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Hyundai HX430L, Manual

The Hyundai HX430L user manual is available for free download on manualshive.com. This comprehensive manual provides detailed instructions and essential information about the operation and maintenance of the Hyundai HX430L model. Easily access the manual to enhance your experience with this exceptional product.

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8-76

Disassemble  separated  plate  (22,  7EA)  and 
friction plate (21, 6EA).

(6)

Remove cylinder block kit.
It  is  easier  to  work  by  placing  the  casing  (1) 
horizontal.

(7)

Disassemble parking piston (23) using jig.

(5)

43098TM10

43098TM12

43098TM14

43098TM15

43098TM09

43098TM11

43098TM13

Summary of Contents for HX430L

Page 1: ... Group 5 Combined Operation 3 24 SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location 4 1 Group 2 Electric Circuit 4 3 Group 3 Electrical Component Specification 4 23 Group 4 Connectors 4 34 SECTION 5 MECHATRONICS SYSTEM Group 1 Outline 5 1 Group 2 Mode selection System 5 3 Group 3 Automatic Deceleration System 5 6 Group 4 Power Boost System 5 7 Group 5 Travel Speed Control System 5 8 Group 6 Au...

Page 2: ...Performance Test 7 1 Group 2 Major Components 7 20 Group 3 Track and Work Equipment 7 30 SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution 8 1 Group 2 Tightening Torque 8 4 Group 3 Pump Device 8 7 Group 4 Main Control Valve 8 31 Group 5 Swing Device 8 51 Group 6 Travel Device 8 76 Group 7 RCV Lever 8 101 Group 8 Turning Joint 8 115 Group 9 Boom Arm and Bucket Cylinder 8 120 Group 10 Undercarri...

Page 3: ...ydraulic circuit single and combined operation SECTION 4 ELECTRICAL SYSTEM This section explains the electrical circuit monitoring system and each component It serves not only to give an understanding electrical system but also serves as reference material for trouble shooting SECTION 5 MECHATRONICS SYSTEM This section explains the computer aided power optimization system and each component SECTIO...

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

Page 5: ...oint one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm was divided by 10 so multiply 2 165 inches by 10 Move the decimal point one place to the right to return to the original value This gives 550mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches 1mm 0 03937 in ͽ 0 1 2 3 4 5 6 7 8 9 0 0 039 0 079 0 118 0 15...

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

Page 7: ...2 455 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 1 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8 ...

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

Page 9: ...280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 233...

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

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

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

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

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

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

Page 16: ...entilated 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 ÂIf you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before wel...

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

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

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

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

Page 21: ...th After treatment device Bucket cylinder Side cutter Connecting link Connecting rod Idler Track roller Carrier roller Track Sprocket Travel motor Cab Boom cylinder Boom Arm cylinder Arm Counterweight Handrail Swing bearing DEF AdBlue R tank Charge air cooler Oil cooler 430F2SP01 1 MAJOR COMPONENT GROUP 2 SPECIFICATIONS ...

Page 22: ...f cab E 3240 10 8 Ground clearance of counterweight F 1295 4 3 Overall height of engine hood G 2755 9 0 Overall height of handrail G 3445 11 4 Minimum ground clearance H 555 1 10 Rear end distance I 3555 11 8 Rear end swing radius I 3640 11 11 Distance between tumblers J 4470 14 8 Undercarriage length K 5462 17 11 Undercarriage width L 3340 10 11 Track gauge M 2740 9 0 Track shoe width standard N ...

Page 23: ...9 5440 mm 17 10 Max digging height D 10390 mm 34 1 10290 mm 33 9 Max dumping height E 7250 mm 23 9 7200 mm 23 7 Min swing radius F 4540 mm 14 11 4490 mm 14 9 Bucket digging force SAE 201 0 219 3 kN 201 0 219 3 kN 20500 22360 kgf 20500 22360 kgf 45190 49300 lbf 45190 49300 lbf ISO 228 5 249 3 kN 228 5 249 3 kN 23300 25420 kgf 23300 25420 kgf 51370 56040 lbf 51370 56040 lbf Arm crowd force SAE 180 7...

Page 24: ...6430 14180 Swing bearing 550 1210 Travel motor assembly 630 1390 Turning joint 65 140 Track recoil spring and idler 325 720 Idler 310 680 Sprocket 95 210 Carrier roller 40 90 Track roller 90 192 Track chain assembly 600 mm standard triple grouser shoe 2700 5950 Front attachment assembly 6 5 m boom 3 2 m arm 1 90 m3 SAE heaped bucket 8910 19640 6 5 m boom assembly 3180 7010 3 2 m arm assembly 1480 ...

Page 25: ...b counterweight 1 Load point height Load radius At max reach 3 0 m 10 0 ft 4 5 m 15 0 ft 6 0 m 20 0 ft 7 5 m 25 0 ft Capacity Reach m ft 9 0 m kg 6110 6110 6 70 30 ft lb 13470 13470 22 0 7 5 m kg 6020 6020 8 02 25 0 ft lb 13270 13270 26 3 6 0 m kg 7120 7120 6600 6600 6110 5360 8 86 20 0 ft lb 15700 15700 14550 14550 13470 11820 29 1 4 5 m kg 11000 11000 8440 8440 7210 7210 6270 4660 9 37 15 0 ft l...

Page 26: ... 10 01 10 0 ft lb 28550 28550 20610 20610 16760 16070 14660 11510 13470 9110 32 8 1 5 m kg 15710 15610 10910 9940 8500 6920 7140 5020 6420 4040 9 98 5 0 ft lb 34630 34410 24050 21910 18740 15260 15740 11070 14150 8910 32 7 Ground kg 12890 12890 17110 14960 11990 9480 9200 6640 7490 4880 6770 4190 9 70 Line lb 28420 28420 37720 32980 26430 20900 20280 14640 16510 10760 14930 9240 31 8 1 5 m kg 1376...

Page 27: ...bucket combination 侍 HEAVY DUTY BUCKET 1 侔 Rock heavy duty bucket 侔1 90 m3 2 10 m3 SAE heaped bucket Capacity Width Weight Recommendation 6 5 m 21 4 boom SAE heaped CECE heaped 2 6 m arm 8 6 3 2 m arm 10 6 侔1 90m3 2 49yd3 1 65m3 2 16yd3 1665mm 66 1980 kg 4370 lb 侐 俔 侔2 10m3 2 75yd3 1 84m3 2 41yd3 1800mm 71 2080 kg 4590 lb 俔 侑 Applicable for materials with density of 2000 kg m3 3370 lb yd3 or less ...

Page 28: ...th triple grousers TYPES OF SHOES NUMBER OF ROLLERS AND SHOES ON EACH SIDE 3 1 2 Model Shapes Triple grouser HX430 L Shoe width mm in 600 24 700 28 750 30 800 32 900 36 Operating weight kg lb 44120 97270 44640 98410 44900 98990 45170 99580 45680 100710 Ground pressure kgf cm2 psi 0 76 10 81 0 66 9 39 0 62 8 82 0 59 8 39 0 53 7 54 Overall width mm ft in 3340 10 11 3440 11 3 3490 11 5 3540 11 7 3640...

Page 29: ...tegory 600 mm triple grouser Standard A 700 mm triple grouser Option B 750 mm triple grouser Option B 800 mm triple grouser Option C 900 mm triple grouser Option C Category Applications Applications A Rocky ground river beds normal soil 余 Travel at low speed on rough ground with large obstacles such as boulders or fallen trees B Normal soil soft ground 余 余 余 These shoes cannot be used on rough gro...

Page 30: ...AE J1349 358Hp at 1800 rpm 267 kW at 1800 rpm Rated gross horse power SAE J1995 372 Hp at 1800 rpm 277 kW at 1800 rpm Maximum torque 166 kgf余m 1200 lbf余ft at 1500 rpm Engine oil quantity 30再 7 9 U S gal Wet weight 708 kg 1560 lb Low idling speed 900佳100 rpm High idling speed 1700 50 rpm Rated fuel consumption 155 g Hp余hr at 1650 rpm Starting motor Denso 24V 7 8 kW Alternator Denso 24V 95A Battery ...

Page 31: ...sure 390 kgf cm2 5550 psi Item Specification Type Axial piston motor Capacity 250 cc rev Relief pressure 290 kgf cm2 4120 psi Braking system Automatic spring applied hydraulic released Braking torque 107 kgf余m 773 lbf余ft Brake release pressure 30 50 kgf cm2 427 711 psi Reduction gear type 2 stage planetary Item Specification Type Variable displacement axial piston motor Relief pressure 360 kgf cm2...

Page 32: ...ract Bucket cylinder Bore dia佴Rod dia佴Stroke 凱150佴凱105佴1295 mm Cushion Extend only Item Width Ground pressure Link quantity Overall width HX430 L Standard 600 mm 24 0 76 kgf cm2 10 81 psi 53 3340 mm 10 11 Option 700 mm 28 0 66 kgf cm2 9 39 psi 53 3440 mm 11 3 750 mm 30 0 62 kgf cm2 8 82 psi 53 3490 mm 11 5 800 mm 32 0 59 kgf cm2 8 39 psi 53 3540 mm 11 7 900 mm 36 0 53 kgf cm2 7 54 psi 53 3640 mm 1...

Page 33: ...h any other lubricating oil as it may result in damage to the systems of major components 侍 Do not use any engine oil other than that specified above as it may clog the diesel particulate filter DPF 侍 For HYUNDAI genuine lubricating oils and grease for use in regions with extremely low temperatures please contact HYUNDAI dealers HYUNDAI genuine lubricating oils have been developed to offer the bes...

Page 34: ...SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device 2 1 Group 2 Main Control Valve 2 20 Group 3 Swing Device 2 46 Group 4 Travel Device 2 58 Group 5 RCV Lever 2 72 Group 6 RCV Pedal 2 79 ...

Page 35: ... a5 A3 a1 a4 a1 a1 PB a2 a2 B3 B3 a3 2 1 1 STRUCTURE The pump device consists of main pump regulator and gear pump SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 380F2MP01 Port Port name Port size A1 2 Delivery port SAE6000 psi 1 B1 Suction port SAE2500 psi 3 Dr Drain port PF 3 4 23 Pi1 i2 Pilot port PF 1 4 15 Psv1 sv2 Servo assist port PF 1 4 15 a1 2 4 5 Gauge port PF 1 4 15 a3 Gauge port P...

Page 36: ...port plate 261 Seal cover F 710 O ring 717 O ring 719 O ring 724 Square ring 725 O ring 728 O ring 732 O ring 774 Oil seal 789 Back up ring 792 Back up ring 808 Hexagon head nut 824 Snap ring 885 Pin 886 Spring pin 901 Eye bolt 953 Set screw 954 Adjust screw 956 Set screw 271 Pump casing 311 Valve cove r F 312 Valve cover R 313 Valve plate R 314 Valve plate L 401 Hexagon socket bolt 402 Hexagon so...

Page 37: ...C 735 436 755 541 545 543 722 497 438 413 697 696 466 755 Hydraulic circuit FRONT 412 876 874 A B 755 858 614 615 613 611 B A 897 612 875 B A P2 Pf Pi1 Psv1 755 496 38092RG01 Port Port name Port size Pi1 Pilot port PF 1 4 15 Psv1 Servo assist port PF 1 4 15 Pf Power shift port P2 Companion delivery port ...

Page 38: ... 644 645 646 728 924 801 438 SECTION B B REAR 412 876 874 A B 755 858 614 615 613 611 B A 897 612 875 P2 Pi2 Psv2 A Pf 430F2RG02 Port Port name Port size Pi1 Pilot port PF 1 4 15 Psv1 Servo assist port PF 1 4 15 Pf Power shift port P2 Companion delivery port ...

Page 39: ...g 626 Inner spring 627 Adjust stem C 628 Adjust screw C 629 Cover C 630 Lock nut 631 Sleeve pf 641 Pilot cover 643 Pilot piston 644 Spring seat Q 645 Adjust stem Q 646 Pilot spring 651 Sleeve 652 Spool 653 Spring seat 654 Return spring 655 Set spring 696 Port cover 697 Check valve plate 699 Valve casing 708 O ring 722 O ring 724 Square ring 725 O ring 728 O ring 730 O ring 732 O ring 733 O ring 73...

Page 40: ...353 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 700 354 351 710 435 361 353 732 312 311 434 309 307 310 308 434 466 725 a3 A3 355 850 433 B3 887 29092MP05 ...

Page 41: ...nsists 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 sliding surface of the shoe and is supported by the swash support If the servo piston moves to the right and left as hydraulic force controlled by the regulator is admitted to hydraulic chamber located on bot...

Page 42: ...ctric motor engine etc it rotates the cylinder block via a spline linkage at the same time If the swash plate is tilted as in Fig previous page the pistons arranged in the cylinder block make a reciprocating motion with respect to the cylinder block while they revolve with the cylinder block If you pay attention to a single piston it performs a motion away from the valve plate oil sucking process ...

Page 43: ...delivery flow Q decreases as the pilot pressure Pi rises With this mechanism when the pilot pressure corresponding to the flow required for the work is commanded the pump discharges the required flow only and so it does not consume the power uselessly REGULATOR Regulator consists of the negative flow control total horse power control and power shift control function 2 1 Pilot pressure Pi Delivery ...

Page 44: ... spool moves to the right The movement of the spool causes the delivery pressure P1 to connect to port CL through the spool and to be admitted to the large diameter section of the servo piston The delivery pressure P1 that is constantly admitted to the small diameter section of the servo piston moves the servo piston to the right due to the area difference resulting in decrease of the tilting angl...

Page 45: ...es and shifts the spool to the left Port CL opens a way to the tank port as the spool moves This deprives the large diameter section of the servo piston of pressure and shifts the servo piston to the left by the discharge pressure P1 in the small diameter section resulting in an increase in the flow rate As the servo piston moves point D also moves to the left the feedback lever rotates around the...

Page 46: ... the screw shifts the control chart to the right as shown in the figure Adjusting values are shown in table Pilot pressure Pi Delivery flow Q 801 924 Adjustment of flow control characteristic 到 侍 R290RE08 1 Speed Adjustment of flow control characteristic Tightening amount of adjusting screw 924 Flow control starting pressure change amount Flow change amount min 1 Turn kgf cm2 min 1800 1 4 1 0 18 9...

Page 47: ...s in the tandem double pump system the prime mover is automatically prevented from being overloaded irrespective of the load condition of the two pumps when horsepower control is under way Since this regulator is of the simultaneous total horsepower type it controls the tilting angles displacement volumes of the two pumps to the same value as represented by the following equation Tin P1Ýq 2 ʆ P2Ýq...

Page 48: ...the feedback lever rotates around the fulcrum of point D as lever 1 rotates and then the spool 652 is shifted to the right As the spool moves the delivery pressure P1 is admitted to the large diameter section of the servo piston via port CL causes the servo piston move to the right reduces the pump delivery flow rate and prevents the prime mover from being overloaded The movement of the servo pist...

Page 49: ...the fulcrum of point D and then the spool 652 to move to the left As a result port CL opens a way to the tank port This causes the servo piston to move to the left and the pump s delivery rate to increase The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism to move it till the opening between the spool and sleeve is closed 651 625 B E 897 D Servo pis...

Page 50: ...he large hole 8 only the lever lessening the tilting angle contacts the pin 897 the hole 8 in the lever of a larger tilting angle command is freed without contacting the pin 897 Such a mechanical selection method permits preference of the lower tilting angle command of the flow control and horsepower control Adjustment of input horsepower Since the regulator is of total cumulative horsepower type ...

Page 51: ...the screw increases the flow and then the input horsepower as shown in the figure Adjusting valves are shown in table b 侍 Delivery pressure P1 P2 Delivery flow Q 626 802 627 8007A2MP04 Speed Adjustment of inner spring Tightening amount of adjusting screw QI 627 Flow change amount Input torque change amount min 1 Turn lpm kgfÂm 1800 1 4 16 7 7 2 ...

Page 52: ...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 the compensating rod 623 moves to the right via the pin 898 and compensating piston 621 This decreases the pump tilting angle and then the set horsepower in the same way as explained in the overload pr...

Page 53: ...m 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 刯 Delivery pressure Pi Delivery flow Q Delivery pressure Pi Delivery flow Q 808 954 808 953 Adjustment of maximum and minimum flows 刮 4 R290RE08 5 3607A2MP02 Speed Adjustment of max flow spring Tightening amount of ad...

Page 54: ...Tb P1g P2g Psp Arm 1 in pilot port Arm 1 out pilot port Boom down pilot port Boom up pilot port Bucket in pilot port Bucket out pilot port Travel right reverse pilot port Travel right forward pilot port Travel left reverse pilot port Travel left forward pilot port Swing left pilot port Swing right pilot port Arm 2 in pilot port Arm 2 out pilot port Boom up confluence pilot port Optional pilot port...

Page 55: ...arm1 side port Drain port Drain port Drain port PF1 4 3 5 4 0 kgfÂm 25 3 29 lbfÂft PL1 Main relief valve pilot port for switching to high pressure PF1 8 1 5 1 9 kgfÂm 10 8 13 7 lbfÂft Aa Ba Ab Bb Ac Bc Ar Br AL BL Ao Bo Arm cylinder head side port in Arm cylinder rod side port out Boom cylinder rod side port down Boom cylinder head side port up Bucket cylinder head side port in Bucket cylinder rod...

Page 56: ...g seat Shim Bolt Rod Orifice Spring Travel straight spool assy Bypass cut spool Boom confluence spool Swing priority spool Poppet O ring Poppet Poppet Bolt Boom priority valve assy Spring Spring seat Spring Plug Plug assy Plug Main relief valve Plug Cover assy 301 Travel spool 524 302 Arm 1 spool 525 541 Steel ball B H B H C C D D E E F F L A A G 273 273 991 992 551 561 551 561 159 212 761 762 P 1...

Page 57: ...51 561 522 511 393 263 332 336 201 165 554 336 165 161 554 603 303 511 552 264 561 553 513 203 274 252 168 273 372 558 561 356 264 275 204 267 525 514 162 562 562 162 163 262 562 162 161 161 524 308 603 155 201 511 263 522 394 262 202 522 511 761 762 751 603 155 751 762 203 264 274 202 262 603 302 511 264 522 274 513 553 561 252 168 158 332 371 332 336 201 335 263 332 332 336 201 263 332 371 332 3...

Page 58: ...PAa2 PBa2 Ck2 Drb PBb2 PSp Dra PAs PBs Dr4 Pns PAr PBr R3 T1 P2g P2 P1 P1g PS PS SWING BOOM 2 TRAVEL LH ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL RH OPTION SWING PRIORITY Px P PS Pa Py PS LCs PAo PBo Ao PAa PBa Bo Bs As Ar Br TRAVEL STRAIGHT CP2 Ccb LCo OPEN CLOSE LCc LCb CP1 PTa CMR1 CMR2 Pa SH port Swing motor P2c1 PAcs Pca A2 A1 PBb2 380F2MC05 2 24 ...

Page 59: ...ols the pump discharge flow rate to its minimum value The oil discharged from the main pump A1 passes through port P2 the main path 3 the bypass circuit 2 passing the spools for swing boom confluence boom 2 option and arm 1 and the arm 1 side negative control orifice and returns to the hydraulic oil tank through the tank port T1 The pressure upstream the arm 1 side negative control orifice the neg...

Page 60: ...GHT SWING PRIORITY TRAVEL RIGHT BOOM 1 BUCKET ARM 2 TRAVEL LEFT SWING BOOM CONFLUENCE OPTION ARM 1 3 2 R3 PAr PAs PSp PAo PAa PBr PBs PBo PBa PBb2 PTa PBL PBa2 PTb PAL PAa2 PAb PAc CUT CUT 2 1 3 PBb 3809A2MC14 2 26 ...

Page 61: ...2 side is shut off and pressurized oil from port P2 passes through port BL and flows to the travel motor On the other hand the return oil from the travel motor passes through port AL and returns to the hydraulic oil tank through the tank port T1 2 PBL FROM TRAVEL MOTOR PAL AL BL TO TRAVEL MOTOR 3607A2MC15 2 27 ...

Page 62: ... supplied to the arm cylinder rod side R On the other hand the oil entering through port P1 passes in the main path 1 and flows into the bypass circuit 2 and the bypass circuit is shut off due to transfer of the arm 2 spool 394 Oil from the parallel circuit pushes open the check valve 514 and oil from the bypass circuit pushes open the check valve 511 and flows through the U shaped path to the arm...

Page 63: ... spool in the inside path and joins into port Aa On the other hand the return oil from the arm cylinder rod side R is pressurized by self weight of the arms and so on and returns to port Ba The pressurized oil returning to Port Ba enters into the spool through the outside hole a of the arm1 spool 302 During a light load only it pushes open the sleeve check valve and part of oil flows the U shaped ...

Page 64: ...ly 2 30 3607A2MC17A 余The pressure in the arm cylinder head side H increases Aa Ba PBa2 PBa PAa2 PAa LCa1 e a d f b 511 511 514 394 302 511 Aa Ba PBa2 PBa PAa2 PAa LCa1 c a Parallel circuit U shaped path Arm self weight 511 514 394 302 ...

Page 65: ...the boom 1 spool is large the oil flows out to port Bb through the periphery of the spool At the same time the pilot pressure enters also through Port PBb2 to transfer the boom 2 spool 393 in the left direction in figure Though the pressurized oil enters into port P2 the bypass is shut off due to transfer of the boom 2 spool Therefore the oil flows in the parallel circuit and flows through the U s...

Page 66: ...is supplied to the boom cylinder rod side R On the other hand the return oil from the boom cylinder head side H passes to the notch of the boom 1 spool Since this return oil has a sufficient pressure caused by the weight of the boom it passes through the path inside the spool pushes the poppet A in the spool in the left direction shown in the figure flows around the outside of the spool Then it is...

Page 67: ... 304 Then it flows through the periphery of the spool to port Ac and is supplied to the bucket cylinder head side H On the other hand the return oil from the bucket cylinder rod side R enters through port Bc passes around the periphery of the spool and returns to the hydraulic oil tank through the tank port T1 During the boom up and bucket in operation the pilot pressure enters through Port PAcs a...

Page 68: ...ucket spool Therefore the pressurized oil flows into the parallel circuit pushes open the check valve 511 and flows through the U shaped path to the bucket spool 304 Then it flows through the periphery of the spool to port Bc and is supplied to the bucket cylinder rod side R On the other hand the return oil from the bucket cylinder head side H enters through port Ac passes around the periphery of ...

Page 69: ...eturns to the hydraulic oil tank through the tank port T1 Swing operation preference function Pilot Circuit The pilot pressure enters through Port PSp to transfer the swing priority spool 395 Main Circuit Due to transfer of the swing priority spool the open area of the swing priority spool decreases and the most of the pressurized oil entering through port P2 flows to the swing side to make the sw...

Page 70: ...ol the port P2 and both travel spools are connected preferentially and the port P1 and the parallel paths of swing boom 2 option and arm 1 boom 1 bucket and arm 2 are connected preferentially Therefore the pressurized oil entering through port P2 passes through mainly ports AL and Ar and flows to both travel motors separately On the other hand the pressurized oil entering through port P1 flows to ...

Page 71: ...llowing is the case of the boom 1 spool The case of the arm 1 spool is in the same way During the boom 1 spool is in neutral position the lock valve is kept in the position shown in figure The spool 511 in lock valve is pushed to the seat of the bushing 541 by the force of the spring 512 In this position pressurized oil from the boom cylinder head side H enters through hole a the periphery of the ...

Page 72: ... head side H does not enter to spring chamber RH Secondly oil in spring chamber RH enters through hole b and flows to port Dr3 Therefore the poppet is lifted by the pressure of the boom cylinder head side H and the function of the lock valve is released Boom cylinder head side H 511 P2c1 Dr3 a b LCb1 RH HV PBb 3809A2MC25 Boom up operation 到 During the boom up operation the pilot pressure enters th...

Page 73: ...nd the poppet 101 is pushed to the casing seat Therefore the most of pressurized oil entering through port P2 flows to the boom priority spool 393 than the swing spool 305 to make the boom hoisting operation most preferential On the other hand in the independent swing operation the pilot pressure does not enter through ports Pns and the path from a to b is not closed and oil of chamber e flows to ...

Page 74: ...he spring 512 the poppet 401 opens to make the hydraulic oil flow through a hole of the seat 2 641 around the poppet 401 and into the low pressure path R Opening of the poppet 401 causes the pressure in the chamber A to fall and the plunger 511 to open As the result the pressurized oil in the path P runs into the low pressure path R directly When the pressurized oil higher than pressure 2 2 MPa en...

Page 75: ...f valve this serves also as an anti cavitation check valve and functions as follows Function as relief valve The pressurized oil passes through hole A of the piston 301 is filled up in chamber B of the inside space and seat the plunger 511 against the seat 541 securely 刮 B A 511 541 301 P R 3607A2MC28 11 1 B A 511 541 301 P R PL 3607A2MC29 ...

Page 76: ... P becomes equal to the set pressure of the spring 621 or 622 the pressurized oil pushes open the poppet 611 flows around it and flows to the low pressure path R through Hole C 刯 P R C 611 621 3607A2MC30 P R PL 106 C 611 622 3607A2MC31 ...

Page 77: ...pressurized oil in the path P runs into the low pressure path R directly 到 P R 611 B 511 3607A2MC32 P R PL 611 622 511 B 624 105 3607A2MC33 When the pressurized oil higher than pressure 1 5 MPa enters through the port PL it pushes the piston 624 to change the relief set pressure of the spring 622 to the high pressure 刱 ...

Page 78: ...h p the oil is supplied through the path R When the pressure at R becomes higher than that in the path P the seat 541 moves in the right direction Then sufficient oil passes around the seat 541 from the path R to the path P and prevents cavitation P R 541 3607A2MC34 2 P R PL 541 3607A2MC35 ...

Page 79: ...elled by the area A of the damping rod 631 621 611 R P 631 B A 刮 3607A2MC36 In this condition the pressurized oil in the path P runs out to the path R through the orifice c R P C 刯 3607A2MC37 When the pressure in the path P goes over the set pressure of the spring 621 the poppet 611 opens Then the pressurized oil in the path P passes around the outside of the poppet 611 and flows to the low pressu...

Page 80: ...parking valve relief valve make up valve and time delay valve GROUP 3 SWING DEVICE 38092SM01A Port Port name Port size A Main port SAE 1 B Main port SAE 1 Dr Drain port PF 1 2 Mu Make up port PF 1 1 4 SH Brake release pilot port PF 1 4 PG Brake release stand by port PF 1 4 GA GB Gauge port PF 1 4 Am Motor air bleed port PF 1 4 AGr R G air bleed port PT 1 8 SGr Grease filling port PT 1 8 Dr R G Gea...

Page 81: ...ess valve assy 35 Plug 36 O ring 37 Back up ring 38 O ring 39 O ring 40 Bushing 1 Body 2 Oil seal 3 Roller bearing 4 Snap ring 5 Shaft 6 Pin 7 Stop ring 8 Shoe plate 9 Cylinder block 10 Spring 11 Ball guide seat 12 Ball guide 13 Set plate 14 Piston assy 15 Friction plate 16 Plate 17 Brake piston 18 O ring 19 Spring 20 Valve plate 21 Pin 22 Needle bearing 23 Rear cover 24 Wrench bolt 25 Wrench bolt...

Page 82: ...ier assy 1 33 Pinion gear 34 Lock plate 35 Hexagon bolt 36 Lock washer 37 Plug 38 Plug 39 Socket bolt 40 Cover 41 O ring 42 Hexagon socket bolt 45 Air breather assy 46 Gauge pipe 47 Gauge bar 48 Post 49 Cap 17 Carrier 1 18 Planetary gear 1 19 Pin 1 20 Needle cage 21 Side plate 1 22 Side plate 2 23 Stop ring 24 Spring pin 25 Thrust ring 26 Sun gear 2 27 Sun gear 1 28 Ring gear 29 Knock pin 30 Cover...

Page 83: ...ment at surroundings of cylinder Since cylinder block has 9 equidistantly arrayed pistons rotational torque is transmitted to cylinder shaft in order by several pistons connected to the inlet port of high pressurized oil When the direction of oil flow is reversed rotational direction of cylinder is also reversed Output torque is given by the equation Where p Effective difference of pressure kgf cm...

Page 84: ...iciency A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action The boost pressure acts on the hydraulic motor s feed port via the make up valve Pressurized oil into the port B the motor rotate counterclockwise If the plunger of MCV moves neutral position the drain oil from Mu port ru...

Page 85: ...hydraulic motor The relief valves relieve high pressure at start or at stop of swing motion and can control the relief pressure in two steps high and low in order to insure smooth operation Function of relief valve Figure illustrates how the pressure acting on the relief valve is related to its rising process Here is given the function referring to the figure following page 1 2 P Ps P2 P1 1 T T ti...

Page 86: ... R at tank pressure When hydraulic oil pressure PÝA1 reaches the preset force FSP of spring 4 the plunger 3 moves to the right as shown P1ÝA1 FSP PgÝA2 P1 Fsp PgÝA2 A1 Θ Η R P A2 4 3 g A1 P P1 R 36072SM07 36072SM08 ...

Page 87: ...Fsp of spring 4 the piston 6 moves left and stop the piston 6 hits the bottom of sleeve 7 When piston 6 hits the end of sleeve 7 it stops moving to the left any further As the result the pressure in chamber g equals PS PSÝA1 FSP PsÝA2 PS Fsp A1 A2 Ι Κ 4 n g P P2 R m 7 6 P Ps R 7 6 g 36072SM09 36072SM10 ...

Page 88: ...1 separate plate 12 and brake piston 13 friction force occurs there Cylinder block 9 is constrained by this friction force and brake acts while brake releases when hydraulic force exceeds spring force BRAKE SYSTEM Control valve swing brake system This is the brake system to stop the swing motion of the excavator for during operation In this system the hydraulic circuit is throttled by the swing co...

Page 89: ... 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 piston 6 to the upward against the force of the spring 9 Thus it releases the brake force Θ a 9 6 G PG 11 D 8 5 3 10 7 P4 P3 SH 1 12 P3 2 4 2 1 Swing control lever 2 Main control valve 3 Time delay valve 4 Pilot pump 5 Spool 6 Piston 7 Poppet 8 ...

Page 90: ...ed lower by spring force and the return oil from the chamber G flows back to tank port At this time the brake works b 9 6 G PG 11 D 8 5 3 10 7 P4 D SH SH 4 1 2 P3 PG 1 Swing control lever 2 Main control valve 3 Time delay valve 4 Pilot pump 5 Spool 6 Piston 7 Poppet 8 Spring 9 Spring 10 Orifice 11 Spring 36072SM13A ...

Page 91: ... and the return and the return oil from the chamber G flows back to D port through orifice 10 of the poppet 7 At this time the poppet 7 works to make a time lag for 5 seconds c 9 6 PG 11 D 8 5 3 10 7 SH 4 1 2 P3 PG G 1 Swing control lever 2 Main control valve 3 Time delay valve 4 Pilot pump 5 Spool 6 Piston 7 Poppet 8 Spring 9 Spring 10 Orifice 11 Spring 38092SM04 ...

Page 92: ...ve parking brake and high low speed changeover mechanism GROUP 4 TRAVEL DEVICE VIEW A HYDRAULIC CIRCUIT A DR MA PS MB VB VA 0 6 0 6 0 6 REG 0 8 PS MB DR MA VA VB FILL LEVEL DRAIN 43092TM01 Port Port name Port size VA VB Valve port PF 1 PS Pilot port PF 1 4 DR Drain port PF 1 2 MA MB Gauge port PF 1 4 ...

Page 93: ... 22 Separated plate 23 Parking piston 24 D ring 25 D ring 26 Valve plate 27 Parallel pin 28 Spring 29 O ring 30 Spring pin 31 Parallel pin 32 Rear cover 33 Main spool assy 34 Spring seat 35 Plug 36 Spring 37 O ring 38 Restrictor 39 Spring 40 O ring 41 O ring 42 O ring 43 O ring 44 O ring 45 Relief valve assy 46 Spool 47 Plug 48 Spring seat 49 Parallel pin 50 Spring 51 Connector 52 O ring 53 Hexago...

Page 94: ...ing 9 Hexagon socket head bolt 10 Coupling 11 Carrier 2 12 Planetary gear 2 13 Needle bearing 2 14 Thrust washer 2 15 Carrier pin 2 16 Spring pin 2 17 Solid pin 2 18 Sun gear 2 19 Carrier 1 20 Planetary gear 1 21 Needle bearing 1 22 Thrust washer 1 23 Carrier pin 1 24 Spring pin 1 25 Sun gear 1 26 Thrust plate 27 Thrust plate 28 Cover 29 Cover seal 30 Hexagon socket head bolt 31 Hexagon socket hea...

Page 95: ...ch are on one side of the lineY Y that connects upper and lower dead points and produces force F1 F1 P佴A P pressure A area of piston section The swash plate 17 with inclined angle of divides this force F1 into thrust force F2 and radial force F31 34 This radial force is applied to axisY Y as turning force and generate drive torque of T T r1余F31 r2余F32 r3余F33 r4余F34 This drive torque is transmitted...

Page 96: ...generated by the friction between the separated plates 22 inserted into the casing 1 and friction plates 21 coupled to cylinder block 16 by the outer splines When no pressure is activated on the parking piston 23 it is pushed by the brake springs 28 and it pushes friction plates 21 and separated plates 22 towards casing 1 and generates the friction force which brakes the rotation of cylinder block...

Page 97: ...e hydraulic tank through restrictor 57 Here nine pistons are there and they equally spaced on the swash plate 15 The force that summed up those of pistons comes to almost the center of the swash plate 15 as shown Since the pivots 14 are off set by S from the center the rotating force of product S and the force moves swash plate 15 to the former position and the speed returns to low When the power ...

Page 98: ...t is inserted in the sleeve 45 6 screw 45 13 that is adjust the spring force nut 45 14 that fix screw 45 13 piston 45 7 that reduce the shock 1 A B 45 11 45 12 45 10 45 6 45 9 45 8 45 7 45 5 45 15 45 4 45 1 45 2 45 3 45 13 45 14 HYD CIRCUIT 43092TM07 OVERLOAD RELIEF VALVE 4 45 1 Plug 45 2 Guide 45 3 O ring 45 4 Spring 45 5 Spring seat 45 6 Sleeve 45 7 Piston 45 8 Seal 45 9 Poppet 45 10 Poppet seat...

Page 99: ...d to the effective diameter of poppet 45 9 which seats on the poppet seat 45 10 and at the same time is delivered via small hole to the spring seat 45 5 located inside the sleeve 45 6 and the seat bore pressure increases up to A port pressure The poppet 45 9 opposes to spring 45 4 by the force of the pressure exerted on the area difference between poppet seat s effective diameter and spring seat b...

Page 100: ...ing stopping and counterbalance operations See page 2 90 2 Operation Check valve built in the spool This valve is located in the oil supplying passage to hydraulic motor and at the same time functions to lock oil displacement Therefore this valve serves as not only a suction valve but also a holding valve for hydraulic motor 5 36 37 34 33 38 39 41 40 43092TM13 1 刮 刯 33 Main spool 34 Spring seat 36...

Page 101: ...of the motor is mechanically prevented If external torque is exerted on the motor shaft the motor would not rotate as usual by this negative parking brake In case the brake should be released for some reason pressure is built on MA or MB port But due to oil leakage inside hydraulic motor or so high pressure oil escapes from the closed circuit and motor rotates a bit So the cavitation tends to occu...

Page 102: ...ure supplied from pump At the same time the pressure of pilot chamber increases to push and move the spool 33 leftwards overcoming the spring 36 force Thus the return line from MB to VB opens to rotate the motor In case inertia load is too big to start rotation accelerating pressure reaches the set pressure of relief valve and high pressure oil is being relieved while the motor gains the rotationa...

Page 103: ...from MA to VA is closed Owing to the inertia force of the load the hydraulic motor tends to continue the rotation Here the motor functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure increases Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last the motor stops Negative brake release pressure is gradually low...

Page 104: ... and the pressure on MA side rises due to increased resistance in the passage and the motor receives hydraulic braking effect If the motor rotates slower than that matched to the volume of supplied oil the pilot chamber pressure on VB port increases and spool 33 moves rightwards to enlarge the area of passage from MA to VA Therefore the braking effect becomes smaller and the rotational speed of mo...

Page 105: ... K1 K2 Ring gear a Carrier k Sun gear s Planetary pinions b REDUCTION GEAR Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force This reduction unit utilizes two stages planetary reduction system Planetary reduction system consists of sun gear planetary gears planetary carriers and ring gear When the sun gear s is driven through input shaft planet...

Page 106: ...ngle operation 25 Simultaneous operation 2 3 T 1 P 4 RH 6 5 6 TYPE L5 8 7 Null Null 300L2RL01 Switches Type No LH RH L1 L3 5 One touch decel Horn 6 Power boost Breaker L5 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 return port Pilot oil return port 1 Left swing port...

Page 107: ...el Horn 6 Power boost Breaker L6 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 return port Pilot oil return port 1 Left swing port Bucket out port 2 Arm out port Boom up port 3 Right swing port Bucket in port 4 Arm in port Boom down port TYPE L2 L4 L6 2 ö Number 7 and...

Page 108: ... construction of the pilot valve is shown in the attached cross section drawing The casing has vertical holes in which reducing valves are assembled The pressure reducing section is composed of the spool 3 spring 5 for setting secondary pres sure return spring 7 spring seat 6 and shim 4 The spring for setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 2...

Page 109: ...IONS Item numbers are based on the type L1 The functions of the spool 3 are to receive the supply oil pressure from the hydraulic pump at its port P and to change over oil paths to determine whether the pressure oil of port P is led to output ports 1 2 3 4 or the output port pressure oil to tank port T The spring 5 works on this spool to determine the output pressure The change the deflection of t...

Page 110: ...hydraulic circuit diagram shown below and the attached operation explanation drawing The diagram shown below is the typical application example of the pilot valve 1 Pilot valve 2 Pilot pump 3 Main pump 4 Main control valve 5 Hydraulic motor 6 Hydraulic cylinder 1 1 P T 3 2 3 4 5 6 3 2 70 ...

Page 111: ...ool 3 Therefore the spool is pushed up by the spring 7 to the position of port 1 3 in the operation explanation drawing Then since the output port is connected to tank port T only the output port pressure becomes equal to tank pressure Case where handle is in neutral position Port 1 Port 3 P T 3 7 5 1 300L2RL03 ...

Page 112: ...e at port 1 increases higher than the set pressure port P is disconnected from port 1 and port T is con nected with port 1 If it decreases lower than the set pressure port P is connected with port 1 and port T is disconnected from port 1 In this manner the secondary pressure is kept at the constant value Besides in some type when the handle is tilted more than a certain angle the upper end of the ...

Page 113: ... pressure and the oil outlet port T tank In addition the secondary pressure is taken out through ports 1 2 3 and 4 provided at the bottom face GROUP 6 RCV PEDAL Port P T 1 2 3 4 Port size PF 1 4 Port Pilot oil inlet port Pilot oil return port Travel LH Forward Travel LH Backward Travel RH Forward Travel RH Backward 21092RP01 ...

Page 114: ...y 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 Spring seat 6 Spring 7 Spring seat 8 Spool 9 Stopper 10 Spring 11 Rod guide 12 O ring 13 Snap ring 14 Push rod 15 Spring pin 16 Seal 17 Steel ball 18 Spring 19 Plate 20 Snap ring 21 Plug 22 O ring 23 R...

Page 115: ... FUNCTIONS OF MAJOR SECTIONS The functions of the spool 8 are to receive the supply oil pressure from the hydraulic pump at its port P and to change over oil paths to determine whether the pressure oil of port P is led to output ports 1 2 3 4 or the output spool to determine the output pressure The spring 6 works on this spool to determine the output pressure The change the deflection of this spri...

Page 116: ...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 3 Main pump 4 Main control valve 5 Hydraulic motor 6 Hydraulic cylinder 1 3 5 4 6 2 36072SF01 ...

Page 117: ...pressure 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 connected to tank port T only the output port pressure becomes equal to tank pressure T P 6 8 10 21092RP03 ...

Page 118: ...essure at port 1 increases higher than the set pressure port P is disconnected from port 1 and port T is connected with port 2 If it decreases lower than the set pressure port P is connected with port 2 and port T is disconnected from port 2 In this manner the secondary pressure is kept at the constant value Besides in some type when the pedal is tilted more than a certain angle the upper end of t...

Page 119: ...SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit 3 1 Group 2 Main Circuit 3 2 Group 3 Pilot Circuit 3 5 Group 4 Single Operation 3 14 Group 5 Combined Operation 3 24 ...

Page 120: ...UPLER 31 E 2 Aa TRAVEL STRAIGHT ARM SAFETY LOCK VALVE 10 2 Ba 25 e Pi1 V2 T FL BL FR BR A1 A2 A3 A4 2 1 3 2 1 3 7 2 7 4 7 1 2 PBL 2 PAL 2 PBr 2 PAr 7 3 3 2 Px SH PG 21 P4 ARG Dr GA A CCW Mu B CW GB Au SGo RG Dr SRG 2 As 2 Bs 2 R4 4 Dr LH RH Dr Dr Dr Mb B A A C P Pk Dr D B 12 B A 2 Ar 2 Br 21 A4 2 BL Pi Pi Pi Pi N N Ma Ma Mb 21 T dr1 21 A1 5 26 SWING ARM P T 1 3 2 4 6 26 21 A1 BUCKET BOOM P T 3 1 2...

Page 121: ...TION AND DELIVERY CIRCUIT To cylinders To motors To hydraulic oil tank Hydraulic oil tank Main control valve Main pump GROUP 2 MAIN CIRCUIT The pumps receive oil from the hydraulic tank through a suction strainer The discharged oil from the pump flows into the control valve and goes out the tank ports The oil discharged from the main pump flows to the actuators through the control valve The contro...

Page 122: ...in the oil temperature being raised quickly at an appropriate level When the oil cooler is clogged the oil returns directly to the hydraulic tank through bypass check valve 1 The full flow filter and bypass relief valve are provided in the hydraulic tank The oil from right and left side of control valve is combined and filtered by the return filter A bypass relief valve is provided in the full flo...

Page 123: ...the drain ports provided in the respective motor casing and join with each other These oils pass through the turning joint and return to the hydraulic tank after being filtered by full flow filter in the hydranlic tank SWING MOTOR DRAIN CIRCUIT Oil leaking from the swing motor come out and return to the hydraulic tank passing through a drain filter MAIN PUMP DRAIN CIRCUIT Oil leaking from main pum...

Page 124: ...remote control valve through line filter EPPR valve solenoid valve assemblies swing parking brake main control valve and safety lock solenoid valve GROUP 3 PILOT CIRCUIT Relief valve 40 kgf cm RCV pedal Remote control valve LH lever Remote control valve RH lever Safety lock solenoid valve Swing parking brake Pilot pump Suction strainer MCV Travel speed solenoid valve Main pump 2 Power boost soleno...

Page 125: ...PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr R3 TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL BL AL Px P PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pcb N1 OPTION ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL LH PS PS PS PS PS A B C TRAVEL P T RCV PEDAL 2 PBr 1 PAr 4 PBL 3 PAL BOOM P T BUCKET ARM P T SWING c e2 d1 h1 h2 P2c1 PAb 4 PBc Pca PAc PAcs PBb2 PBb PAa2...

Page 126: ...s PAs PSp Dr dr T LINE FILTER P3 P2 P1 P4 Pns MCV PL1 MCV P T Joint A1 A2 A4 A5 SAFETY SOLENOID VALVE SH 2 1 3 4 2 3 1 HYDRAULIC TANK LEVER UP LEVER DOWN TRAVEL MOTOR SWING MOTOR ARM CYLINDER BUCKET CYLINDER BOOM CYLINDER PILOT PUMP BL AL Px P PG S Motor Pa MCV Psv1 M PUMP P MCV B a b d e f g h j PUMP A1 PUMP A2 A D E F G H J 3 7 When the lever of the safety solenoid valve is moved upward oil flow...

Page 127: ... BOOM PRIORITY EPPR VALVE Swing reducing spool TRAVEL MOTOR SWING MOTOR ARM CYLINDER BUCKET CYLINDER BOOM CYLINDER PILOT PUMP BL AL PG S Motor Pa MCV Psv1 M PUMP P MCV Boom speed B a b d e f g h j PUMP A1 PUMP A2 A D E F G H J 380L3HC04 When carrying out the combined operation of swing and boom up the boom up operating speed is lowered then normal operation To increase working efficiency swing spe...

Page 128: ...r4 Pns Br Ar PAr PBr R3 TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pcb N1 OPTION ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL LH PS PS PS PS PS A B C TRAVEL P T RCV PEDAL 2 PBr 1 PAr 4 PBL 3 PAL BOOM P T BUCKET ARM P T SWING c e2 d1 h1 h2 P2c1 PAb 4 PBc Pca PAc PAcs PBb2 PBb PAa2 P2c2 PAa PBa2 PBa PBs PAs PSp Dr dr T LINE FILTER P3 P...

Page 129: ... PRESSURE CHANGE CIRCUIT PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr R3 TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pcb N1 OPTION ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL LH PS PS PS PS PS A B C TRAVEL P T RCV PEDAL 2 PBr 1 PAr 4 PBL 3 PAL BOOM P T BUCKET ARM P T SW...

Page 130: ...PL1 MCV P T Joint A1 A2 A4 A5 SH 2 1 3 4 2 3 1 HYDRAULIC TANK SH PG ARG Dr GA A CCW Mu B CW GB Au SGo RG Dr SRG BRAKE VALVE TRAVEL MOTOR SWING MOTOR ARM CYLINDER BUCKET CYLINDER BOOM CYLINDER PILOT PUMP Px P BL AL PG S Motor Pa MCV Psv1 M PUMP P MCV B a b d e f g h j PUMP A1 PUMP A2 A D E F G H J 380L3HC07 When one of the RCV lever except travel lever is tilted the pilot oil flows into SH port thr...

Page 131: ...As PAs PBs Dr4 Pns Br Ar PAr PBr R3 TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pcb N1 OPTION ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL LH PS PS PS PS PS A B C TRAVEL P T RCV PEDAL 2 PBr 1 PAr 4 PBL 3 PAL BOOM P T BUCKET ARM P T SWING c e2 d1 h1 h2 P2c1 PAb 4 PBc Pca PAc PAcs PBb2 PBb PAa2 P2c2 PAa PBa2 PBa PBs PAs PSp Dr dr T LINE...

Page 132: ... 13 8 BOOM FLOATING SYSTEM PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL BL AL Px P PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pcb N1 OPTION ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL LH SH HYDRAULIC TANK TRAVEL MOTOR SWING MOTOR ARM CYLINDER BUCKET CYLINDER PILOT PUMP...

Page 133: ...vented by relief valve When the boom is up and the control lever is returned to neutral position the circuit for the holding pressure at the bottom end of the boom cylinder is closed by the boom holding valve This prevents the hydraulic drift of boom cylinder 1 BOOM UP OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr TRAVEL RH ...

Page 134: ...with the oil from the A2 pump and flows into the small chamber of the boom cylinder This prevents cylinder cavitation by the negative pressure when the A2 pump flow can not match the boom down speed And the excessive pressure in the boom cylinder rod end circuit is prevented by the relief valve 2 BOOM DOWN OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PA...

Page 135: ...sive pressure in the arm cylinder head side is prevented by relief valve The cavitation which will happen to the head side of the arm cylinder is also prevented by the make up valve in the main control valve 3 ARM IN OPERATION Arm holding valve PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4...

Page 136: ...oll out and the control lever is returned to neutral position the circuit for the holding pressure at the rod side of the arm cylinder is closed by the arm holding valve The cavitation which will happen to the rod side of the arm cylinder is also prevented by the make up valve in the main control valve 4 ARM OUT OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs...

Page 137: ...the bucket spool in the main control valve When this happens the bucket rolls in The excessive pressure in the bucket cylinder head side is prevented by relief valve The cavitation which will happen to the head side of the bucket cylinder is also prevented by the make up valve in the main control valve 5 BUCKET IN OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra ...

Page 138: ...t The excessive pressure in the bucket cylinder rod side is prevented by relief valve The cavitation which will happen to the rod side of the bucket cylinder is also prevented by the make up valve in the main control valve 6 BUCKET OUT OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R...

Page 139: ... the swing operation preference function is operated by the pilot pressure PSp refer to page 3 12 7 SWING OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr R3 TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pcb N1 OPTION ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL LH P...

Page 140: ...rated PARKING BRAKE OFF OPERATION The parking brake is released by the pilot pressure oil from the pilot pump When one of the RCV lever except travel lever placed in the operating position the pilot oil flows into SH port through the MCV This pressure transferred to the brake release valve and the brake release valve is change over Then the pilot oil pressure PG lift the brake piston and release t...

Page 141: ...Aa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr R3 TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL Px P PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pcb N1 OPTION ARM 1 ARM 2 BUCKET BOOM 1 TRAVEL LH B PS PS PS PS PS A B C TRAVEL P T RCV PEDAL 2 PBr 1 PAr 4 PBL 3 PAL BOOM P T BUCKET ARM P T SWING c e2 d1 h1 h2 P2c1 PAb 4 PBc Pca PAc PAcs PBb2...

Page 142: ... over run OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 370 kgf cm2 5260 psi for the travel motor type 1 and 360 kgf cm2 5120 psi for the travel motor type 2 to prevent high pressure generated at a time of stopping the machine Stopping the motor this valve sucks the oil from lower pressure passage for preventing the negative pressure and the cavitation of the motor 1 2 380L3H...

Page 143: ...ng the straight travel spool is pushed to the right by the pilot oil pressure from the pilot pump Consequently the left and right travel oil supply passage are connected and equivalent amount of oil flows into the left and right travel motors This keeps the straight travel 1 OUTLINE PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr TRAVEL...

Page 144: ...ugh the boom 1 spool in the right control valve The upper structure swings and the boom is operated Refer to page 3 8 for the boom priority system 2 COMBINED SWING AND BOOM UP OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL BL AL Px P PBb PAb Ab Bb P2c1 Dr3 PB...

Page 145: ...LINDER BOOM CYLINDER PILOT PUMP R3 PUMP A1 PUMP A2 380L3HC22 When the swing and arm functions are operated simultaneously the swing spool and arm spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve The oil from the A1 pump flows into the swing motor through swing spool and the arm cylinder through arm 1 spool The oil from th...

Page 146: ...ket cylinder through the bucket spool in the right control valve The upper structure swings and the bucket is operated 4 COMBINED SWING AND BUCKET OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo Ck2 Drb PBb2 PSp Dra Bs As PAs PBs Dr4 Pns Br Ar PAr PBr TRAVEL RH SWING BOOM 2 T1 Pa P2 P1 P1g P2g R4 PTb PS PL1 Py PBL PAL BL AL Px P PBb PAb Ab Bb P2c1 Dr3 PBc PAc PAcs Bc Ac PBa2 PAa2 Pc...

Page 147: ...t travel spool When the pressure of the travel motors is lower than the pressure of the swing motor some oil from the A2 pump flows into the travel motors through the check valve and orifice in the straight travel spool This prevents the rapid slowdown of the travel The upper structure swings and the machine travels straight 5 COMBINED SWING AND TRAVEL OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa ...

Page 148: ...uence oil passage in case boom up operation When the pressure of the travel motors is lower than the pressure of the boom cylinders some oil from the A2 pump flows into the travel motors through the check valve and orifice in the straight travel spool This prevents the rapid slowdown of the travel The boom is operated and the machine travels straight 6 COMBINED BOOM AND TRAVEL OPERATION PS P4 P3 N...

Page 149: ... oil pressure from the remote control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control valve and the LH travel spool of the right control valve via the straight travel spool The oil from the A2 pump flows into the arm cylinders through the arm 1 spool ...

Page 150: ...he confluence oil passage When the pressure of the travel motors is lower than the pressure of the bucket cylinder some oil from the A2 pump flows into the travel motors through the check valve and orifice in the straight travel spool This prevents the rapid slowdown of the travel The bucket is operated and the machine travels straight 8 COMBINED BUCKET AND TRAVEL OPERATION PS P4 P3 N2 Pca Dr3 P2c...

Page 151: ...nce function is operated by the pilot pressure PAcs and then the bucket spool transfers in the half stroke not full stroke Refer to page 2 33 Therefore the most of pressurized oil flows into boom 1 spool than the bucket spool to make the boom up operation more preferential The boom and bucket are operated 9 COMBINED BOOM UP AND BUCKET OPERATION PS P4 P3 N2 Pca Dr3 P2c2 Ba Aa PAa PBa Bo Ao PAo PBo ...

Page 152: ...SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location 4 1 Group 2 Electrical Circuit 4 3 Group 3 Electrical Component Specification 4 23 Group 4 Connectors 4 34 ...

Page 153: ...Cluster 6 Breaker operation switch 7 Starting switch 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 Master switch 15 Machine control unit 16 Seat heater switch 17 Service socket 18 Speaker 19 Lower wiper washer switch 20 Boom floating switch 21 Travel straight switch 22 Air compressor switch 23 Quick c...

Page 154: ...7 Horn 8 P1 pressure 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 pressure sensor 18 Swing pressure sensor 19 Boom down pressure sensor 20 Arm in swing pressure sensor 21 Attach pressure sensor 22 Travel pressure sensor 23 Air cleaner sensor 24 4 cartri...

Page 155: ...ND 9 NC 10 NC 11 NC 12 NC 13 NC 14 MCU_5V 15 MCU_SUPPLY GND 16 2 WAY SIG 0 8W 105 0 8RW 104 0 8W 105 0 8RW 104 2Br 2B 133 G31 2Br 2B 133 G31 2Br 2B 133 G31 3 2B 1 2 3 4 5 6 7 8 CIGARLIGHT 24V CIGARLIGHT_GND SWITCH_WIPER SWITCH POWER SWITCH_WIPER SWITCH_WASHER TANK NC AIR SHEAT POWER 9 ILLUMINATION 10 NC 11 NC 12 SWITCH SPARE 13 SWITCH FINE SIG 14 GND 15 SWITCH LOCK SIG 35 0 8GW CAN 2 Hi CAN 3 Hi E...

Page 156: ... 5 L 6 Br 7 R 4 2A B WIPER MOTOR HARNESS 30 1 2W 32 0 8YOr 47 1 2R 29 1 2BOr 1 2 3 4 5 6 0 8V CN 5 6 1 2 3 4 5 6 NC NC CAN2_HI NC 7 0 8Y 7 7 CAN1_LO 8 0 8L 8 8 CAN1_HI 9 9 CLUSTER_GND 9 0 8VOr 10 10 CLUSTER_IG 24V 10 0 8RW 11 11 CLUSTER_BATT 24V 12 12 CAM POWER NC CAN2_LO 0 8G 5 13 13 CAM GND 13 0 8W 14 14 CASSETTE RADIO IG 15 15 WIPER MOTOR DRIVE SIG 16 16 WIPER MOTOR IG24V 17 17 WASHER SIG 14 0 ...

Page 157: ...R 1 2 1 3 045 CN 401 IGN 24V IGN 24V CAM0 POWER CAM0 GND CAM0 LVDS POS CAM0 LVDS NEG CAM1 LVDS NEG CAM1 GND CAM2 LIN 23 24 26 27 28 29 30 47 48 49 50 56 CAM2 LVDS POS 58 59 60 76 CAM1 POWER 46 CAN Hi 57 AAVM 0 85B 0 85Y 0 85R 7A 7E 8 8 LEFT VIEW CAMERA DT04 6P 0 85B 0 85Y 0 85R 7A 7E 8 8 CLU VOUT POS 77 78 4 3 2 1 LVDS POS GND LVDS NEG POWER 24V CN 404 5 NC 6 ADJUST SIGNAL REAR VIEW CAMERA 4 3 2 1...

Page 158: ...15 ANTI RESTART RY U422 54 22 A C BLOWER STATE U115 51 15 ALT VOLTAGE U213 52 13 FUEL WARMER RY U419 54 19 BREAKER OPERATING SIG 54 18 EPPR POWER 24V U420 54 20 BOOM FLOATING SELECT SW ARM REGEN SOL 52 07 POWER BOOST SOL 53 10 54 26 P2 REGULATOR EPPR 54 03 P2 REGULATOR EPPR 54 28 PUMP SHIFT EPPR 54 01 PUMP SHIFT EPPR 51 14 MAIN PUMP P2 PS 52 24 ARM IN OUT BUCKET IN PS 52 04 PUMP FLOW SYNC SOL 52 2...

Page 159: ...r LVDS POS NC CASSETTE RADIO 15 0 8Br 3 0 8LOr 2 0 8Or 1 0 8Gr 12 0 8B 16 0 8G 0 8G 16 0 8Br 15 0 8LOr 3 0 8Or 2 0 8Gr 1 4 0 8GW 46B 0 8V 6A 0 8G 5A 74 0 8B 2 10 9 2 3 4 5 6 7 8 9 10 5 6 3 1 8 7 1 4 2 10 9 2 3 4 5 6 7 8 9 10 5 6 3 1 8 7 1 4 0 8LW 3 0 8R 2 0 8VW 1 CS 100 1 2 10 9 2 3 4 5 6 7 8 9 10 8 4 5 6 3 1 7 DPF SW 0 8L 39 AIR COMP SW 0 8YR 37 CS 99 0 8Or 32A 0 8W 40 2 10 9 2 3 4 5 6 7 8 9 10 5...

Page 160: ... 1 LVDS POS GND LVDS NEG POWER 24V CN 404 5 NC 6 ADJUST SIGNAL REAR VIEW CAMERA 4 3 2 1 LVDS POS GND LVDS NEG POWER 24V CN 403 5 NC 6 ADJUST SIGNAL CAM1 LIN CAM2 LVDS NEG CAM1 LVDS POS CAM2 POWER CAM2 GND 1 2 3 4 5 6 7 CN 7 8 9 10 11 12 13 14 15 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 1 2ROr 40 AC COMP START RY STARTER CR 23 CN ...

Page 161: ...4 6 MEMORANDUM HYUNDAI HEAVY INDUSTRIES CO LTD CONSTRUCTION EQUIPMENT DIV ...

Page 162: ...se box No 6 l conn CN 11 5 AC Heater control box A 7 Blower relay 4 Fuse box No 7 I conn CN 5 18 I conn CN 17 5 Wiper motor controller CN 141 7 Wiper motor CN 21 4 Fuse box No 8 I conn CN 5 11 Cluster CN 56A 1 Hour meter CN 48 1 I conn CN 8 6 Haptic controller CN 363 2 侍 I conn Intermediate connector CHECK POINT 侍 GND Ground 1 2 1 POWER CIRCUIT The negative terminal of battery is grounded to the m...

Page 163: ...12 10 CN 5 1 2 3 4 1 2 3 4 GND CAN1 HI IG 24V BATT 24V RW CAN1 LO 5 6 WR B Y Gr 7 8 CAN2 HI WL W CAN2 LO L RS 232 RX 9 L RS 232 TX 10 L AUX LEFT 11 L AUX RIGHT 12 L AUX GND h 1 CN 56A CLUSTER 2 3 4 CN 48 HOER METER CN 27A DOOR SW CS 1 ROOM LAMP CL 1 1 C ST ACC BR H B 2 4 H I 0 I 0 3 5 6 5 4 3 2 1 6 CS 2A 0 8Y RADIO USB PLAYER START KEY SW R 4 3 2 1 4 3 2 1 CN 125 GPS CONN 12 11 10 9 8 7 CN 10 6 5 ...

Page 164: ...y engine stop sw CS 33 2 供 1 l conn CN 4 13 Fuse box No 9 Engine ECM CN 93 5 Start switch ON CS 2A 3 GPS conn CN 125 2 供 4 I conn CN 5 40 Power relay CR 35 86 供 87 Fuse box No 10 MCU CN 51 2 Reader CN 427 1 RMS CN 125A 2 When start key switch is in START position Start switch START CS 2A 6 I conn CN 5 35 Anti restart relay CR 5 2 供 5 l conn CN 2 7 Start relay CR 23 2 Starter motor is activated CHE...

Page 165: ...1 6 CS 2A 40 58 59 60 34 35 36 37 38 39 33 START KEY SW 1 2W 32 31 23 24 ALT VOLTAGE 27 CN 52 MCU 0 8YOr 1 2BOr 1 2R GPS CONN 77 R 77 R 1 2G 4 3 2 1 4 3 2 1 CN 125 CN 125 1 2R 0 8Gr KEY IG 2 CN 125A RMS 1 2R 2 POWER BATTERY 1 1 2W 1 2W CR 36 1 2 3 4 5 2 1 5 3 4 1 2 3 4 5 2 1 5 3 4 1 2 3 4 5 2 1 5 3 4 CR 39 CR 5 AIR HEAT RY STARTER LOCKOUT RY ANTI RESTART RY START RY STARTER CR 23 CN 45 B M M 2 1 C...

Page 166: ...ox No 15 34 3 CHARGING CIRCUIT 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 flows into the battery through the battery relay CR 1 The current also flows from alternator to each electrical component and controller through the fuse box 1 2 1 2 侍 GND Ground Engine Start switch Check p...

Page 167: ...1 2ROr 4 1 2 3 4 5 6 7 8 9 10 11 12 GROUND EPPR ATT EPPR1 2SE PS POWER BOOST SOL 13 14 EPPR POWER 24V 15 16 17 18 TRAVEL SPEED SOL 19 20 21 22 23 ATT FLOW EPPR1 24 TRAVEL BUZZER BOOM PRIORITY EPPR NC NC COOLING FAN EPPR ATT FLOW EPPR2 PUMP EPPR COOLING FAN EPPR NC BOOM PRIORITY EPPR HYD OIL TEMP SENDOR NC ARM REGEN SOL NC 25 FUEL LEVEL SENDOR 26 ALT VOLTAGE 27 NC 28 P1 PRESS SENSOR 29 P2 PRESS SEN...

Page 168: ... l conn CN 5 60 Radio USB player illumination ON CN 27A 9 Hour meter CN 48 4 Work light switch ON Work light switch ON CN 376 4 Work light relay CR 4 85 供 87 l conn CN 12 2 Work light ON CL 5 2 CL 6 2 CL 36 2 CL 37 2 CHECK POINT 1 侍 GND Ground 2 1 2 Engine Start switch Check point Voltage STOP ON 刮 GND fuse box 刯 GND head light switch power output 到 GND head light relay 刱 GND head light 刲 GND fuse...

Page 169: ... 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 SPK FRT LH NC GND 1 5 2RW 1 2Br CN 376 CIGAR LIGHTER CL 2 1 2ROr HEAD LAMP RY CR 13 CL 4 CL 24 CL 3 HEAD LAMP HEAD LAMP REAR HEAD LAMP CL 5 WORK LAMP CL 6 CL 36 CL 37 WORK LAMP RY CN 12 CR 4 1 2Br 0 8Br 1 2ROr 0 8YOr 1 2B 1 2ROr 1 2B 1 2ROr 1 2B 1 2ROr 2RW 0 8RW 2...

Page 170: ...on lamp ON CL 7 Cab light switch ON Cab light switch ON CN 376 5 Cab lamp relay CR 9 85 供 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 2 CHECK POINT 1 2 1 2 侍 GND Ground Engine Start switch Check point Voltage STOP ON 刮 GND fuse box 刯 GND beacon lamp relay 到 GND beacon lamp switch power output 刱 GND beacon lamp 刲 GND fuse box 刳 GND cab light re...

Page 171: ... 1 2BrW 4 CL 10 2B 2V 1 2 2B 1 2BrW 2B 2V 2V 1 2ROr 1 2BrW 1 2ROr 1 2VW 1 2VW 2V BEACON LAMP RELAY CR 45 1 2Br 0 8BOr 0 8ROr 0 8L 0 8GrW 1 2BrW 0 8B 5 1 2 CIGAR UREA FULL LAMP CN 376 RDU Relay Drive Unit 1 2 3 4 5 6 7 8 9 10 11 12 CAN_LO 2 13 IG 24V 14 HEAD LIGHT 15 16 17 18 NC 19 20 21 22 23 CAN_HI 2 NC NC NC NC WASHER OUT F_LH INT WIPER OUT R_LH CABIN LIGHT WIPER OUT R_RH NC BEACON LAMP NC WORK ...

Page 172: ...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 供 4 Wiper motor CN 21 2 Continual operating Auto parking when switch OFF Switch OFF CN 376 3 12 Wiper motor parking position by wiper motor controller OPERATING FLOW LOW WIPER Key switch ON Fuse box No 28 I conn CN 7 8 Low wiper switch CS 79 1 5 Wiper swit...

Page 173: ...15 30A 16 30A 17 10A 18 20A 19 30A 20 20A 21 10A 22 20A 23 10A 24 WIPER 20A 6 HEAD LAMP WIPER SEAT 20A 25 SOLENOID 20A 26 20A 27 OPTION SWITCH 20A 28 SOLENOID 20A 29 DEF MODULE 10A 30 FUEL PUMP 20A 31 SCR HEATER 10A 32 30A 1 33 AAVM 10A 34 10A SENSOR CN 36 FUSE BOX ECM 1 1 1 2GrW 0 8GR 0 8G 0 8RY 1 2GrW 0 8L 0 8B 0 8R 0 8R 0 8V 0 8V 0 8YOr 0 8V 1 2B 0 8G LOW WIPER MOTOR CN 407 0 8B 0 8BW 1 2 3 4 5...

Page 174: ...MISTOR CONT CN J10 NOx SENSOR CN J7B NOx SENSOR CN J7A RESISTOR CN 173 TANK LEVEL SENSOR CN 399 SCR DEF SUPPLY MODULE CN 379 PRS TEMP SENSOR CD 10 WATER LEVEL SENSOR CD 16 CR 50 CR 51 NOx SENSOR MODULE CN 5 3W 0 8L 1 2Br 2L 0 8L 2Br 0 8V 0 8BOr 0 8ROr 0 8L 0 8GrW 00 00 00 2W 2W 2B 2B 2W 2W 2B 2B 2B 2B 2B 2B 2B 2B 2W 0 8V 0 8G 2W 2B 2B 2W 2W 2B 2B 2W 2W 2B 2B 2W 2W 2B 2B 0 8V 0 8Br 0 8V 0 8Br 0 8V ...

Page 175: ..._24V CN 51 22 23 24 NC NC HYD OIL TEMP SENDOR NC 25 FUEL LEVEL SENDOR 26 ALT VOLTAGE 27 28 CN 52 1 2 3 4 5 6 7 8 POWER BOOST SOL NC COOLING FAN EPPR ATT FLOW EPPR2 COOLING FAN EPPR ARM REGEN SOL MCU NC ATT FLOW EPPR2 1 2YOr 1 2BW 1 2YOr 1 2BW 1 2LOr 1 2BW 0 8B 0 8L 0 8Y 0 8V RW WR B WL W L L L 0 8A 3W 0 8Or 0 8V 0 8G 0 8G 0 8BOr 0 8OrW CN 401 CLUSTER CIGAR UREA FULL LAMP AAVM MCU EPPR SPARE SUPPLY...

Page 176: ...OW EPPR2 PUMP EPPR COOLING FAN EPPR NC BOOM PRIORITY EPPR HYD OIL TEMP SENDOR NC ARM REGEN SOL NC 25 FUEL LEVEL SENDOR 26 ALT VOLTAGE 27 NC 28 P1 PRESS SENSOR 29 P2 PRESS SENSOR 30 ATT EPPR2 2SE PS 31 PUMP EPPR 2ND PS 32 N1 PRESS SENSOR 33 ARM IN OUT BUCKET IN PS 34 BOOM UP PS 35 SWING PS 36 WORKING PS 37 TRAVEL PS 38 OVERLOAD PS 39 N2 PRESS SENSOR 40 MCU 1 2 3 4 5 6 7 8 9 10 11 12 POWER BOOST SW ...

Page 177: ... FLOATING SW 2 10 9 2 3 4 5 6 7 8 9 10 5 6 3 1 8 7 1 4 SWING LOCK FINE SWING SW 1 2 3 4 5 6 7 8 9 10 7 2 5 9 8 1 6 10 3 4 CS 73 CN 305 CN 306 CN 307 CN 310 CN 309 P P VALVE PVG 32 CN 68 SAFETY SOL CS 26A BREAKER 2 1 CIGAR UREA FULL LAMP MCU EPPR SPARE SUPPLY MODULE C B A SUPPLY SIG RETURN CD 85 BOOM DOWN ATT RELIEF EPPR2 CN 366 CN 15 1 2 3 4 5 6 7 8 1 2 MCU ATT RELIEF EPPR1 CN 365 1 2 BOOM DOWN FL...

Page 178: ...coil resistance M4 to M4 Normal About 50 ö Check contact Normal â ö Check contact Normal 0 942 For terminal 1 GND ö Check contact OFF â for each terminal ON 0 for terminal 1 3 and 1 2 START 0 for terminal 1 6 ö Check contact Normal 0 1 ö Check resistance A B 120 1 CST ACC BR H B 2 4 H I 0 I 0 3 5 6 5 4 3 2 1 6 CS 2 C B A SUPPLY SIG RETURN CD 7 A B C A B CN 173 CR 1 GROUP 3 ELECTRICAL COMPONENT SPE...

Page 179: ...nce 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 12 600 Empty warning 700 ö Check resistance Normal About 200 for terminal 1 3 0 for terminal 2 4 ö Check resistance Normal About 160 for terminal 1 2 0 for terminal 3 4 â for terminal 3 5 1 2 CD 8 C 2 1 Pa CD 2 Part name Symbol Specifications Check CD 1 CD 10 CN 80 CR 46 3 4 1 2 4 3 2 1 1 2 3 ...

Page 180: ...mal ON 0 for terminal 3 7 4 8 â for terminal 7 9 8 10 OFF â for terminal 3 7 4 8 0 for terminal 7 9 8 10 4 25 1 2 CN 75 CN 133 CN 238 CN 239 CN 240 CN 241 CN 242 87a 30 87 85 86 87a 85 87 86 30 CR 4 CR 7 CR 9 CR 35 CR 46 CR 13 1 2 CN 66 CN 68 CN 70 CN 88 CN 135 CN 140 CN 149 CN 236 CN 237 1 2 CN 23 LH CN 24 RH 1 2 CR 4 CR 7 CR 9 CR 13 CR 35 CR 46 CR 50 CR 52 CN 75 CN 133 CN 154 CN 242 CN 309 CN 31...

Page 181: ...lamp 21V 70W H1 Type 侍 Check disconnection Normal A few Fuel filler pump 24V 10A 35 min 侍 Check resistance Normal 1 0 Hour meter 16 32V 侍 Check operation Supply power 24V to terminal No 2 and connect terminal No 1 and ground Horn DC22 28V 2A 侍 Check operation Supply power 24V to each terminal and connect ground 4 26 1 2 CL 4 CL 5 CL 6 CL 8 CL 9 3 2 1 CL 1 1 2 M CN 61 M CL h 1 4 2 3 CN 48 CN 20 CN ...

Page 182: ...5A 侍 Check contact Normal â Radio USB player 24V 2A 侍 Check voltage 20 25V for terminal 1 3 3 8 Washer pump 24V 3 8A 侍 Check contact Normal 10 7 for terminal 1 2 Wiper motor 24V 2A 侍 Check disconnection Normal 7 for terminal 2 6 CS 20 A B C B C A CS 53 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ACC ILL GND SPK FRT RH SPK FRT LH TEL MUTE ANT 12V BACK UP ILL NC SPK FRT RH REMOCON REMOCON GND SPK FRT LH ...

Page 183: ...oil resistance Normal About 1M 侍 Check contact Normal â Operating time 5 15sec Alternator Denso 24V 95A 侍 Check contact Normal 0 for terminal B L Normal 24 27 5V Starter Denso 24V 7 8kW 侍 Check contact Normal 0 1 Travel alarm 24V 0 5A 侍 Check contact Normal 5 2 4 28 24V GND 12V 1 2 3 24V 12V CN 138 CL CL 2 CN 81 B M M CN 45 CN 74 B L G 3 U Lo M 4 3 2 1 4 E 2 Pf 1 B 3 CN 407 ...

Page 184: ...ower motor 24V 9 5A 侍 Check resistance Normal 2 5 for terminal 1 2 Duct sensor switch 1 C OFF 4 C ON 侍 Check resistance Normal 0 for terminal 1 2 the atmosphere temp Over 4 C Door switch 24V 2W 侍 Check resistance Normal About 5M Switch power max one touch decel horn breaker 24V 6A 侍 Check resistance Normal â 4 29 1 CN 28 CR 23 M 1 2 1 2 CS 1 1 2 CS 5 CS 19 CS 26 CS 29 ...

Page 185: ...Check disconnection Normal 0 1 Breaker switch 24V 侍 Check resistance Normal â Quick clamp buzzer 24V 200mA 107佳4dB Socket 12V 10A Switch 24V 8A 侍 Check contact Normal ON 0 for terminal 1 2 4 5 â for terminal 2 3 5 6 OFF â for terminal 1 2 4 5 0 for terminal 2 3 5 6 4 30 CN 113 2 1 CN 139 2 1 CS 60 CS 95 1 2 CS 74A CS 74B CN 60 CN 95 CS 26A 2 1 CS 79 1 2 10 9 2 3 4 5 6 7 8 9 10 8 4 5 6 3 1 7 ...

Page 186: ...5 5 6 Switch 24V 8A 侍 Check contact Normal OFF â for terminal 1 2 1 3 4 5 5 6 Fuel heater DEF AdBlue line heater WIF sensor Fan speed sensor 4 31 3 4 2 1 1 2 1 2 rpm 1 2 10 9 2 3 4 5 6 7 8 9 10 8 4 5 6 3 1 7 2 1 CS 100 CN 381 CN 382 CN 383 CN 96 CD 45 CS 73 1 2 10 9 2 3 4 5 6 7 8 9 10 8 4 5 6 3 1 7 CD 52 ...

Page 187: ...bient DEF AdBlue Proportional valve sensor DEF AdBlue fill up warning lamp 4 3 2 1 POWER 24V CAN LO CAN HI RETURN 2 1 CN 399 CN J6 CN J7A CN J7B CN J10 CN J17 CL 40 CD 11 AIR PRESS SUPPLY POWER AIR TEMP RETURN 1 2 3 4 CD 10 CD 16 A B C SIGNAL RETURN 29 SUPPLY POWER 5V 72 CN 429 1 2 CN 308 SIG V Us SIG V Udc GND ERROR 1 2 3 4 CN 307 ...

Page 188: ...rning lamp LED Proportional valve sensor Start button Camera RETURN CN 246 CN 247 Proportional A B C SIG 5V CS 2B CAN_H CAN_L A B C GND CN 402 4 3 2 1 LVDS POS GND LVDS NEG POWER 24V 5 NC 6 ADJUST SIGNAL CN 404 CN 403 CN 405 CN 249 CN 402 CN 403 CN 404 CN 405 CL 41 ...

Page 189: ...T06 8S EP06 CN 12 DEUTSCH 2 I conn Frame harness Boom wire harness DT06 2S EP06 DT04 2P E004 CN 13 AMP 8 Boom floating 174262 2 174264 2 CN 15 AMP 8 I conn Frame harness 2 way harness 174982 2 174984 2 CN 16 AMP 6 Emergency engine start speed control S816 006002 S816 106002 CN 17 AMP 8 I conn Side harness RH Wiper harness S816 008002 S816 108002 CN 18 AMP 2 Washer tank 2 174352 2 174354 2 CN 20 MO...

Page 190: ... 2 Boom priority solenoid DT06 2S EP06 CN 135 DEUTSCH 2 Arm regeneration solenoid DT06 2S EP06 CN 138 FASTEN 3 DC DC Converter S810 003202 CN 139 FASTEN 2 12V socket 172434 2 CN 140 DEUTSCH 2 Quick clamp solenoid DT06 2S EP06 DT04 2P E005 CN 141 AMP 13 Wiper motor controller 172498 1 CN 147 AMP 4 Fuel heater 2 967325 3 CN 149 DEUTSCH 2 Attach safety solenoid DT06 2S EP06 CN 154 DEUTSCH 2 Cooling f...

Page 191: ...PR 2 DT06 2S EP06 CN 379 TYCO 12 SCR supply module 1 1703639 1 CN 381 DELPHI 2 DEF AdBlue line heater 1 12162194 CN 382 DELPHI 2 DEF AdBlue line heater 2 12162194 CN 383 DELPHI 2 DEF AdBlue line heater 3 12162194 CN 384 AMP 2 Coolant valve 174352 2 CN 385 7 Fan clutch 965570 CN 398 DEUTSCH 4 RS232 DT06 4S E005 DT04 4P E005 CN 399 TYCO 4 DEF AdBlue tank level sensor 1 967325 1 CN 402 DEUTSCH 6 Fron...

Page 192: ...lue module relay CR 52 5 Line heater relay ÂSwitch CS 1 SHUR 1 Door switch S822 014002 CS 2A WP 6 Start key switch S814 006100 CS 2B DEUTSCH 3 Reader DT06 3S EP06 DT04 3P E005 CS 4 DEUTSCH 3 Safety switch DT06 3S CS 5 DEUTSCH 2 Horn switch DT04 2P CS 19 DEUTSCH 2 One touch decel switch DT04 2P CS 26 DEUTSCH 2 Breaker switch DT06 2S CS 26A AMP 2 Breaker pedal switch S816 002002 S816 102002 CS 29 DE...

Page 193: ... 2S EP06 DT04 2P E005 CL 36 DEUTSCH 2 Work lamp LH DT06 2S EP06 CL 37 DEUTSCH 2 Work lamp RH DT06 2S EP06 CL 40 DEUTSCH 2 DEF AdBlue lamp DT06 2S EP06 CL 41 AMP 2 DEF AdBlue fill up warning lamp S822 01400 ÂSensor sendor CD 1 AMP 2 Hydraulic oil temp sender 85202 1 CD 2 DEUTSCH 2 Fuel sender DT06 2S EP06 CD 6 DEUTSCH 3 Travel pressure switch DT06 3S EP06 CD 7 DEUTSCH 3 Working pressure switch DT06...

Page 194: ... DEUTSCH 3 N1 pressure sensor DT06 3S EP06 CD 71 DEUTSCH 3 N2 pressure sensor DT06 3S EP06 CD 85 DEUTSCH 3 Boom down sensor DT06 3S EP06 CD 87 DEUTSCH 3 Bucket out sensor DT06 3S EP06 CD 90 DEUTSCH 3 Arm in sensor DT06 3S EP06 CD 91 DEUTSCH 3 Bucket in sensor DT06 3S EP06 CD 124 DEUTSCH 3 Boom cylinder rod pressure snensor DT06 3S EP06 ...

Page 195: ...Plug connector male 5 2 5 1 3 S811 005002 1 3 2 5 S811 105002 3 7 1 4 S811 007002 1 4 3 7 S811 107002 1 5 4 9 3S811 109002 5 11 1 6 S811 011002 1 6 5 11 S811 111002 7 9 11 4 9 1 5 S811 009002 2 CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR 1 ...

Page 196: ...4 41 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 197: ...e connector female Plug connector male 2 3 4 8 1 2 2 1 2 3 1 3 1 2 3 1 4 2 4 2 3 1 6 3 1 8 5 2 8 5 2 6 3 1 S816 002001 S816 102001 S816 003001 S816 103001 S816 004001 S816 104001 S816 008001 S816 108001 J TYPE CONNECTOR 2 2 1 ...

Page 198: ...n Receptacle connector female Plug connector male 1 1 S814 001000 2 3 4 1 S814 101000 2 1 1 2 S814 002000 S814 102000 3 2 1 1 2 3 S814 003000 S814 103000 2 4 1 3 1 3 2 4 S814 004000 S814 104000 SWP TYPE CONNECTOR 3 ...

Page 199: ...eptacle connector female Plug connector male 6 8 12 14 3 6 1 4 1 4 3 6 S814 006000 S814 106000 4 8 1 5 1 5 4 8 S814 008000 S814 108000 4 12 1 9 1 9 4 12 S814 012000 S814 112000 3 14 1 11 1 11 3 14 S814 014000 S814 114000 ...

Page 200: ...in Receptacle connector female Plug connector male 1 1 S810 001202 2 3 4 1 S810 101202 2 1 S810 002202 2 1 S810 102202 3 1 2 S810 003202 2 1 3 S810 103202 2 4 1 3 S810 004202 1 3 2 4 S810 104202 CN TYPE CONNECTOR 4 ...

Page 201: ...4 46 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 202: ...02 1 2 S810 102402 375 FASTEN TYPE CONNECTOR 5 No of pin Receptacle connector female Plug connector male 36 1 12 13 25 24 36 344111 1 1 13 25 12 24 36 344108 1 AMP ECONOSEAL CONNECTOR 6 No of pin Receptacle connector female Plug connector male 2 1 2 85202 1 AMP TIMER CONNECTOR 7 ...

Page 203: ...12 174045 2 AMP 040 MULTILOCK CONNECTOR 8 No of pin Receptacle connector female Plug connector male 14 1 7 6 14 173852 AMP 070 MULTILOCK CONNECTOR 9 No of pin Receptacle connector female Plug connector male 6 3 6 1 4 925276 0 1 4 3 6 480003 9 AMP FASTIN FASTON CONNECTOR 10 ...

Page 204: ...No of pin Receptacle connector female Plug connector male 2 1 2 MG610070 KET 090 CONNECTOR 11 No of pin Receptacle connector female Plug connector male 2 2 1 2 1 2 MG640605 MG640795 KET 090 WP CONNECTORS 12 ...

Page 205: ...4 50 No of pin Receptacle connector female Plug connector male 14 1 7 6 14 MG610406 KET SDL CONNECTOR 13 ...

Page 206: ...侏侏侏 14 Modifications see below Number of contacts P Pin S Socket 04 Receptacle 06 Plug Deutsch connectors Modification E003 Standard end cap gray E004 Color of connector to be black E005 Combination E004 E003 EP04 End cap EP06 Combination P012 EP04 P012 Front seal enhancement connectors color to black for 2 3 4 6pin 侍 4 4 2 3 1 DT06 4S 4 1 3 2 DT04 4P ...

Page 207: ...4 52 No of pin Receptacle connector female Plug connector male 6 6 1 4 3 DT06 6S 6 1 4 3 DT04 6P 5 4 8 1 8 5 4 8 1 DT06 8S 12 DT04 8P 6 7 1 12 DT06 12S 7 6 12 1 DT04 12P ...

Page 208: ...tor male 2 35215 0200 1 2 35215 0200 MOLEX 2CKTS CONNECTOR 15 No of pin Receptacle connector female Plug connector male 10 1 2 9 10 SWF593757 ITT SWF CONNECTOR 16 No of pin Receptacle connector female Plug connector male 1 1 NMWP01F B MWP NMWP CONNECTOR 17 ...

Page 209: ...54 No of pin Receptacle connector female Plug connector male 1 2 3 4 ECONOSEAL J TYPE CONNECTORS 18 2 1 S816 001002 2 1 S816 002002 S816 003002 S816 004002 S816 101002 S816 103002 S816 104002 S816 102002 ...

Page 210: ...4 55 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 211: ...5 368301 1 2 85262 1 No of pin Receptacle connector female Plug connector male 2 1 2 12040753 METRI PACK TYPE CONNECTOR 19 No of pin Receptacle connector female Plug connector male 23 A B F J K N Q HD36 24 23SN HD34 24 23PN DEUTSCH HD30 CONNECTOR 20 A B F K Q J N T ...

Page 212: ...40 11 21 20 30 1 5 6 10 31 40 11 21 20 30 35 36 DRC26 40SA B DEUTSCH MCU CONNECTOR 21 No of pin Receptacle connector Female Plug connector Male 9 G F J H C E D A B HD10 9 96P DEUTSCH SERVICE TOOL CONNECTOR 22 No of pin Receptacle connector Female Plug connector Male 4 3 4 1 2 2 967325 3 AMP FUEL WARMER CONNECTOR 23 ...

Page 213: ...9 10 41 42 43 44 45 46 47 48 49 50 11 21 31 20 30 40 1 5 6 10 31 11 21 41 50 20 40 45 46 30 DRC26 50S 04 DEUTSCH ENGINE ECM CONNECTOR 24 No of pin Receptacle connector Female Plug connector Male 60 1 12 13 24 25 31 30 36 49 37 48 60 DRB16 60SAE L018 DEUTSCH INTERMEDIATE CONNECTOR 25 ...

Page 214: ...stem 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 Intelligent Power Control System 5 14 Group 12 Anti Restart System 5 16 Group 13 Self Diagnostic System 5 17 Group 14 Engine Control System 5 56 Group 15 EPPR Valve 5 57 Group 16 Monitoring System 5 62 Gro...

Page 215: ...d by short or open circuit in electric system and display error codes on the cluster SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE ADVANCED CAPO SYSTEM Power mode selection P S E Work mode selection User mode system U MCU cluster protection Open short diagnosis error code display Machine error ECM fault code display Machine condition monitoring Electric signal monitoring Mode selection system Auto...

Page 216: ...oom priority EPPR Attachment flow EPPR MCU pressure switch EPPR pressure Overload pressure sensor SL SR Swing pressure AO AI Arm in out Bucket in pressure BI Boom up pressure BD Work tool Cluster CAN 2 Pressure signal Pressure signal Pressure signal Drive signal Pressure signal Signal Drive signal Normal CN 16 Emergency CN 16A CN 16B Pump power shift EPPR Boom cylinder Shuttle block Switch signal ...

Page 217: ... to a light and precise work 1 POWER MODE SELECTION SYSTEM 300L5MS02 GROUP 2 MODE SELECTION SYSTEM Power shift Standard Option can be changed by Service menu in Management on the cluster Load Power mode Application Engine rpm Power shift by EPPR valve Standard Option Standard Option Unload Load Unload Load Current mA Pressure kgf cm2 Current mA Pressure kgf cm2 P Heavy duty power 1750佳50 1800佳50 1...

Page 218: ... E R A IR C O N O F F CAN 2 GENERAL WORK MODE bucket This mode is used to general digging work ATT WORK MODE breaker crusher It controls the pump flow and system pressure according to the operation of breaker or crusher 1 2 2 WORK MODE SELECTION SYSTEM Work mode consists of the general operation bucket and the optional attachment breaker crusher 330L5MS03 Description General mode Work tool Bucket ...

Page 219: ...r 1 1300 700 0 2 1400 800 3 3 1450 850 6 4 1500 900 9 5 1600 950 12 6 1650 1000 auto decel 16 7 1700 1050 20 8 1800 1100 26 9 1850 1150 32 10 1900 1200 38 1 2 Main pump Pilot pump Engine ECM CAN 1 Main control valve Pump power shift EPPR MCU Drive signal Cluster User mode switch signal User mode pilot lamp Normal CN 16 Emergency CN 16A CN 16B Haptic controller C L U S T E R A IR C O N O F F CAN 2 ...

Page 220: ... 900 rpm As the result of reducing the engine speed fuel consumption and noise are effectively cut down during non operation of the control levers When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated the reduced engine speed rises upto the speed before deceleration in a second 1 WHEN AUTO IDLE PILOT LAMP ON 2 WHEN AUTO IDLE PILOT LAMP OFF The engine s...

Page 221: ...is pushed ON the power mode is set P mode and maximum digging power is increased by 10 When the power boost function is activated the power boost solenoid valve pilot pressure raises the set pressure of the main relief valve to increase the digging power 余 余 When the auto power boost is set to Enable and power mode is set to P mode on the cluster the digging power is automatically increased as wor...

Page 222: ...e signal Cluster CAN 2 Arm 1 Boom 2 Swing Travel RH Boom 1 Arm 2 Travel LH Option Bucket Travel speed can be switched manually by pressing the travel speed switch on the cluster Default Turtle Low 侍 330L5MS07 Speed Travel speed solenoid valve Lamp on cluster Operation Low OFF Turtle Low speed high driving torque in the travel motor High ON Rabbit High speed low driving torque in the travel motor ...

Page 223: ...ydraulic oil temperature signal is substituted In case of the coolant temperature increases up to 30 C the engine speed is decreased to key start speed And if an operator changes power mode set during the warming up function the MCU cancels the automatic warming up function LOGIC TABLE 1 2 3 300L5MS08 Description Condition Function Actuated Coolant temperature below 30 C after engine run Power mod...

Page 224: ...AN 2 300L5MS09 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 reduced Warning lamp buzzer ON Pump input torque is reduced Canceled Coolant temperature Less than 100 C Hydraulic oil temperature Less than 95 C Return to pre set the pump absorption torque Second step warn...

Page 225: ...AN 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 BU PS Boom down pressure The variable power control system controls the engine and pump mutual power according to RCV lever stroke and pump load It makes fuel saving and smooth control at precise work 余 The variable power control function can be activated when t...

Page 226: ...CN 16B Haptic controller C L U S T E R A IR C O N O F F CAN 2 Arm 1 Boom 2 Swing Travel RH Boom 1 Arm 2 Travel LH Option Bucket The system is used to control the pump delivery flow according to set of the work tool on the cluster by the attachment flow EPPR valve 余 侍 Refer to the page 5 79 for the attachment kinds and max flow ୖ When breaker operating button is pushed 330L5MS11 Description Work to...

Page 227: ...e activated just in case the excavator is not in jack up status 330L5MS17 Description Condition Function Work modeୖ1 Floating mode General mode Boom up floatingୖ2 Floating mode sw ON Rod to tank solenoid ON Head to tank solenoid OFF Boom down cutoff solenoid OFF Boom up down floatingୖ2 Floating mode sw ON Breaker button Pressed Boom down pilot pressure倯25 bar Boom up pilot pressure倭5 bar Rod to ta...

Page 228: ...pressure AO AI Arm in out Bucket in pressure BI Boom up pressure BD PS PS PS PS Arm in BU PS Boom down pressure Arm 1 Boom 2 Swing Travel RH Boom 1 Arm 2 Travel LH Option Bucket When the requirement of pump flow rate is low IPC mode controls pump flow rate to improve fuel efficiency 1 330L5MS18 Conditionୖ1 Function IPC mode ONୖ2 Boom up Arm in Not travel motion Not swing motion Limitation of pump ...

Page 229: ... 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 rev IPC mode 1 IPC mode 2 290F3CD311 Balance mode Efficiency mode ...

Page 230: ...STEM Engine Starter MCU Drive signal Start safety relay ECM 1 ANTI RESTART FUNCTION After a few seconds from the engine starts to run MCU turns off the start safety relay to protect the starter from inadvertent restarting 300L5MS12 ...

Page 231: ...e cluster and also stores them in the memory MONITORING Active fault 1 2 1 The active faults of the MCU or engine ECM can be checked by this menu 余 The logged faults of the MCU or engine ECM can be checked by this menu 余 The logged faults of the MCU or engine ECM can be deleted by this menu 余 Logged fault 2 Delete logged fault 3 290F3CD120 290F3CD121 290F3CD125 290F3CD128 290F3CD123 290F3CD124 290...

Page 232: ...ction Auto Idle operation failure Engine variable horse power control operation failure Checking list 1 CD 7 B CN 52 37 Checking Open Short 2 CD 7 A CN 51 3 Checking Open Short 3 CD 7 C CN 51 13 Checking Open Short 108 0 10 seconds continuous Travel Oil Press Sensor Measurement Voltage 5 2V 侑 1 10 seconds continuous 0 3V Travel Oil Press Sensor Measurement Voltage 0 8V 侑 4 10 seconds continuous Tr...

Page 233: ...0 8V 侑 4 10 seconds continuous Main Pump 2 P2 Press Sensor Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Main Pump 2 P2 Press display failure 2 Control Function Automatic voltage increase operation failure Overload at compensation control failure Checking list 1 CD 43 B CN 52 12 Checking Open Short 2 CD 43 A CN 51 3 Checking Open Short 3 CD 43 C CN 51 13 Checking Open Short 122 1 when you ...

Page 234: ... Negative 2 Press Sensor Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Negative 2 Press display failure 2 Control Function Option attachment flow control operation failure Checking list 1 CD 71 B CN 52 17 Checking Open Short 2 CD 71 A CN 51 3 Checking Open Short 3 CD 71 C CN 51 13 Checking Open Short 127 0 10 seconds continuous Boom Up Pilot Press Sensor Measurement Voltage 5 2V 侑 1 10 sec...

Page 235: ...Arm In Pilot Press Sensor Measurement Voltage 0 8V 侑 4 10 seconds continuous Arm In Pilot Press Sensor Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Arm In Pilot Press display failure 2 Control Function IPC operation failure Checking list 1 CD 90 B CN 52 28 Checking Open Short 2 CD 90 A CN 51 3 Checking Open Short 3 CD 90 C CN 51 13 Checking Open Short 133 0 10 seconds continuous Arm In Ou...

Page 236: ...ous 0 3V Attachment Pilot Press Sensor Measurement Voltage 0 8V 侑 4 Monitor Select Attachment breaker crusher 10 seconds continuous Attachment Pilot Press Sensor Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Attachment Pilot Press display failure 2 Control Function Option attachment flow control operation failure Checking list 1 CD 69 B CN 53 14 Checking Open Short 2 CD 69 A CN 53 3 Checki...

Page 237: ...CN 52 9 Checking Open Short 2 CN 75 1 CN 52 10 Checking Open Short 141 5 Model Parameter mounting Boom Priority EPPR Detection When Boom Priority EPPR Current is more than 10 mA 10 seconds continuous Boom Priority EPPR drive current 0 mA Cancellation When Boom Priority EPPR Current is more than 10 mA 3 seconds continuous Boom Priority EPPR drive current 10 mA 侑 6 Detection 10 seconds continuous Bo...

Page 238: ...CN 51 40 Checking Open Short 145 5 Model Parameter mounting Remote Cooling Fan EPPR Detection When Remote Cooling Fan EPPR Current is more than 10 mA 10 seconds continuous Remote Cooling Fan EPPR drive current 0 mA Cancellation When Remote Cooling Fan EPPR Current is more than 10 mA 3 seconds continuous Remote Cooling Fan EPPR drive current 10 mA 侑 6 Detection 10 seconds continuous Remote Cooling ...

Page 239: ...pressure cut off failure Checking list 1 CR 47 85 CN 54 9 Checking Open Short 2 CR 47 30 86 CN 45 B term Checking Open Short 166 4 Detection When Power Max Solenoid is Off 10 seconds continuous Power Max Solenoid drive unit Measurement Voltage 3 0V Cancellation When Power Max Solenoid is Off 3 seconds continuous Power Max Solenoid drive unit Measurement Voltage 3 0V 侑 6 Detection When Power Max So...

Page 240: ...unit Measurement Voltage 3 0V Cancellation When Travel Speed Solenoid is Off 3 seconds continuous Travel Speed Solenoid drive unit Measurement Voltage 3 0V 侑 6 Detection When Travel Speed Solenoid is On 10 seconds continuous Travel Speed Solenoid drive current 4 5 A Cancellation When Travel Speed Solenoid is On 3 seconds continuous Travel Speed Solenoid drive current 4 5 A 侑 Results Symptoms 1 Con...

Page 241: ...g list 1 CD 237 1 CN 53 7 Checking Open Short 2 CD 237 2 CR 35 87 Checking Open Short 170 4 Model Parameter mounting Arm Regenerating Solenoid Detection When Arm Regeneration Solenoid is Off 10 seconds continuous Arm Regeneration Solenoid drive unit Measurement Voltage 3 0V Cancellation When Arm Regeneration Solenoid is Off 3 seconds continuous Arm Regeneration Solenoid drive unit Measurement Volt...

Page 242: ...149 1 CN 53 8 Checking Open Short 2 CD 149 2 CR 35 87 Checking Open Short 179 4 Monitor Selecting attachment breaker crusher Detection When Breaker Operating Solenoid is Off 10 seconds continuous Attachment Safety Solenoid drive unit Measurement Voltage 3 0V Cancellation When Breaker Operating Solenoid is Off 3 seconds continuous Attachment Safety Solenoid drive unit Measurement Voltage 3 0V 侑 6 D...

Page 243: ...ent 4 5 A 侑 Results Symptoms 1 Control Function Cooling Fan reverse control operation failure not applicable 188 5 Detection When Attachment Flow EPPR 1 current is equal or more than 300 mA 10 seconds continuous Attachment Flow EPPR drive current 100 mA Cancellation When Attachment Flow EPPR 1 current is equal or more than 300 mA 3 seconds continuous Attachment Flow EPPR drive current 100 mA 侑 6 D...

Page 244: ... EPPR 1 press Sensor Measurement Voltage 5 2V 1 HW145 10 seconds continuous 0 3V AttachmentflowcontrolEPPR1press SensorMeasurementVoltage 0 8V 4 HW145 10 seconds continuous Attachment flow control EPPR 1 press Sensor Measurement Voltage 0 3V Results Symptoms 1 Control Function Driving second pump joining function operation failure Checking list 1 CD 33 B CN 52 11 Checking Open Short 2 CD 33 A CN 5...

Page 245: ...hecking Open Short 218 4 Mounting pressure sensor HCESPN128 or HCESPN 205 Detection When Boom Up Floating Solenoid is Off 10 seconds continuous Boom Up Floating Solenoid drive unit Measurement Voltage 3 0V Cancellation When Boom Up Floating Solenoid is Off 3 seconds continuous Boom Up Floating Solenoid drive unit Measurement Voltage 3 0V 侑 6 Detection When Boom Up Floating Solenoid is On 10 second...

Page 246: ... Symptoms 1 Control Function Boom floating control operation failure Checking list 1 CD 369 1 CN 53 35 Checking Open Short 2 CD 369 2 CR 35 87 Checking Open Short 221 5 Monitor Selecting attachment breaker crusher Detection When ATT Relief Setting EPPR 1 Current is equal or more than 10 mA 10 seconds continuous ATT Relief Setting EPPR 1 drive current 0 mA Cancellation ATT Relief Setting EPPR 1 Cur...

Page 247: ...Fuel Level Measurement Voltage 3 8V 侑 4 10 seconds continuous Fuel Level Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Fuel remaining display failure Checking list 1 CD 2 2 CN 52 26 Checking Open Short 2 CD 2 1 CN 51 5 Checking Open Short 325 4 Model Parameter mounting Fuel Warmer Relay Detection When Fuel Warmer Relay is Off 10 seconds continuous Fuel Warmer Relay drive unit Measurement V...

Page 248: ...rement Voltage 0 8V 侑 4 10 seconds continuous Brake Oil Press Sensor Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Brake Oil Press display failure Brake Oil low pressure warning failure Checking list 1 CD 3 B CN 54 4 Checking Open Short 2 CD 3 A CN 54 3 Checking Open Short 3 CD 3 C CN 54 13 Checking Open Short 505 0 10 seconds continuous Working Brake Press Sensor Measurement Voltage 5 2V ...

Page 249: ...Short 2 CR 66 2 CN 45 B term Checking Open Short 517 4 Detection When Traveling Cutoff Relay is Off 10 seconds continuous Traveling Cutoff Relay drive unit Measurement Voltage 3 0V Cancellation When Traveling Cutoff Relay is Off 3 seconds continuous Traveling Cutoff Relay drive unit Measurement Voltage 3 0V 侑 6 Detection When Traveling Cutoff Relay is On 10 seconds continuous Traveling Cutoff Rela...

Page 250: ... failure Checking list 1 CN 69 1 CN 54 8 Checking Open Short 2 CN 69 2 CN 45 B term Checking Open Short 527 4 Detection When Creep Solenoid is Off 10 seconds continuous Creep Solenoid drive unit Measurement Voltage 3 0V Cancellation When Creep Solenoid is Off 3 seconds continuous Creep Solenoid drive unit Measurement Voltage 3 0V 侑 6 Detection When Creep Solenoid is On 10 seconds continuous Creep ...

Page 251: ...ress Sensor Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Travel Reverse Press display failure 2 Control Function Driving interoperability power control operation failure Checking list 1 CD 74 B CN 54 23 Checking Open Short 2 CD 74 A CN 54 3 Checking Open Short 3 CD 74 C CN 54 13 Checking Open Short 705 0 10 seconds continuous Battery input Voltage 35V 侑 1 10 seconds continuous Battery inp...

Page 252: ... Sound is On 10 seconds continuous Travel Alarm Buzzer Sound Relay drive current 4 5 A Cancellation When Travel Alarm Buzzer Sound is On 3 seconds continuous Travel Alarm Buzzer Sound Relay drive current 4 5 A 侑 Results Symptoms 1 Control Function Driving alarm operation failure Checking list 1 CN 81 1 CN 52 31 Checking Open Short 2 CN 81 2 CN 45 B term Checking Open Short 831 2 When mounting the ...

Page 253: ...uous Haptic Controller Communication Data Error 侑 Results Symptoms 1 Control Function Haptic Controller operation failure Checking list 1 CN 8 2 CN 51 22 Checking Open Short 2 CN 8 3 CN 51 32 Checking Open Short 850 2 When mounting the RMCU 60 seconds continuous RMCU communication Data Error 侑 Resuluts Symptoms 1 Control Function RMCU operation failure Checking list 1 CN 125 3 CN 51 22 Checking Op...

Page 254: ...N 376 10 CN 51 22 Checking Open Short 2 CN 376 18 CN 51 32 Checking Open Short 868 2 60 seconds continuous Switch Controller communication Data Error 侑 Results Symptoms 1 Control Function Switch Controller operation failure Checking list 1 CN 56A 7 CN 51 22 Checking Open Short 2 CN 56A 6 CN 51 32 Checking Open Short 869 2 When mounting the BKCU 60 seconds continuous BKCU communication Data Error 侑...

Page 255: ...below normal operating range Moderately severe level Intake manifold pressure is below the minimum operating limit Possible reduced engine performance 131 91 3 Accelerator pedal or lever position sensor 1 circuit Voltage above normal or shorted to high source High voltage detected at accelerator pedal position number 1 circuit The engine will operate in limp home mode 132 91 4 Accelerator pedal or...

Page 256: ...rotection shutdown feature is enabled the engine will shut down 30 seconds after the red stop lamp starts flashing 153 105 3 Intake manifold 1 temperature sensor circuit Voltage above normal or shorted to high source High signal voltage detected at intake manifold air temperature circuit Fan will stay ON if controlled by ECM 154 105 4 Intake manifold 1 temperature sensor circuit Voltage below norm...

Page 257: ...ensor supply number 2 circuit Engine power derate 234 190 0 Engine crankshaft speed position Data valid but above normal operational range Most severe level Engine speed signal indicates engine speed above engine protection limit Engine power derate 238 3511 4 Sensor supply 3 circuit Voltage below normal or shorted to low source Low voltage detected on the 5 volt sensor supply circuit to the engin...

Page 258: ...ng remote accelerator pedal or lever position sensor circuit Received network data in error The oem vehicle electronic control unit VECM detected a fault with the remote accelerator Remote accelerator will not operate 295 108 2 Barometric pressure Data erratic intermittent or incorrect An error in the barometric pressure sensor signal was detected by the ECM Engine power derate 322 651 5 Injector ...

Page 259: ...ntrol module calibration memory software Bad intelligent device or component Invalid switch configuration adjustable parameter setting have been detected by the engine control module ECM Various optional switch inputs to the ECM may not operate correctly 351 627 12 Injector power supply Bad intelligent device or component The ECM measured injector boost voltage is low Engine power derate 352 3509 ...

Page 260: ...l 1 pressure Data valid but above normal operational range Most severe level The ECM has detected that fuel pressure in the fuel rail is higher than the normal operating fuel system pressure Possible reduced engine performance 451 157 3 Injector metering rail 1 pressure sensor circuit Voltage above normal or shorted to high source High signal voltage detected at the rail fuel pressure sensor circu...

Page 261: ...urce Open circuit or high voltage detected at starter lockout circuit Either the engine will not start or the engine will not have starter lockout protection 585 677 4 Starter relay driver circuit Voltage below normal or shorted to low source Low voltage detected at starter lockout circuit Either the engine will not start or the engine will not have starter lockout protection 595 103 16 Turbocharg...

Page 262: ...he 2 fuel rail pressure signals Possible reduced engine performance 778 723 2 Engine camshaft speed position sensor Data erratic intermittent or incorrect The ECM has detected a loss of signal from the camshaft position sensor Possible reduced engine performance 784 1590 2 Adaptive cruise control mode Data erratic intermittent or incorrect Loss of communication with adaptive cruise control Adaptiv...

Page 263: ...ormal or shorted to low source Low voltage detected at accelerator pedal position number 2 signal circuit The engine will operate in limp home mode 1242 91 2 Accelerator pedal or lever position sensor 1 and 2 Data erratic intermittent or incorrect Accelerator position sensor number 1 and number 2 are reading different values The engine will only idle 1515 91 19 Sae J1939 multiplexed accelerator pe...

Page 264: ...haust fluid tank temperature sensor circuit Possible reduced engine performance 1678 3031 3 Aftertreatment diesel exhaust fluid tank temperature sensor Voltage above normal or shorted to high source High signal voltage or open circuit detected at the diesel exhaust fluid tank temperature sensor circuit Possible reduced engine performance 1679 3031 2 Aftertreatment diesel exhaust fluid tank tempera...

Page 265: ... diesel exhaust fluid tank heater is continuously in the on position None on performance 1718 1322 31 Engine misfire for multiple cylinders Condition exists Engine misfire has been detected in multiple cylinder numbers Possible reduced engine performance 1776 2634 3 Power relay driver circuit Voltage above normal or shorted to high source High voltage detected at power relay driver circuit Possibl...

Page 266: ...it Voltage below normal or shorted to low source An internal circuit error has been detected by the aftertreatment outlet NOx sensor Possible reduced engine performance 1896 2791 13 EGR valve controller Out of calibration The EGR valve has failed the automatic calibration procedure at initial key ON Possible reduced engine performance 1921 3251 0 Aftertreatment diesel particulate filter differenti...

Page 267: ...e 2183 1072 4 Engine brake actuator driver 1 circuit Voltage below normal or shorted to low source Low voltage detected at the engine brake solenoid number 1 signal circuit Possible reduced engine braking performance 2185 3512 3 Sensor supply 4 circuit Voltage above normal or shorted to high source High voltage detected at 5 VDC sensor supply circuit to the accelerator pedal position sensor Engine...

Page 268: ...intermittent or incorrect Crankshaft engine speed sensor intermittent synchronization Possible reduced engine performance 2322 723 2 Engine camshaft speed position sensor Data erratic intermittent or incorrect Camshaft engine speed sensor intermittent synchronization None on performance 2349 2791 5 EGR Valve control circuit Current below normal or open circuit Motor terminal or motor coil open cir...

Page 269: ...sition Possible reduced engine performance 2398 171 2 Ambient air temperature Data erratic intermittent or incorrect The ambient air temperature sensor is reading an erratic value Possible reduced engine performance 2448 111 17 Coolant level Data valid but below normal operational range Least severe level Low engine coolant level detected none on performance 2449 641 13 Vgt actuator controller Out...

Page 270: ...t NOx sensor Possible reduced engine performance 2777 3703 31 Particulate trap active regeneration inhibited due to inhibit switch Condition exists Regeneration of the diesel particulate filter has been prevented due to the permit switch being disabled Possible frequent need for aftertreatment regeneration 2961 412 15 Exhaust gas recirculation temperature Data valid but above normal operational ra...

Page 271: ...N or during engine operation Possible reduced engine performance 3146 4363 3 Aftertreatment SCR outlet temperature sensor circuit Voltage above normal or shorted to high source High signal voltage detected at the SCR outlet temperature sensor circuit Possible reduced engine performance 3147 4363 4 Aftertreatment SCR outlet temperature sensor circuit Voltage below normal or shorted to low source Lo...

Page 272: ... Aftertreatment diesel exhaust fluid line heater 1 circuit Voltage above normal or shorted to high source High signal voltage detected at the diesel exhaust fluid line heater 1 circuit Possible reduced engine performance 3238 4340 4 Aftertreatment diesel exhaust fluid line heater 1 circuit Voltage below normal or shorted to low source Low signal voltage detected at the diesel exhaust fluid line he...

Page 273: ... time of alert If the engine protection shutdown feature is enabled the engine will shut down 30 seconds after the red STOP lamps starts flashing 3256 3246 15 Aftertreatment diesel particulate filter outlet temperature Data valid but above normal operating range Least severe level The aftertreatment diesel particulate filter outlet temperature sensor reading has exceeded the maximum engine protect...

Page 274: ...tertreatment diesel particulate filter intake temperature sensor circuit Voltage above normal or shorted to high source High signal voltage or open circuit detected at the aftertreatment diesel particulate filter intake temperature sensor circuit Possible reduced engine performance 3318 3242 2 Aftertreatment diesel particulate filter intake temperature Data erratic intermittent or incorrect The af...

Page 275: ... charge air cooler is not cooling the intake air flow sufficiently None on performance 3361 102 10 Intake manifold 1 pressure Abnormal rate of change The VGT position reading is stuck Possible reduced engine performance 3366 111 18 Coolant level Data valid but below normal operating range Moderately severe level Very low engine coolant level detected None on performance 3374 1818 31 Roll over prot...

Page 276: ...ine performance 3423 4344 4 Aftertreatment diesel exhaust fluid line heater 3 circuit Voltage below normal or shorted to low source Low signal voltage detected at the diesel exhaust fluid line heater 3 circuit Possible reduced engine performance 3425 4344 5 Aftertreatment diesel exhaust fluid line heater 3 circuit Current below normal or open circuit Open circuit detected in the diesel exhaust flu...

Page 277: ...ion or an invalid data transfer rate has been detected on the J1939 data link between the ECM and the ambient air temperature sensor Possible reduced engine performance 3532 171 19 Ambient air temperature Received network data in error The J1939 multiplexing controller has indicated a malfunction of the ambient air temperature sensor Possible reduced engine performance 3539 51 3 Engine intake thro...

Page 278: ...rcuit Possible reduced engine performance 3568 5394 7 Aftertreatment diesel exhaust fluid DEF Dosing valve Mechanical system not responding or out of adjustment A mechanical malfunction has been detected in the DEF dosing valve Possible reduced engine performance 3571 4334 3 Aftertreatment diesel exhaust fluid pressure sensor Voltage above normal or shorted to high source High signal voltage detec...

Page 279: ...c intermittent or incorrect The aftertreatment outlet NOx sensor indicates that the power supply to the sensor is incorrect None on performance 3682 3218 2 Aftertreatment Intake NOx sensor power supply Data erratic entermittent or encorrect The aftertreatment intake NOx sensor indicates that the power supply to the sensor is incorrect None on performance 3697 630 12 Engine control module calibrati...

Page 280: ...ntil the starter motor has adequately cooled 3741 5571 0 High pressure common rail fuel pressure relief valve Data valid but above normal operational range Most severe level The fuel rail pressure relief valve has opened due to high fuel rail pressure Engine may run rough may stop running may not start or may be difficult to start 3748 3216 20 Aftertreatment intake NOx sensor Data not rational Dri...

Page 281: ...4 5851 2 Aftertreatment SCR Intermediate NH3 gas sensor power supply Data erratic intermittent or incorrect Intermittent battery voltage supply detected at the after treatment SCR intermediate NH3 sensor Possible reduced engine performance 3935 5848 13 Aftertreatment SCR Intermediate NH3 sensor Out of calibration Incorrect trim resistance has been detected in the aftertreatment SCR intermediate NH...

Page 282: ... Aftertreatment diesel particulate filter temperature sensor module Bad intelligent device or component An internal error has been detected in the aftertreatment diesel particulate filter temperature sensor module Possible reduced engine performance 4159 5743 12 Aftertreatment selective catalytic reduction temperature sensor module Bad intelligent device or component An internal error has been det...

Page 283: ...ow normal or shorted to low source The aftertreatment diesel exhasut fluid dosing unit heater is detected to be stuck off Possible reduced engine performance 4171 5745 18 Aftertreatment diesel exhaust fluid dosing unit heater Data valid but below normal operating range Moderately severe level The aftertreatment diesel exhaust fluid dosing unit failed to thaw Possible reduced engine performance 421...

Page 284: ...l Drifted low An in range low failure has been detected Possible reduced engine performance 4281 5848 2 Aftertreatment SCR Intermediate NH3 Data erratic intermittent or incorrect The aftertreatment SCR intermediate NH3 sensor reading is stuck None on performance 4284 5793 9 Desired engine fueling state Abnormal update rate A valid message from the transmission ECU has NOT been received Engine may ...

Page 285: ...ert If the engine protection shutdown feature is enabled the engine will shut down 30 seconds after the red STOP lamps starts flashing 4525 5862 16 Aftertreatment 1 SCR intermediate gas temperature Data valid but above normal operating range Moderately severe level High SCR Intermediate temperature detected Progressive power and or speed derate increasing in severity from time of alert If the engi...

Page 286: ...mance 4728 1209 18 Exhaust gas pressure Data valid but below normal operating range Moderately severe level The commanded VGT position and exhaust pressure were not met None on performance 4731 3031 13 Aftertreatment diesel exhaust fluid tank temperature sensor Out of calibration The received datalink message was not valid Possible reduced engine performance 4732 1761 13 Aftertreatment diesel exha...

Page 287: ...ine coolant level 2 circuit None on performance 4956 520750 13 Engine variable geometry turbo VGT software Out of calibration VGT software does not match application Possible reduced engine performance 4957 520750 31 Engine variable geometry turbo VGT software Condition exists The VGT actuator and ECM software is not compatible Possible reduced engine performance 侍 Some fault codes are not applied...

Page 288: ...AAVM Communication Error Left Camera A05 AAVM Communication Error Right Camera A06 Manual Setting Fail A07 No MCU CID A08 MCU CID Format Error A09 AAVM Hardware Error AAVM A10 AAVM Hardware Error Front Camera A11 AAVM Hardware Error Rear Camera A12 AAVM Hardware Error Left Camera A13 AAVM Hardware Error Right Camera A14 MCU CID Model is not registered A15 MCU CID Model can t be applied ...

Page 289: ... Three LED lamps on the MCU display as below 1 2 ECM Engine control module LED C N 5 1 C N 5 2 1 2 1 MCU 2 Bolt M8 330L5MS13 G green R red Y yellow LED lamp Trouble Service G is turned ON Normal G and R are turned ON Trouble on MCU 㔽 Change the MCU G andY are turned ON Trouble on serial communication line 㔽 Check if serial communication lines between MCU and cluster are disconnected Three LED are ...

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

Page 291: ...turn 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 Sleeve 2 Spring 3 Spool 4 O ring 5 O ring 6 Solenoid valve 7 Connector P T A P T A 5 22 1 5 22 2 1 2 3 ...

Page 292: ...ck pressure at EPPR valve Remove plug and connect pressure gauge as figure 余Gauge capacity 0 to 50 kgf cm2 0 to 725 psi Start engine Set S mode and cancel auto decel mode Position the multimodal dial at 10 If tachometer show approx 1600佳50 rpm check pressure at relief position of bucket circuit by operating bucket control lever If pressure is not correct adjust it After adjust test the machine EPP...

Page 293: ...l 1 O ring 2 Support ring 3 Valve body 4 Coil 5 Connector 6 Cover cap Operation In de energized mode the inlet port P is closed and the outlet port A is connected to tank port T In energized mode the solenoid armature presses onto the control spool with a force corresponding to the amount of current This will set a reduced pressure at port A The setting is proportional to the amount of current app...

Page 294: ...e from A5 port and connect pressure gauge as figure 余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 1600佳50 rpm check pressure In case of combined boom up and swing operation If pressure is not correct adjust it After adjust test the machine Boom priority EPPR valve Solenoid valve CN 133 Multimeter Adapter P no 21Q6 50410 Boom p...

Page 295: ...red Refer to page 5 65 for details This cluster is adjustable Vertical forward backward each 15 Horizontal left only 8 侍 侍 Backward Forward Left 290F3CD47 GROUP 16 MONITORING SYSTEM 1 OUTLINE Monitoring system consists of the monitor part and switch part The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine Various select switches are b...

Page 296: ...p Low turtle Start of engine Check machine condition RPM display indicates at present rpm Gauge and warning lamp Indicate at present condition When normal condition All warning lamp OFF Work mode selection General work Power mode selection E mode or U mode Travel speed pilot lamp Low turtle When warming up operation Warming up pilot lamp ON After engine started engine speed increases to1000 rpm Ot...

Page 297: ...20 32V 3 GND 4 CAN 1 H 0 5V 5 CAN 1 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 5 CAM 1 NTSC signal 6 CAM 2 NTSC signal 7 CAM 3 NTSC signal 8 CAM shield 1 2 NTSC National Television System Committee ...

Page 298: ...chine is on the normal condition check the electric device as that can be caused by the poor connection of electricity or sensor 刮 刮 刯 侍 290F3CD49 290F3CD53 2 3 GAUGE 2 Default Option 1 2 3 7 4 6 5 6 2 3 8 1 5 4 7 8 290F3CD51 Operation screen When you first turn starting switch ON the operation screen will appear Operation screen type can be set by the screen type menu of the display Refer to page...

Page 299: ...the gauge indicates the red range or lamp blinks in red even though the machine is on the normal condition check the electric device as that can be caused by the poor connection of electricity or sensor Hydraulic oil temperature gauge 刮 刯 侍 刮 刯 侍 290F3CD54 5 4 This gauge indicates the amount of liquid in the DEF AdBlue tank Fill the DEF AdBlue when the red range or lamp pops up and the buzzer soun...

Page 300: ...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 㔽White Idle operation 㔽Green Economy operation 㔽Yellow Non economy operation at a medium level 㔽Red Non economy operation at a high level 刮 刯 到 Eco gauge 290F3CD58 8 ...

Page 301: ... warning lamp moves to the original position and lights ON and the buzzer stops when 2 seconds elapsed 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 2 seconds elapsed Warning lamp pops up on the center of the LCD and the buzzer sounds 㕱Refer to page 5 66 for details Warning lamps and b...

Page 302: ...ing 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 The pop up lamps move to the original position and blinks when the buzzer stop switch is pushed And the buzzer stops and lamps keep blink Check the cooling system when the lamps keep blink 290F3CD61 En...

Page 303: ...switch is ON if equipped Reduce the machine load 刮 刯 Overload warning lamp opt 9 290F3CD67 290F3CD69 290F3CD68 This warning lamp pops up and the buzzer sounds when the engine oil pressure is low If the lamp blinks shut OFF the engine immediately Check oil level Engine oil pressure warning lamp 刮 刯 5 This warning lamp pops up and the buzzer sounds when the communication between MCU and engine ECM o...

Page 304: ...D70 This warning lamp indicates when illuminated the DPF regeneration switch is pushed inhibit position therefore auto matic and manual regeneration can not occur Refer to the operator s manual page 3 36 for the DPF switch 刮 侍 DPF regeneration inhibit warning lamp 2609A3CD20 12 Warning lamp Description SCR Check engine Stop engine Off Off Off Automatic SCR system cleaning Blink Off Off 㕱 The statu...

Page 305: ...mon for the lamp to illuminate on and off during normal equipment operation as the engine completes regeneration 刮 刯 到 侍 Safety button 1 2 OFF DPF warning lamp OFF HEST warning lamp DPF warning lamp HEST warning lamp ON ON Manual regeneration applies if the machine is in a fireproof area and there is no plan to turn off the maching during the regeneration Stop and park the machine Select user mode...

Page 306: ...el Check engine Stop engine On Off Off The DEF AdBlue level has fallen below the initial warning level 10 Blink Off Off The DEF AdBlue level has fallen below the critical warning level 5 Blink On Off The DEF AdBlue level has fallen below the initial derate level 2 5 The engine power will be limited automatically Blink On On This is happened when 30 minutes elapsed with empty conditions 0 of the DE...

Page 307: ...lamp 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 Heavy duty power work mode Standard power mode Economy power mode 2 User mode User preferable power mode 3 Work tool mode General operation IPC speed mode General operation IPC balance mode General...

Page 308: ...is not available when the auto idle pilot lamp is turned ON Refer to the operator s manual page 3 38 刮 刯 侍 侍 Decel pilot lamp This lamp is turned ON when the coolant temperature is below 10 C 50 F or the hydraulic oil temperature 20 C 68 F The automatic fuel warming is cancelled when the engine coolant temperature is above 60 C and the hydraulic oil tem perature is above 45 Csince the start switch...

Page 309: ...efer to the page 5 87 Entertainment pilot lamp 刮 侍 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 5 83 刮 刯 侍 Smart key pilot lamp opt 8 9 290F3CD84 290F3CD214 ...

Page 310: ...machine work mode which shifts from general operation mode to optional attachment operation mode 余 General operation mode 余 Breaker operation mode if equipped 余 Crusher operation mode if equipped 余Not installed Breaker or crusher is not installed Refer to the operator s manual page 4 7 for details Work mode switch 刮 侍 290F3CD86 290F3CD88 2 5 When some of the switches are selected the pilot lamps a...

Page 311: ...is switch is used to activate or cancel the auto idle function 余Pilot lamp ON Auto idle function is activated 余Pilot lamp OFF Auto idle function is cancelled The buzzer sounds when the machine has a problem In this case push this switch and buzzer stops but the warn ing lamp blinks until the problem is cleared This switch is used to operate the work light The pilot lamp is turned ON when operating...

Page 312: ...when switched off The pilot lamp is turned ON when operating the switch If the wiper does not operate with the switch in ON position turn the switch OFF immediately Check the cause If the switch remains ON motor failure can result The washer liquid is sprayed and the wiper is operated only while pressing this switch The pilot lamp is turned ON when operating the switch This switch turns ON the cab...

Page 313: ...e 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 function surrounding when the machine travels to forward and backward On pressing this switch the alarm operates only when the machine is traveling The pilot lamp is turned ON when operating the switch This switch is ...

Page 314: ...ng MCU 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 information Contact Service menu Clinometer Update General record Hourly Daily Mode record Replacement Change interval oils and filters ESL mode setting Password change Model MCU Monitor Haptic swit...

Page 315: ...e U mode can be activated by user mode switch 余 余 Boom speed 到 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 余 Step Engine speed rpm Idle speed rpm Power shift bar 1 1300 700 0 2 1400 800 3 3 1450 850 6 4 1500 900 9 5 1600 950 12 6 1650 1000 auto decel 16 7 1700 1050 20 8 1800...

Page 316: ...ed 余 290F3CD117 210WF3CD118 LSF prgh 刲 The IPC mode can be selected by this menu Speed mode Balance mode default Efficiency mode This mode is applied only general operation mode of the work tool mode Please update the cluster programs if this mode is not displayed in the mode setup menu Refer to the operator s manual page 3 25 1 余 余 侍 290F3CD310 290F3CD311 290F3CD312 290F3CD313 290F3CD304 290F3CD3...

Page 317: ...nitial step 0 9 step 余 余 余 Automatic engine shutdown option 刳 210WF3CD11 210WF3CD12 210WF3CD13 The automatic engine shutdown function can be set by this menu One time Always Disable Wait time setting Max 40 minutes min 2 minutes 余 Emergency mode 刵 This mode can be use when the switches are abnormal on the cluster The cluster switches will be selected by touched each icon 余 余 290F3CD248 290F3CD249 ...

Page 318: ...igital output The activated switch or output pilot lamps are light ON 余 余 余 290F3CD120 290F3CD128 290F3CD134 290F3CD172 290F3CD121 290F3CD123 290F3CD126 290F3CD188 290F3CD124 290F3CD127 290F3CD189 290F3CD125 The active faults of the MCU engine ECM air conditioner or AAVM can be checked by this menu 余 The logged faults of the MCU engine ECM air conditioner or AAVM can be checked by this menu 余 The ...

Page 319: ... One step shift to the right for every one hour Automatic deletion for 12 hours earlier data All hourly records deletion by Reset 㔽Daily record C Daily fuel consumption for past seven days MCU real time No record during key off time One step shift to the right at 24 00 for every day Automatic deletion for 7 days earlier data All daily records deletion by Reset 㔽Mode record D Average fuel rate for ...

Page 320: ...31 No Item Interval 1 Engine oil 500 2 Final gear oil 1000 3 Swing gear oil 1000 4 Hydraulic oil 5000 5 Pilot line filter 1000 6 Drain filter 1000 7 Hydraulic oil return filter 1000 8 Engine oil filter 500 9 Fuel filter 500 10 Pre filter 500 11 Hydraulic tank breather 1000 12 Air cleaner inner outer 4000 13 Radiator coolant 2000 14 Swing gear pinion grease 1000 15 DEF AdBlue supply module filter 4...

Page 321: ...tor 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 侍Default password 00000倜 侍Password length 5 10 digit 倜 余 290F3CD135 290F3CD136 290F3CD137 290F3CD138 Smart key option Smart key is registered when equipped with optional smart key If smart key is not inside of the cabin authentication...

Page 322: ...0F3CD151 Service menu 刳 Power shift standard option Power shift pressure can be set by option menu Operating hours Operating hours since the machine line out can be checked by this menu Breaker mode pump acting 1 pump 2 pump EPPR current level attach flow EPPR 1 2 boom priority EPPR attach relief pressure EPPR 1 2 Overload pressure 100 350 bar 余 余 余 余 余 290F3CD152 290F3CD153 Clinometer 刴 When the ...

Page 323: ...te cluster ETC devices 刵 210WF3CD17 210WF3CD18 380F3CD05 210WF3CD19 380F3CD04 ETC devices and cluster can be updated through CAN 2 network Insert USB memory stick which includes program files start download 余 余 ...

Page 324: ...ear each The second line shows the current time 0 00 23 59 余 余 290F3CD154 290F3CD157 290F3CD159 290F3CD155 290F3CD158 290F3CD160 290F3CD141 290F3CD156 290F3CD139 290F3CD191 290F3CD192 Brightness 到 If Auto is chosen brightness for day and night can be differently set up Also by using the bar in lower side users can define which time interval belongs to day and night in bar figure white area represe...

Page 325: ...e 余 Screen type 刳 A Type Default B Type Option 290F3CD161 290F3CD163 290F3CD164 290F3CD165 290F3CD166 290F3CD156A 290F3CD193 290F3CD194 290F3CD167A 210WF3CD162 Temperature C 侟 F Pressure bar 侟 MPa 侟 kgf cm2 Volume l 侟 gal Flow lpm 侟 gpm Distance km 侟 mile Date format yy mm dd 侟 mm dd yy 侟 dd mm yy 余 余 余 余 余 余 ...

Page 326: ...198 A B C Video A This menu operates the video play function mp4 mkv avi files and so on Audio B This menu operates the play music mp3 mp4 files and so on Smart terminal C The menu features a smartphone and operates the miracast 210WF3CD219 210WF3CD220 210WF3CD22 210WF3CD199 ...

Page 327: ...eter 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 余 余 余 If the rear camera is not installed on the machine set disable If the rear camera installed on the machine set enable 余 余 290F3CD168 290F3CD200 290F3CD156 290F3CD169 290F3CD255 290F3CD221 290F3CD256 ...

Page 328: ...screen AAVM mode 290F3CD246 290F3CD247 When the worker or pedestrian go to the blue line radius 5 m an external danger area of equipping on the cluster screen the warning buzzer sounds and it displays the blue rectangular box for the rec ognition of the worker and pedestrian At this time the operator should stop work imme diately and stop the buzzer by pressing the buzzer stop button And then plea...

Page 329: ...mperature 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 Setting temperature Fan speed Fan speed switch B B B B C D D or Haptic controller 290F3CD201 Haptic controller Refer to the operator s manual page 3 57 㕱 Fan speed switch Fan speed ...

Page 330: ...ains 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 Setting temperature 刮 侍 Auto air conditiner and heater system automatically keeps the optimum condition in accordance with operator s temperature configuration sensing ambient and cabin inside tempe...

Page 331: ...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 time Check out the fresh air filter and the recirculation filter periodically to keep a good efficiency 刮 a b 侍 侍 Operating this switch it beeps and displays symbol of each mode in order Face 㕿 Face Rear 㕿 Face Rear F...

Page 332: ...porate 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 circuit malfunction If not the alternate value is Def Foot F11 Intake actuator open short The alternate value is air recirculation F12 Intake actuator drive circuit malfunction The alternate fresh ai...

Page 333: ...ATTERY BATTERY 0 8A 0 8A 0 8A 0 8A 0 8A 0 8A 0 8A 0 8A 0 8A 0 8A START KEY CLUSTER ROOM LAMP CASSETTE ECM AIR CON HEATER MCU SWITCH PANEL MCU CONT MCU EPPR CASSETTE WORK LAMP CABIN LAMP OPTION CLUSTER CONVERTER FUEL HEATER START AIR HEAT HORN AC HEATER SAFETY SOL 10A 2 10A 3 30A 4 30A 5 10A 7 10A 8 5A 9 20A 10 20A 11 10A 12 10A 13 10A 14 20A 15 30A 16 30A 17 10A 18 20A 19 30A 20 20A 21 10A 22 20A ...

Page 334: ...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 335: ...and Mechatronics system fault codes displayed on monitor display At each system part a service man can check the machine according to the troubleshooting process diagram Troubles occur Mechatronics part Hydraulic Mechanical part GROUP 2 GROUP 3 GROUP 4 Fault codes displayed on monitor display See page 5 18 Electrical part HCESPN 3digit FMI 1 or 2 digit machine 3 or 4 digit engine See page 5 22 Bef...

Page 336: ...the phenomenon of the trouble Was the trouble getting worse or did it come out suddenly for the first time Did the machine have any troubles previously If so which parts were repaired before STEP 3 Inspect the machine Before starting troubleshooting check the machine for the daily maintenance points as shown in the operator s manual And also check the electrical system including batteries as the t...

Page 337: ...o where the trouble parts are located hydraulic mechanical system part or electrical system part or mechatronics system part perform troubleshooting the machine refer to the each system part s troubleshooting process diagram STEP 6 Trace a cause Before reaching a conclusion check the most suspectible causes again Try to trace what the real cause of the trouble is Make a plan of the appropriate rep...

Page 338: ...ecome impossible to find the cause of the problem Ask user or operator the following Was there any strange thing about machine before failure occurred Under what conditions did the failure occur Have any repairs been carried out before the failure Check before troubleshooting Check oil and fuel level Check for any external leakage of oil from components Check for loose or damage of wiring and conn...

Page 339: ...el and check if rubber pieces or particles are not present Coupling hub spline is worn or hub fastening setscrew is slack If hydraulic pump or engine is suspected as a culprit refer to this manual Structure and function Cause Remedy Coupling element is broken Disassemble and repair Replace hub or retighten setscrew ...

Page 340: ...nterior or repair piping Disassemble and repair Repair or replace Disassemble and repair YES YES YES YES YES YES YES NO NO NO NO Is oil level in hydraulic oil tank within standard level Do not hydraulic pump and pump connections make abnormal noise Abnormal noise comes out of pump connection Is pilot pump pressure within standard level Ispilotpiping cloggedorisoil leakagepresent onpilotpiping Is g...

Page 341: ...ot the set pressure of main relief port relief and travel relief valve lower than the standard level Is fan belt tension proper ͽ YES NO YES YES YES YES NO NO NO Drop hydraulic oil sample on hot plate and check if foams come up Water is mixed Air is intruded Put hydraulic oil still separate water and dispose it or replace hydraulic oil Check suction line and return line and eliminate the air intru...

Page 342: ...level Replace oil with one of proper viscosity Clean suction strainer Check for air intrusion in suction line and retighten or replace parts CAVITATION OCCURS WITH PUMP 3 HYDRAULIC OIL IS CONTAMINATED 4 Has not hydraulic oil passed specified replace ment hours Replace hydraulic oil to be specified Flush with hydraulic oil and replace return filter Has return filter been replaced at proper interval...

Page 343: ...lve spool is stuck Hydraulic pump is broken Swing parking brake release valve is broken Swing reduction unit is broken Swing motor is broken Pilot relief valve in gear pump is faulty Gear pump is out of order RCV is broken Replenish specifiedoiltothe standardlevel Repairorreplace Repairorreplace Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair Disassemble...

Page 344: ...Shuttle valve is faulty Pilot relief valve is faulty Gear pump is faulty Disassembleand repair or replace Disassemble and repair Clean pilot piping interior or repair piping Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair Clean pilot piping interior or repair piping Disassembleand repair or replace Disassemble and repair Mainreliefvalve pressureresetting...

Page 345: ...Does swing spool move Is MCV pilot pressure within standard value MACHINE SWINGS BUT DOES NOT STOP 4 Pilot relief valve is faulty Gear pump is broken RCV is faulty Swing spool is stuck Return spring is faulty Disassemble and repair or replace Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and replace Swing port relief valve is faulty Shuttle valve is faulty Swingc...

Page 346: ... A SLOPE 5 ͽ Is swing relief pressure within standard level ͽ Shuttle valve is faulty Brake spring is faulty Return spring of swing control valve is faulty Swing port relief valve is faulty Swing motor is broken Disassemble and replace Disassemble and replace Disassemble and replace Disassemble and repair or replace Disassemble and repair Adjust swing relief valve pressure or replace swing relief ...

Page 347: ...travel motor is faulty Control system is defective Travel spool is stuck Travel reduction unit is faulty Travel motor is out of order Hydraulic pump is broken Travel relief valves are faulty Disassemble and repair or replace Disassemble and repair Disassemble inspect and repair Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair Disassemble and repair or rep...

Page 348: ... Hydraulic pump is broken External pilot piping is clogged or oil is leaking from it Travel motor s parking brake is not released properly Travel motor is faulty Disassemble and repair or replace Disassemble and repair Disassemble inspect and repair Disassemble and repair Disassemble and repair or replace Disassemble and repair Disassemble and clean Disassemble and clean pilot piping Disassemble a...

Page 349: ...that there is no coupling element particles LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE 4 Faulty Hydraulic pump is faulty Travel relief valve is faulty Coupling at pump connection is broken Inspectaccording totheprocedure Traveldoesnot functionatallon oneside However acase wherebothLH andRHtravel motionsare disabledis extremelyseldom statistically Disassemble and repair Disassemble and repair or repla...

Page 350: ... Hydraulic circuit that releases travel parking brake is clogged with dirt Parking brake piston in travel motor is stuck Travel reduction unit is defective Disassemble and repair Disassemble and repair or replace Disassemble and repair or replace Disassemble and clean Disassemble and repair Disassemble and repair 刔 Remove parking brake spring in travel motor draw out piston completely refit cover ...

Page 351: ...RVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME 7 NO Straight spool is faulty Pilot relief valve is defective Gear pump is broken Normal Repair or replace Remove dirt on signal orifice Disassemble and repair or replace Disassemble and repair Is gear pump delivering oil Is pilot relief valve normal Cause Remedy ...

Page 352: ... is faulty Pilot relief valve is faulty Gear pump is broken Hydraulic pump is broken Main relief valve is defective Coupling at pump connection is broken Cylinder interior is broken MCV spool is stuck Disassemble and repair or replace Disassemble and repair Disassemble and repair or replace Disassemble and repair Disassemble and repair Disassemble and repair or replace Disassemble and repair Reple...

Page 353: ... RCV is faulty Normal Replace spring Disassemble and repair Disassemble and repair Disassemble and repair or replace Disassemble and repair Disassemble and repair Clean pilot piping interior or repair piping Disassemble and repair Disassemble and repair or replace Disassemble and repair Adjust engine revolution Clean orifice in control valve Clean pilot piping interior or repair piping Disassemble...

Page 354: ...ween control valve casing and spool is poor Contact surface between poppet and seat is poor Cylinder is faulty Disassemble and repair or replace Disassemble and replace Locate the cause of hydraulic oil temperature rise and lower it to proper level Replace with genuine hydraulic oil or equivalent Disassemble and repair Disassemble and repair Disassemble and repair 刔 Is cylinder internal leakage wi...

Page 355: ...isassemble and repair Disassemble and repair Adjust pressure repair or replace Disassemble and repair Does control valve spool move Does the symptom change when hydraulic pump s discharge hoses are exchanged BOOM ARM OR BUCKET POWER IS WEAK 4 Is relief pressure in main relief valve within standard level Is cylinder internal leakage within standard level Is relief pressure in port relief valve with...

Page 356: ...f grease Frictional noise occurs between the sliding faces of boom cylinder s oil seal and boom proper Supply grease to it 侍 Frictional noise will disappear if they are kept used 侍If seizure is in an initial stage supply sufficient grease If seizure is in a grown state correct it by paper lapping or with an oil stone Cause Remedy ...

Page 357: ...in the cylinder If no oil leaks from piping side and boom cylinder rod is retracted there is an internal leak in the control valve 3 Disconnect hose A from rod side of boom cylinder and drain oil from cylinders and hose put cups on piping and hose ends 2 Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full 1 300L6TS01 210 7 6 20 2 ...

Page 358: ...ately unless 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 8 FUSE NO 14 FUSE Starting switch ON Voltage 20 32V Cause Remedy Defective cluster Disconnection in wiring harness or poor contact between CN 5 CN 56A Disconnection in wiring harness or poor contact between CN 5 9 GND...

Page 359: ...ace Repair or replace after clean Check voltage between CN 5 5 and 6 YES YES NO NO Check voltage between CN 56A 6 7 and 3 300L6ES02 余Before disconnecting the connector always turn the starting switch OFF 余Before carrying out below procedure check all the related connectors are properly inserted 余After checking insert the disconnected connectors again immediately unless otherwise specified COMMUNIC...

Page 360: ...nection in wiring harness or poor contact between CN 52 27 CN 2 13 Disconnection in wiring harness or poor contact between CN 2 13 alternator terminal L Defective alternator Replace Repair or replace after clean Repair or replace after clean Replace YES YES YES NO NO NO MCU 27 CN 52 13 CN 2 ALTERNATOR CN 74 B L G 3 U Engine Running Voltage 20 32V Check voltage between alternator terminal L and cha...

Page 361: ... TOOL A F B C E P DUMP 22 46 34 83 Engine ECM CAN Hi CAN Lo ENGINE COOLANT TEMPERATURE SENSOR C A B Engine harness connector CN 93 300L6ES04 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor engine harness connector Defective coolant temp sensor Check or replace Repair or replace after clean Replace YES YES NO Starting switch OFF Spec 180 160 k See tab...

Page 362: ...immediately unless otherwise specified Cause Remedy Clogged air filter or defective switch Short circuit in wiring harness between CD 10 CN 51 29 Defective MCU Check filter or replace switch Repair or replace After clean Replace 29 CN 51 AIR CLEANER SWITCH Pa MCU CD 10 Starting switch ON Engine Start Does display go off when disconnect CD 10 Check resistance between CN 51 29 and chassis NO YES NO ...

Page 363: ...GINE OIL PRESSURE WARNING LAMP LIGHTS UP engine is started 余Before disconnecting the connector always turn the starting switch OFF 余Before carrying out below procedure check all the related connectors are properly inserted 余After checking insert the disconnected connectors again immediately unless otherwise specified Cause Remedy Defective circuit sensor or ECM Voltage above normal or shorted to h...

Page 364: ...ing switch 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 52 Resistance between CD 1 1 2 is in range of 164 151 Starting switch ON Disconnect CD 1 YES YES YES NO NO NO 300L6ES08 Temperature C 30 10 0 40 70 80 90 100 105 Resistance k 22 22 31 78 8 16 10 74 5 18 6 6 1 06 1 28 0 39 0 476 0 322 0 298 0 243 0 ...

Page 365: ...F B C E P DUMP 22 46 34 83 Engine ECM CAN Hi CAN Lo ENGINE COOLANT TEMPERATURE SENSOR C A B Engine harness connector CN 93 300L6ES04 Cause Remedy Check use HRDT Disconnection in wiring harness or poor contact between temp sensor engine harness connector Defective coolant temp sensor Check or replace Repair or replace after clean Replace YES YES NO Starting switch OFF Spec 180 160 k See table Check...

Page 366: ...EVEL SENDER Cause Remedy Defective MCU or cluster Disconnection in wiring harness or poor contact between fuel sender MCU Defective fuel sender Replace Repair or replace Replace YES YES Starting switch OFF Spec 50 600 See table Check resistance between fuel sender 1 and 2 Check resistance between CN 51 5 and CN 52 26 Starting switch OFF Disconnect CN 51 52 Spec 50 600 NO NO 300L6ES10 Check Table R...

Page 367: ...ective safety switch Disconnection in wiring harness between CN 68 2 fuse No 24 Check hydraulic system Replace Repair or replace after clean Repair or replace after clean Replace Repair or replace Check voltage between CN 68 1 2 YES YES YES YES NO NO NO NO Safety lever OFF Starting switch ON Voltage 20 30V Check operation of solenoid Safety lever ON OFF Starting switch OFF Safety state Spec 0 Disc...

Page 368: ...the travel speed switch on the cluster Check MCU Cause Remedy Disconnection in wiring harness or poor contact between CN 70 CN 52 Defective solenoid Defective hydraulic system Disconnection in wiring harness or poor contact between CN 70 fuse No 26 Defective cluster Defective MCU Repair or replace Replace Check hydraulic system Repair or replace Replace Replace Check voltage between CN 70 1 and 2 ...

Page 369: ...tween CS 33 1 CN 93 5 Defective magnet of start motor Defective start relay ͽ Disconnection in wiring harness or poor contact between CN 2 7 CR 5 5 Defective anti restart relay 刕 Defectivestartrelay Disconnection in wiring harness or poor contact betweenCN 2 7 CR 5 5 Disconnection in wiring harness or poor contact betweenCN 51 20 CR 5 1 Disconnection in wiring harness or poor contact betweenCS 2A ...

Page 370: ...rreplace afterclean Replace Chargeorreplace afterclean Specific gravity MIN 1 28 Voltage MIN 24V Check voltage and specific gravity of battery Voltage 20 30V Voltage 20 30V Starting switch ON Voltage 20 30V STARTER LOCKOUT SIG START MOTOR 1 2 7 8 CN 2 START RY CR 23 ANTI RESTART RY CR 5 1 2 3 4 5 2 1 5 3 4 ANTI RESTART RY 20 MCU CN 51 BATT RY CR 1 BATTERY DO 3 2 1 CN 60 2 1 CN 95 CIRCUIT BREAKER M...

Page 371: ...switch panel 1 Recheck fuse No 7 2 Disconnection in wiring harness or poor contact between CN 141 7 Fuse CN 21 4 Fuse 1 Recheck fuse No 18 2 Disconnection CN 141 6 Fuse Disconnection in wiring harness or poor contact Defective wiper motor Defective wiper motor controller Replace Repair or replace after clean Replace Replace Repair or replace after clean Replace Replace Repair or replace after clea...

Page 372: ...3 34 NC GND GND NC NC NC NC NC NC NC NC NC NC NC NC NC 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 Defective switch panel Disconnection in wiring harness or poor contact between CN 376 13 CR 13 87 Disconnection in wiring harness or poor contact between CR 13 30 and chassis or CR 13 86 chassis Recheck fuse No 19 Replace Repa...

Page 373: ...25 26 27 28 NC GND GND NC NC NC NC NC NC CN 376 Cause Remedy Defective bulb Disconnection in wiring harness or poor contact between CR 4 87 CL 5 2 CL 6 2 CL 36 2 CL 37 2 Defective switch panel Disconnection in wiring harness or poor contact between CR 4 87 CN 376 4 Disconnection in wiring harness or poor contact between CR 4 30 and chassis or CR 4 86 and chassis Recheck fuse No 16 Replace Repair o...

Page 374: ...perly inserted and fault code on the cluster INSPECTION PROCEDURE 侍 侍 侍 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 resistance at EPPR valve Check pressure at EPPR valve YES YES YES YES NO NO NO NO Cause Remedy Defective hydraulic system Defective EPPR valve Defective MCU Short circuit or poor connection between CN ...

Page 375: ...from EPPR valve Check electric current at bucket circuit relief position 2 刮 刯 到 刱 刲 刳 刴 SPEC 15 25 20 C 480L6MS02 Test 3 Check pressure at EPPR valve Remove plug and connect pressure gauge as figure ÂGauge capacity 0 to 50 kgf cm2 0 to 725 psi Start engine Set S mode and cancel auto decel mode Position the multimodal dial at 10 If tachometer show approx 1600Ü50 rpm check pressure at relief positi...

Page 376: ...EC 100 700 mA See TEST 4 SPEC 2 25 kgf cm2 See TEST 5 SPEC 15 25 20 C See TEST 1 Check electric current at EPPR valve Check pressure at EPPR valve Check resistance between at EPPR valve Cause Remedy Not enough engine power Defective EPPR valve Short circuit or poor connection between CN 52 CN 75 Defective EPPR valve Check engine fault Contact cummins Replace Check and repair wire harness Replace Y...

Page 377: ... 5 Check pressure at EPPR valve Remove plug and connect pressure gauge as figure ÂGauge capacity 0 to 50 kgf cm2 0 to 725 psi Start engine Set S mode and cancel auto decel mode Position the multimodal dial at 10 If rpm show approx 1600Ü50 rpm check pressure at relief position of bucket circuit by operating bucket control lever If pressure is not correct adjust it After adjust test the machine 2 刮 ...

Page 378: ...n 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 刔 Cluster failure No connection Check fuse No 4 Replace Replace Check and repair CLUSTER 6 7 CN 56A 6 5 CN 5 CN 51 22 32 MCU FUSE NO 4 1 GND CAN1 HI IG 24V BATT 24V CAN1 LO CAN2 HI CAN2 LO RS 232 RX RS 232 TX AUX LEFT AUX RIGHT AUX GND 刔 R Y G KEYOFF Wiring diagram YES...

Page 379: ...ode 108 displayed Defective work pressure sensor Short circuit or poor connection between CN 51 3 CD 7 A and or CN 51 13 CD 7 C fault code 105 displayed Replace Replace Replace or repair Replace Replace or repair CN 52 38 37 MCU CN 51 3 13 CD 6 CD 7 TRAVEL PRESSURE SENSOR WORK PRESSURE SENSOR SUPPLY SIG RETURN A B C SUPPLY SIG RETURN A B C Check voltage between CN 52 38 GND and CN 52 37 GND NO NO ...

Page 380: ...N 52 37 and ground Prepare 1 piece of thin sharp pin steel or copper Insert prepared pin to rear side of connectors One pin to 37 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 35 CN 52 Female 37 38 PIN 1 2 刮 刯...

Page 381: ... sensor Short circuit or poor connection between CN 1 3 CD 43 B Short circuit or poor connection between CD 43 A CN 1 4 or CD 43 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 12 GND YES YES YES NO NO NO SPEC Key ON 24佳2V Starting switch...

Page 382: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 12 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 12 PIN 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS08 ...

Page 383: ... sensor Short circuit or poor connection between CN 1 5 CD 42 B Short circuit or poor connection between CD 42 A CN 1 4 or CD 42 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 29 GND YES YES YES NO NO NO SPEC Key ON 24佳2V Starting switch...

Page 384: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 29 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 29 PIN 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS06 ...

Page 385: ...rcuit or poor connection between CN 1 7 CD 44 B Short circuit or poor connection between CD 44 A CN 1 4 or CD 44 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 32 GND YES YES YES NO NO NO SPEC Key ON 24佳2V Starting switch ON SPEC Key ON ...

Page 386: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 32 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND 32 PIN 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS10 ...

Page 387: ...sure sensor Short circuit or poor connection between CN 1 1 CD 70 B Short circuit or poor connection between CD 70 A CN 1 4 or CD 70 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 33 GND YES YES YES NO NO NO SPEC Key ON 24佳2V Starting sw...

Page 388: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 33 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 33 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS12 ...

Page 389: ...sure sensor Short circuit or poor connection between CN 1 2 CD 44 B Short circuit or poor connection between CD 44 A CN 1 4 or CD 44 C CN 1 6 Short circuit or poor connection between CN 1 4 CN 51 3 or CN 1 6 CN 51 13 Replace Replace or repair Replace or repair Replace or repair Replace or repair Replace or repair Check voltage between CN 52 17 GND YES YES YES NO NO NO SPEC Key ON 24佳2V Starting sw...

Page 390: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 17 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 17 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS14 ...

Page 391: ... CD 24 SWING PRESSURE SENSOR 300L6MS15 余 Cause Remedy Defective MCU Detective swing pressure sensor Short circuit or poor connection between CN 52 36 CD 24 B Short circuit or poor connection between CD 24 A CN 51 3 or CD 24 C CN 51 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 52 36 GND YES YES NO SPEC Key ON 24佳2V Starting switch ON Check voltage betwee...

Page 392: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 36 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 36 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS16 ...

Page 393: ...RM IN OUT BUCKET IN PRESSURE SENSOR 300L6MS17 余 Cause Remedy Defective MCU Detective arm in out bucket in pressure sensor Short circuit or poor connection between CN 52 14 CD 35 B Short circuit or poor connection between CD 35 A CN 51 3 or CD 35 C CN 51 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 52 14 GND YES YES NO SPEC Key ON 24佳2V Starting switch O...

Page 394: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 14 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 14 1 Η Θ Ι Κ 2 SPEC Actuator operating 1 5 V 300L6MS18 ...

Page 395: ...CD 32 BOOM UP PRESSURE SENSOR 300L6MS19 余 Cause Remedy Defective MCU Detective boom up pressure sensor Short circuit or poor connection between CN 52 19 CD 32 B Short circuit or poor connection between CD 32 A CN 51 3 or CD 32 C CN 51 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 52 19 GND YES YES NO SPEC Key ON 24佳2V Starting switch ON Check voltage bet...

Page 396: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 19 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 19 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS20 ...

Page 397: ...SUPPLY SIG RETURN A B C 13 3 300L6MS25 余 Cause Remedy Defective MCU Detective boom up pressure sensor Short circuit or poor connection between CN 53 23 CD 85 B Short circuit or poor connection between CD 85 A CN 53 3 or CD 85 C CN 51 13 Replace Replace or repair Replace or repair Replace or repair Check voltage between CN 53 23 GND YES YES NO SPEC Key ON 24佳2V Starting switch ON Check voltage betw...

Page 398: ...p pin steel or copper Insert prepared pin to rear side of connectors One pin to 23 of CN 53 Starting switch ON Check voltage as figure MCU CN 53 CN 53 Female 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 23 1 刮 刯 到 刱 2 SPEC Actuator operating 1 5 V 300L6MS26 ...

Page 399: ...poor connectionbetween CN 51 18 CS 29 Shortcircuitorpoor connectionbetween CN 88 2 FuseNo 26 Repairorreplace Repairorreplace Repairorreplace Repairorreplace 14 MALFUNCTION OF POWER MAX Fault code HCESPN 166 FMI 4 or 6 Before carrying out below procedure check all the related connectors are properly inserted INSPECTION PROCEDURE 侍 1 MCU CS 29 2 CN 52 18 CN 51 CN 88 5 CN 4 NO 26 2 1 6 2 1 POWER MAX ...

Page 400: ... of the solenoid valve between CN 88 1 2 Starting switch OFF Disconnect connector CN 88 from power max solenoid valve Check resistance as figure 2 刮 刯 到 LH RCV lever Power max switch Power max solenoid valve CN 88 Multimeter 1 2 1 2 220NL6MS14B LH RCV lever Power max switch Power max solenoid valve CN 88 Multimeter 1 2 1 2 GROUND SPEC Starting switch ON 24Ü1V Starting switch OFF 0V SPEC 15 35 220N...

Page 401: ...CN 52 34 CN 133 2 DefectiveEPPR valve Repairorreplace Repairorreplace 15 MALFUNCTION OF BOOM PRIORITY EPPR VALVE Fault code HCESPN 141 FMI 5 or 6 Before carrying out below procedure check all the related connectors are properly inserted INSPECTION PROCEDURE 侍 1 CN 133 1 2 BOOM PRIORITY EPPR VALVE 35 CN 52 34 MCU Cause Remedy YES NO 300L6MS23 余 ...

Page 402: ...OID FUSE CN 52 1 MCU 380L6MS05 余 SPEC Starting switch ON 24佳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 Remedy Defective MCU Short circuit or poor connection between CN 52 1 CN 135 1 Defective solenoid valve Open circuit between CN 135 2 Fuse No 26 Replace Replace or repair Replace Replace or repair Check voltag...

Page 403: ...in steel or copper Insert prepared pin to rear side of connectors One pin to 1 of CN 52 Starting switch ON Check voltage as figure MCU CN 51 CN 52 Female CN 52 1 2 3 4 5 6 7 8 9 10 31 32 33 34 36 37 38 39 40 11 21 20 30 Multimeter GROUND PIN 1 1 刮 刯 到 刱 2 SPEC Starting switch ON 24佳2 V 300L6MS22 ...

Page 404: ...SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test 7 1 Group 2 Major Components 7 20 Group 3 Track and Work Equipment 7 30 ...

Page 405: ...he machine s operational performance deteriorates so that the machine needs to be serviced periodically to restore it to its original performance level Before servicing the machine conduct performance tests to check the extent of deterioration and to decide what kind of service needs to be done by referring to the Service Limits in this manual OPERATIONAL PERFORMANCE OF A REPAIRED MACHINE After th...

Page 406: ...achine components and parts 1 SERVICE LIMIT The lowest acceptable performance level When the performance level of the machine falls below this level the machine must be removed from work and repaired Necessary parts and components must be replaced 2 21077MS02 21077MS03 ...

Page 407: ...tarted be sure to communicate with each other using these signals and to follow them without fail Operate the machine carefully and always give first priority to safety While testing always take care to avoid accidents due to landslides or contact with high voltage power lines Always confirm that there is sufficient space for full swings Avoid polluting the machine and the ground with leaking oil ...

Page 408: ...peed with a engine rpm display Measure and record the engine speed at each mode P S E Select the P mode Lightly operate the bucket control lever a few times then return the control lever to neutral The engine will automatically enter the auto idle speed after 4 seconds Measure and record the auto deceleration speed 2 1 侍 2 3 刮 刯 到 刱 刲 刮 刯 到 Evaluation The measured speeds should meet the following ...

Page 409: ...adjust the travel mode switch to the speed to be tested then select the following switch positions Power mode switch P mode Start traveling the machine in the acceleration zone with the travel levers at full stroke Measure the time required to travel 20 m After measuring the forward travel speed turn the upperstructure 180Á and measure the reverse travel speed Repeat steps Κ and Λ three times in e...

Page 410: ...he following switch positions Travel mode switch 1 or 2 speed Power mode switch P mode Auto idle switch OFF Operate the travel control lever of the raised track in full forward and reverse Rotate 1 turn then measure time taken for next 3 revolutions Raise the other side of machine and repeat the procedure Repeat steps 到 and 刱 three times and calculate the average values Evaluation Mark 90 110 4 1 ...

Page 411: ...ng each test select the following switch positions Power mode switch P mode Start traveling the machine in the acceleration zone with the travel levers at full stroke Measure the distance between a straight 20 m line and the track made by the machine Dimension a After measuring the tracking in forward travel turn the upperstructure 180Áand measure that in reverse travel Repeat steps 刱 and 刲 three ...

Page 412: ... as the boom foot pin The bucket must be empty Keep the hydraulic oil temperature at 50Ü5 C Measurement Select the following switch positions Power mode switch P mode Operate swing control lever fully Swing 1 turn and measure time taken to swing next 3 revolutions Repeat steps 刯 and 到 three time and calculate the average values Evaluation 6 1 2 刮 刯 到 刱 3 刮 余 刯 到 刱 Unit Seconds 3 revolutions The ti...

Page 413: ...e 360 Keep the hydraulic oil temperature at 50Ü5 C Measurement Conduct this test in the M mode Select the following switch positions Power mode switch P mode Operate the swing control lever fully and return it to the neutral position when the mark on the upperstructure aligns with that on track frame after swinging 360Á Measure the distance between the two marks Align the marks again swing 360Á th...

Page 414: ... Position 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 bottom face of the bucket to the same height of the boom foot pin Record the dial gauge reading h1 Lower the bucket to the ground and use it to raise the front idler 50 cm Record the dial gauge r...

Page 415: ...ime of the bucket cylinder The empty bucket should be positioned at midstroke between roll in and roll out so that the sideplate edges are vertical to the ground Keep the hydraulic oil temperature at 50Ü5 C Measurement Select the following switch positions Power mode switch P mode To measure cylinder cycle times Boom cylinders Measure the time it takes to raise the boom and the time it takes to lo...

Page 416: ... the other stroke 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 Function Standard Maximum allowable Remarks HX430 L Boom raise 4 0佳0 4 4 9 Boom lower 2 7佳0 4 3 8 Arm in 3 1佳0 4 3 8 Arm out 2 9佳0 3 3 2 Bucket load 2 7佳0 4 3 5 Bucket dump 2 4佳0 3 3 5 ...

Page 417: ...ully retracted position Position the bucket cylinder with the rod 20 to 30 mm retracted from the fully extended position With the arm rolled out and bucket rolled in hold the bucket so that the height of the bucket pin is the same as the boom foot pin Keep the hydraulic oil temperature at 50佳5 C Measurement Stop the engine Five minutes after the engine has been stopped measure the changes in the p...

Page 418: ...h Lower the bucket to the ground to raise one track off the ground Operate the travel lever at full stroke and measure the maximum operating force required When finished lower the track and then jack up the other track Repeat steps 到 and 刱 three times and calculate the average values Evaluation 11 1 2 刮 3 刮 刯 余 到 刱 刲 The measured operating force should be within the following specifications 4 Mode...

Page 419: ...urement Stop the engine Measure each lever stroke at the lever top from neutral to the stroke end using a ruler Repeat step 刯 three times and calculate the average values Evaluation 12 1 侍 2 3 刮 刯 到 The measured drift should be within the following specifications 4 Model Kind of lever Standard Maximum allowable Remarks HX430 L Boom lever 90Ü10 115 Arm lever 90Ü10 115 Bucket lever 90Ü10 115 Swing l...

Page 420: ... Power mode switch P mode Travel mode switch Measure the travel speed selecting pressure in the Hi or Lo mode Lower the bucket to the ground to raise the track off the ground Operate the travel lever at full stroke and measure the fast speed pressure Repeat steps 刯 and 到 three times and calculate the average values Evaluation FOR TRAVEL SPEED SELECTING PRESSURE 1 刮 刯 到 刱 刲 2 刮 余 余 刯 到 刱 The averag...

Page 421: ...ositions Power mode switch P mode Operate the swing function or arm roll in function and measure the swing brake control pressure with the brake disengaged Release the control lever to return to neutral and measure the control pressure when the brake is applied Repeat step 刯 three times and calculate the average values Evaluation 1 刮 刯 到 刱 刲 刳 2 刮 余 刯 The average measured pressure should be within...

Page 422: ...50佳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 15 1 2 刮 余 刯 刮 The average measured pressure should meet the following specifications Unit kgf cm2 3 330L7MS03 Model Engine speed Standard Allowable limits Remarks HX430 L High idle 40佳5 ...

Page 423: ...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 Evaluation 1 刮 2 刮 余 刯 到 刱 SYSTEM PRESSURE REGULATOR RELIEF SETTING 16 The average measured pressure should be within the following specifications 3 Unit kgf cm2 Power boost 330L7MS03 Model Function t...

Page 424: ...f cylinder spring 4 L Combined height of set plate 5 spherical bushing 6 H h Surface roughness for valve plate sliding face 7 8 swash plate shoe plate area 9 cylinder 2 sliding face 0 043 0 070 Replace piston or cylinder 0 0 1 0 3 5 4 5 0 47 9 47 1 23 8 22 8 Standard surface roughness corrected value Replace assembly of piston shoe Replace cylinder spring Replace retainer or set plate 3z 0 4z or l...

Page 425: ...plied with held pressure Seal pocket section where spool is inserted Sealing section of port where O ring contacts Sealing section of each relief valve for main and port Sealing section of plug Other damages that may damage normal function 余 Replacement when its outside sliding section has scratch especially on seals contacting section 余 Replacement when its sliding section has scratch 余 Correctio...

Page 426: ...sembly of piston and shoe Replace set of retainer plate and sperical bushing Replace Play between piston and shoe caulking section 儑 Thickness of shoe t Combined height of retainer plate and spherical bushing H h Thickness of friction plate h H SLIDING PARTS 2 t 儑 Part name Shoe Shoe plate Cylinder Valve plate Standard roughness 0 8 Z Ra 0 2 LAPPING 0 4 Z Ra 0 1 LAPPING 1 6 Z Ra 0 4 LAPPING 0 8 Z ...

Page 427: ... roughness by rough ness tester Measure the surface hardness of swash plate by hardness tes ter Measure outer dia of piston and bore of cylinder block at least 3 places in the longitudinal direction with microme ter and obtain max outer dia d max min outer dia d min max inner dia D max min inner dia D min With the jig hold down the shoe on work stand and pull up the piston vertical direction to me...

Page 428: ...he right value Check item Measuring method Judging criteria and remedy Shaft Bearings Splines Overload relief valve Measure the wear at contacting surface of oil seal 3 with the surface roughness tester Replace bearings 10 51 after decided hours Replace if the wear of splines exceeds the allowable value Do not try to adjust the valve since special hydraulic test bench is required for inspecting an...

Page 429: ...0 1 0 3 mm 0 5 mm Dimension check and replacement according to following standards Thrust ring 026 7 mm thick 6 6 mm Replacement if severe wear or seizure is found on sliding surface Thrust ring 027 8 mm thick 7 6 mm Floating seal Replacement of scratch or rust is found in sliding surface Replacement if O ring is deformed of damaged Gear oil SAE 85W 140 API GL 5 1st time 500hr 2nd time and later E...

Page 430: ... wears or so on When abnormal noises hunting primary pressure drop etc are generated during operation and these cannot be remedied referring to section 6 Troubleshooting replace the related parts Leakage Spool Push rod Play at operating section Operation stability Conditions Primary pressure 40 kgf cm2 Oil viscosity 23 cSt The leakage at the left condition is estimated to be nearly equal to the ab...

Page 431: ...n abnormal noises hunting primary pressure drop etc are generated during operation and these cannot be remedied referring to section 6 Troubleshooting replace the related parts Leakage Spool Push rod Play at operating section Operation stability Conditions Primary pressure 40 kgf cm2 Oil viscosity 23 cSt The leakage at the left condition is estimated to be nearly equal to the above leakage When a ...

Page 432: ...余Worn less than 0 5 mm 0 02 in 余 Damage due to seizure or contamination remediable within wear limit 0 5 mm 0 02 in 余Extruded excessively from seal groove square ring 余 Slipper ring 1 5 mm 0 059 in narrower than seal groove or narrower than back ring 余Worn more than 0 5 mm 0 02 in 1 5 mm MAX 0 059 in Sliding surface with sealing sections Sliding surface between body and stem other than sealing sec...

Page 433: ...ot present on plating 余Scratches are not present 余Replace or replate 余Replace or replate 余 Recondition replate or replace 余Rod 余Wear of O D 余Recondition replate or replace 余Bushing at mounting part 余Wear of I D 余Replace Cylinder tube 余Weld on bottom 余Presence of crack 余Replace 余Weld on head 余Presence of crack 余Replace 余Weld on hub 余Presence of crack 余Replace 余Tube interior 余Presence of faults 余Rep...

Page 434: ...uild or replace 250 2 Outside diameter of tread 210 198 3 Width of tread 54 6 60 6 4 Width of flange 34 4 5 Clearance between shaft and bushing Standard size tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 85 85 0 279 to 0 526 2 0 6 Side clearance of roller both side Standard clearance Clearance limit Replace 0 12 1 3 2 0 0 25 0 35 0 176 0 029 ...

Page 435: ...r of flange Standard size Repair limit Rebuild or replace 220 2 Outside diameter of tread 191 181 3 Width of tread 51 56 4 Width of flange 20 5 Clearance between shaft and support Standard size tolerance Standard clearance Clearance limit Replace Shaft Hole 57 15 57 15 0 1 to 0 4 1 2 0 0 1 0 3 0 1 ...

Page 436: ...rotrusion 102 4 Total width 203 5 Width of tread 50 5 57 5 6 Clearance between shaft and support Standard size tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 85 85 35 0 35 to 0 435 2 0 7 Clearance between shaft and support 85 85 0 036 to 0 125 1 2 Replace 8 Side clearance of idler Both side Standard clearance Clearance limit Replace 0 25 to 1 2 2 0 0 0 035 0 0 035 0 05 0 0...

Page 437: ...ia Remedy 1 Link pitch Standard size Repair limit Turn or replace 215 9 226 7 2 Outside diameter of bushing 71 60 4 Rebuild or replace 3 Height of grouser 36 21 4 Height of link 129 115 5 Tightening torque Initial tightening torque 105Ü5 kgfÂm Retighten ...

Page 438: ...e Tolerance Repair limit Rebuild or replace Track frame 123 2 1 137 Idler support 120 0 1 5 116 2 Horizontal width of idler guide Track frame 292 2 1 296 Idler support 290 287 3 Recoil spring Standard size Repair limit Replace Free length Installation length Installation load Free length Installation load 254Ý740 595 24500 kg 19600 kg ...

Page 439: ...8 5 120 5 121 Replacement B Boom Cylinder Head 100 99 98 5 100 5 101 C Boom Cylinder Rod 110 109 108 5 110 5 111 D Arm Cylinder Head 110 109 108 5 110 5 111 E Boom Front 110 109 108 5 110 5 111 F Arm Cylinder Rod 110 109 108 5 110 5 111 G Bucket Cylinder Head 90 89 88 5 90 5 91 H Arm Link 90 89 88 5 90 5 91 I Bucket and Arm Link 100 99 98 5 100 5 101 J Bucket Cylinder Rod 90 89 88 5 90 5 91 K Buck...

Page 440: ...ng Torque 8 4 Group 3 Pump Device 8 7 Group 4 Main Control Valve 8 31 Group 5 Swing Device 8 51 Group 6 Travel Device 8 71 Group 7 RCV Lever 8 101 Group 8 Turning Joint 8 115 Group 9 Boom Arm and Bucket Cylinder 8 120 Group 10 Undercarriage 8 137 Group 11 Work Equipment 8 149 ...

Page 441: ...event any mistake when installing Check the number and thickness of the shims and keep in a safe place When raising components be sure to use lifting equipment of ample strength When using forcing screws to remove any components tighten the forcing screws alternately Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal When rem...

Page 442: ...onnector to remove all oil dirt or water then connect securely When using eyebolts check that there is no deformation or deterioration and screw them in fully When tightening split flanges tighten uniformly in turn to prevent excessive tightening on one side When operating the hydraulic cylinders for the first time after repairing and reassembling the hydraulic cylinders pumps or other hydraulic e...

Page 443: ...een removed and installed again add engine oil to the specified level Run the engine to circulate the oil through the system Then check the oil level again If the piping or hydraulic equipment such as hydraulic cylinders pumps or motors have been removed for repair always bleed the air from the system after reassembling the parts Add the specified amount of grease molybdenum disulphied grease to t...

Page 444: ... bolt M20 Ý 2 5 57 9 Ü 5 8 419 Ü 42 11 Turning joint mounting bolt nut M12 Ý 1 75 12 3 Ü 1 2 89 0 Ü 8 7 12 Power train system Swing motor mounting bolt M24 Ý 3 0 97 8 Ü 15 707 Ü 108 13 Swing bearing upper part mounting bolt M24 Ý 3 0 100 Ü 10 723 Ü 72 3 14 Swing bearing lower part mounting bolt M24 Ý 3 0 100 Ü 10 723 Ü 72 3 15 Travel motor mounting bolt M20 Ý 2 5 57 9 Ü 8 7 419 Ü 62 9 16 Sprocket ...

Page 445: ...lowing table for unspecified torque Fine thread Fine thread BOLT AND NUT BOLT AND NUT Coarse thread Coarse thread 2 TORQUE CHART 2 TORQUE CHART 1 1 1 1 2 2 Bolt size 8 8T 10 9T 12 9T kgf m lbf ft kgf m lbf ft kgf m lbf ft M 6 1 0 0 8 1 2 5 8 8 6 1 2 1 8 8 7 13 0 1 5 2 1 10 9 15 1 M 8 1 25 2 0 3 0 14 5 21 6 2 8 4 2 20 3 30 4 3 4 5 0 24 6 36 1 M10 1 5 4 0 6 0 29 0 43 3 5 6 8 4 40 5 60 8 6 8 10 0 49 ...

Page 446: ... 3 4 36 18 130 2 1 41 21 151 9 1 1 4 50 35 253 2 Thread size UNF Width across flat mm kgf m lbf ft 9 16 18 19 4 28 9 11 16 16 22 5 36 2 13 16 16 27 9 5 68 7 1 3 16 12 36 18 130 2 1 7 16 12 41 21 151 9 1 11 16 12 50 35 253 2 Thread size Width across flat mm kgf m lbf ft 1 4 19 4 28 9 3 8 22 5 36 2 1 2 27 9 5 68 7 3 4 36 18 130 2 1 41 21 151 9 1 1 4 50 35 253 2 ...

Page 447: ...rom the hydraulic tank Hydraulic tank quantity 230ᎌ Remove socket bolts 5 and disconnect pipes 1 2 Disconnect pilot line hoses 6 7 8 9 10 11 12 13 Remove socket bolts 4 and disconnect pump suction tube 3 When pump suction tube is disconnected the oil inside the piping will flow out so catch it in oil pan Sling the pump assembly and remove the pump mounting bolts Weight 190 kg 420 lb Pull out the p...

Page 448: ... the hydraulic tank to the specified level Bleed the air from the hydraulic pump Remove the air vent plug 2EA Tighten plug lightly Start the engine run at low idling and check oil come out from plug Tighten plug Start the engine run at low idling 3 5 minutes to circulate the oil through the system Confirm the hydraulic oil level and check the hydraulic oil leak or not 2 1 2 3 4 5 6 刮 刯 到 刱 7 8 ...

Page 449: ... 710 O ring 717 O ring 719 O ring 724 Square ring 725 O ring 728 O ring 732 O ring 774 Oil seal 789 Back up ring 792 Back up ring 808 Hexagon head nut 824 Snap ring 885 Pin 886 Spring pin 901 Eye bolt 953 Set screw 954 Adjust screw 956 Set screw 271 Pump casing 311 Valve cove r F 312 Valve cover R 313 Valve plate R 314 Valve plate L 401 Hexagon socket bolt 402 Hexagon socket bolt 406 Hexagon socke...

Page 450: ...8 M10 BP 3 8 PO 3 8 M16 M18 17 M20 M22 BP 1 PO 1 1 1 4 1 1 2 Double ring spanner socket wrench double single open end spanner Hexagon head bolt Hexagon head bolt 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 size 1 set Screw driver Minus type screw driver Medium size 2 sets Hammer Plastic hammer 1 set Pliers For snap ring TSR 1...

Page 451: ... 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 侍 Wind a seal tape 1 1 2 to 2 turns round the plug PT1 16 0 7 5 1 0 16 4 PT 1 8 1 05 7 59 0 20 5 PT 1 4 1 75 12 7 0 24 6 PT 3 8 3 5 25 3 0 31 8 PT 1 2 5 0 36 2 0 39 10 PF plug material S45C PF 1 4 3 0 21 7 0 24 6 PF 1 2 10 0 72 3 0 39 10 PF 3 4 15 0 109 0 55 14 PF 1 19 0 137 0 67 17 PF 1 1 4 27 0 195 ...

Page 452: ...68 and let oil out of pump casing front and rear pump Loosen hexagon socket head bolts 401 which tighten swash plate support 251 pump casing 271 and valve cover F 311 If gear pump and so on are fitted to rear face of pump remove them before starting this work 3 1 侍 侍 2 3 5 侍 Remove hexagon socket head bolts 412 413 and remove regulator 4 36078MP02 Loosen hexagon socket head bolts 402 which tighten...

Page 453: ...cover can be removed easily Since oil seal is fitted on seal cover F take care not to damage it when removing cover 10 侍 侍 36078MP03 36078MP04 36078MP05 Separate valve cover F 311 from valve cover R 312 and pull out booster 130 spline coupling 114 8 Separate valve cover R 312 from pump casing and then pull out the cylinder block 012 of pump casing 271 straightly over drive shaft R 113 Pull out als...

Page 454: ...mp casing side separate swash plate support from pump casing 11 Remove shoe plate 211 and swash plate 212 from pump casing 271 12 36078MP06 36078MP07 Tapping lightly shaft ends of drive shafts 111 113 with plastic hammer take out drive shafts from swash plate supports 13 36078MP08 ...

Page 455: ...ing tilting pin use a protector to prevent pin head from being damaged Since loctite is applied to fitting areas of 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 valve cover and swash plate support If loosened flow setting will be changed 15 侍 侍 ...

Page 456: ... For fitting bolts plug etc prepare a torque wrench or so on and tighten them with torques shown in page 8 10 11 For the double pump take care not to mix up parts of the front pump with those of the rear pump 1 4 刮 刯 到 刱 刲 刳 Fit swash plate support 251 to pump casing 271 tapping the former lightly with a hammer After servo piston tilting pin stopper L and stopper S are removed fit them soon to pum...

Page 457: ... 157 Fit spline phases of retainer and cylinder Then insert piston cylinder subassembly into pump casing 271 Assemble seal cover F 261 to pump casing 271 and fix it with hexagon socket head bolts 406 Apply grease lightly to oil seal in seal cover F Assemble oil seal taking full care not to damage it For tandem type pump fit rear cover 263 and seal cover 262 similarly 6 5 侍 侍 侍 To swash plate suppo...

Page 458: ...stake direction of valve cover Fit valve cover with regulator up and with delivery flange left viewed from front side Take care not to mistake direction of booster 130 Refer to the sectional drawing 8 侍 侍 Fit valve plate 313 to valve cover F 311 and fit valve plate 314 to valve cover R 312 entering pin into pin hole Take care not to mistake suction delivery directions of valve plate 7 侍 Fit valve ...

Page 459: ...o feedback lever of regulator fit regulator and tighten hexagon socket head bolts 412 413 Take care not to mistake regulator of front pump for that of rear pump Fit drain port plug 468 This is the end of reassembling procedures 11 侍 36078MP17 12 ...

Page 460: ...B Pi 725 724 408 VIEW C 735 436 755 541 545 543 722 497 438 413 697 696 466 755 Hydraulic circuit FRONT 412 876 874 A B 755 858 614 615 613 611 B A 897 612 875 B A P2 Pf Pi1 Psv1 755 496 430F2RG01 Port Port name Port size Pi1 Pi2 Pilot port PF 1 4 15 Psv1 Psv2 Servo assist port PF 1 4 15 ...

Page 461: ...ing 626 Inner spring 627 Adjust stem C 628 Adjust screw C 629 Cover C 630 Lock nut 631 Sleeve pf 641 Pilot cover 643 Pilot piston 644 Spring seat Q 645 Adjust stem Q 646 Pilot spring 651 Sleeve 652 Spool 653 Spring seat 654 Return spring 655 Set spring 696 Port cover 697 Check valve plate 699 Valve casing 708 O ring 722 O ring 724 Square ring 725 O ring 728 O ring 730 O ring 732 O ring 733 O ring ...

Page 462: ...4 M 5 BP 1 16 M 8 5 M 6 BP1 8 M10 6 M 8 BP 1 4 PO 1 4 M12 M14 Double ring spanner socket wrench double single open end spanner Hexagon head bolt Hexagon head nut VP plug PF thread 6 M8 M8 Adjustable angle wrench Small size Max 36 mm Screw driver Minus type screw driver Medium size 2 sets Hammer Plastic hammer 1 set Pliers For snap ring TSR 160 Steel bar 4 100 mm Torque wrench Capable of tightening...

Page 463: ... 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 ö Wind a seal tape 1 1 2 to 2 turns round the plug PT1 16 0 7 5 1 0 16 4 PT 1 8 1 05 7 59 0 20 5 PT 1 4 1 75 12 7 0 24 6 PT 3 8 3 5 25 3 0 31 8 PT 1 2 5 0 36 2 0 39 10 PF plug material S35C PF 1 4 3 0 21 7 0 24 6 PF 1 2 10 0 72 3 0 39 10 PF 3 4 15 0 109 0 55 14 PF 1 19 0 137 0 67 17 PF 1 1 4 27 0 195 ...

Page 464: ...lean place Spread rubber sheet cloth or so on on top of work bench to prevent parts from being damaged Remove dust rust etc from surfaces of regulator with clean oil 3 Remove hexagon socket head screw 438 and remove cover C 629 Cover C is fitted with adjusting screw C QI 628 adjusting stem C 627 lock nut 630 hexagon nut 801 and set screw 924 Do not loosen these screws and nuts If they are loosened...

Page 465: ... and take out fulcrum plug 614 and adjusting plug 615 Fulcrum plug 614 and adjusting plug 615 can easily be taken out with M6 bolt 8 侍 Remove snap ring 814 and take out spring seat 653 return spring 654 and sleeve 651 Sleeve 651 is fitted with snap ring 836 When removing snap ring 814 return spring 654 may pop out Take care not to lose it 7 侍 侍 Remove hexagon socket head screws 436 438 and remove ...

Page 466: ...611 Push out pin 874 4 mm in dia from above with slender steel bar so that it may not interfere with lever1 612 10 侍 Remove lever2 613 Do not draw out pin 875 Work will be promoted by using pincers or so on 9 侍 36078RE07 36078RE08 36078RE09 36078RE10 ...

Page 467: ...t pilot piston 643 and spool 652 D r a w o u t p i s t o n c a s e 6 2 2 compensating piston 621 and compensating rod 623 Piston case 622 can be taken out by pushing compensating rod 623 at opposite side of piston case This completes disassembly 11 12 13 侍 ...

Page 468: ...lugs 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 Fit spool 652 and sleeve 651 into hole in spool of casing Confirm that spool and sleeve slide smoothly in casing without binding Pay attention to orientation of spool Spool Feedback lever 1 4 侍 侍 Put compensating rod 623 into compens...

Page 469: ...614 so that pin force fitted in fulcrum plug 614 can be put into pin hole of lever 2 Then fix locking ring 858 Insert adjusting plug 615 and fit locking ring Take care not to mistake inserting holes for 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 侍 Put pilot piston 643 into pilot hole of casing Confirm ...

Page 470: ... spring 646 and adjusting stem Q 645 into pilot hole Then fix spring seat 624 inner spring 626 and outer spring 625 into compensating hole When fitting spring seat take care not to mistake direction of spring seat 12 侍 Fit set spring 655 to spool hole and put compensating piston 621 and piston case 622 into compensating hole Fit pilot cover 641 and tighten it with hexagonal socket head screws 436 ...

Page 471: ...l valve assembly and remove the control valve mounting bolts ÂWeight 340 kg 750 lb Remove the control valve assembly When removing the control valve assembly check that all the piping have been disconnected INSTALL Carry out installation in the reverse order to removal Bleed the air from below items Cylinder Boom arm bucket Swing motor Travel motor See each item removal and install Confirm the hyd...

Page 472: ... 168 O ring 201 Spring cover 203 Spring cover 205 Cover sub Bm Priority 251 Plug 252 Lock valve assy 263 O ring 264 O ring 265 O ring 273 Screw 274 Socket bolt 326 Spring 561 O ring 603 Port relief assy 611 Negative relief valve assy 652 Plug 663 O ring 664 O ring 665 Back up ring 751 Flange 761 O ring 762 Screw 972 Screw 973 Screw 974 Screw 991 Name plate 992 Pin 327 Spring 332 Spring seat 335 Sh...

Page 473: ...02 155 Plug 165 O ring 201 Spring cover 202 Spring cover 262 O ring 263 O ring 273 Hex screw 301 Travel spool kit 302 Arm spool kit 522 Spring 554 Stopper plug 557 Plug 603 Port relief assy 652 Plug 663 O ring 664 O ring 665 Back up ring 305 Swing spool kit 308 Option spool kit 332 Spring seat 335 Shim 336 Spacer bolt 372 Spring 393 Boom spool kit 395 Swing priority spool kit 511 Poppet ...

Page 474: ...B 151 Plug 155 Plug 158 Plug 159 Plug 161 O ring 162 O ring 163 O ring 165 O ring 168 O ring 201 Spring cover 203 Spring cover 204 Cover 206 Spring cover 212 O ring 252 Lock valve 263 O ring 264 O ring 267 O ring 273 Screw 274 Socket bolt 275 Screw 332 Spring seat 335 Shim 336 Spacer bolt 351 Orifice 352 Orifice 356 Piston 551 Plug 552 Plug 553 Plug 557 Plug 558 Plug 561 O ring 562 O ring 563 O ri...

Page 475: ...O ring 202 Spring cover 208 Spool cover 211 Plug 212 O ring 251 Plug 262 O ring 263 O ring 265 O ring 394 Am Confluence spool kit 551 Plug 561 O ring 603 Port relief assy 611 Negative relief valve assy 754 Flange 763 O ring 764 Socket screw 273 Hex screw 301 Travel spool kit 303 Boom spool kit 304 Bucket spool kit 313 Plug 326 Spring 327 Spring 337 Rod 391 Travel straight spool kit 392 By pass cut...

Page 476: ...section carefully in carrying transferring and so on of the control valve Do not support the lever exposed spool end cover section or so on without fail After disassembling and assembling of the component it is desired to carry out various tests for the relief characteristics leakage flow resistance etc but the hydraulic test equipment is necessary to these tests Therefore even when its disassembl...

Page 477: ...01 206 ÂHexagon key wrench 8 mm In removing bucket spring cover 206 at first remove plug 558 and piston 356 ÂHexagon key wrench 17 mm Remove spool spring spring seats shim and spacer bolt in spool assembly condition from casing When pulling out spool assembly from casing pay attention not to damage casing 2 Hold spool in mouthpiece attached vise Remove spacer bolt 336 and disassemble spring shim a...

Page 478: ... Do not disassemble arm 1 spool 302 more than these conditions 3 3607A8MC08 3607A8MC09 Η Θ ö Ι Κ Disassembling of travel straight spool Loosen hexagon socket head bolts 273 remove spring cover and pull out travel straight spool 391 spring 373 spring seat 332 and spacer bolt 336 in spool assembly condition from casing ÂHexagon key wrench 8 mm When pulling out spool assembly from casing pay attentio...

Page 479: ...n not to damage casing Hold boom 1 spool 303 in mouthpiece attached vise remove spacer bolt 336 and disassemble spring 371 and spring seats 332 ÂHexagon key wrench 12 mm Remove plug 313 ÂSpanner 27 mm Do not disassemble boom1 spool 303 more than these conditions 5 3607A8MC10 3607A8MC11 刮 侍 刯 到 Disassembly of covers Remove hexagon socket head bolts 273 and remove spool cover 202 and 208 ÂHexagon ke...

Page 480: ...Spanner 32 mm ÂPort relief valve Box wrench 36 mm Spanner 36mm 7 3607A8MC13 刮 Removal of lock valve assembly Loosen hexagon socket head bolts and remove lock valve assembly 252 ÂHexagon key wrench 5 mm 8 3607A8MC14 刮 Removal of bypass cut spool Remove plug 251 spring 326 327 rod 337 and bypass cut spool 392 ÂBox wrench 27 mm 9 3607A8MC15 刮 3607A8MC16 ...

Page 481: ...8 41 Disassembly of negative control relief valve Remove plug 551 ÂHexagon key wrench 17 mm 10 3607A8MC17 刮 3607A8MC18 Remove poppet 611 spring 621 and damping rod 631 刯 ...

Page 482: ...d check cover 203 and take out poppet 551 and spring 522 ÂHexagon key wrench 8 mm Remove plug 553 and take out poppet 513 and spring 522 ÂHexagon key wrench 17 mm Remove plug 552 and take out poppet 512 and spring 523 ÂHexagon key wrench 12 mm Remove plug sub 557 and take out poppet 511 and spring 522 ÂBox wrench 32 mm 刮 刯 到 刱 刲 11 3607A8MC19 3607A8MC20 3607A8MC21 ...

Page 483: ...ÂBox wrench 24 mm Poppet sub 515 Remove assy of poppet 101 102 plug 103 and spring 104 from bush 106 Remove spring 105 and spool 107 Do not disassemble ass y in above Κmore than these conditions 刮 刯 到 刱 刲 刳 12 3607A8MC22 3607A8MC23 3607A8MC24 Disassembly of casing Except when required specially do not disassemble tie bolts of casing A Since plugs not described in above disassembling procedures are...

Page 484: ...deformed replace it with new one When relief valve do not function properly repair it following its disassembling assembling procedures Replace all seats and O rings with new ones 14 刮 a b c 侍 d e f g Relief valve Confirm that all seat faces at ends of all poppets and seats are free of defects and are uniform contact faces Confirm manually that main poppet and seat can slide lightly and smoothly C...

Page 485: ... bolts at all sections with torque wrench to their respective tightening torques shown in Maintenance Standards 4 1 2 3 刮 刯 到 刱 刲 Poppet Spring Plug or cover 511 522 203 204 551 557 512 523 552 513 522 553 514 525 204 Assembly of check valve Assemble poppets 511 513 512 and springs 522 523 Put O rings 561 onto plugs 551 553 Put O rings 563 onto plugs 552 Put O rings 264 on cover 203 Tighten the la...

Page 486: ...et 101 102 plug 103 and spring 104 into bushing 106 Assemble bushing sub in above Θ into cover 205 and assemble them into casing and tighten hexagon socket head bolts 276 277 ÂHexagon key wrench 8 mm ÂTightening torque 5 3 6 3 kgfÂm 38 3 45 6 lbfÂft Assemble piston 356 in cover 205 and tighten plug 559 ÂBox wrench 24 mm ÂTightening torque 20 4 25 5 kgfÂm 147 5 184 4 lbfÂft 5 刮 108 107 106 105 103 ...

Page 487: ...Tightening torque 7 95 10 0 kgfÂm 57 5 72 3 lbfÂft 327 251 326 265 337 392 265 337 327 326 392 251 102 101 38098MC05A 7 刮 Assembling of lock valve assembly Fit O ring 163 to lock valve assembly 252 and tighten hexagon socket head bolts with specified torque ÂHexagon key wrench 5 mm ÂTightening torque 1 0 1 42 kgfÂm 7 2 10 2 lbfÂft 163 252 38098MC15A 8 刮 Assembling of main relief valve and port rel...

Page 488: ...8MC21 10 刮 侍 刯 侍 Assembling of boom 1 spool Hold the middle of boom 1 spool 303 in mouthpiece attached vise set spring seat 332 and spring 371 and tighten spacer bolt 336 with specified torque and tighten plug 313 with specified torque Before tightening spacer bolt 336 and plug 313 apply Loctite 262 to them ÂSpacer bolt 336 Hexagon key wrench 12 mm ÂTightening Torque 3 77 4 18 kgfÂm 27 2 30 2 lbfÂ...

Page 489: ...71 332 336 302 38098MC24 12 刮 侍 刯 侍 Assembling of main spool travel 301 bucket 304 swing 305 option 308 arm 2 394 boom 2 393 swing priority 395 Hold end of each spool in mouthpiece attached vise set spring seats springs shim 335 for arm 2 boom 2 and swing priority spool and tighten spacer bolt 336 with specified torque Before tightening spacer bolt 336 apply Loctite 262 to it ÂHexagon key wrench 1...

Page 490: ...ing covers 201 206 to spring sides of spools and tighten hexagon socket head bolts 273 with specified torque Confirm that O rings 263 have been fitted ÂHexagon key wrench 8 mm ÂTightening torque 5 3 6 3 kgfÂm 38 3 45 5 lbfÂft 263 201 273 206 263 BUCKET 3809A8MC07 到 侍 Bucket spring cover Assemble piston 356 to bucket spring cover 206 Put O ring 561 onto plug 558 and tighten the latter with specifie...

Page 491: ...1 and remove the swing motor mounting bolts 10 Motor device weight 75 kg 165 lb Tightening torque 97 8 15 kgf m 707 108 lbf ft Remove the swing motor assembly When removing the swing motor assembly check that all the piping have been disconnected INSTALL Carry out installation in the reverse order to removal Bleed the air from the swing motor Remove the air vent plug Pour in hydraulic oil until it...

Page 492: ...ctionless valve assy 35 Plug 36 O ring 37 Back up ring 38 O ring 39 O ring 40 Bushing 1 Body 2 Oil seal 3 Roller bearing 4 Snap ring 5 Shaft 6 Pin 7 Stop ring 8 Shoe plate 9 Cylinder block 10 Spring 11 Ball guide seat 12 Ball guide 13 Set plate 14 Piston assy 15 Friction plate 16 Plate 17 Brake piston 18 O ring 19 Spring 20 Valve plate 21 Pin 22 Needle bearing 23 Rear cover 24 Wrench bolt 25 Wrenc...

Page 493: ...g plier for holes axis Snap ring 4 Solder hammer Needle bearing 22 pin 6 21 Oil seal inserting jig Oil seal 2 Induction heating apparatus for bearing Roller bearing 3 B Part name Item Size Torque Wrench size kgfÂm lbfÂft in mm Wrench bolt 24 M14 20 9 151 2 0 47 12 Wrench bolt 25 M14 20 9 151 2 0 47 12 Relief valve 30 M33 18 0 130 2 1 42 36 Wrench bolt 32 PF 1 4 6 9 49 9 0 20 5 Plug 33 PF 1 4 20 9 ...

Page 494: ...valve assy 31 from rear cover 23 2 1 刮 3607A8SM01 01A Hang rear cover 23 on hoist unloose wrench bolt 24 25 and disassemble from body 1 刯 3607A8SM02 Using a jig disassemble break piston 17 from body 1 到 3607A8SM03 Disassemble respectively cylinder block assy fricktion plate 15 plate 16 from body 1 刱 3607A8SM04 ...

Page 495: ...et plate 13 from cylinder block assy 2 刮 Disassemble ball guide 12 friction plate 15 plate 16 and ball guide seat 11 from cylinder block 9 刯 3607A8SM08A 08B Disassemble shoe plate 8 from body 1 刲 3607A8SM05 Using a plier jig disassemble snap ring 4 and shaft assy 5 刳 3607A8SM06 06A ...

Page 496: ...ve plate 20 from rear cover 23 3 刮 Using a torque wrench disassemble relief valve assy 30 2 set from rear cover 23 刯 3607A8SM11 11A Disassemble make up check valve assy with a torque wrench from rear cover 23 到 3607A8SM12 12A Disassemble spring 10 from cylinder block 9 到 3607A8SM09 ...

Page 497: ...es ÂRoller bearing Ý1EA 4 1 刮 3607A8SM21 After assembling and compressing pre heated roller bearing 3 stop ring 7 into shaft 5 ÂStop ring Ý1EA ÂShaftÝ 1EA 刯 3607A8SM22 22A Using a compressing tool and steel stick assemble oil seal 2 into body 1 ÂOil seal Ý1EA 到 3607A8SM23 23A Insert above shaft sub into body 1 and assemble it with a hammer 刱 3607A8SM24 ...

Page 498: ...ase on shoe plate 8 and assemble on the body ÂShoe plate Ý1EA 刳 3607A8SM05 3607A8SM25 Assemble the sub of cylinder block assy Assemble spring 10 9 set into cylinder block 9 ÂSpring Ý9EA 2 刮 Assemble ball guide 12 and ball guide seat 11 into cylinder block 9 ÂBall guide Ý1EA 刯 3607A8SM26 ...

Page 499: ...assy Ý9EA ÂSet plate Ý1EA 到 3607A8SM27 Assemble above item Θ and Ι 刱 3607A8SM28 Assemble cylinder block assy into body 1 刲 3607A8SM04 Assemble 4 set of lining plate 16 fric tion plate 15 respectively into body ÂLining plate Ý4EA ÂFriction plate Ý4EA 刳 3607A8SM29 ...

Page 500: ...Ý19EA 刵 3607A8SM31 31A 3607A8SM32 32A Assemble the sub of rear cover assy sub After assembling needle bearing 22 into rear cover 23 with a hammer assemble pin 6 21 3 刮 Assemble respectively make up check valve assy spring 27 poppet 26 plug 28 into rear cover 23 after then screw it torque wrench ÂMake up check sub Ý2set ÂSpring Ý2EA ÂCheck Ý3EA 刯 3607A8SM33 12A ...

Page 501: ...SM10 10A Assemble relief valve assy 30 2set into rear cover 23 with a torque wrench 3607A8SM34 11A 到 刱 Lift up rear cover assy on body 1 by a crane and assemble it with a wrench bolt 24 25 刲 3607A8SM02 Assemble time delay valve assy 31 into rear cover 23 with a wrench bolt 32 刳 3607A8SM01 01A ...

Page 502: ...ter press air into assembled motor 4 Leakage check After cleaning motor by color check No 1 paint No 3 and be sure of leakage 5 Mount test bench Mounting motor test bench test the avail ability of each part 6 14078SM232 14078SM233 233A 220078SM14 ...

Page 503: ...Pin 2 12 Bushing 2 13 Spring pin 14 Thrust washer 15 Spring pin 16 Carrier 1 33 Pinion gear 34 Lock plate 35 Hexagon bolt 36 Lock washer 37 Plug 38 Plug 39 Socket bolt 40 Cover 41 O ring 42 Hexagon socket bolt 43 Plug 45 Air breather assy 46 Gauge pipe 47 Gauge bar 17 Carrier 1 18 Planetary gear 1 19 Pin 1 20 Needle cage 21 Side plate 1 22 Side plate 2 23 Stop ring 24 Spring pin 25 Thrust ring 26 ...

Page 504: ... pin assy 2 11 by hammering Do not reuse spring pin after removal Removal of sun gear 2 Remove sun gear 2 26 install eye bolt to tap M10 of carrier 2 8 and remove carrier 2 assembly itself Removal of sun gear 1 and thrust ring assembly Remove carrier 1 16 install eye bolt to tap hole M10 and remove carrier 1 assembly itself 2 1 侍 2 3 4 刮 侍 3607A8SR03 3607A8SR04 3607A8SR05 ...

Page 505: ...s assembly Do not reuse oil seal after removal Removal of drive shaft 2 assembly Spread off the corners of spacer 32 cover plate 30 and hex bolt 31 with a tool Removal of ring gear Remove ring gear 28 from casing 1 Fluid packing is applied on contacting face of ring gear and gear casing Therefore remove ring gear from casing by minus screw driver 5 刯 侍 6 刮 刯 侍 3607A8SR06 3607A8SR07 3607A8SR08 3607...

Page 506: ... Insert motor side of shaft 2 into steel tube inner dia 145 mm and push the end of output shaft side with hydraulic press and then remove roller bearing 3 and spacer ring 4 as assembly from drive shaft 2 Remove oil seal 5 from gear casing 1 到 刱 7 3607A8SR10 3607A8SR11 3607A8SR12 ...

Page 507: ...oil seal with grease 刮 2 3 3607A8SR14 Put drive shaft of gear casing 1 upward Assemble drive shaft assembly to gear casing by tightening eye bolt into tap hole M16 of output side of drive shaft 2 Place support approx 150 mm below of gear case 1 for seal protector contact with work table 刯 侍 3607A8SR15 ASSEMBLY Assembly of drive shaft assembly After assembly drive shaft 2 heat roller bearing 3 up t...

Page 508: ...oller bearing Put gear casing under output shaft and heat roller bearing 6 up to 50 C plus surrounding temperature and then assemble it to the shaft 刮 4 5 3607A8SR16 3607A8SR17 Assemble ring gear 28 刯 36078SR18 Assembly of carrier 2 assembly Assemble planetary gear 2 9 to carrier 2 8 with thrust washer 14 and insert pin assy 2 11 Lubricate gear oil to inside of gear and outside of shaft 刮 侍 6 3607...

Page 509: ...ged Insert spring pin 15 by hammering Insert as the clearance between spring pins toward planetary gear 2 9 刯 侍 刮 7 3607A8SR20 3607A8SR21 Insert sun gear 2 26 to planetary gear 2 9 刯 3607A8SR22 Assembly of sun gear 1 carrier 1 assembly Mount eye bolt into tap hole M10 of lift carrier assembly and then insert carrier assembly being engaged with internal teeth of ring gear 28 Rotate holder assembly ...

Page 510: ... gear casing with hands 刯 9 3607A8SR24 Assembly of cover Remove oil from mating faces between ring gear 28 and cover 40 and apply fluid packing Assemble cover 40 and tighten socket bolt 39 with 16mm hexagonal socket Tightening torque 28 5Ü3 0 kgfÂm 206Ü21 7lbfÂft This completes assembly 10 36078SR27 G ...

Page 511: ...ee removal of track shoe assembly Remove the cover Remove the hoses Fit blind plugs to the disconnected hoses Remove the bolts and the sprocket Sling travel device assembly 1 Remove the mounting bolts 2 then remove the travel device assembly ÂWeight 620 kg 1370 lb INSTALL Carry out installation in the reverse order to removal Bleed the air from the travel motor Remove the air vent plug Pour in hyd...

Page 512: ... 22 Separated plate 23 Parking piston 24 D ring 25 D ring 26 Valve plate 27 Parallel pin 28 Spring 29 O ring 30 Spring pin 31 Parallel pin 32 Rear cover 33 Main spool assy 34 Spring seat 35 Plug 36 Spring 37 O ring 38 Restrictor 39 Spring 40 O ring 41 O ring 42 O ring 43 O ring 44 O ring 45 Relief valve assy 46 Spool 47 Plug 48 Spring seat 49 Parallel pin 50 Spring 51 Connector 52 O ring 53 Hexago...

Page 513: ...5 Snap ring 11 Solder hammer Needle bearing 10 Pin 27 Spring pin 30 Torque wrench Size 500 700 5000 Jig for assembling oil seal Oil seal 4 Part name Item Size Torque kgf m lbf ft Plug 2 NPTF 1 16 1 1Ü0 1 8 0Ü0 72 Plug 3 PT 1 8 1 3Ü1 0 9 4Ü7 2 Plug 35 M45Ý1 5 45Ü4 5 325Ü32 5 Plug 40 PF 1 8 3 0Ü0 3 21 7Ü2 17 Relief valve assy 45 26Ü2 6 188Ü18 8 Plug 47 PF 3 8 5 5Ü0 5 39 8Ü3 6 Connector 51 5 5Ü0 5 39...

Page 514: ... handled with great care When motor is removed from the host machine wash around the ports sufficiently and put the plugs so that no dust and or water may invade Take off these plugs just before the piping works when re attach it to the host machine Bofore disassembling review the sectional drawing and prepare the required parts depending on the purpose and the range of disassembling Seals O rings...

Page 515: ...ing 36 spring seat 34 main spool assy 35 in regular sequence 2 Disassemble wrench bolt 53 10EA using torque wrench 3 Take out rear cover 34 from casing 1 4 43098TM06 43098TM07 43098TM08 Disassemble relief valve assy 45 from rear cover 32 using spanner or torque wrench 1 43098TM03 43098TM02 43098TM04 43098TM05 ...

Page 516: ...e 22 7EA and friction plate 21 6EA 6 Remove cylinder block kit It is easier to work by placing the casing 1 horizontal 7 Disassemble parking piston 23 using jig 5 43098TM10 43098TM12 43098TM14 43098TM15 43098TM09 43098TM11 43098TM13 ...

Page 517: ...7 from cylinder block kit 8 43098TM16 43098TM19 43098TM17 43098TM20 43098TM18 Disassemble swash plate 15 from shaft casing 1 9 43098TM22 43098TM21 Disassemble steel ball 13 and swash piston 6 Hole in the casing 1 of two speed line is decomposed by injecting oil 10 侍 43098TM25 43098TM23 43098TM24 ...

Page 518: ...5 using pliers 11 In the casing 1 the arrow part of the shaft 8 using a rubber mallet taps and then disassemble the shaft 8 and bearing roller 9 to the other side 12 Disassemble valve plate 28 from rear cover 32 13 43098TM28 43098TM26 43098TM27 43098TM29 43098TM30 14 ...

Page 519: ...43098TM32 43098TM33 Disassemble plug 40 from rear cover 32 and then disassemble spring 39 restictor 38 from rear cover 34 in regular sequence 16 43098TM34 43098TM35 Disassemble plug 40 from rear cover 34 and then disassemble spring 55 check valve 54 from rear cover 32 in regular sequence Disassemble plug 56 from rear cover 32 17 43098TM36 43098TM37 43098TM38 18 ...

Page 520: ... Insert restrictor 38 spring 39 into rear cover 32 and then assemble plug 40 using torque wrench ÂTightening torque 3 0Ü0 3 kgfÂm 21 7Ü2 17 lbfÂft Apply loctitle 242 on the 14 plug 2 and then assemble them into rear cover 32 1 2 3 43098TM40 43098TM42 43098TM44 43098TM39 43098TM41 43098TM43 Assemble 2 plug 42 56 using torque wrench ÂTightening torque 4 5Ü0 5 kgfÂm 32 5Ü3 62 lbfÂft 4 43098TM45 ...

Page 521: ...ng seat 48 and spring 50 in regular sequence and then assemble plug 47 connector 51 using torque wrench ÂTightening torque 5 5Ü0 5 kgfÂm 39 8Ü3 62 lbfÂft 43098TM46 43098TM51 43098TM47 43098TM52 43098TM48 43098TM53 8 5 Press needle bearing 10 into rear cover 32 using jig 6 Assemble spring pin 30 parallel pin 27 using small hammer 7 43098TM49 43098TM50 ...

Page 522: ...e to the O ring 29 and then assemble it into rear cover 34 10 43098TM55 Assemble the heated roller bearing 9 onto the shaft 8 and then assemble snap ring 6 into shaft 8 The temperature of the roller bearing 100 C Using tool Heater Be careful not to damage the sliding surface for the oil seal on the shaft 11 43098TM57 43098TM58 43098TM59 43098TM56 刮 侍 侍 ...

Page 523: ... arrow into casing 1 using a rubber mallet 15 Assemble oil seal 3 into casing 1 with assembling jig Assemble plug 2 3 into casing 1 14 13 43098TM67 43098TM60 43098TM64 43098TM61 43098TM62 Install casing 1 into assembling jig 12 43098TM63 43098TM65 43098TM66 ...

Page 524: ...emble it into casing 1 Apply the grease to steel ball 15 and then assemble steel ball 15 into casing 1 Apply the grease to swash plate 15 and then assemble swash plate 15 into casing 1 17 18 19 43098TM71 43098TM73 43098TM72 43098TM74 43098TM70 43098TM69 43098TM68 Apply the grease to pivot 14 2EA and then assemble pivot 14 into casing 1 16 ...

Page 525: ... block 16 in regular sequence 43098TM75 43098TM78 43098TM76 43098TM79 43098TM77 20 Assemble cylinder block kit into casing 1 21 43098TM80 Assemble separated plate 21 friction plate 22 into cylinder block in regular sequence Friction plate 6EA Separated plate 7EA 22 43098TM81 43098TM82 ...

Page 526: ...n 31 into casing 1 Apply the grease to D ring 24 25 and then assemble them into parking piston 23 23 24 43098TM83 43098TM84 Assemble parking piston into casing using jig 25 43098TM85 Assemble parking spring 28 14EA 26 43098TM86 ...

Page 527: ...le rear cover 32 into casing 1 and then tighten the wrench bolt 53 using torque wrench ÂTightening torque 33Ü3 3 kgfÂm 239Ü23 9 lbfÂft 28 Assemble spring 37 plug 36 into rear cover 34 in regular sequence and then plug 36 into rear cover 34 using torque wrench ÂTightening torque 45Ü4 5 kgfÂm 325Ü32 5 lbfÂft 30 43098TM87 43098TM90 43098TM93 43098TM92 43098TM89 43098TM94 ...

Page 528: ...8 88 Assemble relief valve assy 45 using torque wrench ÂTightening torque 26Ü2 6 kgfÂm 188Ü18 8 lbfÂft 31 43098TM95 ...

Page 529: ...8 Housing 9 Hexagon socket head bolt 10 Coupling 11 Carrier 2 12 Planetary gear 2 13 Needle bearing 2 14 Thrust washer 2 15 Carrier pin 2 16 Spring pin 2 17 Solid pin 2 18 Sun gear 2 19 Carrier 1 20 Planetary gear 1 21 Needle bearing 1 22 Thrust washer 1 23 Carrier pin 1 24 Spring pin 1 25 Sun gear 1 26 Thrust plate 27 Thrust plate 28 Cover 29 Cover seal 30 Hexagon socket head bolt 31 Hexagon sock...

Page 530: ... 53Ü5 0 383Ü36 2 32 Plug PF 3 4 10Ü1 0 72 3Ü7 2 TOOL AND TIGHTENING TORQUE 2 Tool name B size Name of part applied Hexagonal L wrench 10 Hex socket head bolt 30 12 Hex socket head bolt 9 14 Plug 32 20 Hex socket head bolt 31 Socket wrench Spanner 12 Hex socket head bolt 6 Hammer Needle bearing 13 21 Pin 15 16 17 23 24 Torque wrench Capable of tightening with the specified torques Jig for assemblin...

Page 531: ...ul when handling Therefore disassembling and assembling works should be performed on the clean place where dusts hardly gather Tools and kerosene to wash parts should also be clean and handled with great care Bofore disassembling review the sectional drawing and prepare the required parts depending on the purpose and the range of disassembling Seals O rings etc if once disassembled are not reusabl...

Page 532: ...and cover and tap the tool tenderly 2 3 Ready for disassembling Reduction gear removed from machine usually covered with dirt so clean it with cleaning liquid and dry it Put reduction gear on stable place with drain port down side and remove oil plug PF3 4 to pull out gear oil through drain port When the oil is hot there are high chance to blow out hot oil because of the pressure difference betwee...

Page 533: ...ertical against ground with No 1 sun gear Set eye bolt M10 in No 2 carrier assy pull up slowly 43098TR05 43098TR07 刯 侍 刯 Removing carrier sub No 2 Remove No 2 sun gear slowly When disassemble No 2 sun gear be sure to keep vertical against ground with No 2 sun gear Remove coupling Remove coupling on motor spline 5 6 刮 侍 刮 ...

Page 534: ...head bolt M12Ý20 using torque wrench which is connecting ring and lock plate Remove lock plate from motor casing spline Remove nut ring using designed tools Put disassembled ring gear and housing on work table Be sure to set floating seal upper side and remove floating seal Do not re use floating seal Remove hex socket head bolt M20Ý120 connecting housing and ring gear using torque wrench Put shar...

Page 535: ... pin hole using specially designed tool 10 11 43098TR16 Disassemble No 2 carrier assy Cut solid pin by pressing No 2 pin using press machine Be aware of scattering of components when operator use press machine Disassemble No 2 planetary gear thrust washer No 2 pin needle bearing from No 2 carrier Do not re use No 2 pin 12 刮 刯 侍 刮 侍 刮 Disassemble No 1 planetary gear thrust washer No 1 pin needle be...

Page 536: ...e surface of every gear Whether there is pitting or crack on them Rolling the bearing and check the rolling condition and the noise Check the surface of floating seal and crack of O ring 1 3 刮 刯 到 刱 刲 Carrier No 1 assembly 2 Set No 1 carrier on stable and even place Put No 1 needle bearing in No 1 planetary gear and place No 1 thrust washer 2 pcs on both side of gear Assemble gear in carrier Align...

Page 537: ...ngly After assembly solid pin put spring pin with force Caulking both sides of pressed spring pin 180 using caulking jig 3 刮 刯 到 刱 刲 43098TR21 Assembling floating seal Wipe O ring side of floating seal and contact surface of floating seal of motor casing with oil applied lint free towel and press fitting floating seal into motor casing with special jig Keep the floating seal vertical against groun...

Page 538: ...ing side of floting seal and contact surface of floating seal of seal cover with oil applied lint free towel and press fitting floating seal into seal cover Motor assembled housing components assembly Set eye bolt M20 in housing flange tap hole Assemble assembled housing components on motor using hoist Be sure set eye bolt firmly to keep operator safe Seal cover Apply three bond 1194 on contact su...

Page 539: ...ble them Tighten hex head bolt M12Ý20 with designed torque 8 8Ü0 9 kgf m 63 7Ü6 5 lbf ft 9 刮 刯 到 Coupling Assembly coupling with motor s spline No 2 carrier sub Set eye bolt M10 in No 2 carrier assy lift them using hoist and set down No 2 carrier assy into motor 10 11 刮 刮 43098TR29 43098TR28 To set the align valve ports refer to right drawing 侍 43098TR30 ...

Page 540: ...y Put parallel pin 13Ý20 into parallel pin hole of ring gear with rubber hammer Apply three bond 1194 on cover contacting surface of ring gear and assemble cover Tighten 16 of hex socket head bolt M12Ý35 with designed torque 14 3Ü1 4 kgf m 103Ü10 1 lbf ft using torque wrench Putting gear oil Put gear oil 12Ü0 5 liter through fill port and check the oil level Tighten oil plug with torque 10Ü0 1 kgf...

Page 541: ...Escaping fluid under pressure can penetrate the skin causing serious injury Loosen the socket bolt 1 Remove the cover of the console box Disconnect pilot line hoses 3 Remove the pilot valve assembly 2 When removing the pilot valve assembly check that all the hoses have been disconnected INSTALL Carry out installation in the reverse order to removal Confirm the hydraulic oil level and check the hyd...

Page 542: ... 24 27 300L2RL06 1 Case 2 Bushing 3 Spool 4 Shim 5 Spring 6 Spring seat 7 Spring 8 Plug 9 Push rod 10 O ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut 23 Boot 24 Last guard filter 25 O ring 26 O ring 27 Connector ...

Page 543: ...ench 6 Spanne 22 27 Driver Length 150 Driver Width 4 5 Torque wrench Capable of tightening with the specified torques B Part name Item Size Torque kgfÂm lbfÂft Joint 15 M14 3 5 25 3 Swash plate 16 M14 5 0Ü0 35 36 2Ü2 5 Adjusting nut 17 M14 5 0Ü0 35 36 2Ü2 5 Lock nut 22 M14 5 0Ü0 35 36 2Ü2 5 ...

Page 544: ...ise with copper or lead sheets Remove end of boot 23 from case 1 and take it out upwards 1 ö 2 3 Loosen lock nut 22 and adjusting nut 17 with spanners on them respectively and take out handle section as one body 4 For valve with switch remove cord also through hole of casing ö 3 ö Remove the boot 14 5 300E8RL01 300E8RL02 300E8RL03 1408DA61 ...

Page 545: ...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 ö Loosen adjusting nut 17 and swash plate 16 with spanners on them respectively and remove them 6 36078RL01 36078RL02 36078RL03 36078RL04 ...

Page 546: ... Take it out utilizing external periphery groove of plug and paying attention not to damage it by partial loading During taking out plug may jump up due to return spring 7 force Pay attention to this 9 ö ö Remove plate 12 8 36078RL05 36078RL06 36078RL07 Separate spool 3 spring seat 6 spring 5 and shim 4 individually Pay attention not to damage spool surface Record original position of spring seat ...

Page 547: ...8 107 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 548: ...8 108 Remove lock nut 22 and then boot 23 14 36078RL14 2507ARL10 ...

Page 549: ...tions of reassembled valve will be degraded Therefore control cleanliness of kerosene fully Put parts in final cleaning vessel filled with kerosene turning it slowly to clean them even to their insides finish cleaning Do not dry parts with compressed air since they will be damaged and or rusted by dust and moisture in air Rust prevention of parts Apply rust preventives to all parts If left as they...

Page 550: ...ing Assemble them to their original positions 2 ö ASSEMBLY Put shim 4 springs 5 and spring seat 6 onto spool 3 in this order 1 4 36078RL16 36078RL18 Assemble O ring 10 onto plug 8 3 36078RL19 Assemble seal 11 to plug 8 Assemble seal in such lip direction as shown below 4 ö 36078RL20 ...

Page 551: ... 6 ö Assemble push rod 9 to plug 8 Apply working oil on push rod surface 5 ö 36078RL21 36078RL22 When return spring is strong in force assemble 4 sets at the same time utilizing plate 12 and tighten joint 15 temporarily 7 36078RL23 Tighten joint 15 with the specified torque to casing utilizing jig 9 Fit plate 12 8 36078RL24 ...

Page 552: ...4 push rods evenly Do not screw it over 10 ö ö Assemble adjusting nut 17 apply spanner to width across flat of plate 16 to fix it and tighten adjusting nut to the specified torque During tightening do not change position of disk 11 ö 36078RL25 36078RL26 Fit boot 14 to plate 12 1408DA61 ...

Page 553: ... in direction 60Áto 120Áfrom casing hole 14 Fit boot 23 and lock nut 22 and handle subassembly is assembled completely 13 2507ARL10 36078RL27 1408DA66 Assemble bushing 18 to plate and pass cord and tube through it Provide margin necessary to operation 15 ö 300E8RL04 ...

Page 554: ...reventives through all ports and then put blind plugs in ports 18 19 Apply grease to rotating section of joint and contacting faces of disk and push rod 17 Determine handle direction tighten lock nut 22 to specified torque to fix handle 16 300E8RL05 300E8RL06 300E8RL07 ...

Page 555: ...iping 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 55 kg 120 lb Tightening torque 12 3Ü1 3 kgf m 89Ü9 4 lbf ft Remove the turning joint assembly When removing the turning joint check that all the hoses have been disconnected 8 115 GROUP 8 TURNING JOINT 1 2 1 1 1 2 3 侍 4 5 6 侍 INSTALL Carry out installation in the...

Page 556: ...ND ASSEMBLY 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 11 1 7 2 9 8 11 21098TJ01 ...

Page 557: ... 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 侍 侍 Remove shim 6 and O ring 10 Remove retainer ring 12 spacer 4 and shim 5 2 3 DISASSEMBLY Before the disassembly clean the turning joint Remove bolts 14 washer 15 and cover 3 2 ö 1 21078DA10 21078DA11 8 14 3 ...

Page 558: ... shaft 2 on block tap hub 1 with a plastic hammer to install 3 Fix seven slipper seal 7 and O ring 9 two wear ring 11 to hub 1 Fit O ring 8 to shaft 2 1 2 ASSEMBLY Clean all parts As a general rule replace oil seals and O ring Coat the sliding surfaces of all parts with engine oil or grease before installing 3 侍 侍 侍 21078DA12 21078DA13 21078DA11 ...

Page 559: ...8 119 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 560: ...tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Set block between bucket cylinder and arm 8 120 GROUP 9 BOOM ARM AND BUCKET CYLINDER 1 刮 1 侍 侍 侍 Disconnect bucket cylinder hoses 4 and put plugs 5 on cylinder pipe 到 Remove nuts 3 bolt 2 and pull out pin 1 Tie the rod with wir...

Page 561: ...n 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 刮 侍 侍 2 Sling bucket cylinder assembly and remove bolt 6 plate 7 then pull out pin 5 Remove bucket cylinder assembly 8 余Weight 320 kg 710 lb 刱 刲 36078CY02 ...

Page 562: ...sure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Set block between arm cylinder and boom 2 刮 1 侍 侍 侍 Disconnect arm cylinder hoses 4 and put plugs on cylinder pipe Disconnect greasing pipings 5 到 刱 Remove bolt 2 and pull out pin 1 Tie the rod with wi...

Page 563: ... 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 刮 侍 侍 2 Sling arm assembly 9 and remove bolt 7 plate 8 then pull out pin 6 Remove arm cylinder assembly 9 余Weight 490 kg 1080 lb 刲 刳 36078CY06 ...

Page 564: ... the pressure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Disconnect greasing hoses 1 Sling boom cylinder assembly 3 刮 刯 1 侍 侍 侍 Lower the boom cylinder assembly 6 on a stand 刱 Remove bolt 4 stop plate 5 and pull out pin 2 Tie the rod with wire to pr...

Page 565: ...ert your fingers in the pin hole Bleed the air from the boom cylinder Confirm the hydraulic oil level and check the hydraulic oil leak or not 刮 侍 侍 2 Remove bolt 9 and pull out pin 8 Remove boom cylinder assembly 6 余Weight 370 kg 820 lb 刳 刴 Disconnect boom cylinder hoses 7 and put plugs on cylinder pipe 刲 36078CY10A 36078CY10 ...

Page 566: ...er 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 20 Lock nut 21 Set screw 22 O ring 23 Hexagon socket head bolt 24 Pin bushing 25 Pin bushing 26 Dust seal 27 Band assembly 28 Pipe assembly R 29 Pipe assembly B 30 O ring 31 Hexagon socket head bolt 38098CY01A ...

Page 567: ... O ring 19 Back up ring 20 Lock nut 21 Set screw 22 O ring 23 Hexagon socket head bolt 24 Pin bushing 25 Dust seal 26 Check valve 27 Coil spring 28 O ring 29 Plug 30 Band assembly R 31 Band assembly B 32 Pipe assembly R 33 Pipe assembly B 34 O ring 35 O ring 36 Hexagon socket head bolt 37 Hexagon socket head bolt 9 10 6 7 8 34 3 4 23 5 36 12 13 1 2 Internal detail 26 27 28 29 24 25 32 33 35 37 24 ...

Page 568: ...ston 15 Piston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 20 Lock nut 21 Set screw 22 O ring 23 Hexagon socket head bolt 24 Pin bushing R 25 Pin bushing B 26 Dust seal 27 Dust seal 28 Band assembly 29 Pipe assembly R 30 Pipe assembly B 31 O ring 32 Hexagon socket head bolt 14 18 19 17 16 21 20 31 11 12 1 2 13 23 4 5 8 6 7 9 10 32 22 3 15 29 30 25 27 24 26 28 3809A8CY03 Internal detai...

Page 569: ...3 M20 46佳5 333佳36 1 Boom cylinder 23 M22 63佳6 456佳43 4 Arm cylinder 23 M22 63佳6 456佳43 4 Socket head bolt Bucket cylinder 31 M12 9 4佳1 68 0佳7 2 Boom cylinder 32 M12 9 4佳1 68 0佳7 2 Arm cylinder 36 M12 9 4佳1 68 0佳7 2 37 M12 9 4佳1 68 0佳7 2 Lock nut Bucket cylinder 20 M76 100佳10 723佳72 3 Boom cylinder 20 M80 150佳15 1085佳108 Arm cylinder 20 M90 150佳15 1085佳108 Piston Bucket cylinder 14 150佳15 1085佳109 ...

Page 570: ...ether 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 h a s b e e n d r aw n o u t t o approximately two thirds of its length lift it in its center to draw it completely 刱 侍 Loosen and remove socket bolts 23 of the gland in sequence Cover the extracted rod assembly 2 with rag...

Page 571: ...ove piston and cylinder head Loosen socket set screw 21 and 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 cylinder to remove the lock set screw 21 and lock nut 20 Remove piston assembly 14 back up ring 19 and O ring 18 到 侍 侍 Place the removed rod assembly on a wooden V block that is set level Cover a...

Page 572: ...g 7 rod seal 6 buffer ring 8 and snap ring 5 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 刮 刯 到 侍 侍 侍 Disassemble the piston assembly Remove wear ring 16 Remove dust ring 17 and piston seal 15 Exercise care in this operation not to damage the grooves 3 刮 刯 侍 2907A8CY03 21078DA36 ...

Page 573: ...hat order Coat each packing with hydraulic oil before fitting it Insert the backup ring until one side of it is inserted into groove 刱 侍 侍 Coat dust wiper 9 with grease and fit dust wiper 9 to the bottom of the hole of dust seal At this time press a pad metal to the metal ring of dust seal Fit snap ring 10 to the stop face 刯 到 ASSEMBLY Assemble cylinder head assembly Check for scratches or rough s...

Page 574: ...tes After assembling the piston seal press its outer diameter to fit in 刯 侍 侍 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 刲 侍 刳 Assemble piston assembly Check for scratches or rough surfaces If found smooth with an oil stone Coat the outer face of piston 14 with hydraulic oil 2 侍 刮 21078DA39 8 158 2 2907A8CY04 2907A8CY05 ...

Page 575: ...embly Note that cushion ring 13 has a direction in which it should be fitted 刱 侍 Install piston and cylinder head Fix the rod assembly to the work bench Apply hydraulic oil to the outer surface of rod assembly 2 the inner surface of piston and cylinder head Insert cylinder head assembly to rod assembly 3 刮 刯 到 21078DA40 8 159 2 50078CY09 50078CY10 Item kgfÂm lbfÂft Bucket 20 100Ü10 723Ü72 3 21 5 4...

Page 576: ...hrough 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 thread of tube assembly Match the bolt holes in the cylinder head flange to the tapped holes in the tube assembly and tighten socket bolts to a specified torque Refer to the table of tightening torque 3 刮 刯 侍 ...

Page 577: ... grease is not leaking until the grease nipple is completely coming out If the tension is not released in advance the grease nipple can be suddenly popped out by pressurized grease Push out master pin by using a suitable tool GROUP 10 UNDERCARRIAGE Block Master pin 1 90 110 1 1 2 ö ö 3 INSTALL Carry out installation in the reverse order to removal Adjust the tension of the track link 2 1 ö Move th...

Page 578: ...rrier roller 1 1 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 ÂWeight 80 kg 180 lb 3 4 Jack up the track link height enough to permit carrier roller removal 2 36078UC11 36078UC12 36078UC13 ...

Page 579: ...STALL Carry out installation in the reverse order to removal 2 1 Remove the mounting bolts 1 and draw out the track roller 2 ÂWeight 80 kg 176 4 lb 3 Using the work equipment push up track frame on side which is to be removed After jack up the machine set a block under the unit 2 ö 36078UC14 36078UC15 36078UC16 ...

Page 580: ...e 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 ö Remove the bolts 2 washers 3 and separate ilder from recoil spring 3 Sling the recoil spring 1 and pull out idler and recoil spring assembly from track frame using a pry ÂWeight 550 kg 1210 lb 2 36078UC17 36078UC18 36078UC19 36078UC20 ...

Page 581: ...8 141 8 141 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 1 3 1 Shell 2 Bushing 3 Shaft 4 O ring 5 Seal assembly 6 Bracket 7 Spring pin 8 Plug 36078UC01 ...

Page 582: ... tool Only remove bushing if replacement is necessity Μ ö Pull out the shaft 3 with a press Remove seal 5 from shell 1 and bracket 6 Remove O ring 4 from shaft Ι Κ Λ Disassembly Remove plug and drain oil Draw out the spring pin 7 using a press 2 Η Θ 36078UC21 36078UC22 36078UC23 ...

Page 583: ...l 1 Do not press it at the nor mal temperature or not knock in with a hammer even after the cooling 2 Press 1 4 3 6 7 5 3 1 3 ö ö Η Install shaft 3 to shell 1 Λ Install seal 5 to shell 1 and bracket 6 Κ Coat O ring 4 with grease thinly and install it to shaft 3 Insert shaft 3 into bracket 6 and drive in the spring pin 7 Θ Ι 36078UC24 36078UC25 36078UC26 36078UC27 ...

Page 584: ...44 6 6 7 1 6 Lay bracket 6 on its side Supply engine oil to the specified level and tighten plug Ξ Knock in the spring pin 7 with a hammer Ν Install bracket 6 attached with seal 5 Μ 36078UC28 36078UC29 36078UC30 ...

Page 585: ...DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure 1 4 1 Body 2 Bracket 3 Rod assembly 4 Spring 5 Rod seal 6 Back up ring 7 Dust seal 8 Lock nut 9 Lock plate 10 Hex bolt 11 Spring washer 12 Grease valve 45078UC02 ...

Page 586: ...e bolt 10 spring washer 11 and lock plate 9 Remove lock nut 8 Take enough notice so that the press which pushes down the spring should not be slipped out in its operation Lighten the press load slowly and remove bracket 2 and spring 4 2 Remove rod seal 5 back up ring 6 and dust seal 11 Ν Remove rod 3 from body 1 Remove grease valve 12 from rod 3 Λ Μ Η ö Â Θ Ι Κ 45078UC03 45078UC04 45078UC05 ...

Page 587: ...d tighten lock nut 8 Apply sealant before assembling During the operation pay attention specially to prevent the press from slipping out Κ Λ ö ö Pour grease into body 1 then push in rod 3 by hand After take grease out of grease valve mounting hole let air out If air letting is not sufficient it may be difficult to adjust the tension of crawler Fit grease valve 12 to rod 3 ÂTightening torque 13 0Ü1...

Page 588: ...8 148 8 148 Lighten the press load and confirm the set length of spring 4 After the setting of spring 4 install lock plate 9 spring washer 11 and bolt 10 Μ Ν 45078UC07 ...

Page 589: ...8 149 1 STRUCTURE GROUP 11 WORK EQUIPMENT B SECTION C SECTION B SECTION A C C A B A 21078DA 44 ...

Page 590: ...rry out installation in the reverse 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 operator s manual 2 刮 侍 Remove nuts 3 bolt 4 and draw out the pin A 到 Remove nuts 1 bolt 2 and draw out the pin B 刯 36078A T04 36078A T05 1 2 B 36078A T01 3 4 A 36078A T02 ...

Page 591: ...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 bring the cylinder down to it Remove bolt 2 plate 3 and pull out the pin 4 then remove the arm assembly 余Weight 1243 kg 2740 lb When lifting the arm assembly always lift the center of gravity Crane 2 3 4...

Page 592: ...removal When lifting the arm assembly always lift the center of gravity B leed the air from the cylinder 2 刮 侍 Remove bolt 4 plate 5 and pull out the pin 6 then remove boom assembly 余Weight 2600 kg 5730 lb When lifting the boom assembly always lift the center of gravity 刳 侍 Disconnect head lamp wiring Disconnect bucket cylinder hoses 2 and arm cylinder hoses 1 When the hoses are disconnected oil m...

Page 593: ...MPONENT 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 10 Group 7 Work equipment 9 14 ...

Page 594: ...ility for defects resulted from non genuine parts In such cases Hyundai cannot assume liability for any damage Only metric fasteners can be used and incorrect fasteners may result in machine damage or malfunction Before installation clean all the components with a non corrosive cleaner Bolts and threads must not be worn or damaged SECTION 9 COMPONENT MOUNTING TORQUE GROUP 1 INTRODUCTION GUIDE 1 2 ...

Page 595: ...ine GROUP 2 ENGINE SYSTEM 余Tightening torque ENGINE AND ACCESSORIES MOUNTING HX430L9CM01 Item Size kgf余m lbf余ft 1 M 6佴1 0 1 44佳0 3 10 4佳2 2 2 M 8佴1 25 2 5佳0 5 18 1佳3 6 3 M10佴1 5 6 9佳1 4 49 9佳10 1 4 M10佴1 5 8 27佳1 7 59 8佳12 3 Item Size kgf余m lbf余ft 5 M12佴1 75 11 5佳1 0 83 2佳7 2 6 M12佴1 75 12 8佳3 0 92 6佳21 7 7 M24佴3 0 90佳9 0 651佳65 1 ...

Page 596: ...lue tank supply module 余Tightening torque COOLING SYSTEM AND FUEL TANK MOUNTING HX430L9CM02 Item Size kgf余m lbf余ft 1 M 8佴1 25 2 5佳0 5 18 1佳3 6 2 M 8佴1 25 4 05佳0 8 29 3佳5 8 3 M10佴1 25 7 4佳1 5 53 5佳10 8 4 M10佴1 5 6 9佳1 4 49 9佳10 1 5 M10佴1 5 8 27佳1 7 59 8佳12 3 Item Size kgf余m lbf余ft 6 M12佴1 75 12 8佳3 0 92 6佳21 7 7 M12佴1 75 14 7佳2 2 106佳15 9 8 M16佴2 0 29 7佳4 5 215佳32 5 9 M20佴2 5 46佳5 1 333佳36 9 10 2 3...

Page 597: ...U 1 Buzzer Camera Battery relay Washer tank Pro controller RDU AAVM controller GROUP 3 ELECTRIC SYSTEM 余Tightening torque ELECTRIC COMPONENTS MOUNTING 1 HX430L9CM03 Item Size kgf余m lbf余ft 1 M 6佴1 0 1 05佳0 2 7 6佳1 45 2 M 8佴1 25 2 5佳0 5 18 1佳3 6 3 M 8佴1 25 3 43佳0 7 24 8佳5 1 Item Size kgf余m lbf余ft 4 M10佴1 5 6 9佳1 4 49 9佳10 1 5 M12佴1 75 12 8佳3 0 92 6佳21 7 ...

Page 598: ...erter Remote control unit Work lamp 2 Button key controller unit Smart key reader Warning buzzer ELECTRIC COMPONENTS MOUNTING 2 HX430L9CM04 余Tightening torque Item Size kgf余m lbf余ft 1 M 6佴1 0 1 05佳0 2 7 6佳1 45 2 M 8佴1 25 2 5佳0 5 18 1佳3 6 Item Size kgf余m lbf余ft 3 M10佴1 5 6 9佳1 4 49 9佳10 1 ...

Page 599: ...tening torque HYDRAULIC COMPONENTS MOUNTING 1 HX380L9CM05 Item Size kgf余m lbf余ft 1 M 6佴1 0 1 05佳0 2 7 6佳1 45 2 M 8佴1 25 2 5佳0 5 18 1佳3 6 3 M 8佴1 25 4 05佳0 8 29 3佳5 8 4 M10佴1 5 4 8佳0 3 34 7佳2 2 5 M10佴1 5 6 9佳1 4 49 9佳10 1 6 M10佴1 5 8 27佳1 7 59 8佳12 3 7 M12佴1 75 12 8佳3 0 92 6佳21 7 Item Size kgf余m lbf余ft 8 M12佴1 75 14 7佳2 2 106佳15 9 9 M16佴2 0 29 7佳4 5 215佳32 5 10 M16佴2 0 35 6佳7 1 257佳51 11 M20佴2 5 46...

Page 600: ...e pedal 4 way solenoid valve ATTACH PIPING Stop valve 5 4 4 Pattern change valve Quick clamp solenoid valve Double acting Single acting 5 shuttle 余Tightening torque HYDRAULIC COMPONENTS MOUNTING 2 HX430L9CM06 Item Size kgf余m lbf余ft 1 M 8佴1 25 2 5佳0 5 18 1佳3 6 2 M 8佴1 25 4 05佳0 8 29 3佳5 8 3 M10佴1 5 6 9佳1 4 49 9佳10 1 4 M12佴1 75 12 8佳3 0 92 6佳21 7 Item Size kgf余m lbf余ft 5 M12佴1 75 14 7佳2 2 106佳15 9 6...

Page 601: ...tening torque HYDRAULIC COMPONENTS MOUNTING 3 HX380L9CM07 Item Size kgfÂm lbfÂft 1 M10佴1 5 3 2佳0 3 23 1佳2 2 2 M12佴1 75 5 5佳0 6 39 8佳4 3 3 M12佴1 75 9 4佳1 0 68 0佳7 2 4 M20佴2 5 46佳5 0 333佳36 2 5 M22佴2 5 63 佳6 0 456 佳43 4 Item Size kgfÂm lbfÂft 6 Accumulator 5 6佳0 5 40 5佳3 6 7 EPPR valve 2 5佳0 5 18 1佳3 6 8 Solenoid valve 3 5佳0 5 25 3佳3 6 9 Line filter 2 5佳0 5 18 1佳3 6 10 Check valve 4 0佳0 5 28 9佳3 6 ...

Page 602: ...RIAGE 余Tightening torque HX430L9CM08 UNDERCARRIAGE MOUNTING Item Size kgf余m lbf余ft 1 M10佴1 5 6 9佳1 4 49 9佳10 1 2 M12佴1 75 12 8佳3 0 92 6佳21 7 3 M14佴1 5 21佳3 1 152佳22 4 4 M16佴2 0 29 7佳3 0 215佳21 7 5 M16佴2 0 29 7佳4 5 215佳32 5 Item Size kgf余m lbf余ft 6 M20佴2 5 57 9佳6 0 419佳43 4 7 M24佴1 5 140佳14 1010佳101 8 M24佴3 0 77 4佳11 560佳80 9 M24佴3 0 100佳10 723佳72 3 ...

Page 603: ...4 1 1 5 2 1 1 Item Item 余Tightening torque 1 2 3 4 5 6 M 6佴1 0 M 8佴1 25 M 8佴1 25 M10佴1 5 M12佴1 75 M24佴3 0 1 05佳0 2 2 5佳0 5 3 43佳0 7 6 9佳1 4 12 8佳3 0 100佳15 7 6佳1 45 18 1佳3 6 24 8佳5 1 49 9佳10 1 92 6佳21 7 723佳109 Size Size kgf余m kgf余m lbf余ft lbf余ft CAB AND ACCESSORIES MOUNTING GROUP 6 STRUCTURE HX380L9CM09 ...

Page 604: ...ever 2 2 2 2 2 5 2 5 1 4 4 3 5 5 5 5 5 5 2 5 5 Seat 4 余Tightening torque CAB INTERIOR MOUNTING HX430L9CM10 Item Size kgf余m lbf余ft 1 M 6佴1 0 1 05佳0 2 7 6佳1 45 2 M 8佴1 25 2 5佳0 5 18 1佳3 6 3 M 8佴1 25 3 43佳0 7 24 8佳5 1 Item Size kgf余m lbf余ft 4 M 8佴1 25 4 05佳0 8 29 3佳5 8 5 M10佴1 5 6 9佳1 4 49 9佳10 1 ...

Page 605: ... 1 1 1 3 3 2 3 3 3 1 3 3 3 3 3 3 3 3 3 3 2 3 3 1 3 3 3 3 3 1 1 1 3 3 1 1 3 2 Reservoir tank COWLING MOUNTING HX430L9CM11 余Tightening torque Item Size kgf余m lbf余ft 1 M 8佴1 25 2 5佳0 5 18 1佳3 6 2 M10佴1 5 6 9佳1 4 49 9佳10 1 Item Size kgf余m lbf余ft 3 M12佴1 75 12 8佳3 0 92 6佳21 7 ...

Page 606: ... under cover MCV under cover 3 Engine under cover 3 1 2 3 3 3 3 2 2 2 2 3 3 4 3 3 3 3 3 3 2 2 Tool box DEF AdBlue tank cover 余Tightening torque COUNTERWEIGHT AND COVERS MOUNTING HX380L9CM12 Item Size kgf余m lbf余ft 1 M 8佴1 25 2 5佳0 5 18 1佳3 6 2 M10佴1 5 6 9佳1 4 49 9佳10 1 Item Size kgf余m lbf余ft 3 M12佴1 75 12 8佳3 0 92 6佳21 7 4 M36佴3 0 337佳33 2438佳239 ...

Page 607: ... rod pin Bucket cylinder Arm pin Boom pin Arm cylinder head pin Boom cylinder 2 1 2 2 3 3 2 2 Bucket cylinder head pin Bucket 余Tightening torque GROUP 7 WORK EQUIPMENT HX430L9CM13 Item Size kgf余m lbf余ft 1 M16佴2 0 29 7佳4 5 215佳32 5 2 M20佴2 5 57 9佳8 7 419佳62 9 Item Size kgf余m lbf余ft 3 M24佴3 0 100佳15 723佳109 ...

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