • Page 901 ENGINE MECHANICAL 9–5 Apply appropriate amount of liquid gasket [Threebond TB1211 (white) or equivalent] to the head gasket hole at Application area of liquid gasket the joint surface between the cylinder block and the The arrow flywheel housing. shape area is different •...
  • Page 902 9–6 ENGINE MECHANICAL Tighten head bolts M12 only in the order from the center to outside. Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft} After tightening M12 bolt, tighten the bolts again from the center to outside. Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft} Mark the heads of the head bolts (M12 only) using paint.
  • Page 903 ENGINE MECHANICAL 9–7 Installation of camshaft housing Install new gasket and camshaft housing. Tightening torque : 23 N⋅m {230 kgf⋅cm, 17 lbf⋅ft} • Refer to the figure for the mounting bolt ! CAUTION position. SAPH300020900012 Liquid gasket application procedure for cylinder plug (only when cylinder plug is removed) JP30002090704003...
  • Page 904 9–8 ENGINE MECHANICAL Replacement of head cover JP30002090704004 Installation of head cover Remove liquid gasket near the side of the cylinder plug at the front/rear ends of the camshaft housing, using a scraper. • If there is oil leak from the cylinder plug, do ! CAUTION not remove the cylinder plug.
  • Page 905 ENGINE MECHANICAL 9–9 Overhaul of cylinder head JP30002090702001 Cleaning of cylinder head Remove carbon or other deposit using a scraper. Clean the cylinder head. • To remove carbon or other deposit, do not ! CAUTION damage the lower surface of the cylinder head.
  • Page 906 9–10 ENGINE MECHANICAL Heat the cylinder head to approx. 80 to 100 °C and strike the cooled valve seat into the mounting area of the cylinder head. SAPH300020900023 Apply small amount of lapping compound to the contact surface between the valve and the valve seat. Strike gently while turning the valve using a special tool for adjustment.
  • Page 907 ENGINE MECHANICAL 9–11 Clamp the nozzle seat using a special tool. Nozzle seat Special tool : 09472–1210 Bar 9800–06100 Steel ball Cylinder Head Steel ball Stamp out and clamp SAPH300020900027 Inspection of cylinder head Inspection of cylinder head distortion Measure distortion of the cylinder head lower surface and the manifold mounting surface using a ruler.
  • Page 908 9–12 ENGINE MECHANICAL Cylinder Block Part layout JP30002090402002 SAPH300020900029 11401 Cylinder block assembly 11467 Cylinder liner 11408 Cooling jet Tightening torque 22N ⋅m{220kgf⋅cm, 16lbf⋅ft} 11521 69N⋅m{700kgf⋅cm, 51lbf⋅ft}+90°+45° 15605 Service procedure Overhaul item [S5LC0011E04] [0713CsCshWbYs]...
  • Page 909 ENGINE MECHANICAL 9–13 Overhaul JP30002090702002 Replacement of cylinder liner Put match marks on the flange surfaces of the cylinder block and the cylinder liner using a oil based marker. • Store removed cylinder liners for each ! CAUTION cylinder number. Match mark •...
  • Page 910 9–14 ENGINE MECHANICAL Cylinder liner A, B and C marking position SAPH300020900034 Inspection of protrusion at cylinder liner flange Fix the cylinder liner using a special tool. Tightening torque : 9.8 N⋅m {100 kgf⋅cm, 7 lbf⋅ft} Measure protrusion of the flange using a dial gauge. Special tool : 09420–2100 Cylinder liner puller 0.01 - 0.08 Standard value (mm{in.})
  • Page 911 ENGINE MECHANICAL 9–15 Set a special tool on the cylinder block. Special tool : 09470–1280 Tool assembly Special tool Tool assembly Cylinder liner Cooling jet SAPH300020900038 Inject oil from the nozzle of the cooling jet at the hydraulic Oil injection unit (example) pressure of 196kPa{2kgf/cm , 28lbf/in.
  • Page 912 9–16 ENGINE MECHANICAL Inspection of cylinder block Inspection of cylinder block distortion Measure distortion on the cylinder block using a ruler. Standard value (mm{in.}) Service limit (mm{in.}) Longitudinal direction 0.06{0.0024} 0.2{0.0079} Square direction 0.03{0.0012} If the measurement value is beyond the service limit, replace it.
  • Page 913 ENGINE MECHANICAL 9–17 Timing Gear Cover and Flywheel Housing Part layout JP30002090402003 SAPH300020900043 11056 Flywheel housing stay 11357A Gasket* 11309 Oil seal retainer 11390 End plate 11351 Flywheel housing 9828A Front oil seal* 11357 Gasket* 9828B Rear oil seal* *Parts not to be reused. Tightening torque 9029A 55N⋅m{560kgf⋅cm, 41lbf⋅ft}...
  • Page 914 9–18 ENGINE MECHANICAL Replacement of flywheel housing JP30002090702003 Removal of flywheel housing Remove bolts and remove the flywheel housing. • Remove bolts fixing the flywheel housing ! CAUTION from the cylinder block. SAPH300020900044 Installation of flywheel housing Liquid gasket Remove contamination from the joint surfaces of the flywheel housing and the rear end plate using a scraper.
  • Page 915 ENGINE MECHANICAL 9–19 Installation of rear end plate Install the rear end plate and a new gasket with bolts. • Make sure that there is no dirt or foreign ! CAUTION matter on the installation surface of the cylinder block and the screw holes. Apply sealant (Super 5M or equivalent) to the thread of the Torx bolt.
  • Page 916 9–20 ENGINE MECHANICAL Remove two bolts which installed the plate of the special tool oil seal puller on the crankshaft. Attach the accompanying center bolt to the special tool oil seal puller and tighten it. Pull out the crankshaft front oil seal.
  • Page 917 ENGINE MECHANICAL 9–21 Replacement of crankshaft rear oil seal JP30002090704006 Removal of crankshaft rear oil seal Install the plate of the special tool oil seal puller on the crankshaft using two flywheel assembly mounting bolts. Special tool : 09420–1742 Oil seal puller •...
  • Page 918 9–22 ENGINE MECHANICAL Remove contamination from the joint surface of the crankshaft rear oil seal and the flywheel housing Apply small amount of engine oil to the seal area of the crankshaft rear oil seal. Install the oil seal press guide inserting a new crankshaft rear oil seal with accompanying guide bolts on the crankshaft.
  • Page 919 ENGINE MECHANICAL 9–23 Main Moving Parts Part layout JP30002090402004 SAPH300020900062 11011 Thrust bearing 13260 Connecting rod assembly 11701 Main bearing 13407 Crankshaft damper 11703 Main bearing US 0.25 13411 Crankshaft 11704 Main bearing US 0.50 13450 Flywheel assembly 13005 Piston and piston ring set 13453 Ring gear 13201...
  • Page 920 9–24 ENGINE MECHANICAL Replacement of piston and connecting rod JP30002090702005 Removal of piston Figure is an Remove bolts and remove the connecting rod cap. example of work. • Insert a large flat tip screwdriver into the ! CAUTION flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft.
  • Page 921 ENGINE MECHANICAL 9–25 Disassembly of piston and connecting rod Remove the retainer ring using snap ring pliers. Remove the piston pin using the brass bar and disconnect the piston from the connecting rod. SAPH300020900067 Remove the piston ring using a special tool. Special tool : 09442–1011 Piston ring expander •...
  • Page 922 9–26 ENGINE MECHANICAL Face the side with the piston ring identification print upward and install in the order of the oil ring, second ring and top ring using a special tool. • The identification print is present only on the NOTICE secondary ring and the top and bottom of the top ring and the oil ring are not identified.
  • Page 923 ENGINE MECHANICAL 9–27 Insert the piston carefully so that the connecting rod may not come in contact with the cooling jet. • Face the "0" mark on the piston toward the ! CAUTION exhaust side for insertion. • Set the crankshaft of the cylinder as the top dead center for assembly.
  • Page 924 9–28 ENGINE MECHANICAL Tighten the connecting rod bolt and mark the bolt head in the same direction with paint. Paint mark Tightening torque : 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft} Connecting rod cap (10) Retighten the connecting rod bolt 90 °. (11) Retighten the connecting rod bolt further 45 °.
  • Page 925 ENGINE MECHANICAL 9–29 Measure the piston ring groove using a thickness gauge. If it is out of the service limit, replace the piston. Standard value Service limit (mm{in.}) (mm{in.}) Top ring groove 2.5{0.0984} 2.70{0.1063} Second ring groove 2{0.0787} 2.20{0.0866} Oil ring groove 4{0.1575} 4.10{0.1614} SAPH300020900081...
  • Page 926 9–30 ENGINE MECHANICAL Replacement of connecting rod bushing JP30002090704007 Removal of connecting rod bushing Press Put the special tool press sub-assembly together with the Sub-assembly Wing nut special tool guide nut and fix them using the special tool wing nut. Guide Special tool : 09481–1130 Guide 09402–1530 Press sub-assembly...
  • Page 927 ENGINE MECHANICAL 9–31 Chamfer one side of the connecting rod small end uniformly according to the figure. Chamfer • Remove burr completely. ! CAUTION • After chamfering, remove dirt from the inner surface at the small end and from the oil hole. SAPH300020900089 Installation of connecting rod bushing Install a new bushing on the special tool spindle and...
  • Page 928 9–32 ENGINE MECHANICAL Replacement of crankshaft JP30002090704008 Removal of crankshaft Remove the main bearing cap and the crankshaft bearing. Remove the crankshaft using a hoist. • Since the part is heavy, be careful for ! CAUTION handling. • Store removed main bearing caps and crankshaft bearings for each cylinder number.
  • Page 929 ENGINE MECHANICAL 9–33 Measure the underhead length of the bearing cap bolt using a vernier calipers. If it is out of the service limit, replace it with a new one. Service limit (mm{in.}) 108{4.252} Underhead length SAPH300020900076 Apply engine oil to the bolt seat and the bolt thread of the bearing cap bolt.
  • Page 930 9–34 ENGINE MECHANICAL Inspection of crankshaft JP30002090703002 Inspection of end play Measure the end play of the crankshaft using a dial gauge. If it is beyond the repair limit, replace the thrust bearing. If it is beyond the service limit, replace the crankshaft.
  • Page 931 ENGINE MECHANICAL 9–35 Measure the crankshaft center journal width using a vernier calipers. If it is out of the service limit, replace the Figure is an example of work. crankshaft. Standard value (mm{in.}) Service limit (mm{in.}) 36{1.4173} 37.0{1.4567} SAPH300020900101 Inspection of crankshaft oil clearance Measure the outer diameter of the crankshaft journal using a micrometer.
  • Page 932 9–36 ENGINE MECHANICAL Dimension of fillet "R" Crank pin Radius is 2.5 to 3.0mm {0.0984 to 0.1181 in.} Radius is incomplete. Step Step small. Journal 2.5 to 3.0mm {0.0984 to 0.1181 in.} Good Poor SAPH300020900104 Inspection of crack and damage on crankshaft and of oil hole Figure is an example of work.
  • Page 933 ENGINE MECHANICAL 9–37 Replacement of crankshaft pulley JP30002090704009 Removal of crankshaft pulley Remove bolts and remove the crankshaft pulley. • Insert a large flat tip screwdriver into the NOTICE flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft.
  • Page 934 9–38 ENGINE MECHANICAL Removal of ring gear Heat the entire ring gear circumference with a burner until it is about 200 °C(392°F). • Do not touch the ring gear and the flywheel ! CAUTION with bare hand while they are hot. SAPH300020900112 Hit the circumference of the ring gear gently using a backing rod to remove the ring gear from the flywheel.
  • Page 935 ENGINE MECHANICAL 9–39 Installation of flywheel Make sure that there is no burr or dirt on the joint surface of the crankshaft and the flywheel and the screw hole. Install the special tool into the bolt hole of the crankshaft. Special tool : 09481–1340 Guide •...
  • Page 936 9–40 ENGINE MECHANICAL Camshaft and Idle Gear Part layout JP30002090402005 SAPH300020900120 13501 Camshaft assembly 13572A Thrust plate 13505 Cam idle gear 13572B Thrust plate 13505A Sub-idle gear 13581 Idle gear shaft 13505B Main idle gear 13581A Idle gear shaft 13520 Camshaft gear 13581B Idle gear shaft...
  • Page 937 ENGINE MECHANICAL 9–41 Removal of camshaft JP30002090702006 Removal of rocker arm and camshaft assembly Loosen the lock nut and turn the adjusting screw completely. Rock nut • Removal without turning the adjusting screw ! CAUTION may bend the rocker shaft. Loosen the rocker arm support bolts gradually from the center and remove the rocker arm and the rocker arm shaft.
  • Page 938 9–42 ENGINE MECHANICAL Inspection of camshaft and camshaft bearing JP30002090702008 Inspection of cam height on camshaft Measure the cam height using a micrometer. If it is beyond the service limit, replace the camshaft. Standard value Service limit (mm{in.}) (mm{in.}) 50.067{1.9711} 49.987{1.9680} height 52.104{2.0513}...
  • Page 939 ENGINE MECHANICAL 9–43 Assembly of camshaft JP30002090702009 Measure the camshaft mounting bolt using a vernier calipers. If it is out of the service limit, replace it with a new one. Service limit (mm{in.}) 30.5{1.2008} Underhead length SAPH300020900126 Fix the camshaft gear using a vice. Apply engine oil to the seat and the bolt thread of the camshaft gear mounting bolt.
  • Page 940 9–44 ENGINE MECHANICAL Installation of camshaft JP30002090702010 Align the No. 1 cylinder to the compression top dead center. Installation of camshaft Timing judgment drill hole Place the camshaft so that two holes at 180 degrees from the three drilled holes of the camshaft gear may be horizontal to the upper surface of the camshaft housing.
  • Page 941 ENGINE MECHANICAL 9–45 Gear train layout JP30002090402006 Camshaft gear Main idle gear Cam idle gear Pump drive idle gear Sub-idle gear Oil pump gear Crankshaft gear Air compressor drive gear (supply pump drive gear) Match mark Match mark Match mark SAPH300020900130 Service procedure Overhaul item...
  • Page 942 9–46 ENGINE MECHANICAL Removal of sub-idle gear Remove the idle gear shaft mounting bolt and the idle gear thrust plate and pull out the sub-idle gear assembly using a special tool. Special tool : 09420–1100 Sliding hammer 09420–1442 Sliding hammer Remove the idle gear thrust plate.
  • Page 943 ENGINE MECHANICAL 9–47 Installation of timing gear JP30002090702013 Installation of sub-idle gear Install the idle gear shaft on the sub-idle gear. Thrust plate Install the idle gear thrust plate. Provide the lubricating hole of the idle gear shaft in the vertical direction.
  • Page 944 9–48 ENGINE MECHANICAL Face the lubricating hole of the idle gear shaft toward the oil pan (downward). Install A in the figure by adjusting the timing of the crankshaft gear and the main idle gear as in Sub-idle gear the detailed drawing. Oil pump gear Main idle gear...
  • Page 945 ENGINE MECHANICAL 9–49 Overhaul of sub-idle gear (bearing case side) JP30002090702014 Removal of bearing case assembly Remove the supply pump drive. "Reference : Replacement, Supply pump". Remove 5 bolts and remove the bearing case assembly. • One bolt is tightened from the timing gear ! CAUTION case.
  • Page 946 9–50 ENGINE MECHANICAL Inspection of clearance between sub-idle gear shaft and sub-idle gear bushing Measure the outer diameter of the idle gear shaft. SAPH300020900143 Measure the inner diameter of the sub-idle gear. Calculate the clearance. If it is beyond the standard value, replace the shaft and the bushing.
  • Page 947 ENGINE MECHANICAL 9–51 Inspection of installation status for each gear JP30002090703003 Inspection of backlash between camshaft gear and cam idle gear Insert a large flat tip screwdriver into the cam idle gear from the side of the camshaft gear of the camshaft housing to prevent turning of the cam idle gear.
  • Page 948 9–52 ENGINE MECHANICAL Measure backlash between the main idle gear and the pump drive idle gear using a dial gauge and a magnet stand. If it is beyond the service limit, replace each gear. • If the magnet stand is not stable, provide a NOTICE steel plate for measurement using bolt holes of the cylinder block.
  • Page 949 ENGINE MECHANICAL 9–53 Inspection of backlash between sub-idle gear at cam idle gear and oil pump gear Insert a large flat tip screwdriver into the sub-idle gear to prevent turning of the sub-idle gear. SAPH300020900155 Measure backlash between the sub-idle gear and the oil pump gear using a dial gauge and a magnet stand.
  • Page 950 9–54 ENGINE MECHANICAL Measure backlash between the cam idle gear and the sub-idle gear using a dial gauge. If it is beyond the service limit, replace each gear. Standard value (mm{in.}) Service limit (mm{in.}) 0.050 - 0.218 0.30{0.0118} {0.0020 - 0.0086} Setup layout Layout SAPH300020900159...
  • Page 951 ENGINE MECHANICAL 9–55 Valve System Part layout JP30002090402007 SAPH300020900160 13706 Crosshead assembly 13735 Valve seat upper 13709 Adjusting screw 13830 Rocker arm intake 13711 Intake valve 13840 Rocker arm (exhaust) 13715 Exhaust valve 13901 Rocker shaft 13731 Outer spring 13951 Rocker support 13732 Inner spring...
  • Page 952 9–56 ENGINE MECHANICAL Overhaul of valve system JP30002090702015 Removal of rocker arm and rocker arm shaft Loosen the lock nut and turn the adjusting screw completely. Lock nut • Removal without turning the adjusting screw ! CAUTION may bend the rocker arm shaft. SAPH300020900161 Loosen the rocker arm support bolts gradually from the center and remove the rocker arm and the rocker arm...
  • Page 953 ENGINE MECHANICAL 9–57 Place the rocker arm and the rocker arm shaft on the camshaft housing and make sure that the rocker arm is correctly on the crosshead. Tighten the rocker arm support bolts gradually several times. Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft} •...
  • Page 954 9–58 ENGINE MECHANICAL Remove the intake and exhaust valves. • Attach a tag with the applicable cylinder ! CAUTION number to the valve so that combinations of the valve and the cylinder head may not be mixed. SAPH300020900168 Replacement of valve stem seal Stem seal Special tool After removing the valve stem seal, assemble the valve...
  • Page 955 ENGINE MECHANICAL 9–59 Installation of valve spring Install the valve spring upper seat on the valve spring. Compress the valve spring using a special tool and install the valve spring retainer. Special tool : 09470–1170 Valve spring press • Apply engine oil to the contact surface of ! CAUTION each part before assembly.
  • Page 956 9–60 ENGINE MECHANICAL Inspection of oil clearance between valve guide and valve stem Measure the outer diameter of the valve stem using a micrometer. Standard value (mm{in.}) Intake valve stem 7{0.2756} Exhaust valve stem 7{0.2756} SAPH300020900174 Measure the valve guide inner diameter using a cylinder gauge.
  • Page 957 ENGINE MECHANICAL 9–61 Adjustment of valve clearance JP30002090706001 Precautions before adjustment • Before adjustment, make sure that bolts of ! CAUTION the cylinder head, rocker arm support, nozzle clamp, camshaft housing and camshaft bearing cap are tightened to the specified torque. Adjustment of valve clearance Make sure that there is no dirt between the crosshead and the valve stem...
  • Page 958 9–62 ENGINE MECHANICAL Tighten the adjusting screw of the crosshead until the thickness gauge does not move. Close contact Close contact SAPH300020900179 While loosening the adjusting screw of the crosshead gradually, tighten the lock nut of the crosshead at the Start position where feel on the thickness gauge is appropriate.
  • Page 959 EXHAUST 10–1 ENGINE 10 EXHAUST Setup layout Layout Exhaust Manifold............10-2 Part layout............. 10-2 Replacement............10-3 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 960 10–2 EXHAUST Exhaust Manifold Part layout JP30002100402001 SAPH300021000001 17104 Gasket* 17105 Exhaust manifold *Parts not to be reused. Tightening torque 9209A 53 N⋅m {540 kgf⋅cm, 40lbf⋅ft} Service procedure Replacement procedure item [S5LC0011E04] [0713CsCshWbYs]...
  • Page 961 EXHAUST 10–3 Replacement JP30002100704001 Removal of exhaust manifold Remove nuts and remove the exhaust manifold. Replacement of stud bolt Remove dirt (e.g. sealant) at the female thread of the cylinder head and clean the thread again with tap (M10 x 1.5).
  • Page 962 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 963 COOLING 11–1 ENGINE 11 COOLING System drawing System drawing Cooling System ............11-2 Cooling system drawing........11-2 Part layout............. 11-3 Replacement of thermostat case ......11-4 Inspection of thermostat ........11-5 Adjustment of the fan belt tension......11-6 Replacement of coolant pump ......11-7 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 964 11–2 COOLING Cooling System Cooling system drawing JP30002110803001 Reserve tank Air bleeding Air bleeding Radiator cap EGR cooler Thermo cover (Outlet) Heater Coolant temperature gauge Thermo case Cylinder head Thermo cover Thermostat (Inlet) Turbocharger Cylinder block Drain cock Coolant pump Oil cooler Drain cock valve...
  • Page 965 COOLING 11–3A Part layout JP30002110402001 SAPH300021100002 16100 Coolant pump 16323 Thermostat case cover 16301 Thermostat case 16325 Gasket* 16302 Thermostat case cover 9851A O–ring* *Parts not to be reused. Service procedure Replacement procedure item [S5LC0011E04] [0713CsCshWbYs]...
  • Page 966 11–4A COOLING Replacement of thermostat case JP30002110704001 Removal of thermostat case Remove the EGR cooler. Refer to "Inspection of EGR cooler, Emission control". Remove bolts and remove the thermostat case. Remove the O-ring from the groove on the coolant pump. SAPH3032E1100003 Installation of the thermostat (when it has been removed) Jiggle valve...
  • Page 967 COOLING 11–5 Inspection of thermostat JP30002110703001 Individual inspection of thermostat Wire Thermometer Put the thermostat in water as shown in the figure and heat it. • Support the thermostat in the center to ! CAUTION prevent approach to the heat source. •...
  • Page 968 11–6 COOLING Adjustment of the fan belt tension JP30002110705001 Adjustment of the fan belt tension. Use the special tool and check the fan belt tension at the measuring position (A). Tension Pulley Coolant Pump Adjustment When installing a Pulley Item At the time of inspection Bolt new belt...
  • Page 969 COOLING 11–7 Replacement of coolant pump JP30002110704002 Removal of coolant pump Remove bolts and remove the coolant pump. SAPH300021100010 Installation of coolant pump Liquid gasket Remove contamination on the joint surface between the coolant pump and the cylinder block using a scraper and degrease the surface.
  • Page 970 [S5LC0011E04] [0713CsCshWbYs]...
  • Page 971 LUBRICATION 12–1 ENGINE 12 LUBRICATION System drawing System drawing Oil Cooler, Oil Filter and Oil Pump......12-2 System drawing ............ 12-2 Part layout............. 12-3 Part layout............. 12-4 Replacement of oil cooler ........12-5 Overhaul of oil cooler ..........12-6 Replacement of oil pump ........12-9 Overhaul of oil pump...........
  • Page 972 12–2 LUBRICATION Oil Cooler, Oil Filter and Oil Pump System drawing JP30002120805001 Roller pin Roller Rocker Adjusting Valve Crosshead Rocker arm screw shaft Camshaft Cam idle gear shaft Sub-idle gear shaft Turbocharger Main Oil pump Oil filter Oil cooler oil hole Connecting Piston pin Crankshaft...
  • Page 973 LUBRICATION 12–3 Part layout JP30002120402001 SAPH300021200002 15012 Oil pump cover assembly 15135 Relief valve 15104 Oil strainer 15710 Oil cooler 15107 Driven gear 9500-40400 Cotter pin* 15119 Gasket* 9851A O–ring* 15132 Spring *Parts not to be reused. Tightening torque 9068-08160 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft} 9068-08550 31N⋅m {320kgf⋅cm, 23lbf⋅ft} (Oil strainer...
  • Page 974 12–4 LUBRICATION Part layout JP30002120402002 SAPH300021200003 15662 Drain plug 15720 Oil cooler case assembly 15675 Safety valve 9851A O–ring* 15701 Oil cooler case 9851B O–ring* 15710 Oil cooler 9851C O–ring* 15712 Oil cooler 9851D O–ring* 15717 Gasket* 9851E O–ring* *Parts not to be reused. Tightening torque 15662 44.1±4.9 N⋅m {450±50 kgf⋅cm, 33±4llbf⋅ft}...
  • Page 975 LUBRICATION 12–5 Replacement of oil cooler JP30002120704001 Removal of oil cooler Remove bolts and remove the oil cooler. SAPH300021200004 If it is difficult to remove the oil cooler due to liquid gasket Figure is an sticking to the cylinder block, put a flat tip screwdriver at example of work.
  • Page 976 12–6 LUBRICATION Insert the positioning stud into the screw hole of the cylinder block and install the oil cooler. After temporary tightening with bolts, remove the positioning stud and tighten bolts. Tightening torque : 24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} •...
  • Page 977 LUBRICATION 12–7 Remove the oil pressure warning switch. Soft washer Hydraulic pressure warning switch SAPH300021200012 Inspection of safety valve wear and damage If wear or damage is found, replace it. SAPH300021200013 Inspection of oil pressure warning switch For inspection of oil pressure warning switch, refer to "Inspection of components"- "Electrical".
  • Page 978 12–8 LUBRICATION Installation of oil cooler element Assemble new gasket and new O-ring and assemble the oil cooler element with nuts. Tightening torque : 24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} • In handling the oil cooler element, be careful ! CAUTION not to give damage to it.
  • Page 979 LUBRICATION 12–9 Replacement of oil pump JP30002120704002 Removal of oil pump Dismount the engine from the vehicle. Remove the flywheel. Remove the flywheel housing. Remove the timing gear. Remove the oil pump. Installation of oil pump Apply engine oil to the pump case and the bearing (shaded area) of the cylinder block.
  • Page 980 12–10 LUBRICATION Overhaul of oil pump JP30002120702002 Remove the driven gear. SAPH300021200016 Remove the cotter pin and remove seat 2, seat 1, relief valve spring and safety valve. • When the cotter pin is removed, seat 2 and ! CAUTION the relief valve spring may eject out.
  • Page 981 LUBRICATION 12–11 End play inspection between drive gear and cylinder block Measure the drive gear width and the pump chamber depth at the cylinder block using a depth gauge. Standard value Measuring area (mm{in.}) Width of drive gear 37.5{1.4764} Depth of pump chamber at 37.5{1.4764} cylinder block SAPH300021200020...
  • Page 982 12–12 LUBRICATION Inspection of clearance betweeen outer diameter of driven gear shaft and inner diameter of driven gear bushing Measure the outer diameter of the driven gear shaft using a micrometer and measure the inner diameter of the driven gear bushing using a cylinder gauge. Standard value Measuring area (mm{in.})
  • Page 983 LUBRICATION 12–13 Inspection of drive gear backlash Fix the oil pump assembly with a vice. Measure backlash between the drive gear and the driven gear using a dial gauge. If it is beyond the service limit, replace the oil pump assembly. Standard value (mm{in.}) Service limit (mm{in.}) 0.072 - 0.277...
  • Page 984 12–14 LUBRICATION Oil Pan Part layout JP30002120402003 SAPH300021200029 12101 Oil pan assembly 12149 Drain plug 12151 Oil pan gasket* 9659A Gasket* *Parts not to be reused. Tightening torque 9199A 30 N⋅m {300 kgf⋅cm, 22 lbf⋅ft} 12149 41 N⋅m {420 kgf⋅cm, 30 lbf⋅ft} Service procedure Replacement procedure item [S5LC0011E04] [0713CsCshWbYs]...
  • Page 985 LUBRICATION 12–15 Replacement JP30002120704004 Installation of oil pan Cut the gasket of the rear end plate to be flush to the Bolt tightening direction cylinder block lower surface using a scraper. Make sure that there is no deformation, dirt or oil on the joint surface between the cylinder block and the oil pan.
  • Page 986 12–16 LUBRICATION Inspection of lubrication status JP30002120703001 Inspection of valve system • Perform inspection with the water ! CAUTION temperature at 60 °C{140°F}. Remove the head cover. • To prevent spread of engine oil, attach a jig ! CAUTION which cuts a head cover in half. Cut it to the degree that the camshaft is covered.
  • Page 987 STARTING AND CHARGING 13–1 ENGINE 13 STARTING AND CHARGING Setup layout Layout Starter................ 13-2 Part layout (typical example)......... 13-2 Disassembly............13-3 Inspection of components ........13-9 Assembly ............13-14 Alternator (60A) ............13-21 Part layout (typical example of 60A) ....13-21 Circuit drawing (60A) ..........
  • Page 988 13–2 STARTING AND CHARGING Starter Part layout (typical example) JP30002130402001 SAPH300021300001 28011 Clutch subassembly 28138 Packing* 28100 Starter 28140 Brush holder assembly 28111 Bushing 28142 Brush 28111A Bushing 28143 Spring 28113 Lever 28150 Center bracket 28115 Start drive housing 28160 Armature assembly 28117 Packing*...
  • Page 989 STARTING AND CHARGING 13–3 Disassembly JP30002130702001 • Fix the starter on the working table to ease NOTICE M lead wire accessibility. M terminal MRemoval of lead wire Remove the cap of the M terminal. Remove nuts and remove the M lead wire. SAPH300021300002 Removal of commutator end frame Loosen and remove two through bolts.
  • Page 990 13–4 STARTING AND CHARGING Removal of brush holder assembly Brush holder Lift the spring using a flat tip screwdriver or pliers. Assembly Remove four brushes from the brush holder assembly. • Do not cut the brush lead fixing clamp. ! CAUTION Remove the brush holder assembly from the armature assembly.
  • Page 991 STARTING AND CHARGING 13–5 Removal of armature assembly Remove the armature assembly by lifting. Armature assembly • When the armature assembly is removed, the ! CAUTION washer at the end of the gear may be dropped and lost. Be careful for handling. Center bracket assembly SAPH300021300008...
  • Page 992 13–6 STARTING AND CHARGING 10. Removal of internal gear Remove the internal gear from the center bracket. • Make sure that the gear is not damaged or ! CAUTION chipped. Internal gear Center bracket SAPH300021300012 11. Removal of shim washer Remove the shim washer from the center bracket.
  • Page 993 STARTING AND CHARGING 13–7 13. Removal of center bracket Center bracket Remove two set bolts at the switch using a box screwdriver or offset wrench. Lift and remove the center bracket. Clutch assembly SAPH300021300016 14. Removal of lever Hold the lever holder and press the entire lever to the clutch.
  • Page 994 13–8 STARTING AND CHARGING Remove the brake plate. Brake plate SAPH300021300020 16. Removal of clutch assembly While pressing the clutch assembly to the center bracket Clutch assembly assembly, offset the helical spline by one tooth. Pull out the clutch assembly upward from the offset position and remove it.
  • Page 995 STARTING AND CHARGING 13–9 Inspection of components JP30002130703001 Inspection of yoke assembly Make sure that the coil lead wire has electric continuity using a circuit tester. Make sure that there is no discoloration at the coil. SAPH300021300024 Measure the resistance between the coil lead wire and the Tester rod yoke with a circuit tester and check insulation.
  • Page 996 13–10 STARTING AND CHARGING Make sure that adjacent segments of the commutator have electric continuity using a circuit tester. Make sure that there is no discoloration at the coil. SAPH300021300028 Measure the resistance between the commutator and the core using a circuit tester and check insulation. When the value is below the service limit, replace it.
  • Page 997 STARTING AND CHARGING 13–11 Measure the shaft outer diameter using a micrometer. If it is beyond the service limit, replace the shaft. Standard value Service limit Measuring area (mm{in.}) (mm{in.}) 11.98{0.4717} or Area 12{0.4724} less 8.98{0.3535} or Area 9{0.3543} less SAPH300021300032 Inspection of brush holder assembly Measure the resistance between the holder (plus) and the...
  • Page 998 13–12 STARTING AND CHARGING Inspection of clutch assembly Measure the outer diameter of the inner sleeve using a micrometer. If it is beyond the service limit, replace the clutch assembly. Standard value (mm{in.}) Service limit (mm{in.}) 25{0.9843} 24.90{0.9803} or less SAPH300021300036 Inspection of bearing Measure the bearing metal inner diameter (1 in the figure)
  • Page 999 STARTING AND CHARGING 13–13 Inspection of start magnet switch assembly (resistance of C terminal P coil) Measure the P coil resistance between the C terminal and M terminal the M terminal using a circuit tester. If it is beyond the service limit, replace the start magnet switch.
  • Page 1000 13–14 STARTING AND CHARGING Assembly JP30002130702002 Installation of packing Install a new packing on the center bracket assembly. Packing SAPH300021300023 Installation of shaft assembly Turn the center bracket assembly upside down and hold Washer the carrier plate. Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the shaft assembly.

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