Professional Documents
Culture Documents
WORKSHOP MANUAL
ENGLISH
31102 60413252
Print N. 604.13.255
Edition: 4 /2003
English - Printed in Italy
Printed by Studio ti
0-1
INTRODUCTION
TO THE READER
This manual has been written for a skilled
technician, in order to give him the information
necessary to repair this machine.
14403 60413255
VOLUME
Workshop Manual - "Excavator"
MACHINE TYPE
E200SR EVOLUTION
0-3
PRINT No.
604.13.255
INTRODUCTION
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on
the highway, are caused by the failure of some individuals to follow simple
and fundamental safety rules or precautions. For this reason MOST
ACCIDENTS CAN BE PREVENTED by recognising the real cause and
doing something about it before the accident occurs.
Regardless of the care used in the design and construction of any type of
equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient
operation.
Carefully read indications, cautions and safety warning quoted in the
SAFETY RULES section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many thousand
serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.
ATTENTION
On machines having hydraulically, mechanically and/or cable
controlled equipment (such as showels, loaders, dozers, scrapers
etc.) be certain the equipment is lowered to the ground before servicing,
adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised to gain
access to certain items, be sure the equipment is suitably supported
by means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.
0-4
14403 60413255
INDEX
INDEX
SPECIFICATIONS
Section 1 - Outline
Section 2 - Specification
Section 3 - Attachment dimension
MAINTENANCE
Section 11 - Tools
Section 12 - Standard maintenance time schedule
Section 13 - Maintenance standard and test procedure
SYSTEM
Section 21 - Mechatro control system
Section 22 - Hydraulic system
Section 23 - Electric system
Section 24 - Components system
Section 25 - Air-conditioner system
DISASSEMBLING
Section 31 - Disassembling and assembling
Section 32 - Attachment
Section 33 - Upper structure
Section 34 - Travel system
TROUBLESHOOTING
Section 41 - Troubleshooting (mechatro control)
Section 42 - Troubleshooting (Hydraulic)
Section 43 - Troubleshooting (Electric)
Section 44 - Troubleshooting (Engine)
ENGINE
Section 51 - Engine
OPT
14403 60413255
0-5
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
2.
3.
4.
5.
WARNING
Do not operate this machine unless you have read
and understand the instructions in the OPERATORS
MANUAL. Improper machine operation is dangerous
and could result in injury or death.
6.
7.
8.
9.
0-6
14403 60413255
WARNING
The proper and safe lubrication and maintenance for
this machine, recommended by Distributor, are
outlined in the OPERATORS MANUAL for the
machine.
Improper performance of lubrication or maintenance
procedures are dangerous and could result in injury
or death. Read and understand the MANUAL before
performing any lubrication or maintenance.
SAFETY PRECAUTIONS
and plugs on the machine. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the machine has just been stopped
because fluids can be hot.
13. Always use the proper tools that are in good
condition and that are suited for the job at hand.
Be sure you understand how to use them before
performing any service work.
14. Reinstall all fasteners with the same part number.
Do not use a lesser quality fastener if
replacements are necessary.
15. Repairs which require welding should be
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in welding
procedures. Determine type of metal being
welded and select correct welding procedure
and electrodes, rods or wire to provide a weld
metal strength equivalent at least to that of the
parent metal. Make sure to disconnect battery
before any welding procedures are attempted.
14403 60413255
SAFETY PRECAUTIONS
14403 60413255
NOTE
0-8
SECTION 1
OUTLINE
TABLE OF CONTENTS
1. GENERAL PRECAUTIONS FOR MAKING REPAIRS ............................................... 1
14403 60413255
1.1
(1)
(2)
(3)
(4)
1)
2)
3)
4)
5)
6)
(5)
1)
2)
3)
PREPARATION BEFORE
DISASSEMBLING
Knowledge of operating procedure
Read Operators Manual carefully to
understand the operating procedure.
Cleaning machines
Clean machines of soil, mud, and dust before
carrying into the repair shop.
Carrying a soiled machine into the repair
shop, causes making less efficient work and
damage of parts, and interferes with rust
prevention and dust protection while
reassembling.
Inspecting machines
Confirm the disassembling section before
starting work, determine the disassembly
procedure taking the conditions in repair
shop into account, and request to procure
necessary parts in advance.
Recording
Record the following items to keep contact
and prevent malfunction from recurring.
Inspecting date, place
Model name, Applicable machine No.,
Records on hour meter
Trouble condition, place, cause
Visible oil leakage, water leakage and
damage
Clogging of filters, etc., oil level, oil quality,
oil contamination and looseness which can be
inspected.
Examine the problems on the basis of
operation rate with the last inspection date
and records on hour meter.
Arrangement and cleaning in repair shop
Tools required for repair work.
Specify places to put the disassembled parts
on in advance.
Prepare oil pans for leaking oil, etc.
1.2
1.3
(1)
1)
2)
3)
4)
(2)
1)
2)
3)
4)
SAFETY WHEN
DISASSEMBLING AND
ASSEMBLING
(1) Safety
1) Wear appropriate clothing, safety shoes,
safety helmet, goggles, and clothes with long
sleeves.
2) Suspend warning tag Dont operate from
lever, and begin preliminaries before getting
down to work.
3) Before starting inspection and maintenance
which contain the danger of being caught in
machine, stop the engine.
5)
6)
DISASSEMBLING AND
ASSEMBLING HYDRAULIC
EQUIPMENT
Removing hydraulic equipment assy
Before removing pipes, release the pressure
of hydraulic oil tank, or open the cover on the
return side to tank, and take out the filter.
Put the oil in the removed pipes in reservoir
taking care it is not spilled on the ground.
Pipes with plugs or caps to prevent oil
leaking, entry of dust, etc.
Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
and gear oil before putting them on working
bench.
Disassembling hydraulic equipment
Since performance and function of hydraulic
equipment after disassembly and assembly
results in immunity from responsibility on
the
manufactures
side,
disassembly,
assembly and conversion without permission
are strictly prohibited.
If it is unavoidably necessary to disassemble
and convert, it should be carried out by
experts or personnel authorized through
service training.
Make match mark on parts for reassembling.
Before disassembling, read Disassembling
Instruction supplied with equipment in
advance, and determine if the disassembly
and assembly are permitted or not.
For parts which are required to use jig and
tools, dont fail to use the specified jig and
tools.
For parts which can not be removed in the
specified produre, never force removal. First
check for the cause.
Important Information
LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within level
marks, the oil quantity is
allowable.
Introduction
Although this manual uses the JIS unit system.
If you need SI unit, refer to following
international system of units.
Given hereinunder are an excerpt of the units
that are related to this manual :
1. Etymology of SI Units
French : Le Systme International d Units
English : International System of Units
2. Construction of SI Unit System
Table 2-4
QUANTITIES
Frequency
Force
Pressure,
Stress
Energy
Work,
Quantity of
heat
Power
Motive power,
Electric power
Charge,
Quantity of
electricity
Potential
Voltage,
Electromotive
force
Quantity of
static
electricity
Capacitance
Electric
resistance
Celcius
temperature
Illuminance
Basic units
Table 2-1
SI unit
system
SI units
Supplementary units
Table 2-2
Derived units of
basic units
Table 2-3
Derived
units
Derived units
bearing peculiar
designations
Table 2-4
Prefixes of SI
(n-th power of 10, where n is an integral)
Table 2- 5
Hertz
Newton
Pascal
m
kg
s
A
K
mol
cd
SIGN
rad
sr
SIGN
DERIVED UNIT
Hz 1Hz=1s-1
N 1N=1kgfym/s2
Pa 1Pa=1N/m2
Joule
1J=1Nym
Watt
1W=1J/s
Coulomb
1C=1As
Volt
1V=1J/C
(1W/A)
Farad
1F=1C/V
Ohm
1=1V/A
Celcius degree
or degree
lux
(5) Prefixes of SI
Table 2-5
PREFIX
DESIGNATION SIGN
GigaG
MegaM
Kilok
Hectoh
Decada
Decid
Centic
Millim
Micro
Nanon
Picop
SIGN
DESIGNATION
X 1 X=1 m/m2
POWER
109
106
103
102
10
101
102
103
106
109
1012
SIGN
m2
m3
m/s
m/s2
kg/m3
JIS
kg
kgf
kgfym
kgf/cm2
PS
rpm
SI
kg
N
Nym
MPa
kW
min1
REMARKS
1kgf=9.807N
kgfym=9.807Nym
1kgf/cm2=0.098MPa
1PS=0.7355kW
r/min 1
SECTION 2
SPECIFICATION
TABLE OF CONTENTS
1. NAME OF COMPONENTS ....................................................................................... 1
2. GENERAL DIMENSION ............................................................................................ 2
3. WEIGHT OF COMPONENTS ................................................................................... 3
4. TRANSPORTATION DIMENSION AND WEIGHT ..................................................... 4
5. SPECIFICATIONS AND PERFORMANCE ............................................................... 6
6. TYPE OF CRAWLER ................................................................................................ 7
7. TYPE OF BUCKET .................................................................................................... 8
8. COMBINATIONS OF ATTACHMENT ........................................................................ 9
14403 60413255
1. NAME OF COMPONENTS
2. GENERAL DIMENSION
NOTE :
Dimensions marked
the shoe lug.
2.1 5.05m (167) Boom+2.60m (86) Arm+0.75m3 (0.98cu yd) Bucket
Unit : mm (ft-in)
E200SR
E200SRLC
Unit : mm (ft-in)
3. WEIGHT OF COMPONENTS
Model
Item
Machine complete
1.
E200SR
Shoe
600mm Shoe
E200SR (
(600mm
2.6m Arm )
2.6m Arm )
19,900 (43,870)
Upper frame
2,110 (4,650)
1.2
Counterweight
4,620 (10,900)
1.3
Counterweight (ADD-on)
1.4
Cab
1.5
Engine
1.6
1.7
Fuel tank
1.8
220 (485)
1.9
Control valve
130 (290)
1.10
Boom cylinder
1.11
40 (90)
1.12
Pump
90 (200)
1.13
99 (220)
370 (815)
*
*
*
125 (280)
125 (280)
170 (370)
7,130 (15,720)
7,630 (16,820)
2,450 (5,400)
2,650 (5,840)
Lower frame
2.2
Slewing bearing
245 (540)
2.3
250 (550)X2
2.4
Upper roller
2.5
Lower roller
2.6
Front idler
106 (230)X2
2.7
Idler adjuster
150 (330)X2
2.8
Sprocket
2.9
Swivel joint
2.10
1,260 (2,780)X2
1,360 (3,000)X2
3.
22 (48)X4
35 (77)X14
30 (66)
510 (1,120)X2
2,890 (6,370)
640 (1,410)
3.2
890 (1,960)
3.2.1
Arm
3.2.2
Bucket cylinder
3.2.3
Idler link
20 (44)X2
3.2.4
Bucket link
80 (180)
3.2.5
Pin
70 (150)
3.3.2
Arm cylinder
4.
125 (280)
1,390 (3,060)
Boom assy
Boom
3.3.3
550 (1,210)
3.3.1
1,100 (2,430)
4.1
Hydraulic oil
4.2
Engine oil
4.3
Fuel
4.4
Water
35 (77)X16
54 (120)X2
3.1
3.3
20,400 (44,970)
200 (440)
2.1
2.11
LC
9,880 (21,780)
1.1
2.
Unit : kg (lb)
195 (430)
40 (88)
440 (970)
185 (410)
11 (24)
225 (500)
19 (40)
1,420 (3,130)X2
540 (1,190)X2
#
! "#
! "!
! "#
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! "#
+ (
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#% #&"
Hoe bucket
H
L
5
($%'+'%,')*
!
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ENGINE
$ /
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3
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4
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7
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1 ! 7 1 7 1=
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1A 1!,
HYDRAULIC COMPONENTS
B
3. 3
%/ /
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6//0 ,
0 63.
) .//
,
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; G
WEIGHT
+3 :3
E!!&
/
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D%
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6. TYPE OF CRAWLER
!"" #
'%"" ()*
",#! !,-
$"" %
'("" ()!*
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!"" #
'((" ()+"*
",#& !,"(
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",&& #,!(
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",#! !,-
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#
NOTE :
Use grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate with
other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
damage.
7. TYPE OF BUCKET
,
!"
%$
%
'&
$
&
()
$!
'
'
"
+ * ,
/ 01+,+
.
,
*
1+ *
+,
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%"
!&
%'
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$
!
$$
'$
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7"8
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"-% +,
6 1+ 1+,+
$$
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"-%
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23
23
23
23
23
!&
"-"!
!
"-
%
"-
%#
"-#"
%!
"-#
8. COMBINATIONS OF ATTACHMENT
$ '
4('(
0
0
0
10
0
00
%
)$
&''(
)$
!" #$
NOTE :
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
Use the attachments recommended by the Manufacturer. Reinforcement of arm allows to use it as
nibbler and breaker.
The trouble due to the use in the condition Use not allowed described in the above table is not included in our responsibility
When bucket marked by has been attached or nibbler has been attached on long arm, the specified
stability may not be obtained. So attach add-on type counterweight (1,000kg : 2,200lb) in as required.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to
the arm and bucket may occur.
9. ENGINE SPECIFICATION
9.1 SPECIFICATIONS
E200SR(LC)
Model
Engine model
ISUZU AA-4BG1 TC
Diesel, 4-cycle water-cooled, in-line,
direct injection, turbo charged & inter cooled
Type
Number of cylinder X
Bore X Stroke
Total displacement
mm (in)
cc (cuin)
4,329 (264)
Compression ratio
18.0
PS (kW) at rpm
High idling
rpm
2,420 30
Low idling
rpm
1,000 25
kgf/cm2 (psi)
185 (2,630)
Injection valve
opening pressure
Thermostat action
Start/Full open
82 / 95 (180 / 203)
C (F)
Firing order
Compression
pressure
Lubrication
oil pressure
1-3-4-2
kgf/cm2 (psi)
31 (440)
Valve clearance
Intake valve
Exhaust valve
Starter capacity
Valve clearance
Open
Close
0.4mm (0.016")
in cold condition
0.4mm (0.016")
in cold condition
19 before
top dead point
47 after
bottom dead point
57 before
bottom dead point
15 after
top dead point
V X kW
24 X 4.5
VXA
24 X 40
l (gal)
Dry weight
kg (lb)
370 (820)
g/PSh
174 10
Thermostat action
Start/Full open
Cooling fan drive method
Allowable inclination
Dimension (L X W X H)
Rotating direction
10
/-/0-#
)*+
,0-&%.
0)*+
,0&%.
!"
#0
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,#0&%.
SECTION 3
ATTACHMENT DIMENSION
TABLE OF CONTENTS
1. BOOM
1.1 Boom dimensional drawing ................................................................................................. 1
1.2 Boom maintenance standard .............................................................................................. 2
2. ARM
2.1 Arm dimensional drawing .................................................................................................... 4
2.2 Arm maintenance standard ................................................................................................. 5
3. BUCKET
14403 60413255
7
7
8
9
1. BOOM
1.1 BOOM DIMENSIONAL DRAWING
SECTION B-B
Table 1-1
Unit : mm (ft-in)
DIMENSION
5,050 (167 )
612 (24.1 )
287 (11.3 )
421 (16.6 )
1,023 (34 )
1,132 (39 )
R 2,344.5 (78 )
R 2,435 (712 )
122 (4.8 )
426 (16.8 )
90 (3.54 )
85 (3.35 )
80 (3.15 )
80 (3.15 )
Table 1-2
Standard value
Code
Item
Boom foot
Boom cylinder
(Head side)
Boom cylinder
(Rod side)
Arm cylinder
(Head side)
Unit : mm (in)
Clearance
Standard Repairable Service Remedy
limit
value
level
+0.224
(+0.0088)
+0.053
(+0.0021)
+0.230
(+0.0091)
+0.037
(+0.0015) More than 2.5
2.0
-0.050
+0.270 (0.08) (0.1)
(+0.0106)
(-0.0020)
-0.090 +0.180 +0.150
80 (-0.0035) (+0.0071) (+0.0059)
(3.1496) -0.050 +0.100 +0.290
(+0.0039)
(+0.0114)
(-0.0020)
+0.150
-0.110
(+0.0059)
(-0.0043)
Replace
bushing
or pin
SECTION C-C
SECTION A-A
SECTION D-D
SECTION B-B
Table 1-3
Shim adjusting clearance
Basic size
(Total of both sides)
SecItem
tion
Sym- Size Standard Repairable Service
value
level
limit
bol
Boom
612 (24.1) 0.5 (0.02)
A-A Boom foot
L1
Upper frame
614 (24.2) or less
2.0
2.5
(0.08)
(0.10)
Boom
cylinder
105
(4.13)
0.6~1.0
B-B Boom cylinder
L2
(0.02~0.04)
(Head side)
Upper frame
107 (4.21)
Boom cylinder
C-C Boom cylinder
(Rod side)
Boom
Arm cylinder
D-D (Head side)
Arm cylinder
Arm
L3
Unit : mm (in)
Length under
pin neck
Remedy
No. Length
1
768
(30.2)
217
(8.54)
4.0
(0.16)
690
(27.2)
2.5
(0.10)
249
(9.8)
L4
Shim
adjustment
2. ARM
2.1-1 ARM DIMENSIONAL DRAWING
E
F
G
D
R
C
D1
D2
d5
d3
N
d1
d2
VEIW I
SECTION A-A
D4
d4
M
SECTION B-B
"
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0122 3415
6 ! 3/75
87! /65
83! / !5
87! /65
0 6 64
2 1/!5
1 /15
1! 2/5
! /35
2 /15
4
!
"
9
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9#()- # +&
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9:)- $- '
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(/
(/
(/
(/
(/
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31 / 5
/35
2 /25
12 5
122 /15
! / 35
832 /!5
862 /615
832 /!5
832 /!5
832 /!5
Table 2-3
Standard value
Code
Item
+0.240
(+0.0094)
+0.174
(+0.0069)
+0.300
(+0.0118)
+0.174
(+0.0069)
Bucket link
(Idler link connection)
Clearance
Unit : mm (ft-in)
Bucket cylinder
(Rod side)
Bucket cylinder
(Head side)
+0.000
+0.287
(+0.0000)
(+0.0113)
-0.060
+0.155
(-0.0024) +0.227 (+0.0061)
2.0
(+0.0089)
+0.155 +0.287 (0.08)
(+0.0061) (+0.0113)
+0.155
(+0.0061)
+0.020
+0.250
(+0.0008)
(+0.0098)
-0.020 +0.230 +0.130
(-0.0008) (+0.0091)
(+0.0051)
+0.150
+0.030
+0.260
80 (+0.0012) (+0.0059) (+0.0102)
+0.120
(3.1496) -0.030
(-0.0012)
(+0.0047)
Arm cylinder
(Rod side)
-0.050
+0.270
(-0.0020)
(+0.0106)
-0.090 +0.180 +0.150
(-0.0035) (+0.0071)
(+0.0059)
+0.100
+0.290
-0.050
(-0.0020) (+0.0039) (+0.0114)
-0.110
+0.150
(-0.0043)
(+0.0059)
Arm foot
+0.020
(+0.0008)
-0.020
(-0.0008)
+0.244
(+0.0096)
+0.174
(+0.0069)
+0.264
(+0.0104)
+0.154
(+0.0061)
2.5
(0.1)
Replace
bushing
or pin
SECTION F-F
SECTION A-A
SECTION C-C
SECTION E-E
SECTION B-B
SECTION D-D,D-D
SECTION G-G
6 $
,$
*2
2 (
*2
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*2
,$
&2
6(&,
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7
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7
78
7
7
3. BUCKET
3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
No.
A
B
C
D
E
F
No.
NAME
Distance between pin and bracket
Distance between bucket pin and tooth end
Inner width of bucket top end
Inner width of lug
Inner width of bracket
Outer width of side cutter
G
H
I
I0
d1
d2
Unit : mm (ft-in)
Hoe bucket
Type
[STD]
Capacity
A
B
C
D
E
F
G
H
I
I0
d1
d2
0.75m3 (0.98cuyd)
445 (17.5 )
R1,440 (49 )
964 (38 )
399 (15.7 )
327 (12.9 )
1,122 (38 )
826 (32.5 )
1,020 (34 )
214 (8.43 )
213.5 (8.41 )
95 (3.74 )
80 (3.15 )
0.63m3 (0.82cuyd)
830 (32.7 )
989 (389 )
693 (27.3 )
887 (34.9 )
180.5 (7.11 )
180.5 (7.11 )
NAME
Outer width of bucket bottom
Bucket outer width of front side
Pitch between teeth
Pitch between teeth
Outer dia. of bushing
Pin dia.
VIEW II
Boss X
Boss Y
DETAIL I
Bushing length
Hole dia.
Screw dia.
Boss width.
Boss width.
Capacity
of bucket
m3 (cuyd)
Type of
bucket
Unit : mm (ft-in)
[STD]
67 95 13 180
25 170 36 140
0.75
(0.98) 80 25
Hoe bucket
M16
(3.15) (0.984) (2.64) (3.74) (0.512) (7.09)
(0.984) (6.69) (1.42) (5.51)
0.63 (0.82)
5 (0.2 )
15 (0.59 )
DETAIL K
E
F
Table 3-4
Type of
bucket
Capacity
of bucket A
m3 (cuyd)
Unit : mm (ft-in)
E
23
38
(0.91) (1.50)
10
SECTION 11
TOOLS
TABLE OF CONTENTS
1.TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ....................................... 1
2. SCREW SIZE ............................................................................................................. 2
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES .............................................. 3
4. PLUG .......................................................................................................................... 4
5. SPECIAL SPANNER FOR TUBE ............................................................................... 7
6. SPECIAL TOOLS ....................................................................................................... 8
7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND 10
8. SUCTION STOPPER ................................................................................................ 11
9. COUNTER WEIGHT LIFTING JIG ............................................................................ 12
10. UPPER FRAME LIFTING JIG ................................................................................ 13
11. ENGINE MOUNTING PEDESTAL .......................................................................... 14
14403 60413255
Strength
4.8T
grade
Use No lubrication Oil lubrication
Size
M6
P=1
M8
P=1.25
M10
P=1.5
M12
P=1.75
M14
P=2
M16
P=2
M18
P=2.5
M20
P=2.5
M22
P=2.5
M24
P=3
M27
P=3
M30
P=3.5
M33
P=3.5
M36
P=4
Table 1-2
Size
M8
0.450.05
(3.30.4 )
1.090.11
(7.90.8)
2.20.2
(161)
3.70.4
(273)
5.90.6
(434)
9.00.9
(657)
12.41.2
(909)
17.51.7
(13012)
232
(17014)
303
(22022)
444
(32029)
606
(43043)
818
(59058)
10510
(76072)
0.380.04
(2.70.3)
0.920.09
(6.70.7)
1.830.18
(131)
3.20.3
(232)
5.00.5
(364)
7.60.7
(555)
10.51.0
(767)
14.71.4
(11010)
19.62.0
(14014)
243
(17022)
364
(26029)
505
(36036)
687
(49051)
889
(64065)
7T
10.9T
0.980.1
(7.10.7)
2.40.2
(171)
4.70.5
(344)
8.10.8
(596)
12.81.3
(939)
19.52.0
(14014)
273
(20022)
384
(27029)
515
(37036)
657
(47051)
9610
(69072)
13113
(95094)
17618
(1300130)
22723
(1600170)
0.830.08
(6.00.6)
2.00.2
(141)
4.00.4
(293)
6.80.7
(495)
10.81.1
(788)
16.41.6
(12012)
232
(17014)
323
(23022)
434
(31029)
535
(38036)
788
(56058)
11011
(80080)
14815
(1100110)
19019
(1400140)
Strength
4.8T
grade
Use No lubrication Oil lubrication
P=1
M10
P=1.25
M12
P=1.25
M16
P=1.5
M20
P=1.5
M24
P=2
M30
P=2
M33
P=2
M36
P=3
1.150.11
(8.30.8)
2.30.2
(171)
4.00.4
(293)
9.40.9
(687)
191.9
(14014)
323
(23022)
656
(47043)
879
(63065)
10911
(79080)
0.970.1
(7.00.7)
1.910.19
(141)
3.40.3
(252)
7.90.8
(576)
15.81.6
(11012)
273
(20022)
545
(39036)
727
(52051)
919
(66065)
7T
1.770.18
(131)
4.30.4
(323)
8.50.9
(617)
14.61.5
(11011)
232
(17014)
354
(25029)
495
(35036)
687
(49051)
929
(67065)
11812
(85087)
17317
(1300120)
23524
(1700170)
31732
(2300230)
40941
(3000300)
1.50.15
(111)
3.60.4
(263)
7.20.7
(525)
12.31.2
(899)
19.51.9
(14014)
293
(21022)
414
(30029)
576
(41043)
778
(56058)
9610
(69072)
14014
(1000100)
19820
(1400140)
26627
(1900200)
34334
(2500250)
2.50.2
(181)
4.90.5
(354)
8.70.9
(637)
202
(14014)
414
(30029)
707
(51051)
14214
(1000100)
19019
(1400140)
23823
(1700170)
1
2.10.2
(151)
4.20.4
(303)
7.30.7
(535)
17.21.7
(12012)
343
(25022)
586
(42043)
11812
(85087)
15816
(1100120)
19820
(1400140)
4.50.4
(333)
8.90.9
(647)
15.71.6
(11012)
374
(27029)
747
(54051)
12612
(91087)
25526
(1800190)
34134
(2500250)
42843
(3100310)
3.80.4
(273)
7.50.7
(545)
13.21.3
(959)
313
(22022)
626
(45043)
10510
(76072)
21221
(1500150)
28428
(2100200)
35736
(2600260)
2. SCREW SIZE
(1) Capscrew
B
B
Table 2-1
Table 2-2
Nominal
screw size
B mm
(d)
Tool
size
M6
10
Table 2-3
B mm
Nominal
screw size
B mm
Tool
size
(d)
Tool
size
1/4-20UNC
11
M6
Nominal
screw size
Unified
(screw threads)
M8
13
5/16-18UNC
13
M8
M10
17
3/8-16UNC
14
M10
M12
19
7/16-14UNC
16
M12
10
(M14)
(22)
1/2-13UNC
19
M14
12
M16
24
5/8-11UNC
24
M16
14
(M18)
(27)
3/4-10UNC
29
(M18)
14
M20
30
7/8-9UNC
33
M20
17
19
(M22)
32
1-8UNC
38
M24
M24
36
1 1/8-7UN
43
M30
22
(M27)
(41)
1 1/4-7UN
48
M36
27
M30
46
1 1/2-6UN
57
M42
32
M36
55
M48
36
M42
65
M52
36
M45
70
M48
75
M56
85
(M60)
90
M64
95
(M68)
100
M72
105
Table 2-4
Nominal
screw size
B mm
(d)
Tool
size
M2.5
1.27
1.5
M76
110
M3
M80
115
M4
M5
2.5
M6
M8
M10
M12
M16
M20
10
3.
Manufacturers name
Nippon A.M.C.
Table 3-1
Tube size
Working pressure
OD thickness
kgf / cm (psi)
mm (in)
10 1.5
(0.394 0.059)
15 2.0
(0.591 0.079)
18 2.5
300
(4270)
(0.709 0.098)
2
300
(4270)
Ihara Koatu
Opposing
flats (HEX)
Tightening torque
kgfm (lbfft)
5
(36
12
(87
19
27
1
7)
1.2
9)
32
15 1.5
(108 11)
22 3.0
(0.866 0.118)
36
22 2.2
(159 16)
28
(1.10
35
(1.38
41
28 2.8
(200 20)
55
45 4.5
(330 33)
4.0
0.157)
5.0
0.197)
Table 3-2
NUT
SLEEVE
Tube size
Parts No.
Ihara Koatu
Nippon A.M.C.
Opposing
Tube size
flats (HEX)
d
B
14
17
10
10
19
12
12
22
15
15
27
18
18
32
22
22
36
28
28
41
32
32
50
35
35
55
38
38
60
Parts No.
Ihara Koatu
Nippon A.M.C.
4.
PLUG
Table 4-1
Applicable
pipe
O. D : A
H1
T screw
Opposing flat
T screw
H1
M12 1.5
14
14
M14 1.5
17
17
10
M16 1.5
17
19
12
M18 1.5
19
22
15
M22 1.5
24
27
18
M26 1.5
27
32
22
M30 1.5
32
36
28
M36 1.5
38
41
Table 4-2
Applicable
pipe
O. D : A
6
8
10
12
15
18
Flareless
joint body
22
Nut
28
3) Nut
Table 4-3
HEX
Applicable
pipe
O. D : A
D screw
D screw
Opposing
flat
M12 1.5
14
M14 1.5
17
10
M16 1.5
19
12
M18 1.5
22
15
M22 1.5
27
18
M26 1.5
32
22
M30 1.5
36
28
M36 1.5
41
32
M42 1.5
50
35
M45 1.5
55
38
M48 1.5
60
Table 4-4
PF (G)
screw Plug parts No. B mm
PF 1/4
19
O ring
PF screw
O ring parts
No.
PF 3/8
22
1B
P14
PF 1/2
27
1B
P18
PF 3/4
36
1B
P24
PF 1
41
1B
P29
2) PT(R) screw
Table 4-5
PT(R)
screw
PT 1/8
B
PT(R) screw
PT 1/4
PT 3/8
PT 1/2
10
PT 3/4
14
PT 1
17
PT 1 1/4
22
PT 1 1/2
22
PF(G)
screw
PF 1/4
PF 3/8
17
PF 1/2
Opposing
PF 3/4
flat B
PF 1
22
27
36
Table 4-7
PF (G) Plug parts No. E mm F mm
screw
PF 1/4
14
19
PF(G)
screw
Opposing
flat F
Opposing
flat E
Norminal
O ring
1B P11
PF 3/8
17
22
PF 1/2
23
27
PF 3/4
27
36
PF 1
36
41
PF 1 1/4
40
50
Table 4-8
Screw size A
A
Applicable
hose
O.D
Opposing
flats(HEX)
O ring
1-14UNS
21.7
27
1B
A16
1 3/16-12UN
27.2
36
1B
A18
1 7/16-12UN
34.0
41
1B
A21
HEX
Table 4-9
Female
Screw size A
Applicable
tube
O.D
Opposing
flats(HEX)
A 1-14UNS
1 3/16-12UN
21.7
32
27.2
36
1 7/16-12UN
34.0
41
HEX
5.
Part No.
HEX
mm
Shape mm (in)
70 (2.76)
8(0.315)
15
(0.591)
16
(0.630)
27
HEX27
PART-No.
22(0.866)
40(1.57)
12.7
0.3
0.1
( 0.500
0.012
0.004
70 (2.76)
42(1.65)
18
(0.709)
19
(0.748)
32
22(0.866)
PART-No.
22(0.866)
HEX32
12.7
( 0.500
0.3
0.1
0.012
0.004
70 (2.76)
40(1.57)
22
(0.866)
19
(0.748)
30
22(0.866)
PART-No.
22(0.866)
HEX30
48 (1.89)
22
(0.866)
23
(0.906)
36
HEX36
60 (2.36)
28
(1.10)
29
(1.14)
41
HEX41
80 (3.15)
28
(1.10)
31
(1.22)
46
HEX46
80 (3.15)
32
(1.26)
33
(1.30)
50
HEX50
12.7
( 0.500
0.3
0.1
0.012
0.004
70 (2.76)
11.5 (0.453)
PART-No.
12.7
22(0.866)
0.3
0.1
( 0.500
0.012
0.004
109 (4.29)
14.5 (0.571)
PART-No.
12.7
0.3
0.1
22(0.866)
( 0.500
0.012
0.004
109 (4.29)
PART-No.
19.05
35(1.38)
0.5
0.1
( 0.750
0.020
0.004
109 (4.29)
PART-No.
19.05
35(1.38)
0.5
0.1
( 0.750
0.020
0.004
6.
SPECIAL TOOLS
Table 6-1
No.
Tools name
Allen wrench
Nominal B : 10
Tools No.
Shape
Use
Pump
suction
Commercial tool length (L1)
cut length = Required
length
40(1.57 )
10(0.39 ) = 30(1.18 )
Allen wrench
Nominal B : 14
Pump
install
Commercial tool length (L1)
cut length = Required
length
56(2.20 )
11(0.43 ) = 45(1.77 )
Cut
Swing
motor
A,B port
Spanner
Nominal S : 32
73(2.87 )
13(0.51 )
= 65(2.56 )
Additional M10 22
threading
for M10 eye bolt
Plug
PF3/4
For
slinging
the swing
motor
O ring
PF3/4
Eye bolt
M10 18
5
M10
For
slinging
the swing
motor
&
Flare hose
Table 6-2
No.
Tools name
Tools No.
Shape
Use
M8 Eye bolt
Plug
(Nominal
tube dia. 22 )
6
Nut
(Reference)
Eye bolt
Nut
Flare hose
M8 18
Additional
threading for
M8 Eye bolt
M8 Eye bolt
Plug
7
M8 18
Additional
threading
Nominal
Flare hose
1-14UNS
Eye bolt
Plug
8
M8 Eye bolt
M8 18
Additional
threading
Nominal
Flare hose
1 3/16-12UN
Eye bolt
swing motor
Eye bolt
M8 15
&
Flare hose
M8
M8 20
Additional
threading for
M8 Eye bolt
Plug
10
PF1/2
PF1/2
O RING
7.
(1) For general use
Use
Features
Locktite
Three-Bond
#242
1360K
#262
1374
Middle strength
#271
1305
High strength
#515
1215
Sealing
Application of
screw locking
compound
Sealing
compound
Low strength
Manufacturer
Name
Equivalent
Location
(Manufacture ; Locktite)
Three-Bond
#1901
Anti-seizure
Cylinder
#1215 gray
#5699
Swing motor
#1211 white
#5301J
Swing motor
#1303B
#211
Main pump
(Manufacturer ; Three-Bond)
Sealing
compound
&
#222
#1344N
Main pump
#277
#1307N
Pilot valve
Locktite
adhesive
(Manufacture ; Three-Bond)
Locktite
Sumitomo
Chemical
Co., Ltd.
Parmatex 98D
#1121
Locktite #515
Three-Bond #1215
Showa-Shell
petroleum
10
8.
SUCTION STOPPER
8.1 COMPONENTS
No.
NAME
PARTS No.
Q TY
ROD
NUT
COVER
O RING
1 Rod
2 Nut
3 Cover
4 O ring
8.2 DIMENSION
50
(1.97 )
Fig. 8-1
113 (4.45 )
2
M8 NUT
9(0.354 )
M8
100 +0.5
0
(3.94 +0.0197
)
0
ROD
108
(4.25 )
COVER
fig. 8-2
11
M24
12
10.
SECTION
AA
Q'ty : 2set
Fig. 10-1
Engine stand
Retainer nut
Retainer plate
Stand
Hydraulic jack
Base
Fig. 12-1
SECTION 12
TABLE OF CONTENTS
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR ..................... 1-1
01. Attachment .......................................................................................................................
02. Cab & Guard ....................................................................................................................
03. Swing frame .....................................................................................................................
04. Travel system ....................................................................................................................
06. Electric equipment ............................................................................................................
1-1
1-2
1-3
1-6
1-7
14403 60413255
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE ..... 2-1
Location
Group
Attachment
Cab & Guard
Swing frame
Travel system
Electric
equipments
09 E/G relation
Indicates installing,
removing, replacement
and overhaul.
Indicates the installing,
removing and
replacement of single
items.
Indicates overhaul of the
single engine.
(Materials prepared by
manufacturer )
Work to be
Unit
done
00 Bucket relation
Remark
Unit : Hour
E200SR
E200SRLC
01 Bucket ASSY
02 Bucket attaching and detaching position
Detach/attach
Preparation
1 pc.
1 pc.
Detach/attach
Detach/attach
1
1
Preparation
1 pc.
O/H
1 pc.
07 Tooth
08 Side cutter
Replace
Replace
1 pc.
1 pc.
0.6
1.2
09 Bushing
Replace
1 pc.
0.6
11 Arm ASSY
Bucket cylinder attaching and detaching
12
position and piping
13 Bucket cylinder rod pin
Detach/attach
1 pc.
Preparation
Detach/attach
1 pc.
1 pc.
Detach/attach
Detach/attach
1 pc.
1 pc.
0.1
0.1
Detach/attach
Detach/attach
1 pc.
1 pc.
0.1
0.1
Detach/attach
1 pc.
Detach/attach
1 pc.
1.4
Preparation
Preparation
1 pc.
2 pcs.
0.1
0.2
01 Attachment
Remarks
10 Arm relation
0.6
0.1
0.1
0.1
0.2
2.4
30 Boom relation
31 Boom ASSY
Include adjustment.
1.2
Include lock pin.
0.4
0.1
0.2
4. Reference for boom
11
0.2
Unit : Hour
Group
Location
Boom cylinder piping
Detach/attach
2 pc.
0.2
Detach/attach
1 pc.
0.2
37
Detach/attach
1 pc.
38
Detach/attach
39
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.4
0.1
Include lock pin.
0.2
41
Detach/attach
1 pc.
42
Detach/attach
43
Detach/attach
1 pc.
0.1
Detach/attach 2 pcs.
0.7
0.3
0.2
Include lock pin.
0.1
51
Detach/attach
52
0.2
53
Detach/attach
0.2
O/H
Replace
O/H
Replace
1 set
O/H
Replace
1 set
61
Pin bushing
70 Arm cylinder
71
Pin bushing
80 Boom cylinder
81
Pin bushing
10 Cab relation
11 Cab ASSY
3.6
Include seal.
1.2
3.6
Include seal.
1.2
7.0
Include seal.
1.2
0.1
1 pc.
1 pc.
each
Detach/attach 5 places
1.2
Detach/attach
Detach/attach
1 pc.
0.2
15
Air-con duct
Detach/attach
0.2
16
Detach/attach
0.1
17
Cab slinging
Detach/attach 3 places
12
13
14
20 Guard relation
E200SR
E200SRLC
36
60 Bucket cylinder
02
Remark
35
01 Attachment
Work to be Unit
done
0.2
0.4
4. Reference for guard
21 Box (1-1)
Detach/attach
1 pc.
0.2
22 Box (1-2)
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.2
25 Cover (4)
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.2
28 Cover (7)
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.1
30 Bonnet (9)
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.3
Detach/attach
1 pc.
0.3
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.2
36 Bracket (16)
Detach/attach
1 pc.
0.2
Detach/attach
1 pc
0.3
Detach/attach
1 pc
0.2
39 Bracket (19)
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.3
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.2
12
Unit : Hour
02
Group
Location
Work to be
Unit
done
Remark
E200SR
E200SRLC
43 Cover (52)
Detach/attach
1 pc.
0.1
44 Cover (53)
Detach/attach
1 pc
0.1
45 Cover (54)
Detach/attach
1 pc
0.1
Detach/attach
1 pc.
0.1
51 Cover (1)
Detach/attach
1 pc.
0.1
52 Cover (2)
Detach/attach
1 pc.
0.1
53 Cover (3)
Detach/attach
1 pc.
0.1
54 Cover (4)
Detach/attach
1 pc.
0.1
55 Cover (5)
Detach/attach
1 pc.
0.1
56 Cover (6)
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.6
Detach/attach
1 set
0.1
Preparation
1 pc.
0.2
50 Cover relation
62
63
64
Detach/attach
1 pc.
0.2
65
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
Replace
1 pc.
00 Control relation
01 E/G control ASSY
02
0.2
0.2
Detach/attach
1 pc.
0.4
12
Hose (3)
Detach/attach
0.1
13
Hose (4)
Detach/attach
0.1
Swing frame
14
Element
Replace
0.1
21 Muffler ASSY
Detach/attach
1 pc.
0.4
22
U bolt
Detach/attach
1 pc.
0.1
03
10 Intake relation
Include adjustment.
23
Clamp ASSY
Detach/attach
1 pc.
0.1
24
Gasket
Replace
1 pc.
0.1
Detach/attach
1 pc.
5.0
Replace
1 pc.
0.2
Measuring
1 pc.
0.2
20 Exhaust relation
32
Coolant (LLC)
33
Concentration of coolant
34
A/C condenser
Detach/attach
1 pc.
0.2
35
Stay
Detach/attach
1 pc.
0.1
36
Bracket
Detach/attach
0.3
37
Sub tank
Detach/attach
1 pc.
0.1
38
Fan guard
Detach/attach
1 pc.
0.2
39
Detach/attach
0.2
40
Detach/attach
1 pc.
0.2
41
Under cover
Detach/attach
1 pc.
0.1
42
Attach/detach
1 pc.
0.2
43
Detach/attach
1 pc.
1.0
44
Detach/attach
1 pc.
0.2
45
Detach/attach
0.2
13
Unit : Hour
Group
Location
46
47
Radiator core
48
Work to be
Unit
done
1 pc.
0.2
Cleaning
1 pc
1.0
Check
1 pc.
0.5
Detach/attach
1 pc
1.8
Replace
1 pc.
0.3
52
Fuel
53
Detach/attach
0.1
54
Water separator
Detach/attach
1 pc.
0.1
55
Detach/attach
0.1
57
Detach/attach
1 pc.
0.3
58
Tank slinging
Detach/attach
1 pc.
Detach/attach
1 pc.
Swing frame
03
E200SR
E200SRLC
Detach/attach
50 Fuel relation
51 Fuel tank ASSY
Remark
0.3
Removing and installing guard
0.4
0.2
1 pc.
3.0
Detach/attach
1 pc.
0.2
Replace
1 pc.
0.5
65
Cover
66
Hydraulic oil
68
Detach/attach
1 pc.
0.2
69
Detach/attach
0.5
70
Mounting bolt
Detach/attach
1 pc.
0.2
71
Detach/attach
1 pc.
0.3
72
Return filter
Replace
0.2
73
Suction filter
Cleaning
0.2
Detach/attach
1 pc.
2.3
80 Pump relation
81 Pump ASSY
82
Detach/attach
1 pc.
0.3
83
Detach/attach
1 pc.
0.3
84
Piping
Detach/attach
1 set
0.8
85
Guard
Detach/attach 2 pcs
0.4
86
Pump slinging
Detach/attach
1 pc.
0.4
87
Cleaning
Cleaning
1 pc.
0.1
88
Vent air
Adjust
1 pc.
0.1
O/H
1 pc.
Detach/attach
1 set
Detach/attach
1 pc.
2.7
89 Pump ASSY
Other necessary works
90 Swing motor unit relation
91 Swing motor ASSY
3.0
Counter weight
0.6
92
Piping
Detach/attach
1 set
1.0
93
Detach/attach
0.3
94
Mounting bolt
Detach/attach
1 pc.
0.7
95
Unit slinging
Detach/attach
1 pc.
0.5
96
Cleaning
1 set
0.2
97
Swing motor
O/H
1 pc.
3.6
98
O/H
1 pc.
4.2
14
Unit : Hour
Group
Location
Work to be
Unit
done
E200SR
E200SRLC
2.6
102
Detach/attach
1 set
0.5
103
Detach/attach
0.2
104
Cover
Detach/attach
0.4
105
Detach/attach
1 set
0.4
106
Mounting bolt
Detach/attach
1 set
0.4
107
Detach/attach
0.4
108
Cleaning
Cleaning
1 set
O/H
1 set
3.6
Detach/attach
1 set
Lower piping
0.6
Detach/attach
Detach/attach
1 set
0.3
0.3
1.7
113
Piping
Detach/attach
1 set
0.5
114
Mounting bolt
Detach/attach
1 set
0.3
115
Cleaning
Cleaning
1 set
0.2
Detach/attach
1 set
Detach/attach
1 pc.
1.5
Preparation
1 pc.
0.5
Guard
0.4
122
123
Piping
Detach/attach
1 set
0.8
124
Detach/attach
1 pc.
0.1
125
Valve slinging
Detach/attach
1 pc.
0.1
O/H
1 set
Detach/attach
1 set
03
Swing frame
Remark
5.0
Guard
0.7
Detach/attach
1.0
Preparation
1 set
0.2
Piping
Detach/attach
1 set
0.5
Mounting bolt
Detach/attach
1 set
0.3
Detach/attach
1 pc.
132
133
134
1.6
142
Detach/attach
1 pc.
0.2
143
Fuel hose
Detach/attach
1 pc.
0.1
144
Others
Detach/attach
1 set
0.4
145
Mounting bolt
Detach/attach
1 pc.
0.4
146
Engine slinging
Detach/attach
1 set
0.2
147
Cleaning
Cleaning
1 pc.
O/H
1 set
Detach/attach
1 set
0.7
Detach/attach
1 set
0.6
Detach/attach
1 set
2.3
Detach/attach
1 set
0.4
Detach/attach
1 set
0.4
Detach/attach
1 set
5.0
148 Engine
Other necessary works
15
0.2
Unit : Hour
Group
Work to be
Unit
done
Location
1 pc.
1.3
152
Mounting bolt
Detach/attach
1 set
0.4
153
Detach/attach
1 pc.
0.4
154
Cleaning
Cleaning
1 pc.
0.3
155
Sealant
Apply
1 pc.
0.2
Detach/attach
1 set
Cab
1.2
Detach/attach
1 set
Guard
0.7
Detach/attach
1 set
Counter weight
0.6
Detach/attach
1 set
Boom
1.4
Detach/attach
03
Swing frame
E200SR
E200SRLC
00 Travel relation
02
03
Master pin
Detach/attach
04
Detach/attach
One
side
One
side
One
side
One
side
Replace
1 pc.
Preparation
05 Shoe plate
10 Upper roller relation
11 Upper roller ASSY
Detach/attach
O/H
1.5
0.1
0.5
0.5
0.4
12 Upper roller
0.2
1.0
0.2
O/H
1.5
Detach/attach
Detach/attach
O/H
One
side
One
side
One
side
One
side
One
side
One
side
Replace
One
side
Detach/attach
52
Motor cover
Detach/attach
53
Hydraulic piping
Detach/attach
54
Detach/attach
55
Motor slinging
Detach/attach
22 Lower roller
30 Front idler relation
Detaching
34 Idler ASSY
O/H
O/H
36
Grease cylinder
0.6
0.3
0.3
1.0
Replace spring
2.4
0.6
04
Travel system
Remark
40 Sprocket
41 Sprocket
50 Travel motor relation
0.6
57 Travel motor
O/H
O/H
One
side
One
side
One
side
One
side
One
side
One
side
One
side
One
side
Detach/attach
1 pc.
0.6
O/H
1 pc.
3.6
56 Motor cleaning
Cleaning
1.7
0.1
0.9
0.5
0.1
0.1
3.6
3.6
16
Unit : Hour
04 Travel system
Group
Location
Work to be
Unit
done
70 Swing bearing
Remark
E200SR
E200SRLC
Detach/attach
1pc.
Detach/attach
1pc.
0.5
Detach/attach
1pc.
0.3
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
D-1 Diode
Replace
0.2
D-2 Diode
Replace
0.2
D-3 Diode
Replace
0.2
D-4 Diode
Replace
0.2
D-5 Diode
Replace
0.2
D-6 Diode
Replace
0.2
Replace
E-2 Alternator
Replace
1.0
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
Replace
0.3
Replace
0.5
Replace
Bulb
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
Replace
Replace
0.2
Replace
0.2
Replace
0.5
Replace
0.2
Replace
0.2
Replace
0.2
0.7
Controller
Diode
06
Electric equipments
Electric equipments
Include C1 controller removing and
installing.
0.3
0.2
Light
Motor
17
1.0
0.5
Unit : Hour
Group
Location
Work to be
Unit
done
Remark
E200SR
E200SRLC
Proportional valve
Include proportional valve removing and
installing.
Include proportional valve removing and
installing.
Include proportional valve removing and
installing.
Include proportional valve removing and
installing.
Replace
Replace
2.0
Replace
Replace
Replace
Replace
Replace
Replace
Replace
0.3
Replace
0.3
Replace
0.3
Replace
Replace
0.2
Replace
0.2
Replace
0.2
Replace
0.2
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
0.2
Replace
0.2
Replace
0.2
Replace
Replace
Replace
Replace
Replace
0.2
SW-2 Switch
Replace
0.2
Replace
Replace
1
1
0.2
0.2
Replace
0.2
Replace
0.2
Replace
Replace
1
1
0.2
0.1
Replace
Replace
1
1
0.2
0.3
Replace
0.2
Replace
0.2
2.0
2.0
2.0
Relay
0.2
0.2
Include guard removing and installing
Include C1 controller removing and
installing
0.4
0.3
06
Electric equipments
Sensor
Include removing and installing guard on
cab lower side.
0.4
0.2
0.4
0.4
0.4
0.5
0.2
0.3
Solenoid
Include proportional valve removing and
installing.
Include proportional valve removing and
installing.
Include proportional valve removing and
installing.
Include proportional valve removing and
installing.
2.0
2.0
2.0
2.0
Switch
18
2.
Introduction
This standard working time table provides time
required for maintenance (if the work is carefully
carried out) under the following condition :
Tools designated by us are used.
Genuine parts are prepared.
Correct working procedures are observed.
The engine is mounted correctly to the
machine.
1. The working hours given in this table can not
be applied because of special machine
construction.
2.
Location of work
Work
to be
done
Maintenance
time
Engine body
Location of work
0.9
Replace
0.4
Tappet
Drain plug
Replace
0.1
Detach &
attach
21.6
Engine assy
Incl. overhaul of engine and cylinder body
0.2
Replace
0.1
Detach &
attach
11.8
Replace
Replace
Detach &
attach
Cam shaft
0.2
0.8
Oil pan
0.3
Exhaust manifold
Oil pan
Detach &
attach
0.9
Detach &
attach
2.5
Replace
0.1
0.4
Replace
0.4
Detach &
attach
1.2
Detach &
attach
11.6
Replace
0.3
Retighten
0.3
Detach &
attach
Detach &
attach
Detach &
attach
1.1
0.7
0.8
Adjust
0.5
Detach &
attach
0.5
9.6
etc.
21
0.1
0.5
Detach &
attach
1.8
Detach &
attach
Detach &
attach
Detach &
attach
Detach &
attach
Detach &
attach
Replace
Detach &
attach
5.4
Cylinder head
Valve clearance
Replace
Detach &
attach
Retighten
0.6
11.4
Detach &
attach
Sealing plug
Maintenance
time
Flywheel assy
Work
to be
done
0.1
0.2
0.2
0.2
Location of work
Work
to be
done
Maintenance
time
Lubricating system
Oil filter element cover
Detach &
attach
0.5
Replace
Detach &
attach
Replace
0.4
0.2
Replace
0.4
0.6
Replace
0.4
Fuel hose
Replace
0.2
Detach &
attach
Detach &
attach
Detach &
attach
0.3
Cooling system
0.7
Fan belt
Adjust
0.1
0.9
Fan belt
Replace
Detach &
attach
Detach &
attach
0.1
Replace
0.1
Cooling fan
Replace
0.2
Adjust
Detach &
attach
0.3
3.8
Replace
Detach &
attach
0.3
1.2
Starter assy
Generator pulley
Detach &
attach
Detach &
attach
Detach &
attach
1.0
Detach &
attach
0.6
Detach &
attach
0.8
0.3
Replace
Detach &
attach
0.6
Replace
0.1
0.1
Voltage regulator
Adjust
0.5
0.3
1.2
Replace
Thermostat
0.3
Fuel system
Injection time
Work Mainteto be
nance
done
time
Detach &
0.6
attach
Detach &
0.4
attach
Location of work
Generator assy
1.3
0.2
Voltage regulator
Replace
0.1
Replace
0.1
Replace
0.3
Replace
0.3
Replace
0.4
Primimg pump
Replace
0.4
Replace
0.1
Injection pump
Vent air
0.1
Replace
Detach &
attach
Detach &
attach
Detach &
attach
0.1
Replace
0.2
0.7
Replace
0.1
1.2
Replace
0.1
1.7
Thermo unit
Replace
0.2
Replace
Detach &
attach
0.1
Control resistor
0.2
0.2
Replace
Detach &
attach
22
0.2
SECTION 13
MAINTENANCE STANDARD
AND TEST PROCEDURE
TABLE OF CONTENTS
1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE
EXERCISED .............................................................................................................. 1
2. PERFORMANCE INSPECTION STANDARD TABLE ................................................ 2
3. MEASUREMENT OF ENGINE SPEED ..................................................................... 4
4. MEASUREMENT OF HYDRAULIC PRESSURE ....................................................... 5
5. MEASURING TRAVEL PERFORMANCES ................................................................ 9
6. MEASURING SWING PERFORMANCES ............................................................... 11
7. MEASURING ATTACHMENT OPERATING PERFORMANCES .............................. 13
8. MEASURING PERFORMANCES OF SWING BEARING ........................................ 14
14403 60413255
2) Repairable level;
Values at which readjustment is required. In
order to ensure performance and safety it is
strictly prohibited to use the machine over
the specified values.
3) Service limit ;
This is the limit value at which
reconditioning
is
impossible
without
replacement of parts. If the value is expected
to exceed the service limit before next
inspection and correction are performed,
replace the parts immediately. The operation
over the specified values causes increase of
damage and requires the down time of
machine, and also causes safety problems.
2.
Tank surface
Coolant temperature
Radiator surface
Engine speed
Standard
Measuring condition
Inspection Item
Lo idle
Hi idle
Selector switch on
the gauge cluster
screen
(Injection pipe)
S mode
FC mode
Decel
Bucket
Travel
Boom
RH
LH
Swing
Arm
Main
pump
a2
a1
a2
H
R
Forward
Reverse
Forward
Reverse
LH
PF1/4 a1
a2
a2
RH
H
a2
Travel
straight valve
P1 cut valve
Arm variable
recirculation
P2 cut valve
Travel
straight valve
P1 cut valve
Arm variable
recirculation
21
22
20
23
1
5
(23)
15
(5)
1000
+25
25
LOW throttle
FULL throttle
(HI idle)
(
F)
2420
+30
30
2300
+30
30
1800
+30
30
1050
51
(725)
+50
+3
(40)
50
3
(40)
350
(4980)
+5
(70)
MR1
385
+10
(5470) (140)
5
(70)
MR1
55
(780)
35
(500)
55
(780)
35
(500)
0
0
0
0
Adjustment
Sampling
Ambient temp.
5010
(122
F14
F)
+15
0
(210)
+15
0
(210)
+55
+10
(780) (140)
+55
+10 kgf/cm2
(780) (140) (psi)
35
0
(500)
55
0
(780)
measurement with
the air-conditioner
OFF
.
PR1
HI
idle
RH and LH
Simultaneous
Operation or
Boom up
ATT boost
pressure SW. ON
Boom up
OR3
Boom up
OR4
Boom down
OR1
Bucket digging
OR2
OT1
OT2
OT3
OT4
OR5
Bucket dump
OR6
Swing RH
OR7
Arm in
OR8
Arm out
Simultaneous
Operation of
travel
RH and LH
Swing LH
6.9
(100)
25
(300)
25
(300)
28.6
(410)
25
(300)
425
(60360)
Class
Measuring
condition
+5
(41)
+15
(59)
20
23
Adjusting
Point
+1
21
22
Unit
50
(122)
75
(167)
405
(5760)
385
(5470)
405
(5760)
385
(5470)
350
(4980)
350
(4980)
285
(4050)
285
(4050)
385
(5470)
405
(5760)
a1
Lo
NAS 8
a1
P2 cut valve
Secondary pilot
Pressure circuit
P2
P1
P2
a1
Boost
pressure
a4
P1
Main pump
ATT
Travel
Gauge cluster
C2 Multi display
Main relief
Valve pressure
Hi
+1.5 0.5
(20)
(7)
Indicated
current value
(mA)
3505
642
642
+2 1.5
(30)
(20)
700
642
303642
Performs proportional
calculation from actual
current reading on
display No. Values
which are calculated
by converting pressure
values in the left figure
to current
values are shown.
E/G Hi, Lever on neutral
position
E/G Hi
The max. value is
displayed as the
full lever strokes
differ with types of
operations.
Table 1 (2/2)
P2 pump
proportional valve
&
Position
Gauge cluster
Multi display
P1 pump
proportional valve
Standard
Hi
Screen code value
Measuring Posision
C2
Inspection Item
No.24
&
No.25
Operating speed
Operating time of
cylinder
(At no load)
Swing speed
Travel speed
Amount of travel
deviation
Performance
Adjusting
Measuring
Point
condition
Indicated
6
(90)
+0.5 0.5
(7) (7)
Current value
(mA)
MIN 350
E/G Hi
Lever on
neutral
position
(psi)
No.24
30
+1.5 1.5
&
(430) (20) (20)
No.25
1-speed
2-speed
S mode
2-speed
FC mode 2-speed
Raise
Boom
Lower
In
Arm
Out
Digging
Bucket
Dumping
Variable speed
STD speed
Rubber
1-speed
Iron
Rubber
2-speed
Iron
H mode
2-speed
15Gradient
15Gradient
Tip of the bucket tooth
ATT amount of
drift
Unit
kgf/cm2
Inspection item
Sprocket revolution
(RH,LH)
Lo
Boom cylinder
Arm cylinder
Dozer cylinder
Standard value
26.629.4
39.043.2
37.841.8
29.432.6
2.73.3
3.03.6
3.13.7
2.32.9
2.93.5
1.72.3
5.05.6
20.622.8
14.115.7
0240
0
5575
0
96
3
6
5070
(1.972.76)
MAX 750
E/G Hi
Lever on
full
Unit
rpm
sec
sec/1 rev
sec/20m
mm / 20m
mm / 5min
degree
mm (in)
mm/5min
(At no load)
mm (in)
The port relief valves No.OR1OR8 on the control section are adjusted to the following
operation numbers in advance.
Arm in
Arm out
LH
RH
CONTROL LEVER
3
MONITOR
SYSTEM OK
2250RPM
256 Hr AFT
E/G OIL CH
Example of screen change
BUZZER STOP
SWITCH
(RETURNS)
SCREEN
SELECT SW
(ADVANCES)
WORK MODE
SELECT SW
2205
MEAS
2201
E/G PRS.
LIVE
LIVE/DEAD indication
KPSS SW
H/S/FC indication
PICK UP
SPEED METER
4.
A3
a3
A3
PUMP
a2
a1
Fig. 4
MAIN RELIEF
VALVE
MR1
BUCKET
DUMPING
OR2
ARM IN
OR7
BOOM
UP
OR3
OPTION
OR12
OPTION
OR11
ARM OUT
OR8
BOOM DOWN
OR4
BUCKET
DIGGING
OR1
A3
a3
Dr4
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
Fig.6
SWING LEFT
OVER LOAD RELIEF
SWING RIGHT
OVER LOAD RELIEF
OR5
OR6
PB
PA
Fig. 7
Pressure change
kgf/cm2(psi)
1 turn
Approx. 21 (300)
311
Fig. 8
7
HEX32 HEX19
1 2
4 3
HEX22
Fig. 9 Main relief valve
(Travel section, ATT common section)
2
Fig. 10 Over load relief valve
(Boom, bucket, arm sections)
Pressure change
kgf/cm2 (psi)
1 turn
1
HEX22
HEX38
1
HEX30
2
3
Fig. 11
Fig. 12
2
1
5.
(1ft)
30cm
(2) Condition
A slope with 15deg. gradient and a stopped
condition in a no-load travel position
15deg.
Fig. 17
(3) Preparation
Place an angle meter on the shoe plate and
confirm that it makes an angle more than
15deg..
Hang a perpendicular in parallel with the
guide frame rib on the track frame and put a
mark (matching mark) on the shoe plate.
GUIDE FRAME
Fig. 18
Measuring
position
ANGLE METER
Method of measurement
Table 8
1 (0.04in)
22 PIPE
(0.866 )
FORWARD
limit
2 (0.08in)
10
90
(3.54 ) (0.394 )
40
(1.57 )
RIBA
130
(5.11 )
STOPPER
B
(2) Conditions
4555(113131
F)
Hydraulic oil temperature ; 4555C
Engine speed
; Hi idle
(3) Preparation
1) Place a stopper under the RH and LH travel
sprockets.
2) Stop the engine and vent pressure from the
hydraulic circuit.
3) Connect a hose with the drain port of the
travel motor and take drain in a container.
Parking brake
(4) Measurement
Five minutes after the engine stops, measure
the movement distance of the matching
mark.
5.4 DRAIN RATE OF TRAVEL MOTOR
(1) Purpose
To measure the drain rate of the travel motor
and to confirm the performances of the travel
motor.
70
ROTARY DIRECTION
Fig. 19
(2.76 )
Fig. 20
Drain rate of
travel motor
Measuring
position
Drain rate
10
Method of measuring
the drain rate of travel motor
Table 9
Unit :
/30sec
7 (1.85 gal)
Fig. 21
Fig. 22
15
Fig. 25
Measuring position
of swing brake performances
12
7.
(1ft)
30cm
Fig. 28
Fig. 29
(1ft)
30cm
Fig. 30
Standard
Table 14
Unit :
value
2.93.5
1.72.3
2.73.3
3.03.6
3.13.7
2.32.9
B
3.74.5
2.42.9
3.44.2
3.84.6
4.04.7
3.03.7
4.8
3.0
4.5
5.0
5.1
3.9
13
8.
(1) Purpose
Measure the gap between the lower frame
and the bottom face of the swing bearing and
estimate the degree of wear of the swing
bearing.
SWING BEARING
A
DIAL INDICATOR
(2) Condition
Plain, level and solid ground
The swing bearing mounting bolts are not
loosened.
The swing bearing is lubricated well, not
making abnormal sound during turning.
LOWER FRAME
Fig. 32
(3) Preparation
1) Install a dial indicator to the magnetic base
and fix it to the lower frame.
2) Direct the upper swing body and the lower
frame toward the travel direction, bring the
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing
body side and set the reading at zero.
90110
(1ft)
30cm
Fig. 33
Measuring position
1.5m (5ft)
Fig. 34
Measuring position
Axial play of
swing bearing
Measuring
position
Table 16
Unit : mm (in)
0.81.8
2.33.3
(0.030.07) (0.090.13)
3.6
(0.14)
10mm
(0.4in)
14
Standard
value
Repairable level
Service limit
60 (2.36)
120 (4.72)
180 (7.09)
9. MECHATRO CONTROLLERAADJUSTMENT
9.1 ENGINE CONTROL INPUT/OUTPUT
C-1 MECHATRO CONTROLLER
ENGINE
GOVERNOR
MOTOR
GAUGE CLUSTER
PUMP
ACCEL DIAL
STARTER SWITCH
Fig. 36
9.2 ENGINE CONTROL INSTALLATION
E/G EMERGENCY
STOP KNOB
(1.77_)
DETAIL OF
E/G STOP KNOB
Fig. 37(1/2)
15
Tightening torque
4.0kgfym (29 lbfyft)
ADJUST BOLT
Apply Locktite #262 or equivalent.
Fasten it with the mounting plate
for the engine lifting hook
Tightening torque
2.0kgfym (14 lbfyft)
Apply Locktite
#242 or equivalent.
Tightening torque
1.1kgfym (8.0 lbfyft)
Apply Locktite #262 or equivalent.
GOVERNOR
MOTOR
Tightening torque
0.1kgfym (0.74 lbfyft)
Tightening torque
6.6kgfym (48 lbfyft)
Apply Locktite
#262 or equivalent.
E/G EMERGENCY
STOP CABLE
NORMAL USE
VIEW
Fig. 37 (2/2)
16
MOTOR SECTION
OUTPUT SHAFT
CAM
LIMIT
SWITCH
Fig. 38
(2) Speed sensor
1) Installing place
Engine flywheel housing
M161.5
Opposing flat 19
Opposing flat 17
Fig. 39
SIGNAL(Yellow)
GND(Black)
WORK MODE
SELECT SW
BUZZER STOP
SWITCH
Fig. 40
17
9.4 A
AADJUTMENT OF MECHATRO CONTROL
(1) When adjustment of mechatro control is
required;
Case
GROMMET
Aadjustment
C1 MECHATRO CONTROLLER
Fig. 41
Preparation
Warm up engine.
Turn A/C switch OFF.
Turn starter switch OFF to stop engine.
Pull up the safety lock lever and pull up the
left control box upwards.
5) Pull operator seat forward fully and incline
MULTI DISPLAY
seat back forward.
6) Remove resin cover on the rear side, then
mechatro controller appears. (Remove
5
SCREEN
CHANGE SWITCH
atta-ching bolts from resin cover with driver
,).
Note : Check to be sure that the engine
emergency stop lever knob is fully
pressed down. If mechatro controller is
adjusted in the condition where the knob
is pulled out, the engine speed can not be
Fig. 42
set properly.
Table 18 (1/2)
(3) Adjustment
Procedure
Multi display
Movement of governor motor
(2)
1)
2)
3)
4)
STOP
RUN
FULL
to
TEST .
LEVER
RUN
In normal
position
TEST
During
adjustment
LEVER
GOVERNOR
MOTOR
18
Table 18 (2/2)
Procedure
Keep the buzzer stop switch pressed and
when it is let free after 5 to 10 seconds,
STEP 1 is displayed on the multi display.
Then let your hand free and wait till the
display changes to STEP 2.
Multi display
Lo
A Hi
Hi
MONITOR
SYSTEM OK
19
(Approx.
5 seconds)
A Hi
GAUGE CLUSTER
Fig. 43
20
SECTION 21
TABLE OF CONTENTS
1. SUMMARY OF MECHATRO CONTROL SYSTEM
1.1 Mechatro Control System in General ................................................................................... 1
1.2 Boom Raise Conflux ........................................................................................................... 2
1.3 Swing Cut Valve Control ...................................................................................................... 2
1.4 Arm in Recirculation & Sequence Conflux .......................................................................... 3
1.5 Arm in Anti-cavitation Control .............................................................................................. 4
1.6 Arm Out Conflux ................................................................................................................. 4
1.7 Travel Straight ...................................................................................................................... 5
1.8 Swing Priority Control ......................................................................................................... 6
1.9 Pressure Draining (Releasing) Control ............................................................................... 7
1.10 Pump Control .................................................................................................................... 8
1.11 Standby flow Constant Control .......................................................................................... 9
1.12 FC Mode Control ............................................................................................................. 10
2. MECHATRO CONTROLLER
14403 60413255
11
11
13
14
14
15
1.
System summary
: GOVERNOR MOTOR
: ENGINE SPEED SENSOR
: HIGH PRESSURE SENSOR
Furtures
Purpose
P1, P2 pump is
1
controlled by
proportional valve.
2
P1 pump is controlled by
proportional valve.
P2 pump is controlled by
proportional valve.
you desire.
1.7
TRAVEL STRAIGHT
TRAVEL STRAIGHT
1) Start ATTs work operations (boom, arm, bucket, swing) in travel operation (right and left), and the pilot
pressure switches respective spools, and is input into respective low pressure sensors.
Note: Boom raise operation is explained here.
2) If mechatro controller receives the input satisfying the following combination shown in Table, the
controller determines it as travel straight, and the travel straight signal turns on.
3) After the travel straight signal has turned on, the signal is input to respective proportional valve
corresponding to the following commands.
Travel straight proportional valve command
Outputs switching command corresponding to boom raise pilot pressure
(Selection of the higher ATT pilot pressure in operation)
P1 bypass cut valve command
The P1 bypass cut valve does not operate if the boom raise operation is performed. During the arm and
swing operation, the higher of the remote control pressures is selected to put out a select pressure.
P2 bypass cut valve command
Outputs switching command corresponding to boom raise pilot pressure (Selection of the higher ATT pilot
pressures from C/V on P1 side during operation) and the pressure selected by travel right pilot pressure
as high priority.
Boom
Bucket
Arm
Swing
10
2. MECHATRO CONTROLLER
2.1 SUMMARY OF MECHATRO CONTROLLER
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. However, the mechatro display
and the cumulative engine oil lubrication time may be changed over if the screen change switch is pressed.
RIGHT HAND
OPERATOR
CONTROL LEVER
CIGARETTE LIGHTER
PLUG
(Opt.switch)
The functions displayed on the multidisplay are classified roughly into the following 7 types.
_ ..1. CPU error display ...............................................Display the error of the mechatro controller, etc.
_ 2. Self-diagnosis display ........................................Displays the failure of the I/O system of the mechatro controller such as
the low and high pressure sensors, governor motor, proportional valve,
solenoid valve, etc. (29 items)
3. Service diagnosis display ...................................Displays the information output by the mechatro controller such as the
pressure sensor detection, proportional valve, solenoid valve, etc.
(23 items)
4. Trouble history display .......................................Stores and displays the contents of the troubles detected through the
mechatro self diagnosis.
5. Mechatro A adjustment display ..........................Displays it by procedure during the mechatro A adjustment.
6. E/G oil supply cumulative (integrated) time ......Displays the E/G oil supply cumulative time and E/G speed (rpm) list.
7. Warning displays ................................................When the machine is normal after self-diagnosis (_) but the actual
operation fails, the occurence of any of the following items is indicated
every time.
KCMA
KCME
KCMA
KCME
KCMA
KCME
ACCEL DIAL
STARTER SWITCH
FUSE BOX
GAUGE CLUSTER
MECHATRO
CONTROLLER
INPUT
SERIAL COMMUNICATION
Pressure sensor
SCREEN SELECT
SWITCH
Proportional valve
Selector valve (SOL)
Governor motor
Gauge cluster
Control
(Buzzer alarm)
Battery relay
11
Indication item
No.
Contents
Mechatro controller
fail
ROM data
Boom raising
pressure sensor fail
Boom lowering
pressure sensor fail
Display of monitor
Connector
No.
-Pin No.
CN1425
Wire No.
600
Wire color
CN113
CN112
CN111
CN114
CN115
CN116
CN119
CN118
CN117
CN1110
CN1111
CN1112
CN1115
CN1114
CN1113
CN1116
CN1117
CN1118
CN1121
CN1120
CN1119
CN1127
CN1126
CN1125
CN1128
CN1129
CN1130
CN123
CN122
CN121
CN124
CN125
CN126
902
502
952
903
503
953
904
504
954
905
505
955
900
500
950
901
501
951
906
506
956
908
508
958
909
509
959
941
514
964
915
515
965
WV
LgY
BR
OB
LO
BrW
OL
PW
BrY
OW
PL
Gr
RB
LgR
BrR
RL
LgW
BL
YB
V
GrL
YL
VY
BY
YR
Sb
BG
YL
VY
BrB
YR
Sb
BrL
P1 bypass cut
16 propo-valve fail
CN154
CN155
755
756
BP
PW
P2 bypass cut
17 propo-valve fail
CN156
CN157
751
752
BO
GrR
18 Travel priority
propo-valve fail
CN158
CN159
753
754
BG
GrB
Arm in
pressure sensor fail
Arm out
pressure sensor fail
Bucket digging
pressure sensor fail
Bucket dump
pressure sensor fail
10 Swing
pressure sensor fail
12
Travel right
pressure sensor fail
13
Travel left
pressure sensor fail
14
Pump P1
pressure sensor fail
15
Pump P2
pressure sensor fail
12
Wire color
CN1510
CN1511
757
758
BrG
YV
Pump P1
20 pressure sensor fail
CN1517
CN1518
760
759
VR
BrG
Pump P2
pressure sensor fail
CN1519
CN1520
764
763
VW
GY
Travel two-speed
22 solenoid valve fail
CN1521
702
LgB
Swing parking
solenoid valve fail
CN1522
700
VR
CN1523
703
Governor motor
25 current fail
CN151
CN152
CN1515
CN1516
851
852
853
854
G
B
R
W
CN1134
560
CN1133
CN1132
CN1131
930
530
970
WR
P
BW
28 controller communication
CN1426
CN1427
601
602
W
B
CN1524
805
WG
21
23
Governor motor
26 starting point indexing
fail
27 Accel potentio meter
fail
Gauge clusterMechatro
failure
Display of monitor
Connector
No.
-Pin No.
Wire No.
19
Contents
No.
11
12
GAUGE CLUSTER
DISPLAY
No.11
PRESS. SENSOR
B5 BUCKET DIG
3.5V 37k
B6 BUCKET DUNP
3.5V 37k
No.12
PRESS. SENSOR
B7 SWING (R)
3.5V
38k
B8 SWING (L)
3.5V
38k
REMARKS
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
No.
22
23
DISPLAY
No.22
PROPO-VALVE
D3 S-TRAVEL
COMP. 600mA
MEAS. 600mA
REMARKS
45k
45k
No.23
PROPO-VALVE
D6 A-RECIRCULAT
COMP. 600mA 45k
MEAS. 600mA 45k
Command current /
Pressure converted value
Feedback current /
Pressure converted value
Command current /
Pressure converted value
Feedback current /
Pressure converted value
No.1
MAIN CONTROLLER
PROGRAM VERSION
VER
5.10
No.
DISPLAY
REMARKS
No.
No.1
No.6
SOL. VALVE
F3 1/2-TRAVEL
COMP.
OFF
MEAS.
OFF
SWITCH
OFF
No.7
SOLENOID VALVE
F1 POWER UP
COMP.
OFF
MEAS.
OFF
KEY SWITCH OFF
Service
diagnosis
display
MAIN
CONT
PROGRAM VER
1 VER 5.10
No.2
E/G SET
MEAS
E/G PRS.
KPSS SW
No.3
H1
ACCEL
VOLT.
POS.
MOTOR STEP
POS.
P/No. indication
Version indication
2420
2420
LIVE
H
4.2V
100%
440
100%
No.4
GOVERNOR MOTOR
G1 COIL A
1.0A
G1 COIL B
1.0A
G2 LIMIT
OFF
No.5
SOL. VALVE
F2 SWING-BRAKE
COMP.
OFF
MEAS.
OFF
RELEASE SW
OFF
Potentio voltage
Voltage position
No of motor steps
Step position
A phase current
B phase current
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
DISPLAY
14
REMARKS
15
ON/OFF indication
ON/OFF indication
ON/OFF indication
20
ON/OFF indication
ON/OFF indication
ON/OFF indication
21
No.8
RELAY
I2 BAT. RELAY
COMP.
OFF
MEAS.
OFF
KEY SWITCH OFF
ON/OFF indication
ON/OFF indication
ON/OFF indication
No.9
PRESS. SENSOR
B1 BOOM RAISE
3.5V
35k
B2 BOOM LOWER
3.5V
35k
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
No.10
PRESS. SENSOR
B3 ARM OUT
3.5V 36k
B4 ARM IN
3.5V 36k
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
10
13
No.13
PRESS. SENSOR
B9 TRAVEL (R)
3.5V
39k
B10 TRAVEL (L)
3.5V
39k
No.14
PRESS. SENSOR
C1 PUMP P1
3.5V
350k
C2 PUMP P2
3.5V
350k
No.15
PRESS. SENSOR
B16 P1 OPT.
3.5V
36k
B17 P2 OPT.
3.5V
36k
No.20
PROPO-VALVE
D1 P1 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
No.21
PROPO-VALVE
D2 P2 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
Sensor voltage /
Pressure converted value
Command current /
Pressure converted value
Feedback current /
Pressure converted value
24
25
39
40
No.24
PROPO-VALVE
E1 P1 PUMP
COMP.
600mA 45k
MEAS.
600mA 45k
POWER SHIFT 100mA
Command current /
Pressure converted value
Feedback current /
Pressure converted value
No.25
PROPO-VALVE
E2 P2 PUMP
COMP.
600mA 45k
MEAS.
600mA 45k
POWER SHIFT 100mA
Command current /
Pressure converted value
Feedback current /
Pressure converted value
No.39
MECHATRO ADJT.
CONT. SW
TEST
CONT. VOL
100%
PROG. SW
OFF
RUN/TEST indication
Inner trimmer
ON/OFF indication
No.40
RELEASE SW
KPSS
SWING BRAKE
ON/OFF indication
ON/OFF indication
TEST
OFF
Command current /
Pressure converted value
Feedback current /
Pressure converted value
Note:
Service diagnosis and trouble history can be displyed with the screen select switch and the buzzer stop
switch. Note that the displays do not come out in some cases if the switches are pressed too quickly.
(This is not a fault.) Give one second or more before pressing next switch.
13
DISPLAY
No errors
O
Normal
past
Note :
All the stored items are erased.
It is impossible to erase data partially.
Controller relation
A1
A2
Low pressure
sensor
B1
B2
B3
B4
B5
B6
B7
B9
B10
BOOM RAISING
BOOM LOWERING
ARM OUT
ARM IN
BUCKET DIGGING
BUCKET DUMP
SWING RIGHT
TRAVEL RIGHT
TRAVEL LEFT
C1
C2
PUMP P1
PUMP P1
High pressure
sensor
(Hydraulic pump)
Symbol
G
H
I
14
Display
D1 P1 BYPASS CUT
Proportional valve D2 P2 BYPASS CUT
D3 TRAVEL PRIORITY
(Control valve)
D6 ARM VARIABLE
RECIRCULATION
Portional valve
E1
(Hydraulic pump) E2
F1
Solenoid valve
F2
F3
G1
Operating procedure
Display on multidisplay
(Normal)
None
1515 RPM
Supplementary explanation :
00025H
Symbol
Buzzer sound
display
NO ERROR
Operating procedure
STEP MOTOR
CURRENT-NG
STEP MOTOR S/PT.
ERROR
Potentio relation
I1 RECEIVE ERROR
I2 BAT. RELAY
MONITOR SYSTEM OK
is displayed.
E/G speed is displayed
MONITOR
SYSTEM OK
Press once more, and the engine oil supply E/G speed is displayed
2250RPM
cumulative time screen is displayed.
POWER UP
SWING PARKING
TRAVEL 1,2-SPEED
G2
MONITOR
SYSTEM OK
Press once
2250RPM
100Hr AFT
E/G OIL CH
E/G Accessory
100Hr AFT
E/G OIL CH
MONITOR
SYSTEM OK
100Hr AFT
E/G OIL CH
Cumulative time
increases
101Hr AFT
E/G OIL CH
100Hr AFT
E/G OIL CH
The cumulative
time decreases
99Hr AFT
E/G OIL CH
99Hr AFT
E/G OIL CH
Complete the
correction
100Hr AFT
E/G OIL CH
(Normal)
MONITOR
SYSTEM OK
2 1
10
16
2 1 4 2 1 8
Connector No.
2 1
26
34
27
GROMMET
FOR
ADJUST
22 18
CN12
CN11
13
2 1 8
16 12
CN13
2 1 11
28
CN14
22
2 1
ROM REWRITE COUPLER
Pin
No.
Port
name
B8
CN15
16 9
CN16
22
CN17
12
ADJUSTMENT SWITCH
CN14
Connector No.
2) List of connectors
Connector No.
Pin
No.
Port
name
A1
+5V
+5V
A2
D8
D8
B11
IN
GND / OPEN
D9
B12
IN
GND / OPEN
D9
B13
B14
IN
GND / OPEN
B15
IN
670_/1140_
In/out
put
IN
IN
Signal level
0.5_4.5V
0.5_4.5V
18
19
20
A7
21
+5V
22
+5V
23
A8
24
25
26
A9
27
+5V
28
+5V
29
A10
30
31
32
A11
33
+5V
34
B1
IN
+5V
24
10
+5V
25
11
A15
26
12
27
13
A16
14
A17
15
B2
18
0.5_4.5V
IN
IN
0.5_4.5V
0.5_4.5V
CN13
Accel potentio
Accel motor starting point indexing LS
starting Point/Reguler
IN
IN
IN
0.5_4.5V
0_5.0V
GND / OPEN
Alternator voltage
IN
0_36V
IN
GND / OPEN
+24V / OPEN
IN
+24V / OPEN
B4
IN
GND / OPEN
B5
Swing parking
Release/Normal
B6
20
E1
21
E1
release
switch
IN
23
0.5_4.5V
IN
19
22
Swing pressure sensor
C8
IN
28
A18
+5V
D1
D1
D2
D2
3.0_20Vp-p
D3
12
CN15
D3
D4
D4
+24V
15
F2
16
F2
17
D5
A20
18
D5
+5V
19
D6
+5V
20
D6
9
10
11
A21
12
13
14
A22
15
+5V
16
B7
IN
IN
0.5_4.5V
GND / OPEN
OUT
0_800mA
OUT
0_800mA
OUT
0_800mA
OUT
0_800mA
OUT
OUT
OUT
0_800mA
0_800mA
0_800mA
0_800mA
CN18
D10
D10
D11
10
D11
11
D12
12
D12
Specification
In/out
put
Signal level
13
H1
14
H1
15
B26
16
C22
C15
OUT
GND / OPEN
C16
OUT
GND / OPEN
C17
OUT
GND / OPEN
C18
OUT
GND / OPEN
C19
C20
OUT
GND / OPEN
C21
OUT
GND / OPEN
B20
IN
GND / OPEN
B21
OUT
GND / OPEN
10
B22
IN
GND / OPEN
11
B23
12
B24
OUT
GND / OPEN
13
B25
IN
GND / OPEN
14
TXD2
15
RXD2
16
17
SHG
18
+5V
19
A23
20
A24
21
A25
22
DL
TXD3
RXD3
IN/OUT
Handy checker
IN/OUT
IN/OUT
C11
22
C12
23
C13
24
C14
25
26
21
OUT
OUT
A19
0.5_4.5V
OUT
14
+5V
IN
+24V
13
CN17
_12V / 12V_
0.5_4.5V
IN/OUT
IN
IN
GND / OPEN
10
IN
GND / OPEN
IN/OUT
F1
11
Opt. 1 Pressure sensor
TXD1
IN
OUT
GND / OPEN
F1
OUT
+24V / OPEN
C10
+24V / OPEN
C9
1
3
17_/ OPEN
C6
C7
A14
C5
20
17
0.5_4.5V
22
A6
IN
13
17
17
B3
+5V
OUT
16
+5V
OUT
16
C3
21
12
15
C2
14
C4
CN16
IN
OUT
13
A13
A4
0.5_4.5V
11
IN
C1
B19
+5V
A5
B18
12
19
10
11
+5V
+5V
0.5_4.5V
24V / OPEN
IN
IN
+5V
A3
B17
18
0.5_4.5V
GND / OPEN
+5V
G
IN
IN
G
Arm in pressure senor
A12
CN12
B16
14
CN11
Specification
D7
15
0.5_4.5V
D7
GND / OPEN
16
IN
IN
G
P1 pump pressure sensor
Port
name
Signal level
GND / OPEN
Pin
No.
B10
Port
name
Specification
IN
Connector No.
GND / OPEN
Pin
No.
In/out
put
Signal level
IN
B9
10
14
In/out
put
26
Specification
OUT
0_800mA
OUT
0_800mA
OUT
0_800mA
OUT
0_800mA
OUT
+24V / OPEN
OUT
+24V / OPEN
OUT
+24V / OPEN
OUT
+24V / OPEN
15
Power supply (GND)
Gauge and
Display lamp
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
Screen select
switch etc.
No.
VIEW
Item name
No.
Item name
Fuel sensor
GND
Sourse (+24V)
GND
(None)
CONNECTION DIAGRAM
RED
BROWN
(A)
MOTOR CONNECTOR
LIMIT SWITCH CONNETOR
(B)
YELLOW
ORANGE
(A)
(B)
MOTOR CONNECTOR WIRE TABLE
3) Function
It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
It puts out coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
Screen Select SW: Scroll forward (See Page 11.), and displays of the E/G revolution and the cumulative
hours after changing engine oil (See Page 14.).
Other functions
MODE SW. : The display changes S, H, FC, S, in that order each time the switch is pressed.
After the key is turned OFF, the display begins with S.
Adjusting the engine :
Perform mechatronic adjustment in a conventional way, using the Buzzer
Stop SW.
(See the Maintenance)
Service diagnosis :
This is displayed if the key is turned ON with the Buzzer Stop SW pressed.
This is the same as before.
Trouble history :
Turn ON the key and press the Buzzer Stop SW five times
continuously in ten seconds. (See Page 14.)
Pressure release control : Press both the Screen Select SW and the Buzzer Stop SW. at the same
time and hold it for more than five seconds.
16
Brown
White
COM
Orange
Red
NO
Yellow
NC
Red
Yellow
SECTION 22
HYDRAULIC SYSTEM
TABLE OF CONTENTS
1. SUMMARY ................................................................................................................. 1
2. HYDRAULIC CIRCUITS AND COMPONENT ............................................................ 2
2.1 STD Model .......................................................................................................................... 3
2.2 Boom & Arm Safety ............................................................................................................. 4
2.3 EXTRA ................................................................................................................................ 5
14403 60413255
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability,
safety, mass volume handling and low fuel consumption.
Table. 1
" '
,
4
4
!
"
!
"
#
$
& #
%
!
"
%
#
& #
(
# #' !
(
& #
#
#
"
!
)#
#
,
#
"
#
%
'
#
* +
"
-
#
!
3
#
%
$
!
*
/
$
#
#
!
"
*
#
#
No.
Maker's code
K5V80DTP100R
KMX13YC/B33046
M2X120BCHB10A
M4V 150/100RG3.5B
115801200
115801200
ARM CYL.
125901290
BUCKET CYL.
105751055
SWIVEL JOINT
10
PV48K1008
11
0729100000
12
INLINE FILTER
YTD9257
13
SUCTION STRAINER
SB281JOA0004A
14
SOLENOID VALVE
8KWE5G30/G24WR808
15
BY-PASS VALVE
Y1506
16
SPRING
Y500600
17
RETURN FILTER
Y487000
18
AIR BREATHER
AB0210GA001A
19
E2005A001A
20
VA1000SA001A
21
0757900000
22
0758000000
23
16092-00000
24
SHUTTLE VALVE
25
26
27
KADV22Y / S10102
PSV1
A1 a1
MB
SE-23
P
SE-22
P
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
B1
a5
PUMP ASSY
MA
Pcr
5200
5400psi
TRAVEL LEFT
MA
BDE
HCA
PG
Pi1 PA
26
Dr3
725psi B3
BUCKET DIS.
BUCKET DIG.
18
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
TRAVEL
1/2SPEED
3 CHANGEOVER
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
SWING
1 P/B
PT
PA1
PA2 PB2
10
10
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
CAr
5470psi
CRa
Ab RAI.
11
7
5470psi
OUT Ba
X1
6
P
SE-10
ARM(O125/O90/1290)
ARM
CONFLUENCE
14
PB3
SE-7
PLc2 P
PCb
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
SE-5
P
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
Pi2
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
ARM VARIABLE
RECIRCULATION
PCa
(P4)
PBo2
27
LCo2
5480psi
PAo2
5480psi
Bo2
Ao2
Po
6
5
BOOM(O115/O80/1200)
8
BUCKET(O105/O75/1055)
MODEL NO.
KHCV20PO
KHCV20PO
KHCV20PO
REMARKS
E200SR(LC)
PUMP
P2
P1
HYD. TANK
BOOM(LH)
A B1
DR
51
5760psi
PL
C B
PL
C B
SE-7
PLc2 P
PBb DOWN
Drc
PAb UP
Bb DOWN
PLc1
P
SE-4
Drd
OUT PBa
Pisc
LCa ARM
ARM IN
IN PAa
BOOM
IN Aa
CAr
DR
CRa
5470psi
A B1
ARM
OUT Ba
BOOM(RH)
Ab UP
A B1
DR
52
5760psi
PL
5760psi
C B
50
Extra Spec.
2.3 EXTRA
NO.
50
51
52
53
54
50
NAME
HYD.PUMP ASSY
PILOT VALVE
CONTROL VALVE
HYD. VALVE ASSY
SOLENOID VALVE
MODEL NO.
SGPIA-27
16030-00000
KVS-65-1
X0220463R0
16084-00000
B4
A4
PUMP
REMARKS
E200SR(LC)
P2
P1
HYD. TANK
EXTRA
VALVE
52
TO EXTRA HYD.
A1 B1
3300psi
(R.H)
PA1
PB1
3000psi
51
T
OPT.
PILOT VALVE
GAUGE PORT
T
P
53
A
54
C1
C2
P SE11
SOL/V BLOCK
LEVER
4 LOCK
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
10
Operation:
Even if the engine revolution of the accel potentiometer is set in Lo rpm, the pump delivers a discharge rate equal to the intermediate revolution
between the above decel and the FC mode. For
this reason, the actuator operates faster than the
moving of the operating lever when load is light.
(4) BUCKET DIGGING MAIN CIRCUIT
Operation:
With pilot operation, the pressure oil switches
bucket spool, and is fed into bucket cylinder H
side through C/V (2) BC port. And the return oil
from cylinder R side flows into tank circuit while
being restricted by bucket spool through C/V (2)
AC port.
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
TRAVEL
1/2SPEED
3 CHANGEOVER
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
(P3)
ARM VARIABLE
RECIRCULATION
PCa
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
8
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
11
12
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
6
5
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
13
14
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
6
5
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
15
16
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
MA
BDE
HCA
4060psi
A
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
Pcr
5200
5400psi
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
17
18
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
4980psi
PL1
PTb
CMR2
CT2
LCs
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
TRAVEL
1/2SPEED
3 CHANGEOVER
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
SE-2 P
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
(P3)
ARM VARIABLE
RECIRCULATION
PCa
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
8
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
19
20
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
P
ARM
& SWING
21
PA1
PA2 PB2
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
10
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
X1
11
4
OUT Ba
ARM(
125/
90/1290)
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
6
5
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
BOOM(
115/
80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
10
SE-7
PLc2 P
PCb
14
PB3
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
Pi2
BUCKET(
105/
75/1055)
SWING
1 P/B
PT
21
22
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
6
5
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
23
24
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
4980psi
PL1
PTb
CMR2
CT2
LCs
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
TRAVEL
1/2SPEED
3 CHANGEOVER
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
SE-2 P
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
(P3)
ARM VARIABLE
RECIRCULATION
PCa
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
8
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
25
26
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
6
5
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
27
28
PH1
PSV1
SE-23
P
SE-22
P
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200
5400psi
TRAVEL LEFT
P
MA
BDE
HCA
Pi2
Pi1
PG
PA
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
15,16,17
71psi
2
13
36psi
20
P2
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-5
P
25
PB3
8
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PB3
PA1
PA2 PB2
10
P
ARM
& SWING
21
P
BOOM
& BUCKET
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
4
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
4060psi
A
6
P
SE-10
P
SE-9
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
29
4. PILOT PIPING
No.
(1)
NAME
QTY
REMARKS
Pump delivery
No.
NAME
QTY
40
REMARKS
No.
NAME
QTY
REMARKS
No.
NAME
QTY
REMARKS
CONNECTOR
PF1/4-PF3/8
20
CONNECTOR
PF3/8
21
CONNECTOR
PF1/4 L=23
22
Drain
CONNECTOR
PF1/4-PF3/8 L=23
23
Drain
CONNECTOR
PF3/8 L=46
24
INLINE FILTER
41
TEE
CONNECTOR
PF3/8
42
SHUTTLE VALVE
TEE
PF1/4
43
CAPSCREW
ELBOW
PF3/8
44
WASHER
ELBOW
PF3/4
45
CONNECTOR
CHECK VALVE
25
ELBOW
PF1/4
46
HOSE
PF3/8 L=760
26
ELBOW
PF1/4
CONNECTOR
PF1/4 L=23
47
CONNECTOR
27
TUBE
L=650
ELBOW
48
10
CONNECTOR
28
TEE
PF3/8
TEE
PF3/8
49
11
ELBOW
PF1/4
29
TEE
PF3/8
10
P2 S/V primary
50
12
ELBOW
PF1/4-PF3/8
31
HOSE GUARD
L=500
11
51
HOSE GUARD
13
ELBOW
PF3/8
32
HOSE GUARD
L=600
12
P1 S/V primary
52
CLIP
14
ELBOW
PF3/8
33
HOSE GUARD
L=550
13
53
ELBOW
PF1/4
15
TEE
PF1/4
34
ELBOW
PF3/8
14
CONNECTOR
PF1/4-PF3/8 L=23
54
TUBE
L=500
16
TEE
10
PF3/8
35
HOSE GUARD
L=650
15
CAPSCREW
M10x20
17
TEE
PF1/4
36
CONNECTOR
PF1/4 L=38
16
WASHER
18
TEE
2-PF1/4-PF3/8
37
HOSE GUARD
L=450
17
CONNECTOR
38
TEE
PF1/4
18
PLUG
19
PF1/4
M8x50
PF1/4-PF3/8
L=600
(3)
Pilot primary
19
PF1/4
Pilot primary
20
39
ELBOW
PF1/4
CONNECTOR
PF1/4-PF3/8
Drain
21
40
CONNECTOR
20
ELBOW
PF3/8
Drain
22
Drain
41
CHECK VALVE
21
Drain
Drain
23
Drain
42
CONNECTOR
PF3/8-PF1/4
22
HOSE GUARD
L=250
24
43
23
HOSE GUARD
L=400
25
44
VALVE ASSY
PF3/8
24
HOSE GUARD
L=1900
Boom up secondary
26
ELBOW
PF1/4
45
CONNECTOR
PF3/8
28
PLUG
PF1/4 L=23
27
TUBE
L=650
46
CONEECTOR
PF1/4 L=60
29
TEE
PF3/4-PF1/4
10
29
PLUG
PF3/8
30
CONNECTOR
11
Arm in secondary
30
HOSE GUARD
L=500
(7)
31
CONNECTOR
PF1/4
12
31
HOSE GUARD
L=600
PILOT VALVE
13
32
HOSE GUARD
L=550
14
HOSE
33
ELBOW
PF3/8
CONNECTOR
15
PILOT VALVE
35
HOSE GUARD
L=650
WASHER
(2)
PF3/8
CONNECTOR
PF1/4
16
WASHER
36
CONNECTOR
PF1/4 L=38
CONNECTOR
CONNECTOR
PF3/8
17
CONNECTOR
11
PF3/8
37
HOSE GUARD
L=450
ELBOW
PF3/8
ELBOW
PF1/4
18
CONNECTOR
38
TEE
PF1/4
Pilot primary
ELBOW
19
BOOT
40
CONNECTOR
Drain
GUIDE
20
CLIP
41
CHECK VALVE
1.Travel RH R. 3.Travel LH R.
CLIP
21
CAPSCREW
42
CONNECTOR
PF3/8-PF1/4
10
CAPSCREW
M10x30
CAPSCREW
M10x20
22
GROMMET
43
11
1.Travel RH F. 3.Travel LH F.
CAPSCREW
M10x75
44
VALVE ASSY
PF3/8
10
WASHER
(4)
45
CONNECTOR
PF3/8
(8)
11
WASHER
46
CONEECTOR
PF1/4 L=60
Arm in command
12
Travel straight
47
ELBOW
PF1/4
13
BRACKET
14
BRACKET
15
LC52S00011P1
CONNECTOR
PF1/4
16
RUBBER
L=370
CONNECTOR
PF1/4-PF3/8
17
GROMMET
CONNECTOR
PF3/8
CONNECTOR
PF3/8
18
RUBBER
L=370
CONNECTOR
PF1/4 L=23
HOSE GUARD
19
PLUG
PF1/4
CONNECTOR
PF1/4-PF3/8 L=23
CLIP
16
20
Drain
10
ELBOW
15
PF3/8
CONNECTOR
PF3/8 L=46
21
HOSE GUARD
L=1900
11
BLOCK
CHECK VALVE
22
BRACKET
12
ELBOW
PF3/8
HOSE
PF3/8 L=760
BLOCK
23
CAPSCREW
M10x25
13
CAPSCREW
M8x20
CONNECTOR
CONNECTOR
PF1/4 L=23
24
ELBOW
PF3/8
14
WASHER
10
CONNECTOR
CONNECTOR
PF3/8 L=23
25
GROMMET
15
CAPSCREW
11
ELBOW
PF1/4
ELBOW
PF1/4
26
CLIP
10
16
12
ELBOW
PF1/4-PF3/8
ELBOW
PF3/8
31
HOSE GUARD
L=450
17
13
ELBOW
PF3/8
ELBOW
PF1/4
32
ELBOW
PF1/4-PF3/8
18
14
ELBOW
PF3/8
ELBOW
PF3/8
33
CONNECTOR
PF1/4 L=38
19
CUSHION RUBBER
L=325
15
TEE
PF1/4
PLUG
PF1/4
34
20
CHECK VALVE
16
TEE
13
PF3/8
CAPSCREW
M8 x 40
36
CONNECTOR
PF3/8-PF1/4
17
TEE
PF1/4
10
WASHER
37
TEE
PF1/4
(5)
18
TEE
2-PF1/4-PF3/8
14
PLUG
38
CONNECTOR
PF1/4
19
30
(6)
M8x55
PF1/4
(9)
PF3/8
31
32
33
(4) Block
34
Control valve
35
36
37
38
39
5. MAIN PIPING
No.
40
NAME
QTY
(1)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Pump delivery
TUBE
TUBE
HOSE
(2)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
GROMMET
CLIP
CAPSCREW
CONNECTOR
CAPSCREW
TUBE
TUBE
1
1
1
1
1
1
1
2
1
2
2
1
1
2
22
2
3
5
1
2
1
1
4
1
3
1
4
12
2
1
1
1
2
2
4
2
2
1
1
1
(3)
1
2
3
4
5
1
4
2
2
8
(4)
1
2
3
4
5
6
Return piping
TUBE
TUBE
TUBE
TUBE
HOSE ; PF1/2 L=940
HOSE ; PF1/2 L=2100
1
1
1
1
1
1
1
1
2
HOSE ; L=1110 1-3/16-12UN 1
HOSE ; L=1040 1-3/16-12UN 1
O RING
1
O RING
2
HALF CLAMP
4
CAPSCREW
8
CAPSCREW
4
U-BOLT
2
WASHER
4
LOCK WASHER
8
LOCK WASHER
4
NUT
8
CLIP
8
PRESSURE SENSOR : PF3/8 2
ELBOW
1
GROMMET
2
CLIP
2
CAPSCREW
HOSE ; 1 3/16-12UN L=1400
HOSE ; 1 3/16-12UN L=1500
CAPSCREW
HOSE ; 1 3/16-12UN L=1600
PLATE
O RING
O RING
O RING
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
HOSE ; 1 3/16-12UN L=1450
ELBOW
CONNECTOR
NUT
CLAMP
CLAMP
WASHER
CAPSCREW
SUPPORT
SUPPORT
GROMMET
HOSE ; 1 3/16-12UN L=1300
REMARKS
Suction
Suction
Suction
P1 Pump delivery
P2 Pump delivery
1A G75
1B P26
3/4
M10x35
M12x30
LC52S00012P1
PF1/2
Boom (H)
Boom (R)
Arm (H)
Arm (R)
Bucket (H)
Bucket (R)
Travel right
M12 x 70
Travel right
Swing motor
M12 x 55
Travel left
1-14UNS
1"3/16-12UN
1"7/16-12UN
1"3/16-12UN - PF3/4
1"3/16-12UN - PF3/4
1"3/16-12UN - PF3/4
1"3/16-12UN - PF3/4
1"7/16-12UN - PF3/4
Travel left
1-3/16-12UN - PF3/4
PF3/4 L=60
M12 x 25
Boom (R)
M12 x 30
PF3/4 L=75
M12 x 75
L = 22.0
L = 26.0
PF1/2
1"3/16-12UN - PF1
1"3/16-12UN - PF1
1"3/16-12UN - PF1
1"3/16-12UN - PF1
PF1/2
PF3/4
No.
NAME
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
62
63
64
65
(5)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
HOSE
HOSE
CLIP
CONNECTOR
CONNECTOR
CLAMP
CLAMP
SPACER
CAPSCREW
WASHER
LOCK WASHER
QTY
REMARKS
PF1
L=1600
42.7
48.6
50.8
245 KPa
500 KPa
1
1
3
2
1
1
1
3
1
2
1
3
2
3
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
3
4
3
12
2
4
12
25
2
4
1
1
1
1
1
1
1
1
1
4
2
42.7 P85
42.7 P85
42.7
50.8
1A G45
PF3/4 - PF1
PF3/4
PF3/4
PF1/2
PF3/4 - PF1
PF1/2-PF1/2-PF3/8
PF1/2-PF1/2-PF3/4
L=22.5
L=1000
L=1000
M10 x 25
M10 x 30
M10 x 55
M10 x 90
M12 x 25
M12 x 30
M12 x 35
M12 x 65
NAME
QTY
REMARKS
(6)
1
2
3
4
5
4
2
2
4
2
PF1- 28
PF1/2- 28
PF1/4
1B P29
1B P18
(7)
1
2
3
4
5
4
2
1
4
1
PF1- 28
PF1/4
PF1/2- 18
1B P29
1B P18
(8)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
1
1
1
1
2
7
2
2
4
6
6
4
1
1
2
1
1
(9)
1
2
HOSE ; L=1200
HOSE ; L=1200
Arm (R)
Bucket (H&R)
M12 x 55
Arm (H)
M12 x 60
Arm (H&R)
Arm (H&R)
L=1100
PF1
L=750
44
(LC)
(STD)
1
1
1
1
1
1
1
1
1
1
1
1
2
2
12
4
2
2
2
4
4
4
4
No.
1
1
1
1
1
1
h=17.5
M8x40
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TUBE
TUBE
TUBE
TUBE
HOSE
HOSE
CLAMP
CAPSCREW
CAPSCREW
CONNECTOR
GREASE NIPPLE
O RING
O RING
O RING
LOCK WASHER
PLUG
1
1
1
1
2
2
2
2
16
1
2
2
2
4
2
1
(11)
1
2
3
4
5
6
7
8
9
10
11
12
13
1
1
1
1
1
2
1
8
1
2
1
4
1
(12)
1
2
3
4
1
1
1
1
M12 x 50
M10 x 30
PF1/4
Arm (R)
Arm (H)
PT1/8
M10 x 35
M12 x 55
1B P26
27.2 x t3.2
27.2 x t3.2
M10 x 55
No.
NAME
5
6
7
8
9
10
11
CAPSCREW
CAPSCREW
O RING
O RING
GREASE NIPPLE
GREASE NIPPLE
LOCK WASHER
(13)
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
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
(14)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TAPPED BLOCK
HOSE ; L=860
HOSE ; L=860
HOSE ; L=1300
CONNECTOR
HOLDING VALVE
HOLDING VALVE
CLAMP
CLAMP
ELBOW
ELBOW
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
O RING
O RING
O RING
O RING
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
LOCK WASHER
LOCK WASHER
LOCK WASHER
GREASE NIPPLE
CLIP
BLOCK
CAPSCREW
PLUG
PLUG
TEE
CONNECTOR
HOLDING VALVE
TUBE
HOSE ; L=860
HOSE ; L=860
HOSE ; L=4000
HOSE ; L=3900
HALF CLAMP
CLAMP
ELBOW
ELBOW
CONNECTOR
CONNECTOR
GREASE NIPPLE
O RING
O RING
CLIP
PLUG
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
QTY
REMARKS
4
4
2
2
1
1
1
M10 x 55
M10 x 35
1B P26
1
1
1
1
1
1
1
1
2
2
2
1
4
1
1
2
2
2
2
1
2
2
2
4
4
4
4
2
2
8
8
2
2
2
16
2
4
2
8
2
1
1
1
21.7
21.7
27.2
27.2
15
15
15
15
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
15
1
1
4
4
1
8
PT1/8
PT1/8
Arm (R)
Arm (H)
Equalizer
28- 22
15- 15
1B P26
1B P14
M10 x 65
M8 x 35
M10 x 65
M10 x 30
PT1/8
48 L=188
M10 x 45
27.2
Arm (R)
Arm (H)
18- 18
15- 15
PF3/4 1"3/16-12UNS
PT1/4-PF1/4
PT1/8
1B P26
1B P18
M12 x 55
M10 x 65
M10 x 35
41
42
43
44
45
46
47
48
49
SECTION 23
ELECTRIC SYSTEM
TABLE OF CONTENTS
1. ELECTRIC CIRCUIT DIAGRAM ................................................................................ 1
2. ELECTRICAL EQUIPMENT LIST .............................................................................. 5
2.1 Specification ........................................................................................................................ 5
3. HARNESS
14403 60413255
OPT
Fig.1 (2/4)
Fig.1 (3/4)
Fig.1 (4/4)
C_6
D_1
D_2
D_3
D_4
D_5
D_6
Diode
Diode
Diode
Diode
Diode
Diode
E_1
E_2
E_3
E_4
E_5
E_6
E_7
E_8
E_9
E_10
E_11
Fuse box
Alternator
Hour meter
Horn (Low)
Horn (High)
Cigarette lighter
Tuner AM&FM
Speaker LH
Speaker RH
Receiver dryer
A/C compressor
E_14
MOTOR
PROPORTIONAL
VALVE
C_4
RELAY
Mechatro controller
Gauge_cluster
NAME
E_16
E_17
Converter (DC24V_12V)
Socket
E_23
E_24
Antenna (OPT.)
GPS Antenna (OPT.)
L_1
L_2
L_3
L_4
L_5
L_6
L_7
L_8
L_9
L_10
L_15
Rotary light
Group
Starter motor
Governor motor
Wiper motor
Washer motor
M_11
PSV_A
PSV_B
PSV_C
PSV_D
PSV_P1
PSV_P2
__1
Battery relay
__3
__4
__5
__6
__7
__8
Glow relay
Safety relay
Wiper motor relay
Washer motor relay
Horn relay
Work light relay
__10
__11
__19
__20
SE_1
SE_2
SE_3
SE_4
SE_5
SE_6
SE_7
SE_8
SE_9
SE_10
SE_11
SE_13
SE_14
SE_15
SE_16
Resistor
SENSOR
CONTROLLER
DIODE
ELECTRIC EQUIPMENTS
LIGHT
C_1
C_2
Code
M_1
M_2
M_3
M_4
M_5
M_8
M_9
SE_20
SE_22
SE_23
Code
SV_1
SV_2
SV_3
SV_4
NAME
Swing parking SOL
ATT boost pressure SOL
Travel 1-2 speed SOL
Safety lock lever SOL
SW_1
Key switch
SW_3
SW_4
SW_5
SW_6
SW_7
SW_8
SW_10
SW_11
SW_13
SW_16
SW_17
SW_20
SW_21
SW_22
SW_23
SW_30
SW_32
SW_34
SW-39
Overload switch
SW-42
SOLENOID
Group
SWITCH
NAME
POWER
2.1 SPECIFICATION
Group
Code
B_1
Battery
3.
HARNESS
EQUIPMENT
NAME
3.3
Controller assy
3.4
3.5
UPPER 3.6
3.8
3.9
UPPER
3.10
FRAME
& BOOM 3.11
25
NAME
Cab harness
Starter cable
Battery cable
Main harness
15
Engine harness
Ground cable
(Floor plate)
Harness
Harness
Harness
Harness
2. Deck
3. Cab
ITEM
FRAME
3.7
HARNESS
Fig.3
CONTROLLER ASSY
ITEM
PART NAME
REMARKS
For swing parking release
SWITCH ASSY
RELAY
13 SWITCH ASSY
16 RESISTOR
22 CONTROLLER
23 TIMER
Not shown
Inst-panel harness
25-6 HARNESS
26 FUSE ASSY
QTY
Fig.4 (1/2)
10
11
PART NAME
REMARKS
QTY
PANEL ASSY
RH
11
SPEAKER
17
GAUGE CLUSTER
24
SWITCH
26
CONVERTER
35
TUNER AM/FM
38
SOCKET
41
SWITCH
42
SWITCH
46
HOUR METER
PART NAME
QTY REMARKS
BATTERY RELAY
HORN
High
HORN
Low
LIGHT ASSY
SEMS BOLT
DETAIL OF HORN
TORQUE :
3
1.09kgfym {7.9 lbfyft}
5Y(YELLOW)
5W(WHITE)
1PAF
(R-3)
GLOW RELAY
WL
2PAF
Fix the
connector with clip.
Connect as shown so
as to avoid short
circuit power source
id
VIEW__
VIEW__
(R-1)
BATTERY RELAY
STARTER
CABLE
TORQUE :
0.45kgfym {3.25 lbfyft}
TORQUE :
1.09kgfym
{7.9 lbfyft}
8
SECTION A_A
UPPER
HARNESS
BATTERY
RELAY CABLE
13
PART NAME
QTY
REMARKS
CABLE
Starter
CABLE
Battery relay
CABLE
Battery
CABLE
Ground
HARNESS
Main harness
CABLE
Frame ground
15 HARNESS
NOTE :
1. Torque for battery terminal is 0.34kgfym {2.46 lbfyft}.
2. Unspecified torque for grounding is 2.4kgfym {17.3 lbfyft}.
14
Fig. 7(1/3)
16
Fig.7 (3/3)
TERMINAL
60-8
CAP
YAZAKI 7034-1283
100
(3.94_)
300 (11.8_)
450
(17.7_)
INSTALL
CORRUGATE TUBE
60sq
WHITE TAPING
INSTALL
CORRUGATE
TUBE
TAPING
100
(3.94_)
150
(5.91_)
50
(1.97_)
1PAF-58Y
[20]
(0.787_)
AVX5sq
TERMINAL
BA710
CAP
YAZAKI 7034-1283
TERMINAL
BC816
AV60B
DOUBLEWOUND TAPING
TERMINAL
60-8
TERMINAL
LA310
Fig. 11
DETAIL OF A PORTION
MANUFUC.
1PAF-58Y
YAZAKI
PART. NUMBER
HOUSING
TERMINAL
HARNESS SEAL
7123-4210-40
7116-3250
7157-3580-60
100 (3.94_)
LA308 5B
5B
1PAM
YAZAKI 7122-3010
Fig. 12
Fig. 8
800 (31.5_)
CAP
YAZAKI 7034-1283
TERMINAL
60-8
AV60B
TERMINAL
BC818
CAP
BTC-135-R(RED)
Fig. 9
LA105
2PAM-MK_
L-8 :
E/G ROOM LIGHT
TO UPPER HARNESS
250 (9.84_)
AV60B
CAP LEFT
CAP RIGHT
TERMINAL LEFT
TERMINAL RIGHT
Fig. 10
Fig. 13
17
18
Fig. 14
Main harness
19
GND
LA310
P-31
1PAM-58Y
CN-351M
M-1 :
STARTER MOTOR
GLOW
CAP : YAZAKI 7034-1279
LA304
P-38
PLUG
CB104
F-32
CA104
M-32
LA305
P-35
CB104
F-31
E-11 :
AIR-CON COMPRESSOR
LA306
P-37
E-2 :
ALTERNATOR
CONNECTOR
NAME
(PIN NUM.)
MANUFUC.
2PAF-SWP
YAZAKI
7123-1424-4
7116-1471
1PAM-58Y
YAZAKI
7222-4210-4
7114-3250
STRAIGHT
TERMINAL
YAZAKI
7120-3011
7116-2270
SUMITOMO
6189-0134
1500-0106
8PAF-HW
PART. NUMBER
HOUSING
TERMINAL
CAP :
YAZAKI 7034-1279
LA306
P-36
R-4 :
SAFETY RELAY
8PAF-HW
CN-318F
WITH TAPING
1PAM-58Y
CN-352M
TO MAIN HARNESS
STRAIGHT
FEMALE
F-33
LA104 SW-6 :
P-34 E/G COOLANT TEMP.SW
SE-14 :
E/G COOLANT TEMP. SENSOR
21
PART NAME
QTY
REMARKS
CABLE
GROUND
HARNESS
UNDER FLOOR
22
Fig. 17
Fig. 18
Fig. 19
Ground cable
23
PART NAME
QTY
REMARKS
HARNESS
HARNESS
INST-PANEL(RH)
HARNESS
INST-PANEL(LH)
24
Fig. 21
25
Fig. 22
26
27
PART NAME
QTY
REMARKS
HARNESS
Boom harness
HARNESS
Fig. 24
28
3.10.1
BOOM HARNESS
Fig. 25
3.10.3
Boom harness
Fig. 26
29
3.11.2
INSTALLING
BOOM LIGHT
ITEM
PART NAME
LIGHT
INSTALLING
DECK LIGHT
QTY REMARKS
2
ITEM
1
1
NUT(LIGHT ACCESSORY)
TORQUE ;
1.75kgfym {12.7 lbfyft}
BRACKET
TORQUE ;
1.90kgfym {13.7 lbfyft}
SECTION
30
AA
Fig. 27
Fig. 28
3.11.3
PART NAME
18 HARNESS
QTY REMARKS
1
Fig. 29
31
32
Fig. 30
PART NAME
FUEL PUMP ASSY
QTY REMARKS
1
Fig. 31
33
SECTION 24
COMPONENTS SYSTEM
TABLE OF CONTENTS
I. HYDRAULIC COMPONENTS
1. Hydraulic Pump_Regulator ..............................................................................................
2. Pilot Valve (ATT) ...............................................................................................................
3. Pilot Valve (Travel) ............................................................................................................
4. Control Valve ....................................................................................................................
5. Swing Motor Unit ..............................................................................................................
6. Travel Motor ......................................................................................................................
7. Swivel Joint ......................................................................................................................
8. Hydraulic Cylinder ............................................................................................................
H1-1
H2-1
H3-1
H4-1
H5-1
H6-1
H7-1
H8-1
14403 60413255
A3
No.
3
B3
Dr1
NAME
REGULATOR ASSY
PSV2 a4
6
a3
6
a4 2
PSV1
A3
a5
Dr3
1
B3
Dr1
A1
A2
B1
PH2
Table 1-1
Code
a2
A2
Hydraulic ports
Ports name
Size
A1,2
Delivery port
3/4
B1
Suction port
2 1/2
Dr1
Drain port
PF1/2
PF1/4
PF3/8
PF1/4
A3
PF3/8
B3
PF3/4
Dr3
PF3/8
Fig. 1-1
Solenoid
proportional
reducing valve
Solenoid
proportional
reducing valve
Regulator
Regulator
Engine
Main pump
(3) Specification
Table 1-2
Item
Max.displacement
capacity
cm3 /rev
Rated revolution
rpm
Working pressure
kgf/cm2(psi)
Max. flow
Max. input horsepower
/min(gal/min)
802
10
51(725)
176(46)2
22(5.8)
PS
Main pump
Control function
Others
350(4980)
H12
51(725)
789
732 212 156 532 214 531,548 534 702 792 724 954 124 901 116 711 312 719 151
152
113
252
953
808
251
886
406
717
261
406
111
123
824
774
127
710
262
401
490
271
211 153
467,728 157
Fig. 1-2
886 314
141
468,728
Table 1-3
No.
QTY
No.
NAME
SHAFT(F)
SHAFT(R)
1st GEAR
ROLLER BEARING
1
1
1
2
SEAL COVER(R)
PUMP CASING
VALVE BLOCK
262
271
312
313
314
4
2
18
18
2
2
18
2
2
2
SWASH PLATE SUPPORT(F)
1
1
SWASH PLATE SUPPORT(R)
SEAL COVER(F)
1
401
406
466
467
468
490
531
532
534
535
548
702
710
111
113
116
123
127
141
151
152
153
156
157
211
212
214
251
252
261
NAME
BEARING SPACER
CYLINDER BLOCK
PISTON
SHOE
RETAINER PLATE
SPHERICAL BUSHING
CYLINDER SPRING
SHOE PLATE
SWASH PLATE
TILTING BUSHING
H13
QTY
No.
1
2
1
1
1
711
717
719
724
NAME
O RING : 1B
O RING : 1B
O RING : 1B
O RING : 1B
725 O RING : 1B
QTY
G95
G120
G115
P8
1
2
2
18
P11
2
4
2
1
2
2
4
2
2
4
2
2
2
361
700
354
A
434
351
435
312
353
311
732
SECTION
AA
309
310
Fig.1-3
Table 1-4
No.
NAME
QTY No.
NAME
QTY
307 POPPET
308 SEAT
310 SPRING
700 RING
710 O RING : 1B
G80
725 O RING : 1B
P11
728 O RING : 1B
P18
355 FILTER
732 O RING : 1B
P16
H14
326
118
125
825
GEAR PUMP
(for pilot)
728 468
117
126
128
435
886
827
115
826
FRONT SIDE
REAR SIDE
Fig.1-4
Table 1-5
No.
NAME
QTY
No.
NAME
QTY
728 O RING : 1B
886 PIN
H15
P24
1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear(116) and distribute the rotating power
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft(111)
that drives the two pumps and, at the same time,
drives the pilot gear pump arranged on a different
axis.
The pump assy consists largely of the rotary
group, the main part of the pump that makes
rotary on; the swash plate group that changes the
delivery rate; the valve block group that selects
between oil suction and delivery ; and the PTO
group that transmits the drive power to the gear
pump.
REGULATOR
116
111
PTO
GEAR
GEAR PUMP CASE
(FOR PILOT)
Fig. 1-5
124
313
312
111
141
211
156
151
153
152
314124
116
157
Fig. 1-6
Rotary group
H16
H17
532
531
214
211
212
251
Fig. 1-7
312
116
111
141 314
885
Fig. 1-8
117
126
118
125
125
Fig. 1-9
PTO group
Table1-7
1.3 REGULATOR
1.3.1 CONSTRUCTION
No.
418
415
601
897
496
755
543
614
545
541
708
756
611
SECTION
325
496
AA
079
079
325
402
407
415
418
466
496
541
543
545
601
611
614
624
627
631
643
646
651
652
656
658
708
724
731
733
755
756
801
887
897
924
NAME
SOLENOID PROPORTIONAL
REDUCING VALVE
VALVE CASING
SOCKET BOLT : M616
SOCKET BOLT : M630
SOCKET BOLT : M845
SOCKET BOLT : M512
VP PLUG : PF1/4
PLUG
SEAT
STOPPER
BALL
CASING
FEED BACK LEVER
FULCRUM PLUG : PF1/4
SPRING SEAT
PLUNGER
SLEEVE
PISTON
SPRING
SLEEVE
SPOOL
COVER
PLUG : NPTF1/16
O RING : 1B G75
O RING : 1B P8
O RING : 1B P25
O RING : 1B P18
O RING : 1B P11
O RING : 1B P12.5
HEX NUT : M8
PIN
PIN
SET SCREW
466
755
924
407
A
724
887
631
731
801
651
733
652
Fig. 1-10
658
H18
Construction of regulator
Q'TY
1
1
4
4
6
2
1
9
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
2
2
2
1
1
1
1
1.3.2 OPERATION
DELIVERY RATE Q
(1) Summary
Regulator KR38-0E01 for the inline axial
piston pump K5V series is of electric flow
control type that regulates the tilting angle
(delivery rate) of the pump as the command
current to the solenoid proportional
reducing valve is varied.
This regulator is of positive flow control type
that increases the delivery flow Q as the
command current I increases.
If an electric current is put in by this control
according to the flow needed for the
operation, the pump delivers at a flow rate
that is only required by the pump,
consequently holding down unwanted power
consumption.
(2) Positive control.
As shown in the figure on the right, the
regulator regulates the delivery rate of the
pump by command current I.
1) Flow increasing action
As the command current I rises, the
secondary pressure of solenoid proportional
reducing valve (079) increases. This causes
spool (652) to move via pilot piston (643) and
stops where the hydraulic pressure pushing
the spool rightwards balances with the action
of pilot spring (646).
If the spool (652) moves, port C opens to the
tank port. This causes the pressure of the
large diameter part of servo piston (532) to go
away. This causes the servo piston (532) to
the left by delivery pressure P1 of the small
diameter part, resulting in an increase in the
tilting angle .
643 652
611
651
COMMAND CURRENT
Fig.1-11
624
627
646 801
924
532
808
808
954
953
TILTING MIN.
TILTING MAX.
Fig. 1-12
Functions of regulator
H19
SOLENOID PROPORTIONAL
REDUCING VALVE
REGULATOR
646
652
MAIN
PUMP
643
651
H110
PORT 532
Fig. 1-13
POINT 611
A
KR380E01
Pump revolution
2200rpm1
Adjust screw(954)1/4turn
Flow rateQ=3.5 /min (0.87gal/min)
Max. flow
Adjust screw(953)1/4turn
Min. flow
DELIVERY RATE Q
COMMAND CURRENT
COMMAND CURRENT
Fig. 1-15
H111
DELIVERY RATE Q
Fig. 1-14
DELIVERY RATE Q
COMMAND CURRENT
Fig. 1-16
1.3.4 CAUSES OF FAULT RESULTING FROM
REGULATOR
(1) Engine is overloaded
Load each of the pumps and check which of the
pumps, front or rear is faulty. In case both are faulty,
check the following
and : If only one of the
pumps is faulty, start with
.
Check that the command current
of the solenoid
proportional reducing valve is normal.
The secondary pressure
Check amplifier
of solenoid proportional
dither.
reducing valve is high.
Replace solenoid
proportional
reducing valve.
Spool (652) and
Sleeve (651) are
stuck.
Disassemble and
clean.
Disassemble and
clean.
H1
12
/min (gal/min)
200
(52.8)
(Travel_ATT)
150
(39.6)
100
(26.4)
Simultaneous loading
83.6kw (113PS)
50
(13.2)
0
0
50
711
100
1422
150
2133
200
2844
250
3555
300
4266
kgf/cm
(psi)
350
4977
Delivery pressure Pd
(2) At S mode
1
200
(52.8)
/min (gal/min)
(Travel_ATT)
150
(39.6)
100
(26.4)
(Travel)
Simultaneous loading
79.8kw (108PS)
50
(13.2)
0
0
0
50
711
100
1422
150
2133
200
2844
250
3555
Delivery pressure Pd
H1-13
300
4266
350
4977
kgf/cm
(psi)
(3) At FC mode
1
/min (gal/min)
200
(52.8)
150
(39.6)
Independent loading
2
(P2=5.1kgf/cm (72.5psi),Qmin)
53.1kw (72.2PS)
(Travel_ATT)
100
(26.4)
Simultaneous loading
53.1kw (72.2PS)
50
(13.2)
Min. flow rate
0
0
0
50
711
100
1422
150
2133
200
2844
Delivery pressure Pd
H1-14
250
3555
300
4266
350
4977
kgf/cm
(psi)
(2)
SINGLE
OPERATION
ANGLE
(PORT 2,4)
SINGLE
OPERATION
ANGLE
(PORT 1,3)
Specification
Table 2-1
Item
Specification
Model
PV48K1008
Operating torque
51kgf/cm2 (725psi)
Rated flow
20
Weight
/min (5.3gal/min)
5-PF3/8
T=50.5 (363.6)
PF1/4
T=30.2 (221.4)
Hydraulic simbol
Fig. 2-1
H21
2.2 CONSTRUCTION,FUNCTION_AND
OPERATION
(1) Cross section view
312
501
302
213
301
151
212
Rotating sliding
part, apply
grease.
Beware of the
assembly
direction
Apply grease
246 to top
218_2
211
214
218_1
216_2
216_1
241_1
241_2
201_1
201_2
011_1
011_2
131
217
122
Secondary
101
pressure
adjusting shim
Designed value 126
t=0.4 (0.016 ),
111
1 pc.
121
PORT 2,4
PORT 1,3
125
Not to
be reused
Tightening torque
kgfym (lbfyft)
2.1 (15)
No.
NAME
QTY
Tightening torque
kgfym (lbfyft)
No.
NAME
QTY
101
CASING
111
PORT PLATE
121
SEAL WASHER
122
O RING
125
126
SPRING PIN
011_1 SPRING
131
BUSHING
011_2 SPRING
151
PLATE
241_1 SPRING
201_1 SPOOL
241_2 SPRING
201_2 SPOOL
211
PLUG
212
PUSH ROD
213
SEAL
214
O RING ; 1B_P20
217
4.8 (35)
7 (51) _
H2 - 2
WASHER 2 (SHIM)
246
SPRING
301
JOINT ;M14
302
CIRCULAR PLATE
312
501
BOOTS
(2) Construction
The pilot valve is constructed as shown in the
cross-sectional view (Fig.2-2). The casing has
a vertical shaft hole in which a reducing
valve is assembled.
The reducing valve consists of spool (201),
spring (241) (for secondary pressure setting),
spring (011) (for return), spring seat (216),
and washer (217). The spring (241) (for
secondary pressure setting) is so set as to
achieve the secondary pressure conversion
5~10kgf/cm2 (71~140psi) (varies with the
model.). The spool (201) is pressed against
push rod (212) by spring (011) (for return).
If push rod (212) is pushed down by tilting
the control part of the handle, the spring seat
(216) falls at the same time and changes a set
pressure of spring (241) (for secondary
pressure setting).
The casing (101) and the port plate (111) are
provided with an oil inlet (primary pressure)
port P and an outlet (tank) port T. They are
further provided with ports 1, 2, 3, 4 from
which secondary pressure is discharged.
(3) Function
1) Basic functions
The pilot valve controls the stroke and the
direction of the control valve spool. This is
achieved by applying the output pressure of
the pilot valve to the end of the control valve
spool.
In order to satisfy the functions, the pilot
valve is constructed with the following
elements :
Inlet port (P) to which the oil of the
hydraulic pump is supplied.
Multiple output ports (1, 2, 3, 4) that
exert the supply pressure from the input
port upon the end of the spool of the
control valve.
Tank port (T) to control the above
mentioned output pressure.
Spool that connects the output port with
the inlet port or the tank port.
The mechanical means including springs
that act upon the above- mentioned
spool, in order to control the output
pressure.
2) Main functions
The function of spool (201) is to receive the
supply pressure of the hydraulic pump by
port P and admit the hydraulic pressure at
port P to output ports (1, 2, 3, 4) or admit the
hydraulic pressure at the output ports to port
T. Spring (241) (for secondary pressure
setting) acts upon spool (201) and determines
the output pressure.
Push rod (212) that changes the deflection of
spring (241) (for secondary pressure setting)
is inserted in plug (211) so as to enable
smooth movement.
Spring (011) (for return) acts upon casing
(101) and spring seat (216) and brings push
rod
(212)
toward
zero
displacement
regardless of output pressure, in order to
positively bring spool (201) back to neutral.
The spring also acts as a reactive force that
gives the operator a proper operating feeling.
H23
(4) Function
Now, let us explain the function of the pilot
valve, using the hydraulic diagram (the
figure on the right) and the functional
explanation drawing (Fig.2-3 to 2-5).
3
P T
Pilot valve
Pilot pump
Lever in neutral
216
241
011
201
PORT(2,4)
Fig. 2-3
H24
Handle in neutral
212
216
201
PORT(2,4)
Fig. 2-4
T PORT
P PORT
PORT (2,4)
Fig. 2-5
H25
H26
Port
size
Tightening
Port
torque
kgfym (ftylbs) name
7.50.5
(543.6)
PF3/8
3.70.2
(271.4)
PF1/4
(2) Specification
4-11
Function
Through
1
2
3
4
T
5
6
P
Item
MACHINE FRONT
Specification
Type
07291-00000
Primary pressure
51kgf/cm2 (725psi)
Secondary pressure
5.524kgf/cm2 (78340psi)
Rated flow
10
Weight
Fig. 3-1
/min (2.6gal/min)
RIGHT
LEFT
Hydraulic simbol
Control diagram
H31
33 2
19
37
1,3
20
34
22
20
39
32
44,16
6
18
24
41
14
42
26
30
25
15
21
20
17
40
7
8
25,42
27
10,11
9 31
29
36 33
RORT5
PORT
5
25
42
PORT
PORT66
33 36
33
SECTION AA
35
4-M10
T=4.30.4(3129)
24,41
Tightening
torque
No.
kgfym (lbfyft)
1
2
1.5(11)
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
38
SECTION BB
VIEW
Fig. 3-2
NAME
ORIFICE(SHIM)
SEAT
ORIFICE(SHIM)
SPOOL
BODY
STOPPER
SPRING
SPRING
NAME PLATE
SHIM t=0.2
SHIM t=0.1
CAM
BOOTS
PIN
COVER
PISTON
GUIDE
SLEEVE
HOLDER
RING
ORIFICE(SHIM)
3.3 OPERATION
(1) Construction
The valve consists of the following parts in
terms of hydraulic function :
A : Damper section
B : Reducing valve section
C : Shuttle section
(2) Operation
1) Damper section
z If the primary pressure is supplied by P, it is
flowed to the damper chamber by way of
circuits ,D and ,E .
The pressure is then filled up in the damper
chamber via the orifice and the check valve.
In that case, the air present in the damper
chamber is pushed out to the T port from
circuits ,F and ,G , in order to prevent
the
damper characteristics from
fluctuating by air mixture.
CAM
PISTON
COVER
Er
CHECK
VALVE
GUIDE
ORIFICE
DAMPER
CHAMBER
SPRING FOR
SECONDARY
PRESSURE
Er
T
Er
P
SPOOL
Er
BODY
Fig. 3-3
H33
12
(0.472 )
11
(0.433 )
RETURN
SPRING
Er
Er
P
Er
Er
SECONDARY
PRESSURE PORT
Fig. 3-4
H34
3) Shuttle section
z If pressure is built up at port 1 or 3, the ball
is pressed against the seat by the pressure.
The pressure goes through from port 1 to port
5(or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4
as the ball is sealed metallically by the seat.
If pressure occurs at port 2 or 4, the ball is
pressed against the body by the pressure. The
result is that the pressure connects with port
5 from port 2(with port 6 from port 4).
Only a little leakage occurs at port 1 or 3 as
the ball is sealed metallically against the
body.
PORT 5
PORT 1
PORT 2
BALL
SEAT
BODY
PORT 3
PORT 4
PORT 6
Fig. 3-5
Shuttle section
H35
H36
4. CONTROL VALVE
4.1 SPECIFICATION
(This shows the valve with OPT2.)
TRAVEL
RIGHT
PBr
PBc
PAc
PA1
PAb
P1 CUT
ARM
CONFLUX
15_18
(110_130)
P1
P2
Ab
Bb
Ac
Bc
Ar
Br
AL
BL
Aa
Ba
As
Bs
Ao2
Bo2
Pump P1 port
Pump P2 port
Boom up port
Boom down port
Bucket dump port
Bucket digging port
Travel right port (forward)
Travel right port (reverse)
Travel left port (forward)
Travel left port (reverse)
Arm in port
Arm out port
Swing port (right)
Swing port (left)
Option 2 port (A)
Option 2 port (B)
Port size
Port
name
PF1/2
10_12
(72_87)
(P3)
(P4)
7_8
(51_58)
PAa
PBa
PAb
PBb
PAc
PBc
PAr
PBr
PAL
PBL
PAs
Pss
PBs1
PBs2
Pis
PA1
PB1
PTb
PCa
PCb
PAo2
PBo2
PF1/4
3.5_3.9
(25_28)
PL1
Dra
Drb
Drc
Drd
PLc1
PLc2
M10
5_6.6
(36_48)
PF3/8
TRAVEL LEFT
TRAVEL
RIGHT
PAL
TRAVEL
LEFT
PBL
PCb
SWING
SWING
PBs1
PAs
BOOM
CONFLUX
BUCKET
BOOM
PBb
Description
Tightening
torque
kgfym (lbfyft)
Dra,Drb
PAr
BUCKET
Port
name
P1 (P2)
TRAVEL
STRAIGHT
TRAVEL
STRAIGHT
PTb
Table 4-1(2/2)
Table 4-1(1/2)
Tightening
torque
kgfym (lbfyft)
ARM
BOOM
Pss
(P4)
PB1
PLc2
ARM
PAa
ARM
Pis
RECIRCULATION
P1 CUT
BOOM
CONFLUX
Drd
ARM
RECIRCULATION
Description
Option port
Option port
Tank port
PCa
PA02
PB02
(P3)
CUT
Item
Model
BOOM
ARM
BUCKET
Max flow
BOOM CONFLUX
TRAVEL
RIGHT
STD VALVE
OPT VALVE
KMX13YC/B33046
174 /min_2
SWING
TRAVEL
STRAIGHT
TRAVEL LEFT
405(5760) at 30 /min(7.9gal/min)
386(5490) at 30 /min(7.9gal/min)
386(5490) at 30 /min(7.9gal/min)
P2 (P1)
VIEW_B
VIEW_A
155
4.2 CONSTRUCTION
164
101
273
PBL
H
C
PAL
H
TRAVEL
STRAIGHT
TRAVEL
LEFT
PAs
PBs1
PBs2
Pss
TRAVEL
RIGHT
SWING
BOOM
CONFLUX
BUCKET
E
BOOM
PB1
ARM
PAa
PBa
Pis
PCa
F
ARM
RECIRCULATION
CUT
(ARM
CONFLUX)
OPTION 2
PAo2
PBo2
(CUT)
162
A
166 156
(974)
162
562
562
552
552
P2
973
102
974 973
P1
PTb
CT1
CT2
973
522
522
512
512
162
PAr
PBr
168
158
973
(973)
SECTION
PAc
PBc
JJ
973 PBb
SECTION
PAb
HH
PCb
PA1
973
162 164
H42
155
SECTION
162
B
973
201
166
156
201
201
333
PAL
337
326
325
327
332
325
262
332
601
513
522
552
562
562
552
522
CP2
CMR1
BL
CMR2
512
522
206
552
562
562
162
162
304
333
PAs
338
332
337
327
324
332
262
163
512
Drb
329
332
Ar
262
512
As
522
LCs
552
562
163
Bs
Dra
265
206
552
SECTION
SECTION
206
201
333
PLc1 Drc
(PLc2) (Drd)
262
337
324
329
602
332
SECTION
211
262
562
162
162
512
522
512
303
PAb
PAa
(HEAD
SIDE)
CRb
Aa
522
552
LCb
LCa
Bb
CRa
562
562
556
(ROD SIDE)
Pisc
162
301
265
602
PBs1
(SWING)
PB1
(BOOM CONFLUX)
552
206
PBr
(TRAVEL RIGHT)
PBc
(BUCKET)
305
265
332
556
524
514
562
265
306
(HEAD
SIDE)
332
562
Br
Bc
552
562
329
522
CP1
LCc
324
325
206
Fig. 4-2 (2/3)
Construction of control
262
512
522
552
562
332
337
202
Pss
CCB
Ac
201
333
201
PAr
332
206
PBs2
332
325
265
603
333
326
522
552
PBL
(TRAVEL
LEFT)
SECTION
328
512
206
PTb
(TRAVEL
STRAIGHT)
337
(ROD SIDE)
265
265
332
337
329
332
262
162
163
306
513
162
307
PAc
602
262
162
AL
201
333
332
332
338
166
333
333
332
156
PBb
(BOOM)
PBa
(ARM)
SECTION
524
514
302
211
265
206
H43
204
333
332
337
326
325
332
(CUT)
PCb
204
333
332
(ARM RECIRCULATION)
Pis
337
PAL
262
603
309
512
562
552
CAa
(HEAD SIDE)
522
310
308
512
522
162
552
CCa
(ROD SIDE)
Ba
562
262
332
309
262
332
325
325
326
326
603
337
332
337
332
333
PA1
(ARM CONFLUX)
204
333
PCa
(CUT)
SECTION
204
G
PAo2
272
271
Ao2
214
Bo2
PBo2
271
SECTION
H44
Tightening torque
No.
kgfym (lbfyft)
326
325
332
262
Ab
Table 4-3
272
213
NAME
Q'TY
Tightening torque
No.
kgfym (lbfyft)
NAME
Q'TY
101 CASING A
102 CASING B
78 (5158)
162 O RING ; 1B
G30
18
163 O RING ; 1B
P15
164 O RING ; 1B
P18
166 O RING ; 1B
P14
168 O RING ; 1B
P8
329 SPRING(ARM,BOOM,
338 STOPPER(TRAVEL)
512 POPPET
11
12
513 POPPET
522 SPRING
214 PLATE
262 O RING
265 O RING ; 1B
G35
M1225
BUCKET,SWING OUTER)
332 SPRING SEAT
24
12
10
2
13
M1290
M825
40
14
M22
78 (5158)
78 (5158)
78 (5158)
M14110
M1475
562 O RING ; 1B
P20
16
NAME
103 PLUG
Q'TY
M27
301
Tightening
torque
kgfym (lbfyft)
No.
564 563
511
NAME
Q'TY
611 POPPET
121 C RING
613 STOPPER
122 SPACER
614 PISTON
123 C RING
621 SPRING
125 FILTER
661 O RING
163 O RING
663 O RING
512 PLUNGER
664 O RING
521 SPRING
2.83.2 (2023)
541 SEAT
2.83.2 (2023)
561 O RING
521
522 161
Tightening
torque
No.
kgfym (lbfyft)
124 561
123 125 562
541
NAME
611
621
661 612
102
651
101
162
Fig. 4-5
Tightening
torque
kgfym (lbfyft)
Q'TY
671
No.
NAME
Q'TY
78 (5158)
101 BODY
M27
(HEX 32)
541 SEAT
78 (5158)
102 PLUG
M27
(HEX 30)
125 FILTER
P16
P10
P24
611 POPPET
P22.4
301 PISTON
621 SPRING
511 PLUNGER
521 SPRING
P8
522 SPRING
M14 (HEX
2.83.2 (2023)
22)
353
316
340
317
301
352
320
330
Fig. 4-6
359
Tightening
torque
No.
kgfym (lbfyft)
302
Fig. 4-4
Tightening
torque
No.
kgfym (lbfyft)
56 (3643)
NAME
Q'TY
302 SPOOL
359 PLUG
NAME
Q'TY
Tightening
torque
kgfym (lbfyft)
No.
NAME
Q'TY
301 SPOOL
330 SPRING B2
315 PLUNGER 1
340 SPRING B3
316 PLUNGER 2
56 (3643)
352 PLUG 1
M16
317 PLUNGER 3
56 (3643)
353 PLUG 2
M16
320 SPRING B1
1
H45
S202
S334
PAo
S337
S333
L101
S323
L541
S603
S324
L162
S271
S337
L163
S261
TA
Ao
S101
S301
S162
S512
S522
S561
S551
L171
Po
L511
B
Bo
L512
L161
TB
L201
S262
S204
SECTION
S603
PBo
Fig. 4-8
(Po)
Tightening
torque
kgfym (lbfyft)
Po
SECTION
Fig. 4-7
Tightening
torque
kgfym (lbfyft)
2.53.5 (1825)
H46
No.
NAME
Q'TY
S101 CASING
S162 O RING
No.
NAME
No.
NAME
Q'TY
S333 STOPPER
S334 BOLT M8
S512 POPPET
S261 O RING
S522 SPRING
S262 O RING
S561 O RING
1.61.8 (1213)
1214 (87100)
S301 SPOOL
S992 RIVET
78 (5158)
Over
load
2
1
2
Tightening
torque
kgfym (lbfyft)
No.
NAME
Q'TY
L101 CASING
L161 O RING
L511 SPOOL
L162 O RING
L512 SPRING
L163 O RING
L541 BUSHING
Q'TY
Table 4-4
601
513
307
54
TRAVEL
STRAIGHT
306
No.
512
306
TRAVEL LEFT
303
51
515
56
TRAVEL
RIGHT
SWING
53
304
52
512
512
305
55
BUCKET
BOOM CONFLUX
302
301
602
602
512
602
(CUT)
ARM RECIRCULATION
CUT
(ARM CONFLUX)
514
310
309
514
308
51
52
53
54
55
56
211
301
Boom spool
302
Arm spool
303
Swing spool
304
Bucket spool
305
306
Travel spool
307
308
309
310
512
Poppet D=20
513
Poppet
514
515
Poppet
601
602
ARM
BOOM
211
NAME
OPTION 2
211
309
S603
512
S603
S301
Fig. 4-9
H47
H48
4.4 OPERATION
(1) Control valve in neutral
The oil delivered by hydraulic pump P1
enters port P1 of the control valve and passes
through the travel straight spool (307) and
the main passage (51). It then passes through
the bypass circuit (52) that passes the right
travel bucket and boom circuits and then the
P1 bypass cut spool (309) and is brought back
to the hydraulic tank via the tank port (T).
309
P1
P2
T
307
(54)
(55)
SECTION
309
(51)
(52)
SECTION
AA
Fig. 4-10
BB
Functions at neutral
H49
Br
306
Ar
PILOT PORT
PBr
PAr
51
52
SECTION
Fig. 4-11
51
DD (Travel right)
CMR2 CMR1
P2
307
PTb
CA
DB
T
Position []
CA
DB
At travel straight action
Position []
CA
DB
At unload action
SECTION
CC
Fig. 4-12
Position []
(3) Bucket
1) When the bucket is digging
When the bucket is digging, secondary pilot
pressure coming from port (1) of the pilot
valve enters port PBc of the control valve and
moves the bucket spool (304) to the right.
The pressure oil delivered by pump (P1) flows
to the bypass circuit (52) past the main
passage (51), but since it is blocked by the
bucket spool (304) that has shifted, it pushes
the check valve open, enters the parallel
circuit (53), pushes the load check valve (512)
open, goes between the outer circumference of
(52)
304
PAC
PBC
BC
AC
(53)
U-SHAPED PASSAGE
512
R
BUCKET CYLINDER
SECTION
Fig. 4-13
EE (Bucket)
H412
PILOT PORT
(52)
(53)
PAC
304
PBC
AC
BC
U-SHAPED PASSAGE
512
R
BUCKET CYLINDER
SECTION
Fig. 4-14
EE
H413
(4) Boom
1) When the boom is up
When the boom is up, secondary pilot
pressure from port (3) of the pilot valve
enters port PAb of the control valve and
moves the boom spool (301) to the right. It
also acts upon port PB1 (Refer to next page)
and change over the boom conflux spool (305).
At the same time the secondary pressure of
the electromagnetic valve [B] acts upon port
PCa of the control valve and change over
the P2 bypass cut spool (309).
The pressurized oil delivered by the pump P1
flows into the bypass circuit (52) through the
main passage (51), but since it is blocked by
the boom spool (301), it pushes the check
valve open, enters the parallel circuit (53)
and pushes the load check valve (512) open.
(53)
301
PAb
PBb
(CRb)
Ab
CHAMBER BH
514
R
Bb
512
SECTION
BOOM CYLINDER
Fig. 4-15
H414
U-SHAPED PASSAGE
PCa
SECTION
Fig. 4-16
GG
P2 cut valve
(56)
U-SHAPED PASSAGE
BOOM CONFLUX
PB1
305
SECTION
Fig. 4-17
EE (Boom conflux)
CONFLUX
PASSAGE IN CASING
301 (52) (53)
BOOST CHECK
LOCK VALVE
SELECTOR SPOOL
PBb
PAb
PLC1
Drc
LOCK VALVE
SELECTOR
CHAMBER BH
514
(CRb) Ab
Bb
512
R
SECTION
U-SHAPED PASSAGE
BOOM CYLINDER
Fig. 4-18
FF
(5) Arm
1) Arm out operation
If arm out operation is performed, the
secondary pilot pressure from port (8) of the
pilot valve acts upon ports PBa and PA1 of
the control valve. (refer to next page)
The pressure oil which enters port PBa shifts
the arm spool (302) leftwards. The pressure
oil which enters port PA1 changes over the
arm conflux valve.
The secondary pressure of the electromagnetic
proportional valve [D] acts upon port PCb of
the control valve and changes over the P1
bypass cut valve (309).
The pressure oil delivered by pump P2 flows
into the bypass circuit (55) by way of the main
passage (54), but since it is blocked by the arm
ARM CYLINDER
512
302
514
(Ba)
Aa
CHAMBER AR
PBa
PAa
(55)
(56)
U-SHAPED PASSAGE
SECTION
Fig. 4-19
H417
FF
309
(52)
308
PA1
PCb
(53)
SECTION
Fig. 4-20
512
GG (Arm conflux)
At arm out operation (Bypass cut spool and arm conflux spool)
H418
ORIFICE
SECTION
ARM CYLINDER
D (60)
LOCK VALVE
SELECTOR SPOOL
CHAMBER AR
302
514
(61)
LOCK VALVE
SELECTOR
Aa
Position []
PAa
522
310
(61) (60)
SECTION
(56) (55)
Ba
Pis
D
Fig. 4-21
SECTION
GG
FF
PLc2
Drd
ARM CYLINDER
D (60)
LOCK VALVE
SELECTOR SPOOL
302
CHAMBER AR
514
(61)
Aa
Position []
PAa
310
(61) (60)
522
(56) (55)
SECTION
Ba
Pis
D
Fig. 4-22
SECTION
GG
FF
Drd
ARM CYLINDER
LOCK VALVE
SELECTOR SPOOL
D (60)
H
302
CHAMBER AR
514
(61)
Aa
Pisc
Position []
PAa
310
522
(61) (60)
SECTION
(56) (55)
FF
Ba
Pis
D
Fig. 4-23
SECTION GG
Simultaneous operation of swing and arm digging
H421
Drd
SWING MOTOR
U-SHAPED PASSAGE
FOR SWING MOTION
512
AS
303
Pss
BS
PAs
PBs2
PBS1
(55)
SECTION
Fig. 4-24
DD
H422
Ao2
Bo2
PAo2
PBo2
(56)
Sectional view of option valve
PCa
(55)
SECTION
Fig. 4-25
GG
309
BOOM CYLINDER
HEAD (H) SIDE
L512
L511
CHAMBER RH
PLc1
514
Drc
Sb
Sa
(a)
(301)
Fig. 4-26
H424
(b)
L541
BOOM CYLINDER
HEAD (H) SIDE
L511
CHAMBER RH
PLc1
514
L512
Drc
Sb
Sa
(a)
Pressurized
part of poppet
(514)
PBb
PAa
301
Fig. 4-27
(b) L541
A
R
541
PL
512
Fig. 4-28
2) When the hydraulic pressure of (P) reaches a
set pressure of the spring (621), it pushes
open the poppet (611) through the orifice (B)
and flows through the hole (D) to (R).
D
R
611 PL 621
Fig. 4-29
3) When the poppet (611) opens, the pressure in
chamber A falls, which causes the plunger
(512) to open and the pressure oil of port (P)
to flow directly to (R).
A
R
P
512
611
PL
Fig. 4-30
R
P
621
PL
614
Fig. 4-31
H426
301
P
R
511
541
Fig. 4-32
C
P
R
3. When the poppet (611) opens, the hydraulic
pressure in chamber B falls which causes the
plunger (511) to open and allows the
hydraulic pressure of port (P) to flow directly
to (R).
Fig. 4-33
611
511
P
2) Operation of anti cavitation check valve
The check valve supplies oil from port (R)
when a negative pressure is built up at port
(P). When the pressure at (R) gets higher
than that of port (P), the push-up force of
circuit (R) gets stronger than the pressing
force of chamber B.
This causes seat (541) to move to the right.
Then the oil passes through the clearance of
seat (541) and enters port (P) in sufficient
quantity to fill up the vacancy.
R
611
Fig. 4-34
541
Fig. 4-35
H427
621
H428
Tightening
Port
torque
size kgfym (lbfyft)
Port name
PF3/4
17 (120)
DB
Drain port
PF3/8
7.5 (54)
Make-up port
PF3/4
17 (120)
PF1/4
3.7 (27)
PF1/4
3.7 (27)
PF1/4
3.7 (27)
PG
PT1/2
6.6 (48)
IP
PT3/4
10 (72)
PB
IP
PG
RELIEF VALVE
(A PORT SIDE)
DB
PA
PB
Pi2
SWING SHOCKLESS
PA VALVE BLOCK
Pi1 M
DB
A,(B)
IP
FILLING PORT
PT3/4
PG
DB
M
PB
PA
Pi2
REDUCTION UNIT
DRAIN OIL HOSE
Pi1
Hydraulic diagram
H5-1
(2) Specification
Swing motor unit
Hydraulic motor
Type
M2X120BCHB10A58/285
Displacement
cm3 (in3)
121.6 (7.54)
Working pressure
kgf/cm2 (psi)
285 (4050)
Max. flow
/min (gal/min)
Braking torque
kgfym (lbfyft)
63.5 (460)
Release pressure
(Stroke end)
kgf/cm2 (psi)
29 (410)
kgf/cm2 (psi)
285 (4050)
Weight
kg (lbs)
54 (119)
Planetary 2-stage
Reduction ratio
15.38
Reduction unit
Lublicate oil
Lublicate oil volume
7.5 (1.98)
Grease
Grease volume
Weight
Total weight
179 (47)
A small amount
kg (lbs)
154 (339)
kg (lbs)
208 (458)
H52
5.2 CONSTRUCTION
(1) Swing motor
488
992
469
355
401
ANTI CAVITATION
PLUNGER
351
051-1
391 390
VALVE CASING SECTION
SWING SHOCKLESS
VALVE BLOCK
052
V171
161,
152 162
163
V162
053
303
(400-1)
(400-2)
444
981
485
438
464
472
706
712
743
742
121
052
400
SECTION
A
V981
V162 V163
V164
113 V154
707
980
V252
V262
122
702
123
114
118
V301
116
V154
V101
117
301
(053)
V164
443 491 305
101
437 124
Fig. 5-2
994
Swing motor
H53
V324
TIGHTENING
TORQUE
kgfym (lbfyft)
18 (130)
No.
PARTS
052
053
100
3.7 (27)
7 (51)
G30
No.
PARTS
QTY
451 PIN
3.7(27)
34 (250)
2
1
472 O RING
111 CYLINDER
485 O RING ; 1B
P11
488 O RING ; 1B
P28
12
117 SPACER F
706 O RING
118 SPACER
707 O RING
121 PISTON
24
122 SHOE
0.45 (3.3)
152 PLUG
0.17 (1.2)
161 O RING ; 1B
P11
6.6 (48)
162 O RING ; 1B
P12
10 (72)
163 O RING ; 1B
P6
V154 PLUG
V162 O RING
V163 O RING
351 PLUNGER
V164 O RING
355 SPRING
3.0 (22)
17 (120)
V251 PLUG 1
391 RIVET
11 (80)
V252 PLUG 2
V261 O RING
V262 O RING
V301 SPOOL
V304 SPRING
400
P20
3.7 (27)
301 CASING
400-1 O RING ; 1B
44 (320)
TIGHTENING
TORQUE
QTY
kgfym (lbfyft)
H54
19
29 28 27
26
25
18
22
17
23
16
24
22
14
20
15
21
13
10
12
11
37
34
35
36
9
8
6
2
Fig. 5-3
Tightening
torque
kgfym (lbfyft)
3.4 (25)
18.5 (130)
No.
QTY No.
PARTS
QTY
1 PINION SHAFT
2 SLEEVE
20 SPRING PIN
21 SHAFT
5 O RING
22 THRUST WASHER
6 OIL SEAL
23 #.2 PINION
7 RETAINER
24 NEEDLE BEARING
12
25 THRUST WASHER
9 BEARING
26 #.1 PINION
10 HOUSING
27 ROLLER
11 SPACER
28 THRUST WASHER
12 BEARING
29 SNAP RING
13 SNAP RING
33 SNAP RING
14 #.2 SPIDER
35 CONNECTOR
16 RING GEAR
36 HOSE
37 PLUG
10
H55
3
102
5.3 OPERATION
5.3.1 OPERATION OF HYDRAULIC MOTOR
If the high pressure oil flows into the cilynder
through the inlet port (a) of valve plate (131), as
shown on the right figure, the hydraulic pressure
acts upon piston (121) and generates force F in
the axial direction.
The force F may be divided into force F1 vertical
to shoe plate (124) via shoe (122) and force F2 at
right angles with the shaft.
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of
high pressure oil.
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite
direction.
CYLINDER BLOCK(111)
F2
F1
F
DRIVE SHAFT(101)
SHOE
PLATE
(124)
PISTON
(121)
SHOE
(122)
VALVE
PLATE
(131)
OUTLET
INLET
(a)
pq
2
p : Effective differential pressure kgf/cm2
q : Displacement per revolution c.c. /rev
Fig. 5-4
351
CHAMBER h
PISTON 1(302)
SPRING(321)
ORIFICE m
P
R
PRESSURERECEIVING
AREA A1
PLUNGER (301)
CHAMBER g
A3 A2 ORIFICE n A4
Fig. 5-6-(1)
ORIFICE m
CHAMBER h
SPRING(321)
PIN(303)
PISTON 1(302)
P
R
PLUNGER (301)
ORIFICE n
CHAMBER g
Fig. 5-6-(2)
SPRING(321)
ORIFICE m
H57
PIN(303)
CHAMBER h
PISTON 1(302)
P
R
PLUNGER (301)
ORIFICE n
CHAMBER g
Fig. 5-6-(3)
ORIFICE m SPRING(321)
PIN(303)
PISTON 1(302)
P
R
PLUNGER (301)
Fig. 5-6
ORIFICE n
CHAMBER g
Fig. 5-6-(4)
Functional explanation of relief valve
Fig. 5-7
1) Neutral condition :
Fig.5-8 illustrates the relationship between
the neutral condition of the swing shockless
valve and the hydraulic circuits. Now, let us
consider a braking condition in which brake
pressure generates on the AM port side.
2) When brake pressure occurs :
If pressure (P) generates at the AM port, it
passes through the passage l, the hole on
the shaft of seat (313) and the passage m of
plunger (311) and is admitted to the n
chamber.
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
spring (321) and shifts it to the left.
Seat (313) compresses weak spring (322) as
pushed by plunger (311) and moves to the
left.
3)
At swing shockless action
When inertia load stops moving (point Y,
Fig.5-10), brake pressure (P) tries to fall.
When P<PS, plunger (311) moves toward the
right return side by the action of spring (321).
Seat (313) tries to move to the right by the
action of spring (322), but since chamber p
provides damping action by orifice g, the
return of the seat makes a time delay with
regard to the return of the plunger.
Consequently, seat t opens. This makes a
passage connecting the AM port and BM
ports or both ports of the hydraulic motor by
way of
trk. The result is that the pressures
at the AM and BM ports become equal (PB),
falling into the condition at point Z in
Fig.5-10. This prevents the hydraulic motor
from swing shock by the closing pressure of
the AM port.
k
313
322
321
311
P=PS
322
313
321
311
P<PS
k
r
322 313 g
321
311
Fig. 5-9(3) At swing shockless action
H58
Fig. 5-9
Fig. 5-10
SPOOL
CASING
Pi1
Pi2
PLUG (1)
SPRING (324)
PLUG (2)
Fig. 5-11
111
712
702
712
743
742
702
H59
743
301
742 301
Fig. 5-12
101
PLANETARY SHAFT
SPIDER
SUN
GEAR
PLANETARY PINION
Fig. 5-12
Planetary mechanism
SWING MOTOR
26
19
16
17
15
14
10
23
12
Fig. 5-13
H510
6.
(2) Specifications
TRAVEL MOTOR
6.1 SPECIFICATIONS
(1) General view
M4V150/100-RG3.5B
Type
M4V150/100Z
Reduction
SPROCKET CENTER
Reduction ratio
22-M18
OVERLOAD RELIEF VALVE
M27
T=11 (80)
P
T=5.5 (40)
8-M12
T=10 (72)
Travel motor
Y
MA
VA,VB
PT3/4
17-M20
FILLING PORT
OIL LEVEL CHECK PORT
41.46
2
(gal)
T=5.5 (40)
MB
Unit
5.5 (1.5)
Gear oil SAE#90 (GL-4)
Max. displacement
cc/rev (cuyin/rev)
154.4 (41)
Min. displacement
cc/rev (cuyin/rev)
103.7 (27)
kgf/cm2 (psi)
350 (4,980)
kgf/cm2 (psi)
51 (725)
kgfym (lbfyft)
kgf/cm2 (psi)
kgf/cm2 (psi)
kg (lbs)
Working
2.0 (28)
Surge
10.0 (140)
Dr
8-M16
T=23.5 (170)
T=10 (72)
15-M10
T=8 (58)
LOCKTITE#242
DRAIN
PT3/4
DRAIN PORT
VIEW
T=10 (72)
Fig. 6-1
Travel motor
Rotation direction
Rotation direction
Oil inlet Oil outlet
port
port
(Viewed from valve side)
VA
VB
Right (Clockwise)
VB
VA
Left (Counterclockwise)
Tightening
torque
kgfym(lbfyft)
Function
PF1/4
5.5 (40)
Dr
PF1/2
11.0 (80)
Drain port
VA,VB
PF1
26.0 (190)
MA,MB
PF1/4
3.0 (22)
Pressure measurement
H61
No.
6.2 CONSTRUCTION
6.2.1 TRAVEL MOTOR
35
12 13 3 7 5
37
40 24
28
36
20
33
21
23
29
QTY No.
NAME
QTY No.
NAME
QTY
CASING
21
BALL
41
O RING1B
P11
REAR COVER
22
PIVOT
42
O RING1B
P14
CYLINDER BLOCK
23
PISTON SEAL
43
O RING190.172.62
SHOE RETAINER
24
M6 RESTRICTOR (0.6)
44
FRICTION PLATE
25
OIL SEAL
45
SPOOL
32
17
BRAKE PISTON
26
SPRING
46
PLUGPF3/8
18
26
38
SEPARATOR PLATE
27
SPRING (CYLINDER)
47
SPRING RETAINER
VALVE PLATE
28
SPRING (BRAKE)
12
48
PIN
40
SHAFT
29
BEARING
49
SPRING
10
COUPLING
30
BEARING
50
CONNECTOR
11
SHOE PLATE
31
SOCKET BOLTM1645
51
SPOOL ASSY
12
BALL JOINT
32
SHIM
COVER
13
SPRING RETAINER
33
PARALLEL PIN612
14
PISTON ASSY
15
D RING (SMALL)
35
PLUGNPT1/16
16
D RING (LARGE)
36
17
CHECK VALVE
18
SNAP RING
19
20
39
41
10
2
19
30
8
25
22
44
11
50
4 27
15 16
42 45 48 47
49
43
42
14
46
58
54
60
53
52
57
41
51
31
VIEW
H62
NAME
59
55 56
Travel motor
12 52
1
53
SPRING
54
SPRING RETAINER
55
RESTRICTOR VALVE
PLUGNPT1/16(Meck : TB) 10
56
SPRING
37
PLUG
57
PLUG
38
PLUGPF1/8
58
O RING42.522.62
SNAP RING
39
PLUGPF1/4
59
O RING1B
TILTING PISTON
40
O RING1B
60
SOCKET BOLTM1235
P8
P9
24
15
12
14 13
16
18
25
4
7
3
5
20
10
Clearance :
0.08 to0.02mm
(0.0031 to0.0008in)
Adjust it with one shim.
6
9
8
1
2
11
26
17
21
22
Fig6-3
No.
NAME
QTY No.
23
19
Reduction unit
NAME
QTY No.
NAME
QTY
COVER
10 SUN GEAR 2
19
BEARING
CARRIER 1
11 CARRIER 2
20
SHIM
CARRIER PIN 1
12 CARRIER PIN 2
21
LOCK WASHER
NEEDLE BEARING
13 NEEDLE BEARING
22
SUPPORT RING
THRUST WASHER 1
14 PLANETARY GEAR 2
23
FLOATING SEAL
PLANETARY GEAR 1
15 SPRING PIN636
24
SOCKET BOLTM1025 15
SPRING PIN422
16 THRUST WASHER 2
25
SOCKET BOLTM1680 19
THRUST PLATE
17 RING GEAR
26
SOCKET PLUGPT3/4
SUN GEAR 1
18 HOUSING
H63
44-2
Fig. 6-4
No.
NAME
No.
NAME
44-1 SOCKET
44-8 SHIM
44-2 VALVE
44-9 SPRING
44-10 O RING1B
P7
44-12 O RING1B
44-7 PISTON
H64
G25
53
57
54
0.1kgf/cm2 (1.4psi)
60
58
41
6.110.2kgf/cm2 (87150psi)
56
55
59
51
Fig. 6-5
Brake valve
H65
52
Fig. 6-6
(a)
5 28
9
1
Fig. 6-7
H66
Fig. 6-6
Negative brake
(b)
(3) Functions
of
variable
displacement
mechanism
Fig.6-8
shows
a
modeled
variable
displacement mechanism.
When pressure overcoming spring (49) enters
the high speed travel command line PA,
spring (49) is compressed. Then spool (45)
moves to the right which connects port P with
port C. The highest of motor pressures A, B
and the high speed travel command line
pressure is selected in check valve (17) and
presses tilting piston (20). For that reason,
shoe plate (11) tilts along the broken line
with the line L connecting two pivots (22) as
the axis center, stops tilting when it hits
tilting stopper (H), and keeps that condition.
This decreases the stroke of piston (14) and
makes the motor displacement smaller. The
motor is capable of rotating at high speed
without increasing the oil flow from the main
pump. The speed is approx. 1.5 times on this
machine.
Inversely, if the high speed travel command
line pressure PA disappears, spool (45) is
brought back to the left by the action of
spring (49). The result is that the hydraulic
pressure pressing tilting piston (20) is
released to the tank and makes the pressing
force zero.
The motor has nine pistons that are arranged
evenly over shoe plate (11) and presses shoe
plate (11).
TO CONTROL VALVE
21
20 H
17
14
17
17
22
22
11
45
Fig. 6-8
PB P C
H67
48
49
PLUG
CONNECTING PISTON
B port
(44-4)
(44-5)
VALVE SEAT
(44-3)
A port
Small hole
VALVE
ADJUST SPRING
(44-2)
Fig. 6-9
(44-9)
H68
PISTON
(44-7)
Fig. 6-10
Hold condition
H69
Fig. 6-11
At acceleration
H610
Fig. 6-12
At stop operation
H611
Fig. 6-13
At counterbalance action
H612
CARRIER (k)
PLANETARY
PINION
(b)
INPUT
OUTPUT
PLANETARY PINION
(b)
Fig. 6-14
In Fig.6-15, if the sun gear S1 on the input
side rotates, planetary motion occurs between
gear S1, a and b. The revolution of gear b
conveys the input of carrier K1 to the No.2
sun gear S2 to cause planetary motion to
occur between gear S2, a and d.
On that occasion, since carrier K2 is fixed to
the frame body, gear d transmits the power to
the ring gear and makes ring gear a rotate.
a
b
S1
K1
Fig. 6-15
H613
d
S2
K2
H614
7.
SWIVEL JOINT
E
B
C
B
F
A
VIEW
Fig. 7-1
7.2 SPECIFICATIONS
Table 7-1
Item
High pressure ports
A,B,C,D
Low pressure ports
E
Low pressure ports
F
Revolution
Ports size
Spec.
Working pressure
Max. impact pressure
Rated flow
Working pressure
Rated flow
Working pressure
Rated flow
A,B,C,D
E
F
Length (height)
Weight
H71
350kgf/cm2 (4980psi)
525kgf/cm2 (7470psi)
255 /min (67gal/min)
5kgf/cm2 (71psi)
50 /min(13gal/min)
51kgf/cm2 (725psi)
30 /min (8gal/min)
15rpm
PF1
PF1/2
PF1/4
320mm(12.6)
27kg(60 lbs)
7.3 CONSTRUCTION
Y
D
B
C
E
X
D
VIEW
12
B
A
5
7
SECTION XX
9
8
Fig. 7-2
No.
1
2
3
4
5
NAME
BODY
STEM
THRUST PLATE
COVER
SEAL ASSY
Construction
QTY No.
1
1
1
1
5
7.2.4 OPERATION
The swivel joint consists mainly of body (1) and
stem(2) that rotate mutually, thrust plate (3)
preventing both components from falling off,
cover(4) closing one side of body(1), seal(5) that
partitions off the circuits and seal assy (6) and O
ring (7) that prevent external leaks.
Four ports for the travel main circuits are
provided on body (1) and stem (2). Further, four
oil passing grooves are arranged in the inner
surface of body (1), with seal (5) fixed above and
below the circumferential groove.
6
7
8
9
12
NAME
SEAL ASSY
O RING ; 1A G95
SOCKET BOLT ; M820
SOCKET BOLT ; M830
PLUG
QTY
2
1
2
4
1
H72
8. CYLINDER
8.1 SPECIFICATIONS
(1) General view
Fig. 8-1
(2) Specifications
Table 8-1
Use
Cylinder bore /
Stroke
Rod Dia.
Boom
115 / 80
1,200
(4.53/ 3.15) (41)
Arm
125 / 90
1,290
(4.92/ 3.54) (411)
Bucket
Center distance
Dry
of pins
weight
Cushion
Full extend B /
kg (lbs)
Full retract A
2,970 / 1,770
With cushion
160 (353)
(974/ 58) on rod side
3,060 / 1,770
(10/ 58)
With cushion
on both sides 190 (419)
105 / 75
1,055
2,630 / 1,575
With cushion
120 (264)
(4.13/ 2.95) (346) (862/ 516) on rod side
H81
Unit : mm (ft-in)
0
0
1050.5
(4.13
)
0.0197
660 (26.0
)
M121.75 (Through)
24 25
0
0
1050.5
(4.13
)
0.0197
8.2 CONSTRUCTION
(1) Boom cylinder
25 24
27
SLIT
26
BLACK
GREEN
28,2
T=3.2(23)
With hole
(1 place)
DETAIL B
VIEW
DETAIL C
T=27.2(200)
9
7 6
T=421(3000) T=5.8(42)
12 10,11
2 1
13 14 15 16 17 18 19 20 21 22,23
C
SLIT
Fig. 8-2
P/No.
YB01V00008F1
No.
NAME
QTY No.
NAME
QTY No.
NAME
QTY
CYLINDER TUBE
11 BACK-UP RING
21 NUT
PISTON ROD
12 SOCKET BOLT
10
22 SET SCREW
CYLINDER HEAD
13 CUSHION BEARING
23 STEEL BALL
BUSHING
14 CUSHION SEAL
24 PIN BUSHING
SNAP RING
15 PISTON
25 WIPER RING
BUFFER RING
16 SEAL RING
26 BAND
U RING
17 BACK-UP RING
27 BAND
BACK-UP RING
18 SLIDE RING
28 BOLT
WIPER RING
19 SLIDE RING
29 WASHER
20 SHIM
10 O RING
H82
0
0
120 0.5
(4.72
0.0197)
200 (7.87
)
28 27
0
120 0.5
0
(4.72
0.0197)
27 28
T=3.2(23)
31,32
30
29
SLIT
BLACK
GREEN
With hole
(1 place)
DETAIL B
VIEW
DETAIL C
T=27.2(200)
7,8
T=836.5(6100)
5 3 12 10,11
2 1
T=5.8(42)
13 14 20 15 17 16 18 19 21,22 26 24 23 25
Fig. 8-3
P/No.
YB01V00010F1
No.
NAME
QTY No.
NAME
SLIT
QTY No.
SLIT
NAME
QTY
1 CYLINDER TUBE
12 SOCKET BOLT
12
23 CUSHION BEARING
2 PISTON ROD
13 CUSHION BEARING
24 CUSHION SEAL
3 CYLINDER HEAD
14 CUSHION SEAL
25 STOPPER
4 BUSHING
15 PISTON
26 SNAP RING
5 SNAP RING
16 SEAL RING
27 PIN BUSHING
6 BUFFER RING
17 BACK-UP RING
28 WIPER RING
7 U RING
18 SLIDE RING
29 BAND
8 BACK-UP RING
19 SLIDE RING
30 BAND
9 WIPER RING
20 SHIM
31 BOLT
10 O RING
21 SET SCREW
32 WASHER
11 BACK-UP RING
22 STEEL BALL
H83
0
0
100 0.5
(3.94
0.0197)
0
0
(3.94
100 0.5
0.0197)
210 (8.27
)
24 25
25 24
T=3.2(23)
28,29
27
SLIT
BLACK
GREEN
With hole
(1 place)
DETAIL B
26
VIEW
DETAIL C
T=17.4(130)
8
7 6
3 4
T=491(3600) T=5.8(42)
5 12 10,11
2 1
13 14 15 16 17 18 19 20 21 22,23
C
SLIT
Fig. 8-4
P/No.
YB01V00011F1
No.
NAME
QTY No.
NAME
QTY No.
NAME
QTY
1 CYLINDER TUBE
11 BACK-UP RING
21 NUT
2 PISTON ROD
12 SOCKET BOLT
12
22 SET SCREW
3 CYLINDER HEAD
13 CUSHION BEARING
23 STEEL BALL
4 BUSHING
14 CUSHION SEAL
24 PIN BUSHING
5 SNAP RING
15 PISTON
25 WIPER RING
6 BUFFER RING
16 SEAL RING
26 BAND
7 U RING
17 BACK-UP RING
27 BAND
8 BACK-UP RING
18 SLIDE RING
28 BOLT
9 WIPER RING
19 SLIDE RING
29 WASHER
20 SHIM
10 O RING
H84
CUSHION RING(13)
CHAMBER A
TANK
PATH B
PISTON(15)
8.2.2 OPERATION
If pressurized oil is fed alternatively to the oil
inlet and outlet provided in the cylinder, force
acts on the piston which in turn causes the piston
rod (2) to extend and retract.
ROD(2)
ROD SIDE
HEAD
SIDE
CYLINDER HEAD(3)
CUSHION STROKE
Fig. 8-5
CLEARANCE D
TANK
MOUTH GAP C
H85
Fig. 8-6
H86
TANK
CHAMBER A
Fig. 8-7
CLEARANCE D
ELECTRIC EQUIPMENTS
(E)
LIGHT
(L)
C-4
C-6
D-1
D-2
D-3
D-4
D-5
D-6
Diode
Diode
Diode
Diode
Diode
Diode
E-1
E-2
E-3
E-4
E-5
E-6
E-7
E-8
E-9
E-10
E-11
Fuse box
Alternator
Hour meter
Horn (Low)
Horn (High)
Cigarette lighter
Tuner AM & FM
Speaker LH
Speaker RH
Receiver dryer
A/C compressor
E-14
Resister
E-16
E-17
E-23
E-24
Antenna (OPT.)
GPS Antenna (OPT.)
L-1
L-2
L-3
L-4
L-5
L-6
L-7
L-8
L-9
L-10
L-15
Rotatry light
M-1
M-2
M-3
M-4
M-5
M-8
M-9
Starter motor
Governor motor
Wiper motor
Washer motor
M-11
PROPORTIONAL
VALVE
Mechatro controller
Gauge cluster
(R)
SW-3
SW-4
SW-5
SW-6
SW-7
SW-8
Battery relay
R-3
R-4
R-5
R-6
R-7
R-8
Glow relay
Safety relay
Wiper motor relay
Washer motor relay
Horn relay
Work light relay
R-10
R-11
R-19
R-20
NAME
Key switch
Travel1-2 speed switch
Swing parking release switch
KPSS release switch
Engine water temperature switch
Engine oil pressure switch
Air filter clogging switch
SOLENOID
MOTOR
Group Code
(SW) SW-1
(SV)
(M)
NAME
Arm variable recirculation proportional valve
P2 bypass cut proportional valve
Travel straight proportional valve
P1 bypass cut proportional valve
SWITCH
DIODE
(D)
C-1
C-2
Group Code
(P) PSV-A
PSV-B
PSV-C
PSV-D
RELAY
CONTROLLER
(C)
NAME
Battery
ELECTRIC SENSOR
Group Code
(B) B-1
SE-1
SE-2
SE-3
SE-4
SE-5
SE-6
SE-7
SE-8
SE-9
SE-10
SE-11
SE-13
SE-14
SE-15
SE-16
SE-20
SE-22
SE-23
SV-1
SV-2
SV-3
SV-4
E1 1
NOTES:
E1 2
Specification
Description
B-1
Type
Battery
130E41R
Voltage
12V
Capacity 5HR
92Ah
Weight
130E41R
OR 115E41R
Power
Terminal
C-1
Controller
Maker
Rated voltage
Terminal
SHINKO ELECTRIC
DC 24V
Mechatro controller
C-2
Maker
Rated voltage
Controller
Insulation resistance
KANSEI
DC24V
More than 3M at
500Vmegger
LCD
Gauge cluster
E1 3
File No.
Name of part
Specification
Description
Use
C-4
TKS-C215AO
DC 20~30V
Controller
Air-con controller
D-1,2,3,5,6
Diode
7321-9822-30
400V
3A
200A
D-4
Diode
Part No.
Rated current
7321-9332-60
2.5A
Glow relay
E1 4
CONTROLLER
File No.
Name of part
Specification
Description
Use
E-1
Fuse box
Fuse
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
E-2
Capacity
20A
10A
10A
10A
10A
10A
20A
10A
20A
20A
20A
10A
20A
10A
20A
10A
20A
10A
20A
Name of circuit
Mechatro controller
Wiper / washer relay
Cigarette lighter
DC-DC Converter, Tuner
Horn
Blank
Mechatro controller back-up
Fuel supply pump
Tuner back-up, room lamp
Key switch
Fuel pump, cab work light
Travel alarm,swing flasher
Gauge cluster
Wiper, Washer
Solenoid valve
Work light
Resistor
Air conditioner, Heater
Air conditioner
Spare (24V)
Rated output
24X40A
R
Alternator
18PAF-HD
SUMITOMO
HOUSING : 6098-0257
TERMINAL : 8240-4422
18PAF-HD
II
7PAM-HD
7PAM-HD
SUMITOMO
HOUSING : 6950-1030
TERMINAL : 8230-4050
: 8232-4238
M5 X 0.8
TERMINAL E
12.5
VIEW A
Generator
M6 X 1.0
TERMINAL B
M5 X 0.8
E-3
Movement
Quartz
Hour meter
Service meter
E1 5
File No.
Name of part
Specification
Description
Use
E-4,5
Horn
Type
DC24V
Rated voltage
Warning sound
Drain 2-Hole
E-6
Cigar lighter
409112-0000
Model
DC 24V
Rated voltage
Max. current
5A
Return time
Insulation resistance
Cigar lighter
Fusing temp.
E-7
Rated voltage
Tuner
1
2
3
4
5
6
7
8
9
E-8,9
Speaker
STAMP
H HIGH SOUND
L LOW SOUND
Model
DC24V
L SPEAKER(+)
R SPEAKER(+)
ACC(+B)
OPEN
L SPEAKER(-)
R SPEAKER(-)
GND(-)
BACK UP (+)
OPEN
SX-M1028K
Rated input
8W
Impedance
Freguency
33.3Hz
Radio
E1 6
PLUG COMPLETE
KNOB
JIS CA104
CASE
SOCKET COMPLETE
File No.
Name of part
Specification
Description
Use
E-10
56640-A0450
Receiver dryer
CAULK
Air conditioner
2-M6 X 1.0
E-11
Air compressor
1
DC 24V
Max. revolution
4000rpm
V belt
Refrigerant
Air conditioner
7351-6000
Rated voltage
Oil
Type B
R-134a
SP-20 : 135cc
Cover (clutch)
CP3.96MA
YAZAKI 7120-8019
AVX1.25 (BLACK)
AVX1.25 (GREEN)
E-14
Resistor
40W
16
DC500V /
More than 20M
P1,P2 pump
proportional valve
SILICONE GLASS
Braided wire
(NISSEI DENKI)
NS-GE 1.25sq
FURUKAWA DENKO
Viewmex ER400 or equivalent
heat resistant tube
5X20mm (0.197 X0.787)
Hot soldering treatment
[melting point 240C (464F)]
Sumi-tube K
-55C+175C
(-67F~+347F)
20mm (0.787)
4.70.3
(0.1850.012)
E1 7
File No.
Name of part
Specification
Description
Use
E-15
Rated voltage
DC 12V 36V
Rated current
0.2A at 24V
Input voltage
DC 24V
Output voltage
DC 12V
Output current
2.5A Max
Ground
Negative
Alarm
Travel
E-16
Converter
YV
WG
Power socket
YB
OL
B
E-17
Power supply
For 12V
Socket
Power socket
L-1,9
Light (halogen)
Type
BL84-130
Bulb
24V,70W
CA104
M14X1.5
E1 8
File No.
Name of part
Specification
Description
Use
L-2
Light (halogen)
Type
BL84-200
Bulb
DC 24V,70W
71cm2
CA104 R
CB104 W
L-3
Bulb
24V,5W
BODY
Light
Room light
BULE
BULB
OFF
ON
View Z
L-8
Light
3509-KB
Bulb
12V,10W
SECTION A-A
E1 9
File No.
Name of part
Specification
Description
Use
M-1
Rated output
DC 24V,4.5kW
ISUZU
897029-8634
Motor
Starter motor
TERMINAL (R)
TERMINAL (S)
SAFETY RELAY
M-2
Motor
Drive voltage
DC 24V
Rated voltage
DC 8.5V
Rated current
1.5A / phase
2 phase
Excitation method
2 Excitation
Insulation resistance
MOTOR SECTION
Number of phases
Step angle
Governor motor
1.8
More than 100M
(500V megger)
CAM
LIMIT
SWITCH
Excitation sequence
Step
Brown(A)
Red(B)
Lead
A
B
Yellow(B)
A
B
Orange(A)
ConnecNo. Lead
color
tion
1 White COM
NO
2 Red
3 Yellow NC
+
+
+
+
+
+
-
+
+
-
Motor connector
Lead
2 No. color
1 Blown
2 Orange
3 Red
4 Yellow
MOTOR
LIMIT SWITCH
CONNECTOR CONNECTOR
Connection
A
A
B
B
E1 10
VIEW Z
LIMIT
SWITCH
MOTION
RANGE
File No.
Name of part
Specification
Description
Use
M-3
Motor
5-159200-377
Rated voltage
24V
Wipe-out angle
106
M-4
Rated voltage
Injection pressure
Motor(tank)
Tank capacity
Time rated
Injection nozzle
DC 24V
(+)
(-)
Window washer
PUMP
M-9
Motor (pump)
375-01016
DC24V
Less than 1.5A
HEX24
Light oil
More than 200cc/min
IN
OUT
Z
GROMMET
M6X1
BLACK / RED
VINYL TUBE (WHITE)
L=100 (3.94 )
BLACK
VIEW Z
E1 11
WATERPROOF
CONNECTOR (MALE)
YAZAKI 7322-9021
File No.
Name of part
Specification
Description
Use
M-11
Pump
Flow rate
Voltage
24V
Current
Fuse
15A
R-1
Relay
Battery relay
Rated voltage /
current
Exciting current
TERMINAL A
TERMINAL
B
FLW2.0
FLW2.0
F HOUSING :
SUMITOMO
7123-4220-30
F TERMINAL :
SUMITOMO
7116-3251
REAR HOLDER :
SUMITOMO
7157-6801-30
WATER
RESISTANCE :
SUMITOMO
7157-3580-60
Less than 7V
More than 3M /
500V megger
MODEL
NUMBER STAMPING
POSITION IN A
PRODUCTION PROCESS
AVS1.25B
EARTH
TERMINAL
FLOWING DIRECTION OF
MAIN CURRENT
TERMINAL A
Z
AVS1.25G
AVS1.25L
TERMINAL B
TERMINAL A1
LOCK SECTION
TERMINAL B1
BLACK
EARTH
VIEW I
CIRCUIT DIAGRAM
E1 12
L TERMINAL
B
TERMINAL
HOUSING SUMITOMO
6181-0072
RETAINER SUMITOMO
6918-0327
TERMINAL SUMITOMO
1500-0105
WIRE SEAL SUMITOMO
7165-0119
EARTH TERMINAL
VIEW Z
File No.
Name of part
.
Use
R-3
Specification
Relay
Glow relay
Rated load
Description
894258-0140
DC24V
In-rush current 130A
Breaking current 30A
Operating voltage
Release voltage
Exciting current
Less than 1A
Z
1
CONNECTOR ON
MATED SIDE.
YAZAKI 7323-3010
CONNECTOR ON
MATED SIDE.
YAZAKI 7323-2228
VIEW Z
R-4
897129-9360
DC 24V
Relay
Safety relay
TERMINAL (R)
TERMINAL (S)
SAFETY RELAY
TO ALTERNATOR
TO STARTER SWITCH (C)
SAFETY RELAY STARTER
E1 13
File No.
Name of part
Specification
Description
Use
R-5,6,7,8,10,11,18
Relay
Rated voltage
DC 24V
Coil resistance
360 10%
Wiper motor,
Washer motor,
Horn relay,
Work light relay,
Travel alarm relay,
Applicable connector
VCF41003 (P&B)
CONNECTION DIAGRAM
R-19
Relay
R-20
Relay
Rated voltage
DC 24V
Delay time
1 sec.
Operation
Timer relay
E1 14
File No.
Name of part
Specification
Description
Use
SE-1~5,7~11,20
Pressure range
Pressure sensor
(low pressure)
Rated voltage
0~30kgf/cm2(0~430psi)
5 0.5V DC
More than 100M /
Insulation resistance
DC50V megger
Vcc
Vout
GND
AMP HQS-TYPE
3-poles (TYPE-B)
(HEX) 19
PF1/4
TIGHTENING TORQUE 3.7kgfm (26.8 lbfft)
SE-13
Revolution sensor
Rated
Output voltage
Clearance
1.0mm (0.04in)
M16 X 1.5
TORQUE2.5~3.5kgfm
(18~25 lbfft)
CONNECTOR
YAZAKI 7322-1424
HEX 19
HEX 17
SIGNAL (YELLOW)
GND (BLACK)
SE-14
Water temperature
sensor
E/G Water
temperature
71400-KW0300
Resistance characteristics
50C(122F)
80
60C(140F)
56.3
80C(176F)
29.5
100C(212F)
16.5
106C(222.8F)
14.3
120C(248F)
10
E1 15
M16 X 1.5
TORQUE
2.5 kgfm
(18ftlbs)
VIEW Z
File No.
Name of part
Specification
Description
Use
SE-15
Fuel sensor
Fuel sending
Resistance value
FULL
+0.1
10-0.5
3/4
(19)
1/2
32 3
1/4
(49.5)
EMPTY
80+12
+2
FULL
FLOAT
3/4
110
1/2
1/4
FUEL LEVEL
WARNING LAMP POSITION
FUEL METER
EMPTY
24V3W
SENSOR SWITCH
FLU
S
DC
24V
FLOAT
SUMITOMO CONNECTOR
PART 6187-3231
VIEW A
SE-16
Potentio meter
2K
120
Number of notches
10
Source voltage
5V
NOTCH PART
Accel dial
3MA-JM + AMP
HOUSING : 174359-2
TERMINAL : 171661-1
RETAINER : 1-174360-1
HARNESS SEAL : 172888-2
DIAL
POTENTIO
BRACKET
SE-22,23
Pressure sensor
(High pressure)
Pressure range
0~500kgf/cm2(0~7110psi)
5 0.5V DC
Insulation resistance
P1 pump, P2 pump
1 COMMON
2 OUTPUT (+)
3 POWER SUPPLY (+)
22~25.4 HEX
PF3/8
E1 16
File No.
Name of part
Specification
Description
Use
SV-1,2,3,4
Rated press.
51kgf/cm2 (710psi)
Directional valve
Proportional valve
Specifications of connector
PORT P,T,4
PORT A,B,C,D,1,2,3
PF3/8
PF1/4
PSV-A,B,C,D
Solenoid valve assy
(8-SPOOLS)
Refer to HYD. SYMBOL
SECTION A-01-02-A
E1 17
File No.
Name of part
Specification
Description
Use
PSV-P1,P2
Solenoid
Type
KDRDE-5K
50kgf/cm2 (710psi)
10kgf/cm2 (140psi)
O RING
1B P20
E1 18
HEX 10
Tightening torque
0.5kgfm (3.6 lbfft)
File No.
Name of part
Specification
Description
Use
SW-1
Switch
AUTO RETURN
T
P
G1
G2 ACC
ST
AUTO RETURN
OFF
Starter switch
VIEW A
ACC
ON
K250 STAMPED
START
A
TERMINAL
ARRANGEMENT
SW-3
Type
Switch
(Right travel grip)
Travel 1,2-speed
CA103
E1 19
File No.
Name of part
Specification
Description
Use
SW-4
Switch
Type
Single-pole double-throw
(alternate)
Rated
DC 30V,10A
INSULATION TAPE
R B W
Insulation resistance
VINYL TUBE
SW-5
Contact
construction
T No
Position
ON 1
Normal
ON 2
Type
Switch
(2)
RED (2)
1 2
WHITE (3)
YAZAKI
7122-2237
7114-2020
BLUE (1)
M12P1
ST-425N
(2)
(3)
(5)
KEY WAY
(6)
KPSS release
~
(4)
(8)
(7)
(9)
(11)
(10)
12PAM-HD
SUMITOMO 6098-0252
TERMINAL 8230-4282
(12)
SW-6
Switch
Rated voltage
Operating
temperature
DC24V, DC12V,
Contact type
A
More than 100M
(500V megger)
Insulation resistance
E/G water
temperature switch
[105C (221F)]
ON 105
2C
M4 X 0.7
HEX 21
VIEW Z
PT 3/8
SW-7
Engine oil
pressure switch
182410-0082
DC24V
More than 0.3kgf/cm2
(4psi)
Normally closed
E1 20
M4 X 0.7
File No.
Name of part
Specification
Description
Use
SW-8
Rated output
24X40A
CA104
CB104
CLOGGING SWITCH
Switch
Air filter
clogging switch
SW-10,20,34
Switch
Type
YN03M01367F1
Use
Horn
Rated switch
Horn
power boost
Insulation resistance
125V X 3A
More than 100M /
DC500Vmegger
SW-11
Type
Switch
HEX 17
CONNECTION TABLE
NO
2PAM
2
COM
NC
1
YAZAKI HOUSING 7122-2228
TERMINAL 7114-2020
E1 21
File No.
Name of part
Specification
Description
Use
SW-13
TAP-151N40
DC 20V~30V
Switch
Air conditioner
operation panel
SW-16
Switch
Type
RS-31700
Single-pole single-throw
(Alternate)
Rated voltage
DC 24V
More than 1M /
500V megger
Insulation resistance
Auto accel release SW.
~
(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-17
Switch
Single-pole single-throw
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Insulation resistance
Swing flasher select SW.
(R)
RED
TERMINAL CONNECTOR
(OPT.)
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-21
Switch
Single-pole single-throw
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Insulation resistance
Work light
~
(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
E1 22
File No.
Name of part
Specification
Description
Use
SW-22
Switch
Rated voltage
DC 24V
Single-pole single-throw
Type
(Alternate)
More
than 1M /
Insulation resistance
500V megger
Conflux/single select
(OPT.)
(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-23
Switch
DS-431
Single-pole single-throw
Contact components
ON- (OFF) momently
Makers part No.
Insulation resistance
SW-30
Switch
BLACK
CB104
RED
CA104
Single-pole single-throw
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Insulation resistance
Rotary light
8.7
14
(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-32
Switch
Single-pole single-throw
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Insulation resistance
Overload indicator
(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
E1 23
File No.
Name of part
Specification
Description
Use
SW-42
Switch
Engine room
light switch
CA-104
TERMINAL YAZAKI : 7113-1020-02
CAP YAZAKI
: 7120-8012
CB-104
TERMINAL YAZAKI : 7115-1050-02
CAP YAZAKI
: 7120-1010
E1 24
(R)
RED
LA103 M3
BLACK
(B)
SECTION 25
AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
1. CONSTRUCTION AND PIPING
1.1 Construction ........................................................................................................................ 1
1.2 Piping .................................................................................................................................. 2
3. FUNCTION
3.1 Mechanism of Cooling Circuit ............................................................................................. 7
3.2 Cooling Circuit ..................................................................................................................... 8
3.3 Component Parts ................................................................................................................ 9
5. CHARGING REFRIGERANT
5.1 Precautions to be Exercised in Operation ......................................................................... 18
5.2 Operating Procedure ......................................................................................................... 19
5.3 Charging Procedure .......................................................................................................... 20
6. ELECTRIC CIRCUIT
14403 60413255
7. TROUBLESHOOTING .............................................................................................. 27
1-1
Err
Err
1-3
Err
Err
1-5
1-4
6
2-7
Err
TO CONDENSER
Err
2-3
Err
2-8
TO
COMPRESSOR
Err
2-6
TO CONDENSER
Err
2-4
2-1
Err
2-2
Err
2-5
TO COMPRESSOR
TO AIR CONDITIONER
Err
TO AIR CONDITIONER
Fig. 1
No.
1
1-1
1-3
1-4
1-5
NAME
QTY
AIR-CONDITIONER ASSY
1
AIR-CONDITIONER UNIT
1
SENSOR
1
PLATE
1
MACHINE SCREW
1
No.
2
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
Air-conditioner group
NAME
QTY No.
NAME
AIR DRYER ASSY
1
3 COMPRESSOR ASSY
RECEIVER DRYER
1
4 PANEL ASSY
BRACKET
1
5 FILTER ASSY
L HOSE ASSY
1
6 CONDENSER
D HOSE ASSY
1
S HOSE ASSY
1
L HOSE ASSY
1
D TUBE ASSY
1
S TUBE ASSY
1
QTY
1
1
1
1
1.2 PIPING
T : Tightening torque kgfym (ftylbs)
28
19
T=6.6 (48)
T=6.6 (48) 18
21 24
28
15
27
1
T=1.1 (8.0)
26
AC
OUT
IN
HEATER
10
4
4
10
10
11
6
11
T=2.3 (17)
11
T=4.0 (29)
T=1.0 (7.2)
21
25
28
14
12
3
16
23
12
28
T=1.0
(7.2)
25
20
7
8
20
11
17
T=1.0 (7.2)
T=4.0 (29)
20
23
16
T=0.45 (3.3)
9
Fig. 2(1/2) Installing air conditioner and heater
2
HEATER CIRCUIT
OUT
IN OUT
IN
L HOSE
S HOSE
D HOSE
COMPRESSOR
CONDENSER
L TUBE (HOSE)
Fig. 2(2/2)
RECEIVER DRYER
Tightening
torque
kgfym (ftylbs)
4.0 (29)
1.1 (8.0)
No.
1
2
3
4
5
6
7
8
9
10
11
12
14
15
NAME
BRACKET
SUPPORT
SUPPORT
HOSEL=4150
SPACER
TUBEL=3800
TUBEL=2800
TUBEL=1900
TUBEL=3200
CLIP
CLIP
CLIP
CAPSCREWM816
CAPSCREWM8100
Tightening
torque
QTY
kgfym (ftylbs)
0.45 (3.3)
1
1
1
2
2
2
1
1
1
4
4
2
2
4
6.6 (48)
6.6 (48)
No.
16
17
18
19
20
21
23
24
25
26
27
28
NAME
CAPSCREWM650
CAPSCREWM620
CAPSCREWM1050
CAPSCREWM1060
WASHER
WASHER
LOCK WASHER
LOCK WASHER
NUT
GROMMET
V BELTB42
WASHER
QTY
6
2
2
2
8
6
6
4
2
1
1
6
51
64
62
61
64
50
61
62
52
62
61
48
61
53
62
62
43
49
62
62
62
57
61
62
45
61
44
45
47
42
61
55
46
63
63
63
Fig. 3 Intake unit
4
60
39
36
40
61
37
9
36
14
60
62
1
62
62
31
61 20
64
21
64
26 22
65
62
62
60
19
30
62
18
29 32
10
17 62
24
23
34
25 67
35
24
67
62
33
24 23
67
27
11
62
16
62
12
67
8
23
56
59
58
28
6
13
62 64
20
1 62
5
64
6
56
54
Fig. 4
Air-conditioner unit
5
62
41
15
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
NAME
QTY No.
ACTUATOR
VALVE
THERMISTOR
CLAMP
ROD HOLDER
SENSOR HOLDER
CLAMP
EVAPORATOR
CASING
CASING
CASING
THERMAL INSULATION
THERMAL INSULATION
PACKING
PACKING
PACKING
BRACKET
CLAMP
PLATE
LEVER
LEVER
LEVER
LEVER
NAME
QTY No.
NAME
QTY
3
1
1
2
2
24
25
26
27
28
LEVER
CAM
ROD
ROD
ROD
3
1
1
1
1
47
48
49
50
51
BLOWER MOTOR
CASING
CASING
FILTER
LEVER
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
3
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
DAMPER
DAMPER
DAMPER
DAMPER
DAMPER
DAMPER
HEATER CORE
CONTROLLER
RELAY
CLAMP
BAND
DUCT HOSE
HARNESS
RESISTOR
CASING
CASING
BRACKET
HOSE
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
LEVER
DAMPER
FLANGE PLATE
SENSOR
SEMS BOLT
GASKET
O RING
O RING
TAPPING SCREW
TAPPING SCREW
SCREW
SEMS BOLT
TAPPING SCREW
SCREW
CAPSCREW
TAPPING SCREW
1
1
1
1
1
1
1
1
6
13
30
3
9
1
2
4
2
REFRIGERANT
OUTLET
No.
1
2
3
4
5
6
2-M6
1
3
4
NAME
PRESSURE SWITCH
SIGHT GLASS
DESICCANT
SUCTION PIPE
FILTER
RECEIVER TANK
QTY
1
1
1
1
1
1
3. FUNCTION
3.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that
Table 1
flows through the cooling circuit changes its
Item
HFC-134a (R134a)
phases from liquid to gas and vice versa
Chemical formula
CH2FCF3
during which process heat is transferred from
the low temperature part (compartment) to
Molecular weight
102.03
the high temperature part (outside of the
Boiling point
F)
26.19 (15.14
vehicle).
Critical temperature 101.14 (214.05
F)
1) Kind of Refrigerant
Many kinds of refrigerants that change in
Critical pressure
4.065MPa (41.45kgf/cm2 1)
that way are available, but the following
Critical density
511kg/m3 (31.9 lb/ft3)
requirements are needed for use in such
Density of saturated 1206kg/m3 (75.3 lb/ft3)
applications:
liquid [25 (77.0
F)]
z Latent heat of vaporization (heat of
vaporization) is large.
Specific volume of
0.0310m3/kg (0.496ft3/lb)
z It is easy to liquefy (condense). (It dose not
saturated vapor
require very high pressure for condensation.)
[25 (77
F)]
z It is easy to gasify (evaporate). (It evaporates
Latent heat of
197.5KJ/kg {47.19kcal/kg}
sufficiently at not too low pressure, i.e. cools
vaporization
down an object.)
[0 (32
F )]
z It has small specific heat. (Since the
Flammability
Nonflammable
refrigerant itself is cooled by the expansion
Ozone destruction
0
valve, the loss resulting from it must be held
coefficient
down to a minimum.)
z It has a high critical temperature and a low
1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
solidification point.
(145psi)
z It is stable chemically and does not corrode
and permeate into the circuit parts.
z It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
z It has small specific volume.
z It is easy to find out leakage.
Out
of
refrigerants
meeting
the
above-mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used, sufficient
refrigeration will not be performed or the
equipment in which the refrigerant is used
may be broken. Therefore, always use a PRESSURE
designated refrigerant for the cooling unit.
MPa(kgf/cm2)
Table 1 shows the principal characteristics of
R134a
the R134a refrigerant that is used in this 4 (40.8)
machine.
3 (30.6)
LIQUID
GAS
TEMPERATURE
0
(32)
35
50
15 18
(59)(64) (95) (122)
F)]
100 [ (
(212.0)
EVAPORATOR EXPANSION
VALVE
BLOWER
INSIDE OF ENGINE
S
D ROOM
COMPRESSOR COOLING FAN
RECEIVER
DRYER
CONDENSER
Fig. 7
8
EVAPORATOR
O RING
EXPANSION
VALVE
SOCKET
BOLT
M540
(2 PCS.)
EVAPORATION
SENSOR
Fig. 8
Evaporator
DIAPHRAGM
REFRIGERANT
OUTLET
EVAPORATOR
SIDE
BALL
VALVE
SHAFT
REFRIGERANT
INLET
SPRING
Fig. 9
Fig. 10
10
D HOSE
S HOSE
Fig. 11
Compressor
Fig. 12
Condenser
REFRIGERANT
INLET
SIGHT GLASS
REFRIGERANT
OUTLET
PRESSURE SWITCH
DESICCANT
SUCTION PIPE
FILTER
RECEIVER TANK
Fig. 13
12
Receiver dryer
Table
Tightening Torque
200250 (1418)
200250 (1418)
120150 (8.711)
80120 (5.88.7)
120150 (8.711)
300350 (2225)
120150 (8.711)
200250 (1418)
7090 (5.16.5)
Unit : kgfycm (lbfyft)
Screw Size
Tightening Torque
Amount to be filled in
Evaporator
40cc (2.4cuyin)
Condenser
40cc (2.4cuyin)
Compressor
13
INNER / OUTER
AIR MOTOR
ACTUATOR
CONNECTOR
HARNESS
EVAPORATOR
SENSOR
BLOWER
CONNECTOR CONTROLLER BLOWER MOTOR
CONNECTOR CONNECTOR
Fig. 14
2) Draw out the inner air filter from the intake
casing. Remove four cross-recessed screws
T514 (T1) from the top of the intake casing,
using a screwdriver. Then remove the intake
casing.
INTAKE
CASING
INTAKE
CASING
MOUNTING
SCREWS
(4 PCS.)
BLOWER
CASING
MOUNTING
SCREWS
(3 PCS.)
UNIT
BLOWER
CASING
Fig. 15
BLOWER CASING
BLOWER
MOTOR
BLOWER
CONTROLLER
COOLING
HOSE
BLOWER
CONTROLLER
MOUNTING
SCREWS (2 PCS.)
Fig. 16
z Do not disassemble the blower
controller in any circumstances.
14
BLOWER MOTOR
MOUNTING
SCREWS (3 PCS.)
PIPE CLAMP
PIPE CLAMP
MOUNTING
SCREW
(1 PC.)
AHC BRACKET AHC MOUNTING
SCREW (1 PC.)
Fig. 17
ROD 120
REAR OF
UNIT CASING
ROD HOLDER
MOUNTING SCREW
LEVER MAL1
BOTTOM OF
UNIT CASING
MOUNTING
SCREW
MOUNTING
SCREW
MODE MOTOR
ACTUATOR
Fig. 18
EVAPORATOR ASSY
EXPANSION
VALVE
EVAPORATION
SENSOR
BOTTOM OF
UNIT CASING
TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11 PCS.)
Fig. 19
15
EVAPORATOR
O RING
EXPANSION
VALVE
SOCKET HEAD
CAPSCREW
M5_40 (2 pcs.)
Fig. 20
3rd row
EVAPORATION SENSOR
ROD 120
REAR OF
UNIT CASING
ROD HOLDER
MOUNTING
SCREW
LEVER MAL1
BOTTOM OF
UNIT CASING
MOUNTING
SCREW
MOUNTING
SCREW
Fig. 22
16
MODE MOTOR
ACTUATOR
LEVER AM
ROD 67
ROD HOLDER
LEVER MAL1
AIR MIX MOTOR
ACTUATOR
Fig. 23
3) Replacing the inner/outer air select motor
actuator
Disconnect the connector connected with the
motor actuator.
Separate the motor actuator with lever MAL2
from the unit.
Remove the lever MAL2 from the motor
actuator and install it to a new motor
actuator, in the reverse order of disassembly.
LEVER MAL2
Fig. 24
17
5.
CHARGING REFRIGERANT
(3) Charging
1) When warming the can in which refrigerant
is charged, do not fail to open the service can
valve and the low pressure valve of the gauge
manifold and warm the can in warm water of
40 (104
F) or below (to an extent that you
do not feel hot when you put your hand in the
water.) If the can is put in hot water or
heated by a direct fire, the pressure of the
can may rise sharply, thereby blowing off the
can.
2) When charging refrigerant while running the
engine, do not open the high pressure valve
(HI) of the gauge manifold in any case.
(4) Others
Re-use of service cans is prohibited by law;
never use them again. Do not allow foreign
matter to enter the air-conditioner circuit.
Air, water and dust are detrimental to the
refrigeration cycle. Install the components of
the air-conditioner correctly and speedily.
Pay full attention to the entry of water and
dust.
18
More than
30 min.
Begin vacuum
making
Leave it as it is,
for five minutes.
Stop vacuum
making
Fill in
refrigerant
Check
air-tightness
Check for
gas leak
Fill in
refrigerant
Lower than
750mmHg
Gauge
indicates
b
li
Check and correct joints
(3) Tools
Table
No. Name of Part Q
TY
1 Gauge
Sketch
Service
unit : mm
hose
3 Quick joint
1
27.5
Red : high
pressure
side
Blue : low
pressure
side
Yellow :
vacuum
pump
side
High
pressure
side
5 T joint
6 Service can
For service
can
For
vacuum
pump
valve
7 Vacuum
pump adapter
19
Service
Low
pressure
side
For service
can valve
4 Quick joint
manifold
2 Charging
Sketch
23.5
LOW PRESSURE
GAUGE
(CLOSED) LOW
PRESSURE VALVE
HIGH PRESSURE
VALVE (CLOSED)
BLUE
RED
HIGH
PRESSURE
SIDE
DIS
YELLOW
LOW
PRESSURE
SIDE
SUC
COMPRESSOR
Fig. 25
VACUUM PUMP
(STOP)
BLUE
RED
CHARGING
HOSE
Fig. 26
(CLOSE)
(CLOSE)
GAUGE MANIFOLD
DIS
SUC
Fig. 27
20
AIR PURGE
CLOSE
RED
OPEN SERVICE CAN VALVE
SCREWDRIVER
YELLOW
BLUE
Fig. 28
LOW PRESSURE
VALVE (CLOSE)
BLUE
DIS
SERVICE CAN
VALVE
(OPEN)
(CLOSE)
CHARGE
SUC
Fig. 29
21
HIGH PRESSURE
VALVE (CLOSE)
(MUST BE CLOSED
POSITIVELY)
LOW PRESSURE
VALVE
CLOSE
OPEN
RED
WHEN AIR
BUBBLES IN THE
SIGHT GLASS
DISAPPEAR
BLUE
DIS
YELLOW
SERVICE CAN
VALVE (OPEN)
SUC
COMPRESSOR
OPERATION
SERVICE CAN
(DO NOT TURN IT OVER)
Fig. 30
SIGHT GLASS
Fig. 31
22
Receiver dryer
the
Amount
of
Overcharge
Undercharge
23
6.
ELECTRIC CIRCUIT
Fig. 32
Electric diagram
24
6.2
(1)
1)
2)
3)
2
As viewed from A
Fig. 33
Relay
Fig. 35
Blower controller
Fig. 36
25
Motor actuator
(4)
PRESSURE SWITCH
Fig. 37
(30) (31)
2.1 2.2
(36)
2.5
Pressure switch
(430)
30
(480)
34
2) Performance
Low pressure side : To prevent actuation of
the compressor clutch
where refrigerant is
deficient
High pressure side : To prevent actuation of
the compressor clutch
where pressure rises
abnormally because of
the clogging of the
refrigeration circuit, etc.
(5) Thermistor (C19)
1) Contents of checking (specification)
Resistance across terminals
at 0 (32
F) : 7.2k
at 25 (77
F) : 2.2k
Note :
Normally check that there is no shortcircuit
or disconnection.
2) Performance
In order to prevent freezing of the evaporator,
the blowoff air temperature of the evaporator
is controlled by turning the compressor clutch
ON and OFF. The thermistor operates as the
sensor of the control.
Fig. 38
26
Thermistor
kgf/cm2 (psi)
7. TROUBLESHOOTING
Temperature does not fall.
If A/C switch is pushed, HL.E is indicated on the set temp. display of the panel.
YES
NO
HL. is shown on the set temp. display of the panel.
YES
NO
on display.
is any of the
numbers 0 9.
Note)
YES
NO
YES
NO
1
NO
YES
If M/A is at stop
halfway, eliminate
cause, correct and
measure operating
force.(less than
1.5kgf : OK)
NO
Controller is faulty
or inner air sensor
is faulty.
Refer to Troubleshooting
for refrigeration cycle.
Inspect duct or
eliminate cause for
chilly air intrusion.
: COOL-MAX
action condition
YES
YES
27
NO
Note)
YES
NO
2
YES
NO
If M/A action is at
stop, eliminate cause,
correct and measure
operating force.
(less than 1.5kgf : OK)
YES
NO
YES
Controller or
inner air sensor
is out of order.
Inspect duct or
eliminate causes
for warm air entry.
NO
YES
z Inspect, correct or
replace M/A lever link.
z Clean lever link and apply grease.
28
: HOT-MAX
operating condition.
NO
NO
Replace.
YES
NO
YES
YES
Wire harness is
faulty. Inspect
and correct or replace.
NO
YES
NO
Inspect and repair
harness or replace.
Blower turns if
brown / red of
blower motor
relay is connected
with ground.
NO
YES
Eliminate cause
and replace
blower amplifier.
Inspect and
repair
harness.
YES
Replace relay.
YES
Replace blower
amplifier or controller.
YES
To B
On page 27.
YES
Clutch faulty.
Replace compressor.
YES
NO
YES
Inspect air-conditioner
and machine connector.
Also clutch fuses.
Inspect air-conditioner
harness. No fault.
NO
Replace harness.
YES
Replace controller.
YES
M/A failed
YES
Inspect or replace.
Remove foreign matter
and replace parts.
Replace
30
YES
NO
Repair.
YES
Inspect or replace.
NO
YES
When rod is removed and cam is operated
by hand, it is heavy. (more than 2kgf.)
Repair.
NO
YES
Replace.
31
YES
High pressure
is lower.
YES
Compressor
cylinder does
not get hot.
Hot air
comes out of
heater unit.
Compressor
cylinder gets
very hot.
YES
Expansion
valve is
clogged
or maladjusted.
Expansion
valve is
frozen or
intruded
by water.
Natural
leak from
hose.
Gas leaks
from pipe
joints and
parts.
Expansion
valve is maladjusted.
(too much
open)
Water cock
is maladjusted
or faulty.
Compressor
does not
discharge
well.
Adjust or
replace
expansion
valve.
After making
vacuum, refill
refrigerant
and replace
receiver.
Charge gas.
Retighten
or replace
parts.
Replace
expansion
valve.
Adjust or
replace
water cock.
Replace
compressor
Frost deposits.
Air bubbles are seen in sight glass.
NO
YES
Thermistor does
not cool off.
Condenser is
fouled or clogged.
NO
YES
YES
High pressure
circuit before
receiver is
clogged up.
Remove
clogging
or replace
parts.
NO
Thermostat is
not turned off.
Clean
condenser
Air is mixed.
Make vacuum
and refill
refrigerant.
NO
Functions and
performances
are normal.
Familiarize
the user with
how to use it.
32
YES
Thermistor
is faulty or
cord is
disconnected.
Thermistor position
is normal.
NO
Thermistor
position is
faulty.
Correct
position.
YES
Air
leaks
out of
casing.
SECTION 31
TABLE OF CONTENTS
14403 60413255
SECTION 32
ATTACHMENT
TABLE OF CONTENTS
[Part I. Removing and Installing Assy]
1. ATTACHMENT ASSY AND NAME ..........................................................................
2. BUCKET ..................................................................................................................
3. ARM ........................................................................................................................
4. BOOM .....................................................................................................................
I-1
I-1
I-4
I-7
14403 60413255
ARM CYLINDER
,ABOOM FOOT
4. BOOM
,FBOOM TOP
,EARM
CYLINDER ROD
,GBUCKET
CYLINDER
3. ARM
,IIDLER LINK
,BBOOM
BUCKET LINK
IDLER LINK
BUCKET CYLINDER
CYLINDER
2. BUCKET
Fig. 2-1
BOSS
DRIVER
BOSS SECTION
Fig. 2-2
1
Fig. 2-3
Fig. 2-4
2.2 ATTACHING BUCKET
(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
continue in the reverse procedure of the
pulling out.
CROWBAR
Attaching bucket
BUCKET
12
3
10
(b)
(a)
ARM
13
: 24mm
(6) After adjustment, tighten the capscrews
evenly.
z The gap exceeding the specified
dimension causes a premature wear.
(7) Operate the bucket and confirm that the total
sum of both clearance is within 1.2mm
(0.05in)
(8) Refit O ring (3) to its original position.
z When shifting O ring (3) by means of
a spatula, use care so as not to score
O ring (3).
z Remove shims (12), push out
bushing (8) rightwards by means of
three capscrews (10) and adjust
clearance (B) so it falls within the
standard value evenly all round.
z Check the clearance at 120 hours
intervals in normal operation.
Shorten these intervals in heavy
digging. Adjust the intervals as
necessary.
Fig. 2-6
3.
ARM
Fig. 3-1
SECTION
Fig. 3-3
9
Detail of bucket cylinder rod pin (H)
: 24mm
SECTION
Fig. 3-4
4
Fig. 3-5
(6) Removing arm cylinder rod pin (E)
Put a wooden block between the arm cylinder
and the boom.
Loosen nut (6), remove capscrew M16140
(4), and push out arm cylinder rod pin (E).
: 24mm
Retract arm cylinder rod, and return pin (E)
to the original position (hole).
6
SHIM
After adjustment of shim, the
total gap should be within
0.62.0mm (0.020.08in).
E
BLOCK
SECTION
Fig. 3-6
SECTION
Fig. 3-7
5
Fig. 3-8
3.2 ATTACHING ARM
Install the arm in the reverse order of
removing, paying attention to the following :
1) When aligning the pin holes, do not put your
finger in the pin holes in any circumstances,
but align them visually.
2) Check that the dust seals is not scored and
replace a faulty one if necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Apply Locktite #242 to the pin-securing
capscrews and nuts and fasten them.
Pin lock nut handling procedure
4.
BOOM
Fig. 4-1
STAND
Fig. 4-2
: 24mm
SHIM
3
C
Fig. 4-3
7
SECTION AA
Detail of boom cylinder rod pin (C)
VIEW__
SHIM
DUST SEAL
2
A
SECTION_AA
Fig. 4-6_Details of boom foot pin (A) section
I-8
Fig. 4-7
SHIM
: 36mm,
Tightening torque ; 18kgfym (130 lbfyft)
: 24mm
3) Remove arm cylinder.
Fig. 4-8
(11) Removing boom cylinder
1) Disconnect hose at B section. and plug both
ends.
ORS plug 4-(4)
: 32mm,
Tightening torque ; 14kgfym (100
lbfyft)
: 36mm,
Tightening torque ; 18kgfym (130
lbf ft)
9
Fig. 4-9
SHIM
: 24mm
B
6,7
Fig. 4-10
SECTION
BB
Removing boom cylinder head pin (B)
B
B
Fig. 4-11
10
1. CYLINDER
1.1 PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and
necessary equipment and facilities.
1.1.1 WORK AREA
The following working area is required for
disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder,
the cylinder tube and the piston rod must be
drawn out. For this reason, the first condition
is that the working area is long enough for
the work. In terms of width, it is also
necessary to keep sufficient space so
disassembly,
cleaning
and
measuring
equipment are placed and the work can be
performed.
(2) Suitable working environment
The
hydraulic
cylinder
is
a
precision-machined product that uses seals
and packings made of rubber and plastic
materials. For this reason full care should be
exercised so the hydraulic cylinder is free
from dust, dirt, and in particular, such hard
particles as sand, metal chips, and weld slag
(spatter). If the hydraulic cylinder is
assembled with hard particles adhered on
such components as the cylinder tube and the
piston rod, the tube inner surface and the rod
surface are scratched as the cylinder
operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod
seals will result in oil leaks. For this reason,
grinding and welding operation should not be
performed in the neighborhood of the working
area to keep it clean
1.1.2 APPARATUS
The following equipment are required for
disassembly:
(1) Hoist or crane
The hoist or crane must be capable of
carrying the cylinder in an assembled
condition. It must also be capable of marking
level and liner movement under load for
retracting and extending the piston rod and
the tube.
11
Table 1-1
Tool / Jig
Hammer
Remarks
1. Steel hammer
Remarks
Spatula
Jig
Chisel
Flat chisel
Vise
Wrench
1. Hook wrench
2. Allen wrench
Rust remover
Measuring
instruments
1. Slide calipers
2. Micrometer
3. Cylinder gauge (Fig. 1-1)
4. V-block
Fig. 1-1
Cylinder gauge
WOODEN
BLOCK
PORT B
V BLOCK
12
AIR
PORT A
OIL PAN
Fig. 1-2
Discharging oil
660 (26.0_)
0
0
105 _0.5
(4.13__0.0197_
)
0
0
105 _0.5
(4.13__0.0197_
)
_Z
M12_1.75 (Through)
24 25
25 24
27
SLIT
26
BLACK
28,29
T=3.2(23)
GREEN
DETAIL B
With hole
(1 place)
VIEW_Z
DETAIL C
T=27.2(200)
9
7 6
T=421(3000)
12 10,11
T=5.8(42)
13 14 15 16 17 18 19 20 21 22,23
2 1
C
SLIT
Fig. 1-3_ Construction of boom cylinder
(The figure shows the right-hand cylinder.)
P/No. YB01V00008F1
No.
NAME
QTY
No.
NAME
QTY
No.
NAME
QTY
CYLINDER TUBE
11
BACK-UP RING
21
NUT
PISTON ROD
12
SOCKET BOLT
10
22
SET SCREW
CYLINDER HEAD
13
CUSHION BEARING
23
STEEL BALL
BUSHING
14
CUSHION SEAL
24
PIN BUSHING
SNAP RING
15
PISTON
25
WIPER RING
BUFFER RING
16
SEAL RING
26
BAND
U RING
17
BACK-UP RING
27
BAND
BACK-UP RING
18
SLIDE RING
28
BOLT
WIPER RING
19
SLIDE RING
29
WASHER
10
O RING
20
SHIM
1
II - 1 - 3
1.3 DISASSEMBLY
z When disassembling and servicing
the cylinder, check the construction
and the availability of service parts
as well as necessary tools and jigs on
separate Parts Manual.
z The figures in parentheses after part
names correspond to those in
Fig.1-3.
z The explanations and quantities
below are for a boom cylinder. Apply
the same to other cylinder as well.
1.3.1 REMOVING 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.
2) Pull out piston rod (2) about 200mm (8in).
Because the piston rod (2) is heavy, finish
extending it with air pressure after the
above-mentioned oil draining operation.
Fig. 1-4
ALLEN WRENCH 12
: 14mm
Cover the extended piston rod (2) with rag
to prevent it from being accidentally
damaged during operation.
Turn counterclockwise
3
2
Fig. 1-5
14
LIFT HERE.
3
2
Drawing out piston rod assy (2).
1
LIFT HERE.
PULL
STRAIGHT
SIDEWAYS
O
O
OIL PAN
Fig. 1-7
Fig. 1-8
7) Remove slide ring (18),(19) and back-up ring
(17) from piston (15).
15
TAKE IT OFF BY WIDENING
THE SLIT TOWARD
THE ARROW
17
18,19
Fig. 1-9
15
WOODEN
PIECE
15
21
WOODEN V-BLOCK
(PLACE RAG.)
Fig. 1-10
2) Scrape off the caulked part of setscrew (22) of
piston nut (21) by means of a hand drill and
loosen and remove setscrew (22).
DRILL
: 6mm
21
23
Fig. 1-11
TURN
COUNTER
CLOCKWISE.
15
HOOK
WRENCH
Fig. 1-12
21
Fig. 1-13
16
15
Fig. 1-14
1.3.3 DISASSEMBLING PISTON ASSY
1) Remove seal ring (16) and buck-up ring (17).
8,7 9
HAMMER
BACK-UP RING
17
SEAL RING
16
15
Fig. 1-15
O RING
17
SPATULA
10
11
3
Fig. 1-16
2) Remove buffer ring (6), U ring (7) and
back-up ring (8). Each seal is fixed in the
groove on the bore and removing in flawless
is impossible.
Stab each seal with a gimlet and pull it out of
the groove.
8
7
Fig. 1-17
HAMMER
SCREWDRIVER
WOOD PIECE
WOOD PIECE
VISE
Fig. 1-18
4) Remove snap ring (5) and bushing (4). After
taking out snap ring (5) in the same way as
mentioned above, remove rod bushing (4).
Bushing (4) is impossible to remove as it is
press fitted in cylinder head (3). Machine the
bushing thin on a lathe, insert a steel
spatula hard into the gap at the chamfered
edge of the remaining bushing and pry it up.
4
3
WOOD PIECE
WOOD PIECE
VISE
Fig. 1-19
18
(24)
of
piston
rod
(2).
When
METAL PIECE
(JIG A)
24
Fig. 1-20
BASE
1.4 CLEANING
1) When the cylinder has been disassembled,
wash all parts with a suitable commercial
detergent.
Do not use volatile agents (gasoline
and thinner) as they deteriorate
rubber.
2) Do not reuse the once-removed oil seals, O
rings and back-up rings even though they
have found reusable on inspection.
3) After cleaning, dry all parts with jet air and
place them on a clean work bench so that
they may not be damaged.
1.5 ASSEMBLY
Start assembly with the subassemblies listed
below:
Cylinder tube assy
Piston assy
Cylinder head assy
1.5.1 INSTALLING PIN BUSHING
Press fit pin bushing (24) into cylinder tube (1)
and piston rod (2), using a press.
24
Fig. 1-21
19
PRESS HERE
METAL
HOLDING
JIGD
JIGC
15
16
17
Fig. 1-22
HANDLE
Fig. 1-23
1.5.3 ASSEMBLING CYLINDER HEAD ASSY
1) Press bushing (4) into cylinder head (3) using
a metal ring. There after fix snap ring (5) into
the groove. Before pressing in the bushing,
coat the inner face of cylinder head (3) with
hydraulic oil.
GROOVE FOR
FIXING SNAP RING (5)
Fig. 1-24
PRESS METAL
RING.
METAL RING
Fig. 1-24
110
RUBBER
LIP
Fig. 1-26
10
11
3
Fig. 1-27
1.5.4 INSERTING CYLINDER HEAD ASSY TO
PISTON ROD
Inserting the cylinder head (3) to the piston rod
assy as follows:
1) Fix the piston rod assy into the work bench.
111
7
8
9
14
13 2
V-BLOCK
PISTON ASSY
Fig. 1-29
112
21
HOOK WRENCH
TURN CLOCKWISE.
Fig. 1-30
23
22 ANTI-LOOSENING CAULKING
20
V-BLOCK
13
Fig. 1-31
22
21
18
V-BLOCK
113
12
PLACE RAG.
:14mm,
Tightening torque :
27.2kgfym (200 lbfyft)
Take care so as not to damage the rod
surface by accidentally slip a wrench.
Covering the rod surface with rag is
recommended to prevent damage to it.
For the tightening torques, refer to
(-1-16).
TORQUE WRENCH
TURN
CLOCKWISE.
Fig. 1-34
1.6 INSPECTION AFTER ASSEMBLY
(1) No-load functional test
Place the cylinder level at no load, operate
the piston rod 5 to 6 strokes by the
directional valve and make certain that it
operates without fault.
DIRECTIONAL VALVE
PUMP
HYDRAULIC CYLINDER
Fig. 1-35
MEASURE THE
INTERNAL LEAK.
Fig. 1-36
2) After completing the test, apply a plug to
each port and store it (Fig. 1-37).
CYLINDER ASSY
PLUG
Fig. 1-37
114
Cylinder
tube
Cylinder
head
Inspecting Section
Inspection Item
Remedy
Presence of crack
Replace.
Presence of crack
Replace.
Presence of crack
Replace.
4. Threads
Presence of seizure
Recondition or replace
5. Bend
6. Plated surface
Check that:
1) Plating is not worn off
to base metal
2) Rust is not present on
plating.
3) Scratches are not
present.
1) Replace or replate
2) Replace or replate
3) Recondition, replate or
replace.
7. Rod
Wear of O. D.
8. Bushing at mounting
part
Wear of I. D.
Replace.
1. Weld on bottom
Presence of crack
Replace.
2. Weld on head
Presence of crack
Replace.
3. Weld on hub
Presence of crack
Replace.
4. Tube interior
Presence of faults
5. Bushing at mounting
part
Replace.
1. Bushing
Fig. 1-39
Table 1-4
Cylinder
A
Piston nut
B
Socket bolt
Boom
421
(3050)
27.2
(200)
Arm
837
(6050)
27.2
(200)
Bucket
491
(3550)
17.4
(130)
Measuring Method
Cylinder
Table 1-3 shows an example of measurement.
Table 1-3 Example of Measurement
Remedy
m (in)
1 (33)
1 (0.04)
Replace
Distance
between
V-blocks
Middle of rod
Fig. 1-38
116
Boom
Arm
Bucket
Table 1-6
1.8 TROUBLESHOOTING
Trouble
Faulty Part
Cause
Remedy
1. Cylinder
tube
1. Welds of
fractured.
cylinder
WELDS
USE THIS
PORTION.
Fig. 1-40
1.9.1 ALLEN WRENCH_AW_
(For cylinder head socket bolt)
B
A
C
Fig. 1-41
Table 1-7
Unit : mm (inch)
Cylinder Used
Boom, Arm
A
140 (5.51_)
B
56 (2.20_)
C
14 (0.55_)
Socket Bolt
M16
Bucket
125 (4.92_)
45 (1.77_)
10 (0.39_)
M12
D
E
MATERIAL : SS41
SURFACE TREATMENT : PARKERIZING
A
B
15
C
Fig. 1-42
Table 1-8
Cylinder Used
50_70
(1.97__2.76_)
81
(3.19_)
86
(3.39_)
96
(3.78_)
93
(3.66_)
98
(3.86_)
108
(4.25_)
20_30
(0.787__1.18_)
8
(0.315_)
Bucket
Boom
Arm
Unit : mm (inch)
II - 1 - 18
B
Fig. 1-43
119
Unit : mm (inch)
Cylinder used
95 (3.74)
Arm
85 (3.35)
Boom
80 (3.15)
Bucket
Fig. 1-44
Table 1-10
Cylinder Used
Bucket
Arm
Boom
SEAL
FIXING
Unit : mm (inch)
d
80 (3.15)
89 (3.50)
85 (3.35)
100 (3.94)
JIG
MATERIAL : SS41
Fig. 1-45
Table 1-11
Unit : mm (inch)
Cylinder Used
D1
D2
Bucket
104.6 (4.12)
106 (4.17)
85 (3.35)
Boom
114.6 (4.51)
116 (4.57)
90 (3.54)
Arm
124.6 (4.91)
126 (4.96)
100 (3.94)
120
25 (0.984)
65 (2.56)
MATERIAL : NYLON
O RING
Fig. 1-46
Table 1-12
Unit : mm (inch)
Cylinder Used
O ring
Bucket
105 (4.13)
1B
P105
Boom
115 (4.53)
1B
P115
Arm
125 (4.92)
1B
P125
MATERIAL : SS41
Weld it before
d lathed
Fig. 1-47
Table 1-13
Unit : mm (inch)
Cylinder Used
Bucket
105 (4.13)
120 (4.72)
Boom
115 (4.53)
130 (5.12)
Arm
125 (4.92)
140 (5.51)
121
L
50 (1.97)
SECTION 33
UPPER STRUCTURE
TABLE OF CONTENTS
14403 60413255
II-1
II-2
II-3
II-4
II-5
II-6
1.
CAB
1.1 REMOVAL
(1) Remove floor mat
(2)
1)
2)
3)
4)
(3)
1)
2)
3)
4)
BOLT (25-9)
COVER
24
ANTENNA
GROMMET
To instrument panel
A1
M10
Tool
Tightening torque
kgfm (lbfft)
Nut M16
24
19.5 (140)
Capscrew (A1)
17
4.7 (34)
GROMMET
B2
TUBE
5pcs
Remove washer
tube at connector
TUBE
M16
NUT
4 pcs.
Fig. 1-2
1.2 INSTALLATION
Mount it in reverse procedure of Dismounting
according to the Tightening Torque Table.
Tightening position
CONNECTOR
HAND RAIL
FOR TUNER
A1
2. OPERATOR SEAT
2.1 REMOVAL
(1) Remove seat. (Include upper rail.)
1) Remove four M8 capscrews (15) in the upper
rail.
2) Remove seat
[Approx.15kg (33 lbs) with upper rail]
: 6mm
(2)
1)
2)
3)
4)
M816
15
SEAT
2.2 INSTALLATION
Install it in reverse procedure of removing
according to the tightening torque table.
UPPER RAIL
LOWER RAIL
15
M816
8
6
4.7 (34)
2.4 (17)
M830
13
M816
15
9
M1025
Fig. 2-1
M825
18
PLATE
(STOPPER)
Floor plate
Dismounting and mounting seat
3.
3.1
(1)
1)
2)
3)
4)
BATTERY
REMOVE
Open right cover.
Open it with starter key.
Open cover.
Fix it with stay.
Remove rubber (A7). (See Fig.3-3)
RIGHT COVER
Fig. 3-1
BATTERY RELAY
If
this
order
is
missed,
A2
3.2 INSTALL
(1) Install the battery in the reverse procedure of
removing.
Battery attaching capscrew (A3)
: 17mm,
Tightening torque : 1.1kgfym (8.0 lbfyft)
(2) Installing grounding cable
Install grounding cable last. Especially care
must be taken that the grounding face is free
from painting, rust, etc.
: 13mm
B1
Fig. 3-3
Removing battery
4. GUARD
4.1 PREPARATION FOR REMOVAL
(1) Remove guard in the following procedure.
When removing the components remove only
the guards that are required for removal. The
order of removal of the engine : (4), (5), (9),
and (10)
1-2
1-1
11
2,3
18
4
52,83
14,25,53,54
8
17
7
91
Fig. 4-1
4.2
(1)
1)
2)
3)
4)
5)
REMOVE GUARD
Remove cover assy (11)
Unlock cover assy (11) and lift it up
Remove stay for stopper.
Remove gas spring.
Remove two sems bolts (36) M1230.
Remove cover assy (11).
: 19mm
Weight : 18kg (39 lbs)
10
11
36
HINGE
Fig. 4-2
(2) Remove panel assy (2), (3)
1) Remove two sems bolts (37) M1025 and
open the panel assembly.
: 17mm
2) Remove two nuts (70) M12.
3) Remove panel assy (2).
: 19mm
Weight : 12kg (26 lbs)
4) Remove three sems bolts (36) M12 30, a
capscrew (80) M1230 and panel assy (3).
: 19mm
Weight : 15kg (33 lbs)
37
2
80
36
36
70
Fig. 4-3
(3)
1)
2)
3)
35
9
51
10
27
28
41
28
36
Fig. 4-4
37
35
Fig. 4-6
27
1-2
1-6
1-3
1-5
36
1-1
36
Fig. 4-7 Removing box (1)
(9)
1)
2)
3)
52
83
61
36
61
Fig. 4-8
49
62
36
21
Fig. 4-9
19
35
36
18
35
12
35
35
Fig. 4-10
64
14
35
54
56
53
25
Removing cover assy (14), (25), (53),
(54)
64
47
36
35
17
69
35
68
35
16
Fig. 4-13
20
Fig. 4-14
45
64
Fig. 4-15
(25) Remove cover assy (91)
1) Open cover (91-1).
2) Remove six sems bolts (36) M1230.
: 19mm
3) Remove cover assy (91).
Weight : 32kg (70 lbs)
36
Removing bracket assy (45)
36
36
91
7
91-1
4.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
(2) Tightening torque
: 19mm M12
: 17mm M10
36
36
Fig. 4-16
8.1kgfym (59 lbfyft)
6.7kgfym (48 lbfyft)
91-2
5. UNDER COVER
5.1
(1)
1)
2)
REMOVAL
Remove under cover (1, 2, 3, 4, 5, 6)
Remove sems bolts (7) M1225.
Remove covers.
: 19mm
1
7
2
7
6
7
5
7
4
Fig. 5-1
5.2 INSTALLATION
(1) Install under cover (1, 2, 3, 4, 5, 6)
: 19mm
Tightening torque : 8.1kgfym (59 lbfyft)
7
Under cover assy
6. FUEL TANK
6.1
(1)
1)
2)
3)
A2
RETURN
5,9,12
SUCTION
6,11,12
Fig. 6-1
A2
6.2 REMOVAL
(1) Remove bracket (B17) and stay (B18) that
B20
connect the tank with the upper frame.
1) Remove two sems bolts (B19) M1230.
2) Remove bracket (B17).
: 19mm
B18
3) Remove four sems bolts (B20) M1225 and
separate stay (B18).
: 19mm
(2) Remove fuel tank assy (A1)
1) Remove four capscrews (B1) M16 45 and
three shims (B3).
: 24mm
A1
B17 B19
B20
B6
B4
10
B1
B3
Fig. 6-2
NAME
Tightening torque
kgfym (lbfyft)
B1
CAPSCREW
22 (160)
B6
MACHINE SCREW
0.2 (1.4)
8.1 (59)
7.
HYDRAULIC TANK
11
2,3
Fig. 7-1
(2) Bleeding the tank internal pressure
Push the boot of the cap on breather assy
(A9) by your finger tip, to vent the internal
pressure.
Remove guard
Push
A9
Fig. 7-2
(3) Remove cover (A7).
1) Remove six capscrews (A13) M1020.
: 17mm
2) Remove cover (A7).
A6
A2
A10
A11
A9
Fig. 7-3
11
A14
A8
A6
A5
A4
A3
REMOVAL
Draw out the suction hose (3)
Remove two clips (16) of the tank side.
Pulling out hose (3).
: Flat-blade screwdriver
PLATE
FOR
LIFTING
PILOT
RETURN
HOSE
SECTION
3
B3
16
B1
Fig. 7-4
11
6
7
Fig. 7-5
HYDRAULIC TANK
A21
B5
D23
D23
C20
Fig. 7-6
12
7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
O RING
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of
removing.
(4) Install four attaching capscrews (B1) M16
40 with Locktite #262. (See Fig. 7-4)
: 24mm
Tightening torque : 22kgfym (160 lbfyft)
SUCTION
STRAINER
13
RETURN
FILTER ELEMENT
Fig. 7-7
8. HYDRAULIC PUMP
A13
A7
SUCTION
STOPPER
SUCTION
STRAINER
HYDRAULIC TANK
68
8.2 REMOVAL
(1) Loosen half clamp (8) on hoses (4), (5) and
capscrews (9) M1035 and disconnect two hoses on
the delivery side.
: 17mm
HYDRAULIC
TANK
2)(1.57in)
Remove suction tube (1) from pump.
10
Fig. 12-3
I-14
Size
Tool
Dr1
PF1/2
27
Psv1,2 PF1/4
19
A3
PF3/8
22
B3
PF3/4
36
Dr3
PF3/8
22
Connected
to
Tank
Remarks
Drain
Dr3
A3
Psv1
Gear pump
Line filter delivery port
for pilot
Suction port
Tank
for pilot
Drain port
Tank
for pilot
Psv2
B1
Dr1
A2
A1
B3
Fig. 8-4 Pump port
A4
2) Attach tags to hoses to identify.
(4) Remove main pump
1) Place a wire rope and tension it a little by
utilizing the eye bolt (M10) at the top of the
hydraulic
pump.
Temporarily
loosen
capscrew (4) and remove capscrew (3).
: 14mm, weight : 95kg (209 lbs)
: 17mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the
tension of the wire rope.
On that occasion, the coupling rubber (2-1)
comes out with the hydraulic pump.
0
4
3
1
2-3
2-4
2-1
2-6
2-2
2-5
Fig. 8-5
15
2
Removing pump
8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1)
Install bracket (1) to the pump and temporarily
fasten them together by means of socket bolts (4).
: 14mm
(2) Installing hub (2-2)
Insert hub (2-2) into the spline of the pump till the
end face of the spline enters 4mm (0.16in) inward
(Refer to the Detail A.) and attach two setscrews (25).
: 8mm
Tightening torque : 11kgfym (80 lbfyft)
(3) Installing coupling rubber (2-1)
Insert coupling rubber (2-1) into hub (2-2) and
attach socket bolts (2-4).
On that occasion, do not coat socket bolts (2-4) with
Locktite. (Socket bolts (2-4) are with micro capsule
coating.)
: 14mm
Tightening torque : 22kgfym (160 lbfyft)
(4) Installing the pump
Lift the pump with bracket level and dock it in so
bolts (2-3) enter the holes in coupling rubber (2-1).
Re-fit nine cap screws (3) and two cap screws (6)
where they were.
: 17mm
Tightening torque : 6.6kgfym (48 lbfyft)
(5) Tighten socket bolts (4) regularly.
: 14mm
Tightening torque : 19.5kgfym
(140 lbfyft)
(6) Attach hoses (4), (5) of the delivery side with half
clamp capscrews (9).
: 17mm
Tightening torque : 5.8kgfym
(42 lbfyft)
(7) Install the suction tube (1) attaching socket bolts
(10) M12 (4pcs.)
: 10mm, (_Special service tool No.6-1)
Tightening torque : 10kgfym (72 lbfyft)
(8) Installing the hose
Tool
Tightening torque
kgfym (lbfyft)
27
8.0 (58)
19
3.0 (22)
Cap nut A3
22
5.0 (36)
Cap nut B3
36
12.0 (87)
22
5.0 (36)
Tightening position
2-4
T=Tightening torque
4 T=19.5kgfym (140 lbfyft)
2
_
_
A
2-5
T=11kgfym
(80 lbfyft)
T=6.6kgfym(48 lbfyft)
2-3
T=22kgfym(160 lbfyft)
Do not use Locktite. (The
attached bolts are coated
with micro capsule coating.)
equivalent
BRACKET
2-1
2-2
2-4
2-5
(0.157)
DETAIL A
VIEW__
Fig. 8-6 Installing Hydraulic pump
HYDRAULIC PUMP
HYDRAULIC TANK
10
1
Fig. 8-7
I-16
a2
Tool
19
Tightening torque
kgfym (lbfyft)
8.1 (59)
Fig. 12-8
35
16
Fig. 12-9
17
9. AIR CLEANER
9.1 PREPARATION FOR REMOVAL
(1) Opening bonnet assy (10)
9
(2) Opening cover assy (5)
(3) Unplug terminals on indicator lines (1-5)
9.2
(1)
1)
2)
(2)
1)
2)
(3)
1)
2)
3)
REMOVAL
Pulling out hose (5).
Loosen clips (7) on both sides of hose (5).
Pulling out hose (5)
: Flat-blade screw driver
Pulling out hose (2).
Loosen clips (7) on both sides of hose (2).
Pulling out hose (2)
: Flat-blade screw driver
Removing hoses (3), (4) and intake tube (6)
Loosen clips (8), (9) on both ends of hoses (3), (4).
Loosen nut (12) and remove U bolt (11).
Separate hoses (3), (4) and intake tube (6).
: Flat-blade screw driver
: 13mm
10
1-6
1-2
7
1-5
10
12
2
7
7
7
5
9.3 INSTALLATION
(1) Installing is the reverse order of removing with
attention paid to the following items:
1) The insertion depth of air hose (2) shall be 30mm
(1.2in).
3 8
6
8
8
11
9
4
3) Tightening torque :
(2) Replacing parts
No.
NAME
1-5 INDICATOR
10
SEMS BOLT
Tightening Torque
kgfym (lbfyft)
0.4 (2.9)
4.0 (29) Apply Locktite #262
FILTER ELEMENT (1-2)
I-18
O RING (1-6)
10. MUFFLER
10
16
4
10.2 REMOVAL
(1) Remove U bolt (3).
1) Remove four nuts (5) M8.
2) Remove two U bolts (3).
: 13mm
(2) Remove clamp assy (10)
1) Remove two capscrews (8) M1035
2) Separate clamp assy (10) from muffler (1).
: 17mm
(3) Removing other parts
Remove exhaust tube (7) and brackets (2), (17),
where necessary.
: 13mm, 17mm
69
68
B
A
16
10.3 INSTALLATION
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (3)
1) Tighten four nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm the
C dimensions on the right and left once again.
3) Tighten nuts (B) to specified torque and make sure
that U bolts (3) are not inclined.
4) Tightening torque
Nut A : 0.9kgfym(6.5 lbfyft)
Nut B : 1.1kgfym(8.0 lbfyft)
C
PROCEDURE OF
FASTENING U BOLT
3
1
12
16
5
19
2 18
17
10
18
No.
5-1
NAME
Tightening
torque
kgfym (lbf yft)
NUT ; M8
2.9 (21)
CAPSCREW ; M10
7.2 (52)
12
CAPSCREW ; M10
6.6 (48)
16
CLIP
0.3 (2.2)
(3)19 Replacing
parts
CAPSCREW ; M10
5-1 8
6.0 (43)
REMARK
7
4
NAME
MUFFLER (1)
GASKET (4)
I-19
11
11. COUNTERWEIGHT
BONNET
5
Fig. 11-1 Lifting up counter weight
11.2 REMOVAL
(1) Lifting up counter weight temporarily
Hook wire rope to slinging jig, and lift it and stretch
wire rope to the degree where it is providing no
slack temporarily.
Weight of counterweight ;
Approx. 4,600kg (10,100 lbs)
Wire more than 16 (0.63") ;
1.5m (4ft 11in)2 pcs.
B5
A1
B7
B2
B3
B4
B3
B4
B2
B1
11.3 INSTALLATION
(1) Install counterweight in the reverse procedure of
removing.
B1,B2
Fig. 11-3 Installing counterweight rear section
and tightening capscrew
12.
3
7
Fig. 12-2 Removing under cover (3)
B15
B15
B8
B2
B17
T 1.1kgfm
(8 lbfft))
21
B13
B5
B6
B13
B18
B1
B22
Fig. 12-5
CONDENSER
14
RECEIVER TANK
16
16
ig. 12-6
B3
B14
12.2 REMOVAL
(1) Remove radiator stay (A1), (A2)
1) Remove four sems bolts (A4) M1230.
: 19mm
B14
B4
A4
B14
A1
A4
A4
A2
Fig. 12-7
22
27
26
Fig. 12-8
C1
A3
4
9
23
12.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
C1
A3
Tightening torque
12.3kgfym
(89 lbfyft)
Apply Locktite
#262
Fig. 12-10
Installing radiator
24
Fig. 12-11
Back-and-forth
adjusting position of radiator
13. ENGINE
13.1 PREPARATION FOR REMOVING
(1) Remove battery ground (See 3. BATTERY)
E/
speed
sensor
Prepare a stand, which withstands the
weight of the engine assy and can place
the removed engine firmly.
(Refer to YB11 Tools on Page 13.)
THERMOSTAT
SPEED SENSOR
FUEL FILTER
TURBO CHARGER
STARTER MOTOR
THERMO SWITCH
ALTERNATOR
ISUZU
T=Tightening torque
13.2 REMOVAL
5
4
8
6 CAPSCREW
T=23kgfm (170 lbfft)
Apply Locktite #271
8 WASHER
10 TEMP.SENSOR
4 CAPSCREW
T=23kgfm(170 lbfft)
Apply Locktite #271
1
9 PLATE
9
RUBBER MOUNT 1
2 RUBBER MOUNT
15 SHIM
16 SHIM
3 RUBBER MOUNT
7 NUT
15,16
1,2
1 +1.0
(0.039
0
15
16
15
15
16
16
(1)
1)
2)
3)
4)
5)
6)
(2)
1)
+0.039
0
+1.0
Adjust to 1 0
+0.04
(0.04 0 )
using shims
No.15, 16.
12
12
12
12
LH instrument panel
12
CAP
12 M5_16
12
12
BRACKET
TUNER
ANTENNA CABLE
19
M8_25
37
M6_16
14.3 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
SUPPORT
SEAT STAND
Tool
Tightening torque
kgfym (lbfyft)
13
2.4 (17)
cross recessed
screw driver
0.27 (2.0)
I-27
B5
B15 B13
B14
B3
B14
B13
B13
B16
B4
B14
B13
Fig. 15-1
15.2 REMOVAL
(1) Attach tag on which hose name is entered to
the remote control hoses between multi
control valve and main control valve, and
write numbers C1 to C8 on it.
Remove the hose on the multi valve side and
put a plug in each opening.
Refer to 4. Tool of Plug (3).
(2) Attach tag on which hose name is entered to
the remote control hoses between multi
control valve and pilot V, and write numbers
P1 to P8 on it.
(3) Remove hoses P1 to P8 on multi control valve
side and plug connection.
Refer to 4. Tool of Plug (3).
Fig. 15-2 Connection between
multi control valve and C/V
15.3 INSTALLATION
(1) Installing is done in the reverse order of
removing
(2) Relations between pilot valve and multi
control valve hose
P/V
port
1
2
Right 3
side 4
P
T
5
6
Left 7
side 8
P
T
Hose
Size Color
1/4 Red
1/4 Blue
1/4 Green
1/4 Gray
1/4 Black
3/8 Black
1/4 Gray
1/4 Red
1/4 Blue
1/4 Green
1/4 Black
3/8 Black
ISO
multi mark
operation pattern port -ing
Bucket digging
Bucket dump
Boom up
Boom down
Pilot primary
Drain
Swing left
Swing right
Arm in
Arm out
Pilot primary
Drain
P1
P2
P3
P4
P5
P6
P7
P8
BK
BA
BR
B
SL
SR
AK
AR
28
M
275
O RING
(161)
462
S SENSOR
BLOCK
461
Fig. 15-4
C/V assy with multi
No.
NAME
QTY
S SENSOR BLOCK
1S
M REPAIR KIT WITH MULTI 1S
161 z O RING
1
201 z COVER FOR MULTI 1
261 z DUST SEAL
1
271 z SOCKET BOLT
4
273 z SOCKET BOLT
2
274 z SPACER
2
275 z SLEEVE
4
352 z KNOB
1
353 z LEVER
1
401 z PIN
1
461 z O RING
1
462 z BACK UP RING
1
471 z SPRING PIN
1
472 z WING BOLT
1
Specification of multiless control valve
271 355 356
354
Y
O RING (161)
S SENSOR
BLOCK
Fig. 15-5
Multiless control block assy
No.
NAME
Q
TY
S SENSOR BLOCK
1S
Y MULTILESS REPAIR KIT 1S
161 z O RING
1
271 z SOCKET BOLT
6
354 z COVER
1
355 z PIN
1
356 z SPRING PIN
1
29
Ports
Functions
(on machine)
RIGHT SIDE
Functions
REAR SIDE
PAr
PAr Travel right forward
Ports
PAL
PAc
PLc1
PAa
PAb
Drc Drain
Drc
Pcb
Pis
PAo2
PAa Arm in
Pis
Arm recirculation
Ports
Functions
RIGHT SIDE
Dra Drain
Br
Bc
Bucket digging
Bb
Boom down
(on machine)
Ports
Functions
UPPER SIDE
Drb Drain
30
Ac
Bucket dump
Ab
Boom up
Ports
Functions
AL
As
PAs
Aa
Ao2
Ports
(on machine)
Travel left
Swing (left)
Swing (left)
Arm in
Bs
Swing (right)
Ba
Arm out
Option valve
Functions
(on machine)
Ports
REAR
SIDE
Functions
Arm conflux
Boom dowm
Drd Drain
PBb
Bucket digging
Arm in
PBc
Travel right
reverse
Travel straight
PBr
PTb
Functions
forward
FRONT
SIDE
PA1
Ports
LOWER SIDE
RIGHT SIDE
RIGHT SIDE
MACHINE FRONT
16.3 INSTALLATION
(1) Installing is done in the reverse order of
remove.
: 19mm,
Tightening torque : 12.3kgfym(89 lbfyft)
(2) Make certain that attachment moves
normally in operation.
(3) Check oil level and that it is free from oil
leakage.
31
A1
Fig. 16-1
PANEL ASSY
28
29
12
Removing instrument-panel cover
BOOTS
A1
PILOT VALVE
PF3/8
Opposing
Flats 22
VALVE SIDE
PF1/4
Opposing
Flats 19
MARK F
17.2 REMOVAL
(1) Remove hoses from your side to far side in
order.
: 19mm, 22mm
PF3/8
HOSE SIDE
14,56,T PORT CONNECTOR
Fig. 17-2
8 ARM(R)
(GREEN)
PF1/4
P PORT CONNECTOR
(WITH FILTER)
(GRAY) BUCKET
(R)
(BLUE)
SWING
(R)
(RED)
5
SWING(L)
(GRAY)
17.3 INSTALLATION
Install it in the reverse order of removal and
tighten it to the below tightening torque.
: 5mm
T=1.1kgfym (8 lbfyft)
: 19mm T=3.0kgfym (22 lbfyft)
: 22mm T=5.0kgfym (36 lbfyft)
4 BOOM(R) 2
P BUCKET(H)
7 ARM(H)
(RED)
(BLUE)
BOOM(H)
LEFT SIDE
Fig. 17-3
32
RIGHT SIDE
18.
TRAVEL
2 SPEED
SWITCH
B10
25
24
B2
B1
B2
B8
CONNECTOR
SECTION
B7B9
B9
B11
B11
CA103
Opposing
PF3/8 flats 22
PF3/8
25 and
HOSE
SIDE
VALVE
SIDE
T port connector
Opposing
flats 19
PF1/4
VALVE SIDE
PF3/8
MARK F
PF1/4
Opposing
flats 22
PF3/8
18.3 INSTALLATION
Install it in the reverse order of removal and
tighten it to the below tightening torque.
Hose
: 19mm T=3.0kgfm (22 lbfft)
: 22mm T=5.0kgfm (36 lbfft)
: 8mm
T=4.7kgfm (34 lbfft)
: 17mm T=4.7kgfm (34 lbfft)
Pressure sensor
: 19mm T=3.5kgfm (25 lbfft)
P port connector
HOSE SIDE
1
4 port connector
Fig. 18-1
33
19.__________
19. SWING
MOTOR UNIT
19.1 PREPARATION FOR REMOVING
(1) Park machine on flat and solid ground and put
attachment on ground.
8
(3) Stop engine and release pressure in circuit operating
swing control lever.
(4) Remove the air cleaner at the top of the swing
motor.
B10
(5) Bleed air from the hydraulic oil tank and attach to
each hose a tag showing port name and other
information.
B10
A16
19.2 REMOVAL
(1) Remove hose.
1) Remove hose (8) from the Tee in the makeup port
M.
: 36mm
M PORT
2) Remove hose (5), (6) from the Tee in the drain port
Dr.
: 27mm
B1
B20
B19
I-34
Fig. 19-3
35
20.
SWIVEL JOINT
20.2 REMOVAL
(1) Remove travel motor hose and tube
[Refer to Travel section under HYDRAULIC
SYSTEM 22 4-(6)]
1) Remove tube (A5), (A6). (E port : PF1/2)
: 32mm
Tightening torque :
15.0kgfym (108 lbfyft)
2) Remove tubes (A1), (A2). (A, B port : PF1)
: 41mm
Tightening torque :
28.0kgfym (200 lbfyft)
3) Remove tubes (A3), (A4). (C, D port : PF1)
: 41mm
Tightening torque :
28.0kgfym (200 lbfyft)
4) Remove two hoses (A13). (F port : PF1/4)
: 19mm
Tightening torque : 3.0kgfym (22 lbfyft)
A2
A4
B2 A13
A13
A3
A1
A6
A5
Fig. 20-1
A7
A9
A22
A12
4
Fig. 20-2
15
C5
C3 T=16kgfym
(120 lbfyft)
T=0.69kgfym (5 lbfyft) B9
T=1.5kgfym (11 lbfyft) B8
PLATE
37
EYE BOLT
LOWER FRAME
CAPSCREW 2
M1225
Locktite #262
T=11kgfym(80 lbfyft)
SWIVEL JOINT
Fig. 20-5
(7) Slinging the swivel joint
Weight : Approx.26kg (57 lbs)
20.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
Piping tightening torque
Size
PF1/4
19
3.7(27)
3.0(22)
PF3/8
22
7.5(54)
5.0(36)
PF1/2
27
11.0(80)
8.0(58)
PF3/4
36
16.5(120)
12.0(87)
PF1
41
26.0(180)
14.0(100)
1-3/16-12UN
36
18.0(130)
WIRE ROPE
162.5m
(0.630) (8ft 2in)
Fig. 21-1
MATCH
MARK
Fig. 21-3
39
21.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
13,14
Fig. 21-4
Bearing mount
40
Table 1-1
TIGHTENING
TORQUE
kgfym (lbfyft)
REGULATOR
531,548
535
789
406
534
792
702
532
732
261
774
710
ENGINE
SIDE
886
808
953
724
728
467
113
127
123
824
490
406
251
401
490
151 PISTON
18
152 SHOE
153 PLATE
(RETAINER PLATE)
18
725
466
TIGHTENING
TORQUE
kgfym (lbfyft)
05
211
Refer to Fig.1-34
212
GEAR PUMP
(FOR PILOT)
13 (94)
No.
NAME
QTY
2
18
24 (170)
1.2 (8.7)
3.7 (27)
11 (80)
711
886
157
Refer to Fig.1-2
GEAR PUMP
(FOR DOZER)
141
214
314
151,152
885
124
153
885
156
111
719
116
312
717
710
262
901
271
QTY
313
954
127
NAME
719
124
808
No.
1
1
1
1
1
8
0.9 (6.5)
15
24 (170)
24 (170)
534 STOPPER ( L)
724 O RING ; 1B P8
18
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 1-1 Structural exploded view of main pump
II-1-1
12
433
710
361
700
354
A
434
351
435
312
353
311
732
SECTION
AA
309
310
Fig. 1-2
Table 1-2
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
3 (22)
NAME
Q
TY
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
NAME
Q
TY
307 POPPET
1.7 (12)
308 SEAT
1.7 (12)
3.4 (25)
310 SPRING
1.6 (12)
5.4 (39)
700 RING
710 O RING ; 1B
G80
725 O RING ; 1B
P11
728 O RING ; 1B
P18
355 FILTER
732 O RING ; 1B
P16
Table 1-3
Tool name
Allen wrench
Dimension
Opposing flats
Eye wrench
Socket wrench
19, 27mm
Adjust wrench
Screw driver
Hammer
Plier
Steel bar
(2) Disassembling procedure
1) Selecting a place for disassembly.
4,5,6,8,14mm
Torque wrench
REGULATOR
Fig. 1-3
14
Removing regulator
312
271
271
141(151)
153
156
Fig. 1-5
15
406
261
Fig. 1-6
251
271
212 (211)
251
113
Fig. 1-9
16
312
314
(313:OPPOSITE SIDE)
Fig. 1-10
14) Remove other parts
If necessary, remove stopper (L) (534),
stopper (S) (535), servo piston (532) and
tilting pin (531) from pump casing (271), and
remove needle bearing (124) from valve block
(312).
808
534
535
532
808
271
312
251
Fig. 1-11
17
124
271
251
Fig. 1-12
3) Installing swash plate
Place the pump casing with its mounting
surface of the regulator facing down, insert
the tilting bushing of the swash plate into
tilting pin (531), and fit swash plate (212) to
swash plate support (251) properly.
271(531)
212
Fig. 1-13
18
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251).
251
123
127,824
111
Fig. 1-14
271
261
406
141(151,152)
156
153
Fig. 1-16
19
312
314
(313:OPPOSITE SIDE)
Fig. 1-17
271
401
Fig. 1-18
9) Installing regulator and PTO gear casing
Pinch feedback pin of tilting pin in feedback
lever of the regulator and PTO gear casing,
install the regulator and fasten socket bolt.
Refer to [415 (See Fig.1-20.), 435[See
Fig.1-34.)].
REGULATOR
110
Standard
dimension
Recommended
value for
replacement
0.028
(0.0011)
0.056
(0.0022)
00.1
(0.004)
0.3
(0.012)
3.9
(0.154)
3.7
(0.146)
31.3
(1.23)
30.2
(1.19)
10.5
(0.413)
9.8
(0.386)
Remedy
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section)
Swash plate (shoe plate face)
Cylinder (sliding section)
Roughness of each surface
3Z
Less than 0.4Z (lapping)
1.1.4 TROUBLESHOOTING
(1) Locating causes of troubles
The pump is usually fitted with a regulator,
auxiliary valves and auxiliary pumps, and
this makes fault location extremely difficult.
However, faults would be found out easily if
the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for
abnormal contaminations. Some metallic
particles will be deposited on it as the shoe
and the cylinder wear off. In case metallic
particles are found in large quantity, the
elements may be damaged. In that case check
the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and
make an abnormal sound.
Check that the hunting of the regulator and
the attached valves relief valve are of regular
frequency. In case vibration and sound are
abnormal, the pump may be making a
cavitation or internally broken.
(2) Troubleshooting
1) Overloading to engine
Cause
1. Revolution and pressure are
higher than set values.
2. Regulator torque is set higher
than normal.
3. Pumps internal parts are
seized or broken.
Remedy
1) Set pressure to specified
value.
2) Readjust regulator.
3) Replace damaged parts.
112
Remarks
(2) Pumps oil flow rate is extremely low and delivery pressure is not available.
Cause
1. Regulator is out of order
Remedy
1) Repair regulator.
Remark
1) Refer to Regulator Manual.
Remedy
Remark
1. Cavitation
1) Prevent cavitation.
1-1) The boost pressure is low.
Check that hydraulic oil 1-2) The attached pump is in trouble.
is not clouded.
1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2) Replace piston shoe and
shoe plate.
3. Cylinder is cracked
3) Replace cylinder.
4) Correct installation.
5. Regulator is hunting.
5) Repair regulator,
113
1.2 REGULATOR
1.2.1 STRUCTURAL EXPLODED VIEW
656 402
733
627
646
624
496
601
801
924
415
543
545
541
079
756
755
614
733
887
658
325
724
418
708
652
496
897
Table
651
643
611
631
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
755
466
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
NAME
Q
TY
643 PISTON
646 SPRING
1.2 (8.7)
651 SLEEVE
1.2 (8.7)
652 SPOOL
3.0 (22)
656 COVER
0.7 (5.1)
1.6 (12)
708 O RING ; 1B
G75
0.9 (6.5)
496 PLUG
724 O RING ; 1B
P8
541 SEAT
731 O RING ; 1B
P25
543 STOPPER
733 O RING ; 1B
P18
545 BALL
755 O RING ; 1B
P11
601 CASING
756 O RING ; 1B
P12.5
887 PIN
897 PIN
627 PLUNGER
631 SLEEVE
3.7 (27)
Fig. 1-20
Q
TY
PROPORTIONAL
079 SOLENOID
REDUCING VALVE
325 VALVE CASING
731
407
NAME
1-4
0.9 (6.5)
1.6 (12)
114
Table 1-5
Tool name
Dimension
Allen wrench
Opposing flats
Eye wrench
Socket wrench
2) Cleaning
Remove dust and rust, etc. on regulator
surface with wash oil.
4,5,6,8mm
19mm
Adjust wrench
Screw driver
Socket bolt
Torque wrench
3) Remove regulator
Remove socket bolts (415) and separate the
regulator from the pump body.
: 6mm
REGULATOR
Fig. 1-21
Removing regulator
407
Fig. 1-22
115
5) Remove cover
Remove socket bolt (402) and cover (656).
: 5mm
l The cover is assembled with set
screw (924) and hex nut (801), but do
not loosen them. If they are
loosened, the pressure settings
change.
801
631(643)
Fig. 1-24 Removing sleeve (631)
and pilot piston (643)
7) Remove feedback lever
Remove fulcrum plug (614) and feedback
lever (611).
: 19mm
611
Fig. 1-25
9) Remove plunger, pilot spring and spring seat
Draw out plunger (627). Then take out pilot
spring (646) and spring (624).
627(624,646)
541
543 (545)
z The check valves are placed on two
places; the mating surface of the
pump casing and on the matching
surface of the valve casing.
Fig. 1-27
601
Drawing out the check valve.
543 (545)
601
Fig. 1-28
2) Fitting the sleeve and the spool
Place sleeve (651) and spool (652) into the
sleeve hole of casing (601).
601
651(652)
Fig. 1-29 Fitting the sleeve (651)
and the spool (652).
117
611(897)
614
Fig. 1-30
601
656
Fig. 1-32
402
Installing cover (656)
631
643
Fig. 1-33 Assembling the sleeve (631)
and the pilot piston (643).
118
414
117
128
435
126
826
128
886
711
326
414
115
886
827
262
728
125
468
118
125
825
435
435
Fig. 1-34
Table 1-6
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
3.4 (25)
NAME
Q
TY
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
NAME
Q
TY
3.4 (25)
7.5 (54)
711 O RING ; 1B
G85
728 O RING ; 1B
P24
262 COVER
886 PIN
2
119
Table 1-7
Tool name
Dimension
Allen wrench
Opposing flats
Eye wrench
Socket wrench
8mm
27mm
Plier
2) Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing drain port plug (467), (468).
: 27mm
GEAR PUMP
(FOR DOZER)
COVER
PTO GEAR CASING
435
GEAR PUMP
Fig. 1-35
5) Remove PTO gear casing
Remove flange socket (435) and PTO gear
casing.
: 8mm
PTO
GEAR CASING
Fig. 1-36
120
HOLE FOR
IDLE SHAFT (115)
117(126,128)
Fig. 1-37
125
be
118
121
122
2.
CONTROL VALVE
2.3 DISASSEMBLY
Regarding the construction of the control valve,
refer to 4.2 Construction, 4. Control Valve under
YB24 Components System.
The figures in parentheses after part names in
the
contents
represent
those
in
the
above-mentioned Fig.4 structural exploded view
on YB24, 4 Control valve.
Place the control valve on the workbench with the
ports facing upward.
Disassemble the valve in a clean
location, and be careful not to damage
flange surfaces or plate mounting
surfaces.
2.2 TOOLS
Prepare the following tools before disassembling
the control valve.
No.
Name
Table
2-1
QTY
Remarks
a Vise
1
Box
end
wrench
1
of
each
8,22,24,27,30,32mm
b
size
1 of each 4,5,6,8,10,12,14,22mm
c Allen wrench
size
e Locktite #262
1
f Spatula
g Tweezers
h Adjust wrench
21
213(272)
Fig. 2-3
271
214
Fig. 2-4
204(262)
310
Fig. 2-6
22
333
332
326(337)
325
310
Fig. 2-8
309
Fig. 2-9
3) Fix the cut spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (325), (326) and stopper (337)
from cut spool (309).
333
332
326(337)
325
309
Fig. 2-10
23
273
201(262)
Fig. 2-11
302
Fig. 2-12
3) Fix the arm spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (324), (329) and stopper (337)
from arm spool (302).
: 6mm
333
332
324(337)
329
302
Fig. 2-13
Fig. 2-14
24
201(262)
301
Fig. 2-15
3) Fix the boom spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (324), (329) and stopper (337)
from boom spool (301).
333
332
324(337)
329
301
Fig. 2-16
4) Do not disassemble the boom spool (301)
further unless there is any problem.
(See Fig. 4-6)
Fig. 2-17
273
Fig. 2-18 Removing boom conflux
spool spring cover (201)
25
305
333
332
326(337)
325
305
201(262)
304
Fig. 2-22
2 6
333
332
328(337)
329
304
Fig. 2-23
273
Fig. 2-24
202(262)
Removing swing spool spring cover
303
Fig. 2-25
3) Fix the swing spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (324), (329) and stopper (337)
from swing spool (303).
333
332
324(337)
329
303
Fig. 2-26
27
273
201(262)
306
333
332
327(338)
325
306
Fig. 2-29
(11) Disassembling travel straight spool
(Section C-C)
1) Loosen the socket bolts (273) and remove the
spring cover (201) and the O ring (262) for
travel straight.
: 6mm
273 201(262)
Fig. 2-30 Removing travel straight
l
i
28
307
Fig. 2-31
3) Fix the travel straight spool assy with vise
via a protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
(332), springs (325), (326) and stopper (337)
from travel spool (307).
333
332
326(337)
325
307
Fig. 2-32
L171
211
Fig. 2-33
(13) Disassembling the arm conflux spool
(Section G-G)
1) Loosen socket bolts (273) and remove spring
cover (204) and O ring (262) for arm conflux.
: 6mm
308
Fig. 2-35
333
332
326(337)
325
308
Fig. 2-36
273
206(265)
Fig. 2-37
Fig. 2-38
210
601
Removing main relief valve(601)
602
Fig. 2-39
556
Fig. 2-42
211
514
524
Fig. 2-43
3) Check valve in the travel straight section
(CT1)
Remove plug (552). Then remove poppets
(512) and spring (522).
: 10mm
552
CT1
522
512
SECTION H -H
Fig. 2-44 Removing check valve
in the travel straight section
4) Check valve in the main relief valve section
(CMR1,CMR2)
Remove plug (552) and remove poppet (513)
and spring (522).
: 10mm
513
522
CMR1
552
552
CMR2
522
513
SECTION C-C
Fig. 2-45 Removing check valve
in the main relief valve section
973
Fig. 2-46
212
Disassembling casing
Fig. 2-47
121
103
101
Fig. 2-48
213
2 14
2.5 REASSEMBLY
1) Here, only the reassembly procedures are
described. Regarding drawings, refer to the
disassembly procedures.
215
216
218
219
Inspection item
scratches,
Casing
1) Look for
corrosion.
rusting
Spool
Poppet
Spring and
related parts
220
1) Replace.
2) If damaged, replace.
3) If damaged, replace.
4) Replace.
5) As a general rule, replace all parts with
new ones.
2.7 TROUBLESHOOTING
1) If an abnormal condition is noticed, check to
see if the problem is with the control valve
itself, one of the main pumps, the gear pump,
or a circuit. To this end, you will need to
measure pilot pressure, pump delivery
pressure, load pressure, etc. If any part of the
system is to be disassembled for inspection,
follow the disassembly and reassembly
procedures in this manual.
2) Dust is the enemy of hydraulic components.
Pay strict attention to protection from dust.
Cause
Remedy
221
Trouble
Cause
Remedy
222
Trouble
Cause
Remedy
6. Swing priority
function does not
operate.
7. Boom or arm
conflux does not
operate.
Cause
Remedy
1. No pressure rise.
2. Unstable relief
pressure.
3. Irregular relief
pressure.
4. Oil leak.
1) Damaged seat.
Worn out O ring.
1) Replace
damaged
component.
Confirm
or
worn
that
each
223
224
3.
302
213
Apply grease
on rotating and
sliding sections.
301 Be careful the
assembling
direction.
151
212
Apply
246 grease on
2182
211
214
top section.
2181
2162
2161
2411
2412
2011
2012
0111
0112
131
217
122
Secondary
101
pressure
adjusting shim
126
Target value
t=0.4 (0.016 ),
111
1 piece
121
PORT 2,4
Fig. 3-1
125
PORT 1,3
Not to be
reused.
TIGHTENING
TORQUE
kgfym (lbfyft)
2.1 (15)
No.
101
111
121
122
125
126
131
151
2011
2012
211
212
213
214
NAME
CASING
PORT PLATE
SEAL WASHER
O RING
SOCKET BOLT ; M835
SPRING PIN
BUSHING
PLATE
SPOOL
SPOOL
PLUG
PUSH ROD
SEAL
O RING ; 1B P20
Q
TY
1
1
2
1
2
1
1
1
2
2
4
4
4
4
TIGHTENING
TORQUE
kgfym (lbfyft)
4.8 (35)
7 (51)
31
No.
2161
2162
217
2181
2182
0111
0112
2411
2412
246
301
302
312
501
NAME
SPRING SEAT 1
SPRING SEAT 1
WASHER 2(SHIM)
SPRING SEAT 2
SPRING SEAT 2
SPRING
SPRING
SPRING
SPRING
SPRING
JOINT ;M14
CIRCLE PLATE
ADJUSTING NUT ; M14
BOOTS
Q
TY
2
2
4
2
2
2
2
2
2
4
1
1
1
1
0111
0112
312
2411
2412
501
217
217
2011
2012
302
301
101
151
213
213
211
131
122
211
214
126
214
212
212
111
246
246
2182
2181
2161
2162
121
125
121
125
Fig. 3-2
32
3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it.
P port : PF1/4
14 and T port : PF3/8
(2) Fix pilot valve with vise, and remove boots
(501).
(3) Remove adjusting nut (312) applying
spanners to adjusting nut (312) and circular
plate (302).
: 22mm,32mm
312
302
Fig. 3-3
(5) Turn joint (301) in counterclockwise with Jig A
to remove.
Jig A : Refer to 3.7 Detail of jig
: 24mm
JIG A
301
Fig. 3-4
(6) Remove plate (151)
Fig. 3-5
33
211
101
Fig. 3-6
211
Fig. 3-7
(7) Remove push rod (212), plug (211), pressure
reducing valve assy (spool), return springs
(011-1), (011-2) from casing (101).
Record combination of port holes on casing
and the pulled out parts. The stroke differs
according to direction.
212
211
0111
or 0112
101
111
125
Fig. 3-9
34
126
SPRING
111
131
122
101
Fig. 3-10
2161
or 2162
2011
or 2012
Fig. 3-11
2411
2011
217
or
or
2412
2012
Fig. 3-12
(14) Remove spring (246), spring seat (218-1),
(218-2) from push rod (212).
214
246
211
Fig. 3-13
35
212
213
Fig. 3-14 Removing seal (213)
3.3 CLEANING PARTS
(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean waste cloth.
(4) Apply rust preventives on parts.
3.4 ASSEMBLING
(1) Fit bushing (131) and O ring (122) to casing
(101). (See Fig.3-10.)
Meet the position of spring pin (126).
(2) Install port plate (111) on casing with socket
bolt (125) and seal washer (121).
: 6mm,
Tightening torque ; 2.1kgfym (15 lbfyft)
111
125
121
(3) Fit washer 2 (217), springs (241-1), (241-2),
spring seats (216-1), (216-2) to spool (201-1),
(201-2).
Fig. 3-15
2161
or
2162
217
Fig. 3-16
36
PRESSURE REDUCING
VALVE ASSY
0111
101
Fig. 3-17
(6) Fit O ring (214) and seal (213) into plug
(211).
Apply
hydraulic oil
Fig. 3-17
212
Fig. 3-19
246
211
2181
Assembling push rod, spring (246) and
seat (218)
101
Fig. 3-20
37
211
Installing plug assy (211)
301
151
JIG A
312
302
Fig. 3-23
301
212
4 Fig. 3-24 Applying grease to joint section and
push rod
3 8
Remarks
When
leakage
quantity
reaches
to Conditions
1000cc/min. or more where handle is set in
Primary pressure
30kgf/cm2
neutral position, or to 2000cc/min. or more in
(430psi)
Leakage
operation, replace spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced,
replace pilot valve assy with new one.
When the wear of sliding section is 10m This condition may be the same as the
Spool
more than the that of non sliding section, above.
replace it with new one.
Push rod
When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on In case of the looseness due to the
circle plate (302) on control section and joint loosening on tightening section, adjust
Looseness of
section (301) due to wear is produced, replace it.
control section
them with new ones.
Stability of
operation
Cause
Remedy
39
3.7 JIG
(1) Jig for removing and installing joint (301)
SECTION AA
BUSHING
Material ;
SCM415 ,N
Carburizing
and Quenching
Material ; S45C
Detail of bushing
Material ;
SCM415,N
Carburizing and Quenching
Qty ; 2
310
4.
4.1 CONSTRUCTION
(1) Sectional view
13
33 2
36
19
37
1,3
20
34
22
20
39
32
44,16
6
18
24
41
14
26
30
15
21
20
42
25
25
42
17
40
7
8
25,42
36 33
28
9 31 5
29
33 36
SECTION
27
10,11
33
AA
35
4-M10
T=4.30.4
(312.9)
38
24,41
VIEW
SECTION
Z
Fig. 4-1
TIGHTENING
TORQUE
NO.
kgfym (lbfyft)
1
1.5 (11)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
NAME
ORIFICE (SHIM)
SEAT
ORIFICE (SHIM)
SPOOL
BODY
STOPPER
SPRING
SPRING
NAME PLATE
SHIM t=0.2
SHIM t=0.1
CAM
BOOTS
PIN
COVER
PISTON
GUIDE
SLEEVE
HOLDER
RING
ORIFICE (SHIM)
TIGHTENING
TORQUE
QTY
NO.
kgfym (lbfyft)
4
22
2
1.0 (7.2)
24
4
2.5 (18)
25
4
6.0 (43)
26
1
0.5 (3.6)
27
4
1.5 (11)
28
4
29
4
30
1
31
4
32
4
33
2
34
2
35
2
36
2
37
4
38
4
39
4
40
4
41
12
42
4
44
41
BB
QTY
SPRING
PLUG ; PF1/8
PLUG ; PF1/4
SOCKET BOLT ; M1060
FLANGE BOLT
SET SCREW ; M8
WASHER
WASHER
RIVET
PIN ; 5
BALL
BALL
BALL
BALL
U PACKING
O RING ; 1A P5
O RING ; 1A P24
O RING ; 1A P26
O RING ; 1B P8
O RING ; 1B P11
PISTON ASSY
4
3
3
2
4
4
4
2
2
4
6
4
4
6
4
4
4
4
3
3
4
26
28
12
LIP DETAIL
14
37
15
6
27
18
19
1,3
16,44
20
21
34
22
20
39
20
17
10,11,29
DAMPER SECTION
36
7
40
32
38
24
41
Fig. 4-2
1. Tools used
Tool name
Vise
Small vise
(Place a copper plate on
the mouthpiece.)
Allen wrench
Scriber
(or a sharp point rod of
the same shape)
Hex rod for torque
wrench
Use
For fixing the valve
body
For disassembling the
reducing valve spool
3, 4, 5, 6, 8mm
For disassembling the
U-packing
3, 4, 5, 6, 8mm
Torque wrench
Magnet bar
37
15
36
19
1,3
2. Disassembly
(1) Put a plug into each port (P,T,1,2,3,4,5,6) of
the valve and clean the outside.
(2) Fix the valve after cleaning it in a vise.
(3) Remove two boots (13).
(4) Loosen 22 places of socket head set screws
(28) and remove them from cam (12).
: 4mm
(5) Draw out two pins (14) from cover (15). On
that occasion, the pins may be drawn out
with ease if the pins are pushed out of the
inside by the use of an allen wrench 4mm.
(6) Remove two cams (12).
(7) Loosen socket bolts (26) and remove two of
them with washers (30).
: 8mm
(8) Remove two dampers from the reducing
valve.
43
44,16
20
34
22
20
39
17
Fig. 4-3
21
20
7
40
32
38
24
5
41
Fig. 4-4
27
18
10,11,29
4
Fig. 4-5
33
36
2
33
33
42
Fig. 4-6
42
25
25
Disassembling the shuttle
33
36
2
33
36
2
33
33
42
Fig. 4-7
6
25
7
40
32
38
24
41
Fig. 4-8
45
42
25
REDUCING VALVE
SPOOL ASSY
7. Assembly
z Clean and degrease parts before assembly. In
particular, clean the body with a nylon brush
or something.
Foreign matter intruded into the valve causes
functional faults to occur.
z Prepare new seals (O rings and U packings)
and coat the surface with hydraulic oil or a
thin film of grease.
28
36 12
14
19
37
16,44
20
22
39
32
6
27
34
20
17
40
18
24
41
35
15
26
30
1,3
21
38
8
7
20
10,11,29
25,42
13
Fig. 4-9
28
12
30
26
14
DAMPER
REDUCING
VALVE
488
992
469
355
401
ANTI CAVITATION
PLUNGER
351
051-1
391 390
VALVE CASING SECTION
SWING SHOCKLESS
VALVE BLOCK
052
V171
161,
152 162
163
V162
053
303
(400-1)
(400-2)
444
981
485
438
464
472
706
712
743
742
121
052
400
SECTION_A_A
V981
V162 V163
V164
113 V154
707
980
V252
V262
122
702
123
(053)
114
118
V301
116
V154
V101
117
V164
301
101
437 124
994
V324
TIGHTENING
TORQUE
kgfym (lbfyft)
18 (130)
No.
NAME
052
053
100
3.7 (27)
7 (51)
G30
No.
NAME
QTY
451 PIN
3.7(27)
34 (250)
2
1
472 O RING
111 CYLINDER
485 O RING ; 1B
P11
488 O RING ; 1B
P28
12
117 SPACER F
706 O RING
118 SPACER
707 O RING
121 PISTON
24
122 SHOE
0.45 (3.3)
152 PLUG
0.17 (1.2)
161 O RING ; 1B
P11
6.6 (48)
162 O RING ; 1B
P12
10 (72)
163 O RING ; 1B
P6
V154 PLUG
V162 O RING
V163 O RING
351 PLUNGER
V164 O RING
355 SPRING
3.0 (22)
17 (120)
V251 PLUG 1
391 RIVET
11 (80)
V252 PLUG 2
V261 O RING
V262 O RING
V301 SPOOL
V304 SPRING
400
P20
3.7 (27)
301 CASING
400-1 O RING ; 1B
44 (320)
TIGHTENING
TORQUE
QTY
kgfym (lbfyft)
52
33
19
29 28 27
26
25
22
17
23
16
24
22
14
20
15
21
13
10
12
11
34
37
36
35
9
8
7
6
2
3.4 (25)
NAME
No.
QTY No.
NAME
QTY
PINION SHAFT
19
#1 SUN GEAR
SLEEVE
20
SPRING PIN
21
SHAFT
O RING
22
THRUST WASHER
OIL SEAL
23
#2 PINION
RETAINER
24 NEEDLE BEARING
SOCKET BOLT ; M8 25
12
25
THRUST WASHER
BEARING
26
#1 PINION
10
HOUSING
27
ROLLER
11
SPACER
28
THRUST WASHER
12
BEARING
29
SNAP RING
13
SNAP RING
33
SNAP RING
14
#2 SPIDER
34
15
#2 SUN GEAR
35
CONNECTOR
16
RING GEAR
36
HOSE
17
#1 SPIDER ASSY
37
PLUG
10
5 3
102
Remarks
Socket
wrench
VP plug
Allen
wrench
M8,M14,M20,M20(Set screw)
6,10,12,17mm
Plier
PF1/4
19mm
Screwdriver
Steel bar
Hammer
Torque wrench
Plastic hammer
kgfym(lbfyft)
1 pc.
1.04.5 (7.233)
4.018 (29130)
1248 (87350)
40
(1.57)
100(4)
(0.433 )
BORE DIA.11
M10
150(5.91)
175.5(6.91)
200(7.87)
54
(0.2)
M8
10 (0.4)
250(10)
40 (1.57)
Place this
claw in the
groove of
brake piston.
5.2.2 DISASSEMBLY
(1) General cautions
1) Hydraulic components are precision products
and have small clearance. Therefore,
assemble and disassemble in a less dusty
clean place. Use clean tools and cleaning oil
and handle components with full care.
2) If a component is removed from the main
body, clean the area around the ports
thoroughly and plug them up so no dust and
water do not enter. When fitting them back to
the body, do not remove the plugs till piping
is completed.
3) Study the structural drawing before the work
begins and prepare necessary parts according
to your purpose and the scope of work. Seals
and O rings once removed can not be used
again.
Some parts can not be supplied as single
parts and available only in sub assy. Prepare
such parts according to the parts manual.
4) The piston and the cylinder block are shop
fitted when new. If you intend to reuse them,
put a matching mark on the piston and the
cylinder block.
(2) Disassembly procedure
The figures in parentheses after part names
in this manual represent those item numbers
in Fig. 5-1.
1) Draining oil
Remove the drain plug and drain hydraulic
oil from casing (301).
2) Preparation for removing the valve casing
Fix the motor on a work bench so the drive
shaft (101) end comes down. On that
occasion, put a matching mark on the mating
parts of casing (301) and valve casing (303).
053
303
052
051
712
702
301
Fig.5-3
55
101
Removing valve casing (303)
052
355
303
469
351
401
051
Fig. 5-4 Removing relief valve (651), swing
shockless valve (052), anti-cavitation
plunger (351) and valve casing (303)
BRAKE PISTON
DRAWING JIG
131
702
301
Fig. 5-5
101
124
301
101
Fig. 5-7
443
101
57
Fig. 5-8
5.2.3 ASSEMBLY
(1) General cautions
1) Repair
those
parts
damaged
after
disassembly and prepare replacement parts
beforehands.
2) Clean all parts thoroughly in cleaning oil and
dry them with jet air.
3) Always coat the moving parts with clean
hydraulic oil, before assembly.
4) Replace such seals as O ring and oil seal in
principle.
444
443
101
Fig.5.9
301
101 491
443 437 305
Fig.5.10 Fitting snap ring (437), seal cover (305),
oil seal (491), outer race of roller
bearing (443), and drive shaft (101)
58
124
301
443
Fig. 5-11
117
123
116
118
122
113
114
121
111
101
438
Fig. 5.12
PG PORT
Fig. 5-13
59
702
PG PORT
Fig. 5-14
10
50mm
Material : SS41
Jig
(for press fitting bearing )
(0.394)
Remarks
10mm
Tool name
(1.97)
Code
910.5mm
(3.5830.020)
1400.5mm
(5.5120.020)
For shaft
(0.591)
140mm
(5.51)
15mm
Material : SS41
208 0.5 mm
0
(8.189 0.020
)
Press
Flat screwdriver
Metal bar
(0.787)
Torque wrench
20mm
3 pcs.
155mm
(6.10)
j
k
General tools
Three-Bond 1360K
Sealing compound
Locktite #515
5.3.2 DISASSEMBLY
The figures in parentheses correspond to the ones
in construction drawings (Fig. 5-2).
3) Disconnect the drain hose.
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the maiting parts of the
housing before disassembly.
511
SWING MOTOR
18
h
32
MATCHING
MARK
160
290
(6
(12)
)
Fig. 5-15
Removing swing motor assy
17
19
16
(3) Disassembling reduction unit
1) Remove #1 sun gear (19).
2) Removing #1 spider assy (17).
The spider assy (17) [consisting of thrust
washer (28), #1 pinion (26), needle bearing
(27) and snap ring (29)] can be removed from
the spline easily if it is lifted up in that
condition.
10
Fig. 5-16 Removing #1 sun gear and
#1 spider assy
#2 SPIDER ASSY
16
h
10
15
Fig. 5-18
5 12
180 (7 )
35010(140.4)
Fig. 5-19
8
Fig. 5-20
6
7
Fig. 5-21
513
M10
11
12
13
Fig.5-22
(4)
1)
1.
2.
17
26
29
27
28
25
Fig.5-23
22
21
24
23
22
20
14
Fig.5-24
514
Fig. 5-25
2
1
i
Fig. 5-26
3) Draw out the pinion shaft (1) and
remove
O ring (5) from sleeve (2). Then the pinion
shaft is disassemlbed into the parts in Fig.
5-27.
12
11
9
5
2
Fig. 5-27
515
5.3.3 ASSEMBLY
(1) Preparation
1) Clean parts thoroughly in cleaning oil and
dry them with jet air.
2) Check that parts are not faulty.
2) Insert sleeve
Heat sleeve (2) to 100120 (212248
F),
fit O ring (5) and fix it into pinion shaft (1).
Fig. 5-28
a
13
12
19
9
6) Assembling bearing
Heat bearings (9,12) to 100120 (212
248
F), fit the bearings with spacer (19) into
pinion shaft (1). Push them in, using jig (a)
and fix snap ring (13).
Pressing force : 1112ton
(2400026500 lbs)
516
1
OIL SEAL
Fig. 5-29
17
26
29
27
28
25
Fig. 5-30
MOTOR SIDE
SNAP RING (29)
25, 28
17
29
Fig. 5-31
2) Assembling #2 Spider Assy
1. Coat the bore surface of pinion (23) with
grease. Put pinion (23) on thrust washer (22)
and fit needle bearing (24) to the bore
surface.
26
CAULK TWO
POINTS WITH
A PUNCH.
67mm
(0.240.28in)
VIEW
67mm
(0.240.28in)
22
21
24
23
22
20
14
Fig. 5-32
517
12
10
Fig. 5-33
2) Attaching retainer
1. Fit the oil seal to retainer (7), making sure of
its direction and set it in place by using oil
seal fixing jig (c).
2. Apply sealing compound (Locktite #515) to
the retainer (7) with oil seal and the
matching surface of housing (10). Then fit it
to sleeve (2).
10
Fig. 5-34
M825
8
7
Assembling retainer (7)
#2 SPIDER ASSY
Fig. 5-35
#2 SPIDER ASSY
16
ALIGN
MATCHING MARKS.
10
Fig. 5-37
7) Installing #1 spider assy
1. Mesh the #1 spider assy with ring gear (16)
and set them in place.
2. Mesh #1 sun gear (19) with #1 pinion (26)
and set them in place.
#1 SPIDER ASSY
19
16
26
Fig.5-38
SWING MOTOR
M14130
18
MATCHING
MARKS
160
(6)
Fig. 5-39
519
290
(12)
Installing swing motor assy
Standard
Dimension
mm (in)
Recommended
Value for
Replacement
mm (in)
0.027
(0.00160)
0.052
(0.00205)
0.3
(0.0112)
5.5
(0.217)
5.3
(0.209)
5.5
(0.217)
5.0
(0.197)
1.8
(0.0709)
1.6
(0.0630)
Replace.
Remedy
Thickness of shoe
(t)
520
Standard surface
roughness
Surface roughness
requiring correction
0.8Z
(Ra=0.2)
(lapping)
3Z
(Ra=0.8)
0.4Z
(Ra=0.1)
(lapping)
3Z
(Ra=0.8)
1.6Z
(Ra=0.4)
(lapping)
12.5Z
(Ra=3.2)
0.8Z
(Ra=0.2)
(lapping)
6.3Z
(Ra=1.6)
521
3) Bearing
Turn the bearing and check that it does not
develop abnormal sound, catching and other
faults.
4) O rings and oil seals
Do not reuse O rings and oil seals; always
replace them with new ones at reassembly.
522
(H)
D
C
APPLY LOCKTITE #515.
D
B
Unit : mm (in)
Code
Item
Standard Value
Serviceability
Limit
0.021
39.45 0.032
Gears
2.00.1
(0.0790.004)
Replace
159.5
(6.28 )
Replace
160 0.063
0
(6.29920 0.00248 )
7.5
Replace
(Planetary pinion
should be replaced
in a set of four.)
1.8 (0.0709 )
Replace four
shafts as a set.
No flaking
G
(H)
Replace entire
spider assy.
0.00083
(1.55315 0.00126 )
0
29 0.009
0
(1.14173 0.00035 )
Remedy
(2.0gal)
Apply Three-Bond
1360K and tighten
to specified torque.
Replenish or
replace.
5.5 TROUBLESHOOTING
5.5.1 SWING MOTOR
(1) Hydraulic motor does not rotate.
Trouble
Pressure does not
rise.
Pressure rises.
Cause
Remedy
Cause
Remedy
524
Cause
Remedy
Cause
Remedy
Cause
Remedy
The
swing
motor 1. Relief valve malfunctions.
1.
drifts much when it is
Same as (1).
actuated by external 2. Plunger seat is faulty.
2.
torques. (e.g. Machine 3. Seat of the swing shockless valve is 3.
is on a slope.)
no good.
4. Bypass valve seat is faulty,
4.
malfunction.
525
Same as (1).
Replace.
Replace the swing shockless valve
cartridge or block.
Replace.
Cause
Remedy
Cause
Remedy
1. O ring is missing.
2. O ring has a scratch.
3. Seal surface has a scratch.
4. Bolt is loose or broken.
526
Trouble
Remedy
Overloaded
Check
for
fault
and
2) Oil leakage
Oil leaks through matching surface.
Disassemble, apply
liquid packing and
reassemble as specified.
The
matching
surface
is
Disassemble reduction
unit and replace oil
Fill up grease.
3) Temperature is high.
Temperature of reduction unit casing
is high.
527
528
6. SWIVEL JOINT
6.1 CONSTRUCTION VIEW
Y
D
B
C
E
X
D
VIEW
12
B
A
5
7
SECTION
9
8
XX
Tble 6-1
No.
NAME
QTY No.
NAME
QTY
1 BODY
6 SEAL ASSY
2 STEM
7 O RING(1A
3 THRUST PLATE
4 COVER
5 SEAL ASSY
Fig.6-1
2
G95)
12 PLUG
Tool Name
Hammer
Rubber mat
Wrench
Table 6-2
Used for
Remarks
1. Steel hammer
2. Wooden or plastic mallet
750mm (30in) square or more
1. Allen wrench
2. Double-ended and single-ended wrench
3. Extension pipe
Torque wrench
Assembly
Pin
Disassembly
Disassembly
f
Spatula
Assembly
Vinyl tape
Disassembly
Vise
Locktite
#242
Lubricating oil
Cleaning oil
Assembly
6.2.2 APPARATUS
(1) Hoist or crane
The lifting device should be capable of lifting
the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m
1.5m (4ft5ft).
(3) Others
Also prepare waste cloth, wooden block and
oil pan.
62
6.2.4 DISASSEMBLY
The part numbers used in this disassembly
procedure correspond to those of a construction
drawing in Fig.6-1.
ALLEN
WRENCH
PIPE
V-BLOCK
Fig. 6-2
4
Fig. 6-3
PIPE
2
STEM
Fig. 6-4
WOODEN BLOCK
FOR PROTECTOR
Secure
with hands.
1
2
WORK BENCH
Fig. 6-5
63
V-BLOCK
SPATULA(f)
Fig. 6-6
SLIPPER RING
BUCK-UP RING
DETAIL(5), (6)
GROOVES
FOR SEAL
GROOVES
FOR
HYDRAULIC
PIN(e)
GROOVES
FOR
SLIPPER
SEAL
SEAL
ASSY
Fig. 6-7
6.2.5 ASSEMBLY
Prior to assembly, clean each parts (excluding the
O ring and slipper ring), and arrange in the
sequence of assembly.
SLIPPER RING
64
2 STEM
If stem (2) is pressed in too fast, the
seal may be damaged. Do it slowly.
The clearance between body (1) and
stem (2) is about 0.1mm (0.004in).
Push stem straight along the shaft
center.
SEAL 6
1 BODY
5
SEAL ASSY
WORK BENCH
Fig. 6-9
(3) Assembling thrust plate
1) While holding stem (2) and body (1), match
the hole of thrust plate (3) and the stem (2)
hole.
2) Next, after removing any oil from the thread
of socket bolt (8), coat it with Locktite #242
and tighten to stem (2).
: 6mm,
Tightening torque : 3.1kgfm (22 lbfft)
MATCHING MARK
9
4
ALLEN
WRENCH
PIPE
6 5
Check Item
Checking Procedure
Remedy
Replace O ring or dust seal , if any oil
leakage can be found.
Replace all sealing parts such as slipper
seal with back-up ring and O ring.
Repair or replace referring to their limit
of service.
Check them for seizure, foreign Repair or replace referring to their limit
matters, abnormal wear, and
of service.
defect of seals.
O rings and dust seal should be
replaced.
Body,
Stem
Cover
Sliding surface
between body and
stem other than
sealing sections
Maintenance Standards
Remedy
Smooth with
oilstone.
Replace
Sliding surface
Smooth
Replace
Sliding surface
Smooth
66
Parts
Maintenance Standards
Remedy
(With
back-up
ring)
BACK-UP RING
Replace
(With
Slipper ring
back-up
1.5mm (max.)
(0.06in)
ring)
BACK-UP RING
Replace
(With
back-up
ring)
67
9
Connect to
body side
2
Connect to
stem side
3
8
Hydraulic
source
Table 6-5
Item
Description
1 Pressure Gauge
Remarks
High and Low Pressures
are required.
2 Swivel Joint
3 Stop Valve
5
Setting Pressure :
5kgf/cm2 (71psi)
6 Stop Valve
7
8 Directional Valve
9 Piping, etc.
68
Setting Pressure
(Working pressure1.5times)
6.4
TROUBLESHOOTING
Table 6-6
Trouble
Cause
Remedy
1. External leakage of
hydraulic oil
2. Internal leakage of
hydraulic oil
69
610
SECTION 34
TRAVEL SYSTEM
TABLE OF CONTENTS
[Part I. Removing and Installing]
1. TRAVEL SYSTEM .................................................................................................... I-1
2. CRAWLER
2.1 Removing crawler............................................................................................................... I-1
2.2 Installing ............................................................................................................................. I-2
2.3 Construction ....................................................................................................................... I-3
2.4 Maintenance standard ........................................................................................................ I-4
2.5 Tools and jigs ...................................................................................................................... I-4
3.UPPER ROLLER
3.1 Upper roller assy ................................................................................................................ I-5
3.2 Removing ........................................................................................................................... I-5
3.3 Installing ............................................................................................................................. I-5
3.4 Construction ....................................................................................................................... I-6
3.5 Disassembly and Assembly ............................................................................................... I-6
3.6 Maintenance standard ........................................................................................................ I-9
3.7 Tools and jigs ...................................................................................................................... I-9
14403 60413255
INDEX
5. FRONT IDLER
5.1 Front idler assy .....................................................................................................
5.2 Removing .............................................................................................................
5.3 Idler assy ..............................................................................................................
5.4 Idler adjuster assy ................................................................................................
I-18
I-18
I-19
I-23
6. SPROCKET
6.1 Removing ............................................................................................................
6.2 Installing ..............................................................................................................
6.3 Maintenance standard .........................................................................................
6.4 Sprocket tooth profile gauge ...............................................................................
I-27
I-27
I-28
I-28
I-32
I-32
I-33
I-33
I-33
I-34
34402 60413254
1. TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER
6. SPROCKET
GUARD
LOWER FRAME
3. UPPER ROLLER
4. LOWER ROLLER
Fig. 1-1
2. CRAWLER
2.1 REMOVING CRAWLER
(1) Position the machine to remove crawler.
Fig. 2-1
Removing/fixing
position of master pin
Fig. 2-2
Removing
master pin
Removing crawler
2.2 INSTALLING
Installing is done in the reverse order of
removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in
the figure on the right.
(2) Installing crawler
1) Preparation for installation
Treat paint flaking protection with care not
to damage lower flame.
Front
idler side
Fig. 2-4
2) Winding crawler
Insert a crowbar into the master pin hole, lift
the lower frame 1 to 2cm above the ground
level by holding it by hand so the machine
body weight is not exerted on the shoe.
Reverse the sprocket to help push the back
winding of the crawler.
(3) Preparation for press fitting master pin
1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine
adjustment turning sprocket.
Fig. 2-5
Winding crawler
Fig. 2-6
Standard dimension A
Dimension of iron crawler in a
max. slackened condition
320_350mm
(12.6_13.8in)
PARTS
LINK ASSY
TRACK LINK R
TRACK LINK L
BUSHING
PIN
MASTER BUSHING
MASTER PIN
COLLAR
SEAL
SHOE 600mm
BOLT 2420Z1292
NUT_2420Z1293
1-1
STD
QTY
1
46
46
45
45
1
1
2
90
46
184
184
LC
QTY
1
49
49
48
48
1
1
2
96
49
196
196
1-8
1-4
1-3
1-8
1-7
1-1
4
1-7
1-2
1-5
1-2
I-3
1-6
Fig. 2-10
Table 1-1
No.
ITEM
A Link pitch
B O.D. of bushing
C Height of link
Interference
D between bushing
and link
Interference
E between track pin
and link
STANDARD VALUE
1900.1 (7.48030.0039)
58.780.05 (2.31420.0020)
1060.3 (4.17320.0118)
Basic
Tolerance
dimension
58.78
0.05
(2.3142) Shaft (0.0020)
36.63
(1.4421)
Shaft
0.05
(0.0020)
Unitmm(in)
REPAIRABLE
LEVEL
SERVICE LIMIT
REMEDY
194 (7.64)
55 (2.17)
100 (3.94)
198 (7.80)
54 (2.13)
98 (3.86)
Fit
Fit
Interference
0.05 (0.0020)
Interference
0
Interference
0.05 (0.0020)
Interference
0
0.03
36.50
Interference
0.088
Shaft
(1.43701)
0.05 (0.0020)
0.00118
0.00315
Clearance between
1.5 (0.06)
8 (0.32)
G links
(both side)
(both side)
Tightening torque
H
87kgfym (630 lbfyft)
of shoe bolt
Interference
F between master
pin and link
Unit : mm
Interference
0
Replace
Link
10 (0.39)
(both side)
Replace
Retighten
(2) Jig
OPPOSING FLATS
NAME
30
Master pin
fixing jig
for iron
crawler
Replace
SHAPE
3. UPPER ROLLER
3.1 UPPER ROLLER ASSY
UPPER ROLLER ASSY No.
NAME
ITEM
ASSY
QTY
ROLLER
CAPSCREW
NUT
WASHER
3 4
4
3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
3.3 INSTALLING
Installing is done in the reverse order of
removing.
(1) Inspection
Before reassembling, check it that it rotates
smooth manually and for leakage.
Countersinking
VIEW
2,4
Fig. 3-2
5
3,4
3.4 CONSTRUCTION
No. NAME
QTY
No. NAME
11
QTY
1 ROLLER
7 FLOATING SEAL
2 SHAFT
8 O RING : 1A
3 COLLAR
9 SOCKET BOLT
4 PLATE
10 PLUG
5 COVER
11 SNAP RING
6 BUSHING
P65
10
Fig. 3-3
3.5 DISASSEMBLY AND ASSEMBLY
(1) Disassembly
1) Draining out oil
Remove plug (10) and drain out oil.
: 6mm
1
5
9
Construction of upper roller
11
10
8
5
1
2
7
Fig. 3-5
6
Extruding shaft
Fig. 3-6
3
f
Fig. 3-7
Removing
floating seal
Fig. 3-8
Extruding bushing
(2) Assembly
Assembly of the upper roller is done in the
reverse order of disassembly.
1) Place upper roller (1) on the top end face of
jig ( f ) , with its floating seal setting side
facing down.
2) Confirm that the outer surface of bushing (6)
is not seized and coat the outer surface of the
inserting side of the bushing, with
molybdenum disulfide grease.
3) Put jig (i) into bushing (6) and press it in,
using the bore of the bushing and the bore of
the roller as guides.
i
6
1
Fig. 3-9
If you fail in this operation by pressing
the bushing unevenly, the bushing is
distorted and gets unserviceable. In
that case, do not re-use the bushing as
it may develop malfunctioning after
assembly.
Pushing in bushing
2
7
7
3
Fig. 3-10
7
11
8
5
4
1
Fig. 3-13
8
Filling oil
D
B
Table 3-1
No.
ITEM
Dia.
Width
Tread dia.
Tread width
Clearance
between shaft and
bushing
Interference
between roller
and bushing
Tightening torque
of socket bolt
Oil
Roller rotation
Unit : mm (in)
STANDARD VALUE
REPAIRABLE
LEVEL
SERVICE LIMIT
160 (6.30)
150 (5.91)
130 (5.12)
128 (5.04)
Fit
Fit
Clearance
0.7 (0.028)
Clearance
1.0 (0.039)
Interference
0
Clearance
0.01 (0.0004)
140 (5.51)
33 (1.30)
Basic
dimension
Tolerance
50
Shaft
(1.96850)
55
Hole
(2.16535)
0.025
0.050
0.00098
0.00197
0.030
0
0.00118
0
REMEDY
Replace
Replace bushing.
11.7kgfym(85 lbfyft)
Engine oil API grade CD #30, 50cc (3.05cuyin)
Refill
Reassembly
OPPOSING FLATS
Socket
30
Allen wrench
6,8
(2) Jigs
Unit : mm (in)
No.
NAME
SHAPE
140 (5.51 )
160 (6.30 )
100 (3.94 )
Stand jig
18
(0.71 )
For
extruding
bushing
30
(1.18 )
52.5 (2.07 )
Bushing
fixing jig
49
20
(0.79 )
(1.93 +0.004
)
0
For
extruding
shaft
(2.36 )
+0.1
0
49 (1.93 )
50
(1.97 )
70
(2.76 )
10
NAME
STD LC
Q
TY
REMARKS
LOW ROLLER
14 16 YN64D010013F1
CAPSCREW
56 64 M1880(P=1.5)
TRACK GUIDE
YN01F01039P1
CAPSCREW
M1840(P=1.5)
2
Apply Locktite #262
T=40.5kgfym (290 lbfyft)
Fig. 4-1
4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop
the engine in that condition.
2) Place a safety block (wooden) at the front and
back of the lower frame.
(2) Removing track guide
Remove capscrews (4) and remove track guide.
: 27mm
Weight of track guide : Approx.24kg (52 lbs)
SAFETY BLOCK
(Square timbers)
Fig. 4-2
Fig. 4-3
GREASE NIPPLE
4.4 CONSTRUCTION
No.
NAME
ROLLER
COLLAR
SHAFT
4
5
6
BUSHING
PIN
2
2
2
O RING
1A,G60
PLUG
PT1/4
FLOATING
SEAL
4 1 6 2 7 5
QTY REMARKS
3
Fig. 4-5
Fig. 4-6
JIG P
2
1
3
JIG m
Fig. 4-8
Fig. 4-9
n
1
JIG m
Fig. 4-10
13
(2) Installing
1) Attach O ring (7) to one side
Install O ring (7) to groove on shaft.
z Grease O ring.
z Replace O ring with new one without
fail at reassembling.
Fig. 4-11
JIG Q
Fig. 4-12
3
2
Fig. 4-14
14
Press
z Grease O ring.
z Replace O ring with new one without
fail at reassembling.
Pin hole
2
7
Fig. 4-15
8
Tightening
torque
2.4kgfym
(17 lbfyft)
Fig. 4-16
15
Fig. 4-17
Table 4-1
No.
ITEM
STANDARD VALUE
Unit : mm (in)
REPAIRABLE LEVEL
SERVICE LIMIT
O.D. of flange
185 (7.28)
Tread dia.
150 (5.91)
134 (5.28)
128 (5.04)
Flange width
23.5 (0.925)
18 (0.709)
16.5 (0.65)
Fit
Fit
Clearance between
shaft and bushing
(Wrapped bushing)
Interference
between roller and
bushing
Oil
G
H
Clearance between
roller and collar
Plug (8)
Roller rotation
Basic
dimension
REMEDY
Reinforcement
Tolerance
0.060
65
0.090
Clearance
Clearance
Shaft
0.00236
(2.55905)
0.7 (0.276)
1.0 (0.394)
0.00354
0.030
69
0.020
Interference
Clearance
Hole
(2.71653)
0
0.01 (0.0004)
0.00118
0.00079
Engine oil API grade CD #30, 160cc (9.8cuyin)
weld, repair or
replace
Replace
bushing.
Refill
16
Reassembly
OPPOSING
Socket
19,27
Allen wrench
FLATS
(2) Jigs
Unit : mm (in)
SHAPE
V-block
Pin (5)
100 (3.94 )
extrusion
(0.55 )
NAME
14
No.
Bushing
n
16
(0.63 )
rod
200
extrusion
rod
270
extrusion
jig
64.5
(2.54 )
94.5
(3.72 )
30
86
(1.18 ) (2.52 )
Shaft
125
(4.92 )
Stand jig
64
160
(6.30 )
290
Bushing
fixing jig
+0.1
64.6 0
(2.54 +0.004
)
0
17
NAME
Q TY
IDLER ASSY
GREASE NIPPLE
CAPSCREW
3
Fig. 5-1 Front idler assy
5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
CROWBAR
Removing
and
installation
the
(1)
front
NAME
Q
TY
IDLER
BUSHING
COLLAR
FLOATING SEAL
PIN
SHAFT
O RING
PLUG
1
2
3
7
8
6
5
4
Fig. 5-4
Idler assy
5
R
Fig. 5-5
3
Fig. 5-6
S
6
Fig. 5-7
19
Fig. 5-9
Pressing
6
3
5
Fig. 5-10
4
1
Fig. 5-11
20
3
5
8) Filling oilInspection
Fill in 200cc (12.2cuyin) of engine oil API
grade CD #30 through the plug hole of collar
(3), wind seal tape and tighten plug (8).
: 5mm
Fig. 5-12
160 (6.30)
C
A
Fig. 5-13
Front idler
Table 5-1
No.
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
Dia. of idler
projection
535 (21.1)
Tread dia.
497 (19.6)
490 (19.3)
487 (19.2)
Flange width
840.5 (3.3070.020)
78 (3.07)
76 (2.99)
Fit
Fit
Clearance
1.5 (0.059)
Clearance
2.0 (0.079)
Interference
0
Clearance
0.01 (0.0004)
ITEM
Unit : mm (in)
Clearance
between shaft
and bushing
Interference
between idler
and bushing
Oil
Idler rotation
Basic
dimension
75
(2.95275)
83
(3.26771)
Tolerance
Shaft
Hole
0.030
0.060
0.00118
0.00236
0.036
0
0.00142
0
REMEDY
Replace
Replace
bushing.
Refill
Reassemble
21
OPPOSING
Socket
24
Allen wrench
FLATS
(2) Jigs
Unit : mm (in)
SHAPE
20
striking jig
70
Bushing
Press fitting
jig
(2.91 )
Shaft
push out jig
74
340 (13.4 )
(0.79 )
(2.76 )
90
(3.54 )
Pin
SHAPE
105 (4.13 )
15
105
(4.13 ) (0.59 )
+0.
74.61
(2.94 +0.004
)
0
Bushing
drawing rod
Stand
About.
400
(15.7 )
2 pcs.
22
Collar Press
fitting jig
30
(0.63 )
300 (11.8 )
16
103 (4.06 )
(1.18 )
NAME
30
(1.18 )
No.
(0.59 )
NAME
15
No.
NAME
Q
TY
1 GREASE CYLINDER
2 BRACKET
3 NUT
4 SPRING PIN
5 SPRING
6 PISTON
7 COLLAR
8 O RING
9 OIL SEAL
10 PIN
11 COVER
REMARKS
9 8
880
11
1B
10
G80
Fig. 5-14
M30
Holding-down nut
Retainer plate
V
Hydraulic jack
BASE
Fig. 5-15
2) Preparation for working
Place a hydraulic jack between the jig base
and the stand.
Loosen the holding-down nuts of the jig and
draw out the retainer plate upward.
: 46mm
3) Draw out grease cylinder (See Fig. 5-14)
Draw out piston (6) from grease cylinder (1)
of the idler adjuster assy.
4) Removing oil seal (9), O ring (8)
(See Fig. 5-14)
Taken out oil seal (9) and O ring (8) from
grease cylinder (1).
V
Fig. 5-16
23
: 46mm
Retainer plate
3,4
Fig. 5-17
: 46mm
: 75mm
Fig. 5-18
Retainer plate
2
11
: 46mm
Fig. 5-19
9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M48P2 on
grease cylinder (1) top end and hoist it. Then,
remove the set of grease cylinder (1) and
spring (5) using crane from the jig.
Remove spring (5), collar (7), grease cylinder
(1), in that order.
24
(2) Assembly
Assembly is done in the reverse order of
disassembly.
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into
spring (5) and attach lifting eye nut (W) to
screw M48 P2 at the tip of the grease
cylinder. Lift the grease cylinder by crane
and erect it in the center of the jig stand
upright.
W
1
: 46mm
2
4
3
11
1
5
: 46mm
: 75mm
5) Removing idler adjuster assy
Remove idler adjuster assy from jig.
25
Grease Nipple
Fig. 5-24
ITEM
STANDARD
VALUE
429mm (16.9in)
About. 531.1mm
(20.9in)
C Stroke
50mm (1.97in)
D Set length
630mm (24.8in)
Nor scoring
and rusting
6kgfym
(43 lbfyft)
C
E
A, B
D
26
6. SPROCKET
6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to Section 2.
"Crawler", lift up crawler frame with
attachment, and put it on square timbers to
float and stabilize.
Fig. 6-1
Fig. 6-2
1
Removing sprocket
6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.
(2) Securing sprocket temporarily
Coat the sprocket attaching capscrews with
Locktite #262 and fasten the sprocket
temporarily.
(3) Securing sprocket completely
Remove the wooden blocks under the track
frame, bring the machine down on the ground
and tighten the sprocket.
: 27mm,
Tightening torque : 40.5kgfym (290 lbfyft)
Fig. 6-3
27
6.3
MAINTENANCE STANDARD
Table 6-1
96.07mm
PITCH
(3.78in)
SPECIFICATION
ROLLER 58.72
DIA.
(2.31in)
NUMBER
21
OF TEETH
PITCH
644.602
DIA.
(25.333in)
Fig. 6-4
Sprocket
Table 6-2
No.
NAME
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
REMEDY
664
(26.1)
656
(25.8)
654
(25.7)
Reinforcement weld,
repair or replace.
704 (2.7510.157 )
64 (2.52)
62 (2.44)
586 (23.1)
578 (22.8)
576 (22.7)
A O.D. of sprocket
B
Width of
sprocket teeth
O.D. of sprocket
C bottom
Unit:mm(in)
OPPOSING
FLATS
27
28
Replace.
Reinforcement weld,
repair or replace.
Fig. 6-5
29
7. TRAVEL MOTOR
Apply Locktite #262
or equivalent
T=40.5kgfym (290 lbfyft)
NAME
QTY
SPROCKET
CAPSCREW
44
CAPSCREW
34
3
Apply Locktite #262
or equivalent
T=55kgfym (400 lbfyft)
1
0
Fig. 7-1
7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize.
7
1,2
Fig. 7-2
: 19mm
2
Fig. 7-4
Remove pipes.(Disconnect)
: 30mm
3
Fig. 7-5
Fig. 7-6
7.3 INSTALLING
Installing of the travel motor piping is performed
in the reverse order of removal.
1) Cleaning
Check that contact surface of travel motor
and lower frame is free from burr and stain.
2) Tightening torque
Tighten capscrew and hydraulic pipes to the
torque specified in "Tightening Torque".
NAME
SIZE
Tools
HEX
No.
Sems bolt
M12
19
M18
27
M20
30
55 (400)
5 (36)
15 (110)
28 (200)
3.7 (27)
11 (80)
26 (190)
Capscrew
Flareless
101.5 19
nut for
182.5 32
pipes,
28
41
sleeve
PF1/4 19
Connector PF1/2 27
PF1
41
31
8. SWING BEARING
8.1 SWING BEARING ASSY
No.
NAME
QTY
SWING BEARING
CAPSCREW
36
FRONT
to be applied
SECTION
A A
Fig. 8-1
8.2 REMOVING
(1) Matchmarks
Remove upper structure, apply matchmarks
on inner race of swing bearing and lower
frame.
Swing bearing
Outer race
Inner race
Matchmarks
Matchmarks
Swing bearing
Eye bolt
Grease bath
Fig. 8-3
32
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces
of swing bearing and lower frame are free
from dust and stain.
FRONT
(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark
on inner race as shown in the figure.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with
Locktite #262 and tighten all the capscrews
(2) temporarily.
: 30mm
Fig. 8-4
SECTION
Fig. 8-5
AA
8.4 CONSTRUCTION
No.
1
2
3
4
5
NAME
QTY
1
1
BALL
104
RETAINER 104
SEAL
1
OUTER RACE
INNER RACE
No.
6
7
8
9
NAME
SEAL
TAPER PIN
PLUG
GREASE NIPPLE
QTY
1
1
1
1
(PT1/8)
6
1
9
8
7
3,4
5
2
Fig. 8-6
EYE BOLT
7
1
Square wooden
block
8
5
Fig. 8-7
3
Fig. 8-8
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1)
and the groove for seal (5) located on the
outer surface of inner race (2). Coat the
grooves with adhesive Cyano Bond PX-3000
or equivalent, fit seal (5) and place it on a
surface plate.
2) Lower outer race (1) to the position where
upper surface of inner race (2) and lower
portion of seal groove is mated, put adjusting
washer under outer race (1) so that outer
raceway surface of ball (3) aligns with inner
raceway, and support it.
3) Insert ball (3) and retainer (4), on which
grease is applied, through plug (8) hole on
outer race (1), alternately.
To insert ball (3) and retainer (4), use a
push rod, etc., to protect persons from
injury from inserting fingers into plug
hole.
1
6
Push rod
2
Square
wooden block
Fig. 8-9
Eye bolt
Hooked rod
4
Square
wooden block
Fig. 8-10
12 13 3 7 5
37
40 24
28
36
20
kgfym(lbfyft)
Opposing
flats
mm
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
27
28
29
30
33
21
23
29
32
17
26
38
18
40
39 _Z
41
10
2
19
30
8
25
22
11
44
50
15 16
4 27
42 45 48 47
49
43
42
No.
14
46
NAME
Tightening
torque
QTY
CASING
REAR COVER
CYLINDER BLOCK
SHOE RETAINER
FRICTION PLATE
BRAKE PISTON
SEPARATOR PLATE
VALVE PLATE
SHAFT
COUPLING
SHOE PLATE
BALL JOINT
SPRING RETAINER
PISTON ASSY
D RING (SMALL)
D RING (LARGE)
CHECK VALVE
SNAP RING
SNAP RING
TILTING PISTON
BALL
PIVOT
PISTON SEAL
M6 ORIFICE_0.6
OIL SEAL
SPRING
SPRING(CYLINDER)
SPRING(BRAKE)
BEARING
BEARING
1
1
1
1
3
1
4
1
1
1
1
1
1
9
1
1
3
1
1
1
1
2
1
2
1
3
9
2
1
1
kgfym(lbfyft)
Opposing
flats
mm
23.5 (170)
14
1.4 (10)*
1.5 (11)
3.0 (22)
5
6
11 (80)
32
5.5 (40)
22
5.5 (40)
2.8 (20)
10 (72)
10
No.
NAME
SOCKET BOLT ; M1645
SHIM
PARALLEL PIN ; 612
___
PLUG ; NPT1/16
PLUG ; NPT1/16(Meck : TB)
PLUG
PLUG ; PF1/8
PLUG ; PF1/4
ORING ; 1B P8
ORING ; 1B P11
ORING ; 1B P14
ORING ; 190.172.62
31
32
33
_
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
SPOOL
PLUG ; PF3/8
SPRING RETAINER
PIN
SPRING
CONNECTOR
SPOOL ASSY
COVER
SPRING
SPRING RETAINER
RESTRICTOR VALVE
SPRING
PLUG
ORING ; 42.522.62
ORING ; 1B P9
SOCKET BOLT ; M1235
QTY
8
1~2
1
_
1
10
1
3
2
5
4
2
1
2
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
8
58
54
44-3
44-2
44-1
44-4
44-12 44-13
44-9
44-8 44-12
44-7
44-5
60
53
52
57
41
31
51
59
Opposing
flats
mm
11 (80)
32
16 (120)
35
55 56
No.
44-1
44-2
44-3
44-4
44-5
44-6
44-7
NAME
SOCKET
VALVE
VALVE SEAT
CONNECTING PISTON
PLUG
PILOT BODY
PISTON
QTY
1
1
1
1
1
1
1
Tightening
torque
kgfym(lbfyft)
Opposing
flats
mm
No.
44-8
44-9
44-10
44-11
44-12
44-13
NAME
SHIM
ADJUSTMENT SPRING
O RING ; 1BP7
BACK UP RING
O RING ; 1BG25
BACK UP RING
QTY
1
1
1
2
2
1
II - 1
24
15
16
14 13
12
18
25
20
4
7
3
5
10
6
9
1.1mm
0.42.4mm
(0.016 0.094 )
(0.043 )
1
2
11
26
17
21
22
Fig.1-2
19
23
Tightening
torque
kgfym(lbfyft)
Opposing
flats
mm
No.
QTY
kgfym(lbfyft)
Opposing
flats
mm
No.
NAME
QTY
COVER
14
PLANETARY GEAR 2
CARRIER 1
15
SPRING PIN636
CARRIER PIN 1
16
THRUST WASHER 2
NEEDLE BEARING
17
RING GEAR
THRUST WASHER 1
18
HOUSING
PLANETARY GEAR 1
19
BEARING
SPRING PIN422
20
SHIM
THRUST PLATE
21
LOCK WASHER
SUN GEAR 1
22
SUPPORT RING
10
SUN GEAR 2
23
FLOATING SEAL
11
CARRIER 2
8.0 (58)
24
SOCKET BOLTM1025
15
12
CARRIER PIN 2
28.0 (200)
14
25
SOCKET BOLTM1680
19
SEAL
TAPE
14
26
SOCKET PLUGPT3/4
13
2
NAME
Tightening
torque
NEEDLE BEARING
1.0 (7.2)
Unitmm
SPECIFICATION
Allen wrench
Opposing flats
5, 6, 10, 14
Spanner
Opposing flats
For shaft 45
Plastic hammer
Torque wrench
20
(0.79 )
Screw driver
52
(2.05 )
(0.39 )
90
(3.54 )
10
10
(0.39 )
100
(3.94 )
Others
Seal tape
Cleaning oil (Kerosene)
170
(6.69 )
Grease
190
(7.48 )
Hydraulic oil
Rag
250
(9.84 )
Compressed air
22
(0.87 )
PCD220
(8.66 )
10
(0.39 )
1.3.2 DISASSEMBLY
(1) General cautions
1) In general, the hydraulic components are
made to precision and have very little
clearance. For this reason, disassemble and
assemble them in a less dusty clean place.
Use clean tools and cleaning oil and handle
them with care.
2) When the motor has been separated from the
machine , clean the ports and the neighboring
areas thoroughly and put plugs into ports so
no dirt, water and other foreign matter enter
the motor.
3) Study the assembly drawing before starting
the work and prepare
necessary parts
according to the purpose and the scope of
disassembly. Seals and O rings once
disassembled can not be used again. Some
parts cannot be supplied singly, but must be
supplied as sub-assemblies. Prepare such
parts beforehand according to the parts
manual.
10
44
before
58
60
52
53
54
57 41 56 55 59
Fig. 1-3
51
AIR SUPPLY 28
8 30 43
31
30
Fig.1-5
5
AIR SUPPLY
7 5
13
14
MARK
MATCHING MARK
12
Fig.1-6
4 27
AIR SUPPLY
25
19
29
22
Fig.1-7
20
11
1. Measure
the
dimension
E
as-assembled condition in Fig.1-8.
Make sure that shaft
perpendicularly positioned.
(Not tilted).
in
(9)
the
9
30
is
F
1
Fig.1-8
44-2
44-1
Fig.1-9
44-7
44-5
25
Fig.1-10
19
25
29
20
22
Fig.1-11
9
11
14
13
12
Fig.1-12
27
1 14 7 5
15 16
31
30
Fig.1-13
10
BRAKE
PISTON
FIXING JIG
15
18 10
16
6
28
8
42 2
Fig.1-14
31
44
52 60 58
54
51
57 41 56 5559 53
Fig.1-15
11
60 52
54
53
Assembling the brake valve
1-2
surface
of
cylinder
valve
plate
and
Inspection item
Cylinder block
valve plate
surface roughness
Remedy
Replace
0.4-Z max.
3.0Z max.
or
correct.
of shoe plate
Inspection item
Shoe plate
hardness meter.
(2)
Inspection item
Piston O.D. dd1
Allowable hardness
replacement
Higher than
HS78
Standard
0.01mm(0.0004 )
HS74
Remedy
Replace.
Replace
piston or
of pistons and the bore of the Cylinder bore DD1 0.01mm(0.0004 ) 0.022(0.00087 )
cylinder
0.0350.045mm 0.065(0.0026 )
cylinders
at
least
three Clearance Dd
block.
(0.00140.0018 )
locations longitudinally by
Measure the outside diameter
12
Inspection Item/Method
Standard
dimension
Allowable
value
Remedy
00.1mm
0.3mm
(00.004 )
(0.012 )
Replace piston
DIAL INDICATOR
PISTON
JIG
MAGNET
SHOE
SURFACE
PLATE
Fig.1-16
40
(1.58
27+0.2
+0.1
Measure
70
(2.76 )
(1.06 +0.008
+0.004 )
Fig.1-17
Fig.1-18
Standard
value
Jig
Allowable
value
50kgfym
41kgfym
(360 lbfyft)
(300 lbfyft)
Remedy
Replace all of
separator
plate, friction
plate and
spring.
Inspection Item/Method
(5) Shaft
Measure the wear of the shaft
seal by means of a roughness
meter.
(6) Bearing
Replace bearing
(7) Spline
Replace spline if it is worn
beyond its allowable limit.
14
1.6.2 TROUBLESHOOTING
(1) Motor does not start.
Symptom
Pressure does not
rise.
Pressure rises.
Cause
Remedy
6. Spool malfunctions
(Spool is stuck.)
(The hole in the restrictor valve is
clogged.)
6. Correct or replace
Cause
Remedy
Correct or replace
A set pressure is
Spool malfunctions
(Spool is stuck.)
normal, but brake
release lags behind.
15
Symptom
Cause
Remedy
Negative brake is
released but the
motor is late to
start.
The viscosity of hydraulic oil is too high. Raise the oil temperature.
Negative brake is
released but the
motor starts feebly.
Cause
Remedy
Cause
Remedy
Spool malfunctions
Correct or replace
Cause
Remedy
2. Replace O ring.
16
(6) The motor speed does not change from high to low.
Trouble
Cause
Remedy
Cause
Remedy
Spool malfunctions.
Bleed air.
Correct or replace.
Cause
Remedy
Spool malfunctions.
Correct or replace.
17
Correct or replace.
No.
Tools
Application
Torque wrench
50kgfm (0
360 lbfft)
Allen wrench
Stand
180
(7.09 )
15mm
Caliper
150mm
Eye bolt
M10 M18
Pin
Press machine
Others
1.7.2 DISASSEMBLY
(1) Preparation before removal
1) The travel unit removed from the machine
has dust and mud. Wash them with cleaning
oil.
2) Loosen drain or oil filling plug (26) and drain
the oil out of the reduction unit.
When oil is hot, pressure is built up
inside. Take care as the oil gushes
out in some cases.
3) Leaving matching marks
Put a matching mark on the outside of each
matching surface so it may be installed where
it was.
l The numbers in the parentheses after
part names correspond to those in the
assembly drawing on page II-2.
18
3pcs. each
COVER
MATCHING MARK
Fig.1-19
24
1
Fig.1-20
1
17
Fig.1-21
19
6
(3,4,5,7)
Fig.1-22
(5) Removing carrier 2 assy
1) Remove sun gear 2 (10).
11
14
(12,13,15,16)
Fig.1-23
(6) Removing housing assy
1) Remove support ring (22).
2) Remove lock washer (21) by hammering on
something like a screwdriver that is placed in
the split.
22
21
Fig.1-25
20
25
19
17
23
Fig.1-28_Carrier 1 assy
II-21
18
7
3
Fig.1-29
2
Removing carrier 1 assy
5
6
4
6
Fig.1-30
15
12
11
11
Fig.1-31
14
11
16
13
Fig.1-32
22
1.8 INSTALLATION
(1) General precautions
1) Clean parts thoroughly in cleaning oil and
dry it up by jet air. Degrease areas to coated
with Locktite, using thinner or something.
2) Check that parts are free from fault.
3) Coat socket bolt with Locktite #242, before
tightening them.
4) Coat the parts with a thin film of gear oil,
before proceeding to assembly operation.
5) Use care so you do not pinch your hand
between parts and you do not drop parts.
(2) Installing carrier 2 assy
1) Install planetary gear 2 (14), needle bearing
(13), and thrust washer 2 (16) into carrier 2
(11).
2) Insert carrier pin 2 (12) into carrier 2 (11),
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin(15) into carrier 2 (11) and
carrier pin 2 (12).
[Drive in the spring pin 1 to 2mm (0.04
0.08in) below the surface into which it is
placed.]
4) Caulk two places 180diagonally located.
11
14(13,16)
Fig.1-33
14(13,16)
15
11
Fig.1-34
(3) Installing carrier 1 assy
(See carrier 2 in the figure.)
1) Install planetary gear 1 (6), needle bearing
(4), and thrust washer 1 (5) into carrier 1 (2).
2) Insert carrier pin 1 (3) into carrier 1 (2),
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin (7) into carrier 1 (2) and
carrier pin 1 (3).
[Drive in the spring pin 1 to 2mm (0.04
0.08in) below the surface into which it is
placed.]
4) Caulk two places 180diagonally located.
CAULKING
POSITION
15
Fig.1-35
23
23
Fig.1-36
LOCKTITE #515
Fig.1-37
23
25 18
17
GOOD
BAD
BAD
Fig.1-38
24
A
B
D
C
17 21 22
Fig.1-39
18
20
21
Fig.1-40
25
19
22
PLANETARY GEAR 2
BRAKE VALVE
11
Fig.1-42
Assembling carrier 2
Fig.1-43
Assembling carrier 1
1
LOCKTITE #515
17
26
Fig.1-44
26
(3) Bearing
Turn it by hand and check to see that it turns
without unusual sound and resistance.
(4) Floating seal
Inspect that the moving parts and O rings
are not scored.
(2) Gears
1) There is no pitching and seizure on the gear
tooth surface.
2) Inspect that the root of gears is not cracked
by liquid penetrant examination technique.
1.9.2 SERVICING PARTS
The following are reference values by which the
serviceability of used parts is determined. Since
these serve as general reference, it is
recommended that the extent of disassembly be
decided depending upon performances, excessive
damage or discoloration of components, the
purpose of disassembly and remaining service life
that is expected.
Fig.1-45
Maintenance Standard
Code
Item
Reference value
Allowable value
Remedy
Replace 3 shafts as
a set.
To be smooth, no abnormal
wear and seizure.
Replace shims.
[See.1.8 (6)]
1.80.2mm
(0.0710.008 )
Wear
0.1mm
(0.004 )
Replace
0.70.06mm
(0.0280.002 )
Wear
0.1mm
(0.004 )
Replace
27
Part name
Size
Tightening torque
24
Socket bolt
M10_25
25
Socket bolt
M16_80
26
Socket plug
PT3/4
II-28
SECTION 41
TABLE OF CONTENTS
1. OUTLINE .................................................................................................................... 1
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ................................................. 3
3. TROUBLESHOOTING OUTLINE ............................................................................... 4
14403 60413255
1. OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble
occurred. This manual describes how to solve the
specific phenomenon systematically as early as
possible. For troubleshooting concerning the
inside of equipment, refer to troubleshooting for
each manual of equipment.
1.1 JUDGMENT OF ACTUAL THING AT SITE
(1) Get to the site as quickly as possible.
Verify model, serial number, situation of
trouble and field, and notify person of arrival
time.
(2) Verify background of trouble occurred
1) Model name and serial number
2) Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional
works.
5) Recurrence of past trouble, or problems on
the additional modification.
YR-B76
(3)
1)
2)
3)
YR-B76
YT-B87
YR-B76
Bucket digging
Bucket dump
Swing operation
Travel LH / RH operation
(1st. speed)
Travel LH / RH operation
(2nd speed)
Independent operation
Other
Bucket
Arm
Boom
Swing motor
Travel 1-2speed
Solenoid valve
Cylinder
Motor
Travel left
S
V
Travel right
Operating condition
S
V
Swing
P
S
V
S
V
Bucket
P
S
V
Arm
P
S
V
P
S
V
Actuator
Boom
P
S
V
P2 Pump proportional
valve
P
S
V
Control valve
P1 Pump proportional
valve
P1 bypass cut
proportional valve
Travel straight
proportional valve
S
E
23
P2 bypass cut
proportional valve
S
E
22
Electric
2.
3.
Location
Lever position
Att
Travel
Operation
Pressure sensor
High pressure
(Pump)
Low pressure
(Pilot)
P1
P2
ATT
Proportional valve
Arm variable recirculation valve
P2 bypass cut proportional valve
Travel straight proportional valve
P1 bypass cut proportional valve
Arm variable recirculation proportional valve
Bucket digging
Bucket dump
Boom raise
Neutral ; 642mA
Control lever at
full stroke
Max
Max
Approx 35kgf/cm2 Approx 24kgf/cm2
(500psi)
(340psi)
More than
2.9V
More than
3.7V
Min ; 303mA
Max 750 mA
Max 750 mA
Boom lower
Swing left
Max ; 642mA
Swing right
Arm in
Arm out
TRAVEL
Forward
Reverse
Lever at neutral
Approx6.0kgf/cm2
(85psi) or less
Approx
6.0kgf/cm2
(85psi) or less
Less than
0.5V
Less than
0.5V
Neutral
(Hi idle)
Neutral
(Hi idle)
350mA
350mA
GROUND
PRESSURE SENSOR
(OPTION 1) (SE-11)
PRESSURE SENSOR
(BUCKET DIGGING) (SE-1)
PRESSURE SENSOR
(TRAVEL RIGHT) (SE-9)
PRESSURE SENSOR
(TRAVEL LEFT) (SE-10)
PRESSURE SENSOR
(OPTION 2) (SE-20)
PRESSURE SENSOR
(ARM OUT) (SE-8)
Fig. 1
(2) Location
P
of high pressure sensor and pump proportional valve
PRESSURE SENSOR(P1 PUMP)(SE-22)
PROPORTIONAL
VALVE (P1 PUMP)
(PSV-P1)
Fig. 2
(SE-5)
PRESSURE SENSOR
(SWING)
(SE-2)
PRESSURE SENSOR
(BUCKET DUMP)
(SE-7)
PRESSURE
SENSOR
(ARM PULL)
(SE-4)
PRESSURE SENSOR
(BOOM DOWN)
(SE-3)
PRESSURE SENSOR
(BOOM UP)
Fig. 3
Fig.4
4.2 EQUIPMENT
(1) Solenoid proportional valve block
HYDRAULIC SYMBOLS
Fig. 5
CONNECTER TERMINAL
ARRANGEMENT
TERMINAL NO.
1-COMMON
2-OUT PUT(+)
3-POWER SUPPLY(+)
VIEW
1921.9 HEX
HEX 22
O RING P11
O RING
PF1/4
PF3/8
DETAIL OF SENSOR
7
P14
SECTION 42
TROUBLESHOOTING (HYDRAULIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................. 1
14403 60413255
2. TROUBLESHOOTING ............................................................................................... 3
1.
TROUBLE DIAGNOSIS
Oil pressure
(3)
9 10
Raise
Lower
Arm in
Arm out
All motions
Bucket digging
Boom
Arm in
Boom
Swing
(5)
Raise
(7)
(8)
(9)
(12)
(4)
Raise
11
All actions
Boom
Swivel joint
Bucket cylinder
Other valve
Arm cylinder
Parking brake
Cylinder
Boom cylinder
Travel motor
Motor
Reduction parts
Swing motor
Lock valve
Bucket spool
Arm spool
Boom spool
Swing spool
Travel spool
Pilot pump
P2 pump
P1 pump
E/G revolution
Speed is low.
(2)
No operation is possible.
Fine operation
impossible.
Attachment operation
Travel operation
Swing operation
Hydraulic systems
(1)
Power lacks
Group No.
Classification
Component
Parking brake
Swing
motor
Control valve
Arm variable recirculation valve
Pump
2. TROUBLESHOOTING
(1)-1
No operation is possible.
NO
YES
Only the hydraulic pilot system
(ATT and travel motion) not
operative?
YES
To electric
troubleshooting
pressure is about
50kgf/cm2 (710psi).
P1,P2 ; 350kgf/cm2(4980psi)
(OPT)-P4 ; 250kgf/cm2(3550psi)
YES
YES
NO Replace relief
valve.
Inspect or replace pump.
Also inspect pump
coupling.
YES
NO
YES
NO
YES
The pilot valve P port inlet pressure is approx. 50kgf/cm2 (710psi).
YES
NO
NO
NO
To electric troubleshooting
(1)-2
Machine moves unexpectedly with levers in neutral.
Machine stops moving unexpectedly if the connector (CN-257F,CN-259F)
for proportional valve P1,P2 bypass cut is disconnected.
YES
To electrical troubleshooting
NO
Pump
delivery
pressure in
unloaded
condition is
approx.
5kgf/cm2
(71psi) or
lower.
YES
YES
NO
The spool returning spring of the circuit that
is moving unexpectedly is broken.
NO
YES
NO The outer
circumference of
spool is scratched.
YES
NG
NO
YES
NG
NO
YES Inspect or replace bypass cut valve spool assy and pilot
cover.
NO
NO Spool is scored on
inspection.
NO
YES
NG
Replace control valve.
Replace control valve.
Boom or
arm?
NO
YES When the lock valve, body seat and selector YES Replace lock valve and correct body seat or replace
parts were inspected, faults such as scratch
body or replace selector.
were discovered.
NO
Faults such as scratch are discovered in load
check valve and seats in conflux passage and
recirculation passage.(CCb,CCa, CAr)
YES
NO
NO
Inspect or replace
overload relief valve.
YES
(2)-1
All attachment motions are slow.
(Service diagnosis 24,25)
Command current readings of pump
proportional valve are at standerd levels(below)
during operation.
P1 ; approx. 750mA by bucket operation.
P2 ; approx. 750mA by swing operation.
NO
YES
YES
Do motions get normal if the coupler(PSV-C) for
travel straight proportional valve is
disconnected?
NO
Primary pilot pressure is 50kgf/cm2 (710psi).
YES
Secondary pilot pressure at PTb port (travel
straight) is approx. 5.7kgf/cm2 (81psi).
YES
NO To electric
troubleshooting.
NO
YES
NO
NG
Inspect or replace
proportional valve block.
YES
Travel straight spool moves smoothly by hand.
(Remove the pilot cover.)
NO
NO
NO
YES
NG
Replace control valve.
NO
YES
(2)-2
Only the bucket motion is slow.
Is the motion normal if connector (CN-257F) for
bypass cut proportional valve is disconnected?
P2
NO
YES
To electrical troubleshooting.
NO
YES
(Service diagnosis 24)
Command current readings of pump
proportional valve are within standard
levels(below) during full lever operation.
Bucket digging / dumping operation : 750mA
YES
NO
NO
NO
YES
NO
Bucket spool moves smoothly by hand. (Remove
pilot cover.)
NG
YES
YES
NO
YES To electrical
troubleshooting.
NG
Replace control valve.
YES
YES
NG
NO
YES
Pilot pressure at port PTb (travel straight) is
approx. 7kgf/cm2 (100psi).
NO
To electric troubleshooting.
(toAll motions are slow.)
NO
YES
NG
Inspect or replace
proportional valve block.
NO
YES
NO
YES
NO
YES
NG
Replace control valve.
NO
YES
(2)-3
Only the boom raise motion is slow.
(Service diagnosis 21)
Control current of P2 bypass cut proportional
valve is approx. 640mA when full lever
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port PCa (P2 bypass
cut valve) is approx. 25kgf/cm2 (360psi).
YES
Pilot pressure at PAb, PB1 ports (boom raise
and boom conflux) is 50kgf/cm2 (710psi).
NO
NO
To electric troubleshooting.
NG
NO
Inspect or replace
proportional valve block.
Inspect or replace ATT pilot
valve.
YES
(Diagnosis 24,25)
Command current readings for pump
proportional valve lie within standard levels
(below) during the above operation.
P1 ; approx. 670mA
P2 ; approx. 670mA
NO
YES
To electric troubleshooting.
NO
NG
NG
YES
NO
YES
NO
YES
Return spring for P2 bypass cut valve spool is
broken.
NO
P2 bypass cut valve spool moves smoothly by
hand. (Remove pilot cover.)
YES
NO
YES
YES
NG
NO
NO
Boom spool moves smoothly by hand.
(Remove pilot cover.)
YES
NO
YES
NG
NO
YES
NO
Boom conflux spool moves smoothly by hand.
YES
NO
YES
NO
YES
NG
Replace control valve.
Replace control valve.
(2)-4
Only boom lower action is slow.
(Service diagnosis 22)
Control current for travel straight proportional
valve is approx. 350mA.
(Are the motions slow if coupler (PSV-C) for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PTb (travel straight) is
approx. 7kgf/cm2(100psi).
NO
Return spring for travel straight spool is broken.
NO
Travel straight spool moves smoothly by hand.
(Remove pilot cover.)
NO
YES
To electric troubleshooting
NG
YES
NO
YES
Inspect or replace
proportional valve block.
YES
NO
(2)-5
Only arm in action is slow.
(Service diagnosis 23)
Control current readings for arm recirculation
proportional valve are about 480mA when
H-mode arm in lever is turned to the full.
NO
To electric troubleshooting
YES
Pilot pressure at arm variable recirculation is
port Pis approx. 15kgf/cm2(210psi).
NO
YES
Command current readings for pump
proportional valve lie within standard levels
(below) during the above operation.
P1 ; approx. 350mA
P2 ; approx. 750mA
NO
YES
Secondary pilot pressure at PAa, PLC2 ports
(arm in, lock valve release) is approx. 50kgf/cm2
(710psi).
YES
Relief pressure lies within standard levels
when arm in is operated.
350kgf/cm2(4980psi).
YES
Arm spool or recirculation spool return spring is
broken.
NO
Arm spool or recirculation spool moves smoothly
by hand. (Remove pilot cover.)
NG
YES
NO
Inspect or replace
proportional valve block.
To electric troubleshooting
NO
NO
YES
NO
NO
YES
YES
NG
Replace control valve.
Replace control valve.
(2)-6
Only arm out operation is slow.
(Service diagnosis 20)
Command current for P1 bypass cut proportional
valve is approx. 640mA when arm out lever is
shifted to the full.
NO
To electrical troubleshooting
YES
Secondary pilot pressure at port Pcb
(P1 bypass cut valve) is approx. 25kgf/cm2
(360psi).
YES
Secondary pilot pressure at port PBa (arm out)
is approx. 50kgf/cm2 (710psi) or over.
NO
NG
NO
Inspect or replace
proportional valve block.
YES
(Service diagnosis 24,25)
Command current readings for pump
proportional valve lie within standard levels
(below) during the above operation.
P1 ; approx. 550mA
P2 ; approx. 550mA
NO
YES
Relief pressure lies within standard level
(below) when arm out is turned to the full.
350kgf/cm2(4980psi)
YES
Arm spool return spring is broken.
NO
Arm spool moves smoothly by hand.
(Remove pilot cover.)
YES
To electrical troubleshooting
NO
NO
YES
NO
YES
NG
NO
YES
YES
P1 bypass cut valve spool moves smoothly by
hand.(Remove pilot cover.)
NO
NO
NG
NO
YES
YES
Arm conflux spool moves smoothly by hand.
(Remove pilot cover.)
NO
NO
NO
YES
NG
Replace control valve.
Replace control valve.
(3)-1
All ATT operating power is poor.
Each independent operating speed is within a
standard value.
YES
Relief pressure lies within standard level
P1,P2 ; 350kgf/cm2(4980psi).
YES
Primary pilot pressure is approx. 50kgf/cm2
(710psi).
YES
Travel straight spool return spring is broken.
NO
Travel straight spool moves smoothly by hand.
(Remove pilot cover.)
NO
NO
NO
NG
YES
NO
NO
YES
NG
Replace control valve.
Inspect or replace control
valve or pump.
(3)-2
Bucket digging power is poor.
No-load independent operating speed is within a
standard value.
YES
NO
NO
NO
NG
YES
YES
Bucket spool return spring is broken.
NO
Bucket spool moves smoothly by hand. (Remove
pilot cover.)
YES
NO
NO
YES
YES
NG
Replace control valve.
Replace control valve or
pump.
10
(3)-3
Boom raise operating power is poor.
No-load independent operating speed is within a
standard value.
NO
YES
Relief pressure lies within standard level
(below) when boom up lever is turned to the full.
P1, P2 ; 350kgf/cm2(4980psi).
YES
Secondary pilot pressure at boom raise PAb port
and boom conflux PB1 port is 50kgf/cm2(710psi)
YES
Boom spool return spring is broken.
NO
Boom spool moves smoothly by hand.
NO
NG
NO
YES
NO
YES
YES
NG
NO
NO
Boom conflux spool moves smoothly by hand.
YES
YES
NO
NO
YES
NG
Replace control valve.
Inspect or replace control valve
or pump.
11
(3)-4
Arm in power is poor.
No-load independent operating speed is within a
standard value.
NO
YES
Relief pressure during arm in for both P1 and
P2 pumps lies within standard levels.
P1,P2 ; 350kgf/cm2(4980psi).
YES
NO
NG
NO
YES
Pilot pressure at arm variable recirculation port
Pis is about 15kgf/cm2(210psi)
NO
YES
Secondaly pilot pressure at arm in port PAa and
arm lock valve release PLC2 port is
50kgf/cm2(710psi)
YES
Arm spool return spring is broken.
NO
Arm spool moves smoothly by hand.
(Remove pilot cover.)
NG
NO
YES
NO
YES
NG
NO
YES
Inspect or replace
proportional valve block.
NO
Arm variable recirculation spool moves smoothly
by hand. (Remove pilot cover.)
YES
NO
NO
YES
YES
NG
Replace control valve.
Replace control valve or
pump.
12
(4)-1
Machine can not perform fine operation of bucket digging and dump.
Machine returns normal if connector of P1 bypass cut proportional
valve (PSV-D) is disconnected.
YES
To electric troubleshooting.
NO
Unload pressure of P1
pump is less than 5kgf/cm2
(71psi) when bucket digging
lever is at neutral.
YES
YES
Secondary pilot pressure at
port PCb (P1 bypass cut valve)
is approx. 7kgf/cm2 (100psi)
when lever is at neutral.
NO
P1 bypass cut spool return
spring is broken.
YES
NG Inspect or replace
proportional valve block.
NO
P1 bypass cut spool moves
smoothly by hand. (remove
pilot cover.)
NO Outside of P1 bypass
cut spool is scored.
NO
YES
NG
Replace control valve.
YES
Pilot spool return spring is
broken.
NO
Bucket spool moves
smoothly by hand. (Remove
pilot cover.)
YES
NO
YES
YES
scored.
NG
NO
13
(4)-2
Machine can not perform fine operation of boom raise and lower.
Machine gets normal if connector of P1 bypass cut proportional
valve (PSV-D) is disconnected.
YES
To electrical troubleshooting.
NO
Unload pressure of P1
pump is less than 5kgf/cm2
(71psi) when boom lever is
at neutral.
NO
YES
NO
YES
YES
proportional valve
block.
Inspect or replace P1 bypass
cut spool assy and pilot cover.
NO Outside of P1 bypass
NG Inspect or replace
NG
NO
YES
NO
NO
YES
YES
NO
YES
NG
NO
NO
YES
14
(4)-3
Machine can not perform fine swing operation.
YES
NO
To electrical troubleshooting.
YES
To electrical troubleshooting
NO
Secondary pressure of swing pilot valve is approx. 6kgf/cm2
(85psi), while pilot pressure of parking brake solenoid valve is
0kgf/cm2 (0psi).
NO
Unload pressure of P2
pump is approx. 5kgf/cm2
(71psi) or less when swing
lever is at neutral.
NO
YES
YES
NG Inspect or replace
proportional valve
block.
NG Inspect or replace
proportional valve
block.
Inspect or replace P2 bypass
cut spool and pilot cover.
NO
P2 bypass cut spool moves
smoothly by hand. (Remove
pilot cover.)
NO Outside of P2 bypass
cut spool is scored.
NO
YES
NG
Replace control valve.
Replace control valve.
NO
NG Inspect or replace
proportional valve
block.
YES
Secondary pressure of pilot
valve at startup is approx.
5.5kgf/cm2 (78psi).
YES
Return spring for swing
spool is broken.
NO
Swing spool moves
smoothly by hand.
YES
NO
YES
NO
YES
NG
NO
15
(4)-4
Machine can not perform fine operation of arm in and out.
YES
To electrical troubleshooting
NO
P2 pump unload pressure is
less than 5kgf/cm2 (71psi)
when arm lever is at
neutral.
YES
YES
NO Inspect or replace
YES
NG Inspect or replace
proportional valve
block.
NO
P2 bypass cut spool moves
smoothly by hand.
(Remove pilot cover.)
NO Outside of P2 bypass
NO
YES
NG
Replace control valve.
Secondary pressure is
approx. 5.5kgf/cm2 (78psi)
when arm lever is shifted a
little.
YES
Return spring of arm spool
is broken.
NO
Arm spool moves smoothly
by hand.
NO
YES
NO
YES
NG
NO
YES
NO
YES
Replace control valve.
(5)
Travel 1st and 2nd speeds can not be changed over.
24V is alive across light green/black and black
of connector (CN-255F) for travel 1-2 speed
solenoid (SV-3).
YES
Pilot pressure of travel 1-2 speed select solenoid
(SV-3) is approx. 50kgf/cm2 (710psi).
NO
NO
To electrical troubleshooting
NG Inspect or replace
proportional valve block.
YES
Travel 1-2 speed select can not be done in heavy
duty condition on a slope or on a muddy land.
YES
16
(6)
Travel independent speed is low.
Is the travel motion in both speeds slow
at no load?
(H-mode, Hi idle, 1st-speed, sprocket
revolution ; approx. 28rpm)
NO
YES
Machine is slow on slopes and in muddy
fields?
YES
NO
Current readings of pump proportional
valve lie within standard levels during
both travel speeds.
P1,P2 ; approx. 750mA
NO
YES
NO Inspect or replace
NO
YES
control valve.
NO
To electrical troubleshooting.
YES
NG Inspect or replace
YES
YES
Pump pressure
during travel idling
is 50~70kgf/cm2
(710~1000psi).
NO
Return spring of travel straight
spool is broken.
NO
Travel straight spool moves
smoothly by hand.
NG
travel straight
proportional valve.
Inspect or replace
proportional valve
block.
YES
NO Outside of travel
NO
YES
NG
Replace control valve.
Replace control valve.
NO
Travel spool moves
smoothly by hand.
YES
NO Outside of travel spool is
YES
scored.
YES
Relief pressure during both
travel speeds lies within
standard value.
; 350kgf/cm2 (4980psi)
NG
NO
NO
YES
17
(7)
Travel power is poor.
Both travel speeds are slow during idle
traveling.
(H-mode, Hi idle, 1st-speed, sprocket
revolution ; approx. 28rpm)
NO
YES
(Service diagnosis 22)
Command current for travel straight
proportional valve is approx. 350mA.
YES
Power lack is felt on a slope or in muddy
fields.
NO
To electrical troubleshooting.
Since the delivery rate of pump is small and travel speed is
low in heavy duty condition, power lack is felt in some cases,
but it is normal.
YES
NO
Is the secondary pilot
pressure for travel approx.
24kgf/cm2 (340psi)?
YES
Is a pivot turn possible?
(in both directions)
NO
NO Inspect or replace
YES
NG Inspect or replace
travel straight
proportional valve.
YES
Return spring of travel straight
spool is broken.
NO
Travel straight spool moves
smoothly by hand.
proportional valve
block.
YES
NO Outside of travel
NO
YES
NG
Replace control valve.
Replace control valve.
NO
Travel spool moves
smoothly by hand.
YES
NO Outside of travel spool is
YES
scored.
YES
Relief pressure lies within
standard value in both
travel speeds.
; 350kgf/cm2 (4980psi)
NG
NO
NO
YES
Inspect or replace travel
motor.
18
(8)-1
Machine does not travel straight.
(Service diagnosis 22)
Control current for travel
NO
straight proportional valve
(PSV-C) is 515mA.
To electrical troubleshooting
YES
Secondary pilot pressure at
port PTb (travel straight
valve) is approx. 17kgf/cm2
(240psi).
YES
YES
Return spring of travel
straight spool is broken.
NO
Travel straight spool moves
smoothly by hand.
YES
NO
Inspect or replace
travel straight
proportional valve.
NG Inspect or replace
proportional valve block.
Inspect or replace travel
straight spool assy and pilot
cover.
YES
NO Outside of travel straight spool YES
is scored.
NG
NO
(8)-2
Machine deviates in travel independent motion.
In idle run, the right and the left crawlers rotate
at different speeds. (H-mode, Hi idle,
1st-speed)
NO
YES
Control current for travel straight proportional
valve (PSV-C) is 515mA.
NO
NO
NO
YES
NO
YES
YES
Secondary pilot pressure for
travel is 24kgf/cm2 (340psi).
YES
YES
NO
Travel straight spool moves smoothly by hand.
YES
To electrical troubleshooting.
YES
YES
NO Outside of travel straight
spool is scored.
NO
YES
NG
Replace control valve.
Replace control valve.
19
(9)
Machine drifts on a slope. (Machine can not be held on a slope.)
Machine can not be held on a slope when engine
is off.
NO
Secondary pilot pressure for travel is 0kgf/cm2
(0psi).
YES
Return spring of travel spool is broken.
NO
Travel spool moves smoothly by hand.
YES
YES
NO
YES
NO
NO
YES
NG
Replace control valve.
Replace control valve.
20
(10)
Swing motion dose not work.
YES
To electrical troubleshooting
NO
Is the pilot pressure of parking SOL reduce to
0kgf/cm2 (0psi)when the secondary pressure of
pilot valve is 6kgf/cm2(85psi)? .
YES
Return spring of swing spool is broken.
Inspect or replace
proportional valve block.
Reference
In case of a machine with a
multi control valve, check if
the condition returns normal
by changing swing lever back
& forth operation.
YES
NG
parking solenoid.
NO
YES
NO
Swing spool moves smoothly by hand.
(Remove pilot cover.)
YES
scored.
YES
NG
NO
YES
NO
P2 bypass cut spool moves smoothly by hand.
(Remove pilot cover.)
NO
YES
NO
YES
NG
Replace control valve.
NO
YES
Machine can be held on a slope during swing
motion.
NG
NO
YES
Machine drifts largely when swing parking
brake is released (arm in action) on a slope.
YES
NO
21
(11)
Swing speed is slow.
Command current of P2 bypass cut proportional
valve (PSV-B) is 640mA when swing lever is
turned to the full.
NO
YES
To electrical troubleshooting
Reference
In case of a machine with a multi
control valve, check if the condition
returns normal by changing swing
lever back & forth operation.
NG
NO
YES
YES
Return spring of P2 bypass cut spool is broken.
NO
P2 bypass cut spool moves smoothly by hand.
YES
YES
spool is scored.
YES
Inspect or replace
proportional valve block.
NO
NG
Replace control valve.
NO
YES
Machine drifts largely when swing parking
is released (arm in action) on a slope.
NG
YES
NO
Return spring of swing spool is broken.
NO
Swing spool moves smoothly by hand.
YES
YES
NO
YES
Replace swing spool assy.
NG
Replace control valve.
Replace control valve.
22
(12)-1
Swing power is
YES
Return spring of P2 bypass cut spool is broken.
NO
P2 bypass cut spool moves smoothly by hand.
NO
YES
NO Outer circumference of P2
YES
YES
NO
NG
Reference
In case of a machine with a
multi control valve, check if
the condition returns normal
by changing swing lever back
& forth operation.
Secondary pilot pressure for swing motion is
approx. 50kgf/cm2 (710psi) when lever is turned
to the full in both directions.
NO
YES
NO
YES
Machine drifts largely when swing parking
is released (arm in action) on a slope.
NG
YES
NO
The pressure at the P/B (PG) port of swing
motor is 50kgf/cm2(710psi) when swing lever is
turned to the full or during arm in action.
Inspect or replace
proportional valve block.
YES
Return spring of swing spool is broken.
NO
Swing spool moves smoothly by hand.
(Remove pilot cover.)
YES
YES
NO
YES
NG
Replace control valve.
Replace control valve.
23
(12)-2
Swing motion drifts very large.
Swing relief pressure lies within standard level.
; 285kgf/cm2(4050psi)
NO
YES
Command voltage
Machine can be held on a
slope during swing motion.
YES
NO of swing parking
brake releasing
acts on swing
parking solenoid.
NO
YES
NO
To electrical troubleshooting
YES
NO
Inspect or replace pilot valve .
NO
Swing spool moves smoothly by hand.
(Remove pilot cover.)
YES
YES
NO
YES
NG
Replace control valve.
Replace control valve.
24
(13)
Abnormal sound is heard
during swing motion.
YES
NO
Abnormal sound occurs when swing motion stops.
YES
NO
Swing relief pressure lies within standard level.
; 285kgf/cm2(4050psi)
YES
To electrical troubleshooting
YES
Pressure at P2 bypass cut port PCa
is about 25kgf/cm2(360psi)during
swing operation.
NO Inspect or replace
P2 bypass cut
proprotional valve.
NG Inspect or replace
proprotional valve
block.
YES
Main relief pressure lies
within standard level.
; 350kgf/cm2(4980psi)
swing motor.
NO
Outside of P2 cut valve spool
is scored.
YES
NO
P2 bypass cut spool moves
smoothly by hand.
(Remove pilot cover)
YES
NO
Outside of P2 bypass cut
valve spool is scored.
YES
NO
NG
Replace control valve.
NO
Swing spool moves smoothly by hand.
(Remove pilot cover)
YES
YES
scored.
NO
YES
NG
Replace control valve.
YES
NO
Inspect or replace swing motor
pinion gear, swing bearing race
and swing bearing gear.
25
SECTION 43
TROUBLESHOOTING (ELECTRIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE .................................................................................. 1
2. SELF DIAGNOSIS TABLE .......................................................................................... 4
3. SERVICE DIAGNOSIS TABLE ................................................................................... 4
14403 60413255
4. TROUBLESHOOTING ................................................................................................ 5
Option
Swing operation
Attachment operation
(3)
(8)
(9)
(13)
Speed is slow
(2)
Power is poor
(1)
Group No
System
1 4
2 5
Pin No.
3 6
7
9
10
11
12
13
14
15
(5)
Travel 1-2 speeds can not be
changed
(6)
Travel independent speed is low.
(7)
Travel power is poor
Arm in, out
Swing leftright
16
17
18
CN-11
25
26
27
28
29
30
31 34 1 4 7 13 15 16 17 18 19 20 22 1
32
2 5 8
21
2
33
3 6 9
3
No motions operate.
1
2
3
4
5
7
8
13 15 16 25 28 1
26
2
27
3
All operate
CN-14
Swing
Battery relay
Battery backup
C1 mechatro controller
Switch & relay
P1 bypass cut proportional valve D
Shield grounding
Shield grounding
Gauge cluster
Travel alarm SW
CN-13
Shield grounding
KPSS release SW
Travel 1-2speed SW
Key SW GLOW
Key SW ON
Alternator voltage
Accelerator potentio
CN-12
19
20
21
Connector
No.
Component
Boom lowering pressure sensor
Trouble
(at combined
operation with
ATT swing)
(4)
Fine operation
impossible
Travel operation
Electric systems
1.
TROUBLE DIAGNOSIS TABLE ; ELECTRIC
Governor motor & proportional & SOL
4 6 8 10 12 14 15 17 19 21 22 23 24 25
5 7 9 11 13
16 18 20
26
CN-15
All operate
Bucket digging
Boom raising
Arm in
Pin
No.
(1)
Option
(8)
(9)
Speed is slow
Power is poor
All operate
Bucket digging
Boom raising
Arm in
zigzags.
Machine drifts on a downhill
and does not stop still on a slope
Governor motor
Wiper motor
Washer motor
Fuel pump
Battery relay
Glow relay
Safety relay
Horn relay
E E E E
10 11 12 14
Starter motor
E
9
Room light
E
8
Relay
E
7
Resistor
E
7
Motor
E
4
E
5
Heater (OPT)
E
3
Air compressor
E
2
Horn
E
1
Receiver dryer
D
5
Speaker right
D
4
D
3
Tuner AM
D
2
Light
D
1
Hourmeter
C
5
Alternator
C
4
Fuse box
C
2
Diode
Travel
(13)
(at combined
operation with
ATT swing)
(5)
(6)
(7)
Fine operation
impossible
Attachment opration
Travel operation
(4)
Swing operation
Electric systems
2
(3)
B
1
No motions operate.
All operate
(2)
P P P P
S S S S
V V V V
C D P P
1 2
Gauge cluster
P P
S S
V V
A B
Electrical equipments
Diode
Electrical equipments
Controller
Battery
Trouble
Group No
System
Component
Proportioal valve
L
1
L
2
L
3
M
1
M
2
M
3
M
4
M
5
M
6
M
7
M
8
M M
9 10
R
1
R
3
R
4
R
5
R
6
R
7
R
8
R
9
R
10
(1)
No motions operate.
Machine moves freely when
lever is at neutral.
S
W
5
S
W
4
S
W
3
S
W
1
S
V
4
S
V
3
S
V
2
S
V
1
S S S S S S S S S
E E E E E E E E E
10 11 13 14 15 16 20 22 23
Key switch
S
E
9
S
E
8
S
E
7
S
E
5
Travel left
Travel right
S
E
4
Option 2
Arm out
S
E
3
Accelerator
Arm in
S
E
2
Fuel sensor
Swing
Boom lower
S
E
1
Option 1
Boom raise
Pin
No.
Bucket dump
Trouble
Switch
Pressure
sensor
Bucket digging
Group No
System
Component
Electrical equipments
Solenooid
Senser
Low pressure sensor
S S S S S S S S S
W W W W W W W W W
6 10 11 12 20 21 22 23 34
7
13
Swing operation
(5)
(6)
(7)
(8)
Speed is slow
Bucket digging
Boom raising
Arm in
(9)
All operate
(at combined
operation with
ATT swing)
Travel operation
(4)
Power is poor
(3)
Fine operation
impossible
(2)
Swing leftright
Swing can not be held on a slope
Option
Electric systems
Attachment opration
All operate
3
Regarding the C-1 mechatro controller, refer to two pages back.
2.
3.
The self diagnosis detects errors in the control I/Os of the pressure sensors and the proportional valves
while the machine is in operation and shows them on the multi display of the gauge cluster.
DISPLAY ITEM
No.
Contents
Display of monitor
No.
Contents
16
P1 by-pass cut
propo-valve fail
ROM data
17
P2 by-pass cut
propo-valve fail
18
Travel priority
propo-valve fail
Boom raising
pressure sensor fail
Arm variable
19 recircula-tion
propo-valve fail
Boom lowering
pressure sensor fail
20
Pump P1 pressure
sensor fail
Arm in pressure
sensor fail
21
Pump P2 pressure
sensor fail
22
Bucket digging
pressure sensor fail
23
Travel two-speed
solenoid valve fail
Bucket dump
pressure sensor fail
24
10
Swing pressure
sensor fail
25
12
26
14
Pump P1 pressure
sensor fail
Gauge cluster
28 Mechatro controller
communication failure
15
Pump P2 pressure
sensor fail
Display of monitor
The results of service diagnosis are displayed in up to 23 items according to data from the mechatro
controller.
Displaying procedure:
1) TurnONthe starter switch with the buzzer stop switch pressed.
2) A mechatro controller parts number and a program version are displayed as the No.1 item.
3) The diagnosis advances like No.2, No.3.... each time the display select switch is pressed.
4) The diagnosis returns like No.40, No.39... each time the buzzer stop switch is pressed.
5) The display does not disappear unless the starter switch is turnedOFF.
No.1
PROGRAM VERSION
VER
5.10
DISPLAY
No.
No.1
1 PROGRAM VER
VER
2 E/G
KPSS
No.3
H1
ACCEL
5.10
No.2
E/G
SET
MEAS
PRS.
SW
VOLT.
POS.
MOTOR STEP
POS.
2420
2420
LIVE
H
4.2V
100%
256
100%
No.4
GOVERNOR MOTOR
G1
COIL A
0.9A
G1
COIL B
1.0A
G2
LIMIT
OFF
No.5
SOL.VALVE
F2
SWING-BRAKE
COMP.
OFF
MEAS.
OFF
RELEASE SW
OFF
No.6
SOL.VALVE
F3
1/2-TRAVEL
COMP.
OFF
MEAS.
OFF
SWITCH
OFF
10
11
12
DISPLAY
No.7
SOLENOID
F1 POWER UP
COMP.
MEAS.
SWITCH
No.
OFF
OFF
OFF
No.8
RELAY
I2 BAT. RELAY
COMP.
OFF
MEAS.
OFF
KEY SWITCH OFF
No.9
PRESS. SENSOR
B1
BOOM RAISE
3.5V 35k
B2
BOOM LOWER
3.5V 35k
No.10
PRESS. SENSOR
B3
ARM OUT
3.5V 36k
B4
ARM IN
3.5V 36k
No.11
PRESS. SENSOR
B5
BUCKET DIG
3.5V 37k
B6
BUCKET DUNP
3.5V 37k
No.12
PRESS. SENSOR
B7
SWING (R)
3.5V 38k
B8
SWING (L)
3.5V 38k
13
14
15
20
21
22
DISPLAY
No.
No.13
PRESS. SENSOR
B9
TRAVEL (R)
3.5V 39k
B10 TRAVEL (L)
3.5V 39k
23
No.14
PRESS. SENSOR
C1 PUMP P1
3.5V
42k
C2 PUNP P2
3.5V
42k
24
No.15
PRESS. SENSOR
B16 P1 OPT.
3.5V
36k
B17 P2 OPT.
3.5V
36k
25
No.20
PROPO-VALVE
D1 P1 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
No.21
PROPO-VALVE
D2 P2 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
No.22
PROPO-VALVE
D3 S-TRAVEL
COMP. 600mA
MEAS. 600mA
45k
45k
39
40
DISPLAY
No.23
PROPO-VALVE
D6 A-RECIRCULAT
COMP. 600mA 45k
MEAS. 600mA 45k
No.24
PROPO-VALVE
E1 P1 PUMP
COMP. 600mA
45k
MEAS. 600mA
45k
POWER SHIFT 100mA
No.25
PROPO-VALVE
E2 P2 PUMP
COMP. 600mA
45k
MEAS. 600mA
45k
POWER SHIFT 100mA
No.39
MECHATRO ADJT.
CONT. SW
TEST
CONT. VOL
100%
PROG. SW
OFF
No.40
RELEASE SW
KPSS
SWING BRAKE
TEST
OFF
4. TROUBLESHOOTING
(1)-1
Note: (1)-1 matches the Groupe No. on page
1.
No motions operate.
To hydraulic
troubleshooting
NO
YES
NO
YES
NO
YES
YES
YES
Inspect harness.
YES
NO
YES
YES
YES
Inspect harness.
NO
Inspect if there is no
disconnection in fuse box.
(1)-2
Machine moves unexpectedly when lever is at neutral.
(P1 bypass cut proportional valveandP2 bypass cut
proportional valveare displayed on the gauge cluster.)
The machine operates unexpectedly if the
connector (CN-257F) for the P1 bypass
cut proportional valve is removed.
YES
To hydraulic
troubleshooting
NO
(Service diagnosis No.10)
Arm out operation pressure sensor
YES Trouble disappears if arm out operation
(SE-8) shows more than 1.3V even
pressure sensor (SE-8) is replaced.
when lever is at neutral.
NO
NO
YES
NO
(Service diagnosis No.10)
Arm in operation pressure sensor
YES
(SE-7) shows more than 1.3V when
lever is at neutral.
NO
NO
Arm in pilot pressure is 6kgf/cm2 (85psi)
when lever is at neutral.
YES
NO
The machine operates unexpectedly if the
connector(CN-257F) for the P2 bypass cut
proportional valve is removed.
YES
To hydraulic
troubleshooting.
NO
NO
NO
YES
NO
NO
NO
NO
Swing operation
YES
(2)-2
Only bucket motion is slow.
(Service diagnosis No.11)
The bucket operating pressure sensor value
is more than 4.0V when the bucket
operating lever is turned to the full.
YES
To hydraulic
troubleshooting
YES
NO
Trouble disappears if bucket operation
pressure sensor (SE-1,or SE-2)is changed.
NO
If the harness for the bucket operation
pressure sensor is connected another
pressure sensor, the pressure sensor gets
out of order.
YES
Bucket pilot pressure is more than approx.
35kgf/cm2 (500psi) when lever is at full.
NO
YES
NO
To hydraulic
troubleshooting
(2)-3
Only boom raise speed motion is slow.
(Service diagnosis No.9)
The boom raise operation pressure sensor
(SE-3) value is more than 4.0V when the
boom raise operating lever is turned to the
full.
YES
To hydraulic
troubleshooting
YES
NO
Trouble disappears if boom raise operation
pressure sensor is replaced.
NO
If the harness for the boom raise operation
pressure sensor is connected another
pressure sensor, the pressure sensor gets
out of order.
(2)-4
YES
NO
To hydraulic
troubleshooting
Except for boom raise and arm out motions are slow.
(Service diagnosis No.30)
Command current for travel straight
proportional valve is approx. 350mA or over
at boom raise or arm in motions.
NO
NO
To hydraulic
troubleshooting
NO
Travel right pilot pressure is more than
6kgf/cm2 (85psi) when lever is at
NO
NO
NO
Travel left pilot pressure is more than
6kgf/cm2 (85psi) when lever is at
NO
YES
(2)-5
Only arm in motion is slow.
(Service diagnosis No.10)
Arm in operation pressure sensor shows
4.0V or over when arm in lever is shifted to
the full.
NO
Trouble disappears if arm in operation
pressure sensor (SE-7) is replaced.
YES
To hydraulic
troubleshooting
YES
NO
Faulty symptom changes if the harness for
the arm in operation pressure sensor is
connected with another pressure sensor.
YES
NO
Arm in pilot pressure is approx. 35kgf/cm2
(500psi) or over when arm in lever is shifted
to the full.
(2)-6
YES
NO
To hydraulic
troubleshooting
NO
Trouble disappears if arm out operation
pressure sensor (SE-8) is replaced.
YES
To hydraulic
troubleshooting
Arm out operation
pressure sensor (SE-8) is
faulty.
YES
NO
If the harness for the arm out operation
pressure sensor is connected another
pressure sensor, the pressure sensor gets
out of order.
YES
NO
Arm out pilot pressure is approx. 35kgf/cm2
(500psi) or over when arm out lever is
shifted to the full.
(4)-1
YES
NO
To hydraulic
troubleshooting
Fine operation of bucket digging and dump motions can not be performed.
(Service diagnosis No.11)
Bucket digging (dump)
Trouble gets normal if
operation pressure
NO
NO connector on P1 bypass
sensor shows
cut proportional valve
0.7V or over when
(PSV-D) is disconnected.
lever is at neutral.
YES (Service diagnosis No.10)
Arm in operation pressure
YES
Trouble disappears if arm
YES in operation pressure
sensor (SE-7) shows
approx. 1.3V or over when
sensor (SE-7) is replaced.
lever is at neutral.
NO
NO
NO
To hydraulic
troubleshooting.
YES
NO
YES
NO
NO
YES
NO
YES
YES
NO
If the harness for the bucket digging
operation pressure sensor is connected
another pressure sensor, the pressure
sensor gets out of order.
(4)-2
NO
Fine operation of boom raise and lower motions can not be performed.
(Service diagnosis No. 9)
Boom raise (lower)
operation pressure
sensor shows 0.7V
or over when lever
is at neutral.
YES
(
P1 bypass cut proportional valve is displayed on the gauge cluster.)
NO
To hydraulic
troubleshooting
proportional valve
(PSV-D) is disconnected.
NO
YES
NO
(Service diagnosis No.10)
Arm out operation pressure
YES Trouble disappears if arm
sensor (SE-8) shows
out operation pressure
approx. 1.3V or over when
sensor (SE-8) is replaced.
lever is at neutral.
NO
NO
If the harness for the bucket
digging(dump) operation pressure sensor
is connected to another pressure sensor,
the faulty symptom changes.
NO
NO
YES
YES
YES
NO
(4)-3
Fine operation of swing motion can not be performed.
(P2 bypass cut proportional valve is displayed on the gauge cluster.)
(Service diagnosis No.12)
Trouble gets
Swing operation pressure
Trouble is corrected if swing
YES sensor (SE-5) shows approx. YES operation pressure sensor
normal if
connector of P2
1.3V or over when lever is at
(SE-5) is replaced.
bypass cut
neutral.
NO
proportional
NO
Swing pilot pressure is more
valve (PSV-B) is
than 6kgf/cm2 (85psi) when
disconnected.
lever is at neutral.
NO
YES
NO
(Service diagnosis No.9)
Boom raise operation
YES Trouble disappears if boom
pressure sensor (SE-3)
raise operation pressure
shows approx. 1.3V or over
sensor (SE-3) is replaced.
when lever is at neutral.
NO
NO
YES
NO
NO
YES
NO
Arm in operation pressure
sensor (SE-7) shows 1.3V or
over when lever is at
neutral.
NO
NO
NO
Trouble gets normal if
connector of swing parking
solenoid (SV-1) is
disconnected.
NO
(Service diagnosis No.10)
Arm out operation pressure
Trouble disappears if arm
sensor (SE-8) shows 1.3V or YES out operation pressure
over when lever is at
sensor (SE-8) is replaced.
neutral.
NO
YES
YES
(Service diagnosis No.12)
Swing operation pressure
Trouble disappears if swing
sensor (SE-5) shows approx. NO
operation pressure sensor
4.0V or over when lever is
(SE-5) is replaced.
shifted to the full.
YES
YES
NO
NO
YES
10
(4)-4
Fine operation of arm in and out motions is not possible.
(Displays Service Diagnosis No21.)
Trouble gets normal if
NO
connector of P2 bypass cut
proportional valve (PSV-B) is
disconnected.
To hydraulic
troubleshooting
YES
NO
NO
YES
NO
YES
YES
YES
NO
Arm out pilot pressure is
more than 6kgf/cm2 (85psi)
when lever is at neutral.
YES
NO
Arm in operation pressure
sensor (SE-7) shows 1.3V or
over when lever is at neutral.
NO
Boom raise pilot pressure is
more than 6kgf/cm2 (85psi)
when lever is at neutral.
NO
NO
NO
NO
NO
Arm in pilot pressure is more
than 6kgf/cm2 (85psi) when
lever is at neutral.
NO
YES
11
(5)
Travel 1-2 speeds can not be changed.
24V is alive across light green/black
and black wires of connector
(CN-255F) for travel 1-2 speed select
solenoid (SV-3).
YES
To hydraulic
troubleshooting
NO
If Switch travel 1-2 speed select
switch(SW-3) is pressed in the
service diagnosis No.6, ON is
displayed, and if the switch is not
pressed, OFF is displayed.
NO
NO
If the plugs(two females) connecting
the travel 1-2 speed select
switch(SW-3) with the main harness
are connected together, the switch is
turned ON and if the plugs are
disconnected, the switch is
turned OFF .
YES
YES
NO
Harness (pink and blue) between
travel 1-2 speed select switch
(SW-3) and C-1 controller is
disconnected.
YES
Repair harness.
NO
12
(6)
Travel independent speed is low.
(Service diagnosis No.22)
Command current of travel straight
NO
proportional (PSV-C) is more than
349mA during traveling.
To hydraulic
troubleshooting
YES
(Service diagnosis No.11)
Bucket digging operation pressure
sensor (SE-1) shows 1.3V when lever
is at neutral.
NO
NO
YES
NO
YES
NO
NO
YES
NO
NO
YES
NO
Boom raise pilot pressure is more
than 6kgf/cm2 (85psi) when lever is
at neutral.
YES
NO
(Service diagnosis No.9)
Boom lower operation pressure
sensor (SE-4) shows more than 1.3V
when lever is at neutral.
NO
YES
NO
Boom lower pilot pressure is more
than 6kgf/cm2 (85psi) when lever is
at neutral.
YES
NO
NO
YES
NO
Swing pilot pressure is more than
6kgf/cm2 (85psi) when lever is at
neutral.
NO
YES
13
YES
NO
Arm in pilot pressure is more than
6kgf/cm2 (85psi) when lever is at
neutral.
YES
NO
YES
NO
NO
YES
NO
(8)
Machine does not travel straight.
YES
NO
TRAVEL PROP-VALV is displayed on
gauge cluster.
NO
Machine deviates
to the left.
To hydraulic
troubleshooting
Check harness (green / black and gray /
black) between travel straight proportional
valve (PSV-C) and C-1 controller.
YES
YES
NO
YES
NO
Swing pilot pressure is more
than approx. 35kgf/cm2
(500psi) when lever is
shifted to the full.
NO
(Service diagnosis No.10)
Arm out operation pressure
NO Trouble disappears if arm
sensor (SE-8) shows more
out operation pressure
than 4.0V when lever is
sensor (SE-8) is replaced.
shifted to the full.
YES
NO
NO
14
NO
NO
YES
NO
Inspect ATT pilot valve.
Replace C-1 controller.
(Service diagnosis No.9)
Boom raise
operation pressure
sensor (SE-3) shows
more than 4.0V
when lever is shifted
to the full.
YES
NO
Boom raise pilot pressure is
approx. 35kgf/cm2 (500psi)
or over when lever is shifted
to the full.
YES
NO
YES
NO
Boom lower pilot pressure is
approx. 35kgf/cm2 (500psi)
or over when lever is shifted
to the full.
YES
NO
YES
NO
Bucket digging pilot
pressure is
approx.35kgf/cm2 (500psi) or
over when lever is shifted to
the full.
YES
NO
YES
NO
Bucket dump pilot pressure
is approx. 35kgf/cm2
(500psi) or over when lever
is shifted to the full.
YES
NO
15
(10)
Swing motion does not work.
NO
To hydraulic
troubleshooting
YES
YES
NO
YES
YES
NO
(11)
Swing speed is low.
Actual current readings of P2
pump proportional valve are
more than 619mA when the
swing lever is turned to the full.
YES
To hydraulic
troubleshooting
NO
Command current of P2 pump
proportional valve are more than
619mA when the swing lever is
turned to the full.
YES
NO
The swing operation pressure
sensor value is more than 4.0V
when the swing operation lever
is turned to the full.
NO
YES
NO
YES
YES
YES
NO
Swing pilot pressure is approx.
35kgf/cm2 (500psi) or over when
lever is shifted to the full.
NO
P1 or P2 pump pressure sensor
shows more than 0.7V when
lever is at neutral.
Check piping
NO
P1 or P2 pump pressure
sensor is faulty.
NO
Faulty symptom changes if the
harnesses for P1 and P2 pump
pressure sensors are exchanged.
NO
Swing operating pressure is
normal.
YES
YES
YES
NO
To hydraulic
troubleshooting
16
(12)
Swing power is poor.
Actual current readings of P2
pump proportional valve are
more than 619mA when the
swing lever is turned to the full.
YES
To hydraulic
troubleshooting
NO
Command current of P2 pump
proportional valve are more than
619mA when the swing lever is
turned to the full.
YES
NO
The swing operation pressure
sensor valve is more than 4.0V
when the swing operation lever
is turned to the full.
NO
YES
NO
YES
YES
YES
NO
Swing pilot pressure is approx.
35kgf/cm2 (500psi) or over when
lever is shifted to the full.
NO
P1 or P2 pump pressure sensor
shows more than 0.7V when
lever is at neutral.
Check piping
NO
P1 or P2 pump pressure
sensor is faulty.
YES
NO
Faulty symptom changes if the
harnesses for P1 and P2 pump
pressure sensors are exchanged.
NO
Swing operating pressure is
normal.
YES
YES
NO
To hydraulic
troubleshooting
17
(13)
Swing motion can not be held on a slope.
YES
To hydraulic
troubleshooting
NO
Swing parking release
switch (SW-4) is at
NORMAL.
NO
Turn to NORMAL.
YES
(Service diagnosis No.12)
Swing operation pressure
YES Trouble gets normal if
sensor (SE-5) shows more
swing operation pressure
than 1.3V when lever is at
sensor (SE-5) is replaced.
neutral.
YES
NO
NO
YES
YES
(SE-7) is replaced.
NO
NO
YES
NO
NO
YES
NO
18
SECTION 44
TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE .................................................................................. 1
14403 60413255
2. TROUBLESHOOTING ................................................................................................ 3
Other trouble
Drop in output
Rotation trouble
Starting trouble
Trouble
(1)
(2)
(3)
Over heat
(7)
(8)
Exhaust gas is white
(In cold state, white smoke does
not disappear after idling.)
(9)
(10)
(11)
(12)
Idling unsmooth
(4)
(5)
Lubrication
Cooling
system
Check thermostat.
Service man
Fuel is mixed.
Intake /
exhaust
system
Check if engine oil level goes into combustion
chamber.
Fuel
system
Valve clearance
Injection pump
Inspect nozzle.
Engine side
Electrical fittings
Alternator
Starter relay
Starter motor
Glow
Glow relay
Machine side
Electrical fittings
Safety relay
Accel potentiometer
Governor motor
Mechatoro A adjust.
Mechatoronic controller
Gas / fluid
Battery relay
Visual check
Starter key
Fuse
Fluid
Gas leaks from valve and gasket.
Inspection
Filters
Fuel is of poor quality or leaking.
V-belt slips.
Group No.
System
1.
TROUBLE DIAGNOSIS TABLE ; ENGINE
Engine dealer
Main structure
(6)
Stop
position
2. TROUBLESHOOTING
(1)
Starter does not run.
NO
OK
Check battery relay B1
voltage.
OK
Check fuse box voltage.
OK
The voltage at B1
terminal of battery is
24V ore more.
The voltage at outlet
side of 20A fuse for
keyswitch is 24V or
more.
NO
OK
Check voltage of battery
relay A. Also check
voltage of battery relay
A1.
Replace fuse.
YES
The voltage at L
terminal of battery relay
is 24V or more.
NO
Check electric wiring
and connector.
OK
Check voltage of battery
relay.
OK
The voltage at inlet side
of 20A fuse for
keyswitch is lower than
NO
YES
OK
Check voltage of starter
motor.
OK
OK
Check voltage of starter
motor.
OK
Check voltage of safety
relay.
YES
OK
Check voltage of safety
relay.
NO
(2)
Starter turns but engine is hard to start.
Check starter power is strong or
weak.
WEAK
OK
Check compression
pressure and valve
clearance. Check that
valve spring is not
fatigued, that piston
liner is not worn, that
piston ring is not worn,
that head gasket is not
faulty and that flywheel
gear is not damaged.
Also check radiator and
thermostat.
OK
OK
Check that air cleaner clogged
sensor.
E/G side
Machine
side
E/G side
OK performance, injection
pump, injection nozzle
and injection timing.
YES
NO
24V is alive on wire No. 66 (5W)
of CN-153F on glow relay (R-3).
NO
24V is alive on wire No.53 (5Y)
of CN-154F on glow relay (R-3).
YES
NO
OK
24V is alive across wire No. 62
of CN-155F on glow relay (R-3)
and earth.
NO
Ground connection is poor.
YES
NO
NO
CN-154F
CN-153F
CN-155F
CN-155F
Internal
connection
(3)
E/G revolution is faulty.
Check high pressure pipe
and injection nozzle. Check
that compression
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling is faulty.
Medium revolution is
faulty.
Adjust mechatroA.
YES
Bleed air.
OK
Check air intake system.
OK
Check fuel feed system.
OK
1
Adjust mechatroA.
Note ; (6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Overheat
OK
NO
OK
OK
OK
Check E/G oil system.
Check air intake
system.
OK
OK
Check fuel feed
system.
OK
OK
Check engine
itself.
OK
Bleed air.
Check compression
pressure and valve
clearance. Check that
valve spring is not
fatigued. Check that
control rack moves
smoothly. Check that
piston ring is not worn.
Check also that head
gasket is not faulty.
OK
Check fuel system.
Replace fuel.
OK
Check that blowby gas is not
much and that gas does not
leak from gasket.
Check compression
pressure, injection timing
and injection nozzle.
(8)
Exhaust is abnormal.
OK
Check engine oil viscosity.
Check that engine oil is not too
much.
OK
Check that gas is not leaking
from head gasket.
OK
Check that engine oil goes
into combustion chamber.
Blowby gas is much. A lot of
gas leaks from gasket.
Retighten.
Replace packing and seal.
OK
Check that breather hose is not
bent or clogged.
OK
Check that poor quality fuel is
not used.
OK
Check viscosity of engine oil.
OK
Checking condition ; No engine oil leaks.
(10)
OK
Blowby gas is much.
Check that gas does not leak
from gasket.
(11)
E/G does not stop
when starter key is
turned off.
Check if governor
motor is not faulty
mechanically.
Confirm governor
lever stop bolt
position.
OK
Check that terminal
M of starter key
switch shows 0V.
Check resistance
NG across terminals M
and B on starter
key.
Check C1 controller.
Does resistance
across C1 controller
terminals 11-1 and
14-22 measure 72
?
OK
Check that battery
relay terminal B2
measures 0V four
seconds after key is
turned off.
(12)
NG
Does battery
terminals A and B
measure 0?
NG Replace battery
OK
relay.
See Fig.2.
Replace C1
controller if
resistance measures
0.
Flowing direction of
main current
TERMINAL A1
LOCK
B B1 TERMINAL
FLW
2.0sq
TERMINAL B1
FLW
2.0sq
VIEW
TERMINAL A
FLW2.0sq
GW
WG
B2
L
TERMINAL B
FLW2.0sq
P COIL
H COIL
BRACKET
TERMINAL B2
Circuit diagram
L TERMINAL
GROUND CABLE
AVS1,25B
Fig. 2
Fig. 3
AVS1,25G
L TERMINAL GW
AVS1,25L
B2 TERMINAL
GROUND
TERMINAL
WD
Battery relay
CN-150M
SECTION 51
ENGINE
TABLE OF CONTENTS
1. GENERAL INFORMATION ................................................................................... 1-1
2. MAINTENANCE .................................................................................................... 2-1
3. DISASSEMBLY...................................................................................................... 3-1
4. INSPECTION & REPAIR ....................................................................................... 4-1
5. REASSEMBLY....................................................................................................... 5-1
6. LUBRICATING SYSTEM ....................................................................................... 6-1
7. COOLING SYSTEM .............................................................................................. 7-1
8. FUEL SYSTEM ..................................................................................................... 8-1
9. TURBOCHARGER ................................................................................................ 9-1
10. AIR COMPRESSOR .......................................................................................... 10-1
11. ENGINE ELECTRICALS .................................................................................... 11-1
12. TROUBLESHOOTING ........................................................................................ 12-1
14403 60413255
SECTION 63
TABLE OF CONTENTS
1.LIST OF ADDITIONAL PARTS
1.1 Additional Parts for the Modification of the Nibbler & Breaker ......................................... 1-2
1.2 Additional Parts for the Modification of the Breaker ......................................................... 1-8
2. SUMMARY
2.1 General Precautions ........................................................................................................ 2-1
2.2 Basic Method to be taken when Mounting ....................................................................... 2-1
2.3 Outline of Modification ...................................................................................................... 2-2
14403 60413255
5-1
5-1
5-1
5-2
5-3
5-3
5-4
5-5
5-6
5-6
6-1
6-1
6-2
6-2
INDEX
6-3
6-4
6-4
6-5
6-6
14403 60413255
NAME
UPPER STRUCTURE
BOOM
LABEL
ARM
CONNECTOR
1 1
1.1 ADDITIONAL PARTS FOR THE MODIFICATION OF THE NIBBLER & BREAKER
(1) UPPER STRUCTURE
No.
NAME
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4
1
4
11
12
13
15
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
4
1
1
1
1
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
REMARK
B&A safety
Applicable
Machines
N&B
N&B
No.
16
17
18
19
20
21
22
23
24
25
NAME
QTY
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
O RING
O RING
CAPSCREW
CAPSCREW
LOCK WASHER
1
1
1
(2) BOOM
QTY
REMARK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Applicable
Machines
5
2
4
9
2
2
2
4
8
12
No.
REMARK
1
1
1
1
2
1
1
4
5
1
2
4
13
16
17
16
8
2
1
1
1 3
Applicable
Machines
N&B
(3) 2.6M (8 6
) ARM
No.
QTY
REMARK
N&B
Applicable
Machines
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
RH, LH
N&B
NAME
QTY
REMARK
1
1
Applicable
Machines
N&B
NAME
QTY
1
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4
1
4
11
12
13
15
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
3
4
5
6
7
8
9
1 5
REMARK
Applicable
Machines
N&B
No.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
NAME
QTY
HALF CLAMP
ELBOW
BRACKET
SUPPORT
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
O RING
O RING
CAPSCREW
CAPSCREW
LOCK WASHER
1
1
1
(6) BOOM
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Applicable
Machines
4
1
1
1
1
4
5
2
4
9
2
2
2
4
8
12
No.
REMARK
1
1
1
1
2
1
1
4
5
1
2
4
13
16
17
16
8
2
1
1
REMARK
Applicable
Machines
N&B
(7) 2.6M (8 6
No.
) ARM
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
(8) 3.0M (9 10
No.
REMARK
N&B
Applicable
Machines
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
) LONG ARM
NAME
QTY
REMARK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1 7
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
Applicable
Machines
N&B
NAME
QTY
REMARK
1
1
1
1
1
3
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
4
11
12
13
15
1
1
1
1
1
2
12
17
28
1
1
1
1
1
2
4
5
6
7
9
10
11
12
1
1
1
1
1
1
2
2
1
1
B&A safety
BREAKER
Applicable
Machines
BREAKER
No.
13
14
15
16
17
18
19
20
21
22
23
24
25
NAME
QTY
SUPPORT
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
O RING
O RING
CAPSCREW
CAPSCREW
LOCK WASHER
(2) BOOM
1
1
NOTE) COMMON TO NIBBLER & BREAKER
NAME
QTY
REMARK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Applicable
Machines
1
1
4
5
2
4
9
2
1
2
4
4
8
No.
REMARK
1
1
1
1
2
1
1
4
5
1
2
4
13
16
17
16
8
2
1
1
1 9
Applicable
Machines
BRAKER
QTY
REMARK
BREAKER
Applicable
Machines
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
RH, LH
NAME
BREAKER
QTY
REMARK
1 10
Applicable
Machines
BREAKER
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
NAME
QTY
REMARK
Applicable
Machines
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
RH, LH
BREAKER
NAME
QTY
REMARK
1
1
1
CONNECTOR ASSY
1 CONNECTOR
2 PLUG
3 O RING
1
1
1
111
Applicable
Machines
BREAKER
NAME
QTY
1
4
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
1
1
1
1
1
3
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
4
11
12
13
15
1
1
1
1
1
2
12
17
28
1
1
1
1
1 12
REMARK
Applicable
Machines
BREAKER
No.
1
2
4
5
6
7
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
NAME
QTY
No.
1
1
QTY
Applicable
Machines
1
1
1
1
1
1
2
2
1
1
1
1
4
5
2
4
9
2
1
2
4
4
8
(7) BOOM
REMARK
1
1
1
1
2
1
1
4
5
1
2
4
13
16
17
16
8
2
1
1
13
REMARK
Applicable
Machines
BRAKER
(8) 2.6M (8 6
No.
) ARM
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
(9) 3.0M (9 10
No.
) LONG ARM
REMARK
BREAKER
Applicable
Machines
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
NAME
QTY
REMARK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1 14
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
Applicable
Machines
BREAKER
2. SUMMARY
2.1 GENERAL PRECAUTIONS
(1) Applications of Breaker or Nibbler & Breaker
Breaker piping ................... Applicable only when
a breaker is mounted.
Nibbler & breaker piping .. Applicable only when
a nibbler and a
breaker are mounted.
(2) Modifying a Breaker and a Nibbler &
Breaker
There are specific procedures to be followed
when modifying a breaker and a nibbler &
breaker. Therefore, when they are to be
modified at our service shop, contact the
nearest breaker and nibbler manufacturers
office, and obtain instructions, so that you
install the pipes and handle the machinery
correctly.
z Nibbler Piping
The oil flows to the nibbler is conflux
flow ; the oil flow is changed to the
rod and the head of the nibbler
cylinder.
21
SELECTOR VALVE
UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
STOP
VALVE
RETURN FILTER
ARM
BRACKET
MAIN CONTROL
VALVE
ARM TOP
PIPING
HYDRAULIC
BREAKER
OPTION VALVE
(ADD-ON VALVE)
Replacing the
breaker with the
nibbler is possible.
OPERATING
PEDAL
FLOOR MAT
SINGLE / CONFLUX
FLOW SELECT SWITCH
Fig. 1
ARM HYDRAULIC
PIPING
STOP
VALVE
MAIN CONTROL
VALVE
ARM
BRACKET
ARM TOP
PIPING
HYDRAULIC
BREAKER
OPTION VALVE
(ADD-ON VALVE)
OPERATING
PEDAL
FLOOR MAT
REMOTE CONTROL PIPING
Fig. 2
Conflux / single
select switch
CONFLUX
ON
SINGLE
OFF
Use of
SINGLE
breaker
OFF
Use of
nibbler
NOTE :
1. Marking of selector valve (51.)
Stamped N : NIBBLER, Stamped B : BREAKER
2. Selection condition and proportional valve command when any of nibbler single & conflux flow or
breaker is in service.
Mechatro function
Refer to selection
conditions and
proportionality valve
instructions at the time
of Nibbler conflux and
SINGLE
breaker use of notes
FLOW SIDE
2.
NIbbler
Breaker
Trip condition
Breaker stopping
HYDRALUIC
PUMP
NAME
TYPE
50
51
SELECTOR VALVE
52
STOP VALVE
53
PILOT VALVE
16030-00000
54
RETURN FILTER
Y-487000
54
HYDRALUIC
OIL TANK
53
52
TRAVEL
STRAIGHT
VALVE
51
NIBBLER
BREAKER
P1 BYPASS CUT
P2 BYPASS CUT
50
Fig.1 Hydraulic circuit for Nibbler & Breaker (At nibbler operating)
3-1
N & B SPECIFICATION
No.
NAME
TYPE
51 SELECTOR VALVE
52 STOP VALVE
53 PILOT VALVE
16030-00000
enters
54 RETURN FILTER
Y-487000
the
mechatronic
controller.
The
54
53
HYDRAULIC TANK
TRAVEL
STRAIGHT
VALVE
52
51
BREAKER
P1
BYPASS CUT
P2
BYPASS CUT
50
32
Fig. 2
input voltage.
Then the secondary pressure of the solenoid
proportionate valve changes the P2 bypass
cut valve of the control valve.
2) Pilot circuit
If the heel of the 2-way pilot valve (53) is
stepped on, pressure comes out of the A-port,
enters the PB02 port of the control valve, and
changes the spool of the option valve.
3) Main circuit
The oil discharged by the P2 pump comes out
of the B02 port of the control valve and is
supplied to the breaker to give impact to the
breaker. The oil returned from the breaker
returned directly to the hydraulic tank via
the control valve because the selector valve
(51) is changed.
NAME
TYPE
Y-487000
HYDRAULIC PUMP
53
52
HYDRAULIC TANK
51
BREAKER
P2
BYPASS C/UT
50
Fig. 3
33
With OPT. P2
BREAKER
N&B
TRAVEL
PTb
TRAVEL
STRAIGHT
STRAIGHT
TRAVEL
RIGHT
PBr
PAr
BUCKET
PAc
PBc
P1 (P2)
TRAVEL LEFT
PAL
PAb
TRAVEL
RIGHT
BUCKET
SWING
SWING
BOOM
CONFLUX
Pss
ARM
CONFLUX
PBs1
PAs
BOOM
CONFLUX
PB1
PLc2
BOOM
ARM
P1 CUT
PA1
PBL
Dra,Drb
BOOM
PBb
TRAVEL
LEFT
PCb
P1 CUT
(P4)
ARM
PAa
ARM
Pis
RECIRCULATION
OPTION P2
Drd
ARM
RECIRCU-L
ATION
PCa
PA02
PB02
(P3)
Fig.5
34
OPERATING FORCE
SECONDARY PRESSURE
SECONDARY
PRESSURE OPERATING TORQUE
STROKE
CIRCUIT DIAGRAM
CONTROL DIAGRAM
Fig. 8
CIRCUIT DIAGRAM
4-PF1/4
JISB2351 O
2-11THROUGH
Fig. 9
OPERATING FORCE
SECONDARY PRESSURE
SECONDARY
PRESSURE OPERATING TORQUE
OPERATING ANGLE
CONTROL DIAGRAM
4-1
5.
FRAME
ITEM
5.2
NAME
Modification of the floor mat
HYDRAULIC
Table 1-2
MODIFICATION OF
THE CONTROL VALVE
No.
Floor mat
Option valve, capscrew
5.3
5.4
Block, Elbow,
Connector
Connector
Connector
5.6
Hose, Connector
5.7
5.8
5.5
LABEL ELEC
Modification items to
be added and change
QTY REMARK
CONTROL VALVE
(1) machine
1
OPTION VALVE
CAPSCREW
Standard
M1290
Fig. 1-2
Label
NAME
NAME
271 CAPSCREW
QTY REMARK
4
M1225
CUT OUT
271
Fig. 1-3
Fig. 1-1
Parts to be disused
VALVE
Fig.1-4
Supplementary Explanation :
The internal pressure in the hydraulic tank can be
released by pushing the valve with the rubber cap
on the upper surface of the tank 5 or 6 times.
5.2b.1 REPLACING PROCEDURE
Remove the capscrew on the hydraulic tank and
take out the spring, bypass valve and return
filter. Replace them with return filters shown
below according to the procedure shown in Table
1-4 and Figure 1-5. Replace it by the reverse
procedure of Assembly.
COVER
CAPSCREW
O RING
SPRING
BYPASS
VALVE
LOCK WASHER
18-4
Table 1-4
RETURN FILTER
No.
NAME
QTY
18-4
RETURN FILTER
REMARK
Fig.1-5
52
REMOTE CONTROL
PIPING
No.
NAME
A2
A4
A8
SUPPORT
COVER
SEMS BOLT
NAME
QTY
PILOT VALVE
1
1
1
1
3
1
3
1
PRESSURE SENSOR
CONNECTOR
PLUG
ELBOW
ELBOW
WASHER
HOSE
REMARK
PF1/4
PF1/4 L=23
PF1/4
PF1/4
PF1/4
PF1/4
L=300
CONTROL
BLOCK
QTY REMARK
1
1
2
11
No.
NAME
12
13
14
15
16
17
18
19
PIN
PEDAL
RUBBER
LOCK ASSY
CAPSCREW
CAPSCREW
CAPSCREW
QTY REMARK
LOCK WASHER
1
1
1
1
2
2
2
2
HOSE
PF1/4
L=350
20 WASHER
10
HOSE
PF1/4
L=4100
21 NUT
18
12
21
4
11
12
13
15
13
17
20
15
2
4
8
CONTROL
BLOCK
13
15
6
11
9
5
ELBOW
CONNECTOR
ELBOW
ELBOW
TEE
8
16
CONTROL BLOCK
PIPING
NAME
14
Establishied article
Re-use
4
19
20
7
12
5.4
PIPING
11 CONTROL BLOCK HOSE
1 PF1/4
(NIBBLER & BREAKER)
L=2650
(1) Modification procedure
Assemble the additional parts listed in Table
4 to the control block piping of the standard
machine, as shown in Fig. 4.
Table 4
No.
CONTROL
VALVE
10
Table 2
No.
1
2
3
4
5
6
7
8
10
QTY REMARK
1
1
1
1
1
PF1/4
PF3/8
5
Fig. 4
10
A4
PF1/4
PF3/8 PF1/4
C8
PF3/8
C2
C5
Fig. 2
A2
A8
NAME
CONNECTOR
ELBOW
PLUG
QTY REMARK
1
1
1
PF1/4
PF3/8
PF1/4
Fig. 5
Parts to be disused
Fig. 3
Parts to be disused
53
12
MACHINE
FRONT
Table 6
MAIN REMOTE
CONTROL PPING
No.
2
12
NAME
QTY REMARKS
CONNECTOR
PF1/4-PF3/8
ELBOW
PF1/4-PF3/8
CONTROL
VALVE
OPTION VALVE
2
Fig.6
NAME
2 PLUG
54
QTY REMARKS
2
2
Fig. 7
Parts to be disused
5.6 UPPERHYDRAULICPIPING(NIBBLER&BREAKER)
(1) Modification Procedure
Tightening torque
Fit the additional parts in table 8, according to Fig.
8.
CHANGINGOVERPROCEDUREOFTHESELECTORVALVE
TOTANK
Threadsize
Spanner
(mm)
Hydraulichose
(ORSType)
Tighteningtorque
kgfym(lbfyft)
1_3/16-12UN
36
18(130)
Oringtypecoupling
TOTANK
TO
ATTACHMENT
TO
ATTACHMENT
TOCONTROL
VALVE
TOCONTROL
VALVE
Threadsize
(PF)
Spanner
(mm)
Tighteningtorque
kgfym(lbfyft)
3/4
36
16.5(119.3)
41
STAMP
USENIBBLER
USEBREAKER
Threadsize
14(101)
Capscrew
Tighteningtorque
kgfym(lbfyft)
M10
7.2(52.1)
M12
12.3(89.0)
Table 8
No.
NAME
QTY REMARK
No.
1
TUBE
1
14
2
TUBE
1
15
3
HOSE
1 1_3/16-12UN
16
4
HOSE
1 PF1
17
5
CONNECTOR
1 PF3/4
18
6
CONNECTOR
1 1_3/16-12UN
19
7
SELECTOR VALVE
1
20
8
ELBOW
1 1_3/16-12UN
21
9
O RING
3 1_
22
10
HALF CLAMP
4 1_
23
11
ELBOW
1 PF1
24
12
BRACKET
1
25
13
SUPPORT
1
(2) Parts to be disused
Concerning upper hydraulic piping, the parts listed
in table 9 and in Fig. 9 are disused from the standard
machine.
Table 9
Hydraulichose
(30flare)
Tighteningtorque
kgfym(lbfyft)
3
2
NAME
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
O RING
O RING
CAPSCREW
CAPSCREW
LOCK WASHER
QTY REMARK
1
4
5
2
4
9
2
2
2
4
8
12
M10_30
M12_30
M12_85
21
M12_70
17
21
19
14
1
50
4
25
20
23
13
10
RETURN HYDRAULIC
PIPING
No.
NAME
QTY REMARK
50
PLUG
1
(3) Parts to be disused
Concerning the remote control piping, the parts
listed in table 10 and in Fig. 10 are disused from the
standard machine.
Table 10
11
25
10
12
19
18
1
REMOTE CONTROL
PIPING
16
4
3
15 25
24
No.
1
22
22
NAME
PLUG
QTY REMARK
2
1
Fig. 10 Parts to be disused
Table
INSTALL OF THE
NAME PLATE
No.
INSTRUMENT PANEL
ASSY
20
LABEL
21
LABEL
22
LABEL
NAME
SWITCH
QTY
REMARK
1 1
For single /
conflux
switching
22
13
Table 11
No.
39
14
Fig. 11
NAME
QTY REMARK
20
Fig. 13
21
Table 12
No.
13 CAP
NAME
20
QTY REMARK
1
Fig. 14
13
Fig. 12
Parts to be disused
22
56
21
Right hand view of cab interior
LABEL
HYDRAULIC
FRAME
ITEM
6.2
NAME
Modification items to
be added and change
Floor mat
6.3
6.4
6.5
6.6
6.7
B&A safety
Label
CUT OUT
Fig. 1
61
62
Tightening torque
Thread
size
Spanner
(mm)
Capscrew
Tightening torque
kgfym (lbfyft)
M8
13
3.6 (26)
1/4
REMOTE CONTROL
PIPING
No.
Tightening torque
kgfym (lbfyft)
Hydraulic hose
(30flare)
Tightening torque
kgfym (lbfyft)
3.7 (26.8)
3.0 (21.7)
19
HOSE
HOSE
HOSE
NUT
PIN
WASHER
CAPSCREW
WASHER
BRACKET
PIN
PIN
CONNECTOR
ELBOW
QTY REMARK
1
1
1
1
1
3
2
2
1
1
1
1
1
PF1/4
PF1/4
PF1/4
PF1/4
With filter
No.
14
15
16
17
18
19
20
21
22
23
24
25
17
22
18
NAME
CUSHION RUBBER
CAPSCREW
LOCK ASSY
PEDAL
COVER
WASHER
PLATE
PRESSURE SENSOR
CONNECTOR
TEE
QTY REMARK
1
1
1
2
1
1
1
1
2
1
1
1
14
PF1/4
16
10
ELBOW
PILOT VALVE
11
21
Table 2
NAME
1
2
3
4
5
6
7
8
9
10
11
12
13
20
5
19
15
CONTROL
BLOCK
12
13
R.H
3
2
2
PF1/4
25
23
24
PF1/4
PF1/4
PF1/4
Fig. 3
4
2
Table 3
CONTROL
BLOCK
No.
NAME
QTY REMARK
SUPPORT
COVER
SEMS BOLT
1
2
Fig. 4
Fig. 2
Parts to be disused
63
17
12
Table 6
28
No.
NAME
2 PLUG
MACHINE FRONT
QTY REMARK
Table
4
MAIN REMOTE
CONTROL
PIPING
No.
2
NAME
QTY REMARK
CONNECTOR
1 1 PF1/4-PF3/8
12
ELBOW
1 1 PF1/4-PF3/8
17
TEE
1 1 PF1/4
28
HOSE
1 1 PF1/4
CONTROL VALVE
2
Fig. 5
OPTION VALVE
2
Fig. 7
NAME
11 ELBOW
C11
Table
5
QTY REMARK
1
PF1/4
CONTROL VALVE
64
Fig. 6
Parts to be disused
Parts to be disused
Tightening torque
Thread size
Spanner
(mm)
Hydraulic hose
(ORS Type)
Tightening torque
kgfym (lbfyft)
1_3/16-12UN
36
18 (130)
O ring type coupling
1
2
4
5
6
7
9
10
11
12
13
14
Spanner
(mm)
Tightening torque
kgfym (lbfyft)
3/4
36
16.5 (119.3)
41
CONTROL VALVE
Hydraulic hose
(30flare)
Tightening torque
kgfym (lbfyft)
14 (101)
Thread size
Capscrew
Tightening torque
kgfym (lbfyft)
M10
7.2 (52.1)
M12
12.3 (89.0)
Table 7
No.
Thread size
(PF)
NAME
TUBE
TUBE
HOSE
PLUG
CONNECTOR
BLOCK
O RING
HALF CLAMP
ELBOW
BRACKET
SUPPORT
CLAMP
QTY REMARK
1
1
1
1
1
1
2
2
1
1
1
1
PF1
PF3/4
1_3/16-12UN
1_
1_
PF1
No.
15
16
17
18
19
20
21
22
23
24
25
NAME
QTY REMARK
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
O RING
O RING
CAPSCREW
CAPSCREW
LOCK WASHER
4
5
2
4
9
2
1
2
4
4
8
22
22
M10_30
M12_30
CONTROL
VALVE
M12_85
2
17
19
14
1
M12_70
16
21
19
6
13
50
19
4
20
23
25
11
10
9
RETURN HYDRAULIC
PIPING
No.
NAME
QTY REMARK
24
25
12
19
18
16
15
REMOTE CONTROL
PIPING
50
PLUG
1
(3) Parts to be disused
Concerning the remote control piping, the parts
listed in table 9 and in Fig. 10 are disused from the
standard machine.
Table 9
No.
NAME
PLUG
QTY REMARK
1
Fig. 10 Parts to be disused
22
10
INSTALL OF THE
NAME PLATE
No.
NAME
QTY
21
LABEL
22
LABEL
REMARK
21
21
Fig. 11
22
66
BOOM
ITEM
Types of attachment
Modification
item
Spec.
N&B
Tapped block
N&B
Tube
Tapped block
Tapped block
N&B
Tube
Tube
ARM
7.6
N&B
(KCMA
only)
N&B
N&B
Connector
Plate
(2) Weld
1) Use weld symbol B welding rod (mild steel
50kg grade).
2) Seal the unwelded areas of the tapped block.
71
Table 2
5.05M (167 )
BOOM ASSY
No.
1
2
3
4
5
6
NAME
BOOM ASSY
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
QTY
(1)
2
3
1
2
1
SECTION
AA
VIEW
6
SECTION
DD
3
SECTION
BB
Fig. 1
SECTION
SECTION
CC
EE
REMARK
STD
No.
1
2
3
4
5
6
7
8
9
10
9,13,15
11,12,15
Table 3
NAME
TUBE
TUBE
TUBE
TUBE
PLUG
O RING
O RING
O RING
CLAMP
CLAMP
QTY
REMARKS
1
1
1
1
2
1
1
4
5
1
No.
11
12
13
14
15
16
17
18
19
20
NAME
QTY
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
HALF CLAMP
HOSE
CLIP
CLAMP
REMARKS
2
4
13
16
17
16
8
2
1
1
13,15,20
7
SECTION_A_A
8
9,13,15
9,13,15
SECTION_D_D
SECTION_B_B
3
8,14,16,17
1
4
8,14,16,17
8,14,16,17
2
5
18
NOTE :
z Remove item 5 plug as necessary,
and
install
an
accumulator
recommended by the breaker maker.
5
11,12,15
19
9,13,15
9,13,15
SECTION_E_E
SECTION_C_C
Fig.2 Hydraulic piping for 5.05M (16ft-7in) boom (Breaker, Nibbler & Breaker)
7-3
DETAIL E
No.
No.
(1)
NAME
(1)
QTY REMARK
ARM
(1)
NAME
STD
QTY REMARK
ARM
(1) STD
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
PLATE
PLATE
PLATE
PLATE
PLATE
PLATE
SECTION_D_D
5
DETAIL E
4
(1)
7
(1)
SECTION_A_A
5
2
2
3
SECTION_B_B
SECTION_C_C
Fig. 3_Modification of the 2.6M (8ft-6in) standard arm (Nibbler & Breaker, Breaker)
SECTION_A_A
SECTION_B_B
Finish by grinder
SECTION_D_D
SECTION_C_C
1
2
3
4
5
6
7
8
9
10
NAME
TUBE
TUBE
HOSE
HOSE
STOP VALVE
CONNECTOR
O RING
O RING
BRACKET
HALF CLAMP
CLAMP
11
13,19
DETAIL OF CLAMP
6
7,9,15,17
7, 9,15,17
Table 6
No.
10
QTY
1
1
2
2
2
2
2
2
4
8
1
1
2
2
2
2
2
2
4
8
REMARKS
No.
NAME
11
12
13
14
15
16
17
18
19
20
BUSHING
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
WASHER
WASHER
WASHER
QTY REMARKS
4
4
8
8
8
4
8
4
8
8
4
4
8
8
8
4
8
4
8
8
4
10,11
13,19
13,19
10,11
14,20
12,16,18
4
8
14,20
12,16,1
SECTION
8
SECTION
BB
AA
Fig. 5 2.6M (8ft-6in) STD arm, 3.0M (9ft-10in) long arm hydraulic piping
75
M451.5
3
PF1-1/4
Table 10
IDLER LINK (R.H)
No.
Fig. 6
NAME
QTY
REMARK
IDLER LINK
(1)
(LH) STD
IDLER LINK
(1)
(RH) STD
PLATE
LH, RH
Table 8
CONNECTOR ASSY
FOR NPK
No.
1
2
3
NAME
CONNECTOR
PLUG
O RING
QTY REMARK
1
1
1
NPK
1B
PF1-1 1/4
P38
1
IDLER LINK (R.H)
Fig. 9
Fig. 7
PF1 1
PF1-1/4
Table 9
CONNECTOR ASSY
FOR TOKU, KRUPP
No.
1
2
3
76
NAME
CONNECTOR
PLUG
O RING
QTY REMARK
1
1
1
1B
P38
TOKU,
Fig. 8
KRUPP
N&B
LOW PRESSUSE SIDE
(RETURN)
N&B
HIGH PRESSUSE
SIDE
TO TANK
Fig. 1
TO
ATTACHMENT
TO
ATTACHMENT
TO CONTROL
VALVE
TO CONTROL
VALVE
STAMP
TO TANK
USE NIBBLER
Fig. 2
81
USE BREAKER
(ON)
(OFF)
CONNECTOR(PF3/4)
STOP VALVE
HOSE
5 min
Flushing
1 min
Stop
5 min
Flushing
Fig. 3
5 min
Flushing
1 min
Stop
1 min
Stop
5 min
Flushing
Flushing method
Table 1
Inspection /
maintenance points
Item
Hydraulic oil
Return filter
Replacement intervals
First replacement
2nd replacement
Regular replacement
50h
Every 600h
Every 250h
250h
)
)
Switch position
Circuit
OFF
ON
Single flow
Conflux flow
Fig.4
82
Foot pedal
Operating condition.
depressing section
Depress heel section.
Breaker starts operation.
Pedal in neutral position. Breaker stops operation.
l Nibbler
Foot pedal
depressing section
Depress toe section
Depress heel section
DEPRESS PEDAL
WITH TOE TO
ACTIVATE
Operating condition.
Nibbler close
Nibbler open
8 3
84
K R U P P
O K A D A
FURUKAWA
Installation is necessary.
A relief valve is specified by
each breaker manufacturer.
K R U P P
Since the method of pressure
O K A D A
setting of the relief valve
differs
with
breaker
T A I S E I
manufac-turers, install a relief
FURUKAWA
valve
according
to
the
manufac-turers instructions.
NOTE : Only the B series TOKU machine requires
a relief valve to be installed.
T
N&B
LOW PRESSUSE SIDE
(RETURN)
N&B
HIGH PRESSUSE
SIDE
max
ACCUMULATOR
min
Fig. 1
9 1
Accumulator mounting
(PF1)
TO TANK
RETURN SIDE
TO BREAKER
K R U P P
O K A D A
T A I S E I
K
K
T A I S E I
FURUKAWA
KRUPP
FURUKAWA
HIGH-LOW SPEED
CHANGEOVER VALVE
92
10. REFERENCE
Typical combinations are quoted from breaker
manufacturers catalog use as below, but
concerning applicable breaker models, decide it
after consultation with the breaker manufacturer.
Working press
Applicable
Manufacturer
kgf/cm2
breaker
(psi)
120140
H-10XB
(1,7101,990)
N
P
K
130150
H-4XE
(1,8502,130)
100140
TNB-10B
(1,4201,990)
120140
TNB-14B
(1,7101,990)
100160
T O K U TNB-6E
(1,4202,280)
120170
TNB-10E
(1,7102,420)
130170
TNB-14E
(1,8502,420)
150160
MKB1100
(2,1302,280)
K R U P P
150180
MKB1200
(2,1302,560)
150180
UB 11
(2,1302,560)
O K A DA
130160
OUB 310
(1,8502,280)
150170
T A I
S ETF-150
(2,1302,420)
160180
FURUKAWA HB20G
(2,2802,560)
Table 1
Oil volume
used /min
(gal/min)
160200
(42.252.8)
3560
(9.2415.8)
110140
(29.037.0)
140160
(37.042.2)
4580
(11.921.1)
100140
(26.437.0)
130170
(34.344.9)
80110
(21.129.0)
90130
(23.834.3)
110
(29.0
)
110155
(29.040.9)
100120
(26.431.7)
125150
(33.039.6)
Total weight
kg
(lbs)
1,450
(3,200)
410
(900)
1,000
(2,210)
1,400
(3,100)
391
(860)
997
(2,200)
1,550
(3,400)
1,1001,250
(2,4302,760)
1,1201,200
(2,4702,650)
1,450
(3,200)
1,070
(2,360)
1,330
(2,930)
1,400
(3,100)
Total length
mm
(in)
2,156
(84.9 )
1,644
(64.7 )
1,476
(58.1 )
1,850
(72.8 )
2,190
(86.2 )
2,278
(89.7 )
Bucket
capacity m3
(cuyd)
0.550.70
(0.720.92)
0.700.90
(0.921.18)
0.250.35
(0.330.46)
0.550.70
(0.720.92)
0.700.90
(0.921.18)
0.500.90
(0.651.18)
0.551.00
(0.721.31)
0.70
(0.92
)
0.550.70
(0.720.92)
0.600.90
(0.781.18)
2,240
(88.2)
2,040
(80.3 )
1,596
(62.8 )
2,119
(83.4 )
[
] Excludes chisels.
NPK
TOKU
Series B
TOKU
Series E
KRUPP
OKADA
FURUKAWA
TAISEI
101