hyi
Short Description
Download hyi...
Description
SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications
1-1 1-9
SECTION 1 GENERAL GROUP 1 SAFETY FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury. Before performing any work on the excavator, attach a 「Do Not Operate」tag on the right side control lever. WARN DO NOT OPERATE
USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury. When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine. Do not use any controls as handholds. Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal 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 earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
AVOID POWER LINES Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to electric line than 3m(10ft) plus twice the line insulator length.
1-2
KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.
MOVE AND OPERATE MACHINE SAFELY Bystanders can be run over. Know the location of bystanders before moving, swinging, or operating the machine. Always keep the travel alarm in working condition. warns people when the excavator starts to move.
It
Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the excavator.
OPERATE ONLY FORM OPERATOR'S SEAT Avoid possible injury machine damage. Do not start engine by shorting across starter terminals. NEVER start engine while standing on ground. engine only from operator's seat.
Start
PARK MACHINE SAFELY Before working on the machine: ・Park machine on a level surface. ・Lower bucket to the ground. ・Turn auto idle switch off. ・Run engine at 1/2 speed without load for 2 minutes. ・Turn key switch to OFF to stop engine. Remove key from switch. ・Move pilot control shutoff lever to locked position. ・Allow engine to cool.
1-3
SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
SERVICE 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 SAFELY-AVOID FIRES Handle fuel with care; It is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine. Fill fuel tank outdoors.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; They can ignite and burn spontaneously.
1-4
BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in 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 or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
1-5
SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
STAY CLEAR OF MOVING PARTS Entanglements in moving parts can 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 the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. hands and body from high pressure fluids.
Protect
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.
1-6
AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install fire resisting guards to protect hoses or other materials.
PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a 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 clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling of dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10-15 minutes. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately.
1-7
USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards. Use power tools only to loosen threaded tools and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only recommended replacement parts.(See Parts catalogue.)
DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, 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 drinking from them. DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste.
REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement.
LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
1-8
GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT
21072SP01A
1-9
2. SPECIFICATIONS 1) ROBEX 210LC-7 I(I')
H
F
G
C
E
D
J K
M N B(L)
A
21072SP02
Description Operating weight Bucket capacity(SAE heaped), standard
Unit
Specification
kg(lb)
21700(47840)
m3(ydІ)
0.92(1.20)
Overall length
A
9520(31' 3")
Overall width, with 600mm shoe
B
2990( 9' 10")
Overall height
C
2990( 9' 10")
Superstructure width
D
2700( 8' 10")
Overall height of cab
E
2920( 9' 7")
Ground clearance of counterweight
F
1060( 3' 6")
Engine cover height
G
2320( 7' 7")
Minimum ground clearance
H
Rear-end distance
I
2770( 9' 1")
Rear-end swing radius
I'
2830( 9' 3")
Distance between tumblers
J
3650(12' 0")
Undercarriage length
K
4440(14' 7")
Undercarriage width
L
2990( 9' 10")
Track gauge
M
2390( 7' 10")
Track shoe width, standard
N
600(24")
mm(ft-in)
480( 1' 7")
km/hr(mph)
3.4/5.3(2.1/3.3)
Swing speed
rpm
12.5
Gradeability
Degree(%)
35(70)
Ground pressure(600mm shoe)
kgf/cm (psi)
0.46(6.54)
Travel speed(Low/high)
2
1-10
2) R210LC-7 LONG REACH
21072SP06
Description
Unit
Specification
Operating weight
kg(lb)
24360(53700)
Bucket capacity(PCSA heaped), standard
m3(yd3)
0.51(0.67)
Overall length
A
12030(39' 6")
Overall width, with 800mm shoe
B
3190(10' 6")
Overall height
C
3280(10' 9")
Superstructure width
D
2700( 8' 10")
Overall height of cab
E
2920( 9' 7")
Ground clearance of counterweight
F
1060( 3' 6")
Engine cover height
G
2320( 7' 7")
Minimum ground clearance
H
Rear-end distance
I
2770( 9' 1")
Rear-end swing radius
I'
2830( 9' 3")
Distance between tumblers
J
3650(12' 0")
Undercarriage length
K
4440(14' 7")
Undercarriage width
L
3190(10' 6")
Track gauge
M
2390( 7' 10")
Track shoe width, standard
N
800(31' 5")
Travel speed(Low/high)
mm(ft-in)
480( 1' 7")
km/hr(mph)
3.4/5.3(2.1/3.3)
Swing speed
rpm
12.5
Gradeability
Degree(%)
35(70)
Ground pressure(800mm shoe)
kgf/cm (psi)
0.42(5.97)
2
1-11
3) R210LC-7 HIGH WALKER I(I')
H
F
G
E
C
D
J
M N
K
B(L)
A
29072SP07
Description
Unit
Specification
Operating weight
kg(lb)
23160(51060)
Bucket capacity(PCSA heaped), standard
m3(yd3)
0.92(1.20)
Overall length
A
Overall width, with 600mm shoe
B
3395( 11' 2")
Overall height
C
3080( 10' 1")
Superstructure width
D
2700( 8' 10")
Overall height of cab
E
3100( 10' 2")
Ground clearance of counterweight
F
1240( 4' 1")
Engine cover height
G
2500( 8' 2")
Minimum ground clearance
H
Rear-end distance
I
2770( 9' 1")
Rear-end swing radius
I'
2830( 9' 3")
Distance between tumblers
J
3650(12' 0")
Undercarriage length
K
4440(14' 7")
Undercarriage width
L
3395( 11' 2")
Track gauge
M
2795( 9' 2")
Track shoe width, standard
N
Travel speed(Low/high)
9470( 31' 1")
mm(ft-in)
660( 2' 2")
600(24") km/hr(mph)
3.4/5.3(2.1/3.3)
Swing speed
rpm
12.5
Gradeability
Degree(%)
35(70)
Ground pressure(600mm shoe)
kgf/cm (psi)
0.49(6.97)
2
1-12
3. WORKING RANGE 1) R210LC-7 [5.68m(18' 8") BOOM] A A'
B B' C
E
D
F
8ft 21072SP03
Description
2.0m(6' 7") Arm
2.40m(7' 10") Arm
2.92m(9' 7") Arm
3.90m(12' 10") Arm
Max digging reach
A
9140mm (30' 0")
9500mm (31' 2")
9940mm (32' 7")
10910mm (35' 10")
Max digging reach on ground
A'
8960mm (29' 5")
9330mm (30' 7")
9780mm (32' 1")
10770mm (35' 4")
Max digging depth
B
5820mm (19' 1")
6220mm (20' 5") 6740mm (22' 1")
7720mm (25' 4")
Max digging depth(8ft level)
B'
5580mm (18' 4")
6010mm (19' 9")
6550mm (21' 6")
7580mm (24' 10")
Max vertical wall digging depth
C
5280mm (17' 4")
5720mm (18' 9")
6120mm (20' 1")
7240mm (23' 9")
Max digging height
D
9140mm (30' 0")
9340mm (30' 8")
9470mm (31' 1")
10110mm (33' 2")
Max dumping height
E
6330mm (20' 9")
6520mm (21' 5")
6670mm (21' 11")
7290mm (23' 11")
Min swing radius
F
3750mm (12' 4")
3740mm (12' 3")
3640mm (11' 11")
3650mm (11' 12")
133 [146] kN
133 [146] kN
133 [146] kN
133 [146] kN
SAE 13600 [14840] kgf 13600 [14840] kgf 13600 [14840] kgf 13600 [14840] kgf Bucket digging force ISO
29980 [32710] lbf
29980 [32710] lbf
29980 [32710] lbf
29980 [32710] lbf
152 [166] kN
152 [166] kN
152 [166] kN
152 [166] kN
15500 [16910] kgf 15500 [16910] kgf 15500 [16910] kgf 15500 [16910] kgf 34170 [37280] lbf
34170 [37280] lbf
34170 [37280] lbf
34170 [37280] lbf
135 [148] kN
113 [123] kN
97 [106] kN
79 [87] kN
SAE 13800 [15050] kgf
11500 [12550] kgf
9900 [10800] kgf
8100 [8840] kgf
30420 [33190] lbf
25350 [27650] lbf
21830 [23810] lbf
17860 [19480] lbf
142 [155] kN
118 [128] kN
101 [110] kN
85 [93] kN
14500 [15820] kgf 12000 [13090] kgf 10300 [11240] kgf
8700 [9490] kgf
Arm digging force ISO
31970 [34880] lbf
26460 [28870] lbf
[ ] : Power boost
1-13
22710 [24770] lbf
19170 [20910] lbf
2) R210LC-7 LONG REACH [8.2m(26' 11") BOOM] A A'
B B'
C
E
D
F
8ft 29072SP08
Description
6300(20' 8") Arm
Max digging reach
A
15220(50' 0")
Max digging reach on ground
A'
15120(49' 7")
Max digging depth
B
11760(38' 7")
Max digging depth (8ft level)
B'
11650(38' 3")
Max vertical wall digging depth
C
9610(31' 6")
Max digging height
D
12550(41' 2")
Max dumping height
E
10280(33' 8")
Min swing radius
F
4870(16' 0") 72.6 kN
SAE
7400 kgf 16310 lbf
Bucket digging force
83.4 kN ISO
8500 kgf 18740 lbf 49.0 kN
SAE
5000 kgf 11020 lbf
Arm crowd force
50.0 kN ISO
5100 kgf 11240 lbf
1-14
3) R210LC-7 HIGH WALKER [5.68m(18' 8") BOOM] A A'
B B' C
E
D
F
8ft Description
2.0m(6' 7") Arm
29072SP03
2.40m(7' 10") Arm
2.92m(9' 7") Arm 3.90m(12' 10") Arm
Max digging reach
A
9140mm (30' 0")
9500mm (31' 2")
9940mm (32' 7") 10910mm (35'10")
Max digging reach on ground
A'
8920mm (29' 3")
9290mm (30' 6")
9740mm (31'11") 10730mm (35' 2")
Max digging depth
B
5630mm (18' 6")
6010mm (19' 9")
6550mm (21' 6")
7530mm (24' 8")
Max digging depth (8ft level)
B'
5390mm (17' 8")
5820mm (19' 1")
6360mm (20'10")
7390mm (24' 3")
Max vertical wall digging depth
C
5090mm (16' 8")
5630mm (18' 6")
5930mm (19' 5")
7050mm (23' 1")
Max digging height
D
9330mm (30' 7")
9530mm (31' 3")
9660mm (31' 8") 10300mm (33' 9")
Max dumping height
E
6520mm (21' 5")
6710mm (22' 0")
6860mm (22' 6")
7480mm (24' 6")
Min swing radius
F
3750mm (12' 4")
3740mm (12' 3")
3640mm (11'11")
3650mm (11'12")
133 [146] kN
133 [146] kN
133 [146] kN
133 [146] kN
SAE 13600 [14840] kgf
13600 [14840] kgf
13600 [14840] kgf
13600 [14840] kgf
29980 [32710] lbf
29980 [32710] lbf
29980 [32710] lbf
29980 [32710] lbf
152 [166] kN
152 [166] kN
152 [166] kN
152 [166] kN
15500 [16910] kgf
15500 [16910] kgf
15500 [16910] kgf
15500 [16910] kgf
34170 [37280] lbf
34170 [37280] lbf
34170 [37280] lbf
34170 [37280] lbf
135 [148] kN
113 [123] kN
97 [106] kN
79 [87] kN
SAE 13800 [15050] kgf
11500 [12550] kgf
9900 [10800] kgf
8100 [8840] kgf
30420 [33190] lbf
25350 [27650] lbf
21830 [23810] lbf
17860 [19480] lbf
142 [155] kN
118 [128] kN
101 [110] kN
85 [93] kN
14500 [15820] kgf
12000 [13090] kgf
10300 [11240] kgf
8700 [9490] kgf
31970 [34880] lbf
26460 [28870] lbf
22710 [24770] lbf
19170 [20910] lbf
Bucket digging force ISO
Arm crowd force ISO [ ] : Power boost
1-15
4. WEIGHT 1) R210LC-7 R210LC-7
Item
kg
lb
Upperstructure assembly
8950
19730
Main frame weld assembly
2600
5730
Engine assembly
430
950
Engine assembly(TIER II)
530
1170
Main pump assembly
120
265
Main control valve assembly
200
440
Swing motor assembly
190
420
Hydraulic oil tank assembly
240
530
Fuel tank assembly
195
430
Counterweight
3800
8380
Cab assembly
310
680
Lower chassis assembly
8700
19180
Track frame weld assembly
2720
6000
Swing bearing
260
570
Travel motor assembly
305
670
55
120
Track recoil spring and idler
270
600
Idler
170
370
Carrier roller
20
45
Track roller
40
90
Track-chain assembly(600mm standard triple grouser shoe)
1320
2910
Front attachment assembly(5.68m boom, 2.92m arm, 0.92m3 PCSA heaped bucket)
4050
8930
5.68m boom assembly
1500
3310
2.92m arm assembly
705
1550
0.92m PCSA heaped bucket
660
1460
Boom cylinder assembly
180
400
Arm cylinder assembly
290
640
Bucket cylinder assembly
175
390
Bucket control link assembly
170
370
Turning joint
3
1-16
2) R210LC-7 LONG REACH R210LC-7 LONG REACH
Item
kg
lb
Upperstructure assembly
8950
19730
Main frame weld assembly
2600
5730
Engine assembly
430
950
Engine assembly(TIER II)
530
1170
Main pump assembly
120
265
Main control valve assembly
200
440
Swing motor assembly
190
420
Hydraulic oil tank assembly
240
530
Fuel tank assembly
195
430
Counterweight
5300
11680
Cab assembly
310
680
Lower chassis assembly
8700
19180
Track frame weld assembly
2720
6000
Swing bearing
260
570
Travel motor assembly
305
670
Turning joint
55
120
Track recoil spring and idler
270
600
Idler
170
370
Carrier roller
20
45
Track roller
40
90
Track-chain assembly(800mm standard triple grouser shoe)
1605
3540
Front attachment assembly(8.2m boom, 6.3m arm, 0.51m3 PCSA heaped bucket)
4250
9370
8.2m boom assembly
2470
5450
6.3m arm assembly
1340
2950
0.51m3 PCSA heaped bucket
440
970
Boom cylinder assembly
180
400
Arm cylinder assembly
270
600
Bucket cylinder assembly
130
290
Bucket control rod assembly
170
370
1-17
3) R210LC-7 HIGH WALKER R210LC-7 HIGH WALKER
Item
kg
lb
Upperstructure assembly
8950
19730
Main frame weld assembly
2600
5730
Engine assembly
430
950
Engine assembly(TIER II)
530
1170
Main pump assembly
120
265
Main control valve assembly
200
440
Swing motor assembly
190
420
Hydraulic oil tank assembly
240
530
Fuel tank assembly
195
430
Counterweight
3800
8380
Cab assembly
310
680
Lower chassis assembly
9015
19870
Track frame weld assembly
3730
8220
Swing bearing
285
630
Travel motor assembly
305
670
Turning joint
55
120
Track recoil spring and idler
310
685
Idler
170
370
Carrier roller
20
45
Track roller
40
90
Track-chain assembly(600mm standard triple grouser shoe)
1320
2910
Front attachment assembly(5.68m boom, 2.92m arm, 0.92m3 PCSA heaped bucket)
4050
8930
5.68m boom assembly
1500
3310
2.92m arm assembly
705
1550
0.92m3 PCSA heaped bucket
660
1460
Boom cylinder assembly
180
400
Arm cylinder assembly
290
640
Bucket cylinder assembly
175
390
Bucket control rod assembly
170
370
1-18
5. LIFTING CAPACITIES 1) ROBEX 210LC-7 (1) 5.68m(18' 8") boom, 2.00m(6' 7") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm(24") triple grouser shoe and 3800kg counterweight.
・
・
: Rating over-front
: Rating over-side or 360 degree
Load radius Load point height 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb -4.5m kg (-15ft) lb
Note
3.0m(10ft)
4.5m(15ft)
At max. reach
6.0m(20ft)
7.5m(25ft)
Capacity
Reach m(ft)
*13020 *28700 *11620 *25620 *8770 *19330
12190 26870 *11620 *25620 *8770 *19330
*5360 *11820 *6970 *15370 *8380 *18470 *9020 *19890 *8960 *19750 *8210 *18100
*5360 *11820 6830 15060 6310 13910 6080 13400 6050 13340 6160 13580
*4150 *9150 *4540 *10010 *5240 *11550 *5950 *13120 *6430 *14180 *6510 *14350 *5910 *13030
*4150 *9150 *4540 *10010 4380 9660 4120 9080 3960 8730 3910 8620 3990 8800
*4500 *9920 *4820 *10630 4980 10980
3020 6660 2900 6390 2830 6240
*3750 *8270 *3800 *8380 *3910 *8620 *4050 *8930 4000 8820 4210 9280 *4550 *10030 *4510 *9940
*3750 *8270 3060 6750 2560 5640 2340 5160 2280 5030 2400 5290 2770 6110 3660 8070
6.64 (21.8) 7.78 (25.5) 8.43 (27.7) 8.74 (28.7) 8.73 (28.6) 8.42 (27.6) 7.76 (25.5) 6.61 (21.7)
1. Lifting capacity are based on SAE J1097 and ISO 10567. 2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine on firm, level ground or 87% of full hydraulic capacity. 3. The load point is a hook located on the back of the bucket. 4. *indicates load limited by hydraulic capacity.
1-19
(2) 5.68m(18' 8") boom, 2.40m(7' 10") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm(24") triple grouser shoe and 3800kg counterweight. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)
1.5m(5ft)
3.0m(10ft)
4.5m(15ft)
At max. reach 6.0m(20ft)
7.5m(25ft)
Capacity
Reach m(ft)
kg lb kg lb kg lb kg lb kg lb kg *8300 *8300 lb *18300 *18300 kg *9220 *9220 *12750 11960 lb *20330 *20330 *28110 26370 kg *13340 *13340 *12280 12180 lb *29410 *29410 *27070 26850 kg *9840 *9840 lb *21690 *21690
*6420 *6420 *14150 *14150 *7960 6360 *17550 14020 *8820 6050 *19440 13340 *8970 5970 *19780 13160 *8430 6040 *18580 13320 *6850 6300 *15100 13890
*3750 *8270 *4190 *9240 *4920 *10850 *5690 *12540 *6260 *13800 *6460 *14240 *6110 *13470
*3750 *8270 *4190 *3940 *9240 *8690 4400 *4240 9700 *9350 4130 *4620 9110 *10190 3930 *4920 8660 *10850 3850 8490 3890 8580
3140 6920 3020 6660 2890 6370 2790 6150
*3450 *7610 *3520 *7760 *3630 *8000 3770 8310 3720 8200 3890 8580 *4300 *9480 *4360 *9610
*3450 *7610 2780 6130 2350 5180 2150 4740 2100 4630 2200 4850 2490 5490 3190 7030
7.15 (23.5) 8.20 (26.9) 8.82 (28.9) 9.11 (29.9) 9.10 (29.9) 8.81 (28.9) 8.18 (26.8) 7.12 (23.4)
(3) 5.68m(18' 8") boom, 2.92m(9' 7") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm(24") triple grouser shoe and 3800kg counterweight. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)
1.5m(5ft)
3.0m(10ft)
4.5m(15ft)
At max. reach 6.0m(20ft)
7.5m(25ft)
Capacity
Reach m(ft)
kg lb kg lb kg *3770 lb *8310 kg *9160 *9160 *5760 *5760 *4530 lb *20190 *20190 *12700 *12700 *9990 kg *8660 *8660 *7430 6500 *5380 lb *19090 *19090 *16380 14330 *11860 kg *9310 *9310 *8550 6100 *6060 lb *20530 *20530 *18850 13450 *13360 kg *8550 *8550 *12160 11830 *8950 5940 *6400 lb *18850 *18850 *26810 26080 *19730 13100 *14110 kg *11700 *11700 *13020 11990 *8680 5960 *6280 lb *25790 *25790 *28700 26430 *19140 13140 *13850 kg *11040 *11040 *7560 6130 lb 24340 *24340 *16670 13510
1-20
*3770 *3590 *8310 *7910 4490 *3950 9900 *8710 4180 *4390 9220 *9680 3950 *4770 8710 *10520 3820 4870 8420 10740 3820 8420
3210 7080 3070 6770 2910 6420 2780 6130 2720 6000
*3120 *6880 *3210 *7080 *3340 *7360 *3490 *7690 3440 7580 3580 7890 3970 8750 *4230 *9330 *4140 *9130
*3120 *6880 2530 5580 2170 4780 1980 4370 1930 4250 2000 4410 2230 4920 2770 6110 *4140 *9130
7.72 (25.3) 8.69 (28.5) 9.27 (30.4) 9.55 (31.3) 9.54 (31.3) 9.26 (30.4) 8.67 (28.4) 7.69 (25.2) 6.09 (20.0)
(4) 5.68m(18' 8") boom, 3.90m(12' 10") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm (24") triple grouser shoe and 3800kg counterweight. Load radius Load point height 9.0m (30ft) 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft) -6.0m (-20ft)
kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb
1.5m(5ft)
3.0m(10ft)
4.5m(15ft)
6.0m(20ft)
At max. reach 7.5m(25ft)
9.0m(30ft)
Capacity
Reach m(ft)
*4950 *10910 *7060 *15560 *9410 *20750 *12210 *26920
*4950 *10910 *7060 *15560 *9410 *20750 *12210 *26920
*10430 *22990 *9990 *22020 *10980 *24210 *13520 *29810 *12480 *27510 *9890 *21800
*10430 *22990 *9990 *22020 *10980 *24210 11550 25460 11790 25990 *9890 *21800
*6230 *13730 *7720 *17020 *8560 *18870 *8760 *19310 *8250 *18190 *6620 *14590
*6230 *13730 6170 13600 5860 12920 5760 12700 5830 12850 6110 13470
*3710 *3710 *8180 *8180 *4640 4270 *10230 9410 *5490 3960 *12100 8730 *6070 3750 *13380 8270 *6270 3670 *13820 8090 *5920 3720 *13050 8200
1-21
*1870 *4120 *2670 *5890 *2910 *6420 *3340 *7360 *3860 *8510 *4360 *9610 *4710 *10380 4750 10470
*1870 *4120 *2670 *5890 *2910 *6420 3130 6900 2930 6460 2760 6080 2640 5820 2600 5730
*1930 *1930 *4250 *4250 *2750 2190 *6060 4830 *3260 2090 *7190 4610 3340 2000 *7360 4410 *2240 1950 *4940 4300
*2590 *2590 7.66 *5710 *5710 (25.1) *2640 2470 8.94 *5820 5450 (29.3) *2720 2010 9.77 *6000 4430 (32.1) *2830 1750 10.28 *6240 3860 (33.7) 2940 1610 10.52 6480 3550 (34.5) 2890 1570 10.52 6370 3460 (34.5) 2970 1610 10.27 6550 3550 (33.7) 3220 1760 9.75 7100 3880 (32.0) *3650 2080 8.91 *8050 4590 (29.2) *3770 2770 7.62 *8310 6110 (25.0)
2) R210LC-7 LONG REACH (1) 8.2m(26' 11") boom, 6.3m(20' 8") arm equipped with 0.51m3(PCSA heaped) bucket, 800mm(32") triple grouser shoe and 5300kg counterweight.
・
・
: Rating over-front
: Rating over-side or 360 degree
Load radius Load point height 9.0m kg (30ft) lb 6.0m kg (20ft) lb 3.0m kg (10ft) lb Ground kg Line lb -3.0m kg (-10ft) lb -6.0m kg (-20ft) lb -9.0m kg (-30ft) lb
Note
3.0m(10ft)
6.0m(20ft)
At max. reach
9.0m(30ft)
12.0m(40ft)
Capacity
Reach m(ft)
*4560 *10050 *5710 *12590 *7790 *17170 *8780 *19360
*4560 *10050 *5710 *12590 *7790 *17170 *8780 *19360
*4330 *9550 *5250 *11570 *5370 *11840 *4510 *9940
*4330 *9550 3800 8380 3720 8200 4000 8820
*1990 *4390 *2650 *5840 *3150 *6940 *3280 *7230 *2620 *5780
*1990 *4390 2360 5200 2070 4560 1990 4390 2190 4830
*830 *1830 *1430 *3150 *1670 *3680 *1980 *4370 *2220 *4890
*830 *1830 *1430 *3150 1580 3480 1390 3060 1260 2780
*1330 *2930 *1410 *3110 *1520 *3350 *1670 *3680 *1860 *4100 *2090 *4610
*1330 *2930 1120 2470 940 2070 890 1960 980 2160 1280 2820
13.11 (43.0) 14.37 (47.1) 14.89 (48.9) 14.75 (48.4) 13.92 (45.7) 12.25 (40.2)
1. Lifting capacity are based on SAE J1097 and ISO 10567. 2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine on firm, level ground or 87% of full hydraulic capacity. 3. The load point is a hook located on the back of the bucket. 4. *indicates load limited by hydraulic capacity.
2-22
3) R210LC-7 HIGH WALKER (1) 5.68m(18' 8") boom, 2.92m(9' 7") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm(24") triple grouser shoe and 3800kg counterweight.
・
: Rating over-front
・
: Rating over-side or 360 degree
Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)
Note
1.5m(5ft)
3.0m(10ft)
4.5m(15ft)
At max. reach 6.0m(20ft)
7.5m(25ft)
Capacity
Reach m(ft)
kg lb kg *2390 lb *5270 kg *3850 *3850 *3620 lb *8490 *8490 *7980 kg *9770 *9770 *5990 *5990 *4640 *4640 *4010 lb *21540 *21540 *13210 *13210 *10230 *10230 *8840 kg *8460 *8460 *7610 *7610 *5470 5400 *4450 lb *18650 *18650 *16780 *16780 *12060 11900 *9810 kg *9600 *9600 *8640 8080 *6120 5170 *4810 lb *21160 *21160 *19050 17810 *13490 11400 *10600 kg *8930 *8930 *12600 *12600 *8950 7940 *6420 5060 *4940 lb *19690 *19690 *27780 *27780 *19730 17500 *14150 11160 *10890 kg *12130 *12130 *12840 *12840 *8600 7980 *6220 5070 lb *26740 *26740 *28310 *28310 *18960 17590 *13710 11180 kg *10670 *10670 *7320 *7320 lb *23520 *23520 *16140 *16140
*2390 *5270 *3620 *7980 3950 8710 3790 8360 3670 8090 3610 7960
*3130 *6900 *3230 *7120 *3360 *7410 *3510 *7740 *3690 *8140 3880 8550 *4090 *9020 *4240 *9350
*3130 *6900 3200 7050 2810 6190 2620 5780 2580 5690 2700 5950 3030 6680 3770 8310
7.87 (25.8) 8.79 (28.8) 9.32 (30.6) 9.56 (31.4) 9.52 (31.2) 9.21 (30.2) 8.57 (28.1) 7.53 (24.7)
1. Lifting capacity are based on SAE J1097 and ISO 10567. 2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine on firm, level ground or 87% of full hydraulic capacity. 3. The load point is a hook located on the back of the bucket. 4. *indicates load limited by hydraulic capacity.
1-23
(2) 5.68m(18' 8") boom, 2.0m(6' 7") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm(24") triple grouser shoe and 3800kg counterweight. Load radius Load point height 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb -3.0m kg (-10ft) lb -1.5m kg (-5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb
3.0m(10ft)
4.5m(15ft)
At max. reach
6.0m(20ft)
7.5m(25.0ft)
Capacity
Reach m(ft)
*8080 *17810
*12900 *28440 *11370 *25070
*8080 *17810
*12900 *28440 *11370 *25070
*5550 *12240 *7170 *15810 *8510 *18760 *9050 *19950 *8910 *19640 *8040 *17730
*5550 *12240 *7170 *15810 8290 18280 8080 17810 8070 17790 *8040 *17730
*4170 *9190 *4620 *10190 *5330 *11750 *6030 *13290 *6470 *14260 *6480 *14290
*4170 *9190 *4620 *10190 *5330 *11750 5350 11790 5190 11440 5150 11350
*4540 *10010 *4860 *10710 *5050 *11130
3900 8600 3790 8360 3720 8200
*3750 *8270 *3810 *8400 *3920 *8640 *4070 *8970 *4250 *9370 *4430 *9770 *4560 *10050 *4470 *9850
*3750 *8270 *3810 *8400 3280 7230 3050 6720 3020 6660 3210 7080 3710 8180 *4470 *9850
6.82 (22.4) 7.88 (25.9) 8.49 (27.9) 8.75 (28.7) 8.71 (28.6) 8.36 (27.4) 7.64 (25.1) 6.41 (21.0)
(3) 5.68m(18' 8") boom, 2.4m(7' 10") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm(24") triple grouser shoe and 3800kg counterweight. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)
kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb
1.5m(5ft)
3.0m(10ft)
4.5m(15ft)
At max. reach 6.0m(20ft)
7.5m(25ft)
Capacity
Reach m(ft)
*9710 *9710 *21410 *21410 *13920 *13920 *30690 *30690
*8830 *19470 *13370 *29480 *12060 *26590 *9390 *20700
*8830 *19470 *13370 *29480 *12060 *26590 *9390 *20700
*5010 *11050 *6640 *14640 *8110 *17880 *8870 *19550 *8940 *19710 *8310 *18320 *6500 *14330
*5010 *11050 *6640 *14640 *8110 *17880 8040 17730 7970 17570 8070 17790 *6500 *14330
1-24
*3780 *3780 *8330 *8330 *4270 *4270 *3960 *9410 *9410 *8730 *5020 *5020 *4290 *11070 *11070 *9460 *5780 5350 *4670 *12740 11790 *10300 *6310 5160 *4940 *13910 11380 *10890 *6460 5090 *14240 11220 *6000 5150 *13230 11350
*3960 *8730 3910 8620 3770 8310 3670 8090
*3460 *7630 *3530 *7780 *3650 *8050 *3800 *8380 *3970 *8750 *4150 *9150 *4320 *9520 *4350 *9590
*3460 *7630 3500 7720 3040 6700 2830 6240 2790 6150 2950 6500 3360 7410 4350 9590
7.31 (24.0) 8.30 (27.2) 8.87 (29.1) 9.12 (29.9) 9.08 (29.8) 8.75 (28.7) 8.07 (26.5) 6.94 (22.8)
(4) 5.68m(18' 8") boom, 3.9m(12' 9") arm equipped with 0.92m3(PCSA heaped) bucket, 600mm(24") triple grouser shoe and 3800kg counterweight. Load radius Load point height 9.0m (30ft) 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft) -6.0m (-20ft)
kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb
1.5m(5ft)
3.0m(10ft)
4.5m(15ft)
At max. reach
6.0m(20ft)
7.5m(25ft)
9.0m(30ft)
Capacity
Reach m(ft)
*5210 *11490 *7340 *16180 *9730 *21450 *12610 *27800
*5210 *11490 *7340 *16180 *9730 *21450 *12610 *27800
*10900 *24030 *9980 *22000 *11230 *24760 *13580 *29940 *12250 *27010 *9410 *20750
*10900 *24030 *9980 *22000 *11230 *24760 *13580 *29940 *12250 *27010 *9410 *20750
*6450 *14220 *7870 *17350 *8620 *19000 *8730 *19250 *8120 *17900 *6270 *13820
*6450 *14220 *7870 *17350 7840 17280 7760 17110 7860 17330 *6270 *13820
*3820 *8420 *4760 *10490 *5580 *12300 *6120 *13490 *6260 *13800 *5820 *12830
1-25
*3820 *8420 *4760 *10490 5180 11420 4980 10980 4910 10820 4980 10980
*2100 *4630 *2690 *5930 *2960 *6530 *3410 *7520 *3930 *8660 *4410 *9720 *4740 *10450 *4760 *10490
*2100 *4630 *2690 *5930 *2960 *6530 *3410 *7520 3820 8420 3640 8020 3520 7760 3490 7690
*2060 *4540 *2830 *6240 *3300 *7280 *3280 *7230
*2060 *4540 *2830 *6240 2780 6130 2690 5930
*2590 *5710 *2650 *5840 *2730 *6020 *2850 *6280 2980 6570 3120 6880 3230 7120 *3490 *7690 *3670 *8090 *3770 *8310
*2590 *5710 *2650 *5840 2600 5730 2320 5110 2170 4780 2140 4720 2210 4870 2420 5340 2860 6310 *3770 *8310
7.85 (25.8) 9.06 (29.7) 9.85 (32.3) 10.32 (33.9) 10.54 (34.6) 10.50 (34.4) 10.22 (33.5) 9.67 (31.7) 8.78 (28.8) 7.41 (24.3)
6. BUCKET SELECTION GUIDE 1) GENERAL BUCKET
0.51m3 PCSA heaped bucket
0.80m3 PCSA heaped bucket
Capacity
Width
※0.92m3 PCSA heaped bucket
1.20m3 PCSA heaped bucket
1.34m3 PCSA heaped bucket
Recommendation
Without With side cutter side cutter
Weight
PCSA heaped
CECE heaped
0.51m3 (0.67yd3)
0.45m3 (0.59yd3)
700mm (27.6")
820mm (32.3")
580kg (1280lb)
0.80m3 (1.05yd3)
0.70m3 (0.92yd3)
1000mm (39.4")
1120mm (44.1")
650kg (1430lb)
※0.92m3 (1.20yd3)
0.80m3 (1.05yd3)
1130mm (44.5")
1250mm (49.2")
710kg (1570lb)
1.20m3 (1.57yd3)
1.00m3 (1.31yd3)
1400mm (55.1")
─
770kg (1700lb)
1.34m3 (1.75yd3)
1.15m3 (1.50yd3)
1550mm (61.0")
─
800kg (1760lb)
5.68m (18' 8") boom 2.0m arm (6' 7")
2.4m arm (7' 10")
※ : Standard bucket
Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less Applicable for materials with density of 1600kgf/m3 (2700lbf/yd3) or less Applicable for materials with density of 1100kgf/m3 (1850lbf/yd3) or less
1-26
2.92m arm (9' 7")
3.90m arm (12' 10")
2) HEAVY DUTY, ROCK AND SLOPE FINISHING BUCKET
◈0.74, 0.87, 1.05m3 PCSA heaped bucket
Capacity
0.87m3 PCSA heaped bucket
Recommendation
Width Weight
PCSA heaped
CECE heaped
◈0.74m3 (0.97yd3)
0.65m3 (0.85yd3)
915mm (36.0")
─
750kg (1650lb)
◈0.90m3 (1.18yd3)
0.80m3 (1.05yd3)
1070mm (42.0")
─
790kg (1740lb)
◈1.05m3 (1.37yd3)
0.92m3 (1.20yd3)
1220mm (48.0")
─
870kg (1920lb)
0.87m3 (1.14yd3)
0.75m3 (0.98yd3)
1140mm (44.9")
─
860kg (1900lb)
▣0.75m3 (0.98yd3)
0.65m3 (0.85yd3)
1810mm (71.3")
─
880kg (1940lb)
◈ : Heavy duty bucket
▣0.75m3 PCSA heaped bucket
Without With side cutter side cutter
: Rock bucket(Heavy)
5.68m (18' 8") boom 2.0m arm (6' 7")
2.4m arm (7' 10")
▣ : Slope finishing bucket
Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less Applicable for materials with density of 1600kgf/m3 (2700lbf/yd3) or less Applicable for materials with density of 1100kgf/m3 (1850lbf/yd3) or less
1-27
2.92m arm (9' 7")
3.90m arm (12' 10")
7. UNDERCARRIAGE 1) TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. 2) TYPES OF SHOES Triple grouser Model
R210LC-7
Shapes
Shoe width
mm(in)
600(24)
700(28)
800(32)
-
Operating weight
kg(lb)
21700(47840)
21980(48460)
22270(49100)
-
0.46(6.54)
0.40(5.69)
0.35(4.98)
-
mm(ft-in)
2990(9' 10")
3090(10' 2")
3190(10' 6")
-
Shoe width
mm(in)
-
-
800(32)
-
Operating weight
kg(lb)
-
-
24360(53700)
-
Ground pressure kgf/cm2(psi)
-
-
0.42(5.97)
-
Overall width
mm(ft-in)
-
-
3190(10' 6")
Shoe width
mm(in)
600(24)
700(28)
800(32)
Double grouser 710(28)
Operating weight
kg(lb)
23160(51060)
23440(51680)
23730(52320)
23770(52400)
0.49(6.97)
0.43(6.12)
0.38(5.40)
0.43(6.12)
3395(11' 2")
3495(11' 6")
3595(11' 10")
3505(11' 6")
Ground pressure kgf/cm2(psi) Overall width R210LC-7 LONG REACH
R210LC-7 HIGH WALKER
Ground pressure kgf/cm2(psi) Overall width
mm(ft-in)
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE Item
Quantity
Carrier rollers
2EA
Track rollers
9EA
Track shoes
49EA
1-28
4) SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Confirm the category from the list of applications in table 2, then use table 1 to select the shoe. Wide shoes(Categories B and C) have limitations on applications. Before using wide shoes, check the precautions, then investigate and study the operating conditions to confirm if these shoes are suitable. Select the narrowest shoe possible to meet the required flotation and ground pressure. Application of wider shoes than recommendations will cause unexpected problem such as bending of shoes, crack of link, breakage of pin, loosening of shoe bolts and the other various problems. ※ Table 1 Specification
Category
600mm triple grouser
Standard
A
700mm triple grouser
Option
B
800mm triple grouser
Option
C
Standard
C
Track shoe
800mm triple grouser(Long reach)
※ Table 2 Category A
B
Applications
Precautions
Rocky ground, river beds, normal soil
・ Travel at low speed on rough ground with large obstacles such as
Normal soil, soft ground
・ These shoes cannot be used on rough ground with large obstacles such
boulders or fallen trees
as boulders or fallen trees
・ Travel at high speed only on flat ground ・ Travel slowly at low speed if it is impossible to avoid going over obstacles
C
Extremely soft gound ・ Use the shoes only in the conditions that the machine sinks and it is (Swampy ground) impossible to use the shoes of category A or B ・ These shoes cannot be used on rough ground with large obstacles such as boulders or fallen trees ・ Travel at high speed only on flat ground ・ Travel slowly at low speed if it is impossible to avoid going over obstacles
1-29
8. SPECIFICATIONS FOR MAJOR COMPONENTS 1) ENGINE Item
Specification
Model
Cummins B5.9-C
Type
4-cycle turbocharged diesel engine, low emission
Cooling method
Water cooling
Number of cylinders and arrangement
6 cylinders, in-line
Firing order
1-5-3-6-2-4
Combustion chamber type
Direct injection type
Cylinder boreÝstroke
102Ý120mm(4.02"Ý4.72")
Piston displacement
5880cc(359cu in)
Compression ratio
17.4 : 1
Rated gross horse power(SAE J1995)
*Cummins 6BTAA
*17.3 : 1
155Hp at 2100rpm(116kW at 2100rpm) *150Hp at 1950rpm(112kW at 1950rpm)
Maximum torque at 1600rpm
*at 1500rpm
62.1kgfÂm(450lbfÂft) *62.6kgfÂm(453lbfÂft)
Engine oil quantity
24˶(6.3U.S. gal)
Dry weight
400kg(882lb)
*496kg(1094lb)
High idling speed
2250 50rpm
*2180 50rpm
Low idling speed
950Ü100rpm
*1050Ü100rpm
Rated fuel consumption
171.5g/HpÂhr at 2100rpm
*164.8g/HpÂhr at 1950rpm
Starting motor
Nippon denso(24V-5.5kW)
*(24V-4.5kW)
Alternator
Delco Remy (24V-50A)
Battery
2Ý12VÝ100Ah
* : TIER II
2) MAIN PUMP Item
[
Specification
Type
Variable displacement tandem axis piston pumps
Capacity
2Ý105cc/rev
Maximum pressure
330kgf/cm2 (4694psi) [360kgf/cm2 (5120psi)]
Rated oil flow
2Ý220˶/min (58.1U.S. gpm/ 48.4U.K. gpm)
Rated speed
2100rpm
] : Power boost
* : TIER II
1-30
*2Ý113cc/rev
*1950rpm
3) GEAR PUMP Item
Specification
Type
Fixed displacement gear pump single stage
Capacity
15cc/rev
Maximum pressure
35kgf/cm2(500psi)
Rated oil flow
31.5ℓ/min(8.3U.S. gpm/7.0U.K. gpm)
4) MAIN CONTROL VALVE Item
Specification
Type
9 spools mono-block
Operating method
Hydraulic pilot system
Main relief valve pressure
330kgf/cm2(4695psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure
390kgf/cm2(5550psi)
[ ]: Pooer boost
5) SWING MOTOR Item
Specification
Type
Two fixed displacement axial piston motor
Capacity
151cc/rev
Relief pressure
240kgf/cm2(3414psi)
Braking system
Automatic, spring applied hydraulic released
Braking torque
59kgf·m(427lbf·ft)
Brake release pressure
33~50kgf/cm2(470~711psi)
Reduction gear type
2 - stage planetary
Swing speed
12.5rpm
6) TRAVEL MOTOR (1) TRAVEL MOTOR(GM35VL, up to #2078) Item
★
Specification
Type
Variable displacement axial piston motor
Relief pressure
330kgf/cm2(4695psi)
Reduction gear type
3-stage planetary
Braking system
Automatic, spring applied hydraulic released
Brake release pressure
6kgf/cm2(85psi)
★
Braking torque
40.6kgf·m(294lbf·ft)
★
: HIGH WALKER
1-31
★
325kgf/cm2(4625psi)
11kgf/cm2(157psi) 49.3kgf·m(357lbf·ft)
(2) TRAVEL MOTOR(SBTR220, #2079 and up) Item
Specification
Type
Variable displacement axial piston motor
Relief pressure
330kgf/cm2(4695psi)
Reduction gear type
2-stage planetary
Braking system
Automatic, spring applied hydraulic released
Brake release pressure
11kgf/cm2(156psi)
Braking torque
49.3kgf·m(357lbf·ft)
7) REMOTE CONTROL VALVE Item
Specification
Type
Pressure reducing type
Operating pressure
Single operation stroke
Minimum
6.5kgf/cm2(92psi)
Maximum
26kgf/cm2(370psi)
Lever
61mm(2.4in)
Pedal
123mm(4.84in)
8) CYLINDER Specification
Item Boom cylinder
Arm cylinder
Bucket cylinder
Bore dia×Rod dia×Stroke
Ø120×Ø85×1290mm
Cushion
Extend only
Bore dia×Rod dia×Stroke
Ø140×Ø100×1510mm
Cushion
Extend and retract
Bore dia×Rod dia×Stroke
Ø125×Ø85×1055mm
Cushion
Extend only
#Ø140×Ø95×1460mm #Ø100×Ø70×870mm
※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on the rod surface. ※ Discoloration does not cause any harmful effect on the cylinder performance. # : LONG REACH
1-32
9) SHOE Item
Width
Ground pressure
Link quantity
Overall width
600mm(24")
0.46kgf/cm2(6.54psi)
49
2990mm(9' 10")
700mm(28")
0.40kgf/cm2(5.69psi)
49
3090mm(10' 2")
800mm(32")
0.35kgf/cm2(4.98psi)
49
3190mm(10' 6")
Standard
800mm(32")
0.42kgf/cm2(5.97psi)
49
3190mm(10' 6")
Standard
600mm(24")
0.49kgf/cm2(6.97psi)
49
3395mm(11' 2")
700mm(28")
0.43kgf/cm2(6.12psi)
49
3495mm(11' 6")
800mm(32")
0.38kgf/cm (5.40psi)
49
3595mm(11' 10")
※710mm(28")
0.43kgf/cm2(6.12psi)
49
3505mm(11' 6")
Standard R210LC-7 R210LC-7 LONG REACH
Option
R210LC-7 HIGH WALKER
Option
2
※ : Double grouser.
10) BUCKET Capacity
Item
PCSA heaped STD
0.92m (1.20yd )
0.80m3(1.05yd3)
5
1130mm(44.5")
1250mm(49.2")
0.51m3(0.67yd3)
0.45m3(0.59yd3)
3
700mm(27.6")
820mm(32.3")
0.80m (1.05yd )
0.70m (0.92yd )
5
1000mm(39.4")
1120mm(44.1")
1.20m3(1.57yd3)
1.00m3(1.31yd3)
6
1400mm(55.1")
-
1.34m (1.75yd )
1.15m (1.50yd )
6
1550mm(61.0")
-
◈0.74m3(0.97yd3)
0.65m3(0.85yd3)
5
915mm(36.0")
-
◈0.90m (1.18yd )
0.80m (1.05yd )
5
1070mm(42.0")
-
◈1.05m3(1.37yd3)
0.92m3(1.20yd3)
5
1220mm(48.0")
-
0.87m (1.14yd )
0.75m (0.98yd )
5
1140mm(44.9")
-
▣0.75m3(0.98yd3)
0.65m3(0.85yd3)
-
1810mm(71.3")
-
3
3
3
3
3
R210LC-7
OPT
CECE heaped
Width Tooth quantity Without side cutter With side cutter
3
3
3
3
3
3
3
3
3
3
3
3
3
◈ : Heavy duty bucket : Rock bucket(Heavy) ▣ : Slope finishing bucket
1-33
9. RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil.
Service point
Kind of fluid
Ambient temperature ° C (° F)
Capacity ℓ(U.S. gal)
-20 (-4)
-10 (14)
0 (32)
10 (50)
20 (68)
30 (86)
SAE 30 Engine oil pan
Engine oil
SAE 10W
24.0(6.3)
SAE 10W-30 SAE 15W-40
6.2(1.6)
Swing drive Gear oil Final drive
Hydraulic tank
Hydraulic oil
SAE 85W-140
5.4×2 (1.4×2)
ISO VG 32
Tank; 180(48)
ISO VG 46
System; 270(71)
ISO VG 68
ASTM D975 NO.1 Fuel tank
Diesel fuel
320(84.5) ASTM D975 NO.2
Fitting (Grease nipple)
Grease
Radiator (Reservoir tank)
Mixture of antifreeze and water 50 : 50
SAE API ISO NLGI ASTM
NLGI NO.1
As required
NLGI NO.2
Ethylene glycol base permanent type
35(9.2)
: Society of Automotive Engineers : American Petroleum Institute : International Organization for Standardization : National Lubricating Grease Institute : American Society of Testing and Material
1-34
40 (104)
SECTION 2 STRUCTURE AND FUNCTION Group Group Group Group Group Group
1 2 3 4 5 6
Pump Device Main Control Valve Swing Device Travel Device RCV Lever RCV Pedal
2-1 2-21 2-46 2-58 2-69 2-76
SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. Pi1
Pm1
Qmax adjusting screw
Dr
A3
B3 Psv Pm2
Pi2
a4 Qmin adjusting screw Regulator
Regulator
Pi1
Qmin adjusting screw
Pi2 Pm2
Pm1
a4
Psv B3 Dr B1 a3 a2
a1 Port block
Front pump
Port
A1 Psv a4 A2 a2
a1
Pm1 Pi1
Pm2 Pi2
a3
Dr B1
Rear pump
B3
A3
2-1
Port name
Gear pump Port size
A1,2
Delivery port
SAE6000psi 3/4"
B1
Suction port
SAE2500psi 2 1/2"
Dr
Drain port
PF 3/4 - 20
Pi1,i2
Pilot port
PF 1/4 - 15
Pm1,m2 Qmax cut port Psv
PF 1/4 - 15
Servo assist port
PF 1/4 - 15
a1,2,4
Gauge port
PF 1/4 - 15
a3
Gauge port
PF 1/4-14
A3
Gear pump delivery port
PF 1/2 - 19
B3
Gear pump suction port
PF 3/4 - 20
1) MAIN PUMP(1/2) The main pump consists of two piston pumps(front & rear) and valve block.
702 789, 732 532 214 548 531 724 792 534 901 808 954 717 151 152 211 113 535 806 953 886 717 406 261 774
04
111 824 127 710 123 251 212
04 111 113 114 123 124 127 141 151 152 153 156 157 158 211 212 214
490
153
Gear pump Drive shaft(F) Drive shaft(R) Spline coupling Roller bearing Needle bearing Bearing spacer Cylinder block Piston Shoe Set plate Bushing Cylinder spring Spacer Shoe plate Swash plate Bushing
156 158 157 468 313 124 312 114 466 728 725
251 261 271 312 313 314 401 406 466 468 490 531 532 534 535 548 702
Support Seal cover(F) Pump casing Valve block Valve plate(R) Valve plate(L) Hexagon socket bolt Hexagon socket bolt VP Plug VP Plug Plug Tilting pin Servo piston Stopper(L) Stopper(S) Pin O-ring
2-2
885
314
141
710 717 724 725 728 732 774 789 792 806 808 824 885 886 901 953 954
271
401
O-ring O-ring O-ring O-ring O-ring O-ring Oil seal Back up ring Back up ring Hexagon head nut Hexagon head nut Snap ring Pin Spring pin Eye bolt Set screw Set screw
MAIN PUMP(2/2)
544
543 545 541
079
VIEW A
79 541
Proportional reducing valve Seat
543 544
2-3
Stopper 1 Stopper 2
545
Steel ball
2) REGULATOR(1/2)
412
875
874
755 A
897
858
B
614
612
615 613 A
611
B
647
A
KR3G-9C32
648 P2 Pf
723 642
438 801
801
Pm Pi
924 641
730
643
708
644
645
646
728
B
SECTION B-B
413
438
656
438 735 722
496
724
725
436
VIEW C
2-4
Port
Port name
port size
A
Delivery port
3/4"
B
Suction port
2 1/2"
Pi
Pilot port
PF 1/4-15
Pm
Qmax cut port
PF 1/4-15
REGULATOR(2/2) 734
653
654
836
651 652
601
624
629
630
628
655
641
801 C 925
814 898 631
627
732
733
732
622
621
623
625
626
887
763
756
730 732 733 734 735 755 756 763 801 814 836 858 874 875 887 897 898 924 925
O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring Nut Snap ring Snap ring Snap ring Pin Pin Pin Pin Pin Set screw Adjust screw(QI)
SECTION A-A
412 413 436 438 496 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630
Hexagon socket screw Hexagon socket screw Hexagon socket screw Hexagon socket screw Plug Casing Feed back lever Lever(1) Lever(2) Fulcrum plug Adjust plug Compensator piston Piston case Compensator rod Spring seat(C) Outer spring Inner spring Adjust stem(C) Adjust screw(C) Cover(C) Lock nut
631 641 642 643 644 645 646 647 648 651 652 653 654 655 656 708 722 723 724 725 728
Sleeve, pf Pilot cover Pilot cover(QMC) Pilot piston Spring seat(Q) Adjust stem(Q) Pilot spring Stopper Piston(QMC) Sleeve Spool Spring seat Return spring Set spring Block cover O-ring O-ring O-ring O-ring O-ring O-ring
2-5
3) GEAR PUMP
700
354
351
433
B3
850 355
434 A3
311 312 a3 710
307 308 309 310 311 312 351
435
Poppet Seat Spring seat Spring Screw Nut Gear case
361
353
732
353 354 355 361 433 434 435
309
Drive gear Driven gear Filter Front case Flange socket Flange socket Flange socket
2-6
307
310
308
466 700 710 725 732 850
434
466, 725
Plug Ring O-ring O-ring O-ring Snap ring
2. FUNCTION 1) MAIN PUMP The pumps may classified roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: the swash plate group that varies the delivery rates: and the valve cover group that changes over oil suction and discharge. (1) Rotary group The rotary group consists of drive shaft (F)(111), cylinder block(141), piston shoes(151,152), set plate(153), spherical bush(156), spacer(158) and cylinder spring(157). The drive shaft is supported by bearing(123,124) at its both ends. The shoe is caulked to the piston to from a spherical coupling. It has a pocket to relieve thrust force generated by loading pressure and the take hydraulic balance so that it slides lightly over the shoe plate(211). The sub group composed by a piston and a shoe is pressed against the shoe plate by the action of the cylinder spring via a retainer and a spherical bush. Similarly, the cylinder block is pressed against valve plate(313) by the action of the cylinder spring.
141 151 152
313
124
158 156 153
111
157
123 211
531 548
(2) Swash plate group The swash 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 side of the sliding surface of the shoe and is supported by the swash support. If the servo piston moves to the right and left as hydraulic force controlled by the regulator is admitted to hydraulic chamber located on both sides of the servo piston, the swash plate slides over the swash plate support via the spherical part of the tilting pin to change the tilting angle(α)
214 212 251
211
532
α
α
2-7
(3) Valve block group The valve block group consists of valve block(312), valve plate(313) and valve plate pin(885). The valve plate having two melonshaped ports is fixed to the valve block and feeds and collects oil to and from the cylinder block. The oil changed over by the valve plate is connected to an external pipeline by way of the valve block. Now, if the drive shaft is driven by a prime mover(electric motor, engine, etc), it rotates the cylinder block via a spline linkage at the same time. If the swash plate is tilted as in Fig(previous page) the pistons arranged in the cylinder block make a reciprocating motion with respect to the cylinder block, while they revolve with the cylinder block. If you pay attention to a single piston, it performs a motion away from the valve plate(oil sucking process) within 180 degrees, and makes a motion towards the valve plate(or oil discharging process) in the rest of 180 degrees. When the swash plate has a tilting angle of zero, the piston makes no stroke and discharges no oil.
312 313
2-8
885
2) REGULATOR Regulator consists of the negative flow control, total horse power control and power shift control function.
Delivery flow, Q
(1) Negative flow control By changing the pilot pressure Pi, the pump tilting angle(delivery flow) is regulated arbitrarily, as shown in the figure. This regulator is of the negative flow control in which the delivery flow Q decreases as the pilot pressure Pi rises. With this mechanism, when the pilot pressure corresponding to the flow required for the work is commanded, the pump discharges the required flow only, and so it does not consume the power uselessly.
Pilot pressure, Pi
2-9
① Flow reducing function
643
654
651
P1
652
613
CL
646
B(E) 874 897 C A
875 611 Large diameter chamber
Servo piston
D
548
Small diameter chamber
531
As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the force of the pilot spring(646) balances with the hydraulic force. The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore, when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the fulcrum plug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding pin(897) fixed to the feedback lever(611), the pin(897) moves to the right as lever 2 rotates. Since the opposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the tilting pin(531) that swings the swash plate, the feedback lever rotates around the fulcrum of point D, as the pin(897) moves. Since the feedback lever is connected with the spool(652) via the pin(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 piston. The delivery pressure P1 that is constantly admitted to the small diameter section of the servo piston moves the servo piston to the right due to the area difference, resulting in decrease of the tilting angle. When the servo piston moves to the right, point D also moves to the right. The spool is fitted with the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressed against the large hole section(C) of lever 2. Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the spool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) to close slowly, and the servo piston comes to a complete stop when it closes completely.
2-10
② Flow increasing function
643
654
651
P1
652
613
CL
646
B(E) 874 897 C
875 611 Large diameter chamber
Servo piston
D
548
Small diameter chamber
531
As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the pilot spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897) is pressed against the large hole section(C) of lever 2 by the action of the return spring(654) via the spool(652), pin(874), and feedback lever(611), the feedback lever rotates around the fulcrum of point D as lever 2 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 the left by the discharge pressure P1 in the small diameter section, resulting in an increase in the flow rate. As the servo piston moves, point D also moves to the left, the feedback lever rotates around the fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve is closed.
2-11
③ Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut(801) and by tightening(or loosening) the hexagonal socket head screw(924). Tightening the screw shifts the control chart to the right as shown in the figure.
801 924
※ Adjusting values are shown in table.
Tightening amount of adjusting screw(924)
Flow control Flow change starting amount pressure change amount
(min -1)
(Turn)
(kgf/cm2)
(ℓ/min)
2100
+1/4
+1.5
+13.6
Delivery flow, Q
Speed
Adjustment of flow control characteristic
Pilot pressure, Pi
2-12
(2) Total horsepower control
Delivery flow, Q
The regulator decreases the pump tilting angle(delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump. (The input horsepower is constant when the speed is constant.) Since the regulator is of the simultaneous total horsepower type that operates by the sum of load pressures of the two pumps in the tandem double-pump system, the prime mover is automatically prevented from being overloaded, irrespective of the load condition of the two pumps, when horsepower control is under way. Since this regulator is of the simultaneous total horsepower type, it controls the tilting angles(displacement volumes) of the two pumps to the same value as represented by the following equation : Tin = P1×q/2Л + P2×q/2Л = (P1+P2)×q/2Л The horsepower control function is the same as the flow control function and is summarized in the following.(For detailed behaviors of respective parts, refer to the section of flow control).
Delivery pressure, (P1+P2)
2-13
① Overload preventive function
621
651
652
623
P1
612
601
625
626
CL B(E) 897 F
P2
P1 875 611
Large diameter chamber
Servo piston D
Small diameter chamber
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston(621). It presses the compensating rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with the hydraulic force. The movement of the compensating rod is transmitted to lever 1(612) via pin(875). Lever 1 rotates around the pin(875) (E) fixed to the casing(601). Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback lever(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 diameter section of the servo piston via port CL, causes the servo piston move to the right, reduces the pump delivery, flow rate, and prevents the prime mover from being overloaded. The movement of the servo piston is transmitted to the feedback lever via point D. Then the feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The spool moves till the opening between the spool(652) and sleeve(651) is closed.
2-14
② Flow reset function
621
651
623
652
P1
612
601
625
626
CL B(E) 897 F
P2
P1
875 Large diameter chamber
Servo piston
D
Small diameter chamber
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever 1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate around the fulcrum of point D and then the spool(652) to move to the left. As a result, port CL opens a way to the tank port. This causes the servo piston to move to the left and the pump's delivery rate to increase. The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism to move it till the opening between the spool and sleeve is closed.
2-15
③ Low tilting angle(Low flow) command preferential function As mentioned above, flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However, since sections C and F have the pins(Ø4) protruding from the large hole(Ø8), only the lever lessening the tilting angle contacts the pin(897) ; the hole(Ø8) in the lever of a larger tilting angle command is freed without contacting the pin(897). Such a mechanical selection method permits preference of the lower tilting angle command of the flow control and horsepower control. ④ Adjustment of input horsepower Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both the front and rear pumps, when changing the horsepower set values. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values will be doubled when only one pump is loaded. a. Adjustment of outer spring Adjust it by loosening the hexagon nut(630) and by tightening(or loosening) the adjusting screw C(628). Tightening the screw shifts the control chart to the right and increases the input horsepower as shown in the figure. Since turning the adjusting screw C by N turns changes the setting of the inner spring(626), return the adjusting screw QI(925) by N×A turns at first.(A=2.2)
625
626
925
Adjustment of outer spring Speed
(Turn)
(kgf/cm2)
(kgf・m)
2100
+1/4
+15.9
+4.2
Delivery flow, Q
Compens- Input torque ating control change starting amount pressure change amount
(min -1)
628
801
※ Adjusting values are shown in table
Tightening amount of adjusting screw(C) (924)
630
Delivery pressure, (P1+P2)
2-16
b. Adjustment of inner spring Adjust it by loosening the hexagon nut (801) and by tightening(or loosening) the adjusting screw QI(925). Tightening the screw increases the flow and then the input horsepower as shown in the figure.
626
801 925
※ Adjusting valves are shown in table Adjustment of inner spring Speed Compens- Input torque ating control change starting amount pressure change amount
(min -1)
(Turn)
(kgf/cm2)
(kgf・m)
2100
+1/4
+27.3
+4.1
Delivery flow, Q
Tightening amount of adjusting screw(QI) (925)
Delivery pressure, (P1+P2)
2-17
(3) Power shift control
621
651
652
623
P1
898
612
625
626
CL B(E) 897 F
Pf P2
P1 875 611
Large diameter chamber
Servo piston
Small diameter chamber
D
Delivery flow, Q
The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one proportional pressure reducing Pf= MIN valve is provided. . Pf= MA However, the secondary pressure Pf X. (power shift pressure) is admitted to the horsepower control section of each Delivery pressure, (P1+P2) pump regulator through the pump's internal path to shift it to the same set horsepower level. This function permits arbitrary setting of the pump output power, thereby providing the 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 rises, the compensating rod(623) moves to the right via the pin(898) and compensating piston(621). This decreases the pump tilting angle and then the set horsepower in the same way as explained in the overload preventive function of the horsepower control. On the contrary, the set horsepower rises as the power shift pressure Pf falls.
2-18
(4) Adjustment of maximum and minimum flows Η Adjust it by loosening the hexagon nut(808) and by tightening(or loosening) the set screw(954). The maximum flow only is adjusted without changing other control characteristics.
954
Adjustment of max flow Tightening amount of adjusting screw (954)
Flow change amount
(min -1)
(Turn)
(˶/min)
2100 *1950
+1/4
+4.8 *-5.6
2-19(1)
Delivery flow, Q
Speed
808
* : Tier ll
Delivery pressure, Pi
Θ Adjustment of minimum flow Adjust it by loosening the hexagon nut(808) and by tightening(or loosening) the hexagonal socket 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 pressure(or during relieving) may increase.
953
2-19(2)
Delivery flow, Q
Speed
806
Adjustment of min flow Tightening amount of adjusting screw (953)
Flow change amount
(min -1)
(Turn)
(˶/min)
2100 *1950
+1/4
+4.8 *+4.5
Delivery pressure, Pi
* : Tier ll
2-19
(5) Qmax cut control The regulator regulates the maximum delivery flow by inputting the pilot pressure Pm. Since this is a 2-position control method, the maximum delivery flow may be switched in two steps by turning on/off the pilot pressure Pm.(The maximum control flow cannot be controlled in intermediate level.)
647 648 723 642
438 801
801 924 641
730
708
Delivery flow, Q
① Functional explanation As shown in the figure, the pilot pressure Pm switches the maximum flow in two steps. When the pilot pressure Pm is given, it is admitted to the lefthand side of the piston QMC(648). The piston QMC moves the stopper(647) and pilot piston(643) to the right, overcoming the force of the pilot spring(646), thereby reducing the delivery flow of the pump. Since the adjusting screw QMC(642) is provided with a flange, the piston QMC stops upon contact with the flange, and the position of the pilot piston at this time determines the maximum flow of the pump.
643
644
645
646
Pm
Pilot pressure, Pi
Delivery flow, Q
② Adjustment of Qmax cut flow Adjust it by loosening the hexagon nut(801) and by tightening(or loosening) the adjusting screw QMC(642). Tightening the screw decreases the Qmax cut flow as shown in the figure.
Pilot pressure, Pi
2-20
728
GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE Mark
(PSP)
XAa1 XBtl
XBs
BtL
Bs
Py
HEAD Ck1
Aa1
PH
P1
Pns Dr6
FL
LCa1
As
AtL
CCb
Ba1
HV
Pz
FR
ROD
CMR1
Dr3
PaL
R1
TRAVEL
SWING BOOM2
P2
R2
Dr2
ARM1
(L) Dr4 XAtl
(XBp1)
XBa1
XAs
VIEW A
XAb2 Pns
Dr6
PaL
Dr3 Dr3
Dr2 FR
PG MR
FL
NR1
Px R1 P1 TS TL
A
S
TR OP
B2 B1
A1 BK
BC BC
A2
A2
R2(P2)
PBP Dr4 PbL
XAtr
XAo
TRAVEL
OPTION
XAb1
XBk
XBa2
BOOM1 BUCKET
ARM2
(R)
Dr4
(Ao)
HEAD
HEAD
Ab1
Bk1 LCa2
Atr
LCk
PbL
LCb1
LCo
CP2
C2
C1
Btr (Bo)
XBtr
ROD
ROD
Bb1
Ak1
XBb1
XAk
PBP
XAa2
XBo
2-21
A1 BK
SP(B2) B1
S OP
TL TR
Port size PF 1
Tightening torque 20~25kgf・m (115~180lbf・ft) 15~18kgf・m (109~130lbf・ft)
R1
Make up port for swing
Ck1 Ck2
Bucket in confluence port Bucket in confluence port
PF 3/4
Travel right pilot port Travel right pilot port Option pilot port Option pilot port Bucket out pilot port Bucket in pilot port Boom up pilot port Boom down pilot port Arm in confluence pilot port Arm out confluence pilot port Travel left pilot port Travel left pilot port Swing pilot port Swing pilot port Arm in pilot port Arm out pilot port Boom up confluence pilot port (Swing priority pilot port) (Bucket in confluence pilot port) (Drain port)
PF 3/8
7~8kgf・m (50.6~57.8lbf・ft)
Pz Py PG PH Px Dr1 Dr2 Dr3 Dr4 Dr6 FL FR Pns PaL PbL PBP
Main relief pilot pressure Signal port for travel Pilot pressure port Pilot pressure port Signal for other acutuators Drain port Drain port Drain port Drain port Drain port Negative control signal port(P1 port side) Negative control signal port(P2 port side) Swing logic valve pilot port Lock valve pilot port Lock valve pilot port Drain port
PF 1/4
3.5~3.9kgf・m (25.3~28.2lbf・ft)
Atr Btr (Ao) (Bo) Ak1 Bk1 Ab1 Bb1 Atl Btl As Bs Aa1 Ba1 P1 P2
Travel motor right side port Travel motor right side port Option port Option port Bucket rod side port Bucket head side port Boom head side port Boom rod side port Travel motor left side port Travel motor left side port Swing motor port Swing motor port Arm head side port Arm rod side port Pump port(P1 side) Pump port(P2 side)
M10
5~6.6kgf・m (36.1~47.7lbf・ft)
R2
Return port
M12
8.5~11.5kgf・m (61.5~83.1lbf・ft)
XAtr XBtr XAo XBo XAk XBk XAb1 XBb1 XAa2 XBa2 XAtl XBtl XAs XBs XAa1 XBa1 XAb2 (Psp) (XBp1) (XBp2)
Dr1
SP
CSP CMR2
(XBp2)
Port name
A
103
P1
B
P1
H
Pz MR
TS R2(P2)
H I
Px
P2
TS STRAIGHT TRAVEL
C
Pns Dr4
C
OP S
D
Dr6
B1
E
D
159 PaL
B2
PbL
159
BK
E
A1
F
NR2
XAtl
S SWING
XAs
A J
CS1
159 273
CS2
PG
XBtl
XBo
A1 ARM 1
975
XAa1
XBa1
M 101
153
XBk
BK BUCKET
XBa2
XAa2
A2 ARM 2
N 561
CCb
Ab1 B1
SECTION B-B
Bb1
B2
B1
B2
HV Aa1
Ak1 BK
A1
CMR2
A2
BK Ba1
A1
BC A2
MR
BC
338 153 J1
SECTION M-M 324
976
104
357
Bk1
TS
XAk
SECTION A-A
SECTION H-H
601
B1 BOOM 1
XAb1
102
NZy
CMR1
OP OPTION
XAo
(XBp2)
NZx
Pz
TR TRAVEL(R)
XBb1
G
Dr2
357
XAtr
N (PSP)
J B
XBtr
XAb2
(XBp1) Dr3
G
391
XBs
M
BC
A2
R2
K
K1
F
L
L
TL TRAVEL(L)
B2 BOOM 2
974 158
I
159 TL
164
K
R1
TR
154
975
PG
SECTION N-N
325
391
SECTION I-I
2-22
561
101 102 103 104 153 154 155 156 158 159 163 164 165 166 167 168 169 201 202 203 204 209 251 252 254 261 262 264
Casing A Casing B Straight travel valve Boom priority valve Plug Plug Plug Plug Plug Plug O-ring O-ring O-ring O-ring O-ring O-ring O-ring Cover Cover Cover Cover Flange Control valve assy Lock valve assy Swing logic valve assy O-ring O-ring O-ring
273 301 302 303 304 305 306 307 309 310 324 325 328 329 331 332 333 334 335 336 337 338 339 357 370 372 374 376
Socket screw Travel spool Arm 1 spool assy Boom 1 spool assy Bucket spool Swing spool Arm 2 spool Boom 2 spool Spool(Option) Travel spool Spring Spring Spring Spring Spring seat Spring seat Bolt Stopper Stopper Bolt Stopper Stopper Stopper Orifice Spring Spring Spring Spring
377 378 379 391 392 395 401 424 425 438 511 515 516 521 523 551 552 553 556 561 601 602 611 971 974 975 976
Spring Spring Spring Straight travel spool Bypass cut spool Swing priority spool Spool Spring Spring Rod Poppet Poppet Poppet Spring Spring Plug Plug Plug Plug O-ring Main relief valve Port relief valve Nega-con relief valve Socket screw Socket screw Socket screw Socket screw
203 333 331 334 329 328 331 262 168
XAtr
203 333 331 334 329 328 331 262 166
XAtl
203 333 331 334 329 328 331 262 553 561
165
Atl
Atr
154
Btr
301 169
TR
202
XBtr
AoR
As
LCo
551 561 971 165 (Bo) 209 309 561 553 169 202
310 165 169 202
TL
159
165 209 (Ao) 511 521
551 561
Btl
XAo
971
165 515 521
164
XBtl
XBk
Bs
OP
201 332 336 335 379 370 332 261
Ba1R
602 516 523 552 HV 561 511 521
Bk1
LCk
Ak1
Aa1
561 302 264 204 602
BK A1
602
XAk
264 204
XAa1 Aa1R
AkR
SECTION F-F
B2
165 552 523 Ab1 561 516 LCb1 165 521 551 561 511 Bb1 303 165
251 165 305 264 204
B1 SP
264 602 204
XBb1 Bb1R
BoR XBo
166
XBs
252
201 336 332 335 372 374 332 261 166
XAa2
154 164 203 333 331 337 378 377 331 262 392 551 561 611
Dr2
165
NR2
FR
165 561 153
LCa2
(Ck1) FL
551 561
611 551 561
306 165
A2
264 204
XBa2
BC
164 154
424 425 438
SECTION G-G
2-23
169 202
201 336 332 339 372 374 332 261 307 165 561 CCb 551 521 511 561 CSP 551 521 SP 511 551 561 395 261 332 370 376 339 332 336 201 164 556
K1
P
P
401
SECTION J-J
SECTION P-P
551 561 521 511
551
L1
CP2
C2
C1
C2
155 167 P2
CP2
P2
551 561 521 511
P2
L1
NR1
(XBp2)
164 154
SECTION E-E
(XBp1)
LCa1
551 551 304
XAb2
Ab1R
252
SECTION D-D
166 511 521 561
S
556 XAb1 164
(PSP)
XBa1
BkR
201 336 332 335 379 370 332 261 159 166 166 165 165 254 Pns
SECTION C-C 201 332 336 335 370 379 332 261 602
XAs
201 336 332 335
379 370 332 261 159 602 159
SECTION K-K
SECTION L-L
SECTION L 1 -L 1
561 521 511
2. HYDRAULIC CIRCUIT
BP PBP XBp1 PaL
XBp2
Fl
Fr
NR1
Dr2
NR2
HV
Dr1
BC1
BC2
AaR
(HEAD)
ARM 1
XAa1
(ROD)
Aa1 Ba1
XBa2
ARM 2
BaR
XBa1
XAa2
LCa1
AkR
(ROD) Ak1 XAk
CCb
Bk1 BkR
XAb2
BOOM 2
PbL
HV
SP
Pns As
AbR
Bs
SWING
BbR XAs
TRAVEL(L)
(HEAD) Ab1 XAb1 Bb1
(ROD)
BOOM 1
XBb1 LCs
Dr6 XBtl
BUCKET
Dr4
LCk
Csp (PSP)
XBS
(HEAD) XBk
LCb1 AoR
Atl
(Ao) XAo (Bo)
Btl BoR
XAtl
OPTION
XBo LCo C1
C2 Atr XAtr Btr
XBtr CP2
R1 P2
STRAIGHT TRAVEL BLOCK
0.7 PH
TS
Px
MR
CMR1 CMR2
0.7 0.7
Pz
P1
PG
Py
2-24
R2
TRAVEL(R)
3. FUNCTION 1) CONTROL IN NEUTRAL POSITION
103
P1
TS STRAIGHT TRAVEL
21 TL TRAVEL(L)
XAtl
S SWING
XAs
XBtl
22 XBs
B2 XAb2 BOOM 2 A1 ARM 1
(PSP)
XAa1
XBa1
13 (XBp2)
(XBp1)
101
4 SECTION A-A
P2
R2
TR TRAVEL(R)
XAtr
XBtr
XBo
XAo
OP OPTION
6 B1 BOOM 1
XBb1
XAb1
XAk
XBk
BK BUCKET
XBa2
XAa2
A2 ARM 2
18
K1
4
102
SECTION B-B
2-25
XAa2
(XBp1)
4 Dr2 NR2
4 611 FR
LCa2
(Ck1) FL
A2 BC
611
NR1
13
13
XBa2
(XBp2)
SECTION G-G
A P1
B
PG
H
PZ TS
R2(P2)
Px R1
H
MR
TR TL
C
Dr4
Pns
C
Dr6
D
OP S
D B1 B2
E
PaL
PbL BK
A1
F
F
NR2 A2
BC Dr3
G A J
J
E
B
2-26
Dr2
G
The hydraulic fluid from the pump P1 flows into casing A(101) through the inlet port(P1), through the center bypass(21) and the parallel path(22). The hydraulic fluid from the pump P2 flows into casing B(102) through the inlet port(P2) through the center bypass(18) and the parallel path(6). The hydraulic fluid from the pump P1 is directed to the tank through the center bypass(21), negative control orifice(NR1), the return path(13) and the return port(R2). The hydraulic fluid from the pump P2 also flows to the tank through the center bypass(18), negative control orifice(NR2), return path (4) and return port(R2). The hydraulic fluid in paths (6) and (22) is blocked and cannot return to the tank. In case a control lever is operated, the hydraulic fluid from the pump P2 is supplied to the travel right spool(301) from path(18) and to the spools: option(309), boom1(303), bucket(304) and arm2(306) from path(6). Additionally, the hydraulic fluid from the pump P1 is supplied to the travel left spool (310) from path(7) while the swing(305), boom2(307) and arm(302) spools are supplied from path(22).
2-27
2) NEGATIVE CONTROL (1) General operation
303
18
21
3
4
5
10
7 9 611
P2
P1
611
Fl
19
6
27
28
22
Fr
13
The negative control signal pressure from the center bypass(18, 21) occurs in the following cases and controls the discharge of the pump. 1. Neutral condition when no function is being actuated. 2. The pilot control lever is partially operated. The hydraulic fluid of the pump P1(28) flows into the return passage(13) through the center bypass (21), the path(3) and orifice(9)(Within the poppet(15)). The restriction caused by this orifice thereby pressurizes path(3). This pressure is transferred as the negative control signal pressure Fl to the pump P1 regulator through the negative control line(4). It controls the pump regulator so as to decrease the discharge of the pump P1(28).
2-28
21 FL
15 611 16
BC
NR1
101
13 (XBp2)
Q
FL
Qmax FL1
Qmin FL1
FL
QN
The negative control relief valve(611) consists of poppet(15), spring(16) and casing(101). When the hydraulic fluid in the center bypass increases to the level that the pressure in the path(3) reaches the set pressure of the spring(16), the hydraulic fluid in the path(3) pushes open the poppet (15) and escapes into the return path(13). In the unloaded state, the hydraulic fluid of the pump P1(28) entirely flows to the tank through the path(21), orifice(9) and the return path(13). Therefore the pressure FL in the path(3) becomes maximum(FL1) because all the discharge is reduced by the orifice(9) which in turn destrokes the pump P1(28) so as to minimize the tilting angle and consequent discharge of the pump P1(28). (Qmin)
2-29
(2) Negative control(With fine metering)
370
303 511 4
6
Bb1
LCb1
379
Ab1
Ab1R
Bb1R
XBb1
XAb1 B1
18
19
In the case, for example, when the pilot control lever for main boom is slightly operated, the pilot pressure XAb1 shifts the main boom spool(303) partially in the left direction. So the path(19) is partially opened and the center bypass(18) is shut slightly. The hydraulic fluid thereby separates. One part flows via the orifice(7) through the path(18) and the other portion flows into the parallel path(6), the path(19) and the port Ab1. The flow from the path(18) through the orifice(7) decreases slightly and the pressure Fr in the path(10) thereby also slightly decreases. As the pressure Fr becomes lower, the discharge of the pump P2(27) increases. With the pilot control lever shifted even more the path(18) is shut off by the shifting of the spool(303) and then the flow through the bypass becomes zero. The pressure in the path(10) becomes zero and the discharge of the pump P2(27) becomes maximum.(Qmax) Because the discharge of the pump is adjusted by operating the pilot control lever slightly, the precise moving of the actuator is realized. For the pump P1(28) the same negative control principle of operation occurs utilizing the orifice(9).
2-30
3) EACH SPOOL OPERATION (1) Boom control ① Boom up operation
516
511
303
Bb1
LCb1
8 Ab1
18
370 379
Ab1R
Bb1R
XAb1
XBb1
6
B1
13
SP
(PSP)
B2
4
XAb2
CSP
SP
376 370
511
21
511
CCb
307 374 372
The main boom up operation becomes fast because the hydraulic fluid from the pump P2 that is directed to the port P2 is combined in the casing that of the pump P1 which enters port P1. The confluence flow is supplied to the head side of the boom cylinder. In low speed operation, only the boom1 spool(303) operates and is supplied with hydraulic fluid from the pump P2. The hydraulic fluid from the pump P2 flows into the boom1 spool(303) through port P2 and parallel path(6). The hydraulic fluid from the pump P1 flows to the boom2 spool(307) through pump port P1 and the parallel path(22). During the boom up operation, the pilot pressure from the pilot control valve is supplied into the port XAb1 and shifts the boom1 spool(303) in the left direction against the springs(370) and (370). the hydraulic fluid from the pump P2 enters the parallel path(6) and then passes through the load check valve LCb1(511) and boom1 spool(303) and check valve HV(516) then flows into the port Ab1. Following this it flows into the head side of the boom cylinder. At the same time, the pilot pressure through the port XAb2 shifts the boom2 spool(307) in the left direction against the springs(374) and (372). The hydraulic fluid from the pump P1 enters via the parallel path(22) and center bypass(21), then passes through the load check valve CSP(511), boom2 spool(307) and the load check valve CCb(511). Then flows combine in path(8) and are directed to port Ab1 and the head side of the boom cylinder. The flow from the rod side of the boom cylinder returns to the boom1 spool(303) through the port Bb1. Thereafter it is directed to the return port R2 through path(13). 2-31
② Boom down operation
516
511
303
Bb1
LCb1
370 379
45 Ab1
Ab1R
Bb1R
XBb1
XAb1
6
B1
13
SP
B2
4
(PSP)
XAb2
SP
CCb
CSP
376 370
374 372 511
511
307
During the boom lowering operation, the pilot pressure from the pilot control valve is supplied to port XBb1 and PbL and shifts the boom1 spool(303) in the right direction against the springs(370) and (379). The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bb1 through the load check valve LCb1(511). Following this is flows into the rod side of the boom cylinder. The return flow from the head side of the boom cylinder returns to the boom1 spool(303) through the port Ab1. Thereafter it is directed to the return port R2 through path(4). Additionally, the return flow is restricted in path(45), which lowers the boom cylinder at a suitable speed.
2-32
(2) Arm control ① Arm roll out operation
306
374 372 LCa2
XBa2
XAa2
A2
A1
XAa1
XBa1
Aa1R
Ba1R
13
Aa1
22 302
LCa1
HV Ba1
511
516
370 379
During the arm roll out operation, the pilot pressure from the pilot control valve is supplied to the pilot ports(XBa1& XBa2) and shifts the arm1 spool(302) in the left direction against the springs (370) and (379) and shifts the arm2 spool(306) in the left direction against the springs(374) and (372). The hydraulic fluid from the pump P1 flows through the load check valve LCa1(511), lock valve HV(516), and then through parallel path(22). It is then directed to the rod side of the arm cylinder through the port Ba1. At the same time, the pilot pressure through the port XBa2 shifts the arm2 spool(306) in the left direction against the springs (374) and (372). The hydraulic fluid from the pump P2 enters via the parallel path(22) and center bypass(21), then passes through the check valve of the boom priority valve(104), arm2 spool(306). The flows are combined and directed to port Ba1 and the rod side of the arm cylinder. The flow from the head side of the arm cylinder returns to the arm1 spool(302) through the port Aa1. Thereafter it is directed to the return port R2 through path(13). 2-33
② Arm roll in operation ・During light load only
306
374 372 LCa2
XBa2
XAa2
A2
(a)
(c)
A1
XBa1
XAa1
Aa1R Ba1R
13
Aa1
22 302
LCa1
HV Ba1
511
2-34
516
370 379
・The pressure in the arm cylinder head side increases 306
374 372 LCa2
XBa2
XAa2
A2
(d)
A1
(e)
(a)
(f)
(b) XBa1
XAa1
Aa1r
Ba1R
13
Aa1
22 302
LCa1
HV Ba1
511
2-35
516
370 379
During the arm roll in operation, the pilot pressure from the pilot control valve is supplied to the ports XAa1, XAa2 and PaL and shifts the arm1 spool(302) in the right direction against the springs (370) and (379) and shifts the arm2 spool(306) in the right direction against the springs (384) and (372). During the arm roll in operation, the hydraulic fluid from the pump P1 flows into the arm1 spool(302) through the parallel path(22). Then it enters into the head side of the arm cylinder through the load check valve LCa1(511), check valve HV(516) and port Aa1. At the same time, the hydraulic fluid from the pump P2 flows into the arm2 spool(306) through the parallel path(22). Then it enters into the head side of the arm cylinder through the check valve of boom priority valve(104) and port Aa1. The return flow from the rod side of the arm cylinder is pressurized by self-weight of arms and so on, and returns to port Ba1. The pressurized oil returning to port Ba1 enters into the arm1 spool through the outside of the arm1 spool. During a light load only, it pushes open the sleeve check valve, flows the parallel path reversely from spool hole(c), and joints into port Aa1. This is called the arm regeneration function. When the pressure in the arm cylinder head side increases, the piston(d) and sub spool(e) are transferred in the right direction, and at the same time the sleeve check valve(f) is from the arm cylinder rod side enters flow port Ba1 through the periphery hole(a) of the arm1 spool into the spool, flows out through the periphery hole(b) of the spool, and returns through the tank port R2 to the hydraulic oil tank.
2-36
(3) Bucket control ① Bucket roll in operation
379 370
511 LCk
Ak1
Bk1 BkR
AkR
XAk
XBk
BK
13
304
6
4
During the bucket roll in operation, the pilot pressure from the pilot control valve is supplied to port XBk and shifts the bucket spool(304) in the left direction against the springs(370) and (379). The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bk1 through the load check valve LCk(511). Following this it flows into the head side of the bucket cylinder. The retutn flow from the rod side of the bucket cylinder returns to the bucket spool(304) through the port Ak1. Thereafter it is directed to the return port R2 through path(13).
2-37
② Bucket out operation
379 370 511 LCk
Ak1
Bk1 BkR
AkR
XBk
XAk
BK
13
304
6
4
During the bucket roll out operation, the pilot pressure from the pilot control valve is supplied to port XAk and shifts the bucket spool(304) in the right directed agains the springs (370) and (370). The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port AK1 through the load check valve LCk(511). Following this it flows into the rod side of the bucket cylinder. The return flow from the head side of the bucket cylinder returns to the bucket spool(304) through the port Bk1. Thereafter it is directed to the return port R2 through path(4).
2-38
(4) Swing control
S
XAs
XBs
22 13
4 Bs
305
As
251
254
370 379
Pns
During the swing right or left operation, only the hydraulic fluid of the pump P1 is supplied to the swing motor. The pilot pressure from the pilot control valve is supplied to the port XAs and shifts the swing spool (305) in the left direction against springs (370) and (379). Hydraulic fluid from the pump P1 flows into the swing spool(305) through the parallel path(22). Then it is directed to the swing motor through the check valve LCs(254) and the port As. As a result, the swing motor turns and the return flow from the swing motor enters port Bs. The flow from the motor returns to the tank port R2 through the swing spool(305) and path(13). In the case of the opposite operation, the operation is similar.
2-39
(5) Travel control
328 329
301 Btr
Atr
XBtr
XAtr TR
TL XBtl
XAtl
Btl
Atl
310
328 329
During the travel operation, the hydraulic fluid of the pump P1 is supplied to the travel motor and the hydraulic fluid of the pump P2 is supplied to the other travel motor. The pilot pressure from the pilot control valve is supplied to the port XAtr and XAtl. And it shifts the travel right spool(301) and travel left spool(310) in the left direction against springs (328) and (329). Hydraulic fluid from the pump P1 flows into the travel left spool(310) through the parallel path and hydraulic fluid from the pump P2 flows into the travel right spool(301). Then they are directed to the each travel motor through port Atl and Atr. As a result, the travel motors turn and the return flow from the travel motors enter port Btl and port Btr. The flow from the motors returns to the tank port R2 through the travel spools(310 and 301). In the case of the opposite operation, the operation is similar.
2-40
4) CIRCUIT PRESSURE PROTENCTION The control valve has two kinds of relief valve to limit the pressure in a circuit. (1) Main relief valve Limits the pressure of the main hydraulic system.
Pz
CMR1
CMR2
MR
338 J
601 TS
324
325
391
The hydraulic fluid from the pump P1 and the pump P2 enters the control valve through ports P1 and P2, respectively. From here the flow is directed to the main relief valve(601) through the check valve CMR1 or CMR2(511) and path(11). The pressure in path(11) is limited by the main relief valve(601) to its set pressure.
2-41
Main relief operation while working
30
35
32
33
14
11
31
38
34
24
39
25
While the pressure in path(11) is lower than the set pressure of main relief valve(601), the poppet (24) is seated and the hydraulic fluid in path(11) can not escape to the return(14). When the pressure in path(11) approaches the pressure setting, poppet(24) opens against the spring(39). As the flow in chamber(33) escapes into the return(14) through path(32), its pressure decreases. At the same time, hydraulic fluid in path(11) flows into path(30) with a pressure drop across orifice(31). Then pressure in spring chamber(35) becomes lower because it bleeds off through path(30). The pressure from path(11) pushes the plunger(38) in the left direction against the spring(34). Then plunger(38) opens and hydraulic fluid in path(11) escapes into the return(14) and maintains the pressure setting. The pressure setting is adjusted with adjustment screw(25).
2-42
(2) Port relief valve Limits the service pressure in a cylinder circuit.
10
6
5
9
8
7
4
3
2
1
Port relief valves and make up valves are fitted between the cylinders of the working devices(Boom, arm, bucket) and their spools. In the case of an external force acting on the cylinder rod with its spool in neutral, the pressure in the cylinder could become excessive. The port relief valve(602) restricts this pressure to the set pressure of the valve. Port relief valve(602) have also the additional function of a make up valve. It is possible, under the influence of an external force acting on a cylinder that a condition can occur where insufficient flow is available to match cylinder velocity. If this occurs then a vacuum and thereby cavitation could exist. To eliminate such an occurrence, a make up valve operates to break this vacuum by supplying the return flow into the cylinder. The hydraulic fluid between the cylinder and its spool flows into the path(6) to pressurize the port relief valve(602). The hydraulic fluid in the path(6) flows into the spring chamber(3) through the path(4) in the piston(10). If the pressure is lower than the pressure setting, the poppet(2) is shut off because the force of the spring(1) overcomes the pressure. So the path(6) and the spring chamber(3) have the same pressure. Because the spring chamber(3) side pressured area of the seat(8) and the plunger(9) is larger than that of the path(6) side, seat(8) and the plunger(9) are pushed in the right direction to be seated securely and then the hydraulic fluid in the path(6) doesn't escape into the return path(5).
2-43
① Port relief function
10
6
12 5
9
4
7
3
13
2
11
1
When the pressure in the path(6) is pressurized to the pressure setting, the poppet(2) is pushed open against the spring(1). The hydraulic fluid in the chamber(11) flows into the return path(5) through the path(13) with reducing its pressure. The piston(10) is shifted in the left direction by the pressure in the path(6) and stops on the end of the plug(7). The hydraulic fluid in the path(6) flows into the chamber(11) through the path(4) in the piston(10) and the spring chamber(3). Because the differential pressure occurs between the pass(6) and the pass(4) by the orifice between the outernal diameter of the end of the piston(10) and the internal diameter of the plunger(9), the pressure in the spring chamber(3) becomes low and therefore the plunger(9) is pushed in the left direction with the path(12) opened so that the hydraulic fluid in the path(6) flows into the return path(5).
2-44
② Make up function
9
6
5
8
11
4
3
Following this then the case of a port relief valve operating as a make up valve is now explained. In the case that the hydraulic fluid in the cylinder rod(Head) side escapes from the port relief valve (602), then hydraulic fluid needs to be supplied because vacuum occurs in the head(Rod) side. When cacuum occurs in the side of the path(6), it also occurs in the spring chamber(3) through the path(4). The pressure in the side of the return path(5) acts on the seat(8). The seat(8) is shifted in the left direction by the return pressure because the spring chamber(3) sides of the seat(8) and the plunger(9) are under a vacuum. The hydraulic fluid in the return path(5) flows into the path(6) so as to break the vacuum in the path(6) side.
2-45
4. TROUBLESHOOTING 1) GENERAL COMMENTS (1) When any abnormal phenomenon is noticed, investigate whether it is a failure of the control valve itself or a problem in the pump proper, pilot pump or circuit. For this purpose, the pilot pressure, pump discharge pressure, load pressure, etc. should be measured. Additionally, even when partial disassembly and checking is carried out, follow the previously mentioned disassembly and assembly procedures. (2) Since dust is very harmful to hydraulic components, pay full attention to dust prevention. Even for partial disassembly dust prevention measures should be carried out. (3) Handle movable parts carefully. Even for a small damage, correction using an oilstone should be carried out. (4) Carefully carry out your investigation, paying due attention not to damage the sealing faces of O-rings. Such damage will cause both internal and external oil leakage. 2) TROUBLESHOOTING Phenomenon Machine cannot travel or swing or functions poorly at low speed(Insufficient force) or generally responds slowly.
Possible cause ・ Main relief valve malfunctions. - Dirt is jammed between main plunger and seat. - Dirt is jammed between poppet and seat. - Main plunger is stuck. - Spring is broken or fatigued. - Restriction in main plunger is clogged. - Adjusting screw is loose.
Remedy ・ Measure pressure of main relief valve. - Disassemble valve and clean parts. Replace assembly, if damaged severely. - Same as above. - Correct stuck section with oilstone. - Remove spring. - Remove dirt. - Readjust it and tighten locknut to specified torque.
・ Orifice just before control valve in pilot ・ Remove dirt. line is clogged. Cylinder falls significantly ・ Clearance between spool and casing ・ Replace spool. under its own weight when is excessive. the spool is in neutral. ・ Spool does not return to correct ・ Measure secondary pilot pressure. neutral position. - Dirt is jammed between casing and spool, or casing and spool are stuck together. - Spring is broken or fatigued. - Pilot line is clogged with dirt.
- Disassemble valve and clean parts. Correct stuck section with oilstone. - Replace spring. - Remove dirt.
・ Main relief valve malfunctions.
・ Measure pressure of main relief valve.
・ Port relief valve malfunctions.
・ Measure pressure of main relief valve.
・ Lock valve assembly malfunctions.
・ Replace lock valve assembly.
・ Lockvalve poppet malfunctions - Dirt is jammed between poppet and casing. - Poppet is stuck. - Spring is broken or fatigued.
2-46
- Disassemble poppet and clean parts - Correct stuck section with oilstone. - Replace spring.
2) CONTROL VALVE TROUBLE SHOOTING Phenomenon
Possible cause
When pilot control lever is ・ Load check valve malfunctions operated for cylinder - Dirt is jammed between poppet and hoisting, the cylinder casing. initially falls. - Poppet is stuck. - Spring is broken or fatigued.
Remedy
- Disassemble poppet and clean parts - Correct stuck section with oilstone. - Replace spring.
・ Main spool malfunctions. ・ Disassemble poppet and clean parts Bucket, boom and arm only do not work. - Clearance between casing and - Replace spool. Action is slow(Insufficient spool is excessive. force) or response is slow. - Dirt is jammed between casing and - Disassemble valve and clean parts. spool. - Spool is stuck. - Correct stuck section with oilstone. - Return spring is broken or fatigued. - Replace spring. - Pilot line is clogged with dirt. - Remove dirt.
Main boom and arm confluence does not function.
・ Main relief valve malfunctions.
・ Measure pressure of main relief valve.
・ Port relief valve malfunctions.
・ Measure pressure of main relief valve.
・ Each confluence valve malfunctions.
・ Measure pilot pressure.
- Spool is stuck. - Spring is broken or fatigued. - Clearances between casing A and casing B and spool are excessive.
- Correct stuck section with oilstone. - Replace spring. - Replace spool.
Negative control does not ・ Low pressure relief valve malfunctions. ・ Measure pressure of low pressure function and minimum relief valve. flow cannot be obtained - Dirt is jammed between poppet and - Disassemble valve and clean parts. when lever is in neutral. casing. Replace assembly, if damaged severely. - Spring is broken or fatigued. - Replace spring. - Restriction in poppet is clogged. - Disassemble valve and clean parts. Remove dirt.
2-47
3) RELIEF VALVE TROUBLE SHOOTING Phenomenon
Possible cause
Remedy
Pressure does not rise at ・ Main plunger or pilot poppet in relief ・ Check for dirt that is jammed in the all. valve is stuck or remains open, or dirt seat of the valve. is jammed in the seat of valve. Check if parts slide freely. Clean all parts thoroughly. Relief pressure is unstable.
・ Pilot poppet in relief valve is scored.
・ Replace scored parts. Clean all parts. Remove score on surface.
Relief pressure is not correct.
・ Wear due to dirt.
・ Disassemble valve and clean parts.
Oil leakage
・ Seat is scored. O-ring is worm.
・ Replace scored or worm parts. Check that all parts move smoothly, before reassembling them.
・ Parts are stuck with dirt.
・ Check them for scratch, notch or dirt, before reassembling them.
・ Locknut and adjusting screw are loose. ・ Adjust pressure.
2-48
4) MAIN CONTROL VALVE Phenomenon
Possible cause
Remedy
Casing
・ Existence of scratches, rusting or ・ In case of damage in the following areas, replace part: corrosion. - Sliding sections of casing bore and spool, especially land sections continuously seeing pressure. - Seal pocket section where spool is inserted. - Seal section of port where O-ring contacts. - Seal section of each relief valve fro main and port. - Other defects that may damage normal functions.
Spool
・ Existence of scratches, fretting, ・ REplace if its outside sliding section has scratches or other damage. rusting or corrosion. (Especially on seal contacting section) ・ Insert each spool individually into its respective casing bore, rotate and ・ Replace if its sliding section has scratches or other damage. reciprocate it. ・ Correct or replace if the spool does not move smoothly.
Poppet
・ Damage of poppet or spring.
・ Correct or replace if sealing is incomplete.
・ Insert poppet into casing and move it. ・ Use only if it can moves smoothly without being caught. Spring
・ Rusting, corrosion, deformation or ・ Replace if there is significant damage. breaking of spring, spring seat, plug or cover.
Seal
・ External oil leakage.
・ Correct or replace.
・ Rusting, corrosion or deformation of ・ Correct or replace. seal. ・ External rust or damage. Main relief valve, port relief valve and ・ Contacting face of valve seat. negative control relief valve ・ Contacting face of poppet.
・ Replace ・ Replace if damaged. ・ Replace if damaged.
・ Abnormal spring.
・ Replace.
・ O-rings, back up rings and seals.
・ 100% replacement in general.
2-49
Phenomenon Machine cannot travel or swing or functions poorly at low speed(Insufficient force) or generally responds slowly.
Possible cause ・ Main relief valve malfunctions. - Dirt is jammed between main plunger and seat. - Dirt is jammed between poppet and seat. - Main plunger is stuck. - Spring is broken or fatigued. - Restriction in main plunger is clogged. - Adjusting screw is loose.
Remedy ・ Measure pressure of main relief valve. - Disassemble valve and clean parts. Replace assembly, if damaged severely. - Same as above. - Correct stuck section with oilstone. - Remove spring. - Remove dirt. - Readjust it and tighten locknut to specified torque.
・ Orifice just before control valve in pilot ・ Remove dirt. line is clogged. Cylinder falls significantly ・ Clearance between spool and casing ・ Replace spool. is excessive. under its own weight when the spool is in neutral. ・ Spool does not return to correct ・ Measure secondary pilot pressure. neutral position. - Dirt is jammed between casing and spool, or casing and spool are stuck together. - Spring is broken or fatigued. - Pilot line is clogged with dirt.
- Disassemble valve and clean parts. Correct stuck section with oilstone. - Replace spring. - Remove dirt.
・ Main relief valve malfunctions.
・ Measure pressure of main relief valve.
・ Port relief valve malfunctions.
・ Measure pressure of main relief valve.
・ Lock valve assembly malfunctions.
・ Replace lock valve assembly.
・ Lockvalve poppet malfunctions - Dirt is jammed between poppet and casing. - Poppet is stuck. - Spring is broken or fatigued.
2-50
- Disassemble poppet and clean parts - Correct stuck section with oilstone. - Replace spring.
GROUP 3 SWING DEVICE A. SWING DEVICE(T3X150CHB, UP TO #1937) 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Reduction gear
Swing motor Time delay valve Grease filling port Swing reduction gear oil drain port
Relief valve SH PG
Air vent port
Dr2 Mu
GA
GB
A
Air vent port
Port
B
Port name
Port size
SH
A
Main port
PF 3/4
PG
B
Main port
PF 3/4
Dr2
Drain port
PF 3/8
Mu
Make up port
PF 1
PG
Brake release port
PF 1/4
SH
Stand by port
PF 1/4
Gage port
PF 1/4
GA, GB Dr2
A
Mu
B
21072SF03
2-46
1) SWING MOTOR
27
4 5 6 7 8
9 10 11 12 13 14
3 2 1
29
30, 31 32 33
40
15
41 42 43 35, 44
28
26 25 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
39 23
Inner ring Oil seal Taper roller bearing Backing spring Cam plate Return plate Piston assembly Lining plate Plate O-ring Piston O-ring Spring Parallel pin Piston
38 22
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
21 20 19 18
Cap O-ring Coned disc spring Teflon ring Bushing Balance plate Needle bearing Snap ring Cylinder Housing Collar Plug Snap ring Bypass valve assembly Back up ring
2-47
37 36
31 32 33 34 35 36 37 38 39 40 41 42 43 44
34
35 16, 17
O-ring O-ring Cover Relief assembly O-ring Hexagon socket bolt Time delay valve O-ring O-ring Hexagon socket bolt Check Spring Cap Back up ring
2) REDUCTION GEAR
25 37 36 13
3
35 34 5
2
30 29
6
7
10
9 11 18 19
26 31 28
27 38
33
1 2 3 5 6 7 8 9 10 11 12 13 14
32
Casing Drive shaft Spacer Roller bearing Oil seal Roller bearing Thrust bearing Carrier 2 Stop ring Ring gear Knock pin Pinion gear Thrust gear
1
15 16 17 18 19 20 21 22 23 24 25 26 27
8
14 12 23 15 16 21 17 20 24 22 39
Planet gear 2 Pin 2 Spring pin Sun gear 2 Carrier 1 Side plate 1 Pin 1 Needle cage Bush 2 Planet gear 1 Lock washer Side plate 3 Sun gear 1
2-48
28 29 30 31 32 33 34 35 36 37 38 39
Stop ring Plug Plug Socket bolt Gauge pipe Gauge bar Cover plate Hexagon socket bolt Lock plate Hexagon socket bolt Stop ring Side plate 2
2. FUNCTION 1) ROTARY PART When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(1), hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the piston(2) upon the return plate(3) which acts upon the swash plate(4) via an hydrostatic bearing. Force F1 perpendicular to swash plate(4) and force F2 perpendicular to cylinder center. Being transferred to the cylinder block(5) through piston, force F2 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 to the inlet port of high pressurized oil. When the direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is given by the equation. T=
p×q F , q=Z・A・PCD・tanθ, F1 = , F2=F tanθ, S=PCD×tanθ 2Л COSθ
F2
PCD
Where p : Effective difference of pressure(kgf/cm2) q : Displacement(cc/rev) T : Output torque(kgf・cm) Z : Piston number(9EA) A : Piston area(cm2) θ: Tilting angle of swash plate(degree) S : Piston stroke(cm)
θ
S
F
a High pressure oil 4
3
2
5
1
2-49
a High pressure oil
Low pressure oil
2) MAKE UP VALVE In the system using this type of motor, there is no counter balance functioning valve and there happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency. A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action. The boost pressure acts on the hydraulic motor's feed port via the make up valve. Pressurized oil into the port B, the motor rotate counterclockwise. If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the drain oil run into motor via right make up valve, which prevent the cavitation of motor.
B
A
2-50
3) RELIEF VALVE
5
11
6
10
9
7
1 2 3 4 5 6 7 8 9 10 11 12
8
3
12
1
Body Seat Plunger Spring Adjusting screw Piston Bushing Spring seat Shim O-ring Back up ring O-ring
4 2
(1) Construction of relief valve The valve casing contains two cartridge type relief valves that stop the regular and reverse rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing motion and can control the relief pressure in two steps, high and low, in order to insure smooth operation. (2) Function of relief valve Figure illustrates how the pressure acting on the relief valve is related to its rising process. Here is given the function, referring to the figure following page.
P
P=pressure, T=time
Ps 4
P2 3
P1 2 1
2-51
T
① Ports (P,R) at tank pressure.
A2
m
h
n
g
A1 P
R
② When hydraulic oil pressure(P×A1) reaches the preset force(FSP) of spring(4), the plunger(3) moves to the right as shown. P1×A1=Fsp+Pg×A2 P1=
Fsp+Pg×A2 A1
4
P=P1
2-52
g
③ The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset force(FSP) of spring(4), the piston(6) moves left and stop the piston(6) hits the bottom of bushing(7).
4
m
n
g
P=P2
6
④ When piston(6) hits the bottom of bushing(7), it stops moving to the left any further. result, the pressure in chamber(g) equals(Ps). Ps×A1=Fsp+Ps×A2 Ps=
Fsp A1-A2
P=Ps
7
2-53
6
g
As the
4) BRAKE SYSTEM (1) Control valve swing brake system This is the brake system to stop the swing motion of the excavator during operation. In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance created by this throttling works as a brake force to slow down the swing motion.
Deceleration
Work
A
A
B
B
A
B
MCV
MCV
MCV A, B opened
Stop
MCV
MCV A, B throttled
MCV A, B closed
(2) Mechanical swing parking brake system The mechanical swing parking brake system is installed to prevent the upper structure from swinging downhill because of its own weight when the excavator is parked on a slope since it completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work can be done more easily and safely. ① Brake assembly Circumferential rotation of separate plate(9) is constrained by the groove located at housing(26). When housing is pressed down by brake spring(16) through lining plate(10), separate plate(9) and brake piston(12), friction force occurs there. Cylinder(25) is constrained by this friction force and brake acts, while brake releases when hydraulic force exceeds spring force.
14 12 9 10 25 Groove
26
9 10 12
2-54
Separate plate Lining plate Brake piston
14 25 26
Spring Cylinder Housing
② Operating principle a. When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control valve(2) and to Sh of the time delay valve(3) via the shuttle valve(4), this pressure move spool(5) to the leftward against the force of the spring(8), so pilot pump charged oil(P3) goes to the chamber G. This pressure is applied to move the piston(6) to the upward against the force of the spring(9). Thus, it releases the brake force.
10
3
9
7
11
G 6 D 8 5 Pg 1
1 2 3 4 5 6 7 8 9 10 11 12
Swing control lever Swing control valve(MCV) Time delay valve Shuttle valve Spool Piston Poppet Spring Spring Orifice Spring Pilot pump
12 P3 2
2 4
2-55
Sh
b. Meantime, the oil pressure of port D balance with the preset force of spring(11), the pressure of chamber G keeps constant pressure.
10
3
9
7
11
G 6 D 8 5 Pg 1
1 2 3 4 5 6 7 8 9 10 11 12
Swing control lever Swing control valve(MCV) Time delay valve Shuttle valve Spool Piston Poppet Spring Spring Orifice Spring Pilot pump
12 P3 2
2 4
2-56
Sh
c. When the swing control(1) lever is set the neutral position, the spool(5) returns right in the time delay valve(3). Then, the piston(6) is moved lower by spring force and the return oil from the chamber G flows back to D-port through orifice(10) of the poppet(7). At this time, the poppet(7) works to make a time lag for 5 seconds.
10
3
9
7
11
G 6 D 8 5 Pg 1
1 2 3 4 5 6 7 8 9 10 11 12
Swing control lever Swing control valve(MCV) Time delay valve Shuttle valve Spool Piston Poppet Spring Spring Orifice Spring Pilot pump
12 P3 2
2 4
2-57
Sh
B. SWING DEVICE(RMF151, #1938 and up) 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
Reduction gear Swing gear
A,B
B
A
GA
GB
Mu
Gear oil drain port
Time delay valve
PG
SH
Relief valve
Dr
SH Port
PG
Au
Dr GB
B
Mu
Port size
A
Main port
Ø20
B
Main port
Ø20
Dr
Drain port
PF 1/2
Mu
Make up port
PF 1
PG
Brake release port
PF 1/4
SH
Stand by port
PF 1/4
Gage port
PF 1/4
Air vent port
PF 1/4
GA, GB Au
GA
Port name
A
22007SF03A(1)
2-57-1
1) SWING MOTOR
DETAIL : K 7 6 5 12 11 10
17
20 8 23
39
41
36 35
33 44
40
30 29 31 28 32 K 34
2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 1 25 26
9 14 1316 15 18 19 24 21 22 42 43
Body Oil seal Roller bearing Snap ring Shaft Bushing Stop ring Pin Shoe plate Cylinder block Spring Ball guide Set plate Piston assy Friction plate Plate Brake piston
27
37 38
45 46 220072SM02
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
O-ring O-ring Spring Rear cover Needle bearing Pin Valve plate O-ring O-ring Wrench bolt Plug Back up ring O-ring Spring Check Relief valve Anti-inversion valve
2-57-2
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Time delay valve Wrench bolt Plug O-ring Plug Plug Plug Name plate Rivet Level gauge Flange O-ring Plug O-ring O-ring Back up ring
2) REDUCTION GEAR
25 37 36 13
3
35 34 5
2 30
29 6
7
10
9 11 18 19
26 31 28
27 38
1
8 14 12 23 15 16 21 17 20 24 22 39
220072SF05A
1 2 3 5 6 7 8 9 10 11 12 13
Casing Drive shaft Spacer Roller bearing Oil seal Roller bearing Thrust plate Carrier 2 Stop ring Ring gear Knock pin Pinion gear
14 15 16 17 18 19 20 21 22 23 24 25
Thrust washer Planet gear 2 Pin 2 Spring pin Sun gear 2 Carrier 1 Side plate 1 Pin 1 Needle cage Bush 2 Planet gear 1 Lock washer
2-57-3
26 27 28 29 30 31 34 35 36 37 38 39
Side plate 3 Sun gear 1 Stop ring Plug Plug Socket bolt Cover plate Hexagon bolt Lock plate Hexagon bolt Stop ring Side plate 2
2. PRINCIPLE OF DRIVING 2.1 Generating the turning force The high hydraulic supplied from a hydraulic pump flows into a cylinder(10) through valve casing of motor(21), and valve plate(24). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston(14). The high hydraulic can generate the force, F1=P×A(P : supplied pressure, A : water pressure area), like following pictures, working on a piston. This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the plate of a tilt angle, α. W1 generates torque, T=W1+R1, for Y-Y line connected by the upper and lower sides of the piston as following pictures. The sum of torque(ΣW1×R1), generated from each piston(4~5 pieces) on the side of a high hydraulic, generates the turning force. This torque transfers the turning force to a cylinder(10) through a piston; because a cylinder is combined with a turning axis and spline, a turning axis rotates and a turning force is sent.
Y
W1
Pistion Cylinder
W1
R1 O
f1
N1 F1
A
P
High Y Low pressure pressure
21078TM05
2-57-4
2.2 Working of relief valve Relief valve carries on two functions of followings 1) It standardizes a pressure in case of driving a hydraulic motor; bypasses an extra oil in a motor inlet related to acceleration of an inertia to an outlet. 2) In case of an inertia stopped, it forces an equipment stopped, according to generating the pressure of a brake on the projected side. Once high pressure oil supplied to P port, the inside pressure of shock less spool increases. If the pressure is stronger than the power of the spring, it will be standardized. In case of driving a hydraulic motor, it standardizes a pressure. And in the event of stopping an inertia, it forces an equipment stopped, according to generating the pressure of break on the projected side.
12
6
7
2
8
9
11
10
1
5 4
3
220072SM10
2-57-5
2.3 Working of parking brake 1) Parking brake OFF If swing control level sets the swing position, pilot oil will moves swing spool and also it will be supplied to SH port of time delay valve of swing motor through shuttle salve against the power of the spring. The pressure of the spring switches spool to left and moves awaiting PG port oil of delay valve to parking position. After then it moves up parking piston pressing frictional plate to release parking brake. 2) Parking brake ON If swing control level sets neutrality, swing pilot suplied to SH port of time delay valve through shuttle valve will be stopped. According to this process, spool is returned by the power of the spring and the pressure of PG port of time delay valve which is always standing by release valve is stopped to parking piston. In that time, orifice in spool stops leaking out working oil to create 6 second time delay in order to prevent the impact which may be happened at the moment of sudden stop of swing brake.
5
10
1
9
17
16
20
8
23
15 24
220072SM11
2-57-6
2.4 Make up check valve In case of rapid rotation which is faster than the amount of supplied oil to swing motor entrance, mounted make up check valve supplies working oil to prevent cavitation according to the shortage of supplying oil. In the event of sudden stop of the operating excavator, supplying working oil to entrance of swing motor is stopped. However, by means of inertia of rotation, swing motor will be stopped after more rotation. In that time, make up check valve is opened and supplies working oil according to the pressure of hydraulic oil line to the entrance of the motor, which is lower than working oil awaiting in a make up check valve port.
12
6
7
2
8
9
11
10
1
5 4
3
220072SM10
2-57-7
2.5 Working description of plowing switch The capacity of driving motor is changeable depending on the change of plowing angle of the plate. That is operated by a plowing valve. 1) The pressure of external pilot : when Pi = 0 (large plowing) A high pressure oil operated at a motor works on port P of a switching valve, by the highpressure selecting function installed in valve casing. Spool assembled at the switching part of plowing is adhered to plug by spring. So the high pressure oil of port P flows to port Sb. The pressure of this oil can be operated from port Sb to room A, through valve casing and the path A' of shaft casing. An oil in room B flows into a drain line through the path of B → Sa. Plowing piston moves to the right side because of the high pressure oil; the plate moves to the place adhered to stopper, based on the shaft "0" ; it is fixed.
10
9
8
13
11
12
Sh
Pg 2
7
1
6
3
5
4
220072SM12
2-57-8
2.6 Working of anti-inversion valve In the event of swing motor operates switch part to drive and stop the swing part. By the action of pump on motor, there is break on both-side of port because of the block on both sides. Swing part is stopped by pressure of brake(in order words, 4-5 times of inversion) Under the operating condition, the side of anti-inversion blocks off both ports but bypassing compressed oil which is blocked in processing of anti-inversion fixed time and amount to inverse port, prevent increasing pressure of motor and decrease inversing action.
5
1
3
4
2
6
7
220072SM13
2-57-9
GROUP 4 TRAVEL DEVICE A. TRAVEL DEVICE(GM35VL, up to #2078) 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. 2 speed control port(P)
Parking brake release gauge port(P3)
Oil fill port(PF 1/2)
D1 P1
A
P2
B
P3 D2
Oil level check port(PF 1/2)
Drain port(PF 1/2) Pressure gauge port(P1~P2)
Hi Low
D1 P1
RED
P3
Port
D2 P2 P
Port name
Port size
A
Main port
SAE 5000psi 1"
B
Main port
SAE 5000psi 1"
P1, P2
Gauge port
PT 1/4
P3
Gauge port
PT 1/8
D1, D2
Drain port
PF 1/2
2 speed control port
PF 1/4
P
AB
25032TM01
2-58
1) BASIC STRUCTURE
Reduction gear
Hydraulic motor Brake valve Parking brake High/low speed changeover mechanism
Control valve
Hydraulic pump
2-59
2) STRUCTURE 27 112 116 115 167 171 2 31 21
1
4 17
5
23 12 22 35
42
337
330
13
139
20 A
25
113
7
109
8
150
15
399
6
341
36
301
102
357
3
355
34
323
355
357
325
336
328
324
346
358
354
352
398
368
C SECTION B-B
359 384 382 383
19
A
363
33
145
43
114
37 110 398 397 151 104 111 108 105 107 106 103 162 161 193 149 132 30
B 380
385 381
208
211
209
217
210
SECTION C-C
1 2 3 4 5 6 7 8 9 12 13 15 17 19 20 21 22
327
C
29
366
326
9
379
135
343
Hub Spindle Hold flange RV gear A RV gear B Input gear Spur gear Cover Crank shaft Spacer Distance piece Coupling Pin Hexagon socket bolt Snap ring Ball bearing Taper roller bearing
23 25 27 29 30 31 33 34 35 36 37 42 43 102 103 104 105
Needle roller bearing Snap ring O-ring O-ring O-ring Floating seal Plug Parallel pin Hexagon socket bolt Steel ball Washer Parallel pin O-ring Shaft Swash plate Cylinder block Piston
106 107 108 109 110 111 112 113 114 115 116 132 135 139 145 149 150
Shoe Retainer plate Thrust ball Timing plate Washer Washer Piston Spring Spring Firction plate Mating plate Oil seal O-ring O-ring Snap ring Ball bearing Ball bearing
151 161 162 167 171 193 201 202 203 204 205 206 208 209 210 211 217
2-60
204
205
203
202
219
206
201
220
SECTION A-A
Needle roller Piston Shoe Pivot Parallel pin Spring Valve Sleeve Spring retainer Plug Shim Spring O-ring O-ring O-ring Back up ring Back up ring
219 220 301 323 324 325 326 327 328 330 336 337 341 343 346 352
O-ring Piston seal Rear flanger Spool Plug Stopper Plug Valve Spring Spring O-ring O-ring Parallel pin Hexagon socket bolt Hexagon socket bolt Plug
354 355 357 358 359 363 368 379 380 382 383 384 385 397 398 399
Hexagon socket plug O-ring Plug O-ring O-ring Spool Steel ball Filter Plug Plug O-ring O-ring Steel ball Orifice Hexagon socket plug Name plate
2. FUNCTION 1) HYDRAULIC MOTOR (1) Rotary group Y1
301
104
105
102
F3 F3 ri F3 Y2
F3
P F3
F2 F1
A
P
α 109
103
The pressurized oil delivered from the hydraulic pump flows to rear flange(301) of the motor, passes through the brake valve mechanism, and is introduced into cylinder block(104) via timing plate(109). This oil constructively introduced only to one side of Y1-Y2 connecting the upper and lower dead points of stroke of piston(105). The pressurized oil fed to one side in cylinder block(104) pushes each piston(105, four or five) and generates a force(F kg = P kg/cm2×A cm2). This force acts on swash plate(103), and is resolves into components (F2 and F3) because swash plate(103) is fixed at an angle(α°) with the axis of drive shaft(102). Redial component(F3) generates respective torques(T = F3×ri) for Y1-Y2. This residual of torque(T = F3×ri) rotates cylinder block(104) via piston(105). Cylinder block(104) is spline-coupled with drive shaft(102). So the drive shaft(102) rotates and the torque is transmitted.
2-61
(2) Brake valve ① Brake released(Starting / Running) When the pressurized oil supplied from port Ⓐ, the oil opens valve(327) and flows into port Ⓒ at the suction side of hydraulic motor to rotate motor. At the same time, the pressurized oil passes through pipe line ⓐ from a small hole in spool(323) and flows into chamber ⓑ. The oil acts on the end face of spool(323) which is put in neutral position by the force of spring(328), thus causing spool(323) to side to the left. When spool(323) slides, port Ⓓ on the passage at the return side of hydraulic motor, which is closed by the spool groove during stoppage, connected with port Ⓑ at the tank side and the return oil from the hydraulic motor runs into the tank. In consequence, the hydraulic motor rotates. Moreover, sliding of spool(323) causes the pressurized oil to flow into ports Ⓟ. The pressurized oil admitted into port Ⓟ activates piston(112) of the parking brake to release the parking brake force. (For details, refer to description of the parking brake.) When the pressurized oil is supplied from port Ⓑ, spool(323) move reversely and the hydraulic motor also rotates reversely.
112
P 328
a
323
D
E
b
C
327
B
2-62
A
Drain
② Brake applied(Stopping / Stalling) When the pressurized oil supplied from port Ⓐ is stopped during traveling, no hydraulic pressure is applied and spool(323) which has slid to the left will return on the right(Neutral) via stopper (325) by the force of spring(328). At the same time, the hydraulic motor will rotate by the inertia even if the pressurized oil stopped, so the port D of the motor will become high pressure. This pressurized oil goes from chamber ⓕ to chamber ⓖ through the left-hand valve(201). When the oil enters chamber ⓖ, the piston(381) slids to the right so as not to rise the pressure, as shown in the figure. Meanwhile, the left-hand valve(201) is pushed open by the pressurized oil in port D. Therefore, the pressurized oil in port D flows to port C at a relatively low pressure, controlling the pressure in port D and preventing cavitation in port C. When the piston(381) reaches the stroke end, the pressure in chamber ⓖ and ⓕ increase and the left-hand valve(201) closes again, allowing the oil pressure in port D to increase further. Then, the right-hand valve(201) opens port C with pressure higher than that machine relief set pressure. In this way, by controlling the pressure in port D in two steps, the hydraulic motor is smoothly braked and brought to a stop.
D
C
g
381
f
201
323 325 328 327 330 B
2-63
A
③ Braking effect on downhill travel If the machine traveling downhill with a relatively small supply of high pressure oil to its travel motors should start coasting, the same braking effect as the one described above would automatically occur. In the coasting condition, the motor is driven, instead of driving the track, from the ground and sucks high pressure oil in. In other words, the motor tends to draw more high pressure oil than is being supplied. Under this condition, port A goes negative to pull oil out of chamber ⓑ through oil way ⓐ, moving back the spool(323) rather rapidly. The clearance on the left then becomes smaller to throttle the outgoing oil more than before, thereby obstructing the pumping action of the motor. As in stopping the machine, pressure will build up in port D to make it harder to drive the motor from the ground: This is the braking action.
112
P 328
a
323
D
E
b
C
327
B
2-64
A
Drain
(3) Parking brake ① Running When the pressurized oil is supplied from the brake valve, the spool of brake valve in the hydraulic motor assembly actuates to open the passage to the parking brake and the pressurized oil is introduced into cylinder chamber ⓐ which is composed of the spindle of reduction gear assembly and piston(112). When the hydraulic pressure reaches 6kgf/cm2(0.59Mpa) or more, it overcomes the force of spring (113) and shifts piston(112). With shift of piston(112), no pressing force is applied to mating plate(116) and friction plate (115) and the movement of friction plate (115) becomes free, whereby the brake force to the cylinder in the hydraulic motor assembly is released.
② Stopping When the pressurized oil from the brake valve is shut off and the pressure in cylinder chamber ⓐ drops 6kgf/cm 2 (0.59Mpa) or less, piston(112) will return by the force of spring(113). Piston(112) is pushed by this force of spring(113), and mating plate(116) and friction plate(115) in free condition are pressed against the spindle of reduction gear assembly. The friction force produced by this pressing stops rotation of the cylinder block(104) and gives a braking torque 40.6kgf・m(398N・m) to the hydraulic motor shaft. Note that oil control through a proper oil passage ensures smooth operation.
2-65
113
112
a
116
115
104
113
112
a
116
115
104
(4) High/low speed changeover mechanism ① At low speed - At pilot pressure of less than 20kgf/cm2(1.96Mpa)
Pilot pressure A
P
B
366 363 θ1
Spindle
103
Support
C Motor case
161 a
Drain
When the pilot pressure is shut off from port Ⓟ, valve(363) is pressed upward by the force of spring(366), the pressurized oil supply port Ⓒ is shut off, and oil in chamber ⓐ is released into the motor case through the valve(363). Consequently, swash plate(103) is tilted at a maximum angle(θ1) and the piston displacement of hydraulic motor becomes maximum, thus leading to low-speed operation. ② At high speed - At pilot pressure of 20kgf/cm2(1.96Mpa) or more
Pilot pressure A
P
B
366 363 θ2 103
b Spindle Support
C
161 Motor case
a
Drain
When a pilot pressure supplied from port Ⓟ(At a pressure of 20kgf/cm2(1.96Mpa) or more), the pressure overcomes the force of spring(366) and valve(363) is pressed downward. The pressurized oil supply port Ⓒ is then introduced into chamber ⓐ through the valve(363). Piston (161) pushes up swash plate(103) until it touches side ⓑ of the spindle. At this time, swash plate(103) is tilted at a minimum angle(θ2) and the piston displacement of hydraulic motor becomes minimum, thus leading to high-speed operation.
2-66
2) REDUCTION GEAR (1) Function This reduction gear is composed of spur reduction gears(First reduction) and differential reduction gears(Second reduction). It decrease high rotating speed, increase output torque of a hydraulic motor and rotates a gear case.
Planetary gear mechanism
Spur gear Crank shaft
(2) Operating principle ① First reduction At the right figure, the rotating motion of hydraulic motor is transmitted to the input gear(6) of first reduction. Then three spur gears(7) engaged with the input gear(6) rotate with reducing the rotating speed. Gear ratio of first reduction is described as the following.
Shaft
Zi Zs Zi : Number of input gear teeth Zs : Number of spur gear teeth i1 = -
Input gear
② Second reduction Three spur gears(7) are connected severally to the three crank shafts(9). These crank shafts(9) are input of second reduction.
Differential gear mechanism Spur gear Rotation Needle bearing Eccentric Crank shaft Rotation A
B
Eccentric motion RV gear B RV gear A
2-67
RV gears(4), (5) are fitted up the eccentric crank shaft(9) through bearings. According to rotating of the crank shafts(9), RV gears(4), (5) revolve (Eccentric motion) along pin-gears(17) within hub(1). As these crank shafts are supported by spindle(2), hub (1) rotates with reducing the speed. Gear ratio of second reduction is described as the following.
Combination of planetary gear mechanism and differential gear mechanism 1 22
23
24 1 2
3
Hub Pin
4
RV gear A or B Crank shaft 360 2 x 24
(Zp - ZR) Zp Zp : Number of pin ZR : Number of RV gear teeth i2 =
2 22
23 24
1 2
360 24 3 3
4 5
22
23
24 1
2
3 4
Total gear ratio of this reduction gear is described as the following. i = i1・i2 = -
Zi (Zp-ZR) ・ Zs Zp
Crank shaft half revolution
2-68
Crank shaft one revolution
B. TRAVEL DEVICE(SBTR220, #2079 and up) 1. STRUCTURE A hydraulic motor includes five followings. ·Part of rotary generating turning force ·Part of a valve of relief ·Part of Brake ·Part of a valve of counterbalance ·Part of plowing changeover ·Part of auto changeover T1
T2
P2
P1
Pm1
Ps
Pm2
21078TM12
Pm1
P1 P2
T1.T2
Pm2
Ps 21078TM04
2-68-1
Port
Port name
Port size
P1, P2
Main port(IN)
SAE 4694psi
P2, P1
Main port(OUT)
SAE 4694ps
Pm1, Pm2
Gauge port
PF 1/4
T1, T2
Prain port
PF 1/2
Ps
2 speed control port
PF 1/4
2. PRINCIPLE OF DRIVING 2.1 Generating the turning force The high hydraulic supplied from a hydraulic pump flows into a cylinder(10) through valve casing of motor(29), and valve plate(77). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston(18). The high hydraulic can generate the force, F1 = P×A(P : Supplied pressure, A : water pressure area), like following pictures, working on a piston. This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the plate(09) of a tilt angle, α. W1 generates torque, T = W1+R1, for Y-Y line connected by the upper and lower sides of piston as following pictures. The sum of torque(ΣW1×R1), generated from each piston(4~5pieces) on the side of a high hydraulic, generates the turning force. This torque transfers the turning force to a cylinder(10) through a piston; because a cylinder is combined with a turning axis and spline, a turning axis rotates and a turning force is sent.
Y
W1
Pistion Cylinder
W1
R1 O
f1
N1 F1
A
P
High Y Low pressure pressure
21078TM05
2-68-2
2.2 Working of relief valve Relief valve carries on two functions of followings. 1) It standardizes a pressure in case of driving a hydraulic motor ; bypasses and extra oil in a motor inlet related to acceleration of an inertia to an outlet. 2) In case of an inertia stopped, it forces an equipment stopped, according to generating the pressure of a brake on the projected side. Room A is always connected with port A of a motor. If the pressure of port is increased, press poppet A. And if it is higher than the setting pressure of a spring, the oil of an hydraulic flows from room A to port B, because poppet A is detached from the contact surface of seat A.
Port B
Port A
Chamber A
Poppet A
21078TM06
2-68-3
2.3 Working of negative brake Negative brake operates the pressure supplied through SPOOL(simultaneous peripheral operation online) installed in valve casing(29) to the part of brake piston(21) and releases a brake. When the pressure does not work, the brake always runs. The force of a brake is generated by the frictional force among a plate(20) fixed by shaft casing, brake piston(21) and a frictional plate(19) connected through spline outside a cylinder(10). When a pressure does not work on the part of piston, brake spring presses brake piston; oil in a brake room flows into the drain of a motor through an orifice; in that time, brake piston compresses a frictional plate and a detached plate in the middle of shaft casing and brake piston according to the force that presses 10 pieces of brake springs(68, 67); finally, it makes a frictional force. This frictional force helps the brake fixing a turning axis(06) connected by a cylinder and spline operated.
65
67 1
6
10
20
19
68
21
21078TM07
2-68-4
2.4 Counterbalance valve Av port is connected into a hydraulic pump; Bv port is into a tank. An oil supplied to a hydraulic pump presses check valve on Av → Cv; through L port, is provided to a hydraulic motor. It makes a hydraulic motor circulated. However, the oil pressure out of a pump is increased and transferred to spring room, M, through the path, G, because negative brake is working on. If the pressure of room M is over the power of spring that keeps spool medium, spool moves to the right side. An oil in room N is sent to room M by orifice I and discharged from G line to a tank. So spool moves to the right. The oil flows as the way of K → Bv.
G
Bv
Av
I N
Dv
Cv
M
K
L
21078TM08
2-68-5
2.5 Working description of automatic switch(at normal speed) Due to no pressure on pilot now, spool(47) is not working.
D
D1 Av
Bv
47 2 Speed line 2 Speed line 2 Speed changeover pressure port
(Normal Speed)
21078TM09
2-68-6
2.6 Working description of automatic switch(at high speed) At normal speed, once the hydraulic oil which is through the inner path of spool(47) flows into high speed switching pressure port(The pressure of external pilot : Pi = 35kgf/cm2) spool(47) moves from right to left. At high speed, turning pressure of motor(D1) is over 250kgf/cm2, when the power forcing to spool(59) (Pressure, P1) is stronger than spool(47) and spool(59) is pushed out, after then spool(47) moves from left to right. So it is switched.
D
D1 59 Av
Bv
47 2 Speed line 2 Speed line 2 Speed changeover pressure port
(High Speed)
21078TM10
2-68-7
GROUP 5 RCV LEVER 1. STRUCTURE The casing has the oil inlet port P(Primary pressure) and the oil outlet port T(Tank). In addition the secondary pressure is taken out through ports 1,2,3 and 4 provided at the bottom face.
23.3
19 Single operation
25 Simultaneous operation
Handle bending direction (No. push rod direction)
4
P 2
3 30
1 T
30
VIEW A
A Port
T P 1
32
4
Hydraulic circuit
2-69
LH
RH
P
Pilot oil inlet port
T
Pilot oil return port Pilot oil return port
1
Left swing port
Bucket out port
2
Arm in port
Boom down port
3
Right swing port
Bucket in port
4
Arm out port
Boom up port
Port size
Pilot oil inlet port
PF 1/4
CROSS SECTION The construction of the pilot valve is shown in the attached cross section drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure, return spring(10), stopper(9), spring seat(8) and shim(6). The spring for setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 20.5kgf/cm2(Depending on the type). The spool is pushed against the push rod(14) by the return spring. When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously and changes setting of the secondary pressure spring.
1 2 3 4 5 6 7 8 9 10
Case Plug Plug O-ring Spool Shim Spring Spring seat Stopper Spring
11 12 13 14 15 16 17 18 19 20
Plug Rod seal O-ring Push rod Plate Bushing Joint assembly Swash plate Adjusting nut Lock nut
2-70
21 22 23 24 25 26 27 28 29 30 40
O-ring Handle connector Nut Insert Boot Handle Switch assembly Screw Switch assembly Switch cover Boot
CROSS SECTION
14072SF80
2-71
2. FUNCTIONS 1) FUNDAMENTAL FUNCTIONS The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure(Secondary pressure) of the pilot valve to the other end. For this function to be carried out satisfactorily, the pilot valve is composed of the following elements. (1) Inlet port(P) where oil is supplied from hydraulic pump. (2) Output ports(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools. (3) Tank port(T) necessary to control the above output pressure. (4) Spool to connect output port to inlet port or tank port. (5) Mechanical means to control output pressure, including springs that work on the above spools. 2) FUNCTIONS OF MAJOR SECTIONS 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 P is led to output ports 1,2,3 & 4 or the output port pressure oil to tank port T. The spring(7) works on this spool to determine the output pressure. The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(11). For the purpose of changing the displacement of the push rod through the switch plate(19) and adjusting nut(20) are provided the handle(27) that can be tilted in any direction around the fulcrum of the universal joint(18) center. The spring(10) works on the case(1) and spring seat(8) and tries to return the push rod(14) to the zero-displacement position irrespective of the output pressure, securing its resetting to the center position. This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-72
3) OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve.
5
6
1 3 1 P
T
3
4
2
1 2
Pilot valve Pilot pump
3 4
Main pump Main control valve
2-73
5 6
Hydraulic motor Hydraulic cylinder
(1) Case where handle is in neutral position
T 7 10 P
5
3
1
The force of the spring(7) that determines the output pressure of the pilot valve is not applied to 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 port pressure becomes equal to tank pressure.
2-74
(2) Case where handle is tilted
14
5
T
P
3
1
When the push rod(14) is stroked, the spool(5) moves downwards. Then port P is connected with port(1) and the oil supplied from the pilot pump flows through port(1) to generate the pressure. When the pressure at port(1) increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force. If the pressure at port(1) increases higher than the set pressure, port P is disconnected from port(1) and port T is connected with port(1). If it decreases lower than the set pressure, port P is connected with port(1) and port T is disconnected from port 1. In this manner the secondary pressure is kept at the constant value. Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the spool contacts with the inside bottom of the push rod and the output pressure is left to be connected with port P.
2-75
GROUP 6 RCV PEDAL 1. STRUCTURE The casing(Spacer) has the oil inlet port P(Primary pressure), and the oil outlet port T(Tank). In addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
° 12.4
12.4 °
T
P
1
2
3
4
Port
T P 1
23
4
Port
P
Pilot oil inlet port
T
Pilot oil return port
1
Travel(LH, Forward)
2
Travel(LH, Backward)
3
Travel(RH, Forward)
4
Travel(RH, Backward)
Port size
PF 1/4
Hydraulic circuit 14072SF73
2-76
CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool(8), spring(6) for setting secondary pressure, return spring(10), stopper(9), and spring seat(7). The spring for setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 19kgf/cm2 (depending on the type). The spool is pushed against the push rod(14) 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 pressure spring.
27
31
30 29 28
33
32
25,26
24 23 22
3 36 14 15
16 21 13 12 11 9 5 4
17 18 19 20 6 7 10 8
3
37
1 35
34
2 14072SF70
1 2 3 4 5 6 7 8 9 10 11 12
Body(1) Body(2) Plug Plug Spring seat Spring Spring seat Spool Stopper Spring Rod guide O-ring
13 14 15 16 17 18 19 20 21 22 23 24
Snap ring Push rod Spring pin Seal Steel ball Spring Plate Snap ring Plug O-ring Rod seal Dust seal
2-77
25 26 27 28 29 30 31 32 33 34 35 36 37
Cover Socket bolt Cam Bushing Cam shaft Set screw Set screw Nut Bellows Space O-ring O-ring Socket bolt
2. FUNCTION 1) FUNDAMENTAL FUNCTIONS The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure(Secondary pressure) of the pilot valve to the other end. For this function to be carried out satisfactorily, the pilot valve is composed of the following elements. (1) Inlet port(P) where oil is supplied from hydraulic pump. (2) Output port(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools. (3) Tank port(T) necessary to control the above output pressure. (4) Spool to connect output port to inlet port tank port. (5) Mechanical means to control output pressure, including springs that work on the above spools. 2) FUNCTIONS OF MAJOR SECTIONS The functions of the spool(8) are to receive the supply oil pressure from the hydraulic pump at its port P, and to change over oil paths to determine whether the pressure oil of port P is led to output ports 1, 2, 3 & 4 or the output spool to determine the output pressure. The spring(6) works on this spool to determine the output pressure. The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(21). For the purpose of changing th displacement of the push rod through the cam(27) and adjusting nut(32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam(27) center. The spring(10) works on the casing(1) and spring seat(7) and tries to return the push rod(14) to the zero-displacement position irrespective of the output pressure, securing its resetting to the center position. This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-78
3) OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below ant the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 5
6
1 3 1 2
4
2
36072SF01
1 2
Pilot valve Pilot pump
3 4
Main pump Main control valve
2-79
5 6
Hydraulic motor Hydraulic cylinder
(1) Case where pedal is in neutral position
6
T
8
10 P
1
2 14072SF74
The force of the spring(6) that determines the output pressure of the pilot valve is not applied to the spool(8). Therefore, the spool is pushed up by the spring(10) to the position of port 2 in the operation explanation drawing. Then, since the output port is connected to tank port T only, the output port pressure becomes equal to tank pressure.
2-80
(2) Case where pedal is tilted
14
8 T
P
1
2
14072SF75
When the push rod(14) is stroked, the spool(8) moves downwards. Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1 to generate the pressure. When the pressure at port 1 increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1 increases higher than the set pressure, port P is disconnected from port 1 and port T is connected with port 1. If it decreases lower than the set pressure, port P is connected with port 1 and port T is disconnected from port 1. In this manner the secondary pressure is kept at the constant value. Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the spool contacts with inside bottom of the push rod and the output pressure is left to be connected with port P. 2-81
SECTION 3 HYDRAULIC SYSTEM Group Group Group Group Group
1 2 3 4 5
Hydraulic Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Main Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pilot Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Single Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
3-1 3-2 3-5 3-13 3-23
SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT(red color) 8
11
10
9
4 RED
RED
Dr3
PaL
PBP
(XBp2)
(XBp1) Fr
Fl
2
Dr2
XAa2 XAa1 Dr1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
XBa2
VA
VB
VB
VA XBa1
XAa2 XAk
XBa2
12 XBk XAb2 Dr4
dr3 Pk
As
PbL
XAb2 XAb
XBs
Ab1 Bb1
Bs
3
XAs XBb
Pns XBtl XBs SH
XA0 XB0
Btl
25 PG
Dr6
Atl
XAtl
XAs
dr4
XAtr
Atr Btr
XBtr C
R1
PB
PA
P2
R2
PH Px
A
B
SWING
5
ARM
7
TRAVEL
BUCKET
BOOM
Pz
6
P1
PG
Py
24
1 14 XAs
XBs
XBa1
XAa1
XBk
XAk
XAb1
XBb1
(1)
(3)
(2)
(4)
(3)
(1)
(2)
(4)
XAtl
XBtl
XAtr
XBtr
(1)
(2)
(3)
(4)
23 Pns A5
Pk A4
Pm1
Pm2 A3
PZ A2
dr2~dr8
15
20 dr1
P3 P2
PG(MCV)
21
Pm1 Fl (Pi1)
18
A1 PG(S/Motor)
A2
17
26 22 P4
A1
13 16
Pm2 Fr (Pi2)
M
19
dr1 A3
P1
21073HS01
3-1
Main pump Main control valve Swing motor Travel motor RCV lever(LH) RCV lever(RH) RCV pedal Boom cylinder(LH) Boom cylinder(RH) Arm cylinder Bucket cylinder Turning joint Check valve Check valve Hydraulic tank Oil cooler Air breather Bypass valve Strainer Spin filter Line filter Solenoid valve Accumulator Pressure switch Shuttle valve Last guard filter
HYDRAULIC CIRCUIT(#9307 and up, yellow color)
C1 P2
P1
10
4
R/H
CK1
Rs
11
8
9
Pn1
Pn2
2
A B D B (Foward) D
C2 P3
P4
B5 DR
S/Motor DB Pk
P C1 P3
A5 C5 D5 Pc5 Pd5
P4
D
A
Pb5
C
A
Pa5 CK2
12
C4
B D4
(Backward)
B4
Pc41 DR3
L/H P1
C2 P2
Pb4 Pa4
1
Main pump
Pc42
2
Main control valve
3
Swing motor
4
Travel motor
5
Rcv lever(LH)
6
Rcv lever(RH)
7
Rcv pedal
8
Boom cylinder(LH)
9
Boom cylinder(RH)
Pd40 Pc40
PG SH
3
C
PB
Pb3
Pc3 DR2
Pd41
Pa21
B2
B (CCW)
V3
A2
C2 Pb21
D2
DR1
A
Pb20
Pc2 Pd2
(CW)
Pa20 P02
24
Patt DB(R7)
PA
C1
B1
D1
A1
Pc1
Pb1
Pd1
Pa1
DR0 P01
SWING
5
ARM
BOOM
BUCKET
6
TRAVEL
24
7
(2)
(3)
(3)
(4)
(2)
(1)
A1
(2) Pa1 A
25
B
D
E
G
F
H
(1) Pb1
(4) Pd1
13
14
26 (3) Pc1
J
Pc40
Pd2
Pa5
Pb5
Pa20
A5
Psv a4 A2
a1
17
Pk (T/Joint) Pm1 (Pump) A4
Pu Pm2 (MCV) (Pump) A3
A2
Pm1
15
23 18
A1 P4 P3
PG(S/Motor) Pg1(MCV)
11
Bucket cylinder
12
Turning joint
13
Check valve
14
Check valve
15
Hydraulic tank
16
Oil cooler
17
Air breather
18
Bypass valve
19
Strainer
20
Spin filter
21
Line filter
22
Solenoid valve
23
Accumulator
24
Pressure switch
25
Shuttle valve
26
Last guard filter
27
Shockless valve
a2
Pb20
27 Pd40 Pb4 22 (MCV)
1
T1
16
Dr#,dr#,R# Pc2
Pu
P2
(4)
SH
Arm cylinder
Ptr
P1
(1)
10
20
Pm2 Pi2 (Fr,MCV)
Pi1 (Fl,MCV)
M
19
a3
Dr
P2
B1
B3
A3
P1
21073HS01A
21
3-1-1
GROUP 2 MAIN CIRCUIT The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit. The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders and two travel motors. The swash plate type variable displacement axial piston pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders
To motors
Main control valve
To oil cooler
To hydraulic oil tank
Main pump Suction filter Hydraulic oil tank
(210-7) 3-03
The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the pump flows into the control valve and goes out the tank ports. The oil discharged from the main pump flows to the actuators through the control valve. The control valve controls the hydraulic functions. The return oil from the actuators flows to the hydraulic tank through the control valve and the oil cooler.
3-2
2. RETURN CIRCUIT
Full flow filter Oil cooler
Check valve(2) 1.5kgf/cm 2
Main control valve
Actuators
Check valve(1) 3.0kgf/cm 2
Bypass relief valve 1.5kgf/cm 2
21073CI01
All oil returned from each actuator returns to the hydraulic tank through the control valve. The bypass check valves are provided in the return circuit. The setting pressure of bypass check valves are 1.5kgf/cm2(21psi) and 3.0kgf/cm2(43psi). Usually, oil returns to the hydraulic tank from the left side of control valve through oil cooler. When oil temperature is low, viscosity becomes higher and flow resistance increases when passing through the oil cooler. When the oil pressure exceeds 3.0kgf/cm2(43psi), the oil returns 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 bypass check valve(1). The full-flow filter and bypass relief valve are provided in the hydraulic tank. The oil returned from right and left side of control valve is combined and filtered by the full-flow filter. A bypass relief valve is provided in the full-flow filter. When the filter element is clogged, the bypass relief valve opens at 1.5kgf/cm2(21psi) differential pressure.
3-3
3. DRAIN CIRCUIT
Travel motor
Swing motor
Main pump Turning joint
Bypass valve 1.5kgf/cm2
Spin filter Hydraulic oil tank
(210-7) 3-04
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through spin filter. When the drain oil pressure exceed 1.5kgf/cm2(21psi), the oil returns to the hydraulic tank directly. 1) TRAVEL MOTOR DRAIN CIRCUIT Oil leaked from the right and left travel motors comes 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 filter. 2) SWING MOTOR DRAIN CIRCUIT Oil leaked from the swing motor returns to the hydraulic tank passing through a spin filter with oil drained from the travel circuit . 3) MAIN PUMP DRAIN CIRCUIT Oil leaked from main pump returns to the hydraulic tank passing through spin filter.
3-4
GROUP 3 PILOT CIRCUIT
Remote control valve (LH lever)
RCV pedal
Remote control valve (RH lever)
Safety lock solenoid valve
Swing parking brake
Control valve Travel speed solenoid valve Max flow cut off solenoid valve Power boost solenoid valve Line filter
Main pump
Boom priority valve
Relief valve 35kgf/cm2
Pilot pump
Suction filter
(210-7) 3-05
The pilot circuit consists of suction circuit, delivery circuit and return circuit. The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the suction filter. The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR valve, solenoid valve assemblies, swing parking brake, main control valve and safety lock solenoid valve.
3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT ARM CYLINDER
TRAVEL MOTOR
(XBp2)
(XBp1)
PaL
PBP
Fl
Dr3
BOOM CYLINDER
BUCKET CYLINDER
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XBs
XAb2 XAb
Pns SWING
Ab1
BOOM 1
Bb1
XAs XBtl
PbL
XBb
Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
SW
TR
AM
P1
PG
Py
BK BM
FRONT PUMP
PILOT PUMP
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
Pns A5
dr2
XBtl XAtr
Pk Pm1 A4
XBtr
Pm2 A3
HYDRAULIC TANK
LINE FILTER
Pz A2
REAR PUMP
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
SAFETY SOLENOID VALVE
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to the safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief valve is provided in the pilot pump for limiting the pilot circuit pressure. The oil filtered by line filter flows remote control valve through safety solenoid valve. The return oil flow into the hydraulic tank.
3-6
2. SAFETY VALVE(SAFETY LEVER) ARM CYLINDER
TRAVEL MOTOR
(XBp2)
(XBp1)
PaL
PBP
Fl
Dr3
BOOM CYLINDER
BUCKET CYLINDER
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XBs
XAb2 XAb
Pns SWING
Ab1
BOOM 1
Bb1
XAs XBtl
PbL
XBb
Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
SW
TR
AM
P1
PG
Py
FRONT PUMP
BK BM
REAR PUMP PILOT PUMP
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
Pns A5
XBtl XAtr
Pk Pm1 A4
XBtr
Pm2 A3
LEVER DOWN
Pz A2
A1 P4 P3 P2 P1
dr2
HYDRAULIC TANK
PG(S/Motor) PG(MCV)
SOLENOID VALVE
LEVER UP SAFETY SOLENOID VALVE
When the lever of the safety solenoid valve is moved downward, oil flows into the remote control valve through solenoid valve and line filter. When the lever of the safety solenoid valve is moved upward, oil does not flow into the remote control valve, because of the blocked port.
3-7
3. BOOM PRIORITY SYSTEM ARM CYLINDER
TRAVEL MOTOR
(XBp2)
(XBp1)
PaL
PBP
Fl
Dr3
BOOM CYLINDER
BUCKET CYLINDER
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XBs
XAb2 XAb
Pns SWING
Ab1
BOOM 1
Bb1
XAs XBtl
PbL
XBb
Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
SW
TR
AM
P1
PG
Py
FRONT PUMP
BK BM
REAR PUMP PILOT PUMP
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
Pns A5
dr2
XBtl XAtr
Pk Pm1 A4
XBtr
Pm2 A3
HYDRAULIC TANK
Pz A2
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
When carrying out the combined operation of swing and boom or arm, the boom or arm operating speed is lowered then normal operation. To increase working efficieny, swing speed reducing system is used. When heavy duty working mode in work mode is on, pilot oil from pilot pump flow into Pns port in main control valve through solenoid valve. Pns oil pressure move swing reducing spool to lower positon and oil flow rate to the swing motor decreased. Then, the boom or arm speed is increased. This is called the boom priority system.
3-8
4. TRAVEL SPEED CONTROL SYSTEM CONTROL PISTON PILOT VALVE
TRAVEL MOTOR
RED
RED
VB
VA
VB
ARM CYLINDER
BOOM CYLINDER
BUCKET CYLINDER
VA
(XBp1)
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
Pk XAa2 XAa1 Dr1
dr3
XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XBs
XAb2 XAb
Pns SWING
Ab1
BOOM 1
Bb1
XAs XBtl
PbL
XBb
Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
SW
TR
AM
P1
PG
Py
FRONT PUMP
BK BM
REAR PUMP PILOT PUMP
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
Pns A5
dr2
XBtl XAtr
Pk Pm1 A4
XBtr
Pm2 A3
HYDRAULIC TANK
Pz A2
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the discharged oil from the pilot pump flows to the Pk port of pilot valve in the travel motors. As a result, the control piston is pushed by the main oil flow, thus the displacement is minimized. When the travel speed switch is pushed once more, the travel speed solenoid valve is return to original position by the force of spring, the hydraulic oil of Pk port retums to the hydraulic tank. As a result, the control piston is returned by the main oil flow, thus the displacement is maximized. 3-9
5. MAIN RELIEF PRESSURE CHANGE SYSTEM ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XAk
XBa2 BUCKET
XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl
Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
SW
TR
AM
P1
PG
Py
FRONT PUMP
BK BM
REAR PUMP PILOT PUMP
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
Pns A5
dr2
XBtl XAtr
Pk Pm1 A4
XBtr
Pm2 A3
HYDRAULIC TANK
Pz A2
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve is actuated, the discharged oil from the pilot pump flows into Pz port of the main relief valve of main control valve; then the setting pressure of the main relief valve is raised from 330kgf/cm2 to 360kgf/cm2 for increasing the digging power. And even when pressed continuously, it is canceled after 8 seconds.
3 - 10
6. MAX FLOW CUT OFF SYSTEM ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs
XBb
XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
SW
TR
AM
BK BM Pz
P1
Py
PG
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
XBtl XAtr
XBtr
A1
Pns A5
dr2
Pk Pm1 A4
Pm2 A3
A2
Pz A2
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
HYDRAULIC TANK Pm1 Fl (Pi1)
Pm2 Fr (Pi2)
M dr1 A3
When the breaker operation mode is selected on the cluster, max flow cut off solenoid valve actuates automatically. Thus pilot pressure(Pm1,2) is sent to the regulator and pump discharge volume is decreased.
3 - 11
7. SWING PARKING BRAKE RELEASE ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1
SWING MOTOR
XBa2
XBs SH
ARM 1
ARM 2
XBa1 PG XAs
XAa2 XBa2
XAk
dr4
BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 C PA
XAb2 XAb
XBs Pns
PB
SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6 B
A
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
SW
TR
AM
P1
PG
Py
FRONT PUMP
BK BM
REAR PUMP PILOT PUMP
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
Pns A5
dr2
XBtl XAtr
Pk Pm1 A4
XBtr
Pm2 A3
HYDRAULIC TANK
Pz A2
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
When the swing control lever is tilted, the pilot oil flow into SH port of shuttle valve, this pressure move spool so, discharged oil from pilot valve flow into PG port. This pressure is applied to swing motor disc, thus the brake is released. When the swing control lever is set in the neutral position, oil in the swing motor disc cylinder is drained, thus the brake is applied.
3 - 12
GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the right control lever is pulled back, the boom spools in the main control valve are moved to the up position by the pilot oil pressure from the remote control valve. The oil from the front and rear pump flows into the main control valve and then goes to the large chamber of boom cylinders. At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank through the boom spool in the main 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 up and the control lever is returned to neutral position, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by the boom holding valve. This prevents the hydraulic drift of boom cylinder. 3 - 13
GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the right control lever is pulled back, the boom spools in the main control valve are moved to the up position by the pilot oil pressure from the remote control valve. The oil from the front and rear pump flows into the main control valve and then goes to the large chamber of boom cylinders. At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank through the boom spool in the main 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 up and the control lever is returned to neutral position, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by the boom holding valve. This prevents the hydraulic drift of boom cylinder. 3 - 13
2. BOOM DOWN OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2 PH Px
R2 R2
P2
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the right control lever is pushed forward, the boom spools in the main control valve are moved to the down position by the pilot oil pressure from the remote control valve. The oil from the rear pump flows into the main control valve and then goes to the small chamber of boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the hydraulic tank through the boom spool in the main control valve. When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder combines with the oil from the rear pump, and flows into the small chamber of the cylinder. This prevents cylinder cavitation by the negative pressure when the rear pump flow can not match the boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented by the relief valve.
3 - 14
3. ARM ROLL IN OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the left control lever is pulled back, the arm spools in the main control valve are moved the to roll in position by the pilot oil pressure from the remote control valve. The oil from the front and rear pump flows into the main control valve and then goes to the large chamber of arm cylinder. At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through the arm spool in the main control valve. When this happens, the arm rolls in. The cavitation which will happen to the bottom of the arm cylinder is also prevented by the make-up valve in the main control valve.
3 - 15
4. ARM ROLL OUT OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs
XBb
XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz Pz
PG PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the left control lever is pushed forward, the arm spool in the main control valve are moved to the roll out position by the pilot oil pressure from the remote control valve. The oil from the front and rear pump flows into the main control valve and then goes to the small chamber of arm cylinder. At the same time, the oil from the large chamber of arm cylinder returns to the hydraulic oil tank through the arm spool in the main control valve. When this happens, the arm rolls out. The cavitation which will happen to the rod of the arm cylinder is also prevented by the make-up valve in the main control valve. 3 - 16
5. BUCKET ROLL IN OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the right control lever is pulled left, the bucket spool in the main control valve is moved to the roll in position by the pilot oil pressure from the remote control valve. The oil from the rear pump flows into the main control valve and then goes to the large chamber of bucket cylinder. At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank through the boom spool in the main control valve. When this happens, the bucket rolls in. The cavitation which will happen to the bottom of the bucket cylinder is also prevented by the makeup valve in the main control valve.
3 - 17
6. BUCKET ROLL OUT OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the right control lever is pushed right, the bucket spool in the main control valve is moved to the roll out position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the main control valve and then goes to the small chamber of bucket cylinder. At the same time, the oil from the large chamber of bucket cylinder retums to the hydraulic oil tank through the bucket spool in the main control valve. When this happens, the bucket rolls out. The cavitation which will happen to the rod of the bucket cylinder is also prevented by the make-up valve in the main control valve. 3 - 18
7. SWING OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1
SWING MOTOR
XBa2
XBs SH
ARM 1
ARM 2
XBa1 PG XAs
XAa2 XBa2
XAk
dr4
BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 C PA
XAb2 XAb
XBs Pns
PB
SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6 B
A
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr
R1
P2
R2
PH Px
Pz
SW
TR
AM
PG
P1
Py
FRONT PUMP
BK BM
REAR PUMP PILOT PUMP
XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
Pns A5
dr2
XBtl XAtr
Pk Pm1 A4
XBtr
Pm2 A3
HYDRAULIC TANK
Pz A2
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
When the left control lever is pushed left or right, the swing spool in the main control valve is moved to the left or right swing position by the pilot oil pressure from the remote control valve. The oil from the rear pump flows into the main control valve and then goes to the swing motor. At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the swing spool in the main control valve. When this happens, the superstructure swings to the left or right. The swing parking brake, make up valve and the overload relief valve are provided in the swing motors. The cavitation which will happen to the swing motor is also prevented by the make up valve in the swing motor itself. 3 - 19
SWING CIRCUIT OPERATION
PARKING BRAKE BRAKE RELEASE VALVE BRAKE OFF BRAKE ON
SH
PG dr4
MAKE UP VALVE C(MAKE UP PORT) PA
PB
A
MOTOR BRAKE VALVE
B
TO/FROM MAIN CONTROL VALVE
1) MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation. 2) MAKE UP VALVE The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor. 3) PARKING BRAKE In case that the parking, of the machine at slope is required during operation, there is the danger of involuntary swing caused by the self weight of the machine. The brake 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 position, the pilot pressure at the shuttle valve is transferred to the brake release valve and the brake release valve is change over. Then the pilot pressure lift the brake piston and release the parking brake. PARKING BRAKE "ON" OPERATION When the control lever placed in the neutral position, the pressure of the pilot oil passage down. Then 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". BYPASS VALVE This bypass valve absorbs shocks produced as swing motion stops and reduced oscillation cause by swing motion.
3 - 20
8. TRAVEL FORWARD AND REVERSE OPERATION TRAVEL MOTOR RED
RED
VB
VA
VB
ARM CYLINDER
BOOM CYLINDER
BUCKET CYLINDER
VA
(XBp1)
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
Pk dr3
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
SW
TR
AM
P1
PG
Py
BK BM
FRONT PUMP XAs XBs XBa1XAa1 XBk XAk XAb1 XBb1 XAtl
XBtl XAtr
XBtr
XAs Pns A5
dr2
Pk Pm1 A4
REAR PUMP PILOT PUMP
Pm2 A3
HYDRAULIC TANK
Pz A2
A1 P4 P3 P2 P1
PG(S/Motor) PG(MCV)
When the travel levers are pushed forward or reverse position, the travel spools in the main control valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote control valve. The oil from the both pumps flows into the main control valve and then goes to the both travel motors through the turning joint. The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and the travel spools in the main control valve. When this happens, the machine moves to the forward or reverse. 3 - 21
TRAVEL CIRCUIT OPERATION
RED
RED
VA
dr3
VB
VB
VA
Pk OVERLOAD RELIEF VALVE
CHECK VALVE
COUNTER BALANCE VALVE
TURNING JOINT
TO/FROM MAIN CONTROL VALVE
Valves are provided on travel motors to offer the following functions. 1) COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run. 2) OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 365kgf/cm2 to prevent high pressure generated at at time of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage for preventing the negative pressure and the cavitation of the motor.
3 - 22
GROUP 5 COMBINED OPERATION 1. OUTLINE ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
HYDRAULIC TANK
PG
P1
STRAIGHT TRAVEL SPOOL
Py
FRONT PUMP
REAR PUMP PILOT PUMP
The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and confluence oil passage in the main control valve. Then the oil goes to each actuator and operates them. Check valves and orifices are located on these oil passage in the main control valve. These control the oil from the main pumps so as to correspond to the operation of each actuator and smooth the combined operation. STRAIGHT TRAVEL SPOOL This straight travel spool for straight travel is provided in the main control valve. If any actuator is operated when traveling, the straight travel spool is pushed to the left by the pilot oil pressure. Consequently, the left and right travel oil supply passage are connected, and equivalent amount of oil flows into the left and right travel motors. This keeps the straight travel. 3 - 23
2. COMBINED SWING AND BOOM OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the swing and boom functions are operated, simultaneously the swing spool and boom spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the swing motor through swing spool and the boom cylinder through boom 2 spool. The oil from the rear pump flows into the boom cylinders through the boom 1 spool in the right control valve. The superstructure swings and the boom is operated. 3 - 24
3. COMBINED SWING AND ARM OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the swing and arm functions are operated, simultaneously the swing spool and arm spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the swing motor through swing spool and the arm cylinder through arm 1 spool. The oil from the rear pump flows into the arm cylinder through the arm 2 spool of the right control valve. The superstructure swings and the arm is operated. 3 - 25
4. COMBINED SWING AND BUCKET OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the swing and bucket functions are operated, simultaneously the swing spool and bucket spool in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the swing motor through the swing spool in the left control valve. The oil from the rear pump flows into the bucket cylinder through the bucket spool in the right control valve.
3 - 26
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the swing, boom, arm and bucket functions are operated, simultaneously each spool in the main control valve is moved to the functional position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the swing motor, boom cylinders and arm cylinder through the swing spool, boom 2 spool, arm 1 spool, and the parallel and confluence oil passage in the left control valve. The oil from the rear pump flows into the boom cylinders, arm cylinder and bucket cylinder through the boom 1 spool, arm 2 spool, bucket spool and the parallel and confluence oil passage in the right control valve. The superstructure swings and the boom, arm and bucket are operated.
3 - 27
6. COMBINED SWING AND TRAVEL OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the swing and travel functions are operated, simultaneously the swing spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and straight travel spool is pushed to the left by the pilot oil pressure from the pilot pump. The oil from the front pump flows into the swing motor through the swing spool. The oil from the rear pump flows into the travel motor 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. The superstructure swings and the machine travels straight.
3 - 28
7. COMBINED BOOM AND TRAVEL OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the boom and travel functions are operated, simultaneously the boom spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump. The oil from the front pump flows into the boom cylinders through the boom 2 spool and boom 1 spool via the parallel and confluence oil passage in case boom up operation. The oil from the rear pump flows into the travel motors 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.
3 - 29
8. COMBINED ARM AND TRAVEL OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs
XBb
XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump. The oil from the front pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via the parallel and confluence oil passage. The oil from the rear pump flows into the travel motors 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. The arm is operated and the machine travels straight. 3 - 30
9. COMBINED BUCKET AND TRAVEL OPERATION ARM CYLINDER
TRAVEL MOTOR
(XBp1)
BOOM CYLINDER
BUCKET CYLINDER
(XBp2) PBP
PaL
Fl
Dr3
Fr
Dr2
XAa2 XAa1 Dr1 XBa2 ARM 1
SWING MOTOR
ARM 2
XBa1
XAa2 XBa2
XAk BUCKET XBk
BOOM 2
XAb2
Ak1 Bk1
Dr4 XAb2 XAb
XBs Pns SWING
PbL Ab1
BOOM 1
Bb1
XAs XBb XBtl Dr6
XA0 XB0
OPTION
TRAVEL(LH) XAtl
XAtr TRAVEL(RH)
Atr Btr
XBtr R1 P2
R2
PH Px
Pz
PG
P1
Py
FRONT PUMP
HYDRAULIC TANK
REAR PUMP PILOT PUMP
When the bucket and travel functions are operated, simultaneously the bucket spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve, and the straight travel spool is pushed to the left by the oil pressure from pilot pump. The oil from the front pump flows into the bucket cylinder through the bucket spool via the confluence oil passage. The oil from the rear pump flows into the travel motors 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 of the control valve. The bucket is operated and the machine travels straight. 3 - 31
SECTION 4 ELECTRICAL SYSTEM Group Group Group Group Group
1 2 3 4 5
Component Location Electrical Circuit(up to -#1000) Electrical Component Specification Connectors Electrical circuit(#1001 and up, Tier II)
4-1 4-3 4-23 4-33 4-53
SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1
21074EL01A
1 2 3 4 5 6 7 8 9 10
Horn switch Breaker operation switch Cluster Cigar lighter Hour meter Safety lever Power max switch One touch decel switch Air conditioner switch Master switch
11 12 13 14 15 16 17 18 19 20
Fuse box RS232 serial connector CPU controller Prolix resistor Prolix switch Cassette radio Speaker Main light switch Wiper switch Washer switch 4-1
21 22 23 24 25 26 27 28 29
Preheat switch Travel alarm switch Cab light switch Breaker selection switch Beacon switch Accel dial Start switch Overload switch Quick clamp switch
2. LOCATION 2(up to #1000)
21074EL02
1 2 3 4 5 6
Lamp Fuel sender Fuel filler pump Beacon lamp Horn Speed sensor
7 8 9 10 11 12
Pressure sender Heater valve Start relay Heater relay Temp sender Engine oil pressure switch
4-2
13 14 15 16 17 18
Alternator Air cleaner switch Master switch Battery Travel alarm buzzer Battery relay
2. LOCATION 2(#1001 and up, TIER II)
21074EL02A
1 2 3 4 5 6
Lamp Fuel sender Fuel filler pump Beacon lamp Horn Speed sensor
7 8 9 10 11 12
Heater valve Start relay Heater relay Temp sender Engine oil pressure switch Alternator
4 - 2-1
13 14 15 16 17
Air cleaner switch Battery Travel alarm buzzer Battery relay Pressure sender
GROUP 2 ELECTRICAL CIRCUIT (up to #1000) ¡⁄ Machine serial no : up to #0179
21074EC01
4-3
¡⁄ Machine serial no : #0180~#1000
21074EC01A
4-3-1
1. POWER CIRCUIT (up to #0179) The negative terminal of battery is grounded to the machine chassis through master switch. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. 1) OPERATING FLOW Battery Battery relay Fuse box [No.1] Fuse box [No.2] Fuse box [No.3] Fuse box [No.4]
Fuse box [No.5] Fuse box [No.6]
Reset button[CS-61] I/conn [CN-8(12)] Start switch [CS-2(1)] Power relay [CR-35(30)] I/conn [CN-10(6)] Room lamp [CL-1(2)] Door switch[CS-1] Cassette radio [CN-27(11)] I/conn [CN-11(4)] AC&Heater controller [CN-116(3,4)] I/conn [CN - 5(4)] I/conn [CN -17(5)] Wiper motor Controller [CN-141(7)] Wiper motor [CN-21(4)] CPU controller [CN-50(7)] I/conn [CN-11(5)] Relay(Hi, M2)
I/conn : Intermediate connector 2) CHECK POINT Engine
OFF
Start switch
OFF
Check point - GND (Battery 1 EA) - GND (Battery 2 EA) - GND (Battery 2 EA) - GND (Reset button)
¡ GND : Ground
4-4
Voltage 10~12.5V 20~25V 20~25V 20~25V
POWER CIRCUIT(up to #0179)
21074EL03
4-5
1. POWER CIRCUIT (from #0180 to #1000) The negative terminal of battery is grounded to the machine chassis through master switch. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. 1) OPERATING FLOW Battery Battery relay Fusible link¡†CN-60¡‡ Fuse box¡†No.1¡‡ l/conn¡†CN-8(12)¡‡ Start switch¡†CS-2(1)¡‡ Power relay¡†CR-35(30)] Fuse box¡†No.2¡‡ I/conn¡†CN-10(6)¡‡ Room lamp¡†CL-1(2)¡‡ Door switch¡†CS-1¡‡ Cassette radio¡†CN-27(11)¡‡ Fuse box¡†No.3¡‡ l/conn¡†CN-11(4)¡‡ AC & Heater controller¡†CN -116(3, 4)¡‡ Fuse box¡†No.4¡‡ I/conn¡†CN - 5(4)¡‡ I/conn¡†CN -17(5)¡‡ Wiper motor controller ¡†CN-141(7)¡‡ Wiper motor¡†CN-21(4)¡‡ Fuse box¡†No.5¡‡ CPU controller¡†CN-50(7)¡‡ Fuse box¡†No.6¡‡ I/conn¡†CN-11(5)¡‡ Relay(Hi, M2) ¡ I/conn : Intermediate connector 2) CHECK POINT Engine
OFF
Start switch
OFF
Check point
Voltage
¤ - GND (Battery 1EA)
10~12.5V
¤Ł- GND (Battery 2EA)
20~25V
¤Ø- GND (Battery 2EA)
20~25V
¤Œ - GND (Fusible link)
20~25V
¡ GND : Ground
4 - 5-1
POWER CIRCUIT (from #0180 to #1000)
21074EL03A
4 - 5-2
2. STARTING CIRCUIT(up to #1000) 1) OPERATING FLOW Battery(+) terminal Battery relay[CR-1] Reset button[CS-61] I/conn [CN-8(12)] Start key [CS-2(1)]
Fuse box [No.1]
¡ Start switch : ON Start switch ON [CS-2(2)] I/conn [CN-8(11)] Diode[DO-2] Battery relay [CR-1]:Battery relay operating(All power is supplied with the electric component) Start switch ON [CS-2(3)] I/conn [CN-8(10)] Power relay [CR-35(86)¡ (87)] Fuse box [No.12] I/conn [CN-1(5)] Fuel cut-off [CN-79(1)]
¡ Start switch : START Start switch START[CS-2(5)] I/conn[CN-8(9)] I/conn [CN-3(4)] Start relay [CR-23] I/conn [CN-1(4)] Fuel cut off [CN-79(2)]
Safety relay [CR-5(86) ¡ (30)]
2) CHECK POINT Engine
Operating
Start switch
Start
Check point ¤ ¤ ¤ ¤ ¤ ¤ ¤
-GND (Battery) Ł -GND (Start key) ØGND (Battery relay M4) ŒGND (Starter B ) ºGND (Starter M) GND (Start relay) GND (Battery relay M8)
¡ GND : Ground
4-6
Voltage
20 ~ 25V
STARTING CIRCUIT(up to #1000)
21074EL05
4-7
3. CHARGING CIRCUIT(up to #1000) When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the Battery relay(CR-1). The current also flows from alternator to each electrical component and controller through the fuse box. 1) OPERATING FLOW (1) Warning flow Alternator¡ I¡–terminal I/conn¡†CN-3(6)¡‡ Cluster warning lamp (Via serial interface) (2) Charging flow Alternator "B+" terminal
Battery relay(M8)
CPU Controller [CN-51(9)]
Battery(+) terminal Reset button[CS-61]
Fuse box
2) CHECK POINT Engine
ON
Start switch
ON
Check point ¤ - GND (Battery voltage) ¤Ł- GND (Battery relay) ¤Ø- GND (Alternator B¡qterminal) ¤Œ- GND (Alternator I terminal) ¤º- GND (CPU)
¡ GND : Ground
4 -8
Voltage
20~27V
CHARGINGING CIRCUIT(up to #1000)
21074EL06
4 -9
4. HEAD LAMP CIRCUIT(up to #1000) 1) OPERATING FLOW Fuse box (No.14)
I/conn [CN-7(7)]
Switch panel [CN-116(9)]
¡ When lamp switch ON Switch panel [CN-116(1)] I/conn [CN-7(1)] I/conn [CN-10(2)] Cassette radio illumination [CN-27(7)] I/conn [CN-11(8)] AC & Heater controller illumination [CN-116(5)] Head lamp [CL-4(2)] : Head lamp ON I/conn[CN-6(8)] Cigarlight [CL-2]
2) CHECK POINT Engine
STOP
Key switch
ON
Check point ¤ - GND (Fuse box) ¤Ł- GND (Switch power input) ¤Ø- GND (Switch power output)
¡ GND : Ground
4 - 10
Voltage
20~25V
HEAD LAMP CIRCUIT(up to #1000)
21074EL07
4 - 11
5. WORK LAMP CIRCUIT(up to #1000) 1) OPERATING FLOW Fuse box (No.15)
I/conn [CN-7(8)]
¡ When work lamp switch ON Work lamp switch ON [CN-116(2,3)] Work lamp ON [CL-5(2), CL-6(2)]
Switch panel [CN-116(10,11)] I/conn [CN-7(2)]
I/conn [CN-12(1)]
2) CHECK POINT Engine
STOP
Key switch
ON
Check point ¤ - GND (Fuse box) ¤Ł- GND (Switch power input) ¤Ø- GND (Switch power output) ¤Œ- GND (Work lamp)
¡ GND : Ground
4 - 12
Voltage
20~25V
WORK LAMP CIRCUIT(up to #1000)
21074EL08
4 - 13
6. CAB LAMP CIRCUIT(up to #1000) 1) OPERATING FLOW Fuse box (No.16) I/conn¡†CN-7(12)¡‡ ¡ When Lamp switch ON Lamp switch ON [CN-116(7, 8)] Cab light ON [CL-8(2), CL-9(2)]
Switch panel [CN-116(16,17)]
I/conn [CN-7(6)]
I/conn [CN-10(11)]
2) CHECK POINT Engine
STOP
Start switch
ON
Check point - GND (Fuse box) - GND (Switch power input) - GND (Switch power output) - GND (Cab lamp)
GND : Ground
4 - 14
Voltage
20 ~ 25V
R
2 OR
17
16
15
14
OR
CL-8
CABIN LIGHT 24V
CABIN LIGHT 24V
INT. SIG
TRAVEL ALARM
13
12
11
10
9
8
7
6
5
4
3
2
1
CN-116
3
GND
WASHER SIG
WORK LIGHT 24V
WORK LIGHT 24V
HEAD LIHGT 24V
CABIN LIGHT OUT
CABIN LIGHT OUT
POWER 24V
PRE-HEAT
WIPER MOTOR DRIVE
WORK LIGHT OUT
WORK LIGHT OUT
HEAD LIGHT OUT
R
20A
5A
5A
10A
5A
20A
10A
5A
10A
5A
5A
20A
20A
5A
10A
10A
5A
20A
10A
10A
10A
5A
10A
5A
10A
10A
10A
START KEY ROOM LAMP AC& HEATER WIPER CPU AC& HEATER CLUSTER CASSETTE RADIO CPU CONVERTOR SWITCH PANEL FUEL CUT-OFF WIPER MOTOR HEAD LAMP WORK LAMP CABIN LAMP BEACON LAMP AC& HEATER HORN CIGAR LIGHTER ETHER(PRE-HEAT) TRAVEL SOLENOID 1 SAFETY SOL SOLENOID 3 FUEL FILLER P/P SPARE
CN-46
CL-9
2 7
1 8
CABIN LIGHT OR
OR
2
R
4 - 15 10
5
11
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAB LAMP CIRCUIT(up to #1000)
FUSE BOX
1
CN-10
1
3 2
4
6 5
OR
9
11
12 OR
4
1
CN-7
1
3 2
4
6 OR
7
8
10
9
12
R
SWITCH PANEL
21074EL09
7. BEACON LAMP CIRCUIT(up to #1000) 1) OPERATING FLOW Fuse box (No.17) I/conn [CN-8(3)] ¡ When lamp switch ON Beacon lamp switch ON [CS-23(2)]
Beacon lamp switch [CN-23(6)] Switch lndicator lamp ON [CS-23(9)] l/conn [CN-8(4)] l/conn [CN-10(10)] Beacon lamp ON [CL-7]
2) CHECK POINT Engine
Start switch
Check point
Voltage
¤ - GND(Fuse box) ¤Ł- GND(Switch power input) STOP
ON
¤Ø- GND(Switch power output) ¤Œ- GND(Beacon lamp)
¡ GND : Ground
4 - 16
20~25V
CABIN LIGHT 24V
CABIN LIGHT 24V
INT. SIG
TRAVEL ALARM
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CN-116
R
R
OR
OR
7
GND
WASHER SIG
WORK LIGHT 24V
WORK LIGHT 24V
HEAD LIHGT 24V
CABIN LIGHT OUT
CABIN LIGHT OUT
POWER 24V
PRE-HEAT
WIPER MOTOR DRIVE
WORK LIGHT OUT
WORK LIGHT OUT
HEAD LIGHT OUT
6 OR
B
OR
B
G
B
9
8
7
1
SWITCH PANEL
4 - 17
10
CS-23
6
5
10
9
2
6
3
4
2
BEACON LAMP SW 12
11
10
9
8
7
6
5
4
3
2
G
Y
OR
G
R
OR
5
1
CN-8
12
11
10
9
8
7
6
5
4
3
2
1
CN-10
12
11
10
9
8
7
6
5
4
3
2
1
CN-7
Y
R
5A
10A
5A
20A
10A
5A
10A
5A
5A
20A
20A
5A
10A
10A
5A
20A
10A
AC & HEATER WIPER+ CPU B+ AC BLOWER CLUSTER CASSETTE RADIO CPU CONVERTOR SWITCH PANEL FUEL CUT-OFF WIPER MOTOR HEAD LAMP WORK LAMP CAB LAMP BEACON LAMP AC & HEATER HORN
FUSE BOX
SPARE SPARE
FUEL FILLER PUMP
SOLENOID 3
SAFETY SOLENOID
SOLENOID 1
TRAVEL
ETHER(PRE-HEAT)
20A
10A
10A
10A
5A
10A
5A
10A
10A
5A
ROOM LAMP
CIGAR LIGHTER
20A
START KEY
CN-46
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
BEACON LAMP CIRCUIT(up to #1000)
1
CL-9
2
CAB LIGHT 1
8 CL-8
2
CAB LIGHT 1
CL-7
BEACON LAMP M
4
G
B
7
8
5
Y
G
2
1
3
29074EL08
8. WIPER AND WASHER CIRCUIT(up to #1000) 1) OPERATING FLOW (1) Key switch ON Fuse box (No.11) Fuse box (No.4) Fuse box (No.13)
I/conn [CN-7(5)] I/conn [CN-5(4)]
Switch panel [CN-116(6)] I/conn [CN-17(5)] Wiper motor controller [CN-141(7)] Wiper motor [CN-21(4)] I/conn [CN-6(5)] l/conn [CN-17(4)] Wiper motor controller [CN-141(6)] Washer pump [CN-22(2)]
(2) Wipe switch ON : 1st step(Intermittent) Wiper switch ON [CN-116(15)] I/conn[CN-9(4)] I/conn[CN-17(8)] Wiper motor controller [CN-141(10) ¡ (3)] Wiper motor intermittently operating [CN-21(6)] (3) Wiper switch ON : 2nd step(Low speed) Wiper switch ON [CN-116(4)] I/conn [CN-7(3)] I/conn [CN-6(9)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) ¡ (4)] Wiper motor operating [CN-21(2)] (4) Washer switch ON Washer switch ON [CN-116(12)] I/conn [CN-7(9)] I/conn [CN-5(1)] I/conn [CN-17(7)] Wiper motor controller [CN-141(9) ¡ (8)] I/conn [CN-17(6)] I/conn [CN-6(11)] Washer pump [CN-22(1)] Washer operating. Fuse box(No.13) I/conn [CN-6(5)] I/conn [CN-17(4)] Wiper motor controller [CN-141(6) ¡ (4)] Wiper motor operating [CN-21(2), Low speed] (5) Auto parking(When switch OFF) Switch OFF [CN-116(15)] Wiper motor parking position by wiper motor controller
2) CHECK POINT Engine
Start switch
Check point
Voltage
¤ - GND(Fuse box) ¤Ł- GND(Switch power input) ¤Ø- GND(Switch power output) STOP
ON
¤Œ- GND(Wiper Power input) ¤º- GND(Wiper power output) ¤ - GND(Wiper motor)
¡ GND : Ground
4 - 18
20~25V
WIPER AND WASHER CIRCUIT(up to #1000)
21074EL11
4 - 19
35
4 - 20 22 23 24 25 26 27 28 29 30 31
NC
ACCEL ACT(-)
POWER IG
NC
NC
NC
GND (MAIN)
SERIAL-TX
SERIAL-RX
GND
B
Y
B
OR
CN-76
R
5
OR
Y
Y
B
1
T
6
36
21
ENG OIL FILTER SW
L
PUMP EPPR(+)
20
OVERLOAD SIG
L
35
19
PARKING SW
OR
34
18
NC
OR
33
17
PRE-HEAT SW
V
NC
16
TRAVEL BUZZER
B
32
15
BRAKE FAIL LAMP
6
RS232 (GND)
14
T/M OIL LAMP
4
RS232 (-)
13
TRAVEL SPEED SOL
R
L
OR
W
OR
OR
1
RS232 (+)
12
8
PUMP EPPR(-)
ACCEL ACT(+)
7
BATTERY 24V(+)
11
6
CO CANCEL SOL
ANTI-RESTART RY
5
ENG PREHEATER
9
4
HOUR-METER
10
3
POWER MAX SOL
NC
2
CN-5
NC
1
BOOM PRIORITY SOL
MAX FLOW SOL
CN-50
34
1
36
2
P+
NC
SIG
NC
1
HYD TEMP SENDOR
4 5
OR
5
33
2
32
6
31
M-
M+
NC
WATER TEMP SENDOR
5
30
8
PUMP PROLIX SW
ACCEL DIAL
GND (SENSOR)
7
OR
29
A 5
28
CD-17
NC
11
ACCEL SW
B
T/M OIL PS
B V W/OR
W
PW
27
S B
9
BRAKE FAIL PS
Y
B
L
Y
26
L
8
25
HOUR METER
24
OR
TACHO SENSOR(+)
1
FUEL LEVEL SENSOR
CN-48
TACHO SENSOR(-)
C
W
1
V
CN-142
23
2
OR
B
1
ACCEL DIAL SIG
20
GND (POT&DIAL)
EPPR V/V
22
19
TRAVEL Hi/Lo SW
CN-75
POT-SIG
18
BKT&ARM IN PS
2 2
21
17
HEAVY LIFT SW
h
5V (POT&DIAL)
3
16
m
AIR CLEANER SW
2
rp
TRAVEL ALARM SW
1
M
POWER MAX SW
CN-51
3
-
+
6
WORKING PS
5A
20A
SWITCH PANEL FUEL CUT-OFF SPARE
5A
CONVERTOR
5A
CASSETTE RADIO
10A
10A
CLUSTER
CPU
20A
10A
WIPER
AC& HEATER
5A
AC& HEATER
5A
5A
ROOM LAMP
CPU
20A
START KEY
CN-46
27
12
11
10
9
8
7
6
5
4
3
2
1
CONTROLLER CIRCUIT(up to #1000)
FUSE BOX
2
4 3
7 6 W
8 OR
10 9
11
12
CN-1
2 1
5 4 3
7 6
10 L
W Y
W
12 B
TACHO SENSOR B
CN-9
2 1
3
OR
CN-47
RESISTOR
1
2
CS-7 6
4
3 3
2 1
6
4 5
4 5
3
1 2
2
B
PROLIX SW
3
W
ACCEL ACTUATOR OR
CPU CONTROLLER
21074EL11
MONITORING CIRCUIT(up to #1000)
21074EL13
4 - 21
WORK PS HYD TEMP
CPU CONTROLLER
4-22 7 8
BATTERY 24V(+) PUMP EPPR(-)
11 12 13 14 15 16 17
ANTI-RESTART RY ACCEL ACT(+) TRAVEL SPEED SOL T/M OIL LAMP BRAKE FAIL LAMP TRAVEL BUZZER PRE-HEAT SW
GY
OR
4
6 BR
V
CD-6 G
B 2
1
W
G
TRAVEL BOOM PRIORITY1 POWER MAX
R
4 3
BR
8 B
1
CS-20 EARTH 1 V
2
CN-14 R
V
CN-137
G
V R
R
G R
GND
L
6 1
SIG
1
R
1
2
B 2
G
CN-88
V
V
W
R
Y 3
2
G
B 4
3
1
W
B
2
CN-4 5 V
CN-133
1 B
R
Y
G 6
1
V
2
R
CN-70
R
L
36
4
35
2
34
CN-91
PUMP EPPR(+)
B
B
33
1
NC
5
2
RS232 (GND)
B
32
L
G
31
Y
RS232 (-)
L
30
3
Y
RS232 (+)
CN-13
29
4
B
GND
OR
28
CN-6 1
SERIAL-RX
B
27
SWITCH PANEL 2
SERIAL-TX
8
GND (MAIN)
7 B
NC
Y
24
GY
26
6
NC
12
23
GY
25
B
POWER IG
OR
NC
G
B
22
21
G
NC
20 ENG OIL FILTER SW
G
W
V
11
ACCEL ACT(-)
19
PARKING SW OVERLOAD SIG
18
10
NC
W
6
9
5
ENG PREHEATER
NC
PUMP3 PRESS
CO CANCEL SOL
V
4
B
HOUR-METER
2
L
1
3
CD-44 2 V 5
POWER MAX SOL
6 3
BR
Pa 5 BR
2
B W
MAX FLOW SOL
V B
G
1 3
NC
1 BR 4
1
3 W
BOOM PRIORITY SOL
W B
CN-50
BR 2
V
G B 1
2
36
PUMP1 PRESS R
1
35
R
10A
5A
10A
5A
10A
10A
10A
TRAVEL SOLENOID 1 SAFETY SOL SOLENOID 3 FUEL FILLER P/P SPARE
R R OR
10A
CIGAR LIGHTER ETHER(PRE-HEAT)
8 Y
10A
HORN
B
NC
SIG 2 R
CN-8 GY
CS-27
W
24V W R
GY
GND 3 R
34
G W
33
24V
GY
WATER TEMP SENDOR
9
HYD TEMP SENDOR
CD-43 CN-16
B
CD-42
32
OR 7
31
G
30
GY
PUMP PROLIX SW
ONE TOUCH DECEL 3
29
GY
GND (SENSOR)
B
NC
CS-19
28
B
27
POWER MAX 1
ACCEL SW
2
T/M OIL PS
Y
BRAKE FAIL PS
Y
24
2
26
B
TACHO SENSOR(+)
B
23
BOOM DAMPING SW
25
2
TACHO SENSOR(-)
3 L
22
R 1 B 11
FUEL LEVEL SENSOR
W B
21
GND 2 5 6
ACCEL DIAL SIG
6 GY
20
SIG 3 7 B
POT-SIG
4-19 ELECTRIC CIRCUIT FOR HYDRAURIC
NC
GND R 6 G
19
GY
5V (POT&DIAL)
SIG 8
10
GND (POT&DIAL)
CS-52
18
9
10
17
OR
TRAVEL Hi/Lo SW
G
16
L/W
BKT&ARM IN PS
G 1
HEAVY LIFT SW
3 2
AIR CLEANER SW
Y
GY
OR
15
B
WATER LEVEL SW
4
R
L/W
14
G 17
O/T DECEL SW
24V CABIN LIGHT 24V
V
C 16
10
13
A
15
CABIN LIGHT 24V B
G
TRAVEL OIL PS
SAFETY SW INT. SIG B
G
BR
C
14
12
CS-4 13
P3 PRESS SIG.
2 12
W
1 WASHER SIG
GND
TRAVEL ALARM
11
1 8
10
CS-29 5
6
7
11
P2 PRESS SIG.
7 9
10
WORK LIGHT 24V
P1 PRESS SIG.
1 HEAD LIHGT 24V
WORK LIGHT 24V
B
2 5
9
8 4
8
ALT LEVEL
9 7
R
6 CABIN LIGHT OUT
8
7 POWER 24V
CABIN LIGHT OUT
7
8 2
GND(PRES.SENSOR)
OR 1
5
6
24V(PRES.SENSOR)
10 4
PRE-HEAT
L
B
WIPER MOTOR DRIVE
6
1 Y
5
CN-116
BOOM UP PS
BREAKER SW
NC
1
GY
G
1
4
2 3
4
ENG OIL PS
CS-50
5
Y
5 Y
OR
3
4
BREAKER
TRAVEL ALARM SW
2
Y
5 WORK LIGHT OUT
2
2
3
4
1
7 B
CN-51
6 2
1
GY
POWER MAX SW
8 1
WORK LIGHT OUT
GY
WORKING PS
9 OR
GY
GY
10 HEAD LIGHT OUT
B
5
CS-26
2
6
2
1
7
1
CD-1
1 5
OR
C
7
5
2PCS BOOM AUTO-IDLE PS
1 8
Y
9
Y
2 6
1
9 10
2
2
2
8
CN-15
3
CN-15
2 10
7
1
6
CD-37
1 5
Pa
7
Y
9 6
B
8
1
2
10
2
CS-67 10
CD-7
I
QUICK COUPLING SW
9
Pa
OVERLOAD SW
27
26
25
24
23
22
21
20
20
ELECTRIC CIRCUIT FOR HYDRAULIC(up to #1000) FUSE BOX
3
CN-66 1
2
10
9
BREAKER SOL.
11
CN-7
12
3
9
Y
DO-4 1 2
CN-140
1
2
QUICK COUPLING
L
CD-31
1
Pa
7
GY
OVERLOAD PS
8
10 9
12 L
CD-33 BOOM DOWN PRESS R 24V
CD-32 BOOM UP PRESS R 24V
2 SIG
GND
5
CN-131 BOOM DOWN EPPR
1
R
CN-68
1
2
A
B
G
SAFETY SOL
SAFETY SW
CN-2
R
B
W
Y
CN-81
R 1
TRAVEL BZ
2
PUMP2 PRESS
R
TRAVEL PS
MAX FLOW
21074EL12
1. POWER CIRCUIT (#1001 and up, TIER II) The negative terminal of battery is grounded to the machine chassis through master switch. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. 1) OPERATING FLOW Battery Battery relay Fusible link¡†CN-60¡‡ Fuse box¡†No.1¡‡ l/conn¡†CN-8(12)¡‡ Start switch¡†CS-2(1)¡‡ Power relay¡†CR-35(30)] Fuse box¡†No.2¡‡ I/conn¡†CN-10(6)¡‡ Room lamp¡†CL-1(2)¡‡ Door switch¡†CS-1¡‡ Cassette radio¡†CN-27(11)¡‡ Fuse box¡†No.3¡‡ l/conn¡†CN-11(4)¡‡ AC & Heater controller¡†CN -116(3, 4)¡‡ Fuse box¡†No.4¡‡ I/conn¡†CN - 5(4)¡‡ I/conn¡†CN -17(5)¡‡ Wiper motor controller ¡†CN-141(7)¡‡ Wiper motor¡†CN-21(4)¡‡ Fuse box¡†No.5¡‡ CPU controller¡†CN-50(7)¡‡ Fuse box¡†No.6¡‡ I/conn¡†CN-11(5)¡‡ Relay(Hi, M2) ¡ I/conn : Intermediate connector 2) CHECK POINT Engine
OFF
Start switch
OFF
Check point
Voltage
¤ - GND (Battery 1EA)
10~12.5V
¤Ł- GND (Battery 2EA)
20~25V
¤Ø- GND (Battery 2EA)
20~25V
¤Œ - GND (Fusible link)
20~25V
¡ GND : Ground
4 - 54
POWER CIRCUIT (#1001 and up, TIER II)
21074EL51
4 - 55
2. STARTING CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW Battery(+) terminal Battery relay ¡†CR-1¡‡ Reset button¡†CS-61¡‡ I/conn¡†CN-8(12)¡‡ Start switch¡†CS-2(1)¡‡
Fuse box¡†No.1¡‡
(1) When start key switch is in ON position Start switch ON¡†CS-2(2)¡‡ I/conn¡†CN-8(11)¡‡ Battery relay¡†CR-1¡‡ Battery relay operating (All power is supplied with the electric component) Start switch ON¡†CS-2(3)¡‡ I/conn¡†CN-8(10)¡‡ Power relay¡†CR-35(86) ¡ (87)¡‡ Fuse box¡†No.12¡‡ l/conn¡†CN-2(5)¡‡ Fuel cut-off¡†CN-79(1)¡‡ (2) When start key switch is in START position Start switch START¡†CS-2(5)¡‡ I/conn¡†CN-8(9)¡‡ l/conn¡†CN-3(2)¡‡ Start relay¡†CR-23¡‡ l/conn¡†CN-2(4)¡‡ Fuel cut off¡†CN-79(2)¡‡
Safety relay¡†CR-5(86) ¡ (30)¡‡
2) CHECK POINT Engine
Start switch
Check point
Voltage
¤ - GND(Battery) ¤Ł- GND(Start key)
OPERATING
START
¤Ø- GND(Battery relay M4) ¤Œ- GND(Starter B+) ¤º- GND(Starter M) ¤ - GND(Start relay) ¤ - GND(Battery relay M8)
¡ GND : Ground
4 - 56
20~25V
STARTING CIRCUIT (#1001 and up, TIER II)
21074EL52
4 - 57
3. CHARGING CIRCUIT (#1001 and up, TIER II) When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the battery relay (CR-1). The current also flows from alternator to each electrical component and controller through the fuse box. 1) OPERATING FLOW (1) Warning flow Alternator "I" terminal I/conn¡†CN-3(3)¡‡ CPU alternator level¡†CN-51(9)¡‡ Cluster charging warning lamp(Via serial interface) (2) Charging flow Alternator "B+" terminal
Battery relay(M8)
Battery(+) terminal Reset button¡†CN-60¡‡
Fuse box
2) CHECK POINT Engine
Start switch
Check point
Voltage
¤ - GND(Battery voltage)
Run
ON
¤Ł- GND(Battery relay) ¤Ø- GND(Alternator B+ terminal) ¤Œ- GND(Alternator I terminal) ¤º- GND(CPU)
¡ GND : Ground
4 - 58
20~30V
CHARGING CIRCUIT (#1001 and up, TIER II)
21074EL53
4 - 59
4. HEAD AND WORK LIGHT CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW Fuse box (No.14) I/conn¡†CN-7(7)¡‡ Fuse box (No.15) I/conn¡†CN-7(8)¡‡
Switch panel¡†CN-116(9)¡‡ Switch panel¡†CN-116(10,11)¡‡
(1) Head light switch ON Head light switch ON¡†CN-116(1)¡‡ l/conn¡†CN-7(1)] Head light ON¡†CL-4(2)¡‡: Head lamp ON l/conn¡†CN-10(2)¡‡ Cassette radio illumination ON¡†CN-27(7)¡‡ l/conn¡†CN-11(8)¡‡ AC & Heater controller illumination ON l/conn¡†CN-6(8)¡‡ Cigar light¡†CL-2¡‡ (2) Work light switch ON Work light switch ON¡†CN-116(2,3)¡‡ l/conn¡†CN-7(2)¡‡ Work light ON¡†CL-5(2), CL-6(2)¡‡
l/conn¡†CN-12(1)¡‡
2) CHECK POINT Engine
Start switch
Check point
Voltage
¤ - GND(Fuse box) STOP
ON
¤Ł- GND(Switch power input) ¤Ø- GND(Switch power output)
20~25V
¤Œ- GND(Head light) ¤º- GND(Fuse box) ¤ - GND(Switch power input) STOP
ON
¤ -GND(Switch power output) ¤ - GND(Work light)
¡ GND : Ground
4 - 60
20~25V
HEAD AND WORK LIGHT CIRCUIT (#1001 and up, TIER II)
21074EL54
4 - 61
5. BEACON LAMP AND CAB LIGHT CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW Fuse box (No.17) I/conn¡†CN-8(3)¡‡ Beacon lamp switch¡†CN-23(6)¡‡ Fuse box (No.16) I/conn¡†CN-7(12)¡‡ Switch panel¡†CN-116(16, 17)¡‡ (1) Beacon lamp switch ON Beacon lamp switch ON¡†CS-23(2)¡‡
Switch lndicator lamp ON¡†CS-23(9)¡‡ l/conn¡†CN-8(4)¡‡ l/conn¡†CN-10(10)¡‡ Beacon lamp ON¡†CL-7¡‡
(2) Cab light switch ON Cab light switch ON¡†CN-116(7, 8)¡‡ I/conn¡†CN-7(6)¡‡ Cab light ON¡†CL-8(2), CL-9(2)¡‡
I/conn¡†CN-10(11)¡‡
2) CHECK POINT Engine
Start switch
Check point
Voltage
¤ - GND(Fuse box) ¤Ł- GND(Switch power input) STOP
ON
¤Ø- GND(Switch power output)
20~25V
¤Œ- GND(Beacon lamp) ¤º- GND(Fuse box) ¤ - GND(Switch power input) STOP
ON
¤ - GND(Switch power output) ¤ - GND(Cab light)
¡ GND : Ground
4 - 62
20~25V
BEACON LAMP AND CAB LIGHT CIRCUIT (#1001 and up, TIER II)
21074EL55
4 - 63
6. WIPER AND WASHER CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW (1) Key switch ON Fuse box (No.11) Fuse box (No.4) Fuse box (No.13)
I/conn¡†CN-7(5)¡‡ Switch panel¡†CN-116(6)¡‡ I/conn¡†CN-5(4)¡‡ I/conn¡†CN-17(5)¡‡ Wiper motor controller¡†CN-141(7)¡‡ Wiper motor¡†CN-21(4)¡‡ I/conn¡†CN-6(5)¡‡ l/conn¡†CN-17(4)¡‡ Wiper motor controller¡†CN-141(6)¡‡ Washer pump¡†CN-22(2)¡‡
(2) Wiper switch ON : 1st step(Intermittent) Wiper switch ON¡†CN-116(15)¡‡ I/conn ¡†CN-9(4)¡‡ I/conn ¡†CN-6(10)¡‡ I/conn ¡†CN-17(8)¡‡ Wiper motor controller¡†CN-141(10) ¡ (3)¡‡ Wiper motor intermittently operating¡†CN-21(6)¡‡ (3) Wiper switch ON : 2nd step(Low speed) Wiper switch ON¡†CN-116(4)¡‡ I/conn¡†CN-7(3)¡‡ I/conn¡†CN-6(9)¡‡ I/conn ¡†CN-17(2)¡‡ Wiper motor controller¡†CN-141(2) ¡ (4)¡‡ Wiper motor operating¡†CN-21(2)¡‡ (4) Washer switch ON Washer switch ON¡†CN-116(12)¡‡ I/conn¡†CN-7(9)¡‡ I/conn¡†CN-5(1)¡‡ I/conn¡†CN-17(7)¡‡ Wiper motor controller¡†CN-141(9) ¡ (8)¡‡ I/conn¡†CN-17(6)¡‡ I/conn¡†CN-6(11)¡‡ Washer pump¡†CN-22(1)¡‡ Washer operating Fuse box(No.13) I/conn¡†CN-6(5)¡‡ I/conn¡†CN-17(4)¡‡ Wiper motor controller¡†CN-141(6) ¡ (4)¡‡ Wiper motor operating¡†CN-21(2), Low speed¡‡ (5) Auto parking(When switch OFF) Switch OFF¡†CN-116(15)¡‡ Wiper motor parking position by wiper motor controller
2) CHECK POINT Engine
Start switch
Check point ¤ - GND(Fuse box) ¤Ł- GND(Switch power input)
Voltage 24V
¤Ø- GND(Switch power output) STOP
ON
¤Œ- GND(Wiper Power input) ¤º- GND(Wiper power output) ¤ - GND(Wiper motor)
¡ GND : Ground
4 - 64
0 ~ 5V
0 or 24V
WIPER AND WASHER CIRCUIT (#1001 and up, TIER II)
21074EL56
4 - 65
CONTROLLER CIRCUIT (#1001 and up, TIER II)
21074EL57
4 - 66
MONTORING CIRCUIT (#1001 and up, TIER II)
21074EL58
4 - 67
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name
Symbol
Specification
12V × 100Ah (2EA)
Battery
Check
※ Check specific gravity 1.280 over : Over charged 1.280 ~ 1.250 : Normal 1.250 below : Recharging
※ Check coil resistance (M4 to M4) Rated load : 24V Normal : About 50Ω 100A(continuity) 1000A(30seconds) ※ Check contact Normal : ∞Ω
Battery relay
CR-1
Reset button
24V 60A
※ Check disconnection Normal : About 0Ω Check button is up.
B-BR : 24V 1A B-ACC : 24V 10A B-ST : 24V 40A
※Check contact OFF : ∞Ω(For each terminal) ON : 0Ω(For terminal 1-3 and 1-2) START : 0Ω(For terminal 1-5)
3 ~ 6kgf/cm2 (N.O TYPE)
※ Check contact Normal : ∞(OPEN)
CS-60 CS-61
1 2 3 4 5 6 1
B
Start key
4
2 3
5 6 C ST
Ι ,O
ΙΙ Ι O H
ACC BR H
CS-2
Pressure switch (For overload)
2
Pa
1
CD-31
4 - 23
Part name
Symbol
Pressure switch (For engine oil)
Pa
Specification
0.5 kgf/cm2 (N.C TYPE)
Check
※ Check resistance Normal : 0Ω(CLOSE)
CD-18
1
C Temperature sensor
-
2
CD-8 CD-1
Pressure: ※ Check contact 635mmH2O Normal : ∞Ω (N.O TYPE)
Pa
Air cleaner pressure switch
※ Check resistance 50°C : 804Ω 80°C : 310Ω 100°C : 180Ω
CD-10
2
Coolant level sensor
24V 0.5A
1
※ Check contact High level : ∞Ω Low level : 0Ω
CD-16
-
※ Check resistance Full : 50Ω 6/12 : 350 11/12 : 100Ω 5/12 : 400Ω 10/12 : 150Ω 4/12 : 450Ω 9/12 : 200Ω 3/12 : 500Ω 8/12 : 250Ω 2/12 : 550Ω 7/12 : 300Ω 1/12 : 600Ω Empty warning :700Ω
-
※ Check resistance Normal : 300Ω(For terminal 1,2)
2 Fuel sender
1 CD-2
Tacho sensor
rp
1
m
CD-2
2 CD-17 CD-17
4 - 24
Part name
Symbol
3
Specification
4
4
24V 20A
※ Check resistance Normal : About 200Ω (For terminal 1-3) : 0Ω(For terminal 2-4)
24V 16A0
※ Check resistance Normal : About 160Ω (For terminal 85-86) : 0Ω(For terminal 30-87a) : ∞Ω(For terminal 30-87)
3 2
Heater relay 1
1
2
Check
CR-46
30 87a
86
Relay (Horn, Safety, Ac comp, Power, Preheat)
85
30
86
87 85 87a
CR-2 CR-35 CR-5 CR-36 CR-7
6
Accel actuator
87
5
M 2
M-
6
M+
5
NC
4
P-
3
SIG
2
P+
1
1
3
-
※ Check resistance Normal : 1-2Ω(For terminal 5-6) 0.8-1.2kΩ (For terminal 1-3)
CN-76
Solenoid valve
24V 1A
※ Check resistance Normal : 15~25Ω (For terminal 1-2)
700mA
※ Check resistance Normal : 18~25Ω (For terminal 1-2)
50Ω 20W± 5%
※ Check resistance Normal : 50Ω
CN-66 CN-68 CN-70 CN-88 CN-133 CN-137
2
EPPR valve 1
CN-75 CN-131
1
Resistor 2
CN-47
4 - 25
Part name
Symbol
Specification
Speaker
Check
4Ω 20W
※Check resistance Normal : 4Ω
24V 8A
※ Check contact Normal ON - 0Ω(For terminal 1-5,2-6) - ∞Ω(For terminal 5-7,6-8) OFF - ∞Ω(For terminal 1-5,2-6) - 0Ω(For terminal 5-7,6-8)
24V 8A
※ Check contact Normal ON - 0Ω(For terminal 1-5,2-6) - ∞Ω(For terminal 5-7,6-8) OFF - ∞Ω(For terminal 1-5,2-6) - 0Ω(For terminal 5-7,6-8)
24V 70W (H3 TYPE)
※ Check disconnection Normal : 1.2Ω
24V 10W
※ Check disconnection Nomal : A few Ω
24V 10A 35 ℓ/min
※ Check resistance Normal : 1.0Ω
CN-23(LH) CN-24(RH) 10 9
8
7
10
6
5
6
4
3
2
1
5
Switch (Locking type) 9
8
2
7
1
9
8
2
7
1
CS-23 CS-27 CS-50 CS-52 CS-54
10
9
10
6 8
7
6
5
3
4
2
1
Switch (Quick clamp)
5
I
CS-67
2
Head lamp, Work lamp, Cab lamp
1
CL-4 CL-5 CL-6 CL-8 CL-9
Room lamp CL-1
Fuel filler pump
1 2
M
CN-61
4 - 26
Part name
Symbol
Specification
16V ~ 32V
※ Check operation ・Supply powe(24V) to terminal No. 2 and connect terminal No. 1 and ground.
DC 22.0 ~ 28.0V 2A
※ Check operation ・Supply powe(24V) to each terminal and connect ground.
24V 15A (N.C TYPE)
※ Check contact Normal : 0Ω(For terminal 1-2) : ∞Ω(For terminal 1-3) Operating : ∞Ω(For terminal 1-2) : 0Ω(For terminal 1-3)
24V (N.C TYPE)
※ Check contact Normal : 0Ω(one pin to ground)
24V
※ Check resistance Normal : 15~25Ω
10bar (N.C type)
※ Check contact Normal : 0.1Ω
1
h
Hour meter
2
CN-48
Horn CN-20
Check
CN-25
Safety switch 1
CS-4
Safety switch 2 Wiper cut sw CS-20 CS-53
Fuel cut-off
E
3
S
2
I
1
CN-79
Pressure switch (Travel, Work, 2pcs boom auto idle)
Pa
2 1
CD-6 CD-7 CD-37
4 - 27
Part name
Symbol
Specification
Beacon lamp
Check
24V 70W
※ Check disconnection Normal : 1.1Ω
24V 6A
※Check contact Normal : ∞Ω
24V 3.8A
※Check contact Normal : 10.7Ω(For terminal 1-2)
24V 5A 1.4W
※Check coil resistance Normal : About 1MΩ ※ Check contact Normal : ∞Ω Operating time : 5~15sec
24V 2W
※Check resistance Normal : About 5MΩ
24V 2A
※Check contact Normal : 7Ω(For terminal 2-6)
CL-7
Switch (Power max, One touch decel, Breaker, Horn)
1 2 CS-5 CS-19 CS-26 CS-26A CS-29
Washer tank
CN-22
Cigar lighter
CL-2
Door switch CS-1
3
1 2
5 4
Wiper motor
3 4 5
6
M
2
6
CN-21
4 - 28
Part name
Symbol N.C
Cassette radio
Check
1
S.R-
2
S.R-
3
S.L-
Specification
4
S.L-
5
N.C
6
ILL+
7
S.R+
8
S.R+
9
ACC
10
B+
11
S.L+
12
S.L+
13
GND
14
24V 2A
※ Check voltage 20 ~ 25V (For terminal 10-14,11-14)
24V 2.5A
※ Check contact Normal : 0Ω
24V 300A
※ Check contact Normal : 0.94Ω(For terminal 1-2)
Delco Remy 28MT 24V
※ Check contact Normal : 0.1Ω
24V 60A
※ Check contact Normal : 0Ω(For terminal B⁺-1) Normal : 24 ~ 27.5V
24V 0.5A
※ Check contact Normal : 5.2Ω
CN-27
Receiver dryer
CN-29
Start relay
CR-23
B+
M
Starter M
CN-45
B+
Alternator
G 3~
Ι GND
U
CN-74
Travel alarm buzzer
1 2 CN-81
4 - 29
Part name
Symbol
Specification
Check
1
Aircon compressor
24V 79W
※ Check contact Normal : 13.4Ω
24V ~ 150V 15A
※ Check contact Normal : 0.2Ω(For terminal 1-20) Emergency : 1.2Ω(For terminal 2-3) : 5.2Ω(For terminal 2-6 : 0Ω(For terminal 5-6)
CN-28
Prolix switch (up to #0179) CS-7
Accel dial
Transducer
A + B S C CN-142
-
3
24V
2
SIG
1
GND
※ Check resistance Normal : About 5kΩ (For terminal A-C) ※ Check valtage Normal : About 5V (For terminal A-C) : 2 ~ 4.5V (For terminal C-B)
500 bar
0bar : 1V(For terminal 1-2) 500bar : 5V(For terminal 1-2)
50 bar
0bar : 1V(For terminal 1-2) 50bar : 5V(For terminal 1-2)
CD-32 CD-33 CD-42 CD-43
Transducer
3
24V
2
SIG
1
GND
CD-44
DC/DC Converter
A
24V
B
GND
C
12V
24V 12V
12V 3A
CN-138
4 - 30
24V(A-B) 12V(B-C)
Part name
Symbol
M
1 Blower motor
Aircon resistor
Duct sensor (Switch)
Specification
24V 9.5A
2
1
Lo
1
2
MH
3
3
ML
2
4
Hi
4
1
-
1° C OFF 4° C ON
2
Preheater relay
Check
※ Check resistance 2.5Ω(For terminal 1-2)
※ Check resistance 1.12Ω(For terminal 4-2) 2.07Ω(For terminal 2-3) 3.17Ω(For terminal 3-1)
※ Check resistance : 0Ω(For terminal 1-2, the atmosphere temp : over 4° C)
24V 200A
※ Check contact Normal : 0.94Ω (For terminal 1-GND)
24V 200A
※ check resistance : 0.25 ~ 0.12Ω
24V 6A
※Check contact Normal : 28.9MΩ(For terminal 1-2)
CR-24
Preheater
Quick clamp CN-140
4 - 31
Part name
Symbol
Fusible link
Specification
60A CN-60 CN-95
4 - 32
Check
※Check disconnection Normal : 0Ω (Connect ring terminal and check resist between terminal 1 and 2)
GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION Connector number
Type
No. of
Destination
pin
Connector part No. Female
Male
CN-1
DEUTSCH
12
Engine rear harness
DT06-12S
DT04-12P
CN-2
DEUTSCH
6
Engine rear harness
DT06-6S
DT04-6P
CN-3
DEUTSCH
8
Engine harness
DT06-8S
DT04-8P
CN-4
DEUTSCH
8
Cabin LH wire harness
DT06-8SB
DT04-8PB
CN-5
DEUTSCH
12
RH side harness
-
DT04-12P
CN-6
DEUTSCH
12
RH side harness
DT06-12SB
DT04-12PB
CN-7
DEUTSCH
12
Cabin RH wire harness
DT06-12SB
DT04-12PB
CN-8
DEUTSCH
12
Cabin RH wire harness
DT06-12S
DT04-12P
CN-9
DEUTSCH
8
Cabin RH wire harness
DT06-8S
DT04-8P
CN-10
DEUTSCH
12
Frame haness
DT06-12S
DT06-12P
CN-11
DEUTSCH
8
Aircon harness
DT06-8S
DT04-08P
CN-12
DEUTSCH
2
Work lamp harness
DT06-2S
DT04-2P
CN-15
DEUTSCH
2
2pcs auto idle pressure
DT06-2S
DT04-2P
CN-17
DEUTSCH
8
Wiper harness
DT06-8S
DT04-8P
CN-20
MOLEX
2
Horn
35215-0200
-
CN-21
AMP
6
Wiper motor
925276-0
-
CN-22
KET
2
Washer tank
MG640605
-
CN-23
KET
2
LH speaker
MG610070
-
CN-24
KET
2
RH speaker
MG610070
-
CN-25
MOLEX
2
Horn
35215-0200
-
CN-27
AMP
14
Cassette radio
173852
-
CN-28
MWP
1
Air-con compressor
NMWP01F-B
-
CN-29
KET
2
Receiver dryer
HG640795
-
CN-36
DEUTSCH
3
Fuse box
21N8-20191
-
CN-45
RING TERM
-
Start motor B
ST710264-2
-
CN-47
AMP
2
Resistor
S810-002202
S810-102202
CN-48
AMP
2
Hour meter
S810-002202
-
CN-50
AMP
36
CPU controller
3441110
-
CN-51
AMP
36
CPU controller
3441110
-
CN-56
DEUTSCH
4
Cluster
-
DT04-4P
CN-60
YAZAKI
2
Fusible link
7123-412S-50
7122-412S-50
CN-61
DEUTSCH
2
Fuel filler pump
DT06-2S
-
CN-66
DEUTSCH
2
Breaker solenoid
DT06-2S
DT04-2P
CN-68
DEUTSCH
2
Safety solenoid
DT06-2S
DT04-2P
CN-70
DEUTSCH
2
Travel speed solenoid
DT06-2S
-
CN-74
RING-TERM
1
Alternator “1” term
S820-408000
-
CN-75
Econoseal J
2
EPPR valve
S816-002002
-
CN-76
DEUTSCH
6
DC motor
DT06-6S
-
+
4 - 33
Connector number
Type
No. of
Destination
pin
CN-79
-
3
Fuel cut-off
CN-81
DEUTSCH
2
CN-88
DEUTSCH
CN-92
Connector part No. Female
Male
S818-020311
-
Travel alarm buzzer
DT06-2S
DT04-2P
2
Power max solenoid valve
DT06-2S
-
AMP
1
Safety
S814-101100
S814-001100
CN-95
KET
2
Fusible link
S813-030201
S813-130200
CN-116
PA
17
Switch panel
S811-017002
-
CN-126
DEUTSCH
4
RS232 connector
DT06-4S
DT04-4P-E004
CN-133
DEUTSCH
2
Boom priority solenoid valve
DT06-2S
-
CN-137
DEUTSCH
2
Max flow solenoid valve
DT06-2S
-
CN-138
DEUTSCH
3
DC/DC converter
DT06-3S
DT04-3P
CN-139
DEUTSCH
2
12V Socket
DT06-2S
DT04-2P
CN-141
AMP
13
Wiper motor control unit
172498-1
-
CN-142
DEUTSCH
3
Accel dial
DT06-3S
-
CN-143
KET
14
Cassette radio(with remocon)
MG610406
-
CN-144
AMP
12
Remocon-cassette radio
174045-2
-
CR-1
RING TERM
1
Battery relay
S820-104002
-
CR-2
-
5
Horn relay
-
-
CR-5
-
5
Safety relay
-
-
CR-7
-
5
Ac comp relay
-
-
CR-23
KET
2
Start relay
S814-002001
S814-102001
CR-24
RING TERM
1
Pre-heater relay
S820-106000
-
CR-35
-
5
Power relay
-
-
CR-36
-
5
Pre-heat relay
-
-
CS-1
SHUR
1
Door switch
S822-014004
-
CS-2
-
6
Start key switch
S814-006000
S814-106000
CS-4
DEUTSCH
3
Safety switch
DT06-3S
DT04-3P
CS-5
DEUTSCH
2
Horn switch
DT06-2S
DT04-2P
CS-7
DEUTSCH
6
Prolix switch
DT06-6S
-
CS-19
DEUTSCH
2
One touch decel
DT06-2S
DT04-2P
CS-20
AMP
1
Safety switch
S822-014002
-
CS-23
SWF
10
Beacon lamp switch
SWF593757
-
CS-26
DEUTSCH
2
Breaker switch
DT06-2S
DT04-2P
CS-27
SWF
10
Breaker switch
SWF593757
-
CS-29
DEUTSCH
2
Power max switch
DT06-2S
DT04-2P
CS-50
SWF
10
Overload switch
SWF593757
-
CS-52
SWF
10
Spare switch
SWF593757
-
CS-53
SHUR
1
Wiper cut switch
S822-014002
-
CS-54
SWF
10
Spare switch
SWF593757
-
CS-60
RING-TERM
1
Reset button
S820-205002
-
RELAY
SWITCH
4 - 34
Connector number
Type
No. of
Destination
pin
Connector part No. Female
Male
CS-61
RING-TERM
1
Reset button
S820-305002
-
CS-67
SWF
10
Quick clamp switch
SWF593757
-
CL-1
KET
2
Cabin room lamp
MG610406
-
CL-2
AMP
1
Cigar light
S822-014002
-
CL-4
DEUTSCH
2
Head lamp
DT06-2S
DT04-2P
CL-5
DEUTSCH
2
Work lamp-LH
DT06-2S
DT04-2P
CL-6
DEUTSCH
2
Work lamp-RH
DT06-2S
DT04-2P
CL-7
SHUR
1
Beacon lamp
S822-014004
S822-114004
CL-8
DEUTSCH
2
Cabin ligh-LH
DT06-2S
DT04-2P
CL-9
DEUTSCH
2
Cabin light-RH
DT06-2S
DT04-2P
CD-1
AMP
2
Hydraulic oil temp sender
85202-1
-
CD-2
DEUTSCH
2
Fuel sender
DT06-2S
DT04-2P
CD-6
KET
3
Travel pressure switch
MG640795
-
CD-7
KET
3
Working pressure switch
MG640795
-
CD-8
AMP
2
Water temp sender
85202-1
-
CD-10
RING TERM
1
Air cleaner switch
S820-104002
-
CD-16
KET
2
Water level
S814-002100
S814-102100
CD-17
-
2
Tacho sensor
-
S818-120221
CD-18
RING TERM
1
Engine oil pressure switch
S820-104000
-
CD-31
DEUTSCH
2
Overload pressure switch
DT06-2S
DT04-2P
CD-42
Econoseal J
3
Pump pressure 1
S816-003002
S816-103002
CD-43
Econoseal J
3
Pump pressure 2
S816-003002
S816-103002
CD-44
Econoseal J
3
Pump pressure 3
S816-003002
S816-103002
DO-1
AMP
2
-
21EA-50550
-
DO-2
AMP
2
-
21EA-50550
-
DO-3
AMP
2
-
21EA-50550
-
DO-5
AMP
2
-
21EA-50550
-
LAMP
SENDER
DIODE
4 - 35
2. CONNECTION TABLE FOR CONNECTORS 1) PA TYPE CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
2
5
1
3
1
3
2
5
5
S811-005002
S811-105002
3
7
1
4
1
4
3
7
7
S811-007002
S811-107002
4
9
1
5
1
5
4
9
9
S811-009002
3S811-109002
5
11
1
6
1
6
5
11
11
S811-011002
4 - 36
S811-111002
No. of pin
Receptacle connector(Female)
Plug connector(Male)
6
13
1
1
7
6
7
13
S811-013002 8
17
1
9
13 S811-113002
1
9
8
17
17
S811-017002 10
21
1
11 S811-021002
S811-117002 1
11
10
21 S811-121002
21
4 - 37
2) J TYPE CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
1
2 1
2
12
2
S816-002001
S816-102001 3
2
1
3
3
1
2
S816-003001
S816-103001
3
1
4
2
4
2
3
1
4
S816-004001 6
3 1
8
5 2
S816-104001 8
5 2
6
3 1
8
S816-008001
4 - 38
S816-108001
3) SWP TYPE CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
1
1
1
S814-001000
S814-101000
2
1
1
2
2
S814-002000
S814-102000
3
1
2 1
23
S814-003000
S814-103000
3
2
4
1
3
1
3
2
4
4
S814-004000
4 - 39
S814-104000
No. of pin
Receptacle connector(Female) 3
Plug connector(Male) 6
1
4
3
6
6
1
4
S814-006000 4
S814-106000
8 1
5
8
8 4 S814-108000
5 1 S814-008000 4
12
1
9 S814-012000
1
9
4
12
12
3
14
1
11
S814-112000 1
11
3
14
14
S814-014000
4 - 40
S814-114000
4) CN TYPE CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
1 1
1
S810-001202
S810-101202 2
2
2
1
1 S810-002202
S810-102202 2
3
3
2
1
S810-003202
3
1
S810-103202
2
4
1
4
1
3
2
3
4
S810-004202
4 - 41
S810-104202
No. of pin
Receptacle connector(Female) 3
Plug connector(Male) 1
6
4
6
1
4 S810-006202
3
4
8
1
1
5
4
6 S810-106202 5
8
S810-008202
4 - 42
8 S810-108202
5) 375 FASTEN TYPE CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
2 1
2
2
1
S810-002402
S810-102402
6) AMP ECONOSEAL CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male) 1
12 1
24
13
36 36 13
25
12 24
25 344111-1
36
7) AMP TIMER CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
1 2 2
85202-1
4 - 43
344108-1
8) AMP 040 MULTILOCK CONNECTOR No. of pin
Receptacle connector(Female)
12
1
6
7
12
Plug connector(Male)
174045-2
9) AMP 070 MULTILOCK CONNECTOR No. of pin
14
Receptacle connector(Female)
1
6
7
14
Plug connector(Male)
173852
10) AMP FASTIN - FASTON CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
3
1
6 6 4
4
1
6 925276-0
4 - 44
3 480003-9
11) KET 090 CONNECTOR No. of pin
2
Receptacle connector(Female)
Plug connector(Male)
1
2 MG610070
12) KET 090 WP CONNECTORS No. of pin
Receptacle connector(Female)
Plug connector(Male)
1 2
2 MG640605
2
1
2 MG640795
4 - 45
13) KET SDL CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
1 14 7 14
6 MG610406
4 - 46
14) DEUTSCH DT CONNECTORS No. of pin
Receptacle connector(Female)
Plug connector(Male)
2
1
1
2
2
DT06-2S
2
DT06-2P
2
1
1
3
3
3 DT06-3S
DT06-3P
4
1
1
4
3
2
2
3
4
DT06-4S
DT06-4P
6
1
1
6
4
3
3
4
6
DT06-6S
4 - 47
DT06-6P
No. of pin
Receptacle connector(Female)
Plug connector(Male)
4
5
5
4
1
8
8
1
8
DT06-8S
6
7
1
12
DT06-8P
7
6
12
1
12
DT06-12S
4 - 48
DT06-12P
15) MOLEX 2CKTS CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
2 2
1
35215-0200
16) ITT SWF CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
2 10 1
10
9 SWF593757
17) MWP NMWP CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
1 1
NMWP01F-B
4 - 49
18) ECONOSEAL J TYPE CONNECTORS No. of pin
Receptacle connector(Female)
Plug connector(Male)
1
S816-001002
S816-101002
S816-002002
S816-102002
S816-003002
S816-103002
S816-004002
S816-104002
2
3
4
4 - 50
No. of pin
Receptacle connector(Female)
Plug connector(Male)
6
S816-006002
S816-106002
S816-008002
S816-108002
S816-010002
S816-110002
S816-012002
S816-112002
8
10
12
4 - 51
No. of pin
Receptacle connector(Female)
Plug connector(Male)
15
368301-1
2-85262-1
19) METRI-PACK TYPE CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
2
12040753
20) DEUTSCH HD30 CONNECTOR No. of pin
Receptacle connector(Female)
Plug connector(Male)
23
HD36-24-23SN
4 - 52
HD34-24-23PN
GROUP 5 ELECTRICAL CIRCUIT (#1001 and up, TIER II)
21074EC50
4-53
1. POWER CIRCUIT (#1001 and up, TIER II) The negative terminal of battery is grounded to the machine chassis through master switch. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. 1) OPERATING FLOW Battery Battery relay Fusible link〔CN-60〕 Fuse box〔No.1〕 l/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕 Power relay〔CR-35(30)] Fuse box〔No.2〕 I/conn〔CN-10(6)〕 Room lamp〔CL-1(2)〕 Door switch〔CS-1〕 Cassette radio〔CN-27(11)〕 Fuse box〔No.3〕 l/conn〔CN-11(4)〕 AC & Heater controller〔CN -116(3, 4)〕 Fuse box〔No.4〕 I/conn〔CN - 5(4)〕 I/conn〔CN -17(5)〕 Wiper motor controller 〔CN-141(7)〕 Wiper motor〔CN-21(4)〕 Fuse box〔No.5〕 CPU controller〔CN-50(7)〕 Fuse box〔No.6〕 I/conn〔CN-11(5)〕 Relay(Hi, M2) ※ I/conn : Intermediate connector 2) CHECK POINT Engine
OFF
Start switch
OFF
Check point
Voltage
① - GND (Battery 1EA)
10~12.5V
② - GND (Battery 2EA)
20~25V
③ - GND (Battery 2EA)
20~25V
④ - GND (Fusible link)
20~25V
※ GND : Ground
4 - 54
POWER CIRCUIT (#1001 and up, TIER II)
21074EL51
4 - 55
2. STARTING CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW Battery(+) terminal Battery relay 〔CR-1〕 Reset button〔CS-61〕 I/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕
Fuse box〔No.1〕
(1) When start key switch is in ON position Start switch ON〔CS-2(2)〕 I/conn〔CN-8(11)〕 Battery relay〔CR-1〕 Battery relay operating (All power is supplied with the electric component) Start switch ON〔CS-2(3)〕 I/conn〔CN-8(10)〕 Power relay〔CR-35(86) → (87)〕 Fuse box〔No.12〕 l/conn〔CN-2(5)〕 Fuel cut-off〔CN-79(1)〕 (2) When start key switch is in START position Start switch START〔CS-2(5)〕 I/conn〔CN-8(9)〕 l/conn〔CN-3(2)〕 Start relay〔CR-23〕 l/conn〔CN-2(4)〕 Fuel cut off〔CN-79(2)〕
Safety relay〔CR-5(86) → (30)〕
2) CHECK POINT Engine
Start switch
Check point
Voltage
① - GND(Battery) ② - GND(Start key)
OPERATING
START
③ - GND(Battery relay M4) ④ - GND(Starter B+) ⑤ - GND(Starter M) ⑥ - GND(Start relay) ⑦ - GND(Battery relay M8)
※ GND : Ground
4 - 56
20~25V
STARTING CIRCUIT (#1001 and up, TIER II)
21074EL52
4 - 57
3. CHARGING CIRCUIT (#1001 and up, TIER II) When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the battery relay (CR-1). The current also flows from alternator to each electrical component and controller through the fuse box. 1) OPERATING FLOW (1) Warning flow Alternator "I" terminal I/conn〔CN-3(3)〕 CPU alternator level〔CN-51(9)〕 Cluster charging warning lamp(Via serial interface) (2) Charging flow Alternator "B+" terminal
Battery relay(M8)
Battery(+) terminal Reset button〔CN-60〕
Fuse box
2) CHECK POINT Engine
Start switch
Check point
Voltage
① - GND(Battery voltage)
Run
ON
② - GND(Battery relay) ③ - GND(Alternator B+ terminal) ④ - GND(Alternator I terminal) ⑤ - GND(CPU)
※ GND : Ground
4 - 58
20~30V
CHARGING CIRCUIT (#1001 and up, TIER II)
21074EL53
4 - 59
4. HEAD AND WORK LIGHT CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW Fuse box (No.14) I/conn〔CN-7(7)〕 Fuse box (No.15) I/conn〔CN-7(8)〕
Switch panel〔CN-116(9)〕 Switch panel〔CN-116(10,11)〕
(1) Head light switch ON Head light switch ON〔CN-116(1)〕 l/conn〔CN-7(1)] Head light ON〔CL-4(2)〕: Head lamp ON l/conn〔CN-10(2)〕 Cassette radio illumination ON〔CN-27(7)〕 l/conn〔CN-11(8)〕 AC & Heater controller illumination ON l/conn〔CN-6(8)〕 Cigar light〔CL-2〕 (2) Work light switch ON Work light switch ON〔CN-116(2,3)〕 l/conn〔CN-7(2)〕 Work light ON〔CL-5(2), CL-6(2)〕
l/conn〔CN-12(1)〕
2) CHECK POINT Engine
Start switch
Check point
Voltage
① - GND(Fuse box) STOP
ON
② - GND(Switch power input) ③ - GND(Switch power output)
20~25V
④ - GND(Head light) ⑤ - GND(Fuse box) STOP
ON
⑥ - GND(Switch power input) ⑦- GND(Switch power output) ⑧ - GND(Work light)
※ GND : Ground
4 - 60
20~25V
HEAD AND WORK LIGHT CIRCUIT (#1001 and up, TIER II)
21074EL54
4 - 61
5. BEACON LAMP AND CAB LIGHT CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW Fuse box (No.17) I/conn〔CN-8(3)〕 Fuse box (No.16) I/conn〔CN-7(12)〕 (1) Beacon lamp switch ON Beacon lamp switch ON〔CS-23(2)〕
Beacon lamp switch〔CN-23(6)〕 Switch panel〔CN-116(16, 17)〕 Switch lndicator lamp ON〔CS-23(9)〕 l/conn〔CN-8(4)〕 l/conn〔CN-10(10)〕 Beacon lamp ON〔CL-7〕
(2) Cab light switch ON Cab light switch ON〔CN-116(7, 8)〕 I/conn〔CN-7(6)〕 Cab light ON〔CL-8(2), CL-9(2)〕
I/conn〔CN-10(11)〕
2) CHECK POINT Engine
Start switch
Check point
Voltage
① - GND(Fuse box) STOP
ON
② - GND(Switch power input) ③ - GND(Switch power output)
20~25V
④ - GND(Beacon lamp) ⑤ - GND(Fuse box) STOP
ON
⑥ - GND(Switch power input) ⑦ - GND(Switch power output) ⑧ - GND(Cab light)
※ GND : Ground
4 - 62
20~25V
BEACON LAMP AND CAB LIGHT CIRCUIT (#1001 and up, TIER II)
21074EL55
4 - 63
6. WIPER AND WASHER CIRCUIT (#1001 and up, TIER II) 1) OPERATING FLOW (1) Key switch ON Fuse box (No.11) Fuse box (No.4) Fuse box (No.13)
I/conn〔CN-7(5)〕 Switch panel〔CN-116(6)〕 I/conn〔CN-5(4)〕 I/conn〔CN-17(5)〕 Wiper motor controller〔CN-141(7)〕 Wiper motor〔CN-21(4)〕 I/conn〔CN-6(5)〕 l/conn〔CN-17(4)〕 Wiper motor controller〔CN-141(6)〕 Washer pump〔CN-22(2)〕
(2) Wiper switch ON : 1st step(Intermittent) Wiper switch ON〔CN-116(15)〕 I/conn 〔CN-9(4)〕 I/conn 〔CN-6(10)〕 I/conn 〔CN-17(8)〕 Wiper motor controller〔CN-141(10) → (3)〕 Wiper motor intermittently operating〔CN-21(6)〕 (3) Wiper switch ON : 2nd step(Low speed) Wiper switch ON〔CN-116(4)〕 I/conn〔CN-7(3)〕 I/conn〔CN-6(9)〕 I/conn 〔CN-17(2)〕 Wiper motor controller〔CN-141(2) → (4)〕 Wiper motor operating〔CN-21(2)〕 (4) Washer switch ON Washer switch ON〔CN-116(12)〕 I/conn〔CN-7(9)〕 I/conn〔CN-5(1)〕 I/conn〔CN-17(7)〕 Wiper motor controller〔CN-141(9) → (8)〕 I/conn〔CN-17(6)〕 I/conn〔CN-6(11)〕 Washer pump〔CN-22(1)〕 Washer operating Fuse box(No.13) I/conn〔CN-6(5)〕 I/conn〔CN-17(4)〕 Wiper motor controller〔CN-141(6) → (4)〕 Wiper motor operating〔CN-21(2), Low speed〕 (5) Auto parking(When switch OFF) Switch OFF〔CN-116(15)〕 Wiper motor parking position by wiper motor controller
2) CHECK POINT Engine
Start switch
Check point ① - GND(Fuse box) ② - GND(Switch power input) ③ - GND(Switch power output)
STOP
ON
④ - GND(Wiper Power input) ⑤ - GND(Wiper power output) ⑥ - GND(Wiper motor)
※ GND : Ground
4 - 64
Voltage 24V
0 ~ 5V
0 or 24V
WIPER AND WASHER CIRCUIT (#1001 and up, TIER II)
21074EL56
4 - 65
CONTROLLER CIRCUIT (#1001 and up, TIER II)
21074EL57
4 - 66
MONTORING CIRCUIT (#1001 and up, TIER II)
21074EL58
4 - 67
ELECTRIC CIRCUIT FOR HYDRAULIC(#1001 and up, TIER II)
21074EL59
4-68
7. CONNECTOR DESTINATION Connector number
Type
No. of pin
Destination
CN-1
Econoseal J
6
CN-2
Econoseal J
CN-3
Connector part No. Female
Male
I/conn(Pump ps harness-Frame harness)
S816-006002
S816-106002
12
I/conn(Engine harness 2-Frame harness)
2-85262-1
368301-1
Econoseal J
8
I/conn(Engine harness 1-Frame harness)
S816-008002
S816-108002
CN-4
Econoseal J
8
I/conn(Console harness LH-Frame harness)
S816-008002
S816-108002
CN-5
Econoseal J
15
I/conn(Side harness RH-Frame harness)
2-85262-1
368301-1
CN-6
Econoseal J
12
I/conn(Side harness RH-Frame harness)
S816-012002
S816-112002
CN-7
Econoseal J
15
I/conn(Console harness RH-Frame harness)
2-85262-1
368301-1
CN-8
Econoseal J
12
I/conn(Console harness RH-Frame harness)
S816-012002
S816-112002
CN-9
Econoseal J
8
I/conn(Console harness RH-Frame harness)
S816-008002
S816-108002
CN-10
DEUTSCH
12
I/conn(Cab harness-Frame harness)
DT06-12S
DT04-12P
CN-11
DEUTSCH
8
I/conn(Air-con harness-Frame harness)
DT06-8S
DT04-8P
CN-17
DEUTSCH
8
I/conn (Side harness RH-Wiper motor harness)
DT06-8S
DT04-8P
CN-92
SWP
1
Emergency engine starting connector
S814-001001
S814-101001
CN-95
KET
2
Fusible link
S813-030201
S813-130200
Econoseal J
2
Breaker pedal
S816-002002
S816-102002
・Switch CS-26A
4 - 69
SECTION 5 MECHATRONICS SYSTEM Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9 Group 10 Group 11 Group 12 Group 13 Group 14 Group 15
Outline(up to #1000) Mode Selection System(up to #1000) Automatic Deceleration System Power Boost System Travel Speed Control System Automatic Warming Up Function Engine Overheat Prevention Function Anti-Restart System Self-Diagnostic System Engine Control System EPPR(Electro Proportional Pressure Reducing) Valve Prolix Switch(up to #0179) Monitoring System Outline(#1001 and up, TIER II) Mode selection system(#1001 and up, TIER II)
5-1 5-3 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-15 5-22 5-25 5-26 5-40 5-41
SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE The NEW CAPO(Computer Aided Power Optimization) system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, autodeceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc. It consists for a CPU controller, a cluster, an accel actuator, an EPPR 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, and display error codes on the cluster.
Engine control system Pump control system Work mode selection User mode system(MI, MII)
Mode selection system Auto deceleration system Power boost system
Travel speed control system
Travel speed control system Automatic warming up system
NEW CAPO SYSTEM
Engine overheat prevention system Max flow control system Anti-restart system Self-diagnostic system
Controller & cluster protection Open-short diagnosis & error code display
Machine monitoring system
Machine condition monitoring Electric signal monitoring
One touch deceleration system Boom priority system
5-1
SYSTEM DIAGRAM(up to #1000)
Normal
Emergency
Prolix switch
Resistor
Battery
21075MS01
5-2
GROUP 2 MODE SELECTION SYSTEM(up to #1000) 1. POWER MODE SELECTION SYSTEM
Battery Normal
Emergency
Prolix switch
Battery
Resistor
21075MS02
Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control system) optimizes the engine and pump performance. The combination of 2 power modes(H, S) and accel dial position(10 set) makes it possible to use the engine and pump power more effectively corresponding to the work conditions from a heavy and great power requesting work to a light and precise work.
Mode
Application
Power shift by EPPR valve
Engine rpm
Power set (%)
Unload
Load
Current (mA)
Pressure (kgf/cm2)
Current (mA)
Pressure (kgf/cm2)
Ver 1. X(STD)
Ver 2. X(OPT)
H
High power
100
2250±50
2100
160±30
0
430
18
S
Standard power
85
2150±50
2000
370±30
13
480
22
-
1200±100
-
670±30
31
670±30
31
One touch decel Engine quick deceleration
-
950±100
-
710±30
35
710±30
35
Key switch start position
-
950±100
-
710±30
35
710±30
35
AUTO DECEL
KEY START
Engine deceleration
5-3
2. WORK MODE SELECTION SYSTEM 3 work modes can be selected for the optional work speed of the machine operation. Main control valve
Boom priority valve
Arm 2
Arm 1
Bucket
Boom 2
Boom 1
Swing
Option
Boom priority solenoid valve Power boost solenoid valve Max flow CO solenoid valve
Travel(RH)
Travel(LH) Main relief valve
Engine speed sensor
Engine
Coolant temp sensor
Pilot pump
Main pump Accel actuator
Fuel injection pump
Max flow CO valve
Hyd temp sensor
EPPR valve
Engine speed sensor signal
Motor drive signal
Potentiometer signal
P M
Hyd temperature signal Drive signal
Coolant temperature signal
CPU controller
Drive signal Drive signal Accel dial signal
Accel dial Serial Communication(-)
Drive signal
Serial Communication(+)
Normal
Cluster
Normal
Emergency
Prolix switch
Emergency
Prolix switch
up to #0179
Resistor
Resistor
Battery
Battery
21075MS03
1) HEAVY DUTY WORK MODE The boom priority solenoid is activated to make the boom operation speed faster. 2) GENERAL WORK MODE When key switch is turned ON, this mode is selected and swing operation speed is faster than heavy duty work mode. 3) BREAKER OPERATION MODE It sets the pump flow to the optimal operation of breaker by activating the max flow cut-off solenoid. Work mode
Boom priority solenoid
Max flow cut-off solenoid
Heavy duty
ON
OFF
General
OFF
OFF
Breaker
OFF
ON
5-4
3. USER MODE SELECTION SYSTEM Through 2 memory sets of MI and MII, an operator can change the engine and pump power and memorize it for his preference. Mode
Operation
MI (Memory mode 1)
High idle rpm, auto decel rpm EPPR pressure can be modulated and memorized separately
MII (Memory mode 2)
HOW TO MODULATE THE MEMORY SET 1) Each memory mode has a initial set which are mid-range of max engine speed, auto decel rpm, and EPPR valve input current. When you select MI or MII, cluster LCD displays. 2) To change the engine high idle speed, press the USER mode switch and SELECT switch at the same time and then ACCEL blinks at 0.5 seconds interval. - By pressing or switch, will increase or decrease.
21074OP03G
3) To change DECEL rpm, press the USER mode switch and SELECT switch once more and then DECEL blinks at 0.5 seconds interval. - By pressing or switch, will increase or decrease. 4) To change EPPR current, press the USER mode switch and SELECT switch one more and then EPPR blinks at 0.5 seconds interval. - By pressing or switch, will increase or decrease. ・ LCD segment vs parameter setting Segment ( )
ACCEL (rpm)
1
High idle-900
2
High idle-800
Low idle 950 *1050 1050 *1100
3
High idle-700
1100 *1150
4
High idle-600
DECEL (rpm)
1150
Decel rpm
EPPR (mA) 150 200 250
*1200
300 350
Decel rpm
5
High idle-500
6
High idle-400
1200 *1250 1250 *1300
7
High idle-300
1300 *1350
450
8
High idle-200
1350 *1400
500
9
High idle-100
1400 *1450
550
1500 *1500
600
10 High idle * : TIER II only
400
21074OP03H
5) To memorize the final setting, press the USER mode switch and SELECT switch one more time. 5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
Work equipment pressure switch
Travel oil pressure switch
Accel actuator
Fuel injection pump
Auto decel switch signal
Main control valve
Motor drive signal
Potentiometer signal
P M
CPU controller
Pressure switch signal
Accel dial signal
Accel dial
21075MS04
1. WHEN AUTO DECEL LAMP ON
Engine rpm
If all the work equipment control levers including swing and travel levers are at neutral for at least 4 seconds, CPU controller drives the governor motor to reduce the engine speed to 1200rpm. As the result of reducing the engine speed, fuel consumption and noise are effectively cut down during nonoperation of the control levers. When the Auto decel lamp is turned off by pressing the switch or any control lever is operated, the reduced engine speed rises upto the speed set before deceleration in a second.
Accel dial set rpm
1200 rpm
4sec
Max 1.5sec
Max 1.5sec
Lever neutral
Lever operation
Time 21075MS05
2. WHEN AUTO DECEL LAMP OFF The engine speed can be set as desired using the engine speed switch, and even if the control levers are neutral, the engine speed is not reduced. Note : Auto decel function can be activated when accel dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM Main control valve Arm 1
Arm 2
Boom 2
Bucket Boom 1
Swing
Option
LH travel Boom priority spool
RH travel
Main relief valve
Power boost solenoid valve
Engine speed sensor
Engine
Main pump
Fuel injection pump
Accel actuator
Pilot pump
Max flow CO valve
P M
Engine speed sensor signal
Power boost button
Motor drive signal
LH control lever
Potentiometer signal
EPPR valve
Power boost button signal Drive signal Mode switch signal
CPU controller
Drive signal
21075MS06
・ 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 power boost function is activated, the power boost solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power. Description Power seat Main relief valve set pressure
Power boost switch OFF
ON
H or S
OFF
330kgf/cm2
360kgf/cm2
-
Even when pressed continuously, it is canceled after 8 sec.
Time of operation ※ Default - Power boost solinoid valve : OFF
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM Travel motor
Main control valve Arm 1
Arm 2
Boom 2
Bucket
Swing
Boom 1
LH travel
Service
Regulator
Regulator
RH travel
Travel spped solenoid valve
Engine
Main pump
Pilot pump
Max flow CO valve
EPPR valve
Travel speed switch signal
CPU controller
Drive signal
21075MS07
Travel speed can be switched manually by pressing the travel speed switch on the cluster. Speed
Travel speed solenoid valve
Lamp on cluster
Lo
OFF
Turtle
Low speed, high driving torque in the travel motor
Hi
ON
Rabbit
High speed, low driving torque in the travel motor
Operation
※ Default : Turtle(Lo)
5-8
GROUP 6 AUTOMATIC WARMING UP FUNCTION
Engine
Coolant temp sensor
Main pump Accel actuator
Fuel injection pump
Pilot pump
Max flow CO valve
P M
Motor drive signal
Potentiometer signal
Coolant temperature signal
EPPR valve
Drive signal Warming up lamp signal
CPU controller
21075MS08
1. CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant temperature is less than 30° C, it increases the engine speed from key start rpm to 1200rpm. At this time the mode does not change. 2. In case of the coolant temperature increases up to 30° C,the engine speed is decreased to key start speed. And if an operator changes mode set during the warming up function, the CPU controller cancels the automatic warming up function. 3. LOGIC TABLE Description
Condition
Function
Actuated
- Coolant temperature : Less than 30° C(After engine run) - Accel dial position is under 3
- Mode : Default(S mode) - Warming up time : 10 minutes(Max) - Warming up lamp : ON - Default mode - Default mode - Changed mode
Canceled
- Coolant temperature : Above 30° C - Warming up time : Above 10 minutes - Changed mode set by operator - Increase engine speed by rotating accel dial clockwise ※ If any of the above conditions is applicable, the automatic warming up function is canceled - Coolant temperature : Above 30° C
- Warming up lamp : OFF
Warming up lamp
5-9
GROUP 7 ENGINE OVERHEAT PREVENTION FUNCTION
Engine
Coolant temp sensor
Main pump Accel actuator
Fuel injection pump
Pilot pump
Max flow CO valve
P M
Motor drive signal
Potentiometer signal
Coolant temperature signal
EPPR valve
Drive signal Overheat warming signal
CPU controller
21075MS09
1. CPU controller reads engine coolant temperature through the temperature sensor and when the engine coolant boils up to 110° C, it sends overheat warning signal to the cluster and decrease the engine speed same as accel dial 7 position. 2. If the coolant temperature drops less than 100° C, the CPU controller returns the mode to the mode set before. And if mode set is changed during the function, the CPU controller cancels the function. Even if the overheat prevention function is canceled by mode change, the overheat warning lamp turns OFF only when the coolant temperature is less than 100° C. 3. LOGIC TABLE Description
Condition
Function
Actuated
- Coolant temperature : Above 110° C - Accel dial set : Above 8
- Engine rpm drop to accel dial 7 position - Overheat warning lamp & buzzer : ON - Return to the mode and accel dial set before - Hold on the changed set
Canceled
- Coolant temperature : Less than 100° C - Changed mode set by operator ※ If any of the above conditions is applicable, engine overheat prevention function is canceled
Overheat warning lamp - Coolant temperature : Less than 100° C
5 - 10
- Overheat warning lamp : OFF
GROUP 8 ANTI-RESTART SYSTEM
Engine
Starter
Start safety relay Drive signal
CPU controller CN-92a CN-92b
21075MS10
1. ANTI-RESTART FUNCTION 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 the CPU controller is needed, connect CN-92a and CN-92b to ensure the engine start without the CPU controller.
5 - 11
GROUP 9 SELF-DIAGNOSTIC SYSTEM 1. OUTLINE When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the cluster and also stores them in the memory. The current or recorded error codes are displayed at the error display mode selected by touching SELECT switch 2 times while pressing BUZZER STOP switch.
2. CURRENT ERROR DISPLAY Cluster displays Co : Er and makes buzzer sound itself to warn the communication error when communication problem caused by wire-cut or malfunction of the CPU controller occurs. Cluster displays real time error codes received from CPU controller through communication. In case of no problem it displays CHECK Er : 00. If there are more than 2 error codes, each one can be displayed by pressing and switch respectively. Examples : 1) Communication Error Co : Er & Buzzer sound 2) No problem CHECK Er : 0 0 3) 4 Error codes(03, 06, 10, 43) display CHECK Er : 0 3 Press
0 3 Start
Press
0 6 Press
Press
1 0 Press
4 3
No change Press
Press
3. RECORDED ERROR DISPLAY The recorded error can be displayed only when the key switch is at ON position. Examples : 5 Recorded error codes(03, 06, 10, 20, 32) display 0 3 TIME Er : Press
0 3 Start
Press
0 6 Press
Press
1 0 Press
Press
2 0 Press
3 2 Press
No change Press
4. DELETE ALL RECORDED ERROR CODES Select recorded error(TIME Er) display and press engine and select switch at the same time for 2 seconds or more. Cluster display changes to TIME Er : 00, which shows that CPU controller deleted all the recorded error codes in the memory.
5 - 12
5. ERROR CODES TABLE Fault code No.
Description
1
Short circuit in governor motor system
2
Potentiometer circuit is shorted to Vcc(5V) or battery +
3
Short circuit in pump EPPR valve system
4
Short circuit in boom down EPPR valve system
5
Short circuit in travel speed solenoid system
6
Short circuit in power boost solenoid system
7
Short circuit in max flow solenoid system
10
Short circuit in hour-meter system
11
Accel dial circuit is shorted to Vcc(5V) or battery +
12
P1 pressure sensor circuit is shorted to power supply(24V) line
13
P2 pressure sensor circuit is shorted to power supply(24V) line
14
P3 pressure sensor circuit is shorted to power supply(24) line
15
Boom down pressure circuit is shorted to power supply(24V) line
16
Governor motor circuit is open or shorted to ground
17
Potentiometer circuit is open or shorted to ground
18
Pump EPPR valve circuit is open or shorted to ground
19
Boom down EPPR valve circuit is open or shorted to ground
20
Travel speed solenoid circuit is open or shorted to ground
21
Power boost solenoid circuit is open or shorted to ground
22
Max flow solenoid circuit is open or shorted to ground
25
Hour-meter circuit is open or shorted to ground
26
Accel dial circuit is open or shorted to ground
27
P1 pressure sensor circuit is open or shorted to ground
28
P2 pressure sensor circuit is open or shorted to ground
29
P3 pressure sensor circuit is open or shorted to ground
30
Boom down pressure sensor circuit is open or shorted to ground
31
Engine preheater circuit is open or shorted to ground
32
Travel alarm buzzer circuit is open or shorted to ground
33
Alternator circuit is open or shorted to ground
34
Controller input voltage is below 18V
35
Controller input voltage is over 38V
36
Communication error with cluster
37
Engine speed sensor circuit is open or shorted to ground
38
Anti-restart relay circuit is open or shorted to ground
39
Accel actuator does not stop at a target position
40
There is more than 500rpm difference between target speed and actual speed
5 - 13
Fault code No.
Description
41
Hydraulic oil temperature sensor circuit is shorted to ground
42
Fuel level sensor circuit is shorted to ground
43
Coolant temperature sensor circuit is shorted to ground
44
Boom up pressure sensor circuit is shorted to power supply(24V) line
45
Hydraulic oil temperature sensor circuit is open or shorted to battery +
46
Fuel level sensor circuit is open or shorted to battery +
47
Coolant temperature sensor circuit is open or shorted to battery +
48
Boom up pressure sensor circuit is open or shorted to ground
49
Engine preheater circuit is shorted to battery +
51
Boom priority solenoid circuit is open or shorted to ground
56
Travel alarm buzzer circuit is shorted to battery +
58
Boom priority solenoid circuit is shorted to battery +
5 - 14
GROUP 10 ENGINE CONTROL SYSTEM 1. CPU CONTROLLER MOUNTING
1 2 3
CPU controller Electric box Bolt(M8)
21075MS11A
2. CPU CONTROLLER ASSEMBLY 1) Remove four pieces of bolt(3) of electric box(2). 2) Disconnect 2 connectors from CPU controller. 3) Remove 6 pieces of screw and open the cover of CPU controller. 4) Inspection : Check PCB(Printed Circuit Board) (1) If any damage is found, replace CPU controller assembly. (2) If not, but CAPO system does not work please report it to HHI dealer or A/S department.
5 - 15
3. EXCHANGE METHOD OF THE ROM 1) Disassemble the ash tray(2). 2) Disassemble the wiper motor cover(3). 3) Disassemble the cluster(1).
21075MS12
4) Loosen the screws(6EA) located back of the cluster. 5) Then you can open the upper case of the cluster easily.
21075MS13
6) Install the new ROM.(Be careful of direction and assmelbe the cluster in the reverse order to removal).
21075MS14
5 - 16
4. ENGINE ACCEL ACTUATOR
1 2
Accel actuator Push-pull cable for manual control
21075MS60
1) ENGINE THROTTLE LEVER
Throttle lever
SL : Stopper, low idle SH : Stopper, high idle SL
SH
Accel actuator
(210-7) 5-18(2)
2) EMERGENCY CABLE (Push-pull cable) It controls engine speed by connecting onto the lever of the injection pump when the malfunction of the CPU controller or the accel actuator happen.
5 - 17
3) ACCEL ACTUATOR
3
4
2
1
5
1 2 3 4 5
DC motor Cable Nut Ball joint Connector
(210-7) 5-19(1)
6 5 4
Connector
6P, female
Type
Line color & description
Inspection
1 2 3
1
White(Potentiometer 5V)
2
Blue(Potentiometer SIG)
3
Black(Potentiometer GND)
4
-
5
Green(Motor+)
6
Yellow(Motor -) Check resistance Spec : 1~2Ω(Between No.5-6) 0.8~1.2kΩ(Between No.1-3)
5 - 18
4) ACCEL ACTUATOR CABLE SETTING PROCEDURE (1) Key OFF ① Connect the ball joint of cable to engine throttle lever. ② Pull the cable to high stopper and put nut A edge to yoke of the bracket. ※ Make throttle lever not contact to the edge of high stopper. ③ Turn nut A to clockwise until touching to the edge of high stopper. ④ Make 1 turn more to clockwise in condition of the nut A contact to the edge of high stopper. (2) Key START ⑤ Confirm if the engine speed on cluster is same as each mode specification. ⑥ If the engine speed displayed on cluster is highter than each mode specification, then turn the nut A to counter clockwise and make the engine speed same to each mode specification. ⑦ If the engine speed displayed on cluster is lower than each mode specification, then turn the nut A to clockwise and make the engine speed same to each mode specification. ⑧ Turn nut B to clockwise and fix the cable to bracket.
Nut A
Nut B
Ball joint
Throttle lever
Hi
Lo
Bracket
Cable
130W5MS05
Mode
RPM
H
2250±50
*2150±50
S
2150±50
*2050±50
Auto decel
1200±100
Key start
950±100
*1050±100
* : Tier II Only
5 - 19
5. ENGINE SPEED SENSOR 1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER
3
2
A
2 3 A
Flywheel housing
Gear teeth, flywheel Lock nut, speed sensor Clearance 5-20 (210-7)
2) INSTALLATION (1) Clean contacting point of sensor. (2) Loosen lock nut. (3) Screw speed sensor into flywheel housing. (4) Turn it back 135°when it contacts with gear teeth. (5) Tight lock nut and connect wiring. 3) INSPECTION (1) Check resistance ・SPEC : 300±30 Ω (2) Check voltage while engine run. ・SPEC : 2~28Vac, dependent on the engine speed(rpm)
5 - 20
6. CPU CONTROLLER LED
Y
R
(1) To match the engine torque with the pump absorption torque, CPU controller varies EPPR valve output pressure, which control pump discharge amount whenever feedbacked engine speed drops under the reference rpm of each mode set.
G
(2) Three LED lamps on the CPU controller display as below. MO PA DE RT L:R NO OB :21 EX ER 20 -32 0W 11 -3 0
LED lamp
20W03CD18
Trouble
Service -
G is turned ON
Normal
G and R are turned ON
Trouble on CPU or ROM ・ Change the controller
G and Y are turned ON
Trouble on serial communication line
・ Check if serial communication lines between controller and cluster are disconnected
Three LED are turned OFF
Trouble on CPU controller power
・ Check if the input power wire (24V, GND) of controller is disconnected ・ Check the fuse
G : green,
R : red,
5 - 21
Y : yellow
GROUP 11 EPPR VALVE 1. COMPOSITION OF EPPR VALVE EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main hydraulic pump. 1) ELECTRO MAGNET VALVE Receive electric current from CPU controller and move the spool proportionally according to the specific amount of electric current value. 2) SPOOL VALVE Is the 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 decreases to prevent engine stall. 3) PRESSURE AND ELECTRIC CURRENT VALUE FOR EACH MODE Pressure
Mode
kgf/cm
psi
2
Electric current (mA)
Engine rpm (At accel dial 10)
Standard (Ver : 1.x)
H
0±3
0 ± 40
160 ± 30
2250 ± 50
S
13 ± 3
190 ± 40
370 ± 30
2150 ± 50
Option (Ver : 2.x)
H
18 ± 3
260 ± 40
430 ± 30
2250 ± 50
S
22 ± 3
320 ± 40
480 ± 30
2150 ± 50
Standard (Ver : 5.x)
H
2.5 ± 3
40 ± 40
190 ± 30
2150 ± 50
S
8±3
120 ± 40
290 ± 30
2050 ± 50
Option (Ver : 6.x)
H
4±3
60 ± 40
220 ± 30
2050 ± 50
S
6±3
90 ± 40
260 ± 30
1950 ± 50
19 ± 3
275 ± 40
440 ± 30
-
Tier-I
Tier-II
★
★ Manually operated condition when prolix switch is selected emergency position.
2. HOW TO SWITCH THE VERSION(1.x ↔ 2.x, or 5.x ↔ 6.x) ON THE CLUSTER You can switch the EPPR valve pressure set by selecting the version(1.x ↔ 2.x, or 5.x ↔ 6.x). Step 1. Turn the key switch ON. Step 2. Press the SELECT switch 3 times. Step 3. While 7 segment on the cluster shows the version of the CPU controller program, for example 21C1.4 press the buzzer stop switch( ) + travel speed control switch( ) at the same time for 2 seconds. The display changes to 21C2.4, and it indicates that version 2.4(Option) is selected. ※ If you want to get back to ver:1.x, go to step 1~3.
5 - 22
2. OPERATING PRINCIPLE 1) STRUCTURE 7
6 3
2
4
5
1 5-22(1) (290-7)
1 2 3
4 5
Sleeve Spring Spool
A
P T
P T A
O-ring O-ring
6 7
Solenoid valve Connector
Pilot oil supply line(Pilot pressure) Return to tank Secondary pressure to flow regulator at hydraulic pump
5-22A (290-7)
2) AT H MODE Pressure line is blocked and A oil returns to tank.
P
A
T
P
T A
5-22B (290-7)
3) AT S MODE Secondary pressure enters into A.
P
A
T
P
T A
5-22C (290-7)
5-22(2) (290-7)
5 - 23
3. EPPR VALVE CHECK PROCEDURE
Spec : 200~450mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE (1) Start engine. (2) Set S-mode and cancel auto decel mode. (3) Position the accel dial at 10. CN-75
(4) If tachometer show approx 2150±50rpm, 2050±50rpm(TIER II) disconnect one wire harness from EPPR valve. (5) Install multimeter as figure.
EPPR VALVE Multimeter
(6) Check electric current at bucket circuit relief position.
5-23(1) (290-7)
2) CHECK PRESSURE AT EPPR VALVE
Spec : 2~25kgf/cm2(30~350psi)
(1) Remove plug and connect pressure gauge as figure. ・Gauge capacity : 0 to 40-50kgf/cm2 (0 to 580-725psi) (2) Start engine. Supply line, pilot press
(3) Set S-mode and cancel auto decel mode. (4) Position the accel dial at 10.
CN-75 Pressure adjusting screw locknut
(5) If tachometer show approx 2150±50rpm, 2050±50rpm(TIER II) check pressure at relief position of bucket circuit by operating bucket control lever. (6) If pressure is not correct, adjust it. (7) After adjust, test the machine.
5-23(2) (290-7)
5 - 24
GROUP 12 PROLIX SWITCH (up to # 0179) Is the conversion switch to manual control temporarily when the electronic control system is out of order, until repair work be done. EMERGENCY
Electric box NORMAL 21075MS19
Never place this switch in EMERGENCY position when the CPU is in normal operation. 21075MS18
1. OPERATING PRINCIPLE WIRING DIAGRAM CN-75 2 1
Normal : Emergency :
CN-47
EPPR V/V
2 1
RESISTOR CS-7 6
4
5
5 4
3
6
1
2
2 1
3
T
6 5 4 3 2 1
32
CN-50
CN-51
PROLIX SW
8
24 28
36
CPU CONTROLLER 21075MS17
1) NORMAL POSITION ・EPPR valve supply specified amount of pilot pressure to the flow regulator of hydraulic pump and regulate hydraulic pump delivery amount depending upon the signal of CPU controller by selected mode. 2) EMERGENCY POSITION ・If prolix switch is set at the emergency position when any abnormality occurs in NEW CAPO system, constant electric current from battery 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.
5 - 25
GROUP 13 MONITORING SYSTEM 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine. Various select switches are built into the monitor panel, which act as the control portion of the machine control system.
2. CLUSTER 1) MONITOR PANEL
21075MS65A
5 - 26
2) CLUSTER CHECK PROCEDURE (1) Start key : ON ① Check monitor initial 5 seconds a. All lamps light up. b. Buzzer sound. ② Check monitor after 5 seconds : Indicate cluster version and machine condition Indicates program version 1.4 for 2 seconds. a. Cluster program version : CL : 1.4 b. Tachometer : 0rpm c. Fuel gauge : All light up below appropriate level d. Hydraulic temperature : All light up below appropriate level e. Engine coolant temperature gauge : All light up below appropriate level f. Warning lamp ※ During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not abnormal. C, the warming up lamp lights up. ※ When engine coolant temperature below 30° ③ Indicating lamp state a. b. c. d. e.
Work mode selection : General work Power mode selection : S mode User mode selection : No LED ON Auto decel LED : ON Travel speed pilot lamp : Low(Turttle)
(2) Start of engine ① Check machine condition a. Tachometer indicates at present rpm b. Gauge and warning lamp : Indicate at present condition. ※ When normal condition : All warning lamp OFF c. Work mode selection : General work d. Power mode selection : S mode e. User mode selection : No LED ON f. Auto decel LED : ON g. Travel speed pilot lamp : Low(Turttle) ② When warming up operation a. Warming up lamp : ON b. 10 seconds after engine started, engine speed increases to1200rpm(Auto decel LED : ON) ※ Others same as above ①. ③ When abnormal condition a. The lamp lights up and the buzzer sounds. b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp light up until normal condition.
5 - 27
3. CLUSTER CONNECTOR No.
Signal
Input / Output
1
Power IG(24V)
Input(20~32V)
2
GND
3
Serial-(RX)
Input(Vpp=12V)
4
Serial+(TX)
Output(Vpp=4V)
Cluster
Input(0V)
21075MS16
5 - 28
4. CLUSTER FUNCTION 1) MONITORING DISPLAY (1) This displays the current time and machine information such as engine rpm, coolant/hydraulic oil temperature, hydraulic oil pressure and also error codes. ※ Refer to the page 5-34 for details. 14073CD03
2) FUEL GAUGE (1) This gauge indicates the amount of fuel in the fuel tank.
White range 21073CD04
(2) Fill the fuel when the white range or warning lamp blinks. ※ If the gauge illuminates the white range or warning lamp blinks even though the machine is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.
3) HYDRAULIC OIL TEMPERATURE GAUGE
Red range 21073CD05
(1) This indicates the temperature of coolant. ・White range : Below 30° C(86° F) ・Green range : 30-105 ° C(86-221° F) ・Red range : Above 105° C(221° F) (2) The green range illuminates when operating. (3) Keep idling engine at low speed until the green range illuminates before operation of machine. (4) When the red range illuminates, reduce the load on the system. If the gauge stays in the red range, stop the machine and check the cause of the problem.
4) ENGINE COOLANT TEMPERATURE GAUGE
Red range 21073CD05
(1) This indicates the temperature of coolant. ・White range : Below 30° C(86° F) ・Green range : 30-105 ° C(86-221° F) ・Red range : Above 105° C(221° F) (2) The green range illuminates when operating. (3) Keep idling engine at low speed until the green range illuminates before operation of machine. (4) When the red range illuminates, turn OFF the engine, check the radiator and engine.
5 - 29
5) FUEL LOW LEVEL WARNING LAMP (1) This lamp blinks and the buzzer sounds when the level of fuel is below 31ℓ(8.2U.S. gal). (2) Fill the fuel immediately when the lamp blinks.
21073CD04A
6) HYDRAULIC OIL TEMPERATURE WARNING LAMP (1) This warning lamp operates and the buzzer sounds when the temperature of hydraulic oil is over 105° C(221° F). (2) Check the hydraulic oil level when the lamp blinks. (3) Check for debris between oil cooler and radiator. 21073CD05A
7) OVERHEAT WARNING LAMP (1) This lamp blinks and the buzzer sounds when the temperature of coolant is over the normal temperature 110° C( 230° F) . (2) Check the cooling system when the lamp blinks.
21073CD06A
8) ENGINE OIL PRESSURE WARNING LAMP (1) This lamp blinks and the buzzer sounds after starting the engine because of pressure. (2) If the lamp blinks during engine operation, shut OFF engine immediately. Check oil level. 21073CD07
9) AIR CLEANER WARNING LAMP (1) This lamp is operated by the vacuum caused inside when the filter of air cleaner is clogged which supply air to the engine. (2) Check the filter and clean or replace it when the lamp blinks.
21073CD08
5 - 30
10) COOLANT LEVEL WARNING LAMP (1) This lamp blinks and the buzzer sounds when the coolant is below LOW in the reservoir tank of radiator. (2) Check the reservoir tank when the lamp blinks.
21073CD09
11) CPU CONTROLLER CHECK WARMING LAMP (1) Communication problem with CPU controller makes the lamp blinks and the buzzer sounds. (2) Check if any fuse for CPU burnt off. (3) If not check the communication line between them. 21073CD10
12) BATTERY CHARGING WARNING LAMP (1) This lamp blinks and the buzzer sounds when the starting switch is ON, it is turned OFF after starting the engine. (2) Check the battery charging circuit when this lamp blinks during engine operation. 21073CD13
13) OVERLOAD WARNING LAMP (1) When the machine is overload, the overload warning lamp blinks during the overload switch ON.
21073CD15
14) POWER MAX PILOT LAMP (1) The lamp will be ON when pushing power max switch on the LH RCV lever.
21073CD11
5 - 31
15) DECEL PILOT LAMP (1) Operating auto decel or one touch decel makes the lamp ON. (2) The lamp will be ON when pushing one touch decel switch on the LH RCV lever.
21073CD17
16) WARMING UP PILOT LAMP (1) This lamp is turned ON when the coolant temperature is below 30° C(86 ° F). (2) The automatic warming up is cancelled when the engine coolant temperature is above 30 ° C, or when 10 minutes have passed since starting. 21073CD18
17) PREHEAT PILOT LAMP (1) Turning the start key switch ON position starts preheating in cold weather. (2) Start the engine as this lamp is OFF.
21073CD12
18) WORK MODE SWITCH
21073CD20
(1) This switch is to select the machine operation mode, which shifts from general operation mode to heavy operation mode and breaker mode in a raw by pressing the switch. ・ : Heavy duty work mode ・ : General work mode ・ : Breaker operation mode ※ Refer to the page 5-4 for details.
19) USER MODE SWITCH (1) This switch is to select the memory sets, at which you can change the engine and pump power and memorize it into MI and MII mode for your preference. ※ Refer to the page 5-5 for details. 21073CD21
5 - 32
20) AUTO DECELERATION SWITCH
21073CD22
(1) This switch is used to actuate or cancel the auto deceleration function. When the switch actuated and all control levers and pedals are at neutral position. Engine speed will be lowered automatically to save fuel consumption. ・Light ON : Auto deceleration function is selected. ・Light OFF : Auto deceleration function is cancelled so that the engine speed increased to previous setting value. (2) Operating the auto deceleration function makes the decel indicating lamp on the LCD panel ON.
21) POWER MODE SWITCH (1) The lamp of selected mode is turned ON by pressing the switch( ). ・H : High power work. ・S : Standard power work. 21073CD23
22) TRAVEL SPEED CONTROL SWITCH (1) This switch is to control the travel speed which is changed to high speed(Rabbit mark) by pressing the switch and low speed(Turtle mark) by pressing it again.
21073CD24
23) BUZZER STOP SWITCH (1) When the starting switch is turned ON first, normally the alarm buzzer sounds for 2 seconds during lamp check operation.
21073CD25
(2) The red lamp lights ON and the buzzer sounds when the machine has a problem. In this case, press this switch and buzzer stops, but the red lamp lights until the problem is cleared.
5 - 33
24) SELECT SWITCH (1) This switch is used to select the monitor display function. ※ Refer to the page 5-35 for details.
21073CD25A
(2) If the switch is pressed for 3 seconds in time display mode, it is selected time adjusting function, as below. ・Hour by auto decel( )switch ・Minute by buzzer stop( ) switch. (3) After time set, the switch is pressed, it returns to clock display.
5 - 34
5. MONITORING DISPLAY 1) OUTLINE Information of machine performance as monitored by the CPU controller can be displayed on the cluster when the operator selects a display mode by touching SELECT switch alone or with BUZZER STOP switch on the cluster as below. Display group
Group 0 (Default)
How to select display mode Group selection
Initial
Engine rpm
Way 1 Key switch ON or START
Touch SELECT 1 time
Time
Touch SECLET 2 times
Power shift pressure (EPPR valve)
Way 2 Touch AUTO DECEL switch while pressing BUZZER STOP at group 1~4.
Touch SELECT 3 times
CPU model & version
Touch SELECT 4 times Touch SELECT 5 times Touch SELECT 6 times
Battery voltage(V)
Touch SELECT switch Touch SELECT 1 time once while pressing Touch SELECT 2 times BUZZER STOP. In this group SELECT LED ON Touch SELECT 3 times Touch SELECT 4 times
Group 2 (Error code)
Display on the cluster
Front pump pressure Option (Only when a pressure Rear pump pressure sensor is installed) Pilot pressure
Default Group 1 (Volt, temp, EPPR press, version)
Name
Display mode selection
Touch SELECT switch Default twice while pressing Touch SELECT 1 time BUZZER STOP. In this group BUZZER Press down( ) & STOP LED blinks SELECT at the same time
Potentiometer voltage(V) Accel dial voltage(V) Hydraulic oil temperature(° C) Coolant temperature(° C) Current error Recorded error (Only key switch ON) Recorded error deletion (Only key switch ON)
Default
Pump prolix switch
or
Touch SELECT 1 time
Auto decel pressure switch
or
Power boost switch
or
Travel oil pressure switch
or
One touch decel switch
or
Touch SELECT 5 times
Travel alarm switch
or
Touch SELECT 6 times
Preheat switch
or
Touch SELECT switch Touch SELECT 2 times 3 times while pressing BUZZER STOP. Group 3 Touch SELECT 3 times (Switch input) In this group SELECT LED blinks at 0.5sec Touch SELECT 4 times interval
5 - 35
Display group
How to select display mode Group selection
Touch SELECT switch 4 times while pressing Group 4 (Output)
BUZZER STOP. In this group SELECT
Display mode selection
Name
Display on the cluster
Default
Hourmeter
or
Touch SELECT 1 time
Neutral relay (Anti-restart relay)
or
Touch SELECT 2 times
Travel speed solenoid
or
Touch SELECT 3 times
Power boost solenoid (2-stage relief solenoid)
or
Boom priority solenoid
or
Travel alarm
or
Touch SELECT 6 times
Max flow cut off solenoid
or
Touch SELECT 7 times
Preheat relay
or
LED blinks at 1sec Touch SELECT 4 times interval Touch SELECT 5 times
※By touching SELECT switch once while pressing BUZZER STOP, display group shifts. Example : Group 0 1 2 3 4 0
5 - 36
2) DESCRIPTION OF MONITORING DISPLAY Group
Display
Name
Description
2250 rpm
Engine speed
It displays current engine speed detected by engine speed sensor from 500 to 3000rpm. Range : 500~3000rpm by 10rpm
Time
It displays current time(12 is hour and 30 is minute) Range : Hour(1~12), minute(00~59)
EP : 10bar
Power shift pressure of EPPR valve
It shows that pump power shift pressure of EPPR valve being controlled by the CPU controller is 10bar. Range : 00~50bar by 1bar
21 : C1.4 *21 : C5.0
It shows that machine model(R210LC-7) and the program Model and CPU version of the CPU controller is 1.4. program version Version display range : 0.0~9.9 by 0.1
TIME 12 : 30
Group 0
P1 : 100bar (Option)
Front pump pressure
It displays front pump pressure of 100bar which is detected by pressure sensor. Range : 000~500bar by 10bar
P2 : 200bar (Option)
Rear pump pressure
It displays rear pump pressure of 200bar which is detected by pressure sensor. Range : 000~500bar by 10bar
P3 : 30bar (Option)
Pilot pump pressure
It displays pilot pump pressure of 30bar which is detected by pressure sensor. Range : 00~50bar by 1bar
b : 24.8V
Battery voltage
It shows that battery power of 24.8V is supplied into CPU controller. Range : 00.0~48.0V by 0.1V
Po : 2.5V
Potentiometer voltage
It shows that potentiometer signal voltage is 2.5V. Range : 0.0~5.0V by 0.1V
dL : 3.8V
Accel dial voltage
It shows that accel dial signal voltage is 3.8V. Range : 0.0~5.0V by 0.1V
° Hd : 50° C
Hydraulic oil temperature
It shows that hydraulic oil temperature detected by temperature sensor is 50° C. Range : 0~150° C by 1° C
° Ct : 85° C
Coolant temperature
It shows that coolant oil temperature detected by temperature sensor is 50° C. Range : 0~150° C by 1° C
Group 1
* : TIER II Only
5 - 37
Group
Display
Description
Name
Current error
It shows that current error of 03(Short circuit in pump EPPR valve system) is diagnosed by self diagnosis system in the CPU controller. If more than 2 errors, when pressing or switch, other error codes show. Range : 00~58
TIME Er : 03
Recorded error
It shows recorded error code of 03 which is diagnosed before. If more than 2 error codes, when pressing or switch, other error codes show. Range : 00~58
TIME Er : 00
Recorded error deletion
It shows all recorded error codes are removed in the CPU controller memory.
PP : on or oFF
Pump prolix switch
PP : on Shows that pump prolix switch is turned on(At emergency position). PP : oFF Shows that pump prolix switch is turned off(At normal position).
dP : on or oFF
dP : on Shows that auto decel pressure switch is pressed on Auto decel (No operation of control lever). pressure switch dP : oFF Shows that auto decel pressure switch is released off (Operation of control lever).
Pb : on or oFF
Power boost switch
oP : on or oFF
oP : on Shows that travel oil pressure switch is pressed on Travel oil (No operation of travel control lever). pressure switch oP : oFF Shows that travel oil pressure switch is released off (Operation of travel control lever).
od : on or oFF
One touch decel switch
od : on Shows that one touch decel switch is pressed. od : oFF Shows that one touch decel switch is released.
br : on or oFF
Travel alarm switch
br : on Shows that travel alarm function is selected. br : oFF Shows that travel alarm function is canceled.
PH : on or oFF
Preheat switch
PH : on Shows that preheat switch is pressed. PH : oFF Shows that preheat switch is released.
CHECK Er : 03
Group 2
Group 3
Pb : on Shows that power boost switch is pressed on (Activated). Pb : oFF Shows that power boost switch is released off (Canceled).
5 - 38
Group
Display
Description
Name
Ho : on or oFF
Hourmeter
nr : on or oFF
Neutral relay (Anti-restart relay)
Ho : on Shows that hourmeter is activated by CPU controller. Ho : oFF Shows that hourmeter is turned off. nr : on
Shows that neutral relay for anti-restarting function is activated(Engine start is possible). nr : oFF Shows that neutral relay is turned off to disable the engine restart. ts : on
Travel speed solenoid
Shows that travel speed solenoid is activated (High speed). ts : oFF Shows that travel speed solenoid is released (Low speed).
PS : on or oFF
Power boost solenoid
PS : on Shows that power boost solenoid is activated to maximize the power(Power up). PS : oFF Shows that power boost solenoid is turned off(Cancel the power boost function).
bs : on or oFF
Boom priority solenoid
bs : on Shows that boom priority solenoid is activated. bs : oFF Shows that boom priority solenoid is released.
Ru : on or oFF
Travel alarm
Ru : on Shows that travel buzzer is activated. Ru :oFF Shows that travel buzzer is canceled.
FS : on or oFF
Max flow cut off FS : on Shows that max flow cut off solenoid is activated. FS : oFF Shows that max flow cut off solenoid is released. solenoid
ts : on or oFF
Group 4
PR : on or oFF Preheat relay
PR : on Shows that preheat relay is activated. PR : oFF Shows that preheat relay is released.
5 - 39
GROUP 14 OUTLINE (#1001 and up, TIER II ) SYSTEM DIAGRAM
21075MS51
5 - 40
GROUP 15 MODE SELECTION SYSTEM (#1001 and up, TIER II ) 1. POWER MODE SELECTION SYSTEM
21075MS52
Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control system) optimizes the engine and pump performance. The combination of 2 power modes(H, S) and accel dial position(10 set) makes it possible to use the engine and pump power more effectively corresponding to the work conditions from a heavy and great power requesting work to a light and precise work. Ver 5.X(STD) Mode
Application
E/G RPM Unload
Load
Ver 6.X(OPT)
Power shift EPPR E/G RPM Current Pressure Load (mA) (kfg/cm2) Unload
Power shift EPPR Current Pressure (mA) (kfg/cm2)
H
High power
2150±50
1950
190±30
2.5
2050
1850
220±30
4
S
Standard power
2050±50
1850
290±30
8
1950
1750
260±30
6
1200±100
-
600±30
31
600±30
-
600±30
31
One touch decel Engine quick deceleration 1050±100
-
680±30
35
680±30
-
680±30
35
-
680±30
35
680±30
-
680±30
35
AUTO DECEL Engine deceleration
KEYSTART
Key switch start position
1050±100
5 - 41
2. WORK MODE SELECTION SYSTEM (TIER II) 3 work modes can be selected for the optional work speed of the machine operation.
21075MS53
1) HEAVY DUTY WORK MODE The boom priority solenoid is activated to make the boom operation speed faster. 2) GENERAL WORK MODE When key switch is turned ON, this mode is selected and swing operation speed is faster than heavy duty work mode. 3) BREAKER OPERATION MODE It sets the pump flow to the optimal operation of breaker by activating the max flow cut-off solenoid. Work mode
Boom priority solenoid
Max flow cut-off solenoid
Heavy duty
ON
OFF
General
OFF
OFF
Breaker
OFF
ON
5 - 42
SECTION 6 TROUBLESHOOTING Group Group Group Group Group
1 2 3 4 5
Before Troubleshooting Hydraulic and Mechanical System Electrical System Mechatronics System(up to #1000) Mechatronics System(#1001 and up, TIER II)
6-1 6-4 6-24 6-41 6-58
SECTION 6 TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help an operator 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 according to the troubleshooting process diagram.
Troubles occur
Hydraulic & Mechanical part
GROUP 2
Electrical part
GROUP 3
Mechatronics part
GROUP 4
2 digit (Machine)
HRDT by Hyundal
3 digit (Engine)
INSITE by Cummins
Fault codes displayed on monitor display
※ If fault codes (2 or 3 digits) are displayed on the monitor, please contact Hyundai or Cummins.
6-1
2. DIAGNOSING PROCEDURE To carry out troubleshooting efficiently, the following steps must be observed. STEP 1. Study the machine system Study and know how the machine is operating, how the system is composing, what kinds of function are installed in the machine and what are specifications of the system components by the machine service manual. Especially, deepen the knowledge for the related parts of the trouble. 13031SH02
STEP 2. Ask the operator Before inspecting, get the full story of malfunctions from a witness --- the operator. 1) How the machine is used and when it is serviced? 2) When the trouble was noticed and what work the machine was doing at that time? 3) What is the phenomenon of the trouble? Was the trouble getting worse, or did it come out suddenly for the first time? 4) Did the machine have any troubles previously? If so, which parts were repaired before.
13031SH03
STEP 3. Inspect the machine Before starting troubleshooting, check the machine for the daily maintenance points as shown in the operator's manual. And also check the electrical system including batteries, as the troubles in the electrical system such as low battery voltage, loose connections and blown out fuses will result in malfunction of the controllers causing total operational failures of the machine.
ON THE INSPECTION
(210-7) 6-2(3)
6-2
STEP 4. Inspect the trouble actually on the machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not. (210-7) 6-3(1)
STEP 5. Perform troubleshooting 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 system part's troubleshooting process diagram.
13031SH05
STEP 6. Trace a cause Before reaching a conclusion, check the most suspectible causes again. Try to trace what the real cause of the trouble is. Make a plan of the appropriate repairing procedure to avoid consequential malfunctions. (210-7) 6-3(3)
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION 1) MACHINE IN GENERAL (1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration. Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look for the cause based on the troubleshooting principle and perform maintenance and adjustment to prevent major failure from occurring. Keep in mind that a fault results from a combination of different causes. (2) 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. (3) When carrying out troubleshooting, do not hurry to disassemble the components. It will become impossible to find the cause of the problem. (4) Ask user or operator the following. ① Was there any strange thing about machine before failure occurred? ② Under what conditions did the failure occur? ③ Have any repairs been carried out before the failure? (5) Check before troubleshooting. ① Check oil and fuel level. ② Check for any external leakage of oil from components. ③ Check for loose or damage of wiring and connections.
6-4
2. DRIVE SYSTEM 1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause YES
Remove dust plug under engine flywheel and check if rubber pieces or particles are not present.
Coupling element Disassemble is broken. and repair.
YES
Coupling hub spline is worn or NO hub fastening setscrew is slack.
Remedy
Replace hub or retighten setscrew.
If hydraulic pump or engine is suspected as a culprit refer to this NO manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause NO
Is oil level in hydraulic oil tank within standard level?
Abnormal noise
YES comes out of
Replenish specified oil to the standard level. Hydraulic pump is Disassemble broken. and repair.
YES
hydraulic pump Do not hydraulic Abnormal noise pump and pump YES comes out of connections pump YES make abnormal connection noise?
Remedy
YES
See item 1). at page 6-5
Is primary pilot pressure within NO standard level?
ⓐ
YES
Clean pilot piping interior or repair piping.
Is not pilot piping YES clogged or is not oil leakage present on pilot piping? NO ⓐ
Pilot valve is faulty.
Disassemble and repair.
YES
Pilot relief valve is Repair or replace. faulty.
Is gear pump NO delivering oil? NO
6-6
Gear pump is broken.
Disassemble and repair.
3. HYDRAULIC SYSTEM 1) HYDRAULIC OIL IS CLOUDY Cause YES
Water is mixed.
Put hydraulic oil still, separate water and dispose it or replace hydraulic oil.
Air is intruded.
Check suction line and return line and eliminate the air intruding source.
Drop hydraulic oil sample on hot plate and check if foams come up.
NO
Remedy
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY Cause NO
Is hydraulic oil volume proper?
Replenish specified oil to the standard level. Clean oil cooler. Secure air circulation route.
YES
Is not oil cooler clogged and is YES anything blocking air circulation?
YES
Remedy
ⓐ
Is fan belt NO tension proper? NO
ⓐ
Is not the set YES pressure of main relief, relief and travel relief valve Is main relief YES lower than the valve used very standard level? NO often?
6-7
Adjust belt tension or replace belt. Readjust set pressure. Reduce load.
3) CAVITATION OCCURS WITH PUMP Cause NO
Is hydraulic oil volume proper?
Remedy Replenish specified oil to the standard level.
YES
Replace oil with one of proper viscosity.
Is not viscosity of hydraulic oil YES too high?
YES
Is not suction NO strainer clogged?
Clean suction strainer.
Is not air intruding from pump NO suction line?
Check for air intrusion in suction line and retighten or replace parts.
4) HYDRAULIC OIL IS CONTAMINATED Cause YES
Has not hydraulic oil passed specified replacement hours?
Remedy Replace hydraulic oil to be specified.
Has return filter NO been replaced at NO proper intervals?
Flush with hydraulic oil and replace return filter.
6-8
4. SWING SYSTEM 1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause
Remedy
NO
Replenish specified oil to the ⓐ Is safety solenoid YES standard level. valve pressure within standard? Repair or replace. Safety valve faulty Is gear pump pilot NO pressure within or not operated. YES standard level? Is oil in hydraulic YES tank within Gear pump faulty. Repair or replace. NO standard level? YES
YES
ⓐ Are attachment and travel motions impossible at all?
Pump connection Are broken pieces of coupling present coupling is broken. when dust plug under engine fly Is not main relief NO Hydraulic pump is wheel is removed? NO valve faulty? out of order. Does swing YES control valve
Is MCV pilot YES pressure within standard level? Does RH travel NO function?
spool move lightly by hand?
spool is stuck.
repair.
YES ⓑ
ⓒ
Does not symptom change when front YES NO and rear pump discharge hoses are exchanged?
Hydraulic pump is Disassemble and repair. broken.
YES
Is swing brake release valve faulty?
Disassemble and repair.
NO Swing control valve Disassemble and
NO
ⓑ
Disassemble and repair.
Swing brake release valve is broken.
Disassemble and repair.
YES Swing reduction
unit is broken.
Disassemble and repair.
Swing motor is broken.
Disassemble and repair.
Does swing NO motor rotate? NO
YES Pilot relief valve is NO Is gear pump
faulty.
Disassemble and repair or replace.
Gear pump is out of order.
Disassemble and repair.
Pilot valve is broken.
Clean pilot piping interior or repair piping. Disassemble and repair.
delivering oil?
ⓒ
NO
Is gear pump pilot pressure within standard level? Is not there oil leakage from YES pilot piping or is not it clogged?
YES
NO
6-9
2) SWING SPEED IS LOW Cause YES
Swing port relief valve is faulty.
Does swing control valve spool move smoothly by hand?
YES
YES Clogged or oil
Clean pilot piping interior or repair piping.
leak.
Is not pilot piping clogged or is not NO it leaking oil?
Single direction Is the trouble in one direction or in both direction?
NO
Does swing
Pilot valve or shuttle Disassemble valve is faulty. and repair. YES ⓐ
YES control valve
Both directions
spool move lightly by hand?
Is MCV pilot YES pressure within standard level?
Is Arm speed within standard value?
NO
NO NO
ⓐ
Is swing motor's drain rate within standard value?
NO
Swing control valve Disassemble spool is stuck. and repair. ⓑ ⓒ
Swing motor is broken.
Check that pilot piping is not YES clogged or oil is NO Pilot valve or not leaking from shuttle valve is it? faulty.
Is gear pump pilot pressure within standard level?
ⓑ
Is gear pump NO delivering oil? NO NO
Is main relief valve setting pressure normal? Is safety valve pilot pressure YES within standard level?
6 - 10
Disassemble and repair.
Pilot relief valve is defective.
Disassemble and repair or replace.
Gear pump is broken.
Disassemble and repair.
Main relief valve faulty.
Main relief valve pressure resetting or repair.
Does the symptom YES Hydraulic pump change when front YES is broken. and rear pump discharge hoses are exchanged? NO Shuttle valve is faulty. Is gear pump output pressure NO within standard level?
Disassemble and repair.
Clean pilot piping interior or repair piping.
Clogged or oil leak.
YES
ⓒ
Disassemble and repair or replace.
Swing control valve Disassemble spool is stuck. and repair.
NO
Is MCV pilot pressure same on LH and RH sides?
Remedy
YES
NO
Disassemble and repair. Repair or replace.
Pilot relief valve is faulty.
Repair or replace.
Gear pump is faulty.
Repair or replace.
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause YES Does symptom change when LH YES and RH port relief valves are exchanged? NO Does swing control YES valve spool move smoothly by hand?
Is MCV pilot pressure same for LH and RH?
Swing port relief valve is faulty.
Disassemble and repair.
Shuttle valve is faulty.
Disassemble and repair.
Swing control valve Disassemble and spool is stuck. repair.
NO YES
Check if pilot piping is not clogged or does NO not have oil leakage.
Remedy
Pilot valve is faulty. Disassemble and repair.
Clogged or oil leak.
Clean pilot piping interior or repair piping.
4) MACHINE SWINGS BUT DOES NOT STOP Cause YES Pilot relief valve is YES
Is MCV pilot YES Is gear pump pilot pressure within pressure within standard value? standard level? NO
YES Does swing control
valve spool move smoothly by hand?
Is swing control valve's return spring normal?
NO
faulty.
Disassemble and repair or replace.
Gear pump is broken.
Disassemble and repair.
Pilot valve is faulty. Disassemble and repair. Swing control valve spool is stuck. Return spring is faulty.
NO
NO
6 - 11
Remedy
Disassemble and repair. Disassemble and replace.
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause YES YES Is swing shuttle
valve normal? NO YES Is brake spring
Remedy
ⓐ Shuttle valve is faulty.
Disassemble and replace.
Brake spring is faulty.
Disassemble and replace.
Return spring of swing control valve is faulty.
Disassemble and replace.
normal? Is return spring of swing control valve normal?
NO
NO
ⓐ
Is swing relief pressure within standard level?
Is drain rate of YES swing motor within standard value?
YES
NO
Swing relief valve Disassemble and repair or is faulty. replace. Disassemble Swing motor is and repair. broken. Adjust swing relief valve pressure or replace swing relief valve.
NO
6 - 12
5. TRAVEL SYSTEM 1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause
Is travel brake
Does counterbalance YES spool in travel brake valve move lightly by hand?
NO
YES valve pressure
within standard level? Has travel YES control valve spool changed over positively?
Is bucket or arm operation possible? ⓐ
Does spool move lightly by hand?
Disassemble and repair.
Control system is Disassemble inspect and defective. repair. Travel control valve spool is stuck.
Disassemble and repair.
YES
Travel reduction unit is faulty.
Disassemble and repair.
Travel motor is out of order.
Disassemble and repair.
NO
Does the symptom change when front YES NO and rear pump Does the discharge hoses symptom change are exchanged? when LH/RH NO travel relief valves are exchanged?
6 - 13
Counter spool in Disassemble travel brake valve and repair or replace. is stuck.
NO
Do not metallic particles come out of drain port in travel reduction unit?
YES
Remedy
ⓐ
Does the symptom change when YES relief valves in Relief valve built NO travel motor are in travel motor is exchanged? faulty. YES
NO
YES
Hydraulic pump is Disassemble and repair. broken.
Travel relief valves are faulty.
Disassemble and repair or replace.
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause YES
Do LH and RH travel speeds YES change when LH and RH travel brake valves are exchanged? YES
Has control valve spool changed over positively?
Does the symptom change when relief valves in NO LH and RH travel motors are exchanged? YES
Does spool move lightly when it is NO cut off from control spool?
Is the lower speed(Bucket or arm) within standard level?
NO YES
Do LH and RH travel speeds change over when NO travel relief valves are exchanged?
Brake valve is defective. YES
NO
Relief valve built in travel motor is faulty.
Remedy Disassemble and repair or replace. Disassemble and repair.
ⓐ Control system is Disassemble, inspect and faulty . repair. Control valve spool is stuck.
Disassemble and repair.
Travel relief valve Disassemble and repair or is faulty. replace.
Does the symptom change when YES YES front and rear Hydraulic pump is pump discharge broken. hoses are Is external pilot exchanged? pressure within NO standard level? External pilot NO piping is clogged or oil is leaking Does travel speed from it. change when YES YES parking brake Travel motor's spring in the parking brake is slower travel Is leak rate of motor is removed? not released ⓐ travel motor within properly. standard level? NO
6 - 14
Travel motor is faulty.
Disassemble and repair.
Disassemble and clean.
Disassemble and clean pilot piping.
Disassemble and repair.
3) MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. None Is parking brake
friction plate worn?
YES Check if parking
brake pilot line is not clogged.
Is travel brake pressure within standard level?
YES
Is drain rate of travel motor within standard value?
Cause YES
Friction plate is faulty.
Disassemble and repair.
Travel motor is defective.
Disassemble and clean pilot piping. Disassemble and repair.
Clogged
NO
Brake valve is faulty.
NO
Remedy
Disassemble and repair or replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE Cause
YES
Remedy
Inspect according to the procedure "Travel does not function at all on one side." However, a case where both LH and RH travel motions are disabled is Is bucket or arm extremelyseldom operation statistically. possible? OK Hydraulic pump is Disassemble and faulty. repair. Disassemble both OK travel relief valves Remove dust and inspect for plug under engine any fault. OK flywheel and Travel relief valve Disassemble and check that there is Faulty is faulty. repair or replace. no coupling element particles. Particles present. Coupling at pump Disassemble and Check oil volume in hydraulic oil repair. connection is NO tank. broken. Replenish hydraulic oil.
Short
6 - 15
5) TRAVEL ACTION IS POWERLESS(Travel only) Cause YES
Is travel brake
ⓐ
Is travel motor's YES drain rate within standard level?
Travel motor is faulty.
NO
YES pressure within
standard level?
Is travel relief valve pressure within standard level? NO
YES
ⓐ
Disassemble and repair.
Disassemble Travel brake valve is defective. and repair or replace. Travel relief valve Disassemble and repair or is faulty. replace.
NO
Remove parking brake spring in travel motor, draw out piston completely, refit cover and check if travel power changes.
Remedy
Increases
Remains unchanged
Does parking brake piston move lightly by hand?
Hydraulic circuit that releases travel parking brake is clogged with dirt. Parking brake NO piston in travel motor is stuck.
Disassemble and clean.
Travel reduction unit is defective.
Disassemble and repair.
Disassemble and repair.
6) MACHINE RUNS RECKLESSLY ON A SLOPE
Cause
Travel brake valve (counterbalance valve) is faulty.
Remedy Disassemble and repair or replace.
6 - 16
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
Cause YES
Remedy Normal.
YES Is select valve
normal? Is pilot pressure for travel select valve within standard level?
Select valve is faulty.
NO YES
Is filter in pilot piping between gear pump and NO control valve not clogged?
Repair or replace. Remove dirt on pilot line filter.
YES Is pilot relief
valve normal? Is gear pump NO delivering oil? NO
6 - 17
NO
Pilot relief valve is Disassemble defective. and repair or replace. Gear pump is broken.
Disassemble and repair.
6. ATTACHMENT SYSTEM 1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
YES
YES
YES
Is MCV pilot pressure within standard level?
Are other attachments operatable?
Cause
Remedy
Port relief valve is Disassemble Does the symptom change and repair or faulty. YES when port relief replace. valve is replaced with other valve? NO ⓐ Inspect if pilot piping is not OK clogged or oil is Pilot valve is NO not leaking from faulty. the piping.
Disassemble and repair.
YES
Is gear pump pilot YES Is gear pump pressure within delivering oil? NO standard level? Are LH/RH operations possible?
Pilot relief valve is Disassemble and repair or faulty. replace. Disassemble Gear pump is NO and repair. broken. OK
Hydraulic pump is Disassemble broken. YES main relief valve and check if it is Remove dust plug not irregular. under engine Main relief valve OK flywheel and Faulty is defective. check if coupling element particles Inspect oil are not present. Particles present Coupling at pump volume in NO connection is hydraulic oil tank. broken. Short
YES
ⓐ
Does control valve spool move lightly by hand?
Disassemble and repair or replace. Disassemble and repair. Replenish hydraulic oil.
Cylinder interior is Disassemble and repair. broken.
NO Control valve
spool is stuck.
6 - 18
Disassemble and repair.
Disassemble and repair.
2) BOOM, ARM OR BUCKET SPEED IS LOW Cause YES
Are other
YES
Remedy Normal.
ⓐ
YES attachment
Is combination of oil streams YES normal at boom hoisting and at arm extrusion?
Is speed low only in composite operation?
Are LH/RH travel NO speeds within standard levels?
speeds within standard levels? NO ⓑ YES
Flow summation check valve spool is stuck.
Disassemble and repair.
Hydraulic pump is faulty. YES ⓒ
Disassemble and repair.
Does spool of flow summation check NO valve move lightly by hand? NO YES
Are both LH/RH travel speeds NO low?
Is MCV pilot pressure within NO standard?
NO
ⓓ
OK
Does the Port relief valve is symptom change faulty. YES when port relief valve is replaced Cylinder is faulty. with other valve? Does control NO YES valve spool move lightly by hand? ⓐ
NO
Is MCV pilot pressure within standard level?
ⓑ
ⓒ
Is primary pilot pressure within standard level?
YES
Pilot valve is defective. Pilot relief valve is faulty.
Clean pilot piping interior or repair piping. Disassemble and repair. Disassemble and repair or replace.
NO
Gear pump is broken.
Disassemble and repair.
NO
NO Is gear pump
delivering oil?
AIs engine NO revolution within standard level?
Adjust engine revolution.
YES
ⓓ
Is not orifice in control valve clogged?
Disassemble and repair.
Control valve spool Disassemble and repair. is stuck.
YES
Is not MCV pilot pressure piping NO clogged or is not there oil leakage?
Disassemble and repair or replace.
Clean orifice in control valve. YES
Is pilot piping not clogged or is oil NO not leaking from the piping?
6 - 19
Is pilot valve NO normal?
Clean pilot piping interior or repair piping. Pilot valve is faulty. Disassemble and NO repair.
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause YES
Does the sympto change when Normal port relief valve is replaced with Is control valve normal valve? return spring Is not hydraulic NO YES normal? oil temperature high?
Port relief valve is Disassemble and repair or faulty. replace. YES ⓐ
NO
Control valve's return spring is faulty.
NO
OK
ⓐ
Disassemble and YES inspect check valve in hydraulic circuit and check for any fault. Is cylinder internal leakage within standard level?
Disassemble and replace. Locate the cause of hydraulic oil temperature rise and lower it to proper level. Replace with genuine hydraulic oil or equivalent.
Abnormally high.
Is genuine hydraulic oil or equivalent being used?
Remedy
Abnormal
Pressure tightness between control valve casing and spool is poor. Contact surface between poppet and seat is poor.
Disassemble and repair.
Disassemble and repair.
Cylinder is faulty. Disassemble
NO
6 - 20
4) BOOM, ARM OR BUCKET POWER IS WEAK Cause YES
Check according to the procedure in Item "Speed is low".
Is cylinder
YES internal leakage
within standard level?
Is relief pressure
YES in port relief
Is relief pressure in main relief valve within standard level?
Cylinder is faulty. Disassemble and repair.
NO
valve within standard level?
Remedy
Port relief valve is Adjust pressure, faulty. repair or replace.
NO
Main relief valve is defective.
NO
Adjust pressure, repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause YES
Does the symptom change YES when port relief valve is replaced with other valve? YES
Is RH travel possible?
Is MCV pilot pressure within standard level?
Does control valve spool NO move smoothly by hand?
Port relief valve is Disassemble and repair or defective. replace. YES Cylinder interior is Disassemble broken. and repair.
NO
NO YES Does the symptom change Does the when main relief symptom change NO valves are YES when hydraulic exchanged? NO pump's discharge hoses are exchanged?
6 - 21
Remedy
Control valve spool is stuck.
Disassemble and repair.
Pilot valve is faulty.
Disassemble and repair.
Main relief valve is faulty.
Adjust pressure, repair or replace.
Hydraulic pump is broken. Disassemble and repair.
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause YES
Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom proper.
Is boom foot pin greased sufficiently?
※ Frictional noise will disappear if they are kept used. Boom foot pin has run out of grease.
NO
6 - 22
Supply grease to it. ※ If seizure is in an initial stage, supply sufficient grease. If seizure is in a grown state, correct it by paper lapping or with an oil stone.
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE 1. Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full.
29076TS01
2. Disconnect hose(A) from rod side of boom cylinder and drain oil from cylinders and hose.(Put cups on piping and hose ends)
A
(210-7) 6-20(2)
3. Raise bucket OFF the ground by retracting the arm cylinder rod. If oil leaks from piping side and boom cylinder rod is retracted there is an 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. 29076TS01
6 - 23
GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.7. ・After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause YES Check voltage
YES
Defective clucter
between CN-56 (1) and chassis
Remedy Replace
Disconnection in Repair or wiring harness or replace poor contact (After clean) between CN-5(8), (3)-CN-56(1)
NO
Check voltage between CN-5(8) ,(3) and chassis Starting switch : ON Voltage : 20~32V
Disconnection in Repair or wiring harness or replace poor contact (After clean) between CN-5(8), (3)-and fuse No.7
NO
21076ES51
6 - 24
2. COMMUNICATION ERROR "Co : Er" FLASHES ON THE CLUSTER ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Remedy
Defective controller Replace
YES Check voltage
between CN-56 (3,4) and chassis
Disconnection in Repair or replace wiring harness or (After clean) poor contact between CN-56 (3,4) CN-5(10,11)
NO
Check voltage between CN-5 (10,11)and chassis KEY ON
Disconnection in Repair or replace wiring harness or (After clean) poor contact between CN-5 (10,11)-CN-50 (29,30)
NO
CONTROLLER
Check voltage YES
*4V
*12V
NO
0V
0V
29
30
CN-50
CLUSTER POWER IG(24V) GND RX
*12V
TX
*4V
2
9
3
10 11
4
CN-56
CN-5
29076ES02
6 - 25
3.
BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES YES Check voltage
between CN-51 (9) and chassis NO
Check voltage YES between CN-3 (6),(3) and chassis Check voltage between alternator terminal "I" and chassis
Remedy
Defective controller Replace Disconnection in Repair or replace wiring harness or (After clean) poor contact between CN-51(9) -CN3(6),(3) Disconnection in Repair or replace wiring harness or (After clean) poor contact between CN-3(6),(3)-alternator terminal "I"
NO
Voltage : 20~32V Engine : Running
Defective alternator Replace
NO
21076ES52
6 - 26
4.
WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
Resistance YES between CD-8 (1,2) is in range of 120~150Ω? Does display go off when disconnect CD-8?
Disconnect CD-8
NO
YES Starting switch : ON Engine : Start
Resistance between CN-51 NO (31,33) is 0~1Ω? Disconnect CN-51 KEY OFF
Remedy
Coolant overheat (110°C ±2°C )
Check engine cooling system
Defective temp sensor
Replace
Short circuit in wiring harness
Repair or replace (After clean)
Defective Controller Replace
NO
21076ES53
6 - 27
5.
WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
Clogged air filter or Check filter or defective switch replace switch
Does display go off when disconnect CD10? Starting switch : ON Engine : Start
Remedy
YES
Short circuit in wiring harness
Check resistance between CN-51 NO (16) and chassis Starting switch : OFF Disconnect CN-51
Repair or replace (After clean)
Defective controller Replace
NO
Check resistance YES
MAX 1Ω
NO
MIN 1MΩ
AIR CLEANER SWITCH
CONTROLLER
Pa
16 20 CD-10 CN-50 51
25036EL05
6 - 28
6.
WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
Engine oil leakage, Check engine oil or defective switch level or replace switch
Does display go off when disconnect CD-18? Starting switch : ON Engine : Start
Remedy
YES
Defective controller Replace
Check resistance between CN-51 NO (4) and chassis Starting switch : OFF Disconnect CN-51
Disconnection in wiring harness or poor contact between CN-51(4)-CD-18
NO
Repair or replace (After clean)
Check resistance YES
MAX 1Ω
NO
MIN 1MΩ
CONTROLLER
ENGINE OIL PRESSURE SWITCH
4
CN-51
1
Pa CD-18
CN-2
29076ES03
6 - 29
7.
WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
High temperature
Resistance YES between CD-1 (1,2) is in range of 130~150Ω? Does display go off when disconnect CD-1? Starting switch : ON Engine : Start
Starting switch : ON Disconnect CD-1
Defective torque sensor
NO YES
Short circuit
Remedy Check hydraulic oil temperature (100°C ±2°C ) , Replace Replace
Check and repair
Resistance between CN-51 NO (31,34) is 0~1Ω? Starting switch : OFF Disconnect CN-51
Defective controller Replace
NO
HYDRAULIC OIL TEMPERATURE SENDER
CONTROLLER 34
2
31
1
C
CD-1
CN-51
29076ES04
6 - 30
8.
WHEN COOLANT LEVEL WARNING LAMP LIGHTS UP(Engine is started)
・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
Insufficient coolant Refill coolant or or Defective switch replace switch
Does display go off when disconnect CD16? Starting switch : ON Engine : Start
Remedy
YES
Short circuit
Check and repair
Check resistance between CN-51 NO (15) and chassis Starting switch : OFF Disconnect CN-51
Defective controller Replace
NO
Check resistance YES
MAX 1Ω
NO
MIN 1MΩ COOLANT LEVEL SENSOR
CONTROLLER
1
15 18
2
CN-50 51
CD-16
25036EL08
6 - 31
9. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
Disconnection in wiring harness or poor contact between CN-51-CD-8
Is resistance
YES between CN-51
(31) and (33) over 2kΩ? Does the gauge light up and down at lamp check?
YES
Starting switch : OFF Disconnect CN-50
NO
See Table
Repair or replace (After clean)
Defective controller Replace
Check resistance between CN-3(2) NO ,(5) and (7),(6)
Starting switch : ON
Remedy
NO
Defective temp sensor
Replace
Defective cluster
Replace
Check Table Temperature
Green range Red range
White range (~29° C)
Green range (30~105° C)
Red range (105° C ~)
Unit Resistance(Ω)
1646~
1645~158
~139
Tolerance(%)
±20
±20
±20
Item
White range
21076ES53
6 - 32
10. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF) ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
Remedy
Disconnection in wiring harness
Check and repair
Is resistance
YES between CN-51
(24) and (31) over 1kΩ? Does the gauge light up and down at lamp check?
YES
Starting switch : OFF Disconnect CN-51
Defective controller Replace
Check resistance between CD-2(1) NO and (2) NO
Disconnect CD-2 See Table
Starting switch : ON
NO
Defective fuel sensor
Replace
Defective cluster
Replace
Check Table
Green range Red range
Level
White range
Green range
Red range
Unit Resistance(Ω)
700~601
600~101
~100
Tolerance(%)
±5
±5
±5
Item White range
CONTROLLER FUEL SENDER 1
24
2
CD-2
31
CN-51 29076ES06
6 - 33
11. WHEN SAFETY SOLENOID DOES NOT OPERATE ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.24. ・After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause
Remedy
YES
Hydraulic malfunction
YES Check operation
Check hydraulic system
of solenoid Safety lever : ON-OFF
Defective solenoid Replace
NO YES
ⓐ
YES Check voltage between CS-4 (C) and chassis
Check voltage between CN-68 (1) - CN-68(2)
Check voltage YES between CN-4(8) and chassis
Starting switch : ON Voltage : 20~30V Safety state
Check voltage between CN-68 NO (2) with chassis
Starting switch : ON Voltage : 20~30V Disconnect CN-4
NO
Starting switch : ON Voltage : 20~30V Disconnect CN-4
Safety lever : OFF Starting switch : ON Voltage : 20~30V
NO YES
Check voltage between CS-20 and chassis Starting switch : ON Voltage : 20~30V
Repair or replace (After clean)
Repair or replace Disconnect in wiring harness or (After clean) poor contact between CN-4(8)-CN-68(1)
NO
ⓐ
Disconnect in wiring harness or poor contact between CN-4(8)-CS-4(C)
NO
Disconnection in fuse
Replace
Defective switch (CS-20)
Repair or replace
Defective switch (CS-4)
Repair or replace
21076ES54
6 - 34
12. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.22 . ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES YES Check voltage
between CN-50 (13) and chassis
Check if travel speed lamps( , ) change when pressing the travel speed switch on the cluster
Starting switch : ON Volage : 20~30V Disconnect CN-50
YES
of solenoid Check resistance between CN-70 NO (1) and (2) Starting switch : OFF SPEC : 15~25Ω Disconnect CN-70
YES
Starting switch : ON
Defective hydraulic Check hydraulic system system
YES Check operation
Starting switch : ON : OFF : ON
Y
R
NO
Defective controller Replace
Defective solenoid Replace
Defective cluster
Check controller NO
Remedy
Replace
G
Starting switch : ON
Defective controller Replace
NO
FUSE NO.22
TRAVEL SOLENOID CONTROLLER
2
1
13
CN-70 CN-50
21076ES04
6 - 35
13. WHEN ENGINE DOES NOT START ・Check supply of the power at engine stop solenoid while starting switch is ON. ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted. ・After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause YES
Check operation of start motor
Defective battery
YES
Check voltage YES between starter magnet coil and chassis
Starting switch : START
Starting switch : START SPEC : 20~30V
Check operation NO of start relay
Defective start relay Replace YES
Check voltage between CR-5 (30) and chassis NO
Starting switch : START
Starting switch :START
Check operation of start safety NO relay Starting switch : ON
Check voltage between CRNO 5(87) and chassis
Check engine system charge or replace(After checking specific gravity of battery)
Defective magnet Replace of start motor
NO
YES
Remedy
YES
NO
ⓐ, ⓑ Disconnection in wiring harness or poor contact between CR-5 (86) and CN-8(9)
Repair or replace (After clean)
Defective relay
Replace
ⓒ
Starting switch : ON YES
ⓐ
Check voltage between CN-79 (2) and chassis Voltage : 20~30V Starting switch : START
NO
YES
ⓑ
Check voltage between CR-23 and chassis
Disconnection in wiring harness or poor contact between CN-2(4)CN-79(2)
Repair or replace (After clean)
Defective relay
Replace
Repair or replace wiring harness or (After clean) poor contact between CR-5(30)CR-23
YES
Check voltage between CN-79 (1) and chassis NO Voltage : 20~30V Starting switch : ON
Replace
NO Disconnection in
Voltage : 20~30V Starting switch : ON
ⓒ
Defective fuel cut off solenoid
Defective fuel cutoff solenoid
Replace
Disconnection in wiring harness or poor contact between CN-2(5) and Fuse No.12
Repair or replace (After clean)
21076ES14A
6 - 36
14. WHEN STARTING SWITCH “ON” ELECTRIC PART DOES NOT OPERATE ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted and master switch ON ・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause YES
YES Check voltage
between DO-2 (1) and chassis
Voltage : 20~30V
YES Check voltage
NO
between CS-2 (2) and chassis YES
Check voltage between CS-2(1) and chassis
Voltage : 20~30V
NO
Voltage : 20~30V
Check voltage and specific gravity of battery
NO
Specific gravity : MIN 1.28 Voltage : MIN 24V
NO
Remedy
Repair or replace Disconnection in wiring harness or (After clean) poor contact between DO-2(1)CR-1 or defective battery relay Replace Disconnection in wiring harness or poor contact between CS-2(2)CN-8(11)- DO-2(1) Defective start key Replace switch Replace Disconnection in wiring harness or poor contact between CS-2(1)CN-8(12)-CS-61, CN-60-CR-1 Battery Battery capacity too Charge or replace low (After clean)
21076ES14A
6 - 37
15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.4,11 and 13 is not blown out. ・After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause NO
Defective wiper cut switch YES
Check valtage between CN-141 YES (11) and chassis
YES
Front sliding door-close Voltage : 0~1V
Check operation of switch panel NO LED ON.
NO Check voltage between CN-116 (6) and chassis Starting switch : ON Vottage : 20~30V
Starting switch : ON Push wiper switch button YES
Check voltage between CN-116(4) and chassis
ⓐ
ⓐ
Check voltage CN-116 (15) and chassis Sarting switch : ON Voltage : 0~1V
NO
Check operation of wiper motor and controller check voltage YES CN-141(7) and chassis, CN-21(4) and chassis Starting switch : OFF Voltage : 20~30V
Check continuity NO between CN-141(2)-CN-116(4), CN-141(9)-CN-116(12), CN-141(10)-CN-116(15), CN-141(5)-Chassis , Check wiper CN-141(1)-CN-21(5), motor resistance CN-141(3)-CN-21(6), YES between CN-21 CN-141(4)-CN-21(2), (2)-CN-21(6) CN-141(13)-CN-21(3) Resistance : 3~4Ω
Defective switch panel
Replace
1) Recheck fuse Replace NO.4 2) Disconnection Repair or replace in wiring harness (After clean) or poor contact between CN141(7)-Fuse, CN-21(4)-Fuse NO
Check voltage CN-141(6)-and YES chassis Starting switch : ON Voltage : 20~30V
Replace
1)Recheck fuse Replace NO.11 2)Disconnection in Repair or replace wiring harness or (After clean) poor contact between CN116(6)-Fuse between CN116(13)-Chassis Defective switch panel
Check voltage CN-116 (12) and chassis Washing
ⓑ
NO
NO
Intermittent
Replace
Disconnection in Repair or replace wiring harness or (After clean) poor contact between CN-141 (11)- CS-53
Check operation wiper cut switch Front sliding door open-close
Remedy
YES
1) Recheck fuse Replace NO.13 2) Disconnection Repair or replace CN-141(6)-Fuse (After clean) ⓑ Disconnection in Repair or replace wiring harness or (After clean) poor contact
NO
YES
Defective wiper motor
Replace
Defective wiper motor controller
Replace
21076ES15A
6 - 38
16. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.14. ・After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause NO
Defective lamp switch
Remedy
HEAD LAMP
Replace switch
1 2
CL-4
YES
Check voltage between CN-116 (1) and chassis
YES YES
Starting switch : ON Head lamp switch : ON Voltage : 20~30V
Check voltage between CN-7(1) YES and chassis Starting switch : ON Head lamp switch : ON Voltage : 20~30V
Check voltage between CN-116 (9) and chassis Starting switch : ON Head lamp switch : ON-OFF
YES
Check voltage between CNNO 7(7) and chassis
Check voltage between CL-4(2) and chassis Starting switch : ON Head lamp switch : ON Voltage : 20~30V
NO
Defective bulb
Replace CN-7
NO
Repair or replace Disconnection in wiring harness or (After clean) poor contact between CN-7(1)CL-4(2) Disconnection in wiring harness or poor contact between CN-116(1)-CN7(1)
1
7
Repair or replace (After clean)
10
CN-116 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
HEAD LIGHT OUT WORK LIGHT OUT WORK LIGHT OUT WIPER MOTOR DRIVE PRE-HEAT POWER 24V CABIN LIGHT OUT CABIN LIGHT OUT HEAD LIHGT 24V WORK LIGHT 24V WORK LIGHT 24V WASHER SIG GND TRAVEL ALARM INT. SIG CABIN LIGHT 24V CABIN LIGHT 24V
SWITCH PANEL
Disconnection in wiring harness or poor contact between CN-116 (9)-CN-7(7)
Repair or replace (After clean)
Recheck fuse No.14
Replace
FUSE NO.14
Head lamp switch : ON
NO
29076ES12
6 - 39
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP ・Before disconnecting the connector, always turn the starting switch OFF. ・Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.15. ・After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause NO
Defective lamp switch
Remedy
WORK LAMP
Replace switch
1 2
CL-5 CN-12
Check voltage YES between CN-116 (10,11) and chassis
YES
Check voltage between CL-5(2) and chassis
YES
Starting switch : ON Work lamp switch : ON Voltage : 20~30V
Check voltage between CN-7(2) YES and chassis
NO Starting switch : ON Work lamp switch : ON Voltage : 20~30V
Starting switch : ON Work lamp switch : ON Voltage : 20~30V
Check voltage between CN-116 (10,11) and chassis
NO
Starting switch : ON Work lamp switch : ON-OFF Voltage : 20~30V
Defective bulb
Replace
1
1
2
2
CL-6
Repair or replace Disconnection in wiring harness or (After clean) poor contact between CN-7(2) -CL-5(2) and CL-6 (2)
CN-7 2
Repair or replace Disconnection in wiring harness or (After clean) poor contact between CN-116 (2,3)-CN-7(2)
8
10
YES
Disconnection in Repair or replace wiring harness or (After clean) poor contact between CN-116 (10,11)-CN-7(8)
Check voltage between CN-7(8) NO and chassis
WORK LAMP
CN-116 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
HEAD LIGHT OUT WORK LIGHT OUT WORK LIGHT OUT WIPER MOTOR DRIVE PRE-HEAT POWER 24V CABIN LIGHT OUT CABIN LIGHT OUT HEAD LIHGT 24V WORK LIGHT 24V WORK LIGHT 24V WASHER SIG GND TRAVEL ALARM INT. SIG CABIN LIGHT 24V CABIN LIGHT 24V
SWITCH PANEL
FUSE
Head lamp switch : ON Voltage : 20~30V
NO
Recheck fuse No.15
Replace
NO.15
29076ES13
6 - 40
GROUP 4 MECHATRONICS SYSTEM(up to #1000) 1. ALL ACTUATORS SPEED ARE SLOW(up to #0179) ※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. S-mode 2150 ± 50rpm ※ Spec : H-mode 2250± 50rpm Before carrying out below procedure, check all the related connectors are properly inserted. ※ 1) INSPECTION PROCEDURE
Cause YES YES Check pressure
Remedy
Defective hydraulic system
at EPPR valve NO
Check electric YES current at EPPR
valve
Check if Er : 03 on the cluster
SPEC : 200~550mA See TEST 3
Check resistance between CN-50 YES (8) - (36)
SPEC : 5~20kgf/cm2 See TEST 4
NO
YES
SPEC : 17.5±1Ω(20° C) See TEST 1
Check resistance NO at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2 NO
NO Defective
Replace
EPPR valve Defective CPU controller
Replace
Short circuit or poor connection between CN-50 CN-75
Check & repair wire harness or between CN-50CN-75
Defective EPPR valve
Replace
Wiring diagram
※ Normal : Emergency : PROLIX SWITCH
RESISTOR 1
1
2
2
CN-47
3 2 1
3 4
6
5
4
5
6
CONTROLLER
CS-7
8
FUSE
24
NO.9
28 36
EPPR VALVE
CN-50
32
CN-51
9
2
10
1
CN-2
CN-75 21076MS01
6 - 41
1-1. ALL ACTUATORS SPEED ARE SLOW(from #0180 to #1000) ※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. ※ Spec : H-mode 2250± 50rpm S-mode 2150 ± 50rpm ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES YES Check pressure
Remedy
Defective hydraulic system
at EPPR valve NO
Check electric current at EPPR valve SPEC : 200~550mA See TEST 3
Check if Er : 03 on the cluster
SPEC : 5~20kgf/cm2 See TEST 4
NO
YES
YES
Check resistance at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2 NO
NO Defective
Replace
EPPR valve Defective CPU controller
Replace
Short circuit or poor connection between CN-50 CN-75
Check and repair wire harness or between CN-50CN-75
Defective EPPR valve
Replace
Wiring diagram
21076MS51
6 - 41-1
2) TEST PROCEDURE
SPEC : 17.5±1Ω(20°C )
(1) Test 1 : Check resistance at connector CN-50(8)-(36). ① Starting key OFF. ② Disconnect connector CN-50. ③ Check resistance between pin and at connector CN-50(8)-(36).
Y R G
CN-50 CPU CONTROLLER CN-50
12
8
1
24
13
36
25
CN-51
Multimeter
29076MS02
(2) Test 2 : Check resistance at connector CN-75. ① Starting key OFF. ② Disconnect connector CN-75 from EPPR valve at main hydraulic pump. ③ Check resistance between 2 lines as figure.
SPEC : 17.5±1Ω(20° C)
CN-75
Multimeter
(210-7) 6-38(2)
(3) Test 3 : Check electric current at EPPR valve. ① Install multimeter as figure. ② Start engine. ③ Set the accel dial at "10"(MAX) ④ Set S-mode and cancel auto decel mode. ⑤ If tachometer show approx 2150±50rpm, check electric current.
SPEC : 200~550mA (S mode)
CN-75
EPPR VALVE Multimeter
(210-7) 6-38(3)
6 - 42
(2) Test 4 : Check pressure at EPPR valve. ① Remove plug and connect pressure gauge as figure. ・Gauge capacity : 0 to 40~50kgf/cm2 (0 to 570~710psi) ② Start engine. ③ Set the accel dial at "10"(Max) ④ Set S-mode and cancel auto decel mode. ⑤ If tachometer show approx 2150 50rpm, check pressure. ⑥ If pressure is not correct, adjust it. ⑦ After adjust, test the machine.
SPEC : 5~20kgf/cm2(70~280psi)
Supply line, pilot press CN-75 Pressure adjusting screw locknut
(210-7) 6-39(1)
6 - 43
2. ENGINE SPEED IS SLOW AT ALL MODE ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE Cause Good
If test 7 is good, check TEST 1~4
Check tachometer YES work properly or
YES
not by changing the mode. YES Is resistance
See TEST 6
between CN-50 (12) - (23)
Check cable between accel actuator and injection pump.
Is resistance between CN-51 No good (25) - (26) SPEC : 0.2~0.4kΩ See TEST 7
SPEC : 1~2Ω See TEST 5
Remedy
NO
Misalignment between speed sensor and fly wheel
Clean speed sensor and adjust See : 5-20page
ⓐ Defective accel actuator or short circuit or poor connection between CN-50CN-76
NO
Replace accel actuator or harness assembly
Improper operation Adjust or repair by loosening or interference of cable
NO
YES
ⓐ
Short circuit or poor Check and repair connection between CN-50CN-2-CD-17
Is resistance between CD-17 (1) - (2) SPEC : 0.2~0.4kΩ See TEST 8
Defective speed sensor
NO
Replace
Wiring diagram ACCEL ACTUATOR
CPU CONTROLLER
12
23
1
P+
2
SIG
3
P-
4
NC
5
M+
6
M-
2 1
3
5
M 6 ACCEL DIAL
CN-76
CN-50 20
5
21
7
22
CN-9
C
-
B
S
A
+
CN-142 TACHO SENSOR 1
11
2
CN-51
CN-2
m
12
26
rp
25
CD-17 29076MS03
6 - 44
2) TEST PROCEDURE
SPEC : 1~2Ω
(1) Test 5 : Check resistance between CN-50 (12)-(23). ① Starting key OFF. ② Disconnect connector CN-50 from CPU controller. ③ Check resistance as figure.
Y R G
CPU CONTROLLER CN-50 CN-51
CN-50 12
1 23
13 25
36
Multimeter
29076MS04
Unit : rpm
(2) Test 6 : Check tachometer(Work properly or not) ① Start engine. ② Check tachometer reading.
Spec
6 - 45
Remark
H Tier-I (~#1000) S
2250±50
H Tier-II (#1001~) S
2150±50
2150±50 2050±50
Check rpm after cancel the Auto decel mode. Check rpm after cancel the Auto decel mode.
(3) Test 7 : Check resistance between CN-51 (25) and CN-51(26). ① Starting key OFF. ② Disconnect connector CN-51 from CPU controller. ③ Check resistance as figure.
SPEC : 0.2~0.4kΩ Y R G
CPU CONTROLLER CN-51 CN-50
CN-51
12
1
24
13
36
26 25
Multimeter 29076MS05
(4) Test 8 : Check resistance at speed sensor. ① Starting key OFF. ② Disconnect connector CD-17 of speed sensor at engine flywheel housing. ③ Check resistance as figure.
SPEC : 0.2~0.4kΩ
Speed sensor
CD-17
CD-17 1
2
Engine flywheel
Multimeter (210-7) 6-42(1)
6 - 46
3. ENGINE STALL(up to #0179) ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES
Remedy
Not enough engine Contact cummins power engine dealer
YES Check pressure
at EPPR Valve
Check electric current at EPPR valve SPEC : 200~550mA See TEST 9
NO
SPEC:5~20kgf/cm2 See TEST 10
YES
Check resistance between CN-50 NO (8) - (36)
YES
SPEC : 17.5±1Ω(20° C) See TEST 1
Check resistance
NO at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2
NO
Defective EPPR valve
Replace
Defective CPU controller
Replace
Short circuit or poor connection between CN-50 - CN-2 or CN-50 - CN-75
Check and repair
Defective EPPR valve
Replace
Wiring diagram ※ Normal : Emergency :
PROLIX SWITCH
RESISTOR 1
1
2
2
CN-47
3 2 1
3 4
6
5
4
5
6
CONTROLLER
CS-7
8
FUSE
24
NO.9
28 36
CN-50
EPPR VALVE
32
CN-51
9
2
10
1
CN-2
CN-75 29076MS01
6 - 47
3-1. ENGINE STALL(from #0180 to #1000) ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES
Remedy
Not enough engine Contact cummins power engine dealer
YES Check pressure
at EPPR Valve
Check electric current at EPPR valve
SPEC:5~20kgf/cm2 See TEST 4
NO YES
SPEC : 200~550mA See TEST 3
NO
Check resistance at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2
NO
Defective EPPR valve
Replace
Short circuit or poor connection between CN-50 - CN-2 or CN-50 - CN-75
Check and repair wire harness
Defective EPPR valve
Replace
Wiring diagram
21076MS51
6 - 47-1
2) TEST PROCEDURE
SPEC : 200~550mA
(1) Test 9 : Check electric current at EPPR valve at S-mode ① Install multimeter as figure. ② Start engine. ③ Set the accel dial at "10"(max) ④ Set S-mode with 2150±50rpm. ⑤ Check electric current.
CN-75
EPPR VALVE Multimeter (210-7) 6-44(1)
(2) Test 10 : Check pressure at EPPR valve at S-mode ① Connect pressure gauge at EPPR valve. ② Start engine. ③ Set the accel dial at "10"(max) ④ Set S-mode with 2150±50rpm. ⑤ Operate bucket lever completely push or pull. ⑥ Hold arm lever at the end of stroke. ⑦ Check pressure at relief position.
SPEC : 5~20kgf/cm2(70~280psi)
Supply line, pilot press CN-75 Pressure adjusting screw locknut
(210-7) 6-44(2)
6 - 48
4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES
YES
No power supply to Check fuse the CPU controller
See if all lamps off in the CPU controller case Y
R
YES
CPU failure
G
Y
See if Co : Er on the cluster
Remedy
R
Replace
G
NO NO
Y
R
G
ⓐ
NO OK
ⓐ
Check connection between CN-51 (29) - CN-5(10) or CN-51(30) - CN5(11) NO
Cluster failure
Replace
No connection
Check and repair
KEY OFF
Wiring diagram
21076MS06
6 - 49
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES
Check interference between connecting rod and accel actuator
YES
Check voltage between CN-5(20)YES (21) and check resistance between CN-51(20)-(22) Check resistance NO SPEC : (20)-(21) : 5±1V between CN-50 NO (20)-(22) : 0.1~0.9kΩ (12)-(23) See TEST 12 SPEC : 1~2Ω See TEST 11
NO
Remedy
Slow action of engine speed control due to interference
Check and repair
Defective CPU controller
Replace
Defective accel actuator
Replace
Defective accel actuator
Replace
Wiring diagram ACCEL ACTUATOR
CPU CONTROLLER
12
23
1
P+
2
SIG
3
P-
4
NC
5
M+
6
M-
2 1
3
5
M 6 ACCEL DIAL
CN-76
CN-50
C
-
20
5
B
S
21
7
A
+
22
CN-9
CN-142 TACHO SENSOR
12
1
26
11
2
CN-51
CN-2
m rp
25
CD-17
29076MS03
6 - 50
2) TEST PROCEDURE
SPEC : 1~2Ω
(1) Test 11 : Check resistance. ① Starting key OFF. ② Disconnect connector CN-50 from CPU controller. ③ Check resistance between CN-50(12)(23) as figure.
Y R G
CPU CONTROLLER CN-50 CN-51
CN-50 12
1 23
13 25
36
Multimeter 29076MS04
6 - 51
(2) Test 12 : Check voltage and resistance. ① Check resistance between CN-51(20)(22).
SPEC : 0.1~0.9kΩ Y R G
CPU CONTROLLER
- Starting key OFF. - Disconnect connector CN-51 from CPU controller. - Check resistance value with multimeter as figure.
CN-51 CN-50
CN-51 12 24
1 22
20
13
36
25
Multimeter 29076MS08
② Check voltage between CN-51(20) and CN-51(21).
SPEC : 5±1V Y R G
- Prepare 2 pieces of thin sharp pin, steel or copper. - Starting key ON. - Insert prepared pins to rear side of connectors : One pin to CN-51(20) Other pin to CN-51(21) - Check voltage.
CPU CONTROLLER PIN CN-50
CN-51
CN-51 12 24
1 21 20
36
13 25
Multimeter 29076MS09
6 - 52
6. AUTO DECEL SYSTEM DOES NOT WORK ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES
Check resistance between CN-51 (1)-GND and CN-51(13)-GND SPEC : Actuator operating : 4~5V Actuator stop :0~1V See TEST 13 See TEST 14
Defective CPU controller
NO
Remedy Replace
Short circuit or Replace or repair poor connection vetween CN-51(1), (13)- pressure switches Defective auto decel pressure switch
NO
Replace
Wiring diagram
AUTO DECEL PRESSURE SWITCH
CPU CONTROLLER
1
Pb
2
1
CD-7 1
13
Pa
2 CD-6
CN-51
29076MS10
6 - 53
2) TEST PROCEDURE
SPEC : Actuator stop : 4~5V Actuator operating : 0~1V
(1) Test 13 : Check voltage at CN-51(1) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Starting key ON. ③ Insert prepared pin to rear side of connectors : One pin to (1) of CN-51. ④ Check voltage as figure.
Y R G
CPU CONTROLLER PIN CN-50
(2) Test 14 : Check voltage at CN-51(13)and ground. ① Prepare 1 piece of thin sharp pin, steel or copper ② Starting key ON. ③ Insert prepared pin to rear side of connectors : One pin to (13)of CN-51. ④ Check voltage as figure.
CN-51
12
CN-51
1
24 36
25
Ground
Multimeter
CN-51
12
1
24
13
36
25
Ground
Multimeter 29076MS11
6 - 54
7. MALFUNCTION OF WARMING UP ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES YES
Check resistance between CN -51 (33) - CD-8(1)
Defective cluster or Repair or Replace CPU controller or CD8(Sensor)
Check resistance between CN-51 (31) - CD-8(2) SPEC : Below10Ω KEY OFF
Remedy
NO
Poor connection between CN51(31) - CD-8(1)
Repair
Poor connection between CN51(33) - CD-8(2)
Repair
SPEC : Below 10Ω KEY OFF
NO
Wiring diagram
21076ES53
6 - 55
8. MALFUNCTION OF POWER MAX ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1 ) INSPECTION PROCEDURE
YES Check resistance YES
Resistance between CN-51 (2)-GND normal?
between CN-88 (1) - (2)
Remedy
Defective power Repair or replace max. solenoid valve
SPEC: 15-30Ω See TEST 15
Short circuit or poor Repair or replace connection between CN-51(2) CS-29 and CN-50 (3) -CN-88(2)
NO
Is voltage between CN-88(2) -GND normal?
Cause
SPEC : Power max button pressed ON : 0 Power max button released OFF : See Test 16
SPEC KEY ON : 24±1V KEY OFF : 0V See TEST 15
Short circuit or poor Repair or replace connection between CN-88(1)battery relay(+)
NO
Wiring diagram
CPU CONTROLLER POWER MAX SOLENOID 2
3
1
CN-50
CN-88
1 2
2
FUSE CN-51
CN-4
NO.23
POWER MAX SWITCH 2 1
CS-29
29076MS13
6 - 56
2) TEST PROCEDURE (1) Test 15: Check voltage between connector CN-88 - GND. ① Start key ON. ② Disconnect connector CN-88 from power max solenoid valve. ③ Check voltage as figure.
SPEC : Key ON : 24±1V Key OFF : 0V Resistance : 15~30Ω
Power max. switch
LH RCV-lever
CN-88 CN-88
Power max. solenoid valve
Multimeter
29076MS14
(2) Test 16: Check resistance between connector CN-51(2)-GND. ① Starting key OFF. ② Remove CPU controller and disconnect connector CN-51 from CPU controller. ③ Check resistance as figure.
SPEC : Power max button pressed ON : 0Ω Power max button released OFF : ∞Ω Y R G
CPU CONTROLLER CN-51 CN-50
CN-51 12
2
24
13
36
25
Ground
Multimeter 29076MS15
6 - 57
GROUP 5 MECHATRONICS SYSTEM (#1001 and up, TIER II) 1. ALL ACTUATORS SPEED ARE SLOW ※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. S-mode 2050 ± 50rpm ※ Spec : H-mode 2150± 50rpm Before carrying out below procedure, check all the related connectors are properly inserted. ※ 1) INSPECTION PROCEDURE
Cause YES YES Check pressure
Remedy
Defective hydraulic system
at EPPR valve NO
Check electric current at EPPR valve SPEC : 200~450mA See TEST 3
Check if Er : 03 on the cluster
SPEC : 5~20kgf/cm2 See TEST 4
NO
YES
YES
Check resistance at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2 NO
NO Defective
Replace
EPPR valve Defective CPU controller
Replace
Short circuit or poor connection between CN-50 CN-75
Check and repair wire harness or between CN-50CN-75
Defective EPPR valve
Replace
Wiring diagram
21076MS51
6 - 58
(1) Test 2 : Check resistance at connector CN-75. ① Starting key OFF. ② Disconnect connector CN-75 from EPPR valve at main hydraulic pump. ③ Check resistance between 2 lines as figure.
SPEC : 17.5±1Ω(20° C)
CN-75
Multimeter
(290-7) 6-38(2)
(2) Test 3 : Check electric current at EPPR valve. ① Install multimeter as figure. ② Start engine. ③ Set the accel dial at "10"(MAX) ④ Set S-mode and cancel auto decel mode. ⑤ If tachometer show approx 2050±50rpm check electric current.
SPEC : 200~450mA(S mode)
CN-75
EPPR VALVE Multimeter
(290-7) 6-38(3)
(3) Test 4 : Check pressure at EPPR valve. ① Remove plug and connect pressure gauge as figure. ・Gauge capacity : 0 to 40~50kgf/cm2 (0 to 570~710psi) ② Start engine. ③ Set the accel dial at "10"(Max). ④ Set S-mode and cancel auto decel mode. ⑤ If tachometer show approx 2050 50rpm check pressure. ⑥ If pressure is not correct, adjust it. ⑦ After adjust, test the machine.
SPEC : 5~20kgf/cm2(70~280psi)
Supply line, pilot press CN-75 Pressure adjusting screw locknut
(290-7) 6-39(1)
6 - 59
2. ENGINE STALL ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES
Remedy
Not enough engine Contact cummins power engine dealer
YES Check pressure
at EPPR Valve
Check electric current at EPPR valve
SPEC:5~20kgf/cm2 See TEST 4
NO YES
SPEC : 200~450mA See TEST 3
NO
Check resistance at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2
NO
Defective EPPR valve
Replace
Short circuit or poor connection between CN-50 - CN-2 or CN-50 - CN-75
Check and repair wire harness
Defective EPPR valve
Replace
Wiring diagram
21076MS51
6 - 60
2) TEST PROCEDURE
SPEC : 200~450mA
(1) Test 3 : Check electric current at EPPR valve at S-mode ① Install multimeter as figure. ② Start engine. ③ Set the accel dial at "10"(max) ④ Set S-mode with 2050±50rpm. ⑤ Check electric current.
CN-75
EPPR VALVE Multimeter 6-44(1) 290-7
(2) Test 4 : Check pressure at EPPR valve at S-mode ① Connect pressure gauge at EPPR valve. ② Start engine. ③ Set the accel dial at "10"(max) ④ Set S-mode with 2050±50rpm. ⑤ Operate bucket lever completely push or pull. ⑥ Hold arm lever at the end of stroke. ⑦ Check pressure at relief position.
SPEC : 5~20kgf/cm2(70~280psi)
Supply line, pilot press CN-75 Pressure adjusting screw locknut
6-44(2) 290-7
6 - 61
GROUP 5 MECHATRONICS SYSTEM (#1001 and up, TIER II) 1. ALL ACTUATORS SPEED ARE SLOW ※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. S-mode 2050 ± 50rpm ※ Spec : H-mode 2150± 50rpm Before carrying out below procedure, check all the related connectors are properly inserted. ※ 1) INSPECTION PROCEDURE
Cause YES YES Check pressure
Remedy
Defective hydraulic system
at EPPR valve NO
Check electric current at EPPR valve SPEC : 200~450mA See TEST 3
Check if Er : 03 on the cluster
SPEC : 5~20kgf/cm2 See TEST 4
NO
YES
YES
Check resistance at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2 NO
NO Defective
Replace
EPPR valve Defective CPU controller
Replace
Short circuit or poor connection between CN-50 CN-75
Check and repair wire harness or between CN-50CN-75
Defective EPPR valve
Replace
Wiring diagram
21076MS51
6 - 58
(1) Test 2 : Check resistance at connector CN-75. ① Starting key OFF. ② Disconnect connector CN-75 from EPPR valve at main hydraulic pump. ③ Check resistance between 2 lines as figure.
SPEC : 17.5±1Ω(20° C)
CN-75
Multimeter
(290-7) 6-38(2)
(2) Test 3 : Check electric current at EPPR valve. ① Install multimeter as figure. ② Start engine. ③ Set the accel dial at "10"(MAX) ④ Set S-mode and cancel auto decel mode. ⑤ If tachometer show approx 2050±50rpm check electric current.
SPEC : 200~450mA(S mode)
CN-75
EPPR VALVE Multimeter
(290-7) 6-38(3)
(3) Test 4 : Check pressure at EPPR valve. ① Remove plug and connect pressure gauge as figure. ・Gauge capacity : 0 to 40~50kgf/cm2 (0 to 570~710psi) ② Start engine. ③ Set the accel dial at "10"(Max). ④ Set S-mode and cancel auto decel mode. ⑤ If tachometer show approx 2050 50rpm check pressure. ⑥ If pressure is not correct, adjust it. ⑦ After adjust, test the machine.
SPEC : 5~20kgf/cm2(70~280psi)
Supply line, pilot press CN-75 Pressure adjusting screw locknut
(290-7) 6-39(1)
6 - 59
2. ENGINE STALL ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) INSPECTION PROCEDURE
Cause YES
Remedy
Not enough engine Contact cummins power engine dealer
YES Check pressure
at EPPR Valve
Check electric current at EPPR valve
SPEC:5~20kgf/cm2 See TEST 4
NO YES
SPEC : 200~450mA See TEST 3
NO
Check resistance at EPPR valve SPEC : 17.5±1Ω(20° C) See TEST 2
NO
Defective EPPR valve
Replace
Short circuit or poor connection between CN-50 - CN-2 or CN-50 - CN-75
Check and repair wire harness
Defective EPPR valve
Replace
Wiring diagram
21076MS51
6 - 60
2) TEST PROCEDURE
SPEC : 200~450mA
(1) Test 3 : Check electric current at EPPR valve at S-mode ① Install multimeter as figure. ② Start engine. ③ Set the accel dial at "10"(max) ④ Set S-mode with 2050±50rpm. ⑤ Check electric current.
CN-75
EPPR VALVE Multimeter 6-44(1) 290-7
(2) Test 4 : Check pressure at EPPR valve at S-mode ① Connect pressure gauge at EPPR valve. ② Start engine. ③ Set the accel dial at "10"(max) ④ Set S-mode with 2050±50rpm. ⑤ Operate bucket lever completely push or pull. ⑥ Hold arm lever at the end of stroke. ⑦ Check pressure at relief position.
SPEC : 5~20kgf/cm2(70~280psi)
Supply line, pilot press CN-75 Pressure adjusting screw locknut
6-44(2) 290-7
6 - 61
SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test Group 2 Major Components Group 3 Track and Work Equipment
7-1 7-21 7-31
SECTION 7 MAINTENANCE STANDARD GROUP 1 OPERATIONAL PERFORMANCE TEST 1. PURPOSE Performance tests are used to check: 1) OPERATIONAL PERFORMANCE OF A NEW MACHINE Whenever a new machine is delivered in parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec.
Working condition
Maintenance record
2) OPERATIONAL PERFORMANCE OF A WORKING MACHINE With the passage of time, 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 performance tests to check the extent of deterioration, and to decide what kind of service needs to be done(by referring to the "Service Limits" in this manual).
Operating
3) OPERATIONAL PERFORMANCE OF A REPAIRED MACHINE After the machine is repaired or serviced, it must be tested to confirm that its operational performance was restored by the repair and/or service work done.
21077MS01
7-1
2. TERMINOLOGY 1) STANDARD Specifications applied to the brand-new machine, components and parts.
21077MS02
2) SERVICE LIMIT The lowest acceptable performance level. When the performance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
21077MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS 1) Observe the following rules in order to carry out performance tests accurately and safely. (1) The machine Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. (2) Test area ① Select a hard, flat surface. ② Secure enough space to allow the machine to run straight more than 20m, and to make a full swing with the front attachment extended. ③ If required, rope off the test area and provide signboards to keep unauthorized personnel away. (3) Precautions ① Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. ② Operate the machine carefully and always give first priority to safety. ③ While testing, always take care to avoid accidents due to landslides or contact with high voltage power lines. Always confirm that there is sufficient space for full swings. ④ Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.
(210-7) 7-3
(4) Make precise measurements ① Accurately calibrate test instruments in advance to obtain correct data. ② Carry out tests under the exact test conditions prescribed for each test item. ③ Repeat the same test and confirm that the test data obtained can be procured repeatedly. Use mean values of measurements if necessary.
7-3
2) ENGINE SPEED (1) Measure the engine speed at each power mode ※ The engine speed at each power mode must meet standard RPM; if not, all other operational performance data will be unreliable. It is essential to perform this test first. (2) Preparation ① Warm up the machine, until the engine coolant temperature reaches 50° C or more, and the hydraulic oil is 50±5° C. ② Set the accel dial at 10(Max) position. ③ Push the H-mode switch and confirm that the fuel injection pump governor lever comes into contact with the highidle stopper. ④ Measure the engine RPM. (3) Measurement ① Start the engine. The engine will run at start idle speed. Measure engine speed with a tachometer. ② Measure and record the engine speed at each mode(H, S). ③ Select the H-mode. ④ Lightly operate the bucket control lever a few times, then return the control lever to neutral; The engine will automatically enter the auto-idle speed after 4 seconds. ⑤ Measure and record the auto deceleration speed. (4) Evaluation The measured speeds should meet the following specifications. Unit : rpm Model
R210LC-7
Engine speed
Standard
Start idle
950±100 *1050±100
H mode
2250±50 *2150±50
S mode
2150±50 *2050±50
Auto decel
1200±100
Condition : Set the accel dial at 10(Max) position. * TIER II
7-4
Remarks
3) TRAVEL SPEED (1) Measure the time required for the excavator to travel a 20m test track. (2) Preparation ① Adjust the tension of both tracks to be equal. ② Prepare a flat and solid test track 20m in length, with extra length of 3 to 5m on both ends for machine acceleration and deceleration. ③ Hold the bucket 0.3 to 0.5m above the ground with the arm and bucket rolled in. ④ Keep the hydraulic oil temperature at 50±5° C.
R210LC-7
0.3~0.5m
21077MS04
(3) Measurement ① Measure both the low and high speeds of the machine. ② Before starting either the low 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 ③ Start traveling the machine in the acceleration zone with the travel levers at full stroke. ④ Measure the time required to travel 20m. ⑤ After measuring the forward travel speed, turn the upperstructure 180°and measure the reverse travel speed. ⑥ Repeat steps ④ and ⑤ three times in each direction and calculate the average values.
R210LC-7
R210LC-7
3 ~ 5m
R210LC-7
20m
3 ~ 5m
21077MS05
(4) Evaluation The average measured time should meet the following specifications. Unit : Seconds / 20m Model R210LC-7
Travel speed
Standard
Maximum allowable
1 Speed
21.2±2.0
26.5
2 Speed
13.6±1.0
17.0
7-5
Remarks
4) TRACK REVOLUTION SPEED (1) Measure the track revolution cycle time with the track raised off ground. (2) Preparation ① Adjust the tension of both side tracks to be equal. ② On the track to be measured, mark one shoe with chalk. ③ Swing the upperstructure 90°and lower the bucket to raise the track off ground. Keep the boom-arm angle between 90 to 110°as shown. Place blocks under machine frame. ④ Keep the hydraulic oil temperature at 50±5° C.
90~110
Mark
21077MS06
(3) Measurement ① Select the following switch positions. ・ Travel mode switch : 1 or 2 speed ・ Mode selector : H mode ・ Auto decel switch : OFF ② Operate the travel control lever of the raised track in full forward and reverse. ③ Rotate 1 turn, then measure time taken for next 3 revolutions. ④ Raise the other side of machine and repeat the procedure. ⑤ Repeat steps ③ and ④ three times and calculate the average values. (4) Evaluation The revolution cycle time of each track should meet the following specifications. Unit : Seconds / 3 revolutions Model R210LC-7
Travel speed
Standard
Maximum allowable
1 Speed
28.0±2.0
35.0
2 Speed
18.0±2.0
22.5
7-6
5) TRAVEL DEVIATION (1) Measure the deviation by the tracks from a 20m straight line. (2) Preparation ① Adjust the tension of both tracks to be equal. ② Provide a flat, solid test yard 20m in length, with extra length of 3 to 5m on both ends for machine acceleration and deceleration. ③ Hold the bucket 0.3 to 0.5m above the ground with the arm and bucket rolled in. ④ Keep the hydraulic oil temperature at 50±5° C.
R210LC-7
0.3~0.5m
21077MS04
(3) Measurement ① Measure the amount of mistracking at high and low travel speeds. ② Before beginning each test, select the following switch positions. ・ Mode selector : H mode ③ Start traveling the machine in the acceleration zone with the travel levers at full stroke. ④ Measure the distance between a straight 20m line and the track made by the machine.(Dimension a) ⑤ After measuring the tracking in forward travel, turn the upperstructure 180°and measure that in reverse travel. ⑥ Repeat steps ④ and ⑤ three times and calculate the average values.
3~5m extra length 20 M
a
3~5m extra length
(210-7) 7-7(2)
(4) Evaluation Mistrack should be within the following specifications. Unit : mm / 20m Model
Standard
Maximum allowable
R210LC-7
200 below
240
7-7
Remarks
6) SWING SPEED (1) Measure the time required to swing three complete turns. (2) Preparation ① Check the lubrication of the swing gear and swing bearing. ② Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. ③ With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. The bucket must be empty. ④ Keep the hydraulic oil temperature at 50±5° C.
R210LC-7
21077MS07
(3) Measurement ① Select the following switch positions. ・ Mode selector : Each mode ② Operate swing control lever fully. ③ Swing 1 turn and measure time taken to swing next 3 revolutions. ④ Repeat steps ② and ③ three time and calculate the average values. (4) Evaluation The time required for 3 swings should meet the following specifications. Unit : Seconds / 3 revolutions Model R210LC-7
Power selector switch
Standard
Maximum allowable
H mode
15.2±1.5
19.0
S mode
10.4±1.5
-
7-8
7) SWING FUNCTION DRIFT CHECK (1) Measure the swing drift on the bearing outer circumference when stopping after a 360°full speed swing. (2) Preparation ① Check the lubrication of the swing gear and swing bearing. ② Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. ③ With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. The bucket must be empty. ④ Make two chalk marks: one on the swing bearing and one directly below it on the track frame. ⑤ Swing the upperstructure 360°. ⑥ Keep the hydraulic oil temperature at 50±5° C.
R210LC-7
21077MS07
(3) Measurement ① Conduct this test in the H mode. ② Select the following switch positions. ・ Mode selector : H mode ③ Operate the swing control lever fully and return it to the neutral position when the mark on the upperstructure aligns with that on track frame after swinging 360° ④ Measure the distance between the two marks. ⑤ Align the marks again, swing 360°, then test the opposite direction. ⑥ Repeat steps ④ and ⑤ three times each and calculate the average values.
Drift angle 360 swing Swing start & stop 21077MS08
(4) Evaluation The measured drift angle should be within the following specifications. Unit : Degree Model
Mode select switch
Standard
Maximum allowable
R210LC-7
H mode
90 below
157.5
7-9
Remarks
8) SWING BEARING PLAY (1) Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. (2) Preparation ① Check swing bearing mounting cap screws for loosening. ② Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. ③ Install a dial gauge on the track frame as shown, using a magnetic base. ④ Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers. ⑤ Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race. ⑥ Bucket should be empty.
(210-7) 7-10(1)
(3) Measurement ① With the arm rolled out and bucket rolled in, hold the bottom face of the bucket to the same height of the boom foot pin. Record the dial gauge reading(h1). ② Lower the bucket to the ground and use it to raise the front idler 50cm. Record the dial gauge reading(h2). ③ Calculate bearing play(H) from this data(h1 and h2) as follows. H=h2-h1
Measurement : (h1)
R210LC-7
Measurement : (h2)
R210LC-7
(4) Evaluation The measured drift should be within the following specifications.
21077MS09
Unit : mm Model
Standard
Maximum allowable
R210LC-7
0.5 ~ 1.5
3.0
7 - 10
Remarks
9) HYDRAULIC CYLINDER CYCLE TIME (1) Measure the cycle time of the boom, standard arm, and standard bucket cylinders. (2) Preparation ① To measure the cycle time of the boom cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown. ② To measure the cycle time of the arm cylinder. With the empty bucket rolled in, position the arm so that it is vertical to the ground. Lower the boom until the bucket is 0.5m above the ground. ③ To measure the cycle time of the bucket cylinder. The empty bucket should be positioned at midstroke between roll-in and roll-out, so that the sideplate edges are vertical to the ground. ④ Keep the hydraulic oil temperature at 50±5° C.
Boom cylinder Raise
Lower
Arm cylinder
Roll out
Roll in 90
0.5m
Bucket cylinder
(3) Measurement ① Select the following switch positions. ・ Mode selector : H mode ② To measure cylinder cycle times. - Boom cylinders. Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end then move the control lever to the other stroke end as quickly as possible. - Arm cylinder. Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.
Roll out
Roll in
0.5m 21077MS10
7 - 11
- Bucket cylinders Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible. - Repeat each measurement 3 times and calculate the average values. (4) Evaluation The average measured time should meet the following specifications. Unit : Seconds Model
R210LC-7
Function
Standard
Maximum allowable
Boom raise
3.0±0.4
3.8
Boom lower
3.0±0.4
3.8
Arm in
3.2±0.4
4.0
Arm out
2.8±0.3
3.5
Bucket load
3.8±0.4
4.8
Bucket dump
2.5±0.3
3.1
7 - 12
Remarks
10) DIG FUNCTION DRIFT CHECK (1) Measure dig function drift, which can be caused by oil leakage in the control valve and boom, standard arm, and standard bucket cylinders, with the loaded bucket. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to purge air. (2) Preparation ① Load bucket fully. Instead of loading the bucket, weight(W) of the following specification can be used. ・ W=M3×1.5 Where : M3 = Bucket heaped capacity(m3) 1.5= Soil specific gravity ② Position the arm cylinder with the rod 20 to 30mm extended from the fully retracted position. ③ Position the bucket cylinder with the rod 20 to 30mm retracted from the fully extended position. ④ With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. ⑤ Keep the hydraulic oil temperature at 50±5° C.
R210LC-7
21077MS11
(3) Measurement ① Stop the engine. ② Five minutes after the engine has been stopped, measure the changes in the positions of the boom, arm and bucket cylinders. ③ Repeat step ② three times and calculate the average values. (4) The measured drift should be within the following specifications. Unit : mm / 5min Model
R210LC-7
Drift to be measured
Standard
Maximum allowable
Boom cylinder
40 below
50
Arm cylinder
60 below
75
Bucket cylinder
40 below
50
7 - 13
Remarks
11) CONTROL LEVER OPERATING FORCE (1) Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip. (2) Preparation ① Keep the hydraulic oil temperature at 50±5° C. (3) Measurement ① Start the engine. ② Select the following switch positions. ・ Mode selector : H mode ③ Operate each boom, arm, bucket and swing lever at full stroke and measure the maximum operating force for each. ④ Lower the bucket to the ground to raise one track off the ground. Operate the travel lever at full stroke and measure the maximum operating force required. When finished, lower the track and then jack-up the other track. ⑤ Repeat steps ③ and ④ three times and calculate the average values. (4) Evaluation The measured operating force should be within the following specifications. Unit : kgf Model
R210LC-7
Kind of lever
Standard
Maximum allowable
Boom lever
1.6 or below
2.0
Arm lever
1.6 or below
2.0
Bucket lever
1.6 or below
2.0
Swing lever
1.6 or below
2.0
Travel lever
2.1 or below
3.15
7 - 14
Remarks
12) CONTROL LEVER STROKE (1) Measure each lever stroke at the lever top using a ruler. ※ When the lever has play, take a half of this value and add it to the measured stroke. (2) Preparation Keep the hydraulic oil temperature at 50±5° C. (3) Measurement ① Stop the engine. ② Measure each lever stroke at the lever top from neutral to the stroke end using a ruler. ③ Repeat step ② three times and calculate the average values. (4) Evaluation The measured drift should be within the following specifications. Unit : mm Model
R210LC-7
Kind of lever
Standard
Maximum allowable
Boom lever
87±10
109
Arm lever
87±10
109
Bucket lever
87±10
109
Swing lever
87±10
109
Travel lever
142±10
178
7 - 15
Remarks
13) PILOT PRIMARY PRESSURE
3 A
(1) Preparation ① Stop the engine. ② Remove the top cover of the hydraulic tank oil supply port with a wrench. ③ Loosen and remove plug on the pilot pump delivery port and connect pressure gauge. ④ Start the engine and check for oil leakage from the port. ⑤ Keep the hydraulic oil temperature at 50±5° C.
a4 1 m
P r D
v
Ps
3 B
a2 a1
2 m
P
(2) Measurement ① Select the following switch positions. ・ Mode selector : H mode ・ Auto decel switch : OFF ② Measure the primary pilot pressure in the H mode.
21077MS12
(3) Evaluation The average measured pressure should meet the following specifications: Unit : kgf / cm2 Model
Engine speed
Standard
Allowable limits
R210LC-7
H mode
35±5
-
7 - 16
Remarks
14) FOR TRAVEL SPEED SELECTING PRESSURE: (1) Preparation ① Stop the engine. ② Remove the top cover of the hydraulic tank oil supply port with a wrench. ③ Push the pressure release button to bleed air. ④ To measure the speed selecting pressure: Install a connector and pressure gauge assembly to turning joint P port as shown. ⑤ Start the engine and check for on leakage from the adapter. ⑥ Keep the hydraulic oil temperature at 50±5° C.
P
B A
D C
Dr
(2) Measurement ① Select the following switch positions. Travel mode switch : 1 speed 2 speed ・ Mode selector : H mode ② Measure the travel speed selecting pressure in the Hi or Lo mode. ③ Lower the bucket to the ground to raise the track off the ground. Operate the travel lever at full stroke and measure the fast speed pressure. ④ Repeat steps ② and ③ three times and calculate the average values.
21077MS13
(3) Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm2 Model R210LC-7
Travel speed mode
Standard
Maximum allowable
1 Speed
0
-
2 Speed
35±5
-
7 - 17
Remarks
15) SWING PARKING BRAKE RELEASING PRESSURE (1) Preparation ① Stop the engine. ② Remove the top cover of the hydraulic tank oil supply port with a wrench. ③ The pressure release L wrench to bleed air. ④ Install a connector and pressure gauge assembly to swing motor SH port, as shown. ⑤ Start the engine and check for oil leakage from the adapter. ⑥ Keep the hydraulic oil temperature at 50±5° C.
SH
(2) Measurement ① Select the following switch positions. ・ Mode selector : H mode ② Operate the swing function or arm roll in function and measure the swing brake control pressure with the brake disengaged. Release the control lever to return to neutral and measure the control pressure when the brake is applied. Repeat step ② three times and calculate the average values.
21077MS14
(3) Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm2 Model R210LC-7
Description
Standard
Allowable limits
Brake disengaged
35
26~44
Brake applied
0
-
7 - 18
Remarks
16) MAIN PUMP DELIVERY PRESSURE
A
(1) Preparation ① Stop the engine. ② Remove the top cover of the hydraulic tank oil supply port with a wrench. ③ Push the pressure release button to bleed air. ④ To measure the main pump pressure. Install a connector and pressure gauge assembly main pump gauge port as shown. ⑤ Start the engine and check for oil leakage from the port. ⑥ Keep the hydraulic oil temperature at 50±5° C.
3
a4 1
m P D r
v
Ps
a2 a1
2
m
P
21077MS15
(2) Measurement ① Select the following switch positions. ・ Mode selector : H mode ② Measure the main pump delivery pressure in the H mode(High idle). (3) Evaluation The average measured pressure should meet the following specifications.
Unit : kgf / cm2 Model
Engine speed
Standard
Allowable limits
R210LC-7
High ilde
40±5
-
7 - 19
Remarks
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
A
(1) Preparation ① Stop the engine. ② Remove the top cover of the hydraulic tank oil supply port with a wrench. ③ Push the pressure release button to bleed air. ④ To measure the system relief pressure. Install a connector and pressure gauge assembly main pump gauge port, as shown. ⑤ Start the engine and check for oil leakage from the port. ⑥ Keep the hydraulic oil temperature at 50±5° C.
3
a4 1
m P D r
v
Ps
a2 a1
2
m
P
(2) Measurement ① Select the following switch positions. ・ Mode selector : H mode ② Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and measure the pressure. ③ In the swing function, place bucket against an immovable object and measure the relief pressure. ④ In the travel function, lock undercarriage with an immovable object and measure the relief pressure.
21077MS15
(3) Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm2 Model
R210LC-7 (
Function to be tested
Standard
Maximum allowable
Boom, Arm, Bucket
330(360)±10
390±10
Travel
330±10
-
Swing
240±10
-
) : Power boost
7 - 20
GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 3
9
5
1
6
2
4
7
8
Part name & inspection item Clearance between piston(1) & cylinder bore(2) (D-d)
d D
Play between piston(1) & shoe caulking section(3) (δ) Thickness of shoe (t)
Free height of cylinder spring(4) (L)
Combined height of set plate(5) & spherical bushing(6) (H-h) Surface roughness for valve plate(Sliding face)(7,8), swash plate (shoe plate area)(9), & cylinder(2)(Sliding face)
(210-7) 7-21
Standard dimension
Recommended replacement value
Counter measures
0.039
0.067
Replace piston or cylinder.
0-0.1
0.3 Replace assembly of piston & shoe.
δ t
4.9
4.7
41.1
40.3
Replace cylinder spring.
23.0
22.0
Replace retainer or set plate.
L
h H
Surface roughness necessary to be corrected
3z Lapping
Standard surface roughness (Corrected value)
7 - 21
0.4z or lower
2. MAIN CONTROL VALVE Part name Casing
Inspection item
Criteria & measure
・Existence of scratch, rusting or corrosion.
・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 spool is inserted. - Seal section of port where O-ring contacts. - Seal section of each relief valve for main, travel, and port. - Other damages that may damage normal functions.
・Existence of scratch, gnawing, rusting or corrosion.
・Replacement when its outside sliding section has scratch(Especially on sealscontacting section).
・O-ring seal sections at both ends.
・Replacement when its sliding section has scratch.
・Insert spool in casing hole, rotate and reciprocate it.
・Correction or replacement when O-ring is damaged or when spool does not move smoothly.
・Damage of poppet or spring
・Correction or replacement when sealing is incomplete.
・Insert poppet into casing and function it.
・Normal when it can function lightly without being caught.
Around spring
・Rusting, corrosion, deformation or breaking of spring, spring seat, plug or cover.
・Replacement for significant damage.
Around seal for spool
・External oil leakage.
・Correction or replacement.
・Rusting, corrosion or deformation of seal plate.
・Correction or replacement.
Main relief valve, port relief valve & negative control relief valve
・External rusting or damage.
・Replacement.
・Contacting face of valve seat.
・Replacement when damaged.
・Contacting face of poppet.
・Replacement when damaged.
・Abnormal spring.
・Replacement.
・O-rings, back up rings and seals.
・100% replacement in general.
Spool
Poppet
7 - 22
3. SWING DEVICE Part name Balance plate
Inspection item
Remedy
・Worn less than 0.03mm
・Lapping
・Worn more than 0.03mm
・Replacement
・Sliding surface has a seizure(Even through small). Shoe of piston assembly
・Sliding surface has a damage. ・Sliding surface depression( ) dimension less than 0.45mm or has a large damage.
・Replacement ・Lapping ・Replace parts or motor
Piston of piston assembly
・Sliding surface has a seizure(Even though small).
・Replace motor
Piston hole of cylinder assembly
・Sliding surface has a seizure.
・Replace motor
・Sliding surface has a damage.
・Replace motor
Taper roller bearing ・In case 3000hour operation. Needle bearing ・Rolling surface has a damage. Roller bearing
・Replacement ・Replacement
7 - 23
4. TRAVEL DEVICE Disassembling and inspection of the motor must be done in strict accordance with the servicing standards described here. During servicing, handle each part very carefully not to damage them, especially for their movable or sliding sections. 1) SEALS Once the seals(O-rings, oil seals, and floating seals) have been disassembled, they must be replaced with new ones even if no damage is observed. 2) TABLE OF MAINTENANCE STANDARD (1) Replace all parts having a seriously damaged appearance. (2) Replace the part if any one of the states(Symptoms) listed in the table below is observed. Item No.
Standard dimension
Maximum allowable value(Criteria)
-
-
-
-
・The tooth surface is nonuniformly worn out and damaged.
-
-
・The tooth surface is nonuniformly worn out and damaged.
-
-
・The tooth surface is nonuniformly worn out and damaged. ・The spline section is worn.
-
-
Part name
Situation
Spindle kit 2 8 17
・Spindle assembly ・・Spindle ・・Coupling gear
・Seriously damaged in appearance.
・Pin
・Galling or other forms of excessive wear are observed.
3 6 9 14 25 34
Carrier assembly Carrier Cluster gear Shaft Thrust collar Needle bearing Dowel pin
4
Ring gear A
5
7
Ring gear B
Sun gear
・The tooth surface of the cluster gear(6) is nonuniformly worn out and damaged. ・The cluster gear(6) does not move smoothly.
8
Coupling gear
・Excessive wear or pitching is observed on the tooth surface.
-
-
19
Coupling
・The spline section is worn.
-
-
20
Thrust bearing
・Worn out.
Axial clearance between coupling gear(8) and cover(13) : 0.3 to 0.6m
7 - 24
Clearance : 0.8mm
Item No. 22
Part name Distance piece
Situation
Ball bearing
Maximum allowable value(Criteria)
-
-
-
-
・The sliding surface is damaged. ・The sliding surface is excessively worn out.
24
Standard dimension
・Dents are present. ・Flaking develops. ・Nonuniform wear is present.
Rear flange kit 101 Rear flange
・The movable section contacting the spool(123) is damaged.
Linear clearance : 10 to 20 μ
Linear clearance : 20 μ
・The clearance against the spool (123) is too large. ・The surface contacting the valve (127) is damaged. ・The depth to the surface contacting the valve (127) is too large. 123 Spool
・The outer surface is damaged. ・The outer surface is nonuniformly worn out.
102 Shaft
・The surface contacting the oil seal(132) is worn out.
-
-
-
-
-
-
・The spline section is worn out. 103 Swash plate
・Seizure is observed.
104 Cylinder block
・The spline section is worn out. ・The bore inner surface is worn out too much. ・The sliding surface that contacts the timing plate(109) is damaged or nonuniformly worn out.
Piston assembly 105 Piston 106 shoe
・An axial clearance is present Clearance : 0.05mm between the piston(105) and the shoe(106).
Clearance : 0.15mm
・The shoe is excessively worn out. ・The shoe is nonuniformly worn out. 107 Retainer plate
・The peripheral edge is nonuniformly worn out.
7 - 25
-
-
Item No.
Part name
108 Thrust ball
Situation
Standard dimension
Maximum allowable value(Criteria)
・The spherical sliding section that contacts the retainer plate(107) is nonuniformly worn out.
-
-
109 Timing plate
・The sliding surface has the traces of seizure or nonuniformly wear.
115 Friction plate
・Both edges are nonuniformly worn out.
116 Mating plate
・The required torque cannot be achieved.
Braking torque 49.3kgf・m or more
Braking torque 49.3kgf・m or less
・The traces of seizure are present. 118 Valve seat
・The seat surface is damaged.
119 Valve
・The outer surface is damaged. ・The seat surface is damaged.
Body kit 136 Body
・The sliding section that contacts the spool(137) is damaged.
-
-
-
-
Linear clearance : 7 to 15 μ
Linear clearance : 20 μ
・The clearance against the spool(137) is too large. 137 Spool
・The outer surface is damaged. ・The outer surface is nonuniformly worn out.
149 Roller bearing 150 Ball bearing
・Dents are present. ・Flaking develops.
-
-
-
-
-
-
-
-
-
-
・Nonuniform wear is observed. 163 Valve
・The outer surface is damaged. ・The seat surface is damaged.
164 Stopper
・The seat surface is damaged.
142 Valve
・The outer surface is damaged. ・The seat surface is damaged.
172 Valve seat
・The seat surface is damaged.
7 - 26
5. RCV LEVER Maintenance check item Leakage
Criteria
Remark
The valve is to be replaced when the leakage becomes more than 1000cc/m at neutral handle position, or more than 2000cc/m during operation.
Spool
This is to be replaced when the sliding surface has worn more than 10μm, compared with the nonsliding surface.
Conditions : Primary pressure : 30kgf/cm2 Oil viscosity : 23cSt The leakage at the left condition is estimated to be nearly equal to the above leakage.
Push rod Ø7
1mm This is to be replaced when the top end has worn more than 1mm. Play at operating section
The pin, shaft, and joint of the operating section are to be replaced when their plays become more than 2mm due to wears or so on.
Operation stability
When abnormal noises, hunting, primary pressure drop, etc. are generated during operation, and these cannot be remedied, referring to section 6. Troubleshooting, replace the related parts.
When a play is due to looseness of a tightened section, adjust it.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However, they may be reused, after being confirmed to be free of damage. 2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121) without fail.
7 - 27
6. RCV PEDAL Maintenance check item
Criteria
Remark
Leakage
The valve is to be replaced when the leakage effect to the system. For example, the primary pressure drop.
Conditions : Primary pressure : 30kgf/cm2 Oil viscosity : 23cSt
Spool
This is to be replaced when the sliding surface has worn more than 10μm, compared with the non-
The leakage at the left condition is estimated to be nearly equal to the above leakage.
sliding surface. Push rod Ø7
1mm This is to be replaced when the top end has worn more than 1mm. Play at operating section
The pin, shaft, and joint of the operating section are to be replaced when their plays become more than 2mm due to wears or so on.
Operation stability
When abnormal noises, hunting, primary pressure drop, etc. are generated during operation, and these cannot be remedied, referring to section 6. Troubleshooting, replace the related parts.
When a play is due to looseness of a tightened section, adjust it.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However, they may be reused, after being confirmed to be free of damage.
7 - 28
7. TURNING JOINT Part name
Body, Stem
Maintenance standards
Sliding surface with Plating worn or peeled due to seizure or contamination. sealing sections.
Replace
Sliding surface ・Worn abnormality or damaged more than 0.1mm (0.0039in) in depth due to seizure contamination. between body and stem other than ・Damaged more than 0.1mm(0.0039in) in depth. sealing section.
Replace
Sliding surface with thrust plate.
Cover
Remedy
Sliding surface with thrust plate.
Smooth with oilstone.
・Worn more than 0.5mm(0.02in) or abnormality.
Replace
・Worn less than 0.5mm(0.02in).
Smooth
・Damage due to seizure or contamination remediable within wear limit (0.5mm)(0.02in).
Smooth
・Worn more than 0.5mm(0.02in) or abnormality.
Replace
・Worn less than 0.5mm(0.02in).
Smooth
・Damage due to seizure or contamination remediable within wear limit (0.5mm)(0.02in).
Replace
・Extruded excessively from seal groove square ring.
Replace
Extrusion
Square ring
・Slipper ring 1.5mm(0.059in) narrower than seal groove, or narrower than back ring.
Replace
Seal set 1.5mm (max.) (0.059in) ・Worn more than 0.5mm(0.02in) ~ 1.5mm(MAX.) (0.059in) -
7 - 29
Replace
8. CYLINDER Inspecting section
Part name Piston rod
Cylinder tube
Gland
Inspection item
Remedy
・Neck of rod pin
・Presence of crack
・Replace
・Weld on rod hub
・Presence of crack
・Replace
・Stepped part to which piston is attached.
・Presence of crack
・Replace
・Threads
・Presence of crack
・Recondition or replace
・Plated surface
・Plating is not worn off to base ・Replace or replate metal. ・Rust is not present on plating.
・Replace or replate
・Scratches are not present.
・Recondition, replate or replace
・Rod
・Wear of O.D.
・Recondition, replate or replace
・Bushing at mounting part
・Wear of I.D.
・Replace
・Weld on bottom
・Presence of crack
・Replace
・Weld on head
・Presence of crack
・Replace
・Weld on hub
・Presence of crack
・Replace
・Tube interior
・Presence of faults
・Replace if oil leak is seen
・Bushing at mounting part
・Wear on inner surface
・Replace
・Bushing
・Flaw on inner surface
・Replace if flaw is deeper than coating
7 - 30
GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK 1) TRACK ROLLER
3
1
2
5
6
4 21037MS01
Unit : mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
Ø200
-
Ø160
Ø148
Width of tread
48
54
4
Width of flange
21.5
15.5
5
Clearance between shaft and bushing
1
Outside diameter of flange
2
Outside diameter of tread
3
6
Side clearance of roller (Both side)
Standard size & tolerance Shaft Hole -0.29 +0.046 Ø70 -0.33 Ø70.1 0
Rebuild or replace
Standard clearance
Clearance limit
0.39 to 0.476
2.0
Standard clearance
Clearance limit
0.2 to 1.2
2.0
7 - 31
Replace bushing
Replace
2) CARRIER ROLLER
5
2
1
4 3
21037MS02
Unit : mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
Ø169
-
Ø144
Ø134
Width of tread
44
49
4
Width of flange
17
-
5
Clearance between shaft and bushing
1
Outside diameter of flange
2
Outside diameter of tread
3
Standard size Ø55
Tolerance Shaft Hole +0.085 +0.37 +0.066 +0.33
7 - 32
Rebuild or replace
Standard clearance
Clearance limit
0.245 to 0.304
2.0
Replace bushing
3
7
8
6
2
1
3) IDLER
5
4 21037MS03
Unit : mm No.
Check item
1
Outside diameter of protrusion
2
Outside diameter of tread
3
Criteria
Remedy
Standard size
Repair limit
Ø560
-
Ø520
Ø514
Width of protrusion
84
-
4
Total width
160
-
5
Width of tread
38
44
6
Clearance between shaft and bushing
7
Clearance between shaft and support
8
Side clearance of idler (Both side)
Standard size & tolerance Standard clearance Shaft Hole 0 +0.05 0.35 to 0.43 Ø75 -0.03 Ø75.35 0 0 +0.07 0.03 to 0.1 Ø75 -0.03 Ø75 +0.03
Rebuild or replace
Clearance limit 2.0 1.2
Standard clearance
Clearance limit
0.4 to 1.2
2.0
7 - 33
Replace bushing Replace Replace bushing
4) TRACK
1
3
4
2
5 21037MS04
Unit : mm No. 1
Check item Link pitch
Criteria
Remedy
Standard size
Repair limit
190
194.4
͚59
͚51
2
Outside diameter of bushing
3
Height of grouser
26
16
4
Height of link
105
97
5
Tightening torque
Initial tightening torque : 78Ü8kgfÂm
7 - 32
Turn or replace
Rebuild or replace Retighten
2
5) TRACK FRAME AND RECOIL SPRING
1
3
21037MS05
Unit : mm No.
Check item
Criteria Standard size
1
2
Vertical width of idler guide
Remedy
Tolerance
Track frame
113
+2 0
117
Idler support
110
- 0.5 - 1.0
106
Track frame
272
+2 0
277
Idler support
270
+0.5 -0.5
267
Horizontal width of idler guide Standard size
3
Recoil spring
Repair limit
Free length Ø235×515
Repair limit
Installation Installation length load 431
7 - 35
Rebuild or replace
13716kg
Free length
Installation load
-
10973kg
Replace
2. WORK EQUIPMENT
A
C
K
B
D
E
I
J
H
F
G
21077MS20
Unit : mm Bushing
Pin Mark
Measuring point (Pin and Bushing)
Normal value
Recomm. service limit
Limit of use
Recomm. service limit
Limit of use
Remedy & Remark
A
Boom Rear
90
89
88.5
90.5
91
Replace
B
Boom Cylinder Head
80
79
78.5
80.5
81
〃
C
Boom Cylinder Rod
80
79
78.5
80.5
81
〃
D
Arm Cylinder Head
80
79
78.5
80.5
81
〃
E
Boom Front
90
89
88.5
90.5
91
〃
F
Arm Cylinder Rod
80
79
78.5
80.5
81
〃
G
Bucket Cylinder Head
80
79
78.5
80.5
81
〃
H
Arm Link
70
69
68.5
70.5
71
〃
I
Bucket and Arm Link
80
79
78.5
80.5
81
〃
J
Bucket Cylinder Rod
80
79
78.5
80.5
81
〃
K
Bucket Link
80
79
78.5
80.5
81
〃
7 - 36
SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9 Group 10 Group 11
Precaution Tightening Torque Pump Device Main Control Valve Swing Device Travel Device RCV Lever Turning Joint Boom, Arm and Bucket Cylinder Undercarriage Work Equipment
8-1 8-4 8-7 8-30 8-43 8-68 8-108 8-123 8-128 8-145 8-157
SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK 1) Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. 2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. 3) When draining oil, prepare a container of adequate size to catch the oil. 4) Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. 5) To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. 6) Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. 7) Check the number and thickness of the shims, and keep in a safe place. 8) When raising components, be sure to use lifting equipment of ample strength. 9) When using forcing screws to remove any components, tighten the forcing screws alternately. 10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. 11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank and the hydraulic piping. 12) If the part is not under hydraulic pressure, the following corks can be used. Dimensions
Nominal number
D
d
L
06
6
5
8
08
8
6.5
11
10
10
8.5
12
12
12
10
15
14
14
11.5
18
16
16
13.5
20
18
18
15
22
20
20
17
25
22
22
18.5
28
24
24
20
30
27
27
22.5
34
øD
Taper 1/8
L
8-1
ød
2. INSTALL WORK 1) Tighten all bolts and nuts(Sleeve nuts) to the specified torque. 2) Install the hoses without twisting or interference. 3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. 4) Bend the cotter pin or lock plate securely. 5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive. 6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. 7) Clean all parts, and correct any damage, dents, burrs, or rust. 8) Coat rotating parts and sliding parts with engine oil. 9) When press fitting parts, coat the surface with antifriction compound(LM-P). 10) After installing snap rings, check that the snap ring is fitted securely in the ring groove(Check that the snap ring moves in the direction of rotation). 11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. 12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully. 13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. 14) When operating the hydraulic cylinders for the first time after repairing and reassembling the hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the hydraulic cylinders as follows: (1) Start the engine and run at low idling. (2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm before the end of the stroke. (3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is actuated to bleed the air.) (4) After completing this operation, raise the engine speed to the normal operating condition. ※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to the work equipment. ※ Carry out the same operation on machines that have been in storage for a long time after completion of repairs.
8-2
3. COMPLETING WORK 1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. 2) If the hydraulic equipment has been 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. 3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, always bleed the air from the system after reassembling the parts. 4) Add the specified amount of grease(Molybdenum disulphied grease) to the work equipment related parts.
8-3
GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS No.
Descriptions
Bolt size
Torque kgf・m
lbf・ft
Engine mounting bolt, nut
M24 × 3.0
Radiator mounting bolt
M12 × 1.75
Coupling mounting socket bolt
M16 × 2.0
22 ± 1.0
159 ± 7.2
4
Main pump housing mounting bolt
M10 × 1.5
4.8 ± 0.3
34.7 ± 2.2
5
Main pump mounting socket bolt
M20 × 2.5
42 ± 4.5
304 ± 32.5
Main control valve mounting nut
M12 × 1.75
Fuel tank mounting bolt
M20 × 2.5
45 ± 5.1
325 ± 36.9
8
Hydraulic oil tank mounting bolt
M20 × 2.5
45 ± 5.1
325 ± 36.9
9
Turning joint mounting bolt, nut
M12× 1.75
12.3 ± 1.3
88.9 ± 9.4
10
Swing motor mounting bolt
M20 × 2.5
57.9 ± 8.7
419 ± 62.9
Swing bearing upper part mounting bolt
M20 × 2.5
57.8 ± 6.4
418 ± 46.3
Swing bearing lower part mounting bolt
M20 × 2.5
57.8 ± 6.4
418 ± 46.3
Travel motor mounting bolt
M16 × 2.0
23 ±2.5
166 ± 18.1
14
Sprocket mounting bolt
M16 × 2.0
26 ±4.0
188 ± 28.9
15
Carrier roller mounting bolt, nut
M16 × 2.0
23 ±2.5
166 ± 18.1
Track roller mounting bolt
M20 × 2.5
54.7 ± 5.0
396 ± 36.2
Track tension cylinder mounting bolt
M16 × 2.0
29.7 ± 4.5
215 ± 32.5
18
Track shoe mounting bolt, nut
M20 × 1.5
78 ± 8.0
564 ± 57.9
19
Track guard mounting bolt
M20 × 2.5
57.9 ± 8.7
419 ± 62.9
20
Counter weight mounting bolt
M36 × 3.0
297 ± 33
2148 ± 239
Cab mounting bolt
M12 × 1.75
12.8 ± 3.0
92.6 ± 21.7
Operator's seat mounting bolt
M 8 × 1.25
4.05 ± 0.8
29.3 ± 5.8
1 2 3
Engine
6 7
11 12 13
Hydraulic system
Power train system
16 17
21 22
Under carriage
Others
90 ± 7.0 12.8 ± 3.0
12.2 ± 1.3
651 ± 51 92.6 ± 21.7
88.2 ± 9.4
※ For tightening torque of engine and hydraulic components, see each component disassembly and assembly.
8-4
2. TORQUE CHART Use following table for unspecified torque. 1) BOLT AND NUT - Coarse thread Bolt size
10T
8T kgf・m
lbf・ft
kgf・m
lbf・ft
M 6 × 1.0
0.85 ~ 1.25
6.15 ~ 9.04
1.14 ~ 1.74
8.2 ~ 12.6
M 8 × 1.25
2.0 ~ 3.0
14.5 ~ 21.7
2.73 ~ 4.12
19.7 ~ 29.8
M10 × 1.5
4.0 ~ 6.0
28.9 ~ 43.4
5.5 ~ 8.3
M12 × 1.75
7.4 ~ 11.2
53.5 ~ 79.5
9.8 ~ 15.8
71 ~ 114
M14 × 2.0
12.2 ~ 16.6
88.2 ~ 120
16.7 ~ 22.5
121 ~ 167
M16 × 2.0
18.6 ~ 25.2
135 ~ 182
25.2 ~ 34.2
182 ~ 247
M18 × 2.5
25.8 ~ 35.0
187 ~ 253
35.1 ~ 47.5
254 ~ 343
M20 × 2.5
36.2 ~ 49.0
262 ~ 354
49.2 ~ 66.6
356 ~ 482
M22 × 2.5
48.3 ~ 63.3
350 ~ 457
65.8 ~ 98.0
476 ~ 709
M24 × 3.0
62.5 ~ 84.5
452 ~ 611
85.0 ~ 115
615 ~ 832
M30 × 3.5
124 ~ 168
898 ~ 1214
169 ~ 229
1223 ~ 1655
M36 × 4.0
174 ~ 236
1261 ~ 1703
250 ~ 310
1808 ~ 2242
39.8 ~ 60
2) BOLT AND NUT - Fine thread Bolt size
8T
10T
kgf・m
lbf・ft
kgf・m
lbf・ft
M 8 × 1.0
2.17 ~ 3.37
15.7 ~ 24.3
3.04 ~ 4.44
22.0 ~ 32.0
M10 × 1.25
4.46 ~ 6.66
32.3 ~ 48.2
5.93 ~ 8.93
42.9 ~ 64.6
M12 × 1.25
7.78 ~ 11.58
76.3 ~ 83.7
10.6 ~ 16.0
76.6 ~ 115
M14 × 1.5
13.3 ~ 18.1
96.2 ~ 130
17.9 ~ 24.1
130 ~ 174
M16 × 1.5
19.9 ~ 26.9
144 ~ 194
26.6 ~ 36.0
193 ~ 260
M18 × 1.5
28.6 ~ 43.6
207 ~ 315
38.4 ~ 52.0
278 ~ 376
M20 × 1.5
40.0 ~ 54.0
289 ~ 390
53.4 ~ 72.2
386 ~ 522
M22 × 1.5
52.7 ~ 71.3
381 ~ 515
70.7 ~ 95.7
512 ~ 692
M24 × 2.0
67.9 ~ 91.9
491 ~ 664
90.9 ~ 123
658 ~ 890
M30 × 2.0
137 ~ 185
990 ~ 1338
182 ~ 248
1314 ~ 1795
M36 × 3.0
192 ~ 260
1389 ~ 1879
262 ~ 354
1893 ~ 2561
8-5
3) PIPE AND HOSE Thread size
Width across flat(mm)
kgf・m
lbf・ft
1/4"
19
3
21.7
3/8"
22
4
28.9
1/2"
27
5
36.2
3/4"
36
12
86.8
1"
41
14
101
Thread size
Width across flat(mm)
kgf・m
lbf・ft
1/4"
19
4
28.9
3/8"
22
5
36.2
1/2"
27
6
43.4
3/4"
36
13
94.0
1"
41
15
109
4) FITTING
8-6
GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury.
13031GE18
9 74
2
A
(4) Loosen the drain plug under the hydraulic tank and drain the oil from the hydraulic tank. ・ Hydraulic tank quantity : 180ℓ
1
A
(5) Remove socket bolts(74) and disconnect pipe(9).
72
3
(6) Disconnect pilot line hoses(4, 5, 6, 7, 8, 9).
21078DA01
(7) Remove socket bolts(72) and disconnect pump suction tube(3). ※ When pump suction tube is disconnected, the oil inside the piping will flow out, so catch it in oil pan.
69
55
58
3
A
64 a4 1
i1
m
P
P
(8) Sling the pump assembly and remove the pump mounting bolts. ・ Weight : 120kg(265lb) ※ Pull out the pump assembly from housing. When removing the pump assembly, check that all the hoses have been disconnected.
r
D
v
Ps
71
3 B
49
P i2 2
m
P
48 78
8-7
21078DA02
2) INSTALL (1) Carry out installation in the reverse order to removal. (2) Remove the suction strainer and clean it. (3) Replace return filter with new one. (4) Remove breather and clean it. (5) After adding oil to the hydraulic tank to the specified level. (6) Bleed the air from the hydraulic pump. ① Remove the air vent plug(2EA). ② Tighten plug lightly. ③ Start the engine, run at low idling, and check oil come out from plug. ④ Tighten plug. (7) Start the engine, run at low idling(3~5 minutes) to circulate the oil through the system. (8) Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8-8
2. MAIN PUMP(1/2) 1) STRUCTURE A 702 789, 732 532 214 548 531 724 792 534 901 808 954 717 151 152 211 113
04
535 806 953 886 717 406 261 774
111 824 127 710 123 251 212 490
04 111 113 114 123 124 127 141 151 152 153 156 157 158 211 212 214
153
156 158 157 468 313 124 312 114 466 728 725
Gear pump Drive shaft(F) Drive shaft(R) Spline coupling Roller bearing Needle bearing Bearing spacer Cylinder block Piston Shoe Set plate Bushing Cylinder spring Spacer Shoe plate Swash plate Bushing
251 261 271 312 313 314 401 406 466 468 490 531 532 534 535 548 702
885
Support Seal cover(F) Pump casing Valve block Valve plate(R) Valve plate(L) Hexagon socket bolt Hexagon socket bolt VP Plug VP Plug Plug Tilting pin Servo piston Stopper(L) Stopper(S) Pin O-ring
8-9
314
141
271
401 (210-7) 8-9
710 717 724 725 728 732 774 789 792 806 808 824 885 886 901 953 954
O-ring O-ring O-ring O-ring O-ring O-ring Oil seal Back up ring Back up ring Hexagon head nut Hexagon head nut Snap ring Pin Spring pin Eye bolt Set screw Set screw
MAIN PUMP(2/2)
544
543 545 541
079
VIEW A
541 543
Seat Stopper 1
544 545
Stopper 2 Steel ball
8-10
(210-7) 8-10
079
Proportional reducing valve
2) TOOLS AND TIGHTENING TORQUE (1) Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size
Part name
Name
B
Hexagon socket head bolt
PT plug (PT thread)
PO plug (PF thread)
Hexagon socket head setscrew
Allen wrench
4
M 5
BP-1/16
-
M 8
5
M 6
BP-1/8
-
M10
6
M 8
BP-1/4
PO-1/4
M12, M14
8
M10
BP-3/8
PO-3/8
M16, M18
17
M20, M22
PO-1, 1 1/4, 1 1/2
-
B
Double ring spanner, socket wrench, double(Single) open end spanner B
BP-1
-
Hexagon socket head bolt
Henagon nut
VP plug (PF thread)
19
M12
M12
VP-1/4
24
M16
M16
-
27
M18
M18
VP-1/2
30
M20
M20
-
36
-
-
VP-3/4
Adjustable angle wrench
Medium size, 1 set
Screw driver
Minus type screw driver, Medium size, 2 sets
Hammer
Plastic hammer, 1 set
Pliers
For snap ring, TSR-160
Steel bar
Steel bar of key material approx. 10×8×200
Torque wrench
Capable of tightening with the specified torques
8-11
(2) Tightening torque Part name Hexagon socket head bolt Material : SCM435)
PT Plug(Materal : S45C) ※Wind a seal tape 1 1/2 to 2 turns round the plug
PF Plug(Materal : S45C)
Bolt size
Torque
Wrench size
kgf・m
lbf・ft
in
mm
M 5
0.7
5.1
0.16
4
M 6
1.2
8.7
0.20
5
M 8
3.0
21.7
0.24
6
M10
5.8
42.0
0.31
8
M12
10.0
72.3
0.39
10
M14
16.0
116
0.47
12
M16
24.0
174
0.55
14
M18
34.0
246
0.55
14
M20
44.0
318
0.67
17
PT1/16
0.7
5.1
0.16
4
PT 1/8
1.05
7.59
0.20
5
PT 1/4
1.75
12.7
0.24
6
PT 3/8
3.5
25.3
0.31
8
PT 1/2
5.0
36.2
0.39
10
PF 1/4
3.0
21.7
0.24
6
PF 1/2
10.0
72.3
0.39
10
PF 3/4
15.0
109
0.55
14
PF 1
19.0
137
0.67
17
PF 1 1/4
27.0
195
0.67
17
PF 1 1/2
28.0
203
0.67
17
8-12
3) DISASSEMBLY (1) Select place suitable to disassembling. ※ Select clean place. ※ Spread rubber sheet, cloth or so on on overhaul workbench top to prevent parts from being damaged. (2) Remove dust, rust, etc, from pump surfaces with cleaning oil or so on. (3) Remove drain port plug(468) and let oil out of pump casing(Front and rear pump). (4) Remove hexagon socket head bolts(412, 413) and remove regulator.
(210-7) MP01
(5) Loosen hexagon socket head bolts(401) which tighten swash plate support(251), pump casing(271) and valve block(312). ※ If gear pump and so on are fitted to rear face of pump, remove them before starting this work. (6) 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 workbench without fail to prevent this surface from being damaged.
(210-7) MP02
8-13
(7) Pull cylinder block(141) out of pump casing(271) straightly over drive shaft(111). Pull out also pistons(151), set plate(153), spherical bush(156) and cylinder springs(157) simultaneously. ※ Take care not to damage sliding surfaces of cylinder, spherical bushing, shoes, swash plate, etc. (210-7) MP03
(8) Remove hexagon 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 damage it in removing cover. (9) Remove hexagon socket head bolts(408) and then seal cover(R, 262). In case fitting a gear pump, first, remove gear pump.
(210-7) MP04
(10) Tapping lightly fitting flange section of swash plate support(251) on its pump casing side, separate swash plate support from pump casing.
(210-7) MP05
(11) Remove shoe plate(211)and swash plate(212) from pump casing(271).
(210-7) MP06
8-14
(12) Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports.
(210-7) MP07
(13) Remove valve plates(313, 314) from valve block(312). ※ These may be removed in work(6).
(210-7) MP08
(14) If necessary, remove stopper(L, 534), stopper(S, 535), servo piston(532) and tilting pin(531) from pump casing(271), and needle bearing(124) and splined coupling(114) from valve block(312). ※ In removing tilting pin, use a protector to prevent pin head from being damaged. ※ Since loctite is applied to fitting areas of tilting pin and servo piston, take care not to damage servo piston. ※ Do not remove needle bearing as far as possible, except when it is considered to be out of its life span. ※ Do not loosen hexagon nuts of valve block and swash plate support. If loosened, flow setting will be changed.
8-15
4) ASSEMBLY (1) For reassembling reverse the disassembling procedures, paying attention to the following items. ① Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. ② Clean each part fully with cleaning oil and dry it with compressed air. ③ Do not fail to apply clean working oil to sliding sections, bearings, etc. before assembling them. ④ In principle, replace seal parts, such as O-rings, oil seals, etc. ⑤ For fitting bolts, plug, etc., prepare a torque wrench or so on, and tighten them with torques shown in page 8-11, 12. ⑥ For the double-pump, take care not to mix up parts of the front pump with those of the rear pump. (2) Fit swash plate support(251) to pump casing(271), tapping the former lightly with a hammer. ※ After servo piston, tilting pin, stopper(L) and stopper(S) are removed, fit them soon to pump casing in advance for reassembling. ※ In tightening servo piston and tilting pin, use a protector to prevent tilting pin head and feedback pin from being damaged. In addition, apply loctite(Medium strength) to their threaded sections.
(210-7) MP09
8-16
(3) Place pump casing with its regulator fitting surface down, fit tilting bush of swash plate to tilting pin(531) and fit swash plate (212) to swash plate support(251) correctly. ※ Confirm with fingers of both hands that swash plate can be removed smoothly. ※ Apply grease to sliding sections of swash plate and swash plate support, and drive shaft can be fitted easily.
(210-7) MP10
(4) To swash plate support(251), fit drive shaft(111) set with bearing(123), bearing spacer(127) and snap ring(824). ※ Do not tap drive shaft with hammer or so on. ※ Assemble them into support, tapping outer race of bearing lightly with plastic hammer. Fit them fully, using steel bar or so on. (210-7) MP11
(5) Assemble seal cover(F, 261) to pump casing(271) and fix it with hexagon socket head bolts(406). ※ Apply grease lightly to oil seal in seal cover(F). ※ Assemble oil seal, taking full care not to damage it. ※ For tandem type pump, fit rear cover(263) and seal cover(262) similarly. (210-7) MP12
(6) Assemble piston cylinder subassembly 〔cylinder block(141), piston subassembly (151, 152), set plate(153), spherical bush (156), spacer(158) and cylinder spring (157)〕. Fit spline phases of retainer and cylinder. Then, insert piston cylinder subassembly into pump casing. (210-7) MP13
8-17
(7) Fit valve plate(313) to valve block(312), entering pin into pin hole. ※ Take care not to mistake suction / delivery directions of valve plate.
(210-7) MP14
(8) Fit valve block(312) to pump casing(271) and tighten hexagon socket head bolts (401). ※ At first assemble this at rear pump side, and this work will be easy. ※ Take care not to mistake direction of valve block. ※ Clockwise rotation(Viewed from input shaft side) - Fit block with regulator up and with delivery flange left, viewed from front side. ※ Counter clockwise rotation(Viewed from input shaft side) - Fit block with delivery flange right, viewed from front side.
(210-7) MP16
(9) Putting feedback pin of tilting pin into feedback lever of regulator, fit regulator and tighten hexagon socket head bolts (412, 413). ※ Take care not to mistake regulator of front pump for that of rear pump.
(210-7) MP17
(10) Fit drain port plug(468). This is the end of reassembling procedures.
8-18
3. REGULATOR 1) STRUCTURE(1/2) 412
875
874
755 A
897
858
B
614
612
615 613 A
611
B
647 648
KR3G-9C32
A
P2 Pf
723 642
438 801
801
Pm Pi
924 641
730
643
708
644
645
646
728
B
SECTION B-B (210-7) 8-19
413
438
656
438 735 722
496
724
725
436
VIEW C
8-19
REGULATOR(2/2) 734
653
654
836
651 652
601
624
629
630
628
655
641
801 C 925
814 898 631
627
732
733
732
622
621
623
625
626
887
763
756
SECTION A-A (210-7) 8-20
412 413 436 438 496 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629
Hexagon socket screw Hexagon socket screw Hexagon socket screw Hexagon socket screw Plug Casing Feed back lever Lever(1) Lever(2) Fulcrum plug Adjust plug Compensator rod Piston case Compensator rod Spring seat(C) Outer spring Inner spring Adjust stem(C) Adjust screw(C) Cover(C)
630 631 641 642 643 644 645 646 647 648 651 652 653 654 655 656 708 722 724 725
Nut Sleeve Pilot cover Pilot cover(QMC) Pilot piston Spring seat(Q) Adjust stem(Q) Pilot spring Stopper Piston(QMC) Sleeve Spool Spring seat Return spring Set spring Block cover O-ring O-ring O-ring O-ring 8-20
728 730 732 733 734 735 755 756 763 801 814 836 858 874 875 887 897 898 924 925
O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring Nut Snap ring Snap ring Snap ring Pin Pin Pin Pin Pin Set screw Adjust screw(Q)
2) TOOLS AND TIGHTENING TORQUE (1) Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Name Allen wrench B
Double ring spanner, socket wrench, double(Single) open end spanner
Part name B
Hexagon socket head bolt
PT plug (PT thread)
PO plug (PF thread)
Hexagon socket head setscrew
4
M 5
BP-1/16
-
M 8
5
M 6
BP-1/8
-
M10
6
M 8
BP-1/4
PO-1/4
M12, M14
-
Hexagon head bolt
Hexagon nut
VP plug (PF thread)
6
M 8
M 8
-
B
Adjustable angle wrench
Small size, Max 36mm
Screw driver
Minus type screw driver, Medium size, 2 sets
Hammer
Plastic hammer, 1 set
Pliers
For snap ring, TSR-160
Steel bar
4×100mm
Torque wrench
Capable of tightening with the specified torques
Pincers
-
Bolt
M4, Length : 50mm
8-21
(2) Tightening torque Part name Hexagon socket head bolt Material : SCM435)
PT Plut(Materal : S45C) ※Wind a seal tape 1 1/2 to 2 turns round the plug
PF Plut(Materal : S35C)
Bolt size
Torque
Wrench size
kgf・m
lbf・ft
in
M 5
0.7
5.1
0.16
4
M 6
1.2
8.7
0.20
5
M 8
3.0
21.7
0.24
6
M10
5.8
42.0
0.31
8
M12
10.0
72.3
0.39
10
M14
16.0
116
0.47
12
M16
24.0
174
0.55
14
M18
34.0
246
0.55
14
M20
44.0
318
0.67
17
PT1/16
0.7
5.1
0.16
4
PT 1/8
1.05
7.59
0.20
5
PT 1/4
1.75
12.7
0.24
6
PT 3/8
3.5
25.3
0.31
8
PT 1/2
5.0
36.2
0.39
10
PF 1/4
3.0
21.7
0.24
6
PF 1/2
10.0
72.3
0.39
10
PF 3/4
15.0
109
0.55
14
PF 1
19.0
137
0.67
17
PF 1 1/4
27.0
195
0.67
17
PF 1 1/2
28.0
203
0.67
17
8-22
mm
3) DISASSEMBLY Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly. (1) Choose a place for disassembly. ※ Choose a clean place. ※ Spread rubber sheet, cloth, or so on on top of work-bench to prevent parts from being damaged. (2) Remove dust, rust, etc. from surfaces of regulator with clean oil. (3) Remove hexagon socket head screw (412, 413) and remove regulator main body from pump main body. ※ Take care not to lose O-ring.
(210-7) REG01
(4) Remove hexagon socket head screw (438) and remove cover(C,629) ※ Cover(C) is fitted with adjusting screw (C,QI) (628, 925), adjusting ring(C, 627), lock nut(630), hexagon nut(801) and adjusting screw(924). Do not loosen these screws and nuts. If they are loosened, adjusted pressureflow setting will vary. (210-7) REG02
8-23
(5) After removing cover(C, 629) subassembly, take out outer spring(625), inner spring (626) and spring seat(C, 624) from compensating section. Then draw out adjusting ring(Q, 645), pilot spring(646) and spring seat(644) from pilot section. ※ Adjusting ring(Q,645) can easily be drawn out with M4 bolt. (210-7) REG03
(6) Remove hexagon socket head screws (436, 438) and remove pilot cover(641). After removing pilot cover, take out set spring(655) from pilot section.
(210-7) REG04
(7) Remove snap ring(814) and take out spring seat(653), return spring(654) and sleeve(651). ※ Sleeve(651) is fitted with snap ring(836). ※ When removing snap ring(814), return spring(654) may pop out. Take care not to lose it.
(210-7) REG05
(8) Remove locking ring(858) and take out fulcrum plug(614) and adjusting plug (615). ※ Fulcrum plug(614) and adjusting plug (615) can easily be taken out with M6 bolt.
(210-7) REG06
8-24
(210-7) REG07
(9) Remove lever(2, 613). Do not draw out pin(875). ※ Work will be promoted by using pincers or so on.
(210-7) REG08
(10) Draw out pin(874) and remove 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).
(210-7) REG09
(210-7) REG10
8-25
(11) Remove lever(1, 612). pin(875).
Do not draw out
(12) Draw out pilot piston(643) and spool(652). (13) 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 piston case. This completes disassembly.
8-26
4) ASSEMBLY (1) For assembly, reverse disassembly procedures, but pay attention to the following items. ① Always repair parts that were scored at disassembly. ② Get replacement parts ready beforehand. Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place. ③ Always tighten bolts, plugs, etc. to their specified torques. ④ Do not fail to coat sliding surfaces with clean hydraulic oil before assembly. ⑤ Replace seals such as O-ring with new ones as a rule. (2) Put compensating rod(623) compensating hole of casing(601).
into
(3) Put pin force-fitted in lever(1, 612) into groove of compensating rod and fit lever (1) to pin force-fitted in casing.
(4) Fit spool(652) and sleeve(651) into hole in spool of casing. ※ Confirm that spool and sleeve slide smoothly in casing without binding. ※ Pay attention to orientation of spool. Spool Feedback lever (210-7) 8-27
8-27
(5) Fit feedback lever(611), matching its pin hole with pin hole in spool. Then insert pin(874). ※ Insert pin in feedback lever a little to ease operation. ※ Take care not to mistake direction of feedback lever.
Lever (1) side
Lever (2) side (Fulcrum plug of adjusting plug side)
(210-7) 8-28
(6) Put pilot piston(643) into pilot hole of casing. ※ Confirm that pilot piston slides smoothly without binding. (7) Put pin force-fitted in lever(2, 613) into groove of pilot piston. Then fix lever(2). (210-7) REG11
(8) Fit fulcrum plug(614) so that pin forcefitted in fulcrum plug(614) can be put into pin hole of lever(2). Then fix locking ring(858). (9) Insert adjusting plug(615) and fit locking ring. ※ Take care not to mistake inserting holes for fulcrum plug and adjusting plug. At this point in time move feedback lever to confirm that it has no large play and is free from binding.
(210-7) REG12
(10) Fit return spring(654) and spring seat (653) into spool hole and attach snap ring (814).
(210-7) REG13
8-28
(11) Fit set spring(655) to spool hole and put compensating piston(621) and piston case(622) into compensating hole. Fit pilot cover(641) and tighten it with hexagonal socket head screws(436, 438).
(210-7) REG14
(12) Put spring 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 mistake direction of spring seat.
(210-7) REG15
(13) Install cover(C, 629) fitted with adjusting screws(628, 925), adjusting ring(C, 627), lock nut(630), hexagon nut(801) and adjusting screw(924). Then tighten them with hexagonal socket head screws(438).
This completes assembly.
(210-7) REG16
8-29
GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury. ※ When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.
13031GE18
Atr
Btr
Atl
(4) Remove bolts and disconnect pipe.
As Btl
1
Ba
1
Aa
Bs
(5) Disconnect pilot line hoses. (6) Disconnect pilot piping. 21078MC01
(7) Sling the control valve assembly and remove the control valve mounting bolt. ・Weight : 200kg(441lb) (8) Remove the control valve assembly. When removing the control valve assembly, check that all the piping have been disconnected. 2) INSTALL (1) Carry out installation in the reverse order to removal.
21078MC02
(2) Bleed the air from below items. ① Cylinder(Boom, arm, bucket) ② Swing motor ③ Travel motor ※ See each item removal and install. (3) Confirm the hydraulic oil level and recheck the hydraulic oil leak or not.
D
D
21078MC03
8 - 30
2. STRUCTURE(1/5)
551 561 521 511 551 561 521 511
C1 C2
391
Cp2
252
324
159
325 338
601
425 424 438
103
401
357
561 153
561
104
551
102
254 153
251
561 101 252
21078MC04
101 102 103 104 153 159 251 252
Casing A Casing B Block Block Plug Plug Control valve Lock valve
254 324 325 338 357 391 401 424
Logic valve Spring Spirng Stopper Orifice Travel spool Spool Spring
8 - 31
425 438 511 521 551 561 601
Spring Rod Poppet Spring Plug O-ring Main relief valve
STRUCTURE(2/5) 203
556 201
164
333
201 154 164
336
201
332 335 379
336
273
332 339 372
336
203 333 331 337 378 377
332 335 379
370
332 261
332 261
328 331 262
332 261
374
370
331 334 329
310 305
307
331
159
262
551 561 611
I
K
A
S
A
W
A
395
K
302
)
(L
T
S
2
B
392 1
A
I
C
K
B
A
S
A
W
A
K
)
(L
T
S
P
S
1
A
C
B
602
611 561
602
551 21078MC05
154 159 164 201 203 261 262 273 302 305 307
Plug Plug O-ring Cover Cover O-ring O-ring Socket screw Arm1 spool Swing spool Boom2 spool
310 331 332 333 334 335 336 337 339 370 372
Travel spool Seat Seat Bolt Stopper Stopper Bolt Stopper Stopper Spring Spring
8 - 32
374 377 378 379 392 395 551 556 561 602 611
Spring Spring Spring Spring By pass cut spool Spool Plug Plug O-ring Port relief valve Nega con relief valve
STRUCTURE(3/5)
K A A W S A K I
) (L T
S
S P
A 1
B C
515 521 561 551
516 523 561 552
511 521 561 551
169 202
264
561 153
204 264 204
169
561 551
261 332 339
202
376
164 154
370 332 336 201
273 164 556 21078MC06
153 154 164 169 201 202 204 261
Plug Plug O-ring O-ring Cover Cover Cover O-ring
264 273 332 336 339 370 376 511
O-ring Socket screw Seat Bolt Stopper Spring Spring Poppet
8 - 33
515 516 521 523 551 552 556 561
Poppet Poppet Spring Spring Plug Plug Plug O-ring
STRUCTURE(4/5) 203 203 201 201
333
201
333
273
332 335 372
329 328
332 261
370
328 331 262
331 262
370
379
301
332 261
374 553 561
332 335 379
336 332 335
336
602
331 334
336
331 334 329
309
332 261 303 304 306 158
155 167
)
(R
T T
P
O
1
B
154
K
B
164
156 2
A
163
159
159
561 553
602
21078MC07
154 155 156 158 159 163 164 167 201 203 261 262
Plug Plug Plug Plug Plug O-ring O-ring O-ring Cover Cover O-ring O-ring
273 301 303 304 306 309 328 329 331 332 333
Socket screw Travel spool Boom1 spool Bucket spool Arm2 spool Option spool Spring Spring Seat Seat Bolt
8 - 34
334 335 336 370 372 374 377 379 553 561 602
Stopper Stopper Bolt Spring Spring Spring Spring Spring Plug O-ring Port relief valve
STRUCTURE(5/5)
552 561 523 516 551 561 521
154 164 511
976 974 (R T
551 561
)
O P
971
T
B 1
209
B
Opt
K
A
165 975
2
168 166
971 Opt
209
165 165 169 273
264
202 204
202
204 204 21078MC08
154 164 165 166 168 169 202 204
Plug O-ring O-ring O-ring O-ring O-ring Cover Cover
209 264 273 511 516 521 523
Flange O-ring Socket screw Poppet Poppet Spring Spring
8 - 35
551 552 561 971 974 975 976
Plug Plug O-ring Screw Screw Screw Screw
3. DISASSEMBLY AND ASSEMBLY 1) GENERAL PRECAUTIONS (1) All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. (2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. (3) When a control valve is to be remove from the machine, apply caps and masking seals to all ports. Before disassembling the valve, recheck that these caps and masking seals are fitted completely, and then clean the outside of the assembly. Use a proper bench for working. Spread paper or a rubber mat on the bench, and disassemble the valve on it. (4) Support the body section carefully when carrying or transferring the control valve. Do not lift by the exposed spool, end cover section etc. (5) After disassembling and assembling of the component it is desired to carry out various tests(For the relief characteristics, leakage, flow resistance, etc.), but hydraulic test equipment is necessary for these tests. Therefore, even when its disassembling can be carried out technically, do not disassemble such components that cannot be tested, adjusted, and so on. Additionally one should always prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand. 2) TOOLS Before disassembling the control valve, prepare the following tools beforehand. Name of tool
Quantity
Size(mm)
Vice mounted on bench(Soft jaws)
1 unit
Hexagon wrench
Each 1 piece
5, 6, 10, 12 and 14
Socket wrench
Each 1 piece
27 and 32
Spanner
Each 1 piece
32(Main relief valve)
8 - 36
3) DISASSEMBLY The figure in ( ) shown after the part name in explanation sentence shows its number in the construction figures. (1) Place control valve on working bench ※ Disassemble the valve in a clean and dry environment and pay careful attention not to damage the sealing flange faces. (2) Travel straight valve block Loosen hexagon socket head bolts to and remove straight travel valve block(103) in its assembled state. ・Hexagon wrench : 14mm
21078MC09
(3) Main spool ① Loosen hexagon socket head bolts(273) and remove spring cover(201, 203). ・Hexagon wrench : 6mm
21078MC10
② Remove spool, springs, stopper, spring seats and spacer bolt in spool assembly condition from casing. ※ When extracting each spool assembly from its casing, pay attention not to damage the casing.
21078MC11
8 - 37
(4) Covers Loosen hexagon socket head bolts(273) and then remove the spool cover(202, 204). ・Hexagon wrench : 6mm
21078MC12
(5) Removal of port relief Remove port relief valves(602) from casing. ・Socket wrench : 32mm
21078MC13
(6) Removal of plug(Option section) Remove plugs(553) from casing. ・Socket wrench : 27mm (7) Lock valve Loosen hexagon socket head bolts and remove lock valve(252). ・Hexagon wrench : 5mm
21078MC14
8 - 38
(8) Negative control relief valve ① Remove plug(551). ・Hexagon wrench : 12mm
21078MC15
② Remove poppet(611), spring(621) and damping rod(631).
21078MC16
(9) Swing logic valve and check valve ① Loosen hexagon socket head bolts(251) and remove logic valve(251) and take check valve(254). ② Remove plug(551) or (552) and take out poppet(511) or (515, 516) and spring (521) or (523). ・Hexagon wrench : 6, 12mm
21078MC17
(10) Boom priority valve Loosen hexagon socket head bolts(104) and remove boom priority valve(104). ・Hexagon wrench : 10mm
8 - 39
(11) Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. ① Control valve a. Check whole surfaces of all parts for burrs, scratches, notches and other defects. b. Confirm that seal groove faces of casing and block are smooth and free of dust, dent, rust etc. c. Correct dents and damages and check seat faces within the casing, if any, by lapping. ※ Pay careful attention not to leave any lapping agent within the casing. d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and path's are free foreign matter. e. If any spring is broken or deformed, replace it with new one. f. When a relief valve does not function properly, repair it, following it's the prescribed disassembly and assembly procedures. g. Replace all seals and O-rings with new ones. ② Relief valve a. Confirm that all seat faces at ends of all poppets and seats are free of defects and show uniform and consistent contact faces. b. Confirm manually that main poppet and seat can slide lightly and smoothly. c. Confirm that outside face of main poppet and inside face of seat are free from scratches and so on. d. Confirm that springs are free from breakage, deformation, and wear. e. Confirm that orifices of main poppet and seat section are not clogged with foreign matter. f. Replace all O-rings with new ones. g. When any light damage is found in above inspections, correct it by lapping. h. When any abnormal part is found, replace it with a completely new relief valve assembly.
8 - 40
4) ASSEMBLY (1) General comments ① In this assembly section, explanation only is shown. For further understanding, please refer to the figures and photographs shown in the previous structure & disassembly section. ② Figure in ( ) shown after the part name in the explanation refers to the reference identity number shown on the structure section. ③ Cautions in assembling seals a. Pay close attention to keeping all seals free from handling damage and inspect carefully for damage before using them. b. Apply clean grease or hydraulic oil to the seal so as to ensure it is fully lubricated before assembly. c. Do not stretch seals so much as to deform them permanently. d. In fitting O-rings, pay close attention not to roll them into their final position in addition, a twisted O-ring cannot easily untwist itself naturally and could thereby cause inadequate sealing and thereby both internal and external oil leakage. e. Tighten fitting bolts for all sections with a torque wrench adjusted to the respective tightening torque. (2) Check valve ① Assemble poppet(511, 515, 516) and spring(521, 523). ② Put O-rings(561) on to plug(551, 552). ③ Tighten plug(551, 552) to the specified torque. ・Hexagon wrench : 12mm ・Tightening torque : 23~27kgf・m(166~195lbf・ft) (3) Negative control relief valve ① Assemble the poppets, springs and damping rods(2×611) together into casing A(101). ② Put O-ring(561) on to plug(551) and tighten the latter to its specified torque. ・Hexagon wrench : 12mm ・Tightening torque : 23~27kgf・m(166~195lbf・ft) (4) Lock valve ① Put O-rings onto the casing. ② Tighten hexagon socket head bolts to their specified torques. ・Hexagon wrench : 5mm ・Tightening torque : 1~1.4kgf・m(7.23~10.12lbf・ft) (5) Main relief, port relief valves Install main relief valve(601), port relief valve(602) into the casing and tighten to the specified torque. Component
Tools
Tightening torque kgf・m
lbf・ft
Main relief valve
Spanner 32mm
7~8
50.6~57.8
Port relief valve
Socket wrench 32mm
7~8
50.6~57.8
8 - 41
(6) Main spools ① Carefully insert the previously assembled spool assemblies into their respective bores within of casing A(101) and casing B(102). ※ Fit spool assemblies into casing A(101) and casing B(102) carefully and slowly. Do not under any circumstances push them forcibly in. (7) Covers ① Fit spool covers(202, 204) to the non-spring assembly end of the spool, and tighten the hexagonal socket head bolts(273) to the specified torque. ・Hexagon wrench : 6mm ・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft) ※ Confirm that O-rings(169, 264) have been fitted. ② Fit spring covers(201, 203) to the spring end for the spools, and tighten hexagon socket head bolts(273) to the specified torque. ・Hexagon wrench : 6mm ・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft) ※ Confirm that O-rings(261, 262) have been fitted. (8) Travel straight valve, swing logic valve and boom priority valve ① Put O-rings onto the casing. ② Tighten hexagon socket head bolts to their specified torques. Component
Tools
Tightening torque kgf・m
lbf・ft
Travel straight valve
Hexagon wrench 14mm
28.0~32.0
202~231
Swing logic valve
Hexagon wrench 6mm
2.5~3.5
18.0~25.3
Boom priority valve
Hexagon wrench 10mm
8.5~11.5
61.5~83.1
8 - 42
GROUP 5 SWING DEVICE A. SWING DEVICE(T3X150CHB, UP TO #1937) 1. REMOVAL AND INSTALL OF MOTOR 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury. ö When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.
13031GE18
1
(4) Disconnect hose assembly(2). 2
(5) Disconnect pilot line hoses(3, 4, 5, 6, 7). (6) Sling the swing motor assembly(1) and remove the swing motor mounting bolts (8). ÂMotor device weight : 230kg(507lb)
21078DA03
(7) Remove the swing motor assembly. ö When removing the swing motor assembly, check that all the piping have been disconnected.
3 4
2) INSTALL
8
(1) Carry out installation in the reverse order to removal.
5
(2) Bleed the air from the swing motor. Η Remove the air vent plug. Θ Pour in hydraulic oil until it overflows from the port. Ι Tighten plug lightly. Κ Start the engine, run at low idling and check oil come out from plug. Λ Tighten plug fully.
6
7
21078DA04
(3) Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8-43
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR 1) STRUCTURE
27
4 5 6 7 8
9 10 11 12 13 14
3 2 1
29
30, 31 32 33
40
15
41 42 43 35, 44
28
26 25 24
39 23
38 22
21 20 19 18
37 36
34
35 16, 17 21072SF04
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Inner ring Oil seal Taper roller bearing Backing spring Cam plate Return plate Piston assembly Lining plate Plate O-ring Piston O-ring Spring Parallel pin Piston
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Cap O-ring Coned disc spring Teflon ring Bushing Balance plate Needle bearing Snap ring Cylinder Housing Collar Plug Snap ring Bypass valve assembly Back up ring
8-44
31 32 33 34 35 36 37 38 39 40 41 42 43 44
O-ring O-ring Cover Relief assembly O-ring Hexagon socket bolt Time delay valve O-ring O-ring Hexagon socket bolt Check Spring Cap Back up ring
2) DISASSEMBLY (1) Removal of relief valve assembly Remove cap of relief valve assembly(35) with 14mm hexagonal wrench. ö Assemble removed relief valve assembly (35) to original state when reassembling.
25038SM02(1)
(2) Removal of make up valve and bypass valve assembly Loosen cap(43) with 14mm hexagonal wrench, and remove check valve(41) and spring(42). Remove bypass valve assembly(30) with 10mm hexagonal wrench. ö Assemble removed bypass valve assembly(29) to original state when reassembling.
25038SM02(2)
(3) Marking at swing motor Before disassembling motor, make a matching mark between cover(33) and housing(26) for easy reassembling.
25038SM02(3)
(4) Remove mounting bolts of cover Loosen hexagon socket bolt(37) with 14mm hexagonal wrench.
25038SM02(4)
8-45
(5) Removal of cover assembly Place shaft of motor assembly to downward and take cover(33) out.
25038SM03(1)
(6) Remove snap ring(23) with steel pointer and remove inner race of needlebearing(22) by bearing puller.
25038SM03(2)
(7) Remove O-ring(12) from cover.
25038SM03(3)
(8) Remove balance plate Balance plate(21) is adhered on end surface of cylinder(24) by oil viscosity. Take off balance plate(21) with hands. Assembling method of balance plate(21) depends on cover(34). (Band groove and round groove of high low pressure transmission area) Before removing, check and record location of balance plate(21) to prevent misassembling.
25038SM03(4)
8-46
(9) Remove bushing(20) and coned disk spring (18) from teflon ring(19).
25038SM04(1)
(10) Removal of spring(13, brake area) Remove spring(13) from piston(11). Check and record original position of each spring(14) for correct assembling.
25038SM04(2)
(11) Removal of brake piston When removing piston(11) from housing (25), there is a sliding resistance against tightening of O-rings(10,12). Use tap hole(M6) on piston(11) as shown in the picture.
25038SM04(3)
(12) Remove O-rings(10,12) from piston(11) and housing(25).
25038SM04(4)
8-47
(13) Remove friction plate(9) and lining plate (8) from housing(25).
25038SM05(1)
(14) Removal of cylinder assembly Holding end of cylinder assembly(24) with hand, draw out cylinder assembly from housing. ö Oil seal(2) and outer race of taper roller bearing(3) are left inside of housing. ö End surface of cylinder(24) is sliding face . So, protect the surface with a scrap of cloth against damage. ö Make a matching mark on piston hole of cylinder(24) and piston assembly(7) to fit piston into the same hole when reassembling.
25038SM05(2)
(15) Separate outer race of taper roller bearing(3) from housing.
25038SM05(3)
(16) Removal of oil seal Remove oil seal(2) from housing(25) with driver and hammer. ö Do not reuse oil seal after removal.
25038SM05(4)
8-48
(17) Disassembly of cylinder assembly Η Removal of inner race of taper roller bearing(3). After removing snap ring(28), lift out cylinder(24) with 2 inner race of roller bearing(3) by applying gear puller at the end of spline in the cylinder.
(210-7) SM16
Θ Separate cam plate(5), piston assembly (7), return plate(6) from cylinder(24).
(210-7) SM17
Ι Get cam plate(5) slide on sliding face of piston assembly(7) and remove it. ö Be cautious not to damage on sliding face of cam plate.
(210-7) SM18
Κ Remove backing spring(4) from cylinder (24).
(210-7) SM19
This completes disassembly.
8-49
3) ASSEMBLY (1) Preparation Before reassembling, perform below procedure. Η Check each part for damage caused by using or disassembling. If damaged, eliminate damage by grinding with proper sandpaper, wash them with cleaning oil and dry with compressed air. Θ Replace seal with new one. Ι Grind sliding face of piston assembly(7), balance plate(21) and cam plate(5) with sandpaper #2000.
(210-7) SM20
(210-7) SM21
(210-7) SM22
Κ When assembling, lubricate with specified clean hydraulic oil. Λ When assembling piston assembly(7) to piston hole of cylinder(24), check matching mark between them.
8-50
(2) Cylinder assembly Η Lubricate grease on round area (Contacting area with spring(4)) of cylinder(24) and assemble spring(4).
(210-7) SM23
Θ Insert piston assembly(7) in hole of return plate(6).
(210-7) SM24
Ι Assemble piston assembly(7) and return plate(6) to cylinder(24). When assembling, check matching mark between them. Before assembling, lubricate specified hydraulic oil in piston hole of cylinder(24).
(210-7) SM25
Κ Lubricate specified hydraulic oil on shoe sliding face of piston assembly(7) and assemble cam plate(5).
(210-7) SM26
8-51
Λ Assemble inner race of taper roller bearing(3) to cylinder(24).
(210-7) SM27
Μ Apply loctite to bearing mounting area of inner race of cylinder(24) lightly.
(210-7) SM28
Ν Assemble inner race(1) to cylinder(24).
(210-7) SM29
(3) Oil seal Apply three bond of white color on outer surface of oil seal(2) and assemble and insert it. ö Before assembling, lubricate lip of oil seal with grease.
(210-7) SM30
8-52
(4) Assemble outer race of taper roller bearing(3) to motor housing(25).
25038SM05(3)
(5) Cylinder assembly Hold end of cylinder assembly(24) with hands and assemble cylinder assembly to housing(25). Be careful to prevent damage of seal by spline of shaft. ö When assemble cylinder assembly, spline shaft of cylinder is protruded from end of housing, therefore put pads with length 30~50mm under bottom of housing. (210-7) SM32
(6) Assemble plate(9) and lining plate(8). ö Lubricate specified hydraulic oil on each side.
25038SM05(1)
(7) Insert O-rings(10,12) into housing(25) and piston(11). ö Lubricate O-ring with grease.
25038SM06(1)
8-53
(8) Brake piston Lubricate specified hydraulic oil on outer sliding face of piston(11) and assemble brake piston to housing(25). ö It is too tight to assemble piston(7) because O-rings(10,12) are fitted, therefore it is recommended to push piston(11) horizontally by hands at once. 25038SM06(2)
(9) Spring(13, brake unit) Assemble spring(13) to piston(11) of brake unit. ö Insert spring(13) into original position.
25038SM04(2)
(10) Assemble bushing(20) with teflon ring(19) and coned disk spring(18) to bushing hole of cover(33). ö Lubricate on both end surfaces of bushing(20) and outer face of teflon ring(19) with grease and assemble cover to housing, and parts are adhered on cover by grease viscosity which makes assembling easy. (210-7) SM38
(11) Lubricate locating pin for antirotation of balance plate(21) of cover(33) with grease sufficiently and install locating pin to housing.
25038SM07(1)
8-54
(12) Balance plate Assemble balance plate(21) to cover(33). ö Be cautious of assembling direction.
25038SM07(2)
(13) Assemble inner race of needle bearing (22) and snap ring(23) to cover(33).
25038SM08(1)
(14) Assemble O-ring(12) to cover(33). ö Lubricate O-ring with grease.
(210-7) SM41
(15) Apply three bond of white color to distinguish oil leakage from remaining oil in bolt hole(M16) of cover(33).
25038SM08(2)
8-55
(16) Cover Assemble cover(33) and balance plate (21) to housing(25) lightly, holding them up with hands. ö When assembling, be careful not to detach balance plate(21) and bushing (20) from cover(33). ö Fit matching marks on housing(25) and cover(33) made before disassembling. 25038SM03(1)
(17) Tighten cover(33) and housing(25) with 16mm hexagonal socket bolt(36). ÂTightening torque : 29kgfÂm(210lbfÂft)
25038SM02(4)
(18) Make up valve Assemble check(41) and spring(42) to cover(33) and tighten cap(43) with 14mm hexagonal socket bolt. ÂTightening torque : 14kgfÂm(101lbfÂft) (19) Bypass valve assembly Assemble bypass valve assembly(29) to cover(33) with 10mm hexagonal socket bolt. ÂTightening torque : 8kgfÂm(58lbfÂft)
25038SM09(1)
(20) Relief assembly Assemble relief valve assembly(34) to cover(33) with 14mm hexagonal socket bolt. ÂTightening torque : 8kgfÂm(58lbfÂft) ö Be cautious of assembling method.
25038SM09(2)
8-56
(21) Check of assembly Load pilot pressure of 30kgfcm2 to brake release port after opening inlet and outlet port. Check if output shaft is rotated smoothly around torque of 4kgfÂm. If not rotated, disassemble and check.
(210-7) SM47
This completes assembly.
8-57
B. SWING DEVICE(RMF151, #1938 AND UP) 1. REMOVAL AND INSTALL OF MOTOR 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury. ö When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.
13031GE18
1
(4) Disconnect hose assembly(2). 2
(5) Disconnect pilot line hoses(3, 4, 5, 6, 7). (6) Sling the swing motor assembly(1) and remove the swing motor mounting bolts (8). ÂMotor device weight : 230kg(507lb)
21078DA03
(7) Remove the swing motor assembly. ö When removing the swing motor assembly, check that all the piping have been disconnected.
3 4
2) INSTALL
8
(1) Carry out installation in the reverse order to removal.
5
(2) Bleed the air from the swing motor. Η Remove the air vent plug. Θ Pour in hydraulic oil until it overflows from the port. Ι Tighten plug lightly. Κ Start the engine, run at low idling and check oil come out from plug. Λ Tighten plug fully.
6
7
21078DA04
(3) Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8-57-1
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR 1) STRUCTURE
DETAIL : K 7 6 5 12 11 10
17
20 8 23
39
41
36 35
33 44
40
30 29 31 28 32 K 34
2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 1 25 26
9 14 1316 15 18 19 24 21 22 42 43
Body Oil seal Roller bearing Snap ring Shaft Bushing Stop ring Pin Shoe plate Cylinder block Spring Ball guide Set plate Piston assy Friction plate Plate Brake piston
27
37 38
45 46 220072SM02
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
O-ring O-ring Spring Rear cover Needle bearing Pin Valve plate O-ring O-ring Wrench bolt Plug Back up ring O-ring Spring Check Relief valve Anti-inversion valve
8-57-2
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Time delay valve Wrench bolt Plug O-ring Plug Plug Plug Name plate Rivet Level gauge Flange O-ring Plug O-ring O-ring Back up ring
2) DISASSEMBLING (1) Disassemble the sub of a TURNING AXIS Η Unloosing wrench bolt and disassemble time delay valve assy(35) from rear cover(21)
14078SM201/201A
Θ Disassemble level gauge(44) from body (1).
14078SM202/202A
Ι Hang rear cover(21) on hoist, unloose wrench bolt(27) and disassemble from body(1).
14078SM203/203A
8-57-3
Κ Using a jig, disassemble break piston(17) from body(1).
14078SM204/204A
Λ Disassemble respectively cylinder block assy, fricktion plate(15), plate(16) from body(1).
14078SM205/205A/B
(2) Disassemble cylinder block assy sub Η Disassemble pistion assy(14), set plate (13) from cylinder block assy.
14078SM206/205B
Θ Disassemble ball guide(12) from cylinder block(10).
14078SM207/207A
8-57-4
Ι Disassemble spring(11) from cylinder block(10).
14078SM208/208A
Κ Disassemble shoe plate(9) from body(1).
14078SM209/209A
Λ Using a plier jig, disassemble snap ring (4) from shaft(5).
14078SM210/210A
Μ Disassemble shaft assy from body(1).
14078SM211/211A
8-57-5
(3) Disassemble rear cover assy sub Η Disassemble pin(8, 23), valve plate(24) from rear cover(21).
14078SM212/212A
Θ Using a torque wrench, disassemble relief valve assy(33) 2 set from rear cover(21).
14078SM213/213A
Ι After disassembling plug with a L-wrench from rear cover(21), disassemble respectively back up ring, O-ring, O-ring, spring, anti-inversion valve assy(34)
14078SM214/214A
Κ Disassemble make up check valve assy with a torque wrench from rear cover(21).
14078SM215/215A
8-57-6
Λ Disassemble respectively plug(37, 40, 41), with a L-wrench from rear cover(21).
14078SM216/216A
8-57-7
3) ASSEMBLING (1) Assemble the sub of a turning axls Η Put roller bearing(3), bushing(6) on preheater and provide heat to inner wheel(compressing temp : 290Á C for 2minutes) ÂRoller bearing Ý1EA ÂBushingÝ 1EA 3
6
14078SM217/217A/B
Θ After assembling and compressing preheated roller bearing(3), bushing(6) into shaft(5). ÂStop ring Ý1EA ÂShaftÝ 1EA 7 5 14078SM218/218A/B
Ι Put body(1) on a assembling jig, fix it with bolts to prohibit moving.
14078SM219
8-57-8
Κ Using a compressing tool and steel stick, assemble oil seal(2) into body(1). ÂOil seal Ý1EA
2
14078SM220/220A
Λ Insert above shaft sub into body(1) and assemble it with a steel stick.
14078SM211/211A
Μ Fix snap ring(4) to shaft with a plier jig. ÂSnap ring Ý1EA
4
14078SM210/210A
Ν Spread grease on shoe plate(9) and assemble on the body. ÂShoe plate Ý1EA
9
14078SM222/209A
8-57-9
(2) Assemble the sub of cylinder block assy Η Assemble spring(11) 9 set into cylinder block(10). ÂSpring Ý9EA
11
14078SM208/208A
Θ Assemble ball guide(12) into cylinder. ÂBall guide Ý1EA
12
14078SM207/207A
Ι Assemble piston assy(14) 9 set into set plate(13). ÂPiston assy Ý9EA ÂSET plate Ý1EA
14 13 14078SM223/223A
Κ Assemble above item Θ and Ι.
14078SM224
8-57-10
Λ Assemble cylinder block assy into body (1).
14078SM225
Μ Assemble O-ring(18) into body(1). ÂO-ring Ý1EA
18
14078SM226/226A
Ν Assemble 3 set of plate(16), friction plate(15) respectively into body. ÂPlate Ý3EA ÂFriction plate Ý3EA
16 15
14078SM227/205A
Ξ Assemble O-ring(19) into break piston (17). ÂO-ring Ý2EA
19
14078SM228/226A
8-57-11
Ο Insert break piston assy into body(1) and compress it with a jig and hammer.
14078SM229/229A
Π Assemble spring(20)(20EA) into break piston(17). ÂSpring Ý20EA
20
14078SM230/230A
(3) Assemble the sub of rear cover assy sub Η Assemble the sub of make up check valve assy. Assemble O-ring(30), back up ring(29) into plug(28) with a O-ring assembling jig. ÂPlugÝ1EA ÂBack up ringÝ1EA ÂO-ringÝ1EA
Jig 30
28
29 14078SM231/231A/B
Θ Assemble respectively make up check valve assy spring(31), check(32), plug(28) into rear cover(21) after then screw it torque wrench. ÂMake up check sub Ý2set ÂSpring Ý2EA ÂCheck Ý3EA
28
31
32 14078SM215/215A
8-57-12
Ι Assemble respectively plug(47), back up ring, O-ring, O-ring, spring, anti-rotating valve assy(34) into rear cover(21). (Bilateral symmetry assembling) ÂAnti-Inversion v/v assyÝ2set ÂO-ring(P12)Ý2EA ÂO-ring(P18)Ý2EA ÂBack up ring(P18)Ý2EA 14078SM214/214A
Κ Assemble relief valve assy(33) 2set into rear cover(21) with a torque wrench. (Bilateral symmetry assembling)
33
14078SM213/213A
Λ Assemble plug(37), plug(40, 41) into rear cover(21) with a L-wrench. * PlugÝ3EA(PF1/4)
37
14078SM216/216A
Μ After assembling needle bearing(22) into rear cover(21), with a hammer assemble pin(8, 23). * PinÝ1EA * PinÝ2EA
14078SM212
8-57-13
Ν Spreading grease on valve plate(24), assemble into rear cover(21). ÂValve plateÝ1EA
24
14078SM212/212A
Ξ Lift up rear cover assy on body(1) by a crane and assemble it with a wrench bolt(27).
14078SM203/203A
Ο Assemble level gauge(44) into body(1).
44
14078SM202/202A
Π Assemble time delay valve assy(35) into rear cover(21) with a wrench bolt(36).
35 14078SM01/201A
8-57-14
(4) Air pressing test Be sure of leakage, after press air into assembled motor
14078SM232
(5) Leakage check After cleaning motor by color check No.1, paint No.3 and be sure of leakage.
14078SM233/233A
(6) Mount test bench Mounting motor test bench, test the availability of each part.
220078SM14
8-57-15
3. REMOVAL AND INSTALL OF REDUCTION GEAR 1) REMOVAL (1) Remove the swing motor assembly. For details, see removal of swing motor assembly. (2) Sling reduction gear assembly(1) and remove mounting bolts(2). (3) Remove the reduction gear assembly. ・Reduction gear device weight : 180kg (396lb) 13031GE18
2) INSTALL (1) Carry out installation in the reverse order to removal. ・Tightening torque : 49.2~66.6kgf・m (356~481lbf・ft) 1 2
21078DA05
8 - 58
4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR 1) STRUCTURE
25 37 36 13
3
35 34 5
2 30
29 6
7
10
9 11 18 19
26 31 28
27 38
1
8 14 12 23 15 16 21 17 20 24 22 39 220072SF05A
1 2 3 5 6 7 8 9 10 11 12 13
Casing Drive shaft Spacer Roller bearing Oil seal Roller bearing Thrust plate Carrier 2 Stop ring Ring gear Knock pin Pinion gear
14 15 16 17 18 19 20 21 22 23 24 25
Thrust washer Planet gear 2 Pin & bushing Spring pin Sun gear 2 Carrier 1 Side plate 1 Pin 1 Needle cage Bushing 2 Planet gear 1 Lock washer
8-59
26 27 28 29 30 31 34 35 36 37 38 39
Side plate 3 Sun gear 1 Stop ring Plug Plug Socket bolt Cover plate Hexagon bolt Lock plate Hexagon bolt Stop ring Side plate 2
2) DISASSEMBLY 2
(1) Spread off the 4 corners of lock washer (25) with a tool. ※ Do not reuse lock washer(25). Loosen the hexagon bolts(37) and then remove lock washer(25) and lock plate (36) from the pinion gear(13). Remove pinion gear(13) and spacer(3) from the drive shaft(2). Remove cover plate(34) from the casing (1) by loosening the hexagon socket bolts (35).
25 37 36 13 3
1 35 34
21078SR001
(2) Remove gauge bar(33) and gauge pipe (32) from the swing motor casing. ※ Pour the gear oil out of reduction gear into the clean bowl to check out the friction decrease.
33 32
21078SR002
(3) Loosen the socket bolts(31) to separate swing motor from reduction gear.
31
21078SR003
(4) Tighten 3 M16 eye bolts to the ring gear (11) and then lift the ring gear(11) out of the casing(1).
11 1 21078SR004
8 - 60
(5) Remove stop ring(28) and then sun gear1 (27).
28 27
19
21078SR005
(6) Tighten two M10 eye bolts to carrier1(19) and lift up and remove carrier1(19) as subassembly.
19
21078SR006
(7) Disassembling carrier1(19) assembly. ① Remove stop ring(38). ② Remove side plate2(39), planet gear1 (24), needle cage(22), side plate1(20) and side plate3(26) from the carrier. ③ Using M8 solid drill, crush spring pin(17) so that the pin1(21) can be removed by hammering. ④ Remove side plate3(26) from carrier1(19). ※ Do not reuse spring pin(17). ※ Do not remove pin1(21), carrier1(19) and spring pin(17) but in case of replacement. ※ Put matching marks on the planet gear1 (24) and the pin1(21) for easy reassembly.
26 19
38
39 22 24 20 17 21 21078SR007
8 - 61
(8) Remove sun gear2(18) and thrust gear (14). 18
14
21078SR008
(9) Remove carrier2(9) assembly from casing (1). 9
1 21078SR009
(10) Disassembling carrier2(9) assembly ① Using M8 solid drill, crush spring pin(17) so that the pin2(16) can be removed. ※ Do not reuse spring pin(17). ② Remove pin2(16), planet gear2(15) and bush2(23) from the carrier2(9). ※ Put matching marks on the planet gear2 (15) and the pin2(16) for easy reassembly. ※ Do not disassemble pin2(16), carrier2(9) and spring pin(17) but in case of replacement.
17 9
16 15 23
21078SR010
(11) Remove thrust bearing(8) and stop ring (10) from the drive shaft(2). 8 10
2
21078SR011
8 - 62
(12) Remove drive shaft(2) with roller bearing(7) and oil seal(6) assembled. Remove knock pin(12) from the casing(1).
2 7 6
12
1 21078SR012
(13) Remove roller bearing(7) and oil seal(6) from the drive shaft(2). ※ Do not reuse oil seal(6) once removed. 2
6 7 21078SR013
(14) Using the bearing disassembly tool, remove roller bearing(5). 5
1
21078SR014
(15) Remove plugs(29, 30) from the casing(1). 30
1 29 30 21078SR015
8 - 63
3) ASSEMBLY (1) Assemble roller bearing(5) inside the casing(1).
5
1
21078SR016
(2) Assemble the drive shaft(2) into the casing(1) and then install oil seal(6) and roller bearing(7).
7 6 2
1 21078SR017
(3) Install stop ring(10) and thrust bearing(8) on top of drive shaft(2).
8 10
2
21078SR018
(4) Assembling carrier2(9) assembly. ① Install thrust gear(14) inside the carrier2 (9). ② Install bush2(23) inside the planet gear2 (15) and then assemble them to the carrier2(9). ③ Assemble the pin2(16) to the carrier2(9) and then press the spring pin(17) by hammering. ④ Punch 2 points of the spring pin(17) lip. ※ Take care not to mistake the matching marks of each part.
17 9
16 15 23
21078SR019
8 - 64
(5) Assemble carrier2(9) assembly correctly to the drive shaft(2). 9
1 21078SR020
(6) Assemble sun gear2(18) and thrust gear (14) to the center of the carrier2(9) assembly.
18
14
9 21078SR021
(7) Assembling carrier1(19) assembly. ① Assemble the pin1(21) to the carrier1(19) and then press the spring pin(17) by hammering. ② Punch 2 points of the spring pin's(17) lip. ③ Install side plate3(26) onto the center of carrier1(19). ④ Install needle cage(22) into the planet gear1(24). ⑤ Assemble side plate(20), planet gear1 (24), side plate3(39) and then stop ring (38) to the pin1(21). ※ Take care not to mistake the matching marks of each part.
26 19
38
39 22 24 20 17 21 21078SR022
8 - 65
(8) Install sun gear1(27) onto the side plate3 (26). 27 26
19 21078SR023
(9) Assemble carrier1(19) assembly onto the carrier2 assembly.
19
21078SR024
(10) Apply loctite to the tapped holes of casing (1). (11) Tighten 3 M16 eye bolts to the ring gear(11) and lift up and then assemble it onto the casing(1). ※ Don't fail to coincide the knock pin(12) holes.
11 1 21078SR025
(12) Hammer 4 knock pins(12) around the ring gear(11).
28 12
(13) Assemble stop ring(28) to the drive shaft of the swing motor.
11 1 21078SR026
8 - 66
(14) Apply loctite to the tapped holes of the ring gear(11) and then mount swing motor onto the ring gear(11). ※ Don't fail to coincide the gauge bar(33) hole. (15) Tighten socket bolts(31) around the swing motor assembly. ・Tightening torque : 24kgf・m(173lbf・ft)
31
21078SR027
(16) Assemble plugs(29, 30), gauge bar(33) and gauge pipe(32). 33 32 30 1 29 30
(17) Turn the swing motor assembly upside down and assemble cover plate(34) by tightening the hexagon socket bolts(35). Install spacer(3) and pinion gear(13) to the drive shaft(2). Assemble lock plate(36) on the pinion gear(13). Assemble 2 lock washers(25) on the lock plate(36) with their 2 hole coincided individually to the tapped holes of drive shaft(2). Tighten hexagon socket bolts(37) to the drive shaft(2) and then fold all the lock washer(25) corners over the hexagon bolts(37). ・Tightening torque : 24kgf・m(173lbf・ft)
21078SR028
25 37 36 2
13 3 35 34
21078SR029
(18) Inject oil into the reduction gear.
8 - 67
B. SWING DEVICE(RMF151, #1938 AND UP) 1. REMOVAL AND INSTALL OF MOTOR 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury. ※ When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.
13031GE18
1
(4) Disconnect hose assembly(2). 2
(5) Disconnect pilot line hoses(3, 4, 5, 6, 7). (6) Sling the swing motor assembly(1) and remove the swing motor mounting bolts (8). ·Motor device weight : 230kg(507lb)
21078DA03
(7) Remove the swing motor assembly. ※ When removing the swing motor assembly, check that all the piping have been disconnected.
3 4 r D
2) INSTALL
u M
5
(2) Bleed the air from the swing motor. ① Remove the air vent plug. ② Pour in hydraulic oil until it overflows from the port. ③ Tighten plug lightly. ④ Start the engine, run at low idling and check oil come out from plug. ⑤ Tighten plug fully.
8
G P
H S
(1) Carry out installation in the reverse order to removal.
6
SG
r
7
21078DA04
(3) Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8-57-1
GROUP 6 TRAVEL DEVICE A. TRAVEL DEVICE(GM35VL, up to #2078) 1. REMOVAL AND INSTALL 1) REMOVAL (1) Swing the work equipment 90。and lower it completely to the ground. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
13031GE18
(3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury. ※ When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.
1
Dr
(4) Remove the track shoe assembly. For details, see removal of track shoe assembly.
P
2
B A
(5) Remove the cover. 21078DA47
(6) Remove the hose. ※ Fit blind plugs to the disconnected hoses. (7) Remove the bolts and the sprocket. (8) Sling travel device assembly(1). (9) Remove the mounting bolts(2), then remove the travel device assembly. ·Weight : 305kg(670lb) 2) INSTALL (1) Carry out installation in the reverse order to removal. (2) Bleed the air from the travel motor. ① Remove the air vent plug. ② Pour in hydraulic oil until it overflows from the port. ③ Tighten plug lightly. ④ Start the engine, run at low idling, and check oil come out from plug. ⑤ Tighten plug fully. (3) Confirm the hydraulic oil level and check the hydraulic oil leak or not. 8-68
2) STRUCTURE 27 112 116 115 167 171 2 31 21
1
4 17
5
23 12 22 35
42
337
330
13
139
20 A
25
113
7
109
8
150
15
399
6
341
36
301
102
357
3
355
34
323
355
357
325
336
328
324
346
358
354
352
398
368
C SECTION B-B
359 384 382 383
19
A
363
33
145
43
114
37 110 398 397 151 104 111 108 105 107 106 103 162 161 193 149 132 30
B 380
385 381
208
211
209
217
210
SECTION C-C
1 2 3 4 5 6 7 8 9 12 13 15 17 19 20 21 22
327
C
29
366
326
9
379
135
343
Hub Spindle Hold flange RV gear A RV gear B Input gear Spur gear Cover Crank shaft Spacer Distance piece Coupling Pin Hexagon socket bolt Snap ring Ball bearing Taper roller bearing
23 25 27 29 30 31 33 34 35 36 37 42 43 102 103 104 105
Needle roller bearing Snap ring O-ring O-ring O-ring Floating seal Plug Parallel pin Hexagon socket bolt Steel ball Washer Parallel pin O-ring Shaft Swash plate Cylinder block Piston
106 107 108 109 110 111 112 113 114 115 116 132 135 139 145 149 150
Shoe Retainer plate Thrust ball Timing plate Washer Washer Piston Spring Spring Firction plate Mating plate Oil seal O-ring O-ring Snap ring Ball bearing Ball bearing
151 161 162 167 171 193 201 202 203 204 205 206 208 209 210 211 217
8-69
204
205
203
202
219
206
201
220
SECTION A-A
Needle roller Piston Shoe Pivot Parallel pin Spring Valve Sleeve Spring retainer Plug Shim Spring O-ring O-ring O-ring Back up ring Back up ring
219 220 301 323 324 325 326 327 328 330 336 337 341 343 346 352
O-ring Piston seal Rear flanger Spool Plug Stopper Plug Valve Spring Spring O-ring O-ring Parallel pin Hexagon socket bolt Hexagon socket bolt Plug
354 355 357 358 359 363 368 379 380 382 383 384 385 397 398 399
Hexagon socket plug O-ring Plug O-ring O-ring Spool Steel ball Filter Plug Plug O-ring O-ring Steel ball Orifice Hexagon socket plug Name plate
2) TOOLS AND TIGHTENING TORQUE (1) Tools Tool name
Remark
Allen wrench
B
5, 6, 8, 10, 14
Socket for socket wrench, spanner
Socket
22, 30, 32, 41
Rod
5, 6, 8, 10, 14, 19
Torque wrench
Capable of tightening with the specified torques
Pliers
-
(-) Driver
150mm
Plastic and iron hammer
Wooden hammer allowed. Normal 1 or so
Steel rod approx
7×7×200mm
Monkey wrench
-
Oil seal inserting jig
-
Bearing pliers
-
Seal tape
-
Eye bolt
M12, M16
Press(0.5 ton)
-
Oil stone
-
Bearing assembling jig
-
Liquid packing
Loctite #577
Screw lock
Loctite #243
(2) Tightening torque Part name
Item
Size
Hexagon socket bolt
19
Hexagon socket plug
Torque kgf・m
lbf・ft
M24×3.0
72.3±11.0
523±79.6
33
PF 1/2
10.0±2.0
72.3±14.5
Hexagon socket bolt
35
M12×1.75×32
10.4±1.6
75.2±11.6
Sleeve
202
PF 1
25.0±5.0
181±36.2
Plug
204
PF 1/2
10.0±2.0
72.3±14.5
Plug
324
M36×1.5
45.0±9.0
326±65.1
Plug
326
M36×1.5
26.0±4.0
188±28.9
Hexagon socket bolt
343
M16×2.0
25.7±4.0
186±28.9
Plug
346
PF 1/4
3.0±0.5
21.7±3.6
Plug
352
PF 1/4
3.0±0.5
21.7±3.6
Hexagon socket plug
354
NTPF 1/16
1.0±0.25
7.2±1.8
Plug
357
PF 1/2
10.0±2.0
72.3±14.5
Plug
380
PF 3/8
6.0±1.0
43.4±7.2
Plug
382
PF 1/8
1.5±0.25
10.8±1.8
Hexagon socket plug
398
PF 1/8
1.25±0.25
9.0±1.8
8-70
3. DISASSEMBLY 1) GENERAL PRECAUTIONS (1) Before disassembling the motor, check the items to be inspected and, for remedy against trouble, closely examine the nature of the trouble, so that the motor can be disassembled effectively. (2) To disassemble the motor, use the disassembling procedures described in section 2) and select a clean place. (3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect the surface of the motor to be serviced. (4) During disassembly, give a match mark to the mating surfaces of each part. (5) Arrange removed parts in order so that they will not become damaged or missing during disassembly. (6) Once seals have been disassembled, they should be replaced even if damage is not observed. Have replacement seals ready on hand before starting your disassembling job.
8-71
2) DISASSEMBLING PROCEDURE (1) Disassembling the brake valve section and the hydraulic motor section ※ When inspecting or repairing the motor, use the disassembling procedures described below. ※ Numbers in parentheses ( ) following the part name denote the item numbers shown in the attached assembly drawings. ※ Prior to disassembly, install the motor on an inversion working bench.
25038TM02(1)
① Remove valve kit from the rear flange (301). ② Remove the O-rings(208, 209, 210) and back up rings(211, 217) from the valve kit. ※ Do not reuse the O-ring after removal.
25038TM02(2)
③ Remove the twelve hexagon socket head bolts(343).
25038TM02(3)
④ Remove the rear flange kit(301) from the spindle(2). ※ Pay attention, shaft(102) may pulled up with the rear flange kit. ※ Proceed to pages 8-83 through 8-87 to see the brake valve disassembling procedure.
25038TM02(4)
8-72
⑤ Remove the timing plate(109), the two pins(341) and the ball bearing(150) from the rear flange kit(301). ⑥ Remove the two O-ring(27) and O-ring (29) from spindle(2). ※ Do not reuse the O-rings(27, 29) after removal. ※ Proceed to pages 8-89 through 8-90 to see the description of the hydraulic motor disassembling procedure.
25038TM03(1)
(2) Disassembling the reduction gear/ Hydraulic motor shafts and oil seals ① Turn the motor and cover(8) over. ② Remove three plugs(33). ③ Remove twelve hexagon socket head bolts(35).
25038TM03(2)
④ Install two eye bolt(PF 1/2) to the threads for plugs(33). ⑤ Fasten hook to the eye bolts then lift up cover(8). ※ When cover(8) do not come up easily due to friction of O-ring(30), bang cover (8) evenly using a plastic hammer. ⑥ Remove O-ring(30) from cover(8). ※ Do not reuse the removed O-ring. ⑦ Drain lubricating oil from the reduction gear. ※ Proceed to page 8-92 through 8-95 to see the reduction gear disassembling procedure.
25038TM03(3)
8-73
3) DISASSEMBLY OF BRAKE VALVE (1) Disassembly of the spool(323) ① Remove the two plugs(324) from the rear flange(301). Remove the two O-ring(336) from the plug(324). ※ Removal of the two plugs(324) from the rear flange(301) is facilitated by loosening plugs(324) with rear flange (301) attached to the spindle(2). ※ Do not reuse the O-ring(336) after removal.
25038TM03(4)
② Remove the two springs(328), the two stoppers(325), and the spool(323) from the rear flange(301). ※ Be careful not to damage the outer surface of the spool(323) and the sliding surface of the rear flange(301). ※ Spool is selectively fitted to the rear flange(301). When replacing either or them, therefore, the rear flange kit should be replaced.
25038TM04(1)
(2) Disassembly of the check valves ① Remove the two plugs(326) from the rear flange(301). ※ Removal of the two plug(326) from the rear flange(301) is facilitated by loosening plug(326) with the rear flange (301) attached to the spindle(2).
25038TM04(2)
8-74
② Remove the two springs(330) and the two valves(327) from the rear flange(301). ※ Be careful not to damage the seat sections of the valves(327) or rear flange (301).
25038TM04(3)
③ Remove the O-ring(337) from the plug (326). ※ Do not reuse the O-ring(337) after removal.
(3) Disassembly of the spool(363) from the rear flange(301) ① Remove plug(357) from rear flange(301). ※ Removal of plug(357) from rear flange(301) is facilitated by loosening plugs(324) with rear flange(301) attached to spindle(2).
25038TM04(4)
② Take out spool(363) from rear flange (301). ③ Remove O-ring(355) from plug(357). ※ Do not reuse removed O-ring(355).
25038TM05(1)
8-75
(4) Removal inner parts of the rear flange assembly ① Remove the two plugs(380) from rear flange(301).
25038TM05(2)
② Remove the two O-rings(359) from each plug(380). ③ Take out piston(381) from rear flange (301). ※ Do not reuse removed the O-rings(359). ※ Be careful not to scratch the outer surface of the piston(381) and the sliding surface of the rear flange(301). ※ Piston(381) is selectively fitted to rear flange(301). When replacing either of them, therefore, the rear flange kit should be replaced.
25038TM05(3)
④ Removed the two plugs(382) from rear flange(301).
25038TM05(4)
⑤ Take out each two O-rings(383, 384) from each plug(382). ※ Do not reuse removed O-rings(383, 384).
8-76
⑥ 3Take out two steel balls(385) from the rear flange.
25038TM06(1)
(5) Removal of the valve kit ① Remove the plug(204) from sleeve(202). ※ The valve kit is pressure adjusted by shim(205), when replacing of inner parts, therefore, the valve kit should be replaced.
25038TM06(2)
② Remove the O-ring(210) from plug(204). ③ Take out shim(205) from plug(204). ※ Do not reuse removed the O-ring(210).
25038TM06(3)
8-77
④ Take out spring retainer(203), spring (206) and valve(201) in that order.
25038TM06(4)
25038TM07(1)
25038TM07(2)
⑤ Remove piston seal(220) from valve (201).
Piston seal Valve
25038TM14
8-78
4) DISASSEMBLY OF HYDRAULIC MOTOR (1) Disassembly of the parking brake parts ① Remove the piston(112) by injecting compressed air from the parking brake access hole in the spindle(2). ※ Take care that abrupt injection of compressed air(3~5kgf/cm2) may cause the piston(112) to pop out. To ensure your safety, apply a protective cover to the piston. 25038TM07(3)
② Remove the two O-rings(135, 139) from the piston(112). ※ Do not reuse O-rings(135, 139) after removal.
25038TM07(4)
(2) Disassembly of the internal parts of the motor ① Lay the motor body on the side. ② Drain out the oil from the motor. ③ Hold the cylinder block(104) with both hands, and remove it from the spindle(2). ※ When laying the motor on its side, place a receptacle under it to receive spilling hydraulic oil. ※ Before pull out cylinder block(104), turn it alternately clockwise & counterclockwise two or three times to separate the piston kit from swash plate(103). This means that the parts attached to the cylinder block(104) come out of it and fall in the spindle.
25038TM08(1)
8-79
④ 3Detach the two friction plates(115) and two mating plates(116) from cylinder block(104) which has been taken out in step ③. ⑤ Separate the piston assembly(105, 106), retainer plate(107), thrust ball(108), washer(111) and five needle rollers(151) from cylinder block(104) which has been taken out in step ③. ※ Cylinder block(104), piston assembly, retainer plate, etc. which are included in cylinder & piston kit and are not supplied one by one, therefore, cylinder & piston kit should be replaced.(Refer to class shown in parts list.)
25038TM08(2)
⑥ Take out swash plate(103) from spindle (2).
25038TM08(3)
⑦ Take out shaft(102) from spindle(2). At this time, ball bearing(149) is also taken out together with shaft(102). ※ Oil seal(132) cannot be taken out. ※ Lightly shaft(102) end on the reduction gear side with a plastic hammer to make the removal easier. Take notice when removing the shaft (102) rap strongly and swiftly, the shaft will come quickly free from the spindle. ⑧ Take out two pivots(167) and two pins (171) from spindle(2).
25038TM08(4)
8-80
⑨ Remove the piston assembly and spring (193) by compressed air(3~5kgf/cm 2) trough the passage for the piston assembly in spindle(2). ※ Piston(161) and shoe(162) are included in the piston assembly and are not supplied one by one, therefore, the piston assembly should be replaced. ※ Abrupt compressed air causes the piston assembly to spring out which dangerous. The piston assembly can be taken out safely by putting a protective cover or the lie on it.
25038TM09(1)
(3) Disassembly of the cylinder block ① Place the cylinder block on the work bench and take out snap ring(145) with the snap ring pliers while pressing the retainer against washer(110). ※ Before compressing spring(114), make sure that cylinder block(104), retainer and press arbor are in good alignment: This is for galling or denting cylinder block(104). ※ Put a vinyl cover on the sliding surface of cylinder block(104) for protection. ② Slacking the press force slowly, until free of the spring force. ※ Do not remove spring(114) if it not to be replaced. ※ When disassembling there is a possibility that the spring may be injured. Slacking very slowly in order to prevent injury to the spring.
25038TM09(2)
③ Remove the snap ring(145), washer(110), spring(114) and washer(110).
25038TM09(3)
8-81
5) DISASSEMBLY OF REDUCTION GEAR (1) Disassembly of Input gear ① Remove steel ball(36) and input gear(6) from coupling(15).
25038TM09(4)
(2) Disassembly of Spur gear ① Remove the three snap rings(25) from each crank shaft(9). ② Remove the three spur gears(7) from each crank shaft. ※ Take notes when removing the snap ring with a snap ring plier, the snap ring will spring out form its groove. 25038TM10(1)
25038TM10(3)
(3) Disassembly of Coupling ① Remove coupling(15) from shaft(102).
8-82
(4) Removal of the hold flange ① Turn the motor upside down, bringing the spindle to top. ② Install two fixing jigs to fasten down spindle(2) to hub(1). At the same time the fixing jig screwed symmetry. ※ Fasten hub(1) and spindle(2) securely before removing hold flange(3) so that spindle(2) will not fall from the work bench. ③ Turn the motor upside down once again, bringing the hold flange(3) to top. ④ Remove three snap rings(20) and three distance pieces(13) from hold flange(3). ※ Put an identification marks on distance pieces(13) and hold flange(3) as to their location. Hold flange(3) and distance pieces(13) must be reassembled in its original position. ⑤ Remove the caulking portion of hold flange(3) for six parallel pins(34) with air grinder. ※ Wear a protection glasses and a mask when removing the caulking portion. ⑥ Install puller and screwed puller bolt to parallel pin(34) and screwed the puller nut then parallel pin is pulled up. Pulling up parallel pin until reaches to surface of the puller.
25038TM15
⑦ Slowly remove three hexagon socket head bolts(19). ※ The thread lock compound used on hexagon socket head bolts(19) may cause the bolts to seize during removal. The hexagon socket head bolts should be removed slowly by hand.
25038TM10(2)
⑧ Remove hold flange(3) from spindle(2). ※ Put an identification marks on hold flange (3) and spindle(2) as to their location. Hold flange(3) and spindle(2) must be reassembled in its original position. 8-83
(5) Disassembly of spindle(2) ① Fasten two eye bolts to spindle(2). Remove spindle(2) from hub(1). ※ When hanging up spindle(2), be careful not to scratch the retainer of ball bearing (21).
25038TM10(4)
(6) Removal the RV gear assembly, ball bearing(21) and pin(17) ① Remove ball bearing(21) from hub(1) using a sharpen punch with hammering to pin(17). At the same time the RV gear assembly and pins(17) also removed. ※ When removing ball bearing(21), move a sharpen punch to one of three or four equidistant positions along the side of pins(17) end each after hammering the sharpen punch so as to keep the distortion of ball bearing(21). ※ When ball bearing(21) comes off from hub(1), ball bearing(21), RV gear assembly and pins(17) will drop. To prevent damage due to the dropping, place a receptacle covered with a rubber under the work bench. ※ The RV gear kit, crank shaft(9), spacer (12), tapered roller bearing(22) and needle bearing(2) are included in the RV gear assembly and are not supplied one by one, therefore, the RV gear assembly should be replaced.
Hammer Sharpen punch
Pin Ball bearing 25038TM16
8-84
(7) Disassembly of ball bearing(21) ① Remove the floating seal(31) from hub(1). ② Turn the motor upside down. ③ Remove the ball bearing(21) from hub(1) by applying a sharpen punch to ball bearing(21) and hammering the punch. ※ When ball bearing(21) comes off from hub(1), the ball bearing will drop. To prevent damage due to the dropping, place a receptacle covered with a rubber under the work bench.
Hammer
Sharpen punch
Ball bearing 25038TM17(1)
(8) Disassembly spindle fittings ① Remove the floating seal(31) from hub(1). ② Remove the outer ring of tapered roller bearing(22) from spindle(2).
25038TM11(1)
(9) Disassembly the outer ring of tapered roller bearing(22) from hold flange(3) ① Remove three outer rings of tapered roller bearings(22) from hold flange(3).
25038TM11(2)
(10) Disassembly of oil seal(132) ① Remove oil seal(132) from spindle(2) as shown below. ※ Do not reuse removed oil seal(132).
Oil seal
25038TM17(2)
8-85
(11) Disassembly of ball bearing(149) ① Place a retainer on the press work bench. Insert shaft(102) into retainer. ② Remove ball bearing(149) from shaft (102) by pressing on the shaft end with a press. ※ Do not remove ball bearing(149) if it is not be replaced. ※ Do not reuse removed ball bearing(149).
8-86
4. ASSEMBLY 1) GENERAL PRECAUTIONS (1) Reassemble in work area that is clean and free from dust and grit. (2) Handle parts with bare hands to keep them free of linty contaminates. (3) Repair or replace the damaged parts. Each parts must be free of burrs its corners. (4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly. Provide the new parts. (5) Wash all parts thoroughly in a suitable solvent. Dry thoroughly with compressed air. Do not use the cloths. (6) When reassembling oil motor components of motor, be sure to coat the sliding parts of the motor and valve with fresh hydraulic oil.(NAS class 9 or above) (7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.
8-87
2) ASSEMBLY OF BRAKE VALVE (1) Assembly of the check valve ① Fit the O-ring(337) on the plug(326). ② Insert the spring(330) and the valve(327) into the plug(326), and then grease the spring(330) and the valve(327) and hand-lock the former. ③ Insert the plug(326) in conjunction with the spring(330) and the valve(327) into the rear flange(301), and tighten the plug to the required torque. ※ Apply grease to the O-ring(337). ※ Tighten the plug(326) to a torque of 26±4kgf・m(188±29lbf・ft).
25038TM04(2)
(2) Assembly of the spool ① Insert the spool(323) into the rear flange (301). ※ Apply a working fluid to the spool(323) and insert it into the rear flange(301). ※ Align the center of the hole in the rear flange with the axial center of the spool to prevent damage to the inner surface of the rear flange and the outer surface of the spool due to contact. ※ Above mentioned damage causes internal leakage after reassembly, thus degrading the motor performance. ② Attach the O-ring(336) to the plug(324). ※ Apply grease to O-ring(336).
25038TM04(1)
③ Install stopper(325) and the spring(328) into both plugs(324) and tighten the plugs(324) into the rear flange(301) at the required torque. ※ Apply grease to the O-ring(355). ※ Required torque : 45±9kgf・m (325±65lbf・ft) ※ Even if either the rear flange(301) or the spool(323) is to be replaced, their entire assembly(kit) must be replaced.
25038TM03(4)
8-88
(3) Assembly of the two-speed control valve ① Fit O-ring(355) on plug(357). ② Insert spring(366) in spool(363) and insert spool(363) to rear flange(301). ※ Apply grease to O-ring(355). ※ Apply hydraulic oil to spool(363). ※ Align the center of the hole in the rear flange with the axial center of the spool to prevent damage to the inner surface of the rear flange and the outer surface of the spool due to contact. Above mentioned damage causes internal leakage after reassembly, thus degrading the motor performance.
25038TM05(1)
③ Tighten plug(357) to rear flange(301) with specified torque. ※ Tightening torque : 10±2kgf・m (72.3±14.5lbf・ft)
25038TM04(4)
8-89
(4) Assembly the inner parts of the rear flange assembly ① Insert steel ball(385) to rear flange(301).
25038TM06(1)
② Fit O-rings(383, 385) on plug(382). ③ Tighten plug(382) to rear flange(301) with specified torque. ※ Tightening torque : 1.5±0.25kgf・m (10.8±1.8lbf・ft) ・Apply grease to O-rings(383, 384).
25038TM05(4)
④ Insert piston(381) to rear flange(301). ※ Apply hydraulic oil to piston(381) and then insert it into rear flange(301). ※ Align the center of the hole in the rear flange with the axial center of the spool to prevent damage to the inner surface of the rear flange and the outer surface of the piston due to contact. The above mentioned damage causes internal leakage after reassembly, thus degrading the motor performance. ※ Rear flange(301) and piston(381) constitutes a rear flange kit. When replacing either of them, therefore, replace the rear flange kit.
25038TM05(3)
8-90
⑤ Fit O-ring(359) on plug(380). ⑥ Install plug(380) to rear flange(301), and tighten plug(380) to rear flange(301) with the specified torque. ※ Tightening torque : 6±1kgf・m (43.4±7.2lbf・ft)
25038TM05(2)
(5) Assembly of the relief valve ① Fit O-rings(208, 209, 219) and back up rings(211, 217) on sleeve(202). ② Fit O-ring(210) on plug(204). ※ Apply grease to the O-ring. ③ Insert shim(205) into plug(204). ※ Use the disassembled shim, because the pressure adjustment made by shim. When replacing the inner parts of relief valve, therefore, the valve kit should be replaced.
25038TM06(3)
④ Fit piston seal(220) to valve(201). ※ Piston seal(220) consist of O-ring and polyester ring, apply grease to them and then fit the O-ring and after fit the polyester ring to valve(201).
Piston seal Valve
25038TM14
8-91
⑤ Insert valve(201), spring(206) and spring retainer(203) to sleeve(202) and tighten plug(204) fitted with shim(205) to the specified torque. ※ Apply hydraulic oil to valve(201) and then insert it to sleeve(202). ※ Align the center of hole in sleeve(202) with the axial center of valve(201) to prevent damage to the inner surface of the sleeve and outer surface of the valve due to contact. ・Tightening torque : 10±2kgf・m (72.3±14.5lbf・ft) ※ Use the disassembled parts, because the relief valve is pressure adjusted. When replacing the inner parts of the relief valve, therefore, the valve kit should be replaced. ※ Apply grease to mating surface of the shim and then fit into the plug. The above mentioned will keep the two faces practically glued together, the shim will not drop down when install the plug to the sleeve.
25038TM07(2)
25038TM07(1)
25038TM06(4)
25038TM06(2)
8-92
3) ASSEMBLY OF REDUCTION GEAR AND HYDRAULIC MOTOR ※ Before reassembling the reduction gear and the hydraulic motor following completion of parts replacement, one of the following two operations must be carried out: ・Selecting a distance piece(12) of the appropriate thickness. ・Selecting a thrust bearing(20) of the appropriate thickness. ※ Reassembling must be down only after clearance adjustment of these parts. ※ Prior to the start of reassembling, check for parts that require replacement.
A : Reassembling (See page 8-103 through 8-109)
No
Parts replacement
Parts to be replaced ・Hub kit ・Spindle kit ・Ball bearing(21)
B : Adjusting ball bearings (See page 8-110 through 8-111)
Parts to be replaced ・Spindle kit ・RV gear assembly
C : Adjusting axial clearance of taper roller bearings (See page 8-112 through 8-113)
Yes
※ If all of the above-name parts can be reused in reassembly, be sure to make these adjustments. Disregard of these adjustments will result in malfunction or premature failure of the motor.
8-93
A : REASSEMBLING (1) Assembly of the hub(1) section ① Bring hub(1) in suspended state over to the work stand, and lower it into the stand slowly. Bolt the hub(1) to the stand by using three fixing jigs. ② Press ball bearing(21) into hub(1) by using fitting jig and hammer. ③ Install floating seal into hub(1) by using fitting jigs. ※ Do not use grease put on O-ring. ※ Install floating seal into hub(1) using installation jigs in the following order. Fitting jig, floating seal, then, fitting jig. Press fitting jig until it comes to touch fitting jig. ※ Check to be sure that it is true and square in hub(1). (2) Assembly of the spindle(2) ① Install floating seal into spindle(2) by using fitting jigs. ※ Do not use grease put on O-ring. ※ Install floating seal into spindle(2) using installation jigs in the following order. Fitting jig, floating seal, then, fitting jig. Press fitting jig until it comes to touch fitting jig. ※ Check to be sure that it is true and square in spindle(2).
(3) Assembly of the hub(1) and spindle(2) ① Install two eye bolts to tapped holes of spindle(2) in opposite positions. ② Lift and carry spindle(2) over in suspended state to hub(1) and gently lower it into hub(1).
25038TM10(4)
8-94
③ Remove two eye bolts and install two fixing jigs to hold, hub(1) and spindle(2) in opposite. Tighten two fixing jigs equally. ④ Turn over the work stand to bring the hub (1) to top side. ⑤ Fit three outer races of taper roller bearings(22) into spindle(2). ※ Please turn over 180 degrees. 25038TM12(1)
(4) Assembly of the RV gear assembly ① Install lifter into center hole of RV gear assembly. ② Lift and carry RV gear assembly over in suspended state to spindle(2) and gently lower it into spindle(2). ③ Insert 24 parallel pins into between RV gear A(4), B(5) and hub(1). ※ Apply gear oil to each pins before inserting it.
(5) Assembly of the ball bearing(21) ① Press ball bearing(21) into hub(1) by using fitting jig and hammer. ※ When pressing ball bearing(21) into hub(1) be sure to keep it true and square by shifting hammer around. ② Install three outer races of taper roller bearings on it.
(6) Assembly of the hold flange(3) ① Install hold flange(3) to spindle(2) by inserting it into ball bearings(21). ※ Install hold flange(3) to spindle(2) in the same position as before disassembly, as indicated by the mating marks for spindle (2) and crankshaft(9).
25038TM12(2)
8-95
(7) Assembly of the Parallel pins(34) and tighten hexagon socket bolts ① Apply loctite to tapped holes and install plain washers into three bolts holes. ② Tighten three hexagon socket bolts with about 20kgf・m(144.7lbf・ft). ③ Drive parallel pins by air vibrator to the bottom of parallel pins holes. ④ Does calking by calking jig to parallel pins holes. ※ If parallel pins and hexagon socket bolts are smeared with oil or grease, degrease it with degreasing agent, clean it with solvent and let it stand and get dry. ※ Do not make a mistake a position and a direction.
25038TM12(3)
⑤ Tighten tree hexagon socket bolts with a torque of 72.3±11kgf・m(522.9±79.6lbf・ ft).
25038TM10(2)
Parts to be replaced ・Spindle kit ・RV gear assembly
C : Adjusting axial clearance of taper roller bearings (See page 8-111)
No parts to be replaced
Proceed directly to the next step.
8-96
(8) Assembly of the distance pieces and snap rings ① Install distance pieces(13) into hold flange(3). ② Install snap rings(20) into the snap rings grooves in hold flange(3). ※ Install distance pieces(13) and snap rings (20) in the same position as before disassembly as indicated by the matching marks on hold flange(3).
25038TM12(4)
(9) Assembly of the spur gears(7) ① Install three spur gears(7) to crank shafts (9). ※ Install the gears to crank shafts in the same position defined by the matching marks, as illustrated here.
25038TM10(3)
② Install three snap rings(25) into the snap rings grooves of crank shafts(9). ※ Snap rings(25) are possible to fly away. ※ Sharp edge face should be upward.
25038TM10(1)
(10) Assembly of the oil seal(132) ① Turn the work stand upside down. ② Install oil seal(132) into the oil seals hole of spindle(2). ※ Apply lithium grease or withe petrolatum to the lip portion of oil seal(132), position the squarely over the bore of spindle(2).
25038TM13(1)
8-97
(11) Assembly of the shaft(102) ① Install ball bearing(149) on shaft(102) by shrunk fitting. ※ Wear thick leather groves in handling the heated bearing. ※ Be sure to push the bearing all the way down until inner race seats on the shoulder. (12) Assembly of the piston assembly(161, 162) ① Install spring(193) into piston assembly (161, 162). ② Install it into spindle(2). ※ Apply grease to spring(193). ※ Apply hydraulic oil to piston assembly (161, 162). 25038TM09(1)
(13) Assembly of the pivots(167) ① Fit two parallel pins(171) into spindle(2). ② Fit two pivots(167) to parallel pins(171). ※ Apply grease to the hemisphere surface of pivots(167).
(14) Assembly of the cylinder block(104) ① Insert washer(110), spring(114), washer (110) in that order, into the shaft(102) bore of cylinder block(104). ② Set cylinder block(104) in the press in order to compress spring(114). ※ Wear thick leather groves in handling the heated bearing. ※ Be sure to push the bearing all the way down until inner race seats on the shoulder.
25038TM09(3)
8-98
③ Place the retainer on the last inserted washer(110) and push down this tool with press arbor until the snap ring groove becomes cleared. Fit snap ring(145) into the groove and remove the push to leave the spring in compresses state. ※ When working on the cylinder block as above, protect its sliding face by covering it with a vinyl sheet, as shown. ※ Snap ring(145) are possible to fly away. ※ Refer to right drawing, how to install washers(110) and snap ring(145).
25038TM09(2)
(15) Assembly of the motor assembly ① Install five needle rollers(151) to the pin holes of cylinder block(104). ② Install washer(111) onto five needle rollers(151). ③ Install thrust bow(108) onto washer(111).
25038TM08(2)
④ Insert nine piston assembly(105, 106) into retainer plate(107). ⑤ Insert it into cylinder block(104). ※ Immerse the sub assembly in hydraulic oil.
25038TM13(2)
⑥ As usual under drawing, install swash plate(103), thrust ball(108), washer(111), retainer plate(107), needle rollers(151), cylinder block(104), piston assembly(105, 106) to shaft(102) and set lifter.
8-99
(16) Assembly of the motor assembly ① Lift the motor assembly slowly and install it in spindle(2). ② After installed, remove lifter. ※ Two pivots holes of swash plate(103) adjust to matching two pivots(167). ※ Motor assembly does not injure by hitting another one. ※ After installed motor, turn cylinder block(104) by hand and check nothing loose. If cylinder block(104) is loose, again disassemble motor assembly and reassemble.
8-100
B : ADJUSTING BALL BEARINGS ※ Ball bearings(22) must be given a correct pressure to serve its full life. If a part that affects the bearing pressure is replaced, therefore, readjust the bearing pressure according to the following procedure. ※ Take notice when motor is reassembled ensure that all adjustments are absolutely correct. Failure to have correct adjustments will result in damage to the motor early in use. ※ Parts that affect the bearing pressure include: Hub(1), spindle assembly and ball bearings(21). ※ Confirm and readjust the ball bearings pressure as follows:
Torque lench
Special nut Adjust jig Hub Spindle
C
(1) Attach the ball bearings pressure adjustment jig to spindle(2). Press fit ball bearings(21) into the hub(1) by tightening the special nut with a torque of 12±2kgf・m (86.8±11.5lbf・ft)
A
B
Depth micro meter
Hub Spindle
(2) Insert a depth micrometer through the measuring hole in ball bearings pressure adjustment jig and determine the depth as A.
Adjust jig
A B C
(3) Because the B dimension of ball bearing pressure adjustment jig is known, clearance C can be determined as follows: C = A - B
Measured value Jig dimension Required clearance 25038TM18(1)
8-101
(4) Measure dimension D of hold flange(3). D
(5) Based on the results obtained from step (2) through(4), adjust hold flange(3) as follows.(Dimension C is the required clearance of hold flange): ① If measured dimension D of hold flange (3) is smaller than the required value: Grind down surface E of hold flange(3) with a lathe or other machine so that dimension D equals the required value. ② If measured dimension D of hold flange (3) is within the tolerance of the required value: Use hold flange(3) as it is. ③ If measured dimension D of hold flange (3) is greater than the required value: Use a new spindle assembly. Dimension D of a new hold flange(3) allows for adjustment.
The surface(E) Hold flange
25038TM18(2)
(6) Remove the ball bearings pressure adjustment jig from spindle(2).
8-102
C : ADJUSTING AXIAL CLEARANCE OF TAPER ROLLER BEARINGS ※ If any of the following parts has been replaced, readjust the axial clearance of the taper roller bearings(22) selecting distance pieces(13) having a suitable thickness: Hub(1), spindle assembly, RV gear assembly and snap rings(20). ※ Take notice when motor is reassembled ensure that all adjustments are absolutely correct. ※ Failure to have correct adjustments will result in damage to the motor early in use. ※ If none of the above parts has been replaced, on axial clearance adjustment is required. ※ Adjust the axial clearance of the taper roller bearings as follows:
Retainer Taper roller bearing RV gear assembly
25038TM19
(1) Apply the retainer to the outer races of taper roller bearings(22) on the crankshafts(9) and lightly hammer it. ※ Hammering makes insertion of the RV gear assembly into the spindle(2) easier. (2) Install the least thick distance pieces(13) in the hold flange(3). (3) Move the retainer to another point on distance pieces(13) each after lightly hammering it. ※ Confirm that the RV gear assembly is secured to the spindle(2) in place. (4) Install the snap rings(20) in the snap ring grooves in the hold flange(3). (5) Measure the clearance between the snap rings(20) and the taper roller bearings(22) with a thickness gauge.
8-103
(6) Determine whether the thickness of the snap rings(20) is suitable.
Max = Thickness gauge + Distance piece thickness
Min =
thickness
Thickness gauge + Distance piece thickness thickness
- 0.05
(7) Select another distance pieces from 17 available types, install it in between distance pieces(13) and snap rings(20).
8-104
4) ASSEMBLY PROCEDURE (1) Assembling the brake valve section and hydraulic motor section ① Fit friction plate(115) and then mating plate(116), one by one, into the grooves of the outer surface of cylinder block(104). ※ Immerse the friction plate in a hydraulic oil before fitting them. ※ Do not make a mistake order, friction plate(115) and mating plage(116). Because it make braking torque down.
25038TM08(1)
② Mount O-rings(135, 139) in the O-ring grooves of piston(112) after applying grease them. ③ Mount piston(112) in spindle(2). ※ If the piston(112) do not fit into the spindle(2) because of the resistance of the O-ring tap the edge of the piston(112) lightly and equally with a plastic hammer. Be careful not to damage the O-ring at this time.
25038TM07(4)
④ Ball bearing(150), parallel pin(341), timing plate(109), twelve springs(113) into the rear flange(101). ※ Apply hydraulic oil to ball bearing(150). Apply grease timing plate(109) and twelve springs(113). Because the coat of grease will keep the two faces.
25038TM03(1)
⑤ Hydraulic oil flow into spindle(2). Fit Orings(27, 29) in the grooves provided in the mating face of spindle(2) without grease. Two parallel pins(42) into spindle(2). And install rear flange(301) onto spindle(2) so that the two parallel pins(42) on the spindle enter the dowel holes in the rear flange. ・Quantity required : Hydraulic oil 1.7 liters 25038TM02(4)
8-105
⑥ Tighten the twelve hexagon socket bolts (343) to the specified torque. ・Tightening torque : 25.7±4kgf・m (185.9±28.9lbf・ft) ⑦ The O-ring(355) insert a plug(357) and tighten it to the specified torque.(For not using drain port.) ・Tightening torque : 10±2kgf・m (72.3±14.5lbf・ft) 25038TM02(3)
⑧ Install relief valves to rear flange(301). ⑨ Tighten relief valves to the specified torque. ・Tightening torque : 25±5kgf・m (180.8±36.2lbf・ft)
25038TM02(2)
(2) Assembling the reduction gear / Hydraulic motor shafts and oil seal ① Install coupling(15) to motor shaft. ② Install input gear(6) to coupling(15). And steel ball(36) put into the hole of input gear(6). ※ Apply grease to steel ball(26). ③ Fit O-ring(30) in the O-ring groove of cover(8). ※ Apply grease to O-ring(30). ④ Lift and install cover(8) to hub(1) by using eye bolts, plastic hammer and lifting tool. ※ Need careful handling for not damaging O-ring(30).
25038TM09(4)
25038TM03(3)
8-106
⑤ Tighten the twelve hexagon socket bolts (35) to the specified torque. ⑥ Gear oil flow into the hub(1). ・Tightening torque : 10.4±1.6kgf・m (75.2±11.6lbf・ft) ・Quantity required : Gear oil 5.4 liters
25038TM03(2)
⑦ The O-ring(43) insert hexagon socket plugs(33) and tighten it to the specified torque.(For three gear oil ports.) ・Tightening torque : 10±2kgf・m (72.3±14.5lbf・ft)
25038TM03(3)
⑧ This completes assembly.
25038TM02(1)
8-107
B. TRAVEL DEVICE(SBTR220, #2079 and up) 1. REMOVAL AND INSTALL 1) REMOVAL (1) Swing the work equipment 90。and lower it completely to the ground. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury. ※ When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.
13031GE18
1
Dr
(4) Remove the track shoe assembly. For details, see removal of track shoe assembly.
P
2
B A
(5) Remove the cover. 21078DA47
(6) Remove the hose. ※ Fit blind plugs to the disconnected hoses. (7) Remove the bolts and the sprocket. (8) Sling travel device assembly(1). (9) Remove the mounting bolts(2), then remove the travel device assembly. ·Weight : 300kg(660lb) 2) INSTALL (1) Carry out installation in the reverse order to removal. (2) Bleed the air from the travel motor. ① Remove the air vent plug. ② Pour in hydraulic oil until it overflows from the port. ③ Tighten plug lightly. ④ Start the engine, run at low idling, and check oil come out from plug. ⑤ Tighten plug fully. (3) Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8-107-1
2. TRAVEL MOTOR 1) STRUCTURE 95 91-8
90-5 90-7
90-2 90-6 3 90-3 90-4 90-1
81 82 83
8
9 17 18 20 19
25 24
23 22 26 27
28
36 35 32 31
30 64
71
76
40 41 42
65 91-4
10
91-6
70
91-1
29
91-7 69
91-5
44 90-7
43 39
91-3
38 62 63
91-2 94
73 74
92 37 89
45 33
98
34 97
46
96
72 14 13 88
93
86
87
85
84
2
1
6
4
5
7
16 15 11
12 21 67 68 66
58 57 56 59
47 49 50
48 61 60
51 53 52
55 54 21078TM02
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Shaft casing Plug Oil seal Swash piston Piston ring Shaft Bearing Steel ball Swash plate Cylinder block Spring seat Spring End plate Snap ring Pin Ball guide Set plate Piston assy Friction plate
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Plate Packing piston O-ring Back up ring O-ring Back up ring Orifice O-ring O-ring Rear cover Spool Check Spring Plug O-ring Spring seat Spring Cover Spring
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Spool Steel ball Spring Plug Spring seat O-ring Wrench bolt Relief valve assy Spool Guide O-ring Back up ring O-ring Back up ring Snap ring plug O-ring Spring
57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
8-107-2
Spring seat Plug Spool Orifice Orifice Plug O-ring Plug Pin Pin Spring Spring Bearing Valve plate Wrench bolt Plug Name plate Rivet
75 76 81 82 83 84 85 86 87 88 89 90 90-1 90-2 90-3 90-4 90-5 90-6
Seal kit Orifice Housing Main bearing Floating seal Shim Retainer Hex head bolt Parallel pin Ring gear Coupling Carrier assy No.2 Carrier No.2 Planetary gear No.2 Needle bearing No.2 Thrsut washer Pin No.2 Spring pin
90-7 91 91-1 91-2 91-3 91-4 91-5 91-6 91-7 91-8 92 93 94 95 96 97 98 99
Thrust ring Carrier assy No.1 Carrier No.1 Sun-gear No.2 Retaining ring Planetary gear No.1 Needle bearing No.1 Thrust washer Pin No.1 Spring pin Sun gear No.1 Cover Pad Hex socket head bolt Hex socket Screw Hydraulic plug O-ring Name plate
2) TOOLS AND TIGHTENING TORQUE (1) Tools Tool name
Remark
Allen wrench
B
2.5, 4, 6, 10
Socket for socket wrench, spanner
Socket
8, 14, 24, 27
Torque wrench
Capable of tightening with the specified torques
Pliers
-
Plastic and iron hammer
Wooden hammer allowed. Normal 1 or so
Monkey wrench
-
Oil seal inserting jig
-
Bearing pliers
-
Seal tape
-
Eye bolt
M10, M12, M14
Press(0.5 ton)
-
Oil stone
-
Bearing assembling jig
-
(2) Tightening torque Part name
Item
Size
Plug
2
NPTF 1/16
Orifice
26
Wrench bolt
Torque kgf·m
lbf·ft
1±0.1
7.2±0.7
M5
0.7±0.1
5±0.7
45
M12×40L
10±1.0
72±7.0
Relief valve
46
HEX 27
18±1.0
130±7.0
Plug
54
PF 1/2
8.5±1.0
61±7.0
Plug
58
HEX 24
5±1.0
36±7.0
Plug
62
PF 1/4
5±1.0
36±7.0
Wrench bolt
71
M10×35L
10±1.0
72±7.0
Hex head bolt
-
M12×25L
11±1.5
79±10
Hex socket head bolt
-
M12×155L
11±1.5
79±10
Hex socket head plug
-
PF 3/4
8-107-3
19±1
137±7.0
3. OUTLINE OF DISASSEMBLING 1) GENERAL SUGGESTIONS (1) Select a clean place for dismantling. Spread a rubber plate on a working table in order to prohibit the damage of parts. (2) Clean a deceleration equipment and a motor part, washing out dirt and unnecessary substances. (3) Without any damage of O-ring, oil seal, the adhered surface of other seals, a gear, a pin, the adhered surface of other bearings, and the surface of moisturized copper, treat each parts. (4) Numbers written in the parenthesis, ( ), next to the name of a part represent the part numbers of a cross-sectional view annexed with a drawing. (5) The side of a pipe in a motor can be written as a rear side; the side of out-put as a front side. (6) Using and combining a liquid gasket, both sides must be dried completely before spraying a liquid gasket. (7) In case of bonding volts, combine a standard torque by torque wrench after spraying rocktight 262 on the tab parts. (It can be dealt as assembling NPTF screws and an acceleration equipment.) 3.1 DISASSEMBLING 1) Unloosing wrench bolt and disassemble cover(37). ※ Wrench bolt = M12×40L-8EA (Purchasing goods)
21078TM21
2) Disassemble parts related to C.B.V.
21078TM22
8-107-4
3) Unloosing wrench bolt(M12×35L, 16EA) and disassemble rear cover assembly from motor assembly.
21078TM23
21078TM24
4) Dismantle packing piston(21) using compressed air.
21078TM25
5) Disassembly rotary kit from motor assembly(Cylinder block assembly, piston assembly, ball guide, set plate, friction plate, steel plate...)
21078TM26
8-107-5
6) Using a jig, disassemble swash plate(9) from shaft casing.
21078TM27
7) Using compressed air, disassemble piston swash(4) piston ring(5), respectively.
21078TM28
21078TM29
8) Using a hammer, disassemble shaft(6) from shaft casing(1).
21078TM30
8-107-6
■ Disassemble cylinder sub. 9) Disassemble cylinder block assembly, piston assembly(9) and seat plate(M).
21078TM31
21078TM32
10) Disassemble ball guide(16), ring and pin(15) from cylinder block, respectively.
21078TM33
21078TM34
8-107-7
21078TM35
11) Pushing spring(12) by an assembling jig, disassemble snap ring(14), spring seat(13), spring(12) and spring seat(11), respectively.
21078TM36
21078TM37
■ Disassemble valve casing sub. 12) Using an hexagon wrench, unloosing wrench bolt(45) and disassemble cover(37), spring(38), spool(39), spring seat(43), spring(36) and spring seat(35), respectively. (Same balance on both sides)
21078TM38
8-107-8
21078TM39
13) Disassemble spool(59), spool(47), O-ring (51), guide(48) and snap ring(53) on rear cover, respectively.
21078TM40
21078TM41
14) Using a torque wrench, disassemble relief assembly(46) on rear cover.
21078TM42
8-107-9
4. OUTLINE FOR ASSEMBLING 1) GENERAL SUGGESTIONS (1) After washing each parts cleanly, dry it with compressed air. Provided that you do not wash friction plate with treated oil. (2) In bonding each part, fasten bond torque. (3) When using a hammer, do not forget to use a plastic hammer. 4.1 ASSEMBLING ■ Assemble the sub of turning axis 1) Using a jig, assemble oil seal(3) into shaft casing(1)
21078TM43
2) Have a bearing(8) thermal reacted into shaft(6).
21078TM44
21078TM45
8-107-10
21078TM46
3) Using a jig, assemble shaft assembly into shaft casing(1).
21078TM47
4) After spreading grease on steel ball(8) assemble into shaft casing(1).
21078TM48
5) Assemble swash piston assembly(4, 5) into shaft casing(1).
21078TM49
8-107-11
6) Assemble swash plate(9) into shaft casing (1).
21078TM50
■ Assemble cylinder block sub. 7) Assemble spring seat(13), spring(12), spring seat(11) into cylinder block(10) respectively, pushing spring(12) using by a jig, assemble snap ring(14) with a snap ring(14).
21078TM51
21078TM52
8-107-12
8) Assemble ring, pin(15) on cylinder block(10) ball guide(16) respectively.
21078TM53
21078TM54
21078TM55
9) Assemble cylinder block assembly, piston assembly(9), seat plate(17).
21078TM56
8-107-13
21078TM57
10) Assemble cylinder block assembly(9) into shaft casing(a).
21078TM58
11) Assemble friction plate(19) and plate(20) into shaft casing(1) respectively, prepare 6 set.
21078TM59
21078TM59-1
8-107-14
12) Assemble O-ring(22, 23) into packing piston (21).
21078TM60
21078TM60-1
13) After spreading grease on packing piston(21) bond wrench bolt and assemble shaft casing(1).
21078TM61
■ Assemble rear cover sub. 14) Using a jig, assemble bearing(69) into rear cover(29).
21078TM62
8-107-15
15) After assembling spool(59), spool(47), O-ring(51), guide(48) and snap ring(53) respectively into rear cover(29). Using torque wrench, assemble it.
21078TM63
21078TM64
21078TM65
8-107-16
16) Assemble spring seat(35), spring(36), spring seat(43), spool(39), spring(38), cover(37) respectively and assemble wrench bolt(45). (Same balance on both sides)
21078TM66
21078TM67
21078TM67-1
8-107-17
17) Assemble plug(2). ※Plug(NPT1/16) - 11EA
21078TM68
21078TM69
21078TM70
21078TM71
8-107-18
18) Assemble plug(64). ※Plug(PT3/8) - 11EA
21078TM72
19) Assemble plug(62, 63) into rear cover(29) and assemble relief valve assembly.
21078TM73
21078TM74
20) Put spring(67, 68) together into rear cover (29), prepare 6 set.
21078TM75
8-107-19
21078TM76
21) Assemble valve plate(70) into rear cover (29).
21078TM77
22) After assembling shaft casing(1) and rear cover(29). Assemble spool assembly(30), spring(38), spool(39), cover(37) after then complete assembly with wrench bolt(45).
21078TM78
23) Finish assembly.
21078TM79
8-107-20
5.1 DISASSEMBLING REDUCTION UNIT 1) Preparation for disassembling (1) The reduction units removed from excavator are usually covered with mud. Wash outside of propelling unit and dry it. (2) Locate reducer in order for drain port to be at the lowest level loosen taper screw plug of drain port, and drain oil from reduction gear. ※ While oil is still hot, inside of the unit may be pressurized. Take care of the hot oil gushing out of the unit when loosening the plug. (3) Mark for mating Put marks on each mating parts when disassembling so as to reassemble correctly as before.
21078TM80
2) Setting reduction unit(or whole propelling unit) on work stand for disassembling (1) Remove M12 hexagon socket head bolts(95) at 3 places from cover(93) almost equally apart each other, and then install M12×155L eye bolts. Lift up the unit using them and place it on work stand with cover upward. Take great care not to pinch your hand between parts while disassembling nor let fall parts on your foot while lifting them.
21078TM81
3) Removing cover (1) Remove the rest of M12 hexagon socket head bolts(95) that securering gear and housing. Loosen all the socket bolts and then, disassemble cover. (2) As the cover(93) is adhered to ring gear (88), disassemble ring gear(88) and cover (93) vy lightly hammering slantwise upward using sharpen punch inserted between the cover and ring gear.
8-107-21
21078TM82
4) Removing No.1 carrier sub assembly (1) Screw three M10 eye-bolt in No.1 carrier and lift up and remove No.1 carrier assy.
21078TM83
(2) Remove No.1 sun gear ※ Be sure to maintain it vertical with the ground when disassembling No.1 sun gear.
21078TM84
5) Removing No.2 carrier sub assembly (1) Screw three M10 eye-bolt in No.2 carrier and lift up and remove No.2 carrier assy.
21078TM85
(2) Remove No.2 sun gear ※ Be sure to maintain it vertical with the ground when disassembling No.2 sun gear.
21078TM86
8-107-22
6) Removing ring gear (1) As the ring gear(88) is adhered to housing(81), disassemble ring gear(88) and housing(81) by lightly hammering slantwise upward using sharpen punch inserted between the ring gear and housing. ※ Carefully disassembling ring gear not to make scratch on it. (2) Screw M14 eye-bolt in ring gear and lift up and remove it.
21078TM87
7) Removing coupling (1) Remove coupling.
21078TM88
8) Removing retainer & shim (1) Remove M12 hexagon socket head bolts that secure retainer and motor. (2) Remove retainer & shim.
21078TM89
9) Removing housing sub assembly (1) Screw M12 eye bolt in housing and lift up housing assembly including anguler bearing and floating seal.
21078TM90
8-107-23
10) Removing floating seal (1) Lift up a piece of floating seal of motor side.
21078TM91
11) Disassembling housing assembly (1) After turning housing, lift up a piece of floating seal from housing and then remove it. ※ Don't disassemble anguler bearing.
21078TM92
12) Disassembling No.1 carrier (1) Remove thrust ring(90-7) from carrier. (2) Knock spring pin(91-8) fully into No.1 pin (91-7). (3) Remove planetary, thrust washer, No.1 pin, bearing from carrier.
21078TM93
21078TM94
8-107-24
21078TM95
13) Disassembling No.2 carrier (1) Disassemble No.2 carriers, using the same method for No.1 carrier assembly.
21078TM96
21078TM97
8-107-25
6.1 ASSEMBLY REDUTION GEAR ■ General notes Clean every part by kerosene and dry them by air blow. Surfaces to be applied by locktite must be decreased by solvent. Check every part for any abnormals. Each hexagon socket head bolt should be used with locktite No. 262 applied on its threads. Apply gear oil slightly on each part before assembling. Take great care not to pinch your hand between parts or tools while assembling nor let fall parts on your foot while lifting them.
Inspection before reassembling Thrust washer · Check if there are seizure, abnormal wear or uneven wear. · Check if wear is over the allowable limit. Gears · Check if there are pitting or seizure on the tooth surface. · Check if there are cracks on the root of tooth by die check.
21078TM98
Bearigs · Rotate by hand to see if there are something unusual such as noise or uneven rotation. Floating seal · Check flaw or score on sliding surfaces or O-ring.
1) Assembling No.1 carrier (1) Put No.1 carrier(91-1) on a flat place. (2) Install No.1 needle bearing(91-5) into No.1 planetary gear(91-4), put 2EA of No.1 thrust washer(91-6) on both sides of bearing, and then, install it into carrier.
21078TM99
8-107-26
(3) Install No.1 pin(91-5) into No.1 carrier where the holes for No.1 pin(91-5) are to be in line with those of No.1 carrier, and then, install spring pins into the holes.
21078TM100
(4) Caulk carrier holes as shown on the picture. (5) Assembly ring thrust(90-7) into carrier.
21078TM101
2) Assembling No.2 carrier
Caulk these two in 180
(1) Put No.2 carrier(90-1) on a flat place. (2) Install No.2 needle bearing(90-3) into No.2 planetary gear(90-2), put 2EA of No.2 thrust washer(90-4) on both sides of bearing, and then, install it into carrier. 0.5
Pin & Caulk
1.0 - 2.0 Depth for pinning 21078TM102
(3) Install No.2 pin(90-5) into No.2 carrier where the holes for No.2 pin(90-5) are to be in line with those of No.2 carrier, and then, install spring pins into the holes.
21078TM103
8-107-27
(4) Caulk carrier holes as shown on the picture. (5) Assembly ring thrust(90-7) into carrier.
21078TM104
3) Assembling floating seal(83) and main bearing(82) (1) Assemble floating seal into motor by use of pressing jig. Grease the contact parts for floating seal which is assembled into motor. C and then, put (2) Heat bearing at 60~70。 into the motor side. 21078TM105
※ Be sure to maintain it vertical with the ground when assembling bearing and floating seal.
21078TM106
4) Assembling housing C while clearing it (1) Heat housing at 60~70。 out and then, assemble foating seal into housing by use of pressing jig. ※ Be sure to maintain it vertical with the ground when assembling floating seal.
21078TM705
8-107-28
5) Installing housing assembly (1) Install 2EA of M12 eye-bolt into housing assembly. (2) Assemble housing into motor by use of hoist and eye-bolt. ö Be sure to tighten eye-bolt deep enough.
21078TM108
6) Installing main bearing(82) C and then, (1) Heat main bearing at 60~70Á install. ö Be sure to maintain it vertical with the ground when assembling bearing.
21078TM109
7) Installing retainer(85) and shim(84) (1) Measure clearance between main bearing and retainer by use of jig to decide the thickness of shim and select an appropriate shim, and then, assemble retainer. Apply locktite(#262) on M12 hexagon (2) head bolt, and then, bolt.
21078TM110
8) Installing coupling (1) Install coupling on spline of the motor.
21078TM111
8-107-29
9) Installing ring gear (1) Apply three bone #1104(locktite #515) on housing for ring gear without gap. (2) Insert lock pin into housing hole. (3) Install M14 eye-bolt on the tap of ring gear. (4) Lift ring gear and then, assemble into housing in order for hole of ring gear and parallel pin of housing to be in line.
21078TM112
(5) Temporarily secure 4EA of M12 hexagon socket bolt and shim with cover thickness having appropriate torque.
21078TM113
10) Installing No.2 carrier sub assembly (1) Install M10 eye-bolt on No.2 carrier assembly. (2) Lift No.2 carrier assembly and then, slowly put it down on ring gear. (3) Rotate planetary gear by hands and install on ring gear. 21078TM114
8-107-30
11) Installing No.2 sun gear(91-2) (1) Install No.2 sun gear on the spline of No.2 carrier and No.2 planetary gear, matching teeth of them.
21078TM115
(2) Install No.2 sun gear on the spline of No.2 carrier and No.2 planetary gear, matching teeth of them.
21078TM116
12) Installing No.1 carrier sub assembly (1) Install M10 eye-bolt on No.2 carrier assembly. (2) Lift No.1 carrier assembly and then, slowly put it down on ring gear. (3) Rotate planetary gear by hands and install on ring gear. 21078TM117
13) Installing No.1 sun gear(92) (1) Put down No.1 sun gear on No.1 carrier, maintaining it vertical with spline of coupling. (2) Install No.1 sun gear on No.1 planetary gear, matching their teeth.
21078TM118
8-107-31
14) Installing cover(93) (1) Beat pad(94) with plastic hammer, and press it into the center of cover. (2) Apply three bond #1104(locktite#515) on the ring gear for cover without gap. (3) Put cover on ring gear, apply locktite (#262) on M12 hexagon socket head bolt, and then, bolt. 21078TM119
(4) Fill gear oil(7.5liter) into drain port. (5) Apply gear oil on PF3/4 hydraulic plug(97) and then, bolt.
21078TM120
8-107-32
GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury.
13031GE18
1
(4) Loosen the socket bolt(1). 2
(5) Remove the cover of the console box. (6) Disconnect pilot line hoses(3).
3
(7) Remove the pilot valve assembly(2). ※ When removing the pilot valve assembly, check that all the hoses have been disconnected. 2) INSTALL (1) Carry out installation in the reverse order to removal. (2) Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8- 108
21078DA06
2. DISASSEMBLY AND ASSEMBLY 1) STRUCTURE
14072SF80
8- 109
1 2 3 4 5 6 7 8 9 10
Case Plug Plug O-ring Spool Shim Spring Spring seat Stopper Spring
11 12 13 14 15 16 17 18 19 20
Plug Rod seal O-ring Push rod Plate Bushing Joint assembly Swash plate Adjusting nut Lock nut
8- 110
21 22 23 24 25 26 27 28 29 30 40
O-ring Handle connector Nut Insert Boot Handle Switch assembly Screw Switch assembly Switch cover Boot
2) TOOLS AND TIGHTENING TORQUE (1) Tools Tool name
Remark
Allen wrench
B
6 22
Spanner
27
(+) Driver
Length 150
(-) Driver
Width 4~5
Torque wrench
Capable of tightening with the specified torques
(2) Tightening torque Part name
Item
Size
Plug
2
Joint
Torque kgf・m
lbf・ft
PT 1/8
3.0
21.7
18
M14
3.5
25.3
Swash plate
19
M14
5.0±0.35
36.2±2.5
Adjusting nut
20
M14
5.0±0.35
36.2±2.5
Lock nut
21
M14
5.0±0.35
36.2±2.5
Screw
29
M 3
0.05
0.36
8- 111
3) DISASSEMBLY (1) Clean pilot valve with kerosene. ※ Put blind plugs into all ports (2) Fix pilot valve in a vise with copper(or lead) sheets. (3) Remove end of boot(25) from case(1) and take it out upwards. 1408DA62
※ For valve with switch, remove cord also through hole of casing.
1408DA63
(4) Loosen lock nut(20) and adjusting nut(19) with spanners on them respectively, and take out handle section as one body.
1408DA64
(5) Remove the boot(40)
1408DA61
8- 112
(6) Loosen adjusting nut(19) and plate(18) with spanners on them respectively, and remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it, utilizing jig(Special tool). ※ When return spring(10) is strong in force, plate(15), plug(11) and push rod(14) will come up on loosening joint. Pay attention to this.
36078RL03
36078RL04
8- 113
(8) Remove plate(15).
36078RL05
(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 periphery groove of plug and paying attention not to damage it by partial loading. ※ During taking out, plug may jump up due to return spring(10) force. Pay attention to this.
36078RL06
(10) Remove reducing valve subassembly and return spring(10) out of casing. ※ Record relative position of reducing valve subassembly and return springs.
36078RL07
(11) Loosen hexagon socket head plug(2) with hexagon socket screw key.
36078RL08
8- 114
(12) For disassembling reducing valve section, stand it vertically with spool(5) bottom placed on flat workbench. Push down spring seat(8) and remove two pieces of semicircular stopper(9) with tip of small minus screwdriver. ※ Pay attention not to damage spool surface. ※ Record original position of spring seat(8, 31). ※ Do not push down spring seat more than 6mm.
36078RL09
(13) Separate spool(5), spring seat(8), spring(7) and shim(6) individually. ※ Until being assembled, they should be handled as one subassembly group.
36078RL10
(14) Take push rod(14) out of plug(11).
36078RL11
(15) Remove O-ring(13) and seal(12) from plug(11). Use small minus screwdriver or so on to remove this seal.
36078RL12
8- 115
36078RL13
(16) Remove lock nut(20) and then boot(25).
36078RL14
25038RL02
8- 116
(17) Cleaning of parts ① Put all parts in rough cleaning vessel filled with kerosene and clean them (Rough cleaning). ※ If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil. ※ If this kerosene is polluted, parts will be damaged and functions of reassembled valve will be degraded. Therefore, control cleanliness of kerosene fully. ② Put parts in final cleaning vessel filled with kerosene, turning it slowly to clean them even to their insides(Finish cleaning). ※ Do not dry parts with compressed air, since they will be damaged and/or rusted by dust and moisture in air. (18) Rust prevention of parts. Apply rust-preventives to all parts. ※ If left as they after being cleaned, they will be rusted and will not display their functions fully after being reassembled.
8- 117
4) ASSEMBLY (1) Tighten hexagon socket head plug(2) to the specified torque. ※ Tighten two bolts alternately and slowly.
36078RL15
(2) Put shim(6), springs(7) and spring seat(8) onto spool(5) in this order.
36078RL16
(3) Stand spool vertically with its bottom placed on flat workbench, and with spring 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 seat more than 6mm. 36078RL17
(4) Assemble spring(10) into casing(1). Assemble reducing valve subassembly into casing. ※ Assemble them to their original positions.
36078RL18
8- 118
(5) Assemble O-ring(13) onto plug(11).
36078RL19
(6) Assemble seal(12) to plug(11). ※ Assemble seal in such lip direction as shown below.
36078RL20
(7) Assemble push rod(14) to plug(11). ※ Apply working oil on push-rod surface.
36078RL21
(8) Assemble plug subassembly to casing. ※ When return spring is weak in force, subassembly stops due to resistance of O-ring.
36078RL22
8- 119
(9) When return spring is strong in force, assemble 4 sets at the same time, utilizing plate(15), and tighten joint(17) temporarily.
36078RL23
(10) Fit plate(15).
(11) Tighten joint(17) with the specified torque to casing, utilizing jig.
36078RL24
(12) Assemble swash plate(18) to joint(17). ※ Screw it to position that it contacts with 4 push rods evenly. ※ Do not screw it over.
36078RL25
(13) Assemble adjusting nut(19), apply spanner to width across flat of plate(18) to fix it, and tighten adjusting nut to the specified torque. ※ During tightening, do not change position of disk.
36078RL26
8- 120
(14) Fit boot(40) to plate.
1408DA61
(15) Fit boot(25) and lock nut(20), and handle subassembly is assembled completely.
25038RL02(4)
36078RL27
(16) Pull out cord and tube through adjusting nut hole provided in direction 60°to 120° from casing hole.
1408DA66
8- 121
(17) Assemble bushing(16) to plate and pass cord and tube through it. ※ Provide margin necessary to operation.
1408DA67
(18) Determine handle direction, tighten lock nut(20) to specified torque to fix handle.
1408DA68
(19) Apply grease to rotating section of joint and contacting faces of disk and push rod.
1408DA69
(20) Assemble lower end of bellows to casing. (21) Inject volatile rust-preventives through all ports and then put blind plugs in ports.
25038RL04
8- 122
GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine. (2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. (3) Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious injury. ※ When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan. (4) Disconnect all hoses. (5) Sling the turning joint assembly (1) and remove the mounting bolt(2). ・Weight : 54kg(119lb) ・Tightening torque : 12.3± 1.3kgf・m (88.9± 9.4lbf・ft)
1
(6) Remove the turning joint assembly. ※ When removing the turning joint, check that all the hoses have been disconnected. 2) INSTALL (1) Carry out installation in the reverse order to removal. ※ Take care of turning joint direction. ※ Assemble hoses to their original positions. ※ Confirm the hydraulic oil level and check the hydraulic oil leak or not.
1
2
8-123
2. DISASSEMBLY AND ASSEMBLY 1) STRUCTURE
14
3
15 10 12
6 4 5
11 1
7
11 9 8
2
1 2 3 4 5
Hub Shaft Cover Spacer Shim
6 7 8 9 10
Shim Slipper seal O-ring O-ring O-ring
8-124
11 12 13 14 15
Wear ring Retainer ring Plug Hexagon bolt Spring washer
2) DISASSEMBLY
14
※ Before the disassembly, clean the turning joint. (1) Remove bolts(14), washer(15) and cover(3).
15 3
(2) Remove shim(6) and O-ring(10).
6 10 12
(3) Remove retainer ring(12), spacer(4) and shim(5).
4 5
(4) 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 body with a hammer. ※ Take care not to damage the shaft(2) when remove hub(1) or rest it sideway. ※ Put a fitting mark on hub(1) and shaft(2).
Wooden block
Secure with hand
V block Work bench
(5) Remove six slipper seals(7) and O-ring(9), two ring wear(11) from hub(1).
11 7 11 9 1
8-125
3) ASSEMBLY ※ Clean all parts. ※ As a general rule, replace oil seals and Oring. ※ Coat the sliding surfaces of all parts with engine oil or grease before installing. (1) Fix seven slipper seal(7) and O-ring(9), two ring wear(11) to hub(1).
11
(2) Fit O-ring(8) to shaft(2).
7 11 9 1
(3) Set shaft(2) on block, tap hub(1) with a plastic hammer to install.
2
1
(4) Fit shim(5), spacer(4) and retainer ring (12) to shaft(2).
6 10 12
(5) Fit O-ring(10) to hub(1).
4
(6) Fit shim(6) to shaft(2).
5
8-126
(7) Install cover(3) to body(1) and tighten bolts(14). ・Torque : 10~12.5kgf・m(72.3~90.4lbf・ft)
14 15 3
8-127
GROUP 9 BOOM, ARM AND BUCKET CYLINDER 1. REMOVAL AND INSTALL 1) BUCKET CYLINDER (1) Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. ※ Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank. ※ Escaping fluid under pressure can penetrate the skin causing serious injury. Fit blind plugs in the hoses after disconnecting them, to prevent dirt or dust from entering.
Bucket Cylinder
① Set block between bucket cylinder and arm.
Arm Wooden block
② Remove bolt(2), nut(3) and pull out pin (1). ※ Tie the rod with wire to prevent it from coming out.
2 3
1
③ Disconnect bucket cylinder hoses(4) and put plugs(5) on cylinder pipe.
5 4
4
8-128
④ Sling bucket cylinder assembly(8) and remove bolt(6) then pull out pin (5). ⑤ Remove bucket cylinder assembly(8). ・Weight : 174kg(384lb)
8
5
6
(2) Install ① 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 from the bucket cylinder. ※ Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8-129
2) ARM CYLINDER (1) Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. ※ Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank. ※ Escaping fluid under pressure can penetrate the skin causing serious injury. Fit blind plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. ① Set block between arm cylinder and boom.
Arm cylinder
Block
② Remove bolt(2) and pull out pin(1). ※ Tie the rod with wire to prevent it from coming out.
1 2
③ Disconnect arm cylinder hoses(4) and put plugs on cylinder pipe. ④ Disconnect greasing pipings(5).
4
8-130
5
⑤ Sling arm assembly(8) and remove bolt (7) then pull out pin(6). ⑥ Remove arm cylinder assembly(8). ・Weight : 288kg(635lb)
8
6
(2) Install ① 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 from the arm cylinder. ※ Confirm the hydraulic oil level and check the hydraulic oil leak or not.
8-131
7
3) BOOM CYLINDER (1) Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. ※ Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank. ※ Escaping fluid under pressure can penetrate the skin causing serious injury. Fit blind plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. ① Disconnect greasing hoses(1). ② Sling boom cylinder assembly.
1
③ Remove bolt(4), stop plate(5) and pull out pin(2). ※ Tie the rod with wire to prevent it from coming out.
4
5
2
5
④ Lower the boom cylinder assembly(6) on a stand.
6
8-132
4
⑤ Disconnect boom cylinder hoses(7) and put plugs on cylinder pipe.
7
⑥ Remove bolt(9) and pull out pin(8). ⑦ Remove boom cylinder assembly(6). ・Weight : 182kg(386lb)
6
8
(2) Install ① 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 from the boom cylinder. ※ Conformed the hydraulic oil level and check the hydraulic oil leak or not.
8-133
9
2. DISASSEMBLY AND ASSEMBLY 1) STRUCTURE (1) Bucket cylinder
9,10 6,7 8 4,5 22
27 26 3 11,12
1
2
13 14
15,16 17 18 19 20 21
Internal detail
28,29
1 2 3 4 5 6 7 8 9 10
24
Tube assembly Rod assembly Gland DD2 bushing Snap ring Rod seal Back up ring Buffer ring Dust wiper Snap ring
11 12 13 14 15 16 17 18 19 20
O-ring Back up ring Cushion ring Piston O-ring Back up ring Piston seal Wear ring Dust ring Lock washer
8-134
23
25
21 22 23 24 25 26 27 28 29
28,29
Lock nut Hexagon socket head bolt Band assembly Pipe assembly(R) Pipe assembly(B) O-ring Hexagon socket head bolt Pin bushing Dust seal
(2) Arm cylinder
9,10 6,7 8 4,5 26
32 31 3 11,12
1
2
13 14
20,21 15,16 17 18 19 24 25 22,23
Internal detail
34,35
27
28
29
1 2 3 4 5 6 7 8 9 10 11 12
Tube assembly Rod assembly Gland DD2 bushing O-ring rod seal Back up ring Buffer ring Dust wiper Snap ring O-ring Back up ring
13 14 15 16 17 18 19 20 21 22 23 24
Cushion ring Piston O-ring Back up ring Piston seal Wear ring Dust ring Cushion spear Check valve Coil spring Stop ring Lock washer
8-135
25 26 27 28 29 30 31 32 33 34 35
30
34,35
33
Lock nut Hexagon socket head bolt Band assembly(R) Band assembly(B) Pipe assembly(R) Pipe assembly(B) O-ring Hexagon socket head bolt Hexagon socket head bolt Pin bushing Dust seal
(3) Boom cylinder
9,10 6,7 8 4,5 22
27 26 3 11,12
1
2
13 14
15,16 17 18 19 20 21
Internal detail
28,30
24
1 2 3 4 5 6 7 8 9 10
Tube assembly Rod assembly Gland DD2 bushing Snap ring Rod seal Back up ring Buffer ring Dust wiper Snap ring
11 12 13 14 15 16 17 18 19 20
O-ring Back up ring Cushion ring Piston O-ring Back up ring Piston seal Wear ring Dust ring Lock washer
8-136
23
25
21 22 23 24 25 26 27 28 29 30
29,30
Lock nut Hexagon socket head bolt Band assembly Pipe assembly(R) Pipe assembly(B) O-ring Hexagon socket head bolt Pin bushing Pin bushing Dust seal
2) TOOLS AND TIGHTENING TORQUE (1) Tools
6 B
8
Allen wrench
14 17 7
Spanner
8
(-) Driver
Small and large sizes
Torque wrench
Capable of tightening with the specified torques
(2) Tightening torque Part name
Socket head bolt
Socket head bolt
Item
Size
Bucket cylinder
22
Boom cylinder
kgf・m
lbf・ft
M16
23.0±2.0
166±14.5
22
M16
23.0±2.0
166±14.5
Arm cylinder
26
M18
32.0±3.0
232±21.7
Bucket cylinder
27
M10
5.4±0.5
39.1±3.6
Boom cylinder
27
M10
5.4±0.5
39.1±3.6
32
M12
9.4±1.0
68.0±7.2
33
M10
5.4±0.5
39.1±3.6
Bucket cylinder
21
M60
100±10.0
723±72.3
Boom cylinder
21
M60
100±10.0
723±72.3
Arm cylinder
25
M70
100±10.0
723±72.3
Bucket cylinder
14
-
150±15.0
1085±109
Boom cylinder
14
-
150±15.0
1085±109
Arm cylinder
14
-
150±15.0
1085±109
Arm cylinder
Lock nut
Piston
Torque
8-137
3) DISASSEMBLY (1) Remove cylinder head and piston rod ① Hold the clevis section of the tube in a vise. ※ Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means.
20
0m
m
② Pull out rod assembly(2) about 200mm (7.1in). Because the rod assembly is rather heavy, finish extending it with air pressure after the oil draining operation.
2
③ Loosen and remove socket bolts(22) of the gland in sequence. ※ Cover the extracted rod assembly(2) with rag to prevent it from being accidentally damaged during operation.
Hexagon socket wrench
22
Turn counter clockwise
2
④ Draw out cylinder head and rod assembly together from tube assembly(1). ※ Since the rod assembly is heavy in this case, lift the tip of the rod assembly(2) with a crane or some means and draw it out. However, when rod assembly(2) has been drawn out to approximately two thirds of its length, lift it in its center to draw it completely.
Cover here with rag
Lift
Full straight sideways
Oil pan
8-138
Note that the plated surface of rod assembly(2) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. ⑤ Place the removed rod assembly on a wooden V-block that is set level. ※ Cover a V-block with soft rag.
Piston assy
Wooden block
(2) Remove piston and cylinder head ① Remove lock nut(21). ※ Since lock nut(21) and lock washer(22) is tightened to a high torque, use a hydraulic and power wrench that utilizers a hydraulic cylinder, to remove the lock nut(21) and lock washer (22). ② Remove piston assembly(14), back up ring(16), and O-ring(15).
13 16 15 14 22 21
③ Remove the cylinder head assembly from rod assembly(2). ※ If it is too heavy to move, move it by striking the flanged part of cylinder head with a plastic hammer. ※ Pull it straight with cylinder head assembly lifted with a crane. Exercise care so as not to damage the lip of rod bushing(4) and packing (5,6,7,8,9,10) by the threads of rod assembly(2).
Plastic hammer Lift with a crane Pull straight
8-139
(3) Disassemble the piston assembly ① Remove wear ring(18). ② Remove dust ring(19) and piston seal (17). ※ Exercise care in this operation not to damage the grooves.
19
(4) Disassemble cylinder head assembly ① Remove back up ring(12) and O-ring (11). ② Remove snap ring(10), dust wiper(9). ③ Remove back up ring(7), rod seal(6) and buffer ring(8). ※ Exercise care in this operation not to damage the grooves. ※ Do not remove seal and ring, if does not damaged.
10
8-140
18
17 18 19
9 6 7 8 4 5 12 11
3) ASSEMBLY (1) Assemble cylinder head assembly ※ Check for scratches or rough surfaces if found smooth with an oil stone. ① Coat the inner face of gland(3) with hydraulic oil.
② Coat dust wiper(9) with grease and fit dust wiper(9) to the bottom of the hole of dust seal. At this time, press a pad metal to the metal ring of dust seal. ③ Fit snap ring(10) to the stop face.
Press here (Straight down) Metal 9
④ Fit back up ring(7), rod seal(6) and buffer ring(8) to corresponding grooves, in that order. ※ Coat each packing with hydraulic oil before fitting it. ※ Insert the backup ring until one side of it is inserted into groove.
Wrong
※ Rod seal(6) has its own fitting direction. Therefore, confirm it before fitting them. ※ Fitting rod seal(6) upside down may damage its lip. Therefore check the correct direction that is shown in fig.
Right
Push bar
6
8-141
⑤ Fit back up ring(12) to gland(3). ※ Put the backup ring in the warm water of 30~50° C. ⑥ Fit O-ring(11) to gland(3).
11 12
(2) Assemble piston assembly ※ Check for scratches or rough surfaces. If found smooth with an oil stone. ① Coat the outer face of piston(14) with hydraulic oil.
② Fit piston seal(17) to piston. ※ Put the piston seal in the warm water of 60~100° C for more than 5 minutes. ※ After assembling the piston seal, press its outer diameter to fit in.
17
③ Fit wear ring(18) and dust ring(19) to piston(14).
19 14
8-142
18
17 18
19
(3) Install piston and cylinder head ① Fix the rod assembly to the work bench. ② Apply hydraulic oil to the outer surface of rod assembly(2), the inner surface of piston and cylinder head. ③ Insert cylinder head assembly to rod assembly.
Cylinder head assembly Rod assembly
④ Insert cushion ring(13) to rod assembly. ※ Note that cushion ring(13) has a direction in which it should be fitted.
13 Insert
⑤ Fit piston assembly to rod assembly. ・Tightening torque : 100±10kgf・m (723±72lbf・ft)
Piston assembly
⑥ Fit lock nut(20) to piston. ・Tightening torque :
20
Item
kgf・m
lbf・ft
Bucket 21
100±10
723.3±72.3
Boom
21
100±10
723.3±72.3
Arm
25
100±10
723.3±72.3
8-143
(3) Overall assemble ① Place a V-block on a rigid work bench. Mount the tube assembly(1) on it and fix the assembly by passing a bar through the clevis pin hole to lock the assembly. ② Insert the rod assembly in to the tube assembly, while lifting and moving the rod assembly with a crane. ※ Be careful not to damage piston seal by thread of tube assembly. ③ Match the bolt holes in the cylinder head flange to the tapped holes in the tube assembly and tighten socket bolts to a specified torque. ※ Refer to the table of tightening torque.
Fix with a bar Lift
Straight
Appply liquid packing
Turn clockwise Apply loctite
Place rag
8-144
GROUP 10 UNDERCARRIAGE 1. TRACK LINK 1) REMOVAL (1) Move track link until master pin is over front idler in the position put wooden block as shown.
Master pin
(2) Loosen tension of the track link. ※ If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards. (3) Push out master pin by using a suitable tool.
Block
(4) 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 close to the sprocket side as the track shoe plate may fall down on your feet.
1
2) INSTALL (1) Carry out installation in the reverse order to removal. ※ Adjust the tension of the track link.
90 ~ 110
8-145
2. CARRIER ROLLER
Frame
1) REMOVAL Grease valve
(1) Loosen tension of the track link.
(2) Jack up the track link height enough to permit carrier roller removal.
Jack
(3) Loosen the lock nut (1). 1
(4) Open bracket(2) with a screwdriver, push out from inside, and remove carrier roller assembly. ・Weight : 21kg(46lb)
2
2) INSTALL (1) Carry out installation in the reverse order to removal.
8-146
Carrier roller
Carrier roller
3. TRACK ROLLER
Frame
1) REMOVAL Grease valve
(1) Loosen tension of the track link.
(2) Using the work equipment, push up track frame on side which is to be removed. ※ After jack up the machine, set a block under the unit. 90-110°
(3) Remove the mounting bolt(1) and draw out the track roller(2). ・Weight : 38.3kg(84.4lb)
1
2) INSTALL (1) Carry out installation in the reverse order to removal.
8-147
2
4. IDLER AND RECOIL SPRING 1) REMOVAL (1) Remove the track link. For detail, see removal of track link.
(2) Sling the recoil spring(1) and pull out idler and recoil spring assembly from track frame, using a pry. ・Weight : 270kg(595lb)
1
(3) Remove the bolts(2), washers(3) and separate ilder from recoil spring.
2, 3
2) INSTALL (1) Carry out installation in the reverse order to removal. ※ Make sure that the boss on the end face of the recoil cylinder rod is in the hole of the track frame.
8-148
3) DISASSEMBLY AND ASSEMBLY OF IDLER (1) Structure 7
6
8 3
1
2
4
4 3 7
6 5
1 2 3
Shell Shaft Seal assembly
4 5 6
Bushing Bracket O-ring
8-149
7 8
Spring pin Plug
5
(2) Disassembly ① Remove plug and drain oil. ② Draw out the spring pin(7), using a press.
Press
7
③ Pull out the shaft(2) with a press. ④ Remove seal(3) from idler(1) and bracket (5). ⑤ Remove O-ring(6) from shaft.
Press
2
⑥ Remove the bushing(4) from idler, using a special tool. ※ Only remove bushing if replacement is necessity.
4
8-150
(3) Assembly ※ Before assembly, clean the parts. ※ Coat the sliding surfaces of all parts with oil. ① Cool up bushing(4) fully by some dry ice and press it into shell(1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
1
4
Press
② Coat O-ring(6) with grease thinly, and install it to shaft(2). ③ Insert shaft(2) into bracket(5) and drive in the spring pin(7).
6 2 5 7
④ Install seal(3) to shell(1) and bracket(5).
3
⑤ Install shaft(2) to shell(1).
2
8-151
1
⑥ Install bracket(5) attached with seal(3). 5
⑦ Knock in the spring pin(7) with a hammer.
5
⑧ Lay bracket(5) on its side. Supply engine oil to the specified level, and tighten plug.
5
8-152
7
1
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING (1) Structure
4
7, 8
3
6
5
2
1
9
10
11
12
13
1 2 3 4 5
Body Tie bar Spring Bracket Lock nut
6 7 8 9 10
Lock plate Bolt Spring washer Rod seal Back up ring
8-153
11 12 13
Dust seal Rod assembly Grease valve
(2) Disassembly ① Apply pressure on spring(3) with a press. ※ The spring is under a large installed load. This is dangerous, so be sure to set properly. ・Spring set load : 13716kg(30238lb) ② Remove bolt(7), spring washer(8) and lock plate(6). ③ Remove lock nut(5). Take enough notice so that the press which pushes down the spring, should not be slipped out in its operation. ④ Lighten the press load slowly and remove bracket(4) and spring(3).
4 7, 8 3 6 5
⑤ Remove rod(12) from body(1). ⑥ Remove grease valve(13) from rod(12).
1
12
13
⑦ Remove rod seal(9), back up ring(10) and dust seal(11).
1
8-154
9 10 11
(3) Assembly ① Install dust seal(11), back up ring(10) and rod seal(9) to body(1). ※ When installing dust seal(11) and rod seal(9), take full care so as not to damage the lip.
1
② Pour grease into body(1), then push in rod(12) by hand. After take grease out of grease valve mounting hole, let air out. ※ If air letting is not sufficient, it may be difficult to adjust the tension of crawler. ③ Fit grease valve(13) to rod(12). ・Tightening torque : 10±0.5kg・m (72.3±3.6lb・ft)
1
9 10 11
12
13
④ Install spring(3) and bracket(4) to body (1). ⑤ Apply pressure to spring(3) with a press and tighten lock nut(5). ※ Apply sealant before assembling. ※ During the operation, pay attention specially to prevent the press from slipping out.
Press
4 3
8-155
⑥ Lighten the press load and confirm the set length of spring(3). ⑦ After the setting of spring(3), install lock plate(6), spring washer(8) and bolt(7).
Press
431±1.5
7, 8 3 6 5
8-156
GROUP 11 WORK EQUIPMENT 1. STRUCTURE
B
C C
B
A
A
SECTION A
SECTION B
8-157
SECTION C
2. REMOVAL AND INSTALL 1) BUCKET ASSEMBLY (1) Removal ① Lower the work equipment completely to ground with back of bucket facing down.
A B
36078AT04
② Remove nut(1), bolt(2) and draw out the pin(A).
36078AT01
③ Remove nut(3), bolt(4) and draw out the pin(B).
36078AT02
(2) Install ① 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. ※ Adjust the bucket clearance. For detail, see operation manual. 36078AT05
8-158
2) ARM ASSEMBLY (1) Removal ※ Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury. ① Remove bucket assembly. For details, see removal of bucket assembly. ② Disconnect bucket cylinder hose(1). Fit blind plugs(5) in the piping at the chassis end securely to prevent oil from spurting out when the engine is started. ③ Sling arm cylinder assembly, remove spring, pin stopper and pull out pin. ※ Tie the rod with wire to prevent it from coming out. ④ For details, see removal of arm cylinder assembly. Place a wooden block under the cylinder and bring the cylinder down to it. ⑤ Remove bolt(2), plate(3) and pull out the pin(4) then remove the arm assembly. ・Weight : 1050kg(2310lb) ※ When lifting the arm assembly, always lift the center of gravity.
5 4
4
Crane
2, 3, 4
(2) Install ① Carry out installation in the reverse order to removal. When lifting the arm assembly, always lift the center of gravity. ※ Bleed the air from the cylinder.
8-159
3) BOOM CYLINDER (1) Removal ① Remove arm and bucket assembly. For details, see removal of arm and bucket assembly. ② Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly.
③ Disconnect head lamp wiring. ④ Disconnect bucket cylinder hose(2) and arm cylinder hose(1). ※ When the hose are disconnected, oil may spurt out. ⑤ Sling boom assembly(3).
1 2
1
⑥ Remove bolt(4), plate(5) and pull out the pin(6) then remove boom assembly. ・Weight :1950kg(4300lb) ※ When lifting the boom assembly always lift the center of gravity.
Crane
3
(2) Install ① Carry out installation in the reverse order to removal. When lifting the arm assembly, always lift the center of gravity. ※ Bleed the air from the cylinder.
8-160
4, 5, 6
SECTION 9 COMPONENT MOUNTING TORQUE Group Group Group Group Group Group Group
1 2 3 4 5 6 7
Introduction guide Engine system Electric system Hydraulic system Undercarriage Structure Work equipment
9-1 9-2 9-4 9-6 9-10 9-11 9-14
SECTION 9 COMPONENT MOUNTING TORQUE GROUP 1 INTRODUCTION GUIDE 1. This section shows bolt specifications and standard torque values needed when mounting components to the machine. 2. Use genuine Hyundai spare parts. We expressly point out that Hyundai will not accept any responsibility for defects resulted from non-genuine parts. In such cases Hyundai cannot assume liability for any damage. ※ Only metric fasteners can be used and incorrect fasteners may result in machine damage or malfunction. ※ Before installation, clean all the components with a non-corrosive cleaner. Bolts and threads must not be worn or damaged.
9-1
GROUP 2 ENGINE SYSTEM ENGINE AND ACCESSORIES MOUNTING
2
4
Air cleaner
2
Muffler
Throttle lever
1
5 A
4 6
4 7
7
4
9
B
6
A
8
B
6
Engine
3 2
Fan Accel actuator
6
B
TO
CA
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
kgf・m
lbf・ft
1
M 6×1.0
0.92±0.2
6.7±1.4
6
M12×1.75
10.0±2.0
72.3±14.5
2
M 8×1.25
2.5±0.5
18.1±3.6
7
M12×1.75
12.8±3.0
92.6±21.7
3
M10×1.5
4.4±0.9
31.8±6.5
8
M20×2.5
55±3.5
398±25.3
4
M10×1.5
6.9±1.4
49.9±10.1
9
M24×3.0
90±7.0
651±51
5
M12×1.5
12.5±3.0
92.6±21.7
-
-
-
-
9-2
Size
COOLING SYSTEM AND FUEL TANK MOUNTING
Water seperator
Cooler & radiator
2
Air compressor
2
Air con idle pully
Hyd tank Fuel tank
3
A
DISCHARGE
2
1
Receiver drier
-A
UID
LIQ
Condenser
5
VIEW A Radiator
3
6
Oil cooler
HY
UN
Reservoir tank
Needle valve
DA
3
I
4
FU
LL
LO
W
2
Shroud
3 4 4
2
3 4
Fan guard
4
・Tightening torque Item
Size
kgf・m
1
M 6×1.0
1.05±0.2
2
M 8×1.25
2.5±0.5
3
M10×1.5
6.9±1.4
lbf・ft
Item
Size
4
M12×1.75
18.1±3.6
5
M20×2.5
49.9±10.1
6
7.6±1.45
9-3
-
kgf・m
lbf・ft
12.8±3.0
92.6±21.7
45±5.1
325±36.9
2.3±0.6
16.6±4.3
GROUP 3 ELECTRIC SYSTEM ELECTRIC COMPONENTS MOUNTING 1
Work lamp Alternator
1
4
3 4
2
Start relay
Heater relay
Travel alarm buzzer
3 Fuel filler pump ON
2
OFF
3 3 2 2
3
A Battery Battery relay Horn
DETAIL A 1 Washer tank
・Tightening torque Item
Size
kgf・m
1
M 6×1.0
1.05±0.2
2
M 8×1.25
2.5±0.5
lbf・ft 7.6±1.45 18.1±3.6
9-4
Item
Size
kgf・m
lbf・ft
3
M10×1.5
6.9±1.4
49.9±10.1
4
M12×1.75
12.8±3.0
92.6±21.7
ELECTRIC COMPONENTS MOUNTING 2
Beacon lamp
3
A
Wiper motor Cluster
VIEW A 2
Electric box Fuse box
CPU controller
1 1
2 4 1
Y
1
Wiper motor cover
R
G
1
2 3
・Tightening torque Item
Size
kgf・m
1
M 6×1.0
1.05±0.2
2
M 8×1.25
2.5±0.5
lbf・ft 7.6±1.45 18.1±3.6
9-5
Item
Size
kgf・m
lbf・ft
3
M10×1.5
6.9±1.4
49.9±10.1
-
-
-
-
GROUP 4 HYDRAULIC SYSTEM HYDRAULIC COMPONENTS MOUNTING 1
5
5
Solenoid valve
6
A
2
Air breather
Level gauge
5 3
Spin filter
Main pump
Hydraulic tank
8
Main control valve
11 12
7
Swing motor
5
VIEW A RCV-LH
9 1
5 RCV-RH
Main pump housing
9
Terminal
10
1
Coupling
4
5 Cross
3 3
・Tightening torque Item
Size
kgf・m
1
M 6×1.0
1.05±0.2
2
M 6×1.0
1.44±0.3
3
M 8×1.25
4
lbf・ft
Item
Size
kgf・m
lbf・ft
7
M12×1.75
12.2±1.3
88.2±9.4
10.4±2.2
8
M12×1.75
14.7±2.2
106±15.9
2.5±0.5
18.1±3.6
9
M16×2.0
22±1.0
159±7.2
M10×1.5
4.8±0.3
34.7±2.2
10
M20×2.5
42±4.5
304±32.5
5
M10×1.5
6.9±1.4
49.9±10.1
11
M20×2.5
45±5.1
325±36.9
6
M10×1.5
8.27±1.7
59.8±12.3
12
M20×2.5
57.9±8.7
419±62.9
7.6±1.45
9-6
HYDRAULIC COMPONENTS MOUNTING 2 Double acting attachment piping
Travel motor(RH)
9
7 7
Travel motor(LH)
2
Stop valve
7
9
2
1 D/acting 3 way joint
Turning joint
6 D/acting hose joint
4
2 8
RCV-pedal
Arm safety lock system Arm cylinder
Boom safety lock system Boom safety lock valve
5
Boom cylinder
D/acting single pedal 1 Arm safety lock valve
3
Block
3
5
5
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
Size
kgf・m
lbf・ft
1
M 8×1.25
4.05±0.8
29.3±5.8
6
M12×1.75
12.3±1.3
88.9±9.4
2
M10×1.5
6.9±1.4
49.9±10.1
7
M12×1.75
12.8±3.0
92.6±21.7
3
M10×1.5
8.27±1.7
59.8±12.3
8
M12×1.75
14.7±2.2
106±15.9
4
M12×1.75
11.25±1.25
81.4±9.0
9
M16×2.0
23.0±2.5
166±18.1
5
M12×1.75
12.0±1.3
86.8±9.4
-
-
-
9-7
-
HYDRAULIC COMPONENTS MOUNTING 3
2 Solenoid valve 1
8
Check valve
2
1 Cartridge
Coil
5
8
7
BOOM CYLINDER
2 3 1 3 3
2
1
1
1
2
1 6
5
3
4
ARM CYLINDER
BUCKET CYLINDER
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
Size
kgf・m
lbf・ft
1
M10×1.5
3.2±0.3
23.1±2.2
5
M16×2.0
23±2.0
166±14.5
2
M10×1.5
5.4±0.5
39.1±3.6
6
M18×2.5
32±3.0
232±21.7
3
M12×1.75
5.5±0.6
39.8±4.3
7
-
0.5±0.1
3.6±0.7
4
M12×1.75
9.4±1.0
68.0±7.2
8
-
2.8±0.2
20.3±1.4
9-8
GROUP 5 UNDERCARRIAGE UNDERCARRIAGE MOUNTING
ADJUST COMPONENT
Rod
3 6
Swing bearing
Idler
8 8 8 Idler
7 Carrier roller Track chain
10 Cover 4 1 2
Adjust component
2
Cover
Track roller Track guard Travel motor
9 5
Sprocket
21079CM08
·Tightening torque Item
Size
kgf·m
lbf·ft
Item
Size
kgf·m
lbf·ft
1
M10×1.5
6.9±1.4
49.9±10.1
6
M16×2.0
29.7±4.5
215±32.5
2
M12×1.75
12.8±3.0
92.6±21.7
7
M20×2.5
54.7±5.0
396±36.2
3
M12×1.75
15±0.5
108±3.6
8
M20×2.5
57.8±6.4
418±46.3
4
M16×2.0
23±2.5
166±18.1
9
M20×2.5
57.9±8.7
419±62.9
5
M16×2.0
26±4.0
188±28.9
10
M20×2.5
78±8.0
564±57.9
9-9
UNDERCARRIAGE MOUNTING(HIGH WALKER)
2
Sprocket
1
Carrier roller Idler
Track roller
2 Track guard
Mono track guard type
3
3 Full track guard type
3 21079CM09
·Tightening torque Item
Size
kgf·m
lbf·ft
Item
Size
1
M16×2.0
26±2.5
188±18.1
3
M24×3.0
2
M20×2.5
54.7±5.0
396±36.2
-
9-9-1
-
kgf·m 100±15 -
lbf·ft 723±108 -
GROUP 6 STRUCTURE CAB AND ACCESSORIES MOUNTING
2 Sun roof
4 Sun visor
1 Latch
2
Cab
A
Air vent cover
4
4
VIEW A
4
5
3
2
5
Door latch
6
Striker
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
Size
kgf・m
lbf・ft
1
M 6×1.0
0.49±0.1
3.5±0.7
4
M10×1.5
6.9±1.4
49.9±10.1
18.1±3.6
5
M12×1.75
12.8±3.0
92.6±21.7
34±6.5
6
M16×2.0
29.7±4.5
215±32.5
2 3
M 8×1.25 M10×1.5
2.5±0.5 4.7±0.9
9-10
CAB INTERIOR MOUNTING
Seat
1 1 Storage box cover
4
Aircon upper cover
1
Console box(RH)
Wiper motor cover
1
Storage box
5
5
Defroster hose cover
Aircon lower cover
2
Console box(LH)
3
6
Travel lever
5
Safety lever
5
2
Slide rail Seat base
7
5 Pedal bracket
5 Viscous mount
5 Foot rest
Bottom plate
5
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
Size
kgf・m
lbf・ft
1
M 6×1.0
0.49±0.1
3.5±0.7
5
M10×1.5
6.9±1.4
49.9±10.1
2
M 6×1.0
1.05±0.2
7.6±1.4
6
M10×1.5
8.27±1.7
59.8±12.3
3
M 8×1.25
3.43±0.7
24.8±5.1
7
M16×2.0
29.7±4.5
215±32.5
4
M 8×1.25
4.05±0.8
29.3±5.8
-
-
-
9-11
-
COWLING MOUNTING
2
Engine hood
Side cover(RH) Pump hood Catch
2
1
2 2
2
2
A 1
Pump screen
2
2
Aircon hood
Screen
2 HYD TANK
2
Tank cover
2
MCV hood
A
2
MCV hood support
Engine hood support
2 3 2
2
2 Aircon bracket
2
Base plate
2
2
Side cover(LH)
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
Size
kgf・m
lbf・ft
1
M 8×1.25
2.5±0.5
18.1±3.6
3
M16×2.0
29.7±4.5
215±32.5
2
M12×1.75
12.8±3.0
92.6±21.7
-
-
-
-
9-12
COUNTERWEIGHT AND COVERS MOUNTING
2 Handle pipe
1 Fuel tank Counterweight
Fuel tank cover
A 2
2 Tool box
Upper frame
A
3
Pump under cover
Engine under cover
Hyd tank under cover Radiator under cover
Fuel under cover
1 1 1
Swing bearing grease drain cover
MCV under cover
1
Cab under cover(C) Cab under cover(B)
Cab under cover(A)
1
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
Size
kgf・m
lbf・ft
1
M10×1.5
6.9±1.4
49.9±10.1
3
M36×3.0
308±46
2228±333
2
M12×1.75
12.8±3.0
92.6±21.7
-
-
-
-
9-13
GROUP 7 WORK EQUIPMENT
Arm cylinder rod pin
2 Arm cylinder
2 Stop plate
Bucket cylinder head pin
3
Bucket cylinder
2
1 Boom
Arm pin Arm cylinder head pin Bucket control link 1
Bucket cylinder rod pin
3
Boom cylinder
Bucket
4
3
Boom cylinder head pin
Boom pin
2
2
Side cutter(RH)
2 Bucket control rod pin Cover plate Side cutter(LH)
・Tightening torque Item
Size
kgf・m
lbf・ft
Item
Size
kgf・m
lbf・ft
1
M12×1.75
12.8±3.0
92.6±21.7
3
M20×2.5
57.9±8.7
419±62.9
2
M16×2.0
29.7±4.5
215±32.5
-
M22×2.5
55.8±7.5
404±54.2
9-14
CONTENTS SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
SECTION 2 STRUCTURE AND FUNCTION Group Group Group Group Group Group
1 2 3 4 5 6
Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RCV Pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
2-1 2-21 2-46 2-58 2-69 2-76
SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Main Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2 Group 3 Pilot Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5 Group 4 Single Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13 Group 5 Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23
SECTION 4 ELECTRICAL SYSTEM Group Group Group Group Group
1 2 3 4 5
Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
4-1 4-3 4-23 4-33 4-53
SECTION 5 MECHATRONICS SYSTEM Group 1 Outline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Mode selection System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3 Group 3 Automatic Deceleration System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6 Group 4 Power Boost System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7 Group 5 Travel Speed Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8 Group 6 Automatic Warming Up Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9 Group 7 Engine Overheat Prevention Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10 Group 8 Anti-Restart system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Group 9 Group 10 Group 11 Group 12 Group 13 Group 14 Group 15
Self-Diagnostic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - EPPR(Electro Proportional Pressure Reducing) Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Prolix Switch(up to #0179) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Outline(#1001 and up, Tire II) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Mode selection system(#1001 and up, Tire II) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5-12 5-15 5-22 5-25 5-26 5-39 5-40
SECTION 6 TROUBLESHOOTING Group 1 Before trobleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4 Group 3 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24 Group 4 Mechatronics System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-41 Group 5 Mechatronics System(#1001 and up, Tier II) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-42
SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21 Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 5 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 6 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 7 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 8 Turning Joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 9 Boom, Arm and Bucket Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 10 Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Group 11 Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
8-1 8-4 8-7 8-30 8-43 8-68 8-108 8-123 8-128 8-145 8-157
SECTION 9 COMPONENT MOUNTING TORQUE Group Group Group Group Group Group Group
1 2 3 4 5 6 7
Introduction guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electric system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
9-1 9-2 9-4 9-6 9-10 9-11 9-14
View more...
Comments
