Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9

Group 3 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-38

Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-49

Group 5 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-68

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-10

Group 5 Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-22

SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Monitoring system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3

Group 3 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9

Group 4 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-25

Group 5 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32

SECTION 5 TROUBLESHOOTING

Group 1 Before Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4

Group 3 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-24

SECTION 6 MAINTENANCE STANDARD

Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-21

Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31

CONTENTS

Table of Contents

Troubleshooting

Summary of Contents for Hyundai r35z-7

Page 1: Table Of Contents
CONTENTS SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9 SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1...
Page 2 SECTION 7 DISASSEMBLY AND ASSEMBLY Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4 Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33...
Page 3 This section shows bolt specifications and standard torque values needed when mounting components to the machine. 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( Any additions, amendments or other changes When a manual is revised, an edition mark is will 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 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 Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
Page 6 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 1.378 1.417 1.457...
Page 7 Liter to U.S. Gallon = 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 8.454 8.718 8.982 9.246 9.510...
Page 8 m to lbf 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 to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 10 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 Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9...
Page 12 SECTION 1 GENERAL GROUP 1 SAFETY FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. 13031GE01 WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.
Page 13 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
Page 14 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 Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.
Page 16 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 Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Page 18 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Page 19 USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards. Use power tools only to loosen threaded tools and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.
Page 20: Group 2 Specifications
GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT Swing motor Fuel tank Hydraulic tank Boom swing cylinder Tool box Oil cooler Radiator Engine Main pump Turning joint Main control valve Tooth Bucket Arm cylinder Boom Boom cylinder Swing post Muffler Tail pipe Idler Counterweight Sprocket...
Page 21 2. SPECIFICATIONS 2.5m( 8' 2") MONO BOOM, 1.3m( 4' 3") ARM, WITH BOOM SWING POST I(I') B(L) R35Z72SP02 Description Unit Specification kg(lb) Operating weight 3650(8050) Bucket capacity(SAE heaped), standard 0.11(0.14) Overall length 4790(15' 9") Overall width, with 300mm shoe 1740( 5' 9") Overall height 2500( 8' 2") Overall height of cab...
Page 22 3. WORKING RANGE 2.5m(8' 2") MONO BOOM WITH BOOM SWING POST R35Z72SP03 Description 1.3m(4' 3") Arm Max digging reach 5360mm (17' 7") Max digging reach on ground 5240mm (17' 2") Max digging depth 3150mm (10' 4") Max digging depth (8ft level) 2660mm ( 8' 9") Max vertical wall digging depth...
Page 23 4. WEIGHT Item Upperstructure assembly 2100 4630 Main frame weld assembly 1060 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Boom swing post Counterweight Cab assembly Lower chassis assembly 1170 2580 Track frame weld assembly...
Page 24 5. LIFTING CAPACITIES 2.5m( 8' 2") boom, 1.3m( 4' 3") arm equipped with 0.11m (SAE heaped) bucket and 300mm(12") rubber track, the dozer blade up with 420kg(925lb) counterweight. : Rating over-front : Rating over-side or 360 degree Load radius At max. reach 1.0m(3.3ft) 2.0m(6.6ft) 3.0m(9.9ft)
Page 25 2.5m( 8' 2") boom, 1.3m( 4' 3") arm equipped with 0.11m (SAE heaped) bucket and 300mm(12") rubber track, the dozer blade down with 420kg(925lb) counterweight. : Rating over-front : Rating over-side or 360 degree Load radius At max. reach Load point 1.0m(3.3ft) 2.0m(6.6ft) 3.0m(9.9ft)
Page 26 6. BUCKET SELECTION GUIDE 0.11m SAE heaped bucket Recommendation Capacity Width 2.5m (8' 2") boom Weight CECE Without With 1.3m (4' 3") arm heaped heaped side cutter side cutter 0.11m 0.09m 550mm 610mm 80kg Applicable for materials with density of 1600kgf/m (0.14yd (0.12yd (21.7")
Page 27 Steel double grouser Rubber track Shapes Model Shoe width mm(in) 300(12") 300(12") Operating weight kg(lb) 3750(8267) 3650(8050) R35Z-7 Ground pressure kgf/cm (psi) 0.34(4.83) 0.34(4.83) Overall width mm(ft-in) 1740( 5' 9") 1740( 5' 9") NUMBER OF ROLLERS AND SHOES ON EACH SIDE Item...
Page 28 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Yanmar 3TNV88 Type 4-cycle diesel engine, low emission Cooling method Water cooling Number of cylinders and arrangement 3 cylinders, in-line Firing order 1-3-2 Combustion chamber type Direct injection type Cylinder bore stroke 88 90mm(3.46"...
Page 29 GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 10.7/5.1cc/rev Maximum pressure 230/30kgf/cm (3270/430psi) Rated oil flow 23.5/11.2 /min(6.2/3.0U.S. gpm/ 5.2/2.5U.K. gpm) MAIN CONTROL VALVE Item Specification Type Sectional, 10 spools(11 Blocks) Operating method Hydraulic pilot system Main relief valve pressure 230kgf/cm (3270psi)
Page 30 Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on the rod surface. Discoloration does not cause any harmful effect on the cylinder performance. SHOE (Steel track) Item Width Ground pressure Link quantity Overall width R35Z-7 300mm(12") 0.34kgf/cm (4.83psi) 1740mm( 5' 9") BUCKET Width Capacity Tooth...
Page 31 9. RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C( F) Capacity Service point Kind of fluid (U.S. gal) (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine Engine oil 6.7(1.8) oil pan...
Page 32: Section 2 Structure And Function
SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9 Group 3 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-38 Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-46...
Page 33 SECTION 2 STRUCTURE AND FUNCTION GROUP 1 HYDRAULIC PUMP 1. GENERAL This is a variable displacement double-piston pump for discharge with equal displacements from one cylinder block. This pump is so compact as to appear a single pump though this is actually a double pump.
Page 34 2. MAJOR COMPONENTS AND FUNCTIONS R35Z72MP03 Drive shaft assembly Trochoid pump Swash plate assembly 11 Oil seal Rotary group 12 Bearing Port plate assembly 14 Stopper assembly Spring seat assembly 16 Relief valve Control piston assembly 18 Spring Gear pump 19 Spring Housing This is a variable displacement double-piston pump for discharge with two equal displacements...
Page 35 PRINCIPLE OF OPERATION Function of pump Displacement q(cm /4 tan D Z/2 10 D : Strokes Z : Number of piston Piston Swash plate Bottom dead point (sliding surface) Cylinder block Control plate Suction port Top dead point c t i o r o c l i v e Outside...
Page 36 CONTROL FUNCTIONS Spring Swash plate Piston Piston for P3 shift Shifting flow line Qmax Flow Q R35Z72MP04 The delivery pressure P1 and P2 are directed to the piston which slides on the swash plate and acts on the swash plate. The spring is provided to act against the delivery pressure.
Page 37 CONTROL / ADJUSTMENT PROCEDURE Loosen the hexagonal nut. Tighten or loosen the adjusting screw to set the power shifting line. Spring seat Port plate Adjustment screw Hexagon nut Spring guide Loosen Tighten Tighten Pressure at initiation of tilting Loosen Qmax Flow Q R35Z72MP06...
Page 38 3. ADJUSTMENT This hydraulic pump has been set and inspected according to specified input power and control. Readjustment of all the adjusting portions may lead to the loss of functions specified for each control and the pump proper may be excluded from the scope of guarantee. Never attempt operating the adjusting screw, etc.
Page 39 (14) When the motor has reached the operation speed, check the operation while applying the load to the actuator. (15) Check the monitoring or measuring instrument if installed. (16) Check the noise level. (17) Check the oil level in the tank. Supply the oil. If required. (18) Check the setting of the pressure control valve while applying the load to the actuator.
Page 40 Changing the hydraulic oil After 2000 hours of operation. Every 2000 hours of operation or once a year after that. The change interval may have to be shortened depending on the degree of fouling and the thermal load condition of the hydraulic oil. If the hydraulic oil is not appropriate and need be changed, pay attention to the following points : Be sure to control the oil temperature below the highest temperature and above the lowest temperature during operation in winter and summer.
Page 41: Group 2 Main Control Valve
GROUP 2 MAIN CONTROL VALVE 1. OUTLINE (Pb1) (Pb2) (Pb3) (Pb4) (Pb5) (Pb6) (Pb7) (Pb8) (Pb10) (Pa1) (Pa3) (Pa4) (Pa6) (Pa7) (Pa8) (Pa2) (Pa5) (Pb8') (Pa10) R35Z72MCV01 Port Tightening Port Tightening Mark Port name Mark Port name size torque size torque P1 pump port Bucket out port...
Page 42 2. STRUCTURE(1/3) 4-10 4-11 4-10 4-12 4-11 3-10 4-13 2-10 4-16 4-14 4-15 4-17 4-18 1-10 3-10 2-10 1-10 R35Z72MCV03 Dozer work block 2-9 Cover-pilot 4-6 Plug 1-1 Body-work 2-10 Bolt-soc head w/washer 4-7 O-ring 1-2 Spool assy Swing work block 4-8 Cover-pilot 1-3 Poppet 3-1 Body-work...
Page 43 STRUCTURE(2/3) 6-10 5-10 5-7 5-8 6-10 5-10 R35Z72MCV04 PTO work block 6-2 Spool assy 7-4 Plug 5-1 Body-work 6-3 Poppet 7-5 O-ring 5-2 Spool assy 6-4 Spring 7-6 Cover-pilot 5-3 Poppet 6-5 O-ring 7-7 Cover-pilot 5-4 Spring 6-6 Plug 7-8 Bolt-soc head w/washer 5-5 O-ring 6-7 O-ring Inlet work block...
Page 44 STRUCTURE(3/3) 12-10 12-6 12-8 12-5 11-6 12-7 12-4 11-2 12-3 11-5 11-4 11-11 11-9 108 109 11-12 10-6 10-10 11-10 12-7 10-5 10-8 10-4 12-2 10-3 9-10 12-9 11-7 11-2 11-1 10-7 11-3 11-8 12-10 10-7 10-2 10-9 10-10 9-10 R35Z72MCV05 Travel work block 10-7 O-ring...
Page 45 3. HYDRAULIC CIRCUIT DOZER BOOM SWING SWING MRV3 Boom Up TRAVEL MRV2 MRV1 TRAVEL Pb8' BOOM Pb8' Pb10 Pa10 BUCKET R35Z72MCV02 2-13...
Page 46 4. FUNCTION IN NEUTRAL (When all spools are in neutral position) The oil discharged from the hydraulic pump flows into control valve P1 port, and then flows P1 : through P1 and P2 supply body the P1 side travel spool. The oil flows through the bypass passage in the direction of travel boom bucket spool, and then flows from the bypass...
Page 47 P3 side bypass passage P3 side parallel passage P2 side parallel passage P2 side bypass passage P1 side parallel passage P1 side bypass passage Tank passage Hydraulic oil flow in neutral R35Z72MCV11 2-15...
Page 48 TRAVEL OPERATION For the travel operation, both Pa pressurization and Pb pressurization are the same on operation so that only Pa pressurization is explained as follows. When left (right) travel reverse is operated, the secondary pressure from the remote control valve is applied to Pa6 [Pa7] port to change over the travel spool.
Page 49 BOOM OPERATION Boom up operation When the boom up operation is carried out, the secondary pressure from the remote control valve is applied to Pa8 port to change over the boom spool. Since Pa8 port is connected to boom up port through the piping, the pressure oil supplied to boom up port changes over the connecting spool through the connecting piston in the P3 supply section Also, since the P1 side bypass passage is shut off at the boom section after the boom spool...
Page 50 P1 side circuit Bridge passage Oil flows into lock valve comp. and then out of A9 port through lock valve Spool changeover direction parallel passage Boom Boom lock valve comp To bridge passage To cylinder head side To B8 port in boom comp.
Page 51 Boom down operation When the boom down operation is carried out, the secondary pressure from the remote control valve is applied to Pb8 port to change over the boom spool. Since Pb8 port is connected to Pb8' port through the piping, the pressure is also applied to pb8' port (Boom lock valve release port) to release the boom lock valve.
Page 52 Operation of boom lock valve Holding In the boom spool neutral condition, The pilot piston chamber (a) is connected to the drain passage through the pilot port (Pb8') for releasing the boom lock valve. The piston chamber (b) is also connected to the drain passage through the drain port (Dr2). Therefore, the piston (B) maintains the condition shown in the figure.
Page 53 Release When the pilot pressure is applied to the pilot port (Pb8') for boom lock valve release, the piston (B) moves rightward to open the needle valve through the piston (A1). Then, the oil returned from the boom cylinder flows through the passage in the direction of lock valve's orifice lock valve chamber needle valve seat...
Page 54 BUCKET OPERATION Bucket in operation When the bucket in operation is carried out, the secondary pressure from the remote control valve flows into Pb10 port to change over the bucket spool. Since the P1 side bypass passage is shut off at the bucket section after the bucket spool changeover, the oil flowed from P1 port flows through the check valve provided above the bypass passage in the travel section into the P1 side parallel passage.
Page 55 Bucket out operation When the bucket out operation is carried out, the secondary pressure from the remote control valve flows into Pa10 port to change over the bucket spool. Since the P1 side bypass passage is shut off at the bucket section after the bucket spool changeover, the oil flowed from P1 port flows through the check valve provided above the bypass passage in the travel section into the P1 side parallel passage.
Page 56 ARM OPERATION Arm in operation When the arm in operation is carried out, the secondary pressure from the remote control valve is applied to Pb5 port to change over the arm spool. The secondary pressure is also applied to the pilot chamber (arm in port) on the connecting section spring chamber side that has been connected through the piping.
Page 57 Arm out operation When the arm out operation is carried out, the secondary pressure from the remote control valve is applied to Pa5 port to change over the arm spool. Since the P2 side bypass passage is shut off at the arm section after the arm spool changeover, the oil flowed from P2 port flows through the travel section and a passage between travel section and arm section into the P2 side parallel passage.
Page 58 PTO OPERATION For the PTO operation, both Pa pressurization and Pb pressurization are the same on operation so that only Pa pressurization is explained as follows. When the PTO operation (Pa4 pressurization) is carried out, the secondary pressure from the remote control valve is applied to Pa4 port to change over the PTO spool.
Page 59 DOZER OPERATION Dozer up operation When the dozer up operation is carried out, the secondary pressure from the remote control valve is applied to Pa1 port to change over the dozer spool. Since the P3 side bypass passage is shut off at the dozer section after the dozer spool changeover, the oil flowed from P3 port through the P3 side parallel passage flows into A1 port through the load check valve in the dozer section and the bridge passage since A1 port and the bridge passage have been opened after the spool changeover and then into the rod side of the dozer cylinder.
Page 60 Dozer down operation When the dozer down operation is carried out, the secondary pressure from the remote control valve is applied to Pb1 port to change over the dozer spool. Since the P3 side bypass passage is shut off at the dozer section after the dozer spool changeover, the oil flowed from P3 port through the P3 side parallel passage flows into B1 port through the load check valve in the dozer section and the bridge passage since B1 port and the bridge passage have been opened after the spool changeover and then into the head side of the dozer cylinder.
Page 61 BOOM SWING OPERATION Boom left swing operation When the boom left swing operation is carried out, the secondary pressure from the remote control valve is applied to Pb2 port to change over the boom swing spool. Since the P3 side bypass passage is shut off at the boom swing section after the boom swing spool changeover, the oil flowed from P3 port through the P3 side parallel passage flows into B2 port through the load check valve in the boom swing section and the bridge passage since B2 port and the bridge passage have been opened after the spool changeover and then into the rod side of the...
Page 62 Boom right swing operation When the boom right swing operation is carried out, the secondary pressure from the remote control valve is applied to Pa2 port to change over the boom swing spool. Since the P3 side bypass passage is shut off at the boom swing section after the boom swing spool changeover, the oil flowed from P3 port through the P3 side parallel passage flows into A2 port through the load check valve in the boom swing section and the bridge passage since A2 port and the bridge passage have been opened after the spool changeover and then into the head side of...
Page 63 (10) SWING OPERATION For the swing operation, both Pa pressurization and Pb pressurization are the same on operation so that only Pa pressurization is explained as follows. When the right swing operation is carried out, the secondary pressure from the remote control valve is applied to Pa3 port to change over the swing spool.
Page 64 COMBINED CONTROL OPERATION Boom up + Arm in + bucket When the above combined control is carried out, the secondary pressure from the remote control valve is applied to each spool to change over them. Since the secondary pressure for arm in operation is also applied to the pilot chamber on the connecting section spring chamber side according to the piping, the connecting spool operates against the secondary pressure developed from boom up operation and arm in operation.
Page 65 P3 side (Connecting side) circuit To P2 side parallel passage To P1 side parallel passage Boom up Arm in From P3 side bypass passage To P3 side parallel passage From P3 side bypass passage Oil flows into P2 side parallel passage and To P1 side parallel passage To P2 side parallel passage out of the tank passage through the bypass...
Page 66 COMBINED CONTROL OPERATION Both travels + bucket When the both travels operation is carried out together with the bucket operation at the same time, the oil flowed from Pp1 port flows through the orifice passage and into the travel independent signal passage;...
Page 67 (13) MAIN AND PORT RELIEF VALVE OPERATION Main relief valve operation Main relief valves (MRV) are different in the uses for P1/P2 and P3; however, their structures and operation are the same. Pressure oil flows through the inside of the piston built in the pressure regulating valve (poppet- main V') and the orifice B and then into the internal chamber A until it is filled up.
Page 68 Overload relief valve (ORV) operation Pressure oil flows through the inside of the piston built in the pressure regulating valve (poppet- main V') and the orifice B and then into the internal chamber A until it is filled up. The filled up pressure causes both of the pressure regulating valve and socket and body seat to be seated securely.
Page 69 Overload relief valve (ORV) operation peration during suction If there is negative pressure at port P (or the tank passage pressure is higher than P pressure), the socket is applied with press and open force. Then, the opening between body seat and socket increases to cause the oil to flow into port P from the tank passage, filling up the space.
Page 70: Group 3 Swing Device
GROUP 3 SWING DEVICE 1. STRUCTURE Swing device consists swing motor and swing reduction gear. SWING MOTOR Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Output shaft Name plate Relief valve Check valve B Mu A R35Z72SM01 Port...
Page 71 COMPONENTS 2-13 2-25 2-11 2-3 1-20 1-13 2-12 1-37 1-22 1-21 1-19 1-18 1-14 1-11 2-45 2-12 2-14 1-12 1-10 2-23 1-35 1-36 2-24 2-46 1-16 2-22 2-10 2-10 2-18 2-15 2-19 2-16 2-15 2-27 2-41 2-21 2-42 2-26 2-43 2-44 2-16 2-14 2-1 1-23...
Page 72 2. DESCRIPTION OF FUNCTION AND OPERATION SWASH PLATE MOTOR The cylinder block incorporates nine pistons. The end face of the cylinder block is in contact with the valve plate having two woodruff ports B and C (distributing valve to change over between high and low pressure).
Page 73 PARKING BRAKE The parking brake is of wet type multi-plate construction of hydraulic release type and has a shaft lock mechanism that changes between ON and OFF of the brake by external signal pressures. Parking brake ON When the hydraulic pressure for brake release is shut, the disc coupled to the periphery of the cylinder block via the spline is pushed by the spring force against the brake piston (pinned to the case so that it will not rotate) and the cylinder block and the case secured by the frictional force.
Page 74 RELIEF VALVE The relief valves determine the drive force and the brake force for hydraulic shovel swing and are installed in the main port A and B lines. The circuit is configured to return the relief valve return oil to the counterpart main low pressure line.
Page 75 Relief valve operation First stage At the start of operation, the shockless piston moves to maintain the spring chamber at a low pressure. Thus, the pressure receiving area of the poppet becomes the poppet seat area (S1), a considerably larger area than the pressure receiving area (S1-S2) at the specified relief setting. For this reason, the relief operating pressure is kept at a low pressure until the shockless piston completes its movement.
Page 76 MAKE-UP VALVE The make-up valve has the following two functions. One is to prevent cavitation produced by overrun of the piston motor in order to prevent the overrun of the upper body. When the motor is turned by the inertia of the upper body to cause the pumping action, which then causes the motor revolution to rise above the revolution equivalent to the amount of oil supplied to the motor, the amount of oil equipvalent to the shortage is supplied to the motor main circuit via the make-up valve from outside to prevent occurrence of vacuum inside the circuit.
Page 77 REDUCTION GEAR (Planetary two-stage) Refer to the cross section. The motor shaft (1) is coupled to the drive gear (2) via a spline. The drive force of the hydraulic motor is transmitted from the drive gear (2) to the engaged planetary gear (3). The planetary gear (3) is meshed with the ring gear of the reduction gear housing (4).
Page 78: Group 4 Travel Device
GROUP 4 TRAVEL DEVICE 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes counterbalance valve, parking brake and high/low speed changeover mechanism. Oil fill port(PT 3/8) Oil check port(PT 3/8) Oil drain port(PT 3/8) R35Z72TM20 Port Port name Port size Main port...
Page 79 STRUCTURE R35Z72TM01 1-17 Holder Swash plate 27 Ball bearing 43 Plug 52 Drive screw Gear box 1-1 Flange holder 1-18 Planetary gear (A) Steel ball 28 O-ring 44 O-ring 55 Plug 1-2 Floating seal 1-19 Needle bearing Cylinder block 29 O-ring 45 Plug 57 O-ring 1-20 Inner race...
Page 80 BASIC STRUCTURE Counterbalance valve Swash plate type axial piston motor Reduction gear 1st/2nd speed change mechanism Parking brake mechanism R35Z72TM02 The travel motor is integrated with swash plate type axial piston motor, counterbalance valve, 2 speed change mechanism, parking brake, anti-cavitation valve and reduction gear unit. 2-47...
Page 81 2. FUNCTION HYDRAULIC MOTOR Shaft(2) Swash plate(5) Piston sub assy(14) Cylinder block(7) Valve plate(21) Port B Port C R35Z72TM03 Nine piston assemblies (14) are assembled in cylinder block (7). The end face of cylinder block (7) is in contact with valve plate (21) having two crescent shaped ports, B and C (high and low pressure ports).
Page 82 COUNTERBALANCE VALVE Spring L(37) Spring R(37) Orifice L(40) Orifice R(40) Control valve Spring L(31-3) Spring R(31-3) Check valve L(31-2) Check valve R(31-2) Motor Plunger(31-1) Plunger notch portion R35Z72TM04 The counterbalance valve is provided to stop the axial piston motor and to prevent overrun. When the control valve is set to the neutral position, there is no pressure in the ports P1 and P2, and ports M1 and M2 are blocked by plunger (31-1) and check valve (31-2), consequently the motor does not start rotating.
Page 83 Counterbalance valve work Spring L(37) Spring R(37) Orifice L(40) Orifice R(40) Control valve Spring R(31-3) Spring L(31-3) Check valve R(31-2) Check valve L(31-2) Motor Plunger(31-1) Plunger notch portion R35Z72TM05 When the fluid is supplied from pump to counterbalance valve port P1 through control valve, the fluid flows into piston motor through check valve L (31-2), and rotate the piston motor.
Page 84 Brake work Spring R(37) Spring L(37) Orifice R(40) Orifice L(40) Control valve Spring R(31-3) Spring L(31-3) Check valve L(31-2) Check valve R(31-2) Motor Plunger(31-1) Plunger notch portion R35Z72TM06 Then, when the control valve returns to the neutral position, the pressurized oil from the pump is shut off and the pressures of the ports P1 and P2 become equal.
Page 85 TWO SPEED CHANGE MECHANISM When running at 1st speed (low speed) Swash plate (5) has three faces, from "a" to "c", as shown below in the figure and installed in the flange holder that is piston motor housing with two steel balls (6) in the condition where it can be tilted.
Page 86 When running at 2nd speed (high speed) When control valve is set to the 2nd speed position, the pressure oil delivered by the pump is led to spool (41) and spool (41) is switched to the position shown below in the figure. And the pressurized oil flows into each ports Pi1 and Pi2 through ports M1 and M2 and the motor driving pressure (P1 : high pressure and P2 : low pressure) is led to each swash plate control piston (19).
Page 87 AUTO TWO SPEED CHANGE MECHANISM Auto two speed control mechanism consists of two spools and spring. This valve automatically changes motor displacement in portion to motor pressure. This valve works while the pilot port Ps is pressurized. Motor pressure is low ( ( 1) The motor displacement is small (high speed displacement) as shown in the figure.
Page 88 Motor pressure is high The motor displacement is large (low speed displacement) as shown in the figure. The two speed spool is on the left position if Pin pressure is high. Then, PM1 and PM2 are shutted by the spool. If the motor pressure is higher and keep the following condition, the spool stay on the left position.
Page 89 ANTI CAVITATION VALVE (With parking brake) Anti cavitation valve is always working with counterbalance valve. This system consists of oil passage "A", "B", "C" and spool in addition to traditional counterbalance valve. Counterbalance valve spool Distriction "C" Oil passage "A" Distriction "B"...
Page 90 From stopping to starting (high speed) Counterbalance valve spool is moved to right position by the force of spring when port P1 is pressurized. According as the movement of spool, P1 connects to M1 and M2 connects to P2. Consequently the motor work. At the same time, oil passage A is selected high pressure, however, there is no oil flow to oil passage C because of the movement of spool.
Page 91 Continuous rotating In case of continuous rotating, the oil passage A is also selected high pressure, however, there is no oil flow to oil passage C. So, anti cavitation valve has no influence during motor operation. Counterbalance valve spool Distriction "C" Oil passage "A"...
Page 92 From continuous rotating to deceleration At deceleration, the motor is still rotated by inertia. The oil flows M2 port to P2 port during counterbalance valve is opened. Then, if the flow to P1 is not enough, the cavitation could be appeared in P1-M1 line.
Page 93 From deceleration to stopping Anti cavitation valve works until oil passage from A to P1 is shut. Shitting position from "A" to "P1" Counterbalance valve spool Distriction "C" Oil passage "A" Distriction "B" Inlet Outlet Spool Oil passage "C" Oil passage "B" (Low pressure) (High pressure) Motor...
Page 94 PARKING BRAKE Cylinder block Spline Disk Brake piston Spring Brake piston chamber R35Z72TM18 The parking brake is a kind of negative brake which consist of disk, brake piston and spring. The cylinder block and disk are combined with a spline, and friction material is bonded on both sides of disk.
Page 95 REDUCTION UNIT The reduction unit consists of double stage planetary gear mechanism. R35Z72TM19 Drive gear[1] is engaged with the 1st planetary gear [2], 2nd stage sun gear [4] is engaged with the 2nd planetary gear [5]. The 2nd stage planetary carrier [6] is fixed machine body. Planetary gears [2], [5] are engaged with ring gear (housing).
Page 96: Group 5 Rcv Lever
GROUP 5 RCV LEVER 1. STRUCTURE The casing has the oil inlet port P(Primary pressure) and the oil outlet port T(Tank). In addition the secondary pressure is taken out through ports 1,2,3 and 4 provided at the bottom face. 23.3 Single operation Simultaneous...
Page 97 CROSS SECTION The construction of the pilot valve is shown in the attached cross section drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool(11), spring(8, 9) for setting secondary pressure, return spring(4), stopper(7), spring seat(5, 6) and spring seat(10).
Page 98 CROSS SECTION , 31 R35Z72RL02 2-66...
Page 99 2. 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 applying the output pressure(Secondary pressure) of the pilot valve to the other end.
Page 100 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 (140-7TIER) Pilot valve Main pump Hydraulic motor...
Page 101 Case where handle is in neutral position R35Z72RL03 The force of the spring(8) that determines the output pressure of the pilot valve is not applied to the spool(11). Therefore, the spool is pushed up by the spring(4) to the position of port(1, 3) in the operation explanation drawing.
Page 102 Case where handle is tilted R35Z72RL04 When the push rod(12) is stroked, the spool(11) moves downwards. Then port P is connected with port(1) and the oil supplied from the pilot pump flows through port(1) to generate the pressure. When the pressure at port(1) increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force.
Page 103: 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-10...
Page 104: Group 1 Hydraulic Circuit
SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT "R2" P2(FW) P1(FW) P1(BW) P2(BW) "R1" B(CCW) A(CW) Pa10 Pb8' TRAVEL DOZER DOWN MAIN PUMP MAIN CONTROL VALVE SWING MOTOR TRAVEL MOTOR RCV LEVER-LH RCV LEVER-RH Pb10 SOLENOID VALVE TURNING JOINT BUCKET CYLINDER BOOM CYLINDER DOZER CYLINDER ARM CYLINDER...
Page 105: 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 106 2. RETURN CIRCUIT Full flow filter Oil cooler Main control valve Actuators Check valve 1.5kgf/cm Bypass relief valve 1.5kgf/cm R35Z73HC02 All oil returned from each actuator returns to the hydraulic tank through the control valve. The bypass check valves are provided in the return circuit. The setting pressure of bypass check valves are 1.5kgf/cm (21psi).
Page 107 3. DRAIN CIRCUIT Travel motor Swing motor Return line Turning joint Return filter Hydraulic oil tank R35Z73HC43 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. TRAVEL MOTOR DRAIN CIRCUIT Oil leaked from the right and left travel motors comes out of the drain ports provided in the respective motor casing and join with each other.
Page 108: Group 3 Pilot Circuit
GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve Travel pedal RCV dozer (LH lever) (RH lever) Boom swing pedal Safety lock Swing parking brake solenoid valve Control valve Travel speed solenoid valve Line filter Relief valve 30kgf/cm Pilot pump Suction filter R35Z73HC00 The pilot circuit consists of suction circuit, delivery circuit and return circuit.
Page 109 1. SUCTION, DELIVERY AND RETURN CIRCUIT SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 110 2. SAFETY VALVE(SAFETY LEVER) SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P1(FW) P2(BW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER MAIN CONTROL VALVE...
Page 111 3. TRAVEL SPEED CONTROL SYSTEM CONTROL PISTON PILOT VALVE SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P2(BW) P1(FW) P1(BW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH...
Page 112 4. SWING PARKING BRAKE RELEASE SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER...
Page 113: Group 4 Single Operation
GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL BOOM TURNING JOINT HOLDING VALVE Pa10 Pb8' BUCKET BOOM...
Page 114 2. BOOM DOWN OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL BOOM TURNING JOINT HOLDING VALVE Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING...
Page 115 3. ARM ROLL IN OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER...
Page 116 4. ARM ROLL OUT OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER...
Page 117 5. BUCKET ROLL IN OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER...
Page 118 6. BUCKET ROLL OUT OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER...
Page 119 7. SWING OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER MAIN CONTROL VALVE Pb10...
Page 120 SWING CIRCUIT OPERATION SWING MOTOR PARKING BRAKE "R2" "R1" MOTOR BRAKE VALVE MAKE UP VALVE B(CCW) A(CW) TO/FROM MAIN CONTROL VALVE R35Z73HC40 MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation.
Page 121 8. TRAVEL FORWARD AND REVERSE OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 122 TRAVEL CIRCUIT OPERATION Counterbalance valve P2(FW) P1(BW) P2(BW) P1(FW) Turning joint R35Z73HC42 Valves are provided on travel motors to offer the following functions. COUNTERBALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run. SPEED CHANGE MECHANISM (Auto) Auto two speed control mechnism consists of two spools and spring.
Page 123 9. DOZER UP OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER MAIN CONTROL VALVE...
Page 124 10. DOZER DOWN OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING DOZER MAIN CONTROL VALVE...
Page 125: Group 5 Combined Operation
GROUP 5 COMBINED OPERATION 1. OUTLINE SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM SWING TRAVEL-RH TRAVEL-LH SWING...
Page 126 2. COMBINED SWING AND BOOM OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 127 3. COMBINED SWING AND ARM OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(BW) P2(FW) P1(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 128 4. COMBINED SWING AND BUCKET OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 129 5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH...
Page 130 6. COMBINED SWING AND TRAVEL OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL ARM CYL B/SWING CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 131 7. COMBINED BOOM AND TRAVEL OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 132 8. COMBINED ARM AND TRAVEL OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P2(FW) P1(BW) P2(BW) P1(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 133 9. COMBINED BUCKET AND TRAVEL OPERATION SWING MOTOR TRAVEL MOTOR-RH TRAVEL MOTOR-LH DOZER CYL B/SWING CYL ARM CYL "R2" "R1" P1(BW) P2(BW) P1(FW) P2(FW) STOP VALVES B(CCW) A(CW) BOOM CYL BUCKET CYL TURNING JOINT Pa10 Pb8' BUCKET BOOM BOOM TRAVEL-RH TRAVEL-LH SWING SWING...
Page 134: Section 4 Electrical System
SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Monitoring system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3 Group 3 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9 Group 4 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-25...
Page 135: Group 1 Component Location
SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Switch Switch panel 3 panel 2 Switch panel 1 D IS Location at inside of battery box R35Z74EL02 Cigar light Washer/wiper switch 11 Beacon switch Start switch Heater switch 12 Speaker Travel alarm switch Master switch...
Page 136 2. LOCATION 2 R35Z74EL22 Lamp Battery Temperature sender Horn Fuel sender Air cleaner pressure switch Master switch Travel alarm buzzer Engine oil pressure switch...
Page 137: Group 2 Monitoring System
GROUP 2 MONITORING SYSTEM 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine. Various select switches are built into the monitor panel, which act as the control portion of the machine control system.
Page 138 CLUSTER CHECK PROCEDURE Start key : ON Check monitor initial 6 seconds All lamps light up. Check monitor after 3 seconds : Indicate machine condition Tachometer : 0 rpm Fuel gauge : Pointed at appropriate level Engine coolant temperature gauge : Pointed at appropriate level Warning lamp During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not abnormal.
Page 139 3. CLUSTER CONNECTOR CONNECTOR CN-56 POWER IG 12V LAMP, ENG OIL PRESSURE LAMP, CHARGE LAMP, WATER TEMP LAMP, AIR-CLEANER LAMP, FUEL EMPTY CN-56 LAMP, AIR-HEATER LAMP, QUICK CLAMP LAMP, ILLUMINATION GAUGE, WATER TEMP GAUGE, FUEL LEVEL RETURN, AIR-HEATER BUZZER(+) EARTH HOURMETER(B +) HOURMETER(SIG +) Cluster...
Page 140 4. CLUSTER FUNCTION GAUGES AND DISPLAYS Service meter This meter shows the total operation hours of the machine. Always ensure the operating condition of the meter during the machine operation. Inspect and service the machine based on hours as indicated in chapter 6, maintenance.
Page 141 WARNING AND PILOT LAMPS Fuel low level warning lamp This lamp blinks when the level of fuel is below 8.5 (2.2U.S. gal). Fill the fuel immediately when the lamp blinks. R5573CD10 Engine coolant temperature warning lamp This lamp blinks when the temperature of coolant is over the normal temperature 110 C (230 F ) .
Page 142 Preheat pilot lamp When the start switch turn to HEAT position, pilot lamp comes Refer to "4-2) STARTING ENGINE" of operator's manual for details. R35Z73CD06 Quick clamp warning lamp When the quick clamp switch turned ON, this lamp turn ON and the buzzer sounds.
Page 143 MEMORANDUM 4-10...
Page 144 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 Master switch[CS-74] Fusible link(CN-60) Start switch[CS-2(1)] I/conn[CN-5(2)] Fuse box[No.1]...
Page 145 POWER CIRCUIT R 28E CS-74 BATTERY MASTER SW CN-60 CS-2 CS-2 CS-46 CLUSTER CN-56 POWER IG 12V LAMP, ENG OIL LAMP, CHARGE LAMP, WATER TEMP LAMP, AIR-CLEANER LAMP, FUEL EMPTY LAMP, AIR-HEATER LAMP, QUICK CLAMP LAMP, ILLUMINATION GAUGE, WATER TEMP GAUGE, FUEL LEVEL RETURN, AIR-HEATER BUZZER(+)
Page 146 2. STARTING CIRCUIT 1 1 ) OPERATING FLOW Battery(+) terminal Master switch[CS-74] Fusible link[CN-60] Start key[CS-2(1)] I/conn[CN-5(2)] Fuse box No.1 Safety relay[CN-165(1)] Power relay[CR-35(30)] tart switch : ON Start switch ON [CS-46(2,3)] I/conn [CN-7(1)] Fuse box No. 2, 3 (Power is supplied) Safety relay[CN-165(3)] Power relay[CR-35(85) (87)]...
Page 147 STARTING CIRCUIT CN-74 CN-45 STARTER CS-74 BATTERY MASTER SW CN-60 CLUSTER CN-56 CN-2 POWER IG 12V LAMP, ENG OIL LAMP, CHARGE LAMP, WATER TEMP LAMP, AIR-CLEANER LAMP, FUEL EMPTY LAMP, AIR-HEATER LAMP, QUICK CLAMP LAMP, ILLUMINATION GAUGE, WATER TEMP GAUGE, FUEL LEVEL RETURN, AIR-HEATER BUZZER(+) EARTH...
Page 148 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the battery relay(CR-1). The current also flows from alternator to each electrical component and controller through the fuse box.
Page 149 CHARGING CIRCUIT CN-74 CN-45 STARTER CS-74 CLUSTER CN-56 POWER IG 12V BATTERY LAMP, ENG OIL MASTER SW LAMP, CHARGE LAMP, WATER TEMP LAMP, AIR-CLEANER CN-2 LAMP, FUEL EMPTY LAMP, AIR-HEATER LAMP, QUICK CLAMP LAMP, ILLUMINATION GAUGE, WATER TEMP GAUGE, FUEL LEVEL RETURN, AIR-HEATER BUZZER(+) EARTH...
Page 150 4. HEAD AND WORK LIGHT CIRCUIT OPERATING FLOW Fuse box (No.6) Light switch[CS-21(1)] Fuse box (No.5) Light switch[CS-21(4)] Main light switch ON : 1st step Cabin light switch ON [CS-21(5,7)] I/conn[CN-3(2)] I/conn[CN-2(8)] Cluster illumination ON [CN-56(9)] Cigar light illumination ON [CL-2] I/conn[CN-11(3)] Cabin Lamp ON[CL-9,10(2)] Cassette radio illumination ON [CN-27(7)]...
Page 151 HEAD AND WORK LAMP CIRCUIT CN-2 CLUSTER CN-56 POWER IG 12V LAMP, ENG OIL LAMP, CHARGE LAMP, WATER TEMP LAMP, AIR-CLEANER LAMP, FUEL EMPTY LAMP, AIR-HEATER LAMP, QUICK CLAMP LAMP, ILLUMINATION GAUGE, WATER TEMP GAUGE, FUEL LEVEL RETURN, AIR-HEATER BUZZER(+) EARTH HOURMETER(B +) HOURMETER(SIG +)
Page 152 5. BEACON LAMP CIRCUIT OPERATING FLOW Fuse box (No.19) l/conn[CN-6(15)] Beacon lamp switch[CN-23(5)] Beacon lamp switch ON Beacon lamp switch ON [CS-23(1)] Switch lndicator lamp ON [CS-23(9)] l/conn[CN-3(1)] l/conn[CN-1(5)] l/conn[CN-11(8)] Beacon lamp ON [CL-7] CHECK POINT Voltage Engine Start switch Check point - GND(Fuse box) - GND(Switch power input)
Page 153 BEACON LAMP CIRCUIT CN-1 R35Z74EL08 4-20...
Page 154 6. WIPER AND WASHER CIRCUIT OPERATING FLOW Key switch ON Fuse box (No.7) I/conn[CN-8(1)] I/conn[CN-8(1)] Wiper and washer switch[CS-3(1)] Wiper motor[CN-21(3)] Wipe switch ON : 1st step(Low speed) Wiper switch ON [CS-3(6)] Wiper motor operating[CN-21(4)] Wiper switch ON : 2nd step(Washer) Wiper switch ON [CS-3(6)] Wiper motor operating[CN-21(4)] Wiper switch ON [CS-3(3)]...
Page 155 WASHER CONTROL CIRCUIT R35Z74EL09 4-22...
Page 156 MONITORING CIRCUIT CN-1 R35Z74EL10 4-23...
Page 157 ELECTRIC CIRCUIT FOR HYDRAULIC CN-3 TRAVEL SPEED CN-1 SAFETY SW CS-8 R35Z74EL11 4-24...
Page 158: Group 3 Electrical Circuit
GROUP 3 ELECTRICAL CIRCUIT HEATER WIPER MOTOR HEATER SW WIPER&WASHER LIGHT SW BEACON LAMP WASHER SAFETY SW SPARE 0, I WIRING R35z-7 LH CONSOLE FRONT RH SIDE CN-83 CR-35 AC CON FAN CN-29 POWER RELAY START SW R/DRYER (H) (BR) (ACC) (ST) CN-165 START SIG.
Page 159: Group 4 Electrical Component Specification
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specification Check Check specific gravity 1.280 over : Over charged Battery 100Ah 1.280 ~ 1.250 : Normal 1.250 below : Recharging Check contact OFF : (For each terminal) Start key ON : 0 (For terminal 1-3 and 1-2) START : 0 (For terminal 1-5) CS-2 Check resistance...
Page 160 Part name Symbol Specification Check Check resistance Full : 30 Fuel sender Low : 100 Empty warning : 200 CD-2 Check resistance Normal : About 200 Relay 12V 20A (For terminal 1-3) : 0 (For terminal 2-4) CR-2 CR-7 CR-35 Relay 12V 70A Rated coil current 1.2 0.3A...
Page 161 Part name Symbol Specification Check Check disconnection 12V 55W Lamp (H3 TYPE) Normal : 1.2 CL-5 CL-9 CL-10 Check disconnection Room lamp 12V 10W Normal : A few CL-1 Horn CN-20 Check contact Normal : 0 Operating : Safety switch Micro CS-4 Check operation...
Page 162 Part name Symbol Specification Check Check disconnection Beacon lamp (Strobe type) Normal : A few CL-7 Check contact Wiper switch 0, I 12V 16A Normal : CS-3 Check contact Washer pump 12V 3.8A Normal : 3 (For terminal 1-2) CN-22 Check coil resistance Normal : About 1M Check contact...
Page 163 Part name Symbol Specification Check S.R- S.R- S.L- Check voltage S.L- Cassette radio 12V 3A 10 ~ 12.5V ILL+ S.R+ S.R+ (For terminal 10-14,11-14) S.L+ CN-27 S.L+ Check contact Receiver dryer Normal : 0 CN-29 Check contact Starter Normal : 0.1 CN-45 Check contact Alternator...
Page 164 Part name Symbol Specification Check Air con 12V 8.5A fan motor CN-83 Fuel feed pump CN-145 Master switch 12V 1000A CN-74 Timer CR-50, CN-62 Duct sensor C OFF Check resistance (Switch) : 0 (For terminal 1-2, 4 C ON the atmosphere temp : over 4 C ) Preheater 12V 42A 500W 4-30...
Page 165 Part name Symbol Specification Check START SIG. ¡ Contact capacity : ALT PULSE Safety relay GROUND 1400rpm/ Rush : 100A Steady-State : 50A(30sec) Alternator BATTERY MAGNET CN-165 CN-166 CN-165, CN-166 Detector FUEL LOW LEVEL CN-167 CN-167 4-31...
Page 166: Group 5 Connectors
GROUP 5 CONNECTORS 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male Cabin room harness-RH CN-1 2-85262-1 368301-1 Cabin room harness-RH CN-2 2-85262-1 368301-1 Cabin room harness-LH CN-3 2-85262-1 368301-1 Front-RH side harness CN-4 S810-004202 S810-104202 Relay harness CN-5...
Page 167 Connector part No. Connector No. of Type Destination number Female Male CN-83 Air-con fan MG610164 CN-139 12V socket S810-002202 CN-140 DEUTSCH Quick clamp DT06-2S-P012 DT04-2P-E004 CN-145 Fuel feed pump 7123-6423-30 CN-165 Safety relay 6195-0021 CN-166 Safety relay 6195-0060 CN-167 Detector S810-008202 LAMP CL-1...
Page 168 Connector part No. Connector No. of Type Destination number Female Male S822-014000 CS-26 Breaker switch S822-114000 CS-27 Breaker switch 593757 CS-46 Start switch MG651926 CS-67 Quick clamp switch 593757 CS-74 Master switch ST710287-2 CS-83 Spare 593757 4-34...
Page 169 2. CONNECTION TABLE FOR CONNECTORS 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 4-35...
Page 170 No. of Receptacle connector(Female) Plug connector(Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4-36...
Page 171 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 4-37...
Page 172 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 4-38...
Page 173 No. of Receptacle connector(Female) Plug connector(Male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4-39...
Page 174 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 4-40...
Page 175 No. of Receptacle connector(Female) Plug connector(Male) S810-006202 S810-106202 S810-008202 S810-108202 4-41...
Page 176 375 FASTEN TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 344111-1 344108-1 AMP TIMER CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 85202-1 4-42...
Page 177 AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 174045-2 AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 173852 AMP FASTIN - FASTON CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 925276-0 480003-9 4-43...
Page 178 KET 090 CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) MG610070 KET 090 WP CONNECTORS No. of Receptacle connector(Female) Plug connector(Male) MG640605 MG640795 4-44...
Page 179 KET SDL CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) MG610406 4-45...
Page 180 DEUTSCH DT CONNECTORS DT 06 - 3S - Modifications(See below) Number of contacts(P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connectors Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 181 No. of Receptacle connector(Female) Plug connector(Male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 4-47...
Page 182 MOLEX 2CKTS CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 35215-0200 ITT SWF CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) SWF593757 MWP NMWP CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) NMWP01F-B 4-48...
Page 183: Section 5 Troubleshooting
SECTION 5 TROUBLESHOOTING Group 1 Before Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4 Group 3 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-24...
Page 184: Group 1 Before Troubleshooting
GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help an operator to maintain the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system and Electrical system system. At each system part, an operator can check the machine according to the troubleshooting process diagram.
Page 185 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 186 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. 6-3(1) 140-7 STEP 5.
Page 187: Group 2 Hydraulic And Mechanical System
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION 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. Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look for the cause based on the troubleshooting principle and perform maintenance and adjustment to prevent major failure from occurring.
Page 188 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and check if rubber Replace hub or pieces or particles retighten are not present. setscrew. Coupling hub spline is worn or hub fastening...
Page 189 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 hydraulic pump broken. and repair. standard level? Do not hydraulic Abnormal noise...
Page 190 3 3 . HYDRAULIC SYSTEM 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. oil. Air is intruded.
Page 191 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 Is not suction strainer. Is not air intruding strainer clogged? from pump Check for air...
Page 192 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish specified oil to the Is safety solenoid standard level. valve pressure within standard? Safety valve faulty Repair or replace. Is gear pump pilot pressure within or not operated. standard level? Is oil in hydraulic tank within...
Page 193 SWING SPEED IS LOW Cause Remedy Swing port relief Disassemble and Does swing control valve is faulty. repair or replace. valve spool move smoothly by hand? Swing control valve Disassemble Is MCV pilot spool is stuck. and repair. pressure same on LH and RH Clogged or oil Clean pilot piping...
Page 194 SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble and change when LH valve is faulty. repair. and RH port relief valves are exchanged Shuttle valve is Disassemble and Does swing control faulty. repair. valve spool move smoothly by hand? Is MCV pilot...
Page 195 THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy Is swing shuttle valve normal? Disassemble Shuttle valve is and replace. faulty. Is brake spring normal? Is return spring of swing control Disassemble Brake spring is valve normal? and replace.
Page 196 5 5 . TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause Remedy Does counterbalance spool in travel brake valve move lightly by hand? Disassemble Counter spool in Is travel brake valve pressure and repair or travel brake valve within standard replace.
Page 197 S S PEED 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 Does the symptom brake valves are change when in travel motor is...
Page 198 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. and repair. brake pilot line is not clogged.
Page 199 TRAVEL ACTION IS POWERLESS(Travel only) Cause Remedy Is travel motor's drain rate within standard level? Is travel brake Disassemble Travel motor is pressure within and repair. faulty. standard level? Is travel relief valve pressure Disassemble Travel brake within standard and repair or valve is defective.
Page 200 MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal. Is select valve normal? Select valve is Repair or Is travel lever faulty. replace. operate normal? Remove dirt on Is filter in pilot...
Page 201 6 6 . ATTACHMENT SYSTEM 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. valve is replaced with other valve? Is MCV pilot pressure within standard level? Inspect if pilot...
Page 202 B B OOM, 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? Flow summation Disassemble and hoisting and at Does spool of flow arm extrusion? check valve spool...
Page 203 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 Normal replace. relief valve is replaced with Is control valve normal valve? return spring Is not hydraulic normal?
Page 204 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. Disassemble valve within and repair. standard level? Is relief pressure in main relief...
Page 205 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. sufficiently? Frictional noise will disappear if they are kept used.
Page 206 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. R35Z75TS01 Disconnect hose(A) from rod side of boom cylinder and drain oil from cylinders and hose.(Put cups on piping and hose ends) R5575BY02 Raise bucket OFF the ground by retracting...
Page 207: Group 3 Electrical System
GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 208 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 cluster...
Page 209 WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Coolant overheat...
Page 210 WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Clogged air filter or...
Page 211 WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Engine oil leakage,...
Page 212 6. 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 Repair or replace...
Page 213 7. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Disconnection in...
Page 214 8. 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.10. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Hydraulic...
Page 215 9. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.10 . After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective hydraulic...
Page 216 10. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.8 is not blown out. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 217 11. 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.6. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 218 12. 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.5. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 219 13. WHEN ENGINE DOES NOT START Check supply of the power at engine stop solenoid while starting switch is ON. Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 220 14. 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 and master switch ON. After checking, insert the disconnected connectors again immediately unless otherwise specified. FUSIBLE LINK START SWITCH Cause...
Page 221: Section 6 Maintenance Standard
SECTION 6 MAINTENANCE STANDARD Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-21 Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31...
Page 222: Group 1 Operational Performance Test
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 Working meets Hyundai spec. condition OPERATIONAL PERFORMANCE OF A Operating WORKING MACHINE With the passage of time, the machine's...
Page 223 2. TERMINOLOGY STANDARD Specifications applied to the brand-new machine, components and parts. R35Z76MC02 SERVICE LIMIT The lowest acceptable performance level. When the performance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
Page 224 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 225 50 5 C. Set the accel lever at the maximum stroke. Measure the engine RPM. valuation The measured speeds should meet the following specifications. Unit : t / rpm Model Engine speed Standard Remark Low idle 1100 R35Z-7 High idle 2350 50...
Page 226 R35Z76MC05 values. ( ( 4) valuation The average measured time should meet the following specifications. Unit : Seconds / 20m Model Travel speed Standard Maximum allowable Remarks 1 Speed 28.8 R35Z-7 2 Speed 16.0 1.0...
Page 227 ( ( 4) valuation The revolution cycle time of each track should meet the following specifications. Unit : Seconds / 3 revolutions Model Travel speed Standard Maximum allowable 1 Speed 19.3 24.0 R35Z-7 2 Speed 10.6 2.0 13.2...
Page 228 Repeat steps three times and 7-7(2) 140-7 calculate the average values. ( ( 4) valuation Mistrack should be within the following specifications. Unit : mm / 20m Model Standard Maximum allowable Remarks R35Z-7 200 below...
Page 229 Swing 1 turn and measure time taken to swing next 2 revolutions. Repeat steps three time and calculate the average values. valuation The time required for 2 swings should meet the following specifications. Unit : Seconds / 2 revolutions Model Standard Maximum allowable Remark R35Z-7 12.6 15.8...
Page 230 Repeat steps three times each and calculate the average values. ( ( 4) valuation R35Z76MC08 The measured drift angle should be within the following specifications. Unit : Degree Model Standard Maximum allowable Remarks R35Z-7 40 below...
Page 231 Record the dial gauge reading(h2). Calculate bearing play(H) from this data(h1 and h2) as follows. H=h2-h1 R35Z76MC10 ( ( 4) Evaluation The measured drift should be within the following specifications. Unit : mm Model Standard Maximum allowable Remarks R35Z-7 0.5 ~ 1.2 6-10...
Page 232 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. Preparation To measure the cycle time of the boom cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown.
Page 233 Remarks Boom raise Boom lower 2.1 0.4 Arm in 2.9 0.4 Arm out 2.3 0.4 Bucket load 3.2 0.4 R35Z-7 Bucket dump 2.1 0.4 Boom swing(LH) 5.3 0.4 Boom swing(RH) 4.0 0.4 Dozer up(Raise) 1.3 0.3 Dozer down(Lower) 1.3 0.3...
Page 234 ( ( 4) 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 R35Z-7 Arm cylinder 20 below Bucket cylinder 20 below 6-13...
Page 235 The measured operating force should be within the following specifications. Unit : kgf Model Kind of lever Standard Maximum allowable Remarks Boom lever 1.4 or below Arm lever 1.4 or below R35Z-7 Bucket lever 1.4 or below Swing lever 1.4 or below Travel lever 2.0 or below 6-14...
Page 236 The measured drift should be within the following specifications. Unit : mm Model Kind of lever Standard Maximum allowable Remarks Boom lever Arm lever 87 10 R35Z-7 Bucket lever 87 10 Swing lever 87 10 Travel lever 86 10 6-15...
Page 237 Keep the hydraulic oil temperature at 50 5 C. easurement Measure the primary pilot pressure in the R35Z76MC14 H mode. Evaluation The average measured pressure should meet the following specifications: Unit : kgf / cm Model Standard Remarks R35Z-7 6-16...
Page 238 Repeat steps three times and calculate the average values. valuation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Travel speed mode Standard Maximum allowable Remarks 1 Speed R35Z-7 2 Speed 6-17...
Page 239 Repeat three times and calculate the average values. Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Description Standard Remarks Brake disengaged R35Z-7 Brake applied 6-18...
Page 240 Keep the hydraulic oil temperature at 50 5 C. easurement Measure the main pump delivery R35Z76MC17 pressure at high idle. Evaluation The average measured pressure should meet the following specifications. Unit : kgf / cm Model Engine speed Standard Allowable limits Remarks R35Z-7 High ilde 6-19...
Page 241 Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Function to be tested Standard Boom, Arm, Bucket R35Z-7 Travel 230 10 Swing 230 10 6-20...
Page 242: Group 2 Major Components
GROUP 2 MAJOR COMPONENT 1. MAIN PUMP Before inspection, wash the parts well and dry them completely. Inspect the principal parts with care and replace them with new parts when any abnormal wear exceeding the allowable limit or damage considered harmful is found. Replace the seal also when any remarkable deformation and damage are found.
Page 243 CONTROL PLATE Check the slide surface for any damage. When the damage is large, replace the plate with new one. R55NM7PH48 GUIDE AND RETAINER Check for scouring or stepped wear. If this can not be corrected, replace the guide and retainer with new full-set. Fine scouring or damage can be corrected with lapping.
Page 244 . MAIN CONTROL VALVE Part name Inspection item Criteria & measure Block Existence of scratch, rusting or corrosion. In case of damage in following section, replace part. - Sliding sections of casing fore and spool, especially land sections applied with holded pressure.
Page 245 3. SWING MOTOR Replace the parts referring to the following table. MOTOR Part name Service criteria 1. The sliding parts are scratched deeply or the sliding surface has become rough. 2. The clearance between the piston and the cylinder block bore is too large. Piston assembly (2-13) Upper limit of diameter clearance : 0.04mm.
Page 246 EDUCTION GEAR Part name Service criteria 1. The gear tooth surface is damaged excessively, worn of flaked. Pinion shaft (1-2) 1. The plate is damaged or worn excessively. Plates (1-3), (1-8) 1. The roller or the race is damaged excessively, dented or flaked. Taper roller bearings (1-5), (1-7) 2.
Page 247 4. TRAVEL MOTOR Wash all parts disassembly in treated oil and dry in the compressed air. Perform maintenance including replacement or corrections in accordance with the following criterion. Criterion (Recommended Parts Name Check Points Measures standards for replacement) No remarkable flaws, wear, Floating seal (1-2) Sliding surface Replacement...
Page 248 Criterion (Recommended Parts Name Check Points Measures standards for replacement) Correct lapping (#1000) if Sliding surface and No remarkable flaws (over sliding surface is rough. roughness between 0.02 [mm] in thickness), Swash plate (5) Replace if proper piston sub assembly wear, or seizure are noted.
Page 249 Criterion (Recommended Parts Name Check Points Measures standards for replacement) Sliding surface No remarkable flaws, wear, Replace both base plate between plunger and or seizure are noted. and plunger. base plate. Plunger (31-1) Sliding surface No remarkable flaws, wear, Replace both check valve between plunger and or seizure are noted.
Page 250 5. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination. Replace sealing sections. Sliding surface Worn abnormality or damaged more than 0.1mm Replace between body and (0.0039in) in depth due to seizure contamination. stem other than Body, Damaged more than 0.1mm(0.0039in) in depth.
Page 251 6. CYLINDER Part name Inspecting section Inspection item Remedy Piston rod Neck of rod pin Presence of crack Replace 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 Plated surface Plating is not worn off to base...
Page 252: Group 3 Track And Work Equipment
GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK SHOE STEEL SHOE SPEC R35Z76MC18 Unit : mm Criteria Check item Remedy Standard size Repair limit Replace bushing Link pitch 101.6 105.0 and pin and link Outside diameter of bushing 32.17 28.77 assembly Height of grouser 16.5...
Page 253 RUBBER SHOE SPEC SECTION B-B SECTION A-A R5576MC17 Unit : mm Criteria Check item Remedy Standard size Repair limit Link pitch 52.5 54.5 Height of grouser 23.5 Replace Width of link 6-32...
Page 254 2. IDLER R5576MC18 Unit : mm Criteria Check item Remedy Standard size Repair limit Steel Outside diameter of flange Rubber Rebuild Steel or replace Outside diameter of thread Rubber Width of flange 26.2 20.2 6-33...
Page 255 3. TRACK/CARRIER ROLLER R35Z76MC19 Unit : mm Criteria Check item Remedy Standard size Repair limit Steel Outside diameter of flange Rubber Rebuild Steel or replace Outside diameter of thread Rubber Width of flange 26.2 20.2 6-34...
Page 256 . CARRIER ROLLER R35Z76MC20 Unit : mm Criteria Check item Remedy Standard size Repair limit Outside diameter of flange Replace Width of tread Diameter of shaft 6-35...
Page 257 5. TENSION CYLINDER R35Z76MC21 Unit : mm Criteria Check item Remedy Standard size Repair limit Rebuild Track frame Vertical width of idler guide Idler support Rebuild or replace Track frame Rebuild Horizontal width of idler guide Idler guide Rebuild or replace Standard size Repair limit Free...
Page 258 6. SPROCKET R35Z76MC22 Unit : mm Criteria Check item Remedy Standard size Repair limit Wear out of sprocket tooth 313.72 304.72 lower side diameter Wear out of sprocket tooth 359.75 upper side diameter Repair or Replace Wear out of sprocket tooth upper side width Wear out of sprocket tooth lower side width...
Page 259 7. WORK EQUIPMENT H I J K R35Z76MC30 Unit : mm Bushing Remedy Normal Measuring point Recomm. Recomm. Mark & Limit Limit (Pin and Bushing) value service service Remark of use of use limit limit Boom Rear 48.5 50.5 Replace Boom Cylinder Head 43.5 45.5...
Page 260: Section 7 Disassembly And Assembly
SECTION 7 DISASSEMBLY AND ASSEMBLY Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4 Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33...
Page 261: Group 1 Precaution
SECTION 7 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. When draining oil, prepare a container of adequate size to catch the oil.
Page 262 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 263 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 264: Group 2 Tightening Torque
GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size lbf ft Engine mounting bolt(Engine-Bracket) 50 10.0 Engine mounting bolt(Bracket-Frame) 1.75 25 2.5 181 18.1 Engine Radiator mounting bolt, nut 6.9 1.4 50 10.0 Coupling mounting bolt 1.75 9.25 0.25 67 1.8 Main pump mounting bolt 1.75...
Page 265 2. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf m lbf ft kgf m lbf ft 0.9 ~ 1.3 6.5 ~ 9.4 1.1 ~ 1.7 8.0 ~ 12.3 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
Page 266 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat(mm) lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 PIPE AND HOSE(ORFS TYPE) Thread size(UNF) Width across flat(mm) kgf m lbf ft 28.9 9/16-18 11/16-16 36.2 13/16-16 68.7 130.2...
Page 267 G G ROUP 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 268 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(1EA).
Page 269 2. MAIN PUMP STRUCTURE 14-4 14-1 14-3 14-2 14-11 14-11 14-10 16-5 7-30 5-54 16-2 5-44 16-6 5-34 16-3 16-4 16-1 7-21 4-12 7-16 7-21 7-14 5-10 7-11 4-10 7-10 4-10 7-17 6-21 7-19 6-22 7-17 6-20 7-15 7-12 R35Z77MP102 7-18 Shaft assy Rotary group...
Page 270 NECESSARY TOOLS AND JIGS The following tools and jigs are necessary to disassemble and reassemble the pump. Tools Name Quantity Size (nominal) Hexagon socket screw key One each 4, 6, 8, 10 Spanner One each 14, 24 Plastic hammer Medium size Pliers for retaining ring For hole (retaining ring for 22) Pliers for retaining ring...
Page 271 CAUTIONS DURING DISASSEMBLING AND ASSEMBLING Cautions for disassembling Never attempt operating the adjusting screw unless absolutely necessary. Take utmost care during disassembly not to knock or drop each part. Cautions for disassembling Wash each part thoroughly. During assembling, take utmost care not to damage the part or allow foreign materials to enter. As a rule, the O-ring and oil seal should not be reused.
Page 272 3. DISASSEMBLING PROCEDURE DISASSEMBLING THE GEAR PUMP Remove the hexagon socket head cap screw. (M10 25, 2 pieces) Hexagon socket screw key (8 mm) Be careful because the O-ring (at 2 pieces) are provided to the housing. R35Z77MP01 Remove the coupling. R35Z77MP02 DISASSEMBLING THE TROCHOID PUMP...
Page 273 Remove the gear from the case. R35Z77MP06 Remove the side plate (A) from the case. R35Z77MP07 Remove the side plate (B) from the port plate. R35Z77MP08 Remove the key of the shaft. R35Z77MP09 7-13...
Page 274 DISASSEMBLING THE MAIN PUMP Remove the port plate since the force of the control spring is strong, remove the hexagon socket head cap screws holding the port plate by means of the jigs. (M12 40, 3 pieces), (M12 55, 1 piece) Hexagon socket screw key (10 mm) Hexagon socket R35Z77MP10...
Page 275 Remove the packing. R35Z77MP13 Remove the control spring and the spring seat. Remove the two springs (inner and outer), and the guide. R35Z77MP14 Remove the spring seat. R35Z77MP15 Remove the rotary group. Remove the shim and the retaining ring. (For shafts ; 20) Pliers for retaining rings.
Page 276 Push down sideways the pump. And takes out the rotary group from the shaft. R35Z77MP17 Remove the shaft. The protective taping around the spline part, and pull out straight the shaft, taking care not to damage the oil seal. R35Z77MP18 (10) Remove the swash plate assembly.
Page 277 (12) Disassemble the port plate assembly. Remove the control plate. R35Z77MP21 (13) Remove the hexagon socket head cap screws (M8 30, 2 pieces), in order to remove the cover of the spring seat assembly. Hexagon socket screw key (6mm) R35Z77MP26 (14) Remove the spring seat.
Page 278 (16) Remove the parallel pin and the sleeve. R35Z77MP29 (17) Remove the minimum flow stopper. Remove the retaining ring. (For holes; 22) Pliers for retaining rings. (For holes ; retaining ring for 22) R35Z77MP30 (18) Remove the guide, the coned disk springs, the distance piece, and shim.
Page 279 (20) Remove the adjustment screw. Spanner (14 mm) Be careful because the shim is inserted. R35Z77MP33 (21) Remove the spring. R35Z77MP34 (22) Remove the spool. R35Z77MP35 DISASSEMBLING THE GEAR PUMP (GSP2) Remove the hexagon socket head cap screws. (M10 20, 4 pieces) Hexagon socket screw key (8mm) R35Z77MP36 7-19...
Page 280 Remove the cover. R35Z77MP37 Remove the square ring. R35Z77MP38 Remove the plate, the guides, and the O- rings. R35Z77MP39 Remove the drive gear, the idle gear, and the side plates. R35Z77MP40 7-20...
Page 281 5. ASSEMBLING PROCEDURE ASSEMBLE THE MAIN PUMP Assemble the minimum flow stopper. Install the guide, the coned disk springs, the distance piece, and the shim into the housing. * Pay attention to the direction of the coned disk spring. R35Z77MP41 Guide Coned disk spring...
Page 282 Install the piston, the coned disk springs, the distance piece, and the shim into the housing. Pay attention to the direction of the coned disk springs. Piston Coned disk spring R35Z77MP45 Shim Assembling direction Assemble the swash plate. Install the guides into the housing. Assemble the guides into the housing, taking care on the marking, which was put on during disassembling work.
Page 283 Assemble the shaft. The protective taping around the spline part, and install the shaft vertically, taking care not to damage the oil seal. Confirm that the shim is installed above the bearing. Shim Bearing R35Z77MP49 Assemble the rotary group. Install the pistons (10 pistons) into the retainer.
Page 284 (11) Install the rotary group. Assemble the rotary group along the shaft spline. R35Z77MP53 (12) Install the retaining ring (For shafts; 20), and install the shim. Pliers for retaining rings. (For shafts; retaining ring for 20) Shim Shaft Retaining ring R35Z77MP54 Cylinder block (13)
Page 285 (15) Assemble the port plate. Assemble the spring seat into the port plate. R35Z77MP57 (16) Assemble the cover of the spring seat assembly, and fix it with hexagon socket head cap screws. (M8 30, 2 pieces) Hexagon socket screw key (6 mm) Tightening torque : 3.6 kgf m (21~26 lbf ft) R35Z77MP58...
Page 286 (19) Assemble the spring. R35Z77MP61 (20) Install the shim into the adjustment screw. R35Z77MP62 (21) Assemble the adjustment screw. Spanner (14 mm) R35Z77MP63 (22) Tighten the hexagon nut. After assembling, set the pressure and tighten the nut. Spanner (24 mm) Tightening torque : 1.0 kgf m (7.2 lbf ft) R35Z77MP64...
Page 287 Assemble the port plate. (23) Install the packing. R35Z77MP65 (24) Holding the cover in parallel condition, by using the jig, tightens slowly the hexagon socket set screw of the jigs, in order to install the port plate. Hexagon socket set screw R35Z77MP66 Fix the port plate with the hexagon socket (25)
Page 288 Install the side plate (B) into the port plate. R35Z77MP69 Install the gear (inner rotor) into the shaft. The surface of matching mark should be positioned in the side plate (B) side. Matching mark R35Z77MP70 Inner rotor Outer rotor Install the side plate (A) into the case. R35Z77MP71 Install the gear (outer rotor) into the case.
Page 289 Install the case into the port plate. R35Z77MP73 Tighten the hexagon socket head cap screw. (M5 12, 3 pieces) Hexagon socket screw key (4 mm) Tightening torque : 0.7~0.8 kgf m (5.1~6.1 lbf ft) R35Z77MP74 ATTACH THE GEAR PUMP Install the coupling to the shaft end on the main pump.
Page 290 ASSEMBLE THE GEAR PUMP Assemble the gear pump(GSP2) Assemble the square ring into the side plate. Pay attention to the suction and delivery directions. Suction Delivery side side R35Z77MP77 Suction Delivery side side Square ring inserting direction Assemble the drive gear and the idle gear to the side plates.
Page 291 Insert the O-rings into the guides, then insert them into the plate. Side with Guide large R R35Z77MP80 Assemble the plate, guides and O-rings. Pay attention to the suction and delivery directions. Suction Delivery side side R35Z77MP81 Install the square ring. R35Z77MP82 Assemble the housing and the cover.
Page 292 Fix the housing and the cover with the hexagon socket head cap screws. (M10 20, 4 pieces) Hexagon socket screw key (8 mm) Tightening torque : 5.6~7.0 kgf m (41~51 lbf ft) R35Z77MP84 7-32...
Page 293: 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 294 2. STRUCTURE(1/3) 4-10 4-11 4-10 4-12 4-11 3-10 4-13 2-10 4-16 4-14 4-15 4-17 4-18 1-10 3-10 2-10 1-10 R35Z72MCV03 Dozer work block 2-9 Cover-pilot 4-6 Plug 1-1 Body-work 2-10 Bolt-soc head w/washer 4-7 O-ring 1-2 Spool assy Swing work block 4-8 Cover-pilot 1-3 Poppet 3-1 Body-work...
Page 295 STRUCTURE(2/3) 6-10 5-10 5-7 5-8 6-10 5-10 R35Z72MCV04 PTO work block 6-2 Spool assy 7-4 Plug 5-1 Body-work 6-3 Poppet 7-5 O-ring 5-2 Spool assy 6-4 Spring 7-6 Cover-pilot 5-3 Poppet 6-5 O-ring 7-7 Cover-pilot 5-4 Spring 6-6 Plug 7-8 Bolt-soc head w/washer 5-5 O-ring 6-7 O-ring Inlet work block...
Page 296 STRUCTURE(3/3) 12-10 12-6 12-8 12-5 11-6 12-7 12-4 11-2 12-3 11-5 11-4 11-11 11-9 108 109 11-12 10-6 10-10 11-10 12-7 10-5 10-8 10-4 12-2 10-3 9-10 12-9 11-7 11-1 11-2 10-7 11-8 11-3 12-10 10-7 10-2 10-9 10-10 9-10 R35Z72MCV05 Travel work block 10-7 O-ring...
Page 297 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 298 DISASSEMBLY Disassembly of spools(Pilot type) Loosen hexagon socket head bolts(10) with washer. (Hexagon wrench : 5mm) Remove the pilot cover(8). Pay attention not to lose the O-ring(7) under the pilot cover. R35Z77MCV04 Remove the spool assembly(2) from the body by hand slightly. When extracting each spool from its body, pay attention not to damage the body.
Page 299 Disassembly of holding valve(Boom 1) Loosen hexagon socket head bolts(120). (Hexagon wrench : 5mm) Remove the holding valve. Pay attention not to lose the O-ring and the poppet under the pilot cover. Pay attention not to damage the "piston A" under pilot cover. R35Z77MCV13 When any abnormal parts are found, replace it with completely new holding...
Page 300 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(6) (Hexagon wrench : 10mm). Remove the O-ring(5), spring(4) and R35Z77MCV11 the load check valve(3) with pincers or magnet.
Page 301 Disassembly of the main and overload relief valve Fix the body to suitable work bench. Remove the main relief valve(14). (Spanner : 30mm) Remove the overload relief valve(15). (Spanner : 22mm) When disassembled, tag the relief valve R35Z77MCV09 for identification so that they can be reassembled correctly.
Page 302 Disassembly of the block assembly Fix the body to suitable work bench. Remove the nut(24). (Spanner : 13mm) R35Z77MCV15 Do not removed the tie bolt(23). R35Z77MCV16 7-42...
Page 303 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 304 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 305 ain relief, port relief valves Install the main relief valve(14). Spanner : 30mm Tightening torque : 6kgf m(43.4lbf ft) Install the over load relief valve(15). Spanner : 22mm Tightening torque : 4kgf m(28.9lbf ft) R35Z77MCV09 R35Z77MCV10 Main spools Carefully insert the previously assembled spool assemblies into their respective bores within of body.
Page 306 Holding valve Holding valve Fit the holding valve to the body and tighten hexagon socket head bolt(120) to specified torque. Hexagon wrench : 5mm Tightening torque : 1.1kgf m (7.9lbf ft) R35Z77MCV14 R35Z77MCV13 7-46...
Page 307: Group 5 Swing Device
G G ROUP 5 SWING DEVICE 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 308 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE 2-13 1-20 1-13 2-25 2-11 2-3 2-12 1-37 1-22 1-21 1-19 1-18 1-14 1-11 2-45 2-12 2-14 1-12 1-10 2-23 1-35 1-36 2-24 2-46 1-16 2-22 2-10 2-10 2-18 2-15 2-19 2-16 2-15 2-27 2-41...
Page 309 DISASSEMBLY Disassemble the parts by the following procedure. Separating the motor and the reduction gear Secure the motor assembly in a vice and remove the socket head bolt (3). R35Z77SM01 Disassembling the motor 2-21 Secure the motor assembly in a vice. Remove the socket head bolts (2-27) and 2-27 separate the cover (2-21).
Page 310 Disassemble the check valve. Loosen to remove the plug (2-41). 2-41 R35Z77SM05 Remove the spring (2-40) and the check valve (2-39). 2-39 2-40 R35Z77SM06 Remove the relief valve. Loosen the plug (2-38-6) to remove the relief valve assembly (2-38). Do not move the adjuster kit (2-38-7). Otherwise, the set pressure will change.
Page 311 Remove the cylinder block and other associated parts. (2-5) Cylinder block (2-6) Collar (2-7) Spring (2-8) Washer (2-9) Snap ring (2-10) (2-11) Retainer holder R35Z77SM09 (2-12) Retainer plate (2-13) Piston assembly (2-14) Disc(Parking brake spec. only) Remove the retainer plate (2-12) and the piston assembly (2-13).
Page 312 Remove the thrust plate (2-4). R35Z77SM13 Lightly strike the end of the shaft (2-3) with a plastic hammer to remove the shaft. R35Z77SM14 Disassemble the bearing (2-2) and the ball bearing (2-3). The disassembled bearing must not be used. R35Z77SM15 isassembling the reduction gear Remove the following parts.
Page 313 Remove the sun gear (1-17). 1-17 R35Z77SM21 Remove the holder (1-11) and other associated parts. 1-10 R35Z77SM22 Secure the holder (1-11) in a vice and ¤Œ 1-16 loosen the screw (1-16) to remove the thrust plate (1-15). 1-15 The screw is hard to remove because 1-12 loctite was used during assembly.
Page 314 Remove the pinion shaft (1-2) When removing the shaft, be careful not to drop it. If it is hard to remove, lightly strike it with a plastic hammer. R35Z77SM25 Remove the inner race of the taper roller bearing (1-7). R35Z77SM26 Break the oil seal (1-6) to remove it.
Page 315 SSEMBLY Assemble the parts by the following procedure. ( ( 1) Assembling the motor Install the relief valve assembly (2-38). Tightening torque : 157 10 N¡⁄m 161 1 kgf m 2-38 R35Z77SM30 Assemble the check valve (2-39) and the spring (2-40). 2-39 2-40 R35Z77SM31...
Page 316 While pushing the washer (2-8), assemble the snap ring (2-9). R35Z77SM35 Apply grease to the pin (2-10) and assemble it in the cylinder block (2-5). Assemble the retainer holder (2-11). 2-10 2-11 R35Z77SM11 Set the piston assembly (2-13) on the retainer plate (2-12) and assemble it in the cylinder block (2-5).
Page 317 Press-fit the shaft (2-3) and the ball bearing (2-2) in the case (2-1). R35Z77SM14 Apply grease to the back side of the thrust plate (2-4) and assemble it. The thrust plate must be assembled in the correct direction. R35Z77SM13 Assemble the cylinder block (2-5) and other associated parts.
Page 318 Assemble the spring seat (2-19) and the 2-18 disc spring assembly (2-18) in the correct 2-19 direction. 2-18 2-15 2-18 2-19 2-18 R35Z77SM08 Apply grease to the O-ring (2-20) and § assemble it in the case (2-1). 2-20 Check to see if the pin (2-25) can be assembled in the brake piston and case 2-25 hole.
Page 319 While paying attention to the location of § the pin (2-25), install the cover (2-21) and 2-21 other associated parts to the case (2-1). 2-27 Exercise care so that the pin (2-25) and the valve plate (2-24) will not fall. §...
Page 320 Install the pinion shaft (1-2) and other associated parts. Install the taper roller bearing inner race (1-7). Prior to assembling the pinion shaft (1-2), etc. apply grease to the lip of the oil seal (1-6). R35Z77SM25 Install the collar (1-9) and the plate (1-8). R35Z77SM24 Install the following parts on the holder 1-16...
Page 321 Install the sun gear (1-17). Install the sun gear (1-17) with the snap 1-17 ring facing as shown in the figure. R35Z77SM21 Install the holder (1-18). 1-18 R35Z77SM42 Install the following parts. (1-19) Thrust washer 1-23 (1-20) Inner race 1-20 (1-21) Needle bearing 1-21...
Page 322 Assembling the whole motor assembly Place the reduction gear assembly on the motor assembly and loosely tighten the socket head bolt (3), then tighten it to the specified torque. Tightening torque : 13 0.7 kgf m (94.4 5 lbf ft) R35Z77SM01 7-62...
Page 323: Group 6 Travel Device
GROUP 6 TRAVEL DEVICE 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 324 STRUCTURE R35Z72TM01 1-17 Holder Swash plate 27 Ball bearing 43 Plug 52 Drive screw Gear box 1-1 Flange holder 1-18 Planetary gear (A) Steel ball 28 O-ring 44 O-ring 55 Plug 1-2 Floating seal 1-19 Needle bearing Cylinder block 29 O-ring 45 Plug 57 O-ring 1-20 Inner race...
Page 325 MAINTENANCE INSTRUCTION Tools for disassembly and reassembly Parts name Applicable components or parts Plug (1-5), (1-8), (45), (58), (60), Screw (1-14) Orifice (40), (47), (62) (230) Socket head bolt (50-7), (50-8) Torque wrench Socket head bolt (48) (Preset type) (450) Plug (1-27), (31.4), (43), (46), (50-4), (50-5) Housing (1-6), Ring nut (1-4) (1800)
Page 326 Special Tools Table Parts name Applicable components or parts Pin Dia. 5.5 30mm Plug (31-4) Eyebolt PF 1/4 Cover (1-24), Wire (1-26) Round bar dia. 20 1000mm Cover (1-24), Wire (1-26) Piano wire dia. 0.2 700mm Steel ball (1-7) Housing disassembly jig Housing (1-6) Ring nut tightener Ring nut (1-4)
Page 327 Tools PF1/4 Welding S-2 Eye bolt S-5 Housing disassembly +0.3 12.7 +0.1 S-6 Ring nut tightener S-8 Ball bearing disassembly +0.5 S-9 Floating seal assembly S-10 Angular bearing press fitting +0.1 +0.1 S-11 Flange holder press fitting S-12 Oil seal press fitting +0.1 +0.05 S-13 Ball bearing press fitting...
Page 328 2. DISASSEMBLY GENERAL PRECAUTIONS Before disassembling the TM motors, check the items to be inspected and, for remedy against trouble, closely examine the nature of the trouble, so that the motor can be disassembled effectively. To disassemble the motor, use the disassembling procedures described in section 2-2, and select a clean place.
Page 329 DISASSEMBLE TRAVEL MOTOR BY 50-7 THE FOLLOWING PROCEDURE Fix the motor with vise. Loosen socket head bolt (50-7), (50-8) and remove valve assy (50). Tools required : Torque wrench (No. 1) Hexagonal bit for torque wrench (No. 7) R35Z77TM01 Remove cap (38). Tools required : Torque wrench (No.
Page 330 Disassembly of plunger sub assy is not required when it operates normally. Insert pin S-1, dia. 5.5 30, in the through hole dia.6 of the plunger sub assy, and fix it with vase. Steel pin Tools required : Torque wrench (No. 2) Hexagonal bit for torque wrench (No.
Page 331 Remove socket head bolt (48). Tools required : Torque wrench (No. 3) Hexagonal bit for torque wrench (No. 10) oints (with parking brake type) To disassemble the motor easily, socket head bolt (48) should be loosened evenly because base plate (30) lift up by the reactive force of springs (21), (32).
Page 332 (13) Remove cylinder block sub assy (7), pin (12), retainer holder (13), retainer plate (14), piston sub assy (15). Be careful not to damage the sliding surface of the cylinder block. Only parking brake type, remove disk plate (18) R35Z77TM14 (14) Remove snap ring (11) by use of plier.
Page 333 (16) Remove plugs (1-27), (1-8). Attach eyebolt (PF 1/4) to the threaded hole of plug (1-27) and insert pry-bar (length 1 [m]) in the eye hole, and turn the bar until wire (1-26) can be seen through the threaded hole of plug (1-8). Draw the wire outside when the wire end can be seen.
Page 334 (19) Remove thrust plate (1-13) and screw (1- 14). Tools required : 1-15 1-17 Torque wrench (No. 1) 1-19 1-20 Hexagonal bit for torque wrench (No. 6) 1-18 It is easy to remove the screw after heated fully by heater because screw (1- 14) is applied loctite.
Page 335 (23) Attach jig between flange holder (1-1) and housing (1-6), and tighten 3 bolts M14¡¿ 2.0 uniform from the housing side. Tools required : Torque wrench (No. 3) Hexagonal bit for torque wrench (No. 10) Housing disassembly (S-5) R35Z77TM24 (24) Remove plug (1-5).
Page 336 (27) Remove floating seal (1-2) and angular bearing (1-3). R35Z77TM28 (28) Remove other floating seal (1-2) by use of two drivers. Tools required : Screw driver (No. 13) Be careful not to damage the sliding surface of floating seal (1-2). R35Z77TM29 (29) Apply pre-bar to the hold of spline, and...
Page 337 (31) Take out ball bearing (3) from shaft (2). Tools required : Ball bearing disassembly jig (S-8) Completed. (32) R35Z77TM32 7-77...
Page 338 3. REASSEMBLY GENERAL PRECAUTIONS Reassemble in a work area that is clean and free from dust and grit. Handle parts with bare hands to keep them free or linty contaminants. Repair or replace the damage parts. Each parts must be free of burrs its corners. Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Page 339 ASSEMBLE THE TRAVEL MOTOR BY THE FOLLOWING PROCEDURE Apply grease to floating seal (1-2) and install it on flange holder (1-1). Tools required : Floating seal assembly jig (S-9) R35Z77TM50 Press fit angular bearings (1-3) to housing (1-6). Tools required : Angular bearings press fitting jig (S-10) R35Z77TM51 Apply grease to the second floating seal...
Page 340 Tighten angular bearing (1-3) with ring nut (1-4) Tools required : Torque wrench (No. 3) Ring nut tightener (S-6) Tightening torque 23.9 1.0 kgf m (173 7.2 lbf ft) R35Z77TM54 Tighten plug (1-5). The seal tape is not allowed to wrap for assembling of this plug.
Page 341 Wrap plug (1-8) with seal tape, and tighten Tools required : Torque wrench (No. 1) Hexagonal bit for torque wrench (No. 7) Tightening torque 0.8 0.1 kgf m (5.8 0.7 lbf ft) Tighten plug (1-8) until the head of plug is obscured against the surface of sprocket R35Z77TM58 guide.
Page 342 (13) Install thrust plate (1-23). R35Z77TM60 (14) Apply grease to O-ring (1-25), fit the O- ring on cover (1-24), and install cover (1- 24) to housing (1-6) matching the threaded hole of socket plug (1-8) of housing (1-6) with the U-groove (for piano wire).
Page 343 (17) Press fit ball bearing (3) on shaft (2). Tools required : Ball bearing press fitting jig (S-13) Shaft sub assembly press fitting jig (S-14) R35Z77TM63 (18) Press fit shaft sub assy (2) in flange holder (1-1). Tools required : Shaft sub assembly press fitting jig (S-14) R35Z77TM64 (19)
Page 344 (21) Apply grease to pin (12) install pins in three holes of cylinder block (7). R35Z77TM66 (22) Install retainer holder (13), retainer plate (14) and piston sub assy (15). Apply hydraulic oil in 99 holes of cylinder block (7). Only parking brake type Install disk plate (18).
Page 345 (25) Apply grease to O-ring (28), (29) and install pin (49) and them on flange holder (1-1) R35Z77TM70 (26) Press fit ball bearing (27) on base plate (30). Tools required : Ball bearing press fitting jig (S-16) R35Z77TM71 (27) Apply grease on the back side of valve plate (25), and install it and pin (26), O- ring (29) on base plate.
Page 346 (29) With parking brake type. Install springs (21), base plate (30), Pin (49). Be careful of installing as springs (21), (32) don't fall down. It's difficult to fall down by greased them. R35Z77TM74 (30) Tighten socket head bolt (48). Tools required : Torque wrench (No.
Page 347 (33) Install check valve (31-2), spring (31-3) 31-4 and plug (31-4) with O-ring (31-5) to 31-5 31-3 plunger (31-1). Apply a slight grease to the O-ring. 31-2 Tools required : Torque wrench (No. 2) 31-1 Hexagonal bit for torque wrench (No. 8) Tightening torque : 3.3 0.2 kgf m (23.5 1.8 lbf ft) R35Z77TM75...
Page 348 (37) With parking brake type Install spool (50-2), spring (50-3) and spring seat (50-4) in valve body (50-1), and tighten plug (50-5) 50-2 50-4 Tools required : Torque wrench (No. 2) 50-3 50-5 Hexagonal bit for torque wrench (No. 9) Tightening torque : 5.5 0.5 kgf m (39.8 3.6 lbf ft) R35Z77TM02...
Page 349 QUALITY CHECK AFTER REASSEMBLY Air leak test of reduction unit Remove one plug ( ) of the reduction unit apply compressed air (0.03 [MPa]) through tapped hole of plug in water for two minutes, and observe that are no bubbles. Air leak test of motor Seal all piping ports on the motor except one port with plugs, and apply compressed air (0.03 [MPa]) through open port in water for two minutes.
Page 350: 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 351 2. DISASSEMBLY AND ASSEMBLY STRUCTURE , 31 R35Z72RL02 Case 12 Push rod (1, 3) 23 Connector Plug 13 Push rod (2, 4) 24 Nut O-ring 14 Plug 25 Nut Spring 15 O-ring 26 Insert Spring seat (1, 3) 16 Rod seal 27 Boot Spring seat (2, 4) 17 Plate (A)
Page 352 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark (L) Hexagonal wrench Spanner (+) Driver Length 150 (-) Driver Width 4~5 Capable of tightening with the specified torques Torque wrench 7-92...
Page 353 DISASSEMBLY 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(32) from case(1) and take it out upwards. 1408DA62 For valve with switch, remove cord also through hole of casing.
Page 354 Loosen adjusting nut(22) and plate(31) with spanners on them respectively, and remove them. RE04 (140-7) RE05 (140-7) Turn joint anticlockwise to loosen it, utilizing jig(Special tool). When return spring(8, 9) is strong in force, plate(31), plug(14) and push rod(12, 13) will come up on loosening joint.
Page 355 Remove plate(31). RE08 (140-7) When return spring(8, 9) is weak in force, plug(14) 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 356 (12) For disassembling reducing valve section, stand it vertically with spool(11) bottom placed on flat workbench. Push down spring seat(5, 6) and remove two pieces of semicircular stopper(7) with tip of small minus screwdriver. Pay attention not to damage spool surface.
Page 357 RE18 (140-7) (16) Remove lock nut(24) and then boot(27). RE19 (140-7) 25038RL02(4) 7-97...
Page 358 (17) 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 359 A A SSEMBLY Tighten hexagon socket head plug(2) to the specified torque. Tighten two bolts alternately and slowly. RE29 (140-7) Put spring seat(10), springs(8, 9) and spring seat(5, 6) onto spool(11) in this order. RE30 (140-7) Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper(7) on spring seat...
Page 360 Assemble O-ring(15) onto plug(14). RE33 (140-7) Assemble seal(16) to plug(14). Assemble seal in such lip direction as shown below. RE34 (140-7) Assemble push rod(12, 13) to plug(14). Apply working oil on push-rod surface. RE35 (140-7) Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring.
Page 361 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate(31), and tighten joint(20) temporarily. (10) Fit plate(31). RE37 (140-7) (11) Tighten joint(20) with the specified torque to casing, utilizing jig. RE38 (140-7) (12) Assemble plate(21) to joint(20). Screw it to position that it contacts with 4 push rods evenly.
Page 362 (14) Fit boot(32) to plate. 1408DA61 (15) Fit boot(27) and lock nut(24), and handle subassembly is assembled completely. 25038RL02(4) RE48 (140-7) (16) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. 1408DA66 7-102...
Page 363 (17) Assemble bushing(18) to plate and pass cord and tube through it. Provide margin necessary to operation. 1408DA67 (18) Determine handle direction, tighten lock nut(21) to specified torque to fix handle. 1408DA68 (19) Apply grease to rotating section of joint and contacting faces of disk and push rod.
Page 364: Group 8 Turning Joint
G G ROUP 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 365 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 12,13 R35Z77TJ03 O-ring 10 Plug Shaft O-ring 11 Plug Cover O-ring 12 Hexagon bolt Spacer Retainer ring 13 Spring washer Slipper seal 7-105...
Page 366 D D ISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts(12), washer(13) and cover(3). R35Z77TJ04 Remove O-ring(8). Remove retainer ring(9) and spacer(4). R35Z77TJ05 Place hub(1) on a V-block and by using a wood buffer at the shaft end, hit out Secure with hand Wooden block shaft(2) to about 1/2 from the body with a...
Page 367 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 eight slipper seal(5) and O-ring(6, 7)to hub(1). R35Z77TJ06 Set hub(1) on block, install shaft(2) into hub(1) by hand.
Page 368 Install cover(3) to hub and tighten bolts(12). R35Z77TJ04 7-108...
Page 369: Group 9 Boom, Arm And Bucket Cylinder
GROUP 9 BOOM, ARM AND BUCKET 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 13031GE18 pressure in the hydraulic piping.
Page 370 Sling bucket cylinder assembly(9) and remove bolt(6) and nut(7) then pull out pin (8). Remove bucket cylinder assembly(9). Weight : 30kg(70lb) R35Z77CY05 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 371 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. 13031GE18 Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 372 Sling arm assembly(8) and remove bolt and nut(7) then pull out pin(6). Remove arm cylinder assembly(8). Weight : 40kg(90lb) R35Z77CY09 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 373 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. 13031GE18 Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 374 Disconnect boom cylinder hoses(4) and put plugs on cylinder pipe. R35Z77CY13 Remove bolt(6) and pull out pin(5). Remove boom cylinder assembly(3). Weight : 60kg(130lb) R35Z77CY14 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 375 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder 7,6 8 9,10 12 13 14 15 16,17 18,19 R35Z77CY15 Tube assembly O-ring 17 Back-up ring Rod assembly 10 Back-up ring 18 Piston nut Gland 11 O-ring 19 Set screw Dust wiper 12 Piston 20 Pin bush Retaining ring 13 Dust ring...
Page 376 Arm cylinder 21,22,23 25, 24 5,4 3 11 6,7 8 9,10 16,17 18,19 R35Z77CY16 Tube assembly 10 Back-up ring 19 Set screw Rod assembly 11 O-ring 20 Cushion ring Gland 12 Piston 21 Check valve Dust wiper 13 Dust ring 22 Spring Retaining ring 14 Piston seal...
Page 377 Boom cylinder 21,22 22 21 6,7 8 9,10 12 13 16,17 18,19 R35Z77CY17 Tube assembly O-ring 17 Back-up ring Rod assembly 10 Back-up ring 18 Piston nut Gland 11 O-ring 19 Set screw Dust wiper 12 Piston 20 Cushion ring Retaining ring 13 Dust ring 21 Pin bush...
Page 378 Dozer cylinder 10,11 17,18 R35Z77CY18 Tube assembly Buffer ring 15 Wear ring Rod assembly DU bush 17 Piston nut Gland 10 O-ring 18 Set screw Dust wiper 11 Back-up ring 19 Pin bush Retaining ring 12 O-ring 20 Dust seal Rod seal 13 Piston 21 Grease nipple...
Page 379 Boom swing cylinder 21 20 4,5 3 11 8 9,10 16,17 19 18 R35Z77CY19 Tube assembly O-ring 16 O-ring Rod assembly Back-up ring 17 Back-up ring Gland 10 O-ring 18 Piston nut Dust wiper 11 O-ring 19 Set screw Retaining ring 12 Piston 20 Pin bush Rod seal...
Page 380 TOOLS AND TIGHTENING TORQUE Tools Name Specification Allen wrench Spanner Hook spanner Suitable size(80~120 mm) (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques T T ightening torque Torque Part name Item Size lbf ft Boom cylinder 492 49 Arm cylinder...
Page 381 DISASSEMBLY Procedures are based on the boom cylinder. Remove cylinder head and piston rod 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 382 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 383 isassemble the piston assembly Remove wear ring(15). Remove dust ring(13) and piston seal (14). Exercise care in this operation not to damage the grooves. R35Z77CY25 Disassemble gland assembly Remove back up ring(10) and O-ring (9). 9,10 Remove snap ring(5), dust wiper(4). Remove back up ring(7), rod seal(6).
Page 384 SSEMBLY 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. R5577CY38 Coat dust wiper(4) with grease and fit Press here dust wiper(4) to the bottom of the hole of (Straight down) dust seal.
Page 385 Fit back up ring(10) to gland(3). Put the backup ring in the warm water of 9,10 30~50 C . Fit O-ring(9) to gland(3). R35Z77CY27 ssemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone. Coat the outer face of piston(16) with hydraulic oil.
Page 386 nstall piston and cylinder head Fix the rod assembly to the work bench. Gland assembly Apply hydraulic oil to the outer surface of Rod assembly rod assembly(2), the inner surface of piston and gland. Insert gland assembly to rod assembly. R5577CY45 Insert cushion ring(20) to rod assembly.
Page 387 Overall assemble Fix with a bar Place a V-block on a rigid work bench. Mount the tube assembly(1) on it and fix Lift the assembly by passing a bar through the clevis pin hole to lock the assembly. Insert the rod assembly in to the tube Straight assembly, while lifting and moving the rod assembly with a crane.
Page 388: Group 10 Undercarriage
GROUP 10 UNDERCARRIAGE 1. RUBBER TRACK REMOVAL Grease valve Frame Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards. R35Z77TR04 Remove the rubber track from lower frame using pry.
Page 389 2. TRACK LINK REMOVAL Move track link until master pin is over front idler in the position put wooden block Master pin 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 390 3. CARRIER ROLLER Grease valve Frame REMOVAL Loosen tension of the track link. R35Z77TR04 Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller R35Z77TR05 Loosen the bolt and nut(1) Open bracket(2) with a screwdriver, push out from inside, and remove carrier roller assembly.
Page 391 4. TRACK ROLLER Grease valve Frame REMOVAL Loosen tension of the track link. R35Z77TR04 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 R35Z77TR02 Remove the mounting bolt(1) and draw...
Page 392 5. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link. Sling the idler(1) and pull out idler and recoil spring assembly from track frame, using a pry. Weight : 40kg(90lb) R35Z77TR08 Pull out yoke(2) from track frame, using a pry.
Page 393 DISASSEMBLY AND ASSEMBLY OF IDLER Structure R35Z77TR11 Shell Ball bearing Spring pin Shaft Bracket Plug Seal assembly Snap ring 7-133...
Page 394 Disassembly Press Remove plug and drain oil. Draw out the spring pin(7), using a press. R35Z77TR17 Remove brackets(2) from shaft. R35Z77TR18 Remove seal assembly(3) from shell(1) by pry. Do not reuse seal assembly after removal. Remove snap ring(6) from shell(1) R35Z77TR19 Draw out the ball bearing(4) with shaft(2) using press.
Page 395 Assembly Before assembly, clean the parts. Coat the sliding surfaces of all parts with oil. Do not press it at the normal temperature, assemble ball bearing(4) to shaft by press. R35Z77TR21 Insert shaft(2) with ball bearing(4) assembly to shell(1). R35Z77TR20 Assembly snap ring(6) and seal assembly(3).
Page 396 8-168(1) 140-7 Knock in the spring pin(7) with a Press hammer. R35Z77TR17 Lay bracket(5) on its side. Supply engine oil to the specified level, and tighten plug. 8-168(3) 140-7 7-136...
Page 397 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure R35Z77TR12 Body O-ring Cotter pin Back-up ring Spring Valve assy 10 Packing 7-137...
Page 398 Disassembly Apply pressure on cap(4) with a press. The spring is under a large installed load. 5, 6 This is dangerous, so be sure to set properly. Spring set load : 2700kg(6000lb) Remove split pin(6) and nut(5). Take enough notice so that the press which pushes down the spring, should not be slipped out in its operation.
Page 399 Assembly Install O-ring(8), back-up ring(9), and packing(10) body(1). R35Z77TR15 Pour grease into body(1), then push in rod(2) by hand. After take grease out of grease valve mounting hole, let air out. If air letting is not sufficient, it may be difficult to adjust the tension of crawler.
Page 400 Install spring(3) and cap(4) to body (1). Apply pressure to spring(3) with a press and tighten nut(5). During the operation, pay attention 5, 6 specially to prevent the press from slipping out. Tighten nut(5) and insert split pin(6). R35Z77TR13 Lighten the press load and confirm the set length of spring(2).
Page 401: Group 11 Work Equipment
GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A-A SECTION B-B SECTION C-C SECTION E-E SECTION D-D R35Z77AT01 7-141...
Page 402 2. REMOVAL AND INSTALL BUCKET ASSEMBLY Removal Lower the work equipment completely to ground with back of bucket facing down. R35Z77AT02 Remove nut(1), bolt(2) and draw out the pin(4). R35Z77AT03 Remove nut(1), bolt(2) and draw out the pin(3) then remove the bucket assembly. Weight : 80kg(180lb) R35Z77AT04 Install...
Page 403 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 R5577AT06 assembly. Disconnect bucket cylinder hose(4). Fit blind plugs(5) in the piping at the chassis end securely to prevent oil from spurting out when the engine is started.
Page 404 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. R5577AT08 Disconnect head lamp wiring. Disconnect bucket cylinder hose(2) and arm cylinder hose(1).
Page 405: Section 8 Component Mounting Torque
SECTION 8 COMPONENT MOUNTING TORQUE Group 1 Introduction guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2 Group 3 Electric system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 4 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5...
Page 406: Group 1 Introduction Guide
This section shows bolt specifications and standard torque values needed when mounting components to the machine. Use genuine Hyundai spare parts. We expressly point out that Hyundai will not accept any responsibility for defects resulted from non-genuine parts. In such cases Hyundai cannot assume liability for any damage.
Page 407: Group 2 Engine System
GROUP 2 ENGINE SYSTEM 1. ENGINE AND ACCESSORIES MOUNTING Air cleaner Main pump housing Engine Muffler R35Z78CM01 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 8 1.25 2.5 0.5 18.1 3.6 M16 2.0 25 2.5 181 18.1 M10 1.5...
Page 408 2. COOLING SYSTEM AND FUEL TANK MOUNTING Condenser Eng & comp bracket Water separator Receiver dryer Fuel tank Radiator total assy Feed pump Engine R35Z78CM02 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 6 1.0 1.05 0.2 7.6 1.45 M 10 1.25...
Page 409: Group 3 Electric System
GROUP 3 ELECTRIC SYSTEM 1 1 . ELECTRIC COMPONENTS MOUNTING 1 Cabin top Fuse box Washer tank Travel buzzer R35Z78CM03 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 6 1.0 1.05 0.2 7.6 1.45 M10 1.5 6.9 1.4 49.9 10.1...
Page 410: Group 4 Hydraulic System
GROUP 4 HYDRAULIC SYSTEM 1 1 . HYDRAULIC COMPONENTS MOUNTING 1 RCV-RH RCV-LH Hyd tank Level gauge Coupling Main pump housing Swing motor Main pump MCV bracket Turning joint Terminal Solenoid valve R35Z78CM05 Tightening torque kgf m lbf ft kgf m lbf ft Item Size...
Page 411 2. HYDRAULIC COMPONENTS MOUNTING 2 Boom cylinder Arm cylinder Bucket cylinder Dozer cylinder R35Z78CM07 Tightening torque 1. Gland kgf m lbf ft Item Size Boom cylinder M90 2 68 6.8 492 49 Arm cylinder M85 2 64 6.4 463 46 Bucket cylinder M75 2 56 5.6...
Page 412: Group 5 Undercarriage
GROUP 5 UNDERCARRIAGE Swing bearing Track Travel motor Sprocket Upper roller Idler Adjust component Lower roller R35Z78CM08 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M10 1.5 6.9 1.4 49.9 10.1 M12 1.75 138 2 100 14 M12 1.75 12.8 3.0...
Page 413: Group 6 Structure
GROUP 6 STRUCTURE 1 1 . CANOPY AND ACCESSORIES MOUNTING Canopy assy Travel lever R35Z78CM09 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 8 1.25 2.5 0.5 18.1 3.6 M12 1.75 12.8 3.0 92.6 21.7 M10 1.5 6.9 1.4...
Page 414 2. COWLING MOUNTING Engine hood assy Support Hyd tank Upper frame R35Z78CM10 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 8 1.25 2.5 0.5 18.1 3.6 M20 2.5 57.8 6.4 418 46.3 M12 1.75 12.8 3.0 92.6 21.7...
Page 415: Group 7 Work Equipment
G G ROUP 7 WORK EQUIPMENT Arm cylinder rod pin Arm cylinder head pin Boom pin Boom cylinder Arm cylinder Boom assy Boom cylinder head pin Boom cylinder rod pin Arm assy Dozer cylinder Bucket cylinder Arm pin rod pin Bucket cylinder head pin Bucket control Dozer blade assy...

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