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Hyundai R35Z-7, Workshop Manual

The Hyundai R35Z-7 Workshop Manual is essential for anyone looking to maintain or repair their compact excavator. This comprehensive manual provides detailed instructions and diagrams to help with troubleshooting and servicing. Download your free manual from manualshive.com today and keep your Hyundai R35Z-7 running smoothly.

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5-19

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

Is speed low only
in composite
operation?

Are other
attachment
speeds within
standard levels?

Does the
symptom change
when port relief
valve is replaced
with other valve?

Is pilot valve
normal?

Are LH/RH travel
speeds within
standard levels?

Is combination
of oil streams
normal at boom
hoisting and at
arm extrusion?

Are both LH/RH
travel speeds
low?

Is MCV pilot
pressure within
standard?

Does spool of flow
summation check
valve move lightly
by hand?

ͽ

;

Flow summation

check valve spool

is stuck.  

Hydraulic pump is

faulty.

Ϳ

΀

Port relief valve is

faulty.

Cylinder is faulty.

Control valve spool

is stuck.

Pilot valve is

defective.

Pilot relief valve is

faulty.

Gear pump is

broken.

Pilot valve is faulty.

Normal.

Disassemble and

repair.

Disassemble and

repair.

Disassemble and

repair or replace.

Disassemble and

repair.

Disassemble and

repair.

Clean pilot piping

interior or repair

piping.

Disassemble and

repair.

Disassemble and

repair or replace.

Disassemble and

repair.

Adjust engine

revolution.

Clean orifice in

control valve.

Clean pilot piping

interior or repair

piping.

Disassemble and

repair.

ͽ

;

Ϳ

΀

B

BOOM, ARM OR BUCKET SPEED IS LOW

2)

Does control
valve spool move
lightly by hand?

Is not MCV pilot
pressure piping
clogged or is not
there oil leakage?

Is gear pump
delivering oil?

Is pilot piping not
clogged or is oil
not leaking from
the piping?

Is MCV pilot
pressure within
standard level?

Is primary pilot
pressure within
standard level?

Is engine
revolution within
standard level?

Is not orifice in
control valve
clogged?

Cause

Remedy

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

OK

Summary of Contents for R35Z-7

Page 1: ...ircuit 3 5 Group 4 Single Operation 3 10 Group 5 Combined Operation 3 22 SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location 4 1 Group 2 Monitoring system 4 3 Group 3 Electrical Circuit 4 9 Group 4...

Page 2: ...ice 7 63 Group 7 RCV Lever 7 90 Group 8 Turning Joint 7 104 Group 9 Boom Arm and Bucket Cylinder 7 109 Group 10 Undercarriage 7 128 Group 11 Work Equipment 7 141 SECTION 8 COMPONENT MOUNTING TORQUE Gr...

Page 3: ...ng SECTION 3 HYDRAULIC SYSTEM This section explains the hydraulic circuit single and combined operation SECTION 4 ELECTRICAL SYSTEM This section explains the electrical circuit monitoring system and e...

Page 4: ...ion 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...

Page 5: ...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 6: ...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 7: ...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 32...

Page 8: ...629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 85...

Page 9: ...80 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...

Page 10: ...2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58...

Page 11: ...SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 9...

Page 12: ...xcavator attach a D Do Not Operate tag on the right side control lever USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury When you get on and off the machine always maintain...

Page 13: ...oggles or safety glasses PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protec...

Page 14: ...xcavator starts to move Use a signal person when moving swinging or operating the machine in congested areas Coordinate hand signals before starting the excavator OPERATE ONLY FORM OPERATOR S SEAT Avo...

Page 15: ...Y Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands HANDLE FLUIDS SAFELY AVOID FIRES...

Page 16: ...ll ventilated area Dispose of paint and solvent properly Remove paint before welding or heating Ifyousandorgrindpaint avoidbreathingthedust Wear an approved respirator If you use solvent or paint stri...

Page 17: ...ury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relievin...

Page 18: ...charge a frozen battery It may explode Warm battery to 16 C 60 F P PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause...

Page 19: ...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 drinking from them D...

Page 20: ...Tooth Turning joint Swing motor Engine Oil cooler Radiator Bucket Boom swing cylinder Arm Travel motor Sprocket Counterweight Muffler Cab Boom cylinder Boom Arm cylinder Track Bucket cylinder Side cu...

Page 21: ...stance between tumblers Undercarriage length Undercarriage width Track gauge Track shoe width standard Height of blade Ground clearance of blade up Depth of blade down Travel speed Low high Swing spee...

Page 22: ...all digging depth Max digging height Max dumping height Min swing radius Boom swing radius left right Bucket digging force Arm crowd force Description A A B B C D E F 1 3m 4 3 Arm 5360mm 5240mm 3150mm...

Page 23: ...er Sprocket Rubber track 300mm Dozer blade assembly Front attachment assembly 2 5m boom 1 3m arm 0 11m3 SAE heaped bucket 2 5m boom assembly 1 3m arm assembly 0 11m3 SAE heaped bucket Boom cylinder as...

Page 24: ...indicates load limited by hydraulic capacity Load point height Load radius At max reach 1 0m 3 3ft 2 0m 6 6ft 3 0m 9 9ft 4 0m 13 2ft Capacity Reach m ft 4 0m kg 600 510 3 94 13 2ft lb 1320 1120 12 9 3...

Page 25: ...mited by hydraulic capacity Load point height Load radius At max reach 1 0m 3 3ft 2 0m 6 6ft 3 0m 9 9ft 4 0m 13 2ft Capacity Reach m ft 4 0m kg 700 510 3 94 13 2ft lb 1540 1120 12 9 3 0m kg 760 470 63...

Page 26: ...CECE heaped 0 09m3 0 12yd3 Without side cutter 550mm 21 7 With side cutter 610mm 24 0 80kg 176lb 1 3m 4 3 arm Applicable for materials with density of 1600kgf m3 2700Ib yd3 or less Recommendation 2 5m...

Page 27: ...rbing springs and assembled track type tractor shoes with triple grousers TYPES OF SHOES 1 2 NUMBER OF ROLLERS AND SHOES ON EACH SIDE mm in kg lb kgf cm2 psi mm ft in 300 12 3750 8267 0 34 4 83 1740 5...

Page 28: ...oke Piston displacement Compression ratio Rated gross horse power SAE J1995 Maximum torque at 1400rpm Engine oil quantity Dry weight High idling speed Low idling speed Rated fuel consumption Starting...

Page 29: ...30kgf cm2 3270psi 250kgf cm2 3560psi Item Type Capacity Relief pressure Braking system Braking torque Brake release pressure Reduction gear type Specification Fixed displacement axial piston motor 22c...

Page 30: ...Bore dia Rod dia Stroke Cushion Bore dia Rod dia Stroke Cushion Boom cylinder Arm cylinder Bucket cylinder Boom swing cylinder Dozer cylinder 7 8 9 Discoloration of cylinder rod can occur when the fr...

Page 31: ...Service point Kind of fluid Ambient temperature C F SAE 30 SAE 10W SAE 10W 30 SAE 15W 40 SAE 85W 140 ASTM D975 NO 1 ASTM D975 NO 2 NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type Engine oil p...

Page 32: ...SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device 2 1 Group 2 Main Control Valve 2 9 Group 3 Swing Device 2 38 Group 4 Travel Device 2 46 Group 5 RCV Lever 2 64...

Page 33: ...to the total pressure of P1 P2 Namely the output is controlled to the constant value so that the relationship between the discharge pressure and flow rate Q becomes constant P1 P2 Q Constant The third...

Page 34: ...o equal displacements from one cylinder block Because this is one rotary group there is only one suction port The oil is divided into two equal flows by the control plate in the cover and directed to...

Page 35: ...displacement The oil is discharged to the discharge port discharge process The displacement can be changed by changing the tilting of the hanger swash plate The oil sucked through the port in the cyl...

Page 36: ...the oil pressure via piston acting on the swash plate is less than the installation load of the spring the swash plate is fixed to the maximum tilting position When the oil pressure via piston acting...

Page 37: ...nut Tighten or loosen the adjusting screw to set the power shifting line Flow Q Qmax Pressure at initiation of tilting Tighten Loosen Total pressure Tighten Loosen Hexagon nut Spring guide Spring seat...

Page 38: ...a general petroleum hydraulic oil or wear resistant hydraulic oil ISO 3448 VG 32 56 or equivalent The applicable viscosity range is as follows Maximum allowable viscosity 1000 mm2 s Minimum allowable...

Page 39: ...pump with the speed of 1000 rpm or less and take care not to allow the oil level to lower below the specified level of the oil level gauge When bleeding an air from the hydraulic circuit keep the mot...

Page 40: ...draulic oil as a whole quantity Do not allow dust to mix into the circuit Clean the tank inside Supply the oil through the filter Checking for the oil leakage Daily during the initial period after sta...

Page 41: ...ort Travel RH RR port Travel RH FW port Boom up port Boom down port PF 1 2 PF 3 8 6 7 kgf m 4 0 5 0 kgf m Port name Port size Tightening torque R35Z72MCV01 Mark A10 B10 Pa1 Pb1 Pa2 Pb2 Pa3 Pb3 Pa5 Pb5...

Page 42: ...2 1 Body work 2 2 Spool assy 2 3 Poppet 2 4 Spring 2 5 O ring 2 6 Plug 2 7 O ring 2 8 Cover pilot 2 9 Cover pilot 2 10 Bolt soc head w washer 3 Swing work block 3 1 Body work 3 2 Spool assy 3 3 Poppe...

Page 43: ...Plug 5 7 O ring 5 8 Cover pilot 5 9 Cover pilot 5 10 Bolt soc head w washer 6 Arm work block 6 1 Body work 6 2 Spool assy 6 3 Poppet 6 4 Spring 6 5 O ring 6 6 Plug 6 7 O ring 6 8 Cover pilot 6 9 Cover...

Page 44: ...g 10 5 O ring 10 6 Plug 10 7 O ring 10 8 Cover pilot 10 9 Cover pilot 10 10 Bolt soc head w washer 11 Boom lock valve 11 1 Body work 11 2 O ring 11 3 Plug 11 4 Poppet 11 5 Spring 11 6 Plug 11 7 O ring...

Page 45: ...TRAVEL ARM SWING BOOM SWING DOZER MRV3 Pb7 Pa7 Pb6 Pa6 Pb4 Pa4 Pb1 Pb2 Pa1 Pa2 Boom Up Pb3 Pb5 MRV2 Pa3 P3 Pa5 PTO A6 B6 A3 B3 A4 B4 A2 B2 B1 A1 B5 A5 P2 T1 B10 A10 Pb8 Pb8 T2 MRV1 Dr2 B7 A7 Pb10 Pa1...

Page 46: ...rged from the hydraulic pump flows into the control valve from P3 port and then flows through the parallel passage of dozer boom swing and swing The oil that has followed into the parallel passage flo...

Page 47: ...flow in neutral T2 T1 P3 side bypass passage P3 side parallel passage P3 P2 P2 P1 T2 P2 side bypass passage P2 side parallel passage P1 side bypass passage P1 side parallel passage Tank passage T1 Pp1...

Page 48: ...ide bypass passage flows through A6 A7 port that has been opened by the spool changeover to the travel motor On the other hand the oil returned from the travel motor flows into the control valve from...

Page 49: ...lows through the check valve in the P3 supply section into the P1 side parallel passage Some oil flows through the orifice passage provided in the connecting spool and the check valve in the P3 supply...

Page 50: ...e From P3 side bypass passage Boom up To P1 side parallel passage To P2 side parallel passage Connecting piston P3 P3 side Connecting side circuit T1 T2 P1 Boom Boom lock valve comp P1 Dr1 To cylinder...

Page 51: ...the bypass passage is shut off at the boom section after the spool changeover some oil flows through the orifice passage provided in the boom spool s bypass passage to the downstream side of the bypas...

Page 52: ...cted to the drain passage through the pilot port Pb8 for releasing the boom lock valve The piston chamber b is also connected to the drain passage through the drain port Dr2 Therefore the piston B mai...

Page 53: ...piston A1 Then the oil returned from the boom cylinder flows through the passage in the direction of lock valve s orifice lock valve chamber needle valve seat check valve into the lock valve s downstr...

Page 54: ...n after the bucket spool changeover the oil flowed from P1 port flows through the check valve provided above the bypass passage in the travel section into the P1 side parallel passage Also since a pas...

Page 55: ...shut off at the bucket section after the bucket spool changeover the oil flowed from P1 port flows through the check valve provided above the bypass passage in the travel section into the P1 side par...

Page 56: ...passage between travel section and arm section into the P2 side parallel passage Also since the oil flowed from P3 port flows through the direction of dozer boom swing swing section and then into the...

Page 57: ...ction and then into the P2 side parallel passage via the check valve in the P3 supply section the connecting flow of P2 pump and P3 pump is supplied to the P2 side parallel passage Although the P3 sid...

Page 58: ...side parallel passage Also since the oil flowed from P3 port flows through the direction of dozer boom swing swing section and then into the P2 side parallel passage via the check valve in the P3 sup...

Page 59: ...spool Since the P3 side bypass passage is shut off at the dozer section after the dozer spool changeover the oil flowed from P3 port through the P3 side parallel passage flows into A1 port through th...

Page 60: ...P3 side bypass passage is shut off at the dozer section after the dozer spool changeover the oil flowed from P3 port through the P3 side parallel passage flows into B1 port through the load check valv...

Page 61: ...he P3 side bypass passage is shut off at the boom swing section after the boom swing spool changeover the oil flowed from P3 port through the P3 side parallel passage flows into B2 port through the lo...

Page 62: ...bypass passage is shut off at the boom swing section after the boom swing spool changeover the oil flowed from P3 port through the P3 side parallel passage flows into A2 port through the load check v...

Page 63: ...from the remote control valve is applied to Pa3 port to change over the swing spool Since the P3 side bypass passage is shut off at the swing section after the swing spool changeover the oil flowed fr...

Page 64: ...pump flows to the P1 and P2 side parallel passages through the connecting section Accordingly much oil flows to the arm side normally because of its low working load In this condition since gradually...

Page 65: ...comp Arm in To P1 side parallel passage To P2 side parallel passage P3 P3 side Connecting side circuit T1 T2 P3 T1 To cylinder rod side via A10 port through bridge passage in bucket comp To B10 port...

Page 66: ...to P2 side which is a passage to the tank in restricted the oil from P3 side flows into the P1 side parallel passage that is connected through a check valve With his circuit arrangement the bucket se...

Page 67: ...alve spring the pressure oil is applied to the regulating valve via the piston to open the regulating valve Then the pressure oil flows through a passage in the direction of piston inside orifice B ch...

Page 68: ...n to open the regulating valve Then the pressure oil flows through a passage in the direction of piston inside orifice B chamber A circular orifice C Drill hole D and the external of socket and then i...

Page 69: ...the tank passage pressure is higher than P pressure the socket is applied with press and open force Then the opening between body seat and socket increases to cause the oil to flow into port P from t...

Page 70: ...e make up valve and time delay valve GROUP 3 SWING DEVICE B Mu DB A PB B Mu A HYDRAULIC CIRCUIT GA GB PB PB B Mu DB A GA GB Relief valve Name plate Output shaft Check valve Port A B DB Mu PB GA GB Por...

Page 71: ...10 Pin 2 11 Retainer holder 2 12 Retainer plate 2 13 Piston assy 2 14 Disc 2 15 Brake piston 2 16 O ring 2 17 O ring 2 18 Spring seat 2 19 Spring 2 20 O ring 2 21 Cover 2 22 Ball bearing 2 23 Pin 2 2...

Page 72: ...ck due to the reaction force generates a rotating force The total of rotating force by the reaction force of the high pressure side pistons works on the cylinder block The generated rotating force is...

Page 73: ...brake piston pinned to the case so that it will not rotate and the cylinder block and the case secured by the frictional force Thus the shaft is locked Parking brake OFF When the brake release pressur...

Page 74: ...ncorporated to reduce shock produced at the start of both acceleration and deceleration Construction of the relief valve A direct acting differential area type relief valve A shockless piston The inst...

Page 75: ...relief operating pressure is kept at a low pressure until the shockless piston completes its movement The low pressure holding time depends on the poppet orifice diameter the free piston pressure rec...

Page 76: ...tion equivalent to the amount of oil supplied to the motor the amount of oil equipvalent to the shortage is supplied to the motor main circuit via the make up valve from outside to prevent occurrence...

Page 77: ...3 is held by the holder 5 via the bearing and the holder transmits the revolving motion of the planetary gear 3 to the sun gear 6 coupled via the spline The sun gear 6 meshes with the planetary gear 7...

Page 78: ...eed changeover mechanism GROUP 4 TRAVEL DEVICE P1 P2 R G P1 P2 Ps T1 a1 a2 HYDRAULIC CIRCUIT T2 Oil fill port PT 3 8 Oil check port PT 3 8 Oil drain port PT 3 8 T1 T2 P1 P2 a1 a2 Ps Port P1 P2 a1 a2 T...

Page 79: ...l 7 Cylinder block 8 Color 9 Spring 10 Washer 11 Snap ring 12 Pin 13 Holder 14 Retainer plate 15 Piston assy 17 Brake piston 19 Piston assy 20 Spring 21 Spring 25 Valve plate 26 Pin 27 Ball bearing 28...

Page 80: ...ance valve Reduction gear 1st 2nd speed change mechanism Parking brake mechanism R35Z72TM02 The travel motor is integrated with swash plate type axial piston motor counterbalance valve 2 speed change...

Page 81: ...ive the reaction force against it and produce the reaction force Ft in rotating direction The total force of high pressure side piston assemblies in rotating direction produces a rotating force in the...

Page 82: ...alve R 31 2 Plunger notch portion Motor M1 M2 2 R35Z72TM04 The counterbalance valve is provided to stop the axial piston motor and to prevent overrun When the control valve is set to the neutral posit...

Page 83: ...ugh orifice L 40 pushes the end of face of plunger 31 1 and pushes the plunger rightward against spring R 37 on the opposite side with the force proportional to the pressure When the hydraulic pressur...

Page 84: ...1 and P2 become equal Plunger 31 1 tries to be returned to neutral position by force of spring R 37 When plunger 31 1 moves the throttle opening of plunger becomes small Piston motor tries to rotate w...

Page 85: ...spool 41 is placed in the position shown below in the figure by the force of spring 42 and the passage of swash plate control piston 19 passes across the Pi1 and Pi2 port positions and led to the tank...

Page 86: ...late control piston 19 Therefore the force pushing up the swash plate acts on swash plate control piston 19 Fp1 Ap P1 When steel ball 6 is placed on the tilting center the balance of moment acting on...

Page 87: ...hown in the figure When the two speed spool is on the right position motor pressure PM1 and PM2 are connected to each side of chamber of two speed piston So swash plate is moved to high speed position...

Page 88: ...or pressure is high R35Z72TM09 Motor pressure is high The motor displacement is large low speed displacement as shown in the figure The two speed spool is on the left position if Pin pressure is high...

Page 89: ...C Spool Anti cavitation valve system Counterbalance valve spool 5 R35Z72TM12 Anti cavitation valve is always working with counterbalance valve This system consists of oil passage A B C and spool in ad...

Page 90: ...ssure Counter balance valve spool R35Z72TM13 1 Counterbalance valve spool is moved to right position by the force of spring when port P1 is pressurized According as the movement of spool P1 connects t...

Page 91: ...w pressure High pressure Low pressure Counterbalance valve spool P1 P2 Oil passage B Oil passage C Spool R35Z72TM14 2 In case of continuous rotating the oil passage A is also selected high pressure ho...

Page 92: ...Z72TM15 3 At deceleration the motor is still rotated by inertia The oil flows M2 port to P2 port during counterbalance valve is opened Then if the flow to P1 is not enough the cavitation could be appe...

Page 93: ...ssage A Distriction C Distriction B Inlet Outlet Low pressure High pressure Counterbalance valve spool P1 P2 Oil passage B Oil passage C Spool Shitting position from A to P1 R35Z72TM16 4 Anti cavitati...

Page 94: ...rake When the pressurized oil flows into the motor the plunger moves and the parking brake release port is opened After the oil flows into brake piston chamber the thrust F is generated corresponding...

Page 95: ...ng force is transmitted to ring gear through planetary gear 5 of planetary carrier 6 fixed on the machine body The driving force is also transferred from 1st stage planetary gear 2 The direction of ou...

Page 96: ...d Handle bending direction RH No 4 Push rod Handle bending direction LH No 2 Push rod 6 PF1 4 O ring port View A Single operation Simultaneous operation P 3 2 T 1 4 P T 3 2 1 4 LH RH 4 1 3 2 T P Hydra...

Page 97: ...is 5 to 20 5kgf cm2 Depending on the type The spool is pushed against the push rod 12 13 by the return spring When the push rod is pushed down by tilting the handle the spring seat comes down simulta...

Page 98: ...2 66 CROSS SECTION 23 28 27 22 21 12 16 18 17 5 8 11 3 2 1 10 9 4 6 7 15 14 19 13 32 20 24 25 26 30 29 31 R35Z72RL02...

Page 99: ...F MAJOR SECTIONS The functions of the spool 11 are to receive the supply oil pressure from the hydraulic pump at its port P and to change over oil paths to determine whether the pressure oil of port P...

Page 100: ...lic circuit diagram shown below and the attached operation explanation drawing The diagram shown below is the typical application example of the pilot valve 1 Pilot valve 2 Pilot pump 3 Main pump 4 Ma...

Page 101: ...spool 11 Therefore the spool is pushed up by the spring 4 to the position of port 1 3 in the operation explanation drawing Then since the output port is connected to tank port T only the output port p...

Page 102: ...g force set by tilting the handle the hydraulic pressure force balances with the spring force If the pressure at port 1 increases higher than the set pressure port P is disconnected from port 1 and po...

Page 103: ...SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit 3 1 Group 2 Main Circuit 3 2 Group 3 Pilot Circuit 3 5 Group 4 Single Operation 3 10 Group 5 Combined Operation 3 22...

Page 104: ...ING 22 1 2 Pa4 Pb4 2WAY OPTION 25 ACC P3 A6 B6 A3 B3 A4 B4 A2 B2 B1 A1 B5 A5 B10 A10 B7 A7 A9 B8 Dr1 Pa8 BU 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 MAIN PUMP MAIN CONTROL VALVE TRAVEL MOTOR...

Page 105: ...DELIVERY CIRCUIT To cylinders To motors To hydraulic oil tank Hydraulic oil tank Main control valve Main pump GROUP 2 MAIN CIRCUIT The pumps receive oil from the hydraulic tank through a suction filt...

Page 106: ...ectly 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 bypass c...

Page 107: ...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 return filter SWING MOTOR DRAIN CIRCUIT Oil leak...

Page 108: ...oil from the pilot pump flows to the remote control valve through line filter solenoid valve assemblies swing parking brake main control valve and safety lock solenoid valve Control valve Remote cont...

Page 109: ...BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH 1 2 RH B SWI...

Page 110: ...Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH 1 2 RH B SWING 1 2 Pa4 Pb4 2WAY OPTION ACC P3 A6 B6 A3 B3 A4 B4 A2 B2 B1 A1 B5 A5 B10 A10 B7 A7 A9 B8 Dr1 Pa8 BU 2 4 3 1 L H R H Pb6 Pa6 Pb7 P...

Page 111: ...YSTEM PILOT VALVE A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1...

Page 112: ...T IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH 1 2 RH B SWING 1 2 Pa4 Pb4 2WAY OPTION ACC P3 A6 B6 A3 B3 A4 B4 A2 B2 B1 A1...

Page 113: ...is closed by the boom holding valve This prevents the hydraulic drift of boom cylinder 1 BOOM UP OPERATION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH I...

Page 114: ...valve 2 BOOM DOWN OPERATION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 Pa4 P...

Page 115: ...valve 3 ARM ROLL IN OPERATION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 Pa4...

Page 116: ...l valve 4 ARM ROLL OUT OPERATION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 P...

Page 117: ...trol valve 5 BUCKET ROLL IN OPERATION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6...

Page 118: ...trol valve 6 BUCKET ROLL OUT OPERATION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6...

Page 119: ...also prevented by the make up valve in the swing motor itself 7 SWING OPERATION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3...

Page 120: ...l to the vacuum side of the motor PARKING BRAKE PARKING BRAKE ON OPERATION When the safety solenoid lever is moved to upward the oil in the parking brake is drained to the tank So parking brake is app...

Page 121: ...2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb...

Page 122: ...alves are provided on travel motors to offer the following functions COUNTERBALANCE VALVE When stopping the motor of slope descending this valve to prevent the motor over run SPEED CHANGE MECHANISM Au...

Page 123: ...4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH 1 2 RH...

Page 124: ...NG Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb5 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH...

Page 125: ...right and left travel motor and oil from P3 pump flows into the other operated actuator This keeps the straight travel 1 OUTLINE A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5...

Page 126: ...2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH 1 2 RH B SWING 1 2 Pa4 Pb4 2WAY OP...

Page 127: ...Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 P2 P1 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH 1 2 RH B SWING 1 2 Pa4 Pb4 2WAY OP...

Page 128: ...a10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH 1 2 RH B SWING 1 2 Pa4 Pb4 2WAY OPTION ACC A6 B6 A...

Page 129: ...TION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6...

Page 130: ...TION A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6...

Page 131: ...NG Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 Pb7 Pb4 T1 Pb3 Pp1 Pb1 Pb2 LH...

Page 132: ...Pb5 P2 P1 P3 Dr1 R1 MAIN PUMP TRAVEL MOTOR LH SWING MOTOR TRAVEL MOTOR RH a1 a2 Ps T1 T2 R G R H L H T2 a2 a1 T1 Ps R G GB GA R1 R2 DB P2 BW P1 FW P2 FW P1 BW B CCW A CW Mu PB BOOM TRAVEL RH TRAVEL LH...

Page 133: ...ON A1 A2 A4 A3 S1 S1 BOOM SWING Pb5 4 4 1 3 LH BUCKET ARM A2 1 2 3 2 Pa5 Pb10 Pa10 T A1 A2 RH IN OUT UP DOWN OUT IN P Pa3 Pb2 Pb3 Pa2 Pa8 Pb8 Pa10 Dr2 Pb8 Pa6 Pa7 Pa4 Pa5 Pa3 Pa1 Pa2 Pb10 Pb8 T2 Pb6 P...

Page 134: ...SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location 4 1 Group 2 Monitoring system 4 3 Group 3 Electrical Circuit 4 9 Group 4 Electrical Component Specification 4 25 Group 5 Connectors 4 32...

Page 135: ...14 13 12 HYUN DAI 1 2 3 4 5 TA BAND AST SOURCE RDS VOLUME VOLUME Location at inside of battery box 1 Cigar light 2 Start switch 3 Travel alarm switch 4 Travel speed control 5 Quick clamp switch 6 Wash...

Page 136: ...LOCATION 2 4 2 2 1 3 6 4 5 7 9 8 1 Lamp 2 Horn 3 Master switch 4 Battery 5 Fuel sender 6 Travel alarm buzzer 7 Temperature sender 8 Air cleaner pressure switch 9 Engine oil pressure switch R35Z74EL22...

Page 137: ...nd switch part The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine Various select switches are built into the monitor panel which act as...

Page 138: ...e gauge Pointed at appropriate level Warning lamp During start key ON the engine oil pressure lamp and battery charging lamp go on but it is not abnormal Start of engine Check machine condition Tachom...

Page 139: ...OWER IG 12V LAMP AIR HEATER 7 LAMP QUICK CLAMP 8 LAMP ILLUMINATION 9 GAUGE WATER TEMP 10 GAUGE FUEL LEVEL 11 RETURN AIR HEATER 12 BUZZER 13 HOURMETER SIG 1 HOURMETER B 2 HOURMETER 3 NC 14 EARTH 15 NC...

Page 140: ...indicates the temperature of coolant Red range Above 105 C 221 F When the red range pointed or warning lamp ON engine do not abruptly stop but run it at medium speed to allow it to cool gradually then...

Page 141: ...il pressure warning lamp R5573CD13 3 This lamp blinks when the filter of air cleaner is clogged Check the filter and clean or replace it Air cleaner warning lamp R35Z73CD05 4 This lamp blinks when the...

Page 142: ...2 STARTING ENGINE of operator s manual for details Preheat pilot lamp 6 R35Z73CD06 When the quick clamp switch turned ON this lamp turn ON and the buzzer sounds This lamp turned OFF and the buzzer sto...

Page 143: ...4 10 MEMORANDUM...

Page 144: ...ry terminal as shown below OPERATING FLOW Battery Master switch CS 74 Fusible link CN 60 Start switch CS 2 1 I conn CN 5 2 Engine Start switch Check point Voltage 1 GND Ground OFF OFF GND Battery GND...

Page 145: ...B2 B H BR ACC ST A B C CN 8 1 2 3 4 5 6 15 BrW BrW BrW 1 2 3 4 BrW CN 1 CN 56 1 2 3 4 5 6 LAMP FUEL EMPTY LAMP AIR CLEANER LAMP WATER TEMP LAMP CHARGE LAMP ENG OIL POWER IG 12V LAMP AIR HEATER 7 LAMP...

Page 146: ...box No 2 3 Power is supplied Safety relay CN 165 3 Power relay CR 35 85 87 Fuse box All power is supplied with electric component S Start switch START Start switch START CS 46 4 I conn CN 6 7 Safety r...

Page 147: ...R LAMP WATER TEMP LAMP CHARGE LAMP ENG OIL POWER IG 12V LAMP AIR HEATER 7 LAMP QUICK CLAMP 8 LAMP ILLUMINATION 9 GAUGE WATER TEMP 10 GAUGE FUEL LEVEL 11 RETURN AIR HEATER 12 BUZZER 13 HOURMETER SIG 1...

Page 148: ...attery relay CR 1 The current also flows from alternator to each electrical component and controller through the fuse box OPERATING FLOW Warning flow Alternator L terminal I conn CN 2 13 Cluster CN 56...

Page 149: ...ER TEMP LAMP CHARGE LAMP ENG OIL POWER IG 12V LAMP AIR HEATER 7 LAMP QUICK CLAMP 8 LAMP ILLUMINATION 9 GAUGE WATER TEMP 10 GAUGE FUEL LEVEL 11 RETURN AIR HEATER 12 BUZZER 13 HOURMETER SIG 1 HOURMETER...

Page 150: ...ination ON CL 2 I conn CN 11 3 Cabin Lamp ON CL 9 10 2 Cassette radio illumination ON CN 27 7 Main light switch ON 2nd step Work light switch ON CS 21 2 l conn CN 3 14 l conn CN 12 2 Work light ON CL...

Page 151: ...5 6 LAMP FUEL EMPTY LAMP AIR CLEANER LAMP WATER TEMP LAMP CHARGE LAMP ENG OIL POWER IG 12V LAMP AIR HEATER 7 LAMP QUICK CLAMP 8 LAMP ILLUMINATION 9 GAUGE WATER TEMP 10 GAUGE FUEL LEVEL 11 RETURN AIR...

Page 152: ...n lamp switch ON Beacon lamp switch ON CS 23 1 Switch lndicator lamp ON CS 23 9 l conn CN 3 1 l conn CN 1 5 l conn CN 11 8 Beacon lamp ON CL 7 CHECK POINT 1 2 1 GND Ground Engine Start switch Check po...

Page 153: ...GAR SAFETY TRAVEL BEACON FUEL FEED ALT 10A 1 10A 2 20A 5 6 30A 7 20A 8 20A 9 20A 10 10A 11 20A 12 30A 3 FUSE BOX OPTION B 20A AIR CON HEATER 30A 4 CN 36 CN 1 CN 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1...

Page 154: ...asher Wiper switch ON CS 3 6 Wiper motor operating CN 21 4 Wiper switch ON CS 3 3 I conn CN 4 3 I conn CN 3 3 Washer pump operating CN 22 2 Auto parking When switch OFF Switch OFF Wiper motor CN 21 1...

Page 155: ...WIPER MOTOR HORN CIGAR SAFETY TRAVEL BEACON FUEL FEED ALT 10A 1 10A 2 20A 5 6 30A 7 20A 8 20A 9 20A 10 10A 11 20A 12 30A 3 FUSE BOX OPTION B 20A AIR CON HEATER 30A 4 CN 36 CN 8 1 2 3 4 5 6 7 8 9 10 11...

Page 156: ...T OFF CABIN LAMP WIPER MOTOR HORN CIGAR SAFETY TRAVEL BEACON FUEL FEED ALT 10A 1 10A 2 20A 5 6 30A 7 20A 8 20A 9 20A 10 10A 11 20A 12 30A 3 FUSE BOX OPTION B 20A AIR CON HEATER 30A 4 CN 36 1 2 3 4 CN...

Page 157: ...R SAFETY TRAVEL BEACON FUEL FEED ALT 10A 1 10A 2 20A 5 6 30A 7 20A 8 20A 9 20A 10 10A 11 20A 12 30A 3 SAFETY SW Y RW 1 2 3 OUT GND IG 3 2 4 4 R TIMER FOR STOP SOL CR 50 OUT 1 CS 4 Or Y FUSE BOX FUEL F...

Page 158: ...2 BATTERY MAGNET NC GROUND ALT PULSE IG NC START SIG 24 RW 22E W 25 B G5 5R 28A 5LY 27 GOr 26 B G4 2GW9A 2L 23 5LY 27 5R 28 G L Or Gr Br Y V GW 3R RW BrW RW 30 31 Y 3R 10 13 3W B G3 16 Or L 17 18 Br R...

Page 159: ...minal ON 0 For terminal 1 3 and 1 2 START 0 For terminal 1 5 12V Start key Battery Part name Symbol Specification Check Check resistance Normal 0 CLOSE 0 5kgf cm2 N C TYPE Pressure switch For engine o...

Page 160: ...2 3 4 CR 2 CR 7 CR 35 Rated coil current 1 2 0 3A 87 30 86 85 85 86 30 87 70A 2 1 CN 70 CN 68 CN 140 Solenoid valve Check resistance Normal 15 25 For terminal 1 2 12V 1A Relay 12V 70A CR 51 Speaker Ch...

Page 161: ...ection Normal A few Check disconnection Normal 1 2 12V 10W 12V 55W H3 TYPE CN 20 Horn 100 5dB 12V 2 1 1 2 3 E F H CS 4 Fuel cut off Safety switch Check operation Rated full current 12V 33A Rated hold...

Page 162: ...witch Washer pump Check contact Normal Check contact Normal 3 For terminal 1 2 12V 16A 12V 3 8A CS 3 Cigar lighter Switch Check resistance Normal About 5M Check coil resistance Normal About 1M Check c...

Page 163: ...8 7 6 5 4 3 2 1 GND S L 14 13 Part name Symbol Specification Check CN 27 1 2 Pa B M M CN 29 CN 45 Receiver dryer Starter 12V 12V Check contact Normal 0 Check contact Normal 0 1 2 1 3 2 1 U 3 G L P I...

Page 164: ...r 12V 8 5A CN 83 M 2 1 M 2 1 Fuel feed pump 12V CN 145 1 OUT 4 4 2 3 IG GND OUT 3 2 1 Master switch Timer 12V 12V 1000A 2 1 Duct sensor Switch 1 C OFF 4 C ON Check resistance 0 For terminal 1 2 the at...

Page 165: ...6 1 2 BATTERY MAGNET NC GROUND ALT PULSE IG NC START SIG CN 165 CN 166 Safety relay 12V 1400rpm Alternator Contact capacity Rush 100A Steady State 50A 30sec CN 165 CN 166 GN 1 FUEL LOW LEVEL 3 12V 5 6...

Page 166: ...Cabin harness Canopy harness Boom harness Horn Wiper harness Washer tank Speaker LH Speaker RH Cassette radio Air con comp Receiver dryer Air con harness Starter Heater Hour meter Travel alarm PS Clus...

Page 167: ...y lamp Cabin lamp Canopy lamp Horn relay Air con relay Power relay Timer relay Engine stop sol relay Fuel sender Water temp sender Water temp switch Air cleaner Engine oil pressure Diode Diode Diode S...

Page 168: ...r part No Male Female No of pin CS 26 CS 27 CS 46 CS 67 CS 74 CS 83 SWF KET SWF SWF 1 1 10 4 10 1 10 Breaker switch Breaker switch Start switch Quick clamp switch Master switch Spare S822 014000 59375...

Page 169: ...lug connector Male 5 2 5 1 3 S811 005002 1 3 2 5 S811 105002 3 7 1 4 S811 007002 1 4 3 7 S811 107002 1 5 4 9 3S811 109002 5 11 1 6 S811 011002 1 6 5 11 S811 111002 7 9 11 4 9 1 5 S811 009002 2 CONNECT...

Page 170: ...4 36 No of pin Receptacle connector Female Plug connector Male 13 6 13 1 7 S811 013002 17 21 1 7 6 13 S811 113002 8 17 1 9 S811 017002 1 9 8 17 S811 117002 1 21 1 11 S811 021002 1 11 1 21 S811 121002...

Page 171: ...connector Female Plug connector Male 2 3 4 8 1 2 2 1 2 3 1 3 1 2 3 1 4 2 4 2 3 1 6 3 1 8 5 2 8 5 2 6 3 1 S816 002001 S816 102001 S816 003001 S816 103001 S816 004001 S816 104001 S816 008001 S816 10800...

Page 172: ...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 173: ...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 174: ...n Receptacle connector Female Plug connector Male 1 1 S810 001202 2 3 4 1 S810 101202 2 1 S810 002202 2 1 S810 102202 3 1 2 S810 003202 2 1 3 S810 103202 2 4 1 3 S810 004202 1 3 2 4 S810 104202 CN TYP...

Page 175: ...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 176: ...2 1 2 S810 102402 375 FASTEN TYPE CONNECTOR 5 No of pin Receptacle connector Female Plug connector Male 36 1 12 13 25 24 36 344111 1 1 13 25 12 24 36 344108 1 AMP ECONOSEAL CONNECTOR 6 No of pin Recep...

Page 177: ...2 174045 2 AMP 040 MULTILOCK CONNECTOR 8 No of pin Receptacle connector Female Plug connector Male 14 1 7 6 14 173852 AMP 070 MULTILOCK CONNECTOR 9 No of pin Receptacle connector Female Plug connector...

Page 178: ...o of pin Receptacle connector Female Plug connector Male 2 1 2 MG610070 KET 090 CONNECTOR 11 No of pin Receptacle connector Female Plug connector Male 2 2 1 2 1 2 MG640605 MG640795 KET 090 WP CONNECTO...

Page 179: ...4 45 No of pin Receptacle connector Female Plug connector Male 14 1 7 6 14 MG610406 KET SDL CONNECTOR 13...

Page 180: ...14 Modifications See below Number of contacts P Pin S Socket 04 Receptacle 06 Plug Deutsch connectors Modification E003 Standard end cap gray E004 Color of connector to be black E005 Combination E004...

Page 181: ...4 47 No of pin Receptacle connector Female Plug connector Male 6 6 1 4 3 DT06 6S 6 1 4 3 DT04 6P 5 4 8 1 8 5 4 8 1 DT06 8S 12 DT04 8P 6 7 1 12 DT06 12S 7 6 12 1 DT04 12P...

Page 182: ...nnector Male 2 1 2 35215 0200 MOLEX 2CKTS CONNECTOR 15 No of pin Receptacle connector Female Plug connector Male 10 1 2 9 10 SWF593757 ITT SWF CONNECTOR 16 No of pin Receptacle connector Female Plug c...

Page 183: ...SECTION 5 TROUBLESHOOTING Group 1 Before Troubleshooting 5 1 Group 2 Hydraulic and Mechanical System 5 4 Group 3 Electrical System 5 24...

Page 184: ...p an operator to maintain the machine with easy The trouble of machine is parted Hydraulic Mechanical system and Electrical system system At each system part an operator can check the machine accordin...

Page 185: ...he phenomenon of the trouble Was the trouble getting worse or did it come out suddenly for the first time Did the machine have any troubles previously If so which parts were repaired before STEP 3 Ins...

Page 186: ...where the trouble parts are located hydraulic mechanical system part or electrical system part or mechatronics system part perform troubleshooting the machine refer to the each system part s troubles...

Page 187: ...mbination 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 repai...

Page 188: ...eeland checkifrubber piecesorparticles arenotpresent Coupling hub spline is worn or hub fastening setscrew is slack If hydraulic pump or engine is suspected as a culprit refer to this manual Structure...

Page 189: ...r piping Disassemble and repair Repair or replace Disassemble and repair YES YES YES YES YES YES YES NO NO NO NO Is oil level in hydraulic oil tank within standard level Do not hydraulic pump and pump...

Page 190: ...set pressure of main relief relief and travel relief valve lower than the standard level Is fan belt tension proper YES NO YES YES YES YES NO NO NO Drophydraulicoil sampleonhot plateandcheckif foamsc...

Page 191: ...dard level Replaceoilwith oneofproper viscosity Cleansuction strainer Checkforair intrusionin suctionlineand retightenor replaceparts CAVITATION OCCURS WITH PUMP 3 HYDRAULIC OIL IS CONTAMINATED 4 Hasn...

Page 192: ...olisstuck Hydraulicpumpis broken Swingbrake releasevalveis broken Swingreduction unitisbroken Swingmotoris broken Pilotreliefvalveis faulty Gearpumpisout oforder Pilotvalveis broken Replenish specifie...

Page 193: ...broken Main relief valve faulty Hydraulic pump is broken Shuttle valve is faulty Pilot relief valve is faulty Gear pump is faulty Disassembleand repair or replace Disassemble and repair Cleanpilotpipi...

Page 194: ...ardlevel Doesswingcontrol valvespoolmove smoothlybyhand Is MCV pilot pressure within standard value MACHINE SWINGS BUT DOES NOT STOP 4 Pilotreliefvalveis faulty Gearpumpis broken Pilotvalveisfaulty Sw...

Page 195: ...INE IS AT REST ON A SLOPE 5 Is swing relief pressure within standard level Shuttle valve is faulty Brake spring is faulty Return spring of swing control valve is faulty Swing relief valve is faulty Sw...

Page 196: ...ck Relief valve built in travel motor is faulty Control system is defective Travel control valve spool is stuck Travel reduction unit is faulty Travel motor is out of order Hydraulic pump is broken Tr...

Page 197: ...ive Relief valve built in travel motor is faulty Control system is faulty Control valve spool is stuck Travel relief valve is faulty Hydraulic pump is broken Travel motor s parking brake is not releas...

Page 198: ...eeland checkthatthereis nocoupling elementparticles LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE 4 Faulty Hydraulic pump is faulty Travel relief valve is faulty Coupling at pump connection is broken Inspec...

Page 199: ...Hydraulic circuit that releases travel parking brake is clogged with dirt Parking brake piston in travel motor is stuck Travel reduction unit is defective Disassemble and repair Disassemble and repair...

Page 200: ...A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME 7 NO Select valve is faulty Pilot relief valve is defective Gear pump is broken Normal Rep...

Page 201: ...lot valve is faulty Pilot relief valve is faulty Gear pump is broken Hydraulic pump is broken Main relief valve is defective Coupling at pump connection is broken Cylinder interior is broken Control v...

Page 202: ...fvalveis faulty Gearpumpis broken Pilotvalveisfaulty Normal Disassembleand repair Disassembleand repair Disassembleand repairorreplace Disassembleand repair Disassembleand repair Cleanpilotpiping inte...

Page 203: ...en control valve casing and spool is poor Contact surface between poppet and seat is poor Cylinder is faulty Disassemble and repair or replace Disassemble and replace Locatethecause ofhydraulicoil tem...

Page 204: ...ir Disassemble and repair Disassemble and repair Does control valve spool move smoothly by hand BOOM ARM OR BUCKET POWER IS WEAK 4 Is relief pressure in main relief valve within standard level Is cyli...

Page 205: ...ng faces of boom cylinder s oil seal and boom proper Supply grease to it BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED 6 Frictional noisewill disappearif theyarekept used If seizure is in an init...

Page 206: ...the cylinder If no oil leaks from piping side and boom cylinder rod is retracted there is an internal leak in the control valve 3 Disconnect hose A from rod side of boom cylinder and drain oil from c...

Page 207: ...erly inserted and short of fuse No 2 After checking insert the disconnected connectors again immediately unless otherwise specified YES NO Check voltage between CN 56 2 and chassis CLUSTER POWER IG 12...

Page 208: ...e cluster Disconnectionin wiringharnessor poorcontact betweenCN 56 3 CN2 13 Disconnectionin wiringharnessor poorcontact between CN 2 13 alternator terminal 1 Defectivealternator Replace Repairorreplac...

Page 209: ...or defective temp switch Defective temp detector Short circuit in wiring harness Defective cluster Check engine cooling system or replace temp switch Repair or replace the detector Repair or replace A...

Page 210: ...CN 8 9 2 DETECTOR CN 167 Pa YES NO MAX 1 MIN 1M C Check resistance R35Z75TS13 Cause Remedy Clogged air filter or defective switch Defective the detector Short circuit in wiring harness Defective clust...

Page 211: ...less otherwise specified Cause Remedy Engineoilleakage ordefectiveswitch Defective cluster Disconnectionin wiringharnessor poorcontact between CN 56 2 CD 18 Checkengineoil levelorreplace switch Replac...

Page 212: ...arness or poor contact between CN 56 CD 30 Defective cluster Defective temp sensor Defective cluster Repair or replace After clean Replace Replace Replace YES YES YES NO NO NO Temperature 50 C 80 C 12...

Page 213: ...N 2 CLUSTER CN 56 10 FUEL SENDER CD 2 11 3 2 1 1 2 3 Cause Remedy Disconnection in wiring harness Defective cluster Defective fuel sensor Defective cluster Check and repair Replace Replace Replace YES...

Page 214: ...ontact between CN 3 12 CN 68 2 Disconnectionin Checkhydraulic system Replace Repairorreplace Repairorreplace Afterclean Repairorreplace Afterclean Replace Check voltage between CN 68 1 CN 68 2 YES YES...

Page 215: ...EL SOLENOID FUSE 10 13 CN 6 1 5 9 10 1 2 3 4 5 6 7 8 9 10 2 6 8 7 TRAVEL SPEED CS 8 YES NO NO Checkiftravel speedlamps changewhen pressingthetravel speedswitch Cause Remedy Defectivehydraulic system D...

Page 216: ...s otherwise specified Cause Remedy Recheck fuse Defective wiper switch Defective wiper motor Recheck fuse Replace Replace Replace Replace Check voltage between CS 3 1 and chassis NO NO Wiper switch ON...

Page 217: ...21 5 CN 3 2 Disconnectionin wiringharnessor poorcontact betweenCS 21 5 andfuse Replaceswitch Replace Repairorreplace Afterclean Repairorreplace Afterclean Repairorreplace Afterclean Check voltage bet...

Page 218: ...21 2 CN 3 14 Disconnectionin wiring harness or poor contact between CS 21 4 and fuse Replaceswitch Replace Repairorreplace Afterclean Repairorreplace Afterclean Repairorreplace Afterclean Check voltag...

Page 219: ...start motor Repair or replace safety relay Repair or replace safety relay Repair or replace After clean NO YES YES Starting switch START Starting switch START With in 1 sec Check operation of start m...

Page 220: ...low Replace Replace Replace Charge or replace After clean Specificgravity MIN1 28 Voltage MIN12V Check voltage and specific gravity of battery Voltage 10 12 5V Voltage 10 12 5V Check voltage between C...

Page 221: ...SECTION 6 MAINTENANCE STANDARD Group 1 Operational Performance Test 6 1 Group 2 Major Components 6 21 Group 3 Track and Work Equipment 6 31...

Page 222: ...machine s operational performance deteriorates so that the machine needs to be serviced periodically to restore it to its original performance level Before servicing the machine conduct performance t...

Page 223: ...hine components and parts 1 SERVICE LIMIT The lowest acceptable performance level When the performance level of the machine falls below this level the machine must be removed from work and repaired Ne...

Page 224: ...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 always t...

Page 225: ...m this test first Preparation and measurement Warm up the machine until the engine coolant temperature reaches 50 C or more and the hydraulic oil is 50 5 C Set the accel lever at the maximum stroke Me...

Page 226: ...ore starting either the low or high speed tests adjust the travel mode switch to the speed to be tested Start traveling the machine in the acceleration zone with the travel levers at full stroke Measu...

Page 227: ...ure at 50 5 C M Measurement Select the following switch positions Travel mode switch 1 or 2 speed Operate the travel control lever of the raised track in full forward and reverse Rotate 1 turn then me...

Page 228: ...mistracking at high and low travel speeds Start traveling the machine in the acceleration zone with the travel levers at full stroke Measure the distance between a straight 20m line and the track mad...

Page 229: ...so that the height of the bucket pin is the same as the boom foot pin The bucket must be empty Keep the hydraulic oil temperature at 50 5 C M Measurement Operate swing control lever fully Swing 1 turn...

Page 230: ...one on the swing bearing and one directly below it on the track frame Swing the upperstructure 360 Keep the hydraulic oil temperature at 50 5 C M Measurement Operate the swing control lever fully and...

Page 231: ...e dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race Bucket should be empty Measurement With the arm rolled out and bucket rolled in hold the bottom...

Page 232: ...t cylinder The empty bucket should be positioned at midstroke between roll in and roll out so that the sideplate edges are vertical to the ground Keep the hydraulic oil temperature at 50 5 C M Measure...

Page 233: ...ch measurement 3 times and calculate the average values Evaluation The average measured time should meet the following specifications Unit Seconds 4 Model R35Z 7 Function Boom raise Boom lower Arm in...

Page 234: ...om 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...

Page 235: ...ff the ground Operate the travel lever at full stroke and measure the maximum operating force required When finished lower the track and then jack up the other track Repeat steps and three times and c...

Page 236: ...M Measurement Stop the engine Measure each lever stroke at the lever top from neutral to the stroke end using a ruler Repeat step three times and calculate the average values Evaluation 12 1 2 3 The m...

Page 237: ...nect pressure gauge Start the engine and check for oil leakage from the port Keep the hydraulic oil temperature at 50 5 C M Measurement Measure the primary pilot pressure in the H mode Evaluation 13 1...

Page 238: ...lowing switch positions Travel mode switch 1 speed 2 speed 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...

Page 239: ...nction or arm roll in function and measure the swing brake control pressure with the brake disengaged Release the control lever to return to neutral and measure the control pressure when the brake is...

Page 240: ...gauge to the main pump gauge port G1 G2 G3 as shown Start the engine and check for oil leakage from the port Keep the hydraulic oil temperature at 50 5 C M Measurement Measure the main pump delivery...

Page 241: ...operate each control lever of 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 p...

Page 242: ...any remarkable deformation and damage are found PISTON SHOE AND PISTON Check the axial play of the piston and piston shoe 0 2mm PISTON ASSEMBLY AND CYLINDER BLOCK Check the appearance visually No dama...

Page 243: ...lace the plate with new one GUIDE AND RETAINER Check for scouring or stepped wear If this can not be corrected replace the guide and retainer with new full set Fine scouring or damage can be corrected...

Page 244: ...land sections applied with holded pressure Seal pocket section where spool is inserted Seal section of port where O ring contacts Seal section of each relief valve for main travel and port Other damag...

Page 245: ...tion material is scratched deeply or peeled 2 The meshing surface is worn excessively or cut 1 The rolling contact surface has been flaked or peeled 2 The rolling contact surface is dented 3 Bearing r...

Page 246: ...y damaged worn or flaked 1 The sliding surface is excessively damaged worn or seized Pinion shaft 1 2 Plates 1 3 1 8 Taper roller bearings 1 5 1 7 Oil seal 1 6 Housing 1 1 Holders 1 10 1 18 Drive gear...

Page 247: ...Recommended standards for replacement No remarkable flaws wear or seizure are noted No remarkable flaws wear or flaking are noted on balls and race No remarkable flaws wear or flaking are noted on gea...

Page 248: ...between plunger and base plate Sliding surface between spool and base plate Criterion Recommended standards for replacement No remarkable flaws over 0 02 mm in thickness wear or seizure are noted 0 4a...

Page 249: ...check valve Sliding surface between spool and valve body Criterion Recommended standards for replacement No remarkable flaws wear or seizure are noted No remarkable flaws wear or seizure are noted No...

Page 250: ...rn less than 0 5mm 0 02in Damage due to seizure or contamination remediable within wear limit 0 5mm 0 02in Extruded excessively from seal groove square ring Slipper ring 1 5mm 0 059in narrower than se...

Page 251: ...esence of crack Presence of crack Presence of crack Presence of crack Plating is not worn off to base metal Rust is not present on plating Scratches are not present Wear of O D Wear of I D Presence of...

Page 252: ...o 1 2 3 4 Remedy Replace bushing and pin and link assembly Lug welding rebuild or replace Check item Link pitch Outside diameter of bushing Height of grouser Height of link Standard size 101 6 32 17 1...

Page 253: ...BER SHOE SPEC SECTION A A B B A A 2 3 1 SECTION B B 2 R5576MC17 Criteria Unit mm No 1 2 3 Remedy Replace Check item Link pitch Height of grouser Width of link Standard size 52 5 23 5 34 Repair limit 5...

Page 254: ...MC18 Criteria Unit mm No 1 2 3 Remedy Rebuild or replace Check item Outside diameter of flange Outside diameter of thread Width of flange Standard size 293 327 269 285 26 2 Repair limit 263 279 20 2 S...

Page 255: ...ER R35Z76MC19 Unit mm Criteria No 1 2 3 Remedy Rebuild or replace Check item Outside diameter of flange Outside diameter of thread Width of flange Standard size 131 135 107 95 26 2 Repair limit 101 89...

Page 256: ...6 35 Unit mm No Check item Criteria Remedy Standard size 70 100 30 Repair limit 66 Outside diameter of flange Width of tread Diameter of shaft 1 2 3 Replace R35Z76MC20 4 4 CARRIER ROLLER...

Page 257: ...Vertical width of idler guide Horizontal width of idler guide Recoil spring Criteria Standard size Installed length 233 5 Installed load 2 698 kg Free length Installed load 2 158 kg Repair limit Track...

Page 258: ...e Check item Wear out of sprocket tooth lower side diameter Wear out of sprocket tooth upper side diameter Wear out of sprocket tooth upper side width Wear out of sprocket tooth lower side width Crite...

Page 259: ...Rod Bucket Cylinder Head Arm Link Bucket and Arm Link Bucket Cylinder Rod Bucket Link Boom swing post Boom swing cylinder Blade cylinder Blade and frame link 50 45 45 45 45 45 40 40 40 40 40 70 45 45...

Page 260: ...g Torque 7 4 Group 3 Pump Device 7 7 Group 4 Main Control Valve 7 33 Group 5 Swing Device 7 47 Group 6 Travel Device 7 63 Group 7 RCV Lever 7 90 Group 8 Turning Joint 7 104 Group 9 Boom Arm and Bucket...

Page 261: ...vent any mistake when installing Check the number and thickness of the shims and keep in a safe place When raising components be sure to use lifting equipment of ample strength When using forcing scre...

Page 262: ...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 263: ...en removed and installed again add engine oil to the specified level Run the engine to circulate the oil through the system Then check the oil level again If the piping or hydraulic equipment such as...

Page 264: ...weight mounting bolt Cab mounting bolt nut Operator s seat mounting bolt 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Engine Power train system Under carriage Others Hydraulic system 6 9 1 4 25 2...

Page 265: ...5 1 47 5 49 2 66 6 65 8 98 0 85 0 115 169 229 250 310 lbf ft 8 0 12 3 19 5 29 7 39 8 60 0 70 9 114 121 163 182 247 254 344 356 482 476 709 615 832 1223 1656 1808 2242 8T 10T kgf m Bolt size M 8 1 0 M1...

Page 266: ...size 1 4 3 8 1 2 3 4 1 1 1 4 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 2 151 9 253 2 Thread size UNF 9 16 18 11 16 16 13 16 16 1 3 16 12 1 7 16 12 1 11 16...

Page 267: ...he hydraulic tank Hydraulic tank quantity 37 9 8U S gal Disconnect hoses 79 80 and remove connectors 47 48 Disconnect pilot line hoses 21 90 and remove connectors 49 54 Remove socket bolts 28 and disc...

Page 268: ...o the hydraulic tank to the specified level Bleed the air from the hydraulic pump Remove the air vent plug 1EA Tighten plug lightly Start the engine run at low idling and check oil come out from plug...

Page 269: ...Thrust plate assy 7 10 Plate 7 11 Guide 7 12 Coupling 7 14 O ring 7 15 O ring 7 16 Square ring 7 17 Square ring 7 18 O ring 7 19 Bolt 7 21 Socket head screw 7 30 Name plate 8 Housing assy 11 Oil seal...

Page 270: ...ct 55 or more 110 or more 35 55 R35Z77MP98 Jigs for disassemble the port plate Jigs are necessary to protect the shaft when disassembly and assembly the port plate Disassembly When hexagon socket head...

Page 271: ...care during disassembly not to knock or drop each part Cautions for disassembling Wash each part thoroughly During assembling take utmost care not to damage the part or allow foreign materials to ente...

Page 272: ...agon socket screw key 8 mm Be careful because the O ring at 2 pieces are provided to the housing 1 1 R35Z77MP03 DISASSEMBLING THE TROCHOID PUMP Remove the hexagon socket head cap screw M5 12 3 pieces...

Page 273: ...7 13 Remove the side plate A from the case 4 Remove the side plate B from the port plate 5 Remove the gear from the case 3 R35Z77MP06 Remove the key of the shaft 6 R35Z77MP09 R35Z77MP08 R35Z77MP07...

Page 274: ...ieces M12 55 1 piece Hexagon socket screw key 10 mm 3 3 1 Hexagon socket set screw This photo shows the state with the port plate removed 3 Remove the cover Use the jig to hold the port in a horizonta...

Page 275: ...prings inner and outer and the guide 5 Remove the spring seat 6 R35Z77MP15 R35Z77MP14 R35Z77MP13 R35Z77MP16 Remove the rotary group Remove the shim and the retaining ring For shafts 20 Pliers for reta...

Page 276: ...spline part and pull out straight the shaft taking care not to damage the oil seal 9 R35Z77MP18 R35Z77MP17 Remove the swash plate assembly Remove the swash plate 10 R35Z77MP19 R35Z77MP20 Remove the gu...

Page 277: ...ocket head cap screws M8 30 2 pieces in order to remove the cover of the spring seat assembly Hexagon socket screw key 6mm 13 R35Z77MP26 R35Z77MP27 Remove the spring seat Disassemble the control pisto...

Page 278: ...holes 22 Pliers for retaining rings For holes retaining ring for 22 R35Z77MP30 16 17 R35Z77MP31 Remove the guide the coned disk springs the distance piece and shim Remove the relief valve Remove the h...

Page 279: ...er 14 mm Be careful because the shim is inserted Remove the spring R35Z77MP34 20 21 Remove the spool R35Z77MP35 22 R35Z77MP36 DISASSEMBLING THE GEAR PUMP GSP2 Remove the hexagon socket head cap screws...

Page 280: ...7 20 Remove the square ring 3 Remove the cover 2 R35Z77MP37 R35Z77MP38 Remove the drive gear the idle gear and the side plates 5 R35Z77MP40 Remove the plate the guides and the O rings 4 R35Z77MP39...

Page 281: ...e distance piece and the shim into the housing Pay attention to the direction of the coned disk spring 1 1 Guide Coned disk spring Shim Assembling direction Install the parallel pin and the sleeve int...

Page 282: ...on of the coned disk springs 4 Piston Coned disk spring Shim Assembling direction Assemble the swash plate Install the guides into the housing Assemble the guides into the housing taking care on the m...

Page 283: ...d above the bearing 7 R35Z77MP49 Bearing Shim Assemble the rotary group Install the pistons 10 pistons into the retainer 8 R35Z77MP50 Insert the guide between the retainer and the cylinder block and a...

Page 284: ...ts 20 and install the shim Pliers for retaining rings For shafts retaining ring for 20 R35Z77MP54 12 Shim Shaft Retaining ring Cylinder block Assemble the control spring Apply grease to the spherical...

Page 285: ...socket head cap screws M8 30 2 pieces Hexagon socket screw key 6 mm Tightening torque 3 6 kgf m 21 26 lbf ft R35Z77MP58 15 16 R35Z77MP59 Apply grease to the backside of the control plate to prevent di...

Page 286: ...him into the adjustment screw R35Z77MP62 19 20 R35Z77MP63 Assemble the adjustment screw Spanner 14 mm Tighten the hexagon nut After assembling set the pressure and tighten the nut Spanner 24 mm Tighte...

Page 287: ...te R35Z77MP66 23 24 R35Z77MP67 Fix the port plate with the hexagon socket head cap screws M12 40 3 pieces M12 55 1 pieces Hexagon socket screw key 10 mm Tightening torque 10 12 5 kgf m 72 3 91 lbf ft...

Page 288: ...he surface of matching mark should be positioned in the side plate B side 3 R35Z77MP70 Matching mark Outer rotor Inner rotor Install the side plate A into the case 4 R35Z77MP71 Install the gear outer...

Page 289: ...ing torque 0 7 0 8 kgf m 5 1 6 1 lbf ft 7 R35Z77MP74 ATTACH THE GEAR PUMP Install the coupling to the shaft end on the main pump R35Z77MP75 3 1 Connect the main pump and the gear pump And fix the gear...

Page 290: ...tention to the suction and delivery directions R35Z77MP77 4 1 Assemble the drive gear and the idle gear to the side plates 2 R35Z77MP78 Suction side Delivery side Square ring inserting direction Sucti...

Page 291: ...the plate 4 R35Z77MP80 Side with large R Guide Assemble the plate guides and O rings Pay attention to the suction and delivery directions 5 R35Z77MP81 Suction side Delivery side Install the square rin...

Page 292: ...7 32 Fix the housing and the cover with the hexagon socket head cap screws M10 20 4 pieces Hexagon socket screw key 8 mm Tightening torque 5 6 7 0 kgf m 41 51 lbf ft 8 R35Z77MP84...

Page 293: ...ine hoses Sling the control valve assembly and remove the control valve mounting bolt Weight 25kg 55lb Remove the control valve assembly When removing the control valve assembly check that all the pip...

Page 294: ...2 1 Body work 2 2 Spool assy 2 3 Poppet 2 4 Spring 2 5 O ring 2 6 Plug 2 7 O ring 2 8 Cover pilot 2 9 Cover pilot 2 10 Bolt soc head w washer 3 Swing work block 3 1 Body work 3 2 Spool assy 3 3 Poppe...

Page 295: ...Plug 5 7 O ring 5 8 Cover pilot 5 9 Cover pilot 5 10 Bolt soc head w washer 6 Arm work block 6 1 Body work 6 2 Spool assy 6 3 Poppet 6 4 Spring 6 5 O ring 6 6 Plug 6 7 O ring 6 8 Cover pilot 6 9 Cover...

Page 296: ...g 10 5 O ring 10 6 Plug 10 7 O ring 10 8 Cover pilot 10 9 Cover pilot 10 10 Bolt soc head w washer 11 Boom lock valve 11 1 Body work 11 2 O ring 11 3 Plug 11 4 Poppet 11 5 Spring 11 6 Plug 11 7 O ring...

Page 297: ...on carefully when carrying or transferring the control valve Do not lift by the exposed spool end cover section etc After disassembling and assembling of the component it is desired to carry out vario...

Page 298: ...ol assembly 2 from the body by hand slightly When extracting each spool from its body pay attention not to damage the body When extracting each spool assembly it must be extracted from spring side onl...

Page 299: ...lose the O ring and the poppet under the pilot cover Pay attention not to damage the piston A under pilot cover When any abnormal parts are found replace it with completely new holding valve assembly...

Page 300: ...ief valve The load check valve Fix the body to suitable work bench Pay attention not to damage the body Loosen the plug 6 Hexagon wrench 10mm Remove the O ring 5 spring 4 and the load check valve 3 wi...

Page 301: ...4 Spanner 30mm Remove the overload relief valve 15 Spanner 22mm When disassembled tag the relief valve for identification so that they can be reassembled correctly Pay attention not to damage seat fac...

Page 302: ...7 42 Disassembly of the block assembly Fix the body to suitable work bench Remove the nut 24 Spanner 13mm 5 24 R35Z77MCV15 23 R35Z77MCV16 Do not removed the tie bolt 23...

Page 303: ...e it with new one When a relief valve does not function properly repair it following it s the prescribed disassembly and assembly procedures Replace all seals and O rings with new ones Relief valve Co...

Page 304: ...o deform them permanently In fitting O rings pay close attention not to roll them into their final position in addition a twisted O ring cannot easily untwist itself naturally and could thereby cause...

Page 305: ...Install the main relief valve 14 Spanner 30mm Tightening torque 6kgf m 43 4lbf ft Install the over load relief valve 15 Spanner 22mm Tightening torque 4kgf m 28 9lbf ft 3 14 R35Z77MCV09 15 R35Z77MCV1...

Page 306: ...lding valve Fit the holding valve to the body and tighten hexagon socket head bolt 120 to specified torque Hexagon wrench 5mm Tightening torque 1 1kgf m 7 9lbf ft 6 Holding valve R35Z77MCV14 120 R35Z7...

Page 307: ...ine hoses 27 29 32 Sling the swing motor assembly 1 and remove the swing motor mounting bolts 24 Motor device weight 39kg 86lb Remove the swing motor assembly When removing the swing motor assembly ch...

Page 308: ...Spring 2 8 Washer 2 9 Snap ring 2 10 Pin 2 11 Retainer holder 2 12 Retainer plate 2 13 Piston assy 2 14 Disc 2 15 Brake piston 2 16 O ring 2 17 O ring 2 18 Spring seat 2 19 Spring 2 20 O ring 2 21 Co...

Page 309: ...ecure the motor assembly in a vice Remove the socket head bolts 2 27 and separate the cover 2 21 When separating the cover 2 21 be careful not to drop the valve plate 2 24 Remove the valve plate 2 24...

Page 310: ...the work set a lower air pressure and adjust it while checking the piston for ejection Disassemble the check valve Loosen to remove the plug 2 41 2 41 2 39 2 40 2 15 2 19 2 18 2 18 2 38 2 38 6 2 38 7...

Page 311: ...2 5 2 12 2 13 2 11 2 10 R35Z77SM09 R35Z77SM10 R35Z77SM11 While pushing the washer 2 8 remove the snap ring 2 9 Remove the collar 2 6 the spring 2 7 and the washer 2 8 2 6 2 7 2 8 2 9 R35Z77SM12 2 5 2...

Page 312: ...emble the bearing 2 2 and the ball bearing 2 3 The disassembled bearing must not be used 2 2 2 3 R35Z77SM15 D Disassembling the reduction gear Remove the following parts 1 18 1 22 1 24 1 21 1 20 1 19...

Page 313: ...s used during assembly To facilitate the removal of the screw warm the screw with a drier Remove the following parts 1 10 1 10 1 14 1 13 1 12 1 15 1 16 1 11 R35Z77SM22 R35Z77SM23 1 14 1 13 1 12 Planet...

Page 314: ...ng the shaft be careful not to drop it If it is hard to remove lightly strike it with a plastic hammer Remove the inner race of the taper roller bearing 1 7 Break the oil seal 1 6 to remove it The rem...

Page 315: ...ssemble the collar 2 6 in the correct direction Assemble the check valve 2 39 and the spring 2 40 2 38 2 39 2 40 2 41 2 6 2 7 2 8 R35Z77SM30 R35Z77SM31 R35Z77SM32 R35Z77SM33 A ASSEMBLY Assemble the pa...

Page 316: ...hydraulic fluid to the sliding part before assembly Apply grease to the pin 2 10 and assemble it in the cylinder block 2 5 Assemble the retainer holder 2 11 Press fit the ball bearing 2 2 on the shaft...

Page 317: ...rrect direction Assemble the cylinder block 2 5 and other associated parts During assembly be sure that the pin 2 10 will not come out The disk 2 14 is assembled only for the parking brake spec only A...

Page 318: ...8 2 18 R35Z77SM08 2 18 2 18 2 19 Apply grease to the O ring 2 20 and assemble it in the case 2 1 Check to see if the pin 2 25 can be assembled in the brake piston and case hole If not remove the brake...

Page 319: ...que wrench tighten them to the specified torque Tightening torque 13 0 7 kgf m 94 4 5 lbf ft A Assembling the reduction gear Press fit the oil seal 1 7 Prior to press fit apply grease to the oil seal...

Page 320: ...pply grease to the lip of the oil seal 1 6 1 2 1 1 R35Z77SM25 Install the collar 1 9 and the plate 1 8 Install the following parts on the holder 1 10 Apply loctite 242 to the screw prior to tightening...

Page 321: ...23 1 24 1 37 Thrust washer Inner race Needle bearing Planetary gear A Thrust plate Drive gear O ring E R35Z77SM43 Selection for thrust plate 15 When any consisting parts of reduction unit were change...

Page 322: ...whole motor assembly Place the reduction gear assembly on the motor assembly and loosely tighten the socket head bolt 3 then tighten it to the specified torque Tightening torque 13 0 7 kgf m 94 4 5 lb...

Page 323: ...see r removal of track shoe assembly Remove the cover Remove the hose Fit blind plugs to the disconnected hoses Remove the bolts and the sprocket Sling travel device assembly 1 Remove the mounting bo...

Page 324: ...l 7 Cylinder block 8 Color 9 Spring 10 Washer 11 Snap ring 12 Pin 13 Holder 14 Retainer plate 15 Piston assy 17 Brake piston 19 Piston assy 20 Spring 21 Spring 25 Valve plate 26 Pin 27 Ball bearing 28...

Page 325: ...1 6 Ring nut 1 4 Cap 38 Orifice 40 Orifice 47 62 Plug 45 Screw 1 14 Plug 1 8 31 4 Socket head bolt 50 7 50 8 Plug 1 5 1 27 31 4 43 58 60 Socket head bolt 48 Plug 1 5 50 4 50 5 Housing 1 6 Socket head...

Page 326: ...Ball bearing 3 Shaft 2 Ball bearing 3 Snap ring 11 Ball bearing 27 Parts name Pin Dia 5 5 30mm Eyebolt PF 1 4 Round bar dia 20 1000mm Piano wire dia 0 2 700mm Housing disassembly jig Ring nut tighten...

Page 327: ...1 100 S 9 Floating seal assembly 3 179 5 173 8 170 2 15 179 5 174 170 2 169 161 7 5 15 0 0 2 0 5 0 0 2 0 1 0 1 S 10 Angular bearing press fitting 20 158 165 24 S 11 Flange holder press fitting 180 9...

Page 328: ...and select a clean place Place a rubber or vinyl sheet or other such protective materials on your working bench to protect the surface of the motor to be serviced During disassembly give a match mark...

Page 329: ...required Torque wrench No 1 Hexagonal bit for torque wrench No 7 2 2 1 50 7 R35Z77TM01 Remove cap 38 Tools required Torque wrench No 3 Socket for torque wrench No 12 2 38 38 R35Z77TM03 Take out spring...

Page 330: ...TM06 Remove spring 31 3 check valve 31 2 And store the parts so that the respective parts make a set as it was when assembling again taking care of the combination of the right and left check valves t...

Page 331: ...strike it by use of plastic hammer If it is more difficult to remove remove it by lightly prying with screwdriver Tools required Plastic hammer No 15 Screwdriver No 13 10 30 R35Z77TM11 With parking br...

Page 332: ...3 15 14 13 7 12 18 R35Z77TM14 Remove snap ring 11 by use of plier Remove washer 8 spring seat 10 and spring 9 Be careful not to damage the sliding surface of the cylinder block Tools required Snap rin...

Page 333: ...required Torque wrench No 1 No 2 Eyebolt PF 1 4 S 2 Hexagonal bit for torque wrench No 7 No 8 Round bar dia 20 1000mm S 3 Screw driver No 13 cutting pliers No 16 16 R35Z77TM17 Hook eyebolt and remove...

Page 334: ...ooth surface of gear and the rolling section of the collar 20 1 9 1 10 1 11 1 12 R35Z77TM21 Remove plug 1 8 Tools required Torque wrench No 1 Hexagonal bit for torque wrench No 7 21 R35Z77TM22 Take ou...

Page 335: ...bit for torque wrench No 9 24 1 5 R35Z77TM25 Removing ring nut 1 4 Tools required Torque wrench No 3 Ring nut tightener S 6 If fix them by vise fix around of outside of flange holder absolutely 25 R35...

Page 336: ...ired Screw driver No 13 Be careful not to damage the sliding surface of floating seal 1 2 28 R35Z77TM29 Apply pre bar to the hold of spline and remove shaft 2 striking it by hammer Tools required Scre...

Page 337: ...7 77 Take out ball bearing 3 from shaft 2 Tools required Ball bearing disassembly jig S 8 Completed 31 32 2 3 R35Z77TM32...

Page 338: ...not reuse O rings oil seal and floating seal that were removed in disassembly Provide the new parts Wash all parts thoroughly in a suitable solvent Dry thoroughly with compressed air Do not use the c...

Page 339: ...jig S 10 2 R35Z77TM51 Apply grease to the second floating seal and place it on the concentric circle Install it on housing 1 6 Tools required Floating seal assembly jig S 9 3 1 2 1 6 R35Z77TM52 Apply...

Page 340: ...wrap for assembling of this plug Tools required Torque wrench No 1 Hexagonal bit for torque wrench S 9 Tightening torque 3 5 0 5 kgf m 25 2 3 6 lbf ft 6 1 5 R35Z77TM55 Caulk plug 1 5 two positions wi...

Page 341: ...1 9 1 10 1 11 1 12 R35Z77TM59 Put thrust plate 1 13 on the trunnion section of flange holder apply loctite 262 to screw 1 14 and tighten it Before applying the loctite degrease the parts completely an...

Page 342: ...nd 6 mm of the top end of wire 1 26 at right angle insert it into the threaded hole of the housing and wind the piano wire turning the cover Wrap socket plug 1 8 with seal tape before tightening Tools...

Page 343: ...required Shaft sub assembly press fitting jig S 14 2 R35Z77TM64 Install steel ball 6 spring 20 piston assy 19 and swash plate 5 on flange holder 1 1 Apply hydraulic oil to the sliding surface of the s...

Page 344: ...erally and install the cylinder block sub assy regarding the spline of the shaft as a guide Location of spline tooth of cylinder block 7 should be aligned that of retainer holder 13 to install them ea...

Page 345: ...late 25 and install it and pin 26 O ring 29 on base plate 25 26 29 R35Z77TM72 This process is only parking brake type Apply grease to O rings 22 24 and install them to brake piston 17 Install brake pi...

Page 346: ...bit for torque wrench No 10 Tightening torque 13 1 0 7 kgf m 94 8 5 1 lbf ft 48 R35Z77TM10 Place spool 41 and spring 42 in Place the spool in while turning to prevent them from sticking Apply hydrauli...

Page 347: ...31 4 31 5 R35Z77TM75 Install plunger assy 31 on base plate 30 Install it while turning to prevent it from sticking Apply hydraulic oil to plunger assy 31 before installation 31 R35Z77TM05 Place sprin...

Page 348: ...n socket head bolt 50 7 50 8 Tools required Torque wrench No 1 Hexagonal bit for torque wrench No 7 Tightening torque 3 8 0 2 kgf m 27 2 1 4 lbf ft 50 7 R35Z77TM01 Pour the gear oil through the thread...

Page 349: ...ll piping ports on the motor except one port with plugs and apply compressed air 0 03 MPa through open port in water for two minutes Observe that there are no bubbles Upon completion of leak test in s...

Page 350: ...ping fluid under pressure can penetrate the skin causing serious injury Loosen the socket bolt 1 Remove the cover of the console box Disconnect pilot line hoses 3 Remove the pilot valve assembly 2 Whe...

Page 351: ...O ring 4 Spring 5 Spring seat 1 3 6 Spring seat 2 4 7 Stopper 8 Spring 1 3 9 Spring 2 4 10 Spring seat 11 Spool 12 Push rod 1 3 13 Push rod 2 4 14 Plug 15 O ring 16 Rod seal 17 Plate A 18 Bushing 19...

Page 352: ...7 92 TOOLS AND TIGHTENING TORQUE Tools 1 2 Tool name Remark L Hexagonal wrench Spanner Driver Driver Torque wrench 10 22 27 Length 150 Width 4 5 Capable of tightening with the specified torques B...

Page 353: ...or lead sheets Remove end of boot 32 from case 1 and take it out upwards 1 2 3 Loosen lock nut 24 and adjusting nut 22 with spanners on them respectively and take out handle section as one body 4 For...

Page 354: ...When return spring 8 9 is strong in force plate 31 plug 14 and push rod 12 13 will come up on loosening joint Pay attention to this 7 Loosen adjusting nut 22 and plate 31 with spanners on them respec...

Page 355: ...ings 10 When return spring 8 9 is weak in force plug 14 stays in casing because of sliding resistance of O ring Take it out with minus screwdriver Take it out utilizing external periphery groove of pl...

Page 356: ...on flat workbench Push down spring seat 5 6 and remove two pieces of semicircular stopper 7 with tip of small minus screwdriver Pay attention not to damage spool surface Record original position of sp...

Page 357: ...7 97 Remove lock nut 24 and then boot 27 16 RE18 140 7 RE19 140 7 25038RL02 4...

Page 358: ...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 359: ...pieces of semicircular stopper 7 on spring seat without piling them on Assemble stopper 7 so that its sharp edge side will be caught by head of spool Do not push down spring seat more than 6mm 3 Put s...

Page 360: ...bassembly stops due to resistance of O ring 8 Assemble push rod 12 13 to plug 14 Apply working oil on push rod surface 7 Assemble seal 16 to plug 14 Assemble seal in such lip direction as shown below...

Page 361: ...ing jig 11 Fit plate 31 10 When return spring is strong in force assemble 4 sets at the same time utilizing plate 31 and tighten joint 20 temporarily 9 Assemble adjusting nut 22 apply spanner to width...

Page 362: ...ube through adjusting nut hole provided in direction 60 to 120 from casing hole 16 Fit boot 27 and lock nut 24 and handle subassembly is assembled completely Fit boot 32 to plate 15 14 1408DA61 25038R...

Page 363: ...ports 20 21 Apply grease to rotating section of joint and contacting faces of disk and push rod 19 Determine handle direction tighten lock nut 21 to specified torque to fix handle 18 Assemble bushing...

Page 364: ...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 15kg 35lb Tightening torque 6 9 1 4kgf m 49 9 10 1lbf ft Remo...

Page 365: ...SSEMBLY AND ASSEMBLY STRUCTURE 1 1 Hub 2 Shaft 3 Cover 4 Spacer 5 Slipper seal 6 O ring 7 O ring 8 O ring 9 Retainer ring 10 Plug 11 Plug 12 Hexagon bolt 13 Spring washer 7 6 5 2 3 12 13 9 4 8 10 11 1...

Page 366: ...he shaft end hit out shaft 2 to about 1 2 from the body with a hammer Take care not to damage the shaft 2 when remove hub 1 or rest it sideway Put a fitting mark on hub 1 and shaft 2 4 Remove O ring 8...

Page 367: ...et hub 1 on block install shaft 2 into hub 1 by hand 2 Fix eight slipper seal 5 and O ring 6 7 to hub 1 1 ASSEMBLY Clean all parts As a general rule replace oil seals and O ring Coat the sliding surfa...

Page 368: ...7 108 3 13 12 Install cover 3 to hub and tighten bolts 12 5 R35Z77TJ04...

Page 369: ...ulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconn ecting them to prevent dirt or dust from entering Set block between buc...

Page 370: ...pin do not insert your fingers in the pin hole Bleed the air from the bucket cylinder Confirm the hydraulic oil level and check the hydraulic oil leak or not 6 7 9 8 2 Sling bucket cylinder assembly...

Page 371: ...essure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconn ecting them to prevent dirt or dust from enterin...

Page 372: ...tion of the pin do not insert your fingers in the pin hole Bleed the air from the arm cylinder Confirm the hydraulic oil level and check the hydraulic oil leak or not 2 Sling arm assembly 8 and remove...

Page 373: ...slowly 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 disconn ecting them to prevent...

Page 374: ...do not insert your fingers in the pin hole Bleed the air from the boom cylinder Conformed the hydraulic oil level and check the hydraulic oil leak or not 2 Remove bolt 6 and pull out pin 5 Remove boo...

Page 375: ...5 4 R35Z77CY15 1 Tube assembly 2 Rod assembly 3 Gland 4 Dust wiper 5 Retaining ring 6 Rod seal 7 Back up ring 8 DU bush 9 O ring 10 Back up ring 11 O ring 12 Piston 13 Dust ring 14 Piston seal 15 Wear...

Page 376: ...ssembly 3 Gland 4 Dust wiper 5 Retaining ring 6 Rod seal 7 Back up ring 8 DU bush 9 O ring 10 Back up ring 11 O ring 12 Piston 13 Dust ring 14 Piston seal 15 Wearing 16 O ring 17 Back up ring 18 Pisto...

Page 377: ...assembly 2 Rod assembly 3 Gland 4 Dust wiper 5 Retaining ring 6 Rod seal 7 Back up ring 8 DU bush 9 O ring 10 Back up ring 11 O ring 12 Piston 13 Dust ring 14 Piston seal 15 Wearing 16 O ring 17 Back...

Page 378: ...7CY18 1 Tube assembly 2 Rod assembly 3 Gland 4 Dust wiper 5 Retaining ring 6 Rod seal 7 Back up ring 8 Buffer ring 9 DU bush 10 O ring 11 Back up ring 12 O ring 13 Piston 14 Piston seal 15 Wear ring 1...

Page 379: ...1 Tube assembly 2 Rod assembly 3 Gland 4 Dust wiper 5 Retaining ring 6 Rod seal 7 Back up ring 8 DU bush 8 O ring 9 Back up ring 10 O ring 11 O ring 12 Piston 13 Dust ring 14 Piston seal 15 Wear ring...

Page 380: ...ame Item Size Torque kgf m lbf ft T Tightening torque 2 Gland Piston nut Boom cylinder Arm cylinder Bucket cylinder Dozer cylinder Boom swing cylinder Boom cylinder Arm cylinder Bucket cylinder Dozer...

Page 381: ...ly together from tube assembly 1 Since the rod assembly is heavy in this case lift the tip of the rod assembly 2 with a crane or some means and draw it out However when rod assembly 2 has been drawn o...

Page 382: ...bly 2 Remove piston and gland Remove set screw 19 Remove piston nut 18 Since piston nut 18 is tightened to a high torque use a hydraulic and power wrench that utilizers a hydraulic cylinder to remove...

Page 383: ...back up ring 7 rod seal 6 Remove the cushion ring 8 Exercise care in this operation not to damage the grooves Do not remove seal and ring if does not damaged 4 D Disassemble the piston assembly Remove...

Page 384: ...oat each packing with hydraulic oil before fitting it Insert the backup ring until one side of it is inserted into groove Coat dust wiper 4 with grease and fit dust wiper 4 to the bottom of the hole o...

Page 385: ...es After assembling the piston seal press its outer diameter to fit in Fit back up ring 10 to gland 3 Put the backup ring in the warm water of 30 50 C Fit O ring 9 to gland 3 A Assemble piston assembl...

Page 386: ...rew 19 Tightening torque Fit piston assembly to rod assembly Insert cushion ring 20 to rod assembly Note that cushion ring 20 has a direction in which it should be fitted I Install piston and cylinder...

Page 387: ...ng a bar through the clevis pin hole to lock the assembly Insert the rod assembly in to the tube assembly while lifting and moving the rod assembly with a crane Be careful not to damage piston seal by...

Page 388: ...se valve is loosened move the machine backwards and forwards GROUP 10 UNDERCARRIAGE Frame Grease valve Pry 90 110 1 1 INSTALL Carry out installation in the reverse order to removal Adjust the tension...

Page 389: ...and forwards Push out master pin by using a suitable tool 1 90 110 1 1 2 3 Master pin Block INSTALL Carry out installation in the reverse order to removal Adjust the tension of the track link 2 1 Move...

Page 390: ...1 INSTALL Carry out installation in the reverse order to removal 2 1 Loosen the bolt and nut 1 Open bracket 2 with a screwdriver push out from inside and remove carrier roller assembly Weight 5kg 11I...

Page 391: ...Carry out installation in the reverse order to removal 2 1 Remove the mounting bolt 1 and draw out the track roller 2 Weight 8kg 17 5lb 3 Using the work equipment push up track frame on side which is...

Page 392: ...ght 40kg 90lb 1 2 3 1 2 1 INSTALL Carry out installation in the reverse order to removal Make sure that the boss on the end face of the recoil cylinder rod is in the hole of the track frame 2 1 Sling...

Page 393: ...7 133 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 1 3 1 Shell 2 Shaft 3 Seal assembly 4 Ball bearing 5 Bracket 6 Snap ring 7 Spring pin 8 Plug 1 5 3 6 4 2 7 8 4 6 3 5 7 R35Z77TR11...

Page 394: ...rom shell 1 Remove brackets 2 from shaft Disassembly Remove plug and drain oil Draw out the spring pin 7 using a press 2 R35Z77TR17 R35Z77TR18 R35Z77TR19 4 2 1 R35Z77TR20 Draw out the ball bearing 4 w...

Page 395: ...th oil Do not press it at the normal temperature assemble ball bearing 4 to shaft by press 2 4 4 2 1 1 3 3 6 6 1 2 2 3 Assemble bracket 2 to shell 1 Assembly snap ring 6 and seal assembly 3 Insert sha...

Page 396: ...7 136 7 Press 5 Lay bracket 5 on its side Supply engine oil to the specified level and tighten plug Knock in the spring pin 7 with a hammer 8 168 1 140 7 R35Z77TR17 8 168 3 140 7 5...

Page 397: ...7 137 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure 1 4 1 Body 2 Rod 3 Spring 4 Cap 5 Nut 6 Cotter pin 7 Valve assy 8 O ring 9 Back up ring 10 Packing 1 2 7 3 4 5 6 9 8 10 R35Z77TR12...

Page 398: ...Remove split pin 6 and nut 5 Take enough notice so that the press which pushes down the spring should not be slipped out in its operation Lighten the press load slowly and remove cap 4 and spring 3 1...

Page 399: ...then push in rod 2 by hand After take grease out of grease valve mounting hole let air out If air letting is not sufficient it may be difficult to adjust the tension of crawler Fit grease valve 7 to...

Page 400: ...ing 3 with a press and tighten nut 5 During the operation pay attention specially to prevent the press from slipping out Tighten nut 5 and insert split pin 6 R35Z77TR13 233 5mm Lighten the press load...

Page 401: ...1 STRUCTURE 7 141 GROUP 11 WORK EQUIPMENT SECTION A A SECTION B B SECTION C C SECTION D D SECTION E E D D C B A A B C E E R35Z77AT01...

Page 402: ...n the reverse order to removal When aligning the mounting position of the pin do not insert your fingers in the pin hole Adjust the bucket clearance For detail see operator s manual 2 Remove nut 1 bol...

Page 403: ...ed Sling arm cylinder assembly remove spring pin stopper and pull out pin Tie the rod with wire to prevent it from coming out For details see removal of arm cylinder assembly Place a wooden block unde...

Page 404: ...der to removal When lifting the arm assembly always lift the center of gravity Bleed the air from the cylinder 2 Remove bolt 3 nut 4 and pull out the pin 5 then remove boom assembly Weight 140kg 310lb...

Page 405: ...PONENT MOUNTING TORQUE Group 1 Introduction guide 8 1 Group 2 Engine system 8 2 Group 3 Electric system 8 4 Group 4 Hydraulic system 8 5 Group 5 Undercarriage 8 7 Group 6 Structure 8 8 Group 7 Work eq...

Page 406: ...ibility for defects resulted from non genuine parts In such cases Hyundai cannot assume liability for any damage Only metric fasteners can be used and incorrect fasteners may result in machine damage...

Page 407: ...SSORIES MOUNTING 2 2 2 3 3 3 1 2 Muffler Engine Air cleaner Fan Main pump housing 1 1 Item Tightening torque 1 2 M 8 1 25 M10 1 5 2 5 0 5 6 9 1 4 18 1 3 6 49 9 10 1 Size kgf m lbf ft Item 3 M16 2 0 25...

Page 408: ...ine Feed pump Water separator Fuel tank Radiator total assy 4 4 2 2 1 Condenser Receiver dryer R35Z78CM02 Item Tightening torque 1 2 M 6 1 0 M 8 1 25 1 05 0 2 2 5 0 5 7 6 1 45 18 1 3 6 Size kgf m lbf...

Page 409: ...Cabin top Travel buzzer GROUP 3 ELECTRIC SYSTEM Item Tightening torque 1 2 M 6 1 0 M 8 1 25 1 05 0 2 2 5 0 5 7 6 1 45 18 1 3 6 Size kgf m lbf ft Item 3 M10 1 5 6 9 1 4 49 9 10 1 Size kgf m lbf ft 1 1...

Page 410: ...enoid valve Terminal Turning joint GROUP 4 HYDRAULIC SYSTEM Item Tightening torque 1 2 3 M 6 1 0 M 8 1 25 M10 1 5 1 05 0 2 2 5 0 5 6 9 1 4 7 6 1 45 18 1 3 6 49 9 10 1 Size kgf m lbf ft Item 4 5 6 M12...

Page 411: ...M75 2 M100 2 M85 2 68 6 8 64 6 4 56 5 6 75 7 5 64 6 4 492 49 463 46 405 41 542 54 463 46 Size kgf m lbf ft Item Boom cylinder Arm cylinder Bucket cylinder Dozer cylinder Boom swing cylinder M40 2 M40...

Page 412: ...Adjust component 1 2 2 Swing bearing 3 Upper roller GROUP 5 UNDERCARRIAGE Item Tightening torque 1 2 M10 1 5 M12 1 75 6 9 1 4 12 8 3 0 49 9 10 1 92 6 21 7 Size kgf m lbf ft Item 3 4 M12 1 75 M18 2 0 1...

Page 413: ...Travel lever 3 3 Item Tightening torque 1 2 M 8 1 25 M10 1 5 2 5 0 5 6 9 1 4 18 1 3 6 50 10 Size kgf m lbf ft Item 3 M12 1 75 12 8 3 0 92 6 21 7 Size kgf m lbf ft 1 1 CANOPY AND ACCESSORIES MOUNTING...

Page 414: ...1 1 1 1 1 1 1 1 1 Hyd tank Engine hood assy Support 1 Upper frame 1 1 3 R35Z78CM10 Item Tightening torque 1 2 M 8 1 25 M12 1 75 2 5 0 5 12 8 3 0 18 1 3 6 92 6 21 7 Size kgf m lbf ft Item 3 M20 2 5 57...

Page 415: ...rol rod pin Bucket cylinder rod pin Bucket cylinder rod pin Boom cylinder rod pin Arm cylinder head pin Boom cylinder head pin Dozer cylinder rod pin Dozer cylinder head pin Arm cylinder rod pin Boom...

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