Page 1: Table Of Contents
CONTENTS SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10 SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1 Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-20 Group 3 Swing Device ----------------------------------------------------------------------------------------------------- 2-47 Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-58 Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-96 Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-103 SECTION 3 HYDRAULIC SYSTEM...
Page 2 Group 9 Attachment Flow Control System --------------------------------------------------------------------- 5-12 Group 10 Boom Floating Control System------------------------------------------------------------------------- 5-13 Group 11 Intelligent Power Control System---------------------------------------------------------------------- 5-14 Group 12 Anti-Restart System ------------------------------------------------------------------------------------------ 5-16 Group 13 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-17 Group 14 Engine Control System ------------------------------------------------------------------------------------- 5-53 Group 15 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-54 Group 16 Monitoring System --------------------------------------------------------------------------------------------- 5-59 Group 17 Fuel Warmer System ----------------------------------------------------------------------------------------- 5-95...
Page 3 The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 4 Revised edition mark(①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 5 3. CONVERSION TABLE 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Example Method of using the Conversion Table to convert from millimeters to inches...
Page 6 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
Page 7 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
Page 8 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
Page 9 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
Page 10 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 11: Section 1 General
SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...
Page 12 SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
Page 13 PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
Page 14 KEEP RIDERS OFF EXCAVATOR KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.
Page 15 SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under 13031GE10 continuous load.
Page 16 BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
Page 17 SERVICE MACHINE SAFELY SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
Page 18 AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Page 19 PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.
Page 20 DISPOSE OF FLUIDS PROPERLY DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Page 21: Group 2 Specifications
GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT DEF/AdBlue tank Main control valve Fuel tank Hydraulic tank Main pump Engine After treatment device Radiator Oil cooler Tooth Turning joint Swing motor Battery Bucket Guardrail Counterweight Arm cylinder Boom Boom cylinder Muffler...
Page 22 2. SPECIFICATIONS 2. SPECIFICATIONS HX145 CR HX145 CR 1) 1) (1) (1) 4. 4.60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm 60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm I(I') B(L) 145ZF2SP02...
Page 23 (2) (2) 4.60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm 60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm I(I') B(L) 145ZF2SP02 Specification Description Unit 2.50 m (8' 2") arm 3.0 m (9' 10") arm Operating weight kg (lb)
Page 24 (3) (3) 4.60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm with dozer 4.60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm with dozer I(I') B(L) 145ZF2SP03 Specification Description Unit 1.9 m (6' 3") arm...
Page 25 (4) (4) 4.60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm with dozer 4.60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm with dozer I(I') B(L) 145ZF2SP03 Specification Description Unit 2.50 m (8' 2") arm...
Page 26 2) 2) HX145 LCR HX145 LCR 4. 4.60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm 60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm (1) (1) I(I') B(L) 145ZF2SP02 Specification...
Page 27 (2) (2) 4.60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm 60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm I(I') B(L) 145ZF2SP02 Specification Description Unit 2.50 m (8' 2") arm 3.0 m (9' 10") arm Operating weight kg (lb)
Page 28 (3) (3) 4.60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm with dozer 4.60 m (15' 1") boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm with dozer I(I') B(L) 145ZF2SP03 Specification Description Unit 1.9 m (6' 3") arm...
Page 29 (4) (4) 4.60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm 4.60 m (15' 1") boom and 2.50 m (8' 2"), 3.0 m (9' 10") arm with dozer with dozer I(I') B(L) 145ZF2SP03 Specification Description Unit 2.50 m (8' 2") arm...
Page 30 3) 3) HX145 LCR 2- HX145 LCR 2-PIECE BOOM PIECE BOOM (1) (1) 4.939 m (16' 2") 2-piece boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm 4.939 m (16' 2") 2-piece boom and 1.9 m (6' 3"), 2.1 m (6' 11") arm I (I') B (L) 145ZF2SP06...
Page 31 (2) (2) 4.939 m (16' 2") 2-piece boom 4.939 m (16' 2") 2-piece boom and 2.50 m (8' 2") arm and 2.50 m (8' 2") arm I (I') B (L) 145ZF2SP06 Description Unit Specification Operating weight kg (lb) 15860 (34970) Bucket capacity (SAE heaped), standard 0.52 (0.68) Overall length...
Page 32 (3) (3) 4.939 m (16' 2") 2-piece boom and 1.9 m (6' 3"), 2.1m (6' 11") arm 4.939 m (16' 2") 2-piece boom and 1.9 m (6' 3"), 2.1m (6' 11") arm with dozer with dozer I (I') B (L) 145ZF2SP07 Specification Description...
Page 33 (4) (4) 4.939 m (16' 2") 2-piece boom and 2.50 m (8' 2") arm with dozer 4.939 m (16' 2") 2-piece boom and 2.50 m (8' 2") arm with dozer I (I') B (L) 145ZF2SP07 Description Unit Specification Operating weight kg (lb) 16680 (36770) Bucket capacity (SAE heaped), standard...
Page 34 3. 3. WORKING RANGE WORKING RANGE 4.60 4.60 m (15' 1") MONO (15' 1") MONO BOOM BOOM 1) 1) 145ZF2SP04 2.10 m (6' 11") Arm ※2.50 m ( 8' 2") Arm 3.00 m ( 9' 10") Arm Description 1.90 m (6' 3") Arm Max digging reach 7730 mm (25' 4") 7900 mm (25'11")
Page 35 2) 2) 4.939 M (16' 2") 2-PIECE BOOM 4.939 M (16' 2") 2-PIECE BOOM 145ZF2SP08 Description 1.90 m (6' 3") Arm 2.10 m (6' 11") Arm 2.50 m ( 8' 2") Arm Max digging reach 8000 mm (26' 3") 8270 mm (27' 2") 8675 mm (28' 6") Max digging reach on ground 7850 mm (25' 9")
Page 36 4. WEIGHT 4. WEIGHT HX145LCR HX145 LCRD Item Upper structure assembly 6950 15320 7555 16656 Main frame weld assembly 1300 2870 1266 2791 ← ← Engine assembly 1230 ← ← Main pump assembly ← ← Main control valve assembly ←...
Page 37 The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
Page 38 Dozer Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX145LCR Mono 4600 2100 2800 · · : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft)
Page 39 Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX145LCR Mono 4600 3000 2800 · · : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft)
Page 40 The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
Page 41 Dozer Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX145LCR 2PCS 4939 2100 2800 · · : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft)
Page 42 Select an optimum combination according to the working conditions and the type of work that is being done. is being done. Consult your Hyundai dealer for information on selecting the correct boom-arm-bucket combination. Consult your Hyundai dealer for information on selecting the correct boom-arm-bucket combination. 1-18...
Page 43 (2) (2) Special bucket Special bucket Slope finishing bucket Ditch cleaning bucket ◎ 0.55 m ★ 0.45 m heaped bucket heaped bucket Recommendation Capacity Width 4.6 m (15' 1") 4.9 m (16' 9") Mono boom Adjust boom Weight CECE Without With 1.9 m arm 2.1 m arm...
Page 44 2) 2) HX140 LCR 2-PIECE BOOM HX140 LCR 2-PIECE BOOM General bucket General bucket (1) (1) 0.52, ※0.58, 0.65, 0.71 m 0.23 m 0.40, 0.46 m heaped bucket heaped bucket heaped bucket Recommendation Capacity Width 4.9 m (16' 1") adjust boom Weight CECE Without...
Page 45 (2) (2) Special bucket Special bucket Ditch cleaning bucket Slope finishing bucket ★0.45 m ◆0.55 m heaped bucket heaped bucket Recommendation Capacity Width 4.9 m (16' 1") boom Weight CECE Without With 1.9 m arm 2.1 m arm 2.5 m arm heaped heaped side cutter...
Page 46 Shoe width mm (in) 500 (20) 600 (24) 700 (28) Operating weight kg (lb) 15310 (33750) 15540 (34260) 15750 (34720) HX145LCR Ground pressure 0.46 (6.53) 0.39 (5.52) 0.34 (4.8) kgf/cm (psi) Overall width mm (ft-in) 2500 (8' 2") 2600 (8' 6") 2700 (8' 10")
Page 47 4) 4) SELECTION OF TRACK SHOE SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Method of selecting shoes Confirm the category from the list of applications in table table 2 2, then use table table 1 1 to select the shoe.
Page 48 8. SPECIFICATIONS FOR MAJOR COMPONENTS 8. SPECIFICATIONS FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Perkins 1204F Type 4-cycle turbocharged charge air cooled diesel engine Cooling method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type...
Page 49 3) 3) GEAR PUMP GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 40 kgf/cm (570 psi) Rated oil flow 29.2ℓ/min (7.7 U.S. gpm / 6.4 U.K. gpm) 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification Type...
Page 50 Ground pressure Link quantity Overall width Standard 500 mm (20") 2500 mm ( 8' 2") 0.45 kgf/cm (6.40 psi) HX145LCR 600 mm (24") 2600 mm ( 8' 6") 0.38 kgf/cm (5.40 psi) Option 700 mm (28") 2700 mm ( 8' 10") 0.33 kgf/cm...
Page 51 ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
Page 52: Section 2 Structure And Function
SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1 Group 2 Main Control Valve --------------------------------------------------------------------------------------------- 2-20 Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-47 Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-58 Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-96 Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-103...
Page 53: Group 1 Pump Device
SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. VIEW A Qmax adjusting screw Qmin adjusting screw Front regulator Rear regulator a4 P1 (Dr1) (Dr1) a1(PH1) a2(PH2) Gear pump A1 pump Valve block...
Page 54 MAIN PUMP (1/2) The main pump consists of two piston pumps (front & rear) and valve block. 533 789 733 732 532 214 548 531 702 792 534 901 808 954 724 717 723 402 151 981 983 140Z92MP02 111 Drive shaft (F) 272 Pump casing (R) 711 O-ring 113 Drive shaft (R)
Page 55 MAIN PUMP (2/2) 711 326 728 125 468 118 825 04 FRONT SIDE REAR SIDE 140Z92MP03 04 Gear pump 128 Bearing spacer 711 O-ring 115 Shaft 262 Cover 728 O-ring 117 Gear No. 2 326 Gear case 825 Retainer ring 118 Gear No.
Page 56 REGULATOR (1/2) 412 753 612 897 874 874 726 646 438 730 643 708 645 728 801 924 SECTION B-B 413 496 140Z92MP04 VIEW C (FRONT) VIEW C (REAR) 079 753 755 466 755 656 496 KR76-9N01-V (FRONT) Port Port name Port size KR76-9N02-V (REAR) SAE6000...
Page 57 REGULATOR (2/2) 653 654 734 836 651 652 601 624 629 630 628 802 623 887 757 753 627 SECTION A-A 140Z92MP05 079 EPPR valve assembly 624 Spring seat (C) 708 O-ring 412 Hexagon socket screw 625 Outer spring 724 O-ring 413 Hexagon socket screw 626 Inner spring 725 O-ring...
Page 58 GEAR PUMP 354 351 307 310 308 434 466,725 14092MP06 307 Poppet 353 Drive gear 466 Plug 308 Seat 354 Driven gear 700 Ring 309 Ring 355 Filter 710 O-ring 310 Spring 361 Front case 725 O-ring 311 Screw 433 Flange socket 732 O-ring 312 Nut 434 Flange socket...
Page 59 2. FUNCTION MAIN PUMP The pumps may be classified roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: the swash plate group that varies the delivery rates: and the valve cover group that changes over oil suction and discharge : and the PTO group that transfers drive shaft of gear pump.
Page 60 Valve block group The valve block group consists of valve block (312), valve plate (313, 314) and spring pin(886). The valve plate having two kidmey ports is fixed to the valve block and feeds and collects oil to and from the cylinder block. The oil changed over by the valve plate is connected to an external pipeline by way 140Z92MP07...
Page 61 REGULATOR Regulator consists of the negative flow control, total horse power control and power shift control function. Negative flow control By changing the pilot pressure Pi, the pump tilting angle (delivery flow) is regulated arbitrarily, as shown in the figure. This regulator is of the negative flow control in which the delivery flow Q decreases as the pilot pressure Pi rises.
Page 62 Flow reducing function B(E) Pi(From MCV) Large diameter Servo piston Small diameter chamber chamber 140Z92MP12 As the pilot pressure Pi rises, the pilot piston (643) moves to the right to a position where the force of the pilot spring (646) balances with the hydraulic force. The groove (A) in the pilot piston is fitted with the pin (875) that is fixed to lever 2 (613).
Page 63 Flow increasing function 651 652 B(E) Pi(From MCV) Large diameter Servo piston Small diameter chamber chamber 140Z92MP13 As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin (897) is pressed against the large hole section (C) of lever 2 by the action of the return spring (654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left.
Page 64 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut (801) and by tightening (or loosening) the hexagonal socket head screw (924). Tightening the screw shifts the control chart to the right as shown in the figure.
Page 65 Total horsepower control The regulator decreases the pump tilting angle (delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump.
Page 66 Overload preventive function 621 652 623 612 601 B(E) Small diameter Large diameter Servo piston chamber chamber 140Z92RG03 When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston (621). It presses the compensating rod (623) to the right till the force of the outer spring (625) and inner spring (626) balances with the hydraulic force.
Page 67 Flow reset function 621 652 612 601 B(E) Small diameter Large diameter Servo piston chamber chamber 140Z92RG04 As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod (623) is pushed back by the action of the springs (625 & 626) to rotate lever 1 (612) around point E.
Page 68 Low tilting angle (low flow) command preferential function As mentioned above, flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2. However, since sections C and F have the pins ( 4) protruding from the large hole ( 8), only the lever lessening the tilting angle contacts the pin (897) ;...
Page 69 Adjustment of inner spring Adjust it by loosening the hexagon nut (802) and by tightening (or loosening) the adjusting stem C (627). Tightening the screw increases the flow and then the input horsepower as shown in the figure. Adjusting value Adjustment of input horsepower Speed Tightening...
Page 70 Power shift control 621 652 623 612 601 B(E) Small diameter Large diameter Servo piston chamber chamber 140Z92RG05 The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one propor tional pressure reducing valve is provided.
Page 71 Adjustment of maximum and minimum flows Adjustment of maximum flow Adjust it by loosening the hexagon nut (808) and by tightening (or loosening) the set screw (954). The maximum flow only is adjusted w i t h o u t c h a n g i n g o t h e r c o n t r o l characteristics.
Page 72: Group 2 Main Control Valve
GROUP 2 MAIN CONTROL VALVE GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE 1. STRUCTURE Mark Port name Port size Tightening torque Make up for swing motor UNF 1 3/16 18 kgf·m (130 lbf·ft) Travel left pilot port (BW) Travel left pilot port (FW) Travel right pilot port (FW) Travel right pilot port (BW) Pa20...
Page 73 53 56 77 34 65 62 31 49 48 46 47 50 56 53 61 30 50 53 56 69 11 43 79 72 28 63 29 80 44 26 Housing-P1 Load check-poppet Housing-P2 Load check-poppet Spool-straight travel Signal-poppet Spool-travel (LH, RH) Travel straight-sleeve Spool-swing Travel straight-piston...
Page 74 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT (Pump) (Pump) OPTION C (DOZER) BUCKET OPTION B B4(Breaker) Pc41(Unlock signal) Pb4(Regeneration cut) Pc40 Pd40 Pa4(Breaker) ARM REGENERATION ARM 1 Pd41 & OPTION B (BREAKER) Pc42(Arm crowd pilot) Pc40 V3(Carry over port) Pc41 Pc3(Swing priority) (Arm dump pilot) Pa21(Boom up pilot) Pa20...
Page 75 3. FUNCTION 3. FUNCTION 1) 1) CONTROL IN NEUTRAL CONTROL IN NEUTRAL (1) (1) P1 SIDE P1 SIDE The hydraulic fluid from pump A2 flows into the main control valve through the inlet port "P1", pass the straight travel spool into the P1 bypass passage and P1parallel passage. The hydraulic fluid from the pump A2 is directed to the tank through the bypass passage of spools : travel left, boom 1, arm 2, arm regeneration &...
Page 76 (2) (2) P2 SIDE P2 SIDE The hydraulic fluid from pump A1 flows into the main control valve through the inlet port "P2", into the P2 bypass passage and P2 parallel passage. The hydraulic fluid from the pump A1 is directed to the tank through the bypass passage of spools : travel right, swing, boom 2 &...
Page 77 2) 2) TRAVEL OPERATION TRAVEL OPERATION (1) (1) TRAVEL FORWARD OPERATION TRAVEL FORWARD OPERATION P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT From RCV Tank passage P2 Bypass passage 14092MC18 (2) (2) TRAVEL BACKWARD OPERATION TRAVEL BACKWARD OPERATION P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT...
Page 78 (3) (3) TRAVEL STRAIGHT FUNCTION TRAVEL STRAIGHT FUNCTION P2 Parallel passage P1 port Orifice P2 Bypass passage Check valve Tank port T1 Straight travel spool P2 port P1 Bypass passage P1 Parallel passage P1 Parallel passage P1 Bypass passage 14092MC19 This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm, bucket, swing) during a straight travel.
Page 79 3) 3) BOOM OPERATION BOOM OPERATION (1) (1) BOOM UP OPERATION BOOM UP OPERATION During boom up operation, the pilot secondary pressure from RCV is supplied to the port Pa20 of the spring side and shifts the boom 1 spool in the left direction. The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic oil fluid from pump A2 is entered P1 parallel passage and then passes through the load check, bridge passage and boom holding valve then flows into the port A2.
Page 80 (2) (2) BOOM DOWN OPERATION BOOM DOWN OPERATION During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 of the spring opposite side and shifts the boom 1 spool in the right direction. The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic fluid from the pump A2 enters the parallel passage and is directed to the port B2 through the load check.
Page 81 4) 4) HOLDING VALVE OPERATION HOLDING VALVE OPERATION (1) (1) HOLDING OPERATION HOLDING OPERATION At neutral condition, the pilot piston chamber is connected to drain port through the pilot port. And the piston "B" is supported with spring "B". Also, the pressured fluid from actuator entered to inside of the holding valve through the periphery hole of check, crevice of the check and the plug and the periphery hole of plug.
Page 82 (2) (2) RELEASE HOLDING OPERATION RELEASE HOLDING OPERATION The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the left direction against the spring "B", and shifts the poppet in the left direction through piston "B"...
Page 83 5) 5) BUCKET OPERATION BUCKET OPERATION (1) (1) BUCKET IN OPERATION BUCKET IN OPERATION During the bucket in operation, the pilot secondary pressure from RCV is supplied to port Pa5 of the spring side and shifts the bucket spool in the left direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port A5 through the check 1.
Page 84 (2) (2) BUCKET OUT OPERATION BUCKET OUT OPERATION During the bucket out operation, the pilot secondary pressure from RCV is supplied to port Pb5 of the spring opposite side and shifts the bucket spool in the right direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port B5 through the check 1.
Page 85 (3) (3) BUCKET IN OPERATION WITH BOOM UP OPERATION BUCKET IN OPERATION WITH BOOM UP OPERATION When combined operation, mostly same as previous page but the fluid from P1 bypass passage is empty. So only the fluid from P1 parallel passage is supplied to the bucket cylinder. Also, parallel passage is installed the bucket stroke limiter for supplying the fluid from pump A2 to the boom operation prior to the bucket operation.
Page 86 6) 6) SWING OPERATION SWING OPERATION (1) (1) SWING LEFT & RIGHT OPERATION SWING LEFT & RIGHT OPERATION During the swing left operation, the pilot secondary pressure from the RCV is supplied to the port Pd2 of the spring side and shift the swing spool in left direction. The bypass passage is shut off by the movement of the swing spool and the hydraulic fluid from pump A1 flows into swing spool through the P2 parallel passage.
Page 87 (2) (2) SWING LEFT OPERATION WITH ARM OR BOOM OPERATION SWING LEFT OPERATION WITH ARM OR BOOM OPERATION When combined operation, mostly same as previous page but the fluid from P2 bypass passage is empty. So only the fluid from parallel passage is supplied to the swing motor. Also, parallel passage is installed the orifice of swing logic valve for supplying the fluid from pump A1 to the boom or the arm operation prior to the swing operation.
Page 88 7) 7) ARM OPERATION ARM OPERATION ARM IN OPERATION ARM IN OPERATION (1) (1) During arm in operation, the pilot secondary pressure from the RCV is supplied to the port Pc40 of spring opposite side and shifts arm 1 spool in the right direction. The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic oil from the pump A1 flows into the arm cylinder head side through P2 parallel passage, the load check valve, bridge passage and the port C4.
Page 89 ARM REGENERATION ARM REGENERATION The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool through the arm holding valve and the arm 1 spool.
Page 90 (2) (2) ARM OUT OPERATION ARM OUT OPERATION During arm out operation, the pilot secondary pressure from RCV is supplied to the port Pd40 of spring side and shifts arm 1 spool in the left direction. The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic fluid from pump A1 flows into arm 1 spool through the P2 parallel passage.
Page 91 8) 8) SWING PRIORITY FUNCTION SWING PRIORITY FUNCTION During swing priority operation, the pilot secondary pressure is supplied to the port Pc3 of the spring side of the swing priority spool and shift swing priority spool in the right direction. The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm 1 side through swing priority spool and the path "A"...
Page 92 DOZER OPERATION DOZER OPERATION 9) 9) (1) (1) Dozer down operation ozer down operation P2 Parallel passage Dozer spool From dozer RCV DOZER Tank passage 14W92MC30 (2) (2) Dozer up operation ozer up operation P2 Parallel passage Dozer spool DOZER From dozer RCV Tank passage 14W92MC31...
Page 93 NEGATIVE RELIEF VALVE OPERATION NEGATIVE RELIEF VALVE OPERATION When no function is being actuated on P1 side, the hydraulic fluid from the pump A2, flows into the tank passage through the P1 bypass passage and orifice. The restriction caused by this orifice thereby pressurizes.
Page 94 OPERATION OF MAIN RELIEF VALVE OPERATION OF MAIN RELIEF VALVE The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the inside space, and seats the plunger against the housing securely. Socket Chamber A Piston A Poppet Hole A...
Page 95 The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by spring force. Then the pressure at port P becomes equal to set pressure of the spring and the plunger is seated to the socket. Poppet Spring Socket...
Page 96 OPERATION OF OVERLOAD RELIEF VALVE OPERATION OF OVERLOAD RELIEF VALVE FUNCTION AS RELIEF VALVE FUNCTION AS RELIEF VALVE The pressurized oil passes through the piston A and orifice A is filled up in chamber A of the inside space and seat the plunger against the socket and the socket against the housing securely. Piston A Socket Chamber A Poppet...
Page 97 Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As the result the pressurized oil at port P runs into tank passage (T). Tank passage Chamber A Poppet Housing Tank passage Plunger 14W92MC43 The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by spring force.
Page 98 MAKE-UP FUNCTION MAKE-UP FUNCTION When negative pressure exists at port P, the oil is supplied through tank passage (T). When the pressure at tank passage (T) becomes higher than that of at port P, the socket moves in the right direction.
Page 99: Group 3 Swing Device
GROUP 3 SWING DEVICE 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Reduction gear Relief valve Oil level gauge & oil supply port Oil level &...
Page 100 SWING MOTOR SWING MOTOR 3 2 11 10 1 16 19 18 44 17 36 37 44 39 40 38 18 21 20 29 30 42 25 26 24 23 47 31 46 23 24 26 25 42 VIEW X 125LCR2SM22 Casing 17 Spring pin...
Page 101 REDUCTION GEAR REDUCTION GEAR 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 17 24 22 125LCR2SM23 Ring gear 11 Planetary gear No. 2 21 Carrier pin No.
Page 102 2. PRINCIPLE OF DRIVING 2. PRINCIPLE OF DRIVING 2.1 Generating the turning force The high hydraulic supplied from a hydraulic pump flows into a cylinder block (8) through valve casing of motor (22), and valve plate (20). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston (12).
Page 103 MAKE UP VALVE MAKE UP VALVE In the system using this type of motor, there is no counter balance functioning valve and there happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency. A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action.
Page 104 3) 3) RELIEF VALVE RELIEF VALVE Sleeve Poppet Poppet seat Spring Spring seat Shim Piston Stopper Plug O-ring O-ring 145WF2SM25 Construction of relief valve Construction of relief valve The valve casing contains two cartridge type relief valves that stop the regular and reverse rotations of the hydraulic motor.
Page 105 ① Ports (P,R) at tank pressure. A2 m h 145WF2SM26 ② When hydraulic oil pressure (P×A ) reaches the preset force (F ) of spring (4), the poppet (2) moves to the right as shown. ×A Fsp+Pg×A Fsp+Pg×A 145WF2SM27 2-53...
Page 106 ③ The oil flows into chamber (g) via orifice (m) and (n). When the pressure of chamber (g) reaches the preset force (F ) of spring (4), the piston (7) moves left and stop the piston (7) hits the bottom of stopper (8).
Page 107 4) 4) BRAKE SYSTEM BRAKE SYSTEM (1) (1) Control valve swing brake system Control valve swing brake system This is the brake system to stop the swing motion of the excavator during operation. In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance created by this throttling works as a brake force to slow down the swing motion.
Page 108 ② Operating principle Operating principle When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (35). This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump charged oil (P3) goes to the chamber G through port PG.
Page 109 When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right. Then, the parking piston (15) is moved lower by spring force and the return oil from the chamber G flows back to tank port. At this time, the brake works.
Page 110: Group 4 Travel Device
GROUP 4 TRAVEL DEVICE GROUP 4 TRAVEL DEVICE (TYPE 1) (TYPE 1) 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Travel motor Reduction gear R/G Oil check port(PF 3/8) R/G Oil inlet port(PF 3/8) R/G Oil drain port(PF 3/8)
Page 111 1) 1) BASIC STRUCTURE BASIC STRUCTURE Reduction gear Travel motor Brake valve Parking brake High/low speed changeover mechanism Main control valve Main pump 14092TM02 2-59...
Page 112 2) 2) STRUCTURE STRUCTURE 42 26 36 30 27 43 38,21 25 37 67 49 89,90 SECTION A - A 209 210 46 205 208 207 204 203 202 71 126 10 11 5 101 129 130 103 61 108 14092TM03 Rear flange 19 Valve...
Page 113 2. 2. HYDRAULIC MOTOR ASSEMBLY HYDRAULIC MOTOR ASSEMBLY With brake valve, parking brake and high/low speed changeover mechanism. 1) 1) FUNCTION UNCTION Hydraulic motor Hydraulic motor This hydraulic motor is a swash plate type piston motor and converts the force of pressurized oil delivered from the pump into a rotational movement.
Page 114 2) 2) OPERATING PRINCIPLE OPERATING PRINCIPLE Hydraulic motor Hydraulic motor (Y1) ( Y2) 14092TM05 The pressurized oil delivered from the hydraulic pump flows to rear flange (1) of the motor, passes through the brake valve mechanism and is introduced into cylinder block (4) via timing plate (9). This oil constructively introduced only to one side of (Y1) - (Y2) connecting the upper and lower dead points of stroke of piston (5).
Page 115 Brake valve Brake valve ① Brake released Brake released When the pressurized oil supplied from port (A), the oil opens valve (27) and ﬂ ows into port (C) at the suction side of hydrau- lic motor to rotate motor. At the same time, the pressurized oil passes through pipe line (a) from a small hole in spool (23) and flow into chamber (b).
Page 116 ② Stopping and stalling Stopping and stalling (brake applied) When the pressurized oil supplied from port (A) is stopped during traveling, no hydraulic pressure is applied and spool (23) which has slid to the left will return on the right (neutral) via stopper (25, 26) by the force of spring (31).
Page 117 Parking brake Parking brake ① Running Running When the pressurized oil is supplied from 12 101 a 15 16 the valve, the spool of brake valve in the hydraulic motor assembly actuates to open the passage to the parking brake and the pressurized oil is introduced into cylinder chamber (a) which is composed of the spindle of reduction gear assembly and...
Page 118 High/low speed changeover mechanism High/low speed changeover mechanism ① At low speed At low speed - pilot pressure of less than 10 kgf/cm When no pilot pressure is supplied from (D) (at a pressure of 10 kgf/cm or less), valve (65) is pressed toward the top by the force of spring (66) and (A) port or (B) port, the pressurized oil supply port (C) is shut off, and oil in chamber (P) is released into the motor case via valve(65).
Page 119 3. 3. REDUCTION GEAR REDUCTION GEAR The reduction gear is composed of a two-stage planetary gear mechanism shown in the following ﬁ gure. Flange 14092TM12 The rotating motion of the hydraulic motor is transmitted to drive gear (121) of 1st stage, and the drive gear rotate planetary gears (R, 117).
Page 120 GROUP 4 TRAVEL DEVICE GROUP 4 TRAVEL DEVICE (TYPE 2) (TYPE 2) 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Travel motor Reduction gear PF1/2 FILL PF1/2...
Page 121 1) 1) STRUCTURE STRUCTURE 2 4 6 9 15 17 18 19 20 21 22 24 45 23 52 50 61 32 33 34 31 27 28 26 30 29 60 25 5 A" B" 8 7 1 16 14 10 11 12 13 51 45 49 47 43 35 36 62 28 37 53 48 DETAIL T...
Page 122 1 2 3 4 5 6 7-1 7-2 7-3 7-5 7-4 7-6 10-2 10-4 10-1 10-5 10-6 10-3 145Z9A2TM02A Spindle 7-4 Washer 2 10-5 Bearing 1 Floating sesal 7-5 Bearing 2 10-6 Pin 1 Ball bearing 7-6 Pin 2 11 Sun gear 1 Housing Coupling 12 Plate 1...
Page 123 3. PRINCIPLE OF DRIVING 3. PRINCIPLE OF DRIVING Travel motor comprises with rotary, relief valve, parking brake, counterbalance valve and 2-speed control. 1) 1) WORKING OF ROTARY PART WORKING OF ROTARY PART In the figure below, axis directional force F1 occurs when the high pressure oil flows into the cylinder block through to the valve plate (1) port, and the piston moves to the left hand side.
Page 124 2) 2) WORKING OF RELIEF VALVE WORKING OF RELIEF VALVE When the control valve spool is returned to neutral, the circuit between control valve and motor is blocked, and traveling movement stops. However, motor continues rotating because of the traveling inertia of the excavator's heavy weight. Then the motor will act as a pump, and oil blocked between control valve and motor will be pressured sharply and the increased oil pressure will damage internal parts.
Page 125 AT THE BEGINNING OF TRAVELING AT THE BEGINNING OF TRAVELING RELIEF VALVE A RELIEF VALVE A When travel control lever moves, high pressure oil works to rise the pressure of RA port up. This pressurized oil press plunger to the right, and then sustain the power of the spring, the plunger moves to the right and release the pressure oil of RA port to RB port (Stage 1) The plunger moves slowly by the pressure oil which flows into chamber 1 through orifice 1.
Page 126 DURING TRAVELING OPERATION DURING TRAVELING OPERATION RELIEF VALVE B RELIEF VALVE B During traveling operation, RA port pressure goes up and RB port pressure goes down. Thus RA port pressure oil flows into chamber 3, and pushes plunger to the left with a high pressure and the power of the spring.
Page 127 3) 3) WORKING OF PARKING BRAKE WORKING OF PARKING BRAKE Parking brake system consists of a brake piston, springs, friction plates and separating plates, and some orifices to control responsibility of the brake piston. The brake is usually held with the force of compressed spring, and it is released automatically by traveling oil pressure coming from inlet A, or B when the motor starts to run.
Page 128 • • Parking brake ON Parking brake ON When the control lever is returned to neutral position, the circuit between control valve and motor is blocked. As oil pressure in spool chamber drops to zero and the counter balance spool returns to neutral position.
Page 129 4) 4) COUNTERBALANCE VALVE COUNTERBALANCE VALVE (1) (1) Function Function ① Control oil flow in the action of mechanical parking brake operation. ② Prevent overrun while traveling on down slope. ③ Work as a hydraulic brake when motor stops, and prevent motor not to slip on slope. (2) (2) NEUTRAL NEUTRAL...
Page 130 (3) (3) How to work How to work ① When motor travel When motor travel When operator moves a traveling control lever, pressurized oil flows from pump to motor inlet A, and passes into spool chamber through counter orifice, and hydraulic force moves counter balance spool to the right, it makes pump oil flow into cylinder block through check poppet and kidney port.
Page 131 ② When motor stop When motor stop When operator moves a travel control lever to neutral position, pump oil flow is blocked. It reduce oil pressure of supply line down to zero, and oil in the spool chamber moves back to oil tank through counter orifice by the return force of spring in opposite side, and then counter balance spool returns to neutral position.
Page 132 5) 5) TWO SPEED (LOW SPEED - HIGH SPEED) CHANGEOVER EQUIPMENT TWO SPEED (LOW SPEED - HIGH SPEED) CHANGEOVER EQUIPMENT Rotating speed of the motor depends on slope angle of swash plate (9). Motor rotates slow when the angle is large, and rotates fast when the angle is small. •...
Page 133 • High speed When pilot pressure signal Pi is activated on spool (35), the spool moves to left hand end, and high pressure oil from Port is transferred to S1 which is connected to chamber A. The high pressure transferred to chamber B lift the piston (7) up, then the swash plate (9) tilts to smaller angle, and the motor rotates higher speed.
Page 134 4. REDUCTION GEAR 4. REDUCTION GEAR 1) 1) PLANETARY GEAR MECHANISM PLANETARY GEAR MECHANISM Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force. This reduction unit utilizes two stages, planetary reduction system. Planetary reduction system consists of sun gear, planetary gears, carriers and ring gear.
Page 135: Group 4 Travel Device
GROUP 4 TRAVEL DEVICE GROUP 4 TRAVEL DEVICE (TYPE 3, 4) (TYPE 3, 4) 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. P/No.(39Q4-40100, 38Q4-40100) Reduction gear Travel motor VIEW A...
Page 136 2. 2. STRUCTURE STRUCTURE 49 40 43 42 41 44 72 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 71 70 59 77 64 3 63 7 10 11 14 15 13 16 26 27 6 8 125LCR2TM21...
Page 137 3. 3. OPERATION OPERATION 1) 1) MOTOR MOTOR High pressure oil delivered form hydraulic pump is led to inlet port that is provided in the brake valve portion and, through the rear cover (30) and valve plate (24), led to cylinder block (12). The oil flow and direction of shaft rotation are indicated in table.
Page 138 2) 2) PARKING BRAKE PARKING BRAKE Parking brake is released when high pressure oil selected by the brake valve portion that is connected directly to the rear cover (30), is applied to the parking piston (19). Otherwise the braking torque is always applied. This braking torque is generated by the friction between the separated plates (18), inserted into the casing (1), and friction plates (17), coupled to cylinder block (12) by the outer splines.
Page 139 3) 3) CAPACITY CONTROL MECHANISM CAPACITY CONTROL MECHANISM Figure typically shows the capacity control mechanism. When high speed pilot line is charged with the pressure P that overcome the spring (44), the spring (44) is compressed and spool (40) shifts to the right to connect the port P and port C. Then, the highest pressure is selected by the check valve (50) from inlet and outlet pressure of the motor and high speed pilot line pressure and pushes shifter piston (4).
Page 140 4) 4) OVERLOAD RELIEF VALVE OVERLOAD RELIEF VALVE (1) (1) Structure tructure This valve is screwed in the motor rear cover (30) and consists of : plug (38-1) that is screwed and fixed in the rear cover (30), poppet (38-8) and supports the poppet seat (38-9), spring (38-2) that is operating relief valve setting pressure and supports the spring seat (38-3), that is inserted in the sleeve (38-4), piston (38-5) that reduce the shock.
Page 141 (2) (2) Operation Operation Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and have the following functions : ① When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating, bypasses surplus oil to return line.
Page 142 5) 5) BRAKE VALVE BRAKE VALVE (1) (1) Structure Structure The brake valve portion mainly consists of the following parts: ① Spool Spool By shifting the spool (31), the discharged oil from hydraulic motor is automatically shut off or restricted according to the condition and give the effect of holding, accelerating, stopping and counterbalance operations.
Page 143 (2) (2) Operation Operation ① Holding operation Holding operation When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (33) located on both spool ends holds the spool (31) at central position. Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
Page 144 ② Accelerating operation Accelerating operation When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool (31), and oil flows to motor via MA port to rotate the motor. Therefore, the pressure increases and negative brake is released by the pressure supplied from pump.
Page 145 ③ Stopping operation Stopping operation Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends become equal, and the spool (31) returns to the neutral position by spring (33) force.
Page 146 ④ Counterbalance operation Counterbalance operation Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force. In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on MB to VB side decreases and the spring (33) force moves the spool (31) leftwards towards neutral position.
Page 147 6) 6) REDUCTION GEAR REDUCTION GEAR Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force. This reduction unit utilizes two stages, planetary reduction system. Planetary reduction system consists of sun gear, planetary gears, (planetary) carriers, and ring gear.
Page 148: Group 5 Rcv Lever
GROUP 5 RCV LEVER GROUP 5 RCV LEVER 1. STRUCTURE 1. STRUCTURE The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face. ※...
Page 149 2) 2) TYPE M2, M4, M6, M9 TYPE M2, M4, M6, M9 Null Null TYPE M2, M4, M9 TYPE M6 Switches Switches Type One touch decel Horn M2, M4, Single Simultaneous operation Power boost Breaker operation One touch decel Horn Power boost Null CCW rotation...
Page 150 3) 3) CROSS SECTION CROSS SECTION Case Bushing Spool Shim Spring Spring seat Spring Plug Push rod 10 O-ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut...
Page 151 2. FUNCTIONS 2. FUNCTIONS 1) 1) FUNDAMENTAL FUNCTIONS FUNDAMENTAL FUNCTIONS The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and apply- ing the output pressure (secondary pressure) of the pilot valve to the other end.
Page 152 3) 3) OPERATION OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 2-70 Pilot valve Main pump...
Page 153 Case where handle is in neutral position Case where handle is in neutral position Port 1 Port 3 300L2RL03 The force of the spring (5) that determines the output pressure of the pilot valve is not applied to the spool (3). Therefore, the spool is pushed up by the spring (7) to the position of port (1, 3) in the operation explanation drawing.
Page 154 Case where handle is tilted Case where handle is tilted Port 3 Port 1 300L2RL04 When the push rod (9) is stroked, the spool (3) moves downwards. Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port (1) to generate the pressure.
Page 155: Group 6 Rcv Pedal
GROUP 6 RCV PEDAL GROUP 6 RCV PEDAL 1. STRUCTURE 1. STRUCTURE The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size...
Page 156 CROSS SECTION CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool (8), spring (6) for setting secondary pressure, return spring (10), stopper (9), and spring seat (7).
Page 157 2. FUNCTION 2. FUNCTION 1) 1) FUNDAMENTAL FUNCTIONS FUNDAMENTAL FUNCTIONS The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the pilot valve to the other end.
Page 158 3) 3) OPERATION OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 36072SF01 Pilot valve Main pump...
Page 159 (1) (1) Case where pedal is in neutral position Case where pedal is in neutral position Port 1 Port 2 235ZF2RP03 The force of the spring (6) that determines the output pressure of the pilot valve is not applied to the spool (8).
Page 160 (2) (2) Case where pedal is tilted Case where pedal is tilted Port 1 Port 2 235ZF2RP04 When the push rod (14) is stroked, the spool (8) moves downwards. Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1 to generate the pressure.
Page 161: Section 3 Hydraulic System
SECTION 3 HYDRAULIC SYSTEM SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1 Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-2 Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-5 Group 4 Single Operation ------------------------------------------------------------------------------------------------ 3-15 Group 5 Combined Operation ----------------------------------------------------------------------------------------- 3-27...
Page 162: Group 1 Hydraulic Circuit
SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT GROUP 1 HYDRAULIC CIRCUIT <BOOM SAFETY LOCK> <ARM SAFETY LOCK> <PROPOTIONAL RCV DOUBLE ACTING & ROTATING> ( 59 ,C) ( 25 ,e1) ( 2 ,Po5) ( 49 ,P3) SPRING 4k [PEDAL [BREAKER] [FLOW ( 21 ,A1) SAFETY]...
Page 163: Group 2 Main Circuit
GROUP 2 MAIN CIRCUIT GROUP 2 MAIN CIRCUIT The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit. The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders and two travel motors. The swash plate type variable displacement axial piston pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
Page 164 2. RETURN CIRCUIT 2. RETURN CIRCUIT Check valve(2) 1.5kgf/cm Full flow filter Oil cooler Main control valve Actuators Check valve(1) 3.0kgf/cm Bypass relief valve Bypass relief valve 1.5kgf/cm 1.5 kgf/cm 21073CI01 All oil returned from each actuator returns to the hydraulic tank through the main control valve. The bypass check valves are provided in the return circuit.
Page 165 3. DRAIN CIRCUIT 3. DRAIN CIRCUIT Travel motor Swing motor Main pump From return line Turning joint Dr#, dr# Drain filter Hydraulic oil tank Check valve 1.5kgf/cm 21093CI02 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through drain filter.
Page 166: Group 3 Pilot Circuit
GROUP 3 PILOT CIRCUIT GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve RCV pedal (RH lever) (LH lever) Safety lock Swing parking brake solenoid valve Travel speed solenoid valve Arm regeneration solenoid valve • • Power boost solenoid valve •...
Page 167 1. SUCTION, DELIVERY AND RETURN CIRCUIT Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT TRAVEL LEFT TRAVEL STRAIGHT...
Page 168 2. SAFETY VALVE (SAFETY LEVER) Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL STRAIGHT Dr#, dr#...
Page 169 3. BOOM PRIORITY SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL STRAIGHT Dr#, dr# SWING...
Page 170 4. TRAVEL SPEED CONTROL SYSTEM Pi1(Pump) Pi2(Pump) P2(BW) P1(FW) P1(BW) P2(FW) OPTION C (DOZER) TURNING JOINT OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT...
Page 171 5. MAIN RELIEF PRESSURE CHANGE SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL MAIN RELIEF VALVE...
Page 172 6. ARM REGENERATION CUT SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN ARM REGEN VALVE Pa21 Arm regeneration BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 173 7. SWING PARKING BRAKE RELEASE Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET SPRING 4k Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 VB(CCW) VA(CW) Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT...
Page 174 8. SWING PRIORITY SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL STRAIGHT Dr#, dr# SWING...
Page 175 9. BOOM FLOATING SYSTEM Pi1(Pump) Pi2(Pump) Boom safety lock valve Head to Rod to tank solenoid tank solenoid TURNING OPTION C JOINT (DOZER) Boom floating OPTION B BUCKET solenoid valve Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Make up Pc41 valve Boom...
Page 176: Group 4 Single Operation
GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 BOOM Pa21 HOLDING Pa20 VALVE BOOM 2 ARM 2 Pd41 Pb21 SWING RELIEF Pb20 VALVE...
Page 177 2. BOOM DOWN OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING RELIEF Pb20 VALVE Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 178 3. ARM IN OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET MAKE UP VALVE RELIEF VALVE Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 179 4. ARM OUT OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) BUCKET OPTION B RELIEF VALVE MAKE UP VALVE Pc41 Pc40 Pd40 Pd41 ARM 1 HOLDING Pc42 VALVE REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1...
Page 180 5. BUCKET IN OPERATION Pi1(Pump) Pi2(Pump) RELIEF TURNING VALVE OPTION C JOINT MAKE UP (DOZER) VALVE OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 181 6. BUCKET OUT OPERATION Pi1(Pump) Pi2(Pump) MAKE UP RELIEF TURNING VALVE VALVE JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 182 7. DOZER UP OPERATION Pi1(Pump) Pi2(Pump) MAKE UP VALVE TURNING RELIEF OPTION C JOINT VALVE (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 183 8. DOZER DOWN OPERATION Pi1(Pump) Pi2(Pump) RELIEF VALVE MAKE UP TURNING VALVE JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 184 9. SWING OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET SPRING 4k Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 VB(CCW) VA(CW) Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL...
Page 185 SWING CIRCUIT OPERATION PARKING BRAKE BRAKE OFF BRAKE RELEASE VALVE BRAKE ON SPRING 4k MAKE UP VALVE MOTOR BRAKE VALVE MAKE UP PORT(MU) ANTI-INVERSION VALVE VA(CW) VB(CCW) TO / FROM MAIN CONTROL VALVE 140L3HC18A MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation and controls the swing motor operating pressure.
Page 186 10. TRAVEL FORWARD AND REVERSE OPERATION Pi1(Pump) Pi2(Pump) P2(FW) P2(BW) P1(FW) P1(BW) OPTION C (DOZER) TURNING JOINT OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 187 TRAVEL CIRCUIT OPERATION OVERLOAD RELIEF VALVE TRAVEL MOTOR DEVICE COUNTER BALANCE VALVE TURNING JOINT TO/FROM MAIN CONTROL VALVE 140L3HC19A Valves are provided on travel motors to offer the following functions. COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run. OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 350 kgf/cm (4980 psi) to prevent high pressure...
Page 188: Group 5 Combined Operation
GROUP 5 COMBINED OPERATION 1. OUTLINE Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 189 2. COMBINED SWING AND BOOM UP OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL...
Page 190 3. COMBINED SWING AND ARM OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 191 4. COMBINED SWING AND BUCKET OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) BUCKET OPTION B Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 192 5. COMBINED SWING AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 193 6. COMBINED BOOM AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 194 7. COMBINED ARM AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 195 8. COMBINED BUCKET AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 196 9. COMBINED BOOM UP AND BUCKET OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL...
Page 197: Section 4 Electrical System
SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1 Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3 Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-22 Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-34...
Page 198: Group 1 Component Location
SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 Switch panel Switch panel CN-16B CN-16 & 16A 145ZF4EL01 Cigar lighter 12 Power max switch 23 Heated seat switch Aircon and heater switch 13 Safety lever 24 Speaker...
Page 199 2. LOCATION 2 2. LOCATION 2 BOOM SAFETY VALVE BOOM 4 CARTRIDGE SAFETY VALVE SOL VALVE MAIN PUMP Patt MAIN CONTROL VALVE SHUTTLE BLOCK 145ZF4EL02 Lamp 12 Start relay 25 Pump EPPR valve Fuel sender 13 Heater relay 26 Boom priority EPPR valve Fuel filler pump 14 Alternator 27 Machine control unit - attach...
Page 200: Group 2 Electrical Circuit
GROUP 2 ELECTRICAL CIRCUIT (1/2) ELECTRICAL CIRCUIT (1/4, SERIAL NO. : -#0967) PVG CONTROLLER CN-231 8W 145 AAVM R/DRYER MASTER SW WASHER P/P CABIN LAMP CAMERA FUSE BOX AC COMP 2-PCS SOL BEACON LAMP HORN ANTI-RESTART PRE-HEAT POWER RY CS-74A CN-95 MASTER SW CS-74...
Page 201 ELECTRICAL CIRCUIT (2/4, SERIAL NO. : -#0967) CS-67 => HARNESS-RH SIDE FRONT CAMERA HARNESS SIDE<= DC/DC CONVERTER Service Tool 0.8Br CS-1 12V SOCKET HOUR METER SMT CAN 0.8G CN-10 0.8V DESTINATION CL-1 CS-26A 0.8Or 1.2V DOOR S.W 0.8BW CABIN LIGHT RY 0.8Y 0.8Y 0.8B...
Page 202 ELECTRICAL CIRCUIT (3/4, SERIAL NO. : #0968-) PVG CONTROLLER CN-231 AAVM 8W 145 R/DRYER MASTER SW WASHER P/P CABIN LAMP FUSE BOX CAMERA 2-PCS SOL AC COMP HORN ANTI-RESTART PRE-HEAT BEACON LAMP POWER RY CS-74A CN-95 MASTER SW CS-74 CIRCUIT BREAKER FEED PUMP RY SCR TEMP BATTERY...
Page 203 ELECTRICAL CIRCUIT (4/4, SERIAL NO. : #0968-) CS-67 FRONT CAMERA HARNESS SIDE<= => HARNESS-RH SIDE Service Tool DC/DC CONVERTER 0.8Br CS-1 12V SOCKET HOUR METER SMT CAN 0.8G 0.8V CN-10 DESTINATION CS-26A CL-1 0.8Or 1.2V DOOR S.W 0.8BW CABIN LIGHT RY 0.8Y 0.8Y FUSE...
Page 204 MEMORANDUM HYUNDAI HEAVY INDUSTRIES CO., LTD CONSTRUCTION EQUIPMENT DIV.
Page 205 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW Battery Battery relay Circuit breaker [CN-60] Master switch [CS-74A] I/conn [CN-231 (2)] Fuse box [No.1]...
Page 206 POWER CIRCUIT CN-231 FUSE BOX POWER RY CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 CL-40 CN93-J1 REGEN READINESS DEF LAMP STG RETURN ID DEF/SCR CR-101 CN-3 AIR TEMP SENSOR 2.0R BATTERY(+) 85 87 87a CR-1 2.0R BATTERY(+) 2.0R BATTERY(+) 2.0B 1.2G BATTERY(-) 2.0B...
Page 207 2. STARTING CIRCUIT OPERATING FLOW Battery (+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74A] I/conn [CN-231 (2)] Fuse box [No.2] I/conn [CN-36-1 (7)] Master switch [CS-74B] I/conn [CN-5 (36)] Start switch [CS-2A (1)] When start key switch is in ON position Start switch ON [CS-2A (2)] I/conn [CN-5 (39)] Battery relay [CR-1]...
Page 208 STARTING CIRCUIT CN-231 FUSE BOX POWER RY ANTI-RESTART RY PRE-HEAT RY CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 CR-1 1.2B 1.2G BATTERY (12VX2) BATT RY CS-74 MASTER SW CN93-J1 BATTERY(-) KEY IG ANALOGUE RETURN AIR INLET TEMP 8V SENSOR SUPPLY CN-2 8V SENSOR RETURN WIF SWITCH...
Page 209 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the starting switch to the ON position. Charging current generated by operating the alternator flows into the battery through the battery relay [CR-1]. The current also flows from the alternator to each electrical component and controller through the fuse box.
Page 210 CHARGING CIRCUIT CN-231 FUSE BOX CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 CN-56A 0.8RW BATT.24V 0.8VOr IG 24V 0.8B CR-1 CAN1 HI 1.2B CAN1 LO CAN2 HI BATTERY CAN2 LO (12VX2) BATT RY RS-232 RX RS-232 TX CN-2 AUX LEFT AUX RIGHT AUX GND CLUSTER...
Page 211 4. HEAD AND WORK LIGHT CIRCUIT OPERATING FLOW Fuse box (No.16) I/conn [CN-36-2 (4)] Head light relay [CR-13 (30, 86)] Fuse box (No.17) I/conn [CN-36-2 (5)] Work light relay [CR-4 (30, 86)] Head light switch ON Head light switch ON [CN-376 (13)] Head light relay [CR-13 (85) (87)] Head light ON [CL-3 (2), CL-4 (2)]...
Page 212 HEAD AND WORK LIGHT CIRCUIT FUSE BOX CR-13 1.2Br CN-376 0.8Br IG 24V 1.2ROr TRAVEL ALARM 0.8BrW WIPER WORK LIGHT HEAD LAMP RY CABIN LIGHT CL-4 1.2B 1.2ROr CAN HI (2) HEAD LAMP WASHER CL-3 INT.WIPER 1.2B HEAD LIGHT 1.2ROr BEACON HEAD LAMP CAN LO (2)
Page 213 5. BEACON LAMP AND CAB LIGHT CIRCUIT OPERATING FLOW Fuse box (No.19) I/conn [CN-36-1 (5)] Beacon lamp relay [CR-85 (30, 86)] Fuse box (No.18) I/conn [CN-36-2 (6)] Cab light relay [CR-9 (30, 86)] Beacon lamp switch ON Beacon lamp switch ON [CN-376 (15)] Beacon lamp relay [CR-85 (85) (87)] I/conn [CN-5 (50)]...
Page 214 BEACON LAMP AND CAB LIGHT CIRCUIT FUSE BOX CR-85 1.2Gr 0.8WOr 87 85 0.8W 0.8B BEACON LAMP RELAY CN-376 IG 24V CR-9 TRAVEL ALARM 0.8R 87 85 WIPER WORK LIGHT 0.8Gr CABIN LIGHT CABIN LAMP RELAY CAN HI (2) WASHER INT.WIPER HEAD LIGHT BEACON...
Page 215 6. WIPER AND WASHER CIRCUIT OPERATING FLOW Key switch ON Fuse box (No.11) I/conn [CN-36-1 (16)] Membrane controller [CN-376 (1)] Fuse box (No.6) I/conn [CN-36-1 (11)] I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141 (7)] Wiper motor [CN-21 (4)] Fuse box (No.21) I/conn [CN-36-1 (4)] I/conn [CN-5 (16)]...
Page 216 WIPER AND WASHER CIRCUIT FUSE BOX CN-376 IG 24V TRAVEL ALARM WIPER WORK LIGHT CABIN LIGHT CN-22 0.8GrW 0.8V CAN HI (2) WASHER WASHER PUMP INT.WIPER DO-5 0.8GrW HEAD LIGHT 0.8V BEACON CAN LO (2) DIODE MEMBRANE CONTROLLER WIPER CUT WIPER MOTOR WIPER MOTOR CONTROLLER 145ZF4EL10...
Page 217 CONTROLLER CIRCUIT FUSE BOX CN-J7A J1939 HI J1939 LO ADDRESS SELEC J1939- BATT+ TAIL OUT NOX SENSOR CN-J7B J1939 HI J1939 LO ADDRESS SELEC J1939- BATT+ CR-101 TURBO OUT NOX SENSOR 0.8L 85 87 87a 1.2Br 3W 120 DCU RY CD-16 CL-41 3W 120...
Page 218 MONITORING CIRCUIT FUSE BOX CD-16 CN-3 0.8 B RETURN(29) 3W 120 0.8 Gr SIGNAL 0.8 R CN-429 SUPPLY POWER 5V(72) WATER LEVEL SENSOR CN-126A 0.8G 5V SUPPLY CAN-A_Hi 0.8G DEF ID MODULE CAN-A_Lo CN93-J1 CDL- CDL+ REGEN READINESS STG RETURN ID DEF/SCR IG 24V AIR TEMP SENSOR...
Page 219 ELECTRIC CIRCUIT FOR HYDRAULIC ELECTRIC CIRCUIT FOR HYDRAULIC (1/2) FUSE BOX DOZER & ADJUST BOOM SW AIR-COMP SW QUICK CLAMP SW BUZZER CN-5 CD-6 SUPPLY RETURN TRAVEL PS CD-7 SUPPLY CN-263 RETURN SEE : 140ZF4EL14 WORK PS 2-PCS SOL CD-35 SUPPLY RETURN ARM IN_OUT...
Page 220 ELECTRIC CIRCUIT FOR HYDRAULIC ELECTRIC CIRCUIT FOR HYDRAULIC (2/2) FUSE BOX SWING SWING SWING PARKING PARKING PARKING SOL A3 SOL A2 SOL A1 CN-3 CN-8 CS-73A SWING FINE SW CS-73 EPPR EPPR VALVE VALVE SOL A2 SOL A1 SEE : 140ZF4EL13 SEE : 140ZF4EL13 P/P VALVE (PVG 32)
Page 221: Group 3 Electrical Component Specification
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check Check specific gravity 1.280 over : Over charged 100Ah Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging Rated load Check coil resistance(M4 to M4) Normal : About 50 Battery relay 100A (continuity) Check contact...
Page 222 Part name Symbol Specifications Check Check resistance Glow plug 24V 200A 0.25~0.12 CN-80 Check resistance Temperature 50˚C : 804 sensor 80˚C : 310 (hydraulic) 100˚C : 180 CD-8 CD-1 Air inlet temperature sensor CD-98 CD-98A Check contact Air cleaner N.O TYPE High level : pressure switch Low level : 0...
Page 223 Part name Symbol Specifications Check Check resistance Normal : About 160 Relay 24V 16A (for terminal 85-86) 0 (for terminal 30-87a) CR-2 CR-4 CR-5 CR-7 CR-9 CR-13 CR-35 CR-36 (for terminal 30-87) CR-85 CR-95 CR-101 Check resistance CN-66 CN-68 CN-70 Solenoid valve 24V 1A Normal : 15~25...
Page 224 Part name Symbol Specifications Check Head lamp, 24V 65W Check disconnection Work lamp, (H3 Type) Normal : 1.2 Cab lamp CL-3 CL-4 CL-5 CL-6 CL-8 CL-9 CL-10 Check disconnection Beacon lamp 70W (H1 Type) Normal : A few 2.4W (LED Type) CL-7 CL - 24V 10A...
Page 225 Part name Symbol Specifications Check Check contact Normal : 1.0 ON : 0 (for terminal A-B) 24V 15A Safety switch (N.C TYPE) (for terminal A-C) OFF : (for terminal A-B) CS-20 CS-4 0 (for terminal A-C) Wiper cut Check contact switch (N.O TYPE) Normal : 0 (one pin to ground)
Page 226 Part name Symbol Specifications Check Check voltage DC/DC 24V 3A 24V (for terminal 1-2) Converter 12V (for terminal 1-3) CN-138 Check coil resistance Normal : About 1M Cigar lighter 24V 5A 1.4W Check contact Normal : Operating time : 5~15sec CL - CL-2 Check contact...
Page 227 Part name Symbol Specifications Check Check contact Start relay 24V 300A Normal : 0.94 (for terminal 1-2) CR-23 Check resistance Blower motor 24V 14A Normal : 2.5 (for terminal 1-2) Check resistance 1˚C OFF Air conditioner Normal : 0 (for terminal 1-2), duct sensor 4˚C ON the atmosphere temp :...
Page 228 Part name Symbol Specifications Check Check disconnection Master switch 6-36V Normal : 0.1 CS-74A CS-74B Breaker pedal switch CS-26A Quick clamp 24V 80mA buzzer Min 65dB CN-113 12V Socket 12V 10A CN-139 Check contact Engine emergency Normal stop switch 0 (for terminal 1-2) CS-33 SCR TEMP SIG temperature...
Page 229 Part name Symbol Specifications Check DOC TEMP SIG temperature 0V RETURN sensor CN-426 LINE HEATER 3 HS DEF/AdBlue® LINE HEATER 3 LS line heater CN-381 CN-382 CN-383 Check disconnection WIF sensor Normal : 68.8~4.94 CD-45 DEF/AdBlue® fill up warning lamp (LED) CL-40 RETURN Proportional...
Page 230 Part name Symbol Specifications Check Accel dial LED CN-267 DEF/AdBlue® full lamp CL-41 Temperature sensor (A/C incar, A/C ambient, water) CN-429 VALVE HS Coolant diverter valve VALVE LS CN-384 CN-J31 SIG. V(Us) SIG. V(Udc) Proportional valve sensor ERROR CN-308 Check resistance Dozer act N.O type pressure switch...
Page 231 Part name Symbol Specifications Check RETURN(29) Water level SIGNAL 5V 12.5mA SUPPLY POWER 5V(72) sensor CD-16 UREA INJECTOR LS DEF/AdBlue® UREA INJECTOR HS injector CN-424 LVDS POS LVDS NEG Camera 7V 100mA POWER 24V ADJUST SIGNAL CN-249 J1939 HI J1939 LO NOx sensor ADDRESS SELEC (tail out,...
Page 232 Part name Symbol Specifications Check SENSOR OUT SENSOR GND 24V COIL - 24V COIL + Fan clutch SENSOR 5V CN-385 CAN HI CAN LO SAFETY KEY IG PVG 32 5V POWER controller 5V GND ROTATE / LH ROTATE /RH CN-3A 4-33...
Page 233: Group 4 Connectors
GROUP 4 CONNECTORS GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002 CN-2 I/conn (Frame harness-Engine harness) 936777-2 936780-2 CN-3 I/conn (Frame harness-Engine harness) 1897009-2 1897013-2 CN-3A...
Page 234 Connector part No. Connector No. of Type Destination number Female Male CN-51 DEUTSCH DRC26-40SA CN-52 DEUTSCH DRC26-40SB CN-53 DEUTSCH MCU (option) DRC26-40SA CN-56A Cluster 174663-2 CN-56B Cluster 174984-2 CN-60 YAZAKI Circuit breaker 7122-4125-50 CN-61 DEUTSCH Fuel filler pump DT06-2S-EP06 CN-66 DEUTSCH Breaker solenoid DT06-2S-EP06...
Page 235 Connector part No. Connector No. of Type Destination number Female Male CN-245 PTC power CN-245A Remote controller assy 368542-1 CN-245E Remote controller assy 174045-2 CN-246 USB & socket assy 174045-2 CN-246 DEUTSCH Proportional valve-RH DT06-3S DT04-3P CN-247 DEUTSCH Proportional valve-LH DT06-3S DT04-3P CN-249...
Page 236 Connector part No. Connector No. of Type Destination number Female Male CN-423 DEUTSCH Tank header unit DT06-4S CN-424 DEF/AdBlue® injector temperature sensor 2098557-1 CN-425 SCR temperature sensor 282080-1 CN-426 DOC temperature sensor 282080-1 CN-427 MOLEX Reader-RMS 039012040 026013096 CN-429 DEF/AdBlue® ID module sensor 776433-3 CN-J7A NOx sensor (tail)
Page 237 Connector part No. Connector No. of Type Destination number Female Male CS-74A Master switch S813-030201 CS-74B Master switch S813-030201 CS-83 Spare switch SWF589790 CS-99 Air compressor switch SWF589790 CS-100 Spare switch SWF589790 CS-107 Travel straight switch SWF589790 CS-111 Boom floating switch SWF589790 ·Light CL-1...
Page 238 Connector part No. Connector No. of Type Destination number Female Male CD-71 DEUTSCH N2 pressure sensor DT06-3S-EP06 CD-85 DEUTSCH Boom down sensor DT06-3S-EP06 CD-86 DEUTSCH Arm out pressure sensor DT06-3S-E005 CD-87 DEUTSCH Bucket out pressure sensor DT06-3S-E005 CD-90 DEUTSCH Arm in pressure sensor DT06-3S-EP06 CD-91 DEUTSCH...
Page 239 2. CONNECTION TABLE FOR CONNECTORS 2. CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR PA TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 3S811-109002 S811-011002 S811-111002 4 - 40...
Page 240 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4 - 41...
Page 241 J TYPE CONNECTOR J TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 4 - 42...
Page 242 SWP TYPE CONNECTOR SWP TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 4 - 43...
Page 243 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4 - 44...
Page 244 CN TYPE CONNECTOR CN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 4 - 45...
Page 245 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 4 - 46...
Page 246 375 FASTEN TYPE CONNECTOR 375 FASTEN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR AMP ECONOSEAL CONNECTOR No. of Receptacle connector (female) Plug connector (male) 344111-1 344108-1 AMP TIMER CONNECTOR AMP TIMER CONNECTOR No.
Page 247 AMP 040 MULTILOCK CONNECTOR AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 174045-2 AMP 070 MULTILOCK CONNECTOR AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 173852 AMP FASTIN - FASTON CONNECTOR AMP FASTIN - FASTON CONNECTOR No.
Page 248 KET 090 CONNECTOR KET 090 CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610070 KET 090 WP CONNECTORS KET 090 WP CONNECTORS No. of Receptacle connector (female) Plug connector (male) MG640605 MG640795 4 - 49...
Page 249 KET SDL CONNECTOR KET SDL CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610406 4 - 50...
Page 250 DEUTSCH DT CONNECTORS DEUTSCH DT CONNECTORS DT 06 - 3S - ★★★★ Modifications (see below) Number of contacts (P : Pin, S : Socket) 06 : Receptacle, 04 : Plug Deutsch connectors ※ Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 251 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 4 - 52...
Page 252 MOLEX 2CKTS CONNECTOR MOLEX 2CKTS CONNECTOR No. of Receptacle connector (female) Plug connector (male) 35215-0200 35215-0200 ITT SWF CONNECTOR ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF593757 MWP NMWP CONNECTOR MWP NMWP CONNECTOR No. of Receptacle connector (female) Plug connector (male) NMWP01F-B 4 - 53...
Page 253 ECONOSEAL J TYPE CONNECTORS ECONOSEAL J TYPE CONNECTORS No. of Receptacle connector (female) Plug connector (male) S816-001002 S816-101002 S816-002002 S816-102002 S816-003002 S816-103002 S816-004002 S816-104002 4 - 54...
Page 254 No. of Receptacle connector (female) Plug connector (male) S816-006002 S816-106002 S816-008002 S816-108002 S816-010002 S816-110002 S816-012002 S816-112002 4 - 55...
Page 255 No. of Receptacle connector (female) Plug connector (male) 368301-1 2-85262-1 METRI-PACK TYPE CONNECTOR METRI-PACK TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) 12040753 DEUTSCH HD30 CONNECTOR DEUTSCH HD30 CONNECTOR No. of Receptacle connector (female) Plug connector (male) HD36-24-23SN HD34-24-23PN 4 - 56...
Page 256 DEUTSCH MCU CONNECTOR DEUTSCH MCU CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-40SA/B DEUTSCH SERVICE TOOL CONNECTOR DEUTSCH SERVICE TOOL CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) HD10-9-96P AMP FUEL WARMER CONNECTOR FUEL WARMER CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) 2-967325-3...
Page 257 DEUTSCH E DEUTSCH ENGINE NGINE ECM CONNECTOR ECM CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-50S-04 DEUTSCH DEUTSCH INTERMEDIATE INTERMEDIATE CONNECTOR CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRB16-60SAE-L018 4 - 58...
Page 258: Section 5 Mechatronics System
SECTION 5 MECHATRONICS SYSTEM Group 1 Outline ----------------------------------------------------------------------------------------------------------------- 5-1 Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-3 Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6 Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7 Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-8 Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-9 Group 7 Engine Overheat Prevention System --------------------------------------------------------------- 5-10 Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-11 Group 9 Attachment Flow Control System --------------------------------------------------------------------- 5-12...
Page 259: Group 1 Outline
SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
Page 260 SYSTEM DIAGRAM Work tool Attachment pilot Work Travel pressure pressure pressure SOLENOID VALVE Option (Dozer) Swing fine EPPR VALVE control Option Bucket Swing parking Breaker(opt) Arm 1 Arm regen Attachment Boom priority Travel speed Arm 2 Boom 2 pressure(opt) EPPR Attachment Swing Boom 1...
Page 261: Group 2 Mode Selection System
GROUP 2 MODE SELECTION SYSTEM 1. POWER MODE SELECTION SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Cluster Drive signal Power mode Accel dial pilot lamp Emergency CN-16B Power mode switch signal Accel dial signal CN-16A CN-16 CAN #2...
Page 262 2. WORK MODE SELECTION SYSTEM Work mode consists of the general operation (bucket) and the optional attachment (breaker, crusher). Attachment pilot pressure sensor Main control valve Work tool Option (Dozer) SOLENOID VALVE Option Bucket Breaker Arm 1 Arm regen Attachment Arm 2 Boom 2 conflux...
Page 263 3. USER MODE SELECTION SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Cluster Drive signal Accel dial User mode pilot lamp Emergency CN-16B User mode switch signal Accel dial signal CN-16A CN-16 CAN #2 Normal 145ZF5MS04 Engine speed, idle speed and pump power shift pressure can be adjusted and memorized in the U-mode.
Page 264: Group 3 Automatic Deceleration System
GROUP 3 AUTOMATIC DECELERATION SYSTEM Work Travel pressure pressure Main control valve Engine Pilot pump Main pump Cluster Pressure signal Auto idle Accel dial pilot lamp Emergency CN-16B Accel dial signal Auto idle switch signal CN-16A CN-16 CAN #2 Normal 145ZF5MS05 1.
Page 265: Group 4 Power Boost System
GROUP 4 POWER BOOST SYSTEM Main control valve Option (Dozer) Option Bucket Arm 1 Arm regen Arm 2 Boom 2 Boom 1 Swing Travel(RH) Travel(LH) Main relief valve pressure pressure Power boost solenoid valve Engine Pilot pump Main pump Power boost Pump power button shift EPPR...
Page 266: Group 5 Travel Speed Control System
GROUP 5 TRAVEL SPEED CONTROL SYSTEM Main control valve Option Travel motor (Dozer) Option Bucket Arm 1 Arm regen Regulator Arm 2 Boom 2 Swing Boom 1 Travel(RH) Travel(LH) Travel speed solenoid valve Engine Pilot pump Main pump Cluster Drive signal Travel speed pilot lamp Travel speed switch signal...
Page 267: Group 6 Automatic Warming Up System
GROUP 6 AUTOMATIC WARMING UP SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Hydraulic temp signal Cluster Hydraulic temp sensor Drive signal Accel dial Emergency CN-16B Warming up pilot lamp signal Accel dial signal CN-16A CN-16 CAN #2 Warming up...
Page 268: Group 7 Engine Overheat Prevention System
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM Main control valve Engine Main pump Pilot pump Pump power shift EPPR Emergency warning lamp Cluster Hydraulic temp signal Hydraulic temp sensor Drive signal Accel dial Emergency CN-16B Overheat warning signal Accel dial signal CN-16A CN-16 CAN #2...
Page 269: Group 8 Variable Power Control System
GROUP 8 NEW VARIABLE POWER CONTROL SYSTEM Travel pressure Main control valve Engine Main pump Pilot pump Pump power shift EPPR Drive signal Switch signal RH control LH control Pressure signal lever lever Pressure signal Accel dial signal CN-16A CN-16 Normal CN-16B Emergency...
Page 270: Group 9 Attachment Flow Control System
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM Attachment pilot pressure sensor Main control valve Work tool Option (Dozer) SOLENOID VALVE Option Bucket Breaker Arm 1 Arm regen Attachment Arm 2 Boom 2 conflux Attachment Boom 1 Swing safety Travel(RH) Travel(LH) Engine Pilot pump Main pump Attachment...
Page 271: Group 10 Boom Floating Control System
GROUP 10 BOOM FLOATING CONTROL SYSTEM Boom cylinder Rod pressure Head pressure Rod to tank Head to tank solenoid solenoid Boom down pilot cutoff solenoid Boom 1 spool Boom down pilot Main control valve RH control LH control lever lever Breaker Pilot pump Main pump...
Page 272: Group 11 Intelligent Power Control System
GROUP 11 INTELLIGENT POWER CONTROL SYSTEM Travel pressure Main control valve Option (Dozer) Option Bucket Arm 1 Arm regen Boom 2 Arm 2 Swing Boom 1 Travel(RH) Travel(LH) Attach flow EPPR 1 Engine Pilot pump Main pump Power boost Pump power button shift EPPR One touch...
Page 273 IPC MODE SELECTION IPC mode ON/OFF and the levels of flow rate limit can be selected at "Mode setup > IPC mode" Q(cc/rev) Balance mode IPC mode 1 Efﬁ ciency mode IPC mode 2 Pi(bar) 290F3CD311 IPC mode Description Balance mode (default) IPC mode ON, limit level 1 Efficiency mode IPC mode ON, limit level 2...
Page 274: Group 12 Anti-Restart System
GROUP 12 ANTI-RESTART SYSTEM Engine Starter Start safety relay Drive signal 300L5MS12 1. ANTI-RESTART FUNCTION After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the starter from inadvertent restarting. 5-16...
Page 275: Group 13 Self-Diagnostic System
GROUP 13 SELF-DIAGNOSTIC SYSTEM OUTLINE When any abnormality occurs in the ADVANCED CAPO system caused by electric parts malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster and also stores them in the memory. MONITORING Active fault 290F3CD120...
Page 276 3. MACHINE ERROR CODES TABLE Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.8V 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Hydraulic oil temperature display failure 2.
Page 277 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V ≤ Main Pump 1 (P1) Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage <...
Page 278 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Negative 1 Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 279 Application Diagnostic Criteria HCESPN FMI (when you had conditions mounting pressure sensor) 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement Voltage > 5.2V (when you had conditions mounting pressure sensor) 10 seconds continuous, 0.3V≤ Boom Down Pilot Press. Sensor Measurement Voltage <...
Page 280 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Swing Pilot Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 281 Application Diagnostic Criteria HCESPN FMI (Detection) (When Pump EPPR Current is more than 10 mA) 10 seconds continuous, Pump EPPR drive current < 0 mA (Cancellation) (When Pump EPPR Current is more than 10 mA) 3 seconds continuous, Pump EPPR drive current ≥10 mA (Detection) 10 seconds continuous, Pump EPPR drive current >...
Page 282 Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel EPPR Current is more than 10 mA) 10 seconds continuous, Travel EPPR drive current = 0 mA (Cancellation) (When Travel EPPR Current is more than 100 mA) 3 seconds continuous, Travel EPPR drive current ≥ 10 mA (Detection) 10 seconds continuous, Travel EPPR drive current >...
Page 283 Application Diagnostic Criteria HCESPN FMI (Detection) (When Working Cutoff Relay is Off) 10 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Working Cutoff Relay is Off) 3 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage >...
Page 284 Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel Speed Solenoid is Off) 10 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Travel Speed Solenoid is Off) 3 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage >...
Page 285 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(breaker / crusher) (Detection) (When Attachment Conflux Solenoid is Off) 10 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Attachment Conflux Solenoid is Off) 3 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage >...
Page 286 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When Attachment Safety Solenoid is Off) 10 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Attachment Safety Solenoid is Off) 3 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage >...
Page 287 Application Diagnostic Criteria HCESPN FMI (Model Parameter) mounting Reverse Cooling Fan Solenoid (Detection) (When Reverse Cooling Fan Solenoid is Off) 10 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Reverse Cooling Fan Solenoid is Off) 3 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage >...
Page 288 Application Diagnostic Criteria HCESPN FMI (Detection) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 10 seconds continuous, Attachment Flow EPPR drive current < 100 mA (Cancellation) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 3 seconds continuous, Attachment Flow EPPR drive current ≥...
Page 289 Application Diagnostic Criteria HCESPN FMI (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement Voltage > 5.2V (Mounting pressure sensor) 10 seconds continuous, 0.3V≤ Boom Cylinder Rod Press. Sensor Measurement Voltage < 0.8V (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement Voltage <...
Page 290 Application Diagnostic Criteria HCESPN FMI Mounting pressure sensor (HCESPN 128 or 205) (Detection) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 10 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 3 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage >...
Page 291 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 10 seconds continuous, ATT Relief Setting EPPR 2 drive current = 0 mA (Cancellation) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 3 seconds continuous, ATT Relief Setting EPPR 2 drive current ≥...
Page 292 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Transmission Oil Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 293 Application Diagnostic Criteria HCESPN FMI (Detection) (When Parking Relay is Off) 10 seconds continuous, Parking Relay drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Parking Relay is Off) 3 seconds continuous, Parking Relay drive unit Measurement Voltage > 3.0V (Detection) (When Parking Relay is On) 10 seconds continuous, Parking Relay drive current >...
Page 294 Application Diagnostic Criteria HCESPN FMI (Detection) (When Ram Lock Solenoid is Off) 10 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Ram Lock Solenoid is Off) 3 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage > 3.0V (Detection) (When Ram Lock Solenoid is On) 10 seconds continuous, Ram Lock Solenoid drive current >...
Page 295 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Travel Forward Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 296 Application Diagnostic Criteria HCESPN FMI (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage > 5.2V (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Acc. Dial Voltage display failure 2.
Page 297 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, ECM Communication Data Error (Results / Symptoms) 1. Control Function – ECM operation failure (Checking list) 1. CN-93 (#22) – CN-51 (#21) Checking Open/Short 2. CN-93 (#46) – CN-51 (#31) Checking Open/Short (When mounting the I/O Controller 1) 60 seconds continuous, I/O Controller 1 Communication Data Error (Results / Symptoms)
Page 298 Application Diagnostic Criteria HCESPN FMI (When mounting the AAVM) 60 seconds continuous, AAVM communication Data Error (Results / Symptoms) 1. Control Function – AAVM operation failure (Checking list) 1. CN-401 (#86) – CN-51 (#22) Checking Open/Short 2. CN-401 (#87) – CN-51 (#32) Checking Open/Short 60 seconds continuous, RDU communication Data Error (Results / Symptoms) 1.
Page 299 4. ENGINE FAULT CODE J1939 Code Description Refer to Procedure Engine Exhaust Gas Recirculation Valve Position 27-3 Valve Position Sensor - Test Sensor : Voltage Above Normal Engine Exhaust Gas Recirculation Valve Position 27-4 Valve Position Sensor - Test Sensor : Voltage Below Normal Accelerator Pedal Position 2 : Erratic, Intermittent, or 29-2 Throttle Switch Circuit - Test...
Page 300 J1939 Code Description Refer to Procedure 100-1 Engine Oil Pressure : Low - most severe (3) Low Engine Oil Pressure Engine Pressure Sensor Open or Short 100-3 Engine Oil Pressure : Voltage Above Normal Circuit - Test Engine Pressure Sensor Open or Short 100-4 Engine Oil Pressure : Voltage Below Normal Circuit - Test...
Page 301 J1939 Code Description Refer to Procedure Engine Coolant Temperature : Engine Temperature Sensor Open or Short 110-4 Voltage Below Normal Circuit - Test (Passive Sensors) Engine Coolant Temperature : 110-15 Coolant Temperature Is Too High High - least severe (1) Engine Coolant Temperature : 110-16 Coolant Temperature Is Too High...
Page 302 J1939 Code Description Refer to Procedure Engine Speed : Abnormal Frequency, Pulse Width 190-8 Engine Speed/Timing Sensor Circuit - Test or Period 190-15 Engine Speed : High - least severe (1) Engine Overspeeds Engine Exhaust Gas Recirculation Differential 411-3 Sensor Signal (Analog, Active) - Test Pressure : Voltage Above Normal Engine Exhaust Gas Recirculation Differential 411-4...
Page 303 J1939 Code Description Refer to Procedure Engine Injector Cylinder #01 : Current Below 651-5 Injector Solenoid Circuit - Test Normal Engine Injector Cylinder #01 : Current Above 651-6 Injector Solenoid Circuit - Test Normal Engine Injector Cylinder #02 : Erratic, Intermittent or 652-2 Injector Data Incorrect - Test Incorrect...
Page 304 J1939 Code Description Refer to Procedure Engine Speed Sensor #2 : Abnormal Frequency, 723-8 Engine Speed/Timing Sensor Circuit - Test Pulse Width or Period Engine Electric Lift Pump For Engine Fuel Supply : 1075-5 Fuel Pump Relay Circuit - Test Current Below Normal Engine Electric Lift Pump For Engine Fuel Supply : 1075-6...
Page 305 J1939 Code Description Refer to Procedure Engine Exhaust Gas Recirculation (EGR) Valve 2791-7 Motorized Valve - Test Control : Not Responding Properly Engine Alternate Rating Select : Erratic, Intermittent, 2882-2 Mode Selection Circuit - Test or Incorrect Accelerator Pedal 2 Low Idle Switch : Erratic, 2970-2 Idle Validation Switch Circuit - Test Intermittent, or Incorrect...
Page 306 J1939 Code Description Refer to Procedure Particulate Trap Intake Gas Temperature : Low - 3242-17 Diesel Particulate Filter Temperature Is High least severe (1) Particulate Trap Intake Gas Temperature : Low - 3242-18 Diesel Particulate Filter Temperature Is Low moderate severity (2) Engine Exhaust Gas Recirculation Inlet Pressure : Engine Pressure Sensor Open or Short 3358-3...
Page 307 J1939 Code Description Refer to Procedure Aftertreatment #1 DEF/AdBlue® Concentration : 3516-12 DEF/AdBlue® Concentration Is Incorrect Failure Aftertreatment #1 DEF/AdBlue® Concentration : 3516-16 DEF/AdBlue® Concentration Is Incorrect High - moderate severity (2) Aftertreatment #1 DEF/AdBlue® Concentration : 3516-18 DEF/AdBlue® Concentration Is Incorrect Low - moderate severity (2) Engine Intake Manifold #1 Absolute Pressure : Engine Pressure Sensor Open or Short...
Page 308 J1939 Code Description Refer to Procedure Aftertreatment #1 SCR Catalyst Intake Gas 4360-3 Sensor Signal (Analog, Passive) - Test Temperature : Voltage Above Normal Aftertreatment #1 SCR Catalyst Intake Gas 4360-4 Sensor Signal (Analog, Passive) - Test Temperature : Voltage Below Normal Aftertreatment #1 SCR Catalyst Intake Gas SCR Catalyst Has Incorrect Inlet 4360-16...
Page 309 J1939 Code Description Refer to Procedure Diesel Particulate Filter #1 Mean Soot Signal : Data 4783-19 Soot Sensor - Test Error Diesel Particulate Filter #1 Mean Soot Signal : Data 4783-21 Soot Sensor - Test Drifted Low Engine Exhaust Gas Recirculation Outlet Pressure Engine Pressure Sensor Open or Short 5019-3 : Voltage Above Normal...
Page 310 J1939 Code Description Refer to Procedure Aftertreatment #1 Diesel Exhaust Fluid Pump 5706-6 DEF/AdBlue® Pump - Test Heater : Current Above Normal Aftertreatment #1 Intake Gas Sensor Power Supply 5758-11 Electrical Power Supply - Test : Other Failure Mode Aftertreatment #1 Outlet Gas Sensor Power Supply 5759-11 Electrical Power Supply - Test : Other Failure Mode...
Page 311 5. AAVM FAULT CODE 5. AAVM FAULT CODE Fault Code Description AAVM Communication Error -AAVM AAVM Communication Error -Front Camera AAVM Communication Error -Rear Camera AAVM Communication Error -Left Camera AAVM Communication Error -Right Camera Manual Setting Fail No MCU CID MCU CID Format Error AAVM Hardware Error -AAVM AAVM Hardware Error -Front Camera...
Page 312: Group 14 Engine Control System
GROUP 14 ENGINE CONTROL SYSTEM GROUP 14 ENGINE CONTROL SYSTEM 1. MCU and Engine ECM 1. MCU and Engine ECM (Electronic Control Module) ECM(Engine control module) Bolt (M8) 145LCR5MS01 2. MCU ASSEMBLY 2. MCU ASSEMBLY To match the pump absorption torque with the engine torque, MCU varies EPPR valve output pressure, which control pump discharge amount whenever feedbacked engine speed drops under the reference rpm of each mode set.
Page 313: Group 15 Eppr Valve
GROUP 15 EPPR VALVE GROUP 15 EPPR VALVE 1. PUMP EPPR VALVE PUMP EPPR VALVE COMPOSITION COMPOSITION EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main pump. Electro magnet valve Electro magnet valve Receive electric current from MCU and move the spool proportionally according to the specific amount of electric current value.
Page 314 OPERATING PRINCIPLE OPERATING PRINCIPLE Structure Structure 5-22(1) Sleeve O-ring Solenoid valve Spring O-ring Connector Spool Pilot oil supply line (pilot pressure) Return to tank Secondary pressure to flow regulator at main pump Neutral eutral Pressure line is blocked and A oil returns to tank.
Page 315 EPPR VALVE CHECK PROCEDURE EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA Check electric current value at EPPR valve Check electric current value at EPPR valve Adapter(P/no.:21Q6-50410) ① Disconnect connector CN-75 from EPPR valve EPPR valve. Multimeter CN-75 ② Insert the adapter to CN-75 and install multimeter as figure.
Page 316 2. BOOM PRIORITY EPPR VALVE BOOM PRIORITY EPPR VALVE COMPOSITION COMPOSITION The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil. This EPPR valve installed under the solenoid valve. 2) 2) CONTROL CONTROL The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is Ω...
Page 317 EPPR VALVE CHECK PROCEDURE EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA (combined boom up and swing operation) Check electric current value at EPPR Check electric current value at EPPR Safety solenoid valve valve valve Solenoid valve ① Disconnect connector CN-133 from EPPR valve.
Page 318: Group 16 Monitoring System
GROUP 16 MONITORING SYSTEM GROUP 16 MONITORING SYSTEM 1. OUTLINE 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine. Also, monitor part is to set and display for modes, monitoring and utilities with the switches.
Page 319 Start key : ON ① Check monitor Check monitor Buzzer sounding for 4 seconds with HYUNDAI logo on cluster. ※ If the ESL mode is set to the enable, enter the password to start engine. ② After initialization of cluster, the operating screen is displayed on the LCD.
Page 320 CLUSTER CONNECTOR CLUSTER CONNECTOR CN-56A CN-56A Name Signal Battery 24V 20~32V Power IG (24V) 20~32V CN-56B CN-56A CAN 1 (H) 0~5V CAN 1 (L) 0~5V CAN 2 (H) 0~5V CAN 2 (L) 20~32V N.C. Cluster N.C. Aux left 0~5V Aux right 0~5V Aux GND CN-56A...
Page 321 4) 4) GAUGE GAUGE (1) (1) Operation screen Operation screen When you first turn starting switch ON, the operation screen will appear. Default Option 235F3CD07 RPM / Speed gauge DEF/AdBlue® level gauge Engine coolant temperature gauge Tripmeter display Hydraulic oil temperature gauge Eco guage Fuel level gauge Accel dial gauge...
Page 322 (4) (4) Hydraulic oil temperature gauge Hydraulic oil temperature gauge ① This gauge indicates the temperature of hydraulic oil. ·White range : 40-105˚C(104-221˚F) ·Red range : Above 105˚C(221˚F) ② If the indicator is in the red range or lamp pops up and the buzzer sounds reduce the load on the system.
Page 323 (8) (8) Eco gauge Eco gauge ① This gauge indicates the fuel consumption rate and machine load status. So that operators can be careful with fuel econo- ② The fuel consumption rate or machine load is higher, the number of segment is increased. ③...
Page 324 5) 5) WARNING LAMPS WARNING LAMPS Battery charging warning lamp Air cleaner warning lamp Check engine warning lamp Overload warning lamp Engine oil pressure warning lamp Emergency warning lamp Engine stop warning lamp Engine coolant Fuel level warning lamp temperature warning lamp DEF/AdBlue level warning lamp Hydraulic oil temperature...
Page 325 (1) (1) Engine coolant temperature warning lamp Engine coolant temperature warning lamp ① Engine coolant temperature warning is indicated two steps. 103˚C over : The lamp pops up and the buzzer sounds. 107˚C over : The lamp pops up and the buzzer sounds. ②...
Page 326 (5) (5) Engine oil pressure warning lamp Engine oil pressure warning lamp ① This warning lamp pops up and the buzzer sounds when the engine oil pressure is low. ② If the lamp blinks, shut OFF the engine immediately. Check oil level.
Page 327 (10) (10) Engine stop warning lamp Engine stop warning lamp ① This warning lamp pops up and the buzzer sounds when 30 minutes elapsed with empty condition of the DEF/AdBlue® tank, stop the engine immediately and check the DEF/ AdBlue® tank. ②...
Page 328 (11) (11) DEF/AdBlue® level warning lamp DEF/AdBlue® level warning lamp ① This warning lamp indicates when ON, that the DEF/AdBlue® level is low as table below. ※ It is recommended that the DEF/AdBlue® tank be filled It is recommended that the DEF/AdBlue® tank be filled completely full of the DEF/AdBlue®...
Page 329 PILOT LAMPS Warming up pilot lamp Decel pilot lamp Preheat pilot lamp Power max pilot lamp Fuel warmer pilot lamp Maintenance pilot lamp Power/User mode pilot mode lamp Auto idle pilot lamp Work tool mode pilot lamp Travel speed pilot lamp Smart key pilot lamp Entertainment pilot lamp Entertainment pilot lamp...
Page 330 Preheat pilot lamp Preheat pilot lamp (3) (3) ① Turning the start key switch ON position starts preheating in cold weather. ② Start the engine after this lamp is OFF. 290F3CD79 (4) (4) Warming up pilot lamp Warming up pilot lamp ①...
Page 331 (8) (8) Entertainment pilot lamp Entertainment pilot lamp ① This lamp is on when audio or video files are playing. ※ Refer to the page 5-89. Refer to the page 5-89. 290F3CD84 (9) (9) Smart key pilot lamp Smart key pilot lamp (opt) ①...
Page 332 5) 5) SWITCHES SWITCHES Entertainment quick touch switch Main menu quick touch switch Work mode Travel speed pilot lamp pilot lamp Auto idle pilot lamp Power/User mode pilot lamp User mode switch Travel speed switch Auto idle/Buzzer stop switch Power mode switch Escape(previous or parent menu) Work mode switch Rear camera(option)
Page 333 (3) (3) User mode switch User mode switch ① This switch is used to memorize the current machine operating status in the MCU and activate the memorized user mode. ·Memory : Push more than 2 seconds. ·Action : Push within 2 seconds. ·Cancel : Push this switch once more within 2 seconds.
Page 334 (8) (8) Head light switch Head light switch ① This switch is used to operate the head light. ② The pilot lamp is turned ON when operating the switch. 290F3CD94 (9) (9) Intermittent wiper switch Intermittent wiper switch ① This switch is used to wipe operates intermittently. ②...
Page 335 (13) (13) Beacon switch eacon switch ① This switch turns ON the rotary light on the cab. ② The pilot lamp is turned ON when operating the switch. 290F3CD97 (14) (14) Overload switch verload switch ① When this switch turned ON, buzzer makes sound and over- load warning lamp comes ON in case that the machine is overload.
Page 336 MAIN MENU You can select or set the menu by touch screen. On the operation screen, tap MENU to access the main menu screen. On the sub menu screen, you can tap the menu bar to access functions or applications. Operation screen Main menu screen Sub menu screen...
Page 337 (2) (2) Mode setup Mode setup ① Work tool Work tool 290F3CD108 290F3CD253 290F3CD254 · Select on installed optional attachment A : It can set the user's attachment. It is available in setting #1~#10. B : Max ﬂ ow - Set the maximum ﬂ ow for the attachment. Relief pressure - Set the relief pressure.
Page 338 Auto power boost 210WF3CD118 290F3CD117 The power boost function can be activated or cancelled. Enable - The digging power is automatically increased as working conditions by the MCU. It is operated max 8 seconds. Disable - Not operated. 290F3CD310 290F3CD311 290F3CD304 290F3CD312 290F3CD305...
Page 339 Automatic engine shutdown (option) 210WF3CD11 210WF3CD12 210WF3CD13 The automatic engine shutdown function can be set by this menu. One time Always Disable Wait time setting : Max 40 minutes, min 2 minutes Initial mode 290F3CD122 290F3CD119 Key on initial mode Selected the power mode is activated when the engine is started.
Page 340 (3) (3) Monitoring Monitoring ① Active fault Active fault 290F3CD120 290F3CD121 290F3CD125 · The active faults of the MCU, engine ECM or air conditioner can be checked by this menu. ② Logged fault Logged fault 290F3CD128 290F3CD123 290F3CD124 · The logged faults of the MCU, engine ECM or air conditioner can be checked by this menu. ③...
Page 341 (4) (4) Management Management ① Fuel rate information Fuel rate information 210WF3CD14 210WF3CD15 ·General record (A) General record (A) Average fuel rate (left) (from "Reset" to now) Fuel consumption devided by engine run time (service meter time). A days fuel used (right) Fuel consumption from 24:00 (or "Reset"...
Page 342 Maintenance information 290F3CD131 290F3CD132 290F3CD133 Alarm lamp ( ) is ON when oil or ﬁ lter needs to be changed or replaced. Replacement : The elapsed time will be reset to zero (0). Change interval : The change or replace interval can be changed in the unit of 50 hours. Change or relpace interval Item Interval...
Page 343 ③ Machine security Machine security 290F3CD190 290F3CD135 290F3CD136 · ESL mode setting ESL mode setting ESL : Engine Starting Limit ESL mode is desingned to be a theft deterrent or will pre- vent the unauthorized operation of the machine. If the ESL mode was selected Enable, the password will be required when the start switch is turned ON.
Page 344 Machine Information 290F3CD144 290F3CD145 This can conﬁ rm the identiﬁ cation of the model information (ECU), MCU, monitor, switch controller, RMCU, relay driver unit, FATC (air conditioner controller), AAVM (opt). Contact (A/S phone number) 290F3CD146 290F3CD147 290F3CD148 Enter the new A/S phone number Service menu 290F3CD149 145ZF3CD250...
Page 345 ⑧ Update (cluster & ETC devices) Update (cluster & ETC devices) 210WF3CD17 210WF3CD18 210WF3CD19 380F3CD06 380F3CD04 · ETC devices and cluster can be updated through CAN 2 network. · Insert USB memory stick which includes program ﬁ les, start download. 5-86...
Page 346 (5) (5) Display Display ① Display item Display item 290F3CD154 290F3CD155 290F3CD156 · The center display type of the LCD can be selected by this menu. · The engine speed or each of the tripmeter (A,B,C) is displayed on the center display. ②...
Page 347 ④ Unit Unit 290F3CD161 290F3CD162 290F3CD193 Temperature : ˚C ↔ ˚F · : bar ↔ MPa ↔ kgf/cm · Pressure : l ↔ gal · Volume : lpm ↔ gpm · Flow : km ↔ mile · Distance Date format : yy/mm/dd ↔ mm/dd/yy ↔ dd-mm-yy ·...
Page 348 (6) (6) Utilities Utilities ① Entertainment Entertainment 290F3CD195 290F3CD196 210WF3CD219 290F3CD197 210WF3CD220 290F3CD198 210WF3CD199 210WF3CD22 Video (A) : This menu operates the video play function. mp4, mkv, avi ﬁ les and so on. Audio (B) : This menu operates the play music. mp3, mp4 ﬁ...
Page 349 ② Tripmeter Tripmeter 290F3CD168 290F3CD169 · Maximum 3 kinds of tripmeters can be used at the same time. · Each tripmeter can be turned on by choosing "Start" while it also can be turned off by choosing "Stop". · If the tripmeter icon is activated in the operation screen, it can be controlled directly there. ③...
Page 350 3. AIR CONDITIONER AND HEATER 3. AIR CONDITIONER AND HEATER Full auto air conditioner and heater system automatically keeps the optimum condition in accordance with operator's temperature configuration sensing ambient and cabin inside temperature. · Location of air flow ducts Location of air flow ducts Switch panel Fresh air switch...
Page 351 1) 1) POWER OFF SWITCH POWER OFF SWITCH This switch makes the system and the LED OFF. Just before the power OFF, set values are stored. (2) (2) Default setting values Default setting values Function Air conditioner In/outlet Temperature Mode Value Inlet Previous sw OFF...
Page 352 5) 5) TEMPERATURE CONTROL SWITCH TEMPERATURE CONTROL SWITCH Setting temperature indication ① Type A : 17~32˚C, scale : 1˚C ② Type B : Lo, 18~31˚C, Hi, scale : 1˚C Max cool and max warm beeps 5 times. The max cool or the max warm position operates as following table. 370074CD57 Temperature Compressor...
Page 353 8) 8) SELF DIAGNOSIS FUNCTION SELF DIAGNOSIS FUNCTION (1) (1) Procedure Procedure Starting switch ON Press the air recirculation button over 5 times within 2 seconds during pressing the AUTO switch All symbol of LCD blink 5 times Switch OFF Error check System OFF Press AUTO switch...
Page 354: Group 17 Fuel Warmer System
GROUP 17 F GROUP 17 FUEL WARMER SYSTEM UEL WARMER SYSTEM 1. S 1. SPECIFICATION PECIFICATION Operating voltage : 24±4 V Power : 350±50 W Current : 15 A Filter head & 2. O 2. OPERATION PERATION fuel warmer T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s automatically controlled without thermostat according to fuel temperature.
Page 355: Section 6 Troubleshooting
SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1 Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4 Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24 Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-40...
Page 356: Group 1 Before Trobleshooting
SECTION 6 TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help service men repair the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics system.
Page 357 2. DIAGNOSING PROCEDURE To carry out troubleshooting efficiently, the following steps must be observed. STEP 1. Study the machine system Study and know how the machine is operating, how the system is composing, what kinds of function are installed in the machine and what are specifications of the system components by the machine service manual.
Page 358 STEP 4. Inspect the trouble actually on the machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not. (210-7) 6-3(1) STEP 5.
Page 359: Group 2 Hydraulic And Mechanical System
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION 1. INTRODUCTION MACHINE IN GENERAL MACHINE IN GENERAL If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration.
Page 360 2. DRIVE SYSTEM 2. DRIVE SYSTEM 1) 1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and Replace hub or check if rubber pieces or particles retighten...
Page 361 2) 2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard Is oil level in level. Abnormal noise hydraulic oil comes out of Hydraulic pump is Disassemble tank within...
Page 362 3. HYDRAULIC SYSTEM 3. HYDRAULIC SYSTEM 1) 1) HYDRAULIC OIL IS CLOUDY HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and Drop hydraulic oil dispose it or sample on hot plate and check if replace hydraulic foams come up.
Page 363 CAVITATION OCCURS WITH PUMP CAVITATION OCCURS WITH PUMP Cause Remedy Replenish specified oil to the standard level. Is hydraulic oil volume proper? Replace oil with one of proper Is not viscosity viscosity. of hydraulic oil too high? Clean suction strainer. Is not suction strainer clogged? Is not air intruding...
Page 364 4. SWING SYSTEM 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish Does safety ⓐ specified oil to the solenoid valve standard level. operation Safety solenoid Repair or replace. Is gear pump pilot normal? pressure within...
Page 365 SWING SPEED IS LOW SWING SPEED IS LOW Cause Remedy Swing port relief Disassemble and Does swing spool valve is faulty. repair or replace. move? Swing control valve Disassemble Is MCV pilot spool is stuck. and repair. pressure same on LH and RH Clogged or oil Clean pilot piping sides?
Page 366 3) 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble change when LH valve is faulty. and repair. and RH port relief valves are exchanged? Shuttle valve is Disassemble Does swing control faulty.
Page 367 5) 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy ⓐ Is swing shuttle valve normal? Shuttle valve is Disassemble faulty.
Page 368 5. TRAVEL SYSTEM 5. TRAVEL SYSTEM 1) 1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause Remedy ⓐ Does counterbalance spool move lightly by hand? Counter spool is Disassemble Is travel brake valve pressure stuck.
Page 369 2) 2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble Do LH and RH defective. and repair or travel speeds replace. change when LH and RH travel Relief valve built Disassemble...
Page 370 3) 3) MACHINE DOES NOT STOP ON A SLOPE MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None Friction plate is Disassemble friction plate worn? Check if parking faulty.
Page 371 5) 5) TRAVEL ACTION IS POWERLESS TRAVEL ACTION IS POWERLESS (travel only) Cause Remedy ⓐ Is travel motor's drain rate within standard level? Is travel brake Travel motor is Disassemble pressure within faulty. and repair. standard level? Is travel relief Travel brake valve Disassemble valve pressure...
Page 372 7) 7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal.
Page 373 6. ATTACHMENT SYSTEM 6. ATTACHMENT SYSTEM 1) 1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace.
Page 374 2) 2) BOOM, ARM OR BUCKET SPEED IS LOW BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. ⓐ Are other attachment speeds within Is combination ⓑ Is speed low only standard levels? of oil streams in composite normal at boom operation? Replace spring up and at arm...
Page 375 3) 3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the symptom faulty. and repair or change when port replace.
Page 376 4) 4) BOOM, ARM OR BUCKET POWER IS WEAK BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder in Item "Speed is internal leakage within standard low". level? Is relief pressure in port relief Cylinder is faulty.
Page 377 6) 6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom Is boom foot pin greased proper.
Page 378 ※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full. 145ZF6TS01 Disconnect hose (A) from rod side of boom cylinder and drain oil from cylinders and hose.
Page 379: Group 3 Electrical System
GROUP 3 ELECTRICAL SYSTEM GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 380 COMMUNICATION ERROR FLASHES ON THE CLUSTER COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective cluster...
Page 381 BATTERY CHARGING WARNING LAMP LIGHTS UP BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU...
Page 382 WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 383 WHEN AIR CLEANER WARNING LAMP LIGHTS UP WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 384 WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 385 7. 7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 386 8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE 8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
Page 387 9. WHEN FUEL GAUGE DOES NOT OPERATE 9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 388 10. WHEN SAFETY SOLENOID DOES NOT OPERATE 10. WHEN SAFETY SOLENOID DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 26. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 389 11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE 11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 390 12. WHEN ENGINE DOES NOT START 12. WHEN ENGINE DOES NOT START ( lights up condition) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 391 13. WHEN STARTING SWITCH ON DOES NOT OPERATE 13. WHEN STARTING SWITCH ON DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted, master switch ON and check open circuit of circuit breaker (CN-60, CN-95).
Page 392 14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE 14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse CN-21 No.
Page 393 15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP 15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.16.
Page 394 16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP 16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.17.
Page 395: Group 4 Mechatronics System
GROUP 4 MECHATRONICS SYSTEM GROUP 4 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW 1. ALL ACTUATORS SPEED ARE SLOW ※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. ※ Spec : P-mode 1850 ± 50 rpm 1750 ±...
Page 396 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : 15~25Ω(20˚C) (1) (1) Test 1 Test 1 : Check resistance at connector CN-75 EPPR valve CN-75. ① Starting switch OFF. ② Disconnect connector CN-75 from EPPR Multimeter valve at main hydraulic pump. Valve casing ③...
Page 397 2. ENGINE STALL 2. ENGINE STALL ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Not enough Check engine engine power fault Check pressure Contact cummins at EPPR valve Defective EPPR Replace SPEC:2~25 kgf/cm...
Page 398 2) 2) TEST PROCEDURE TEST PROCEDURE Spec : 100~700 mA Test 4 Test 4 : Check electric current at EPPR (1) (1) Adapter(P/no.:21Q6-50410) valve. EPPR valve ① Disconnect connector CN-75 from EPPR Multimeter CN-75 valve. ② Insert the adapter to CN-75 and install multimeter as figure.
Page 399 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse No.8 the MCU See if all lamps...
Page 400 4. AUTO DECEL SYSTEM DOES NOT WORK 4. AUTO DECEL SYSTEM DOES NOT WORK · Fault code : HCESPN 105, FMI 0~4 (work pressure sensor) HCESPN 108, FMI 0~4 (travel oil pressure sensor) ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE...
Page 401 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 7 Test 7 : Check voltage at CN-52 (38) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of CN-51 CN-52 connectors : One pin to (38) of CN-52.
Page 402 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR · Fault code : HCESPN 120, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy...
Page 403 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 9 Test 9 : Check voltage at CN-52 (29) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (29) of CN-52.
Page 404 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR · Fault code : HCESPN 121, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy...
Page 405 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 10 : Check voltage at CN-52 (12) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (12) of CN-52.
Page 406 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
Page 407 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 11 Test 11 : Check voltage at CN-52 (32) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (32) of CN-52.
Page 408 8. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR 8. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR · Fault code : HCESPN 123, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy...
Page 409 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 12 Test 12 : Check voltage at CN-52 (33) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (33) of CN-52.
Page 410 9. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR 9. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR · Fault code : HCESPN 124, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy...
Page 411 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 13 Test 13 : Check voltage at CN-52 (17) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (17) of CN-52.
Page 412 10. MALFUNCTION OF SWING PRESSURE SENSOR 10. MALFUNCTION OF SWING PRESSURE SENSOR · Fault code : HCESPN 135, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Defective MCU...
Page 413 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 14 : Check voltage at CN-52 (36) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (36) of CN-52.
Page 414 11. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR 11. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR · Fault code : HCESPN 133, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE INSPECTION PROCEDURE 1) 1)
Page 415 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 15 Test 15 : Check voltage at CN-52 (14) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (14) of CN-52.
Page 416 12. MALFUNCTION OF BOOM UP PRESSURE SENSOR 12. MALFUNCTION OF BOOM UP PRESSURE SENSOR · Fault code : HCESPN 127, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy...
Page 417 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 16 Test 16 : Check voltage at CN-52 (19) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (19) of CN-52.
Page 418 13. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR 13. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR · Fault code : HCESPN 128, FMI 0~4 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy...
Page 419 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 17 Test 17 : Check voltage at CN-53 (23) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (23) of CN-53.
Page 420 14. MALFUNCTION OF POWER MAX 14. MALFUNCTION OF POWER MAX · Fault code : HCESPN 166, FMI 4 or 6 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Short circuit or poor...
Page 421 TEST PROCEDURE TEST PROCEDURE 2) 2) SPEC : Starting switch ON : 24±1V Starting switch OFF : 0V (1) (1) Test 18 Test 18: Check voltage between connector CN-88 (2) - GND. ① Disconnect connector CN-88 from power max solenoid valve. Power max switch ②...
Page 422 15. MALFUNCTION OF 15. MALFUNCTION OF BOOM PRIORITY EPPR VALVE BOOM PRIORITY EPPR VALVE · Fault code : HCESPN 141, FMI 5 or 6 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause...
Page 423 16. MALFUNCTION OF ARM 16. MALFUNCTION OF ARM REGENERATION SOLENOID REGENERATION SOLENOID · Fault code : HCESPN 170, FMI 4 or 6 ※ Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy...
Page 424 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Starting switch ON : 24±2 V Test 20 Test 20 : Check voltage at CN-52 (1) and ground. ① Prepare 1 piece of thin sharp pin, steel or copper. ② Insert prepared pin to rear side of connectors : One pin to (1) of CN-52.
Page 425: Section 7 Maintenance Standard
SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1 Group 2 Major Components -------------------------------------------------------------------------------------------- 7-21 Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-32...
Page 426: Group 1 Operational Performance Test
NEW MACHINE Whenever a new machine is delivered in parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec. Working condition OPERATIONAL PERFORMANCE OF A WORKING MACHINE...
Page 427 2. TERMINOLOGY STANDARD Specifications applied to the brand-new machine, components and parts. 145ZF7MS02 SERVICE LIMIT The lowest acceptable performance level. When the perfor mance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
Page 428 3. OPERATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. The machine Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. Test area Select a hard, flat surface.
Page 429 Engine speed Standard Remarks Start idle 1000 100 P mode 1850 50 S mode 1750 50 HX145CR HX145LCR E mode 1650 50 Auto decel 1100 100 One touch decel 1000 100 Condition : Set the accel dial at 10 (Max) position.
Page 430 Evaluation The average measured time should meet the following specifications. Unit : Seconds / 20 m Model Travel speed Standard Maximum allowable Remarks 1 Speed 22.5 2.0 28.1 HX145CR HX145LCR 2 Speed 13.3 1.0 16.6...
Page 431 Evaluation The revolution cycle time of each track should meet the following specifications. Unit : Seconds / 3 revolutions Model Travel speed Standard Maximum allowable 1 Speed 26.1 2.0 32.6 HX145CR HX145LCR 2 Speed 15.2 2.0...
Page 432 180 and measure that in reverse travel. (210-7) 7-7(2) Repeat steps three times and calculate the average values. Evaluation Mistrack should be within the following specifications. Unit : mm / 20 m Model Standard Maximum allowable Remarks HX145CR 200 below HX145LCR...
Page 433 Repeat steps three time and calculate the average values. Evaluation The time required for 3 swings should meet the following specifications. Unit : Seconds / 3 revolutions Model Power mode switch Standard Maximum allowable HX145CR P mode 16 1.5 HX145LCR...
Page 434 Repeat steps three times each and calculate the average values. 145ZF7MS08 Evaluation The measured drift angle should be within the following specifications. Unit : Degree Model Power mode switch Standard Maximum allowable Remarks HX145CR P mode 90 below 157.5 HX145LCR...
Page 435 Record the dial gauge reading (h2). Calculate bearing play (H) from this data (h1 and h2) as follows. H=h2-h1 Evaluation 145ZF7MS09 The measured drift should be within the following specifications. Unit : mm Model Standard Maximum allowable Remarks HX145CR 0.5 ~ 1.5 HX145LCR 7-10...
Page 436 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. Preparation Boom cylinder To measure the cycle time of the boom cylinders: Raise With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown.
Page 437 Unit : Seconds Maximum Function Standard Model Remarks allowable Boom raise 4 0.4 Boom lower 3.3 0.4 Regen ON 2.8 0.4 HX145CR Arm in Regen OFF 3.2 0.4 HX145LCR Arm out 2.8 0.3 Bucket in 3.5 0.4 Bucket out 2.2 0.3 7-12...
Page 438 The measured drift should be within the following specifications. Unit : mm / 5min Model Drift to be measured Standard Maximum allowable Remarks Boom cylinder 10 below HX145CR Arm cylinder 10 below HX145LCR Bucket cylinder 40 below 7-13...
Page 439 Unit : kgf Model Kind of lever Standard Maximum allowable Remarks Boom lever 1.3 or below Arm lever 1.3 or below HX145CR Bucket lever 1.3 or below HX145LCR Swing lever 1.3 or below Travel lever 2.1 or below 3.15 7-14...
Page 440 The measured drift should be within the following specifications. Unit : mm Model Kind of lever Standard Maximum allowable Remarks Boom lever 90 10 Arm lever 90 10 HX145CR Bucket lever 90 10 HX145LCR Swing lever 90 10 Travel lever 142 10 7-15...
Page 441 Measure the primary pilot pressure by the monitoring menu of the cluster. Cluster 145ZF7MS12 Evaluation The average measured pressure should meet the following specifications: Unit : kgf / cm Model Engine speed Standard Allowable limits Remarks HX145CR P mode HX145LCR 7-16...
Page 442 Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Travel speed mode Standard Maximum allowable Remarks 1 Speed HX145CR HX145LCR 2 Speed 40 5 7-17...
Page 443 Repeat step three times and calculate the average values. Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Description Standard Allowable limits Remarks Brake disengaged Over 9 HX145CR HX145LCR Brake applied 7-18...
Page 444 Measure the main pump deliver y pressure in the P mode (high idle). Cluster 145ZF7MS15 Evaluation The average measured pressure should meet the following specifications. Unit : kgf / cm Model Engine speed Standard Allowable limits Remarks HX145CR High idle HX145LCR 7-19...
Page 445 The average measured pressure should be within the following specifications. Unit : kgf / cm Model Function to be tested Standard Port relief setting at 20 lpm Boom, Arm, Bucket 350 (380) 10 400 10 HX145CR Travel 350 10 HX145LCR Swing 285 10 ) : Power boost 7-20...
Page 446: Group 2 Major Components
GROUP 2 MAJOR COMPONENT GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 1. MAIN PUMP 140Z97MP01 Recommended Standard Part name & inspection item replacement Counter measures dimension value Clearance between piston (1) & Replace piston or 0.032 0.056 cylinder bore (2) cylinder.
Page 447 2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE Part name Inspection item Criteria & measure · Existence of scratch, rusting or corrosion. · In case of damage in following section, replace Casing part. - Sliding sections of casing fore and spool, especially land sections applied with holded pressure.
Page 448 3. SWING DEVICE 3. SWING DEVICE WEARING PARTS WEARING PARTS 1) 1) Recommended Standard Inspection item replacement Counter measures dimension value Replace piston or Clearance between piston and cylinder block bore 0.041 0.060 cylinder block Thickness of valve plate 5.88 Replace Replace assembly Play between piston and shoe caulking section (δ)
Page 449 4. TRAVEL MOTOR 4. TRAVEL MOTOR 1) 1) TYPE 1 TYPE 1 Problem Cause Remedy · · Does not Pressure is not Pump failure Check if action other than traveling is start developed available. If faulty, repair. · · Control valve malfunction Check if spool moves correctly.
Page 450 2) 2) TYPE 2 TYPE 2 Troubleshooting Troubleshooting ① The motor does not rotate The motor does not rotate Problem Cause Remedy The pressure of a motor · The oil is bypassed at relief valve - Fix or exchange relief valve does not increase ·...
Page 451 ④ Shortage of rotating force at the standard value Shortage of rotating force at the standard value Problem Cause Remedy Brake is released, but the · Excavator main relief valve is not set - Resetting the main relief valve turning force is low correctly ·...
Page 452 Wearing parts Wearing parts Recommended Standard Part name & inspection item value for Remedy dimension replacement Piston and cylinder block bore tolerance D : Cylinder block bore dia 0.05 mm 0.065 mm ( space = D – d ) d : Piston out dia After pulling the piston Piston and shoe tolerance ( space = k ) 0.3 mm...
Page 453 5. RCV LEVER 5. RCV LEVER Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage becomes Conditions : more than 1000 cc/m at neutral handle position, or more Primary pressure : 40 kgf/cm than 2000 cc/m during operation. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has worn...
Page 454 6. RCV PEDAL 6. RCV PEDAL Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage effect Conditions : to the system. For example, the primary pressure Primary pressure : 40 kgf/cm drop. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has...
Page 455 7. TURNING JOINT 7. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination. Replace sealing sections. ·Worn abnormality or damaged more than 0.1 mm Sliding surface Replace between body and (0.0039 in) in depth due to seizure contamination.
Page 456 8. CYLINDER 8. CYLINDER Inspecting section Inspection item Part name Remedy ·Neck of rod pin ·Presence of crack ·Replace Piston rod ·Weld on rod hub ·Presence of crack ·Replace · Stepped part to which piston ·Presence of crack ·Replace is attached. ·Threads ·Presence of crack ·Recondition or replace...
Page 457: Group 3 Track And Work Equipment
GROUP 3 TRACK AND WORK EQUIPMENT GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK 1. TRACK 1) 1) TRACK ROLLER TRACK ROLLER 21037MS01 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø190 Rebuild or Ø150 Ø138 Outside diameter of tread...
Page 458 2) 2) CARRIER ROLLER CARRIER ROLLER 21037MS02 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø175 Rebuild or Ø151 Ø141 Outside diameter of tread replace Width of tread 37.25 42.25 Width of flange 18.25 Standard size &...
Page 459 3) 3) IDLER IDLER 21037MS03 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø552 Ø507 Ø497 Outside diameter of tread Rebuild or replace Width of protrusion Total width Width of tread Standard size & Tolerance Standard Clearance clearance...
Page 460 4) 4) TRACK TRACK 21037MS04 Unit : mm Check item Criteria Remedy Standard size Repair limit Turn or Link pitch replace 171.45 175.65 Ø53.75 Ø43.95 Outside diameter of bushing Rebuild or Height of grouser replace Height of link 94.5 86.5 Tightening torque Initial tightening torque : 42±4 kgf·m Retighten...
Page 461 5) 5) TRACK FRAME AND RECOIL SPRING TRACK FRAME AND RECOIL SPRING 21037MS05 Unit : mm Check item Criteria Remedy Standard size Tolerance Repair limit Track frame Vertical width of idler guide Rebuild or Idler support - 0.5 replace Track frame Horizontal width of idler guide Idler support Standard size...
Page 462 2. WORK EQUIPMENT 2. WORK EQUIPMENT 145ZF7MS20 Unit : mm Bushing Remedy Measuring point Normal Recomm. Recomm. Mark & Limit Limit (Pin and Bushing) service value service Remark of use of use limit limit Boom Rear 68.5 70.5 Replace 〃 Boom Cylinder Head 68.5 70.5...
Page 463: Section 8 Disassembly And Assembly
SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 8-1 Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 8-4 Group 3 Pump Device ------------------------------------------------------------------------------------------------------ 8-7 Group 4 Main Control Valve -------------------------------------------------------------------------------------------- 8-32 Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 8-46 Group 6 Travel Device ------------------------------------------------------------------------------------------------------ 8-92 Group 7 RCV Lever ---------------------------------------------------------------------------------------------------------- 8-178 Group 8 Turning Joint ------------------------------------------------------------------------------------------------------- 8-192 Group 9 Boom, Arm, Bucket and Dozer Cylinders ------------------------------------------------------- 8-197...
Page 464: Group 1 Precaution
SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
Page 465 2. INSTALL WORK Tighten all bolts and nuts (sleeve nuts) to the specified torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive.
Page 466 3. COMPLETING WORK If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Page 467: Group 2 Tightening Torque
GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf m lbf ft Engine mounting bolt (engine-bracket, FR) 1.75 12.3 Engine mounting bolt (engine-bracket, RR) 1.75 12.3 Engine mounting bolt (bracket-frame, FR) 28.9 Engine Engine mounting bolt (bracket-frame, RR) 28.9 Radiator mounting bolt 29.7...
Page 468 2. TORQUE CHART 2. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
Page 469 PIPE AND HOSE (FLARE TYPE) kgf m lbf ft Thread size (PF) Width across flat (mm) 28.9 1/4" 36.2 3/8" 68.7 1/2" 3/4" 1" 1-1/4" PIPE AND HOSE (ORFS TYPE) Thread size (UNF) Width across flat (mm) kgf m lbf ft 9/16-18 28.9 11/16-16...
Page 470: Group 3 Pump Device
GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 471 INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level. Bleed the air from the hydraulic pump. Remove the air vent plug (2EA).
Page 472 2. MAIN PUMP STRUCTURE (1/2) 533 789 733 732 532 214 548 531 702 792 534 901 808 954 724 717 723 402 151 981 983 140Z92MP02 111 Drive shaft (F) 272 Pump casing (R) 711 O-ring 113 Drive shaft (R) 312 Valve block 717 O-ring 116 1st Gear...
Page 473 STRUCTURE (2/2) 711 326 728 125 468 118 825 04 FRONT SIDE REAR SIDE 140Z92MP03 04 Gear pump 128 Bearing spacer 711 O-ring 115 Shaft 262 Cover 728 O-ring 117 Gear No. 2 326 Gear case 825 Retainer ring 118 Gear No. 3 414 Hexagon socket bolt 826 Retainer ring 125 Ball bearing...
Page 474 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug ROH / VP / UNF Hexagon socket Name head bolt (PT thread) plug (PF screw) head setscrew BP-1/16...
Page 475 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug (material : S45C) PT1/16 0.16 Wind a seal tape 1.5 to 2...
Page 476 DISASSEMBLY Select place suitable to disassembling. Select clean place. Spread rubber sheet, cloth or so on overhaul workbench top to prevent parts from being damaged. Remove dust, rust, etc, from pump surfaces with cleaning oil or so on. Remove drain port plug (468) and drain oil pump casing (271, 272).
Page 477 Remove flange socket (435) and remove gear pump (04). 140Z98MP14 Loosen hexagon socket head bolt (401) which tighten pump casing (271, 272) and valve block (312). 140Z98MP15 Place pump horizontally on workbench with its regulator fitting surface down, and separate pump casing (271,272) from valve block (312).
Page 478 (11) Remove hexagon socket head bolts (406) and then seal cover (F, 261). In the case removing it is difficult, and hooking pull thin rod into notch, and the cover can be removed easily. Since oil seal is fitted on seal cover (F) (261), take care not to damage it at removing the cover.
Page 479 (15) Remove valve plate (313, 314) from valve block (312). These may be removed in Work 8. 140Z98MP22 If necessary, remove stopper (L) (534), Qmin. plug (533), servo piston (532) and tilting pin (531) from pump casing (271, 272), and needle bearing (124) from valve block.
Page 480 ASSEMBLY F o r r e a s s e m b l i n g r e v e r s e t h e disassembling procedures, paying attention to the following items. Do not fail to repair the parts damaged during disassembling, and repair replacement parts in advance.
Page 481 Fit tilting bush (214) of swash plate (212) to tilting pin (531), and fit swash plate (212) with shoe plate (211) to swash plate support (251) correctly. Confirm with fingers of both hands that swash plate can be removed smoothly. Apply grease to sliding sections of swash plate (212) and swash plate support (251), and drive shaft (111, 113) can be...
Page 482 Fit valve plate (313, 314) to valve block (312), spring pin (886) into pin hole. Take care not to mistake suction / delivery direction of valve plate (312). 140Z98MP28 Place pump horizontally on workbench with its regulator fitting surface down, and attach pump casing (271, 272) to valve b l o c k ( 3 1 2 ) .
Page 483 (11) Attach the PTO unit (05) by fastening the flange socket (435) to the valve block (312). 140Z98MP32 (12) In case the pump is not provided with the PTO unit (05), attach the cover (262) with the hexagon socket head cap screw (414).
Page 484 3. REGULATOR STRUCTURE (1/2) 412 753 612 897 874 874 726 646 438 730 643 708 645 728 801 924 SECTION B-B 413 496 VIEW C (FRONT) VIEW C (REAR) 079 753 755 466 755 656 496 KR76-9N01-V (FRONT) KR76-9N02-V (REAR) 753 439 SECTION E-E (REAR) 140Z92MP04...
Page 485 STRUCTURE (2/2) 653 654 734 836 651 652 601 624 629 630 628 802 623 887 757 753 627 SECTION A-A 140Z92MP05 079 EPPR valve assembly 624 Spring seat (C) 708 O-ring 412 Hexagon socket screw 625 Outer spring 724 O-ring 413 Hexagon socket screw 626 Inner spring 725 O-ring...
Page 486 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
Page 487 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug (material : S45C) PT1/16 0.16 Wind a seal tape 1 1/2 to 2...
Page 488 DISASSEMBLY Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
Page 489 After removing cover (C, 629) subassembly, take out outer spring (625), inner spring (626) and spring seat (C, 624) from compensating section. Then draw out adjusting ring (Q, 645), pilot spring (646) and spring seat (644) from pilot section. Adjusting ring (Q,645) can easily be drawn out with M4 bolt.
Page 490 (210-7) REG07 Remove lever (2, 613). Do not draw out pin (875). Work will be promoted by using pincers or so on. (210-7) REG08 (10) Draw out pin (874) and remove feedback lever (611). Push out pin (874, 4 mm in dia.) from above with slender steel bar so that it may not interfere with lever (1, 612).
Page 491 (11) Remove lever (1, 612). Do not draw out pin (875). (12) Draw out pilot piston (643) and spool (652). (13) D r a w o u t p i s t o n c a s e ( 6 2 2 ) , c o m p e n s a t i n g p i s t o n ( 6 2 1 ) a n d compensating rod (623).
Page 492 ASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following items. Always repair parts that were scored at disassembly. Get replacement parts ready beforehand. Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
Page 493 Fit feedback lever (611), matching its pin hole with pin hole in spool. Then insert pin (874). Insert pin in feedback lever a little to ease Lever (1) side Lever (2) side operation. (fulcrum plug of Take care not to mistake direction of adjusting plug side) feedback lever.
Page 494 (11) Fit set spring (655) to spool hole and put compensating piston (621) and piston case (622) into compensating hole. Fit pilot cover (641) and tighten it with hexagonal socket head screws (437, 438). (210-7) REG14 (12) Put spring seat (644), pilot spring (646) and adjusting ring (Q, 645) into pilot hole.
Page 495: Group 4 Main Control Valve
GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 496 2. STRUCTURE (1/4) 145LCR8MC04 Housing-P1 27 Regeneration block 53 Socket head bolt Spool assy-travel LH 28 Plug 56 Plain washer Spool assy-boom 1 33 Plug 58 O-ring 10 Spool assy-arm 2 41 Orifice 59 O-ring 12 Spool assy-arm regen 42 Plug 69 O-ring 14 Spool assy-bucket 45 Poppet...
Page 497 STRUCTURE (2/4) 145LCR8MC05 16 Main relief valve 42 Plug 71 O-ring 17 Overload relief valve 43 Poppet 1 72 O-ring 28 Plug 44 Poppet 2 74 Back up ring 29 Plug 59 O-ring 75 Back up ring 31 Plug 61 O-ring 76 Back up ring 32 Plug 62 O-ring...
Page 498 STRUCTURE (3/4) REAR FRONT 145LCR8MC06 Housing-P2 26 Lock valve kit-B 54 Socket head bolt Spool assy 29 Plug 55 Socket head bolt Spool assy-travel RH 30 Plug 56 Plain washer Spool assy-swing 40 Plug 57 Spring washer Spool assy-swing priority 46 Travel straight sleeve 59 O-ring Spool assy-boom 2...
Page 499 STRUCTURE (4/4) REAR HOUSING-P2 FRONT REAR HOUSING-P2 FRONT 145LCR8MC07 17 Overload relief valve 37 Plug 67 O-ring 18 Overload relief valve 43 Poppet 1 68 O-ring 21 Swing logic valve 44 Poppet 2 72 O-ring 23 ON/OFF valve-option 48 Orifice-signal 73 O-ring 28 Plug 49 Coin type filter...
Page 500 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be remove from the machine, apply caps and masking seals to all ports.
Page 501 DISASSEMBLY Disassembly of spools without holding valve Loosen hexagon socket head bolts with washer. (hexagon wrench : 5 mm) Remove the pilot cover. Pay attention not to lose the O-ring under the pilot cover. Remove the spool assembly from the body by hand slightly. When extracting each spool from its body, pay attention not to damage the body.
Page 502 Disassembly of spools with holding valve (boom 1, Arm 1 spool) Loosen hexagon socket head bolts with washer. (hexagon wrench : 5 mm) Remove the pilot cover with internal parts. Pay attention not to lose the O-ring and the poppet under the pilot cover. Pay attention not to damage the "piston A"...
Page 503 Disassembly of the holding valve Remove the pilot cover with the holding valve as described on previous page. Do not disassembled internal parts of the pilot cover. Loosen the poppet seat and remove the poppet, spring seat, spring and check. (spanner : 26 mm) Pay attention not to lose the poppet.
Page 504 Disassembly of the load check valve and the negative relief valve The load check valve Fix the body to suitable work bench. Pay attention not to damage the body. Loosen the plug (hexagon wrench : 10 mm). Remove the spring and the load check valve with pincers or magnet. The negative relief valve Loosen the socket (spanner : 32 mm).
Page 505 Disassembly of the main and overload relief valve Fix the body to suitable work bench. Remove the main relief valve. (spanner : 32 mm) Remove the overload relief valve. (spanner : 32 mm) When disassembled, tag the relief valve for identification so that they can be reassembled correctly.
Page 506 Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. Control valve Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
Page 507 ASSEMBLY General precaution In this assembly section, explanation only is shown. For further understanding, please refer to the figures shown in the previous structure & disassembly section. Pay close attention to keeping all seals free from handling damage and inspect carefully for damage before using them.
Page 508 Pilot covers Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket head bolts to the specified torque. Hexagon wrench : 5 mm Tightening torque : 1.0~1.1 kgf m (7.2~7.9 lbf ft) Confirm that O-rings have been fitted. Fit spring covers to the spring end for the spools, and tighten hexagon socket head bolts to the specified torque.
Page 509: Group 5 Swing Device
GROUP 5 SWING DEVICE GROUP 5 SWING DEVICE (TYPE 1) 1. REMOVAL AND INSTALL OF MOTOR 1. REMOVAL AND INSTALL OF MOTOR REMOVAL REMOVAL 1) 1) Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 510 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE STRUCTURE 1) 1) 3 2 11 10 1 16 19 18 44 17 36 37 44 39 40 38 18 21 20 29 30 42 25 26 24 23 47 31 46 23 24 26 25 42 VIEW X 125LCR2SM22 Casing...
Page 511 2) 2) DISASSEMBLY DISASSEMBLY For easy assembly, put motor on worktable with the spline side of shaft (3) facing downwards. ※ Lay rubber plate on worktable and take care not to damage the components. Remove snap ring (4) using snap ring plier. Disassemble level gauge assembly (41) using pipe wrench.
Page 512 Unscrew socket bolt (42) (4EA) using 12 mm hexagon wrench. 125LCR8SM07 Remove valve plate (20) from valve casing. ※ Take care not to drop the valve plate (20). 125LCR8SM08 Remove O-ring (18) from valve casing. 125LCR8SM09 Remove plug (33) using 10 mm hexagon wrench and take out anti-rotating valve assembly (32).
Page 513 Remove plug (29) (1EA), plug (27) (2EA) using 4 mm, 6 mm hexagon wrench. 125LCR8SM11 (10) Remove plug (25) using 32 mm socket wrench and separate spring ; spring (24) and check valve (23). (same for the set on opposite side) 125LCR8SM12 (11) Separate each one of O-ring (40) and spring...
Page 514 (13) Remove spring (16) (24EA) from parking piston. 125LCR8SM15 (14) Disassemble parking piston (15) from casing using air gun. 125LCR8SM16 (15) Lay casing down horizontally and remove cylinder block assembly from shaft. And remove all friction plate (13) and separator plate (14).
Page 515 (17) Remove O-ring (19) from casing. 125LCR8SM19 (18) Use a magnet to separate swash plate (7) from casing. ※ Sliding surface should be carefully treated to avoid scratches and damage. 125LCR8SM20 (19) Disassemble shaft (3) and cylinderical roller bearing (5). ※...
Page 516 3) 3) ASSEMBLY ASSEMBLY ※ Even though assembly is accomplished by reversing disassembly steps, be careful of the following. ① Repair the damaged part when disassemblying and prepare parts for exchange in advance. ② All parts should be cleaned with cleaner, dried with compressed air.
Page 517 Assemble shaft assembly in casing using urethane hammer. ※ Take care not to damage oil seal. 125LCR8SM25 Insert swash plate (7). ※ Take care not to damage sliding surface. 125LCR8SM26 After applying grease on O-ring (19), insert O-ring in casing (1). 125LCR8SM27 Assemble spring (9) (9EA) in cylinder block (8).
Page 518 Assemble ball guide (10) in cylinder block. ※ Take care not to damage sliding surface of cylinder block. 125LCR8SM29 Insert piston assembly (12) in retainer plate (11). ※ Do not mix piston with other piston (9EA/1set). ※ Spread sufficient amount of hydraulic oil on piston assembly.
Page 519 (11) Put friction plate (13) in casing. 125LCR8SM33 (12) Put separator plate (14) in casing. ※ Put friction plate and separator plate alternately. 125LCR8SM34 (13) Assemble O-ring (18) in parking piston (15). ※ Apply grease on O-ring. 125LCR8SM35 (14) Assemble parking piston (15) in casing using jig. ※...
Page 520 (15) Put spring (16) (24EA) in each hole of parking piston. 125LCR8SM37 (16) Assemble restrictor (39) in spool (36). ※ Spread loctite #242. 125LCR8SM38 (17) Place spool in casing. 125LCR8SM39 (18) Assemble spring (38) & spring seat (37) in casing. 125LCR8SM40 8-57...
Page 521 (19) Assemble plug (27) using 6 mm hexagon wrench. ※ Tightening torque : 4.5 kgf · m (32.5 lbf · ft) 125LCR8SM41 (20) Assemble plug (29) using 4 mm hexagon wrench. ※ Tightening torque : 3 kgf · m (21.7 lbf · ft) 125LCR8SM42 (21) Assemble anti-rotating valve assembly (32) in...
Page 522 (23) Caulk check valve (23) using jig. (same for the set on opposite side) 125LCR8SM45 (24) Assemble spring (24), plug (25). (in that order) (same for the set on opposite side) ※ Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8SM46 (25) Assemble spring pin (21) in valve casing using...
Page 523 (27) Apply grease on steel side of valve plate (20) to prevent plate from sliding. Assemble valve plate with the copper side facing upwards. ※ Pay attention to the assembly direction. ※ Take care not to damage sliding surface. 125LCR8SM49 (28) Assemble valve casing by matching its holes and pins of casing and parking piston.
Page 524 (31) Wrap teflon tape 2 or 3 times around the tap part of level gauge assembly (41). And assemble it using pipe wrench. 125LCR8SM53 8-61...
Page 525 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove mounting bolts (2). Remove the reduction gear assembly. Reduction gear device weight : 75 kg (165 lb) 13031GE18 INSTALL...
Page 526 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 17 24 22 125LCR2SM23 Ring gear 11 Planetary gear No. 2 21 Carrier pin No.
Page 527 DISASSEMBLY Remove the swing motor, and then place swing reduction gear on the bench. 125LCR8SM60 Disassemble sun gear No.1 (22). 125LCR8SM61 Disassemble carrier No.1 sub assembly. 125LCR8SM62 Carrier No.1 sub assy disassembly Put carrier No.1 sub assembly on the bench, then remove the snap ring (23).
Page 528 Disassemble thrust washer No.1 (upper) (32).(3 pcs) 125LCR8SM64 Disassemble planetary gear No.1 (18). (3 pcs) 125LCR8SM65 Disassemble thrust plate (24). 125LCR8SM66 Disassemble needle bearing No.1 (19). (3 pcs) 125LCR8SM67 8-65...
Page 529 Disassemble thrust washer No.1 (lower) (20). (3 pcs) 125LCR8SM68 (10) After placing spring pin (15) to center of carrier pin No.1 (21) with a jig, disassemble it. (3 pcs) Do not reuse spring pin, carrier and carrier pin. 125LCR8SM69 (11) Disassemble sun gear No.2 (16).
Page 530 Carrier No.2 sub assy disassembly (13) After placing spring pin (15) to center of carrier pin No.2 (14) with a press machine, disassemble it.(3 pcs) Do not reuse spring pin. 125LCR8SM72 (14) Disassemble planetary gear No.2.(3 pcs) 125LCR8SM73 (15) Disassemble thrust plate (24). 125LCR8SM74 (16) Disassemble thrust washer No.2 (13).(6 pcs)
Page 531 (17) Disassemble needle bearing No.2 (12). (3 pcs) 125LCR8SM76 (18) Separate ring gear (1) from casing (8). 125LCR8SM77 (19) Loosen a bolt (7) (4 pcs), and disassemble lock plate (6). 125LCR8SM78 (20) Disassemble nut ring (5) by using the jig. 125LCR8SM79 8-68...
Page 532 Drive shaft sub assy disassembly (21) Separate drive shaft sub assembly from casing (8). 125LCR8SM80 (22) Disassemble taper bearing (3) and oil seal (27) by using a press machine. 125LCR8SM81 (23) Disassemble sleeve (25) and O-ring (26). 125LCR8SM82 (24) Disassemble the outer ring of taper bearing (3) in casing (8) by using the jig.
Page 533 ASSEMBLY Even though assembly is accomplished by reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried with compressed air. Sliding surface, O-ring, bearing and oil seal should be lubricated with clean hydraulic oil, prior to final assembly.
Page 534 Caulking is performed on the assembled spring pin unit. Caulking To cover pins, implement the caulking in two two places places that are located direction of 180 degrees around assembled spring pin. 125LCR8SM86 Assemble thrust washer No.1 (lower) (20). (3 pcs) 125LCR8SM87 Assemble needle bearing No.1 (19).(3 pcs) 125LCR8SM88...
Page 535 Assemble planetary gear No.1 (18) of which groove is faced downward.(3 pcs) 125LCR8SM90 Assemble thrust washer No.1 (upper) (32). (3 pcs) 125LCR8SM91 Assemble snap ring (23) (3 pcs), complete carrier No.1 sub assembly. Gear rotation state should be smooth. 125LCR8SM92 Carrier No.2 sub assy assembly (10) Assemble needle bearing No.2 (12) in the...
Page 536 After spreading grease on thrust washer (11) No.2 (13), assemble it on both upper side and lower side of planetary gear No.2. 125LCR8SM94 (12) Assemble thrust plate (24). 125LCR8SM95 (13) Assemble planetary gear No.2 in the carrier No.2 (10).(3 pcs) Thrust washer No.2 should notseparated.
Page 537 Assemble spring pin (15).(3 pcs) (15) 125LCR8SM98 (16) Caulking is performed on the assembled spring pin unit. Caulking To cover pins, implement the caulking in two two places places that are located direction of 180 degrees around assembled spring pin. 125LCR8SM99 Drive shaft sub assy assembly (17)
Page 538 (19) Shrink fit taper bearing (3) on drive shaft, complete drive shaft sub assembly. 125LCR8SM102 Casing assembly (20) Press outer ring of the taper bearing in the casing (8) by using the jig. 125LCR8SM103 (21) Press in oil seal (27) by using the jig. Be careful of the direction of the assembly.
Page 539 (23) After fixing drive shaft so that it does not fall, and then turn it over, press taper bearing (4). 125LCR8SM106 (24) Assemble nut ring (5) by using the jig. Tightening torque : 3.5 0.4 kgf · m (25.3 2.9 lbf · ft) 125LCR8SM107 (25) Place lock plate (6) on the nut ring.
Page 540 (27) Press parallel pin (31) by using press machine. 125LCR8SM110 (28) Spread the loctite #515 on the casing with Loctite #515 reference to the right detail view. Loctite should not flow into casing. Detail view 125LCR8SM111 (29) Assemble ring gear (1) in accordance with a pin hole on casing.
Page 541 (31) Assemble sun gear No.2 (16). 125LCR8SM114 (32) Assemble carrier No.1 sub assembly. 125LCR8SM115 (33) Assemble sun gear No.1 (22) of which grinding surface is faced downward. 125LCR8SM116 (34) Fill with gear oil 3.5 liter. 125LCR8SM117 8-70-8...
Page 542 GROUP 5 SWING DEVICE GROUP 5 SWING DEVICE (TYPE 2) 1. REMOVAL AND INSTALL OF MOTOR 1. REMOVAL AND INSTALL OF MOTOR 1) 1) REMOVAL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 543 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE STRUCTURE 1) 1) DETAIL K 11 10 9 22 7 37 30 32,33 8 13 12 15 14 17 2 3 4 14W92SM02 Body 16 Brake piston 31 Anti-rotating valve Oil seal 17 O-ring...
Page 544 2) 2) DISASSEMBLY DISASSEMBLY Lift the motor out. Clean the motor in kerosene and dry with compressed air. ※ To avoid dust inside the motor, mask all the ports of the motor with tapes. 32038SM01 Loosen the drain plug to discharge oil in the body(1).
Page 545 Remove the relief valve (30) from rear cover (20). 32038SM05 Remove plug (25) from rear cover (20) and spring (28), check (29). ※ Be careful not to damage the check seat assembly. 32038SM06 Remove rear cover (20) from body (1). Then, remove the valve plate (23) from rear cover (20) with care.
Page 546 Remove brake piston (16) from body (1). 32038SM09 (10) Remove the cylinder (9) from the drive shaft (5) with the motor positioned horizontally. Remove ball guide (11), set plate (12), piston (13) and shoe plate (8). 32038SM10 (11) Remove friction plate (14) and separate plate (15) from body (1).
Page 547 (13) Remove the cone of roller bearing (3) by press. ※ Do not reuse bearings. Press Output shaft Roller bearing 32038SM15 (14) Remove bushing (6) and oil seal (2) from body (1). 25038SM05 (15) Remove the needle bearing (21) from the rear cover (20) by using slide hammer bearing puller.
Page 548 (16) When disassembling the relief valve, release the adjusting screw (5). Remove the piston (6), spring seat (8), spring (4) and plunger (3) with the body (1) downwards. 14007A2SM05 This completes disassembly. 8-77...
Page 549 3) 3) ASSEMBLY ASSEMBLY Do the reassembly in the reverse procedure of the disassembly. Apply three bond of white color on outer surface of oil seal (2) and insert it to the body (1). 11078SM22 Install the roller bearing (3) to the drive shaft (5).
Page 550 Insert the shoe plate (8) with the body (1) position horizontally. 32038SM28 Insert the ball guide (11) into the cylinder (9). 32038SM29 Install the piston sub-assembly (13) to the set plate (12). 32038SM30 Reassemble the piston assembly (9) to the body (1).
Page 551 Assembly friction plate (14) and separate plate (15) to the body (1). 11078SM26 (10) Insert O-ring (17) inside the body (1). 32038SM33 (11) Reassemble brake piston (16) to the body (1). 32038SM34 (12) Reassemble brake spring (19) to the brake piston (16).
Page 552 (13) When assembling the needle bearing (21), insert the needle bearing (21) into rear cover (20) by hammering. 32038SM36 (14) Reassemble valve plate (23) to the rear cover (20) and reassemble O-ring (18). 32038SM37 (15) Connect the rear cover (20) with the body (1) and tighten the wrench bolt (24).
Page 553 (17) Insert O-rings to the relief valve (30) and reassemble them to rear cover (20). This completes assembly. 32038SM42 8-82...
Page 554 3. REMOVAL AND INSTALL OF REDUCTION GEAR 3. REMOVAL AND INSTALL OF REDUCTION GEAR 1) 1) REMOVAL REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove mounting bolts (2). Remove the reduction gear assembly.
Page 555 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE STRUCTURE 1) 1) 23 5 1 16 10 11 9 21 12 24 Oil drain Grease port VIEW A 14W92SM03 Casing Pin No.2 assembly Stop ring Drive shaft Sun gear No.
Page 556 2) 2) DISASSEMBLY DISASSEMBLY Remove level gauge (38) from the swing motor casing. ※ Pour the gear oil out of reduction gear into the clean bowl to check out the friction decrease. 14W98SM05 Loosen the socket bolts (24) to separate swing motor from reduction gear.
Page 557 Disassembling carrier 1 (12) assembly. ① Remove stop ring (18). ② Remove thrust washer (15) and planet gear 1(13) from the carrier 1 (12). ③ Using M8 solid drill, crush spring pin (17) so that the pin 1 (14) can be removed by hammering.
Page 558 Disassembling carrier 2 (8) assembly. ① Using M8 solid drill, crush spring pin (17) so that the pin 2 (10) can be removed. ※ Do not reuse spring pin (17). ② Remove pin 2 (10) and planet gear 2 (9) from the carrier 2 (8).
Page 559 (12) Remove roller bearing (6) and oil seal (7) from the drive shaft (2). ※ Do not reuse oil seal (20) once removed. 14W98SM16 (13) Using the bearing disassembly tool, remove roller bearing (5). 14W98SM17 (14) Remove plugs (25, 26) from the casing (1).
Page 560 3) 3) ASSEMBLY ASSEMBLY Assemble roller bearing (5) inside the casing (1). 14W98SM17 Assemble the drive shaft (2) into the casing (1) and then install oil seal (7) and roller bearing (6). 14W98SM19 Install stop ring (19) on top of drive shaft (2).
Page 561 Assembling carrier 2 (8) assembly. ① Install the planet gear 2 (9) inside the carrier 2 (8). ② Assemble the pin 2 (10) to the carrier 2 (8) and then press the spring pin (17) by hammering. ③ Punch 2 points of the spring pin (17) lip. ※...
Page 562 (10) Assemble carrier 1 (12) assembly into the ring gear (21). 14W98SM20 (11) Hammer 4 knock pins (22) around the ring gear (21). (12) Assemble sun gear 1 (16) to the drive shaft of the swing reduction gear. 14W98SM21 (13) Apply loctite to the tapped holes of the ring gear (21) and then mount swing motor onto the ring gear (21).
Page 563: Group 6 Travel Device
GROUP 6 TRAVEL DEVICE TRAVEL MOTOR (TYPE 1) 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90˚and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 564 2. TRAVEL MOTOR 2. TRAVEL MOTOR STRUCTURE STRUCTURE 1) 1) 42 26 36 30 27 43 38,21 25 37 67 49 89,90 SECTION A - A 209 210 46 205 208 207 204 203 202 71 126 10 11 5 101 129 130 103 61 108 14092TM03...
Page 565 TOOLS Standard tools Name Description/Size 6 (M8) (PT1/4), 8 (M10) each 1 Hexagon wrench 10 (M12) (PF1/2) each 1 (JIS B 4650) 4 (M6) Socket wrench Nominal 30 kgf m dial type Torque wrench Nominal 90 kgf m dial type Socket 26, 27, 36 each 1 Adapter for torque wrench...
Page 566 Special tools Inversion working bench 25098TM101 Pressurize jig ( ) 14098TM90 Pressurize jig ( ) 25098TM102 Aluminum bar 14098TM91 Steel bar 25098TM103 8-95...
Page 567 Sharp punch 14098TM92 Draw bar 14098TM93 TIGHTENING TORQUE Tightening torque Item No. Parts name Size kgf m lbf ft Plug PF 3/8 72.3 14.5 Plug M30 1.5 52.1 Plug M24 1.5 24.6 Socket bolt M10 1.5 42.7 RO plug PF 1/4 21.7 Plug NPTF 1/16...
Page 568 3. DISASSEMBLY GENERAL PRECAUTIONS Spread rubber or vinyl cover on the work bench. When disassembling the travel motor, provide a match mark on the mating face or each part. Arrange the detached parts to prevent them from being damaged or lost. The disassembled seals must be replaced with new ones as a rule even if they are free from dam- age.
Page 569 Remove planetary gear R (117), needle bearing, inner race (119) and holder (116) from hub (105). 14098TM62 Remove sun gear (114), screw (110) and thrust plate F (113). 14098TM63 Remove the thrust washer (109), planetary gears F (108), needle bearings (111) and collar (112) from hub (105).
Page 570 Remove the nut ring (103) from hub (105). 14098TM66 Remove the spindle (101) from the hub (105). Remove it using a crane after eye bolt is assem- bled at the hub (105). 14098TM67 (10) Remove the floating seal (102), seal ring (129), angular bearings (125, 2EA), snap ring (106) and O-ring (130) from the hub (105).
Page 571 (12) Remove the oil seal (32) from spindle (101). 14098TM70 DISASSEMBLING THE HYDRAULIC MOTOR PART Remove the relief valve (70, 2EA) from rear ﬂ ange (1). Tools Hexagon socket Torque wrench 14098TM05 Remove hexagon socket head bolts (43, 8EA) from the rear ﬂ ange (1). Tools Hexagon wrench 8 14098TM06...
Page 572 Remove the parallel pin (42) from the spindle (101). 14098TM08 Remove the O-ring (126) from the spindle (101). Do not reuse the O-ring (126). 14098TM09 Disassembling the rear ﬂ ange (1) part Place the rear ﬂ ange with the contact surface of the spindle upward.
Page 573 Remove the ball bearing (50) from the rear ﬂ ange (1). 14098TM12 Disassembling the brake valve part Remove two plugs (24) from the rear ﬂ ange (1). User can work easily if sub-disassembly was done on the reversal table. Tools Hexagon wrench 36 Torque wrench 14098TM13...
Page 574 Remove the springs (30, 2EA), valves (27, 2EA) from rear ﬂ ange (1). 14098TM16 Remove the O-ring (37) from plug (24). Do not reuse the O-ring (37). 14098TM17 Remove the O-ring (36) from plug (26). Do not reuse the O-ring (36). 14098TM18 Disassembling the two speed change valve Remove the plug (63) from the rear ﬂ...
Page 575 Remove the spool (65) and spring (66) from rear ﬂ ange (1). 14098TM20 (10) Disassembling the plug (52). Do not remove plug (52) if it not to be necessary. Disassembling the plug (52) if it was malfunction because of get mixed with dust. Clean the plug (52) after disassembled.
Page 576 Remove the valve seat (18) by injecting com- pressed air from the access hole in the spindle (101) after caulking the hole of valve seat (18). 14098TM23 Remove the valve (19) and spring (20) from rear ﬂ ange (1) downside hole with shaking lightly. 14098TM24 Remove the O-ring (33) and valve seat (18).
Page 577 Remove the O-rings (35, 39) and backup rings (47 , 48) from the piston (12). Do not reuse O-rings (35, 39) and backup rings (47, 48) after removal. 14098TM27 Disassembling the hydraulic motor part (13) Lay the travel motor body on the side. Drain out the oil from the travel motor.
Page 578 (14) Disassembling the cylinder block kit Piston assembly [piston (5), shoe (6)] from the removed cylinder block (4). 14098TM30 Piston (5) and shoe (6) from the removed retainer plate (7). 14098TM31 Thrust ball (8) from the removed cylinder block (4). 14098TM32 Roller (51, 5EA) from the removed cylinder block (204).
Page 579 (15) Disassembling the spring of the cylinder block Put the cylinder block (4) on the pressurize jig. Press the washer (10) with pressurize jig, and re- move the spring (14) after snap ring (45) removed. Put a vinyl cover on the sliding surface of cylinder block (4) for protection.
Page 580 4. REASSEMBLY GENERAL PRECAUTIONS Reassemble in a work area that is clean and free from dust and dirt. Handle parts with bare hands to keep them free of linty contaminants. Repair or replace the damaged parts. Each parts must be free of burrs its corners. Do not reuse O-ring, oil seal and ﬂ...
Page 581 Reassembe the cylinder block kit Install washer (10), spring (14, 9EA), washer (10) and snap ring (45) in that order, into the cylinder block (4) inner part. Put the cylinder block (4) on the pressurize jig. 14098TM35 While pressing washer (10) by pressurize jig, install snap ring (45).
Page 582 Install cylinder block (4) assembly to the shaft (2). After ﬁ tting splines of both cylinder block (4) and shaft (2), assemble them. After installing the cylinder (4), conﬁ rm whether it revolves or not by turning using both hands. Motor is malfunction when it isn’t revolve.
Page 583 Install spring (30) and valve (27) into the plug (26). Install plug (26) into the rear ﬂ ange (1). Install spring (30) and valve (27) into the plug (26), and then grease the spring (30) and the valve (27) and hand-lock the former. 14098TM46 Install plug (26) in conjunction with the spring (30) and the valve (27) into the rear ﬂ...
Page 584 Install spring retainer (25) and spring (28) into the plug (24). Install plug (24) into the rear ﬂ ange (1). Tighten the plug (24) to the required torque. Tightening torque : 36 5.4 kgf m (260 39 lbf ft) Socket (#36) / Torque for hexagon wrench. Tools Hexagon socket 36 14098TM13...
Page 585 Mount the rear ﬂ ange (1) on a working bench that the mounting side of the spindle (101) faces up- ward. Install valve (19), spring (20) and valve seat (18) in that order. 14098TM49 After new ring (22) bend somewhat and put the valve seat (18), then into the rear ﬂ...
Page 586 Install timing plate (9) into the rear ﬂ ange (1). Apply hydraulic oil to the contact surface of rear ﬂ ange. 14098TM10 Reassembe the rear ﬂ ange (1) and spindle (101) Tilt the work bench 90˚ for travel motor reassembling. Insert the O-ring (75, 126) on the spindle (101).
Page 587 Tighten the socket bolt (43) into the spindle (101) to the required torque. Tightening torque : 5.9 1.0 kgf m (42.7 7.2 lbf ft) Tools Adapter for hexagon wrench 8 Torque wrench 14098TM06 Tighten the plug (24) into the rear ﬂ ange (1) to the required torque.
Page 588 Install angular bearing (125) and snap ring (106) into the hub (105). Be careful for the insert direction. 14098TM72 Insert the O-ring (130), the sealing (129) and ﬂ oat- ing seal (102) in the hub (105). Apply grease to the ﬂ oating seal (102) thinly. 14098TM73 Install the spindle (101) into the hub (105) assem- bly.
Page 589 Install thrust washer (109) and collar (112) into the hub (105). 14098TM74 Install needle bearing (111) planetary gear F (108), thrust washer (109), thrust plate F (113) and screw (110) into the hub (105). Tightening torque : 0.83 kgf m (6.0 lbf ft) Hexagon socket 5 Torque wrench 14098TM75...
Page 590 (10) Install cover (123), thrust plate (150), plug (301, 128) and socket bolt (124) into the hub (105). Apply grease to the cover (123) after installed O-ring (127). 14098TM60 (11) Pressing the oil seal Insert the oil seal (32) by hit the pressurize jig with Pressurerize jig plastic hammer.
Page 591 TRAVEL MOTOR (TYPE 2) 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90˚ and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. 13031GE18 Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 592 2. SPECIFICATION STRUCTURE 2 4 6 9 15 17 18 19 20 21 22 24 45 23 52 50 61 32 33 34 31 27 28 26 30 29 60 25 5 A" B" 8 7 1 16 14 10 11 12 13 51 45 49 47 43 35 36 62 28 37 53 48 DETAIL T...
Page 593 1 2 3 4 5 6 7-1 7-2 7-3 7-5 7-4 7-6 10-2 10-4 10-1 10-5 10-6 10-3 145Z9A2TM02A Spindle 7-4 Washer 2 10-5 Bearing 1 Floating sesal 7-5 Bearing 2 10-6 Pin 1 Ball bearing 7-6 Pin 2 11 Sun gear 1 Housing Coupling 12 Plate 1...
Page 594 TOOL AND TIGHTENING TORQUE Tools Name of tools B (mm) Name of part applied Plug (42, 45, 46, 47) Hexagonal Plug (43, 44) L-Wrench Plug (39) Plug (37, 57), Wrench bolt (53) Relief plug (48) Socket wrench/ spanner Main spool plug (32) Snap ring plier (for holes, axis) 42 (13) Hammer...
Page 595 2. DISASSEMBLING AND ASSEMBLING GENERAL INSTRUCTIONS Generally, hydraulic equipment is precisely manufactured and clearances between each parts are very narrow. Therefore, disassembling and assembling works should be performed on the clean place where dusts hardly gather. Tools and kerosene to wash parts should also be clean and handled with great care.
Page 596 DISASSEMBLING MOTOR UNIT Disassemble relief valve (48) from valve casing (25) using a torque wrench. 145Z9A8TM01 145Z9A8TM02 Disassemble wrench bolt (53) (M12 30) and take out valve casing sub assembly. 145Z9A8TM03 Remove parking spring (52) - 12EA. 145Z9A8TM04 Remove O-ring (23). 145Z9A8TM05 8-125...
Page 597 Disassemble brake piston (20) using a jig. 145Z9A8TM06 145Z9A8TM07 Disassemble friction plate (19)-3EA, steel plate (18)-4EA. 145Z9A8TM08 145Z9A8TM09 145Z9A8TM10 Remove the cylinder block kit (II). It is easier to work by placing the shaft casing (1) horizontal. 145Z9A8TM12 145Z9A8TM11 8-126...
Page 598 Disassemble cylinder block (10), ball guide (15), set plate (16), piston assy (17), pin (14) from cylinder block kit (II). Press spring (12) using a jig and take out snap ring (14) using a plier. Disassemble snap ring (13), spring seat (11), spring (12) from cylinder block kit (II).
Page 599 (11) Disassemble shaft (3) from shaft casing (1). 145Z9A8TM21 145Z9A8TM22 After disassembled shaft (3) is placed on a jig, top of shaft is pressed down using a press. It can remove ball bearing (4) portion. Remove ball bearing (4) in case it is replaced only.
Page 600 (14) Disassemble valve plate (51) and ball bearing (49) from valve casing (25). 145Z9A8TM31 145Z9A8TM30 145Z9A8TM32 (15) Disassemble plug (47) from valve casing (25). 145Z9A8TM33 (16) Disassemble plug (37) from valve casing (25) using a torque wrench and disassemble two speed control spool (35), spring (36) in regular sequence.
Page 601 (18) Disassemble plug (43) from valve casing (25) and then disassemble orifice (42), steel ball (41) one by one. 145Z9A8TM39 145Z9A8TM38 (19) Disassemble plug (39), relief valve damping piston (38) from valve casing (25). 145Z9A8TM41 145Z9A8TM40 (20) Disassemble plug (43) from valve casing (25) and disassemble orifice (63).
Page 602 ASSEMBLING MOTOR UNIT Put oil seal into shaft casing (1) using a jig. Caution direction of oil seal. 145Z9A8TM46 145Z9A8TM45 Assemble swash spring (8) into shaft casing (1) and put swash piston (7) into shaft casing (1). 145Z9A8TM48 145Z9A8TM47 Press the ball bearing (4) into shaft (3) after preheating of ball bearing (4).
Page 603 Assemble swash ball (6)-2EA. 145Z9A8TM54 Apply grease to swash plate (9) and assemble swash plate (9) into shaft casing (1). 145Z9A8TM56 145Z9A8TM55 Slant the shaft casing (1) and then assemble cylinder block kit (II). Assemble spring seat (11), spring (12), spring seat (11) into cylinder block kit (II) in regular sequence.
Page 604 Assemble friction plate (19), steel plate (18) into cylinder block in regular sequence. Friction plate : 3 EA Steel Plate : 4 EA 145Z9A8TM64 145Z9A8TM65 145Z9A8TM66 Assemble parking piston (20) into shaft casing (1) using a jig. 145Z9A8TM68 145Z9A8TM67 (10) Put O-ring (23) into shaft casing (1).
Page 605 (11) Put spring (36), two speed control spool (35) into valve casing (25) in regular sequence and assemble plug (37) into valve casing (25) using a torque wrench. Tighten torque : 10 kgf-m (72.3 lbf-ft) 145Z9A8TM70 145Z9A8TM71 (12) Assemble check (30), spring (29), plug (27) into main spool (26) in regular sequence.
Page 606 (15) Put steel ball (41), orifice (42) into valve casing (25) and tighten the plug (43). Tighten torque : 1.25 kgf-m (9.0 lbf-ft) 145Z9A8TM80 145Z9A8TM81 (16) Put steel ball (56) into valve casing (25) and tighten the plug (57). Tighten torque : 1.25 kgf-m (9.0 lbf-ft) 145Z9A8TM82 145Z9A8TM83 (17)
Page 607 (19) Assemble pin (50) into valve casing (25). 145Z9A8TM86 (20) Assemble pin (5) into valve casing (25). 145Z9A8TM87 (21) Assemble ball bearing (49) into valve casing (25). 145Z9A8TM88 (22) Apply grease on the face of valve plate and assemble valve plate (51) into valve casing (25).
Page 608 (23) Apply grease to brake spring (52)-12EA and assemble brake spring (52)-12EA into valve casing (25). 145Z9A8TM91 (24) Assemble valve casing (25) into shaft casing (1) and tighten the wrench bolt (53) using a torque wrench. Tighten torque : 10.4 kgf-m (75.2 lbf-ft) 145Z9A8TM92 (25) Assemble relief valve (48) into valve casing...
Page 609 DISASSEMBLING REDUCTION GEAR Loose plug (26)-3EA and drain reduction oil. 145Z9A8TR02 Loose wrench bolt (25) using a tool. 145Z9A8TR03 Disassemble end cover (24). 145Z9A8TR04 Disassemble trust plate (23). 145Z9A8TR06 145Z9A8TR05 8-138...
Page 610 Disassemble driver gear (16). 145Z9A8TR07 145Z9A8TR08 Disassemble carrier No.1 (17) sub assy. Assemble eyebolt into carrier No.1 tap hole and disassemble carrier No.1 (17) sub assy using a hoist. 145Z9A8TR09 Disassemble carrier No.1 sub assy. Remove spring pin No.1 (22) from carrier No.1 (17) and planetary gear No.1 (18), washer No.1 (19), needle bearing No.1 (20), carrier pin No.1 (21) in regular...
Page 611 Disassemble carrier No.2 (7) sub assy. Assemble eyebolt into carrier No.2 tap hole and disassemble carrier No.2 (7) sub assy using a hoist. 145Z9A8TR15 Disassemble carrier No.2 (7) sub assy. Remove spring pin No.2 (12) from carrier No.2 (7) and disassemble planetary gear No.2 (8), washer No.2 (9), needle bearing No.2 (10), carrier pin No.2 (11) in regular sequence.
Page 612 (11) Disassemble ring gear sub assy (4) into Ring gear motor assy. sub assy Assemble eye bolt into tap hole of ring gear sub assy (4) and disassemble ring gear sub assy (4) using a hoist. 145Z9A8TR23 (12) Disassemble floating seal (2) from ring gear sub assy (4).
Page 613 ASSEMBLING REDUCTION GEAR Before assembing please observe following item. • Wash all parts cleanly using solvent and dry all parts perfectly using compressed air. • Check metal dust in casing and cleansing solution. • Before application packing, please remove oil certainly. •...
Page 614 Press angular bearing (3) into ring gear Press (4) using a jig. 145Z9A8TR31 145Z9A8TR30 Assemble floating seal(2) into ring gear(4) using a jig. 145Z9A8TR33 145Z9A8TR32 Assemble ring gear sub assy (4) into Ring gear motor assy using a assembly epuipment. sub assy 145Z9A8TR34 Push down ring gear (4) using a jig and...
Page 615 Assemble carrier No.2 sub assy. Assemble planetary gear No.2 (8), washer No.2 (9), needle bearing No.2 (10) and carrier pin No.2 (11) into carrier No.2 (7) in regular sequence. Assemble spring pin No.2 (12). Assemble spring pin No.2 (12) and caulk spring pin into pin hole.
Page 616 Assemble carrier No.1 (17) sub assy. Assemble eyebolt into carrier No.1 and assemble carrier No.1 (17) sub assy into ring gear using hoist. 145Z9A8TR48 (10) Assemble driver gear(16). 145Z9A8TR50 145Z9A8TR49 (11) Assemble trust plate (23). 145Z9A8TR52 145Z9A8TR51 (12) Assemble end cover (24). 145Z9A8TR53 8-145...
Page 617 (13) Tighten wrench bolt (25) using a air impact. Tighten torque : 68 kgf-m (491.8 lbf-ft) 145Z9A8TR54 (14) Adjust control lever to be sunk the product under the test oil and then check the air leak. *TEST : Air pressure 0.7 kgf/cm ×...
Page 618 TRAVEL MOTOR (TYPE 3, 4) 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90˚and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 619 2. TRAVEL MOTOR 2. TRAVEL MOTOR 1) 1) STRUCTURE STRUCTURE 49 40 43 42 41 44 72 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 71 70 59 77 64 3 63 7 10 11 14 15 13 16 26 27 6 8 125LCR2TM21...
Page 620 DISASSEMBLY Choose a clean place, remove contaminants (dust, etc) and cleans motor before placing it on worktable. Lay the rubber plate on worktable and take care not to damage the component. 125LCR8TM02 Remove the connector (45) using 21 mm socket wrench.
Page 621 Remove spring seat (42) and spool (40). 125LCR8TM06 Disassemble relief valve assembly (38) using 26 mm socket wrench. (2 sets) 125LCR8TM07 Disassemble cover (32) using 41 mm socket wrench. 125LCR8TM08 Disassemble spring seat (37) and spring (33). (2 sets) 125LCR8TM09 8-149...
Page 622 Separate main spool assembly (31) from rear cover. 125LCR8TM10 (10) Unscrew socket bolt (47) (1EA), (48) (3EA), (49) (6EA) from rear cover. 125LCR8TM11 (11) Remove parallel pin (29). 125LCR8TM12 (12) From rear cover, disassemble valve plate (24) and O-ring (27). Take care not to damage assembly surface of rear cover.
Page 623 (13) Disassemble restrictor (55, 56) (2EA). Mark the number on restrictor and its hole to avoid confusing (55) and (56). 125LCR8TM14 (14) Remove plug (52). 125LCR8TM15 (15) Remove restrictor (34) and spring (35). (2 sets) Do not confuse restrictor (34) and check valve (50).
Page 624 (17) Remove check valve (50) and spring (51). (2 sets) Do not confuse restrictor (34) and check valve (50). Do not confuse spring (35) and spring (51). Do not lose spring. Do not mix spring with other springs. 125LCR8TM18 (18) From parking piston, remove spring (26) (12ea).
Page 625 (21) From parking piston separate O-ring (20) and back-up ring (21). 125LCR8TM22 (22) Lay casing down horizontally and remove cylinder block assembly, friction plate (17) (3EA) and separator plate (18) (4EA). 125LCR8TM23 (23) Separate retainer plate (15) and piston assembly (16).
Page 626 (25) Disassemble swash plate (11) and steel ball (10). Take care not to damage sliding surface. 125LCR8TM26 (26) Disassemble shaft (6) and ball bearing (7). Do not remove ball bearing unless malfunction is detected, since it is mounted by shrink fit. 125LCR8TM27 (27) Disassemble 1, 2 speed piston (4) and steel ball...
Page 627 (29) Turn casing (1) upside down and remove oil seal (3) using jig. 125LCR8TM30 8-155...
Page 628 ASSEMBLY Even though assembly is accomplished by reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried with compressed air. Sliding surface, O-ring, bearing and oil seal should be lubricated with clean hydraulic oil, prior to final assembly.
Page 629 After applying grease on steel ball (10), insert steel ball in casing. 125LCR8TM33 After assembling piston seal (5) and steel ball (9) in 1, 2 speed piston (4), insert piston in hole of casing. Check whether piston sticks in hole. Use piston seal jig.
Page 630 Assemble spring (13) (9ea) and ball guide (14) in cylinder block (12) in that order. 125LCR8TM37 Insert piston assembly (16) in retainer plate (15) and assemble them in cylinder block. Spread hydraulic oil on piston assembly. Take care not to damage each component. Check cylinder block and piston assembly runs properly.
Page 631 (11) Insert back-up ring & O-ring in parking piston. 125LCR8TM41 (12) Align the pin hole of parking piston (19) with oil hole of casing, assemble them using jig. Spread grease on O-ring and back-up ring. Take care not to damage components. 125LCR8TM42 (13) Insert spring (26) (12EA) in parking piston.
Page 632 (15) Assemble check valve (50) and spring (51) in order. Do not confuse check valve (50) and restrictor (34). Do not confuse spring (51) and spring (35) 125LCR8TM45 (16) Clamp plug (52) using 5 mm hexagon wrench. Tightening torque : 1.5 kgf · m (10.9 lbf · ft) 125LCR8TM46 (17) Assemble restrictor (34) and spring (35) in order.
Page 633 (19) Clamp plug (54). Tightening torque : 3 kgf · m (21.7 lbf · ft) 125LCR8TM49 (20) Assemble restrictor (55) and (56) in rear cover. Check whether the restrictor is placed in exact hole. Do not confuse (55) and (56). 125LCR8TM50 (21) Assemble ball bearing (8) in rear cover using jig.
Page 634 (23) After spreading grease sufficiently to the bottom side of valve plate (24), assemble valve plate in rear cover by matching its holes with pins. Take care not to damage sliding surface. Pay attention to the assembly direction. 125LCR8TM53 (24) Assemble O-ring (27) in rear cover.
Page 635 (27) Settle cover (32). Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8TM57 (28) Insert relief valve (38) in rear cover. Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8TM58 (29) After clamping connector (45) to rear cover, assemble spool (40).
Page 636 (31) After assembling spring (44) in order, clamp plug (41). Tightening torque : 5 kgf · m (36 lbf · ft) 125LCR8TM61 8-164...
Page 637 TRAVEL REDUCTION GEAR DISASSEMBLY While travel reduction gear is tilted to one side disassemble PF3/8 plug (24), remove gear oil and place motor sideto the bench. 125LCR8TM70 Disassemble cover (22) by unscrewing the M10 bolts (23) (12 pcs). 125LCR8TM71 Disassemble sun gear No.1 (20), steel ball (21). 125LCR8TM72 Disassemble carrier No.1 assembly.
Page 638 Carrier No. 1 sub assy disassembly Disassemble M8 bolt (18) from the carrier assembly. (3 pcs) 125LCR8TM74 Disassemble thrust plate No.1 (17) from the carrier assembly. 125LCR8TM75 Disassemble planetary gear No.1 (14).(3 pcs) 125LCR8TM76 Disassemble needle bearing (15).(3 pcs) Do not disassemble inner race in the absence of abnormalities.
Page 639 Disassemble Sun gear No.2 (12). 125LCR8TM78 Disassemble M10 bolt (6).(4 pcs) 125LCR8TM79 Disassemble thrust washer No.2 (11).(4 pcs) 125LCR8TM80 Disassemble planetary gear No.2 (8).(4 pcs) 125LCR8TM81 8-167...
Page 640 Disassemble needle bearing No.2 (9).(4 pcs) 125LCR8TM82 Disassemble thrust plate No.2 (7).(4 pcs) Do not disassemble inner race in the absence of abnormalities. 125LCR8TM83 Disassemble M10 bolt (6) and M8 screw bolt (19). 125LCR8TM84 Disassemble lock plate (5). 125LCR8TM85 8-168...
Page 641 Disassemble nut ring (4) by using the jig. 125LCR8TM86 Disassemble ring gear sun assembly from motor assembly. 125LCR8TM87 Disassemble folating seal assembly (3) from ring gear sun assembly and motor assembly. 125LCR8TM88 Disassemble bearing (2) (2ea) from ring gear assembly. Do not disassemble bearing in the absence of abnormalities.
Page 642 TRAVEL REDUCTION GEAR ASSEMBLY Even though assembly is accomplished by reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried with compressed air. Sliding surface, O-ring, bearing and oil seal should be lubricated with clean hydraulic oil, prior to final assembly.
Page 643 Assemble planetary gear No.1 (14) of which groove is faced downward. (3 places) 125LCR8TM92 Assemble thrust plate No.1(17). 125LCR8TM93 After spreading loctite #242, assemble the M8 bolt (18).(3 pcs) Tightening torque : 2.7 0.3 kgf · m After the assembly, instantly check the noise and interference by rotatong the gear.
Page 644 After turning ring gear over, assemble bearing the same way. Be care of nick and safety when turn ring gear over. 125LCR8TM96 Assemble folating seal assembly (3) by usingthe jig. After assembling, wipe steel-lined section with alcohol. Flatness deviation has to be less than 1 mm. 125LCR8TM97 Place folating seal assembly on the motor assem- bly then assemble it.
Page 645 After assembling nut ring (4) by using the jig, disassemble the clamping. Tightening torque : 60 kgf · m (434 lbf · ft) 125LCR8TM100 Place lock plate (5) on the nut ring groove. Select best position from one of 4 casing hole to assemble lock plate.
Page 646 Shrink fit the inner race No.2 (10).(4 pcs) 125LCR8TM104 Assemble thrust plate No.2 (7).(4 pcs) 125LCR8TM105 Assemble needle bearing No.2 (9).(4 pcs) 125LCR8TM106 Assemble planetary gear No.2 (8).(4 pcs) Grooves of planetary gear will be facingup. 125LCR8TM107 8-174...
Page 647 Assemble thrust washer No.2 (11).(4 pcs) 125LCR8TM108 After spreading loctite #242, assemble the M10 bolt (6).(4 pcs) Tightening torque : 5.5 0.6 kgf · m (39.8 4.3 lbf · ft) 125LCR8TM109 Assemble sun gear No.2 (12). 125LCR8TM110 Assemble carrier No.1 assembly. 125LCR8TM111 8-175...
Page 648 Assemble sun gear No.1 (20). 125LCR8TM112 Place steel ball (21) on the sun gear No.1. 125LCR8TM113 Spread the loctite #515 on the cover (22) with reference to the right detail view. Detail view 125LCR8TM114 Place cover (22) to fit the bolt holes. 125LCR8TM115 8-176...
Page 649 After spreading loctite #242, assemble the M10 bolt (23).(12 pcs) Tightening torque : 6.3 0.7 kgf · m (45.6 5.1 lbf · ft) 125LCR8TM116 Inject the 2.5 0.3 liter gear oil to PF3/8 tap section. 125LCR8TM117 After assembling the O-ring (25) to the plug (24), assemble it to the cover.(3 pcs) Tightening torque : 5 0.5 kgf ·...
Page 650: Group 7 Rcv Lever
GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 651 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 300L2RL06 Case Plug 15 Joint assembly 22 Nut Bushing Push rod 16 Swash plate 23 Boot Spool 10 O-ring 17 Adjusting nut 24 Last guard filter Shim 11 Rod seal 18 Bushing 25 O-ring Spring 12 Plate 19 Plug 26 O-ring...
Page 652 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanne (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Joint 25.3 Swash plate 5.0 0.35...
Page 653 DISASSEMBLY Procedures are based on the type M1. Clean pilot valve with kerosene. Put blind plugs into all ports Fix pilot valve in a vise with copper (or lead) sheets. Remove end of boot (23) from case (1) and take it out upwards. 300E8RL01 For valve with switch, remove cord also through hole of casing.
Page 654 Loosen adjusting nut (17) and swash plate (16) with spanners on them respectively, and remove them. 36078RL01 36078RL02 Turn joint anticlockwise to loosen it, utilizing jig (Special tool). When return spring (7) is strong in force, plate (12), plug (8) and push rod (9) will come up on loosening joint.
Page 655 Remove plate (12). 36078RL05 When return spring (7) is weak in force, plug (8) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
Page 656 Take push rod (9) out of plug (8). (12) 36078RL11 (13) Remove O-ring (10) and seal (11) from plug (8). Use small minus screwdriver or so on to remove this seal. 36078RL12 36078RL13 8-184 8-184...
Page 657 (14) Remove lock nut (22) and then boot (23). 36078RL14 2507ARL10 8-185 8-185...
Page 658 (15) Cleaning of parts Put all parts in rough cleaning vessel filled with kerosene and clean them (rough cleaning). If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil.
Page 659 ASSEMBLY Put shim (4), springs (5) and spring seat (6) onto spool (3) in this order. 36078RL16 Assemble spring (7) into casing (1). Assemble reducing valve subassembly into casing. Assemble them to their original positions. 36078RL18 Assemble O-ring (10) onto plug (8). 36078RL19 Assemble seal (11) to plug (8).
Page 660 Assemble push rod (9) to plug (8). Apply working oil on push-rod surface. 36078RL21 Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring. 36078RL22 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate (12), and tighten joint (15) temporarily.
Page 661 (10) Assemble swash plate (16) to joint (15). Screw it to position that it contacts with 4 push rods evenly. Do not screw it over. 36078RL25 (11) Assemble adjusting nut (17), apply spanner to width across flat of plate (16) to fix it, and tighten adjusting nut to the specified torque.
Page 662 (13) Fit boot (23) and lock nut (22), and handle subassembly is assembled completely. 2507ARL10 36078RL27 (14) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. 1408DA66 (15) Assemble bushing (18) to plate and pass cord and tube through it.
Page 663 Determine handle direction, tighten lock (16) nut (22) to specified torque to fix handle. 300E8RL05 (17) Apply grease to rotating section of joint and contacting faces of disk and push rod. 300E8RL06 (18) Assemble lower end of bellows to casing. (19) Inject volatile rust-preventives through all ports and then put blind plugs in ports.
Page 664: Group 8 Turning Joint
GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 665 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 14098TJ03 Shim 11 Wear ring Shaft Slipper seal 12 Retainer ring Cover O-ring 13 Plug Spacer O-ring 14 Hexagon bolt Shim 10 O-ring 15 Spring washer 8-193...
Page 666 DISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts (14), washer (15) and cover (3). 21078DA10 Remove shim (6) and O-ring (10). Remove retainer ring (12), spacer (4) and shim (5). 21078DA11 Place hub (1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out shaft Wooden block...
Page 667 ASSEMBLY Clean all parts. As a general rule, replace oil seals and O-ring. Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix seven slipper seal (7) and O-ring (9), two wear ring (11) to hub (1). Fit O-ring (8) to shaft (2).
Page 668 Install cover (3) to body (1) and tighten bolts (14). Torque : 10~12.5 kgf m (72.3~90.4 lbf ft) 21078DA10 8-196...
Page 669: Group 9 Boom, Arm, Bucket And Dozer Cylinders
GROUP 9 BOOM, ARM, BUCKET AND DOZER CYLINDERS 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 670 Sling bucket cylinder assembly (8) and remove bolt (6) then pull out pin (5). Remove bucket cylinder assembly (8). Weight : 100 kg (220 lb) 145WF8DA17 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
Page 671 ARM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 672 Sling arm cylinder assembly (9) and remove bolt (8) then pull out pin (7). Remove arm cylinder assembly (9). Weight : 160 kg (350 lb) 235ZF8CY21 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
Page 673 BOOM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 674 Disconnect boom cylinder hoses (7) and put plugs on cylinder pipe. 21078DA25 Remove bolt (9) and pull out pin (8). Remove boom cylinder assembly (6). Weight : 130 kg (285 lb) 21078DA26 Install Carry out installation in the reverse order to removal.
Page 675 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder 9,10 6,7 8 4,5 22 3 11,12 2 13 14 17 15 18,19 20 21 Internal detail 23, 25 24, 25 145WF8CY01 Tube assembly 11 O-ring 21 Hexagon socket set screw Rod assembly 12 Back up ring 22 Hexagon socket head bolt Gland...
Page 676 Arm cylinder , 9 , 10 11 , 12 18 , 19 23 33 13 14 17 16 15 Internal detail 24 , 25 24 , 25 25 , 26 , 27 , 28 145WF8CY02 Tube assembly 12 Back up ring 23 Hexagon socket head bolt Rod assembly 13 Cushion ring...
Page 677 Boom cylinder 4,5 22 29 9,10 6,7 8 11,12 13 14 17 16 15 18,19 20 21 Internal detail 23, 24 23, 24 145WF8CY03 Tube assembly 11 O-ring 21 Hexagon socket set screw Rod assembly 12 Back up ring 22 Hexagon socket head bolt Gland 13 Cushion ring 23 Pin bushing...
Page 678 Dozer cylinder 4, 5 3 6, 7 8 9 10, 11 21 16, 17 13 29 14 15 18, 19 23 25 24 27, 28 21 22 145ZF8CY05 Tube assembly 11 Back up ring 21 Hexagon socket head bolt Rod assembly 12 O-ring 22 O-ring Gland...
Page 679 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanner (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Bucket cylinder ( 1) 15 2.0 108 14.5 Socket head bolt...
Page 680 DISASSEMBLY Remove cylinder head and piston rod Procedures are based on the bucket cylinder. 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.
Page 681 Note that the plated surface of rod assembly (2) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. Place the removed rod assembly on a wooden V-block that is set level.
Page 682 Disassemble the piston assembly Remove wear ring (16). Remove dust ring (17) and piston seal (15). Exercise care in this operation not to damage the grooves. 14W98CY12 Disassemble cylinder head assembly 9 6 7 8 12 11 Remove back up ring (12) and O-ring (11).
Page 683 ASSEMBLY Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil stone. Coat the inner face of gland (3) with hydraulic oil. 21078DA37 Coat dust wiper (9) with grease and fit Press here dust wiper (9) to the bottom of the hole of (Straight down) dust wiper.
Page 684 Fit back up ring (12) to gland (3). Put the backup ring in the warm water of 30~50˚C . Fit O-ring (11) to gland (3). 21078DA39 Assemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone. Coat the outer face of piston (14) with hydraulic oil.
Page 685 Install piston and cylinder head Cylinder head assembly Fix the rod assembly to the work bench. Apply hydraulic oil to the outer surface of Rod assembly rod assembly (2), the inner surface of piston and cylinder head. Insert cylinder head assembly to rod assembly.
Page 686 Overall assemble Fix with a bar Place a V-block on a rigid work bench. Mount the tube assembly (1) on it and Lift fix the assembly by passing a bar through the clevis pin hole to lock the Straight assembly. Insert the rod assembly in to the tube assembly, while lifting and moving the Appply liquid packing...
Page 687: Group 10 Undercarriage
GROUP 10 UNDERCARRIAGE 1. TRACK LINK REMOVAL Move track link until master pin is over front idler in the position put wooden Master pin block as shown. Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards.
Page 688 2. CARRIER ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-162(1) Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller 8-162(2) Loosen the lock nut (1). Carrier Tightening torque : 29.7 4.4 kgf m roller (215 31.8 lbf ft) Open bracket(2) with a screwdriver, push...
Page 689 3. TRACK ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-163(1) Using the work equipment, push up track frame on side which is to be removed. After jack up the machine, set a block under the unit. 90~110 140Z98UC05 Remove the mounting bolt (1) and draw...
Page 690 4. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link. 8-164(1) Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry. Weight : 192 kg (423 lb) 8-164(2) Remove the bolts (2), washers (3) and separate ilder from recoil spring.
Page 691 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 21078DA43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 8-219 8-219...
Page 692 Disassembly Press Remove plug (8) and drain oil. Draw out the spring pin (7), using a press. 8-166(1) Pull out the shaft (2) with a press. Press Remove seal (3) from idler (1) and bracket (5). Remove O-ring (6) from shaft. 8-166(2) Remove the bushing (4) from idler, using a special tool.
Page 693 Assembly Before assembly, clean the parts. Press Coat the sliding surfaces of all parts with oil. Cool up bushing (4) fully by some dry ice and press it into shell (1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
Page 694 Install bracket (5) attached with seal (3). 8-168(1) Knock in the spring pin (7) with a hammer. 8-168(2) Lay bracket (5) on its side. Supply engine oil to the specified level, and tighten plug (8). 8-168(3) 8-222 8-222...
Page 695 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure 7, 8 R210UCG01 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod assembly Spring Spring washer 13 Grease valve Bracket Rod seal Lock nut 10 Back up ring 8-223 8-223...
Page 696 Disassembly Apply pressure on spring (3) with a press. The spring is under a large installed load. This is dangerous, so be sure to set properly. Spring set load : 11132 kg (24542 lb) 7, 8 Remove bolt (7), spring washer (8) and lock plate (6).
Page 697 Assembly Install dust seal (11), back up ring (10) 9 10 11 and rod seal (9) to body (1). When installing dust seal (11) and rod seal (9), take full care so as not to damage the lip. R210UCG2(3) Pour grease into body (1), then push in rod (12) by hand.
Page 698 Lighten the press load and confirm the set length of spring (3). After the setting of spring (3), install lock plate (6), spring washer (8) and bolt (7). 16078UC08 8-226 8-226...
Page 699: Group 11 Work Equipment
GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A SECTION B SECTION C SECTION A SECTION B SECTION C 21078DA 44 8-227 8-227...
Page 700 2. REMOVAL AND INSTALL BUCKET ASSEMBLY Removal Lower the work equipment completely to ground with back of bucket facing down. 36078AT04 Remove nut (1), bolt (2) and draw out the pin (B). 145WF8AT01 Remove nut (3), bolt (4) and draw out the pin (A) then remove the bucket assembly.
Page 701 ARM ASSEMBLY Removal Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury. Remove bucket assembly. For details, see removal of bucket 8-175(1) assembly. Disconnect bucket cylinder hose (1). Fit blind plugs (5) in the piping at the Arm cylinder chassis end securely to prevent oil from...
Page 702 BOOM CYLINDER Removal Remove arm and bucket assembly. For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly. 8-176(1) Disconnect head lamp wiring. Disconnect bucket cylinder hose (2) and arm cylinder hose (1).

Hyundai HX145LCR Manual

Quick Links

Troubleshooting

Related Manuals for Hyundai HX145LCR

Summary of Contents for Hyundai HX145LCR

Table of Contents