HYD.

EXCAVATOR
SERVICE TRAINING

YN11-45001~
YQ11-06001~
LC10-07001~
YC10-03501~

Technical Service Group,

Customer Support Department

Book Code No. S6OA00801ZE03

Printed in Japan 2006.08 (KE)
 CONTENTS

1. OUTLINE
1.1 SK200-8.................................................................................................................... 1-3
1.2 SK330-8.................................................................................................................... 1-4

2. CONSTRUCTION & FUNCTION

2.1 NAME OF COMPONENTS ...................................................................................... 2-3
2.2 SPECIFICATIONS AND PERFORMANCE .............................................................. 2-5
2.3 OPERATOR CAB NOMENCLATURE (SK200-8, SK330-8) .................................... 2-7
2.4 SUMMARY OF MECHATRO CONTROL SYSTEM ................................................. 2-10
2.5 HYDRAULIC SYSTEM ............................................................................................. 2-29
2.6 HYDRAULIC COMPONENTS (SK200-8)................................................................. 2-43
2.7 HYDRAULIC COMPONENTS (SK330-8)................................................................. 2-67
2.8 ELECTRICAL EQUIPMENT AND HARNESS LAYOUT (SK200-8) ......................... 2-85
2.9 ELECTRICAL EQUIPMENT AND HARNESS LAYOUT (SK330-8) ......................... 2-101
2.10 AIR-CONDITIONER SYSTEM ................................................................................. 2-111

3. MECHATRO CONTROL SYSTEM

3.1 ADJUSTMENT OF MECHATRO CONTROLLER .................................................... 3-3
3.2 SUMMARY OF MULTI DISPLAY ............................................................................. 3-9
3.3 SELF DIAGNOSIS DISPLAY ................................................................................... 3-14
3.4 SERVICE DIAGNOSIS DISPLAY FUNCTION ......................................................... 3-16
3.5 TROUBLE HISTORY DIAGNOSIS........................................................................... 3-31
3.6 TROUBLE DIAGNOSIS MODE................................................................................ 3-32
3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE............................................. 3-33
3.8 ADJUSTING PROCEDURE OF DISPLAY ............................................................... 3-35
3.9 MECHATRO CONTROL EQUIPMENT .................................................................... 3-39
3.10 EMERGENCY MODE............................................................................................... 3-50

4. ENGINE
4.1 ENGINE SPECIFICATIONS (SK200-8) ................................................................... 4-3
4.2 ENGINE OUTSIDE VIEW (SK200-8) ....................................................................... 4-5
4.3 ENGINE MOUNTING (SK200-8).............................................................................. 4-5
4.4 FUEL INJECTION SYSTEM..................................................................................... 4-6
4.5 CONSTRUCTION & FUNCTION.............................................................................. 4-10
4.6 HOW TO READ TROUBLESHOOTING................................................................... 4-24
4.7 ENGINE SPECIFICATIONS (SK330-8) ................................................................... 4-32
4.8 ENGINE OUTSIDE VIEW (SK330-8) ....................................................................... 4-34

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4.9 ENGINE MOUNTING (SK330-8).............................................................................. 4-35

5. MACHINE STRUCTURE
5.1 BOOM (SK200-8) ..................................................................................................... 5-3
5.2 ARM (SK200-8) ........................................................................................................ 5-7
5.3 BUCKET (SK200-8) ................................................................................................. 5-12
5.4 LOWER PARTS (SK200-8)...................................................................................... 5-15
5.5 REMOVING AND INSTALLING PROCEDURE OF ASSY
(RELEVANT UPPER FRAME) (SK200-8)................................................................ 5-23
5.6 WEIGHT OF COMPONENTS (SK200-8)................................................................. 5-35
5.7 BOOM (SK330-8) ..................................................................................................... 5-37
5.8 ARM (SK330-8) ........................................................................................................ 5-41
5.9 BUCKET (SK330-8) ................................................................................................. 5-46
5.10 LOWER PARTS (SK330-8)...................................................................................... 5-49
5.11 REMOVING AND INSTALLING PROCEDURE OF ASSY
(RELEVANT UPPER FRAME) (SK330-8)................................................................ 5-58
5.12 WEIGHT OF COMPONENTS (SK330-8)................................................................. 5-66

6. CHECK-UP & SERVICE

6.1 CHECK-UP & MAINTENANCE ................................................................................ 6-3
6.2 LUBRICANT, FUEL & COOLANT SPECIFICATIONS (SK200-8)............................ 6-10
6.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS (SK330-8)............................ 6-12
6.4 MAINTENANCE PARTS (SK200-8)......................................................................... 6-14
6.5 MAINTENANCE PARTS (SK330-8)......................................................................... 6-16
6.6 USE OF BIO-DEGRADABLE OILS.......................................................................... 6-18
6.7 INSPECTION & MAINTENANCE CHART (For Asia)............................................... 6-19
6.8 INSPECTION & MAINTENANCE CHART (For Oceania) ........................................ 6-23
6.9 PERFORMANCE INSPECTION STANDARD TABLE (SK200-8) ............................ 6-27
6.10 PERFORMANCE INSPECTION STANDARD TABLE (SK330-8) ............................ 6-29

7. DATA 1.
7.1 WORKING RANGES (SK200-8) .............................................................................. 7-3
7.2 WORKING RANGES (SK330-8) .............................................................................. 7-5

8. DATA (CIRCUIT DIAGRAM)

8.1 HYDRAULIC CIRCUIT DIAGRAM (STANDARD) (SK200-8)................................... 8-3
8.2 HYDRAULIC CIRCUIT DIAGRAM (STANDARD) (SK330-8)................................... 8-4
8.3 HYDRAULIC CIRCUIT N&B SPECIFICATION (OPTION) (SK200-8, SK330-8) ..... 8-5

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8.4 ELECTRIC CIRCUIT DIAGRAM (SK200-8, SK330-8) ............................................. 8-6

8.5 ELECTRICAL EQUIPMENT LIST ............................................................................ 8-10

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1. OUTLINE

1-1
1. OUTLINE

1-2
 1. OUTLINE

1.1 SK200-8
Comparison between old and new model's
Item Description Concept
(Old New)
Center section at engine bottom Fabricated plates 1 piece plate Increase strength to standardize the
frame conventional model and the
Upper others severe job application.
machinery Strengthened side deck D frame Sectional area of D-shaped frame 1.5 times larger size Less damage when slewing and
impact against object.

Under Slant shaped track frame. Slant shape Slant shape (continued) Mud stuck prevention
carriage
Strengthen boom top and boom foot boss. Steel plates fabricating type Cast steel made Improving durability of attachment
Moving boom cylinder head side port to the back. At front side At back side Preventing hydraulic piping damage
Strengthen Foot boss of arm. Steel plates fabricating type Forged material Improving durability of attachment
Attachment Strengthen arm equalizing current one with Nibbler and breaker
New 2 stage bushing Conventional bushing (1 pc) Flange type and Hard material
Continue urethane packing for hydraulic cylinders Long life without oil leakage

New style control valve Low fuel consumption

Large size hydraulic tubes at attachment
Hydraulic Hydraulic return line joints change.
tubes and Hydraulic tube joint to control valve change. ORS 4 volt flange
pipings New Nibbler and Breaker selector valve Manual shifting type Remote switching from cab Specification UP
New location of solenoid valve block. Air cleaner room Central section LHS

Large Capacity of fuel tank 340 litters 370 liters (SK200-8) Longer refueling interval
Large size port drain cock 9 mm in diameter Easier cleaning work
Fuel tank
New flange plate at bottom of tank No flange plate

Counter New shape and design

weight
New design of engine bonnet and toolbox at right side front
Large storage space of toolbox at right side front
Guards Larger Fire wall covering area Safety requirement
Improve visibility of front guard for dismantle spec. Grid plates in parallel Grid plates in radial arrangement Widening front view

Appearance of cab has no change

New one-touch-lock for front top window Manual snapped lock Auto-lock and manual one-touch Easier lock and release work
Standardized Tapped blocks for optional 3-face-guard None Tapped block standards Less modification work in field
Cab
Removable floor mat Easier cleaning work
New roof window polycarbonate material Steel plate made To meet FOPS regulation as std.

New design instrument panel

Increasing swing up left console Raising angle Plus 10 degrees Easier access to cab
New design rear stand of cab (Remove Hot & cool box) Slant shape rear cover Flat shape for more room Improve conformability
New graphic design of side guard
Interior
Larger size cluster gauge Better visibility
New mounting way of arm rest Operators seat mounted Side console mounted Prevent interference to left lever
Lighter shifting force of control lever 10% reduction compare with previous model Less fatigue even long hours

Air New location of air conditioner unit Inside rear cover Underneath of operators seat Easier cleaning work for air filters
conditioner
New HINO engine (With common rail and EGR system) Mitsubishi 6 cylinders Hino 4 cylinders To comply Tier 3 emission
Engine horsepower UP 110 kW / 2,000 rpm 114 kW / 2,000 rpm Maximize performance
New arrangement of oil cooler, radiator and inter cooler Inline arrangement Side by side arrangement Easier cleaning work
Removable oil cooler, radiator and inter cooler Radiator All 3 units can be removable Easier cleaning work
New remote type engine oil filter and fuel filter Engine room pump room Easier replacement work
Power plant New fuel filter Conventional type Standardized for common rail
New fuel stop valve Easier replacement work for fuel
New Large capacity of air cleaner Double time life till clogged Longer maintenance time interval
New design air intaking chamber Preventing rain water
New engine oil drain cock Standardized drain cock Easier engine oil exchange work

New location of battery Too l box at right front In front of radiator Enlarge space of toolbox
Improve installation of Controllers Horizontal Vertical direction Preventing wet from condensation
Electric Improve reliability of mechatro controller Two sided print One side print Durability improvement
system Dustproof sealing of mechatro controller No gasket With Gasket
New Relay and fuse box Individual lay outing of relay and fuse Integrated into one box Easier maintenance work

New valve plate and pump casing Less noise while running
Main pump Increased pump capacity 105 cc 110 cc / rev Enlarge performance and long life

New long life oil seal NBR made Fluoro rubber made Improve of durability
Slewing
New structure of reduction unit Gear oil lubrication at lower bearing Change to grease
motor
New elec-volume style emergency mode for engine acceleration Mechanical cable type Electrical volume switch type Prevention of machine down
Emergency New auto-set style emergency mode for main pump Auto-set by controller
mode New emergency mode for control valve New system for unloading valve and cut valve

1-3
1. OUTLINE

1.2 SK330-8
Comparison with conventional model
Item Description Aim
(new models of conventional model)
Center section at engine bottom Fabricated plates 1 piece plate Increase strength to standardize the
frame conventional model and the
Upper others severe job application.
machinery Strengthened side deck D frame Sectional area of D-shaped frame 1.5 times larger size Less damage when slewing and
impact against object.

Under New slant shaped track frame. Slant shape Mud stuck prevention
carriage
Standardized heavy duty boom STD and optional HD boom Standardize HD boom only Improving durability of attachment
Strengthen boom top and boom foot boss. Steel plates fabricating type Cast steel made Improving durability of attachment
Moving boom cylinder head side port to the back. At front side At back side Preventing hydraulic piping damage
Standardized heavy duty arm Standardize HD arm only Improving durability of attachment
Attachment Strengthen Foot boss of arm. Steel plates fabricating type Forged material Improving durability of attachment
New 2 stage bushing Conventional bushing (1 pc) Flange type and Hard material
bushing
Continue urethane packing for hydraulic cylinders Long life without oil leakage

New style control valve Low fuel consumption

Large size hydraulic tubes at attachment
Hydraulic Hydraulic return line joints change.
tubes and Hydraulic tube joint to control valve change. ORS 4 volt flange
pipings New Nibbler and Breaker selector valve Manual shifting type Remote switching from cab Specification UP
New location of solenoid valve block. Air cleaner room Central section LHS

Large Capacity of fuel tank 560 litters 580 liters (SK330-8) Longer refueling interval
Large size port drain cock 5 9 mm in diameter Easier cleaning work
Fuel tank 200 mm dia opening with flange plate
Continue flange plate at bottom of tank

Counter New shape and design

weight
New design of engine bonnet and toolbox at right side front
Large storage space of toolbox at right side front
Right rear side guard arrangement changed 2 piece guard Large 1 piece guard
Guards Right front side guard arrangement changed 1 guard next to fuel tank none in the place
Larger Fire wall covering area Safety requirement
Improve visibility of front guard for dismantle spec. Grid plates in parallel Grid plates in radial arrangement Widening front view

Appearance of cab has no change

New one-touch-lock for front top window Manual snapped lock Auto-lock and manual one-touch Easier lock and release work
Standardized Tapped blocks for optional 3-face-guard None Tapped block standards Less modification work in field
Removable floor mat Easier cleaning work
Cab New roof window polycarbonate material Steel plate made To meet FOPS regulation as std.
It corresponds to the pains down
method head guard.

New design instrument panel

Increasing swing up left console Raising angle Plus 10 degrees Easier access to cab
New design rear stand of cab (Remove Hot & cool box) Slant shape rear cover Flat shape for more room Improve conformability
New graphic design of side guard
Larger size cluster gauge Better visibility
Interior New mounting way of arm rest Operators seat mounted Side console mounted Prevent interference to left lever
control
Lighter shifting force of control lever 10% reduction compare with previous model Less fatigue even long hours
operation

Air New location of air conditioner unit Inside rear cover Underneath of operators seat Easier cleaning work for air filters
conditioner
New HINO engine (With common rail and EGR system) Mitsubishi 6 cylinders Hino 6 cylinders To comply Tier 3 emission
Engine horsepower UP 184 kW / 2,200 rpm 197 kW / 2,100 rpm Maximize performance
New arrangement of oil cooler, radiator and inter cooler Inline arrangement Side by side arrangement Easier cleaning work
Removable oil cooler, radiator and inter cooler Radiator All 3 units can be removable Easier cleaning work
New remote type engine oil filter and fuel filter Engine room pump room Easier replacement work
New fuel filter Conventional type Standardized for common rail
Power plant system
New fuel stop valve Easier replacement work for fuel
filter
New Large capacity of air cleaner 1.7 time life till clogged Longer maintenance time interval
New design air intaking chamber Preventing rain water
New engine oil drain cock Standardized drain cock Easier engine oil exchange work

New location of battery Too l box at right front In front of radiator Enlarge space of toolbox
Improve installation of Controllers Horizontal Vertical direction Preventing wet from condensation
Electric Improve reliability of mechatro controller Two sided print One side print Durability improvement
system Dustproof sealing of mechatro controller No gasket With Gasket
New Relay and fuse box Individual lay outing of relay and fuse Integrated into one box Easier maintenance work

New valve plate and pump casing Less noise while running
Main pump Increased pump capacity 105 cc 110 cc / rev Enlarge performance and long life

New long life oil seal NBR made Fluoro rubber made Improve of durability
Slewing
New structure of reduction unit Gear oil lubrication at lower bearing Change to grease
motor
New elec-volume style emergency mode for engine acceleration Mechanical cable type Electrical volume switch type Prevention of machine down
Emergency New auto-set style emergency mode for main pump Auto-set by controller
mode New emergency mode for control valve New system by unloading valve and cut valve

1-4