Hyundai HX130 LCR Manual Download | Manualshive

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7-22

7-22

2. MAIN CONTROL VALVE

Part name

Inspection item

Criteria & measure

Casing

·

Existence of scratch, rusting or corrosion.

·

In case of damage in following section, replace
part.

- Sliding sections of casing fore and spool,

especially land sections applied with holded

pressure.
- Seal pocket section where spool is inserted.
- Seal section of port where O-ring contacts.
- Seal section of each relief valve for main,
travel, and port.
- Other damages that may damage normal
functions.

Spool

·

·

·

Existence of scratch, gnawing, rusting or
corrosion.

O-ring seal sections at both ends.

Insert spool in casing hole, rotate and
reciprocate it.

·

·

·

Replacement when its outside sliding section
has scratch (especially on seals-contacting
section).

Replacement when its sliding section has
scratch.

Correction or replacement when O-ring is
damaged or when spool does not move
smoothly.

Poppet

·

·

Damage of poppet or spring

Insert poppet into casing and function it.

·

·

Correction or replacement when sealing is
incomplete.

Normal when it can function lightly without
being caught.

Around spring

·

Rusting, corrosion, deformation or breaking of
spring, spring seat, plug or cover.

·

Replacement for significant damage.

Around seal
for spool

·

·

External oil leakage.

Rusting, corrosion or deformation of seal
plate.

·

·

Correction or replacement.

Correction or replacement.

Main relief valve,
port relief valve &
negative control
relief valve

·

·

·

·

·

External rusting or damage.

Contacting face of valve seat.

Contacting face of poppet.

Abnormal spring.

O-rings, back up rings and seals.

·

·

·

·

·

Replacement.

Replacement when damaged.

Replacement when damaged.

Replacement.

100

%

replacement in general.

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Summary of Contents for HX130 LCR

Page 1: ...Circuit 3 5 Group 4 Single Operation 3 14 Group 5 Combined Operation 3 26 SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location 4 1 Group 2 Electrical Circuit 4 3 Group 3 Electrical Component Specification 4 22 Group 4 Connectors 4 33 SECTION 5 MECHATRONICS SYSTEM Group 1 Outline 5 1 Group 2 Mode selection System 5 3 Group 3 Automatic Deceleration System 5 6 Group 4 Power Boost System 5 7 Group 5...

Page 2: ...ical System 6 4 Group 3 Electrical System 6 24 Group 4 Mechatronics System 6 40 SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test 7 1 Group 2 Major Components 7 21 Group 3 Track and Work Equipment 7 29 SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution 8 1 Group 2 Tightening Torque 8 4 Group 3 Pump Device 8 7 Group 4 Main Control Valve 8 32 Group 5 Swing Device 8 46 Group 6 Tr...

Page 3: ...al for troubleshooting SECTION 3 HYDRAULIC SYSTEM This section explains the hydraulic circuit single and combined operation SECTION 4 ELECTRICAL SYSTEM This section explains the electrical circuit monitoring system and each component It serves not only to give an understanding electrical system but also serves as reference material for trouble shooting SECTION 5 MECHATRONICS SYSTEM This section ex...

Page 4: ...ation before you start any work Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 2 3 Item number 2 Structure and Function Consecutive page number for each item Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example 1 2 3 Symbol Item ...

Page 5: ...l point one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm was divided by 10 so multiply 2 165 inches by 10 Move the decimal point one place to the right to return to the original value This gives 550mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches 1mm 0 03937 in ⓑ ⓐ 0 1 2 3 4 5 6 7 8 9 0 0 039 0 079 0 118...

Page 6: ...3 425 3 465 3 504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 9...

Page 7: ... 22 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1ℓ 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139...

Page 8: ...0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2...

Page 9: ... 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 2...

Page 10: ...2 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 8 27 8...

Page 11: ...1 1 SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 ...

Page 12: ... excavator attach a Do Not Operate tag on the right side control lever USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury When you get on and off the machine always maintain a three point contact with the steps and handrails and face the machine Do not use any controls as handholds Never jump on or off the machine Never mount or dismount a moving machine Be careful of sl...

Page 13: ...r goggles or safety glasses PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises AVOID POWER LINES Serious injury or death can result from contact with electric lines Never move any part of the machine or load closer to elect...

Page 14: ...excavator starts to move Use a signal person when moving swinging or operating the machine in congested areas Coordinate hand signals before starting the excavator OPERATE ONLY FORM OPERATOR S SEAT Avoid possible injury machine damage Do not start engine by shorting across starter terminals NEVER start engine while standing on ground Start engine only from operator s seat PARK MACHINE SAFELY Befor...

Page 15: ...FELY Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care It is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank outdoors Store flam...

Page 16: ... ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before weld...

Page 17: ...injury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids...

Page 18: ...ials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area Install fire resisting guards to protect hoses or other materials PREVENT BATTERY EXPLOSIONS Keep sparks lighted matches and flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a froze...

Page 19: ...a or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediate ly If acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately 13031GE22 USE TOOLS PROPERLY Use tools appropriate to the work Makeshift tools parts and procedures can create safety hazards...

Page 20: ...m them DO NOT pour oil into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant brake fluid filters batteries and other harmful waste REPLACE SAFETY LABELS Replace missing or damaged safety labels See the machine operator s manual for correct safety label placement LIVE WITH SAFETY Before returning machine t...

Page 21: ...trol rod Track roller Travel motor Carrier roller Fuel tank Hydraulic tank Main pump Tooth Turning joint Swing motor Engine Radiator Oil cooler Bucket Main control valve Battery After treatment device Dozer blade cylinder Dozer blade 130ZF2SP01 GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1 MAJOR COMPONENT 1 MAJOR COMPONENT ...

Page 22: ...erstructure width D 2500 8 2 Overall height of cab E 2900 9 6 Ground clearance of counterweight F 900 2 11 Engine cover height G 2215 7 3 Minimum ground clearance H 440 1 5 Rear end distance I 1500 4 11 Rear end swing radius I 1500 4 11 Distance between tumblers J 2780 9 1 Undercarriage length K 3490 11 5 Undercarriage width L 2500 8 2 Track gauge M 1990 6 6 Track shoe width standard N 500 20 Trav...

Page 23: ...clearance of counterweight F 900 2 11 Engine cover height G 2215 7 3 Minimum ground clearance H 440 1 5 Rear end distance I 1500 4 11 Rear end swing radius I 1500 4 11 Distance between tumblers J 2780 9 1 Undercarriage length K 3490 11 5 Undercarriage width L 2500 8 2 Track gauge M 1990 6 6 Track shoe width standard N 500 20 Height of blade O 580 1 11 Ground clearance of blade up P 545 1 9 Depth o...

Page 24: ... height of cab E 2900 9 6 侜 Ground clearance of counterweight F 900 2 11 侜 Engine cover height G 2215 7 3 侜 Minimum ground clearance H 440 1 5 侜 Rear end distance I 1500 4 11 侜 Rear end swing radius I 1500 4 11 侜 Distance between tumblers J 2610 8 6 侜 Undercarriage length K 3300 10 8 侜 Undercarriage width L 2500 8 2 侜 Track gauge M 1990 6 6 侜 Track shoe width standard N 500 20 侜 Travel speed low h...

Page 25: ...6 侜 Ground clearance of counterweight F 900 2 11 侜 Engine cover height G 2215 7 3 侜 Minimum ground clearance H 440 1 5 侜 Rear end distance I 1500 4 11 侜 Rear end swing radius I 1500 4 11 侜 Distance between tumblers J 2780 9 1 侜 Undercarriage length K 3490 11 5 侜 Undercarriage width L 2500 8 2 侜 Track gauge M 1990 6 6 侜 Track shoe width standard N 500 20 侜 Height of blade O 580 1 11 侜 Ground cleara...

Page 26: ...0 mm 26 7 8480 mm 27 10 Max dumping height E 5620 mm 18 5 5800 mm 19 0 6170 mm 20 3 Min swing radius F 2310 mm 7 6 2340 mm 7 8 2470 mm 8 1 Bucket digging force SAE 87 8 95 8 kN 87 8 95 8 kN 87 8 95 8 kN 8954 9768 kgf 8954 9768 kgf 8954 9768 kgf 19740 21534 lbf 19740 21534 lbf 19740 21534 lbf ISO 101 7 111 0 kN 101 7 111 0 kN 101 7 111 0 kN 10369 11312 kgf 10369 11312 kgf 10369 11312 kgf 22860 2493...

Page 27: ...0 mm 13 4 4380 mm 14 4 Max digging height D 8600 mm 28 3 8825 mm 28 11 Max dumping height E 6230 mm 20 5 6455 mm 21 2 Min swing radius F 2220 mm 7 3 2430 mm 8 0 Bucket digging force SAE 87 8 95 8 kN 87 8 95 8 kN 8954 9768 kgf 8954 9768 kgf 19740 21534 lbf 19740 21534 lbf ISO 101 7 111 0 kN 101 7 111 0 kN 10369 11312 kgf 10369 11312 kgf 22860 24938 lbf 22860 24938 lbf Arm crowd force SAE 60 6 66 1 ...

Page 28: ... 3140 Swing bearing 262 580 侜 Travel motor assembly 140 310 侜 Turning joint 56 120 侜 Track recoil spring 95 210 侜 Idler 108 240 侜 Carrier roller 12 26 侜 Track roller 24 53 侜 Sprocket 40 88 侜 Track chain assembly 500 mm standard triple grouser shoe 716 1580 侜 Dozer blade assembly 500 mm shoe 485 1070 Front attachment assembly 4 30 m boom 2 26 m arm 0 40 m3 SAE heaped bucket 1530 3370 侜 4 30 m boom ...

Page 29: ...ry or property damage Make adjustments to the rated load as necessary for non standard configurations Lift point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 6 0m kg 2600 2600 4 24 19 7ft lb 5730 5730 13 9 4 5m kg 3340 3340 2300 2300 5 43 14 8ft lb 7360 7360 5070 5070 17 8 3 0m kg 5320 5320 3930 3220 2480 2050 2260 2040 6 03 9 ...

Page 30: ...ft point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 6 0m kg 2600 2600 4 24 19 7ft lb 5730 5730 13 9 4 5m kg 3340 2940 2300 2140 5 43 14 8ft lb 7360 6480 5070 4720 17 8 3 0m kg 5320 5300 3930 2810 2480 1780 2260 1760 6 03 9 8ft lb 11730 11680 8660 6190 5470 3920 4980 3880 19 8 1 5m kg 7280 4790 3920 2640 2520 1730 2390 1640 6 ...

Page 31: ...ft point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 6 0m kg 2780 2780 2340 2340 4 64 19 7ft lb 6130 6130 5160 5160 15 2 4 5m kg 3070 3070 2100 2090 5 75 14 8ft lb 6770 6770 4630 4610 18 9 3 0m kg 4800 4800 3690 3000 2590 1910 2060 1750 6 32 9 8ft lb 10580 10580 8140 6610 5710 4210 4540 3860 20 7 1 5m kg 7130 5160 3920 2830 25...

Page 32: ...ft point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 6 0m kg 2460 2460 1760 1760 5 36 19 7ft lb 5420 5420 3880 3880 17 6 4 5m kg 2550 2550 2380 2120 1600 1600 6 34 14 8ft lb 5620 5620 5250 4670 3530 3530 20 8 3 0m kg 3820 3820 3210 3210 2980 2080 1570 1570 6 86 9 8ft lb 8420 8420 7080 7080 6570 4590 3460 3460 22 5 1 5m kg 6270 5810 4150 3090 3380...

Page 33: ...ift point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 6 0m kg 2460 2460 1760 1760 5 36 19 7ft lb 5420 5420 3880 3880 17 6 4 5m kg 2550 2550 2380 1850 1600 1600 6 34 14 8ft lb 5620 5620 5250 4080 3530 3530 20 8 3 0m kg 3820 3820 3210 2870 2610 1800 1570 1420 6 86 9 8ft lb 8420 8420 7080 6330 5750 3970 3460 3130 22 5 1 5m kg 627...

Page 34: ...t point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 6 0m kg 3290 3290 2660 2660 4 68 19 7ft lb 7250 7250 5860 5860 15 4 4 5m kg 3660 3660 3290 3290 2350 2170 5 78 14 8ft lb 8070 8070 7250 7250 5180 4780 19 0 3 0m kg 5610 5610 3910 3130 2730 2000 2290 1820 6 35 9 8ft lb 12370 12370 8620 6900 6020 4410 5050 4010 20 8 1 5m kg 409...

Page 35: ...ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 7 5m kg 3530 3530 3290 3290 3 08 24 6ft lb 7780 7780 7250 7250 10 1 6 0m kg 2940 2940 2380 2380 5 07 19 7ft lb 6480 6480 5250 5250 16 6 4 5m kg 3050 3050 2620 2230 2140 2140 6 10 14 8ft lb 6720 6720 5780 4920 4720 4720 20 0 3 0m kg 5110 5110 3700 3420 3200 2180 2090 1840 6 64 9 8ft lb 11270 11270 8160 7540 7050 4810 4610 4060 21 8 1 5...

Page 36: ...ft point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft Capacity Reach m ft 7 5m kg 3530 3530 3290 3290 3 08 24 6ft lb 7780 7780 7250 7250 10 1 6 0m kg 2940 2940 2380 2380 5 07 19 7ft lb 6480 6480 5250 5250 16 6 4 5m kg 3050 3050 2620 1940 2140 1880 6 10 14 8ft lb 6720 6720 5780 4280 4720 4140 20 0 3 0m kg 5110 5110 3700 2990 2750 1900 2090 1590 6 6...

Page 37: ...marm 6 5 2 26marm 7 5 2 81marm 9 3 1 96marm 6 5 2 26marm 7 5 0 30m3 0 39yd3 0 27m3 0 35yd3 610mm 24 0 700mm 27 6 332 kg 730 lb 侑侑侑侑侑侍 0 40m3 0 52yd3 0 35m3 0 46yd3 760mm 29 9 850mm 33 5 383 kg 840 lb 侑侑侑侑侑 0 45m3 0 59yd3 0 40m3 0 52yd3 830mm 32 7 920mm 36 2 401 kg 880 lb 侑侑俗侑侑 0 50m3 0 65yd3 0 45m3 0 59yd3 900mm 35 4 990mm 39 0 419 kg 920 lb 侑侑俗侑俗 0 59m3 0 77yd3 0 52m3 0 68yd3 103...

Page 38: ...MBER OF ROLLERS AND SHOES ON EACH SIDE 3 3 Model Shapes Triple grouser HX130LCR Shoe width mm in 500 20 600 24 700 28 Operating weight kg lb 12700 28000 12850 28330 13000 28660 Ground pressure kgf cm2 psi 0 42 5 95 0 35 5 02 0 31 4 35 Overall width mm ft in 2500 8 2 2600 8 6 2700 8 10 HX130LCRD Shoe width mm in 500 20 600 24 Operating weight kg lb 13400 29540 13560 29890 Ground pressure kgf cm2 ps...

Page 39: ...nd pressure Application of wider shoes than recommendations will cause unexpected problem such as bending of shoes crack of link breakage of pin loosening of shoe bolts and the other various problems 4 4 Table 2 Table 2 Table 1 Table 1 Track shoe Specification Category 500 mm triple grouser Standard A 600 mm triple grouser Option A 700 mm triple grouser Option B Category Applications Applications ...

Page 40: ...ton displacement 3400 cc 207 cu in Compression ratio 17 1 Rated gross horse power SAE J1995 73 6 Hp 55 kW at 2200 rpm Maximum torque 43 2 kgf m 313 lbf ft at 1200 rpm Engine oil quantity 8 0ℓ 2 1 U S gal Dry weight 341 kg 752 lb High idling speed 2310 50 rpm Low idling speed 800 100 rpm Rated fuel consumption 160 g Hp hr at 1900 rpm Starting motor 24 V 4 5 kW Alternator 24 V 65 A Battery 2 12 V 10...

Page 41: ...400 psi Item Specification Type 1 Type 2 Type Fixed displacement axial piston motor Capacity 72 cc rev 71 cc rev Relief pressure 285 kgf cm2 4050 psi Braking system Automatic spring applied hydraulic released Braking torque Min 30 kgf m 217 lbf ft 31 4 kgf m 227 lbf ft Brake release pressure 15 50 kgf cm2 273 711 psi 19 2 50 kgf cm2 273 711 psi Reduction gear type 2 stage planetary Item Specificat...

Page 42: ...oke Ø100 975 mm Cushion Extend only Arm cylinder Bore dia Stroke Ø110 1070 mm Cushion Extend and retract Bucket cylinder Bore dia Stroke Ø100 855 mm Cushion Extend only Dozer cylinder option Bore dia Stroke Ø100 240 mm Cushion Adjust cylinder opt Bore dia Stroke Ø145 613 mm Cushion Adjust boom cylinder opt Bore dia Stroke Ø100 975 mm Cushion Item Width Ground pressure Link quantity Overall width H...

Page 43: ...oir tank Mixture of antifreeze and soft water 2 20 5 3 SAE 5W 40 SAE 10W 30 SAE 10W 40 SAE 15W 40 SAE 80W 90 ISO VG 46 HBHO VG 46 3 ISO VG 32 ISO VG 68 ASTM D975 NO 1 ASTM D975 NO 2 NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type 50 50 SAE 0W 40 SAE 75W 90 ISO VG 15 Ethyleneglycolbasepermanenttype 60 40 50 30 20 10 0 10 20 30 40 58 22 4 14 32 50 68 86 104 1 2 3 Ultra low sulfur diesel sulf...

Page 44: ...SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device 2 1 Group 2 Main Control Valve 2 20 Group 3 Swing Device 2 47 Group 4 Travel Device 2 61 Group 5 RCV Lever 2 74 Group 6 RCV Pedal 2 81 ...

Page 45: ... a4 P1 A3 Dr2 a3 PH2 B3 A1 pump Valve block A2 pump Gear pump VIEW A A A1 A2 Hydraulic circuit B1 Dr2 PH1 PH2 Dr1 a2 PH2 Dr1 a4 130ZF2MP01 Port Port name Port size A1 A2 Delivery port SAE6000 psi 3 4 B1 Suction port SAE2500 psi 2 1 2 Dr1 Drain port PF 1 2 19 Dr2 Drain port PF 3 4 20 Pi1 Pi2 Pilot port PF 1 4 15 P1 EPPR port PF 1 4 13 a1 a2 Gauge port PF 1 4 15 a3 Gauge port PF 1 4 14 PH1 PH2 Servo...

Page 46: ...ing 157 Cylinder spring 211 Shoe plate 212 Swash plate 214 Bushing 251 Support 255 Lock pin 261 Seal cover F 263 Seal cover R 271 Pump casing F 272 Pump casing R 312 Valve block 313 Valve plate R 314 Valve plate L 401 Hexagon socket bolt 402 Hexagon socket bolt 406 Hexagon socket bolt 415 Hexagon socket bolt 466 Plug 467 plug 468 Plug 497 Plug 531 Tilting pin 532 Servo piston 533 Plug 534 Stopper ...

Page 47: ...ller bearing 128 Bearing spacer 262 Cover 326 Gear case 414 Hexagon socket bolt 435 Flange socket bolt 468 Plug 711 O ring 728 O ring 825 Retainer ring 826 Retainer ring 885 Spring pin 886 Pin 826 115 128 435 126 414 886 117 262 711 326 728 125 468 118 825 04 885 A1 pump side A2 pump side 130ZF2MP03 ...

Page 48: ...VIEW C A2 pump VIEW C A1 pump E E SECTION E E 496 724 437 079 753 755 466 755 656 496 753 439 753 418 Pi Pi Pi P1 P1 P2 KR76 9N01 V A1 pump KR76 9N02 V A2 pump A B P1 Pi 130ZF2MP04 Port Port name Port size A Delivery port SAE 6000 psi 3 4 B Suction port SAE 2500 psi 2 1 2 Pi Pilot port PF 1 4 15 P1 EPPR valve primary port PF 1 4 13 P2 Companion delivery port internal ...

Page 49: ...2 614 Center plug 615 Adjust plug 616 Plug 621 Compensator piston 622 Piston case 623 Compensator rod 624 Spring seat C 625 Outer spring 626 Inner spring 627 Adjust stem C 628 Adjust screw C 629 Cover C 630 Lock nut 631 Sleeve Pf 641 Pilot cover 643 Pilot piston 644 Spring seat Q 645 Adjust stem Q 646 Pilot spring 651 Sleeve 652 Spool 653 Spring seat 654 Return spring 655 Set spring 656 Block cove...

Page 50: ... 354 Driven gear 355 Filter 361 Front case 433 Flange socket bolt 434 Flange socket bolt 435 Flange socket bolt 466 Plug 700 Square ring 710 O ring 725 O ring 732 O ring 850 Snap ring 887 Pin Z Z SECTION Z Z 887 700 354 351 710 435 361 353 732 312 311 434 309 307 310 308 434 466 725 a3 A3 355 850 433 B3 887 130ZF2MP06 ...

Page 51: ...11 swash plate support 251 lock pin 255 tilting bushing 214 tilting pin 531 and servo piston 532 The swash plate is a cylindrical part formed on the opposite side of the sliding surface of the shoe and is supported by the swash support If the servo piston moves to the right or left as hydraulic force controlled by the regulator connects to hydraulic chamber located on both sides of the servo pisto...

Page 52: ...t is driven by a prime mover electric motor engine etc it rotates the cylinder block via a spline linkage at the same time If the swash plate is tilted as in Fig previous page the pistons arranged in the cylinder block make a reciprocating motion with respect to the cylinder block while they revolve with the cylinder block If you pay attention to a single piston it performs a motion away from the ...

Page 53: ...delivery flow Q decreases as the pilot pressure Pi rises With this mechanism when the pilot pressure corresponding to the flow required for the work is commanded the pump discharges the required flow only and so it does not consume the power uselessly REGULATOR Regulator consists of the negative flow control total horse power control and power shift control function 2 1 Pilot pressure Pi Delivery ...

Page 54: ...spool moves to the right The movement of the spool causes the delivery pressure P1 to connect to port CL through the spool and to be admitted to the large diameter section of the servo piston The delivery pressure P1 that is constantly admitted to the small diameter section of the servo piston moves the servo piston to the right due to the area difference resulting in decrease of the tilting angle...

Page 55: ...shifts the spool to the left Port CL opens a way to the tank port as the spool moves This deprives the large diameter section of the servo piston of pressure and shifts the servo piston to the left by the discharge pressure P1 in the small diameter section resulting in an increase in the flow rate As the servo piston moves point D also moves to the left the feedback lever rotates around the fulcru...

Page 56: ...ew 924 Tightening the screw shifts the control chart to the right as shown in the figure Adjusting value Adjustment of flow control characteristic 801 924 Speed Adjustment of flow control characteristic Tightening amount of adjusting screw 924 Flow control starting pressure change amount Flow change amount min 1 Turn kgf cm2 ℓ min 1900 1 4 1 4 7 1 Pilot pressure Pi Delivery flow Q ...

Page 57: ...mps in the tandem double pump system the prime mover is automatically prevented from being overloaded irrespective of the load condition of the two pumps when horsepower control is under way Since this regulator is of the simultaneous total horsepower type it controls the tilting angles displacement volumes of the two pumps to the same value as represented by the following equation Tin P1 q 2Л P2 ...

Page 58: ...11 the feedback lever rotates around the fulcrum of point D as lever 1 rotates and then the spool 652 is shifted to the right As the spool moves the delivery pressure P1 is admitted to the large diameter section of the servo piston via port CL causes the servo piston move to the right reduces the pump delivery flow rate and prevents the prime mover from being overloaded The movement of the servo p...

Page 59: ...fulcrum of point D and then the spool 652 to move to the left As a result port CL opens a way to the tank port This causes the servo piston to move to the left and the pump s delivery rate to increase The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism to move it till the opening between the spool and sleeve is closed Servo piston Small diameter cha...

Page 60: ...w command preferential function As mentioned above flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large hole sections C F of levers 1 and 2 However since sections C and F have the pins Ø4 protruding from the large hole Ø8 only the lever lessening the tilting angle contacts the pin 897 the hole Ø8 in the lever of a larger tilting a...

Page 61: ...g the screw increases the flow and then the input horsepower as shown in the figure Adjusting value b Delivery pressure P1 P2 Delivery flow Q 625 626 627 802 630 628 140Z92RG08 Speed Adjustment of input horsepower Tightening amount of adjusting stem C 627 Flow change amount Input torque change amount min 1 Turn ℓ min kgf m 1900 1 4 3 2 3 2 ...

Page 62: ...timum power level according to the operating condition The power shift pressure Pf controls the set horsepower of the pump to a desired level as shown in the figure As the power shift pressure Pf rises the compensating rod 623 moves to the right via the pin 898 and compensating piston 621 This decreases the pump tilting angle and then the set horsepower in the same way as explained in the overload...

Page 63: ...e maximum flow other characteristics are not changed However remember that if tightened too much the required horsepower during the maximum delivery pressure or during relieving may increase Adjustment of maximum and minimum flows 4 Delivery pressure Pi Delivery flow Q 808 954 806 953 Delivery pressure Pi Delivery flow Q 140Z92MP23 140Z92MP24 Speed Adjustment of max flow Tightening amount of adjus...

Page 64: ...in regen cut signal selector port Arm out pilot port Arm out confluence pilot port Bucket in pilot port Bucket out pilot port Option B pilot port Option B pilot port Option C pilot port dozer blade down Travel straight pilot port Option C pilot port dozer blade up Pilot pressure port Main relief pressure up pilot port Auto idle signal port Auto idle signal attachment Pilot signal port Boom priorit...

Page 65: ... Housing P1 2 Housing P2 3 Spool straight travel 4 Spool travel LH RH 6 Spool swing 7 Spool boom 1 8 Spool swing priority 9 Spool boom 2 10 Spool arm 2 11 Spool arm 1 12 Spool arm regeneration 13 Spool option B 14 Spool bucket 15 Spool option C dozer 16 Main relief valve 17 Overload relief valve 18 Overload relief valve 20 Negacon relief valve 21 Swing logic valve 22 Bucket logic valve 23 Option o...

Page 66: ...Pc41 DR3 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 Pi1 Pi2 Pump Pump DR4 Boom priority P03 P04 Boom up pilot PS P1 P2 P3 DR5 Patt P02 Pn2 Pn1 Pd0 P05 Puo PS OPTION C DOZER ARM 1 BOOM 2 SWING PRIORITY SWING TRAVEL RH BUCKET OPTION A ARM REGENERATION CUT ARM 2 BOOM 1 TRAVEL LH OPTION B C4 D4 C2 D2 C1 D1 A2 A1 Pd40 Pd41 Shuttle Pc42 Pb3 Pb20 Pa21 P04 STRAIGHT TRAVEL BLOCK 130ZF2MC05 ...

Page 67: ... A2 is directed to the tank through the bypass passage of spools travel left boom 1 arm 2 arm regeneration option A and bucket the negative relief valve of P1 tank passage and the tank port T1 1 1 B B SECTION A A A A BUCKET ARM REGEN OPTION A ARM 2 BOOM 1 TRAVEL LH Tank passage P1 Negative relief valve SECTION B B P2 Negative relief valve P1 Bypass passage P1 port P1 Parallel passage P1 Bypass pas...

Page 68: ...o the tank through the bypass passage of spools travel right swing boom 2 swing priority arm 1 option B and option C dozer the negative relief valve of P2 tank passage and the tank port T1 2 SECTION A A SECTION B B P2 Parallel passage P2 port B B Tank port T1 A A ARM 1 BOOM 2 SW PRIORITY SWING TRAVEL RH OPTION B OPTION C DOZER Tank passage P2 Bypass passage P2 Bypass passage Straight travel spool ...

Page 69: ... pc1 And it shifts travel right and left spools in the left direction against springs Hydraulic fluid from the pump A1 flow into the travel right spool through the bypass passage and hydraulic fluid from the pump A2 flow into the travel left spool through the bypass passage Then they are directed to the each travel motor through port A1 and C1 As a result the travel motors turn and hydraulic fluid...

Page 70: ...e keep travel straight The other actuator operation during straight travel operation When the other actuator spool s is selected under straight travel operation the straight travel spool is moved The hydraulic fluid from pump A2 is supplied actuator through P2 and P1 parallel pass and travel motors through orifice at side of straight travel spool The hydraulic oil fluid from pump A1 is supplied to...

Page 71: ...ifts the boom 2 spool The bypass passage is shut off by the movement of the boom 2 spool and the hydraulic oil fluid from pump A1 entered boom summation passage via the P2 parallel passage the land of the swing priority spool notch of the boom 2 spool arm 2 spool and the check The flows combine in passage and are directed to port A2 and head side of boom cylinder At the same time the flow from rod...

Page 72: ...e time the return flow from the head side of the boom cylinder returns to the port A2 and boom holding valve And it is directed to the hydraulic oil tank through opened tank passage by movement of the boom 1 spool Meanwhile some of return flow is directed to P1 parallel passage through the internal passage of the boom 1 spool boom regeneration In this case the holding valve is open condition for d...

Page 73: ...lding valve through the periphery hole of check crevice of the check and the plug and the periphery hole of plug Then this pressured oil pushed the poppet to the poppet seat and the check to the seat of body So the hydraulic fluid from actuator is not escaped and the actuator is not moved 4 1 PILOT PISTON CHAMBER ACTUATOR PORT DRAIN PORT PILOT PORT FOR RELEASE HOLDING VALVE PISTON B SPRING B PISTO...

Page 74: ...he periphery hole of check crevice of the check and the plug the periphery hole of the plug in side of holding valve crevice of the poppet and the poppet seat the periphery hole of the poppet seat crevice of socket and spool and internal passage of spool When the poppet is opened pressure of inside of holding valve is decreased and the return fluid from actuator returns to the tank passage through...

Page 75: ...e and is directed to the port A5 through the check 1 At the same time the hydraulic fluid from P1 bypass passage is directed to the port A5 through the check 2 Following this it flows into the head side of the bucket cylinder The return flow from the rod side of the bucket cylinder returns to the bucket spool through the port B5 Thereafter it is directed to the hydraulic oil tank through the tank ...

Page 76: ... hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port B5 through the check 1 At the same time the hydraulic fluid from P1 bypass passage is directed to the port B5 through the check 2 The return flow from the head side of the bucket cylinder returns to the hydraulic oil tank through the port A5 and the tank passage 2 Bucket limiter B5 A5 P1 Bypass passage P1 Paralle...

Page 77: ...el passage is supplied to the bucket cylinder Also parallel passage is installed the orifice of bucket limiter for supplying the fluid from pump A2 to the boom operation prior to the bucket operation In case of the bucket out operation with boom operation operation is similar 3 Orifice B5 A5 Tank passage From RCV Bucket spool Bucket limiter P1 Parallel passage Pa5 130ZF2MC29 ...

Page 78: ...ing motor turns and flow from the swing motor returns to the hydraulic oil tank through the port C2 swing spool and the tank passage In case of swing right operation the operation is similar to swing left operation but the pilot secondary pressure from the RCV is supplied to the port Pc2 of the spring opposite side Accordingly the hydraulic fluid from pump A1 flows into swing motor through the por...

Page 79: ... passage is installed the orifice of swing logic valve for supplying the fluid from pump A1 to the boom or the arm operation prior to the swing operation In case of the swing right operation with arm or boom operation operation is similar 2 C2 D2 From RCV P2 Parallel passage P2 Bypass passage Tank passage Swing spool Pd2 Swing logic valve Orifice P03 Boom up pilot pressure Boom 1 spool 125LCR2MC20...

Page 80: ...arm 2 spool in the right direction The bypass passage is shut off by the movement of the arm 2 spool and the hydraulic fluid from the pump A2 flows into the arm summation passage through P1 parallel passage the check valve the arm 2 spool and the boom 2 spool Then it entered the arm cylinder head side with hydraulic fluid from arm 1 spool 7 1 C4 P2 Parallel passage Piston C Selector spool Arm rege...

Page 81: ...ssure from RCV Then the arm regeneration spool shifts to right side and flow to tank pass increases and regeneration flow decreases Therefore pressure of arm cylinder head increases then arm regeneration flow decreases Furthermore the arm regeneration cut pressure is supplied to the port Pb4 of spring opposite side and arm regeneration spool is move into the right direction fully The flow from the...

Page 82: ...vement of the arm 2 spool and some of the hydraulic fluid from pump A2 bypassed through bypass notch The rest of hydraulic fluid from pump A2 flows into the arm summation passage through P1 parallel passage the check valve arm 2 spool and boom 2 spool Then it enters into the arm cylinder rod side with the fluid from the arm 1 spool The return flow from the arm cylinder head side returns to the hyd...

Page 83: ...side through swing priority spool and the path A and also flows into the boom 2 spool When the swing priority spool is neutral condition the passage is same as normal condition But due to shifting of the swing priority spool the fluid from pump A1 flows to swing side more then the boom 2 arm 1 option B and dozer spools to make the swing operation most preferential 8 Arm 2 spool Boom 2 spool Swing ...

Page 84: ...l in the left direction The hydraulic fluid from the pump A1 enters the parallel passage and is direction to the head side of the dozer cylinder through port D6 The return flow from the rod side of the dozer cylinder returns to the dozer spool through C6 port Thereafter it is directed to the hydraulic tank through tank passage In case of the dozer up operation operation is similar C6 D6 Dozer spoo...

Page 85: ...pass passage is shut off when the shifting of one or more spools and the flow through bypass passage became zero The pressure of negative control signal becomes zero and the discharge of the pump A2 becomes maximum The negative control pressure reaches to the set level the hydraulic fluid in the passage pushes open negative control valve and escapes into the return passage For the pump A1 the same...

Page 86: ...pen the poppet and flows to tank passage T through the plunger internal passage periphery orifice A chamber A periphery orifice B and the hole E 2 Opening the poppet causes the pressure in chamber A to fall and the plunger to open As the result the pressurized oil at port P runs into tank passage T 3 Chamber A Piston A Piston B Housing Socket P Spring Orifice A Plunger Hole A Poppet Tank passage T...

Page 87: ...ing and the plunger is seated to the socket 4 Poppet Housing P Spring Tank passage T Socket Plunger 14W92MC39 Piston B Housing P Spring Hole A Tank passage T 14W92MC40 When the power boost switch is ON the pilot pressure enters through hole A It pushes the piston B in the left direction to increase the force of the spring and change the relief set pressure to the high pressure 5 ...

Page 88: ...sing securely 12 1 When the pressure at port P becomes equal to the set pressure of the spring the pressurized oil pushes open the poppet and flows to tank passage T through the plunger internal passage orifice A chamber A periphery orifice B and hole E 2 P Piston A Socket Housing Chamber A Tank passage T Poppet Spring Plunger Orifice A 14W92MC41 Housing P Tank passage T Hole E Poppet Periphery or...

Page 89: ... 3 The pressure at port P becomes lower than set pressure of the spring the poppet is seated by spring force Then the pressure at port P becomes equal to set pressure of the spring and the plunger is seated to the socket 4 P Housing Tank passage T Tank passage T Chamber A Poppet Plunger 14W92MC43 P Socket Housing Tank passage T Poppet Spring Plunger 14W92MC44 ...

Page 90: ...tank passage T When the pressure at tank passage T becomes higher than that of at port P the socket moves in the right direction Then sufficient oil passes around the socket from tank passage T to port P and fills up the space 5 P Housing Tank passage T Tank passage T Socket Poppet 14W92MC45 ...

Page 91: ...l supply port Oil level air vent port Reduction gear Reduction gear oil drain port PT 1 2 Swing motor Relief valve Hydraulic circuit AU MU MA MB DR VA VB PG SH R G 130ZF2SM21 GROUP 3 SWING DEVICE Port Port name Port size VA Main port Ø13 VB Main port Ø13 DR Drain port PF 3 8 MU Make up port PF 3 4 PG Brake release stand by port PF 1 4 SH Brake release pilot port PF 1 4 MA MB Gauge port PF 1 4 AU A...

Page 92: ...9 O ring 20 Valve plate 21 Spring pin 22 Valve casing 23 Check valve 24 Spring 25 Plug 26 O ring 27 Plug 28 O ring 29 Plug 30 O ring 31 Relief valve assy 32 Anti rotating valve assy 33 Plug 34 O ring 35 O ring 36 Time delay valve assy 37 Level gauge assy 38 Socket bolt 39 Plug 40 Name plate 41 Rivet 36 X 3 2 11 10 1 16 19 18 17 18 21 20 29 30 38 25 26 24 23 41 31 40 23 24 26 25 38 35 33 38 34 32 3...

Page 93: ...ng No 2 13 Thrust washer No 2 14 Carrier pin No 2 15 Spring pin 16 Sun gear No 2 17 Carrier No 1 18 Planetary gear No 1 19 Needle bearing No 1 20 Thrust washer No 1 21 Carrier pin No 1 22 Sun gear No 1 23 Snap ring 24 Thrust plate 25 Sleeve 26 O ring 27 Oil seal 30 Plug 31 Parallel pin 32 Thrust washer No 1 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 17 24 22 5 4 30 3 2 12...

Page 94: ...1 2 R G grease fill port PT 1 4 Au SH PG GB B Mu Dr GA A GA Dr Mu GB PG SH PG SH Relief valve Time delay valve Swing motor Reduction gear Oil level gauge Oil supply port Hydraulic circuit Au 130ZF2SM01 Port Port name Port size A Main port Ø13 B Main port Ø13 Dr Drain port PF 3 8 Mu Make up port PF 3 4 PG Brake release stand by port PF 1 4 SH Brake release pilot port PF 1 4 GA GB Gauge port PF 1 4 ...

Page 95: ...20 Rear cover 21 Needle bearing 22 Pin 23 Valve plate 24 Wrench bolt 25 Plug 26 Back up ring 27 O ring 28 Spring 29 Check 30 Relief valve 31 Anti rotating valve 32 Time delay valve 33 Wrench bolt 34 Plug 35 O ring 36 Plug 37 Plug 38 Level gauge 39 Name plate 40 Rivet 41 Plug 42 O ring 43 O ring 44 Back up ring 45 Plug 45 2 3 4 1 18 8 13 12 15 14 17 21 23 20 40 39 24 6 5 16 11 10 9 19 34 22 7 35 36...

Page 96: ... 2 sun gear 15 No 1 carrier assy 16 No 1 carrier 17 No 1 planet gear 18 No 1 pin assy 19 No 1 pin 20 No 1 bushing 21 Thrust washer 22 Spring pin 23 Stop ring 24 No 1 sun gear 25 Stop ring 26 Side plate No 1 27 Ring gear 28 Knock pin 29 Hexagonal bolt 30 Socket bolt 31 Plug 32 Plug 22 11 8 14 16 17 18 15 VIEW A 2 4 3 29 5 1 32 31 25 21 12 13 10 27 30 26 7 6 9 24 19 20 23 21 22 A 28 Oil drain Grease...

Page 97: ...ing pictures working on a piston This force F1 is divided as N1 thrust partial pressure and W1 radial partial pressure in case of the plate of a tilt angle α W1 generates torque T W1 R1 forY Y line connected by the upper and lower sides of the piston as following pictures The sum of torque ΣW1 R1 generated from each piston 4 5 pieces on the side of a high hydraulic generates the turning force This...

Page 98: ...y before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action The boost pressure acts on the hydraulic motor s feed port via the make up valve Pressurized oil into the port B the motor rotate counterclockwise If the plunger of MCV moves neutral position the oil in the motor is drain via left relief valve the drain oil run into ...

Page 99: ...otor The relief valves relieve high pressure at start or at stop of swing motion and can control the relief pressure in two steps high and low in order to insure smooth operation Function of relief valve Figure illustrates how the pressure acting on the relief valve is related to its rising process Here is given the function referring to the figure following page 10 8 5 1 4 3 9 6 9 2 11 P pressure...

Page 100: ... at tank pressure When hydraulic oil pressure P A1 reaches the preset force FSP of spring 4 the poppet 2 moves to the right as shown P1 A1 Fsp Pg A2 A1 P R A2 m h n g P P1 2 g 4 P1 Fsp Pg A2 A1 145WF2SM26 145WF2SM27 ...

Page 101: ...orce FSP of spring 4 the piston 7 moves left and stop the piston 7 hits the bottom of stopper 8 When piston 7 hits the bottom of stopper 8 it stops moving to the left any further As the result the pressure in chamber g equals Ps Ps A1 Fsp Ps A2 Ps Fsp A1 A2 7 8 P P2 4 m n g 7 8 g P Ps 145WF2SM28 145WF2SM29 ...

Page 102: ...ot operated Brake assembly Circumferential rotation of separate plate 14 is constrained by the groove located at casing 1 When housing is pressed down by brake spring 16 through friction plate 13 separate plate 14 and parking piston 15 friction force occurs between friction plate and separate plate Friction force constrains motion of cylinder block 8 When hydraulic force exceeds spring force brake...

Page 103: ...s pressure moves spool 5 to the leftward against the force of the spring 8 so pilot pump charged oil P3 goes to the chamber G through port PG This pressure is applied to move the parking piston 15 to the upward against the force of the brake spring 16 Thus it releases the brake force 16 15 G 1 2 P3 5 8 SH PG Time delay valve 1 RCV lever 2 Main control valve 5 Spool 8 Spring 15 Parking piston 16 Br...

Page 104: ...ht Then the parking piston 15 is moved lower by spring force and the return oil from the chamber G flows back to tank port At this time the brake works b Time delay valve 16 15 G 1 2 P3 5 8 SH PG 1 RCV lever 2 Main control valve 5 Spool 8 Spring 15 Parking piston 16 Brake spring 140WF2SM37 ...

Page 105: ...rking brake and high low speed changeover mechanism GROUP 4 TRAVEL DEVICE PS DR MA MB VB VA Parts number Travel motor Reduction gear Ps MB VB VA MA DR Hydraulic circuit A VIEW A RE 130ZF2TM20 Port Port name Port size VA VB Valve port PF 3 4 Ps Pilot port PF 1 4 DR Drain port PF 1 2 MA MB Gauge port PF 1 4 ...

Page 106: ... Cover 33 Spring 34 Restrictor 35 Spring 36 O ring 37 Spring seat 38 Relief valve assy 39 O ring 40 Spool 41 Plug 42 Spring seat 43 Parallel pin 44 Spring 45 Connector 46 O ring 47 Hexagon socket head bolt 48 Hexagon socket head bolt 49 Hexagon socket head bolt 50 Check valve 51 Spring 52 Plug 53 O ring 54 Plug 55 Restrictor 56 Restrictor 57 Name plate 58 Rivet 59 Ring gear 60 Bearing 61 Floating ...

Page 107: ...ich are on one side of the lineY Y that connects upper and lower dead points and produces force F1 F1 P A P pressure A area of piston section The swash plate 11 with inclined angle of divides this force F1 into thrust force F2 and radial force F31 34 This radial force is applied to axisY Y as turning force and generate drive torque of T T r1 F31 r2 F32 r3 F33 r4 F34 This drive torque is transmitte...

Page 108: ...enerated by the friction between the separated plates 18 inserted into the casing 1 and friction plates 17 coupled to cylinder block 12 by the outer splines When no pressure is activated on the parking piston 19 it is pushed by the brake springs 26 and it pushes friction plates 17 and separated plates 18 towards casing 1 and generates the friction force which brakes the rotation of cylinder block ...

Page 109: ...hydraulic tank through restrictor 55 Here nine pistons are there and they equally spaced on the swash plate 11 The force that summed up those of pistons comes to almost the center of the swash plate 11 as shown Since the steel balls 10 are off set by S from the center the rotating force of product S and the force moves swash plate 11 to the former position and the speed returns to low When the pow...

Page 110: ...lief valve setting pressure and supports the spring seat 38 3 that is inserted in the sleeve 38 4 piston 38 5 that reduce the shock 1 38 1 38 12 38 2 38 13 38 7 38 6 38 9 38 11 38 10 38 8 38 4 38 3 38 5 125LCR2TM25 OVERLOAD RELIEF VALVE 4 38 1 Plug 38 2 Spring 38 3 Spring seat 38 4 Sleeve 38 5 Piston 38 6 O ring 38 7 Back up ring 38 8 Poppet 38 9 Poppet seat 38 10 Back up ring 38 11 O ring 38 12 R...

Page 111: ...lied to the effective diameter of poppet 38 8 which seats on the poppet seat 38 9 and at the same time is delivered via small hole to the spring seat 38 3 located inside the sleeve 38 4 and the seat bore pressure increases up to A port pressure The poppet 38 8 opposes to spring 38 2 by the force of the pressure exerted on the area difference between poppet seat s effective diameter and spring seat...

Page 112: ...ing accelerating stopping and counterbalance operations See page 2 66 2 Operation Check valve built in the spool This valve is located in the oil supplying passage to hydraulic motor and at the same time functions to lock oil displacement Therefore this valve serves as not only a suction valve but also a holding valve for hydraulic motor 5 36 33 37 31 35 34 125LCR2TM28 1 31 Main spool 33 Spring 34...

Page 113: ...n of the motor is mechanically prevented If external torque is exerted on the motor shaft the motor would not rotate as usual by this negative parking brake In case the brake should be released for some reason pressure is built on MA or MB port But due to oil leakage inside hydraulic motor or so high pressure oil escapes from the closed circuit and motor rotates a bit So the cavitation tends to oc...

Page 114: ...ure supplied from pump At the same time the pressure of pilot chamber increases to push and move the spool 31 leftwards overcoming the spring 33 force Thus the return line from MB to VB opens to rotate the motor In case inertia load is too big to start rotation accelerating pressure reaches the set pressure of relief valve and high pressure oil is being relieved while the motor gains the rotationa...

Page 115: ...e from MA to VA is closed Owing to the inertia force of the load the hydraulic motor tends to continue the rotation Here the motor functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure increases Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last the motor stops Negative brake release pressure is gradually l...

Page 116: ...ller and the pressure on MA side rises due to increased resistance in the passage and the motor receives hydraulic braking effect If the motor rotates slower than that matched to the volume of supplied oil the pilot chamber pressure on VB port increases and spool 31 moves rightwards to enlarge the area of passage from MA to VA Therefore the braking effect becomes smaller and the rotational speed o...

Page 117: ... K1 K2 Ring gear a Carrier k Sun gear s Planetary pinions b REDUCTION GEAR Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force This reduction unit utilizes two stages planetary reduction system Planetary reduction system consists of sun gear planetary gears planetary carriers and ring gear When the sun gear s is driven through input shaft planet...

Page 118: ... A 4 1 T 2 3 P P 3 T 4 1 2 LH Hydraulic circuit TYPE M1 M3 5 A A 19 Single operation 25 Simultaneous operation 2 3 T 1 P 4 RH 6 Null Switches Type No LH RH M1 M3 5 One touch decel Horn 6 Power boost Breaker Pilot ports Port LH RH Port size P Pilot oil inlet port Pilot oil inlet port PF 3 8 T Pilot oil return port Pilot oil return port 1 Left swing port Bucket out port 2 Arm out port Boom up port 3...

Page 119: ...0ZF2RL05 Switches Type No LH RH M2 5 One touch decel Horn 6 Power boost Breaker Pilot ports Port LH RH Port size P Pilot oil inlet port Pilot oil inlet port PF 3 8 T Pilot oil return port Pilot oil return port 1 Left swing port Bucket out port 2 Arm out port Boom up port 3 Right swing port Bucket in port 4 Arm in port Boom down port TYPE M2 2 ...

Page 120: ... construction of the pilot valve is shown in the attached cross section drawing The casing has vertical holes in which reducing valves are assembled The pressure reducing section is composed of the spool 3 spring 5 for setting secondary pres sure return spring 7 spring seat 6 and shim 4 The spring for setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 2...

Page 121: ...IONS Item numbers are based on the type M1 The functions of the spool 3 are to receive the supply oil pressure from the hydraulic pump at its port P and to change over oil paths to determine whether the pressure oil of port P is led to output ports 1 2 3 4 or the output port pressure oil to tank port T The spring 5 works on this spool to determine the output pressure The change the deflection of t...

Page 122: ...hydraulic circuit diagram shown below and the attached operation explanation drawing The diagram shown below is the typical application example of the pilot valve 1 Pilot valve 2 Pilot pump 3 Main pump 4 Main control valve 5 Hydraulic motor 6 Hydraulic cylinder 1 1 P T 3 2 3 4 5 6 3 2 70 ...

Page 123: ...ool 3 Therefore the spool is pushed up by the spring 7 to the position of port 1 3 in the operation explanation drawing Then since the output port is connected to tank port T only the output port pressure becomes equal to tank pressure Case where handle is in neutral position Port 1 Port 3 P T 3 7 5 1 300L2RL03 ...

Page 124: ...e at port 1 increases higher than the set pressure port P is disconnected from port 1 and port T is con nected with port 1 If it decreases lower than the set pressure port P is connected with port 1 and port T is disconnected from port 1 In this manner the secondary pressure is kept at the constant value Besides in some type when the handle is tilted more than a certain angle the upper end of the ...

Page 125: ...pressure and the oil outlet port T tank In addition the secondary pressure is taken out through ports 1 2 3 and 4 provided at the bottom face GROUP 6 RCV PEDAL Port P T 1 2 3 4 Port size PF 1 4 Port Pilot oil inlet port Pilot oil return port Travel LH Forward Travel LH Backward Travel RH Forward Travel RH Backward 130ZF2RP01 ...

Page 126: ...st the push rod 13 by the return spring When the push rod is pushed down by tilting pedal the spring seat comes down simultaneously and changes setting of the secondary pressure spring 1 Body 2 Plug 3 Plug 4 Spring seat 5 Spring 6 Spring seat 7 Spool 8 Stopper 9 Spring 10 Rod guide 11 O ring 12 Snap ring 13 Push rod 14 Spring pin 15 Seal 16 Steel ball 17 Spring 18 Plate 19 Snap ring 20 Plug 21 O r...

Page 127: ... FUNCTIONS OF MAJOR SECTIONS The functions of the spool 8 are to receive the supply oil pressure from the hydraulic pump at its port P and to change over oil paths to determine whether the pressure oil of port P is led to output ports 1 2 3 4 or the output spool to determine the output pressure The spring 6 works on this spool to determine the output pressure The change the deflection of this spri...

Page 128: ...of the hydraulic circuit diagram shown below and the attached operation explanation drawing The diagram shown below is the typical application example of the pilot valve 3 1 Pilot valve 2 Pilot pump 3 Main pump 4 Main control valve 5 Hydraulic motor 6 Hydraulic cylinder 36072SF01 ...

Page 129: ...s the output pressure of the pilot valve is not applied to the spool 7 Therefore the spool is pushed up by the spring 9 to the position of 1 and port 2 Then since the output port is connected to tank port T only the output port pressure becomes equal to tank pressure T P 5 7 9 130ZF2RP03 ...

Page 130: ...e pressure at port 1 increases higher than the set pressure port P is disconnected from port 1 and port T is connected with port 1 If it decreases lower than the set pressure port P is connected with port 1 and port T is disconnected from port 1 In this manner the secondary pressure is kept at the constant value Besides in some type when the handle is tilted more than a certain angle the upper end...

Page 131: ...SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit 3 1 Group 2 Main Circuit 3 2 Group 3 Pilot Circuit 3 5 Group 4 Single Operation 3 14 Group 5 Combined Operation 3 26 ...

Page 132: ...GEN BUCKET BOOM 2 SWING ARM BUCKET BOOM BOOM UP BOOM2 UP BOOM PRI BOOM DOWN BOOM HOLDING BUCKET IN BUCKET OUT ARM IN ARM HOLDING ARM IN ARM HOLDING ARM2 IN ARM REGEN ARM2 IN ARM2 IN ARM OUT ARM2 OUT ARM OUT ARM2 OUT SWING CW SWING CW SWING CCW SWING CCW BUCKET IN BUCKET OUT BOOM UP BOOM2 UP BOOM PRI BOOM DOWN BOOM HOLDING LH FW LH BW RH FW RH BW RH BW RH FW LH BW LH FW ARM 2 ARM REGEN BOOM PRI HYD...

Page 133: ...UX BREAKER PEDAL SAFETY PS 24 21 A1 2 Po5 59 C 61 EV1 EV2 TS2 TS1 56 86 85 54 79 80 26 38 78 88 87 Dr B1 89 PATTERN CHANGE FROM TO ITEM PORT ITEM PORT J1 J3 J4 J2 M1 M2 M3 M4 51 5 2 4 2 4 6 25 D J E H 51 51 J1 J2 J3 J4 M1M2 M3 M4 Mu MA MB B A SWING FINE CONTROL 3 65 SWING PARKING BY FORCE 90 2 84 47 2 80 26 46 83 95 30 31 32 90 93 2 84 92 2 26 60 47 83 46 HYD TANK RETURN A B T T1 HYD TANK HYD TANK...

Page 134: ...VERY CIRCUIT To cylinders To motors Main control valve To hydraulic oil tank Suction strainer Main pump To oil cooler Hydraulic oil tank GROUP 2 MAIN CIRCUIT The pumps receive oil from the hydraulic tank through a suction strainer The discharged oil from the pump flows into the control valve and goes out the tank ports The oil discharged from the main pump flows to the actuators through the main c...

Page 135: ...draulic tank resulting in the oil temperature being raised quickly at an appropriate level When the oil cooler is clogged the oil returns directly to the hydraulic tank through bypass check valve 1 The full flow filter and bypass relief valve are provided in the hydraulic tank The oil returned from right and left side of control valve is combined and filtered by the full flow filter A bypass relie...

Page 136: ...t of the drain ports provided in the respective motor casing and join with each other These oils pass through the turning joint and return to the hydraulic tank after being filtered by drain filter SWING MOTOR DRAIN CIRCUIT Oil leaked from the swing motor returns to the hydraulic tank passing through a drain filter MAIN PUMP DRAIN CIRCUIT Oil leaked from main pump returns to the hydraulic tank pas...

Page 137: ... valve through line filter EPPR valve solenoid valve assemblies swing parking brake main control valve and safety lock solenoid valve GROUP 3 PILOT CIRCUIT MCV Remote control valve LH lever RCV pedal Remote control valve RH lever Safety lock solenoid valve Swing parking brake Main pump Line filter Relief valve 40kgf cm2 Travel speed solenoid valve Pilot pump Suction strainer Power boost solenoid v...

Page 138: ...3 Po5 T P1 A3 A2 A1 A1 T5 T4 T3 T2 T1 P5 P1 P4 P3 P2 A4 P3 P2 MCV P03 MCV Pb4 MCV Pu T Joint P Dr4 Pa4 P F CNTL EPPR PG S Motor P02 MCV P0 MCV SAFETY SOLENOID VALVE Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd40 PS ...

Page 139: ... F CNTL EPPR PG S Motor P02 MCV P0 MCV Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd40 PS PS Pi1 Pump Dr dr Pi2 Pump 3 1 2 4 3 1 P T P T 2 4 a b d f h j c d1 B e1 D A E F G H J g e e2 SWING ARM BUCKET BOOM PS PS PS P...

Page 140: ...c2 Pd2 SH Pc3 3 4 1 2 P T TRAVEL Pc1 Pd1 Pa1 Pb1 Pb5 Pa5 Pb3 Pc40 Pc41 Pc42 P04 Pa20 Pa21 Pb20 Pb21 ARM CYLINDER BUCKET CYLINDER BOOM CYLINDER TURNING JOINT TRAVEL MOTOR SWING MOTOR BOOM PRIORITY EPPR VALVE Boom speed HYDRAULIC TANK PILOT PUMP A1 PUMP A2 PUMP When carrying out the combined operation of swing and boom up the boom up operating speed is lowered then normal operation To increase worki...

Page 141: ...P3 P2 MCV P03 MCV Pb4 MCV Pu T Joint P Dr4 Pa4 P F CNTL EPPR PG S Motor P02 MCV P0 MCV T Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd40 PS PS Pi1 Pump HYDRAULIC TANK PILOT PUMP Dr dr Pi2 Pump 3 1 2 4 3 1 P T P T 2 4...

Page 142: ...EN Pu P1 P2 P3 Pd0 Dr3 Po5 P1 A3 A2 A1 A1 T5 T4 T3 T2 T1 P5 P1 P4 P3 P2 A4 P3 P2 MCV P03 MCV Pb4 MCV Pu T Joint P Dr4 Pa4 P F CNTL EPPR PG S Motor P02 MCV P0 MCV T HYDRAULIC TANK PILOT PUMP A1 PUMP A2 PUMP Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21...

Page 143: ... A2 A1 A1 T5 T4 T3 T2 T1 P5 P1 P4 P3 P2 A4 P3 P2 MCV P03 MCV Pb4 MCV Pu T Joint P Dr4 Pa4 P F CNTL EPPR PG S Motor P02 MCV P0 MCV T HYDRAULIC TANK PILOT PUMP A1 PUMP A2 PUMP Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd40 PS PS ...

Page 144: ... P1 P2 P3 Pd0 Dr3 Po5 A3 A2 A1 A1 T5 T4 T3 T2 T1 P5 P1 P4 P3 P2 A4 P3 P2 MCV P03 MCV Pb4 MCV Pu T Joint P Dr4 Pa4 P F CNTL EPPR PG S Motor P02 MCV P0 MCV T HYDRAULIC TANK PILOT PUMP A1 PUMP A2 PUMP Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb...

Page 145: ...Po5 Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Rs C6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd40 PS PS Pi1 Pump Dr dr Pi2 Pump 3 1 2 4 3 1 P T P T 2 4 a b d f h j c d1 B e1 D A E F G H J g e e2 SWING ARM BUCKET BOOM PS PS PS PS h1 h2 Pd40 Pd41 Pc2 Pd2 SH Pc3 3 4 1 2 P T TRAVEL...

Page 146: ...m is up and the control lever is returned to neutral position the circuit for the holding pressure at the head side of the boom cylinder is closed by the boom holding valve This prevents the hydraulic drift of boom cylinder 1 BOOM UP OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 Pd41 B2 A2 Pb1 A1 B1 Pa1 T...

Page 147: ... the cylinder This prevents cylinder cavitation by the negative pressure when the A2 pump flow can not match the boom down speed And the excessive pressure in the boom cylinder rod side is prevented by the relief valve 2 BOOM DOWN OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 RELIEF VALVE Pb3 Pd41 B2 Pb1 ...

Page 148: ...ef valve The cavitation which will happen to the head side of the arm cylinder is also prevented by the make up valve in the main control valve 3 ARM IN OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 MAKE UP VALVE RELIEF VALVE Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 Pc1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 P...

Page 149: ... is roll out and the control lever is returned to neutral position the circuit for the holding pressure at the rod side of the arm cylinder is closed by the arm holding valve This prevent the hydraulic drift of arm cylinder 4 ARM OUT OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 MAKE UP VALVE RELIEF VALVE...

Page 150: ... is prevented by relief valve The cavitation which will happen to the head side of the bucket cylinder is also prevented by the make up valve in the main control valve 5 BUCKET IN OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 TURNING JOINT TRAVEL MOTOR SWING MOTOR Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 P...

Page 151: ...de is prevented by relief valve The cavitation which will happen to the rod side of the bucket cylinder is also prevented by the make up valve in the main control valve 6 BUCKET OUT OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 TURNING JOINT TRAVEL MOTOR SWING MOTOR Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3...

Page 152: ... When this happens the dozer goes up 7 DOZER UP OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 MAKE UP VALVE RELIEF VALVE TURNING JOINT TRAVEL MOTOR SWING MOTOR Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 Pc1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 Pc41 Rs C6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 D...

Page 153: ...DER BUCKET CYLINDER BOOM CYLINDER A1 PUMP A2 PUMP PILOT PUMP HYDRAULIC TANK Pd41 Pc40 Pc41 DOZER CYLINDER D2 C2 D1 C1 D4 C4 Pa21 Pa20 P04 Pc5 Pd5 D6 Pd6 Pc6 130ZF3HC17 When the dozer control lever is pushed forward the dozer spool in the main control valve is moved to the dozer down position by the pilot oil pressure from the remote control valve The oil from the A1 pump flows into the main contro...

Page 154: ...the swing motor itself 9 SWING OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd...

Page 155: ...ATION The parking brake is released by the pilot pressure oil from the pilot pump When the swing control lever or arm in control lever placed in the operating position the pilot oil flows into SH port through the MCV This pressure transferred to the brake release valve and the brake release valve is change over Then the pilot oil pressure PG lift the brake piston and release the parking brake PARK...

Page 156: ...M BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd40 PS PS Pi1 Pump Dr dr Pi2 Pump 3 1 2 4 3 1 P T P T 2 4 a b d f h j c d1 B D A E F G H J g e e2 SWING ARM BUCKET BOOM PS PS PS PS h1 ...

Page 157: ...r the following functions COUNTER BALANCE VALVE When stopping the motor of slope descending this valve to prevent the motor over run OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 350 kgf cm2 4980 psi to prevent high pressure generated at a time of stopping the machine Stopping the motor this valve sucks the oil from lower pressure passage for preventing the negative pressure ...

Page 158: ...ght by the pilot oil pressure Consequently the left and right travel oil supply passage are connected and equivalent amount of oil flows into the left and right travel motors This keeps the straight travel 1 OUTLINE RIGHT LEFT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C1 P0 DR0...

Page 159: ... and the boom is operated Refer to page 3 8 for the boom priority system 2 COMBINED SWING AND BOOM UP OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 Pc1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 Pc41 Rs DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P04 DR2 Pc3 Pb21 Pb20 Pa20 DR...

Page 160: ...m is operated Refer to page 3 13 for the swing operation preference function 3 COMBINED SWING AND ARM OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 SWING MOTOR Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 Pc1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 Pc41 Rs C6 D6 DR4 P03 Patt P02 Pn2 Pn1 Po5 Puo P0...

Page 161: ...r structure swings and the bucket is operated 4 COMBINED SWING AND BUCKET OPERATION RIGHT LEFT TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN Pu P1 P2 P3 Pd0 SWING MOTOR TURNING JOINT TRAVEL MOTOR SWING MOTOR Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 Pc1 P0 DR0 Pd1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 Pc41 Rs C6 D6 DR4 P03 Patt P02 Po5 Puo...

Page 162: ...multaneously the swing spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and straight travel spool is pushed to the right by the pilot oil pressure from the pilot pump The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control valve and the LH travel spool of the ...

Page 163: ...nd travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control valve and the LH travel spool of the right control valve via the straight...

Page 164: ... main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control valve and the LH travel spool of the right control valve via the straight travel spool The oil f...

Page 165: ...bucket spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control valve and the LH travel spool of the right control valve vi...

Page 166: ...ol valve is moved to the functional position by the pilot oil pressure from the remote control valve The oil from the A1 pump flows into the boom cylinders through the boom 2 spool in the left control valve The oil from the A2 pump flows into the boom cylinders and bucket cylinder through the boom 1 spool bucket spool and the parallel and confluence oil passage in the right control valve Also when...

Page 167: ...SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location 4 1 Group 2 Electrical Circuit 4 3 Group 3 Electrical Component Specification 4 22 Group 4 Connectors 4 33 ...

Page 168: ... touch decel switch 12 Power max switch 13 Safety lever 14 Emergency engine stop switch 15 DC DC converter 16 Remote controller unit 17 Handsfree control unit 18 Emergency engine connector 19 Fuse box assy 20 Master switch 21 RS232 J1939 service socket 22 Radio USB player 23 Heated seat switch 24 Speaker 25 Option attachment switch 26 Quick clamp switch 28 Swing fine switch 29 Swing lock switch 30...

Page 169: ...r 12 Start relay 13 Power relay 14 Alternator 15 Travel alarm buzzer 16 Arm Bucket in pressure sensor 17 Boom up pressure sensor 18 Swing pressure sensor 20 Arm in pressure sensor 21 Attach pressure sensor 22 Travel pressure sensor 24 4 cartridge valve 25 Pump EPPR valve 26 Boom priority EPPR valve 27 Machine control unit option 28 Nega control pressure sensor 29 Flow control EPPR valve 30 Relay d...

Page 170: ... PS SPARE PROGRAM DUMP SW ATT RELIF EPPR1 PS C B A SUPPLY SIG RETURN 1 2ROr 1 CD 69 ATT PS 0 8BW 2 1 2BW 3 CONFLUX ATT CN 237 1 2GW 6 1 2Or 5 SOL SAFETY ATT CN 149 1 2Br 1 2Or 7 SOL BREAKER CN 66 1 2B 1 2Br 10 11 D C B CN 398 A D C B A CONT SOL FINE SWING CN 370 0 75YR 257A 0 75V 30D EARTH2 1 2 3 4 5 6 7 8 9 10 11 12 GROUND EPPR ATT EPPR1 2SE PS POWER BOOST SOL 13 14 EPPR POWER 24V 15 16 17 18 TRA...

Page 171: ...N 10A POWER 24V LVDS NEG GND LVDS POS 1 2 3 4 FRONT VIEW CAMERA 0 75R 0 75L 0 75B CABIN LIGHT FRONT RH CL 9 7 2 0B 10 2 0V CS 73 SWING LOCK 2 12 1 2 9 10 8 4 12 11 10 9 8 7 6 5 4 3 11 12 7 3 74 1 2BrW 28 1 2Br 74 0 8BrW 84 0 8B POWER GND sig GND 2 12 1 2 9 10 8 4 12 11 10 9 8 7 6 5 4 3 11 12 7 3 74 1 2BrW 28 1 2Br 84 1 2B C ST ACC BR H B 2 4 H I 0 I 0 3 5 1 6 5 4 3 2 1 6 13 CONTINUE 24V 12 WASHER ...

Page 172: ... CL 3 2 0W 2 0W 62 36 CS 74B 1 2 CS 74 MASTER SW 90D 0 75Br 216 0 75RB OVER LOAD CD 31 80B 1 0ROr RETURN SIG SUPPLY A B C 229 0 75G 10 9 8 7 DO 5 19A 16B 0 75VW 0 75RY G12 0 75B 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 CN 5 6 5 4 3 2 1 CR 13 HEAD LAMP 173 0 75G 60 1 0ROr 116A 1 0Br...

Page 173: ...UST SIGNAL CN 10A FRONT VIEW CAMERA CL 8 1 0B 1 0V 7 6 2 1 CABIN LIGHT FRONT_lh 1 2 1 2 FRONT CAMERA HARNESS SIDE CAMERA LAMP SIDE HARNESS CABIN SIDE FRONT VIEW CAMERA CL 8 21K3 11300 RH SIDE HARNESS H13 H12 H8 H14 H8 H13 H15 H15 H14 H12 AAVM SYSTEM CS 29 CS 19 0 8V 15 0 8R 14 0 8RY 70 1 2B 73 0 8GR 69 1 2Or 20 1 2BW 22 1 2Or 60 12V SOCKET CN 139 DC DC CONVERTER CN 138 1 2Or 60 1 2B 22A HOUR METER...

Page 174: ...4 5 MEMORANDUM HYUNDAI HEAVY INDUSTRIES CO LTD CONSTRUCTION EQUIPMENT DIV ...

Page 175: ...nn CN 11 5 AC Heater controller 3 Blower relay 3 Fuse box No 6 l conn CN 36 1 11 I conn CN 5 18 I conn CN 17 5 Wiper motor controller CN 141 7 Wiper motor CN 21 4 Fuse box No 7 I conn CN 36 1 12 I conn CN 5 11 Cluster CN 56A 1 Fuse box No 8 I conn CN 36 1 13 MCU CN 51 1 MCU CN 53 1 I conn Intermediate connector CHECK POINT GND Ground 1 2 1 POWER CIRCUIT The negative terminal of battery is grounded...

Page 176: ...C BR H B 2 4 H I 0 I 0 3 5 6 5 4 3 2 1 6 CS 2A START KEY SW R 4 3 2 1 4 3 2 1 CN 125 GPS CONN BATTERY POWER 1 RMS CN 125A KEY IG 2 1 2 3 4 IG 24V GND CAN LOW CAN HIGH READER CN 427 0 8W 1 2W 1 2G 0 8YOr 1 2W 1 2G 1 2W R 2 0Y 0 8R 0 8YOr 1 2W 1 2G 0 8Y 3R 2W 2W 1 0G 60R 60B 8R 8R 8W 8W 8R 8R 0 8Y R R R 0 8R RADIO USB PLAYER START KEY ROOM LAMP CASSETTE AC HEATER WIPER SWITCH PANEL CLUSTER SPARE MCU...

Page 177: ... 1 1 Power relay CR 35 86 87 Fuse box No 9 12 l conn CN 4 4 Emergency engine stop sw CS 33 2 1 l conn CN 4 13 I conn CN 36 1 2 Fuse box No 13 I conn CN 36 1 6 ECM IG CR 45 86 Reader CN 427 1 RMS CN 125A 2 When start key switch is in START position Start switch START CS 2A 6 I conn CN 5 35 I conn CN 36 3 9 Anti restart relay CR 5 86 87 I conn CN 36 3 1 ECM start relay CR 106 86 87 ECM CN 94 8 53 St...

Page 178: ... 2 3 4 5 6 7 8 9 10 11 12 0 75WG 0 9BOr 1 0BOr 13 14 15 CN 36 3 0 8 0 8 30 86 87 85 87a 86 85 87 30 87a 3 1 7 BATTERY 12VX2 CR 1 BATT RY 60R 60B 1 2G 1 2B 1 2 CS 74B MASTER SW CS 74 2W 2W BATT POWER 24V 1 1 0R 30A 2 20A 3 30A 4 30A 5 10A 7 20A 8 10A 9 10A 10 10A 11 30A 12 5A 13 20A 14 20A 16 20A 17 20A 18 20A 19 30A 20 20A 21 20A 22 10A 23 20A 24 20A 25 10A 26 20A 27 20A 6 30A 28 30A 1 10A 15 STAR...

Page 179: ...CN 231 1 Fuse box No 14 28 3 CHARGING CIRCUIT When the starter is activated and the engine is started the operator releases the starting switch to the ON position Charging current generated by operating the alternator flows into the battery through the battery relay CR 1 The current also flows from the alternator to each electrical component and controller through the fuse box 1 2 1 2 GND Ground E...

Page 180: ... 2SE PS POWER BOOST SOL 13 14 EPPR POWER 24V 15 16 17 18 TRAVEL SPEED SOL 19 20 21 22 23 ATT FLOW EPPR1 24 TRAVEL BUZZER BOOM PRIORITY EPPR OPTION PS ACCEL DIAL SIG COOLING FAN EPPR ATT FLOW EPPR2 PUMP EPPR COOLING FAN EPPR RETURN CHECK V V PS BOOM PRIORITY EPPR HYD OIL TEMP SENDOR SPARE ARM REGEN SOL ENG COOLANT TEMP 25 FUEL LEVEL SENDOR 26 ALT LEVEL 27 ARM IN PS 28 P1 PRESS SENSOR 29 P2 PRESS SE...

Page 181: ... l conn CN 5 60 Radio USB player illumination ON CN 27 9 Remote controller illumination ON CN 245A 9 USB socket illumination ON CN 246 7 Cigar lighter CL 2 l conn CN 11 8 AC heater controller illumination ON 4 Work light switch ON Work light switch ON CN 376 4 Work light relay CR 4 85 87 l conn CN 12 2 Work light ON CL 5 2 CL 6 2 CHECK POINT 1 GND Ground 2 1 2 Engine Start switch Check point Volta...

Page 182: ...ER 0 8RG 1 2 3 4 5 6 7 8 9 10 11 12 BEACON INT WIPER 13 15 18 26 27 GND GND WASHER CAN HI 2 NC NC NC NC CABIN LIGHT WORK LIGHT WIPER TRAVEL ALARM IG 24V HEAD LIGHT CAN LO 2 34 NC 2 34 58 59 60 28 29 30 31 32 33 10 9 8 6 7 CN 5 1 2 3 4 5 5 1 CN 36 2 1 2 3 4 5 6 7 8 2 0RW 1 0Br CN 36 FUSE BOX 30A 2 20A 3 30A 4 30A 5 10A 7 20A 8 10A 9 10A 10 10A 11 30A 12 5A 13 20A 14 20A 16 20A 17 20A 18 20A 19 30A ...

Page 183: ... CN 36 3 7 I conn CN 5 50 I conn CN 10 10 Beacon lamp ON CL 7 Cab light switch ON Cab light switch ON CN 376 5 Cab lamp relay CR 9 85 87 I conn CN 5 34 38 I conn CN 10 2 Cab light FR LH ON CL 8 2 I conn CN 10 12 Cab light FR RH ON CL 9 2 I conn CN 10 11 Cab light RR ON CL 10 2 CHECK POINT 1 2 1 2 GND Ground Engine Start switch Check point Voltage STOP ON GND fuse box GND beacon lamp relay GND beac...

Page 184: ...9 8 7 CN 10 6 5 4 3 2 1 CAB LIGHT CL 8 2 0B 2 0V 2 1 BEACON LAMP CL 7 M 1 0B 1 0BrW 4 CL 10 1 0B 2 0V 1 2 2B 1 2BrW 2B 2 0V 2 0V 1 2ROr 1 2BrW 1 2VW 1 2VW 2 0V BEACON LAMP RELAY CR 85 CR 9 1 2Gr 0 8WOr 0 8W 0 8B 1 2BrW 5 1 2 1 2B 1 2ROr CN 376 MEMBRANE CONTROLLER 1 2 3 4 5 6 7 8 9 10 11 12 BEACON INT WIPER 13 15 18 26 27 GND GND WASHER CAN HI 2 NC NC NC NC CABIN LIGHT WORK LIGHT WIPER TRAVEL ALARM...

Page 185: ... conn CN 5 15 I conn CN 17 2 Wiper motor controller CN 141 2 4 Wiper motor CN 21 2 Continual operating Washer switch ON Washer switch ON CN 376 11 I conn CN 5 17 I conn CN 17 7 Wiper motor controller CN 141 9 8 I conn CN 17 6 I conn CN 5 19 Washer pump CN 22 1 Washer pump operating Wiper switch ON CN 376 3 I conn CN 5 15 I conn CN 17 2 Wiper motor controller CN 141 2 4 Wiper motor CN 21 2 Continua...

Page 186: ...R SIG 11 WASHER P P 12 CONTINUE 24V 13 5 WIPER MOTOR CONTROLLER 5 7 CN 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 0 8RY B WASHER PUMP CN 22 0 75RY 0 75VW 1 2 M 2 1 DIODE DO 5 0 75RY 0 75VW 0 75G 1 0RY 0 75WG 0 75R 0 75VW 0 75VB 0 75B 4 4 2 4 0 8GR 0 8RY 0 8L 0 8R 0 8V 0 8YOr 1 2B 3 6 1 CN 376 MEMBRANE CONTROLLER 1 2 3 4 5 6 7 8 9 10 11 12 BEAC...

Page 187: ...ART RY 30 87 85 86 85 87 86 30 61 60 58 57 GLOW PLUG 1 61A GLOW PLUG 2 60A GLOW PLUG 3 58A GLOW PLUG 4 57A CN 93B 2 0Y 2 0L 2 0Y 2 0L 2 5R 2 5R 0 75WR 0 75BY 0 75LW 0 7Br 0 75R 0 75LW 0 75V 0 75Y 0 75Gr 0 75Y 0 75Y 0 75L 0 75Or 0 75GrB 0 75V 0 75B 0 75RW 0 75 0 75 0 75 0 75 0 75 0 75 0 75 0 8Gr 0 75 0 75 0 75 6 0R 6 0R ROOM LAMP CASSETTE ATT FLOW EPPR1 39 40 ATT FLOW EPPR1 7 CN 36 2 1 2 1 2 1 2 3 ...

Page 188: ... RIGHT 12 L AUX GND 4 5 6 7 8 9 10 11 12 13 14 15 3 2 1 16 17 18 19 20 CN 2 A B C D E F G H J RS232 P_DUMP RS232_RX CAN_Lo CAN2_Hi CAN2_Lo IG 24V RS232_TX GND CAN_Hi 0 8V 0 8G 8 7 6 5 4 3 2 1 0 8G 0 8V 9 0 8G CN 126 1 2 3 4 5 6 7 8 9 10 11 12 GND_MAIN KEY IG 24V GOV MOTOR SENSOR 24V 20 21 22 23 Urea level full warn ANTI RESTART RY CAN 1 Hi ENG SPEED INPUT POWER_5V OUT FAN CLUTCH GND_SENSOR GOV MOT...

Page 189: ... 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 CN 36 3 30A 1 10A 15 SEE 130ZF4EL14 SEE 130ZF4EL14 SOL 1 2 2 PCS SOL CN 263 3 7 12 11 3 4 5 6 7 8 9 10 11 12 4 8 10 9 2 1 12 1 CN 113 2 1 CS 67 3 7 12 11 3 4 5 6 7 8 9 10 11 12 4 8 10 9 2 1 12 1 CS 52 1 2 3 4 5 6 7 8 9 10 11 12 GROUND EPPR ATT EPPR1 2SE PS POWER BOOST SOL 13 14 EPPR POWER 24V 15 16 17 18 TRAVEL SPEED SOL 19 20 21 22 23 ATT FLOW EPPR1 24 T...

Page 190: ... BREAKER SIG ATT RELIEF EPPR1 ATT RELIEF EPPR2 SWING FINE CONT SOL BOOM DOWN PS CAN3_HI 25 CAN3_LO 26 CAN_SH 27 RS232 1 TX 28 RS232 1 RX 29 SENSOR 24V 30 GND SENSOR 24V 31 32 33 EPPR POWER 24V 34 EPPR GND 35 BATTERY POWER 24V 36 KEY IG 24V 37 MAIN GND 38 BOOM DOWN FLOATING SW 39 TRAVEL PRIORTY SW 40 1 2 BOOM CYL ROD PS SPARE PROGRAM DUMP SW ATT RELIF EPPR1 PS C B A SUPPLY SIG RETURN 2 1 1 2 1 2 1 ...

Page 191: ...24V 1A B ACC 24V 10A B C 24V 40A Check contact OFF Ω for each terminal ON 0Ω for terminal 1 3 and 1 2 START 0Ω for terminal 1 6 Pressure sensor 8 30V Check contact Normal 0 1Ω Resistor 3W 200Ω Check resistance 1 2 200Ω Breather heater 24V 4 22 CD 6 C B A SUPPLY SIG RETURN CD 7 CD 24 CD 31 CD 32 CD 35 CD 42 CD 43 CD 44 CD 69 CD 70 CD 71 CD 85 CD 86 CD 87 CD 90 CD 91 CD 124 GROUP 3 ELECTRICAL COMPON...

Page 192: ...12 550Ω 7 12 300Ω 1 12 600Ω Empty warning 700Ω Relay air con blower 24V 16A Check resistance Normal About 200Ω for terminal 1 3 Ω for terminal 2 4 Relay 24V 16A Check resistance Normal About 160 Ω for terminal 85 86 0Ω for terminal 30 87a Ω for terminal 30 87 4 23 CR 46 3 4 1 2 4 3 2 1 1 2 CD 8 C C B A C B A 2 1 CD 10 Pa CD 2 CS 2C CN 1 CR 2 CR 4 CR 5 CR 7 CR 9 CR 13 CR 35 CR 36 CR 85 CR 95 CR 101...

Page 193: ...terminal 1 2 Ω For terminal 1 3 OFF Ω For terminal 1 2 0Ω For terminal 1 3 Switch quick clamp 24V Check contact Normal ON 0 Ω for terminal 5 3 Ω for terminal 5 9 OFF Ω for terminal 5 3 0 Ω for terminal 7 9 4 24 1 2 CN 75 CN 133 CN 238 CN 239 CN 240 CN 241 CN 242 CN 66 CN 68 CN 70 CN 88 CN 135 CN 140 CN 149 CN 237 CN 262 CN 263 CN 367 CN 368 CN 369 CN 370 CN 419 CN 420 CN 421 1 2 3 2 1 CL 1 1 2 12 ...

Page 194: ...rmal 1 2Ω Beacon lamp 24V 70W H1 Type 2 4W LED Type Check disconnection Normal A fewΩ Fuel filler pump 24V 10A 35ℓ min Check resistance Normal 1 0Ω Fuel feed pump 24V Hour meter 16 32V Check operation Supply power 24V to terminal No 2 and connect terminal No 1 and ground 4 25 CL 3 1 2 CL 4 CL 5 CL 6 CL 8 CL 9 CL 10 1 2 M CN 61 CN 145 1 2 M M CL CL 7 h 3 2 1 CN 48 7 6 3 9 0 1 2 4 10 12 11 10 9 8 7 ...

Page 195: ...witch 24V N O TYPE Check contact Normal 0Ω one pin to ground Receiver dryer 24V 2 5A N O TYPE Check contact Normal Ω Radio USB player 24V 2A Check voltage 20 25V for terminal 1 3 3 8 Washer pump 24V 3 8A Check contact Normal 10 7Ω for terminal 1 2 4 26 CS 53 CN 27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ACC ILL NC SPK FRT RH SPK FRT LH TEL MUTE ANT 12V BACK UP ILL NC SPK FRT RH REMOCON REMOCON GND ...

Page 196: ... lighter 24V 5A 1 4W Check coil resistance Normal About 1MΩ Check contact Normal Ω Operating time 5 15sec Alternator Delco Remy 24V 65A Check contact Normal 0Ω for terminal B D Normal 24 27 5V Starter 24V 4 5kW Check contact Normal 0 1Ω Travel alarm 24V 0 5A Check contact Normal 5 2Ω 4 27 CL CL 2 B M M CN 45 D CN 74 B G 3 U 24V GND 12V 1 2 3 24V 12V CN 138 CN 81 4 6 5 3 2 1 2 3 4 5 6 M CN 21 ...

Page 197: ...motor 24V 14A Check resistance Normal 2 5Ω for terminal 1 2 Air conditioner duct sensor switch 1 C OFF 4 C ON Check resistance Normal 0Ω for terminal 1 2 the atmosphere temp Over 4 C Door switch 24V 2W Check resistance Normal About 5MΩ Switch power max one touch decel horn breaker 24V 6A Check resistance Normal Ω 4 28 M 1 2 1 2 CS 1 1 2 CS 5 CS 19 CS 26 CS 29 CR 23 2 1 1 CN 28 ...

Page 198: ...nd check resist between terminal 1 and 2 Master switch 6 36V Check disconnection Normal 0 1Ω Breaker pedal switch Quick clamp buzzer 24V 80mA Min 65dB 12V Socket 12V 10A Engine emergency stop switch 24V Check contact Normal 0Ω for terminal 1 2 CN 113 2 1 CN 139 2 1 CS 33 5 4 3 2 1 6 1 3 6 4 2 5 T 4 29 CS 26A 2 1 CS 74 CN60 CN 95 2 1 ...

Page 199: ...re sensor WIF sensor Check disconnection Normal 68 8 4 94Ω Proportional valve sensor 3 2 1 DPF PS GND DPF PS SUPPLY DPF PS SIG CN 153 CN 152 1 2 DOC INLET TEMP GND DOC INLET TEMP SIG CN 153 2 1 DPF INLET TEMP SIG DPF INLET TEMP GND 2 1 CL 40 CD 154 RETURN CN 246 RH CN 247 LH Proportional A B C SIG 5V CN 150 2 1 AIR INLET TEMP AIR INLET GND ...

Page 200: ...el dial LED 24V Temperature sensor A C incar A C ambient water Proportional valve sensor Dozer act pressure switch N O type Check resistance Normal Ω open CN 429 1 2 CN 308 SIG VOLT Us SIG VOLT Udc GND ERROR 1 2 3 4 CD 50 Pa 1 2 CN 142 S C B A CN 267 LED GND LED 2 1 ...

Page 201: ... 24V 5 NC 6 ADJUST SIGNAL CN 435 4 3 2 1 INPUT 24V GND OUTPUT 12V OUTPUT 12V 4 3 5 LAMBDA BATT LAMBDA VOLT LAMBDA GND LAMBDA PUMP 2 LAMBDA ADJUST 6 LA M B D A H E A T I N 1 CD 151 LAMBDA HEATING CN 3A 2 1 CAN HI CAN LO GND SAFETY KEY IG GND 5V POWER 5V GND ROTATE LH ROTATE RH 10 9 8 7 6 5 4 3 11 12 NC NC CN 249 CN 402 CN 403 CN 404 CN 405 CN 3 ...

Page 202: ...SCH 8 I conn Frame harness Aircon harness DT06 8S CN 12 DEUTSCH 2 I conn Frame harness Boom wire harness DT06 2S EP06 DT04 2P E005 CN 13 AMP 8 I conn Frameharness Boomfloatingharness 174982 2 174984 2 CN 14 DEUTSCH 2 I conn Frameharness Swingparkingharness DT06 2S EP06 DT04 2P E005 CN 15 AMP 8 I conn Frame harness 2 way harness 174982 2 174984 2 CN 16 AMP 6 Emergency engine start speed control S81...

Page 203: ... max solenoid DT06 2S EP06 CN 93A DELPHI 10 EIC 1 15326600 CN 93B AMP 62 EIC 2 1 148883 1 CN 93 60 ECU A1 284742 1 CN 94 94 ECU K1 284743 1 CN 95 2 Circuit breaker S813 130201 CN 113 KET 2 Buzzer MG651205 5 CN 125 Econoseal J 4 GPS connector S816 004002 S816 104002 CN 125A DEUTSCH 9 RMS DT06 12S EP06 HD10 9 96P CN 126 AMP 10 I conn Service tool Frame harness S816 010002 S816 110002 CN 126A 9 Servi...

Page 204: ...PVG controller DTM06 12SB CN 307 DEUTSCH 3 Proportional Service tool DT06 3S EP06 DT04 3P E005 CN 308 AMP 4 Proportional PVG32 2 967059 1 CN 309 DEUTSCH 2 Proportional EPPR valve A1 DT06 2S EP06 CN 310 DEUTSCH 2 Proportional EPPR valve A2 DT06 2S EP06 CN 365 DEUTSCH 2 Attach relief EPPR valve 1 DT06 2S EP06 CN 366 DEUTSCH 2 Attach relief EPPR valve 2 DT06 2S EP06 DT04 2P E005 CN 367 DEUTSCH 2 Boom...

Page 205: ...elay CR 4 5 Work lamp relay 8JA 003 526 001 CR 5 5 Anti restart relay CR 7 5 Aircon compressor relay CR 9 5 Cabin lamp relay 8JA 003 526 001 CR 13 5 Head lamp relay 8JA 003 526 001 CR 23 KET 2 Start relay MG640322 CR 23A Start relay MG612017 5 CR 24 RING TERM 1 Preheat relay S822 014000 CR 35 5 Power relay CR 36 5 Preheat relay CR 45 5 ECU IG relay 8JA 003 526 001 CR 85 5 Beacon lamp relay 8JA 003...

Page 206: ...ght CL 1 KET 3 Room lamp MG651032 CL 2 AMP 1 Cigar lighter S822 014002 S822 114002 CL 3 DEUTSCH 2 Head lamp LH DT06 2S EP06 CL 4 DEUTSCH 2 Head lamp RH DT06 2S EP06 CL 5 DEUTSCH 2 Work lamp LH DT06 2S CL 6 DEUTSCH 2 Work lamp RH DT06 2S CL 7 SHUR 1 Beacon lamp S822 014002 S822 114002 CL 8 DEUTSCH 2 Cab light LH DT06 2S EP06 DT04 2P CL 9 DEUTSCH 2 Cab light RH DT06 2S EP06 DT04 2P CL 10 DEUTSCH 2 C...

Page 207: ...3S EP06 CD 86 DEUTSCH 3 Arm out pressure sensor DT06 3S E005 CD 87 DEUTSCH 3 Bucket out pressure sensor DT06 3S E005 CD 90 DEUTSCH 3 Arm in pressure sensor DT06 3S EP06 CD 91 DEUTSCH 3 Bucket in pressure sensor DT06 3S E005 CD 98 AMP 2 Air inlet temperature sensor 776427 1 CD 98A AMP 2 Air intake temperature sensor 776427 1 CD 124 DEUTSCH 3 Boom cylinder rod pressure snensor DT06 3S E005 CD 150 AM...

Page 208: ...e Plug connector male 5 2 5 1 3 S811 005002 1 3 2 5 S811 105002 3 7 1 4 S811 007002 1 4 3 7 S811 107002 1 5 4 9 3S811 109002 5 11 1 6 S811 011002 1 6 5 11 S811 111002 7 9 11 4 9 1 5 S811 009002 2 CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR 1 ...

Page 209: ... 40 4 40 No of pin Receptacle connector female Plug connector male 13 6 13 1 7 S811 013002 17 21 1 7 6 13 S811 113002 8 17 1 9 S811 017002 1 9 8 17 S811 117002 1 21 1 11 S811 021002 1 11 1 21 S811 121002 ...

Page 210: ...acle connector female Plug connector male 2 3 4 8 1 2 2 1 2 3 1 3 1 2 3 1 4 2 4 2 3 1 6 3 1 8 5 2 8 5 2 6 3 1 S816 002001 S816 102001 S816 003001 S816 103001 S816 004001 S816 104001 S816 008001 S816 108001 J TYPE CONNECTOR 2 2 1 ...

Page 211: ... pin Receptacle connector female Plug connector male 1 1 S814 001000 2 3 4 1 S814 101000 2 1 1 2 S814 002000 S814 102000 3 2 1 1 2 3 S814 003000 S814 103000 2 4 1 3 1 3 2 4 S814 004000 S814 104000 SWP TYPE CONNECTOR 3 ...

Page 212: ...eceptacle connector female Plug connector male 6 8 12 14 3 6 1 4 1 4 3 6 S814 006000 S814 106000 4 8 1 5 1 5 4 8 S814 008000 S814 108000 4 12 1 9 1 9 4 12 S814 012000 S814 112000 3 14 1 11 1 11 3 14 S814 014000 S814 114000 ...

Page 213: ... pin Receptacle connector female Plug connector male 1 1 S810 001202 2 3 4 1 S810 101202 2 1 S810 002202 2 1 S810 102202 3 1 2 S810 003202 2 1 3 S810 103202 2 4 1 3 S810 004202 1 3 2 4 S810 104202 CN TYPE CONNECTOR 4 ...

Page 214: ...4 45 4 45 No of pin Receptacle connector female Plug connector male 6 3 6 1 4 S810 006202 8 1 4 3 6 S810 106202 1 5 4 8 S810 108202 4 8 1 5 S810 008202 ...

Page 215: ...02402 1 2 S810 102402 375 FASTEN TYPE CONNECTOR 5 No of pin Receptacle connector female Plug connector male 36 1 12 13 25 24 36 344111 1 1 13 25 12 24 36 344108 1 AMP ECONOSEAL CONNECTOR 6 No of pin Receptacle connector female Plug connector male 2 1 2 85202 1 AMP TIMER CONNECTOR 7 ...

Page 216: ... 6 12 174045 2 AMP 040 MULTILOCK CONNECTOR 8 No of pin Receptacle connector female Plug connector male 14 1 7 6 14 173852 AMP 070 MULTILOCK CONNECTOR 9 No of pin Receptacle connector female Plug connector male 6 3 6 1 4 925276 0 1 4 3 6 480003 9 AMP FASTIN FASTON CONNECTOR 10 ...

Page 217: ...48 No of pin Receptacle connector female Plug connector male 2 1 2 MG610070 KET 090 CONNECTOR 11 No of pin Receptacle connector female Plug connector male 2 2 1 2 1 2 MG640605 MG640795 KET 090 WP CONNECTORS 12 ...

Page 218: ...4 49 4 49 No of pin Receptacle connector female Plug connector male 14 1 7 6 14 MG610406 KET SDL CONNECTOR 13 ...

Page 219: ...ORS DT 06 3S 14 Modifications see below Number of contacts P Pin S Socket 06 Receptacle 04 Plug Deutsch connectors Modification E003 Standard end cap gray E004 Color of connector to be black E005 Combination E004 E003 EP04 End cap EP06 Combination P012 EP04 P012 Front seal enhancement connectors color to black for 2 3 4 6pin 4 4 2 3 1 DT06 4S DT04 4P ...

Page 220: ...4 51 6 1 4 3 5 4 8 1 7 6 12 1 4 51 No of pin Receptacle connector female Plug connector male 6 6 1 4 3 DT06 6S DT04 6P 8 5 4 8 1 DT06 8S 12 DT04 8P 6 7 1 12 DT06 12S DT04 12P ...

Page 221: ...ector male 2 35215 0200 1 2 35215 0200 MOLEX 2CKTS CONNECTOR 15 No of pin Receptacle connector female Plug connector male 10 1 2 9 10 SWF593757 ITT SWF CONNECTOR 16 No of pin Receptacle connector female Plug connector male 1 1 NMWP01F B MWP NMWP CONNECTOR 17 ...

Page 222: ... 4 53 No of pin Receptacle connector female Plug connector male 1 2 3 4 ECONOSEAL J TYPE CONNECTORS 18 2 1 S816 001002 2 1 S816 002002 S816 003002 S816 004002 S816 101002 S816 103002 S816 104002 S816 102002 ...

Page 223: ...4 54 4 54 No of pin Receptacle connector female Plug connector male 6 8 10 12 S816 106002 S816 108002 S816 110002 S816 112002 S816 006002 S816 008002 S816 010002 S816 012002 ...

Page 224: ...e 15 368301 1 2 85262 1 No of pin Receptacle connector female Plug connector male 2 1 2 12040753 METRI PACK TYPE CONNECTOR 19 No of pin Receptacle connector female Plug connector male 23 A B F J K N Q HD36 24 23SN HD34 24 23PN DEUTSCH HD30 CONNECTOR 20 A B F K Q J N T ...

Page 225: ...40 11 21 20 30 1 5 6 10 31 40 11 21 20 30 35 36 DRC26 40SA B DEUTSCH MCU CONNECTOR 21 No of pin Receptacle connector Female Plug connector Male 9 G F J H C E D A B HD10 9 96P DEUTSCH SERVICE TOOL CONNECTOR 22 No of pin Receptacle connector Female Plug connector Male 4 3 4 1 2 2 967325 3 AMP FUEL WARMER CONNECTOR 23 ...

Page 226: ...9 10 41 42 43 44 45 46 47 48 49 50 11 21 31 20 30 40 1 5 6 10 31 11 21 41 50 20 40 45 46 30 DRC26 50S 04 DEUTSCH ENGINE ECM CONNECTOR 24 No of pin Receptacle connector Female Plug connector Male 60 1 12 13 24 25 31 30 36 49 37 48 60 DRB16 60SAE L018 DEUTSCH INTERMEDIATE CONNECTOR 25 ...

Page 227: ...utomatic Warming Up System 5 9 Group 7 Engine Overheat Prevention System 5 10 Group 8 Variable Power Control System 5 11 Group 9 Attachment Flow Control System 5 12 Group 10 Intelligent Power Control System 5 13 Group 11 Anti Restart System 5 15 Group 12 Self Diagnostic System 5 16 Group 13 Engine Control System 5 49 Group 14 EPPR Valve 5 50 Group 15 Monitoring System 5 55 Group 16 Fuel Warmer Sys...

Page 228: ...nctions caused by short or open circuit in electric system and display error codes on the cluster SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE ADVANCED CAPO SYSTEM Power mode selection P S E Work mode selection User mode system U MCU cluster protection Open short diagnosis error code display Machine error ECM fault code display Machine condition monitoring Electric signal monitoring Mode selectio...

Page 229: ...PPR pressure Overload pressure sensor SL SR Swing pressure AO AI Arm in out Bucket in pressure BI Work tool Cluster CAN 2 Pressure signal Pressure signal Pressure signal Drive signal Pressure signal Drive signal Drive signal Normal CN 16 Emergency CN 16A CN 16B Pump power shift EPPR Boom cylinder Shuttle block Switch signal PS PS PS PS PS PS PS PS PS PS Camera PS Arm in pressure PS Negacon 1 press...

Page 230: ...ise work 1 POWER MODE SELECTION SYSTEM 130ZF5MS02 GROUP 2 MODE SELECTION SYSTEM Power shift Standard Option can be changed by Service menu in Management on the cluster Load Power mode Application Engine rpm Power shift by EPPR valve Standard Option Standard Option Unload Load Unload Load Current mA Pressure kgf cm2 Current mA Pressure kgf cm2 P Heavy duty power 1850 50 1950 50 2100 50 2050 50 290 ...

Page 231: ...ion Travel RH Travel LH Dozer GENERAL WORK MODE bucket This mode is used to general digging work ATT WORK MODE breaker crusher It controls the pump flow and system pressure according to the operation of breaker or crusher 1 2 2 WORK MODE SELECTION SYSTEM Work mode consists of the general operation bucket and the optional attachment breaker crusher 130ZF5MS03 Description General mode Work tool Buck...

Page 232: ...e bar 1 1300 1000 0 2 1400 1050 3 3 1500 1100 Auto decel 6 4 1600 1130 9 5 1700 1150 12 6 1800 1180 16 7 1900 1200 20 8 2000 1230 26 9 2050 1250 32 10 2100 1280 38 1 2 Main pump Pilot pump Engine ECM Main control valve Pump power shift EPPR MCU Drive signal Cluster User mode switch signal User mode pilot lamp Normal CN 16 Emergency CN 16A CN 16B CAN 2 CAN 1 Accel dial signal Accel dial 130ZF5MS04 ...

Page 233: ...o 1000 rpm As the result of reducing the engine speed fuel consumption and noise are effectively cut down during non operation of the control levers When the auto idle pilot lamp is turned off by pressing the switch or any control lever is operated the reduced engine speed rises upto the speed before deceleration in a second 1 WHEN AUTO IDLE PILOT LAMP ON 2 WHEN AUTO IDLE PILOT LAMP OFF The engine...

Page 234: ...is pushed ON the power mode is set P mode and maximum digging power is increased by 10 When the power boost function is activated the power boost solenoid valve pilot pressure raises the set pressure of the main relief valve to increase the digging power When the auto power boost is set to Enable and power mode is set to P mode on the cluster the digging power is automatically increased as working...

Page 235: ...ol valve Option Arm 1 Boom 2 Swing Bucket Arm 2 Arm regen Boom 1 Option Travel RH Travel LH Dozer Travel speed can be switched manually by pressing the travel speed switch on the cluster Default Turtle Low speed 130ZF5MS07 Speed Travel speed solenoid valve Lamp on cluster Operation Low OFF Turtle Low speed high driving torque in the travel motor High ON Rabbit High speed low driving torque in the ...

Page 236: ...hydraulic oil temperature signal is substituted In case of the coolant temperature increases up to 30 C the engine speed is decreased to key start speed And if an operator changes power mode set during the warming up function the MCU cancels the automatic warming up function LOGIC TABLE 1 2 3 130ZF5MS08 Description Condition Function Actuated Coolant temperature Below 30 C after engine run Power m...

Page 237: ...l signal Accel dial 130ZF5MS09 Description Condition Function First step warning Activated Coolant temperature Above 103 C Hydraulic oil temperature Above 100 C Warning lamp Pops up and buzzer sounds Pump input torque is reduced Canceled Coolant temperature Less than 100 C Hydraulic oil temperature Less than 95 C Return to pre set the pump absorption torque Second step warning Activated Coolant te...

Page 238: ...m in out Bucket in pressure BI Boom up pressure PS PS PS Arm in pressure BU PS Accel dial signal The new variable power control system makes constantly exact pump control through improvement variable engine speed control and response and optimization of control input sensor signal It makes fuel saving and smooth control at precise work 130ZF5MS10 The variable power control function can be activate...

Page 239: ... tool SOLENOID VALVE PS Main control valve Option Arm 1 Boom 2 Swing Bucket Arm 2 Arm regen Boom 1 Option Travel RH Travel LH Dozer The system is used to control the pump delivery flow according to set of the work tool on the cluster by the attachment flow EPPR valve Refer to the page 5 76 for the attachment kinds and max flow When breaker operating switch is pushed 130ZF5MS11 Description Work too...

Page 240: ...ing pressure AO AI Arm in out Bucket in pressure BI Boom up pressure BU PS PS PS Arm in pressure PS Option Arm 1 Boom 2 Swing Bucket Arm 2 Arm regen Boom 1 Option Travel RH Travel LH Dozer When the requirement of pump flow rate is low IPC mode controls pump flow rate to improve fuel efficiency 1 145ZF5MS13 Condition 1 Function IPC mode ON 2 Boom up Arm in Not travel motion Not swing motion Limitat...

Page 241: ...N limit level 1 Efficiency mode IPC mode ON limit level 2 Speed mode IPC mode OFF IPC MODE SELECTION IPC mode ON OFF and the levels of flow rate limit can be selected at Mode setup IPC mode 2 130ZF5MS19 290F3CD311 Pi bar Q cc rev Balance mode Efficiency mode ...

Page 242: ...STEM Engine Starter MCU Drive signal Start safety relay ECM 1 ANTI RESTART FUNCTION After a few seconds from the engine starts to run MCU turns off the start safety relay to protect the starter from inadvertent restarting 300L5MS12 ...

Page 243: ...ores them in the memory MONITORING Active fault 1 2 1 The active faults of the MCU engine ECM or air conditioner can be checked by this menu The logged faults of the MCU engine ECM or air conditioner can be checked by this menu The logged faults of the MCU engine ECM or air conditioner can be deleted by this menu Logged fault 2 Delete logged fault 3 290F3CD120 290F3CD121 290F3CD125 290F3CD128 290F...

Page 244: ...tion Auto Idle operation failure Engine variable horse power control operation failure Checking list 1 CD 7 B CN 52 37 Checking Open Short 2 CD 7 A CN 51 3 Checking Open Short 3 CD 7 C CN 51 13 Checking Open Short 108 0 10 seconds continuous Travel Oil Press Sensor Measurement Voltage 5 2V 1 10 seconds continuous 0 3V Travel Oil Press Sensor Measurement Voltage 0 8V 4 10 seconds continuous Travel ...

Page 245: ... 0 8V 4 10 seconds continuous Main Pump 2 P2 Press Sensor Measurement Voltage 0 3V Results Symptoms 1 Monitor Main Pump 2 P2 Press display failure 2 Control Function Automatic voltage increase operation failure Overload at compensation control failure Checking list 1 CD 43 B CN 52 12 Checking Open Short 2 CD 43 A CN 51 3 Checking Open Short 3 CD 43 C CN 51 13 Checking Open Short 122 1 when you had...

Page 246: ... Negative 2 Press Sensor Measurement Voltage 0 3V Results Symptoms 1 Monitor Negative 2 Press display failure 2 Control Function Option attachment flow control operation failure Checking list 1 CD 71 B CN 52 17 Checking Open Short 2 CD 71 A CN 51 3 Checking Open Short 3 CD 71 C CN 51 13 Checking Open Short 127 0 10 seconds continuous Boom Up Pilot Press Sensor Measurement Voltage 5 2V 1 10 seconds...

Page 247: ...V Arm In Pilot Press Sensor Measurement Voltage 0 8V 4 10 seconds continuous Arm In Pilot Press Sensor Measurement Voltage 0 3V Results Symptoms 1 Monitor Arm In Pilot Press display failure 2 Control Function IPC operation failure Checking list 1 CD 90 B CN 52 28 Checking Open Short 2 CD 90 A CN 51 3 Checking Open Short 3 CD 90 C CN 51 13 Checking Open Short 133 0 10 seconds continuous Arm In Out ...

Page 248: ...s 0 3V Attachment Pilot Press Sensor Measurement Voltage 0 8V 4 Monitor Select Attachment breaker crusher 10 seconds continuous Attachment Pilot Press Sensor Measurement Voltage 0 3V Results Symptoms 1 Monitor Attachment Pilot Press display failure 2 Control Function Option attachment flow control operation failure Checking list 1 CD 69 B CN 53 14 Checking Open Short 2 CD 69 A CN 53 3 Checking Ope...

Page 249: ...52 9 Checking Open Short 2 CN 75 1 CN 52 10 Checking Open Short 141 5 Model Parameter mounting Boom Priority EPPR Detection When Boom Priority EPPR Current is more than 10 mA 10 seconds continuous Boom Priority EPPR drive current 0 mA Cancellation When Boom Priority EPPR Current is more than 10 mA 3 seconds continuous Boom Priority EPPR drive current 10 mA 6 Detection 10 seconds continuous Boom Pr...

Page 250: ...51 40 Checking Open Short 145 5 Model Parameter mounting Remote Cooling Fan EPPR Detection When Remote Cooling Fan EPPR Current is more than 10 mA 10 seconds continuous Remote Cooling Fan EPPR drive current 0 mA Cancellation When Remote Cooling Fan EPPR Current is more than 10 mA 3 seconds continuous Remote Cooling Fan EPPR drive current 10 mA 6 Detection 10 seconds continuous Remote Cooling Fan E...

Page 251: ...ssure cut off failure Checking list 1 CR 47 85 CN 54 9 Checking Open Short 2 CR 47 30 86 CN 45 B term Checking Open Short 166 4 Detection When Power Max Solenoid is Off 10 seconds continuous Power Max Solenoid drive unit Measurement Voltage 3 0V Cancellation When Power Max Solenoid is Off 3 seconds continuous Power Max Solenoid drive unit Measurement Voltage 3 0V 6 Detection When Power Max Solenoi...

Page 252: ...it Measurement Voltage 3 0V Cancellation When Travel Speed Solenoid is Off 3 seconds continuous Travel Speed Solenoid drive unit Measurement Voltage 3 0V 6 Detection When Travel Speed Solenoid is On 10 seconds continuous Travel Speed Solenoid drive current 4 5 A Cancellation When Travel Speed Solenoid is On 3 seconds continuous Travel Speed Solenoid drive current 4 5 A Results Symptoms 1 Control F...

Page 253: ...list 1 CD 237 1 CN 53 7 Checking Open Short 2 CD 237 2 CR 35 87 Checking Open Short 170 4 Model Parameter mounting Arm Regenerating Solenoid Detection When Arm Regeneration Solenoid is Off 10 seconds continuous Arm Regeneration Solenoid drive unit Measurement Voltage 3 0V Cancellation When Arm Regeneration Solenoid is Off 3 seconds continuous Arm Regeneration Solenoid drive unit Measurement Voltag...

Page 254: ... 1 CN 53 8 Checking Open Short 2 CD 149 2 CR 35 87 Checking Open Short 179 4 Monitor Selecting attachment breaker crusher Detection When Breaker Operating Solenoid is Off 10 seconds continuous Attachment Safety Solenoid drive unit Measurement Voltage 3 0V Cancellation When Breaker Operating Solenoid is Off 3 seconds continuous Attachment Safety Solenoid drive unit Measurement Voltage 3 0V 6 Detect...

Page 255: ...ent 4 5 A Results Symptoms 1 Control Function Cooling Fan reverse control operation failure not applicable 188 5 Detection When Attachment Flow EPPR 1 current is equal or more than 300 mA 10 seconds continuous Attachment Flow EPPR drive current 100 mA Cancellation When Attachment Flow EPPR 1 current is equal or more than 300 mA 3 seconds continuous Attachment Flow EPPR drive current 100 mA 6 Detec...

Page 256: ...PPR 1 press Sensor Measurement Voltage 5 2V 1 HW145 10 seconds continuous 0 3V AttachmentflowcontrolEPPR1press SensorMeasurementVoltage 0 8V 4 HW145 10 seconds continuous Attachment flow control EPPR 1 press Sensor Measurement Voltage 0 3V Results Symptoms 1 Control Function Driving second pump joining function operation failure Checking list 1 CD 33 B CN 52 11 Checking Open Short 2 CD 33 A CN 51 ...

Page 257: ...ing Open Short 218 4 Mounting pressure sensor HCESPN128 or HCESPN 205 Detection When Boom Up Floating Solenoid is Off 10 seconds continuous Boom Up Floating Solenoid drive unit Measurement Voltage 3 0V Cancellation When Boom Up Floating Solenoid is Off 3 seconds continuous Boom Up Floating Solenoid drive unit Measurement Voltage 3 0V 6 Detection When Boom Up Floating Solenoid is On 10 seconds cont...

Page 258: ...mptoms 1 Control Function Boom floating control operation failure Checking list 1 CD 369 1 CN 53 35 Checking Open Short 2 CD 369 2 CR 35 87 Checking Open Short 221 5 Monitor Selecting attachment breaker crusher Detection When ATT Relief Setting EPPR 1 Current is equal or more than 10 mA 10 seconds continuous ATT Relief Setting EPPR 1 drive current 0 mA Cancellation ATT Relief Setting EPPR 1 Curren...

Page 259: ...uel Level Measurement Voltage 3 8V 4 10 seconds continuous Fuel Level Measurement Voltage 0 3V Results Symptoms 1 Monitor Fuel remaining display failure Checking list 1 CD 2 2 CN 52 26 Checking Open Short 2 CD 2 1 CN 51 5 Checking Open Short 325 4 Model Parameter mounting Fuel Warmer Relay Detection When Fuel Warmer Relay is Off 10 seconds continuous Fuel Warmer Relay drive unit Measurement Voltag...

Page 260: ...ment Voltage 0 8V 4 10 seconds continuous Brake Oil Press Sensor Measurement Voltage 0 3V Results Symptoms 1 Monitor Brake Oil Press display failure Brake Oil low pressure warning failure Checking list 1 CD 3 B CN 54 4 Checking Open Short 2 CD 3 A CN 54 3 Checking Open Short 3 CD 3 C CN 54 13 Checking Open Short 505 0 10 seconds continuous Working Brake Press Sensor Measurement Voltage 5 2V 1 10 s...

Page 261: ...rt 2 CR 66 2 CN 45 B term Checking Open Short 517 4 Detection When Traveling Cutoff Relay is Off 10 seconds continuous Traveling Cutoff Relay drive unit Measurement Voltage 3 0V Cancellation When Traveling Cutoff Relay is Off 3 seconds continuous Traveling Cutoff Relay drive unit Measurement Voltage 3 0V 6 Detection When Traveling Cutoff Relay is On 10 seconds continuous Traveling Cutoff Relay dri...

Page 262: ...ilure Checking list 1 CN 69 1 CN 54 8 Checking Open Short 2 CN 69 2 CN 45 B term Checking Open Short 527 4 Detection When Creep Solenoid is Off 10 seconds continuous Creep Solenoid drive unit Measurement Voltage 3 0V Cancellation When Creep Solenoid is Off 3 seconds continuous Creep Solenoid drive unit Measurement Voltage 3 0V 6 Detection When Creep Solenoid is On 10 seconds continuous Creep Solen...

Page 263: ... Sensor Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Travel Reverse Press display failure 2 Control Function Driving interoperability power control operation failure Checking list 1 CD 74 B CN 54 23 Checking Open Short 2 CD 74 A CN 54 3 Checking Open Short 3 CD 74 C CN 54 13 Checking Open Short 705 0 10 seconds continuous Battery input Voltage 35V 侑 1 10 seconds continuous Battery input V...

Page 264: ...und is On 10 seconds continuous Travel Alarm Buzzer Sound Relay drive current 4 5 A Cancellation When Travel Alarm Buzzer Sound is On 3 seconds continuous Travel Alarm Buzzer Sound Relay drive current 4 5 A Results Symptoms 1 Control Function Driving alarm operation failure Checking list 1 CN 81 1 CN 52 31 Checking Open Short 2 CN 81 2 CN 45 B term Checking Open Short 831 2 When mounting the A C C...

Page 265: ...us Haptic Controller Communication Data Error Results Symptoms 1 Control Function Haptic Controller operation failure Checking list 1 CN 8 2 CN 51 22 Checking Open Short 2 CN 8 3 CN 51 32 Checking Open Short 850 2 When mounting the RMCU 60 seconds continuous RMCU communication Data Error Resuluts Symptoms 1 Control Function RMCU operation failure Checking list 1 CN 125 3 CN 51 22 Checking Open Sho...

Page 266: ...76 10 CN 51 22 Checking Open Short 2 CN 376 18 CN 51 32 Checking Open Short 868 2 60 seconds continuous Switch Controller communication Data Error Results Symptoms 1 Control Function Switch Controller operation failure Checking list 1 CN 56A 7 CN 51 22 Checking Open Short 2 CN 56A 6 CN 51 32 Checking Open Short 869 2 When mounting the BKCU 60 seconds continuous BKCU communication Data Error Result...

Page 267: ...tch Circuits Test Oil Pressure Switch 100 17 Engine Oil Pressure Low least severe 1 Oil Pressure Is Low 102 3 Engine Intake Manifold 1 Pressure Voltage Above Normal Sensor Signal Analog Active Test 102 4 Engine Intake Manifold 1 Pressure Voltage Below Normal Sensor Signal Analog Active Test 102 20 Engine Intake Manifold 1 Pressure Data Drifted High Sensor Signal Analog Active Test 102 21 Engine In...

Page 268: ...t 157 4 Engine Injector Metering Rail 1 Pressure Voltage Below Normal Sensor Signal Analog Active Test 157 10 Engine Injector Metering Rail 1 Pressure Abnormal Update Rate Sensor Signal Analog Active Test 157 16 Engine Injector Metering Rail 1 Pressure High moderate severity 2 Fuel Rail Pressure Problem 157 17 Engine Injector Metering Rail 1 Pressure Low least severe 1 Fuel Rail Pressure Problem 1...

Page 269: ...amp will come on 623 5 Red Stop Lamp Current Below Normal Indicator Lamp Test 623 6 Red Stop Lamp Current Above Normal Indicator Lamp Test 624 5 Amber Warning Lamp Current Below Normal Indicator Lamp Test 624 6 Amber Warning Lamp Current Above Normal Indicator Lamp Test 630 2 Calibration Memory Erratic Intermittent or Incorrect Injector Data Incorrect Test 637 11 Engine Timing Sensor Other Failure...

Page 270: ... 3 Engine Starter Motor Relay Voltage Above Normal Relay Test Start Relay 677 5 Engine Starter Motor Relay Current Below Normal Relay Test Start Relay 677 6 Engine Starter Motor Relay Current Above Normal Relay Test Start Relay 723 8 Engine Speed Sensor 2 Abnormal Frequency Pulse Width or Period Speed Timing Test 970 31 Engine Auxiliary Shutdown Switch This code indicates that the shutdown switch ...

Page 271: ...pport Status Special Instruction Another diagnostic code has requested engine speed limitation The warning lamp will flash The engine speed is limited to 1200 rpm Troubleshoot all other diagnostic codes If this code is the only active diagnostic code replace the ECM Refer to Troubleshooting ECM Replace 1239 0 Engine Fuel Leakage 1 High most severe 3 Fuel Rail Pressure Problem 1485 7 ECM Main Relay...

Page 272: ...7 15 Aftertreatment 1 Intake O2 High least severe 1 Oxygen Level Test 3219 15 Aftertreatment 1 Intake Gas Sensor at Temperature High least severe 1 Oxygen Level Test 3219 17 Aftertreatment 1 Intake Gas Sensor at Temperature Low least severe 1 Oxygen Level Test 3222 3 Aftertreatment 1 Intake Gas Sensor Heater Voltage Above Normal Oxygen Level Test 3222 4 Aftertreatment 1 Intake Gas Sensor Heater Vo...

Page 273: ...ratic Intermittent or Incorrect Sensor Supply Test 3697 5 Particulate Trap Lamp Command Current Below Normal Indicator Lamp Test 3697 6 Particulate Trap Lamp Command Current Above Normal Indicator Lamp Test 3698 5 Exhaust System High Temperature Lamp Command Current Below Normal Indicator Lamp Test 3698 6 Exhaust System High Temperature Lamp Command Current Above Normal Indicator Lamp Test 3702 5 ...

Page 274: ...y Glow Plug Starting Aid Test 5357 31 Engine Fuel Injection Quantity Error for Multiple Cylinders ECM Memory Test 5419 5 Engine Throttle Actuator 1 Current Below Normal Motorized Valve Test 5419 6 Engine Throttle Actuator 1 Current Above Normal Motorized Valve Test 5419 7 Engine Throttle Actuator 1 Not Responding Properly Motorized Valve Test 5571 2 High Pressure Common Rail Fuel Pressure Relief V...

Page 275: ...agnostic code first troubleshoot any active codes that are listed in table below Once all other codes are cleared cycle the start switch in order to clear the 5246 or 5826 diagnostic code 27 3 27 4 102 3 102 4 102 20 102 21 105 3 105 4 108 3 108 4 157 0 157 2 157 16 157 18 173 3 173 4 1076 5 1076 6 1188 5 1209 3 1209 4 1239 0 2791 5 2791 6 2791 7 3251 3 3251 4 3251 7 3251 10 3251 18 3358 10 3509 2...

Page 276: ...AAVM Communication Error Left Camera A05 AAVM Communication Error Right Camera A06 Manual Setting Fail A07 No MCU CID A08 MCU CID Format Error A09 AAVM Hardware Error AAVM A10 AAVM Hardware Error Front Camera A11 AAVM Hardware Error Rear Camera A12 AAVM Hardware Error Left Camera A13 AAVM Hardware Error Right Camera A14 MCU CID Model is not registered A15 MCU CID Model can t be applied ...

Page 277: ...ED lamps on the MCU display as below 1 2 SEEK VOL MODE CALL MUTE V LCD 1 2 ECM Engine Control Module 1 MCU 2 Bolt M8 130ZF5MS101 G green R red Y yellow LED lamp Trouble Service G is turned ON Normal G and R are turned ON Trouble on MCU Change the MCU G andY are turned ON Trouble on serial communication line Check if serial communication lines between MCU and cluster are disconnected Three LED are ...

Page 278: ...o flow regulator of main pump Pressure and electric current value for each mode 1 HOW TO SWITCH THE POWER SHIFT STANDARD OPTION ON THE CLUSTER You can switch the EPPR valve pressure set by selecting the power shift standard option Management Service menu Power shift standard option Power shift pressure can be set by option menu 290F3CD149 290F3CD126 290F3CD150 290F3CD151 Enter the password 1 2 3 2...

Page 279: ...tank A Secondary pressure to flow regulator at main pump Neutral Pressure line is blocked and A oil returns to tank Operating Secondary pressure enters into A P T A P T A P T A 2 3 4 5 6 7 1 1 Sleeve 2 Spring 3 Spool 4 O ring 5 O ring 6 Solenoid valve 7 Connector P T A P T A 5 22 1 5 22 2 1 2 3 ...

Page 280: ...ure at EPPR valve Remove plug and connect pressure gauge as figure Gauge capacity 0 to 50 kgf cm2 0 to 725 psi Start engine Set S mode and cancel auto decel mode Position the accel dial at 10 If tachometer show approx 1750 50 rpm check pressure at relief position of bucket circuit by operating bucket control lever If pressure is not correct adjust it After adjust test the machine Multimeter CN 75 ...

Page 281: ...l 1 O ring 2 Support ring 3 Valve body 4 Coil 5 Connector 6 Cover cap Operation In de energized mode the inlet port P is closed and the outlet port A is connected to tank port T In energized mode the solenoid armature presses onto the control spool with a force corresponding to the amount of current This will set a reduced pressure at port A The setting is proportional to the amount of current app...

Page 282: ... and connect pressure gauge as figure Gauge capacity 0 to 50 kgf cm2 0 to 725 psi Start engine Set S mode and cancel auto decel mode If rpm display approx 1750 50 rpm check pressure In case of combined boom up and swing operation If pressure is not correct adjust it After adjust test the machine Solenoid valve Spec 400 600 mA combined boom up and swing operation Boom priority EPPR valve CN 133 Mul...

Page 283: ...e machine Daily inspection should be performed according to chapter 6 Maintenance When the cluster provides a warning immediately check the problem and perform the required action The warning lamp pops up and or blinks and the buzzer sounds when the machine has a problem The warning lamp lights up or blinks until the problem is cleared Refer to page 5 60 for details This cluster is adjustable Vert...

Page 284: ...ilot lamp Low turtle Start of engine Check machine condition RPM display indicates at present rpm Gauge and warning lamp Indicate at present condition When normal condition All warning lamp OFF Work mode selection General work Power mode selection E mode or U mode Travel speed pilot lamp Low turtle When warming up operation Warming up pilot lamp ON After engine started engine speed increases to 10...

Page 285: ...32Vdc 3 GND 4 CAN 1 H 0 5Vdc 5 CAN 1 L 0 5Vdc 6 CAN 2 H 0 5Vdc 7 CAN 2 L 20 32Vdc 8 N C 9 N C 10 Aux left 0 5Vdc 11 Aux right 0 5Vdc 12 Aux GND No Name Signal 1 CAM 6 5V 6 3 6 7Vdc 2 CAM GND 3 CAM DIFF H 0 5Vdc 4 CAM DIFF L 0 5Vdc 5 CAM 1 NTSC signal 6 CAM 2 NTSC signal 7 CAM 3 NTSC signal 8 CAM shield 0 5Vdc 3 1 2 NTSC National Television System Committee ...

Page 286: ...ven though the machine is on the normal condition check the electric device as that can be caused by the poor connection of electricity or sensor 290F3CD49 290F3CD53 2 3 GAUGE 2 Default Option 1 2 3 6 4 5 5 2 3 7 1 4 6 7 130ZF3CD207 Operation screen When you first turn starting switch ON the operation screen will appear Operation screen type can be set by the screen type menu of the display Refer ...

Page 287: ...oblem If the gauge indicates the red range or lamp blinks in red even though the machine is on the normal condition check the electric device as that can be caused by the poor connection of electricity or sensor Hydraulic oil temperature gauge 290F3CD54 5 4 This displays the engine the tripmeter Refer to page 5 88 for details Tripmeter display 290F3CD56 6 130ZF3CD255 This gauge indicates the level...

Page 288: ...the original position and light ON and the buzzer stops when 2 seconds elapsed Refer to page 5 65 for details Warning lamp pops up on the center of the LCD and the buzzer sounds Refer to page 5 61 for details Warning lamps and buzzer Refer to page 5 72 for the buzzer stop switch HEST warning lamp DPF regen inhibit warning lamp PDF warning lamp Fuel level warning lamp Engine coolant temperature war...

Page 289: ...ency warning lamp 4 290F3CD63 290F3CD64 Engine coolant temperature warning is indicated two steps 103 C over The lamp pops up and the buzzer sounds 107 C over The lamp pops up and the buzzer sounds The pop up lamps move to the original position and blinks when the buzzer stop switch is pushed And the buzzer stops and lamps keep blink Check the cooling system when the lamps keep blink 290F3CD61 Eng...

Page 290: ...arging circuit when this lamp blinks Battery charging warning lamp 290F3CD67 5 6 7 This warning lamp pops up and the buzzer sounds when the engine oil pressure is low If the lamp ON shut OFF the engine immediately Check oil level But when key on status the lamp is ON for initial lamp check If the lamp blinks engine oil change and oil life reset are required Refer to page 5 64 for details Engine oi...

Page 291: ...eration Off Off Flash 2Hz The engine oil change due soon Triggered at 480 hours from last oil change reset Pop up window is seen in a cluster On Off Flash 2Hz The engine oil life has reached the maximum recommended life Triggered by the oil life algorithm Pop up window is seen in a cluster Flash Off Flash 2Hz The engine oil life has exceeded the maximum allowable life for the monitored operating c...

Page 292: ... without engine running 2 Then press Menu Manage Engine Oil Life Reset 3 Press OK and Put User Password 4 When the oil life reset is completed the pop up window below is seen and oil pressure warning lamp flashes at 1 Hz until starting switch cycle is reset 5 Turn the starting switch off and then starting switch on again to perform starting switch cycle reset 130ZF3CD101 130ZF3CD102 ...

Page 293: ...tion does not occur To clear the Inhibit lamp pressing the DPF switch once again at inhibit position II at least 2 seconds This warning lamp indicate high temperature of the exhaust system due to DPF regeneration The lamp will also illuminate during the manual DPF regeneration When this lamp is illuminated be sure the exhaust pipe outlet is not directed at any surface or material that can be melte...

Page 294: ...gh exhaust temperature lamp ON during active or manual regeneration The lamp will turn OFF 1 min after regeneration is completed Soot midium OFF OFF ON OFF OFF DPF above 130 soot loading warns the operator that regen eration is required Soot high Blink OFF ON OFF OFF DPF above 180 soot loading Engine power derates depen dent on soot load Regeneration is required Soot full Blink ON ON OFF OFF DPF a...

Page 295: ...accelerate automatically from low idle to The engine speed will accelerate automatically from low idle to 2000 rpm at a rate of 100 rpm s The engine speed shall be 2000 rpm at a rate of 100 rpm s The engine speed shall be maintained for a period of 15 to 25 minutes depending on the initial maintained for a period of 15 to 25 minutes depending on the initial soot load Once the regeneration has comp...

Page 296: ...ilot lamp Smart key pilot lamp 130ZF3CD274 Mode pilot lamps 1 No Mode Pilot lamp Selected mode 1 Power mode Heavy duty power work mode Standard power mode Economy power mode 2 User mode User preferable power mode 3 Work mode General operation IPC speed mode General operation IPC balance mode General operation IPC efficiency mode Breaker operation mode Crusher operation mode 4 Travel mode Low speed...

Page 297: ...e at neutral position and the auto idle function is selected One touch decel is not available when the auto idle pilot lamp is turned ON Refer to the operator s manual page 3 37 Decel pilot lamp This lamp is turned ON when the coolant temperature is below 10 C 50 F or the hydraulic oil temperature 20 C 68 F The automatic fuel warming is cancelled when the engine coolant temperature is above 60 C a...

Page 298: ...s Refer to the page 5 82 Smart key pilot lamp opt 8 9 290F3CD84 290F3CD214 This lamp will be ON when the consuming parts are needed to change or replace It means that the change or replacement interval of the consuming parts remains below 30 hours Check the message in maintenance information of main menu Also this lamp lights ON for 3 minutes when the start switch is ON position Refer to the page ...

Page 299: ...t the machine work mode which shifts from general operation mode to optional attachment operation mode General operation mode Breaker operation mode if equipped Crusher operation mode if equipped Not installed Breaker or crusher is not installed Refer to the operator s manual page 4 7 for details Work mode switch 130ZF3CD286 290F3CD88 2 5 When some of the switches are selected the pilot lamps are ...

Page 300: ...his switch is used to activate or cancel the auto idle function Pilot lamp ON Auto idle function is activated Pilot lamp OFF Auto idle function is cancelled The buzzer sounds when the machine has a problem In this case push this switch and buzzer stops but the warning lamp blinks until the problem is cleared This switch is used to operate the work light The pilot lamp is turned ON when operating t...

Page 301: ...ark when switched off The pilot lamp is turned ON when operating the switch If the wiper does not operate with the switch in ON position turn the switch OFF immediately Check the cause If the switch remains ON motor failure can result The washer liquid is sprayed and the wiper is operated only while pressing this switch The pilot lamp is turned ON when operating the switch This switch turns ON the...

Page 302: ...he overload warning device before you handle or lift objects This switch is to activate the main menu in the cluster Refer to the page 5 75 This switch is to activate travel alarm function surrounding when the machine travels to forward and backward On pressing this switch the alarm operates only when the machine is traveling The pilot lamp is turned ON when operating the switch This switch is to ...

Page 303: ...achine information Switch status Output status 3 Fuel rate information Maintenance information Machine security Machine information Contact Service menu Clinometer Update Engine oil life reset General record Hourly Daily Mode record Replacement Change interval oils and filters ESL mode setting Password change Model MCU Monitor Switch controller RMCU Relay drive unit FATC A S phone number A S phone...

Page 304: ... Boom speed Boom priority function can be activated or cancelled Enable Boom up speed is automatically adjusted as working conditions by the MCU Disable Normal operation Arm speed Arm regeneration function can be activated or cancelled Enable Arm in speed is up Disable Normal operation Step Engine speed rpm Idle speed rpm Power shift bar 1 1300 1000 0 2 1400 1050 3 3 1500 1100 auto decel 6 4 1600 ...

Page 305: ...e Not operated 290F3CD117 210WF3CD118 IPC mode The IPC mode can be selected by this menu Speed mode Balance mode default Efficiency mode This mode is applied only general operation mode of the work tool mode Please update the cluster programs if this mode is not displayed in the mode setup menu Refer to the page 5 87 290F3CD310 290F3CD311 290F3CD312 290F3CD313 130ZF3CD256 130ZF3CD258 130ZF3CD259 ...

Page 306: ...l initial step 0 9 step Automatic engine shutdown option 210WF3CD11 210WF3CD12 130ZF3CD213 The automatic engine shutdown function can be set by this menu One time Always Disable Wait time setting Max 40 minutes min 2 minutes Emergency mode This mode can be use when the switches are abnormal on the cluster The cluster switches will be selected by touched each icon 290F3CD248 290F3CD249 ...

Page 307: ...rmed by this menu Digital input Digital output The activated switch or output pilot lamps are light ON 290F3CD120 290F3CD128 290F3CD134 290F3CD172 290F3CD121 290F3CD123 290F3CD126 290F3CD188 290F3CD124 290F3CD127 290F3CD189 290F3CD125 The active faults of the MCU or engine ECM can be checked by this menu The logged faults of the MCU or engine ECM can be checked by this menu The logged faults of th...

Page 308: ...One step shift to the right for every one hour Automatic deletion for 12 hours earlier data All hourly records deletion by Reset Daily record C Daily fuel consumption for past seven days MCU real time No record during key off time One step shift to the right at 24 00 for every day Automatic deletion for 7 days earlier data All daily records deletion by Reset Mode record D Average fuel rate for eac...

Page 309: ...ce interval No Item Interval 1 Engine oil 500 2 Final gear oil 1000 3 Swing gear oil 1000 4 Hydraulic oil 5000 5 Pilot line filter 1000 6 Drain filter 1000 7 Hydraulic oil return filter 1000 8 Engine oil filter 500 9 Fuel filter 500 10 Pre filter 500 11 Hydraulic tank breather 1000 12 Air cleaner inner outer 2000 13 Radiator coolant 2000 14 Swing gear pinion grease 1000 290F3CD131 290F3CD132 290F3...

Page 310: ...operator starts engine first But the operator can restart the engine within the interval time without input ting the password The interval time can be set maximum 4 hours Default password 00000 Password length 5 10 digit 290F3CD190 290F3CD135 290F3CD136 290F3CD137 290F3CD138 Smart key option Smart key is registered when equipped with optional smart key If smart key is not inside of the cabin authe...

Page 311: ...CD151 Service menu Power shift standard option Power shift pressure can be set by option menu Operating hours Operating hours since the machine line out can be checked by this menu Breaker mode pump acting 1 pump 2 pump EPPR current level attach flow EPPR 1 2 boom priority EPPR attach relief pressure EPPR 1 2 Overload pressure 100 350 bar 290F3CD152 290F3CD153 Clinometer When the machine is on the...

Page 312: ...fe reset Engine oil life rese 210WF3CD17 130ZF3CD100 210WF3CD18 130ZF3CD101 380F3CD06 210WF3CD19 130ZF3CD102 380F3CD04 ETC devices and cluster can be updated through CAN 2 network Insert USB memory stick which includes program files start download ...

Page 313: ...r each The second line shows the current time 0 00 23 59 290F3CD154 290F3CD157 290F3CD159 290F3CD155 290F3CD158 290F3CD160 290F3CD141 130ZF3CD256 290F3CD139 290F3CD191 290F3CD192 Brightness If Auto is chosen brightness for day and night can be differently set up Also by using the bar in lower side users can define which time interval belongs to day and night in bar figure white area represents nig...

Page 314: ...lected language Screen type A Type Default B Type Option 290F3CD161 290F3CD163 290F3CD162 290F3CD164 290F3CD165 290F3CD166 130ZF3CD256 290F3CD193 290F3CD194 130ZF3CD257 Temperature C F Pressure bar MPa kgf cm2 Volume l gal Flow lpm gpm Distance km mile Date format yy mm dd mm dd yy dd mm yy ...

Page 315: ...98 A B C Video A This menu operates the video play function mp4 mkv avi files and so on Audio B This menu operates the play music mp3 mp4 files and so on Smart terminal C The menu features a smartphone and operates the miracast 210WF3CD219 210WF3CD220 210WF3CD22 210WF3CD199 ...

Page 316: ...e tripmeter icon is activated in the operation screen it can be controlled directly there 290F3CD168 290F3CD169 Camera setting In the operation screen rear camera screen show up when ESC CAM button is pushed If the rear camera is not installed on the machine set disable If the rear camera installed on the machine set enable 290F3CD200 290F3CD156 290F3CD255 290F3CD221 290F3CD256 ...

Page 317: ...en AAVM mode 290F3CD246 290F3CD247 When the worker or pedestrian go to the blue line radius 5 m an external danger area of equipping on the cluster screen the warning buzzer sounds and it displays the blue rectangular box for the rec ognition of the worker and pedestrian At this time the operator should stop work imme diately and stop the buzzer by pressing the buzzer stop button And then please w...

Page 318: ...Fan speed switch Air recirculation switch Temperature control switch A C SEEK SEEK VOL MODE CALL MUTE V B Full auto air conditioner and heater system automatically keeps the optimum condition in accordance with operator s temperature configuration sensing ambient and cabin inside temperature 145ZF3CD06 AIR CONDITIONER AND HEATER 7 ...

Page 319: ...sensed by duct evaporator sensor compressor turns ON or OFF automatically Air conditioner operates to remove vapor and drains water through a drain hose Water can be sprayed into the cab in case that the drain cock at the ending point of drain hose has a problem In this case exchange the drain cock 1 2 Fan speed is controlled automatically by setted temperature This switch controls fan speed manua...

Page 320: ... the fresh air filter periodically to keep a good efficiency Air recirculation It recycles the heated or cooled air to increase the energy efficiency Change air occasionally when using recirculation for a long time Check out the recirculation filter periodically to keep a good efficiency 7 1 36073CD58 Temperature unit can be changed between celsius C and fahrenheit F Default status C Push Up Down ...

Page 321: ...0 5 second If error code is more than two each code flickers 2 times in sequence Error code Fail safe function 8 2 3 Error description Fail safe function Cabin inside sensor 11 25 C alternate value control Ambient sensor 12 20 C alternate value control Duct evaporator sensor 14 1 C alternate value control Temp actuator 15 If opening amount is 0 the alternate value is 0 If not the alternate value i...

Page 322: ...R 8W 8W 8R 8R CN 36 FUSE BOX 3L 5R V POWER RY CR 35 2 0 30 86 87 85 87a 86 85 87 30 87a 0 8 0 8 1 2 CN 36 1 1 2 3 4 5 6 7 8 9 10 11 12 2 0GW 0 75W 1 0G 1 0B 13 14 15 16 1 2 CN 231 8W 8R 8W 8R 1 2 ANTI RESTART RY CR 5 5 0 75WG CN 36 3 0 8 30 86 87 85 87a 86 85 87 30 87a BATTERY 12VX2 CR 1 BATT RY 60R 60B BATT POWER 24V 1 1 0R 30A 2 20A 3 30A 4 30A 5 10A 7 20A 8 10A 9 10A 10 10A 11 30A 12 5A 13 20A ...

Page 323: ...SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting 6 1 Group 2 Hydraulic and Mechanical System 6 4 Group 3 Electrical System 6 24 Group 4 Mechatronics System 6 40 ...

Page 324: ...ctrical system and Mechatronics system At each system part service men can check the machine according to the troubleshooting process diagram Troubles occur Mechatronics part Hydraulic Mechanical part GROUP 2 GROUP 3 GROUP 4 Fault codes displayed on monitor display See page 5 16 Electrical part HCESPN 3digit FMI 1 or 2 digit machine 3 to 6 digits engine See page 5 40 Before carring out troubleshoo...

Page 325: ...the phenomenon of the trouble Was the trouble getting worse or did it come out suddenly for the first time Did the machine have any troubles previously If so which parts were repaired before STEP 3 Inspect the machine Before starting troubleshooting check the machine for the daily maintenance points as shown in the operator s manual And also check the electrical system including batteries as the t...

Page 326: ...o where the trouble parts are located hydraulic mechanical system part or electrical system part or mechatronics system part perform troubleshooting the machine refer to the each system part s troubleshooting process diagram STEP 6 Trace a cause Before reaching a conclusion check the most suspectible causes again Try to trace what the real cause of the trouble is Make a plan of the appropriate rep...

Page 327: ...will become impossible to find the cause of the problem Ask user or operator the following Was there any strange thing about machine before failure occurred Under what conditions did the failure occur Have any repairs been carried out before the failure Check before troubleshooting Check oil and fuel level Check for any external leakage of oil from components Check for loose or damage of wiring an...

Page 328: ...el and check if rubber pieces or particles are not present Coupling hub spline is worn or hub fastening setscrew is slack If hydraulic pump or engine is suspected as a culprit refer to this manual Structure and function Cause Remedy Coupling element is broken Disassemble and repair Replace hub or retighten setscrew ...

Page 329: ...nterior or repair piping Disassemble and repair Repair or replace Disassemble and repair YES YES YES YES YES YES YES NO NO NO NO Is oil level in hydraulic oil tank within standard level Do not hydraulic pump and pump connections make abnormal noise Abnormal noise comes out of pump connection Is pilot pump pressure within standard level Ispilotpiping cloggedorisoil leakagepresent onpilotpiping Is g...

Page 330: ...ot the set pressure of main relief port relief and travel relief valve lower than the standard level Is fan belt tension proper ⓐ YES NO YES YES YES YES NO NO NO Drop hydraulic oil sample on hot plate and check if foams come up Water is mixed Air is intruded Put hydraulic oil still separate water and dispose it or replace hydraulic oil Check suction line and return line and eliminate the air intru...

Page 331: ...level Replace oil with one of proper viscosity Clean suction strainer Check for air intrusion in suction line and retighten or replace parts CAVITATION OCCURS WITH PUMP 3 HYDRAULIC OIL IS CONTAMINATED 4 Has not hydraulic oil passed specified replace ment hours Replace hydraulic oil to be specified Flush with hydraulic oil and replace return filter Has return filter been replaced at proper interval...

Page 332: ...e spool is stuck Hydraulic pump is broken Swing parking brake release valve is broken Swing reduction unit is broken Swing motor is broken Pilot relief valve in gear pump is faulty Gear pump is out of order RCV is broken Replenish specifiedoiltothe standardlevel Repairorreplace Repairorreplace Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair Disassemble a...

Page 333: ...Shuttle valve is faulty Pilot relief valve is faulty Gear pump is faulty Disassembleand repair or replace Disassemble and repair Clean pilot piping interior or repair piping Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair Clean pilot piping interior or repair piping Disassembleand repair or replace Disassemble and repair Mainreliefvalve pressureresetting...

Page 334: ...Does swing spool move Is MCV pilot pressure within standard value MACHINE SWINGS BUT DOES NOT STOP 4 Pilot relief valve is faulty Gear pump is broken RCV is faulty Swing spool is stuck Return spring is faulty Disassemble and repair or replace Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and replace Swing port relief valve is faulty Shuttle valve is faulty Swingc...

Page 335: ... A SLOPE 5 ⓐ Is swing relief pressure within standard level ⓐ Shuttle valve is faulty Brake spring is faulty Return spring of swing control valve is faulty Swing port relief valve is faulty Swing motor is broken Disassemble and replace Disassemble and replace Disassemble and replace Disassemble and repair or replace Disassemble and repair Adjust swing relief valve pressure or replace swing relief ...

Page 336: ...travel motor is faulty Control system is defective Travel spool is stuck Travel reduction unit is faulty Travel motor is out of order Hydraulic pump is broken Travel relief valves are faulty Disassemble and repair or replace Disassemble and repair Disassemble inspect and repair Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair or rep...

Page 337: ... Hydraulic pump is broken External pilot piping is clogged or oil is leaking from it Travel motor s parking brake is not released properly Travel motor is faulty Disassemble and repair or replace Disassemble and repair Disassemble inspect and repair Disassemble and repair Disassemble and repair or replace Disassemble and repair Disassemble and clean Disassemble and clean pilot piping Disassemble a...

Page 338: ...that there is no coupling element particles LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE 4 Faulty Hydraulic pump is faulty Travel relief valve is faulty Coupling at pump connection is broken Inspectaccording totheprocedure Traveldoesnot functionatallon oneside However acase wherebothLH andRHtravel motionsare disabledis extremelyseldom statistically Disassemble and repair Disassemble and repair or repla...

Page 339: ... Hydraulic circuit that releases travel parking brake is clogged with dirt Parking brake piston in travel motor is stuck Travel reduction unit is defective Disassemble and repair Disassemble and repair or replace Disassemble and repair or replace Disassemble and clean Disassemble and repair Disassemble and repair ⓐ Remove parking brake spring in travel motor draw out piston completely refit cover ...

Page 340: ...RVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME 7 NO Straight spool is faulty Pilot relief valve is defective Gear pump is broken Normal Repair or replace Remove dirt on signal orifice Disassemble and repair or replace Disassemble and repair Is gear pump delivering oil Is pilot relief valve normal Cause Remedy ...

Page 341: ... is faulty Pilot relief valve is faulty Gear pump is broken Hydraulic pump is broken Main relief valve is defective Coupling at pump connection is broken Cylinder interior is broken MCV spool is stuck Disassemble and repair or replace Disassemble and repair Disassemble and repair or replace Disassemble and repair Disassemble and repair Disassemble and repair or replace Disassemble and repair Reple...

Page 342: ... RCV is faulty Normal Replace spring Disassemble and repair Disassemble and repair Disassemble and repair or replace Disassemble and repair Disassemble and repair Clean pilot piping interior or repair piping Disassemble and repair Disassemble and repair or replace Disassemble and repair Adjust engine revolution Clean orifice in control valve Clean pilot piping interior or repair piping Disassemble...

Page 343: ...ween control valve casing and spool is poor Contact surface between poppet and seat is poor Cylinder is faulty Disassemble and repair or replace Disassemble and replace Locate the cause of hydraulic oil temperature rise and lower it to proper level Replace with genuine hydraulic oil or equivalent Disassemble and repair Disassemble and repair Disassemble and repair ⓐ Is cylinder internal leakage wi...

Page 344: ...isassemble and repair Disassemble and repair Adjust pressure repair or replace Disassemble and repair Does control valve spool move Does the symptom change when hydraulic pump s discharge hoses are exchanged BOOM ARM OR BUCKET POWER IS WEAK 4 Is relief pressure in main relief valve within standard level Is cylinder internal leakage within standard level Is relief pressure in port relief valve with...

Page 345: ... of grease Frictional noise occurs between the sliding faces of boom cylinder s oil seal and boom proper Supply grease to it Frictional noise will disappear if they are kept used If seizure is in an initial stage supply sufficient grease If seizure is in a grown state correct it by paper lapping or with an oil stone Cause Remedy ...

Page 346: ... the cylinder If no oil leaks from piping side and boom cylinder rod is retracted there is an internal leak in the control valve 3 Disconnect hose A from rod side of boom cylinder and drain oil from cylinders and hose put cups on piping and hose ends 2 Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full 1 145ZF6TS01 210 7 6 20 2 1...

Page 347: ...ess otherwise specified YES YES NO NO Check voltage between CN 56A 2 and 3 Check voltage between CN 5 9 and 10 CLUSTER BATT 24V GND POWER IG 24V 1 2 3 CN 56A 11 10 9 CN 5 NO 7 FUSE NO 10 FUSE 12 15 CN 36 1 Starting switch ON Voltage 20 32V Cause Remedy Defective cluster Disconnection in wiring harness or poor contact between CN 5 CN 56A Disconnection in wiring harness or poor contact between CN 5 ...

Page 348: ...place Repair or replace after clean Check voltage between CN 5 5 and 6 YES YES NO NO Check voltage between CN 56A 6 7 and 3 300L6ES02 Before disconnecting the connector always turn the starting switch OFF Before carrying out below procedure check all the related connectors are properly inserted After checking insert the disconnected connectors again immediately unless otherwise specified COMMUNICA...

Page 349: ...nection in wiring harness or poor contact between CN 52 27 CN 6 3 Disconnection in wiring harness or poor contact between CN 6 3 alternator terminal D Defective alternator Replace Repair or replace after clean Repair or replace after clean Replace YES YES YES NO NO NO MCU 27 CN 52 3 CN 6 ALTERNATOR CN 74 B D G 3 U Engine Running Voltage 20 32V Check voltage between alternator terminal D and chassi...

Page 350: ...94 CN 126 31 21 24 CN 51 42 34 27 16 SERVICE TOOL B G D E F GND CDL CAN A_Hi CDL CAN A_Lo 7 8 41 CN 126A 130ZF6ES03 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor engine harness connector Defective coolant temp sensor Check or replace Repair or replace after clean Replace YES YES NO Starting switch OFF Spec 180Ω 160 kΩ See table Check resistance bet...

Page 351: ...ediately unless otherwise specified Cause Remedy Clogged air filter or defective switch Short circuit in wiring harness between CD 10 CN 51 29 Defective MCU Check filter or replace switch Repair or replace After clean Replace 29 CN 51 AIR CLEANER SWITCH Pa MCU CD 10 Starting switch ON Engine Start Does display go off when disconnect CD 10 Check resistance between CN 51 29 and chassis NO YES NO YES...

Page 352: ... OIL PRESSURE WARNING LAMP LIGHTS UP engine is started Before disconnecting the connector always turn the starting switch OFF Before carrying out below procedure check all the related connectors are properly inserted After checking insert the disconnected connectors again immediately unless otherwise specified Cause Remedy Defective circuit sensor or ECM Voltage above or below normal Low engine oi...

Page 353: ...witch ON Engine Start Does display go off when disconnect CD 1 Resistance between CN 51 5 and CN 52 24 is 0 1Ω Starting switch OFF Disconnect CN 51 CN 52 Resistance between CD 1 1 2 is in range of 164 151Ω Starting switch ON Disconnect CD 1 YES YES YES NO NO NO 300L6ES08 Temperature C 30 10 0 40 70 80 90 100 105 Resistance kΩ 22 22 31 78 8 16 10 74 5 18 6 6 1 06 1 28 0 39 0 476 0 322 0 298 0 243 0...

Page 354: ...26 31 21 24 CN 51 42 34 27 16 SERVICE TOOL B G D E F GND CDL CAN A_Hi CDL CAN A_Lo 7 8 41 CN 126A 130ZF6ES03 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor engine harness connector Defective coolant temp sensor Check or replace Repair or replace after clean Replace YES YES NO Starting switch OFF Spec 180Ω 160 kΩ See table Check resistance between te...

Page 355: ...ENDER Cause Remedy Defective MCU or cluster Disconnection in wiring harness or poor contact between fuel sender MCU Defective fuel sender Replace Repair or replace Replace YES YES Starting switch OFF Spec 50 600Ω See table Check resistance between fuel sender 1 and 2 Check resistance between CN 51 5 and CN 52 26 Starting switch OFF Disconnect CN 51 CN 52 Spec 50 600Ω NO NO 300L6ES10 Check Table Ra...

Page 356: ...n wiring harness between CN 68 2 fuse No 26 Check hydraulic system Replace Repair or replace after clean Repair or replace after clean Replace Repair or replace Check voltage between CN 68 1 2 YES YES YES YES NO NO NO NO Safety lever OFF Starting switch ON Voltage 20 30V Check operation of solenoid Safety lever ON OFF Starting switch OFF Safety state Spec 0Ω Disconnect CN 4 Starting switch OFF Saf...

Page 357: ...l speed switch on the cluster Check MCU Cause Remedy Disconnection in wiring harness or poor contact between CN 70 CN 52 Defective solenoid Defective hydraulic system Disconnection in wiring harness or poor contact between CN 70 fuse No 24 Defective cluster Defective MCU Repair or replace Replace Check hydraulic system Repair or replace Replace Replace Check voltage between CN 70 1 and 2 Starting ...

Page 358: ...ection in wiring harness or poor contact between 45 87 CN 94 54 Defective ECM IG relay or disconnection in wiring harness or poor contact between CR 45 86 fuse No 13 Defective start relay or start motor or disconnection in wiring harness or poor contact between CR 23 2 CN 45 M Disconnection in wiring harness or poor contact between CR 23A 87 CR 23 2 ⓐ Defective ECM start relay or disconnection in ...

Page 359: ... specific gravity of battery Voltage 20 30V Voltage 20 30V Starting switch ON 36 39 MCU GPS CONN 4 3 2 1 4 3 2 1 CN 125 START RY STARTER CR 23 CN 45 B M M 2 1 CN 94 ANTI RESTART RY 20 CN 51 CN 5 CN 4 4 13 EM CY STOP SW 5 4 3 2 5 4 3 2 1 1 CS 33 ECM 1 C ST ACC BR H B 2 4 H I 0 I 0 3 5 6 5 4 3 2 1 6 CS 2A START KEY SW START CNTL OUT 27 START CNTL OUT 53 KEY IG 54 CS 74A 1 2 CS 74 MASTER SW 2 1 CN 60...

Page 360: ...ring harness or poor contact between CN 141 7 Fuse CN 21 4 Fuse 1 Recheck fuse No 21 2 Disconnection CN 141 6 Fuse ⓑ Disconnection in wiring harness or poor contact Defective wiper motor Defective wiper motor controller Replace Repair or replace after clean Replace Replace Repair or replace after clean Replace Replace Repair or replace after clean Replace Repair or replace after clean Repair or re...

Page 361: ...D LAMP CN 376 Cause Remedy Defective bulb Disconnection in wiring harness or poor contact between CR 13 87 CL 4 2 or CR 13 87 CL 3 2 Defectivemembrane controller Disconnection in wiring harness or poor contact between CN 376 13 CR 13 87 Disconnection in wiring harness or poor contact between CR 13 30 andfuseNo 16 or CR 13 86 fuse No 16 Recheck fuse No 16 Replace Repair or replace after clean Repla...

Page 362: ...a 30 86 85 87 87a CL 5 2 1 CN 12 2 1 Cause Remedy Defective bulb Disconnection in wiring harness or poor contact between CR 4 87 CL 5 2 Defectivemembrane controller Disconnection in wiring harness or poor contact between CR 4 85 CN 376 4 Disconnection in wiring harness or poor contact between CR 4 30 and fuse No 17 or CR 4 86 and fuse No 17 Recheck fuse No 17 Replace Repair or replace after clean ...

Page 363: ...perly inserted and fault code on the cluster INSPECTION PROCEDURE 1 SPEC 100 700 mA See TEST 2 SPEC 2 25 kgf cm2 See TEST 3 SPEC 15 25Ω 20 C SeeTEST 1 Check electric current at EPPR valve Check resistance at EPPR valve Check pressure at EPPR valve YES YES YES YES NO NO NO NO Cause Remedy Defective hydraulic system Defective EPPR valve Defective MCU Short circuit or poor connection between CN 52 CN...

Page 364: ... EPPR valve Check electric current at bucket circuit relief position 2 SPEC 15 25Ω 20 C 130ZF6MS33 Test 3 Check pressure at EPPR valve Remove plug and connect pressure gauge as figure Gauge capacity 0 to 50 kgf cm2 0 to 725 psi Start engine Set S mode and cancel auto decel mode Position the multimodal dial at 10 If tachometer show approx 1750 50 rpm check pressure at relief position of bucket circ...

Page 365: ...EC 100 700 mA See TEST 4 SPEC 2 25 kgf cm2 See TEST 5 SPEC 15 25Ω 20 See TEST 1 Check electric current at EPPR valve Check pressure at EPPR valve Check resistance between at EPPR valve Cause Remedy Not enough engine power Defective EPPR valve Short circuit or poor connection between CN 52 CN 75 Defective EPPR valve Check engine fault Contact cummins Replace Check and repair wire harness Replace YE...

Page 366: ...ing screw locknut CN 75 EPPR valve Pilot pressure supply line Valve casing Test 5 Check pressure at EPPR valve Remove plug and connect pressure gauge as figure Gauge capacity 0 to 50 kgf cm2 0 to 725 psi Start engine Set S mode and cancel auto decel mode Position the multimodal dial at 10 If rpm show approx 1750 50 rpm check pressure at relief position of bucket circuit by operating bucket control...

Page 367: ...ction between CN 51 22 CN 56A 6 or CN 51 32 CN 56A 7 Cause Remedy No power supply to the MCU MCU failure ⓐ Cluster failure No connection Check fuse No 8 Replace Replace Check and repair CLUSTER 6 7 CN 56A 6 5 CN 5 CN 51 22 32 MCU FUSE NO 8 1 GND CAN1 HI IG 24V BATT 24V CAN1 LO CAN2 HI CAN2 LO RS 232 RX RS 232 TX AUX LEFT AUX RIGHT AUX GND ⓐ G G R R R Y Y Y G Wiring diagram YES YES YES NO OK NO NO ...

Page 368: ...fault code 108 displayed Defective work pressure sensor Short circuit or poor connection between CN 51 3 CD 7 A and or CN 51 13 CD 7 C fault code 105 displayed Replace Replace Replace or repair Replace Replace or repair CN 52 38 37 MCU CN 51 3 13 CD 6 CD 7 TRAVEL PRESSURE SENSOR WORK PRESSURE SENSOR SUPPLY SIG RETURN A B C SUPPLY SIG RETURN A B C Check voltage between CN 52 38 GND and CN 52 37 GND...

Page 369: ...age at CN 52 37 and ground Prepare 1 piece of thin sharp pin steel or copper Insert prepared pin to rear side of connectors One pin to 37 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 35 CN 52 Female 37 38 PIN...

Page 370: ...ssure sensor Short circuit or poor connection between CN 1 5 CD 42 B Short circuit or poor connection between CD 42 A CN 1 4 or CD 42 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 29 GND YES YES YES NO NO NO SPEC Starting switch ON 24 2...

Page 371: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 29 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 29 PIN 1 2 SPEC Actuator operating 1 5 V 300L6MS06 ...

Page 372: ...ssure sensor Short circuit or poor connection between CN 1 3 CD 43 B Short circuit or poor connection between CD 43 A CN 1 4 or CD 43 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 12 GND YES YES YES NO NO NO SPEC Starting switch ON 24 2...

Page 373: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 12 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 12 PIN 1 2 SPEC Actuator operating 1 5 V 300L6MS08 ...

Page 374: ...ort circuit or poor connection between CN 1 7 CD 44 B Short circuit or poor connection between CD 44 A CN 1 4 or CD 44 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 32 GND YES YES YES NO NO NO SPEC Starting switch ON 24 2V SPEC Starting...

Page 375: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 32 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 32 PIN 1 2 SPEC Actuator operating 1 5 V 300L6MS10 ...

Page 376: ... pressure sensor Short circuit or poor connection between CN 1 1 CD 70 B Short circuit or poor connection between CD 70 A CN 1 4 or CD 70 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 33 GND YES YES YES NO NO NO SPEC Starting switch ON ...

Page 377: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 33 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 33 1 2 SPEC Actuator operating 1 5 V 300L6MS12 ...

Page 378: ... pressure sensor Short circuit or poor connection between CN 1 2 CD 71 B Short circuit or poor connection between CD 71 A CN 1 4 or CD 71 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 17 GND YES YES YES NO NO NO SPEC Starting switch ON ...

Page 379: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 17 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 17 1 2 SPEC Actuator operating 1 5 V 300L6MS14 ...

Page 380: ...B C CD 24 SWING PRESSURE SENSOR 300L6MS15 Cause Remedy Defective MCU Detective swing pressure sensor Short circuit or poor connection between CN 52 36 CD 24 B Short circuit or poor connection between CD 24 A CN 51 3 or CD 24 C CN 51 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 52 36 GND YES YES NO SPEC Starting switch ON 24 2V Check voltage between CD 2...

Page 381: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 36 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 36 1 2 SPEC Actuator operating 1 5 V 300L6MS16 ...

Page 382: ...35 ARM IN OUT BUCKET IN PRESSURE SENSOR 300L6MS17 Cause Remedy Defective MCU Detective arm in out bucket in pressure sensor Short circuit or poor connection between CN 52 14 CD 35 B Short circuit or poor connection between CD 35 A CN 51 3 or CD 35 C CN 51 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 52 14 GND YES YES NO SPEC Starting switch ON 24 2V Che...

Page 383: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 14 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 14 1 2 SPEC Actuator operating 1 5 V 300L6MS18 ...

Page 384: ... C CD 32 BOOM UP PRESSURE SENSOR 300L6MS19 Cause Remedy Defective MCU Detective boom up pressure sensor Short circuit or poor connection between CN 52 19 CD 32 B Short circuit or poor connection between CD 32 A CN 51 3 or CD 32 C CN 51 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 52 19 GND YES YES NO SPEC Starting switch ON 24 2V Check voltage between C...

Page 385: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 19 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 19 1 2 SPEC Actuator operating 1 5 V 300L6MS20 ...

Page 386: ...OR SUPPLY SIG RETURN A B C 13 3 300L6MS25 Cause Remedy Defective MCU Detective boom up pressure sensor Short circuit or poor connection between CN 53 23 CD 85 B Short circuit or poor connection between CD 85 A CN 53 3 or CD 85 C CN 53 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 53 23 GND YES YES NO SPEC Starting switch ON 24 2V Check voltage between CD...

Page 387: ...sharp pin steel or copper Insert prepared pin to rear side of connectors One pin to 23 of CN 53 Starting switch ON Check voltage as figure MCU CN 53 CN 53 Female 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 23 1 2 SPEC Actuator operating 1 5 V 300L6MS26 ...

Page 388: ...itorpoor connectionbetween CN 51 18 CS 29 Shortcircuitorpoor connectionbetween CN 88 2 FuseNo 24 Repairorreplace Repairorreplace Repairorreplace Repairorreplace 14 MALFUNCTION OF POWER MAX Fault code HCESPN 166 FMI 4 or 6 Before carrying out below procedure check all the related connectors are properly inserted INSPECTION PROCEDURE 1 MCU CS 29 2 CN 52 18 CN 51 CN 88 6 CN 4 NO 24 2 1 5 2 1 POWER MA...

Page 389: ...ce of the solenoid valve between CN 88 1 2 Starting switch OFF Disconnect connector CN 88 from power max solenoid valve Check resistance as figure 2 LH RCV lever Power max switch Power max solenoid valve CN 88 Multimeter 1 2 1 2 130ZF6MS15 LH RCV lever Power max switch Power max solenoid valve CN 88 Multimeter 1 2 1 2 GROUND SPEC Starting switch ON 24 1V Starting switch OFF 0V SPEC 15 35Ω 130ZF6MS...

Page 390: ... 1 orCN 52 34 CN 133 2 DefectiveEPPR valve Repairorreplace Repairorreplace 15 MALFUNCTION OF BOOM PRIORITY EPPR VALVE Fault code HCESPN 141 FMI 5 or 6 Before carrying out below procedure check all the related connectors are properly inserted INSPECTION PROCEDURE 1 CN 133 1 2 BOOM PRIORITY EPPR VALVE 35 CN 52 34 MCU Cause Remedy YES NO 300L6MS23 ...

Page 391: ...NOID FUSE CN 52 1 MCU 145LCR6MS04 SPEC Starting switch ON 24 2V See TEST 20 SPEC 15 35Ω Check voltage between CN 52 1 GND Check resistance between arm regen solenoid NO YES YES NO YES NO Cause Remedy Defective MCU Short circuit or poor connection between CN 52 1 CN 135 1 Defective solenoid valve Open circuit between CN 135 2 Fuse No 24 Replace Replace or repair Replace Replace or repair Check volt...

Page 392: ...rp pin steel or copper Insert prepared pin to rear side of connectors One pin to 1 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 1 1 2 SPEC Starting switch ON 24 2 V 300L6MS22 ...

Page 393: ...SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test 7 1 Group 2 Major Components 7 21 Group 3 Track and Work Equipment 7 29 ...

Page 394: ...e machine s operational performance deteriorates so that the machine needs to be serviced periodically to restore it to its original performance level Before servicing the machine conduct performance tests to check the extent of deterioration and to decide what kind of service needs to be done by referring to the Service Limits in this manual OPERATIONAL PERFORMANCE OF A REPAIRED MACHINE After the...

Page 395: ...chine components and parts 1 SERVICE LIMIT The lowest acceptable performance level When the performance level of the machine falls below this level the machine must be removed from work and repaired Necessary parts and components must be replaced 2 130ZF7MS02 130ZF7MS03 ...

Page 396: ...ate with each other using these signals and to follow them without fail Operate the machine carefully and always give first priority to safety While testing always take care to avoid accidents due to landslides or contact with high voltage power lines Always confirm that there is sufficient space for full swings Avoid polluting the machine and the ground with leaking oil Use oil pans to catch esca...

Page 397: ...speed with a engine rpm display Measure and record the engine speed at each mode P S E Select the P mode Lightly operate the bucket control lever a few times then return the control lever to neutral The engine will automatically enter the auto idle speed after 4 seconds Measure and record the auto deceleration speed 2 1 2 3 Evaluation The measured speeds should meet the following specifications 4 ...

Page 398: ...d tests adjust the travel mode switch to the speed to be tested then select the following switch positions Power mode switch P mode Start traveling the machine in the acceleration zone with the travel levers at full stroke Measure the time required to travel 20 m After measuring the forward travel speed turn the upperstructure 180 and measure the reverse travel speed Repeat steps and three times i...

Page 399: ... Select the following switch positions Travel mode switch 1 or 2 speed Power mode switch P mode Auto idle switch OFF Operate the travel control lever of the raised track in full forward and reverse Rotate 1 turn then measure time taken for next 3 revolutions Raise the other side of machine and repeat the procedure Repeat steps and three times and calculate the average values Evaluation 90 110 Mark...

Page 400: ...beginning each test select the following switch positions Power mode switch P mode Start traveling the machine in the acceleration zone with the travel levers at full stroke Measure the distance between a straight 20 m line and the track made by the machine Dimension a After measuring the tracking in forward travel turn the upperstructure 180 and measure that in reverse travel Repeat steps and thr...

Page 401: ...e same as the boom foot pin The bucket must be empty Keep the hydraulic oil temperature at 50 5 C Measurement Select the following switch positions Power mode switch P mode Operate swing control lever fully Swing 1 turn and measure time taken to swing next 3 revolutions Repeat steps and three time and calculate the average values Evaluation 6 1 2 3 Unit Seconds 3 revolutions The time required for ...

Page 402: ...erstructure 360 Keep the hydraulic oil temperature at 50 5 C Measurement Conduct this test in the M mode Select the following switch positions Power mode switch P mode Operate the swing control lever fully and return it to the neutral position when the mark on the upperstructure aligns with that on track frame after swinging 360 Measure the distance between the two marks Align the marks again swin...

Page 403: ...he dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race Bucket should be empty Measurement With the arm rolled out and bucket rolled in hold the bottom face of the bucket to the same height of the boom foot pin Record the dial gauge reading h1 Lower the bucket to the ground and use it to raise the front idler 50cm Record the dial gauge reading h2 Ca...

Page 404: ...ycle time of the bucket cylinder The empty bucket should be positioned at midstroke between roll in and roll out so that the sideplate edges are vertical to the ground Keep the hydraulic oil temperature at 50 5 C Measurement Select the following switch positions Power mode switch P mode To measure cylinder cycle times Boom cylinders Measure the time it takes to raise the boom and the time it takes...

Page 405: ...end as quickly as possible Repeat each measurement 3 times and calculate the average values Evaluation The average measured time should meet the following specifications Unit Seconds 4 Model HX130CR HX130LCR Boom raise Boom lower Arm in Arm out Bucket in Bucket out 3 4 0 4 2 3 0 4 2 9 0 3 3 7 0 4 2 4 0 3 4 5 3 3 5 4 4 7 3 1 Remarks Function Standard Maximum allowable Regen ON Regen OFF 2 7 0 4 2 9...

Page 406: ...the fully retracted position Position the bucket cylinder with the rod 20 to 30 mm retracted from the fully extended position With the arm rolled out and bucket rolled in hold the bucket so that the height of the bucket pin is the same as the boom foot pin Keep the hydraulic oil temperature at 50 5 C Measurement Stop the engine Five minutes after the engine has been stopped measure the changes in ...

Page 407: ... each Lower the bucket to the ground to raise one track off the ground Operate the travel lever at full stroke and measure the maximum operating force required When finished lower the track and then jack up the other track Repeat steps and three times and calculate the average values Evaluation 11 1 2 3 The measured operating force should be within the following specifications Model HX130CR HX130L...

Page 408: ...urement Stop the engine Measure each lever stroke at the lever top from neutral to the stroke end using a ruler Repeat step three times and calculate the average values Evaluation 12 1 2 3 The measured drift should be within the following specifications 4 Model HX130CR HX130LCR Kind of lever Boom lever Arm lever Bucket lever Swing lever Travel lever Standard 85 10 85 10 85 10 85 10 139 10 Maximum ...

Page 409: ...ch P mode Auto decel switch OFF Measure the primary pilot pressure by the monitoring menu of the cluster Evaluation 13 1 2 The average measured pressure should meet the following specifications Unit kgf cm2 a3 Coupling Main pump Monitoring analog Cluster 3 Model HX130CR HX130LCR Engine speed P mode Standard 38 Allowable limits Remarks 130ZF7MS12 2 0 ...

Page 410: ...draulic oil temperature at 50 5 C Measurement Select the following switch positions Travel mode switch 1 speed 2 speed Mode selector P mode Measure the travel speed selecting pressure in the Hi or Lo mode Repeat step three times and calculate the average values Evaluation FOR TRAVEL SPEED SELECTING PRESSURE 1 2 The average measured pressure should be within the following specifications Unit kgf cm...

Page 411: ...positions Power mode switch P mode Operate the swing function or arm roll in function and measure the swing brake control pressure with the brake disengaged Release the control lever to return to neutral and measure the control pressure when the brake is applied Repeat step three times and calculate the average values Evaluation 1 2 The average measured pressure should be within the following spec...

Page 412: ...0 5 C Measurement Select the following switch positions Power mode switch P mode Measure the main pump delivery pressure in the P mode high idle Evaluation 16 1 2 The average measured pressure should meet the following specifications Unit kgf cm2 3 130ZF7MS15 Model Engine speed Standard Allowable limits Remarks HX130CR HX130LCR High idle 34 3 ...

Page 413: ... measure the relief pressure In the travel function lock undercarriage with an immovable object and measure the relief pressure Evaluation 1 2 The average measured pressure should be within the following specifications Unit kgf cm2 SYSTEM PRESSURE REGULATOR RELIEF SETTING 17 3 Model HX130CR HX130LCR Function to be tested Boom Arm Bucket Travel Swing Type 1 Type 2 Standard 330 360 10 330 10 260 10 ...

Page 414: ...g section 3 δ 0 0 1 0 3 Replace assembly of piston shoe Thickness of shoe t 3 9 3 7 Free height of cylinder spring 4 L 41 1 40 3 Replace cylinder spring Combined height of set plate 5 H spherical bushing 6 h H h 17 0 15 8 Replace set plate or spherical bushing Surface roughness for valve plate Sliding face 7 8 swash plate shoe plate area 9 cylinder 2 Sliding face Surface roughness necessary to be ...

Page 415: ... section Replacement when its sliding section has scratch Correction or replacement when O ring is damaged or when spool does not move smoothly Poppet Damage of poppet or spring Insert poppet into casing and function it Correction or replacement when sealing is incomplete Normal when it can function lightly without being caught Around spring Rusting corrosion deformation or breaking of spring spri...

Page 416: ...eplace assembly of piston and shoe Thickness of shoe t 6 6 6 5 Replace assembly of piston and shoe Combined height of retainer plate and spherical bushing H h 17 6 17 3 Replace set of retainer plate and sperical bushing Thickness of friction plate 2 94 2 7 Replace Part name Standard roughness Allowable roughness Remark Shoe Rmax 1S Ra 0 2a LAPPING 4S Ra 0 1a Shoe plate Rmax 0 4S Ra 0 1a LAPPING 3S...

Page 417: ... Correct by oilstone or sandpaper Coasts on slope excessively Poor volumetric efficiency of hydraulic motor Increase of internal leakage of brake valve Parking brake not actuated Spring breakage Wear of friction plate Replace hydraulic motor Replace brake valve Replace spring Replace parking brake Excessive temperature on reduction gear case Pitting on bearing Lack of gear oil Hydraulic oil introd...

Page 418: ...eakage Push rod This is to be replaced when the top end has worn more than 1 mm Play at operating section The pin shaft and joint of the operating section are to be replaced when their plays become more than 2 mm due to wears or so on When a play is due to looseness of a tightened section adjust it Operation stability When abnormal noises hunting primary pressure drop etc are generated during oper...

Page 419: ...orn more than 10μm compared with the non sliding surface The leakage at the left condition is estimated to be nearly equal to the above leakage Push rod This is to be replaced when the top end has worn more than 1 mm Play at operating section The pin shaft and joint of the operating section are to be replaced when their plays become more than 2 mm due to wears or so on When a play is due to loosen...

Page 420: ...Worn less than 0 5 mm 0 02 in Damage due to seizure or contamination remediable within wear limit 0 5 mm 0 02 in Extruded excessively from seal groove square ring Slipper ring 1 5 mm 0 059 in narrower than seal groove or narrower than back ring Worn more than 0 5 mm 0 02 in 1 5 mm MAX 0 059 in Sliding surface with sealing sections Sliding surface between body and stem other than sealing section Sl...

Page 421: ...resence of crack Presence of crack Presence of crack Presence of crack Plating is not worn off to base metal Rust is not present on plating Scratches are not present Wear of O D Wear of I D Presence of crack Presence of crack Presence of crack Presence of faults Wear on inner surface Flaw on inner surface Inspecting section Neck of rod pin Weld on rod hub Stepped part to which piston is attached T...

Page 422: ...imit Rebuild or replace Ø190 2 Outside diameter of tread Ø150 Ø138 3 Width of tread 36 5 42 5 4 Width of flange 26 5 5 Clearance between shaft and bushing Standard size tolerance Standard clearance Clearance limit Replace bushing Shaft Hole Ø65 0 25 0 35 0 12 0 075 0 325 to 0 47 2 0 6 Side clearance of roller both side Standard clearance Clearance limit Replace 0 1 to 1 3 2 0 ...

Page 423: ...ge Standard size Repair limit Rebuild or replace Ø175 2 Outside diameter of tread Ø151 Ø141 3 Width of tread 37 25 42 25 4 Width of flange 18 25 5 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole Ø41 27 Ø41 5 0 13 to 0 48 1 2 0 0 05 0 2 0 1 ...

Page 424: ...f protrusion 67 4 Total width 135 5 Width of tread 34 39 6 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole Ø70 Ø70 3 0 3 to 0 38 2 0 7 Clearance between shaft and support Ø70 Ø70 0 03 to 0 1 1 2 Replace 8 Side clearance of idler both side Standard clearance Clearance limit Replace bushing 0 25 to 1 15 2 0 0 0 03 0 05 0 0 0 0...

Page 425: ...andard size Repair limit Turn or replace 171 45 175 65 2 Outside diameter of bushing Ø53 75 Ø43 95 Rebuild or replace 3 Height of grouser 25 16 4 Height of link 94 5 86 5 5 Tightening torque Tightening angle method Initial tightening torque 42 4 kgf m Additional tightening angle 32 Retighten ...

Page 426: ...guide Recoil spring 1 2 3 Track frame Idler support Track frame Idler support Rebuild or replace Replace Standard size Tolerance Repair limit 2 0 0 0 5 2 0 103 100 192 190 107 98 196 188 Standard size Repair limit Free length Ø192 470 Installation length 405 Installation load 8 497kg Free length Installation load 6 978kg 2 1 3 21037MS05 ...

Page 427: ...oom Cylinder Head Boom Cylinder Rod Arm Cylinder Head Boom Front Arm Cylinder Rod Bucket Cylinder Head Arm Link Bucket and Arm Link Bucket Cylinder Rod Bucket Link 70 70 70 65 70 65 65 65 65 65 65 69 69 69 64 69 64 64 64 64 64 64 68 5 68 5 68 5 63 5 68 5 63 5 63 5 63 5 63 5 63 5 63 5 70 5 70 5 70 5 65 5 70 5 65 5 65 5 65 5 65 5 65 5 65 5 71 71 71 66 71 66 66 66 66 66 66 Replace A B C D E F G H I J...

Page 428: ...ng Torque 8 4 Group 3 Pump Device 8 7 Group 4 Main Control Valve 8 32 Group 5 Swing Device 8 46 Group 6 Travel Device 8 99 Group 7 RCV Lever 8 131 Group 8 Turning Joint 8 145 Group 9 Boom Arm and Bucket Cylinder 8 150 Group 10 Undercarriage 8 169 Group 11 Work Equipment 8 181 ...

Page 429: ...ent any mistake when installing Check the number and thickness of the shims and keep in a safe place When raising components be sure to use lifting equipment of ample strength When using forcing screws to remove any components tighten the forcing screws alternately Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal When remov...

Page 430: ... connector to remove all oil dirt or water then connect securely When using eyebolts check that there is no deformation or deterioration and screw them in fully When tightening split flanges tighten uniformly in turn to prevent excessive tightening on one side When operating the hydraulic cylinders for the first time after repairing and reassembling the hydraulic cylinders pumps or other hydraulic...

Page 431: ...een removed and installed again add engine oil to the specified level Run the engine to circulate the oil through the system Then check the oil level again If the piping or hydraulic equipment such as hydraulic cylinders pumps or motors have been removed for repair always bleed the air from the system after reassembling the parts Add the specified amount of grease molybdenum disulphied grease to t...

Page 432: ...6 2 0 35 6 7 1 257 5 1 10 Main control valve mounting bolt M12 1 75 12 2 1 3 88 2 9 4 11 Hydraulic oil tank mounting bolt M20 2 5 57 8 5 8 418 42 0 12 Turning joint mounting bolt nut M14 2 0 19 6 2 9 142 21 0 13 Power train system Swing motor mounting bolt M16 2 0 29 6 3 2 214 23 1 14 Swing bearing upper part mounting bolt M18 2 5 41 3 4 0 299 28 9 15 Swing bearing lower part mounting bolt M16 2 0...

Page 433: ...72 217 294 1570 2126 Bolt size 8 8T 10 9T 12 9T kgf m lbf ft kgf m lbf ft kgf m lbf ft M 6 1 0 0 8 1 2 5 8 8 6 1 2 1 8 8 7 13 0 1 5 2 1 10 9 15 1 M 8 1 25 2 0 3 0 14 5 21 6 2 8 4 2 20 3 30 4 3 4 5 0 24 6 36 1 M10 1 5 4 0 6 0 29 0 43 3 5 6 8 4 40 5 60 8 6 8 10 0 49 2 72 3 M12 1 75 6 8 10 2 50 0 73 7 9 6 14 4 69 5 104 12 3 16 5 89 0 119 M14 2 0 10 9 16 3 78 9 117 16 3 21 9 118 158 19 5 26 3 141 190 ...

Page 434: ... size 1 4 3 8 1 2 3 4 1 1 1 4 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 2 151 9 253 2 Thread size UNF 9 16 18 11 16 16 13 16 16 1 3 16 12 1 7 16 12 1 11 16 12 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 2 151 9 253 2 4 PIPE AND HOSE FLARE TYPE 2 PIPE AND HOSE ORFS TYPE 3 ...

Page 435: ...ightening torque 6 9 1 4 kgf m 49 9 10 1 lbf ft Disconnect pilot line hoses 5 6 7 8 9 10 Tightening torque 12 8 3 0 kgf m 92 6 21 7 lbf ft Remove socket bolts 12 and disconnect pump suction pipe 4 When pump suction tube is disconnect ed the oil inside the piping will flow out so catch it in oil pan Sling the pump assembly and remove the pump mounting socket bolts 13 Weight 90 kg 200 lb Mounting so...

Page 436: ...to the hydraulic tank to the specified level Bleed the air from the hydraulic pump Remove the air vent plug 2EA Tighten plug lightly Start the engine run at low idling and check oil come out from plug Tighten plug Start the engine run at low idling 3 5 minutes to circulate the oil through the system Confirm the hydraulic oil level and check the hydraulic oil leak or not 2 1 2 3 4 5 6 7 8 ...

Page 437: ...spring 211 Shoe plate 212 Swash plate 214 Bushing 251 Support 255 Lock pin 261 Seal cover F 263 Seal cover R 271 Pump casing F 272 Pump casing R 312 Valve block 313 Valve plate R 314 Valve plate L 401 Hexagon socket bolt 402 Hexagon socket bolt 406 Hexagon socket bolt 415 Hexagon socket bolt 466 Plug 467 plug 468 Plug 497 Plug 531 Tilting pin 532 Servo piston 533 Plug 534 Stopper L 535 Stopper S 5...

Page 438: ...ide A2 pump side 130ZF2MP03 04 Gear pump 115 Idler shaft 117 Gear No 2 118 Gear No 3 125 Ball bearing 126 Roller bearing 128 Bearing spacer 262 Cover 326 Gear case 414 Hexagon socket bolt 435 Flange socket bolt 468 Plug 711 O ring 728 O ring 825 Retainer ring 826 Retainer ring 885 Spring pin 886 Pin ...

Page 439: ... M16 M18 10 M12 BP 1 2 PF 1 2 M20 14 M16 M18 BP 3 4 PF 3 4 17 M20 M22 BP 1 PF 1 Hexagon bolt Hexagon nut VP plug PF screw 19 M12 M12 PF 1 4 24 M16 M16 27 M18 M18 PF 1 2 30 M20 M20 41 PF 1 Adjustable angle wrench Medium size 1 set Screw driver Minus type screw driver Medium size 2 sets Hammer Plastic hammer 1 set Pliers For snap ring TSR 160 Steel bar Steel bar of key material approx 10 8 200 Torqu...

Page 440: ...12 M16 24 0 174 0 55 14 M18 34 0 246 0 55 14 M20 44 0 318 0 67 17 PT Plug material S45C Wind a seal tape 1 5 to 2 turns round the plug PT1 16 0 7 5 1 0 16 4 PT 1 8 1 05 7 59 0 20 5 PT 1 4 1 75 12 7 0 24 6 PT 3 8 3 5 25 3 0 31 8 PT 1 2 5 0 36 2 0 39 10 PF Plug material S45C PF 1 4 3 0 21 7 0 24 6 PF 3 8 7 55 54 6 0 31 8 PF 1 2 10 0 72 3 0 39 10 PF 3 4 15 0 109 0 55 14 PF 1 19 0 137 0 67 17 PF 1 1 4...

Page 441: ...tally on workbench with its regulator fitting surface down and remove flange socket 435 and remove PTO unit 05 Be careful about the attaching direction of the PTO unit 05 Before bringing regulator fitting surface down spread rubber sheet on workbench without fail to prevent this surface from being damaged 5 Remove hexagon socket head bolts 412 413 and remove regulator 4 140Z98MP11 140Z98MP12 140Z9...

Page 442: ... fitting surface down and separate pump casing 271 272 from valve block 312 Remove 1st gear 116 when separating pump casing from valve block 312 too 9 Pull out cylinder 141 pistons 151 set screw 153 spherical bush 156 and cylinder springs 157 simultaneously from pump casing 271 272 straightly over drive shaft 111 113 Take care not to damage sliding surface of cylinder 141 spherical bush 156 shoes ...

Page 443: ...age it at removing the cover 11 140Z98MP18 Tapping shaft ends of drive shaft 111 113 lightly with plastic hammer remove it from pump casing 271 272 12 140Z98MP19 Remove shoe plate 211 and swash plate 212 from pump casing 271 272 13 140Z98MP20 Insert thin steel bar into the hole and remove the lock pin 255 from pump casing 271 272 When holding with thin steel bar do not confuse the unlocking hole w...

Page 444: ...m valve block When removing tilting pin use a protector to prevent pin head from being damaged Since lock tight is applied to fitting areas of tilting pin 531 and servo piston 532 take care not to damage servo piston 532 Do not remove needle bearing 124 as far as possible except the case that considered to be out of its life span Do not loosen hexagon nuts of valve block 312 and Qmin plug 533 If l...

Page 445: ...are a torque wrench or so on and tighten them with torques shown in page 8 11 12 For the double pump take care not to mix up parts of the front pump with those of the rear pump 1 4 Insert the lock pin 255 after the swash plate support 251 into the pump casing 271 272 and fit the lock pin 255 into the hole of the swash plate support 251 In case the servo piston tilting pin stopper L stopper S and Q...

Page 446: ... 272 fit drive shaft 111 113 set with bearing 123 bearing spacer 127 and stop ring 824 4 140Z98MP25 In assemble of front pump assemble seal cover F 261 to pump casing 271 and fix it with hexagon socket head bolt 406 Apply grease lightly to oil seal in seal cover F 261 For assemble oil seal 774 taking full care not to damage it 5 140Z98MP26 Assemble piston cylinder subassembly cylinder 141 piston s...

Page 447: ...efore bringing regulator fitting surface down spread rubber sheet on workbench without fail to prevent this surface from being damaged Take care not to mistake direction of valve block 312 Clockwise rotation viewed from input shaft side Fit the valve block 312 with suction flange left when regulator side below viewed from front side 8 140Z98MP29 Fix valve block 312 to pump casing 271 272 with hexa...

Page 448: ...tach the cover 262 with the hexagon socket head cap screw 414 12 140Z98MP33 Putting feedback lever 611 of regulator into feedback pin 548 of tilting pin 531 fit regulator with hexagon socket head bolt 415 Take care not to mix up regulator of front pump and that of rear pump 13 140Z98MP34 Fit drain port plug 468 This is the end of reassembling procedures 14 ...

Page 449: ... 611 A B B A 641 646 438 730 643 708 644 645 728 801 924 SECTION B B 413 497 496 724 437 413 497 496 VIEW C A2 pump VIEW C A1 pump E E SECTION E E 496 724 437 079 753 755 466 755 656 496 753 439 753 418 Pi Pi Pi P1 P1 P2 KR76 9N01 V A1 pump KR76 9N02 V A2 pump A B P1 Pi 130ZF2MP04 ...

Page 450: ...2 614 Center plug 615 Adjust plug 616 Plug 621 Compensator piston 622 Piston case 623 Compensator rod 624 Spring seat C 625 Outer spring 626 Inner spring 627 Adjust stem C 628 Adjust screw C 629 Cover C 630 Lock nut 631 Sleeve Pf 641 Pilot cover 643 Pilot piston 644 Spring seat Q 645 Adjust stem Q 646 Pilot spring 651 Sleeve 652 Spool 653 Spring seat 654 Return spring 655 Set spring 656 Block cove...

Page 451: ... 16 M 8 5 M6 BP 1 8 M10 6 M8 BP 1 4 PO 1 4 M12 M14 Hexagon head bolt Hexagon nut VP plug PF thread 6 M 8 M 8 Adjustable angle wrench Small size Max 36 mm Screw driver Minus type screw driver Medium size 2 sets Hammer Plastic hammer 1 set Pliers For snap ring TSR 160 Steel bar 4 100 mm Torque wrench Capable of tightening with the specified torques Pincers Bolt M4 Length 50 mm B Allen wrench B Doubl...

Page 452: ...0 116 0 47 12 M16 24 0 174 0 55 14 M18 34 0 246 0 55 14 M20 44 0 318 0 67 17 PT Plug material S45C Wind a seal tape 1 1 2 to 2 turns round the plug PT1 16 0 7 5 1 0 16 4 PT 1 8 1 05 7 59 0 20 5 PT 1 4 1 75 12 7 0 24 6 PT 3 8 3 5 25 3 0 31 8 PT 1 2 5 0 36 2 0 39 10 PF Plug material S35C PF 1 4 3 0 21 7 0 24 6 PF 1 2 10 0 72 3 0 39 10 PF 3 4 15 0 109 0 55 14 PF 1 19 0 137 0 67 17 PF 1 1 4 27 0 195 0...

Page 453: ...lean place Spread rubber sheet cloth or so on on top of work bench to prevent parts from being damaged Remove dust rust etc from surfaces of regulator with clean oil 1 2 3 Remove hexagon socket head screw 438 and remove cover C 629 Cover C is fitted with adjusting screw C 628 adjusting ring C 627 lock nut 630 hexagon nut 801 and adjusting screw 924 Do not loosen these screws and nuts If they are l...

Page 454: ... spring 654 may pop out Take care not to lose it 7 Remove hexagon socket head screws 436 438 and remove pilot cover 641 After removing pilot cover take out set spring 655 from pilot section 6 After removing cover C 629 subassembly take out outer spring 625 inner spring 626 and spring seat C 624 from compensating section Then draw out adjusting ring Q 645 pilot spring 646 and spring seat 644 from p...

Page 455: ... Push out pin 874 4 mm in dia from above with slender steel bar so that it may not interfere with lever 1 612 10 Remove lever 2 613 Do not draw out pin 875 Work will be promoted by using pincers or so on 9 210 7 REG07 210 7 REG08 210 7 REG09 210 7 REG10 ...

Page 456: ...ut pilot piston 643 and spool 652 D r a w o u t p i s t o n c a s e 6 2 2 compensating piston 621 and compensating rod 623 Piston case 622 can be taken out by pushing compensating rod 623 at opposite side of piston case This completes disassembly 11 12 13 ...

Page 457: ...olts plugs etc to their specified torques Do not fail to coat sliding surfaces with clean hydraulic oil before assembly Replace seals such as O ring with new ones as a rule 1 4 Spool Feedback lever Put compensating rod 623 into compensating hole of casing 601 Put pin force fitted in lever 1 612 into groove of compensating rod and fit lever 1 to pin force fitted in casing 2 3 Fit spool 652 and slee...

Page 458: ...r fulcrum plug and adjusting plug At this point in time move feedback lever to confirm that it has no large play and is free from binding 8 9 Put pilot piston 643 into pilot hole of casing Confirm that pilot piston slides smoothly without binding Put pin force fitted in lever 2 613 into groove of pilot piston Then fix lever 2 6 7 Fit feedback lever 611 matching its pin hole with pin hole in spool ...

Page 459: ...t spring 646 and adjusting ring Q 645 into pilot hole Then fix spring seat 624 inner spring 626 and outer spring 625 into compensating hole When fitting spring seat take care not to mistake direction of spring seat 12 Fit set spring 655 to spool hole and put compensating piston 621 and piston case 622 into compensating hole Fit pilot cover 641 and tighten it with hexagonal socket head screws 437 4...

Page 460: ...bly and remove the control valve mounting bolt and bracket Weight 80 kg 175 lb Mounting bolt Tightening torque 12 2 1 3 kgf m 88 2 9 4 lbf ft Remove the control valve assembly When removing the control valve assembly check that all the piping have been disconnected INSTALL Carry out installation in the reverse order to removal Bleed the air from below items Cylinder Boom arm bucket Swing motor Tra...

Page 461: ...travel LH 7 Spool assy boom 1 10 Spool assy arm 2 12 Spool assy arm regen 14 Spool assy bucket 20 Nega con relief valve 22 Bucket stroke limiter 24 Holding valve kit A1 26 Lock valve kit B 27 Regeneration block 33 Plug 41 Orifice 42 Plug 45 Poppet 48 Orifice 49 Coin type filter 50 Pilot A cap 51 Pilot B1 cap 53 Socket head bolt 56 Plain washer 58 O ring 59 O ring 69 O ring 81 Spring 82 Pin ...

Page 462: ... 79 28 72 59 HOUSING P1 REAR FRONT RH LH 62 31 16 Main relief valve 17 Overload relief valve 28 Plug 29 Plug 31 Plug 32 Plug 35 Plug 38 Plug 39 Plug 42 Plug 43 Poppet 1 44 Poppet 2 59 O ring 61 O ring 62 O ring 63 O ring 66 O ring 67 O ring 71 O ring 72 O ring 74 Back up ring 75 Back up ring 76 Back up ring 79 Spring 80 Spring 125LCR8MC05 ...

Page 463: ...Spool assy travel RH 6 Spool assy swing 8 Spool assy swing priority 9 Spool assy boom 2 11 Spool assy arm 1 13 Spool assy option B 15 Spool assy option C 25 Holding valve kit A2 26 Lock valve kit B 29 Plug 30 Plug 40 Plug 46 Sleeve 47 Piston 50 Pilot A cap 51 Pilot B1 cap 52 Pilot B2 cap 53 Socket head bolt 54 Socket head bolt 55 Socket head bolt 56 Plain washer 57 Spring washer 59 O ring 61 O rin...

Page 464: ...H LH 36 73 64 78 73 36 64 78 17 Overload relief valve 18 Overload relief valve 21 Swing logic valve 23 ON OFF valve option 28 Plug 29 Plug 31 Plug 32 Plug 34 Plug 36 Plug 37 Plug 43 Poppet 1 44 Poppet 48 Orifice 49 Coin type filter 60 O ring 62 O ring 63 O ring 64 O ring 65 O ring 67 O ring 68 O ring 72 O ring 73 O ring 77 Back up ring 78 Back up ring 79 Spring 80 Spring 130ZF8MC07 ...

Page 465: ...rrying or transferring the control valve Do not lift by the exposed spool end cover section etc After disassembling and assembling of the component it is desired to carry out various tests for the relief characteristics leakage flow resistance etc but hydraulic test equipment is necessary for these tests Therefore even when its disassembling can be carried out technically do not disassemble such c...

Page 466: ... spool assembly from the body by hand slightly When extracting each spool from its body pay attention not to damage the body When extracting each spool assembly it must be extracted from spring side only When any abnormal parts are found replace it with completely new spool assembly When disassembled tag the components for identification so that they can be reassembled correctly 3 1 Socket head bo...

Page 467: ... pilot cover Remove the spool assembly from the body by hand slightly When extracting each spool from its body pay attention not to damage the body When extracting each spool assembly it must be extracted from spring side only When any abnormal parts are found replace it with completely new spool assembly When disassembled tag the components for identification so that they can be reassembled corre...

Page 468: ...t disassembled internal parts of the pilot cover Loosen the poppet seat and remove the poppet spring seat spring and check spanner 26 mm Pay attention not to lose the poppet Do not disassembled internal parts of the check 3 Boom 1 spool Socket head bolt Pilot cover Poppet Poppet seat Check Spring Spring seat 125LCR8MC12 ...

Page 469: ... body Loosen the plug hexagon wrench 10 mm Remove the spring and the load check valve with pincers or magnet The negative relief valve Loosen the socket spanner 32 mm Remove the spring spring holder piston and negative control poppet 4 Spring Plug Load check valve Negative control poppet Piston Coin type filter Spring holder Spring Socket a b c a b 14W98MC13 ...

Page 470: ... work bench Remove the main relief valve spanner 32 mm Remove the overload relief valve spanner 32 mm When disassembled tag the relief valve for identification so that they can be reassembled correctly Pay attention not to damage seat face When any abnormal parts are found replace it with completely new relief valve assembly 5 14098MC14 ...

Page 471: ...ce it with new one When a relief valve does not function properly repair it following it s the prescribed disassembly and assembly procedures Replace all seals and O rings with new ones Relief valve Confirm that all seat faces at ends of all poppets and seats are free of defects and show uniform and consistent contact faces Confirm manually that main poppet and seat can slide lightly and smoothly ...

Page 472: ...tive tightening torque Do not reuse removed O rings and seals Load check valve Assemble the load check valve and spring Put O rings on to plug Tighten plug to the specified torque Hexagon wrench 10 mm Tightening torque 6 7 kgf m 43 4 50 6 lbf ft Negative control relief valve Assemble the nega con poppet piston spring holder and spring together into body Put O ring on to plug and tighten the latter...

Page 473: ...t head bolts to the specified torque Hexagon wrench 5mm Tightening torque 1 0 1 1 kgf m 7 2 7 9 lbf ft Confirm that O rings have been fitted Holding valves Assemble the check spring seat and poppet together into body Tighten the poppet seat to the specified torque Spanner 26 mm Tightening torque 6 7 kgf m 43 4 50 6 lbf ft Fit the piston A under pilot cover with internal parts into hole on the popp...

Page 474: ... Sling the swing motor assembly 1 and remove the swing motor mounting socket bolts 9 Motor device weight 34 kg 75 lb Tightening torque 17 5 1 8 kgf m 127 13 0 lbf ft Remove the swing motor assembly When removing the swing motor assem bly check that all the piping have been disconnected INSTALL Carry out installation in the reverse order to removal Bleed the air from the swing motor Remove the air ...

Page 475: ...ller bearing 7 Swash plate 8 Cylinder block 9 Spring 10 Ball guide 11 Retainer plate 12 Piston assy 13 Friction plate 14 Separate plate 15 Parking piston 16 Spring 17 Spring pin 18 O ring 19 O ring 20 Valve plate 21 Spring pin 22 Valve casing 23 Check valve 24 Spring 25 Plug 26 O ring 27 Plug 28 O ring 29 Plug 30 O ring 31 Relief valve assy 32 Anti rotating valve assy 33 Plug 34 O ring 35 O ring 3...

Page 476: ...of shaft 3 facing downwards Lay rubber plate on worktable and take care not to damage the components Disassemble two sets of relief valve assembly 31 using 36 mm socket wrench 1 4 Disassemble level gauge assembly 37 using pipe wrench 3 Remove snap ring 4 using snap ring plier 2 2 ...

Page 477: ... using 10 mm hexagon wrench and take out anti rotating valve assembly 32 same for the set on opposite side 8 Remove O ring 18 from valve casing 7 Remove valve plate 20 from valve casing Take care not to drop the valve plate 20 6 125LCR8SM07 125LCR8SM08 125LCR8SM09 125LCR8SM10 ...

Page 478: ...ve plug 25 using 32 mm socket wrench and separate spring spring 24 and check valve 23 same for the set on opposite side 10 125LCR8SM11 125LCR8SM12 Remove spring 16 24EA from parking piston Disassemble parking piston 15 from casing using air gun 11 12 125LCR8SM15 125LCR8SM16 ...

Page 479: ...d separator plate 14 13 125LCR8SM17 125LCR8SM18 Separate piston assembly 12 ball guide 10 retainer plate 11 and cylinder spring 9 14 125LCR8SM20 125LCR8SM19 Remove O ring 19 from casing Use a magnet to separate swash plate 7 from casing Sliding surface should be carefully treated to avoid scratches and damage 15 16 ...

Page 480: ...2 Disassemble shaft 3 and cylinderical roller bearing 5 Do not remove cylinderical roller bearing 5 unless malfunction is detected since it is mounted by shrink fit 17 Turn casing 1 upside down and remove oil seal 2 using jig 18 ...

Page 481: ... be careful of the following Repair the damaged part when disassemblying and prepare parts for exchange in advance All parts should be cleaned with cleaner dried with compressed air Sliding surface O ring bearing and oil seal should be lubricated with clean hydraulic oil prior to final assembly Replacement of O ring and oil seal with new parts is generally recommended Use a torque wrench to make s...

Page 482: ... Take care not to damage oil seal 3 125LCR8SM26 Insert swash plate 7 Take care not to damage sliding surface 4 125LCR8SM27 125LCR8SM25 After applying grease on O ring 19 insert O ring in casing 1 5 125LCR8SM28 Assemble cylinder spring 9 9EA in cylinder block 8 6 ...

Page 483: ...th other piston 9EA 1set Spread sufficient amount of hydraulic oil on piston assembly 8 Place all 9 pistons simultaneously into the holes of cylinder block Take care not to damage sliding surface 9 Lay casing down horizontally and put cylinder block assembly in casing Check whether cylinder block assembly rotates smoothly 10 125LCR8SM30 125LCR8SM31 125LCR8SM32 125LCR8SM29 ...

Page 484: ...plate alternately 12 Put friction plate 13 in casing 11 Assemble O ring 18 in parking piston 15 Apply grease on O ring 13 Assemble parking piston 15 in casing using jig Pay attention to the hole location of parking piston 14 125LCR8SM33 125LCR8SM34 125LCR8SM35 125LCR8SM36 ...

Page 485: ...mble plug 29 using 4 mm hexagon wrench Tightening torque 3 0 0 3 kgf m 2 2 lbf ft 17 Assemble plug 27 using 6 mm hexagon wrench Tightening torque 4 5 0 45 kgf m 32 5 3 3 lbf ft 16 Assemble anti rotating valve assembly 32 in valve casing 18 125LCR8SM42 125LCR8SM41 125LCR8SM43 ...

Page 486: ...01 7 2 lbf ft 19 Assemble spring 24 plug 25 in that order same for the set on opposite side Tightening torque 25 2 5 kgf m 181 18 1 lbf ft 21 Caulk check valve 23 using jig same for the set on opposite side 20 Assemble spring pin 21 in valve casing using jig 22 125LCR8SM46 125LCR8SM47 125LCR8SM45 ...

Page 487: ... When tightening bolts make sure mating surfaces between casing and valve casing maintain parallel to each other 25 Apply grease on steel side of valve plate 20 to prevent plate from sliding Assemble valve plate with the copper side facing upwards Pay attention to the assembly direction Take care not to damage sliding surface 24 Assemble relief valve assembly 31 using 36 mm socket wrench in valve ...

Page 488: ...8 60 125LCR8SM52 Assemble snap ring 4 in shaft by using snap ring plier 27 Wrap teflon tape 2 or 3 times around the tap part of level gauge assembly 37 And assemble it using pipe wrench 28 125LCR8SM53 ...

Page 489: ... motor assembly Sling reduction gear assembly 1 and remove dowel pin 3 and mounting bolts 2 Remove the reduction gear assembly Reduction gear device weight 75 kg 165 lb INSTALL Carry out installation in the reverse order to removal Tightening torque 29 6 3 2 kgf m 214 23 1 lbf ft 3 1 2 1 2 3 1 2 1 13031GE18 130ZF8SM03 ...

Page 490: ...r No 2 12 Needle bearing No 2 13 Thrust washer No 2 14 Carrier pin No 2 15 Spring pin 16 Sun gear No 2 17 Carrier No 1 18 Planetary gear No 1 19 Needle bearing No 1 20 Thrust washer No 1 21 Carrier pin No 1 22 Sun gear No 1 23 Snap ring 24 Thrust plate 25 Sleeve 26 O ring 27 Oil seal 30 Plug 31 Parallel pin 32 Thrust washer No 1 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 ...

Page 491: ...ing motor and then place swing reduction gear on the bench 1 2 2 Disassemble carrier No 1 sub assembly 3 Carrier No 1 sub assy disassembly Put carrier No 1 sub assembly on the bench then remove the snap ring 23 4 125LCR8SM60 125LCR8SM61 125LCR8SM62 125LCR8SM63 ...

Page 492: ...sassemble thrust washer No 1 upper 32 3 pcs 5 Disassemble planetary gear No 1 18 3 pcs 6 Disassemble thrust plate 24 7 125LCR8SM64 125LCR8SM65 125LCR8SM66 125LCR8SM67 Disassemble needle bearing No 1 19 3 pcs 8 ...

Page 493: ... placing spring pin 15 to center of carrier pin No 1 21 with a jig disassemble it 3 pcs Do not reuse spring pin carrier and carrier pin 10 Disassemble carrier No 2 sub assembly 12 Disassemble sun gear No 2 16 11 125LCR8SM68 125LCR8SM69 125LCR8SM70 125LCR8SM71 ...

Page 494: ...assy disassembly After placing spring pin 15 to center of carrier pin No 2 14 with a press machine disassemble it 3 pcs Do not reuse spring pin 13 Disassemble planetary gear No 2 3 pcs 14 Disassemble thrust plate 24 15 125LCR8SM72 125LCR8SM73 125LCR8SM74 125LCR8SM75 ...

Page 495: ...76 125LCR8SM77 125LCR8SM78 125LCR8SM79 Disassemble ring nut 5 by using the jig 20 Disassemble needle bearing No 2 12 3 pcs 17 Separate ring gear 1 from casing 8 18 Loosen bolt 7 4 pcs and disassemble lock plate 6 19 ...

Page 496: ... by using the jig 24 Drive shaft sub assy disassembly Separate drive shaft sub assembly from casing 8 21 Disassemble taper roller bearing 3 and oil seal 27 by using a press machine 22 Disassemble sleeve 25 and O ring 26 23 125LCR8SM80 125LCR8SM81 125LCR8SM82 125LCR8SM83 ...

Page 497: ...l of the following Repair the damaged part when disassemblying and prepare parts for exchange in advance All parts should be cleaned with cleaner dried with compressed air Sliding surface O ring bearing and oil seal should be lubricated with clean hydraulic oil prior to final assembly Replacement of O ring and oil seal with new parts is generally recommended Use a torque wrench to make sure that a...

Page 498: ...led spring pin unit To cover pins implement the caulking in two places that are located direction of 180 degrees around assembled spring pin Assemble needle bearing No 1 19 3 pcs 3 5 Assemble thrust washer No 1 lower 20 3 pcs Assemble thrust plate 24 4 6 Caulking two places 1 0 2 0 0 5 Pin ...

Page 499: ... of which groove is faced downward 3 pcs Assemble snap ring 23 3 pcs complete carrier No 1 sub assembly Gear rotation state should be smooth 7 9 Assemble thrust washer No 1 upper 32 3 pcs 8 Carrier No 2 sub assy assembly Assemble needle bearing No 2 12 in the planetary gear No 2 11 10 ...

Page 500: ...ower side of planetary gear No 2 Assemble planetary gear No 2 in the carrier No 2 10 3 pcs Thrust washer No 2 should notseparated 11 13 Assemble thrust plate 24 Assemble carrier pin No 2 14 to match the pin hole of the carrier No 2 3 pcs 12 14 125LCR8SM94 125LCR8SM95 125LCR8SM96 125LCR8SM97 ...

Page 501: ...7 Caulking is performed on the assembled spring pin unit To cover pins implement the caulking in two places that are located direction of 180 degrees around assembled spring pin Shrink fit the sleeve on drive shaft 2 Be careful of fully seat at the bottom 16 18 125LCR8SM98 125LCR8SM99 125LCR8SM100 125LCR8SM101 Caulking two places 1 0 2 0 0 5 Pin ...

Page 502: ...0 Shrink fit taper roller bearing 3 on drive shaft complete drive shaft sub assembly Press in oil seal 27 by using the jig Be careful of the direction of the assembly Assemble drive shaft sub assembly Be careful of damage of oil seal 19 21 22 125LCR8SM102 125LCR8SM103 125LCR8SM104 125LCR8SM105 ...

Page 503: ...ring 4 23 Place lock plate 6 on the ring nut 25 Assemble ring nut 5 by using the jig Tightening torque 3 5 0 4 kgf m 25 3 2 9 lbf ft After spreading loctite 242 assemble the bolt 7 4 pcs Tightening torque 2 5 0 25 kgf m 18 1 1 8 lbf ft 24 26 125LCR8SM106 125LCR8SM107 125LCR8SM108 125LCR8SM109 ...

Page 504: ...h a pin hole on casing Be careful of damage of the ring gear 29 Spread the loctite 515 on the casing with reference to the right detail view Loctite should not flow into casing Assemble carrier No 2 sub assembly 28 30 125LCR8SM110 125LCR8SM111 125LCR8SM112 125LCR8SM113 Loctite 515 Detail view ...

Page 505: ... sun gear No 2 16 31 Assemble sun gear No 1 22 of which grinding surface is faced downward 33 Assemble carrier No 1 sub assembly Fill with gear oil 3 5 liter 32 34 125LCR8SM114 125LCR8SM115 125LCR8SM116 125LCR8SM117 ...

Page 506: ...ses 3 4 5 6 7 8 Sling the swing motor assembly 1 and remove the swing motor mounting socket bolts 9 Motor device weight 32kg 71lb Tightening torque 23 5 4 0 kgf m 170 28 9 lbf ft Remove the swing motor assembly When removing the swing motor assem bly check that all the piping have been disconnected INSTALL Carry out installation in the reverse order to removal Bleed the air from the swing motor Re...

Page 507: ... 18 O ring 19 Brake spring 20 Rear cover 21 Needle bearing 22 Pin 23 Valve plate 24 Wrench bolt 25 Plug 26 Back up ring 27 O ring 28 Spring 29 Check 30 Relief valve 31 Anti rotating valve 32 Time delay valve 33 Wrench bolt 34 Plug 35 O ring 36 Plug 37 Plug 38 Level gauge 39 Name plate 41 Plug 42 O ring 43 O ring 44 Back up ring 45 Plug 45 2 3 4 1 18 8 13 12 15 14 17 21 23 20 40 39 24 6 5 16 11 10 ...

Page 508: ... motor mask all the ports of the motor with tapes Remove the valve 32 1 4 Fix the drive shaft 5 on the workbench with the end of output shaft down Put matching marks on body 1 and valve rear cover 20 for easy reassembly 3 Loosen the drain plug to discharge oil in the body 1 2 2 32038SM01 32038SM02 32038SM03 32038SM04 ...

Page 509: ...ring 19 from brake piston 16 8 Remove rear cover 20 from body 1 Then remove the valve plate 23 from rear cover 20 with care 7 Remove plug 25 from rear cover 20 and spring 28 check 29 Be careful not to damage the check seat assembly 6 32038SM05 32038SM06 32038SM07 32038SM08 ...

Page 510: ...ive shaft 5 from body 1 12 Remove friction plate 14 and separate plate 15 from body 1 11 Remove the cylinder 9 from the drive shaft 5 with the motor positioned horizontally Remove ball guide 11 set plate 12 piston 13 and shoe plate 8 10 32038SM09 32038SM10 32038SM11 11078SM23 ...

Page 511: ... Remove the cone of roller bearing 3 by press Do not reuse bearings Remove bushing 6 and oil seal 2 from body 1 13 14 32038SM15 25038SM05 Remove the needle bearing 21 from the rear cover 20 by using slide hammer bearing puller 32038SM17 15 ...

Page 512: ... 7 8 12 1 4 2 5 6 9 3 When disassembling the relief valve release the adjusting screw 5 Remove the piston 6 spring seat 8 spring 4 and plunger 3 with the body 1 downwards This completes disassembly 14007A2SM05 16 ...

Page 513: ...bond of white color on outer surface of oil seal 2 and insert it to the body 1 1 3 Install the roller bearing 3 to the drive shaft 5 2 Insert the drive shaft 5 into the body 1 with the plastic hammer lightly 3 11078SM22 11078SM21 11078SM24 Install the snap ring 4 to the body 1 4 11078SM25 ...

Page 514: ...ith the body 1 position horizontally 5 32038SM28 Insert the ball guide 11 into the cylinder 9 6 32038SM29 Install the piston sub assembly 13 to the set plate 12 7 32038SM30 Reassemble the piston assembly 9 to the body 1 8 32038SM31 ...

Page 515: ...n plate 14 and separate plate 15 to the body 1 9 11078SM26 Reassemble brake spring 19 to the brake piston 16 12 Reassemble brake piston 16 to the body 1 11 Insert O ring 17 inside the body 1 10 32038SM33 32038SM34 32038SM35 ...

Page 516: ...36 Insert check 29 and spring 28 in the valve casing and install O ring 27 and back up ring 26 Tighten plug 25 to the rear cover 20 16 Connect the rear cover 20 with the body 1 and tighten the wrench bolt 24 15 Reassemble valve plate 23 to the rear cover 20 and reassemble O ring 18 14 32038SM37 32038SM38 32038SM39 ...

Page 517: ...8 89 Insert O rings to the relief valve 30 and reassemble them to rear cover 20 This completes assembly 17 32038SM42 ...

Page 518: ... motor assembly Sling reduction gear assembly 1 and remove dowel pin 3 and mounting bolts 2 Remove the reduction gear assembly Reduction gear device weight 60 kg 132 lb INSTALL Carry out installation in the reverse order to removal Tightening torque 29 6 3 2 kgf m 214 23 1 lbf ft 3 1 2 1 2 3 1 2 1 13031GE18 130ZF8SM23 ...

Page 519: ... 13 No 2 bushing 14 No 2 sun gear 15 No 1 carrier assy 16 No 1 carrier 17 No 1 planet gear 18 No 1 pin assy 19 No 1 pin 20 No 1 bushing 21 Thrust washer 22 Spring pin 23 Stop ring 24 No 1 sun gear 25 Stop ring 26 Side plate No 1 27 Ring gear 28 Knock pin 29 Hexagonal bolt 30 Socket bolt 31 Plug 32 Plug 22 11 8 14 16 17 18 15 VIEW A 2 4 3 29 5 1 32 31 25 21 12 13 10 27 30 26 7 6 9 24 19 20 23 21 22...

Page 520: ...gauge 38 from the swing motor casing Pour the gear oil out of reduction gear into the clean bowl to check out the friction decrease 1 2 2 Remove sun gear 1 24 3 24 Tighten two M10 eye bolts to carrier 1 assy 15 and lift up and remove carrier 1 15 as subassembly 15 4 14W98SM05 130ZF8sm06 130ZF8sm07 130ZF8sm08 ...

Page 521: ... be removed by hammering Remove thrust washer 21 Do not reuse spring pin 22 Do not remove pin 1 19 carrier 1 16 and spring pin 22 but in case of replacement Put matching marks on the planet gear 1 17 and the pin 1 19 for easy reassembly 5 Remove sun gear 2 14 and side plate 1 26 from carrier 2 assy 8 14 26 8 6 Remove carrier 2 assembly 8 from casing 1 8 1 7 130ZF8sm10 14W98SM11 130ZF8sm09 ...

Page 522: ...emove pin 2 12 planet gear 2 10 and thrust washer 21 from the carrier 2 9 Put matching marks on the planet gear 2 10 and the pin 2 22 for easy reassembly Do not disassemble pin 2 12 carrier 2 9 and spring pin 22 but in case of replacement 8 9 Remove stop ring 25 from the drive shaft 2 25 2 10 Remove drive shaft 2 with roller bearing 6 and oil seal 7 assembled Remove knock pin 28 from the casing 1 ...

Page 523: ...6 and oil seal 7 from the drive shaft 2 Do not reuse oil seal 7 once removed 2 7 6 12 Using the bearing disassembly tool remove roller bearing 5 13 Remove plugs 31 32 from the casing 1 1 31 32 32 14 14W98SM16 14W98SM17 130ZF8sm18 ...

Page 524: ...al 7 and roller bearing 6 1 2 7 6 1 3 2 Install stop ring 25 on top of drive shaft 2 25 2 3 Apply loctite to the tapped holes of casing 1 Tighten 2 M16 eye bolts to the ring gear 27 and lift up and then assemble it onto the casing 1 Don t fail to coincide the knock pin 28 holes 27 1 4 5 14W98SM17 14W98SM19 130ZF8sm14 130ZF8sm13 ...

Page 525: ...ble carrier 2 assembly 8 correctly to the casing 1 8 1 7 Assemble sun gear 2 14 and side plate 1 26 to the center of the carrier 2 assembly 8 14 26 8 8 23 21 19 17 22 16 Assembling carrier 1 assembly 12 Assemble the pin1 19 to the carrier 1 16 and then press the spring pin 22 by hammering Punch 2 points of the spring pin s 22 lip Assemble thrust washer 21 planet gear 1 17 and then stop ring 23 to ...

Page 526: ...duction gear 24 28 11 12 30 Apply loctite to the tapped holes of the ring gear 27 and then mount swing motor onto the ring gear 27 Don t fail to coincide the gauge bar hole Tighten socket bolts 30 around the swing motor assembly Tightening torque 13 5 kgf m 98 lbf ft 31 32 32 38 13 14 Assemble plugs 31 32 and level gauge 38 15 130ZF8sm20 130ZF8sm26 130ZF8sm06 130ZF8sm27 ...

Page 527: ...er Remove the hose Fit blind plugs to the disconnected hoses Remove the bolts and the sprocket Tightening torque 29 7 3 0 kgf m 215 21 7 lbf ft Sling travel device assembly 1 Remove the mounting bolts 2 then remove the travel device assembly Weight 140 kg 310 lb Tightening torque 23 2 5 kgf m 166 18 1 lbf ft DR VB VA 2 PS 1 1 1 2 3 4 5 6 7 8 9 13031GE18 125LCR9A8TM01 GROUP 6 TRAVEL DEVICE INSTALL ...

Page 528: ... spool assy 32 Cover 33 Spring 34 Restrictor 35 Spring 36 O ring 37 Spring seat 38 Relief valve assy 39 O ring 40 Spool 41 Plug 42 Spring seat 43 Parallel pin 44 Spring 45 Connector 46 O ring 47 Hexagon socket head bolt 48 Hexagon socket head bolt 49 Hexagon socket head bolt 50 Check valve 51 Spring 52 Plug 53 O ring 54 Plug 55 Restrictor 56 Restrictor 57 Name plate 58 Rivet 59 Ring gear 60 Bearin...

Page 529: ...y the rubber plate on worktable and take care not to damage the component Disassemble parallel pin 43 and spring 44 Do not lose spring Do not mix spring with other springs 1 4 Remove plug 41 using 21 mm socket wrench 3 Remove the connector 45 using 21 mm socket wrench 2 2 125LCR8TM03 125LCR8TM02 125LCR8TM04 125LCR8TM05 ...

Page 530: ...d spool 40 5 Disassemble spring seat 37 and spring 33 2 sets 8 Disassemble cover 32 using 41 mm socket wrench 7 Disassemble relief valve assembly 38 using 26 mm socket wrench 2 sets 6 125LCR8TM07 125LCR8TM08 125LCR8TM09 125LCR8TM06 ...

Page 531: ...10 Separate main spool assembly 31 from rear cover 9 Unscrew socket bolt 47 1EA 48 3EA 49 6EA from rear cover Remove parallel pin 29 From rear cover disassemble valve plate 24 and O ring 27 Take care not to damage assembly surface of rear cover 10 11 12 ...

Page 532: ... restrictor and its hole to avoid confusing 55 and 56 Remove plug 52 Remove restrictor 34 and spring 35 2 sets Do not confuse restrictor 34 and check valve 50 Do not confuse spring 35 and spring 51 Do not lose spring Do not mix spring with other springs Remove plug 52 using 5 mm hexagon wrench 13 14 15 16 ...

Page 533: ... check valve 50 Do not confuse spring 35 and spring 51 Do not lose spring Do not mix spring with other springs From parking piston remove spring 26 12ea Do not lose spring Do not mix spring with other springs Disassemble parking piston 19 using air gun or jig From parking piston separate O ring 22 and back up ring 23 17 18 19 20 ...

Page 534: ...g down horizontally and remove cylinder block assembly friction plate 17 3EA and separator plate 18 4EA Separate retainer plate 15 and piston assembly 16 Take care not to damage sliding surface of each component Disassemble ball guide 14 and spring 13 9EA Do not lose spring Do not mix spring with other springs 21 22 23 24 ...

Page 535: ...and pivot 10 Take care not to damage sliding surface Disassemble shaft 6 and ball bearing 7 Do not remove ball bearing unless malfunction is detected since it is mounted by shrink fit Disassemble 1 2 speed piston 4 and steel ball 9 using air gun Disassemble piston seal 5 25 26 27 28 ...

Page 536: ...8 108 125LCR8TM30 Turn casing 1 upside down and remove oil seal 3 using jig 29 ...

Page 537: ...amaged part when disassemblying and prepare parts for exchange in advance All parts should be cleaned with cleaner dried with compressed air Sliding surface O ring bearing and oil seal should be lubricated with clean hydraulic oil prior to final assembly Replacement of O ring and oil sealwith new parts is generally recommended Use a torque wrench to make sure that assembly fasteners are tightened ...

Page 538: ...haft 6 by shrink fit Insert shaft in casing Take care not to damage oil seal 3 5 After assembling piston seal 5 and steel ball 9 in 1 2 speed piston 4 insert piston in hole of casing Check whether piston sticks in hole Use piston seal jig Assemble swash plate 11 by matching its hole and steel ball Take care not to damage sliding surface 4 6 ...

Page 539: ...raulic oil on piston assembly Take care not to damage each component Check cylinder block and piston assembly runs properly Lay casing down horizontally and assemble cylinder block assembly by matching its spline with shaft Make sure swash plate stays in place Check the assembling status of cylinder block by pressing it 7 8 9 125LCR8TM40 Assemble separator plate 18 4EA and friction plate 17 3EA al...

Page 540: ... ring in parking piston Insert spring 26 12EA in parking piston Align the pin hole of parking piston 19 with oil hole of casing assemble them using jig Spread grease on O ring and back up ring Take care not to damage components Insert parallel pin 29 2EA in casing 11 13 12 14 ...

Page 541: ...ictor 34 Do not confuse spring 51 and spring 35 Assemble restrictor 34 and spring 35 in order Do not confuse check valve 50 and restrictor 34 Do not confuse spring 51 and spring 35 Clamp plug 52 using 5 mm hexagon wrench Tightening torque 3 0 0 3 kgf m 21 7 2 2 lbf ft Clamp plug 52 Tightening torque 3 0 0 3 kgf m 21 7 2 2 lbf ft 15 17 16 18 ...

Page 542: ... and 56 in rear cover Check whether the restrictor is placed in exact hole Do not confuse 55 and 56 Clamp plug 54 Tightening torque 4 5 0 5 kgf m 32 5 3 6 lbf ft Insert spring pin 25 2ea and 28 in rear cover using jig Assemble ball bearing 8 in rear cover using jig 20 19 22 21 ...

Page 543: ...age sliding surface Pay attention to the assembly direction Assemble O ring 27 in rear cover Spread grease on O ring Put rear cover upon casing paying attention to the location of pin and hole And tighten bolt 47 48 and 49 Tightening torque 17 5 1 8 kgf m 127 13 0 lbf ft Make sure valve plate stays in place Check bolt position Assemble main spool assembly 31 spring seat 37 and spring 33 in rear co...

Page 544: ...LCR8TM59 125LCR8TM58 125LCR8TM60 Insert relief valve 38 in rear cover Tightening torque 15 1 8 kgf m 108 13 0 lbf ft After clamping connector 45 to rear cover assemble spool 40 Tightening torque 5 5 0 5 kgf m 39 8 3 6 lbf ft After inserting parallel pin 43 assemble seat spring 42 28 29 30 ...

Page 545: ...8 117 125LCR8TM61 After assembling spring 44 in order clamp plug 41 Tightening torque 5 5 0 5 kgf m 39 8 3 6 lbf ft 31 ...

Page 546: ...s tilted to one side disassemble PF3 8 plug 82 remove gear oil and place motor sideto the bench Disassemble cover 80 by unscrewing the M10 bolts 81 12 pcs Disassemble sun gear No 1 78 Disassemble carrier No 1 assembly 1 2 3 4 125LCR8TM70 125LCR8TM72 125LCR8TM71 125LCR8TM73 ...

Page 547: ...arrier assembly 3 pcs Disassemble thrust plate No 1 75 from the carrier assembly Disassemble planetary gear No 1 72 3 pcs Disassemble needle bearing 73 3 pcs Do not disassemble inner race in the absence of abnormalities 5 6 7 8 125LCR8TM74 125LCR8TM76 125LCR8TM75 125LCR8TM77 ...

Page 548: ... 120 125LCR8TM78 125LCR8TM80 125LCR8TM79 125LCR8TM81 Disassemble Sun gear No 2 70 9 Disassemble M10 bolt 64 4 pcs Disassemble thrust washer No 2 65 4 pcs Disassemble planetary gear No 2 66 4 pcs 10 11 12 ...

Page 549: ...5LCR8TM85 Disassemble needle bearing No 2 67 4 pcs Disassemble thrust plate No 2 69 4 pcs Do not disassemble inner race in the absence of abnormalities Disassemble lock plate 63 Disassemble M10 bolt 89 plain washer 88 and M8 screw 77 13 14 16 15 ...

Page 550: ...62 by using the jig Disassemble ring gear assembly 59 from motor assembly Disassemble bearing 60 2ea from ring gear assembly Do not disassemble bearing in the absence of abnormalities Disassemble folating seal assembly 61 from ring gear assembly and motor assembly 17 18 20 19 ...

Page 551: ... and oil seal should be lubricated with clean hydraulic oil prior to final assembly Replacement of O ring and oil seal with new parts is generally recommended Use a torque wrench to make sure that assembly fasteners are tightened to specified values When assembling bolt spread loctite 4 Put carrier No 1 71 on the jig and shrink fit inner race No 1 74 to carrier pin 3 places Do not tilt inner race ...

Page 552: ...ard 3 places After spreading loctite 242 assemble the M8 bolt 76 3 pcs Tightening torque 2 7 0 3 kgf m After the assembly instantly check the noise and interference by rotatong the gear Assemble thrust plate No 1 75 First place bearing 60 on the ring gear 59 then put jig on it then press it with press machine 3 5 4 6 ...

Page 553: ...le bearing the same way Be care of nick and safety when turn ring gear over Place folating seal assembly on the motor assem bly then assemble it After assembling wipe steel lined section with alcohol Flatness deviation has to be less than 1 mm 8 7 9 After arriving safely ring gear assembly in the motor assembly press it with press machine After press fitting clamp ring gear to fixit When using the...

Page 554: ...ate 11 12 Place lock plate th the direction which nut ring is loosed and then assemble M10 bolt 89 with M8 screw 77 after spreading loctite 242 Refer to assembly detail drawing Tightening torque M10 5 5 0 6 kgf m 39 8 4 3 lbf ft Tightening torque M8 2 7 0 3 kgf m 19 5 2 2 lbf ft Make sure that M8 screw doesn t stick out of lock plate Assembly detail drawing lock plate 13 125LCR8TM100 125LCR8TM102 ...

Page 555: ... No 2 68 4 pcs Assemble needle bearing No 2 67 4 pcs Assemble thrust plate No 2 69 4 pcs Assemble planetary gear No 2 66 4 pcs Grooves of planetary gear will be facingup 14 16 15 17 125LCR8TM104 125LCR8TM106 125LCR8TM105 125LCR8TM107 ...

Page 556: ...ter spreading loctite 242 assemble the M10 bolt 64 4 pcs Tightening torque 5 5 0 6 kgf m 39 8 4 3 lbf ft Assemble carrier No 1 assembly 20 19 21 Assemble thrust washer No 2 65 4 pcs 18 125LCR8TM108 125LCR8TM110 125LCR8TM109 125LCR8TM111 ...

Page 557: ...e right detail view Assemble sun gear No 1 72 Place cover 80 to fit the bolt holes 23 22 24 125LCR8TM112 125LCR8TM114 125LCR8TM115 Detail view After spreading loctite 242 assemble the M10 bolt 81 12 pcs Tightening torque 6 3 0 7 kgf m 45 6 5 1 lbf ft 25 125LCR8TM116 ...

Page 558: ...ter assembling the O ring 83 to the plug 82 assemble it to the cover 3 pcs Tightening torque 5 5 0 5 kgf m 39 8 3 6 lbf ft Inject the 2 3 0 3 liter gear oil to PF3 8 tap section 27 26 125LCR8TM118 125LCR8TM117 ...

Page 559: ... can penetrate the skin causing serious injury Loosen the bolt 1 Tightening torque 2 5 0 5 kgf m 18 1 3 6 lbf ft Remove the cover of the console box Disconnect pilot line hoses 3 Remove the pilot valve assembly 2 When removing the pilot valve assembly check that all the hoses have been disconnected INSTALL Carry out installation in the reverse order to removal Confirm the hydraulic oil level and c...

Page 560: ... 27 300L2RL06 1 Case 2 Bushing 3 Spool 4 Shim 5 Spring 6 Spring seat 7 Spring 8 Plug 9 Push rod 10 O ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut 23 Boot 24 Last guard filter 25 O ring 26 O ring 27 Connector ...

Page 561: ...ench 6 Spanne 22 27 Driver Length 150 Driver Width 4 5 Torque wrench Capable of tightening with the specified torques B Part name Item Size Torque kgf m lbf ft Joint 15 M14 3 5 25 3 Swash plate 16 M14 5 0 0 35 36 2 2 5 Adjusting nut 17 M14 5 0 0 35 36 2 2 5 Lock nut 22 M14 5 0 0 35 36 2 2 5 ...

Page 562: ...a vise with copper or lead sheets Remove end of boot 23 from case 1 and take it out upwards 1 2 3 Loosen lock nut 22 and adjusting nut 17 with spanners on them respectively and take out handle section as one body 4 For valve with switch remove cord also through hole of casing 3 Remove the boot 14 5 300E8RL01 300E8RL02 300E8RL03 1408DA61 ...

Page 563: ...tool When return spring 7 is strong in force plate 12 plug 8 and push rod 9 will come up on loosening joint Pay attention to this 7 Loosen adjusting nut 17 and swash plate 16 with spanners on them respectively and remove them 6 36078RL01 36078RL02 36078RL03 36078RL04 ...

Page 564: ...iver Take it out utilizing external periphery groove of plug and paying attention not to damage it by partial loading During taking out plug may jump up due to return spring 7 force Pay attention to this 9 Remove plate 12 8 36078RL05 36078RL06 36078RL07 Separate spool 3 spring seat 6 spring 5 and shim 4 individually Pay attention not to damage spool surface Record original position of spring seat ...

Page 565: ...8 137 Remove O ring 10 and seal 11 from plug 8 Use small minus screwdriver or so on to remove this seal 13 Take push rod 9 out of plug 8 12 36078RL11 36078RL12 36078RL13 ...

Page 566: ...8 138 Remove lock nut 22 and then boot 23 14 36078RL14 2507ARL10 ...

Page 567: ...d functions of reassembled valve will be degraded Therefore control cleanliness of kerosene fully Put parts in final cleaning vessel filled with kerosene turning it slowly to clean them even to their insides finish cleaning Do not dry parts with compressed air since they will be damaged and or rusted by dust and moisture in air Rust prevention of parts Apply rust preventives to all parts If left a...

Page 568: ...asing Assemble them to their original positions 2 ASSEMBLY Put shim 4 springs 5 and spring seat 6 onto spool 3 in this order 1 4 36078RL16 36078RL18 Assemble O ring 10 onto plug 8 3 36078RL19 Assemble seal 11 to plug 8 Assemble seal in such lip direction as shown below 4 36078RL20 ...

Page 569: ...ng 6 Assemble push rod 9 to plug 8 Apply working oil on push rod surface 5 36078RL21 36078RL22 When return spring is strong in force assemble 4 sets at the same time utilizing plate 12 and tighten joint 15 temporarily 7 36078RL23 Tighten joint 15 with the specified torque to casing utilizing jig 9 Fit plate 12 8 36078RL24 ...

Page 570: ...th 4 push rods evenly Do not screw it over 10 Assemble adjusting nut 17 apply spanner to width across flat of plate 16 to fix it and tighten adjusting nut to the specified torque During tightening do not change position of disk 11 36078RL25 36078RL26 Fit boot 14 to plate 12 1408DA61 ...

Page 571: ...d in direction 60 to 120 from casing hole 14 Fit boot 23 and lock nut 22 and handle subassembly is assembled completely 13 2507ARL10 36078RL27 1408DA66 Assemble bushing 18 to plate and pass cord and tube through it Provide margin necessary to operation 15 300E8RL04 ...

Page 572: ...reventives through all ports and then put blind plugs in ports 18 19 Apply grease to rotating section of joint and contacting faces of disk and push rod 17 Determine handle direction tighten lock nut 22 to specified torque to fix handle 16 300E8RL05 300E8RL06 300E8RL07 ...

Page 573: ...e piping will flow out so catch it in oil pan Disconnect all hoses Sling the turning joint assembly 1 and remove the mounting bolt 2 Weight 50 kg 110 lb Tightening torque 19 6 2 9 kgf m 142 21 0 lbf ft Remove the turning joint assembly When removing the turning joint check that all the hoses have been disconnected GROUP 8 TURNING JOINT A D B C 2 1 1 1 2 3 4 5 6 INSTALL Carry out installation in th...

Page 574: ...b 2 Shaft 3 Cover 4 Spacer 5 Shim 6 Shim 7 Slipper seal 8 O ring 9 O ring 10 O ring 11 Wear ring 12 Retainer ring 13 Plug 14 Hexagon bolt 15 Spring washer 14 3 15 6 10 4 5 12 11 1 7 2 9 8 11 14098TJ03 Descriptions are based on the without dozer blade ...

Page 575: ... at the shaft end hit out shaft 2 to about 1 2 from the body with a hammer Take care not to damage the shaft 2 when remove hub 1 or rest it sideway Put a fitting mark on hub 1 and shaft 2 4 Remove shim 6 and O ring 10 Remove retainer ring 12 spacer 4 and shim 5 2 3 DISASSEMBLY Before the disassembly clean the turning joint Remove bolts 14 washer 15 and cover 3 2 1 21078DA10 21078DA11 8 14 3 360 7 ...

Page 576: ... shaft 2 on block tap hub 1 with a plastic hammer to install 3 Fix seven slipper seal 7 and O ring 9 two wear ring 11 to hub 1 Fit O ring 8 to shaft 2 1 2 ASSEMBLY Clean all parts As a general rule replace oil seals and O ring Coat the sliding surfaces of all parts with engine oil or grease before installing 3 21078DA12 21078DA13 21078DA11 ...

Page 577: ...8 149 14 15 3 Install cover 3 to body 1 and tighten bolts 14 Torque 10 12 5 kgf m 72 3 90 4 lbf ft 7 21078DA10 ...

Page 578: ...ydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Set block between bucket cylinder and arm GROUP 9 BOOM ARM BUCKET AND DOZER CYLINDERS 1 1 Disconnect bucket cylinder hoses 4 and put plugs 5 on cylinder pipe Remove bolt 2 nut 3 and pull out pin 1 Tie the rod with wire...

Page 579: ...f the pin do not insert your fingers in the pin hole Bleed the air from the bucket cylinder Confirm the hydraulic oil level and check the hydraulic oil leak or not 6 8 5 2 Sling bucket cylinder assembly 8 and remove bolt 6 then pull out pin 5 Remove bucket cylinder assembly 8 Weight 78 kg 172 lb 130ZF8DA83 ...

Page 580: ...e hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Set block between arm cylinder and boom Arm cylinder Block 1 2 Arm cylinder 4 5 2 1 Disconnect arm cylinder hoses 4 and put plugs on cylinder pipe Disconnect greasing pipings 6 Remove bolt 2 and pull out pin 1 Tie t...

Page 581: ...on of the pin do not insert your fingers in the pin hole Bleed the air from the arm cylinder Confirm the hydraulic oil level and check the hydraulic oil leak or not 2 Sling arm cylinder assembly 8 and remove bolt 7 then pull out pin 6 Remove arm cylinder assembly 8 Weight 118 kg 260 lb 8 7 6 130ZF8CY21 ...

Page 582: ...e the pressure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Disconnect greasing hoses 1 Sling boom cylinder assembly 1 2 4 5 4 5 6 3 1 Lower the boom cylinder assembly 6 on a stand Remove bolt 4 stopper 5 and pull out pin 2 Tie the rod with wire to pr...

Page 583: ...o not insert your fingers in the pin hole Bleed the air from the boom cylinder Conformed the hydraulic oil level and check the hydraulic oil leak or not 2 Remove bolt 9 and pull out pin 8 Remove boom cylinder assembly 6 Weight 96 kg 212 lb Disconnect boom cylinder hoses 7 and put plugs on cylinder pipe 130ZF8CY25 130ZF8CY26 ...

Page 584: ... seal 9 U packing 10 Back up ring 11 Dust wiper 12 Retaining ring 13 O ring 14 Back up ring 15 O ring 16 Cushion ring 17 Piston 18 Piston seal 19 Wear ring 20 Dust ring 21 O ring 22 Back up ring 23 Set screw 24 Hexagon socket bolt 25 Pipe band assembly 26 Pipe band 27 Spring washer 28 Hexagon bolt 29 O ring 30 Pipe assembly 31 Spring washer 32 Hexagon socket bolt 33 O ring 34 Pipe assembly 35 Spri...

Page 585: ...0 Back up ring 11 Dust wiper 12 Retaining ring 13 O ring 14 Back up ring 15 O ring 16 Cushion ring 17 Piston 18 Piston seal 19 Wear ring 20 Dust ring 21 O ring 22 Back up ring 23 Piston nut 24 Set screw 25 Cushion plunger 26 Stop ring 27 Hexagon socket bolt 28 Check 29 Spring 30 Bracket 31 O ring 32 Plug 33 Pipe band assembly 34 Pipe band 35 Spring washer 36 Hexagon bolt 37 Pipe assembly 38 O ring...

Page 586: ...up ring 11 Dust wiper 12 Retaining ring 13 O ring 14 Back up ring 15 O ring 16 Cushion ring 17 Piston 18 Piston seal 19 Wear ring 20 Dust ring 21 O ring 22 Back up ring 23 Piston nut 24 Set screw 25 Hexagon socket bolt 26 Pipe band assembly 27 Pipe band 28 Spring washer 29 Hexagon bolt 30 Pipe assembly 31 O ring 32 Spring washer 33 Hexagon socket bolt 34 Pipe assembly 35 O ring 36 Spring washer 37...

Page 587: ... seal 6 Back up ring 7 Buffer ring 8 Dust wiper 9 Retaining ring 10 O ring 11 Back up ring 12 Piston 13 O ring 14 Back up ring 15 Piston seal 16 Wear ring 17 Steel ball 18 Set screw 19 Hexagon socket head bolt 20 Pin bushing 21 Dust seal 22 Pipe assembly 23 Double pilot check valve 24 O ring 25 O ring 26 Hexagon socket head bolt 27 Hexagon socket head bolt Type 1 ...

Page 588: ...ng 7 Retaining ring 8 Buffer seal 9 U packing 10 Back up ring 11 Dust wiper 12 Retaining ring 13 O ring 14 Back up ring 15 O ring 16 Piston 17 Piston seal 18 Wear ring 19 Dust ring 20 O ring 21 Back up ring 22 Set screw 23 Hexagon socket bolt 24 Check valve 25 Hexagon socket bolt 26 Pipe assembly 27 O ring 28 Spring washer 29 Hexagon socket bolt 30 Pin wiper 31 Grease nipple Type 2 ...

Page 589: ...cket cylinder 25 M10 6 5 0 7 47 0 5 1 Boom cylinder 33 37 M8 3 25 0 25 23 5 1 8 Arm cylinder 40 M10 5 75 0 25 41 6 1 8 Dozer cylinder Type 1 26 M8 2 7 0 3 19 5 2 2 27 M10 5 4 0 5 39 1 3 6 Type 2 25 M10 5 75 0 25 41 6 1 8 29 M8 3 25 0 25 23 5 1 8 Piston nut Boom cylinder 23 M48 130 13 940 94 Arm cylinder 23 M55 130 13 940 94 Piston Bucket cylinder 14 M50 125 12 5 904 90 4 Boom cylinder 17 M60 75 7 ...

Page 590: ... together from tube assembly 1 Since the rod assembly is heavy in this case lift the tip of the rod assembly 3 with a crane or some means and draw it out However when rod assembly 3 has been drawn out to approximately two thirds of its length lift it in its center to draw it completely Loosen and remove socket bolts 25 of the gland in sequence Cover the extracted rod assembly 3 with rag to prevent...

Page 591: ... assembly 3 Remove piston and cylinder head Remove set screw 24 and lock nut 23 Since set screw 24 and piston nut 23 is tightened to a high torque use a hydraulic and power wrench that utilizers a hydraulic cylinder to remove the lock set screw 24 and piston nut 23 Remove piston assembly 17 back up ring 22 and O ring 21 Place the removed rod assembly on a wooden V block that is set level Cover a V...

Page 592: ...r 11 Remove back up ring 10 U packing 9 and buffer seal 8 Exercise care in this operation not to damage the grooves Do not remove seal and ring if does not damaged Do not remove bushing 6 4 Disassemble the piston assembly Remove wear ring 19 Remove dust ring 20 and piston seal 18 Exercise care in this operation not to damage the grooves 3 125LCR8DA33 130ZF8DA34 ...

Page 593: ...ith hydraulic oil before fitting it Insert the backup ring until one side of it is inserted into groove Coat dust wiper 11 with grease and fit dust wiper 11 to the bottom of the hole of dust seal At this time press a pad metal to the metal ring of dust seal Fit snap ring 12 to the stop face ASSEMBLY Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil s...

Page 594: ...After assembling the piston seal press its outer diameter to fit in Fit back up ring 14 to rod cover 5 Put the backup ring in the warm water of 30 50 C Fit O ring 13 and O ring 15 to rod cover 5 Assemble piston assembly Check for scratches or rough surfaces If found smooth with an oil stone Coat the outer face of piston 17 with hydraulic oil 2 130ZF8DA37 8 158 2 125LCR8DA38 125LCR8DA39 ...

Page 595: ...on ring 16 has a direction in which it should be fitted Install piston and cylinder head Fix the rod assembly to the work bench Apply hydraulic oil to the outer surface of rod assembly 3 the inner surface of piston and cylinder head Insert cylinder head assembly to rod assembly 3 21078DA40 125LCR8DA40 14W98CY14 125LCR8DA41 Item kgf m lbf ft 23 Boom 130 13 940 94 Arm 24 1 5 10 8 Item kgf m lbf ft 1...

Page 596: ...embly Insert the rod assembly in to the tube assembly while lifting and moving the rod assembly with a crane Be careful not to damage piston seal by thread of tube assembly Match the bolt holes in the cylinder head flange to the tapped holes in the tube assembly and tighten socket bolts to a specified torque Refer to the table of tightening torque 3 21078DA41 21078DA42 21 Bucket cylinder Tighten t...

Page 597: ...e grease is not leaking until the grease nipple is completely coming out If the tension is not released in advance the grease nipple can be suddenly popped out by pressurized grease Push out master pin by using a suitable tool GROUP 10 UNDERCARRIAGE Master pin Block 1 1 1 2 3 130ZF8UC01 130ZF8UC04 Move the machine slowly in reverse and lay out track link assembly 1 Jack up the machine and put wood...

Page 598: ... Grease valve INSTALL Carry out installation in the reverse order to removal 2 1 Loosen the lock nut 1 Open bracket 2 with a screwdriver push out from inside and remove carrier roller assembly Weight 12 kg 26 lb 3 4 Jack up the track link height enough to permit carrier roller removal 2 8 162 1 8 162 2 130ZF8UC07 ...

Page 599: ...rry out installation in the reverse order to removal 2 1 Remove the mounting bolt 1 and draw out the track roller 2 Weight 24 kg 53 lb 3 Using the work equipment push up track frame on side which is to be removed After jack up the machine set a block under the unit 2 8 163 1 8 163 3 90 110 140Z98UC05 ...

Page 600: ...e that the boss on the end face of the recoil cylinder rod is in the hole of the track frame 2 1 Remove the bolts 2 washers 3 and separate ilder from recoil spring Tightening torque 29 7 3 0 kgf m 215 21 7 lbf ft 3 Sling the recoil spring 1 and pull out idler and recoil spring assembly from track frame using a pry Weight 215 kg 474 lb 2 130ZF8UC10 130ZF8UC11 130ZF8UC12 130ZF8UC13 ...

Page 601: ...8 173 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 1 3 1 Shell 2 Shaft 3 Seal assembly 4 Bushing 5 Bracket 6 O ring 7 Spring pin 8 Plug 1 4 3 8 7 5 4 3 7 6 2 5 6 21078DA43 ...

Page 602: ...special tool Only remove bushing if replacement is necessity Pull out the shaft 2 with a press Remove seal 3 from idler 1 and bracket 5 Remove O ring 6 from shaft Disassembly Remove plug and drain oil Draw out the spring pin 7 using a press 2 8 166 1 8 166 2 8 166 3 ...

Page 603: ...nto shell 1 Do not press it at the normal temperature or not knock in with a hammer even after the cooling 3 Press 6 2 5 7 3 2 1 1 4 Install shaft 2 to shell 1 Install seal 3 to shell 1 and bracket 5 Coat O ring 6 with grease thinly and install it to shaft 2 Insert shaft 2 into bracket 5 and drive in the spring pin 7 8 167 1 8 167 2 8 167 3 8 167 4 ...

Page 604: ...8 176 5 5 7 1 5 Lay bracket 5 on its side Supply engine oil to the specified level and tighten plug Knock in the spring pin 7 with a hammer Install bracket 5 attached with seal 3 8 168 1 8 168 2 8 168 3 ...

Page 605: ...IL SPRING Structure 1 4 1 Body 2 Tie bar 3 Spring 4 Bracket 5 Lock nut 6 Lock plate 7 Bolt 8 Spring washer 9 Rod packing 10 Back up ring 11 Dust seal 12 Rod assembly 13 Grease valve 14 Spring pin 4 7 8 6 5 3 2 14 1 9 10 11 12 13 130ZF8UC30 ...

Page 606: ... washer 8 and lock plate 6 Remove lock nut 5 Take enough notice so that the press which pushes down the spring should not be slipped out in its operation Lighten the press load slowly and remove bracket 4 and spring 3 1 12 13 4 7 8 6 5 Press 3 1 11 10 9 2 Remove rod seal 9 back up ring 10 and dust seal 11 Remove rod 12 from body 1 Remove grease valve 13 from rod 12 130ZF8UC31 130ZF8UC32 130ZF8UC33...

Page 607: ...ith a press and tighten lock nut 5 Apply sealant before assembling During the operation pay attention specially to prevent the press from slipping out Pour grease into body 1 then push in rod 12 by hand After take grease out of grease valve mounting hole let air out If air letting is not sufficient it may be difficult to adjust the tension of crawler Fit grease valve 13 to rod 12 Tightening torque...

Page 608: ...8 180 Press m 405 1 5 3 6 7 8 5 Lighten the press load and confirm the set length of spring 3 After the setting of spring 3 install lock plate 6 spring washer 8 and bolt 7 130ZF8UC36 ...

Page 609: ...8 181 1 STRUCTURE GROUP 11 WORK EQUIPMENT SECTION C SECTION B SECTION A 130ZF8DA44 SECTION A SECTION B SECTION C ...

Page 610: ...se order to removal When aligning the mounting position of the pin do not insert your fingers in the pin hole Adjust the bucket clearance For detail see operation manual 2 Remove nut 3 bolt 4 and draw out the pin A then remove the bucket assembly Weight 0 45 m3 430 kg 948 lb Remove nut 1 bolt 2 and draw out the pin B B A 130ZF8BK01 130ZF8BK04 B 2 1 130ZF8BK02 3 4 A 130ZF8BK03 ...

Page 611: ...mbly remove spring pin stopper and pull out pin Tie the rod with wire to prevent it from coming out For details see removal of bucket cylinder assembly Place a wooden block under the cylinder and bring the cylinder down to it Remove bolt 2 plate 3 and pull out the pin 4 then remove the arm assembly Weight 385 kg 850 lb When lifting the arm assembly always lift the center of gravity 2 3 4 Crane 1 2...

Page 612: ...order to removal When lifting the arm assembly always lift the center of gravity Bleed the air from the cylinder 2 Remove bolt 4 plate 5 and pull out the pin 6 then remove boom assembly Weight 2 26 m 345 kg 761 lb When lifting the boom assembly always lift the center of gravity Disconnect head lamp wiring Disconnect bucket cylinder hose 2 and arm cylinder hose 1 When the hose are disconnected oil ...

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