Hyundai R 160 LC-3 Скачать руководство пользователя страница 1 | Manualshive

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FOREWORD

1. STRUCTURE

This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.

SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.

SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.

SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.

SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.

SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.

SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.

SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.

The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

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Содержание R 160 LC-3

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

Страница 2: ...before you start any work Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 2 3 Item number 2...

Страница 3: ...t one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm was divided by 10 so multiply 2 165 inches by 10 Move the d...

Страница 4: ...425 3 465 3 504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26...

Страница 5: ...2 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 3...

Страница 6: ...29 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853...

Страница 7: ...0 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1...

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

Страница 9: ......

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

Страница 11: ...al or debris Wear goggles or safety glasses PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as ear muffs o...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 33: ...Cover C 630 Nut 631 Sleeve 641 Pilot cover 642 Pilot cover QMC 643 Pilot piston 644 Spring seat Q 645 Adjust stem Q 646 Pilot spring 651 Sleeve 652 Spool 653 Spring seat 654 Return spring 655 Set spri...

Страница 34: ...nut 351 Gear case 353 Drive gear 354 Driven gear 355 Filter 361 Front case 433 Flange socket 434 Flange socket 435 Flange socket 466 Plug 700 Ring 710 O ring 725 O ring 732 O ring 850 Snap ring B3 A3...

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

Страница 36: ...gine etc it rotates the cylinder block via a spline linkage at the same time If the swash plate is tilted as in Fig Previous page the pistons arranged in the cylinder block make a reciprocating motion...

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

Страница 38: ...n 874 the spool moves to the right The movement of the spool causes the delivery pressure P1 to connect to port CL through the spool and to be admitted to the large diameter section of the servo pisto...

Страница 39: ...rotates and shifts the spool to the left Port CL opens a way to the tank port as the spool moves This deprives the large diameter section of the servo piston of pressure and shifts the servo piston to...

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

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

Страница 42: ...ver 611 the feedback lever rotates around the fulcrum of point D as lever 1 rotates and then the spool 652 is shifted to the right As the spool moves the delivery pressure P1 is admitted to the large...

Страница 43: ...nd the fulcrum of point D and then the spool 652 to move to the left As a result port CL opens a way to the tank port This causes the servo piston to move to the left and the pump s delivery rate to i...

Страница 44: ...ding from the large hole 8 only the lever lessening the tilting angle contacts the pin 897 The hole 8 in the lever of a larger tilting angle command is freed without contacting the pin 897 Such a mech...

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

Страница 46: ...optimum power level according to the operating condition The power shift pressure Pf controls the set horsepower of the pump to a desired level as shown in the figure As the power shift pressure Pf r...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 74: ...2 causes rotational moment at surroundings of cylinder Since cylinder block has 9 equidistantly arrayed pistons rotational torque is transmitted to cylinder shaft in order by several pistons connected...

Страница 75: ...ufficiency A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action The boost pressure...

Страница 76: ...rt or at stop of swing motion and can control the relief pressure in two steps high and low in order to insure smooth operation Function of relief valve Figure illustrates how the pressure acting on t...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 99: ...ONSOFMAJORSECTIONS The functions of the spool 5 are to receive the supply oil pressure from the hydraulic pump at its port P and to change over oil paths to determine whether the pressure oil of port...

Страница 100: ...hydraulic circuit diagram shown below and the attached operation explanation drawing The diagram shown below is the typical application example of the pilot valve 1 Pilot valve 2 Pilot pump 3 Main pu...

Страница 101: ...o the spool 5 Therefore the spool is pushed up by the spring 10 to the position of port 1 3 in the operation explanation drawing Then since the output port is connected to tank port T only the output...

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

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

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

Страница 105: ...NCTIONSOFMAJORSECTIONS The functions of the spool 8 are to receive the supply oil pressure from the hydraulic pump at its port P and to change over oil paths to determine whether the pressure oil of p...

Страница 106: ...he hydraulic circuit diagram shown below ant the attached operation explanation drawing The diagram shown below is the typical application example of the pilot valve 3 1 Pilot valve 2 Pilot pump 3 Mai...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 142: ...4 4...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 172: ...connector Female Plug connector Male 5 2 5 1 3 S811 005002 1 3 2 5 S811 105002 3 7 1 4 S811 007002 1 4 3 7 S811 107002 1 5 4 9 3S811 109002 5 11 1 6 S811 011002 1 6 5 11 S811 111002 7 9 11 PATYPECONNE...

Страница 173: ...35 No of pin Receptacle connector Female Plug connector Male 13 6 13 1 7 S811 013002 17 21 1 7 6 13 S811 113002 8 17 1 9 S811 017002 1 9 8 17 S811 117002 10 21 1 11 S811 021002 1 11 10 21 S811 121002...

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

Страница 175: ...cle connector Female Plug connector Male 2 3 4 8 1 2 2 1 2 3 1 3 1 2 3 1 4 2 4 2 3 1 6 3 1 8 5 2 8 5 2 6 3 1 S816 002001 S816 102001 S816 003001 S816 103001 S816 004001 S816 104001 S816 008001 S816 10...

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

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

Страница 178: ...in Receptacle connector Female Plug connector Male 1 1 S810 001202 2 3 4 1 S810 101202 2 1 S810 002202 2 1 S810 102202 3 1 2 S810 003202 2 1 3 S810 103202 2 4 1 3 S810 004202 1 3 2 4 S810 104202 CNTYP...

Страница 179: ...4 41 No of pin Receptacle connector Female Plug connector Male 6 3 6 1 4 S810 006202 8 1 4 3 6 S810 106202 1 5 4 8 S810 108202 4 8 1 5 S810 008202...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 221: ...t time What is the phenomenon of the trouble Was the trouble getting worse or did it come out suddenly for the first time Did the machine have any troubles previously If so which parts were repaired b...

Страница 222: ...ting According to where the trouble parts are located hydraulic mechanical system part or electrical system part or mechatronics system part perform troubleshooting the machine refer to the each syste...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 242: ...internal leak in the cylinder If no oil leaks from piping side and boom cylinder rod is retracted there is an internal leak in the control valve 3 Disconnect hose A from rod side of boom cylinder and...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 279: ...the test is started be sure to communicate with each other using these signals and to follow them without fail Operate the machine carefully and always give first priority to safety While testing alw...

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

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

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

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

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

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

Страница 286: ...ers Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race Bucket should be empty Measurement With the arm rolled out and bucket rolled in h...

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

Страница 288: ...the other stroke end as quickly as possible Repeat each measurement 3 times and calculate the average values Evaluation The average measured time should meet the following specifications Unit Seconds...

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

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

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

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

Страница 293: ...vel mode switch 1 speed 2 speed Mode selector H mode Measure the travel speed selecting pressure in the Hi or Lo mode Lower the bucket to the ground to raise the track off the ground Operate the trave...

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

Страница 295: ...erate the swing function or arm roll in function and measure the swing brake control pressure with the brake disengaged Release the control lever to return to neutral and measure the control pressure...

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

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

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

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

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

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

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

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

Страница 304: ...ry pressure drop etc are generated during operation and these cannot be remedied referring to section 6 troubleshooting replace the related parts Leakage Spool Push rod Play at operating section Opera...

Страница 305: ...abnormal noises hunting primary pressure drop etc are generated during operation and these cannot be remedied referring to section 6 troubleshooting replace the related parts Leakage Spool Push rod P...

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

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

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

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

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

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

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

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

Страница 314: ...event any mistake when installing Check the number and thickness of the shims and keep in a safe place When raising components be sure to use lifting equipment of ample strength When using forcing scr...

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

Страница 316: ...n removed and installed again add engine oil to the specified level Run the engine to circulate the oil through the system Then check the oil level again If the piping or hydraulic equipment such as h...

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

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

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

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

Страница 321: ...o the hydraulic tank to the specified level Bleed the air from the hydraulic pump Remove the air vent plug 2EA Tighten plug lightly Start the engine run at low idling and check oil come out from plug...

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

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

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

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

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

Страница 327: ...areas of tilting pin and servo piston take care not to damage servo piston Do not remove needle bearing as far as possible except when it is considered to be out of its life span Do not loosen hexagon...

Страница 328: ...eals etc For fitting bolts plug etc prepare a torque wrench or so on and tighten them with torques shown in page 8 10 11 For the double pump take care not to mix up parts of the front pump with those...

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

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

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

Страница 332: ...Cover C 630 Nut 631 Sleeve 641 Pilot cover 643 Pilot piston 644 Spring seat Q 645 Adjust stem Q 646 Pilot spring 651 Sleeve 652 Spool 653 Spring seat 654 Return spring 655 Set spring 708 O ring 722 O...

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

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

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

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

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

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

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

Страница 340: ...e inserting holes for fulcrum plug and adjusting plug At this point in time move feedback lever to confirm that it has no large play and is free from binding 8 9 Put pilot piston 643 into pilot hole o...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 377: ...e cover Remove the hose 3 4 5 6 Fit blind plugs to the disconnected hoses Remove the bolts and the sprocket Sling travel device assembly 1 Remove the mounting bolts 2 then remove the travel device ass...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 428: ...e inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt or dust from entering Set...

Страница 429: ...assembly 9 Weight 125kg 276lb Install Carry out installation in the reverse order to removal When aligning the mounting position of the pin do not insert your fingers in the pin hole Bleed the air fr...

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

Страница 431: ...ssembly 10 Weight 183kg 403lb Install Carry out installation in the reverse order to removal When aligning the mounting position of the pin do not insert your fingers in the pin hole Bleed the air fro...

Страница 432: ...wly to release the pressure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disconnecting them to prevent dirt...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 454: ...operly Spring set load 11000kg 24250lb Remove lock nut 4 Take enough notice so that the press which pushes down the spring should not be slipped out in its operation Lighten the press load slowly and...

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

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

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

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

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

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