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Hyundai HX140L, Manual

The Hyundai HX140L user manual is available for free download on manualshive.com. This comprehensive manual provides detailed instructions on operating and maintaining your Hyundai HX140L excavator. Get the most out of your machine by downloading the manual today.

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GROUP  1  HYDRAULIC CIRCUIT

GROUP  1  HYDRAULIC CIRCUIT

SECTION  3  HYDRAULIC SYSTEM

P1

T

dr6

B2

DR1

Pb20

Pb21

A2

T

P

A

A1

A2

T

LC0

SC0

LC1

SC1

E

Pi1

V2

E

Pi1

V2

T

Dr
B1

S1

P1

T

P

B

A

M

LS

C6

Pd6

Pc6

D6

A1

A2

P

T

Pu

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

P1

P2

P3

Patt

P02

Pn2

Pn1

Pd0

Po5

Puo

P04

DR#,dr#

DR2

Pc3

Pa21

A5

P4

P3

P2

P1

A4

A3

A2

A1

T

SH

MU

VA(CW)

VB(CCW)

 DR

MA

MB

AU

PG

P2(BW)

P1(FW)

A

C

B

D

P

Dr

P2(FW)

P1(BW)

VB

VA

Ps

DR

MB

MA

LH

MA

MB

Ps

VA

VB

RH

DR

A1

A2

Dr

A3

P1

a4

B1

B3

a2

a1

a3

 Pi2

Pi1

Pb21

Pb20

Pa20

A1

A2

P

T

FC1

FC2

A1 A2

P1

T

DR1

DR5

DR3

Pc40

Pd40

TRAVEL

BOOM

SAFETY

PRIORITY

ARM

REGEN' 2nd SPEED

POWER

BOOST

[LH-BW]

BOOM1

[BOOM DOWN]

<ROTATOR>

<DOZER BLADE & ADJUST BOOM>

<BOOM FLOATING>

<BOOM SAFETY LOCK>

<PROPOTIONAL RCV DOUBLE ACTING & ROTATING>

A1

A2

PS

PS

PS

E

PS

PS

REG

REG

REG

E

PS

PS

PS

PS

PS

[LH-FW]

52

52

22

(  2  ,A2) (  2  ,B2)

(  2  ,Pb20)

C5

D5

Pc5

Pd5

DR5

Po5

A1

B1

C

B

A

( 61 ,P2)

59

OP-B

2

Pc42

Pb3

Pd41

B2
A2

Pb21

Pa4

A

P

Pi

2

59

35

(  2  ,Pd40)

(  2  ,Pc40)

( 61 ,A3)

A2

A1

A3

P1

T

P2

[FLOW

CONFLUX]

[BREAKER]

[PEDAL 

SAFETY]

PS

24

( 21 ,A1)

(  2  ,Po5)

( 59 ,C)

61

T1

T

A

B

EV1

EV2

TS2

TS1

55

56

56

54

79

80

26

38

78

56

56

2

62

22

22

63

16

13

14

E

Pi1

V2

E

Pi1

V2

T

PS

52

52

22

( 25 ,j)

32

33

30

34

2

A

C

B

D

P

Dr

E

F

31

74

73

P

T

(2)

(1)

26

60

( 21 ,A1)

27

46

( 21 ,A1)

(  2  ,Pd0)

24

13

14

16

20

17

15

19

18

23

23

26

22

22

1

26

23

(  2  ,Pn1)

(  2  ,Pn2)

45

24

47

( 25 ,h)

(  7  ,1)

(  7  ,2)

[BOOM UP]

( 21 ,P3)

( 25 ,j) [BOOM DOWN]

( 25 ,j) [BOOM HOLDING]

( 12 ,A)

( 12 ,C)

( 25 ,d) [ARM2 OUT]

( 25 ,e) [ARM2 IN]

( 25 ,e) [ARM REGEN]

( 21 ,A4) [ARM REGEN]

( 25 ,h) [BOOM PRI']

( 25 ,F) [BUCKET IN]

( 25 ,g) [BUCKET OUT]

[RH-FW] (  7  ,4)

[RH-BW](  7  ,3)

( 21 ,P3)

( 12 ,B)

( 12 ,D)

( 21 ,A5)

[BOOM PRI']

( 25 ,B)

[SWING CCW]

( 25 ,A)

[SWING CW]

(  3  ,VB)

(  3  ,VA)

( 25 ,h)

[BOOM2 UP]

( 25 ,C)

( 25 ,d)

[ARM OUT]

( 25 ,e)

[ARM IN]

( 25 ,e)

[ARM HOLDING]

(  1  ,Pi1)

(  1  ,Pi2)

2

10

11

8

9

4

( 21 ,A3)

(  2  ,A1)

12

(  2  ,B1)

(  2  ,C1)

(  2  ,D1)

3

( 25 ,e1)

( 21 ,P4)

(  2  ,D2)

(  2  ,C2)

( 12 ,P)

21

(  2  ,P03)

(  2  ,Pb4)

(  2  ,Pu)

(  5  ,P)

(  6  ,P)

(  7  ,P)

(  3  ,PG)

(  2  ,P02)

(  2  ,P0)

SPRING 4k

ON/OFF

( 21 ,A2)

(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

[BOOM UP]

[BOOM2 UP]

[BOOM PRI']

[BOOM DOWN]

[BOOM HOLDING]

[BUCKET IN]

[BUCKET OUT]

[ARM IN]

[ARM HOLDING]

[ARM2 IN]

[ARM2 IN]

[ARM OUT]

[ARM2 OUT]

[SWING CW]

[SWING CCW]

PS

PS

PS

PS

PS

h1

h2

( 21 ,A1)

5

6

( 21 ,A1)

24

24

24

24

25

24

(  2  ,Pb20)

(  2  ,Pb21)

(  2  ,Pa20)

(  2  ,Pa21)

(  2  ,P04)

(  2  ,Pb5)

(  2  ,Pa5)

(  2  ,Pc42)

(  2  ,Pb3)

(  2  ,Pc40)

(  2  ,Pc41)

(  2  ,Pd40)

(  2  ,Pd41)

(  2  ,Pc2)

(  2  ,Pd2)

(  3  ,SH)

(  2  ,Pc3)

(3)

(4)

(1)

(2)

P

T

TRAVEL

[LH-FW]

[LH-BW]

[RH-FW]

[RH-BW]

( 21 ,A1)

7

26

(  2  ,Pc1)

(  2  ,Pd1)

(  2  ,Pa1)

(  2  ,Pb1)

Pi1

V2

E

dr5

ARM

<ARM SAFETY LOCK>

53

( 25 ,e)

(  2  ,C4)

(  2  ,D4)

<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

M1 M2 M3 M4

Mu

MA

MB

B

A

P

A

B

T

A1

A2

A3

B1

B2

B3

R

<SWING FINE CONTROL>

<QUICK CLAMP>

<SWING PARKING BY FORCE>

P1

P2

P3

T

50

2

3

(  2  ,Pc2)

( 25 ,b) ( 25 ,a) ( 25 ,e1)

(  2  ,Pd2) (  3  ,SH)

64

65

A

B

T

T1

C5

D5

Pc5

Pd5

Pc42

Pb3

Pd41

B2
A2

Pb21

Pa4

A

P

Pi

A2

A1

P

T

P2

DR5

Po5

[FLOW
CONFLUX]

[BREAKER]

PS

55

56

56

54

14

13

16

57

2

81

( 21 ,A1)

2

59

35

<SINGLE ACTING>

(  2  ,Pd40)

(  2  ,Pc40)

OPTION-B

A

C

B

D

P

Dr

E

F

P

T

(2)

(1)

C6

Pd6

D6

31

<DOZER BLADE>

Pc6

32

27

46

30

2

26

60

( 21 ,A1)

 dr5

<ADJUST BOOM>

C6

Pd6

D6

Pc6

27

46

2

P

T

(2)

(1)

26

60

( 21 ,A1)

74

73

T1

T

A

B

C5

D5

Pc5

Pd5

DR5

Po5

A2

A1

A3

P1

T

P2

A1

B1

C

B

A

P

T

(1)

(2)

[FLOW

CONFLUX]

[BREAKER]

[PEDAL 

SAFETY]

<DOUBLE ACTING>

EV1

EV2

TS2

TS1

PS

55

56

56

54

79

26

60

61

24

( 21 ,A1)

(  2  ,Po5)

( 59 ,C)

( 61 ,P2)

59

OPTION-B

2

Pc42

Pb3

Pd41

B2
A2

Pb21

Pa4

A

P

Pi

2

59

35

(  2  ,Pd40)

(  2  ,Pc40)

( 61 ,A3)

Shuttle block

1

Main pump

2

Main control valve

3

Swing motor

4

Travel motor

5

RCV lever(LH)

6

RCV lever(RH)

7

RCV pedal

8

Boom cylinder(LH)

9

Boom cylinder(RH)

10

Arm cylinder

11

Bucket cylinder

12

Turning joint

13

Check valve

14

Check valve

15

Hydraulic tank

16

Oil cooler

17

Air breather

18

Return filter

19

Strainer

20

Drain filter

21
22

5 cartridge valve

23

Pressure sensor

24

Pressure sensor

25
26

Last guard filter

31

Dozer cylinder(LH, option)

34
35

Pilot selector valve(option)

38

Fan drive pump(option)

46
47
50

Solenoid valve(option)

52
53

56

Stop valve(option)

57

Proportional relief valve(option)

Pressure sensor

27

Shuttle valve(option)

30

Turning joint(option)

33

51

54
55

59

Shuttle valve(option)

60

2 way pedal(option)

61
62

Float cartridge valve(option)

63
64
65
73

32

Dozer cylinder(RH, option)
Selector valve(option)
Solenoid valve(option)

Pressure switch(option)
Solenoid valve(option)

Pattern change valve(option)
Boom safety valve(option)
Arm safety valve(option)
Accumulator(option)
Accumulator(option)

Solenoid valve(option)

Solenoid valve(option)
Solenoid valve(option)
Solenoid valve(option)

74
78

Proportional valve(option)

79
80

2 EPPR valve(option)

Adjust boom cylinder(option)
Adjust boom safety valve(option)

81

Solenoid valve(option)

Proportional relief valve(option)

44
45

Solenoid valve(option)
2 EPPR cartridge valve(option)

24

T*

[SWING CW]

[SWING CCW]

TRAVEL
STRAIGHT

TRAVEL
RIGHT

TRAVEL
LEFT

BOOM 1

SWING

BOOM 2

ARM 1

OPTION B

OPTION C
(DOZER)

ARM

BUCKET

ARM 2

REGEN

3-1

140L3HC01

Summary of Contents for HX140L

Page 1: ...roup 3 Pilot Circuit 3 5 Group 4 Single Operation 3 15 Group 5 Combined Operation 3 27 SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location 4 1 Group 2 Electrical Circuit...

Page 2: ...chanical System 6 4 Group 3 Electrical System 6 24 Group 4 Mechatronics System 6 40 SECTION 7 MAINTENANCE STANDARD SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test 7 1 Group 2 Major...

Page 3: ...RQUE SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide 9 1 Group 2 Engine system 9 2 Group 3 Electric system 9 4 Group 4 Hydraulic system 9 6 Group 5 Undercarriage 9 9 Group 6 Structure 9...

Page 4: ...ON 4 ELECTRICAL SYSTEM 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 a...

Page 5: ...ributors Get the most up to date information before you start any work Filing method Filing method See the page number on the bottom of the page File the pages in correct order Following examples show...

Page 6: ...e so divide by 10 Move the decimal 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...

Page 7: ...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 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...

Page 8: ...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 Liter to U K Gallon 1 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0...

Page 9: ...8 622 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 8...

Page 10: ...266 90 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 1...

Page 11: ...1 0 32 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 1...

Page 12: ...SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10...

Page 13: ...e excavator attach a Do Not Operate Do Not Operate tag on the right side control lever USE HANDHOLDS AND STEPS USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury When you ge...

Page 14: ...Wear goggles or safety glasses PROTECT AGAINST NOISE PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as e...

Page 15: ...vator 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 OPERAT...

Page 16: ...YSTEM SAFELY 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 A...

Page 17: ...ide or in a well 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...

Page 18: ...serious injury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serio...

Page 19: ...e materials 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 PREVEN...

Page 20: ...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 mag...

Page 21: ...m 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...

Page 22: ...diator Main control valve Swing motor Bucket Tooth Cab Boom cylinder Boom Arm cylinder Arm Counterweight After treatment device Swing bearing Oil cooler Guardrail DEF AdBlue tank R Carrier roller Doze...

Page 23: ...860 9 4 Ground clearance of counterweight F 940 3 1 Engine cover height G 2390 7 10 Minimum ground clearance H 440 1 5 Rear end distance I 2330 7 8 Rear end swing radius I 2330 7 8 Distance between tu...

Page 24: ...l height of cab E 2860 9 4 Ground clearance of counterweight F 940 3 1 Engine cover height G 2390 7 10 Minimum ground clearance H 440 1 5 Rear end distance I 2330 7 8 Rear end swing radius I 2330 7 8...

Page 25: ...3 1 Engine cover height G 2390 7 10 Minimum ground clearance H 440 1 5 Rear end distance I 2330 7 8 Rear end swing radius I 2330 7 8 Distance between tumblers J 3000 9 10 Undercarriage length K 3708 1...

Page 26: ...round clearance of counterweight F 1200 3 11 Engine cover height G 2650 8 8 Minimum ground clearance H 600 2 0 Rear end distance I 2330 7 8 Rear end swing radius I 2330 7 8 Distance between tumblers J...

Page 27: ...19 11 6330 mm 20 9 Min swing radius F 2630 mm 8 8 2670 mm 8 9 2650 mm 8 8 2680 mm 8 10 Bucket digging force SAE 87 3 94 8 kN 87 3 94 8 kN 87 3 94 8 kN 87 3 94 8 kN 8900 9660 kgf 8900 9660 kgf 8900 966...

Page 28: ...mm 13 11 4350 mm 14 3 Max digging height D 7700 mm 25 3 7770 mm 25 6 Max dumping height E 5260 mm 17 3 5340 mm 17 6 Min swing radius F 2350 mm 7 9 2460 mm 8 1 Bucket digging force SAE 87 3 94 8 kN 87...

Page 29: ...2 9270 mm 30 5 Max dumping height E 6330 mm 20 9 6410 mm 21 0 6780 mm 22 3 Min swing radius F 2670 mm 8 9 2830 mm 9 3 2690 mm 8 10 Bucket digging force SAE 87 3 94 8 kN 87 3 94 8 kN 87 3 94 8 kN 8900...

Page 30: ...5 6010 mm 19 8 6320 mm 20 9 6590 mm 21 7 Min swing radius F 2630 mm 8 8 2670 mm 8 9 2650 mm 8 8 2680 mm 8 10 Bucket digging force SAE 87 3 94 8 kN 87 3 94 8 kN 87 3 94 8 kN 87 3 94 8 kN 8900 9660 kgf...

Page 31: ...weld assembly 1590 3510 1840 4060 Swing bearing 260 570 Travel motor assembly 480 1060 Turning joint 50 110 Track recoil spring 87 192 Idler 108 238 Carrier roller 19 42 Track roller 33 73 Track chain...

Page 32: ...ck frame weld assembly 2180 4810 Swing bearing 260 570 Travel motor assembly 305 670 Turning joint 50 110 Tension cylinder assembly 132 291 Idler assembly 151 333 Carrier roller assembly 40 88 Track r...

Page 33: ...7650 4740 4810 2890 26 1 1 5 m kg 8460 6060 5190 3230 3340 2040 2100 1250 8 03 5 0 ft lb 18650 13360 11440 7120 7360 4500 4630 2760 26 3 Ground kg 8800 5710 5130 3030 3240 1940 2190 1300 7 77 Line lb...

Page 34: ...b 8330 8070 6240 3880 22 6 3 0 m kg 6770 6600 4630 3450 3450 2140 2480 1520 7 37 10 0 ft lb 14930 14550 10210 7610 7610 4720 5470 3350 24 2 1 5 m kg 7280 5900 5320 3210 3350 2050 2390 1450 7 45 5 0 ft...

Page 35: ...5370 13930 9700 7430 7560 4630 4960 2950 25 5 1 5 m kg 5230 3090 3310 1980 2170 1280 7 84 5 0 ft lb 11530 6810 7300 4370 4780 2820 25 7 Ground kg 5470 5470 5060 2940 3220 1900 2270 1340 7 58 Line lb 1...

Page 36: ...5 620 mm 24 4 335 kg 740 lb 0 40 m3 0 52 yd3 0 35 m3 0 46 yd3 760mm 29 9 860mm 33 9 410 kg 900 lb 0 46 m3 0 60 yd3 0 40 m3 0 52 yd3 850mm 33 5 950mm 37 4 435 kg 960 lb 0 52 m3 0 68 yd3 0 45 m3 0 59 y...

Page 37: ...3 or less Ditch cleaning bucket Slope finishing bucket 0 45 m3 SAE heaped bucket 0 55 m3 SAE heaped bucket Special bucket 2 Capacity Width Weight Recommendation 4 6 m 15 1 boom 4 1 m 13 5 boom SAE hea...

Page 38: ...5 m arm 8 2 0 23 m3 0 30 yd3 0 20 m3 0 26 yd3 520 mm 20 5 620 mm 24 4 335 kg 740 lb 0 40 m3 0 52 yd3 0 35 m3 0 46 yd3 760 mm 29 9 860 mm 33 9 410 kg 900 lb 0 46 m3 0 60 yd3 0 40 m3 0 52 yd3 850 mm 33...

Page 39: ...terials with density of 1100 kgf m3 1850 lbf yd3 or less Ditch cleaning bucket Slope finishing bucket 0 45 m3 SAE heaped bucket 0 55 m3 SAE heaped bucket Capacity Width Weight Recommendation 4 9 m 16...

Page 40: ...m arm 9 10 0 23 m3 0 30 yd3 0 20 m3 0 26 yd3 520 mm 20 5 620 mm 24 4 335 kg 740 lb 0 40 m3 0 52 yd3 0 35 m3 0 46 yd3 760 mm 29 9 860 mm 33 9 410 kg 900 lb 0 46 m3 0 60 yd3 0 40 m3 0 52 yd3 850 mm 33...

Page 41: ...terials with density of 1100 kgf m3 1850 lbf yd3 or less Ditch cleaning bucket Slope finishing bucket 0 45 m3 SAE heaped bucket 0 55 m3 SAE heaped bucket Capacity Width Weight Recommendation 4 9 m 16...

Page 42: ...0 14200 31310 14410 31770 Ground pressure kgf cm2 psi 0 43 6 11 0 37 5 26 0 32 4 55 Overall width mm ft in 2500 8 2 2600 8 6 2700 8 10 HX140 L DOZER BLADE Shoe width mm in 500 20 600 24 700 28 Operati...

Page 43: ...l cause unexpected problem such as bending of shoes crack of link breakage of pin loosening of shoe bolts and the other various problems 4 Table 2 Table 1 Track shoe Specification Category 600 mm trip...

Page 44: ...d net horse power SAE J1349 116 Hp 87 kW at 1950 rpm Rated gross horse power SAE J1995 124 Hp 92 6 kW at 1950 rpm Maximum torque 54 kgf m 391 lbf ft at 1400 rpm Engine oil quantity 10 5 2 8 U S gal Dr...

Page 45: ...ecification Type Fixed displacement axial piston motor Capacity 76 96 cc rev Relief pressure 285 kgf cm2 4054 psi Braking system Automatic spring applied hydraulic released Braking torque Minimum 30 k...

Page 46: ...ption 500 mm 20 0 43 kgf cm2 6 11 psi 46 2500 mm 8 2 700 mm 28 0 32 kgf cm2 4 55 psi 46 2700 mm 8 10 HX140 L DOZER BLADE Standard 600 mm 24 0 39 kgf cm2 5 55 psi 46 2600 mm 8 6 Option 500 mm 20 0 46 k...

Page 47: ...by We recommend that you use only HYUNDAI genuine lubricating oils and grease officially approved by HYUNDAI HYUNDAI Using any lubricating oils other than HYUNDAI genuine products may lead to a deteri...

Page 48: ...SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device 2 1 Group 2 Main Control Valve 2 19 Group 3 Swing Device 2 46 Group 4 Travel Device 2 57 Group 5 RCV Lever 2 78 Group 6 RCV Pedal 2 85...

Page 49: ...A2 pump Gear pump Pi2 Pi1 Dr B1 B3 a4 a3 A3 P1 B3 Qmin adjusting screw Qmin adjusting screw P1 Regulator VIEW A A2 A1 a1 a2 B1 A 326 414 14092MP01 Port Port name Port size A1 A2 Delivery port SAE6000...

Page 50: ...3 886 717 406 774 111 261 127 123 710 824 251 490 212 211 153 156 157 467 728 468 727 466 725 313 116 885 314 141 981 983 271 401 406 262 808 04 312 Valve block 313 Valve plate R 314 Valve plate L 326...

Page 51: ...01 438 P2 KR38 9N62 FRONT KR38 9N61 REAR A B 413 438 496 724 725 D D VIEW C REAR 413 438 438 722 496 724 725 079 735 722 466 755 496 753 P1 a 875 P1 a 405 699 Pi 735 Pi Pi C 753 Pi 436 436 656 SECTION...

Page 52: ...2 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 S...

Page 53: ...53 Drive gear 354 Driven gear 355 Filter 361 Front case 433 Flange socket 434 Flange socket 435 Flange socket 466 Plug 700 Ring 710 O ring 725 O ring 732 O ring 850 Snap ring 887 Pin 700 354 351 710 4...

Page 54: ...p consists of swash plate 212 shoe plate 211 swash plate support 251 tilting bush 214 tilting pin 531 and servo piston 532 The swash plate is a cylindrical part formed on the opposite side of the slid...

Page 55: ...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...

Page 56: ...elivery 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 o...

Page 57: ...pool 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 deliv...

Page 58: ...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...

Page 59: ...24 Tightening the screw shifts the control chart to the right as shown in the figure Adjusting value Adjustment of flow control characteristic 801 924 Pilot pressure Pi Delivery flow Q 21092MP11 Speed...

Page 60: ...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 thi...

Page 61: ...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 diame...

Page 62: ...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...

Page 63: ...ow 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...

Page 64: ...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 625 626 630 628 627 802 2107A2MP08 Speed Adjustment of inp...

Page 65: ...um 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 t...

Page 66: ...he 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 Adjustme...

Page 67: ...ot port arm Arm 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 por...

Page 68: ...rt 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 Option C pilot port dozer bl...

Page 69: ...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...

Page 70: ...2MC102 1 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...

Page 71: ...c41 Unlock signal Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 P1 P2 Patt P02 Pn2 Pn1 P05 P04 DR2 Pc3 Swing priority Pa20 DR1 DR5 DR3 Pc40 BUCKET Pb21 Unlock signal Pb20 Pd40 Pd41 Pb3 Pc42 Arm crowd pilot Pc40 Pc...

Page 72: ...t C5 D5 D4 C4 Pc41 Unlock signal Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 P1 P2 Patt P02 Pn2 Pn1 P05 P04 DR2 Pc3 Swing priority Pa20 DR1 DR5 DR3 Pc40 BUCKET Pb21 Unlock signal Pb20 Pd40 Pb3 Pc42 Arm crowd pil...

Page 73: ...pump 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...

Page 74: ...mp 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 B B S...

Page 75: ...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...

Page 76: ...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 fr...

Page 77: ...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 h...

Page 78: ...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...

Page 79: ...same 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...

Page 80: ...e same 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 o...

Page 81: ...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 bod...

Page 82: ...iphery 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 o...

Page 83: ...irected to the port A5 through the check 1 of bucket logic valve 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...

Page 84: ...ssage 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 hea...

Page 85: ...fluid from pump A2 entered P1 parallel passage and is directed to the port B5 through the check 1 of bucket logic valve At the same time the hydraulic fluid from P1 bypass passage is directed to the...

Page 86: ...pool and the 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...

Page 87: ...ation prior to the bucket operation In case of the bucket out operation with boom operation operation is similar Also the boom up operation the boom up pilot pressure is supplied the pilot port P04 of...

Page 88: ...d operation the boom up pilot pressure is supplied the pilot port P04 of bucket spool stroke limit and the piston is shifted to the right and then the bucket in spool stroke is limited and the open of...

Page 89: ...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...

Page 90: ...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...

Page 91: ...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 p...

Page 92: ...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 regenerat...

Page 93: ...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 p...

Page 94: ...ide 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 t...

Page 95: ...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...

Page 96: ...p A2 The bypass 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 th...

Page 97: ...ump A2 The bypass 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...

Page 98: ...en 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...

Page 99: ...ng 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...

Page 100: ...ing 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 passag...

Page 101: ...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 s...

Page 102: ...ank 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...

Page 103: ...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 125LCR2SM21 GROUP 3 SWING DEVICE TYPE 1 Port...

Page 104: ...ing 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 spool 37 Spring seat...

Page 105: ...ust 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...

Page 106: ...on This force F1 is divided as N1 thrust partial pressure and W1 radial partial pressure in case of the plate of a tilt angle W1 generates torque T W1 R1 for Y Y line connected by the upper and lower...

Page 107: ...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 m...

Page 108: ...tor 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 val...

Page 109: ...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 145WF2S...

Page 110: ...rce 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 pres...

Page 111: ...t 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 separ...

Page 112: ...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 t...

Page 113: ...t 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...

Page 114: ...ase 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...

Page 115: ...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 P...

Page 116: ...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 plat...

Page 117: ...owing 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 W1 generates torque T W1 R1 forY Y line co...

Page 118: ...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...

Page 119: ...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 va...

Page 120: ...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 145WF2...

Page 121: ...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 pre...

Page 122: ...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 sepa...

Page 123: ...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...

Page 124: ...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 RC...

Page 125: ...d high low speed changeover mechanism GROUP 4 TRAVEL DEVICE TYPE 1 PS DR MA MB VB VA P No 38Q3 40100 Travel motor Reduction gear Ps MB VB VA MA DR Hydraulic circuit A VIEW A RE 125LCR2TM20 Port Port n...

Page 126: ...Rear cover 31 Main 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...

Page 127: ...ch 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 forc...

Page 128: ...nerated 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...

Page 129: ...e 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...

Page 130: ...ief 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...

Page 131: ...ied 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 bo...

Page 132: ...ng accelerating stopping and counterbalance operations See page 2 65 2 Operation Check valve built in the spool This valve is located in the oil supplying passage to hydraulic motor and at the same ti...

Page 133: ...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 som...

Page 134: ...re 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...

Page 135: ...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...

Page 136: ...ler 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...

Page 137: ...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 u...

Page 138: ...ve of counterbalance Part of flowing changeover Part of auto changeover A T1 T2 P1 P2 Pm1 Pm2 Ps Pm2 Hydraulic circuit Reduction gear Travel motor RED Pm1 Ps P1 P2 T1 T2 16092TM01 TRAVEL DEVICE TYPE 2...

Page 139: ...pring 39 Spool 40 Steel ball 41 Spring 42 Plug 43 Spring seat 44 O ring 45 Wrench bolt 46 Relief valve assy 47 Spool 48 Guide 49 O ring 50 Back up ring 51 O ring 52 Back up ring 53 Snap ring 54 plug 5...

Page 140: ...1 is divided as N1 thrust partial pressure and W1 radial partial pressure in case of the plate 09 of a tilt angle W1 generates torque T W1 R1 forY Y line connected by the upper and lower sides of pist...

Page 141: ...nertia stopped it forces an equipment stopped according to generating the pressure of a brake on the projected side Room A is always connected with port A of a motor If the pressure of port is increas...

Page 142: ...tional plate 19 connected through spline outside a cylinder block 10 When a pressure does not work on the part of piston brake spring presses brake piston oil in a brake room flows into the drain of a...

Page 143: ...pump is increased and transferred to spring room M through the path G because negative brake is working on When the pressure of room M exceeds the force of spring that keeps spool at its neutral posit...

Page 144: ...escription of automatic switch at normal speed Due to no pressure on pilot now spool 47 is not working 2 Speed line 2 Speed changeover pressure port 2 Speed line Av Bv D D1 47 Normal Speed 21078TM09 N...

Page 145: ...external pilot Pi 35 kgf cm2 spool 47 moves from right to left At high speed turning pressure of motor D1 is over 250 kgf cm2 when the power forcing to spool 59 pressure P1 is stronger than spool 47...

Page 146: ...Simultaneous operation 2 3 T 1 P 4 RH 6 5 6 TYPE L5 8 7 Null Null 300L2RL01 Switches Type No LH RH M1 M3 M10 5 One touch decel Horn 6 Power boost Breaker M5 5 One touch decel Horn 6 Power boost Null...

Page 147: ...ower boost Breaker M6 5 One touch decel Horn 6 Power boost Null 7 CCW rotation Close 8 CW rotation Open Pilot ports Port LH RH Port size P Pilot oil inlet port Pilot oil inlet port PF 3 8 T Pilot oil...

Page 148: ...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 spo...

Page 149: ...ONS 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 th...

Page 150: ...ydraulic 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...

Page 151: ...ol 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 press...

Page 152: ...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 an...

Page 153: ...ure 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 0293 Port P T 1 2 3 4 Port size PF 1 4 Port P...

Page 154: ...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 1 2 Body 2 3 Plug 4 Plug 5 Sp...

Page 155: ...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 oi...

Page 156: ...s of the hydraulic circuit diagram shown below ant 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...

Page 157: ...ressure of the pilot valve is not applied to the spool 8 Therefore the spool is pushed up by the spring 10 to the position of port 2 in the operation explanation drawing Then since the output port is...

Page 158: ...the 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 wit...

Page 159: ...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 RCV PEDAL 0294 Port P T 1 2 3 4 Port size PF 1 4 Port Pil...

Page 160: ...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...

Page 161: ...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 oi...

Page 162: ...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...

Page 163: ...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...

Page 164: ...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...

Page 165: ...SECTION 3 HYDRAULIC SYSTEM 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 15 Group 5 Combined Operation 3 27...

Page 166: ...c3 3 4 1 2 P T TRAVEL LH FW LH BW RH FW RH BW 21 A1 7 26 2 Pc1 2 Pd1 2 Pa1 2 Pb1 Pi1 V2 E dr5 ARM ARM SAFETY LOCK 53 25 e 2 C4 2 D4 PATTERN CHANGE FROM TO ITEM PORT ITEM PORT J1 J3 J4 J2 M1 M2 M3 M4 5...

Page 167: ...DELIVERY 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 GROUP 2 MAIN CIRCUIT The pumps receive...

Page 168: ...l pressure exceeds 6 0 kgf cm2 85 psi the oil returns directly to the hydraulic tank resulting in the oil temperature being raised quickly at an appropriate level When the oil cooler is clogged the oi...

Page 169: ...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 MOTO...

Page 170: ...solenoid valve assemblies swing parking brake main control valve and safety lock solenoid valve GROUP 3 PILOT CIRCUIT GROUP 3 PILOT CIRCUIT RCV pedal Safety lock solenoid valve MCV One pedal straight...

Page 171: ...1 Ai B4 B5 A5 Pa5 Pb5 Pa4 Pb4 C5 D5 D4 C4 Pc41 Pc5 Pd5 Rs C6 Pd6 Pc6 D6 DR4 P03 P1 P2 P3 Patt P02 Pn2 Pn1 Pd0 Po5 Puo P04 DR2 Pc3 Pa21 Pb21 Pb20 Pa20 DR1 DR5 DR3 Pc40 Pd40 PS PS Pi1 Pump HYDRAULIC TAN...

Page 172: ...DR5 DR3 Pc40 Pd40 PS PS Pi1 Pump HYDRAULIC TANK PILOT PUMP Dr dr Pi2 Pump A5 P4 P3 P1 A4 A3 A2 A1 MCV PG S Motor P02 MCV P03 MCV Pb4 MCV Pu T Joint P P0 MCV T 3 1 2 4 3 1 P T P T 2 4 a b d f h j c d1...

Page 173: ...YLINDER TURNING JOINT TRAVEL MOTOR SWING MOTOR P2 BOOM PRIORITY EPPR VALVE Boom speed A1 PUMP A2 PUMP TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 R...

Page 174: ...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 HYDRAULIC TANK PILOT PUMP Dr dr Pi2 Pump A5 P4 P3 P1 A4 A3 A2 A1 MCV PG S Motor P02 MCV P03...

Page 175: ...GHT LEFT 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 P...

Page 176: ...1 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 P...

Page 177: ...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 PUM...

Page 178: ...b5 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 HYDRAULIC TANK PILOT PUMP Dr dr Pi2 Pump A5 P4 P3 P1 A4 A3 A2...

Page 179: ...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 DR1 DR5 DR3 Pc40 Pd40 PS PS Pi1 Pump Pi2 Pump BUCKET CYLINDER A1 PUMP A2 P...

Page 180: ...ontrol 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 cy...

Page 181: ...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...

Page 182: ...he 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 3 ARM IN OPERATION RIGHT LEFT Pc42 Pb3 Pd41 B2...

Page 183: ...e 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 cyli...

Page 184: ...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 5 BUCKET IN OPERATION RIGHT LEFT TURNIN...

Page 185: ...e 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 6 BUCKET OUT OPERATION RIGHT LEFT TURN...

Page 186: ...happens the dozer goes up 7 DOZER UP OPERATION 7 DOZER UP OPERATION RIGHT LEFT 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...

Page 187: ...04 Pc5 Pd5 Pu P1 P2 P3 Pd0 TRAVEL STRAIGHT TRAVEL TRAVEL BOOM 1 SWING BOOM 2 ARM 1 OPTION B OPTION C DOZER ARM BUCKET ARM 2 REGEN D6 Pd6 Pc6 MAKE UP VALVE RELIEF VALVE 140L3HC17 When the dozer control...

Page 188: ...make up valve in the swing motor itself 9 SWING OPERATION 9 SWING OPERATION RIGHT LEFT 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 C...

Page 189: ...RKING BRAKE OFF OPERATION 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 oi...

Page 190: ...1 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 191: ...llowing functions COUNTER BALANCE VALVE COUNTER BALANCE VALVE When stopping the motor of slope descending this valve to prevent the motor over run OVERLOAD RELIEF VALVE OVERLOAD RELIEF VALVE Relief va...

Page 192: ...ht 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 tr...

Page 193: ...ted Refer to page 3 8 for the boom priority system 2 COMBINED SWING AND BOOM UP OPERATION 2 COMBINED SWING AND BOOM UP OPERATION LEFT RIGHT Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1...

Page 194: ...to page 3 13 for the swing operation preference function 3 COMBINED SWING AND ARM OPERATION 3 COMBINED SWING AND ARM OPERATION LEFT RIGHT Pc42 Pb3 Pd41 B2 A2 Pb1 A1 B1 Pa1 T1 V3 Pd2 Pc2 D2 C2 Pc1 D1 C...

Page 195: ...the bucket is operated 4 COMBINED SWING AND BUCKET OPERATION 4 COMBINED SWING AND BUCKET OPERATION LEFT RIGHT 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...

Page 196: ...functions are operated simultaneously 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 strai...

Page 197: ...y the boom spools 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 th...

Page 198: ...ved 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...

Page 199: ...ated simultaneously the 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 sp...

Page 200: ...nctional 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...

Page 201: ...SECTION 4 ELECTRICAL SYSTEM 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 202: ...Breaker operation switch 6 Starting switch 7 Cluster 8 Service meter 9 Power max switch 10 Emergency engine stop switch 11 One touch decel switch 12 RS232 J1939 service socket 13 Fuse relay box 14 Ma...

Page 203: ...ure sensor 9 P2 pressure sensor 10 EPPR pressure sensor 11 Overload pressure sensor 12 Start relay 13 Heater relay 14 Alternator 15 Travel alarm buzzer 16 Arm Bucket in pressure sensor 17 Boom up pres...

Page 204: ...NC 10 NC 11 NC 12 NC 13 EM CY STOP OUT 14 GND SAFETY 15 NC 16 SAFETY SOL 1 2R 1 2B 1 2 3 4 5 6 7 8 CAN_HI 2 CAN_SHIELD POWER_BATT POWER_IG GND CAN_LO 2 NC 5V_HAPTIC 9 SIG_HAPTIC 10 GND_HAPTIC 1 2 3 4...

Page 205: ...5 4 3 M 2 1 6 7 1 4 2 5 7 AIR CON HARNESS INCAR SENSOR 0 0 AMBIENT SENSOR 0 0 FET DESTINATION NO 2 3 4 5 6 7 8 BLOWER ON SIG IG 24V NC AC CONTROLLER B COMP DPS CAN HI AC GND 1 CAN LOW 20 19 18 17 15...

Page 206: ...TIVE 2 N2 PS U121 51 21 ARM IN PS U4171 ATT RELIEF EPPR 54 17 U417 U410 54 10 ATT RELIEF EPPR2 ATT RELIEF SET EPPR1 54 09 U409 U1323 U209 52 09 TRAVEL BUZZER VW LW CL 41 UREA LAMP U301 U301 U301 U234...

Page 207: ...OR 26 25 25 25A 26 24 24A 24 8 8 8A IGN 24V 1 1 1A BATTERY CONTROL BOX A CONTROL BOX B GND CAN HI CAN LOW 17 16 16 17 17A 16A 19A 19 19 BLOWER ON SIG 18 18 A C THERMO EVAP SENSOR 5V 23 23 20E 20 SENSO...

Page 208: ...F 14 SOURCING RETURN 18 CAN C LO 17 CAN C HI 57 NOX EO ON OFF 2 KEY SWITCH_HS 3 KEY SWITCH_LS 15 5 DCU POWER 82 BATTERY 56 8V SENSOR SUPPLY 49 RELAY RETURN RETURN ON OFF WATER LEVEL SIG 60 5V SPPLY AN...

Page 209: ...4 5 MEMORANDUM...

Page 210: ...GPS connection CN 125 1 Power relay CR 35 30 Fuse box No 7 l conn CN 11 5 AC Heater control box A 7 Blower relay 4 Fuse box No 8 I conn CN 5 18 I conn CN 17 5 Wiper motor controller CN 141 7 Wiper mo...

Page 211: ...11 10 9 8 7 CN 10 6 5 4 3 2 1 3 2 1 0 8Y 1 2Gr 1 2Gr 0 8Y CN 27A 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 212: ...gency engine stop sw CS 33 2 1 l conn CN 4 13 Fuse box No 10 I conn CN 2 6 Engine ECM CN 93 J1 69 Start switch ON CS 2A 3 GPS conn CN 125 2 4 I conn CN 5 40 Power relay CR 35 86 87 Fuse box No 12 I co...

Page 213: ...4 3 2 5 4 3 2 1 1 CS 33 1 2Y 0 8Y 0 8BOr 1 2W 0 8V 0 8BOr 0 8ROr 0 8L 0 8GrW 0 8Br 1 2BOr 0 8Y 0 8BOr 1 2GrW 15R 15R 0 8Br 1 2BOr 1 2W 0 8YOr 1 2G 0 8G 22 1 2Gr CN 80 GLOW PLUG GLOW PLUG RY ECM 0 8B 0...

Page 214: ...ox 3 CHARGING CIRCUIT SERIAL NO 0610 When the starter is activated and the engine is started the operator releases the key switch to the ON position Charging current generated by operating alternator...

Page 215: ...0A 33 HAPTIC 10A 2 34 35 36 FUEL FEED PUMP AVM MODULE AMP 10A 10A HAPTIC 10A DCU POWER 30A 1 1 2W 1 2W 1 2W 1 2W 1 2W B P L G 3 U 1 2 FI NC 16 1 2RW 0 8Gr 0 8Br 0 8V 0 8B 0 8VOr 0 8RW 1 2 3 4 GND CAN1...

Page 216: ...2 l conn CN 7 1 Cigar light CL 2 l conn CN 5 60 Radio USB player illumination ON CN 27A 9 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 C...

Page 217: ...11 12 BEACON INT WIPER 13 15 18 26 27 GND GND WASHER CAN HI NC NC NC NC CABIN LIGHT WORK LIGHT WIPER TRAVEL ALARM IG 24V HEAD LIGHT CAN LO 34 NC 2 CN 36 FUSE BOX START KEY CLUSTER ROOM LAMP CASSETTE...

Page 218: ...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 11 Cab light ON CL 8 2 I conn CN 10 12 Cab light ON CL 9 2 CL 10...

Page 219: ...R CAN HI NC NC NC NC CABIN LIGHT WORK LIGHT WIPER TRAVEL ALARM IG 24V HEAD LIGHT CAN LO 34 NC 3 CN 36 FUSE BOX START KEY CLUSTER ROOM LAMP CASSETTE ECM AIR CON HEATER MCU SWITCH PANEL MCU CONT MCU_EPP...

Page 220: ...I conn CN 17 6 I conn CN 5 19 Washer pump CN 22 1 Washer 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 Continual operating Auto...

Page 221: ...8Gr 1 2Br 1 2BOr 1 2BW 1 2BOr 1 2B 1 2Br 1 2 4 4 8 1 2Br CN 376 MEMBRANE CONTROLLER 1 2 3 4 5 6 7 8 9 10 11 12 CAN_LO 2 INT WIPER NC 13 NC 14 OVERLOAD SW 15 16 17 18 TRVEL ALARM 19 26 27 CAN_HI 2 GND...

Page 222: ...A 1 DEF INJECTOR 2 1 UREA INJECTOR LS UREA INJECTOR HS CN 424 SERVICE TOOL A B C D E F G 0 8R H J IG 24V GND CAN A_Lo CAN A_Hi NC NC NC CDL CDL 0 8G 0 8G CN 126A WIF SENSOR 0 8R 0 8V 1 2 3 0 8B CD 45...

Page 223: ...2_LO L RS 232 RX 0 8L 9 L RS 232 TX 10 L AUX LEFT 11 L AUX 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 4 5 6 7 8 9 10 11 12 13 14 15 3 2 1 16 17 18 19 20 21 22 23 24 25 26 2R...

Page 224: ...29 A C BLOWER STATE 30 CAN 1 Lo 31 RETURN CHECK V V SOL 32 33 RS232 1 RX 34 35 PREHEAT SW 36 ENG OIL FILTER SW 37 DOZER PS 38 REVERSE FAN SW_AUTO 39 REVERSE FAN SW_ON 40 FUEL WARMER RY CAN 2 Hi CAN 3...

Page 225: ...ATING 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 2 1 2 1 2 1 2 2 1 1 2 1 2 1 2 3 4 5 6 7 8 CN 68 CN 264 CD 85 CN 366...

Page 226: ...ox No 7 l conn CN 11 5 AC Heater control box A 7 Blower relay 4 Fuse box No 8 I conn CN 5 18 I conn CN 17 5 Wiper motor controller CN 141 7 Wiper motor CN 21 4 I conn CN 8 6 Haptic controller CN 363 2...

Page 227: ...5 35 36 37 38 39 40 34 17 18 19 20 21 22 42 43 33 32 23 24 11 12 10 CN 5 1 2 3 4 25 26 DOOR SW CS 1 ROOM LAMP CL 1 12 11 10 9 8 7 CN 10 6 5 4 3 2 1 3 2 1 0 8Y 1 2Gr 1 2Gr 0 75Y CN 27A 1 2 3 4 5 6 7 8...

Page 228: ...3 GPS conn CN 125 2 4 I conn CN 5 40 Reader CN 427 1 RMS CN 125A 2 When start key switch is in START position CHECK POINT 1 1 2 2 Engine Start switch Check point Voltage OPERATING START GND battery GN...

Page 229: ...WER RY 87a 30 87 85 86 87a 85 87 86 30 2 0Gr CR 35 1 2 DO 3 1 0WOr 2 0RW 0 75B 1 2G 1 2G 1 2B 1 2B 40 44 59 60 34 35 36 37 38 39 33 1 2W 32 31 23 24 ALT VOLTAGE 51 15 UNITED MCU 0 8YOr 1 2BOr 1 2R GPS...

Page 230: ...box 3 CHARGING CIRCUIT SERIAL NO 0611 When the starter is activated and the engine is started the operator releases the start switch to the ON position Charging current generated by operating alternat...

Page 231: ...20A 10A 10A 20A 10A 10A 10A 10A 10A 10A 20A 20A 20A 15A 10A 10A 20A 20A 20A 20A 10A 10A 30A 30A 30A 5A 10A 20A 15A 10A 15A 30A SPARE 22 30A 10 B IG BATTERY RY IG POWER RY ALT VOLTAGE 51 15 UNITED MCU...

Page 232: ...87 Head light ON CL 3 1 CL 4 1 CL 24 1 l conn CN 7 1 Cigar light CL 2 l conn CN 5 60 Radio USB player illumination ON CN 27A 9 Work light switch ON Work light switch ON CN 376 4 Work light relay CR 4...

Page 233: ...87 85 87a 86 85 87 30 87a 1 2 1 2 30 86 87 85 87a 86 85 87 30 87a 2 1 1 2 1 2 CN 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 CN 27A 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 T...

Page 234: ...relay CR 85 1 5 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 11 Cab light ON CL 8 2 I co...

Page 235: ...22 30A 10 B IG BATTERY RY IG POWER RY 0 75WBr 3 7 5 1 1 0 75G 0 75Gr 0 75B 0 75B CN 5 1 2 3 4 5 6 31 57 58 59 60 39 32 33 34 35 36 37 38 49 50 51 52 53 56 0 75G 2 0R 2 0V 0 75R CABIN LAMP RELAY 87a 3...

Page 236: ...onn 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...

Page 237: ...8L 0 8YOr GrW B R L W G M 6 5 4 3 2 1 2 3 5 6 4 Gr R L G R WIPER MOTOR CN 21 CN 141 Gr R Or Br L V Or CS 53 WIPER CUT 1 2 3 CN 17 4 5 6 7 8 W B GrW V L Br R 1 2 3 4 5 6 7 VCC GND MOTOR DRIVE MOTOR DRI...

Page 238: ...HEATER 3 ACU SUPPLY B XDRG 0V CN379 XN1 DEF HEATER LINE 3 DEF HEATER LINE 2 DEF HEATER LINE 1 3W 120 TANK HEADER UNIT COOLANT DIVERTER VALVE 4 3 2 1 J1939 CAN C J1939 CAN C BATT GND 3 2 1 VALVE HS NC...

Page 239: ...RY DRVP 2 LINE 1 HEATER SUCTION 22 23 21 20 5 6 7 17 1 2 18 15 16 13 14 12 PH INJECTOR 11 PH INJECTOR 8 SCR TEMP 9 DOC TEMP 24 4 IGNITION 19 TANK HEATER 3 ACU SUPPLY B XDRG 0V CN379 XN1 SERVICE TOOL A...

Page 240: ...52 24 52 28 51 28 54 33 TRAVEL SPEED SOL 52 23 52 05 P1 REGULATOR EPPR TRAVEL BUZZER BOOM PRIORITY EPPR P2 REGULATOR EPPR PUMP EPPR BOOM PRIORITY EPPR ARM REGEN SOL ARM IN PS 51 21 P1 PRESS SENSOR 52...

Page 241: ...NFLUX ATT SAFETY SOL BREAKER SWING PARKING A1 SWING PARKING A2 SWING PARKING A3 SWING FINE CONT SOL BOOM DOWN FLOATING SOL BOOM UP FLOATING SOL BOOM DOWN CUTOFF SOL BOOM CYL ROD PS C B A SUPPLY SIG RE...

Page 242: ...contact Normal 0 942 For terminal 1 GND Start key B BR 24V 1A B ACC 24V 10A B ST 24V 40A Check contact OFF for each terminal ON 0 for terminal 1 3 and 1 2 START 0 for terminal 1 6 Pressure sensor 8 3...

Page 243: ...sure switch N O TYPE Check contact High level Low level 0 Fuel level sender Check resistance Full 50 6 12 350 11 12 100 5 12 400 10 12 150 4 12 450 9 12 200 3 12 500 8 12 250 2 12 550 7 12 300 1 12 60...

Page 244: ...nal 1 2 4 5 OFF for terminal 2 3 5 6 0 for terminal 1 2 4 5 87a 30 87 85 86 87a 85 87 86 30 CR 4 CR 7 CR 9 CR 35 CR 46 CR 13 4 24 1 2 CN 75 CN 133 CN 238 CN 239 CN 240 CN 241 CN 242 1 2 CN 66 CN 68 CN...

Page 245: ...on lamp 21V 70W H1 Type Check disconnection Normal A few Fuel filler pump 24V 10A 35 min Check resistance Normal 1 0 Hour meter 16 32V Check operation Supply power 24V to terminal No 2 and connect ter...

Page 246: ...eck contact Normal Radio USB player 24V 2A Check voltage 20 25V for terminal 1 3 3 8 Washer pump 24V 3 8A Check contact Normal 10 7 for terminal 1 2 Wiper motor 24V 2A Check disconnection Normal 7 for...

Page 247: ...sistance Normal About 1M Check contact Normal Operating time 5 15sec Alternator Delco Remy 24V 100A Check contact Normal 0 for terminal B 2 Normal 24 27 5V Starter 24V 4 8kW Check contact Normal 0 1 T...

Page 248: ...2 Blower motor 24V 9 5A Check resistance Normal 2 5 for terminal 1 2 Thermistor 1 C OFF 4 C ON Check resistance Normal 0 for terminal 1 2 the atmosphere temp Over 4 C Door switch 24V 2W Check resistan...

Page 249: ...er switch 6 36V Check disconnection Normal 0 1 Breaker switch Quick clamp buzzer 24V 200mA 107 4dB Socket 12V 10A Switch 24V 8A Check contact Normal ON 0 for terminal 2 3 5 6 for terminal 1 2 4 5 OFF...

Page 250: ...5 6 DEF AdBlue line heater WIF sensor Check disconnection Normal 68 8 4 94 DEF AdBlue fill up warning lamp LED Proportional valve sensor CD 45 1 2 3 CS 79 CS 100 1 2 10 9 2 3 4 5 6 7 8 9 10 8 4 5 6 3...

Page 251: ...nt Coolant diverter valve Proportional valve sensor Dozer act pressure switch N O type Check resistance Normal open Water level sensor CL 41 2 1 CN 429 1 2 CN 308 SIG V Us SIG V Udc GND ERROR 1 2 3 4...

Page 252: ...mbol Specifications Check Camera NOx sensor tail out turbo out CN 402 4 3 2 1 LVDS POS GND LVDS NEG POWER 24V 5 NC 6 ADJUST SIGNAL CN 403 CN J7A CN J7B 3 4 5 J1939 LO GND ADDRESS SELEC 2 1 6 J1939 J19...

Page 253: ...6 12S EP06 DT04 12PA P021 CN 11 DEUTSCH 8 I conn Frame harness Aircon harness DT06 8S EP06 CN 12 DEUTSCH 2 I conn Frame harness Boom wire harness DT06 2S EP06 DT04 2P E005 CN 13 AMP 8 I conn Frameharn...

Page 254: ...A P021 CN 126 AMP 10 I conn Frame harness Service tool 2 1418390 1 S816 110002 CN 126 DEUTSCH 4 Service tool DT06 4S DT04 4P CN 126A 9 Service tool HD10 9 969 CN 133 DEUTSCH 2 Boom priority solenoid D...

Page 255: ...solenoid DT06 2S EP06 CN 376 AMP 34 Membrane controller 4 1437290 1 CN 378 DEUTSCH 2 Attach EPPR 1 MCU 1 DT06 2S EP06 CN 379 XNI DEUTSCH 24 DCU module HDP24 24 31ST CN 381 DEUTSCH 2 DEF AdBlue line he...

Page 256: ...ay CR 23 KET 2 Start relay MG640322 CR 24 RING TERM 1 Preheat relay S822 014000 CR 35 5 Power relay CR 36 5 Preheat relay CR 85 5 Beacon lamp relay CR 95 5 Feed pump relay CR 101 5 DCU relay Switch CS...

Page 257: ...002 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 Cab light DT06 2S EP06 DT04 2P CL 24 DEUTSCH 2 Head lamp DT06 2S EP06 DT04 2P E005...

Page 258: ...sensor DT06 3S EP06 CD 70 DEUTSCH 3 N1 pressure sensor DT06 3S EP06 CD 71 DEUTSCH 3 N2 pressure sensor DT06 3S EP06 CD 85 DEUTSCH 2 Boom down sensor DT06 2S EP06 CD 90 DEUTSCH 2 Arm in pressure senso...

Page 259: ...UTSCH 2 I conn Frame harness Boom wire harness DT06 2S EP06 DT04 2P E005 CN 13 AMP 8 Boom floating solenoid 174982 2 174984 2 CN 14 DEUTSCH 2 I conn Frameharness Swingparkingharness DT06 2S EP06 DT04...

Page 260: ...n Frame harness Service tool S816 010002 S816 110002 CN 126 DEUTSCH 4 Service tool DT06 4S DT04 4P CN 126A 9 Service tool HD10 9 96P CN 133 DEUTSCH 2 Boom priority solenoid DT06 2S EP06 CN 135 DEUTSCH...

Page 261: ...0 DEUTSCH 2 Swing fine control solenoid DT06 2S EP06 DT04 2P E005 CN 376 AMP 34 Membrane controller 4 1437290 1 CN 379 XN1 DEUTSCH 24 DCU module HDP24 24 31ST CN 381 DEUTSCH 2 DEF AdBlue line heater 3...

Page 262: ...2 CR 24 1 Preheat relay S822 014000 CR 35 5 Power relay CR 36 5 Preheat relay CR 85 5 Beacon lamp relay CR 95 5 Feed pump relay CR 101 5 DCU relay Switch CS 1 SHUR 1 Door switch S822 014002 CS 2A WP 6...

Page 263: ...2S EP06 DT04 2P CL 9 DEUTSCH 2 Cab light RH DT06 2S EP06 DT04 2P CL 10 DEUTSCH 2 Cab light DT06 2S EP06 DT04 2P CL 24 DEUTSCH 2 Head lamp rear DT06 2S EP06 DT04 2P E005 CL 40 DEUTSCH 2 DEF AdBlue purg...

Page 264: ...6 CD 70 DEUTSCH 3 N1 pressure sensor DT06 3S EP06 CD 71 DEUTSCH 3 N2 pressure sensor DT06 3S EP06 CD 85 DEUTSCH 3 Boom down pressure sensor DT06 3S EP06 CD 90 DEUTSCH 3 Arm in pressure sensor DT06 3S...

Page 265: ...lug 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 CONNECT...

Page 266: ...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 267: ...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 10800...

Page 268: ...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 TYP...

Page 269: ...ptacle 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...

Page 270: ...n 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 TYP...

Page 271: ...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 272: ...2 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 Recep...

Page 273: ...2 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...

Page 274: ...o 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 CONNECTO...

Page 275: ...4 49 No of pin Receptacle connector female Plug connector male 14 1 7 6 14 MG610406 KET SDL CONNECTOR 13...

Page 276: ...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 Combinat...

Page 277: ...4 51 6 1 4 3 5 4 8 1 7 6 12 1 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 278: ...or 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...

Page 279: ...3 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 1020...

Page 280: ...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 281: ...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 HD3...

Page 282: ...20 30 1 5 6 10 31 40 11 21 20 30 35 36 DRC26 40SA B DEUTSCH MCU CONNECTOR SERIAL NO 0610 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 TOO...

Page 283: ...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 1...

Page 284: ...1 5 3 25 1 10 18 26 9 34 17 25 27 28 29 31 32 33 4 5 6 3 7 1 10 18 26 9 34 17 25 27 28 29 31 32 33 4 5 6 3 7 No of pin Receptacle connector Female Plug connector Male 26 1473416 1 34 4 1437290 0 34 4...

Page 285: ...tem 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 Boom Floating Control System 5 13 Group 11 Intell...

Page 286: ...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 Use...

Page 287: ...2 P3 EPPR pressure Overload pressure sensor SL SR Swing pressure AO AI Arm in out Bucket in pressure BI Boom down pressure BD Work tool Cluster CAN 1 2 Pressure signal Pressure signal Pressure signal...

Page 288: ...work to a light and precise work 1 POWER MODE SELECTION SYSTEM 140L5MS02 GROUP 2 MODE SELECTION SYSTEM Power shift Standard Option can be changed by Service menu in Management on the cluster Load Powe...

Page 289: ...gen Boom 1 Option 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...

Page 290: ...00 750 0 2 1400 800 3 3 1500 850 6 4 1600 900 9 5 1700 950 12 6 1800 1000 16 7 1850 1050 20 8 1900 1100 auto decel 26 9 1950 1150 32 10 2000 1200 38 1 2 CAN 1 2 Main pump Pilot pump Engine ECM CAN 1 M...

Page 291: ...eed to 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...

Page 292: ...l lever knob 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...

Page 293: ...ontrol 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 T...

Page 294: ...he 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 du...

Page 295: ...CAN 1 2 140L5MS09 Description Condition Function First step warning Activated Coolant temperature Above 103 C Hydraulic oil temperature Above 100 C Warning lamp ON buzzer OFF Pump input torque is redu...

Page 296: ...2 RH control lever LH control lever SL SR Swing pressure AO AI Arm in out Bucket in pressure BI Boom up pressure BD PS PS PS PS Arm in pressure BU PS Boom down pressure The variable power control syst...

Page 297: ...C L U S T E R A IR C O N O F F CAN 2 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 a...

Page 298: ...ctivated just in case the excavator is not in jack up status 300L5MS17 Description Condition Function Work mode 1 Floating mode General mode Boom up floating 2 Floating mode sw ON Rod to tank solenoid...

Page 299: ...rm in out Bucket in pressure BI Boom up pressure BU PS PS PS PS Arm in pressure BD PS Boom down pressure Option Arm 1 Boom 2 Swing Bucket Arm 2 Arm regen Boom 1 Option Travel RH Travel LH Dozer When t...

Page 300: ...rate limit can be selected at Mode setup IPC mode 2 IPC mode Description Balance mode default IPC mode ON limit level 1 Efficiency mode IPC mode ON limit level 2 Speed mode IPC mode OFF Pi bar Q cc re...

Page 301: ...TEM Engine Starter MCU Drive signal Anti restart 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 in...

Page 302: ...res 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 c...

Page 303: ...o 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...

Page 304: ...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 failu...

Page 305: ...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 1...

Page 306: ...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...

Page 307: ...V 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 Mon...

Page 308: ...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 Pri...

Page 309: ...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...

Page 310: ...e cut off failure Checking list 1 CR 47 85 CN 54 9 Checking Open Short 2 CR 47 30 86 Fuse box 28 Checking Open Short 166 4 Detection When Power Max Solenoid is Off 10 seconds continuous Power Max Sole...

Page 311: ...easurement 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 se...

Page 312: ...ode crusher mode Checking list 1 CN 237 1 CN 53 7 Checking Open Short 2 CN 237 2 Fuse box 27 Checking Open Short 170 4 Model Parameter mounting Arm Regenerating Solenoid Detection When Arm Regeneratio...

Page 313: ...list 1 CN 149 1 CN 53 8 Checking Open Short 2 CN 149 2 Fuse box 27 Checking Open Short 179 4 Monitor Selecting attachment breaker crusher Detection When Breaker Operating Solenoid is Off 10 seconds c...

Page 314: ...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 contin...

Page 315: ...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 pre...

Page 316: ...en 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 Canc...

Page 317: ...1 Control Function Boom floating control operation failure Checking list 1 CN 369 1 CN 53 35 Checking Open Short 2 CN 369 2 Fuse box 14 Checking Open Short 221 5 Monitor Selecting attachment breaker...

Page 318: ...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 CN 2 2 CN 52 26 Checking Open Short...

Page 319: ...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 C...

Page 320: ...CR 66 2 Fuse box 30 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...

Page 321: ...e Checking list 1 CN 69 1 CN 54 8 Checking Open Short 2 CN 69 2 Fuse box 33 Checking Open Short 527 4 Detection When Creep Solenoid is Off 10 seconds continuous Creep Solenoid drive unit Measurement V...

Page 322: ...sor Measurement Voltage 0 3V 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 2...

Page 323: ...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...

Page 324: ...tic 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 Shor...

Page 325: ...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 oper...

Page 326: ...uto Idle operation failure Engine variable horse power control operation failure Checking list 1 CD 7 B CN 52 19 Checking Open Short 2 CD 7 A CN 51 32 Checking Open Short 3 CD 7 C CN 51 31 Checking Op...

Page 327: ...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 fail...

Page 328: ...e 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 51...

Page 329: ...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...

Page 330: ...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 Mo...

Page 331: ...Checking Open Short 2 CN 75 1 CN 54 01 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 Pr...

Page 332: ...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...

Page 333: ...e cut off failure Checking list 1 CR 47 85 CN 54 9 Checking Open Short 2 CR 47 30 86 Fuse box 28 Checking Open Short 166 4 Detection When Power Max Solenoid is Off 10 seconds continuous Power Max Sole...

Page 334: ...easurement 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 se...

Page 335: ...de crusher mode Checking list 1 CN 237 1 CN 52 16 Checking Open Short 2 CN 237 2 Fuse box 19 Checking Open Short 170 4 Model Parameter mounting Arm Regenerating Solenoid Detection When Arm Regeneratio...

Page 336: ...list 1 CN 149 1 CN 53 09 Checking Open Short 2 CN 149 2 Fuse box 19 Checking Open Short 179 4 Monitor Selecting attachment breaker crusher Detection When Breaker Operating Solenoid is Off 10 seconds c...

Page 337: ...A Results Symptoms 1 Control Function Cooling Fan reverse control operation failure not applicable 188 5 Detection When pump P1 regulator EPPR current is equal or more than 300 mA 10 seconds continuo...

Page 338: ...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 p...

Page 339: ...pen 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 Can...

Page 340: ...1 Control Function Boom floating control operation failure Checking list 1 CN 369 1 CN 53 08 Checking Open Short 2 CN 369 2 Fuse box 19 Checking Open Short 221 5 Monitor Selecting attachment breaker...

Page 341: ...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 51 19 Checking Open Short...

Page 342: ...oltage 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...

Page 343: ...CR 66 2 Fuse box 30 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...

Page 344: ...Checking list 1 CN 69 1 CN 53 12 Checking Open Short 2 CN 69 2 Fuse box 33 Checking Open Short 527 4 Detection When Creep Solenoid is Off 10 seconds continuous Creep Solenoid drive unit Measurement V...

Page 345: ...or Measurement Voltage 0 3V 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 52 20...

Page 346: ...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...

Page 347: ...g the RMCU 60 seconds continuous RMCU communication Data Error Resuluts Symptoms 1 Control Function RMCU operation failure Checking list 1 CN 125A 3 CN 51 09 Checking Open Short 2 CN 125A 11 CN 51 08...

Page 348: ...list 1 CN 56A 7 CN 51 08 Checking Open Short 2 CN 56A 6 CN 51 09 Checking Open Short 869 2 When mounting the BKCU 60 seconds continuous BKCU communication Data Error Results Symptoms 1 Control Functio...

Page 349: ...bination of positions for the multi position switch If equipped the warning light will come on The ECM will log the diagnostic code Throttle Switch Circuit Test 29 2 Accelerator Pedal Position 2 Errat...

Page 350: ...at least 3 seconds Diagnostic codes 29 3 774 3 29 4 and 774 4 are not active There are no active 678 or 41 codes The ECM sets the Throttle Position to 0 If equipped the warning lamp will come on The d...

Page 351: ...imit has been exceeded for one second If equipped the warning lamp will come on The diagnostic code will be logged Digital Throttle Position Sensor Circuit Test 91 8 Accelerator Pedal Position 1 Abnor...

Page 352: ...e derated Low Engine Oil Pressure 100 3 Engine Oil Pressure Voltage Above Normal The Electronic Control Module ECM detects signal voltage that is not in the accept able range The code is logged The va...

Page 353: ...lectronic Control Module ECM detects the following conditions The signal voltage from the intake manifold air temperature sensor is greater than 4 95 VDC for more than 8 seconds Engine coolant tempera...

Page 354: ...s logged Normal The value of the parameter is set to a gauge pressure Sensor Signal Analog Active Test 107 4 Engine Air Filter 1 Differential Pressure High Voltage Below Normal The ECM detects signal...

Page 355: ...The ECM detects the following conditions The signal voltage from the engine coolant temperature sensor is less than 0 2 VDC for more than 8 seconds An active diagnostic code will be generated after 8...

Page 356: ...ring Rail 1 Pressure High least severe 1 Fuel Rail Pressure Problem 157 16 Engine Injector Metering Rail 1 Pressure High moderate severity 2 No other 157 XX or 1797 XX codes are active 3509 XX or 262...

Page 357: ...Circuit Test Passive Sensors 174 4 Engine Fuel Temperature 1 Voltage Below Normal The ECM detects the following conditions The signal voltage from the fuel temperature sensor is less than 0 2 VDC for...

Page 358: ...of the parameter is set to a gauge pressure Sensor Signal Analog Active Test 411 4 Engine Exhaust Gas Recirculation Differential Pressure Voltage Below Normal The ECM detects signal voltage that is no...

Page 359: ...l 1 Low Idle Switch Erratic Intermittent or Incorrect The EIectronic Control Module ECM detects the following condition The signal from the Idle Validation Switch IVS is invalid If equipped the warnin...

Page 360: ...649 5 Engine Exhaust Back Pressure Regulator Solenoid Current Below Normal The ECM detects the following conditions A low current condition in the output for the exhaust back pressure regulator for 2...

Page 361: ...operate the electronic unit injector after the diagnostic code has been logged An open circuit will prevent the operation of the electronic unit injector Injector Solenoid Circuit Test 651 6 Engine I...

Page 362: ...he operation of the electronic unit injector Injector Solenoid Circuit Test 652 6 Engine Injector Cylinder 02 Current Above Normal These diagnostic codes indicate a short circuit high current in eithe...

Page 363: ...he operation of the electronic unit injector Injector Solenoid Circuit Test 653 6 Engine Injector Cylinder 03 Current Above Normal These diagnostic codes indicate a short circuit high current in eithe...

Page 364: ...circuit high current in either the solenoid or the wiring for the electronic unit injector The ECM detects the following conditions A high current condition short circuit for each of five consecutive...

Page 365: ...he following conditions The engine is not cranking The ECM has been powered for at least one second There is a high current condition short circuit in the glow plug start aid relay circuit for more th...

Page 366: ...r Circuit Test 1075 5 Engine Electric Lift Pump For Engine Fuel Supply Current Below Normal The Electronic Control Module ECM detects the following conditions There are no active 168 diagnostic codes...

Page 367: ...iagnostic code This diagnostic code detects a fault in the circuit for the fuel pump solenoid This fault is most likely to be caused by a high side short to ground or a low side short to power Solenoi...

Page 368: ...Electronics Unit PEU the ammonia sensor the soot sensor or a NOx sensor has incorrectly stopped or started transmitting a data request This diagnostic code applies to the CAN C datalink The ECM will...

Page 369: ...l Voltage Above Normal Motorized Valve Test 2791 5 Engine Exhaust Gas Recirculation EGR Valve Control Current Below Normal The ECM detects the following conditions A low current condition in the outpu...

Page 370: ...detects a failure of the temperature sensor The code is logged DEF AdBlue Tank Sensor Test 3031 16 Aftertreatment 1 DEF AdBlue Tank Temperature High moderate Severity 2 The temperature of the Diesel E...

Page 371: ...ted Sensor Data Link Type Test 3227 16 Aftertreatment 1 Outlet O2 High Moderate Severity 2 The Engine Out NOx Sensor is reading a higher than expected level of Oxygen 02 Clean Emissions Module Has Hig...

Page 372: ...3 Engine Exhaust Gas Recirculation Inlet Pressure Calibration Required The ECM detects the following conditions The offset between the NRS inlet pressure and the barometric pressure is outside the acc...

Page 373: ...ECM detects the following conditions A low current condition in the output from the DCU to the solenoid in the DEF There are no active 168 diagnostic codes The warning lamp will come on The diagnosti...

Page 374: ...ode 168 4 is not active The warning lamp will come on The ECM sets all the sensors on the 5 VDC circuit to the default values The engine will be derated 5 V Sensor Supply Circuit Test 3511 3 Sensor Su...

Page 375: ...ter is set to a gauge pressure Engine Pressure Sensor Open or Short Circuit Test 3563 13 Engine Intake Manifold 1 Absolute Pressure Calibration Required The ECM detects the following conditions The of...

Page 376: ...DEF AdBlue Line Heater 1 Current Above Normal This code indicates that there is a fault in the 1 suction line heater circuit that is probably a short circuit DEF AdBlue Line Heater Test 4355 5 Aftert...

Page 377: ...temperature sensor has detected that the SCR intake temperature is far below the normal operating range SCR Catalyst Has Incorrect Inlet Temperature 4360 20 Aftertreatment 1 SCR Catalyst Intake Gas Te...

Page 378: ...ure on the electronic service tool Sensor Signal Analog Passive Test 4765 17 Aftertreatment 1 Diesel Oxidation Catalyst Intake Gas Temperature Low least severe 1 ECM detects that the DOC inlet tempera...

Page 379: ...the Action lamp is flashing and the warning horn may sound The engine is derated The engine may stop SCR Warning System Problem 5246 15 Aftertreatment SCR Operator Inducement Severity High least seve...

Page 380: ...o signal is detected from the aftertreatment identification module There are no active 5 V supply diagnostic codes The ECM has been powered for 2 seconds Do not continue to operate the engine with the...

Page 381: ...it Relay Test Aftertreatment Power Relay 5966 5 Aftertreatment 1 DEF AdBlue Control Module Power Supply Current Below Normal A low current condition has been detected on the start switch circuit betwe...

Page 382: ...ge from the aftertreatment ambient air temperature sensor is less than 0 2 VDC for more than 8 seconds An active diagnostic code will be generated after 8 seconds The diagnostic code will be logged if...

Page 383: ...nication 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 A...

Page 384: ...s below 1 2 ECM Engine control module LED C N 5 1 C N 5 2 1 2 1 MCU 2 Bolt M8 140L5MS52 G green R red Y yellow LED lamp Trouble Service G is turned ON Normal G and R are turned ON Trouble on MCU Chang...

Page 385: ...C N 5 2 C N 5 3 LED C N 5 1 C N 5 4 1 2 ECM Engine control module 1 United MCU 2 Bolt M8 140L5MS152 G green R red Y yellow LED lamp Trouble Service G is turned ON Normal G and R are turned ON Trouble...

Page 386: ...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...

Page 387: ...to 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 Sle...

Page 388: ...e 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 ta...

Page 389: ...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 sole...

Page 390: ...Remove hose from A5 port 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 pr...

Page 391: ...the machine control system 2 CLUSTER MONITOR PANEL 1 The warning lamp pops up and or blinks and the buzzer sounds when the machine has a problem The warning lamp blinks until the problem is cleared R...

Page 392: ...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 m...

Page 393: ...L 0 5V 6 CAN 2 H 20 32V 7 CAN 2 L 20 32V 8 RS 232 RX 15V 9 RS 232 TX 15V 10 Aux left 0 5V 11 Aux right 0 5V 12 Aux GND No Name Signal 1 CAM 6 5V 6 3 6 7V 2 CAM GND 3 CAM DIFF H 0 5V 4 CAM DIFF L 0 5V...

Page 394: ...32V 2 Power IG 24V 20 32V 3 GND 4 CAN 1 H 0 5V 5 CAN 1 L 0 5V 6 CAN 2 H 0 5V 7 CAN 2 L 20 32V 8 NC 9 NC 10 Aux left 0 5V 11 Aux right 0 5V 12 Aux GND No Name Signal 1 CAM 6 5V 6 3 6 7V 2 CAM GND 3 CAM...

Page 395: ...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 7 4 6 5 6 2 3 8...

Page 396: ...problem 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 electric...

Page 397: ...us So that operators can be careful with fuel econo my The fuel consumption rate or machine load is higher the number of segment is increased The color of Eco gauge indicates operation status White Id...

Page 398: ...All warning lamps except below Warning lamp pops up on the center of the LCD and the buzzer sounds The pop up warning lamp moves to the original position and blinks and the buzzer stops when the buzz...

Page 399: ...ng lamp 4 0 0 0 0 0 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 Th...

Page 400: ...sure warning lamp 5 This warning lamp pops up and the buzzer sounds when the communication between MCU and engine ECM on the engine is abnormal or if the cluster received specific fault code from engi...

Page 401: ...lamp 7 This warning lamp pops up and the buzzer sounds when the filter of air cleaner is clogged Check the filter and clean or replace it Air cleaner warning lamp 8 When the machine is overload the ov...

Page 402: ...the DEF AdBlue tank Fill the DEF AdBlue immediately in the DEF AdBlue tank Refer to page 5 70 Engine stop warning lamp 10 290F3CD252 This warning lamp pops up and the buzzer sounds when the water sep...

Page 403: ...any more when this lamp lights ON Otherwise DEF AdBlue tank may freeze and burst in winter season DEF AdBlue level warning lamp DEF AdBlue fill up warning lamp 12 13 290F3CD272 LCD Warning lamp Descr...

Page 404: ...Decel pilot lamp Maintenance pilot lamp Power max pilot lamp Preheat pilot lamp Warming up pilot lamp Smart key pilot lamp 290F3CD74 Mode pilot lamps 1 No Mode Pilot lamp Selected mode 1 Power mode H...

Page 405: ...cel is not available when the auto idle pilot lamp is turned ON Refer to the operator s manual page 3 38 Decel pilot lamp This lamp is turned ON when the coolant temperature is below 10 C 50 F or the...

Page 406: ...ng Refer to the page 5 88 Entertainment pilot lamp This lamp is ON when the engine is started by the start button This lamp is red when the a authentication fails green when succeeds Refer to the page...

Page 407: ...select 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 equippe...

Page 408: ...is 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 pro...

Page 409: ...rk 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 re...

Page 410: ...ways activate the 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 78 This switch is to activate travel alarm funct...

Page 411: ...CU Engine ECM MCU Engine ECM All logged fault delete Initialization canceled Machine information Switch status Output status 3 Fuel rate information Maintenance information Machine security Machine in...

Page 412: ...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 fun...

Page 413: ...rated 290F3CD117 210WF3CD118 LSF prgh 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 P...

Page 414: ...l initial step 0 9 step Automatic engine shutdown option 210WF3CD11 210WF3CD12 210WF3CD13 The automatic engine shutdown function can be set by this menu One time Always Disable Wait time setting Max 4...

Page 415: ...input Digital output The activated switch or output pilot lamps are light ON 290F3CD120 290F3CD128 290F3CD134 290F3CD172 290F3CD121 290F3CD123 290F3CD126 290F3CD188 290F3CD124 290F3CD127 290F3CD189 2...

Page 416: ...ne 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...

Page 417: ...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...

Page 418: ...erator 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...

Page 419: ...50 290F3CD151 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 mod...

Page 420: ...date cluster ETC devices 210WF3CD17 210WF3CD18 380F3CD06 210WF3CD19 380F3CD04 ETC devices and cluster can be updated through CAN 2 network Insert USB memory stick which includes program files start do...

Page 421: ...ar each The second line shows the current time 0 00 23 59 290F3CD154 290F3CD157 290F3CD159 290F3CD155 290F3CD158 290F3CD160 290F3CD141 290F3CD156 290F3CD139 290F3CD191 290F3CD192 Brightness If Auto is...

Page 422: ...language Screen type A Type Default B Type Option 290F3CD163 290F3CD164 290F3CD165 290F3CD166 290F3CD156A 290F3CD194 290F3CD167A Unit 290F3CD161 210WF3CD162 290F3CD193 Temperature C F Pressure bar MP...

Page 423: ...8 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...

Page 424: ...meter can be turned on by choosing Start while it also can be turned off by choosing Stop If the tripmeter icon is activated in the operation screen it can be controlled directly there If the rear cam...

Page 425: ...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 b...

Page 426: ...perature configuration sensing ambient and cabin inside temperature 7 Cluster Auto switch Power switch Air conditioner switch Fersh air air recirculation switch Temperature switch A A Air mode switch...

Page 427: ...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 Air conditioner switch Se...

Page 428: ...method Fresh air Inhaling air from the outside Air recirculation It recycles the heated or cooled air to increase the energy efficiency Change air occasionally when using recirculation for a long tim...

Page 429: ...orate temperature sensor open 0 C alternate value control F06 Evaporate temperature sensor short F07 Null F08 Null F09 Mode 1 actuator open short The alternate value is face F10 Mode 1 actuator drive...

Page 430: ...Y POWER 24V CN 53 1 1 2B 0 8RW MCU 1 2R START KEY CLUSTER ROOM LAMP CASSETTE ECM AIR CON HEATER MCU SWITCH PANEL MCU CONT MCU_EPPR FLOATING SOL WORK LAMP CABIN LAMP OPTION CLUSTER CONVERTER PVG CONTRO...

Page 431: ...28 BREAKER 31 SEAT HEAT 27 SOLENOID 19 2 13 21 HEAD LAMP 29 30 9 16 CLUSTER B CLUSTER IG 15 RADIO IG 20 WIPER 8 CONVERTER 32 ROOM LAMP RADIO B 4 36 CABIN LAMP 24 33 FUEL FILLER PUMP 26 34 25 7 AIR CO...

Page 432: ...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 433: ...ctrical system and Mechatronics system At each system part an operator can check the machine according to the troubleshooting process diagram Troubles occur Mechatronics part Hydraulic Mechanical part...

Page 434: ...he 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 Ins...

Page 435: ...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 troubles...

Page 436: ...ill 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...

Page 437: ...l 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 Stru...

Page 438: ...terior 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 hydrauli...

Page 439: ...t 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 an...

Page 440: ...evel 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...

Page 441: ...valve 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 o...

Page 442: ...huttle 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 Disa...

Page 443: ...ing 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 fault...

Page 444: ...N 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 i...

Page 445: ...ravel 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 Disassembl...

Page 446: ...raulic 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 Disassem...

Page 447: ...hat 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 Inspectaccordin...

Page 448: ...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...

Page 449: ...VED 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...

Page 450: ...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...

Page 451: ...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...

Page 452: ...een 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 oi...

Page 453: ...sassemble 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 exc...

Page 454: ...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 in...

Page 455: ...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 c...

Page 456: ...ss 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 9 FUSE NO 15 FUSE Starting...

Page 457: ...air 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 Befo...

Page 458: ...wiring harness or poor contact between CN 52 27 CN 2 18 Disconnection in wiring harness or poor contact between CN 2 18 alternator terminal L Defective alternator Replace Repair or replace after clea...

Page 459: ...N 51 2 34 1 16 SERVICE TOOL B G D E F GND 9 10 CN 3 CDL CAN A_Hi CDL CAN A_Lo 6 5 3 CN 126A 140L6ES03 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor en...

Page 460: ...y 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 A...

Page 461: ...AMP 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...

Page 462: ...h ON Engine Start Does display go off when disconnect CD 1 Resistance between CN 51 5 and CN 52 24 is 0 1 Starting switch OFF Disconnect CN 51 Resistance between CD 1 1 2 is in range of 164 151 Starti...

Page 463: ...4 1 16 SERVICE TOOL B G D E F GND 9 10 CN 3 CDL CAN A_Hi CDL CAN A_Lo 6 5 3 CN 126A 140L6ES03 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor engine har...

Page 464: ...DER 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 Sp...

Page 465: ...fety switch Disconnection in wiring harness between CN 68 2 fuse No 25 Check hydraulic system Replace Repair or replace after clean Repair or replace after clean Replace Repair or replace Check voltag...

Page 466: ...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...

Page 467: ...e start relay Disconnection in wiring harness or poor contact between CN 2 16 CR 5 5 Defective anti restart relay Defectivestartrelay Disconnection in wiring harness or poor contact betweenCN 2 16 CR...

Page 468: ...clean Replace Replace Chargeorreplace afterclean Chargeorreplace afterclean Replace Chargeorreplace afterclean Specific gravity MIN 1 28 Voltage MIN 24V Check voltage and specific gravity of battery...

Page 469: ...wiring harness or poor contact between CN 141 7 Fuse CN 21 4 Fuse 1 Recheck fuse No 19 2 Disconnection CN 141 6 Fuse Disconnection in wiring harness or poor contact Defective wiper motor Defective wip...

Page 470: ...LAMP SW IG 24V WASHER 34 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 Defective switch panel Disconnection in wiring harness o...

Page 471: ...NC NC NC BEACO LAMP SW IG 24V WASHER 34 Cause Remedy Defective bulb Disconnection in wiring harness or poor contact between CR 4 87 CL 5 2 Defective switch panel Disconnection in wiring harness or po...

Page 472: ...otherwise specified YES YES NO NO Check voltage between CN 56A 2 and 3 Check voltage between CN 5 9 and 10 No 16 CLUSTER BATT 24V GND IG 24V 1 2 3 CN 56A 11 10 9 CN 5 No 9 FUSE FUSE Starting switch ON...

Page 473: ...lace 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 140L6ES102 Before disconnecting the connector always turn the starting switch...

Page 474: ...ess or poor contact between CN 51 15 CN 2 18 Disconnection in wiring harness or poor contact between CN 2 18 alternator CN 74 2 Defective alternator Replace Repair or replace after clean Repair or rep...

Page 475: ...CN 52 2 03 4 SERVICE TOOL D F B C E P DUMP 25 26 ENGINE ECM CAN Hi CAN Lo CN93 J1 9 10 CN 3 140L6ES103 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor...

Page 476: ...e Remedy Clogged air filter or defective switch Short circuit in wiring harness between CD 10A CN 54 13 Defective united MCU Check filter or replace switch Repair or replace After clean Replace 25 AIR...

Page 477: ...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 inser...

Page 478: ...Starting switch ON Engine Start Does display go off when disconnect CD 1 Resistance between CN 51 16 and CN 51 25 is 0 1 Starting switch OFF Disconnect CN 51 Resistance between CD 1 1 2 is in range o...

Page 479: ...03 4 SERVICE TOOL D F B C E P DUMP 25 26 ENGINE ECM CAN Hi CAN Lo CN93 J1 9 10 CN 3 140L6ES103 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor engine h...

Page 480: ...EL LEVEL SENDER Cause Remedy Defective united MCU or cluster Disconnection in wiring harness or poor contact between fuel sender united MCU Defective fuel sender Replace Repair or replace Replace YES...

Page 481: ...afety switch Disconnection in 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 volta...

Page 482: ...ravel speed switch on the cluster CheckunitedMCU Cause Remedy Disconnection in wiring harness or poor contact between CN 70 CN 52 Defective solenoid Defective hydraulic system Disconnection in wiring...

Page 483: ...of start motor Defective start relay Disconnection in wiring harness or poor contact between CN 2 16 CR 5 5 Defective anti restart relay Defectivestartrelay Disconnection in wiring harness or poor con...

Page 484: ...Chargeorreplace afterclean Chargeorreplace afterclean Replace Chargeorreplace afterclean Specific gravity MIN 1 28 Voltage MIN 24V Check voltage and specific gravity of battery Voltage 20 30V Voltage...

Page 485: ...ce Repair or replace after clean Replace Replace Repair or replace after clean Replace Repair or replace after clean Repair or replace after clean Replace Replace Cause Remedy Check voltage between CN...

Page 486: ...IG 24V WASHER 34 Cause Remedy Defective bulb Disconnection in wiring harness or poor contact between CR 13 87 CL 4 1 or CR 13 87 CL 3 1 or CR 13 87 CL 24 1 Defective RDU membrane controller Disconnec...

Page 487: ...5 87a 30 86 85 87 87a CL 5 1 2 CN 12 1 2 Cause Remedy Defective bulb Disconnection in wiring harness or poor contact between CR 4 87 CL 5 1 Defective RDU membrane controller Disconnection in wiring ha...

Page 488: ...are properly 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 25 20 C SeeTEST 1 Check electric current at EPPR valve Check...

Page 489: ...valve Check electric current at bucket circuit relief position 2 SPEC 15 25 20 C 14096MS33 Test 3 Check pressure at EPPR valve Remove plug and connect pressure gauge as figure Gauge capacity 0 to 50 k...

Page 490: ...YES SPEC 100 700 mA See TEST 4 SPEC 2 25 kgf cm2 See TEST 5 SPEC 15 25 20 See TEST 1 Check electric current at EPPR valve Check pressure at EPPR valve Check resistance between at EPPR valve Cause Rem...

Page 491: ...w locknut Valve casing CN 75 EPPR valve Pilot pressure supply line 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 Star...

Page 492: ...in the MCU case Check connection 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 5 Replace Replace Check...

Page 493: ...D 6 C 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...

Page 494: ...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 Fem...

Page 495: ...P1 pressure 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...

Page 496: ...eel 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...

Page 497: ...P2 pressure 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...

Page 498: ...teel 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 3...

Page 499: ...sor Short 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...

Page 500: ...teel 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 3...

Page 501: ...ive N1 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...

Page 502: ...teel 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 3...

Page 503: ...ive N2 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...

Page 504: ...teel 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 3...

Page 505: ...TURN A 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 b...

Page 506: ...teel 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 3...

Page 507: ...C CD 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 circui...

Page 508: ...teel 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 3...

Page 509: ...URN A B 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 connectio...

Page 510: ...teel 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 3...

Page 511: ...RE SENSOR 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...

Page 512: ...n 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 4...

Page 513: ...onnectionbetween CN 51 18 CS 29 Shortcircuitorpoor connectionbetween CN 88 2 FuseNo 30 Repairorreplace Repairorreplace Repairorreplace Repairorreplace 14 MALFUNCTION OF POWER MAX SERIAL NO 0610 Fault...

Page 514: ...olenoid 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 M...

Page 515: ...34 CN 133 2 DefectiveEPPR valve Repairorreplace Repairorreplace 15 MALFUNCTION OF BOOM PRIORITY EPPR VALVE SERIAL NO 0610 Fault code HCESPN 141 FMI 5 or 6 Before carrying out below procedure check all...

Page 516: ...N SOLENOID FUSE CN 52 1 MCU 140L6MS04 SPEC Starting switch ON 24 2V See TEST 20 SPEC 15 35 Check voltage between CN 52 1 GND Check resistance between arm regen solenoid NO YES YES NO YES NO Cause Reme...

Page 517: ...teel 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...

Page 518: ...are properly 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 25 20 C SeeTEST 1 Check electric current at EPPR valve Check...

Page 519: ...valve Check electric current at bucket circuit relief position 2 SPEC 15 25 20 C 14096MS33 Test 3 Check pressure at EPPR valve Remove plug and connect pressure gauge as figure Gauge capacity 0 to 50...

Page 520: ...EDURE 1 YES SPEC 100 700 mA See TEST 4 SPEC 2 25 kgf cm2 See TEST 5 SPEC 15 25 20 See TEST 1 Check electric current at EPPR valve Check pressure at EPPR valve Check resistance between at EPPR valve Ca...

Page 521: ...ew locknut Valve casing CN 75 EPPR valve Pilot pressure supply line 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 Sta...

Page 522: ...MCU case Check connection between CN 51 09 CN 56A 6 or CN 51 08 CN 56A 7 Cause Remedy No power supply to the united MCU United MCU failure Cluster failure No connection Check fuse No 2 Replace Replace...

Page 523: ...D 6 C fault code 108 displayed Defective work pressure sensor Short circuit or poor connection between CN 51 32 CD 7 A and or CN 51 31 CD 7 C fault code 105 displayed Replace Replace Replace or repair...

Page 524: ...52 19 and ground Prepare 1 piece of thin sharp 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 CN 52 CN 53 CN 52 Fe...

Page 525: ...etective P1 pressure 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 C...

Page 526: ...or copper Insert prepared pin to rear side of connectors One pin to 22 of CN 52 Starting switch ON Check voltage as figure 1 2 SPEC Actuator operating 1 5 V 140L6MS106 SERIAL NO 0611 CN 52 CN 53 22 30...

Page 527: ...ctive P2 pressure 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...

Page 528: ...or copper Insert prepared pin to rear side of connectors One pin to 14 of CN 51 Starting switch ON Check voltage as figure PIN CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 14...

Page 529: ...n between CN 51 13 CN 1 7 Detective P3 pressure sensor Short 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 o...

Page 530: ...or copper Insert prepared pin to rear side of connectors One pin to 13 of CN 51 Starting switch ON Check voltage as figure CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 13 PIN...

Page 531: ...Detective N1 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...

Page 532: ...or copper Insert prepared pin to rear side of connectors One pin to 22 of CN 51 Starting switch ON Check voltage as figure CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 22 PIN...

Page 533: ...Detective N2 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...

Page 534: ...or copper Insert prepared pin to rear side of connectors One pin to 28 of CN 51 Starting switch ON Check voltage as figure CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 28 PIN...

Page 535: ...51 32 31 SUPPLY SIG RETURN A B C CD 24 140L6MS115 Cause Remedy Defective united MCU Detective swing pressure sensor Short circuit or poor connection between CN 52 18 CD 24 B Short circuit or poor con...

Page 536: ...or copper Insert prepared pin to rear side of connectors One pin to 18 of CN 52 Starting switch ON Check voltage as figure 1 2 SPEC Actuator operating 1 5 V 140L6MS116 SERIAL NO 0611 CN 52 CN 53 30 1...

Page 537: ...B C CD 35 ARM IN OUT BUCKET IN PRESSURE SENSOR 140L6MS117 Cause Remedy Defective united MCU Detective arm in out bucket in pressure sensor Short circuit or poor connection between CN 52 24 CD 35 B Sho...

Page 538: ...or copper Insert prepared pin to rear side of connectors One pin to 24 of CN 52 Starting switch ON Check voltage as figure CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 PIN 24...

Page 539: ...TURN A B C CD 32 BOOM UP PRESSURE SENSOR 140L6MS119 Cause Remedy Defective united MCU Detective boom up pressure sensor Short circuit or poor connection between CN 52 23 CD 32 B Short circuit or poor...

Page 540: ...or copper Insert prepared pin to rear side of connectors One pin to 23 of CN 52 Starting switch ON Check voltage as figure CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 PIN 23...

Page 541: ...CN 51 32 31 SUPPLY SIG RETURN A B C CD 85 140L6MS125 Cause Remedy Defective united MCU Detective boom up pressure sensor Short circuit or poor connection between CN 52 31 CD 85 B Short circuit or poo...

Page 542: ...or copper Insert prepared pin to rear side of connectors One pin to 31 of CN 52 Starting switch ON Check voltage as figure CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 PIN 31...

Page 543: ...onbetween CN 54 21 CS 29 1 Shortcircuitorpoor connectionbetween CN 88 2 FuseNo 28 Repairorreplace Repairorreplace Repairorreplace Repairorreplace 14 MALFUNCTION OF POWER MAX SERIAL NO 0611 Fault code...

Page 544: ...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...

Page 545: ...CN 133 2 DefectiveEPPR valve Repairorreplace Repairorreplace 15 MALFUNCTION OF BOOM PRIORITY EPPR VALVE SERIAL NO 0611 Fault code HCESPN 141 FMI 5 or 6 Before carrying out below procedure check all th...

Page 546: ...ID FUSE CN 52 07 UNITED MCU 140L6MS127 SPEC 24 2V Starting switch ON See TEST 20 SPEC 15 35 Check voltage between CN 52 07 GND Check resistance between arm regen solenoid NO YES YES NO YES NO Cause Re...

Page 547: ...or copper Insert prepared pin to rear side of connectors One pin to 07 of CN 52 Starting switch ON Check voltage as figure CN 52 CN 53 30 1 2 3 4 5 6 7 8 9 26 27 28 29 31 32 33 34 10 18 17 25 PIN 07...

Page 548: ...SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test 7 1 Group 2 Major Components 7 21 Group 3 Track and Work Equipment 7 30...

Page 549: ...the passage of time the 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 machi...

Page 550: ...hine 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 Ne...

Page 551: ...te 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 l...

Page 552: ...ngine 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 neu...

Page 553: ...speed 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 t...

Page 554: ...ment 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 revers...

Page 555: ...ore 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 b...

Page 556: ...s the 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 l...

Page 557: ...e upperstructure 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 l...

Page 558: ...on the 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 bo...

Page 559: ...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 temperatu...

Page 560: ...ke 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 HX140...

Page 561: ...rom the fully retracted position Position the bucket cylinder with the rod 20 to 30mm retracted from the fully extended position With the arm rolled out and bucket rolled in hold the bucket so that th...

Page 562: ...for 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 th...

Page 563: ...Measurement 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 mea...

Page 564: ...tch 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...

Page 565: ...e hydraulic 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...

Page 566: ...tch 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...

Page 567: ...t 50 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 shou...

Page 568: ...ssure In the swing function place bucket against an immovable object and measure the relief pressure In the travel function lock undercarriage with an immovable object and measure the relief pressure...

Page 569: ...ing section 3 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 31 3 30 5 Replace cylinder spring Combined height of set plate 5 H spherical bush...

Page 570: ...ion Replacement when its sliding section has scratch G 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...

Page 571: ...on and shoe Thickness of shoe t 5 5 5 3 Replace assembly of piston and shoe Combined height of retainer plate and spherical bushing H h 6 5 6 0 Replace set of retainer plate and spherical bushing Thic...

Page 572: ...rrect 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...

Page 573: ...lay between piston and shoe caulking section T 0 0 3 Replace assembly of piston and shoe Thickness of shoe t 4 5 4 3 Replace assembly of piston and shoe Combined height of set plate and ball guide H 7...

Page 574: ...eakage Push rod This is to be replaced when the top end has worn more than 1mm Play at operating section The pin shaft and joint of the operating section are to be replaced when their plays become mor...

Page 575: ...rn more than 10 m Gcompared 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 wor...

Page 576: ...rn less than 0 5 mm 0 02 in G Damage due to seizure or contamination remediable within wear limit 0 5 mm 0 02 in Extruded excessively from seal groove square ring G Slipper ring 1 5 mm 0 059 in narrow...

Page 577: ...sence of crack Presence of crack Presence of crack Presence of crack G 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 o...

Page 578: ...it Rebuild or replace 190 T 2 Outside diameter of tread 150 138 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 Clear...

Page 579: ...Standard size Repair limit Rebuild or replace 175 T 2 Outside diameter of tread 151 141 3 Width of tread 37 25 42 25 4 Width of flange 18 25 5 Clearance between shaft and bushing Standard size Toleran...

Page 580: ...sion 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 GG 70 G 70 3 0 3 to 0 38 2...

Page 581: ...dard size Repair limit Turn or replace 171 45 175 65 2 Outside diameter of bushing 53 75 43 95 Rebuild or replace 3 Height of grouser 25 16 4 Height of link 94 5 86 5 5 Tightening torque Tightening an...

Page 582: ...e 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 Rep...

Page 583: ...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 70 70 70 70 65 65 70 65 69 69...

Page 584: ...g Torque 8 4 Group 3 Pump Device 8 7 Group 4 Main Control Valve 8 29 Group 5 Swing Device 8 43 Group 6 Travel Device 8 59 Group 7 RCV Lever 8 123 Group 8 Turning Joint 8 137 Group 9 Boom Arm and Bucke...

Page 585: ...vent 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 scre...

Page 586: ...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 un...

Page 587: ...en 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...

Page 588: ...2 5 46 5 1 333 36 9 11 Hydraulic oil tank mounting bolt M20 2 5 46 5 1 333 36 9 12 Turning joint mounting bolt nut M12 1 75 12 8 3 0 92 6 21 7 13 Power train system Swing motor mounting bolt M16 2 0...

Page 589: ...181 245 1310 1772 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...

Page 590: ...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...

Page 591: ...draulic tank Hydraulic tank quantity 124 32 8 U S gal Remove socket bolts 11 and disconnect hoses 1 2 Disconnect pilot line hoses 5 6 7 8 9 10 Remove socket bolts 12 and disconnect pump suction pipe 4...

Page 592: ...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 plu...

Page 593: ...Set plate 156 Bushing 157 Cylinder spring 211 Shoe plate 212 Swash plate 214 Bushing 251 Support 261 Seal cover F 271 Pump casing 312 Valve block 313 Valve plate R 314 Valve plate L 326 Cover 401 Hexa...

Page 594: ...BP 3 8 PO 3 8 M16 M18 17 M20 M22 BP 1 PO 1 1 1 4 1 1 2 Hexagon bolt Hexagon nut VP plug PF thread 19 M12 M12 VP 1 4 24 M16 M16 27 M18 M18 VP 1 2 30 M20 M20 36 VP 3 4 Adjustable angle wrench Medium siz...

Page 595: ...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...

Page 596: ...rizontally on workbench with its regulator fitting surface down and separate pump casing 271 from valve block 312 Before bringing this surface down spread rubber sheet on workbench without fail to pre...

Page 597: ...261 Fit bolt into pulling out tapped hole of seal cover F and cover can be removed easily Since oil seal is fitted on seal cover F take care not to damage it in removing cover Remove hexagon socket he...

Page 598: ...tilting pin and servo piston take care not to damage servo piston Do not remove needle bearing as far as possible except when it is considered to be out of its life span Do not loosen hexagon nuts of...

Page 599: ...s oil seals etc For fitting bolts plug etc prepare 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...

Page 600: ...and cylinder spring 157 Fit spline phases of retainer and cylinder Then insert piston cylinder subassembly into pump casing 6 Assemble seal cover F 261 to pump casing 271 and fix it with hexagon sock...

Page 601: ...Fit valve block 312 to pump casing 271 and tighten hexagon socket head bolts 401 At first assemble this at rear pump side and this work will be easy Take care not to mistake direction of valve block C...

Page 602: ...C FRONT 897 612 641 730 643 708 644 645 646 SECTION B B 728 924 801 438 P2 KR38 9N62 FRONT KR38 9N61 REAR A B 413 438 496 724 725 D D VIEW C REAR 413 438 438 722 496 724 725 079 735 722 466 755 496 7...

Page 603: ...22 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...

Page 604: ...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 siz...

Page 605: ...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...

Page 606: ...clean 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...

Page 607: ...n 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 r...

Page 608: ...1 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 s...

Page 609: ...out 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 opposit...

Page 610: ...bolts 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 P...

Page 611: ...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...

Page 612: ...ot 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...

Page 613: ...ressure sensor and so on Remove bolts and disconnect pipe Disconnect pilot line hoses Disconnect pilot piping Sling the control valve assembly and remove the control valve mounting bolt and bracket We...

Page 614: ...ock Plug Orifice plug Plug Signal poppet Signal orifice Coin type filter Pilot A cap Pilot B1 cap Spool assy boom 1 Spool assy arm 2 Spool assy arm regen Spool assy bucket Nega con relief valve Holdin...

Page 615: ...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...

Page 616: ...l Spool assy option C 29 30 40 50 51 52 53 Lock valve kit B Plug Plug Plug Pilot A cap Pilot B1 cap Pilot B2 cap Socket head bolt Spool assy travel RH Spool assy swing Spool assy swing priority Spool...

Page 617: ...8 18 64 78 68 37 32 67 21 REAR RH LH FRONT 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 Popp...

Page 618: ...Spool assy arm 2 12 Spool assy arm regen 14 Spool assy bucket 20 Nega con relief valve 23 Boom holding valve 24 Pilot cover assy 25 Arm regeneration block 27 Plug 32 Plug 37 Plug 38 Signal poppet 39 S...

Page 619: ...30 34 68 30 67 65 26 66 16 Main relief valve 17 Overload relief valve 26 Overload plug 27 Plug 28 Plug 29 Plug 30 Plug 31 Plug 34 Plug 35 Plug 40 Load check poppet 41 Load check poppet 45 Load check...

Page 620: ...Housing P2 3 Straight travel spool assy 4 Travel spool assy 6 Swing spool assy 8 Swing priority spool assy 9 Boom 2 spool assy 11 Arm 1 spool assy 13 Option B1 spool assy 15 Option C spool assy 28 Pl...

Page 621: ...6 66 28 61 60 62 65 70 71 17 Overload relief valve assy 18 Overload relief valve assy 21 Swing logic valve 22 Option logic valve 27 Plug 28 Plug 30 Plug 31 Plug 32 Plug 39 Signal orifice 40 Load check...

Page 622: ...rying 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 reli...

Page 623: ...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 on...

Page 624: ...ot 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...

Page 625: ...ssembled 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 par...

Page 626: ...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 pi...

Page 627: ...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...

Page 628: ...e 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 Co...

Page 629: ...ive 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...

Page 630: ...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 tog...

Page 631: ...the swing motor assembly 1 and remove the swing motor mounting socket bolts 8 Motor device weight 34 kg 75 lb Tightening torque 29 6 3 2 kgf m 214 23 1 lbf ft Remove the swing motor assembly When rem...

Page 632: ...pring 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 valv...

Page 633: ...f 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 gau...

Page 634: ...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 t...

Page 635: ...ng seat 37 12 Separate each one of O ring 40 and spring 38 Do not lose spring Do not mix spring with other springs 11 Remove plug 25 using 32 mm socket wrench and separate spring spring 24 and check v...

Page 636: ...asing using air gun 13 14 Lay casing down horizontally and remove cylinder block assembly from shaft And remove all friction plate 13 and separator plate 14 15 125LCR8SM15 125LCR8SM16 125LCR8SM17 125L...

Page 637: ...from casing Sliding surface should be carefully treated to avoid scratches and damage 17 18 Disassemble shaft 3 and cylinderical roller bearing 5 Do not remove cylinderical roller bearing 5 unless ma...

Page 638: ...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 r...

Page 639: ...mer 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...

Page 640: ...h 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...

Page 641: ...late 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 locati...

Page 642: ...trictor 39 in spool 36 Spread loctite 242 16 Put spring 16 24EA in each hole of parking piston 15 Place spool in casing 17 125LCR8SM40 125LCR8SM38 Assemble spring 38 spring seat 37 in casing 18 125LCR...

Page 643: ...t 20 Assemble plug 27 using 6 mm hexagon wrench Tightening torque 4 5 kgf m 32 5 lbf ft 19 Assemble anti rotating valve assembly 32 in valve casing 21 125LCR8SM44 125LCR8SM42 Assemble plug 33 using 32...

Page 644: ...15 kgf m 108 lbf ft 24 Caulk check valve 23 using jig same for the set on opposite side 23 Assemble spring pin 21 in valve casing using jig 25 125LCR8SM48 125LCR8SM46 Assemble O ring 18 cylinderical...

Page 645: ...allel to each other 28 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...

Page 646: ...8 58 Wrap teflon tape 2 or 3 times around the tap part of level gauge assembly 41 And assemble it using pipe wrench 31 125LCR8SM53...

Page 647: ...val of swing motor assembly Sling reduction gear assembly 1 and remove mounting bolts 2 Remove the reduction gear assembly Reduction gear device weight 75 kg 165 lb INSTALL Carry out installation in t...

Page 648: ...dle 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...

Page 649: ...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 sn...

Page 650: ...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 1...

Page 651: ...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...

Page 652: ...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...

Page 653: ...6 125LCR8SM77 125LCR8SM78 125LCR8SM79 Disassemble nut ring 5 by using the jig 20 Disassemble needle bearing No 2 12 3 pcs 17 Separate ring gear 1 from casing 8 18 Loosen a bolt 7 4 pcs and disassemble...

Page 654: ...by using the jig 24 Drive shaft sub assy disassembly Separate drive shaft sub assembly from casing 8 21 Disassemble taper bearing 3 and oil seal 27 by using a press machine 22 Disassemble sleeve 25 a...

Page 655: ...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 beari...

Page 656: ...ssembled 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 thr...

Page 657: ...8 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 N...

Page 658: ...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 t...

Page 659: ...t 15 17 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 s...

Page 660: ...ig 20 Shrink fit taper 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...

Page 661: ...aring 4 23 Place lock plate 6 on the nut ring 25 Assemble nut ring 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 t...

Page 662: ...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 s...

Page 663: ...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 125LCR8SM1...

Page 664: ...ng the swing motor assembly 1 and remove the swing motor mounting socket bolts 8 Motor device weight 32 kg 71 lb Tightening torque 23 5 4 0 kgf m 170 28 9 lbf ft Remove the swing motor assembly When r...

Page 665: ...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 dela...

Page 666: ...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...

Page 667: ...pring 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 t...

Page 668: ...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 pl...

Page 669: ...s 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...

Page 670: ...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 14...

Page 671: ...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...

Page 672: ...with 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 asse...

Page 673: ...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 32038S...

Page 674: ...M36 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...

Page 675: ...8 58 29 Insert O rings to the relief valve 30 and reassemble them to rear cover 20 This completes assembly 17 32038SM42...

Page 676: ...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...

Page 677: ...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...

Page 678: ...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...

Page 679: ...n 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...

Page 680: ...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 sp...

Page 681: ...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 1...

Page 682: ...eal 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 t...

Page 683: ...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...

Page 684: ...eduction 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 ar...

Page 685: ...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...

Page 686: ...9 Parallel pin 30 Rear cover 31 Main 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 Sp...

Page 687: ...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...

Page 688: ...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 125LC...

Page 689: ...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 no...

Page 690: ...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...

Page 691: ...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...

Page 692: ...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...

Page 693: ...steel ball 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...

Page 694: ...8 68 125LCR8TM30 Turn casing 1 upside down and remove oil seal 3 using jig 29...

Page 695: ...aged 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 lubrica...

Page 696: ...shaft 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 pi...

Page 697: ...aulic 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...

Page 698: ...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 car...

Page 699: ...restrictor 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...

Page 700: ...r 55 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 3 kgf m 21 7 lbf ft Insert spring pin 25 2ea and 28 in rear cove...

Page 701: ...damage 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...

Page 702: ...125LCR8TM59 125LCR8TM58 125LCR8TM60 Insert relief valve 38 in rear cover Tightening torque 15 kgf m 108 lbf ft After clamping connector 45 to rear cover assemble spool 40 Tightening torque 5 kgf m 36...

Page 703: ...8 77 125LCR8TM61 After assembling spring 44 in order clamp plug 41 Tightening torque 5 kgf m 36 lbf ft 31...

Page 704: ...to one side disassemble PF3 8 plug 24 remove gear oil and place motor sideto the bench Disassemble cover 22 by unscrewing the M10 bolts 23 12 pcs Disassemble sun gear No 1 20 steel ball 21 Disassemble...

Page 705: ...rier assembly 3 pcs Disassemble thrust plate No 1 17 from the carrier assembly Disassemble planetary gear No 1 14 3 pcs Disassemble needle bearing 15 3 pcs Do not disassemble inner race in the absence...

Page 706: ...80 125LCR8TM78 125LCR8TM80 125LCR8TM79 125LCR8TM81 Disassemble Sun gear No 2 12 9 Disassemble M10 bolt 6 4 pcs Disassemble thrust washer No 2 11 4 pcs Disassemble planetary gear No 2 8 4 pcs 10 11 12...

Page 707: ...M83 125LCR8TM85 Disassemble needle bearing No 2 9 4 pcs Disassemble thrust plate No 2 7 4 pcs Do not disassemble inner race in the absence of abnormalities Disassemble lock plate 5 Disassemble M10 bol...

Page 708: ...by using the jig Disassemble ring gear sun assembly from motor assembly Disassemble bearing 2 2ea from ring gear assembly Do not disassemble bearing in the absence of abnormalities Disassemble folatin...

Page 709: ...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 asse...

Page 710: ...rd 3 places After spreading loctite 242 assemble the M8 bolt 18 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...

Page 711: ...earing 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 Flat...

Page 712: ...te 11 12 Place lock plate th the direction which nut ring is loosed and then assemble M10 bolt 6 with M8 screw 19 after spreading loctite 242 Refer to assembly detail drawing Tightening torque M10 5 5...

Page 713: ...No 2 10 4 pcs Assemble needle bearing No 2 9 4 pcs Assemble thrust plate No 2 7 4 pcs Assemble planetary gear No 2 8 4 pcs Grooves of planetary gear will be facingup 14 16 15 17 125LCR8TM104 125LCR8T...

Page 714: ...er spreading loctite 242 assemble the M10 bolt 6 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 11 4 pcs 18 125LCR8TM108 125L...

Page 715: ...he cover 22 with reference to the right detail view Assemble sun gear No 1 20 Place steel ball 21 on the sun gear No 1 Place cover 22 to fit the bolt holes 24 22 23 25 125LCR8TM112 125LCR8TM114 125LCR...

Page 716: ...tening torque 6 3 0 7 kgf m 45 6 5 1 lbf ft 26 After assembling the O ring 25 to the plug 24 assemble it to the cover 3 pcs Tightening torque 5 0 5 kgf m 36 2 3 6 lbf ft Inject the 2 5 0 3 liter gear...

Page 717: ...emove 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 t...

Page 718: ...ing 37 Cover 38 Spring 39 Spool 40 Steel ball 41 Spring 42 Plug 43 Spring seat 44 O ring 45 Wrench bolt 46 Relief valve assy 47 Spool 48 Guide 49 O ring 50 Back up ring 51 O ring 52 Back up ring 53 Sn...

Page 719: ...erting jig Bearing pliers Seal tape Eye bolt M10 M12 M14 Press 0 5 ton Oil stone Bearing assembling jig Part name Item Size Torque kgf m lbf ft Plug 2 NPT 1 16 1 0 1 7 2 0 7 Orifice 26 M5 0 7 0 1 5 0...

Page 720: ...t to the name of a part represent the part numbers of a cross sectional view annexed with a drawing The side of a pipe in a motor can be written as a rear side the side of out put as a front side Usin...

Page 721: ...cover assembly from motor assembly 3 21078TM23 21078TM24 Dismantle packing piston 21 using compressed air 4 21078TM25 Disassembly rotary kit from motor assembly cylinder block assembly piston assembl...

Page 722: ...isassemble swash plate 9 from shaft casing 6 21078TM27 Using compressed air disassemble piston swash 4 piston ring 5 respectively 7 21078TM28 21078TM29 Using a hammer disassemble shaft 6 from shaft ca...

Page 723: ...semble cylinder sub Disassemble cylinder block assembly piston assembly 9 and seat plate M 9 21078TM31 21078TM32 Disassemble ball guide 16 ring and pin 15 from cylinder block respectively 10 21078TM33...

Page 724: ...t 13 spring 12 and spring seat 11 respectively 11 21078TM36 21078TM37 Disassemble valve casing sub Using an hexagon wrench unloosing wrench bolt 45 and disassemble cover 37 spring 38 spool 39 spring s...

Page 725: ...78TM39 Disassemble spool 59 spool 47 O ring 51 guide 48 and snap ring 53 on rear cover respectively 13 21078TM40 21078TM41 Using a torque wrench disassemble relief valve assembly 46 on rear cover 14 2...

Page 726: ...do not wash friction plate with treated oil In bonding each part fasten bond torque When using a hammer do not forget to use a plastic hammer 1 1 2 3 4 1 ASSEMBLING Assemble the sub of turning axis Us...

Page 727: ...Using a jig assemble shaft assembly into shaft casing 1 3 21078TM47 After spreading grease on steel ball 8 assemble into shaft casing 1 4 21078TM48 Assemble swash piston assembly 4 5 into shaft casin...

Page 728: ...haft casing 1 6 21078TM50 Assemble cylinder block sub Assemble spring seat 13 spring 12 spring seat 11 into cylinder block 10 respectively pushing spring 12 using by a jig assemble snap ring 14 with a...

Page 729: ...8 103 Assemble ring pin 15 on cylinder block 10 ball guide 16 respectively 8 21078TM53 21078TM54 21078TM55 Assemble cylinder block assembly piston assembly 9 seat plate 17 9 21078TM56...

Page 730: ...8 104 21078TM57 Assemble cylinder block assembly 9 into shaft casing 1 10 21078TM58 Assemble friction plate 19 and plate 20 into shaft casing 1 respectively prepare 6 set 11 21078TM59 21078TM59 1...

Page 731: ...packing piston 21 12 21078TM60 21078TM60 1 After spreading grease on packing piston 21 bond wrench bolt and assemble shaft casing 1 13 21078TM61 Assemble rear cover sub Using a jig assemble bearing 69...

Page 732: ...8 106 After assembling spool 59 spool 47 O ring 51 guide 48 and snap ring 53 respectively into rear cover 29 Using torque wrench assemble it 15 21078TM63 21078TM64 21078TM65...

Page 733: ...8 107 Assemble spring seat 35 spring 36 spring seat 43 spool 39 spring 38 cover 37 respectively and assemble wrench bolt 45 same balance on both sides 16 21078TM66 21078TM67 21078TM67 1...

Page 734: ...8 108 Assemble plug 2 Plug NPT1 16 11 EA 17 21078TM68 21078TM69 21078TM70 21078TM71...

Page 735: ...ble plug 64 Plug PT3 8 11 EA 18 21078TM72 Assemble plug 62 63 into rear cover 29 and assemble relief valve assembly 19 21078TM73 21078TM74 Put spring 67 68 together into rear cover 29 prepare 6 set 20...

Page 736: ...te 70 into rear cover 29 21 21078TM77 After assembling shaft casing 1 and rear cover 29 Assemble spool assembly 30 spring 38 spool 39 cover 37 after then complete assembly with wrench bolt 45 22 21078...

Page 737: ...ling unit and dry it Locate reducer in order for drain port to be at the lowest level loosen taper screw plug of drain port and drain oil from reduction gear While oil is still hot inside of the unit...

Page 738: ...sun gear Be sure to maintain it vertical with the ground when disassembling No 1 sun gear 21078TM84 2 Removing No 2 carrier sub assembly Screw three M10 eye bolt in No 2 carrier and lift up and remov...

Page 739: ...ring gear not to make scratch on it Screw M14 eye bolt in ring gear and lift up and remove it 6 21078TM87 1 2 Removing coupling Remove coupling 7 21078TM88 1 Removing retainer shim Remove M12 hexagon...

Page 740: ...urning housing lift up a piece of floating seal from housing and then remove it Don t disassemble angular bearing 11 21078TM92 1 Disassembling No 1 carrier Remove thrust ring 90 7 from carrier Knock s...

Page 741: ...8 115 21078TM95 Disassembling No 2 carrier Disassemble No 2 carriers using the same method for No 1 carrier assembly 13 21078TM96 21078TM97 1...

Page 742: ...m Inspection before reassembling Thrust washer Check if there are seizure abnormal wear or uneven wear Check if wear is over the allowable limit Gears Check if there are pitting or seizure on the toot...

Page 743: ...ling No 2 carrier Put No 2 carrier 90 1 on a flat place Install No 2 needle bearing 90 3 into No 2 planetary gear 90 2 put 2 EA of No 2 thrust washer 90 4 on both sides of bearing and then install it...

Page 744: ...ating seal which is assembled into motor Heat bearing at 60 70 C and then put into the motor side 3 21078TM105 1 2 Be sure to maintain it vertical with the ground when assembling bearing and floating...

Page 745: ...ring at 60 70 C and then install Be sure to maintain it vertical with the ground when assembling bearing 6 1 Installing retainer 85 and shim 84 Measure clearance between main bearing and retainer by u...

Page 746: ...for hole of ring gear and parallel pin of housing to be in line Temporarily secure 4EA of M12 hexagon socket bolt and shim with cover thickness having appropriate torque 9 21078TM112A 1 2 3 4 5 21078T...

Page 747: ...them 2 21078TM116 Installing No 1 carrier sub assembly Install M10 eye bolt on No 2 carrier assembly Lift No 1 carrier assembly and then slowly put it down on ring gear Rotate planetary gear by hands...

Page 748: ...er Apply three bond 1104 loctite 515 on the ring gear for cover without gap Put cover on ring gear apply loctite 262 on M12 hexagon socket head bolt and then bolt 14 21078TM119 1 2 3 Fill gear oil 5 8...

Page 749: ...penetrate the skin causing serious injury Loosen the socket 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 v...

Page 750: ...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 Bus...

Page 751: ...nch 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...

Page 752: ...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...

Page 753: ...ool 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 resp...

Page 754: ...ver 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 th...

Page 755: ...8 129 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 756: ...8 130 Remove lock nut 22 and then boot 23 14 36078RL14 2507ARL10...

Page 757: ...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 i...

Page 758: ...sing 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...

Page 759: ...g 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 join...

Page 760: ...h 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 n...

Page 761: ...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 tu...

Page 762: ...eventives 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 2...

Page 763: ...the 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 12 3 1 3 kgf m 88 9 9 4 lb...

Page 764: ...SSEMBLY STRUCTURE 1 1 Hub 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 1...

Page 765: ...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...

Page 766: ...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 rep...

Page 767: ...8 141 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 768: ...draulic 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 b...

Page 769: ...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 5 6 8 2 Sling bucket cylinder assembl...

Page 770: ...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 betwee...

Page 771: ...n 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...

Page 772: ...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 e...

Page 773: ...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 c...

Page 774: ...g 5 Snap ring 6 Rod seal 7 Back up ring 8 Buffer ring 9 Dust wiper 10 Snap ring 11 O ring 12 Back up ring 13 Cushion ring 14 Piston 15 Piston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 2...

Page 775: ...on seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 20 Lock nut 21 Hexagon socket set screw 22 O ring 23 Hexagon socket head bolt 24 Pin bushing 25 Dust seal 26 Check valve 27 Coil spring 28 O...

Page 776: ...14 Piston 15 Piston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 20 Lock nut 21 Hexagon socket set screw 22 Hexagon socket head bolt 23 Pin bushing 24 Dust seal 25 Band assembly 26 Pipe as...

Page 777: ...g 11 Back up ring 12 O ring 13 Piston 14 Piston seal 15 Wear ring 16 O ring 17 Back up ring 18 Steel ball 19 Set screw 20 Pipe assembly 21 Hexagon socket head bolt 22 O ring 23 Check valve assembly 24...

Page 778: ...ylinder 25 M10 5 4 0 5 39 1 3 6 Pipe mounting socket head bolt Bucket 30 M10 5 4 0 5 39 1 3 6 Boom 29 M8 2 7 0 3 19 6 2 2 Arm 33 M10 5 4 0 5 39 1 3 6 Dozer cylinder 21 M8 2 7 0 3 19 5 2 2 Lock nut Buc...

Page 779: ...ly together from tube assembly 1 Since the rod assembly is heavy in this case lift the tip of the rod assembly 2 with a crane or some means and draw it out However when rod assembly 2 has been drawn o...

Page 780: ...ads of rod assembly 2 Remove piston and cylinder head Remove set screw 21 Since set screw 21 and lock nut 20 is tightened to a high torque use a hydraulic and power wrench that utilizers a hydraulic c...

Page 781: ...ove back up ring 7 rod seal 6 and buffer ring 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 4 4 Disassemble the pist...

Page 782: ...in that order Coat each packing with hydraulic oil before fitting it Insert the backup ring until one side of it is inserted into groove Coat dust wiper 9 with grease and fit dust wiper 9 to the botto...

Page 783: ...5 minutes After assembling the piston seal press its outer diameter to fit in Fit back up ring 12 to gland 3 Put the backup ring in the warm water of 30 50 C Fit O ring 11 to gland 3 Assemble piston a...

Page 784: ...n ring 13 to rod assembly Note that cushion ring 13 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 oute...

Page 785: ...ar through the clevis pin hole to lock the assembly 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 threa...

Page 786: ...ple 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...

Page 787: ...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...

Page 788: ...out installation in the reverse order to removal 2 1 Remove the mounting bolt 1 and draw out the track roller 2 Weight 38 3 kg 84 4 lb 3 Using the work equipment push up track frame on side which is...

Page 789: ...rse order to removal Make sure 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 3 Sling...

Page 790: ...8 164 DISASSEMBLY AND ASSEMBLY OF IDLER Structure type 1 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 791: ...8 164 1 Structure type 2 3 high walker 1 1 Shell 2 Shaft 3 Seal assy 4 Bushing 5 Bracket 6 O ring 7 Spring pin 8 Hex Plug 1 4 3 8 7 5 4 3 7 6 2 5 6 140L8DA143...

Page 792: ...ve 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 The illustrations are base on the type 1 Remove...

Page 793: ...to 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 C...

Page 794: ...167 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...

Page 795: ...PRING Structure type 1 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...

Page 796: ...h walker 1 Body 2 Tie bar 3 Spring 4 Bracket 5 Lock nut 6 Lock plate 7 Bolt 8 Spring washer 9 Rod seal 10 Back up ring 11 Dust seal 12 Rod assembly 13 Grease valve 14 Spring pin 15 Spacer 4 7 8 6 3 2...

Page 797: ...ing 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 br...

Page 798: ...Spring set load 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 grea...

Page 799: ...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 Tightening torque 15 0 5 kgf m 108 3 6 lbf ft 140L8UC36 Type...

Page 800: ...8 172 1 STRUCTURE GROUP 11 WORK EQUIPMENT B SECTION C SECTION B SECTION A C C A B A 21078DA 44 SECTION A SECTION B SECTION C...

Page 801: ...everse order to removal When aligning the mounting position of the pin do not insert your fingers in the pin hole A djust the bucket clearance For detail see operation manual 2 Remove nut 3 bolt 4 and...

Page 802: ...assembly remove spring pin stopper and pull out pin Tie the rod with wire to prevent it from coming out For details see removal of arm cylinder assembly Place a wooden block under the cylinder and bri...

Page 803: ...der to removal When lifting the arm assembly always lift the center of gravity B leed the air from the cylinder 2 Remove bolt 4 plate 5 and pull out the pin 6 then remove boom assembly Weight 1020 kg...

Page 804: ...RQUE SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide 9 1 Group 2 Engine system 9 2 Group 3 Electric system 9 4 Group 4 Hydraulic system 9 6 Group 5 Undercarriage 9 9 Group 6 Structure 9...

Page 805: ...Hyundai cannot assume liability for any damage Only metric fasteners can be used and incorrect fasteners may result in machine damage or malfunction Be careful not to use metric fastener in case inch...

Page 806: ...Tightening torque 1 ENGINE AND ACCESSORIES MOUNTING 1 ENGINE AND ACCESSORIES MOUNTING 140L9CM01 Item Size kgf m lbf ft 4 M12 1 75 7 9 2 0 57 1 14 5 5 M12 1 75 11 2 1 1 81 8 0 6 M16 2 0 34 0 4 0 246 2...

Page 807: ...k DEF AdBlue supply module Tightening torque 2 COOLING SYSTEM AND FUEL TANK MOUNTING 2 COOLING SYSTEM AND FUEL TANK MOUNTING 140L9CM02 Item Size kgf m lbf ft 1 M 6 1 0 1 05 0 2 7 6 1 45 2 M 8 1 25 2 5...

Page 808: ...2 4 4 4 4 D DETAIL D 4 1 1 GROUP 3 ELECTRIC SYSTEM GROUP 3 ELECTRIC SYSTEM Tightening torque 1 ELECTRIC COMPONENTS MOUNTING 1 1 ELECTRIC COMPONENTS MOUNTING 1 140L9CM03 Item Size kgf m lbf ft 3 M 8 1...

Page 809: ...r Remote control unit Work lamp 2 1 3 3 Smart key control unit Smart key reader Camera RMS bracket Warning buzzer Tightening torque 2 ELECTRIC COMPONENTS MOUNTING 2 2 ELECTRIC COMPONENTS MOUNTING 2 14...

Page 810: ...P 4 HYDRAULIC SYSTEM Tightening torque 1 HYDRAULIC COMPONENTS MOUNTING 1 1 HYDRAULIC COMPONENTS MOUNTING 1 140L9CM05 Item Size kgf m lbf ft 1 M 6 1 0 1 05 0 2 7 6 1 45 2 M 6 1 0 1 44 0 3 10 4 2 2 3 M1...

Page 811: ...ing 1 2 EPPR valve 1 Upper frame Solenoid valve 6 5 Shuttle block 1 6 Multimode selector valve 1 6 Manifold 7 6 Rotate pump Proportional valve 3 Select valve 3 Tightening torque 2 HYDRAULIC COMPONENTS...

Page 812: ...3 3 HYDRAULIC COMPONENTS MOUNTING 3 140L9CM07 Tightening torque Item Size kgf m lbf ft 1 M 8 1 25 2 7 0 3 19 5 2 2 2 M10 1 5 3 2 0 3 23 1 2 2 3 M10 1 5 5 4 0 5 39 1 3 6 4 M12 1 75 5 5 0 6 39 8 4 3 5...

Page 813: ...roller GROUP 5 UNDERCARRIAGE GROUP 5 UNDERCARRIAGE Tightening torque 140L9CM08 Item Size kgf m lbf ft 1 M10 1 5 6 9 1 4 49 9 10 1 2 M12 1 75 12 8 3 0 92 6 21 7 3 M16 1 5 31 3 3 2 226 23 1 4 M16 2 0 2...

Page 814: ...DERCARRIAGE MOUNT UNDERCARRIAGE MOUNTING HIGH WALKER ING HIGH WALKER 140L9CM09 Tightening torque Item Size kgf m lbf ft 1 M10 1 5 6 9 1 4 49 9 10 1 2 M12 1 75 12 8 3 0 92 6 21 7 3 M16 2 0 29 6 3 2 214...

Page 815: ...UNTING 1 CAB AND ACCESSORIES MOUNTING GROUP 6 STRUCTURE GROUP 6 STRUCTURE 140L9CM10 Tightening torque Item Size kgf m lbf ft 1 M 6 1 0 1 05 0 2 7 6 1 45 2 M 8 1 25 2 5 0 5 18 1 3 6 3 M 8 1 25 3 43 0 7...

Page 816: ...ty lever 2 2 2 2 2 5 2 5 1 4 4 3 5 5 5 5 5 2 5 5 4 5 2 CAB INTERIOR MOUNTING 2 CAB INTERIOR MOUNTING 140L9CM11 Tightening torque Item Size kgf m lbf ft 1 M 6 1 0 1 05 0 2 7 6 1 45 2 M 8 1 25 2 5 0 5 1...

Page 817: ...3 1 3 3 2 1 3 3 3 3 2 Side cover LH Air cleaner Engine hood Side cover RH 3 COWLING MOUNTING 3 COWLING MOUNTING 140L9CM12 Item Size kgf m lbf ft 1 M 8 1 25 2 5 0 5 18 1 3 6 2 M10 1 5 6 9 1 4 49 9 10 1...

Page 818: ...ump under cover MCV under cover DEF AdBlue tank under cover DEF AdBlue tank cover Tool box Upper frame Counterweight 4 COUNTERWEIGHT AND COVERS MOUNTING 4 COUNTERWEIGHT AND COVERS MOUNTING 140L9CM13 T...

Page 819: ...rm cylinder Boom cylinder rod pin Bucket cylinder Arm pin 2 2 2 1 2 1 Boom pin Arm cylinder head pin 2 2 2 Boom cylinder 2 Side cutter LH 3 Tightening torque GROUP 7 WORK EQUIPMENT GROUP 7 WORK EQUIPM...

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