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Hyundai R 160 LC-3, Service Manual

The Hyundai R 160 LC-3 is a reliable and efficient excavator designed for various construction projects. Ensure optimal performance with the Service Manual available for free download from manualshive.com. This comprehensive manual provides detailed instructions on maintenance and repairs, maximizing the longevity of your equipment.

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When the swing and bucket functions are operated, the swing and bucket spools changed.  The oil
flows from the rear pump through the bucket section of the main control valve to the bucket cylinder
and the bucket function.  The oil flows from front pump through swing section of the main control
valve to the swing motor and swing the superstructure. 

4. COMBINED SWING AND BUCKET OPERATION

TRAVEL MOTOR

ARM CYLINDER

BOOM CYLINDER

SWING MOTOR

HYD
TANK

FRONT
PUMP

REAR
PUMP

PILOT
PUMP

P1

P2

R

XBb2

XAb1

dr4

P1

Bb1

XBb1

XBb2

BUCKRT CYLINDER

XBa1

XBa2

XAa1

Pal

XBa2

XAa2

XAah

Ck1

XAk2

dr8

XAtl

XBtl

XAtr

XBtr

XAk

XBk

XAs

XBs

BOOM2

BOOM1

ARM1

ARM2

TRAVEL(LH)

TRAVEL(RH)

OPTION

BUCKET

SWING

dr2

XAas

Summary of Contents for R 160 LC-3

Page 1: ...for troubleshooting SECTION 3 HYDRAULIC SYSTEM This section explains the hydraulic circuit single and combined operation SECTION 4 ELECTRICAL SYSTEM This section explains the electrical circuit monito...

Page 2: ...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...

Page 3: ...t 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 d...

Page 4: ...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...

Page 5: ...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 3...

Page 6: ...29 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...

Page 7: ...0 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 1...

Page 8: ...31 1 88 190 4 26 7 16 3 2 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9...

Page 9: ......

Page 10: ...the excavator attach a Do Not Operate tag on the right side control lever USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury When you get on and off the machine always main...

Page 11: ...al or debris Wear 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 ear muffs o...

Page 12: ...when the excavator starts to move Use a signal person when moving swinging or operating the machine in congested areas Coordinate hand signals before starting the excavator OPERATE ONLY FORM OPERATOR...

Page 13: ...COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands HANDLE FLUIDS...

Page 14: ...a well ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent o...

Page 15: ...an cause serious injury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid th...

Page 16: ...drometer Do not charge a frozen battery It may explode Warm battery to 16 C 60 F PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clot...

Page 17: ...s find out the proper way to dispose of waste from your local environmental agency Use proper containers when draining fluids Do not use food or beverage containers that may mislead someone into drink...

Page 18: ...Cab Muffler Counterweight Side cutter Bucket cylinder Connecting link Connecting rod Idler Track roller Carrier roller Track Sprocket Travel motor Tooth Turning joint Bucket Swing motor Main control v...

Page 19: ...tance between tumblers Undercarriage length Undercarriage width Track gauge Track shoe width standard Travel speed Low high Swing speed Gradeability Ground pressure 600mm shoe kg lb m3 yd3 mm ft in km...

Page 20: ...23300 25480 78 85 7920 8660 17460 19100 81 89 8260 9030 18210 19920 2 60m 8 6 Arm 8950mm 8800mm 6090mm 5860mm 5370mm 8940mm 6310mm 2920mm 29 4 28 10 20 0 19 3 17 7 29 4 20 8 9 7 3 10m 10 2 Arm 9340mm...

Page 21: ...r roller Track roller Track chain assembly 600mm standard triple grouser shoe Front attachment assembly 5 10m boom 2 60m arm 0 65m3 PCSA heaped bucket 5 10m boom assembly 2 60m arm assembly 0 65m3 PCS...

Page 22: ...170 20 3 6 0m kg 2620 2620 2800 2040 7 46 20ft lb 5780 5780 6170 4500 24 5 4 5m kg 3220 2910 2810 1660 8 20 15ft lb 7100 6420 6190 3660 26 9 3 0m kg 6720 6720 4530 4420 3670 2760 2400 1840 2550 1470 8...

Page 23: ...600mm 24 triple grouser shoe 3 Ground kg 6990 6990 6610 3820 4300 2490 2780 1610 8 01 Line lb 15410 15410 14570 8420 9480 5490 6130 3550 26 3 Load point height Load radius At max reach 1 5m 5ft 3 0m...

Page 24: ...0mm 44 1200mm 47 410kg 900lb 490kg 1080lb 510kg 1120lb 540kg 1190lb 570kg 1260lb 2 25m arm 7 5 2 60m arm 8 6 3 10m arm 10 2 Recommendation 5 10m 16 9 boom Capacity Width Weight 0 39m3 PCSA heaped buck...

Page 25: ...ck type tractor shoes with triple grousers TYPES OF SHOES NUMBER OF ROLLERS AND SHOES ON EACH SIDE 3 1 2 mm in kg lb kg cm2 psi mm ft in 600 24 16600 36600 0 40 5 69 2590 8 6 700 28 16970 37410 0 35 4...

Page 26: ...Battery Specification Cummins B3 9 C 4 cycle turbocharged after cooled and low emission diesel engine Water cooling 4 cylinders in line 1 3 4 2 Direct injection type 102 120mm 4 02 4 72 3900cc 238cu i...

Page 27: ...y Relief pressure Braking system Braking torque Brake release pressure Reduction gear type Swing speed Specification Fixed displacement axial piston motor 99 2cc rev 260kgf cm2 3911psi Automatic sprin...

Page 28: ...cylinder Bucket cylinder Item Width 600mm 24 500mm 20 700mm 28 800mm 32 Ground pressure 0 40kgf cm2 5 69psi 0 47kgf cm2 6 68psi 0 35kgf cm2 4 98psi 0 31kgf cm2 4 41psi Link quantity 49 49 49 49 Overal...

Page 29: ...Reservoir tank Grease As required Tank 120 31 7 System 210 55 5 24 6 3 20 10 0 10 20 30 40 4 14 32 50 68 86 104 SAE Society of Automotive Engineers API American Petroleum Institute ISO International...

Page 30: ...usting screw Regulator Pilot pump Pf A3 B3 B3 B1 Pi1 Dr Dr Pi2 a1 a2 a3 Pi1 A1 A2 B1 B3 a3 Pi2 a4 Hydraulic circuit a1 a2 Dr A3 Pf Front Rear Port A1 2 B1 Dr Pf Pi1 i2 a1 2 3 4 A3 B3 Port name Deliver...

Page 31: ...Valve plate L 401 Hexagon socket bolt 406 Hexagon socket bolt 435 Flange socket bolt 466 VP plug 468 VP plug 490 VP plug 531 Tilting pin 532 Servo piston 534 Stopper L 535 Stopper S 548 Pin 702 O rin...

Page 32: ...4 611 613 615 614 858 755 612 897 875 412 735 079 722 SECTION D D a 755 466 a 699 413 496 438 725 724 VIEW C 641 730 643 708 644 645 646 728 924 801 438 Port A B Pi Pf P2 Port name Delivery port Sucti...

Page 33: ...Cover C 630 Nut 631 Sleeve 641 Pilot cover 642 Pilot cover QMC 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 spri...

Page 34: ...nut 351 Gear case 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 B3 A3...

Page 35: ...sh plate group consists of swash plate 212 shoe plate 211 swash plate support 251 tilting bush 214 tilting pin 531 and servo piston 532 The swash plate is a cylindrical part formed on the opposite sid...

Page 36: ...gine 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...

Page 37: ...elivery flow Q decreases as the pilot pressure Pi rises With this mechanism when the pilot pressure corresponding to the flow required for the work is commanded the pump discharges the required flow o...

Page 38: ...n 874 the 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 pisto...

Page 39: ...rotates 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...

Page 40: ...ightening the screw shifts the control chart to the right as shown in the figure Adjusting values are shown in table Adjustment of flow control characteristic Pilot pressure Pi Delivery flow Q 801 924...

Page 41: ...mps in the tandem double pump system the prime mover is automatically prevented from being overloaded irrespective of the load condition of the two pumps when horsepower control is under way Since thi...

Page 42: ...ver 611 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...

Page 43: ...nd 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 i...

Page 44: ...ding from the 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 mech...

Page 45: ...ew increases the flow and then the input horsepower as shown in the figure Adjusting valves are shown in table b Delivery pressure P1 P2 Delivery flow Q 626 801 925 Adjustment of inner spring Tighteni...

Page 46: ...optimum 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 r...

Page 47: ...head set screw 953 Similarly to the adjustment of the maximum flow other characteristics are not changed However remember that if tightened too much the required horsepower during the maximum delivery...

Page 48: ...31 1 Cap 2 O ring 3 Socket bolt 4 Spring washer 5 Overload assy 6 O ring 7 Orifice 8 Cap 9 O ring 10 Cover 11 Socket bolt 12 Sleeve 13 Check 14 Cap 15 O ring 16 Cap 17 Spring 18 Spring guide 19 Spring...

Page 49: ...ng 48 Retainer 49 Socket bolt 50 Housing 51 Plunger assy OPT 52 Plunger assy BKT 53 Plunger assy BM1 54 Plunger assy AM2 55 Cap 56 Back up ring 57 Nylon chip 58 Overload assy 59 Spring 60 Check 61 O r...

Page 50: ...1 Px Py P2 R Pi 320K 350K XAah Aa1 Ba1 XAa1 XBa2 XBa1 XAas Op XBb2 dr6 XAs Bs As XBs Btl Atl XAtl XBtl XAa2 XBa2 dr4 5Pi Bb1 XBb1 XBb2 Ak1 Bk1 XAk XAk2 XBk Ck2 Atr Btr Ao Bo XBo XAo XAtr XBtr Ab1 XAb1...

Page 51: ...m pump P2 is fed into cylinder port Ak1 by adding pressure to bucket plunger pilot port XAk and the oil from actuator flow tank through cylinder port Bk1 The center bypass valve is changeover by the p...

Page 52: ...er port Bs via center bypass passage by adding pressure to swing plunger pilot port XBs In case of simultaneous operation of swing and arm the delivery oil from P1 for swing is also supplied to arm cy...

Page 53: ...l position The high pressure feed passage is shut off by the plunger Oil from the pump flows through the center bypass 3 1 Parallel feed passage Cylinder port B Pilot port b Low pressure passage Cente...

Page 54: ...to cylinder port A via the high pressure feed passage The return oil from cylinder port B flows into the tank via the low pressure feed passage Reversed when pressure is applied to pilot port b Parall...

Page 55: ...pump delivery flow fp is higher than spring force If a large amount flows due to delayed pump response etc and pressure fp reaches the preset spring force then the poppet is lifted and functions as a...

Page 56: ...preset spring force the spool A moves left and orificed the flow to the foot relief valve Then the oil from center bypass flow into bucket summation port Ck2 via out side piping 3 Spool A Drain line...

Page 57: ...e enters chamber 3 via orifice 2 of main poppet A Because d2 d1 main poppet A is securely seated When hydraulic oil reaches the pressure preset by spring C pilot poppet D opens oil flows around poppet...

Page 58: ...f chamber 3 x area d1 main poppet A is opened and hydraulic oil flows into the low pressure passage High pressure setting pilot signal ON Piston E move to left by high pressure setting pilot signal Se...

Page 59: ...g D pilot poppet E opens Oil flows around pilot poppet E and into the low pressure passage via side hole 4 and passage 5 Oil flow is formed Pressure drops before and behind orifice 3 Piston A moves to...

Page 60: ...a side hole 4 and passage 5 Pressure drops before and behind throttle 6 making pressure of chamber 1 x area d1 pressure of chamber 2 x area d2 Main poppet B is opened and hydraulic oil flows into the...

Page 61: ...egative pressure until the cylinder port pressure is lower than the tank pressure poppet C opens receiving the tank pressure for the difference in area between d3 and d4 oil flows from the low pressur...

Page 62: ...e center bypass passage is shut off Oil from the parallel feed passage opens check valve C1 and flows into cylinder port Aa1 Head side via the high pressure feed passage 6 Center bypass passage Pilot...

Page 63: ...high pressure feed passage via passage 1 and 2 in the plunger At this time the regeneration selector spool B is at the shown position as passage 3 is shut off from passage 4 return oil from cylinder r...

Page 64: ...C and pushes piston A in the regeneration selector to right as shown Spool B move to right Passage 3 and passage 4 are connected Return oil from cylinder rod side flows into tank passage via low press...

Page 65: ...n Passages 5 and 6 are shut off by poppet C Therefore the pressure of chamber 1 becomes pressure Pc as it is connected with chamber 2 via orifice 4 Since d1 d2 poppet E is seated and chambers 2 and 3...

Page 66: ...amber 3 Therefore the pressure of chamber 1 becomes Pc as it is connected to chamber 2 via orifice 4 Poppet E is opened Oil from high pressure feed passage flows into the cylinder rod side Drain port...

Page 67: ...se of arm in operation oil from chamber 1 pushes up check valve C via passages 5 and 6 and enters chamber 3 through passage 7 Chamber 3 is connected with the tank passage because the arm plunger is mo...

Page 68: ...dr4 are shut off by spool A Therefore the pressure of chamber 1 becomes pressure Pc as it is connected with chamber 2 via orifice 4 Since d1 d2 poppet B is seated and chambers 2 and 3 are completely...

Page 69: ...l enters to chamber 3 Therefore the pressure of chamber 1 becomes Pc as it is connected to chamber 2 via orifice 4 Poppet B is opened by pressure Pv of chamber 3 Oil from high pressure feed passage fl...

Page 70: ...pressure of pilot signal Chamber 1 and drain port dr4 are connected Therefore pressure of chamber 1 becomes low Pressure Pc is applied to Area d1 area d2 pushing open poppet B and return oil from the...

Page 71: ...3 SWING DEVICE Pg Sh A B PA PB Mu Dr3 X View X Grease filling port Reduction gear Sh Pg Mu PB dr3 PA A B Hydraulic circuit Time delay valve Swing motor Relief valve Gear oil drain port Port A B dr3 M...

Page 72: ...400 Reactionless valve 400 1 O ring 400 2 Back up ring 401 Hexagon socket bolt 437 Snap ring 438 Snap ring 443 Roller bearing 444 Roller bearing 451 Pin 464 Plug 469 Plug 472 O ring 485 O ring 488 O r...

Page 73: ...5 Side plate 286 Side plate 287 Side plate 288 Side plate 311 Level bar 312 Pipe 401 Roller bearing 402 Roller bearing 403 Needle cage 602 Hexagon socket bolt 801 Seal 901 Plug 902 Plug 910 Spring pin...

Page 74: ...2 causes rotational moment 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...

Page 75: ...ufficiency 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...

Page 76: ...rt 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 t...

Page 77: ...draulic oil pressure P A1 reaches the preset force FSP of spring 321 the plunger 301 moves to the right as shown Also the oil flow chamber g via orifice m P1 A1 Fsp Pg A2 Fsp Pg A2 P1 A1 301 m P R g h...

Page 78: ...ing 321 the piston 320 moves right and stop the piston 320 hits the end of body When piston 320 hits the end of body it stops moving to the right any further As the result the pressure in chamber g eq...

Page 79: ...ce it completely eliminates the hydraulic drift of swing motion while the excavator is on a slop work can be done more easily and safely Brake assembly Circumferential rotation of separate plate 743 i...

Page 80: ...valve 4 this pressure shift time delay vlave so pilot pump charged oil P3 go to the chamber G This pressure is applied to move the piston 702 to the upward against the force of the spring 712 thus rel...

Page 81: ...position and the pilot oil blocked chamber G Then the piston 702 is moved lower by spring force and the return oil from the chamber G is drain Sh 3 G 702 712 5 P3 2 2 4 1 1 Swing control lever 2 Swin...

Page 82: ...ef valve GROUP 4 TRAVEL DEVICE P1 T2 P2 T1 VIEW A VIEW C A C Level Drain Filling T1 T2 Ps P1 P2 R G a2 Hydraulic circuit a1 Ps a1 a2 Port P1 P2 a1 a2 T1 T2 Ps Port name Main port Main port Gauge port...

Page 83: ...Cap 8 O ring 9 Socket head bolt 10 Steel ball 11 Spring 12 O ring 13 Plug 14 Spring seat 15 Spring 16 Relief valve assembly 17 Relief housing 18 Poppet 19 Poppet seat 20 Spring seat 21 Spring 22 Plug...

Page 84: ...Retainer plate 53 Retainer holder 54 Snap ring 55 Collar 56 Spring 57 Collar 58 Pin 59 Swash plate 60 Steel ball 61 Piston assembly 62 Roller bearing 63 Roller bearing 64 Spring pin 65 Socket head bo...

Page 85: ...C Roller bearing Gear shaft C Floating bushing Collar Thrust washer Spring pin Drive gear Thrust plate Sun gear B Sun gear C Spring washer Flange Floating seal Angular bearing Housing 14 15 16 17 18 1...

Page 86: ...e result the total sum of radial forces of the pistons on the high pressure side produces a rotating torque in the direction of the shaft Inversely if high pressure oil is admitted to port C the motor...

Page 87: ...valve controls according to oil supply so as to prevent reckless of running of the motor When the control valve is in neutral position oil does not supply the port P1 and P2 This blocks the motor port...

Page 88: ...t Since the return oil from motor port M2 is blocked by check valve the pressure of port P1 is increased Accordingly the pressure applied through the orifice to left chamber of plunger and move plunge...

Page 89: ...by spring force But the motor is rotated by inertia so the pressure at the output port of motor rises then motor is braked If the pressure reaches the set pressure of relief valve oil flows into port...

Page 90: ...ef valve 2 The release valve determines the drive force and the brake force of the machine during running and is mounted to the cross line The relief valve is provided with a shockless function to rel...

Page 91: ...g regular relief setting This makes the operating relief pressure low About a third of a regular set pressure which is maintained till the shockless piston finishes travel The duration in which low pr...

Page 92: ...g the motor drive pressure to act on the 2 speed control piston This pushes the swash plate up inclines it to a position in which the propelling force Fp of the piston and the spring force Fs balance...

Page 93: ...n that occasion the tilting angle of the swash plate is and the motor revolution gets to the 1st shift low speed condition If the changeover pilot pressure is shut off at an engine stop or on some oth...

Page 94: ...oportion to the pressure receiving area of the piston This force overcomes the spring action and pushes the brake piston to release the braking force At parking or on stop of the machine the hydraulic...

Page 95: ...stage planetary gear mechanism shown in the figure 8 6 5 10 3 2 1 4 11 7 9 1 Drive gear 1st sun gear 2 1st planetary gear 3 1st carrier 4 2nd sun gear 5 2nd planetary gear 6 2nd carrier 7 3rd sun gea...

Page 96: ...RCV LEVER 23 3 A 30 19 25 Handle bending direction Single operation Simultaneous operation No push rod direction 4 P 3 2 T 1 3 0 VIEW A T P 1 3 2 4 Hydraulic circuit Port LH RH Port size Pilot oil in...

Page 97: ...ary pressure is 5 to 20 5kgf cm2 Depending on the type The spool is pushed against the push rod 14 15 by the return spring When the push rod is pushed down by tilting the handle the spring seat comes...

Page 98: ...2 69 CROSSSECTION 27 23 26 18 19 15 12 17 13 8 7 30 22 1 2 4 3 5 10 6 31 9 11 16 14 20 21 24 25 29 28 Port 1 3 Port 2 4...

Page 99: ...ONSOFMAJORSECTIONS The functions of the spool 5 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...

Page 100: ...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 pu...

Page 101: ...o the spool 5 Therefore the spool is pushed up by the spring 10 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...

Page 102: ...e pressure at port 1 increases higher than the set pressure port P is disconnected from port 1 and port T is connected with port 1 If it decreases lower than the set pressure port P is connected with...

Page 103: ...on the secondary pressure is taken out through ports 1 2 3 and 4 provided at the bottom face GROUP 6 RCVPEDAL 12 4 1 1 2 3 4 T P T P 3 Hydraulic circuit 2 4 12 4 Port P T 1 2 3 4 Port Pilot oil inlet...

Page 104: ...pe The spool is pushed against the push rod 19 by the return spring When the push rod is pushed down by tilting pedal the spring seat comes down simultaneously and changes setting of the secondary pre...

Page 105: ...NCTIONSOFMAJORSECTIONS 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 p...

Page 106: ...he 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 Mai...

Page 107: ...ressure of the pilot valve is not applied to the spool 8 Therefore the spool is pushed up by the spring 18 to the position of port 2 in the operation explanation drawing Then since the output port is...

Page 108: ...the pressure at port 1 increases higher than the set pressure port P is disconnected from port 1 and port T is connected with port 1 If it decreases lower than the set pressure port P is connected wi...

Page 109: ...ah Aa1 Ba1 XAa1 XBa2 XBa1 XAas Op XBb2 dr6 XAs Bs As XBs Btl Atl XAtl XBtl XAa2 XBa2 XAb1 dr4 P1 Bb1 XBb1 XBb2 Ak1 Bk1 XAk XAk2 XBk Ck2 Atr Btr Ao Bo XBo XAo XAtr XBtr Ab1 1 Main pump 2 Main control v...

Page 110: ...ON AND DELIVERY CIRCUIT To cylinders To motors To hydraulic oil tank Hydraulic oil tank Main control valve Main pump GROUP 2 MAINCIRCUIT The pumps receive oil from the hydraulic tank through a suction...

Page 111: ...rns directly to the hydraulic tank resulting in the oil temperature being raised quickly at an appropriate level When the oil cooler is clogged the oil returns directly to the hydraulic tank through b...

Page 112: ...mes out of the drain ports provided in the respective motor casing and join with each other These oils pass through the turning joint and return to the hydraulic tank after being filtered by spin filt...

Page 113: ...emote control valve through line filter EPPR valve solenoid valve assemblies swing parking brake main control valve and safety lock solenoid valve GROUP 3 PILOTCIRCUIT Control valve Remote control val...

Page 114: ...filtered by line filter flows remote control valve through safety solenoid valve The return oil from remote control valve returned to hydraulic tank through the spin filter 1 SUCTION DELIVERYANDRETUR...

Page 115: ...not flow into the remote control valve because of blocked by the spool BOOM2 TRAVEL MOTOR ARM CYLINDER BOOM CYLINDER SWING MOTOR HYD TANK PILOT PUMP BOOM1 BUCKRT CYLINDER TRAVEL SWING ARM BUCKET BOOM...

Page 116: ...s from 320kgf cm2 to 350kgf cm2 for increasing the digging power And even when pressed continuously it is canceled after 8 seconds 3 MAINRELIEFPRESSURECHANGECIRCUIT BOOM2 TRAVEL MOTOR ARM CYLINDER BOO...

Page 117: ...control lever is set neutral position oil in the swing motor disc cylinder is drain thus the brake is applied 4 SWINGPARKINGBRAKERELEASE BOOM2 TRAVEL MOTOR ARM CYLINDER BOOM CYLINDER SWING MOTOR DEVI...

Page 118: ...ction This function is useful to fine control of the arm in case of finishing work 5 ARMHALFFLOWSYSTEM BOOM2 TRAVEL MOTOR ARM CYLINDER BOOM CYLINDER SWING MOTOR HYD TANK PILOT PUMP BOOM1 BUCKRT CYLIND...

Page 119: ...sition the oil of Pk port return to the tank and the control piston is returned thus maximizing the displacement 6 TRAVEL SPEED CONTROL PRESSURE BOOM2 TRAVEL MOTOR DEVICE ARM CYLINDER BOOM CYLINDER HY...

Page 120: ...in control valve When this happens the boom goes up The excessive pressure in the boom cylinder bottom end circuit is prevented by relief valve When the boom is raised and the control lever is returne...

Page 121: ...valve When the lowering speed of boom is faster the oil returned from the large chamber of boom cylinder combines with the oil from the front pump and flows into the small chamber of the cylinder This...

Page 122: ...d to roll in arm The return oil flows from the rod end of the cylinder through the arm1 section returned to the tank Then cavitation which will happen to the bottom of the arm cylinder is prevented by...

Page 123: ...cylinder and to roll out arm The return oil flows from the bottom end of the cylinder through the arm section returned to the tank The cavitation which will happen to the rod of the arm cylinder is p...

Page 124: ...pump via confluence passage The oil flows from both pump through rod end of the cylinder through the bucket section returned to the tank The cavitation which will happen to the bottom of the bucket c...

Page 125: ...r and to roll out bucket The return oil flows from the bottom end of the cylinder through the bucket section returned to the tank The cavitation which will happen to the rod of the bucket cylinder is...

Page 126: ...n the brake release valve returned to the neutral position and the oil is returned from the brake piston to the tank And the brake is set to ON The swing parking brake make up valve and the overload r...

Page 127: ...is connected to prevent this involuntary swing PARKING BRAKE OFF OPERATION The parking brake is released by the pilot pressure oil from the pilot pump When the left control lever placed in the swing p...

Page 128: ...ravel LH section of the main control valve and turning joint to the left travel motor and move the machine forward or reverse The return oil flows from both travel motor through the turning joint and...

Page 129: ...offer the following functions COUNTER BALANCE VALVE When stopping the motor of slope descending this valve to prevent the motor over run OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure b...

Page 130: ...ling the spool of pilot valve is pushed to the downward by the pilot oil pressure from the pilot pump At the same time the straight travel spool is pushed to the left by the oil through the pilot valv...

Page 131: ...in the boom circuits can be high while the swing pressure is low therefore the oil flows from front pump to boom cylinders through boom2 section via confluence passage in case boom raise operation 2 C...

Page 132: ...rear pump to arm cylinder through arm2 section via confluence passage Mean while the pilot oil pressure XAas of swing shuttle valve flows into the stroke limiter of arm spool then the swing priority...

Page 133: ...front pump through swing section of the main control valve to the swing motor and swing the superstructure 4 COMBINEDSWINGANDBUCKETOPERATION TRAVEL MOTOR ARM CYLINDER BOOM CYLINDER SWING MOTOR HYD TAN...

Page 134: ...each actuators According to the state of each actuators functioning the oil flows from front and rear pump through the confluence oil passage to the each actuators 5 COMBINEDSWING BOOM ARMANDBUCKETOP...

Page 135: ...s into the swing motor through the swing spool The oil from the front pump flows into the travel motor through the RH travel spool of the right control valve and the LH travel spool of the left contro...

Page 136: ...s through the RH travel spool of the right control valve and the LH travel spool of the left control valve via the straight travel spool Check valve the pressure in the travel circuit can be high whil...

Page 137: ...the downward by the pilot oil pressure from the pilot pump At the same time the straight travel spool is pushed to the left by the oil through the pilot valve for straight travel The oil from the rea...

Page 138: ...l of the right control valve and the LH travel spool of the left control valve via the straight travel spool of the control valve Check valve the pressure in the travel circuit can be high while the b...

Page 139: ...on switch 7 Service meter 8 Travel alarm switch 9 Cold start switch 10 Arm half switch 11 Aircon switch 12 Main light switch 13 Wiper washer switch 14 Cassette radio 15 Speaker 16 Safety lever 17 Airc...

Page 140: ...art relay 3 Air cleaner switch 4 Fuel sender 5 Fuel filler pump 6 Lamp 7 Hyd temperature sender 8 Engine speed sensor 9 Engine oil pressure switch 10 Water temperature sender 11 Heater valve 12 Heater...

Page 141: ...UP 2 ELECTRICALCIRCUIT 5A 10A 20A 10A 5A 10A 20A 20A 30A 20A 10A 10A 20A 10A 20A 20A 10A 10A 5A 5A F PUMP T ALARM 14 13 12 20 18 17 16 15 19 10 9 8 7 6 5 4 3 2 1 TO STARTER FROM BATT RY 11 CPU CONTROL...

Page 142: ...4 4...

Page 143: ...ING FLOW Battery Battery relay Fusible link CN 60 1 Fuse box No 11 I conn CN 1 N Start switch CS 2 1 Fuse box No 12 I conn CN 1 B I conn CN 6 4 Room lamp CL 1 2 Cassette radio CN 27 7 Fuse box No 13 C...

Page 144: ...POWER CIRCUIT 4 6 FUSE BOX BATTERY RELAY MASTER SW CASSETTE RADIO START KEY SW 3 4 2 1 _ _ ROOM LAMP CPU CONTROLLER CN 6 CL 1 CN 1 CN 27 CS 2 CN 60 CR 1 CN 36 CN 53...

Page 145: ...supplied with the electric component Start switch ON CS 2 3 I conn CN 1 L Fuse box No 1 Fuse box No 2 I conn CN 3 B Fuel cut off CN 79 1 When start key switch is in START position Start switch START...

Page 146: ...TART SAFETY RY MASTER SW BATT RY CPU CONTROLLER STARTER START RY ALTERNATOR FUEL CUT OFF START KEY SW FUSE BOX 1 7 4 3 2 6 5 _ _ CR 5 CN 7 CN 8 CN 51 CN 1 CS 2 CN 3 CR 23 CN 45 M CN 74 CN 79 CN 36 CN...

Page 147: ...alternator to each electrical component and controller through the fuse box OPERATINGFLOW Warning flow Alternator I terminal I conn CN 3 K CPU Alternator power level CN 50 5 Cluster charging warning...

Page 148: ...CHARGINGCIRCUIT 4 10 CPU CONTROLLER STARTER START RY ALTERNATOR CLUSTER 4 3 5 CN 2 CN 9 CN 56 CR 23 CN 51 CN 50 CN 45 CN 74 CN 3 MASTER SW BATT RY 1 2 _ _ CN 60 CR 1 DO 3 CN 36 FUSE BOX M...

Page 149: ...21 9 Work light switch ON 2nd step Work light switch ON CS 21 2 I conn CN 1 Q Work light relay CR 3 1 I conn CN 10 2 Work light ON CL 6 2 CL 5 2 Cluster work light pilot lamp ON CN 52 8 CHECKPOINT 1...

Page 150: ...4 12 HEADANDWORKLIGHTCIRCUIT FUSE BOX WORK LAMP RY WORK LAMP MAIN LIGHT SW CPU CONTROLLER WORK LAMP HEAD LAMP 1 2 4 5 3 6 11 10 9 8 7 CN 36 CN 1 CS 21 CN 52 CN 10 CR 3 CL 6 CL 5 CL 3 CN 2...

Page 151: ...2 When Lamp switch ON Beacon lamp switch ON CS 23 6 Switch indicator lamp ON CS 23 9 I conn CN 6 6 I conn CN 14 3 Beacon lamp ON CL 7 CHECKPOINT Engine Start switch Check point Voltage STOP ON GND Fu...

Page 152: ...4 14 BEACONLAMPCIRCUIT FUSE BOX BEACON LAMP SW BEACON LAMP 2 3 1 4 4 CN 2 CN 14 CL 7 CN 6 CN 1 CN 36 CS 23...

Page 153: ...k CN 22 2 1 Washer operation I conn CN 6 1 I conn CN 13 1 Wiper motor operation CN 21 1 Auto parking When switch OFF Wiper washer switch OFF CS 3 6 8 Wiper motor CN 21 1 Fuse box No 5 I conn CN 1 V I...

Page 154: ...4 16 WIPERANDWASHERCIRCUIT CN 36 6 FUSE BOX WIPER WASHER SW WASHER TANK WIPER MOTOR 2 7 3 1 4 5 CN 1 CN 6 CN 2 CN 22 M CN 21 CN 13 M CS 3...

Page 155: ...4 17 CONTROLLERCIRCUIT FUSE BOX DC MOTOR PROLIX SW EPPR RESISTOR TACHO SENSOR EPPR VALVE CPU CONTROLLER CN 47 CS 7 CN 3 CN 76 M CN 36 CN 53 CN 52 CN 51 CN 50 CD 17 CN 75...

Page 156: ...BREAKER SOL FUSE BOX TRAVEL BUZZER CPU CONTROLLER TRAVEL POWER MAX ARM HALF SW SAFETY SW POWER MAX CS 26 CN 1 CS 27 CS 16 CN 2 CS 29 CS 4 CS 50 CN 88 CN 70 CN 52 CN 53 CN 50 CD 11 CD 14 CD 12 CD 13 CN...

Page 157: ...OX CLUSTER HOUR METER CPU CONTROLLER FUEL SENDER HYD TEMP WATER LEVEL AIR FILTER ENG OIL PS WATER TEMP CN 48 CN 56 CN 9 CN 53 CN 51 CN 50 CN 2 CN 1 CN 3 CN 36 CD 8 CD 18 CD 10 CD 16 CD 1 CD 2 h MONITO...

Page 158: ...N O TYPE Check specific gravity 1 280 over Over charged 1 280 1 250 Normal 1 250 below Recharging Check coil resistance M4 to M4 Normal About 50 Check contact Normal Check disconnection Normal About...

Page 159: ...PE 24V 0 5A Check resistance Normal 9 0 CLOSE Check resistance 50 C 800 80 C 310 100 C 180 Check contact Normal 9 Check contact High level Low level 0 Check resistance Full 100 5 6 200 4 6 300 3 6 400...

Page 160: ...l 1 2 For terminal 5 6 0 8 1 2k For terminal 1 3 Check resistance Normal 15 25 For terminal 1 2 Check resistance Normal 15 25 For terminal 1 2 Check resistance Normal 45 55 Check resistance Normal 3 5...

Page 161: ...2 6 For terminal 5 7 6 8 OFF For terminal 1 5 2 6 0 For terminal 5 7 6 8 Check disconnection Normal 1 2 For terminal 1 2 Check disconnection Normal 1 2 For terminal 1 2 Check disconnection Normal A fe...

Page 162: ...nd connect terminal to ground Check operation Supply power 24V to each terminal and connect ground Check contact Normal 0 For terminal 1 2 For terminal 1 3 Operating For terminal 1 2 0 For terminal 1...

Page 163: ...6A 24V 15A 24V 3 8A 24V 15A Check disconnection Normal 1 1 Check contact Normal 15M Check contact Normal 15M Check contact Normal 1 1 Check contact Normal 10 7 For terminal 1 2 Check contact Normal O...

Page 164: ...About 5M Check contact Normal 10 5 For terminal 1 2 Washer spray 0 2 For terminal 1 4 Wiper operating 24V For terminal 1 4 0V For terminal 2 GND Check contact Power ON 15W 15W 4 4 For terminal 1 6 4 8...

Page 165: ...Normal 0 1 Check contact Normal 0 For terminal B Normal 24 27 5V Check contact Normal 5 2 Check contact Normal 13 4 Check contact Normal 0 2 For terminal 1 2 Emergency 1 2 For terminal 2 3 50 For term...

Page 166: ...ormal 0 9 For terminal 2 4 3 3 For terminal 1 3 5 4 For terminal 1 4 5 7 For terminal 1 2 Workingtemperatureofcontact point ACON 4 5 C AC OFF 1 5 C Differential of temperature 3 C Reted input volt 24V...

Page 167: ...s main harness I conn Boom harness frame harness I conn Wiper harness cabin harness I conn Cabin harness beacon lamp Horn Wiper motor Washer tank Speaker LH Speaker RH Horn Cassette radio Compressor R...

Page 168: ...olenoid AC EVA assembly AC EVA assembly Battery relay Horn relay Work lamp relay Start safety Start relay Door switch Start switch Wiper washer switch Safety switch Horn switch Prolix switch Travel al...

Page 169: ...p Beacon lamp Hydraulic oil temp sender Fuel sender Auto idle pressure switch Water temp sender Air cleaner switch Travel alarm pressure switch Travel alarm pressure switch Travel alarm pressure switc...

Page 170: ...4 32 No of pin Receptacle connector Female Plug connector Male 1 1 S813 030100 1 S813 130100 2 1 2 S813 030200 1 2 S813 130200 2 CONNECTIONTABLEFORCONNECTORS 58 L TYPE CONNECTOR 1...

Page 171: ...4 33 No of pin Receptacle connector Female Plug connector Male 20 1 11 10 20 S817 020105 MULTILOCK TYPE CONNECTOR 2...

Page 172: ...connector Female 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 PATYPECONNE...

Page 173: ...35 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 10 21 1 11 S811 021002 1 11 10 21 S811 121002...

Page 174: ...n Receptacle connector Female Plug connector Male 1 2 3 4 1 1 2 1 1 2 2 1 3 1 3 2 2 4 1 3 1 3 2 4 S813 060100 S813 160100 S813 060200 S813 160200 S813 060300 S813 160300 S813 060400 S813 160400 58 XTY...

Page 175: ...cle 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 10...

Page 176: ...Receptacle connector Female Plug connector Male 1 1 S814 001000 2 3 4 1 S814 101000 2 1 1 2 S814 002000 S814 102000 3 2 1 1 2 3 S814 003000 S814 103000 2 4 1 3 1 3 2 4 S814 004000 S814 104000 SWP TYP...

Page 177: ...ptacle connector Female Plug connector Male 6 8 12 14 3 6 1 4 1 4 3 6 S814 006000 S814 106000 4 8 1 5 1 5 4 8 S814 008000 S814 108000 4 12 1 9 1 9 4 12 S814 012000 S814 112000 3 14 1 11 1 11 3 14 S814...

Page 178: ...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 CNTYP...

Page 179: ...4 41 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 180: ...ptacle connector Female Plug connector Male 2 1 2 S812 002001 3 4 6 2 1 S812 102001 1 3 2 S812 003001 1 2 3 S812 103001 2 4 1 3 S812 004001 1 3 2 4 S812 104001 3 6 1 4 S812 006001 1 4 3 6 S812 106001...

Page 181: ...4 43 No of pin Receptacle connector Female Plug connector Male 10 5 10 1 6 S815 010000 12 16 18 6 12 1 7 S815 012000 8 16 1 9 S815 016000 9 18 1 10 S815 018000 LCTYPECONNECTOR 9...

Page 182: ...4 44 No of pin Receptacle connector Female Plug connector Male 24 12 24 1 13 S815 024000...

Page 183: ...4 45 No of pin Receptacle connector Female Plug connector Male 2 1 2 S810 002402 1 2 S810 102402 375FASTENTYPECONNECTOR 10...

Page 184: ...R valve and other components The CPU controller and the cluster protect themselves from over current and high voltage input and diagnose malfunctions caused by short or open circuit in electric system...

Page 185: ...y Resistor Prolix switch Drive signal Pressure switch signal P M Engine Coolant temp sensor Fuel injection pump Accel actuator Power boost button Hyd temp sensor LH control lever CPU controller Serial...

Page 186: ...tem optimizes the engine and pump performance The combination of 4 power modes H S L F makes it possible to use the engine and pump power more effectively corresponding to the work conditions from a h...

Page 187: ...alve to match engine torque with pump torque optimally by controlling the pump discharge volume H Heavy duty operation mode S General operation mode L Lifting operation mode F Finishing operation mode...

Page 188: ...possible to maximize the work performance by using 100 of the engine power at this mode If the pump load becomes too high and the engine speed drops the CPU controller reduces the pump discharge amoun...

Page 189: ...es the pump discharge So the pump absorption horsepower is reduced by 15 At S mode operation energy saving is about 15 and engine speed sensing at the matching point is the same as for H mode 1 2 Engi...

Page 190: ...to EPPR valve which reduces the pump absorption horsepower 30 So at this mode it is useful for light work and energy saving Engine speed and pump absorption torque are different but the engine speed...

Page 191: ...e the pump absorption horsepower to 50 of full horsepower So at this mode it is useful for light and precise work especially for finishing work Engine speed is set at highly efficient area for engine...

Page 192: ...ncreased by power boost solenoid valve T N Q P Fuel consumption improved by partial use of engine power T N Q P Slow and precise machine operation T N Q P Increase of fine control range High improveme...

Page 193: ...el levers are at neutral for at least 4 seconds CPU controller drives the accel actuator to reduce the engine speed to 1200rpm As the result of reducing the engine speed fuel consumption and noise are...

Page 194: ...OWER MODE H S L F Power boost button signal When the power boost switch on the left control lever knob is pushed ON the maximum digging power is increased by 10 When the power set is at H or S and the...

Page 195: ...ter Travel motor Regulator Regulator Main control valve Arm 1 Boom 2 Swing LH travel Arm 2 Bucket Boom 1 Service RH travel Main relief valve Power boost solenoid valve Travel spped solenoid valve Main...

Page 196: ...time the mode does not change In case of the coolant temperature increases upto 30 C the engine speed is decreased to key start speed And if an operator changes mode set during the warming up function...

Page 197: ...ABLE GROUP 7 ENGINEOVERHEATPREVENTIONFUNCTION Actuated Canceled Overheat warning lamp Coolant temperature Above 110 C Coolant temperature Less than 100 C Changed mode set by operator If any of the abo...

Page 198: ...The portion for one pump is taken as 100 When the arm out and bucket are operated simultaneously the Arm half flow function does not work Engine OFF ON Arm half flow switch LH control lever Arm half f...

Page 199: ...RESTARTFUNCTION After 10 seconds from the engine starts to run CPU controller turns off the start safety relay to protect the starter from inadvertent restarting 2 When a replacement or taking off of...

Page 200: ...odes each one is displayed for 2 seconds respectively and there is short term beep at every number change Examples 1 Communication Error Co Err Buzzer sound 2 No problem Err 3 4 Error codes 03 06 10 4...

Page 201: ...s than 18V Controller input voltage is greater than 38V Error in data receiving from cluster Engine speed sensor circuit is open or shorted to ground or sensor signal is less than 1V Anti restart rela...

Page 202: ...r Remove 6 pieces of screw and open the cover of CPU controller Inspection Check PCB Printed Circuit Board If any damage is found replace CPU controller assembly If not but CAPO system does not work t...

Page 203: ...ontrols engine speed by connecting onto the lever of the injection pump when the malfunction of the CPU controller or the accel actuator happen 1 2 1 2 1 Accel actuator 2 Push pull cable for manual co...

Page 204: ...spection 6P female White Potentiometer 5V Blue Potentiometer SIG Black Potentiometer GND Green Motor Yellow Motor Check resistance Spec 1 2 Between No 5 6 0 8 1 2k Between No 1 3 1 2 3 4 5 1 DC motor...

Page 205: ...ew speed sensor into flywheel housing Turn it back 135 when it contacts with gear teeth Tight lock nut and connect wiring INSPECTION Check resistance SPEC 300 Check voltage while engine run SPEC 2 28V...

Page 206: ...two way direction control valve for pilot pressure to reduce hydraulic pump flow When the electro magnet valve is activated pilot pressure enters into flow regulator of hydraulic pump So pump flow dec...

Page 207: ...o tank A Secondary pressure to flow regulator at hydraulic pump ATHMODE Pressure line is blocked and A oil returns to tank ATS L FMODE Secondary pressure enters into A P T A P T A P T A 2 3 4 5 6 7 1...

Page 208: ...R VALVE Remove plug and connect pressure gauge as figure Gauge capacity 0 to 40 50kgf cm2 0 to 570 710psi Start engine Set S mode and cancel auto decel mode If tachometer show approx 2250 50rpm Check...

Page 209: ...ttery flows to EPPR valve so that EPPR valve can be fixed at the predetermined position In this case excavator can be operated at an equivalent performance to S mode Is the conversion switch to manual...

Page 210: ...rol system 2 CLUSTER MONITORPANEL 1 bar rpm TIME F H C E F L S H POWER MODE SELECT ENGINE SPEED TRAVEL SPEED AUTO DECEL H M Fuel gauge Battery charging lamp Overheat warning lamp Coolant level warning...

Page 211: ...ture below 30 C the warming up lamp lights up Switch portion Mode selection S mode Auto decel LED ON Travel speed switch Low Turtle Start of engine Check machine condition Tachometer indicate at prese...

Page 212: ...5 29 3 CLUSTERCONNECTOR CONNECTOR 1 2 3 4 CN 56 Cluster No Signal Input Output 1 2 3 4 Power IG 24V GND Serial RX Serial TX Input 20 32V Input 0V Input Vpp 12V Output Vpp 4V 1...

Page 213: ...ately 143 Segment D Approximately 178 Segment E Approximately 213 Segment F Approximately 250 Quantity of fuel tank Approximately 250 FUELGAUGE 3 F E Red Green A B C D E F This gauge indicates the tem...

Page 214: ...is turned OFF after starting the engine Check the battery charging circuit when this lamp comes ON while the engine runs BATTERYCHARGINGLAMP 6 When the work lamp switch is turned ON the work lamp moun...

Page 215: ...0 minutes have passed since starting WARMINGUPLAMP 12 The lamp of selected mode is turned ON by pressing the right switch when selecting the mode to use H This is used for heavy duty work S This is us...

Page 216: ...installed pump pressure display P1 P2 P3 is also selected by this switch At each pressing of the switch a short term beep sounds SELECTIONSWITCH Tachometer and clock 16 SELECT M The buzzer sounds is...

Page 217: ...ks at 1sec intervals How to select display mode Group selection Display mode selection Name Display group Display on the cluster Option Only when a pressure sensor is installed Engine rpm Time Front p...

Page 218: ...mperature sensor is 50 C Range Lo Below 20 C 30 90 C by 10 C Hi Above 100 C It shows that pump power shift pressure of EPPR valve being controlled by the CPU controller is 10bar Range 00 50bar by 1bar...

Page 219: ...ased off No operation of travel control lever Shows that hourmeter is activated by CPU controller Shows that hourmeter is turned off Shows that neutral relay for anti restarting function is activated...

Page 220: ...erator to maintain the machine with easy The trouble of machine is parted Hydraulic Mechanical system Electrical system and Mechatronics system At each system part an operator can check the machine ac...

Page 221: ...t time What is 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 b...

Page 222: ...ting According to 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 syste...

Page 223: ...ination of different causes The following lists up commonly occurring faults and possible causes with this machine For the troubleshooting of the engine refer to the coming troubleshooting and repair...

Page 224: ...eland check if rubber piecesorparticles arenotpresent Coupling hub spline is worn or hub fastening setscrew is slack Ifhydraulicpumporengineissuspected asaculpritrefertoservicemanual Structureandfunct...

Page 225: ...mble and repair Repairofreplace Disassemble and repair YES NO YES NO YES NO YES YES YES YES Is oil level in hydraulic oil tank within standard level Do not hydraulic pump and pump connections make abn...

Page 226: ...used very often Is not the set pressure of main relief port relief and travel relief valve lower than thestandardlevel Is fan belt tension proper NO NO YES NO Drop hydraulic oil sample on hot plate an...

Page 227: ...placeoilwith oneofproper viscosity Cleansuction strainer Checkforair intrusionin suction line and retightenor replaceparts NO CAVITATIONOCCURSWITHPUMP 3 HYDRAULICOILISCONTAMINATED 4 YES NO NO Has not...

Page 228: ...nnection couplingisbroken Hydraulicpumpis outoforder Swingcontrolvalve spoolisstuck Hydraulicpumpis broken Swingbrake releasevalveis broken Swingreduction unitisbroken Swingmotoris broken Pilotreliefv...

Page 229: ...pis broken Mainreliefvalve faulty Hydraulicpumpis broken Shuttlevalveis faulty Pilotreliefvalveis faulty Gearpumpis faulty Disassembleand repairorreplace Disassembleand repair Cleanpilotpiping interio...

Page 230: ...trol valve spool move smoothly by hand Is MCV pilot pressure within standard value NO MACHINESWINGSBUTDOESNOTSTOP 4 YES NO Pilotreliefvalveis faulty Gearpumpis broken Pilot valve is faulty Swingcontro...

Page 231: ...NTHEMACHINEISATRESTONASLOPE 5 Is swing relief pressure within standard level Shuttlevalveis faulty Brakespringis faulty Returnspringof swing control valve isfaulty Swingreliefvalve isfaulty Swingmotor...

Page 232: ...ES NO Counterspoolin travel brake valve isstuck Relief valve built in travelmotoris faulty Control system is defective Travelcontrol valve spool is stuck Travelreduction unit is faulty Travelmotorisou...

Page 233: ...move lightly when it is cut off from control spool NO YES NO YES YES YES NO Brake valve is defective Relief valve built in travelmotoris faulty Control system is faulty Controlvalvespool isstuck Trave...

Page 234: ...gine flywheel and check that there is no coupling element particles LHANDRHTRAVELMOTIONSAREIMPOSSIBLE 4 OK Faulty Hydraulicpumpis faulty Travel relief valve isfaulty Coupling at pump connectionis brok...

Page 235: ...ty Hydrauliccircuit thatreleasestravel parking brake is cloggedwithdirt Parkingbrake piston in travel motorisstuck Travelreduction unitisdefective Disassemble and repair Disassemble and repairorreplac...

Page 236: ...AKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME 7 NO YES YES NO NO YES Select valve is faulty Pilotreliefvalveis defective Gearpumpis...

Page 237: ...YES NO Portreliefvalveis faulty Pilot valve is faulty Pilotreliefvalveis faulty Gearpumpis broken Hydraulicpumpis broken Main relief valve is defective Couplingatpump connectionis broken Cylinderinte...

Page 238: ...ck Pilotvalveis defective Pilotreliefvalveis faulty Gearpumpis broken Pilot valve is faulty Normal Disassemble and repair Disassemble and repair Disassemble and repairorreplace Disassemble and repair...

Page 239: ...ween control valve casing and spoolispoor Contactsurface betweenpoppet andseatispoor Cylinderisfaulty Disassemble and repairorreplace Disassemble and replace Locatethecause ofhydraulicoil temperaturer...

Page 240: ...epair Disassemble and repair Disassemble and repair Adjustpressure repairorreplace Disassemble and repair Does control valve spool move smoothly by hand Does the symptom change when hydraulic pump s d...

Page 241: ...e sliding faces ofboom cylinder s oil seal andboom proper Supply grease toit BOOMMAKESASQUEAKINGNOISEWHENBOOMISOPERATED 6 Frictional noise will disappearif they are kept used Ifseizureisin aninitial s...

Page 242: ...internal leak 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...

Page 243: ...YES NO NO YES Checkvoltage betweenCN 2 A andchassis Checkvoltage betweenCN 9 1 andchassis Checkvoltage betweenCN 56 1 andchassis NO CLUSTER POWER IG 24V GND RX TX 2 CN 56 2 CN 9 B CN 2 FUSE NO 3 A 1 1...

Page 244: ...iringharnessor poor contact betweenCN 56 3 4 CN9 3 4 Disconnectionin wiringharnessor poor contact between CN 9 3 4 CN2 C D Disconnectionin wiringharnessor poor contact between CN 2 C D CN51 2 13 Repla...

Page 245: ...Defectivecontroller Disconnectionin wiringharnessor poor contact betweenCN 50 5 CN3 K Disconnectionin wiringharnessor poor contact between CN 3 K alternator terminal I Defectivealternator Replace Rep...

Page 246: ...ly unless otherwise specified Cause Remedy Coolantoverheat 110 C 2 C Defective temp sensor Shortcircuitin wiringharness Defectivecontroller Check engine cooling system Replace Repairorreplace Aftercle...

Page 247: ...s again immediately unless otherwise specified Cause Remedy Clogged air filter or defective switch Shortcircuitin wiringharness Defectivecontroller Check filter or replaceswitch Repairorreplace Afterc...

Page 248: ...otherwise specified Cause Remedy Engineoilleakage or defective switch Defectivecontroller Disconnectioninwiring harnessorpoor contactbetween CN 50 10 CD 18 Check engine oil levelorreplace switch Repl...

Page 249: ...ess otherwise specified Cause Remedy High temperature Defective torque sensor Short circuit Defectivecontroller Check hydraulic oil temperature 100 C 2 C Replace Checkandrepair Replace HYDRAULIC OIL T...

Page 250: ...ed connectors again immediately unless otherwise specified Cause Remedy Insufficientcoolant orDefectiveswitch Short circuit Defectivecontroller Refill coolant or replace switch Checkandrepair Replace...

Page 251: ...essorpoor contactbetween CN 50 CD 8 Defectivecontroller Defective temp sensor Defective cluster Repairorreplace Afterclean Replace Replace Replace NO NO U WATER TEMPERATURE SENSOR CD 8 CN 50 C 1 2 CN...

Page 252: ...d FUEL SENDER CD 2 CN 50 13 CN 51 11 2 1 CONTROLLER F E Level Empty A Full Check Table Item Unit Resistance Tolerance 700 50 400 50 100 50 Cause Remedy Disconnectioninwiring harness Defectivecontrolle...

Page 253: ...Disconnectioninwiring harnessorpoor contactbetween CS 4 3 CN 68 2 Disconnectinwiring harnessorpoor contactbetween CN 2 X CN 68 2 Disconnection in fuse Check hydraulic system Replace Checkand replace...

Page 254: ...53 16 NO NO NO YES YES YES NO Checkiftravelspeed lamps changewhen pressingthetravel speedswitchon thecluster Checkcontroller Cause Remedy Defective hydraulic system Defectivecontroller Defective sole...

Page 255: ...lenoid Disconnectionin wiringharnessor poor contact betweenCN 3 A CN 79 2 Defectiverelay Disconnectionin wiringharnessor poor contact betweenCR 5 4 CR 23 1 Defectivefuelcut offsolenoid Disconnectionin...

Page 256: ...ioninwiring harnessorpoor contactbetween CS 2 1 CN 1 N CN 60 1 CR 1 Battery Battery capacity too low Repairorreplace After clean Replace Replace Replace Chargeorreplace After clean Specific gravity MI...

Page 257: ...30V Checkvoltage betweenCN 6 2 andchassis Starting switch ON Wiper switch ON Voltage 20 30V Starting switch ON Wiper switch ON Voltage 20 30V Starting switch ON Wiper switch OFF Voltage 20 30V Starti...

Page 258: ...arnessorpoor contactbetween CN 1 O CL 3 2 Disconnectioninwiring harnessorpoor contactbetween CS 21 5 9 CN 1 O Disconnectioninwiring harnessorpoor contactbetween CS 21 1 CN 1 R Recheck fuse Replace swi...

Page 259: ...ectioninwiring harnessorpoor contactbetween CS 21 2 CR 3 1 Defective lamp switch Disconnectioninwiring harnessorpoor contactbetween CR 3 2 3 fuseNo 17 Recheck fuse Repairorreplace Afterclean Repairorr...

Page 260: ...re check all the related connectors are properly inserted INSPECTION PROCEDURE 1 Cause Remedy Defective hydraulicsystem Defective EPPRvalve DefectiveCPU controller Shortcircuitor poorconnection betwee...

Page 261: ...timeter CN 75 Multimeter EPPR VALVE 1 2 Test 2 Check resistance at connector CN 75 Starting key OFF Disconnect connector CN 75 from EPPR valve at main hydraulic pump Check resistance between 2 lines a...

Page 262: ...4 Check pressure at EPPR valve Remove plug and connect pressure gauge as figure Gauge capacity 0 to 40 50kgf cm2 0 to 570 710psi Start engine Set S mode and cancel auto decel mode If tachometer show a...

Page 263: ...tcircuit orpoorconnection betweenCN 53 CS 64 CN 76 Improperoperation bylooseningor interferenceofcable Shortcircuitorpoor connectionbetween CN 50 CN 3 CD 17 Defective speed sensor Clean speed sensoran...

Page 264: ...1 CN 52 CN 53 15 12 11 10 9 1 2 3 17 18 19 Multimeter CN 50 20 21 22 4 5 6 13 14 7 8 16 23 24 SPEC 0 2 0 4k SPEC 1 2 Test 6 Check tachometer Work properly or not Start engine Check tachometer reading...

Page 265: ...imeter CD 17 Speed sensor Engine flywheel 1 2 SPEC 0 2 0 4k Test 8 Check resistance at speed sensor Starting key OFF Disconnect connector CD 17 of speed sensor at engine flywheel housing Check resista...

Page 266: ...YES YES YES YES SPEC 350 450mA See TEST 9 SPEC 10 20kgf cm2 See TEST 10 NO SPEC 17 5 1 20 C See TEST 2 NO NO SPEC 17 5 1 20 C See TEST 1 Check electric currentatEPPR valve Check pressure at EPPR Valv...

Page 267: ...ultimeter EPPR VALVE CN 75 Supply line pilot press Pressure adjusting screw locknut 1 2 Test 10 Check pressure at EPPR valve at F mode Connect pressure gauge at EPPR valve Start engine Set F mode with...

Page 268: ...ter Seeifalllampsoff intheCPU controllercase Checkconnection betweenCN 51 2 CN 56 3 orCN 51 13 CN 56 4 Cause Remedy Nopowersupplyto theCPUcontroller CPU failure Cluster failure No connection Checkfuse...

Page 269: ...rmotor Checkvoltage betweenCN 50 6 22 andcheck resistancebetween CN 50 14 22 SPEC 1 2 See TEST 11 Checkresistance betweenCN 53 1 13 Cause Remedy Slowactionof engine speed control due to interference D...

Page 270: ...resistance Starting key OFF Disconnect connector CN 53 from CPU controller Check resistance between CN 53 1 13 as figure CPU CONTROLLER CN 50 CN 51 CN 52 CN 53 10 9 8 7 1 2 3 13 14 15 Multimeter CN 53...

Page 271: ...CN 50 from CPU controller Check resistance value with multimeter as figure 2 Check voltage between CN 50 6 and CN 50 22 Prepare 2 pieces of thin sharp pin steel or copper Starting key ON Insert prepar...

Page 272: ...ch Opencircuitorpoor connection betweenpressure switchesandCN 50 3 11 Replace Replace Repair CPU CONTROLLER CN 50 3 Pa AUTO DECEL PRESSURE SWITCH CD 6 1 2 11 Pa TRAVEL PRESSURE SWITCH 1 2 CD 15 SPEC A...

Page 273: ...in steel or copper Starting key ON Insert prepared pin to rear side of connectors One pin to 3 of CN 50 Check voltage as figure 15 CPU CONTROLLER CN 50 12 11 10 9 1 2 3 17 18 19 Multimeter CN 50 20 21...

Page 274: ...24 CD 8 1 Poorconnection betweenCN 50 15 CD 8 2 RepairorReplace Replace Repair Repair NO 7 MALFUNCTION OF WARMING UP Before carrying out below procedure check all the related connectors are properly i...

Page 275: ...8 1 2 Defectivepower max solenoidvalve Shortcircuitorpoor connectionbetween CN 50 21 CS 29andCN 53 10 CN 88 1 Shortcircuitorpoor connectionbetween CN 88 1 battery relay Repairorreplace Repairorreplace...

Page 276: ...rting key OFF Remove CPU controller and disconnect connector CN 50 from CPU controller Check resistance as figure 2 Power max solenoid valve CN 88 Multimeter CN 88 LH lever Power max switch CN 50 CPU...

Page 277: ...the machine s operational performance deteriorates so that the machine needs to be serviced periodically to restore it to its original performance level Before servicing the machine conduct performanc...

Page 278: ...rand new machine components and parts SERVICELIMIT The lowest acceptable performance level When the performance level of the machine falls below this level the machine must be removed from work and re...

Page 279: ...the test is started 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 alw...

Page 280: ...le stopper To measure engine RPM Measurement Start the engine The engine will run at start idle speed Measure engine speed with a tachometer Measure and record the engine speed at each mode H S L F Se...

Page 281: ...ow or high speed tests adjust the travel mode switch to the speed to be tested then select the following switch positions Mode selector H mode Start traveling the machine in the acceleration zone with...

Page 282: ...Measurement Select the following switch positions Travel mode switch 1 or 2 speed Mode selector H mode Auto decel switch OFF Operate the travel control lever of the raised track in full forward and re...

Page 283: ...el speeds Before beginning each test select the following switch positions Mode selector H mode Start traveling the machine in the acceleration zone with the travel levers at full stroke Measure the d...

Page 284: ...is the same as the boom foot pin The bucket must be empty Keep the hydraulic oil temperature at 50 5 C Measurement Select the following switch positions Mode selector Each mode Operate swing control l...

Page 285: ...Swing the upperstructure 360 Keep the hydraulic oil temperature at 50 5 C Measurement Conduct this test in the H mode Select the following switch positions Mode selector H mode Operate the swing contr...

Page 286: ...ers 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 h...

Page 287: ...n and roll out so that the sideplate edges are vertical to the ground Keep the hydraulic oil temperature at 50 5 C Measurement Select the following switch positions Mode selector H mode To measure cyl...

Page 288: ...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...

Page 289: ...the fully retracted position Position the bucket cylinder with the rod 20 to 30mm retracted from the fully extended position With the arm rolled out and bucket rolled in hold the bucket so that the h...

Page 290: ...each Lower the bucket to the ground to raise one track off the ground Operate the travel lever at full stroke and measure the maximum operating force required When finished lower the track and then j...

Page 291: ...asurement Stop the engine Measure each lever stroke at the lever top from neutral to the stroke end using a ruler Repeat step three times and calculate the average values Evaluation 12 1 2 3 The measu...

Page 292: ...the engine and check for oil leakage from the port Keep the hydraulic oil temperature at 50 5 C Measurement Select the following switch positions Mode selector H mode Auto decel switch OFF Measure th...

Page 293: ...vel mode switch 1 speed 2 speed Mode selector H mode 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 trave...

Page 294: ...and check for oil leakage from the adapter Keep the hydraulic oil temperature at 50 5 C Measurement Select the following switch positions Mode selector H mode Auto decel switch OFF Power boost switch...

Page 295: ...erate 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...

Page 296: ...pump gauge port as shown Start the engine and check for oil leakage from the port Keep the hydraulic oil temperature at 50 5 C Measurement Select the following switch positions Mode selector H mode A...

Page 297: ...boom arm and bucket functions at full stroke over relief and measure the pressure In the swing function place bucket against an immovable object and measure the relief pressure In the travel function...

Page 298: ...of cylinder spring t L Combined height of set plate H spherical bushing h H h Surface roughness for valve plate Sliding face 7 8 swash plate Shoe plate area 9 cylinder 2 Sliding face 0 028 0 056 Repl...

Page 299: ...e control relief valve In case of damage in following section replace part Sliding sections of casing fore and spool especially land sections applied with holded pressure Seal pocket section where spo...

Page 300: ...bore 2 D d Play between piston 1 shoe caulking section 3 Thickness of shoe t Thickness of friction plate 4 Combined height of set plate 5 spherical bushing 6 H h 0 028 0 058 Replace piston or cylinder...

Page 301: ...hing gear teeth have been abnormally worn or broken Sliding surface is deeply scored or roughened The clearance between the valve and base plate 103 is large Sliding surface is deeply scored or roughe...

Page 302: ...the steel ball with swash plate 162 is seized Sliding surface is deeply scored or roughened The clearance between the plunger and base plate 103 is large Sliding surface is deeply scored or roughened...

Page 303: ...arings develops pitting or peeling Bore of gears When the needle and the rolling surface develop flaking and peeling When the needle and the rolling surface develop blow marks The rotation of bearings...

Page 304: ...ry 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 Opera...

Page 305: ...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 P...

Page 306: ...maged more than 0 1mm 0 0039in in depth due to seizure contamination Damaged more than 0 1mm 0 0039in in depth Worn more than 0 5mm 0 02in or abnormality Worn less than 0 5mm 0 02in Damage due to seiz...

Page 307: ...e of crack Presence of crack Presence of crack Plating is not worn off to base metal Rust is not present on plating Scratches are not present Wear of O D Wear of I D Presence of crack Presence of crac...

Page 308: ...en shaft and bushing Interference between roller and bushing Side clearance of roller 1 2 3 4 5 6 7 Standard size Tolerance Shaft Hole 0 0 055 0 40 0 35 60 Standard size Tolerance Shaft Hole 0 132 0 1...

Page 309: ...018 to 0 073 Outside diameter of flange Outside diameter of tread Width of tread Width of flange Clearance between shaft and bearing Interference between bearing and roller 1 2 3 4 5 6 Standard size T...

Page 310: ...earance between shaft and bushing Clearance between shaft and support Side clearance of idler Both side 1 2 3 4 5 6 7 8 Standard size Tolerance Shaft Hole Standard clearance Clearance limit 1 5 0 27 t...

Page 311: ...ink Interference between bushing and link Interference between regular pin and link Tightening torque 1 2 3 4 5 6 7 Standard size Tolerance Shaft Hole Standard interference Interference limit 0 16 to...

Page 312: ...uide Recoil spring 1 2 3 Track frame Idler support Track frame Idler support Rebuild or replace Replace Standard size Tolerance Repair limit 2 0 0 5 1 0 3 1 108 105 249 247 112 101 254 244 Standard si...

Page 313: ...Boom cylinder head Boom cylinder rod Arm cylinder head Boom front Arm cylinder rod Bucket cylinder head Arm link Bucket and arm link Bucket cylinder rod Bucket link 75 70 75 70 75 70 70 70 70 70 70 7...

Page 314: ...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 scr...

Page 315: ...connector to remove all oil dirt or water then connect securely When using eyebolts check that there is no deformation or deterioration and screw them in fully When tightening split flanges tighten un...

Page 316: ...n 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 h...

Page 317: ...nting bolt Track tension cylinder mounting bolt Track shoe mounting bolt nut Track guard mounting bolt Counter weight mounting bolt Cab mounting bolt nut Operator s seat mounting bolt 1 2 3 4 5 6 7 8...

Page 318: ...2 35 1 47 5 49 2 66 6 65 8 98 0 85 0 115 169 229 250 310 lbf ft 8 2 12 6 19 7 29 8 39 8 60 71 114 121 167 182 247 254 343 356 482 476 709 615 832 1223 1655 1808 2242 8T 10T METRICBOLT Fine thread 2 B...

Page 319: ...1 4 3 8 1 2 3 4 1 Width across flat mm 19 22 27 36 41 kgf m 3 4 5 12 14 lbf ft 21 7 28 9 36 2 86 8 101 FITTING Thread size 1 4 3 8 1 2 3 4 1 Width across flat mm 19 22 27 36 41 kgf m 4 5 6 13 15 lbf f...

Page 320: ...hydraulic tank and drain the oil from the hydraulic tank Hydraulic oil quantity 210 Remove socket bolts 10 and disconnect pipe 1 2 Disconnect pilot line hoses 4 5 6 7 8 9 Remove socket bolts 11 and di...

Page 321: ...o 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...

Page 322: ...cket bolt 406 Hexagon socket bolt 435 Flange socket bolt 466 VP plug 468 VP plug 490 VP plug 531 Tilting pin 532 Servo piston 534 Stopper L 535 Stopper S 548 Pin 702 O ring 710 O ring 717 O ring 719 O...

Page 323: ...M 8 M10 M12 M14 M16 M18 PT plug PT thread PO plug PF thread Hexagon socket head setscrew Name Tool name size Part name Allen wrench B B 4 5 6 8 17 19 24 27 30 36 Adjustable angle wrench Screw driver...

Page 324: ...PF 1 4 PF 1 2 PF 3 4 PF 1 PF 1 1 4 PF 1 1 2 0 7 1 2 3 0 5 8 10 0 16 0 24 0 34 0 44 0 0 7 1 05 1 75 3 5 5 0 3 0 10 0 15 0 19 0 27 0 28 0 5 1 8 7 21 7 42 0 72 3 115 7 173 6 245 9 318 3 5 1 7 59 12 66 25...

Page 325: ...rear pump 3 Place pump horizontally on workbench with its regulator fitting surface down and separate pump casing 271 from valve block 312 Before bringing this surface down spread rubber sheet on wor...

Page 326: ...xagon socket head bolts 406 and then seal cover F 261 Fit bolt into pulling out tapped hole of seal cover F and cover can be removed easily Since oil seal is fitted on seal cover F take care not to da...

Page 327: ...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...

Page 328: ...eals etc 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...

Page 329: ...58 and cylinder spring 157 Fit spline phases of retainer and cylinder Then insert piston cylinder subassembly into pump casing 6 Assemble seal cover F 261 to pump casing 271 and fix it with hexagon so...

Page 330: ...ake care not to mistake regulator of front pump for that of rear pump 9 Fit valve block 312 to pump casing 271 and tighten hexagon socket head bolts 401 At first assemble this at rear pump side and th...

Page 331: ...STRUCTURE 1 2 1 753 SECTION B B Pf Pf D D 496 A B B A 405 436 874 611 613 615 614 858 755 612 897 875 412 735 079 722 SECTION D D a 755 466 699 413 496 438 725 724 VIEW C 641 730 643 708 644 645 646...

Page 332: ...Cover C 630 Nut 631 Sleeve 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 708 O ring 722 O...

Page 333: ...screw driver Medium size 2 sets Plastic hammer 1 set For snap ring TSR 160 4 100mm Capable of tightening with the specified torques M4 Length 50mm Tool name size Part name Hexagon socket head bolt PT...

Page 334: ...PF 1 4 PF 1 2 PF 3 4 PF 1 PF 1 1 4 PF 1 1 2 0 7 1 2 3 0 5 8 10 0 16 0 24 0 34 0 44 0 0 7 1 05 1 75 3 5 5 0 3 0 3 0 10 0 15 0 27 0 28 0 5 1 8 7 21 7 42 0 72 3 115 7 173 6 245 9 318 3 5 1 7 59 12 66 25...

Page 335: ...oose a clean place Spread rubber sheet cloth or so on on top of work bench to prevent parts from being damaged Remove dust rust etc from surfaces of regulator with clean oil 1 2 3 Remove hexagon socke...

Page 336: ...snap ring 814 return spring 654 may pop out Take care not to lose it 7 Remove hexagon socket head screws 436 438 and remove pilot cover 641 After removing pilot cover take out set spring 655 from pil...

Page 337: ...move feedback lever 611 Push out pin 874 4mm in dia from above with slender steel bar so that it may not interfere with lever 1 612 10 Remove lever 2 613 Do not draw out pin 875 Work will be promoted...

Page 338: ...Draw out pilot piston 643 and spool 652 Draw out piston case 622 compensating piston 621 and compensating rod 623 Piston case 622 can be taken out by pushing compensating rod 623 at opposite side of...

Page 339: ...en bolts plugs etc to their specified torques Do not fail to coat sliding surfaces with clean hydraulic oil before assembly Replace seals such as O ring with new ones as a rule 1 4 Spool Feedback leve...

Page 340: ...e 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 Put pilot piston 643 into pilot hole o...

Page 341: ...pring seat 644 pilot spring 646 and adjusting ring Q 645 into pilot hole Then fix spring seat 624 inner spring 626 and outer spring 625 into compensating hole When fitting spring seat take care not to...

Page 342: ...atch it in oil pan Remove bolts 2 and disconnect pipe Disconnect pilot line hoses Disconnect pilot piping Sling the control valve assembly 1 and remove the control valve mounting bolt 3 Weight 135kg 2...

Page 343: ...21 24 23 80 83 82 9 8 40 42 31 1 Cap 2 O ring 3 Socket bolt 4 Spring washer 5 Overload assy 6 O ring 7 Orifice 8 Cap 9 O ring 10 Cover 11 Socket bolt 12 Sleeve 13 Check 14 Cap 15 O ring 16 Cap 17 Spri...

Page 344: ...ng 48 Retainer 49 Socket bolt 50 Housing 51 Plunger assy OPT 52 Plunger assy BKT 53 Plunger assy BM1 54 Plunger assy AM2 55 Cap 56 Back up ring 57 Nylon chip 58 Overload assy 59 Spring 60 Check 61 O r...

Page 345: ...s end made like a shoehorn Be careful not to damaged the slot If the components are left disassembled or half disassembled they may get rust from moisture or dust If the work has to be interrupted tak...

Page 346: ...y Valves should be mounted after making sure that all O rings and caps are placed on the assembling faces of 4 plunger valve Carry out assembly in the reverse manner of disassembly Tighten the bolts t...

Page 347: ...ring guide Tools Hexagon socket 8mm Torque wrench 3 2 1 3 4 5 4 3 Remove plunger cap 3 spring guide 4 and spring 5 in this order Place the plunger between holders and loosen plunger cap 3 by using a v...

Page 348: ...elief assembly as a rule Loosen the hexagon nut 2 with a holding adjust screw 1 Loosen the hexagon nut 3 with a holding cap 4 Loosen the cap 4 and remove the cartridge Pull out the sleeve 6 and take o...

Page 349: ...the relief sleeve 1 and remove the cartridge Tightening torque 4kgf m 29lbf ft Loosen the relief seat 2 and remove the subassembly Tightening torque 6kgf m 43 4lbf ft Pull out the poppet 3 and take of...

Page 350: ...t 2 Tightening torque 6kgf m 43 4lbf ft 6 1 2 Tools Hexagon socket 30mm Torque wrench 1 2 3 4 5 Tools Hexagon socket 30mm Torque wrench Remove cap 3 and take off shim 4 and spring 5 Tightening torque...

Page 351: ...orque 5kgf m 36 2lbf ft Install cover assy 2 after making sure that O ring is placed on the edge of the valve hole Remove the spring guide 3 spring 4 and poppet 5 7 1 2 8 6 7 Remove the cap 6 spring 7...

Page 352: ...8 39 CENTER BYPASS VALVE ASSEMBLY Remove cap 1 Tightening torque 8kgf m 57 9lbf ft Remove spool 2 and spring 3 1 2 8 Tools Hexagon socket 36mm Torque wrench 1 2 3...

Page 353: ...spring 2 spring guide 3 check 4 and sleeve 5 Tightening torque 10kgf m 72 3lbf ft 1 Remove cap 6 and spring guide 7 Tightening torque 6kgf m 43 4lbf ft 2 9 1 5 4 3 2 1 7 6 Tools Hexagon socket 10mm T...

Page 354: ...e inserting direction of the spacer 2 1 2 Tools Hexagon socket 6mm Torque wrench 5 4 3 ARMLOADHOLDINGVALVE Basic unit Loosen socket bolt 1 and remove cover assembly 2 Tightening torque 10kgf m 72 3lbf...

Page 355: ...cap 13 Be careful not to damage the guideway 5 of the sleeve Remove cap 8 Take off spring 9 and poppet 10 Tightening torque 5kgf m 36 2lbf ft 3 5 6 7 Tools Hexagon socket 8mm Torque wrench Tools Hexa...

Page 356: ...10kgf m 72 3lbf ft 12 1 BUCKET FLOW SUMMATION CHECK Remove the cap 1 and take off check 2 and spring 3 Tightening torque 6kgf m 43 4lbf ft 13 1 Tools Hexagon socket 12mm Torque wrench Tools Hexagon s...

Page 357: ...4 2 3 3 2 4 Remove spring 2 and check 3 Tightening torque 10kgf m 72 3lbf ft 2 CHECKASSEMBLY ARM2 Remove cap 1 15 1 Remove spring 2 and check 3 4 Tightening torque 10kgf m 72 3lbf ft 2 Tools Hexagon s...

Page 358: ...e 10kgf m 72 3lbf ft 16 1 Take off spring 2 and check 3 2 CHECK ASSEMBLY P1 Remove cap 1 Tightening torque 10kgf m 72 3lbf ft 17 1 Remove spring 2 and check 3 2 Tools Hexagon socket 12mm Torque wrench...

Page 359: ...ake off spring 4 and check 5 Tightening torque 4kgf m 29lbf ft 2 SELECTORVALVEASSEMBLY Remove cap 1 and take off spring 2 and spool 3 Tightening torque 3kgf m 21 7lbf ft 19 1 Tools Hexagon socket 32mm...

Page 360: ...d remove the swing motor mounting bolts 9 Motor device weight 218kg 481lb Tightening torque 57 9kgf m 418 8lbf ft Remove the swing motor assembly When removing the swing motor assembly check that all...

Page 361: ...ner ring 114 Spring 116 Push rod 117 Spacer 118 Spacer 121 Piston 122 Shoe 123 Plate 124 Shoe plate 131 Valve plate 151 Plug 161 O ring 162 O ring 163 O ring 171 Hexagon socket bolt 301 Casing 303 Val...

Page 362: ...de the motor mask all the ports of the motor with tapes Loosen the drain plug to discharge oil in the casing 301 Fix the output drive shaft 101 on the workbench with the end of output shaft down Put m...

Page 363: ...m valve casing 303 Remove RO plug 469 from valve casing 303 and take off spring 355 and plunger 351 Be careful not to damage the plunger seat assembly Loosen the socket bolt 401 and remove valve casin...

Page 364: ...ove the cylinder 111 from the drive shaft 101 with the motor positioned horizontally Remove piston 121 pushing plate 123 spherical bush 113 and spacer 117 If shoe plate would not removed easily try ag...

Page 365: ...oved with sliding shaft if necessary Remove drive shaft 101 from casing 301 Remove the shoe plate 124 from casing 301 Proceed with following job only when necessary Remove the cone of roller bearing 4...

Page 366: ...puller When disassembling the relief valve release the plug 201 and remove the bush 343 spring 322 and spring seat 333 from the rod 303 of the body 101 Remove the piston 302 rod 303 spring 321 spring...

Page 367: ...ench with the valve casing 303 downward Install the cone of roller bearing 443 to the output drive shaft 101 Pay attention to roller bearing 443 direction Insert the drive shaft 101 into the casing 30...

Page 368: ...ve shaft 101 in the casing Tack oil seal 491 to the casing 301 Reassemble the seal cover 305 to the casing 301 Apply grease to the rib of oil seal to avoid damage to the rib Install the snap ring 437...

Page 369: ...cylinder 111 Place the spherical bush 113 assembled with spacer 117 onto the cylinder Insert two push rods in each hole Install the piston sub assembly 121 122 to the push plate 123 Reassemble the pi...

Page 370: ...nd reassemble 3 sheets of separate plate 743 and then 2 sheets of friction plate 742 to the casing 301 Insert O ring 706 707 in the casing 301 Reassemble brake piston 702 to the casing 301 Reassemble...

Page 371: ...hammering Reassemble valve plate 131 to the valve casing 303 and reassemble O ring 472 Connect the valve casing 303 with the casing 301 and tighten the hex socket bolt 401 Insert plunger 351 and sprin...

Page 372: ...f m 21 7lbf ft Insert back up ring 162 and O ring 161 to the relief valve 051 and reassemble them to valve casing 303 Tightening torque 18kgf m 130 2lbf ft Connect the time delay valve 031 with the ca...

Page 373: ...see removal of swing motor assembly Slide reduction gear assembly 1 and remove mounting bolts 2 Remove the reduction gear assembly Reduction gear device weight 150kg 330lb INSTALL Carry out installat...

Page 374: ...3 Pin 285 Side plate 286 Side plate 287 Side plate 288 Side plate 311 Level bar 312 Pipe 401 Roller bearing 402 Roller bearing 403 Needle cage 602 Hexagon socket bolt 801 Seal 901 Plug 902 Plug 910 Sp...

Page 375: ...t support bearing when it was damaged Do not reuse the disassemble shaft support bearing Inspect the No 2 planetary gear thrust button thrust washer and shaft support bearing as in assembly DISASSEMBL...

Page 376: ...Insert the No 1 pin 285 with the spring pin 910 in the No 1 carrier 231 Insert the spring pin 910 in the No 1 carrier Insert the side plate 287 in the center of No 1 carrier Insert the side plate 288...

Page 377: ...e cover Remove the hose 3 4 5 6 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 ass...

Page 378: ...Cap 8 O ring 9 Socket head bolt 10 Steel ball 11 Spring 12 O ring 13 Plug 14 Spring seat 15 Spring 16 Relief valve assembly 17 Relief housing 18 Poppet 19 Poppet seat 20 Spring seat 21 Spring 22 Plug...

Page 379: ...Retainer plate 53 Retainer holder 54 Snap ring 55 Collar 56 Spring 57 Collar 58 Pin 59 Swash plate 60 Steel ball 61 Piston assembly 62 Roller bearing 63 Roller bearing 64 Spring pin 65 Socket head bo...

Page 380: ...M16 Part name Item Size Torque Wrench size kgf m lbf ft in mm Plug Socket head bolt Relief valve Plug Plug Orifice Socket head bolt Plug 5 9 16 33 80 36 38 39 43 66 81 M20 1 5 M10 1 5 1 5 16 NPT 1 16...

Page 381: ...rate them If nut 30 and setscrew 29 are loosened to remove the relief valve assembly 15 the set relief pressure will vary Therefore do not loosen them Do not disassemble the relief valve assembly exce...

Page 382: ...valve Loosen plugs 36 and remove spring 35 and spool 34 Draw out it by turning is slowly Draw out the plunger assembly 4 Draw it out turning it slowly 3 Disassembling the base plate Loosen socket bolt...

Page 383: ...8 70 Remove socket bolts 66 and take off base plate assembly 3 using a screwdriver Do not pry the base plate assembly gerkily with a screwdriver Remove O ring 79 80 from casing 1...

Page 384: ...y pop up by air pressure Therefore use care to avoid danger by utilizing a pop out preventing jig or something 5 Disassembling the cylinder block assembly With casing 1 placed on the side on the work...

Page 385: ...separate collar 56 spring 57 and collar 58 Separate swash plate 60 from casing 1 and then take off steel ball 61 spring 76 and piston assembly 62 Steel balls 61 can easily be taken out if a magnet is...

Page 386: ...8 73 Separate spring 7 and check valve 6 This completes disassembly Disassembling the plunger assembly Fit round bar 10 into plunger 5 and fix in a vise and then remove plug 8 8...

Page 387: ...Precautions Clean parts with clean washing oil and blow it with jet air Handle cleaned parts with care to be free from dust and scoring Replace seals bearings and pins with new ones Tighten the faste...

Page 388: ...the small diameter part of the retainer plate bore taper comes in contact with the flange of the piston shoe Fix it after coating the piston hole with hydraulic oil 3 Fixing Casing 1 Place a suitable...

Page 389: ...sing 1 Fix shaft 40 to casing 1 Insert the cylinder block assembly 50 into casing 1 and assemble them together Insert the cylinder block so piston assembly 62 and retainer holder 54 may not come off F...

Page 390: ...8 77 Fix O ring 70 72 and back up ring 71 73 to brake piston 69 Fix brake piston 69 to casing 1 Place a suitable jig on the brake piston and insert brake piston by tapping with plastic hammer...

Page 391: ...able jig on a work bench and mount base plate 3 on it Fix the out race of roller bearing 64 to base plate 3 Fix pin 75 spring pin 65 and valve plate 77 to the base plate 3 5 Assembling the base plate...

Page 392: ...assembling applying hydraulic oil to sliding surface of plunger Fix plunger 4 by turning it slowly and confirm that it slides smoothly 6 Assembling the plunger Fix round bar 10 into plunger 4 and fix...

Page 393: ...ring 11 Fit flange 12 to base plate 3 and fasten them with socket bolts 13 together Since it is pushed by spring 11 tighten socket bolts 13 holding it down by hand 7 Fit relief valve 15 to base plate...

Page 394: ...8 81 8 Fit spool 34 spring 35 to base plate 3 and tighten plug 36 Pay attention to spool direction...

Page 395: ...13 Planet gear C Roller bearing Gear shaft C Floating seal Collar Thrust washer Spring pin Drive gear Thrust plate Sun gear B Sun gear C Spring washer Flange Floating seal Angular bearing Housing 14...

Page 396: ...the specified torques 6 100 Steel and plastic M10 M16 Part name Item Size Torque Wrench size kgf m lbf ft in mm Socket head bolt Plug 16 17 21 25 26 27 28 M16 2 0 M18 2 5 M12 1 75 M10 1 5 PF 3 4 PT 1...

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Page 408: ...tank Escaping fluid under pressure can penetrate the skin causing serious injury Loosen the socket bolt 2 Remove the cover of the console box Disconnect pilot line hoses 3 Remove the pilot valve assem...

Page 409: ...8 96 2 DISASSEMBLYANDASSEMBLY STRUCTURE 1 27 23 26 18 19 15 12 17 13 8 7 30 22 1 2 4 3 5 10 6 31 9 11 16 14 20 21 24 25 29 28 Port 1 3 Port 2 4...

Page 410: ...9 Stopper 10 Spring 11 Plug 12 Rod seal 13 O ring 14 Push rod 15 Push rod 16 Plate 17 Bushing 18 Joint assembly 19 Swash plate 20 Adjusting nut 21 Lock nut 22 O ring 23 Handle connector 24 Nut 25 Inse...

Page 411: ...7 Length 150 Width 4 5 Capable of tightening with the specified torques Part name Item Size kgf m lbf ft Torque Plug Joint Swash plate Adjusting nut Lock nut Screw 2 18 19 20 21 29 PT 1 8 M14 M14 M14...

Page 412: ...valve in a vise with copper or lead sheets Remove end of boot 26 from case 1 and take it out upwards 1 2 3 Loosen lock nut 21 and adjusting nut 20 with spanners on them respectively and take out hand...

Page 413: ...lizing jig Special tool When return spring 10 is strong in force plate 16 plug 11 and push rod 14 15 will come up on loosening joint Pay attention to this 6 Loosen adjusting nut 20 and plate 19 with s...

Page 414: ...assembly and return springs 9 When return spring 10 is weak in force plug 11 stays in casing because of sliding resistance of O ring Take it out with minus screwdriver Take it out utilizing external p...

Page 415: ...l 5 bottom placed on flat workbench Push down spring seat 8 31 and remove two pieces of semicircular stopper 9 with tip of small minus screwdriver Pay attention not to damage spool surface Record orig...

Page 416: ...8 103 Remove lock nut 21 and then boot 26 15...

Page 417: ...functions of reassembled valve will be degraded Therefore control cleanliness of kerosene fully Put parts in final cleaning vessel filled with kerosene turning it slowly to clean them even to their i...

Page 418: ...seat pushed down put two pieces of semicircular stopper 9 on spring seat without piling them on Assemble stopper 9 so that its sharp edge side will be caught by head of spool Do not push down spring...

Page 419: ...ng is weak in force subassembly stops due to resistance of O ring 8 Assemble push rod 14 15 to plug 11 Apply working oil on push rod surface 7 Assemble seal 12 to plug 11 Assemble seal in such lip dir...

Page 420: ...orque to casing utilizing jig 11 Fit plate 16 10 When return spring is strong in force assemble 4 sets at the same time utilizing plate 16 and tighten joint 18 temporarily 9 Assemble adjusting nut 20...

Page 421: ...ord and tube through it Provide margin necessary to operation 16 Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole 15 Fit boot 26 and lock nut 21 and h...

Page 422: ...ts and then put blind plugs in ports 20 Assemble lower end of bellows to casing 19 Apply grease to rotating section of joint and contacting faces of disk and push rod 18 Determine handle direction tig...

Page 423: ...cted the oil inside the piping will flow out so catch it in oil pan Disconnect all hoses Sling the turning joint assembly 1 and remove the mounting bolt 2 Weight 36kg 79lb Tighteningtorque 12 2 1 3kgf...

Page 424: ...SSEMBLY STRUCTURE 1 1 Hub 2 Shaft assembly 3 Cover 4 Spacer 5 Shim 6 Shim 7 Sipper seal 8 O ring 9 O ring 10 O ring 11 Retaining ring 12 Plug 13 Plug 14 Hexagon head bolt 15 Spring washer 10 15 4 5 7...

Page 425: ...ck 2 Remove six slipper seals 7 and O ring 9 from hub 1 5 Place hub 1 on a V block and by using a wood buffer at the shaft end hit out shaft 2 to about 1 2 from the hub with a hammer Take care not to...

Page 426: ...plastic hammer to install Fit shim 5 spacer 4 and retainer ring 11 to shaft 2 Fit O ring 10 to hub 1 Fit shim 6 to shaft 2 1 2 3 4 5 6 9 7 1 2 1 6 10 11 4 5 ASSEMBLY Clean all parts As a general rule...

Page 427: ...8 114 Install cover 3 to hub 1 and tighten bolts 14 Torque 5 5 12 5kgf m 40 90lbf ft 7 14 15 3...

Page 428: ...e 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...

Page 429: ...assembly 9 Weight 125kg 276lb Install Carry 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 Bleed the air fr...

Page 430: ...e the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious in injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Set bloc...

Page 431: ...ssembly 10 Weight 183kg 403lb Install Carry 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 Bleed the air fro...

Page 432: ...wly to release 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...

Page 433: ...move boom cylinder assembly 5 Weight 135kg 298lb Install Carry out installation in the reverse order to removal When aligning the mounting position of the pin do not insert your fingers in the pin hol...

Page 434: ...4 Du bushing 5 Rod seal 6 Back up ring 7 Step seal 8 Dust wiper 9 Snap ring 10 O ring 11 Back up ring 12 Back up ring 13 Cushion ring 14 Piston 15 O ring 16 Back up ring 17 Piston seal 18 Wear ring 19...

Page 435: ...p ring 17 Piston seal 18 Wear ring 19 Dust ring 20 Cushion spear 21 Steel ball 22 Lock nut 24 Hexagon socket head bolt 25 Band assembly R 25 4 Hexagon bolt 25 5 Hexagon nut 29 Band assembly B 33 Pipe...

Page 436: ...O ring 16 Back up ring 17 Piston seal 18 Wear ring 19 Dust ring 20 Lock nut 22 Hexagon socket head bolt 23 Band assembly 23 4 Hexagon bolt 23 5 Hexagon nut 29 Pipe assembly R 30 Pipe assembly B 31 O...

Page 437: ...m cylinder Bucket cylinder Arm cylinder Boom cylinder Bucket cylinder Boom cylinder Arm cylinder Bucket cylinder Arm cylinder Boom cylinder M16 M20 M10 M12 M10 M10 M10 23 2 46 4 6 3 2 0 3 5 5 0 6 5 4...

Page 438: ...nd remove socket bolts 22 of the cylinder head in sequence Cover the extracted piston rod 2 with rag to prevent it from being accidentally damaged during operation Draw out gland 3 and piston rod asse...

Page 439: ...hydraulic and power wrench that utilizers a hydraulic cylinder to remove the lock nut 20 Remove piston assembly 14 back up rings 16 and O ring 15 and cushion ring 13 Remove the cylinder head assembly...

Page 440: ...rooves Disassemble cylinder head assembly Remove back up ring 12 and O ring 10 Remove back up ring 11 and O ring 10 Remove snap ring 9 and dust wiper 8 Remove back up ring 6 rod seal 5 and step seal 7...

Page 441: ...of dust wiper Fit snap ring 9 to the stop face Fit back up ring 6 rod seal 5 and step seal 7 to corresponding grooves in that order Coat each packing with hydraulic oil before fitting it Insert the ba...

Page 442: ...ooth with an oil stone Coat the outer face of piston 14 with hydraulic oil Fit piston seal 17 to piston 14 Put the piston seal in the warm water of 60 100 C for more than 5 minutes After assembling th...

Page 443: ...assembly to piston rod Insert cushion ring 13 to piston rod Note that cushion ring 13 has a direction in which it should be fitted Fit piston assembly to piston rod 2 Tightening torque 100 10kgf m 723...

Page 444: ...cylinder tube assembly while lifting and moving the piston rod assembly with a crane Be careful not to damage piston seal by thread of tube assembly Match the bolt holes in the gland flange to the tap...

Page 445: ...s and forwards Push out master pin by using a suitable tool Move the machine slowly in reverse and lay out track link assembly 1 Jack up the machine and put wooden block under the machine Don t get cl...

Page 446: ...to permit carrier roller removal Loosen the lock nut 1 Open bracket 2 with a screwdriver push out from inside and remove carrier roller assembly Weight 20 6kg 45 4lb INSTALL Carry out installation in...

Page 447: ...ush up track frame on side which is to be removed After jack up the machine set a block under the unit Remove the mounting bolt 1 and draw out the track roller 2 Weight 38 3kg 84 4lb INSTALL Carry out...

Page 448: ...out idler and recoil spring assembly from track frame using a pry Weight 270kg 595lb Remove the bolts 2 washers 3 and separate idler from recoil spring INSTALL Carry out installation in the reverse or...

Page 449: ...8 136 DISASSEMBLYANDASSEMBLYOFIDLER Structure 1 3 8 6 5 7 4 6 7 8 2 5 1 3 2 1 Idler 2 Bushing 3 Plug 4 Shaft 5 Seal assembly 6 O ring 7 O ring 8 Bracket 9 Dowel pin...

Page 450: ...dowel pin 8 using a press Pull out the shaft 4 with a press Remove seal assembly 5 from idler 1 and bracket 8 Remove O ring 6 from shaft Remove the bushing 2 from idler using a special tool Only remov...

Page 451: ...press it into shell 1 Do not press it at the normal temperature or not knock in with a hammer even after the cooling Coat O ring 6 with grease thinly and install it to shaft 4 Insert shaft 4 into bra...

Page 452: ...8 139 Install bracket 7 attached with seal assembly 5 Knock in the dowel pin 8 with a hammer Lay bracket 7 on its side Supply engine oil to the specified level and tighten plug 7 7 8 1 7...

Page 453: ...8 140 DISASSEMBLYANDASSEMBLYOFRECOILSPRING Structure 1 4 3 4 1 9 7 2 5 6 8 1 Spring 2 Cylinder 3 Fork 4 Nut 5 Packing 6 Piston 7 Packing 8 Plug 9 Tie rod...

Page 454: ...operly Spring set load 11000kg 24250lb Remove lock nut 4 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...

Page 455: ...is not sufficient it may be difficult to adjust the tension of crawler Fit plug 8 to piston 6 Tightening torque 10 1kgf m 72 3 7 2lbf ft Install spring 1 and fork 3 to cylinder liner 2 Apply pressure...

Page 456: ...8 143 1 STRUCTURE GROUP 11 WORKEQUIPMENT SECTION A SECTION B SECTION C C B B A A C...

Page 457: ...Remove nut 4 bolt 3 and draw out the pin 1 Remove nut 4 bolt 3 and draw out the pin 2 Install Carry out installation in the reverse order to removal When aligning the mounting position of the pin do n...

Page 458: ...ssis end securely to prevent oil from spurting out when the engine is started Sling arm cylinder assembly and remove nut bolt then pull out pin Tie the rod with wire to prevent it from coming out For...

Page 459: ...er hose 2 and arm cylinder hose 1 When the hoses are disconnected oil may spurt out Sling boom assembly 3 Remove bolt 4 nut 5 and pull out the pin 6 then remove boom assembly Weight 1230kg 2710lb When...

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