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Hyundai Robex 22-7, Service Manual

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Hyundai Robex 22-7 Service Manual Download Page 30

3-2 Inspection and adjustment

3-2-1  Measuring the natural fall of the attachment

1. Measuring the location of the attachment

Set the temperature of the hydraulic oil to 50

±

5

°

C.  Adjust the height of arm/bucket joint

so that it equals that of the boom joint.  Then, retract the dozer cylinder to the minimum
length and stop the engine.

2. Measurement

Draw a reference line on the cylinder head with a Magic Marker and measure the
length from the line to the cylinder tube.  Measure the length again 3 minutes later.
Then record the difference in the length

Unit: mm or less

Cylinder name

Standard value

Allowance

Boom cylinder

3

10

Arm cylinder

3

10

Bucket cylinder

3

10

Dozer cylinder

3

10

Make 1 and 2 the same height.

W: Weight

About: 108kg

3-5

Arm cylinder

Boom joint...1,

Boom cylinder

Bucket cylinder

Arm/bucket joint...2,

Dozer cylinder

Mark: Direction of cylinder movement

Summary of Contents for Robex 22-7

Page 1: ...SERVICE MANUAL SER NO HY2270001...

Page 2: ......

Page 3: ...e structure and operation inspection and adjustment disassembly and assembly standard maintenance and repair and re placement of parts of the machine which are necessary to carry out the inspections a...

Page 4: ......

Page 5: ...Engine 5 Main Pump 6 Hydraulic Oil Filter 7 Control Valve 8 Joystick 9 Slew Motor 10 Travel Motor 11 Hydraulic Cylinder 12 Swivel Joint 13 Crawler 14 Spring Case and Grease Cylinder 15 Idler 16 Sproc...

Page 6: ...er match marks are necessary For the electrical system disconnect the cable from the battery terminal 3 Precautions for disassembly In stead of checking all of the disassembled parts at once check eac...

Page 7: ...TS 2 1 Location of serial No 2 2 Name of each part 2 3 Dimensions and specification 2 4 Weight list 2 5 Oil and grease supply points 2 6 List of supply oil and grease 2 7 When to repair 2 8 Hydraulic...

Page 8: ...2 1 Location of Serial Number 2 1...

Page 9: ...st 24 Swing cylinder 25 Operation levers 1 Meter unit 2 Starter switch 3 Horn switch 4 Fuse box 5 Right operation lever 6 Left operation lever 7 Accelerator lever 8 Dozer operation lever 9 Right trave...

Page 10: ...2 3 Dimensions and Specifications 2 3 465 1405 L80 Swing 1445 280 2250 Height 1150 1380 1325 1745 1795 190275 1 2 5 5 1255 1255 3745 2510 885 1795 2365 4065 3965 4075 2820 8 0 5 0 50 520 455...

Page 11: ...1 255 Boom swing angle L R deg 80 50 Max digging force Bucket kN 16 3 Max digging force Arm kN 11 2 Max drawbar pull kN 16 2 Travel speed low high km h 2 2 3 8 Slew speed min 1 11 5 Gradeability Angle...

Page 12: ...ivel joint 11 Pump 15 Pump frange 9 Control valve 23 Tops roof 110 Cabin 230 Part name Boom 70 Arm 40 Bucket 57 Dump link 9 4 Bucket link R 1 7 Bucket link L 2 0 Boom joint pin 2 0 Arm joint pin 1 7 B...

Page 13: ...y points 2 6 Swing cylinder head pin Bucket link pin Bucket pin Swing post pin Boom joint pin Boom arm joint pin Travel motor Track roller Dozer joint pin Front idler Adjust cylinder Fuel tank Hydraul...

Page 14: ...capacity Total 1 7 3 5 0 4 5 6 Type of oil according to ambient condition 10 C 40 C 20 C 0 C Soft water antifreeze is mixed in water Diesel fuel with freezing point below 7 C SAE10W 30 SAE 30 ISO VG...

Page 15: ...intenance 2 8 Prestart up inspection Execute every day before beginning operation Maintenance after the first 25 service hours Execute every 25 hours by the hour meter Maintenance after the first 50 s...

Page 16: ...aintenance interval hours 7 50 100 250 500 1 000 Replace the engine oil Replace the cartridge Drain water and sediment Clean Replace oil Replace oil Check and clean Check and clean Replace the cartrid...

Page 17: ...10 1 2 3 Remarks Before starting engine Check that the fuel level is above the center of level gauge Check that the amount of water in sub tank is within a specified level Refer to page 2 6 Refer to t...

Page 18: ...ess If any bolt or nut is loose retighten according to the table below N m Tightening torque of the bolt and nut Body Material 8 8 10 9 12 9 Size N m N m N m M6 12 5 16 20 M8 30 39 45 M10 62 72 80 M12...

Page 19: ...diment and water Clean the strainer Clean the fins Inspect and grease Liquid quantity Specific gravity Clean Oil and grease Remove the drain plug on the lower part of the tank Wash strainer with diese...

Page 20: ...ne After 50 service hours for a new machine After air is vent loosen the drain plug 1 8 2 7 8 Maintenance every 250 service hours Item Fuel filter Engine valve clearance Radiator Air cleaner Hydraulic...

Page 21: ...rks Clean the inside of the tank Refer to Table of Oil Grease Supply Points For new machine every 500 service hours Remarks 1 8 17 15 2 7 12 Maintenance every 2 000 service hours Table of Oil Grease S...

Page 22: ...r Left travelling motor Bucket cylinder Boom cylinder Swing cylinder Arm cylinder Pilot filter J S valve R J S valve L P3 P2 P1 Pi7 Pi8 Pi5 Pi6 Pi3 Pi4 Pi2 Pi1 R G PP PL PR PL PR Dozer cylinder Dr B A...

Page 23: ...8 Travel motor PHV 190 39 1 8003A Item P1 10cm3 rev P2 10cm3 rev P3 6 4cm3 rev P1 18 6MPa 190kgf cm2 P2 18 6MPa 190kgf cm2 P3 17 2MPa 175kgf cm2 Port relief 22 5MPa 230kgf cm2 Slew 11 8MPa 120kgf cm2...

Page 24: ......

Page 25: ...ACHMENT CONTENTS 3 1 Standard of maintenance 3 1 1 Attachment 3 2 Inspection and adjustment 3 2 1 Measuring the fall of the attachment of its own weight 3 2 2 Measuring the speed of the attachment cyl...

Page 26: ...ard of maintenance 3 1 1 Attachment 1 Swing cylinder head 1 4 3 2 5 6 7 8 9 10 12 13 14 11 15 16 17 3 1 2 Swing cylinder rod 3 S w i n g p o s t bracket and swing post 4 Boom joint 5 Boom cylinder hea...

Page 27: ...nder head 11 Bucket cylinder rod 12 Bucket dump link joint 13 Arm bucket link joint 14 A r m b u c k e t joint 15 Dozer joint 16 Dozer cylinder head 17 Dozer cylinder rod R S L K T U P Q M N O V W X a...

Page 28: ...h Boom joint pin and swing post Boom cylinder head pin and swing post Boom cylinder rod pin and boom Arm cylinder head pin and boom Arm cylinder rod pin and arm Boom arm joint pin and bush Boom arm jo...

Page 29: ...n boom and arm Clearance between bucket cylinder head and arm Clearance between bucket cylinder rod and dump link Clearance between dump link and bucket Clearance between arm and bucket link Clearance...

Page 30: ...Measurement Draw a reference line on the cylinder head with a Magic Marker and measure the length from the line to the cylinder tube Measure the length again 3 minutes later Then record the differenc...

Page 31: ...2 9 0 5 3 9 2 3 0 5 3 3 1 2 0 3 1 5 0 8 0 3 1 1 6 6 0 5 7 6 6 3 0 5 7 3 3 6 Make bucket teeth touch the ground BOOM Extend cylinder to the Maximum length Retract cylinder to the minimum length ARM Ex...

Page 32: ......

Page 33: ...4 ENGINE CONTENTS 4 1 Specification 4 2 Performance curve 4 3 Location of serial number 4 3 1 Engine 4 3 2 Standard engine speed...

Page 34: ...m Overall width 450mm Overall height 550 mm Rated output 12 5kW 17ps 2 400 min 1 Maximum torque 55N m 1 600min 1 Maximum idling speed rpm 2 650 min 1 Minimum idling speed rpm 1 100 min 1 30 Fuel consu...

Page 35: ...4 60 50 40 12 16 20 24 200 280 270 260 190 Nm kgf m PS kW Brake horse power 6 8 10 12 14 16 18 20 Output torque g kW h g PS h Engine speed min 1 102 55 0 N m 1 600 100min 1 12 5kW 2 400min 1 280g kW...

Page 36: ...ial number 4 3 1 Engine 4 3 2 Standard engine speed at new machine delivery 4 3 Conditions Idling speed Maximum idling speed 2 550 min 1 Speed when 1P relief is used 2 450 min 1 Engine No identificati...

Page 37: ...5 2 Structure 5 3 Removing and installing the pump 5 3 1 Removing the pump 5 3 2 Installing the pump 5 4 Performance test of the hydraulic pump 5 4 1 Measuring instrument 5 4 2 Preparation 5 4 3 Conne...

Page 38: ...2 PF3 8 P3 PF3 8 L1 221mm L2 134mm L3 201 5mm L4 88mm L5 45mm L6 24mm P1 10mm Displacement rev P2 10mm P3 6 4mm Rated pressure P1 18 6MPa 190kgf cm2 P2 18 6MPa 190kgf cm2 P3 17 2MPa 175kgf cm2 Directi...

Page 39: ...iner 34 Seal washer 7 Shoe 21 Stopper pin 35 Plug 8 Shoe holder 22 Pin 36 Gear pump 9 Barel holder 23 Bearing 37 Coupling 10 Swash plate 24 Bearing 38 Collar 11 Needle 25 Oil seal 39 O ring 12 Pin 26...

Page 40: ...difficult insert a screwdriver and remove the pump little by little with equal force applied on the right and left sides 5 3 2 Installing the pump 1 Replace with a new pump and install it on the pump...

Page 41: ...op engine 5 4 3 Connecting tester 1 Remove the hose on the pump port of the control valve 2 Connect the removed hose to the outlet of the tester 3 Connect the hose on the discharge of the pump to the...

Page 42: ...5 5 Throttle valve Hydraulic pressure tester OUT IN OPEN CLOSE...

Page 43: ...to indicate a pressure value on P Q characteristic curve P1 P2 175 10 2 2 100 0 10 P_Q characteristics curve 37 2 P3 17 2MPa 175kgf cm2 P3 0 98MPa 10kgf cm2 Rated pressure P1 P2 MPa P1 P2 P1 P2 18 6MP...

Page 44: ......

Page 45: ...6 1 Installation 6 2 Hydraulic oil filter 6 2 1 Line filter 6 2 2 Suction filter 6 2 3 Pilot filter 6 3 Maintenance procedure 6 3 1 Replacing the line filter 6 3 2 Replacing the suction filter 6 3 3...

Page 46: ...6 1 Installation 6 1 J S Left J S J S Right J S...

Page 47: ...filter SP08 Grain size 150 mesh Oil temperature 20 C 120 C 2 PT1 Tightening torque 19 6Nm 2kgf m Filtration accuracy 10 Filtration capacity 50 min Max 0 15MPa 1 5kgf cm2 Proof pressure 0 69MPa 7kgf cm...

Page 48: ...Pilot filter 6 3 Filtration capacity 2 min Max Proof pressure 3 92MPa 40kgf cm2 Filtration accuracy 31 Filtration area 5 cm2 Oil temperature 30 C 120 C PT 1 4 PT 1 4 Tightening torque 58 8 78 5N m 6 8...

Page 49: ...ine 2 Remove the pilot filter 6 2 3 with a wrench 27 mm width 3 Remove the filter to check whether the net of the element is damaged Replace with a new one if the net is damaged or the mesh is widened...

Page 50: ......

Page 51: ...bly 7 2 2 Replacing the O ring on the spool 7 2 3 Removing the load check valve and replacing the O ring 7 2 4 Replacing the relief valve assembly and the O ring 7 3 Structure of the relief valve 7 3...

Page 52: ...min Port Port size T1 T2 G 1 2 A1 A9 B1 B9 P1 P3 G 3 8 Pa1 Pa2 Pa7 Pa9 P P G 1 4 Pb1 Pb2 Pb7 Pb9 Dr P1 T1 P2 Pb1 B1 A1 B2 A2 Pa1 Pa2 Pb2 B3 A3 B4 A4 Bucket Boom P T O Right travelling Left travelling...

Page 53: ...Block assembly 21 Nut 9 Block assembly 22 Relief valve assembly 10 Block assembly 23 Relief valve assenbly 11 Block assembly 24 Relief valve assembly 12 Block assembly 25 Relief valve assembly 13 Bloc...

Page 54: ...7 Socket head bolt 21 Spring 8 Spring seat 22 Spring sea 9 Spring 23 Spur end 10 Spring seat 24 O ring 11 Poppet 25 Cap 12 Spring 26 Socket head bolt 13 Spacer 27 34 Spool 14 Spool end 1 2 27 28 29 30...

Page 55: ...embling clean the contact surface so that no dust sticks to the surface Then attach the O ring and reassemble in the reverse order of the above procedure When attaching the O ring give grease to it 5...

Page 56: ...d check valve from the valve block 2 Keep each load check valve in order so as not to confuse it with other valve block 2 Clean the parts sufficiently before assembling them 7 2 4 Replacing the relief...

Page 57: ...Cap 7 Spring 13 Backup ring 2 Plug 8 Pilot spring 14 O ring 3 Poppet 9 Adjuster kit 15 O ring 4 Poppet 10 O ring 16 Wave washer 5 Piston 11 Backup ring 17 Name plate 6 Pilot poppet 12 O ring 18 O rin...

Page 58: ...be higher than the NAS12 class 2 Keep the oil temperature between 20 C and 80 C If the temperature falls below 0 C warm up the machine 3 Never raise the set pressure of the main relief valve and port...

Page 59: ...8 JOYSTICK PILOT VALVE CONTENTS 8 1 Specification 8 2 Structure...

Page 60: ...3 5 1 0 1 34 1 78 2 0 2 14 2 52 3 0 3 02 3 5 Secondary Pressure kgf cm 2 Secondary Pressure MPa Operating Torque Nm Operating Torque kgf cm Push rod Stroke mm Operating Angle 35 7 30 8 30 6 25 7 21 8...

Page 61: ...Seal 23 Lever 4 Seal washer 14 O ring 24 Knob 5 O ring 15 Spring seat 25 Spring pin 6 Hex bolt 16 Washer 2 26 Bush 7 Spring pin 17 Spring 27 Connector 8 Bush 18 Spring 28 Housing 4P 9 Plate 19 Joint...

Page 62: ...2 Structure 9 3 Standard of maintenance 9 3 1 Slew bearing slew case 9 4 Inspection and adjustment 9 4 1 Measuring the natural slew distance 9 4 2 Measuring the over slew distance after stopping 9 4...

Page 63: ...unterclockwise B A Port Port size A G 3 8 O ring Port B G 3 8 O ring Port T G 3 8 O ring Port Initial oil replace 500Hr 1 000Hr Second and later replace 9 1 Type 2 160DOS E3768 Output torque 296 Nm 30...

Page 64: ...ew motor Ass y 2 Seal Kit 3 X ring 4 O ring 5 Seal shaft face 6 O ring 7 O ring 8 Seal inner face 9 Seal outer face 10 O ring 11 O ring 12 O ring 13 O ring 14 Relief valve Assy 9 8 11 13 14 view A A 1...

Page 65: ...9 3 Standard of maintenance 9 3 1 Slew bearing and slew case 9 3 M10 60 P 1 5 12 9 Tightening torque 80Nm M12 40 P 1 75 12 9 Tightening torque 130Nm M12 30 P 1 75 12 9 Tightening torque 130Nm...

Page 66: ...ar length Unit mm or less Standard value Allowance Weight W kg 100 200 108 9 4 2 Measuring the over slew distance after stopping Maintain the oil temperature at 50 5 C while the engine is running at f...

Page 67: ......

Page 68: ...10 TRAVEL MOTOR CONTENTS 10 1 Specification 10 2 Structure 10 3 Operation 10 4 Handling the travel motor 10 5 Measuring travel motor idling and travelling time 10 6 Inspection and adjustment...

Page 69: ...7 9 327 6 Output speed min 1 36 3 69 6 Oil ISO VG46 Reduction ratio 1 39 Oil temperature C 20 100 Capacity cm3 rev 16 1 8 4 Filtering M 10 Working pressure MPa 18 6 190kgf cm2 Engine oil equivalent Ou...

Page 70: ...eal 68 Snap ring 15 Plug 42 Ball 69 Snap ring 16 Pulg 43 Snap ring 70 Snap ring 17 O ring 44 Screw 71 Snap ring 18 O ring 45 Spring pin 72 Spring pin 19 O ring 46 Pin 73 O ring 20 Choke 47 Plug 74 O r...

Page 71: ...oil quantity check port with an Allen wrench 3 Add lubricating oil through the oil intake until the oil comes out of oil quantity check port 4 Plug the oil intake oil drain and oil quantity check por...

Page 72: ...After travelling 3m on ground level measure the required time to travel 20m Standard value Low 19 2 High 33 2 Engine running at full speed and oil temperature of 50 5 C 10 5 Inspection and adjustment...

Page 73: ......

Page 74: ...ENTS 11 1 Structure 11 2 Disassembly and assembly 11 2 1 Disassembly procedure 11 2 2 Procedure for disassembling inner parts 11 3 Assembly 11 3 1 Assembly procedure 11 3 2 Inspection procedure 11 3 3...

Page 75: ...Cylinder bore mm 65 60 70 Maximum extended length mm Maximum contracted length mm F Stroke mm 450 500 400 425 100 Clevis width mm 45 H Tightening torque N m kgf m 294 30 0 284 29 0 304 31 0 I tighteni...

Page 76: ...Backup ring 10 O ring 11 Piston 12 Slide ring 13 Seal ring Ass y 14 Steel ball 15 Set screw 16 Pin bush 17 Dust seal 18 Cylinder head Ass y 19 Piston Ass y 20 Rod packing Ass y 21 Piston packing Ass...

Page 77: ...emove the piston pull the piston rod about a third of the length 2 Loosen and remove the cylinder head from the cylinder tube assembly with a hook wrench 3 Disassembling the piston rod assembly Slowly...

Page 78: ...cover assembly on the workbench and move the rod cover to and fro to remove it Remove the backup ring then the O ring with a screwdriver If they are to be reused be careful not to damage them 3 Disas...

Page 79: ...heck all parts for flaws cracks deformation rust or burrs which may affect the operation Inside of the tube rod etc 2 Check each part for metallic powder or other foreign matter sticking to it 3 Check...

Page 80: ...12 SWIVEL JOINT CONTENTS 12 1 Specification and Structure 12 2 Structure disassembly and assembly...

Page 81: ...Travelling rightward B D F port Control valve Dozer Dozer cylinder Dozer cylinder Over drive Rightward travelling motor Leftward travelling motor Rightward travelling motor Leftward travelling motor...

Page 82: ...ring does not become trapped Assembly 1 Before assembly check the O ring and sliding part for flaws and other defects 2 Assembly is usually executed in the opposite order of disassembly Coat a little...

Page 83: ......

Page 84: ...er Steel 13 1 2 Track frame 13 2 Standard of maintenance 13 2 1 Crawler Steel 13 3 Disassembly and assembly 13 3 1 Installing the crawler 13 3 2 Removing the crawler 13 3 3 Track frame spring 13 3 4 L...

Page 85: ...1 2 13 1 Structure and operation 13 1 1Crawler steel 1 Shoe 2 Pin 13 1 2Track frame 1 Idler 2 Track frame 3 Track roller 4 Spring 230 13 1 4 1 2 3 90...

Page 86: ...4 43 7 2 21 Item Link pitch Link height Grouser height Pin clearance Bush outer diameter No 1 2 3 4 5 Remarks Measure by stretching 5 links except for the master link Pad or replace Pad or replace Rep...

Page 87: ...e idler and for steel crawler fix the master pin 3 into the hole For a rubber crawler the crawler by using the idler as it is Install steel bar and heavy duty hammer into the undercarriage 2 Tension t...

Page 88: ...achment and put blocks under to lift the machine 2 Turning in the direction of the idler side remove crawler master pin 3 and then the crawler 2 from track frame Weight steel crawler 148 kg 74 2 3 As...

Page 89: ...value 2 1 Track frame 52 2 2 Idler frame 50 3 1 Track frame 152 3 2 Idler support 150 Standard value 274 Set length 207 Unit mm Remedy Correct Pad or replace Replace Replace Item Deformation of frame...

Page 90: ...edges protruding on the ground 3 Avoid using on beach This may affect the adhesion of the core metal 4 If the machine is going to be stored for a long time never store it where it will be directly ex...

Page 91: ...ring the rubber crawler Foreign matter will strain the crawler and cut it 3 No sharp turns Do not turn sharply on a road with a high friction factor such as a concrete road 4 Keep oil products away fr...

Page 92: ...E AND GREASE CYLINDER CONTENTS 14 1 Structure 14 2 Specification of spring 14 3 Disassembly and assembly 14 3 1 Howtodisassembleandassembletheadjust cylinder 14 3 2 How to disassemble and assemble the...

Page 93: ...n of spring Name Value Name Value No of active coils 8 5 Length at max shrinkage mm 140 Total number of coils 10 5 O D outer diameter mm 80 Spring constant N mm 288 P C D Center diameter mm 64 Set for...

Page 94: ...re a Attach the O ring backup ring and spacer to adjust cylinder tube Coat grease on the O ring and dust seal before assembly b Attach the adjust cylinder rod to adjust the cylinder tube carefully so...

Page 95: ...mounting spring b Remove the spring from adjust cylinder tube Note Be careful when using the tool when removing the spring Also be careful during assembly 2 Assembly The assembly procedure is the rev...

Page 96: ...15 IDLER CONTENTS 15 1 Standard of maintenance 15 1 1 Idler...

Page 97: ...1Idler 15 1 No Item Unit Allowance Remarks 1 Width of idler teeth mm 22 16 Pad or replace 2 Minor diameter mm 253 241 Pad or replace 3 Number of teeth 19 4 Quality of lubricating oil cm3 40 Engine oi...

Page 98: ...16 SPROCKET CONTENTS 16 1 Disassembly and assembly 16 1 1 Removing the sprocket 16 1 2 Installing the sprocket 16 2 Standard of maintenance 16 2 1 Sprocket...

Page 99: ...procket Remove sprocket mounting bolts 1 and then sprocket 2 from the travelling motor assembly 16 1 2Installing the sprocket 1 Sprocket Attach the sprocket to travelling motor assembly and tighten th...

Page 100: ...Unit Allowance Remarks 1 Width of sprocket teeth mm 22 16 Pad or replace 2 Minor diameter of sprocket mm 253 241 Pad or replace 3 4 Tightening torque of sprocket mounting bolt M10 P1 5 Tightening tor...

Page 101: ......

Page 102: ...17 TRACK ROLLER CONTENTS 17 1 Standard of maintenance 17 1 1 Track roller...

Page 103: ...or replace 2 Outer diameter of tread mm 86 83 Pad or replace 3 Width of projected part mm 22 19 Pad or replace 4 Overall width mm 99 Pad or replace 5 Width of tread mm 28 Pad or replace 6 Tightening...

Page 104: ...18 ELECTRICAL EQUIPMENT CONTENTS 18 1 Structure and function 18 1 1 Electric circuit diagram 18 2 Failure and remedy 18 2 1 Starter system 18 2 2 Alternator system...

Page 105: ...E M E M L H 1 25R 1 25R 0 85LW 0 85L 0 85WL 0 85RL 0 5LB 0 5LB 0 5WB 0 5YG 0 5GW 0 5LW 0 5GR 0 5LY 0 5YG 0 5YR 0 5B 0 85B 0 85W 0 85WL 0 85RY 0 85Or G OPTION LIGHT SRM 12CS OPTION REV LIGHT SRM 12CS...

Page 106: ...st Replace Replace Replace switch Replace Disconnection of the wire harness loose connection of the battery or switch terminal Spline which engaged with the pinion of armature shaft is caught and the...

Page 107: ...er contact or insufficient movement of brush and slip ring Short circuit of coil Defective diode Defective alternator Wrong installation Defective fan belt Defective bearing Diodes on and sides broke...

Page 108: ...9 3 Slewing system 19 3 1 No operation both right left slewing 19 3 2 It is possible to turn right left but not left right 19 3 3 Turning acceleration slow the overturn is highter than tolerance 19 3...

Page 109: ...HYD oil Clean up suction filter Repair faulty piping part Check cause of bubbles and remove it Replace pump Ass y Replace HYD oil Adjust to correct pressure Clean disassemble adjust or replace Ass y...

Page 110: ...weak then replace Clean or replace Clean or replace Clean or replace control valve Fuse has blown Check the pressure on pump No 3 Check control valve and inner parts of pilot system Blocked up with co...

Page 111: ...ve is faulty Check plunger repair or replace Ass y Faulty relief valve Pump was faulty Check the counter balance valve Drive motor broken Adjustment or replace Replace seals or block Ass y Internal le...

Page 112: ...age Faulty action on spool Faulty pump Faulty relief valve Internal leak on swivel joint Check the counter balance valve Internal wear or breakage OK Remove any foreign matter and re adjust to correct...

Page 113: ...can see any movement outside tolerance Replace counter balance valve brake valve Replace drive motor Faulty counter balance valve Faulty drive motor Replace counter balance valve Replace drive motor A...

Page 114: ...tc Replace pinion gear or turning bearing Replace turning bearing Disassemble repair or replace turning motor Ass y Faulty pump Faulty control valve Spool is sticking Faulty turning relief valve Repla...

Page 115: ...lief valve OK Clean or replace Replace turning motor Ass y Above tolerance Low pressure OK Yes Change over control valve pilot port A B then test Faulty control valve block Faulty joystick Faulty reli...

Page 116: ...ce then test Check the turning circuit pressure Internal leak on turning motor Faulty relief valve Faulty relief valve Disassemble clean or replace Faulty control valve Change over outlet hoses to pum...

Page 117: ...assmble clean or replace Change over outlet hoses from the other pump then test Faulty pump Faulty control valve Disassemble replace seals or replace Replace inner parts or Ass y Does move Does not mo...

Page 118: ...r Ass y OK OK Adjust to correct pressure or replace relief valve Replace inner parts or Ass y Adjust to correct pressure or replace relief valve Disassemble replace seals or replace pump Ass y Replace...

Page 119: ...then check Internal leak on boom cylinder OK Replace inner parts or cylinder Ass y Yes No Faulty Check the internal leak on control valve Change over hoses boom section A boom section B Faulty port re...

Page 120: ...ction valve Clean or replace Replace or change over the relief valve with the other pump s port and then test Change over the outlet hoses No 2 3 pumps and then test Yes Faulty No Faulty control valve...

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