Page 1 Seral No.215000003~ CC8E005 WETB215R_A-XI...
Page 2 FOREWORD This manual, which is written for engineers who service the machine, describes procedures for disassembly and assem- bly, inspection and maintenance, and troubleshooting, as well as maintenance reference values and an outline of the specifications. Refer to this manual during daily work to improve your services. Note that the information is subject to change without notice due to design modifications made to the machine from time to time by the manufacturer.
Page 3 SAFETY...
Page 4 SAFETY SAFETY ALERT SYMBOL SAFETY ALERT SYMBOL This symbol represents the safety alert. The message that follows the sym- bol contains important information regarding human safety. Read and understand the message to avoid personal injury or death. Safety label Safety labels are used to alert operators or other people exposed to the risks of injury or damage.
Page 5 SAFETY SAFETY PRECAUTIONS SAFETY PRECAUTIONS Install an extinguisher and a first aid kit Observe all safety rules • Operation, inspection and maintenance of this ma- chine must be performed only by a trained and quali- fied person. • All rules, regulations, precautions and safety proce- dures must be understood and followed when per- forming operation, inspection and maintenance of this machine.
Page 6 SAFETY SAFETY PRECAUTIONS Regularly replace the safety-critical parts When the canopy is tilted up • Regularly replace fuel hoses to prevent a fire hazard. • If the canopy is raised or lowered while the engine is Hoses wear out over time, even if they do not show any moving, the machine may accidentally start moving, symptom of wear.
Page 7 SAFETY SAFETY PRECAUTIONS Keep clear of the moving fan and belt When working on the machine 1BAA07Z 1BAA09Z • Any object that can be easily caught in moving parts • To prevent slipping/falling from machine, clear the must be kept away. footing and observe the following: •...
Page 8 SAFETY SAFETY PRECAUTIONS Caution when filling with fuel or oil Be careful with hot and pressurized components 1BAA11Z 1BAA12Z • Keep away from heat, sparks and flame while filling Before performing inspection and maintenance, stop the with fuel or oil. engine and allow the machine to cool down.
Page 9 SAFETY SAFETY PRECAUTIONS Be careful with oils under pressure Be careful with grease under pressure 1BAA14Z 1BAA15Z Pressure is maintained in the hydraulic circuit long after In the track adjuster, the grease has been injected under the engine has been shut down. high pressure.
Page 10 SAFETY SAFETY PRECAUTIONS Use caution when handling batteries Have a service agent repair welding cracks or other damage Ask a service agent to make any repairs that require welding. If the agent is unavailable, make sure the weld- ing is done by a qualified person in a properly equipped workplace.
Page 11 SAFETY CAUTIONS WHEN WORKING CAUTIONS WHEN WORKING When removing/installing the hydraulic unit • Make sure that the temperature of the hydraulic oil has When disassembling or assembling dropped and is cool enough to work with. • To prevent the hydraulic oil from escaping under pres- •...
Page 12 Pressure adjustment for hydraulic devices • The pressure for hydraulic devices is adjusted by Takeuchi Mfg. to optimal conditions before products are shipped for delivery to the customer. The pressure 1CAA04Z will not need to be adjusted again except in products that undergo disassembly and assembly procedures.
Page 13 SERVICE DATA...
Page 14 SERVICE DATA DIMENSIONAL DRAWING DIMENSIONAL DRAWING Machine dimensions 2A0AX03 DIMENSIONAL DRAWING 2A0AX001...
Page 15 SERVICE DATA DIMENSIONAL DRAWING Unit: mm (in.) Standard arm Long arm 215000003 to 215000003 to from 215002408 from 215002408 215002407 215002407 Rubber crawler Rubber crawler 3445 (135.6) 3455 (136.1) 3440 (135.5) 3450 (135.9) 980 (38.5) 980 (38.5) 980 (38.5) 980 (38.5) 2345 (92.2) 2345 (92.2) 2345 (92.2)
Page 16 SERVICE DATA DIMENSIONAL DRAWING Operating range 2A0AX02 DIMENSIONAL DRAWING 2A0AX001...
Page 17 SERVICE DATA DIMENSIONAL DRAWING Unit: mm (in.) Standard arm Long arm 215000003 to 215000003 to from 215002408 from 215002408 215002407 215002407 Rubber crawler Rubber crawler 3815 (150.2) 3815 (150.2) 4000 (157.5) 4000 (157.5) 3760 (148.0) 3760 (148.0) 3945 (155.4) 3945 (155.4) 2190 (86.2) 2190 (86.2) 2390 (94.1)
Page 18 SERVICE DATA SPECIFICATION TABLES SPECIFICATION TABLES Rubber kg (lb) 1575 (3470) crawler 215000003 to Steel 215002407 kg (lb) 1670 (3680) crawler Operating mass Rubber kg (lb) 1610 (3550) crawler from 215002408 Steel kg (lb) 1675 (3695) crawler Net (ISO 14396) kW/min (hp/rpm) 11.5/2400 (15.4/2400) Rated output...
Page 19 SERVICE DATA SPECIFICATION TABLES Dimensions of base machine Rubber mm (in.) 1560 (61.4) crawler 215000003 to Steel 215002407 mm (in.) 1565 (61.6) crawler Overall length of base machine Rubber mm (in.) 1570 (61.8) crawler from 215002408 Steel mm (in.) 1565 (61.6) crawler During normal operation mm (in.)
Page 20 SERVICE DATA SPECIFICATION TABLES Engine Model Yanmar 3TNV70 4-cycle, vertical, water-cooled, in-line, 3-cylinder, Type indirect injection Number of cylinders Quantity Cylinders Bore mm (in.) 70 (2.76) Stroke mm (in.) 74 (2.91) Total displacement mL (cu. in.) 854 (52.1) N·m (ft-lb) 48.2 to 52.6 (35.6 to 38.8) Maximum torque (rpm)
Page 21 SERVICE DATA SPECIFICATION TABLES Operating device Position Center Construction Suspension seat Cab or canopy Construction Canopy with steel support columns Variable travel speed switch Shifting operation (handle grip of operating lever) Travel operation Mechanical system, 2 levers Slew operation Hydraulic pilot-operated Arm operation Hydraulic pilot-operated Bucket operation...
Page 22 SERVICE DATA SPECIFICATION TABLES Lower machinery Power transmission device Variable displacement (2-speed) piston motor, Type with counterbalance valve Travel motor Quantity Reduction gears Type Epicyclic gearing (2-stage) Travel brake Type Counterbalance valve, differential delay type Parking brake Type Wet friction plate type Undercarriage Type Rubber crawler...
Page 23 SERVICE DATA SPECIFICATION TABLES Working equipment Backhoe attachment Heaped capacity 0.038 (1.34) Bucket capacity Struck capacity 0.028 (0.99) Standard mm (in.) 405 (16.0) Bucket width With side cutter mm (in.) 435 (17.1) Bucket mass kg (lb) 34 (75) Boom length mm (in.) 1705 (67.1) Arm length...
Page 24 SERVICE DATA SPECIFICATION TABLES Hydraulic cylinder Number of cylinders Quantity Boom cylinder Bore mm (in.) 60 (2.4) Stroke mm (in.) 480 (18.9) Number of cylinders Quantity Arm cylinder Bore mm (in.) 60 (2.4) Stroke mm (in.) 385 (15.2) Number of cylinders Quantity Bucket cylinder Bore...
Page 25 SERVICE DATA SPECIFICATION TABLES Dozer blade Type Straight type Operation type Hydraulic hoisting type Number of cylinders Quantity Dozer blade cylinder Bore mm (in.) 60 (2.4) Stroke mm (in.) 120 (4.7) Dimensions Width mm (in.) 1300 (51.2) Rubber 250 (9.8) crawler Standard mm (in.)
Page 26 SERVICE DATA TABLE OF MASSES TABLE OF MASSES Upper structure kg (lb.) Part name Remarks Mass Engine Dry mass 103 (227) Radiator With assembly parts attached 13 (28) Main pump 13 (29) Gear pump – Hydraulic tank With assembly parts attached 20 (43) Fuel tank With assembly parts attached...
Page 27 The replacement interval for hydraulic oil depends on the type of oil being used. New machines are shipped from the factory with the Takeuchi genuine hydraulic oil 46. This manual describes when to replace the hydraulic oil assuming that this Takeuchi oil is used. When a conventional anti-wear hydraulic oil is used, replace it every 2000 hours.
Page 28 SERVICE DATA LUBRICANT AND FUEL CHART Diesel fuel standards Use a diesel fuel that is compliant with any of the stan- dards listed below. The table below shows standards from various countries/regions. Diesel fuel standards Country/Region ASTM D975 No. 1-D, S15 Canada No.
Page 29 SERVICE DATA PERFORMANCE CRITERIA PERFORMANCE CRITERIA Standard values table Item Standard value Allowable value Idling 1060 +100 1060 +100 -100 -100 (rpm) Engine speed Maximum R.P.M. 2560 2560 (rpm) Boom MPa (psi) 21.0 +1.2 3046 +145 -0.3 +1.2 +145 MPa (psi) 21.0 3046 -0.3...
Page 30 SERVICE DATA PERFORMANCE CRITERIA Bucket Straight travel func- To be moved forward using simultaneous tion check operation Boom Dozer blade +0.8 Bucket cylinder speed Retracted -0.8 Boom cylinder mm (in.) 10 (0.4) -0.2 Arm cylinder mm (in.) 10 (0.4) -0.2 Natural cylinder Bucket cylinder mm (in.)
Page 31 SERVICE DATA PERFORMANCE CRITERIA Hydraulic pump assignment table Boom swing, 1st auxiliary line piping, right travel, 16.8 L/min. (4.4 US gal/min.) boom, bucket Boom swing, 1st auxiliary line piping, arm, left travel 16.8 L/min. (4.4 US gal/min.) Slew, blade, 2nd auxiliary line piping, 3rd auxiliary 10.8 L/min.
Page 32 SERVICE DATA PERFORMANCE CRITERIA Methods for inspecting performance Hydraulic oil pressure (Boom, arm, dozer blade) Measurement method • Engine: Maximum R.P.M. • Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F) • Install a pressure gauge on the pressure detection port.
Page 33 SERVICE DATA PERFORMANCE CRITERIA Hydraulic oil pressure (Slew) Measurement method • Engine: Maximum R.P.M. • Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F) • Install a pressure gauge on the pressure detection port. Operate the hydraulic circuit to be tested, and measure the relief pressure.
Page 34 SERVICE DATA PERFORMANCE CRITERIA Travel speed (5 revs.) • Engine: Maximum R.P.M. • Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F) • Measuring attitude: Excavator body to be raised using both the hoe attachment and the dozer blade • Set crawler belts in motion. Starting after one full revo- lution, measure the time required for five revolutions.
Page 35 SERVICE DATA PERFORMANCE CRITERIA Natural travel drop • Engine: Stopped • Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F) • Inclination angle: 15° • Measuring attitude: Fully extend the boom, arm, and bucket cylinders. Completely retract the dozer blade cylinder.
Page 36 SERVICE DATA PERFORMANCE CRITERIA Boom cylinder speed • Engine: Maximum R.P.M. • Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F) • Measuring attitude: Completely retract the arm cylin- der, and fully extend the bucket cylinder. • Next, measure the time required for the bucket to reach its highest elevation point (lowest point) from its lowest point (highest point) at rest on the ground.
Page 37 SERVICE DATA PERFORMANCE CRITERIA Swing cylinder speed • Engine: Maximum R.P.M. • Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F) • Measuring attitude: Same as that for measuring slew time • While swinging the boom from left (right) to right (left), measure the time required for a full stroke in each di- rection.
Page 38 SERVICE DATA PERFORMANCE CRITERIA Lever operating force • With the engine turned off, place a push-pull scale on the handle grip center or the pedal edge to measure the force. Record the readings at the point at which the lever/pedal reaches a full stroke. Lever play •...
Page 39 SERVICE DATA PERFORMANCE CRITERIA Track tension • Measuring attitude: Excavator body to be raised using both the hoe attachment and the dozer blade. For models with rubber crawlers, line up the crawler seam joint (marked with an M or  symbol) with the upper center of the upper structure.
Page 40 SERVICE DATA TIGHTENING TORQUE TIGHTENING TORQUE Hydraulic hose Tightening torque Parallel internal-thread Nominal thread Tapered external- external-seat union diameter thread joint for piping joint for piping N·m ft-lb N·m ft-lb +4.9 +3.6 G(R)1/8 11.8 ± 1.2 8.7 ± 0.8 +4.9 +3.6 G(R)1/4 29.4 ±...
Page 41 SERVICE DATA TIGHTENING TORQUE Joint for piping Tightening torque Nominal thread Port material: Steel Port material: Cast steel diameter N·m ft-lb N·m ft-lb R1/8 11.8 ± 1.2 8.7 ± 0.8 10.8 ± 1.1 8.0 ± 0.7 R1/4 29.4 ± 2.9 21.7 ±...
Page 42 SERVICE DATA TIGHTENING TORQUE Bolts and nuts (JIS strength category 10.9) Tightening torque Thread Size × pitch General tightening points Special tightening points N·m ft-lb N·m ft-lb M6 × 1.0 9.8 ± 0.8 7.2 ± 0.6 12 ± 1.0 9.0 ± 0.7 M8 ×...
Page 43 SERVICE DATA TIGHTENING TORQUE Joint for piping Tightening torque Nominal thread Steel Cast steel diameter (R) N·m ft.-lb N·m ft.-lb 11.8 ± 1.2 8.7 ± 0.8 10.8 ± 1.1 8.0 ± 0.7 29.4 ± 2.9 21.7 ± 2.1 24.5 ± 2.5 18.1 ± 1.7 53.9 ±...
Page 44 SERVICE DATA TIGHTENING TORQUE Bolts and nuts (JIS strength category 10.9) Tightening torque Thread Size × pitch General tightening points Special tightening points N·m ft.-lb N·m ft.-lb M6 × 1.0 9.8 ± 0.8 7.2 ± 0.6 12 ± 1.0 9.0 ± 0.7 M8 ×...
Page 45 SERVICE DATA HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC CIRCUIT DIAGRAM 2F0AX001...
Page 46 SERVICE DATA HYDRAULIC CIRCUIT DIAGRAM Control valve 19010-50900 Part number 19010-51000* 19010-51100** Type KVSE-36B-2 MPa at L/min. P1, P2 21.0 at 16.8 (3045 at 4.4) (psi at US gal./min.) Set main relief valve pressure MPa at L/min. 20.0 at 10.8 (2900 at 2.9) (psi at US gal./min.) A1, A2, B2, A5, MPa at L/min.
Page 47 SERVICE DATA HYDRAULIC CIRCUIT DIAGRAM Travel motor Part number 19031-30300 Type PHV-1B-12B-PT /rev (cu. in./rev) 421.3 (25.7) Total displacement /rev (cu. in./rev) 232 (14.2) /rev (cu. in./rev) 11.4 (0.7) Motor displacement /rev (cu. in./rev) 5.8 (0.3) Reduction gear ratio 1/36.96 2nd-speed switching speed MPa (psi) 3.4 (493)
Page 48 SERVICE DATA HYDRAULIC CIRCUIT DIAGRAM Swing cylinder Part number 19001-16000 Type – Bore diameter × rod diameter mm (in.) 60×35 (2.4×1.4) Stroke mm (in.) 340 (13.4) Maximum retraction length* mm (in.) – * Length from the center of the pinhole on the tube side to the center of the pinhole on the rod side Dozer blade cylinder Part number 19001-13900...
Page 49 SERVICE DATA HYDRAULIC CIRCUIT DIAGRAM Travel lever lock cylinder Part number 19000-74800 Type – Stroke mm (in.) 320 (12.6) Maximum retraction length* mm (in.) – * Overall length Solenoid valve (3rd auxiliary line piping) Part number 19017-56100 Type AGCD-16587 Power supply voltage HYDRAULIC CIRCUIT DIAGRAM 2F0AX001...
Page 50 SERVICE DATA ELECTRICAL CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM Wire/cable color symbols Wiring/cable Colors Symbol Color Symbol Color Symbol Color Black White Violet Green Yellow Dark green Blue Pink Chocolate Orange 1 Cross-sectional area (mm 2 Base color 3 Stripe color* * There may be wires of solid color with no stripe.
Page 51 SERVICE DATA ELECTRICAL CIRCUIT DIAGRAM Electrical Schematic Diagram ELECTRICAL CIRCUIT DIAGRAM 2G0AX00...
Page 52 SERVICE DATA WIRE HARNESS DIAGRAM WIRE HARNESS DIAGRAM Wiring diagram WIRE HARNESS DIAGRAM 2H0AX00...
Page 53 SERVICE DATA WIRE HARNESS DIAGRAM Body harness: 03342-68000 WIRE HARNESS DIAGRAM 2H0AX00...
Page 54 SERVICE DATA WIRE HARNESS DIAGRAM WIRE HARNESS DIAGRAM 2H0AX00...
Page 55 SERVICE DATA WIRE HARNESS DIAGRAM WIRE HARNESS DIAGRAM 2H0AX00...
Page 56 SERVICE DATA WIRE HARNESS DIAGRAM WIRE HARNESS DIAGRAM 2H0AX00...
Page 57 SERVICE DATA WIRE HARNESS DIAGRAM WIRE HARNESS DIAGRAM 2H0AX00...
Page 58 FUNCTION...
Page 59 FUNCTION HYDRAULIC PUMP (PISTON) HYDRAULIC PUMP (PISTON) This pump is a variable displacement piston pump with a single cylinder block that discharges two separate but equal volumes of fluid. The pistons (2) are installed in the cylinder block (1), and the end surface of which is in contact with the valve plate (3).
Page 60 FUNCTION HYDRAULIC PUMP (PISTON) If the discharge pressure becomes higher than the pre- set value for the spring (7), the angle of inclination of the swash plate (4) becomes smaller due to the net force on the piston, F1 × a, and the force, F2, of the piston (9), which allows the plate to be retained at the position at which the discharge pressure and the spring force are balanced.
Page 61 FUNCTION GEAR PUMP GEAR PUMP The gear pump (1) is a constant-volume pump with dou- ble-gear pumps (P3, P4) that discharges a constant vol- ume of discharge material over a constant speed. The pump P3 is used for the 2nd and 3rd auxiliary line piping, blade, and slew motor, and the pump P4 is used to discharge the pilot pressure oil.
Page 62 FUNCTION CONTROL VALVE CONTROL VALVE When the spools are in the neutral position: When the control valve spools are not moved, the oil flows through the center bypass passage (1) and the tank passage T to return to the tank, as shown by the ar- row.
Page 63 FUNCTION CONTROL VALVE Main relief valves A main relief valve is mounted between the pump circuit and tank circuit of each inlet housing and works to main- tain the circuit pressure at the set value. The relief valve remains turned off: As long as the pressure in the circuit is lower than the set pressure, the relief valve will maintain the pressure equi- librium and remain shut off.
Page 64 FUNCTION CONTROL VALVE Port relief valve The port relief valve is located between the actuator and the tank circuit T. It protects the actuator from pressure shocks caused by the sudden blocking of the actuator port or by overloading, or absorbs abnormal pressure generated by an external force.
Page 65 FUNCTION CONTROL VALVE The pressure in chamber C drops below that in chamber B, causing the pressure to become unequal. This causes the main poppet (6) to open up, which allows the pres- sure oil to flow to the tank passage T. When the valve is engaged in valve suction opera- tion: If the cylinder is operated at a speed too fast for the oil...
Page 66 FUNCTION CONTROL VALVE Anti-cavitation valve This valve is inserted between the cylinder port and the tank passage. It works to supply oil from the tank to pre- vent cavitation when the cylinder is operated at a speed that is too fast for the oil supply to keep up, which would cause the pressure of the cylinder port to become almost negative.
Page 67 FUNCTION CONTROL VALVE Switch valve This valve switches among the circuits of the bucket, arm, boom, swing, and auxiliary line hydraulics when any of them is activated during travel operation. The oil sup- plied by the pump P3 is directed to a section other than the travel section, which enables straight travel together with other operations under combined control.
Page 68 FUNCTION CONTROL VALVE Arm In regeneration The speed at which the arm cylinder is extended (Arm In operation speed) can be increased by directing part of the oil returned from the arm cylinder to the supply side again to increase the supply flow. When the Arm In operation is performed, the pilot pres- sure is directed to the port PiA, which causes the spool (1) to be pushed up.
Page 69 FUNCTION PILOT VALVE (CONTROL LEVER) PILOT VALVE (CONTROL LEVER) The pilot valve is a remote-controlled valve with a reducing valve system used to operate the spool in the control valve. The pilot valve comes with right and left control levers. The pilot valve casing (1) contains a vertical shaft hole that incorporates a reducing valve (2).
Page 70 FUNCTION PILOT VALVE (CONTROL LEVER) When the lever (3) is kept at a certain position: When the pressure in the output port A increases to a lev- el equivalent to the force of the spring (6) set by the incli- nation of the lever (3), the hydraulic pressure is balanced with the spring force.
Page 71 FUNCTION PROPORTIONAL CONTROL SOLENOID VALVE (2ND AUXILIARY LINE PIPING) PROPORTIONAL CONTROL SOLENOID VALVE (2ND AUXILIARY LINE PIPING) The proportional lever (2) and proportional ampliﬁer (3) of the pilot valve (1) control the driving current that ﬂows to the proportional control solenoid valve (4), which con- trols the pilot pressure of the control valve (5) (auxiliary section) whereby the ﬂow rate of the auxiliary line piping changes.
Page 72 FUNCTION SOLENOID VALVE(3RD AUXILIARY LINE PIPING) SOLENOID VALVE(3RD AUXILIARY LINE PIPING) This valve switches circuit connections by moving the spool using magnets and supplies the pilot pressure to the 3rd auxiliary section. Solenoid valve When the solenoid is not energized: The oil in the port P (pump side) is blocked by the spool (1).
Page 73 FUNCTION SOLENOID VALVE (LEVER LOCK) SOLENOID VALVE (LEVER LOCK) This valve switches circuit connections by moving the spool using magnets and supplies the pilot pressure to the pilot valve and 2nd-speed travel switch. The pilot pressure is kept constant with the relief valve. Solenoid switching and relief function For simplification purposes, only port A will be used in the descriptions below as port A and port B in the valve...
Page 74 FUNCTION SOLENOID VALVE (LEVER LOCK) Check function Port P Port PAC and Port B When the pressure in port P exceeds the force applied by the spring (2), the plunger (1) moves to the right, al- lowing the pressure oil to flow from port P to port PAC. Port PAC Port P The plunger (1) is returned to the left by the spring (2),...
Page 75 FUNCTION SELECTOR VALVE SELECTOR VALVE The selector valve is connected between the control valve and the pilot valve (control lever). Turn the selector valve lever to switch the connection port to switch the control lever pattern. 3K8AQ00Z 1. Position A (ISO) 2.
Page 76 FUNCTION SELECTOR VALVE Position A (ISO) Port A ⇔ Port 1 Port B ⇔ Port 2 Port C ⇔ Port 3 Port D ⇔ Port 4 3K8AQ01Z 1. Position A (ISO) 2. Position G (JCB) 3. Rotation of 90° Position G (JCB) Port A ⇔...
Page 77 FUNCTION SELECTOR VALVE Switching from Position A (ISO) to Position G (JCB) 1. Loosen the wing bolt (1) enough for its end to emerge from the hole in the body (2). 3K8AQ03Z 2. Turn the lever (3) counterclockwise 90°. 3K8AQ04Z 3.
Page 78 FUNCTION SELECTOR VALVE 2. Turn the lever (3) clockwise 90°. 3K8AQ07Z 3. Tighten the wing bolt (1) by hand. • The end of the wing bolt (1) should go into the anti-rotation hole in the body (2). 3K8AQ08Z SELECTOR VALVE 3K8AQ00...
Page 79 FUNCTION CYLINDERS CYLINDERS The pressure oil flowing alternately in through the outlet and inlet on both sides (head and rod sides) of the piston acts on the piston and its force causes the piston to move back and forth. For those cylinders with a cushion mechanism, the shock resulting from the piston colliding with the cover at the stroke end is dampened by the mechanism.
Page 80 FUNCTION TRAVEL MOTOR TRAVEL MOTOR Hydraulic motor The cylinder block (1) is formed of the pistons (2), and its end surface comes in contact with the valve plate (3) that contains the two half-moon-shaped ports B and C. The cylinder block (1) rotates freely and is connected to the drive shaft (4) via the splines.
Page 81 FUNCTION TRAVEL MOTOR When the high-pressure oil that is directed to the port P1 is shut off, the pressure in the port P1 becomes equal to that in the port P2 and the spool (8) attempts to return to the neutral position using the force of the spring. This pushes the oil in the chamber B out to the port P1 side.
Page 82 FUNCTION TRAVEL MOTOR Swash plate As shown in the figure, the swash plate (5) has three planes, A, B and C, and is mounted to the flange holder (6) such that its angle of inclination with respect to the flange holder (6) can be changed using the two steel balls (7).
Page 83 FUNCTION TRAVEL MOTOR Parking brake The friction disc (2) and the disc (1) are connected via the spline. The friction disc (2) and the disc (1) are pressed against the flange holder (6) by the springs (4) via the brake piston (5). The friction force between these discs generates a braking torque that works to prevent the cylinder block (3) from rotating.
Page 84 FUNCTION SLEW MOTOR SLEW MOTOR Hydraulic motor 1 The high-pressure oil that flows from the main port (1) passes through the valve (2) and valve plate (3) and into the geroler (4). The geroler (4) is formed of a stator (5), which is installed in the housing and has seven rollers on its inner side, and a roller (6).
Page 85 FUNCTION SLEW MOTOR Hydraulic motor 2 Figure 1 shows that the rotor (6) rotates in the direction of the arrow while making contact with the inside of the stator (5) when the high-pressure oil is directed into the chambers B, C and D. This in turn causes the valve (2) to rotate, which causes the chambers into which the high-pressure oil is directed to be successively shifted in the direction op- posite the direction of the arrow.
Page 86 FUNCTION SLEW MOTOR Brake valve This valve is equipped with a shockless function. When the high-pressure oil enters the port Av, it flows through the orifice (1) and into the damper chamber (2) where it attempts to move the plunger (3) to the right. At this time, the spring (4) remains in its set position.
Page 87 FUNCTION SWIVEL JOINT SWIVEL JOINT The swivel joint is located at the slew center of the ma- chine and has the role of continuing to connect the oil cir- cuit regardless of the slew angle of the upper frame. A number of ports (3) equal to the number of fluid circuits is provided on a hub (1) and shaft (2) that are mutually rotatable.
Page 88 DISASSEMBLY AND ASSEMBLY...
Page 89 DISASSEMBLY AND ASSEMBLY SERVICE STANDARDS SERVICE STANDARDS Track roller Criteria, mm (in.) Code Standard dimension Allowable value 75 (3.0) 69 (2.7) 25 (1.0) – Shoe slider Criteria, mm (in.) Code Standard dimension Allowable value 9 (0.4) 4.5 (0.2) Sprocket Criteria, mm (in.) Code Standard dimension Allowable value...
Page 90 DISASSEMBLY AND ASSEMBLY SERVICE STANDARDS Clearance for pin and bushing SERVICE STANDARDS 4A0AX00...
Page 91 DISASSEMBLY AND ASSEMBLY SERVICE STANDARDS Unit: mm (in.) Code Item Standard dimension Bucket and arm 30 (1.18) Bucket and link 30 (1.18) Arm and link 30 (1.18) Bucket cylinder and link 30 (1.18) Bucket cylinder and arm 30 (1.18) Arm and boom 35 (1.38) Arm cylinder and arm 35 (1.38)
Page 92 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM DRIVE SYSTEM Engine 25.4 N·m (18.8 ft.-lb) or below 1 Use a shim to adjust the clearance between the en- 1. Radiator assembly 8. Drain valve gine hood and stopper. 2. Fan guard 9. Tank •...
Page 93 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM ThreeBond #1324 1 Use the included bolts which have been coated to prevent them from 15. Coupling 21. Hose becoming loose. 16. Housing 22. Engine hood FR 54.9 N·m (40.5 ft-lb) 17. Pipe 23. Engine hood FL Press-fit the three included spring pins into the assembly to insert 18.
Page 94 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM 27. RAD/HOC 32. Cushion rubber 28. Plate 33. Plate 29. Elbow 34. Shroud assembly 30. Pipe 35. Nipple 31. Plate DRIVE SYSTEM 4B0AX00...
Page 95 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Removing the engine 1. Remove the battery ground cable from the battery terminal. 2. Remove the covers. “Removing the covers” 3. Disconnect the hoses, and take out the air cleaner assembly (3). 4. Loosen the radiator cap, and bleed out the engine coolant from the drain valve (8).
Page 96 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Hydraulic pump Apply molybdenum disulfide grease on the spline. • Applying a large amount of grease on the spline hole in the coupling assembly may cause the grease to drip down onto rubber parts and cause the rubber to dete- riorate.
Page 97 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Removing the hydraulic pump 1. Remove the battery ground cable from the battery terminal. 2. Remove the covers. “Removing the covers” 3. Drain the hydraulic oil from the tank. “Removing the hydraulic tank” 4. Disconnect the suction hose from the hydraulic pump.
Page 98 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Fuel tank 1 To engine 1. Fuel tank 9. Drain plug 2. Plate 10. Fuel hose 3. Plate 11. Fuel hose 4. Fuel sender 12. Fuel hose 5. Sedimenter 13. Fuel hose 6. Feed pump 14.
Page 99 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Removing the fuel tank 1. Remove the canopy. 2. Remove the covers from the perimeter around the tank. 3. Loosen the drain plug (9), and let the fuel drain out. • Fuel tank capacity: 22 L (5.8 US·gal) 4.
Page 100 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Battery 1 Body earth point 1. Earth ground cable 4. Battery 2 Connection to the starter 2. Battery cable 5. Hook bolt 3. Battery clamp DRIVE SYSTEM 4B0AX00...
Page 101 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Removing the battery WARNING • Wear protective glasses and gloves when working with batteries. • Batteries generate flammable hydrogen gas which may explode. Keep away from flames and sparks. • Be sure to stop the engine by turning off the starter switch before inspecting or handling the battery.
Page 102 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Throttle lever Apply molybdenum disulfide grease to both surfac- es of the lever. • Line up the conical washers (3) so that the indented sides are all on the same side. ThreeBond #1324 1. Lever 6.
Page 103 DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM Adjusting the throttle lever Engine speed 1. Secure the wire (2) to the throttle lever (1) using the wire lock pin (7). 2. Push the throttle lever (1) down to the low-idling side A, and position the governor (10) to the idling posi- tion C.
Page 104 DISASSEMBLY AND ASSEMBLY TRAVEL SYSTEM TRAVEL SYSTEM Removing the crawler WARNING When working under the machine while it is raised up, be sure to use a stand to support the machine. Important: When replacing crawlers, replace both the right and left ones at the same time. 1.
Page 105 DISASSEMBLY AND ASSEMBLY TRAVEL SYSTEM Removing the track roller 1. Loosen the crawler tension. 2. Loosen the roller bolt (1) slightly (about one turn). 3. Lift up the machine, take out the bolt (1), and remove the roller (2). Installing the track roller 1.
Page 106 DISASSEMBLY AND ASSEMBLY TRAVEL SYSTEM Removing the travel motor 1. Remove the crawler. “Removing the crawler" 2. Take out the bolts (1), and remove the sprocket (2). Bolt: ThreeBond #1324 Bolt: 55 N·m (40.6 ft.-lb) 3. Remove the cover, and disconnect the hydraulic hoses (4).
Page 107 DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT SLEW EQUIPMENT Slew motor Construction ThreeBond #1324 1. Slew motor 2. Cover SLEW EQUIPMENT 4D0AX00...
Page 108 DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT Removing the slew motor 1. Disconnect the hydraulic hoses from the slew motor (1). 2. Remove the bolts from the slew motor. Bolt: ThreeBond #1324 Bolt: 102 N·m (75.2 ft.-lb) 3. Raise the slew motor (1), and remove it. Slew motor: 22 kg (49 lb) Installing the slew motor To install, follow the same procedures as for removal but...
Page 109 DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT Slew bearing Construction ThreeBond #1324 Grease the tooth surfaces and grease bus with lithium grease EP-2. 1 Supply port hole 1. Reamer bolt 2 Use a reamer bolt at this position only 2. Slew bearing 3 “S”...
Page 110 DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT Removing the slew bearing 1. Remove the hoe attachment. “Removing the hoe attachment” 2. Remove the upper frame. 3. Remove the fixing bolts for the inner race. Bolt: ThreeBond #1324 Bolt: 102 N·m (75.2 ft.-lb) 4.
Page 111 DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT Swivel joint Construction ThreeBond #1324 1. Swivel joint 2. Stopper SLEW EQUIPMENT 4D0AX00...
Page 112 DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT Removing the swivel joint 1. Remove the upper frame. “Removing the upper frame” 2. Disconnect the hydraulic hoses from the swivel joint (1). 3. Take out the bolt holding the stopper in place, and remove the stopper (2). Bolt: ThreeBond #1324 Bolt: 102 N·m (75.2 ft.-lb) 4.
Page 113 DISASSEMBLY AND ASSEMBLY UPPER FRAME UPPER FRAME Upper frame Construction Apply molybdenum disulfide grease. ThreeBond #1324 1. Upper frame 5. Cover 2. Counterweight 6. Cover 3. Bushing 7. Cover 4. Shim (Selected usage) UPPER FRAME 4E0AX00...
Page 114 DISASSEMBLY AND ASSEMBLY UPPER FRAME 1 To the slew motor 8. Grease fitting 12. Hose 2 To the slew bearing 9. Adapter 13. Hose 3 To the swing cylinder 10. Elbow 14. Spiral tube 4 Use the spiral tube to keep the hoses and machine body from coming 11.
Page 115 DISASSEMBLY AND ASSEMBLY UPPER FRAME Removing the upper frame 1. Remove the hoe attachment. “Removing the hoe attachment” 2. Take out the canopy. “Removing the canopy” 3. Remove the covers. “Removing the covers” 4. Disconnect the hydraulic hoses from the swivel joint. “Removing the swivel joint”...
Page 116 DISASSEMBLY AND ASSEMBLY UPPER FRAME Covers Construction 1. Engine hood 8. Bracket 2. Side cover L 9. Pin 3. Side cover R 10. Rod 4. Side frame L 11. Plate 5. Side frame R 12. Plate 6. Cover 13. Plate 7.
Page 117 DISASSEMBLY AND ASSEMBLY UPPER FRAME Removing the covers 1. Remove the engine hood (1). a. Open the engine hood, and raise it up temporari- b. Take out the mounting bolts in the hinge, and re- move the pins. Engine hood: 11 kg (26.5 lb.) 2.
Page 118 DISASSEMBLY AND ASSEMBLY UPPER FRAME CANOPY Construction 1. Canopy 2. Roof UPPER FRAME 4E0AX00...
Page 119 DISASSEMBLY AND ASSEMBLY UPPER FRAME Removing the canopy 1. Remove the battery ground cable from the battery terminal. 2. Disconnect the electrical wiring from the canopy. 3. Take out the mounting bolts. Bolt: 135 N·m (99.6 ft-lb) 4. Suspend the canopy and then remove it. Canopy: 48 kg (105 lb) UPPER FRAME 4E0AX00...
Page 120 DISASSEMBLY AND ASSEMBLY OPERATING DEVICE OPERATING DEVICE Control levers Construction OPERATING DEVICE 4F0AX00...
Page 121 DISASSEMBLY AND ASSEMBLY OPERATING DEVICE ThreeBond #1324 Apply grease to the inside surfaces of the DU bushing during assembly. 1 Adjust the pedal so that it is not de- 1. Bracket 17. Bracket 33. Lever pressed at a position away from the 2.
Page 122 DISASSEMBLY AND ASSEMBLY OPERATING DEVICE Dozer blade lever Construction Apply grease to the inside surfaces of the DU bushing during assembly. 1 Lever control force: 28 N (6.31 lbf) 1. Control cable 2. Yoke 3. Lever OPERATING DEVICE 4F0AX00...
Page 123 DISASSEMBLY AND ASSEMBLY OPERATING DEVICE Lever stand Construction Pilot valve (Left) 1 Adjusting the limit switch: When the limit switch is in the ON posi- 1. Control box L 6. Lever tion, the tip of the switch should be visible from the boot. 2.
Page 124 DISASSEMBLY AND ASSEMBLY OPERATING DEVICE Pilot valve (Right) 1. Control box R 2. Bracket 3. Plate 4. Pilot valve (Right) OPERATING DEVICE 4F0AX00...
Page 125 DISASSEMBLY AND ASSEMBLY OPERATING DEVICE Hydraulic piping OPERATING DEVICE 4F0AX00...
Page 126 DISASSEMBLY AND ASSEMBLY OPERATING DEVICE Table of Connections R1 ↔ Pa1 1. Pilot valve (Right) R2 ↔ Pb2 2. Pilot valve (Left) R3 ↔ Pb1 3. Solenoid valve (Lever lock) R4 ↔ Pa2 4. Control valve RP ↔ SOL B1 5.
Page 127 DISASSEMBLY AND ASSEMBLY ATTACHMENTS ATTACHMENTS Hoe attachment Construction ATTACHMENTS 4G0AX001...
Page 128 DISASSEMBLY AND ASSEMBLY ATTACHMENTS 1 2nd auxiliary line piping 2 Do not overtighten the castle nut. After tightening down the castle nut by hand, firmly tighten it down further until the tightening hole positions line up properly and then secure the castle nut in place with a cotter pin. 3 After applying NEVER-SEEZ NS (Regular grade) or an equivalent anti-seizing lubricant, put the parts together.
Page 129 DISASSEMBLY AND ASSEMBLY ATTACHMENTS 3 After applying NEVER-SEEZ NS (Regular grade) or an equivalent anti-seizing 27. Boom bracket lubricant, put the parts together. 28. Pin 4 Position with the grooved side facing upward. 29. Pin 30. Pin 31. Pin 32. Swing cylinder 33.
Page 130 DISASSEMBLY AND ASSEMBLY ATTACHMENTS 34. Blade 35. Blade cylinder 36. Pin 37. Plate R 38. Plate L ATTACHMENTS 4G0AX001...
Page 131 DISASSEMBLY AND ASSEMBLY ATTACHMENTS Removing the hoe attachment WARNING • Be sure to release any residual pressure in the piping before disconnecting the hydraulic hose. • Do not attempt to insert any fingers into the hole when adjusting the pin hole position. Important: •...
Page 132 DISASSEMBLY AND ASSEMBLY ATTACHMENTS Removing the link Completely retract the bucket cylinder, and lower the tip of the arm to the ground. 1. Take out the pin (5), and remove the link arm (2). a. Guide links R (3) and L (4) .......Exercise caution as they may drop b.
Page 133 DISASSEMBLY AND ASSEMBLY ATTACHMENTS Removing the boom Lower the tip of the boom all the way to the ground. 1. Disconnect the hydraulic hoses from the arm cylin- der (26). 2. Suspend the arm cylinder (26) temporarily and then pull out the pin and remove the arm cylinder. Arm cylinder: 17 kg (37 lb) 3.
Page 134 DISASSEMBLY AND ASSEMBLY ATTACHMENTS Removing the boom bracket 1. Take out the pin (31), and disconnect the swing cyl- inder (32) from the boom bracket. 2. Suspend the boom bracket (27) temporarily and then pull out the pins and remove the boom bracket. •...
Page 135 DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK HYDRAULIC TANK ThreeBond #1324 1. Hydraulic tank 6. Oil plug 11. O-ring 2. Lid 7. Suction filter 12. Sight gauge 3. Pipe 8. Return filter 13. Drain plug 4. Bushing 9. O-ring 5. Plug 10. O-ring HYDRAULIC TANK 4H0AX00...
Page 136 DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK Removing the hydraulic tank The numbers in parentheses ( ), listed after the names of parts throughout this document are used to refer to the same parts as the numbers listed in the construction di- agram and parts lists.
Page 137 DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK Inspecting and refilling the oil in the hydraulic tank WARNING • Oil may spurt out if caps or filters are removed or pipes are disconnected before the pressure in the hydraulic system is released. • Slowly loosen the oil plug (6) to release the internal pressure in the hydraulic tank.
Page 138 DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK Bleeding off the air Important: After replacing the hydraulic oil, bleed the air from the hydraulic circuits and hydraulic devices. Failure to do so may damage the hydraulic devices. 1. Start the engine, and let it idle. 2.
Page 139 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP HYDRAULIC PUMP Construction 1. Body S 13. Packing 25. Oil seal 37. Seal washer 2. Body H 14. Spring C 26. Belleville spring 38. Gear pump 3. Shaft 15. Spring T1 27. Snap ring 39. Coupling 4.
Page 140 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP Disassembly and assembly General precautions The numbers in parentheses, ( ), listed after the names of parts throughout this document are used to refer to the same parts as the numbers listed in the construction di- agram and parts lists.
Page 141 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 4. Remove the spring (15) and spring holder (16) from the body S (1). 5. Remove the cylinder block (4) from the body S (1). 6. Remove the swash plate (10) and the oscillating pin (12) from the body S (1).
Page 142 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 9. Remove the shaft (3) and oil seal (25) from the body S (1). • Tap the shaft (with the bearing attached) with a plastic hammer to remove it. 10. Remove the spring guide (17) from the body H (2). HYDRAULIC PUMP 4I0AY001...
Page 143 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP Assembly 1. Insert the oil seal (25) into the body S (1). • Make sure to use a new oil seal. • Apply a small amount of grease to the lip on the oil seal and around the outer circumference of the oil seal itself.
Page 144 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 7. Insert the spring (15) into the spring holder (16). Fi- nally, insert the spherical part of the spring holder into the hole on the swash plate. 8. Insert the spring guide (17) and O-ring (30) into the body H (2).
Page 145 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 12. Insert the two cap screws (M10×50) for temporary assembly into the proper positions on the top side and loosely tighten them down. Once the gap be- tween the joining surfaces reaches 10 mm (0.39 in.), insert the cap screws (M10×40) into the remaining two screw positions and tighten them down.
Page 146 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP Inspection and adjustments Checking the parts Item Criteria Action Piston and cylinder block • When the width of the clearance (S) • Replace assembly between the piston and cylinder block assembly is above 0.05 mm (0.0022 in.) •...
Page 147 Disassembly anD assembly Control valve Control valve Construction Standard 11. swing section 1. tie rod 12. switch valve 2. nut 3. outlet housing 13. slew section 4. bucket section 14. Dozer blade section 5. boom section 15. main relief valve 16.
Page 148 Disassembly anD assembly Control valve Auxiliary 2 1. tie rod 11. swing section 2. nut 12. switch valve 3. outlet housing 13. slew section 4. bucket section 14. Dozer blade section 5. boom section 15. 2nd auxiliary section 6. right travel section 16.
Page 149 Disassembly anD assembly Control valve Auxiliary 2 + 3 1. tie rod 12. switch valve 2. nut 13. slew section 3. outlet housing 14. Dozer blade section 4. bucket section 15. 2nd auxiliary section 5. boom section 16. 3rd auxiliary section 6.
Page 150 Disassembly anD assembly Control valve Right travel section 1. Housing 2. spool 3. o-ring 4. Wiper 5. seal holder 6. spring holder 7. spring 8. screw 9. Cover 10. Cap screw 11. screw 12. Plug 13. Poppet 14. spring 15. o-ring Left travel section 1.
Page 151 Disassembly anD assembly Control valve Boom section 1. Housing 8. Cap screw 15. spacer 2. spool 9. Poppet 16. backup ring 3. spring holder 10. spring 17. Plug 4. spring 11. Plug 18. Poppet 5. spring holder 12. o-ring 19. Cap screw 6.
Page 152 Disassembly anD assembly Control valve Arm section 1. Housing 17. Plug 2. spool 18. o-ring 3. Plug 19. o-ring 4. orifice 20. o-ring 5. Poppet 21. Cover 6. spring 7. Plug 8. o-ring 9. spring holder 10. spring 11. spring holder 12.
Page 153 Disassembly anD assembly Control valve Switch valve 1. Housing 2. spool 3. spring holder 4. spring 5. spring holder 6. Cover 7. o-ring 8. Cap screw 9. Cover 10. Filter 11. Washer 12. Plug 13. o-ring Auxiliary section 1. Housing 2.
Page 154 Disassembly anD assembly Control valve Port relief valve 1. Housing 11. lock nut 2. Plug 12. o-ring 3. sleeve 13. backup ring 4. main poppet 14, o-ring 5. Piston 15, backup ring 6. needle valve 16, o-ring 7. spring 17. o-ring 8.
Page 155 Disassembly anD assembly Control valve Disassembly For disassembly of the control valve, follow the procedure below. For assembly of the control valve, follow the same procedure as for disassembly in the reverse order. Valve assembly 1. loosen the nuts (1) and remove the tie rods (2), then remove the sections.
Page 156 Disassembly anD assembly Control valve 5. remove the load check valve. a. remove the spring (3) and then the poppet (4). 6. remove the load check valve. a. take out the plug (5) and spring (6) and remove the poppet (7). Plug: 29.4 n·m (21.7 ft-lb.) b.
Page 157 Disassembly anD assembly Control valve Pilot operated section 1. remove the cap screws and cover (1), and then re- move the o-ring from the cover (1). Cap screw: 7.3 n·m (5.4 ft-lb.) 2. remove the spring holder (2), spring (3) and spring holder (4).
Page 158 Disassembly anD assembly Control valve Main relief valve 1. remove the plug (1) from the housing (2). Plug: 49 to 54 n·m (36.1 to 39.8 ft-lb.) 2. remove the o-ring (3) from the plug (1). 3. remove the sleeve (4) from the plug (1), and then re- move the spring (5) and the main poppet (6) from the sleeve (4).
Page 159 Disassembly anD assembly Control valve Inspection and adjustment Checking the parts Parts Judgment criteria treatment Housing, valve body • Scratches, rust or corrosion on the parts sliding against the replace spool • Scratches, rust or corrosion on the seal pocket part that replace the spool enters • Scratches, rust or corrosion on the seal part on the port replace that is in contact with the o-ring • Scratches, rust or corrosion on the seal part of the relief...
Page 160 DISASSEMBLY AND ASSEMBLY PILOT VALVE PILOT VALVE Construction 1. Casing 7. Seal 13. Spring 2. Plate 8. O-ring 14. Spring 3. Spool 9. Spring seat 15. Spring 4. Plug 10. Spring seat 16. Joint 5. Push rod 11. Washer 2 17.
Page 161 DISASSEMBLY AND ASSEMBLY PILOT VALVE Special tools Unit: mm Installation jig A Quantity: 1 Material A: S45C Material B: SCM415N (case hardened) 4KAC02Z Installation jig B Quantity: 2 Material B: SCM415N (case hardened) ±0.1 15.5 ±0.1 C0.5 C0.5 11.6 ±0.1 4KAC03Z Disassembly and Assembly The numbers in parentheses () listed after the names of...
Page 162 DISASSEMBLY AND ASSEMBLY PILOT VALVE Disassembly WARNING The spring may fly out during disassembly. Refer to the construction diagram and take precautions. 1. Remove the adjusting nut (18) and remove the cam (17) from the joint. • Fasten the valve to the vice using copper or lead sheet.
Page 163 DISASSEMBLY AND ASSEMBLY PILOT VALVE 4. Remove the O-ring (8) and the seal (7) from the plug. 5. Remove the pressure reducing valves and springs (12) (13) from the casing. • Put alignment marks on the pressure reducing valves and casing holes, to ensure the same po- sition during reassembly.
Page 164 DISASSEMBLY AND ASSEMBLY PILOT VALVE Assembly 1. Assemble the pressure reducing valve. a. Install washer 2 (11), the springs (14) (15), and the spring seats (9) (10) onto the spool (3). b. Push in the spring seats (9) (10) to compress the springs (14) (15).
Page 165 DISASSEMBLY AND ASSEMBLY PILOT VALVE 4. Install the push rod (5) or (6) into the plug (5). • Apply hydraulic oil to the push rod. 4K2AQ11Z 5. Attach the plugs and plate (2) and install the (16) joint. • Use the installation jigs A and B to install the joint. Joint: 47.1±...
Page 166 DISASSEMBLY AND ASSEMBLY PILOT VALVE Inspection and adjustment Checking the parts Part Criteria Action O-ring — • Replace Seal — • Replace Spool • Wear on the sliding surfaces is 10 μm or more than the non-sliding • Replace surfaces. •...
Page 167 DISASSEMBLY AND ASSEMBLY PROPORTIONAL CONTROL SOLENOID VALVE PROPORTIONAL CONTROL SOLENOID VALVE Construction 1. Proportional control solenoid 2. Bolt PROPORTIONAL CONTROL SOLENOID VALVE 4K4AQ00...
Page 168 DISASSEMBLY AND ASSEMBLY PROPORTIONAL CONTROL SOLENOID VALVE Disassembly and Assembly The numbers in parentheses () listed after the names of parts in this document match the numbers used in the construction diagrams and parts lists. General Precautions • Perform disassembly and assembly work in a clean place.
Page 169 DISASSEMBLY AND ASSEMBLY SOLENOID VALVE (3RD AUXILIARY LINE PIPING) SOLENOID VALVE (3RD AUXILIARY LINE PIPING) Construction 1. Plug 5. Spring 2. Solenoid coil 6. Spool 3. O-ring 7. Body 4. O-ring 8. Cap screw SOLENOID VALVE (3RD AUXILIARY LINE PIPING) 4K6AV01...
Page 170 DISASSEMBLY AND ASSEMBLY SOLENOID VALVE (3RD AUXILIARY LINE PIPING) Disassembly and Assembly The numbers in parentheses () listed after the names of parts in this document match the numbers used in the construction diagrams and parts lists. General Precautions • Perform disassembly and assembly work in a clean place.
Page 171 DISASSEMBLY AND ASSEMBLY SOLENOID VALVE (3RD AUXILIARY LINE PIPING) Inspection and adjustment Checking the parts Part Criteria Action O-ring — • Replace Seal — • Replace Spool • Wear on the sliding surfaces is 10 μm or more than the non-sliding •...
Page 172 DISASSEMBLY AND ASSEMBLY SOLENOID VALVE (LEVER LOCK) SOLENOID VALVE (LEVER LOCK) Construction 1. Plunger 15. Plug 2. Spring 16. Plug 3. Plug 17. Cap screw 4. Spring 18. Cap screw 5. Spool 19. Washer 7. Adjust screw 20. Nut 8. Cover 22.
Page 173 DISASSEMBLY AND ASSEMBLY SOLENOID VALVE (LEVER LOCK) Disassembly Solenoid valve 1. Remove the cap screws (13). Cap screw: 3.9 N·m (2.9 ft-lb.) 2. Take out the solenoids (12) and remove the O-rings (22). • Place alignment marks on the solenoids and the body for easy reassembly.
Page 174 DISASSEMBLY AND ASSEMBLY SOLENOID VALVE (LEVER LOCK) Check valve 1. Remove the plug (3) from body (13). Plug: 21.0 N·m (15.5 ft-lb.) 2. Remove the spring (2) and the plunger (1). 3. Remove the O-ring (23). 4. Remove the plugs (16) and O-rings (25). Plug: 26.5 N·m (19.5 ft-lb.) Assembly For assembly, follow the same procedure as for disassem-...
Page 175 DISASSEMBLY AND ASSEMBLY SELECTOR VALVE SELECTOR VALVE Construction 1. Body 2. Rotor 3. Lever 4. Bolt 5. O-ring 6. O-ring 7. O-ring 8. O-ring 9. Spring pin 10. Snap ring 11. Cap screw 12. Washer SELECTOR VALVE 4K8AQ00...
Page 176 DISASSEMBLY AND ASSEMBLY SELECTOR VALVE Disassembly and Assembly The numbers in parentheses () listed after the names of parts in this document match the numbers used in the construction diagrams and parts lists. General Precautions • Perform disassembly and assembly work in a clean place.
Page 177 DISASSEMBLY AND ASSEMBLY SELECTOR VALVE 3. Remove the rotor (2) with the lever (3) attached from the body (1). 4. Remove the cap screws (11) and remove the lever (3) from the rotor (2). 5. Remove the spring pins (9) from the body (1) and ro- tor (2).
Page 178 DISASSEMBLY AND ASSEMBLY SELECTOR VALVE 6. Remove the O-rings (5) (6) (7) (8) from the body (1) and rotor (2). SELECTOR VALVE 4K8AQ00...
Page 179 DISASSEMBLY AND ASSEMBLY SELECTOR VALVE Assembly 1. Install the spring pins (9) in the body (1). • Lightly tap with a hammer. 2. Fit the O-rings (5) (6) to the body (1). 3. Install the spring pin (9) in the rotor (2). •...
Page 180 DISASSEMBLY AND ASSEMBLY SELECTOR VALVE 5. Attach the lever (3) to the rotor (2). Tighten the cap screws (11). Cap screw: 4.9 to 6.86 N·m 6. Install the rotor (2) to the body (1). 7. Fit the snap ring (10). 8.
Page 181 DISASSEMBLY AND ASSEMBLY SELECTOR VALVE Inspection and adjustment Checking the parts Part Criteria Action O-ring — • Replace Seal — • Replace Spool • Wear on the sliding surfaces is 10 μm or more than the non-sliding • Replace surfaces. •...
Page 182 Disassembly anD assembly Cylinders Cylinders Construction Boom cylinder 1. Tube 9. backup ring 17. Cushion seal 2. bushing 10. O-ring 18. stopper 3. Piston rod 11. Piston 19. snap ring 4. rod cover 12. Piston packing 20. Plug 5. bushing 13.
Page 183 Disassembly anD assembly Cylinders Bucket cylinder 1. Tube 8. Dust seal 15. set screw 2. bushing 9. O-ring 16. ball 3. Piston rod 10. backup ring 17. Plug 4. rod cover 11. O-ring 18. O-ring 5. bushing 12. Piston 19. Dust seal 6.
Page 184 Disassembly anD assembly Cylinders Swing cylinder 1. Tube 9. O-ring 17. Piston 2. bushing 10. backup ring 18. Piston packing 3. Piston rod 11. O-ring 19. Wear ring 4. rod cover 12. backup ring 20. set screw 5. bushing 13. O-ring 21.
Page 185 Disassembly anD assembly Cylinders special tools Unit: mm Installation jig B Quantity: 1 material: s45C boom bucket blade swing Sliding jig C Quantity: 1 material: sTKm13C boom 60.5 58.3 20.8 12.3 60.5 58.3 20.8 12.3 bucket 50.5 10.8 12.3 blade 60.5 58.3 20.8...
Page 186 Disassembly anD assembly Cylinders disassembly Cylinder assembly 1. Keep the cylinder in a level position by securing the clevis of the tube in a vise and placing a wooden sup- port under the other end. 2. Drain the remaining hydraulic oil from the cylinder. • Move the piston rod slowly to prevent the hydraulic oil from spurting out.
Page 187 Disassembly anD assembly Cylinders 2. remove the piston assembly. a. Take out the setscrew (1) and remove the ball (2). • The setscrew (1) is caulked in two places with a punch. Grind off the caulked portions with a hand drill. b. Remove the piston assembly (3). c. Pull out the cushion bearing (4). (Boom cylinder, swing cylinder) <Only for boom cylinder (c to f)> c. Remove the snap ring (4). • When removing, lightly tap the ring with a plastic hammer while taking care not to damage the pis- ton rod or cushion bearing.
Page 188 Disassembly anD assembly Cylinders Piston 1. Remove the wear rings (10). • Spread the wear ring just enough to disengage it in axial direction. 2. remove the piston packing from the piston. 4LAA16Z Rod cover 1. Remove the O-rings (20) and (21) and the backup ring (22) from the outer diameter section of the rod cover. <Only for swing cylinder> 2. remove the cushion ring. a. Remove the stopper (13). b. Remove the spacer (14). c. Remove the cushion ring (12). 3. remove the rod packing. a. Remove the rod packing (15).
Page 189 Disassembly anD assembly Cylinders 4. Remove the dust seal (26). • Tap alternately on several points around the inner circumference of the metal ring, gradually pushing the seal out of the groove. 4LAA21Z Clevis 1. remove the dust seals from the tube and the piston rod clevis.
Page 190 Disassembly anD assembly Cylinders Assembly Clevis 1. Using the installation jig B, press fit the bushings (28) into the piston rod and tube. 4LAA24Z 2. install the dust seal by using the supporting metal (29). 4LAA25Z Rod cover 1. install the rod packing. a. Install the backup ring (16). (Bucket cylinder, Swing cylinder) b. Install the rod packing (15). <Only for swing cylinder> 2. install the cushion ring. a. Install the cushion ring (12).
Page 191 Disassembly anD assembly Cylinders 3. Install the dust seal (26). • For a dust seal with a metal ring around its perim- eter, use a supporting metal (30) for installation. 4LAA26Z 4. Install the backup ring (22) and the O-rings (20) and (21). • Make sure that the cut portion of the backup ring does not get out of place. Piston 1.
Page 192 Disassembly anD assembly Cylinders c. Since the slipper ring (35) is extended when it is in- stalled, correct it using the corrective jig E. 4LAA31Z 2. Install the wear ring (10). • Spread the wear ring (10) just enough so that it can be installed on the piston in axial direction. 4LAA16Z Piston rod assembly 1. install the rod cover assembly on the piston rod. 4LAA13Z <Only for swing cylinder> 2. install the cushion bearing on the piston rod. • The cushion bearing must be installed in the correct direction.
Page 193 Disassembly anD assembly Cylinders 3. install the piston on the piston rod. <Only for boom cylinder (a to d)> a. Place the cushion seal (7) in the groove with the seal’s slitted portion facing the thread side. b. Install the cushion bearing (6) with its worked sur- face portion facing the correct side as shown in the figure.
Page 194 Disassembly anD assembly Cylinders 3. bend down the lock rib on the tube and fit it into the notch of the rod cover to lock it. CylinDers 4l0aX00...
Page 195 Disassembly anD assembly Cylinders inspection and adjustment Inspection after disassembly Clean each part thoroughly with cleaning oil, then carry out the following checks. When a cylinder has been disassem- bled, replace all the seals with new ones. 1. Piston rod • Replace the rod if there are cracks.
Page 196 Disassembly anD assembly Cylinders inspection after assembly No load operation test 1. Place the cylinder in a horizontal position with no load. 2. apply gentle pressure alternately to the ports at both ends, operating the piston rod 5 or 6 times. 3.
Page 197 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR TRAVEL MOTOR Construction Hydraulic motor 1. Valve body 12. Spring 23. Friction disc 2. Flange holder 13. Retainer 24. Center disc 3. Shaft 14. Bearing 25. Oil seal 4. Cylinder block 15. Bearing 26. Spring pin 5.
Page 198 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR Reduction gears 1. Housing 11. Needle 21. Spring pin 2. Cover 12. Needle 22. O-ring 3. Carrier 2 13. Floating seal 23. O-ring 4. Planet gear B1 14. O-ring 24. Plug 5. Planet gear B2 15.
Page 199 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR Valves 1. Spool 7. Shuttle spool 13. Plug 2. Check valve 8. Spring 14. O-ring 3. Spring guide 9. Spring 15. O-ring 4. Spool 10. Plug 16. O-ring 5. Spool 11. Plug 17. O-ring 6. Spool 12.
Page 200 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR Assembly The assembly procedures are given below. For disas- sembly, follow the same procedures as for assembly but in the reverse order by referring to the construction dia- gram. Counter balance valve and hydraulic motor 1.
Page 201 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 4. Insert the 2-speed spool (4) and spring (5) into the valve body. 5. Attach the O-rings to the plugs, and tighten the plugs on each end of the body. Plug: 46 to 51 N·m (33.9 to 37.6 ft.-lb) 6.
Page 202 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 8. Attach the O-rings (large and small) to the valve body. 9. Press-fit the oil seal into the flange holder. • Do not disassemble the oil seal unless necessary. Add grease between the lips of the oil seal. 10.
Page 203 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 12. Insert the shaft into the flange holder. • The bearing is press-fitted and thus cannot be disassembled. • Be careful not to damage the oil seal with the shaft. 13. Place the balls and the swash plate in the flange holder.
Page 204 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 16. Insert the piston (12) and guide (13) into the shoe holder (11) to form the shoe holder assembly. 17. Place the shoe holder assembly into the cylinder block to form the cylinder block assembly. 18.
Page 205 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 20. Insert the center disc (15) into the groove on the flange holder. 21. Attach the two O-rings and two backup rings to the brake piston. • Attach the O-rings on the inside and then attach the backup rings on the outside.
Page 206 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 24. Fill the flange holder with 100 ml (3.4 fl.oz) hydraulic oil, and align the valve body with the flange holder. 25. Secure the hydraulic motor in a vise, and tighten the screws. Screw: 28.4 to 30.4 N·m (20.9 to 22.4 ft.-lb) •...
Page 207 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 3. Fit the O-ring to the seal ring and then attach them to the housing. • Align the seal ring pin with the pin hole on the housing. Apply grease to the O-ring. 4. Attach the housing, and insert the hydraulic motor. •...
Page 208 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 7. Place the rings, thrust washers, planet gears B1, and needles on the pins. • Be sure to attach the ring (20) in the correct direc- tion. The side with the chamfered internal diame- ter must be on the motor side. 8.
Page 209 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 11. Insert the carrier 2 assembly into the housing. 12. Attach the O-ring to the housing. 13. Place the ring on the cover. Apply grease. 14. Add 330 ml (11.2 fl.oz) of lubricant. TRAVEL MOTOR 4M0AX00...
Page 210 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 15. Attach the cover to the housing. • Align the notch on the housing with the drain plug hole. 16. Attach the snap ring to secure the cover in place. • Set a flat head screwdriver against the edge of the snap ring to hammer it in around its circumfer- ence.
Page 211 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR Inspection and adjustments Use limit for parts Part Item to check Criteria Action Floating seal Sliding surface If there are abnormal scratches, wear, or seizure Replace on the surface Angular bearing Rolling surface If there are abnormal scratches, or flaking on the Replace ball or race Planet gear...
Page 212 DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR Part Item to check Criteria Action Valve body Sliding surface with If there are abnormal scratches, wear, or seizure Replace both the the spool on the surface valve body and spool Spool Sliding surface with If there are abnormal scratches, wear, or seizure the valve body on the surface...
Page 213 DISASSEMBLY AND ASSEMBLY SLEW MOTOR SLEW MOTOR Construction Hydraulic motor 1. X-ring 12. Bearing housing 23. Snap ring 34. Pin 2. O-ring 13. Flange mounting 24. Snap ring 35. Valve housing 3. O-ring 14. Pinion gear 25. Rear bearing 36. Ball 4.
Page 214 DISASSEMBLY AND ASSEMBLY SLEW MOTOR Brake valve 1. Plunger 2. Pinion 3. Spring 4. Timer orifice 5. Damper orifice SLEW MOTOR 4N0AX00...
Page 215 DISASSEMBLY AND ASSEMBLY SLEW MOTOR Disassembly and assembly General precautions • Perform disassembly and assembly work in a clean place. Provide clean containers to hold parts during disassembly. • Before disassembly, clean around the ports and re- move coating or thread-locking compound on the joints with a wire brush.
Page 216 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 4. Remove the valve plate and the valve drive gear. 5. Remove the gerolor. 6. Remove the drive. 7. Take out the socket bolts, and remove the flange mounting. • Do not disassemble the rear bearing unless nec- essary.
Page 217 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 8. Remove the spring from the flange mounting. 9. Remove the brake piston. 10. Remove the ring. 11. Remove the center disc (20), the friction disc (19), and the plate. SLEW MOTOR 4N0AX00...
Page 218 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 12. Remove the snap ring. 13. Remove the pinion gear. • Pull out the shaft assembly with a press using a support. • Do not disassemble the ball bearing and collar unless necessary. 14. Remove the X-ring from the bearing housing. 15.
Page 219 DISASSEMBLY AND ASSEMBLY SLEW MOTOR Assembly 1. Insert the X-ring into the bearing housing. 2. Insert the shaft into the bearing housing. • Using a support, press-fit the shaft with a press. 3. Attach the snap ring to secure the front bearing in place.
Page 220 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 5. Fit the O-rings to the inner part and outer part of the ring and then insert the ring into the bearing housing. 6. Fit the O-ring to the piston and then insert them into the housing.
Page 221 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 9. Tighten the socket bolts. • Apply Loctite #242 to the socket bolt. Bolt: 34.3 N·m (29.3 ft.-lb) 10. Insert the drive gear. 11. Fit the O-rings (large and small) to the flange mount- ing, and attach them to the gerolor. •...
Page 222 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 14. Attach the valve. Important: The valve timing determines the rotation direc- tion of the motor. Carefully attach the valve by referring to the figure below. 15. Insert the plug, spring, and ball into the valve hous- ing.
Page 223 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 17. Fit the inner face seal (11) and the outer face seal (12) to the balancing plate (5). 18. Align the notch on the balancing plate (5) with the pin, and attach the plate to the valve housing (13). 19.
Page 224 DISASSEMBLY AND ASSEMBLY SLEW MOTOR 22. Insert the O-ring into the housing. 23. Attach the brake valve to the hydraulic motor, and tighten with socket bolts. Socket bolt: 54 N·m (39.3 ft.-lb) SLEW MOTOR 4N0AX00...
Page 225 DISASSEMBLY AND ASSEMBLY SLEW MOTOR Inspection and adjustments Checking the parts Brake valve Part Criteria Action Body • If there is severe damage to sliding parts or excessive surface rough- • Replace ness • If there is damage, etc. that allows oil leakages to occur •...
Page 226 DISASSEMBLY AND ASSEMBLY SWIVEL JOINT SWIVEL JOINT CONSTRUCTION 1. Slipper Seal 9. Cover 17. Flange 2. O-ring 10. Spring 18. Thrust Ring 3. O-ring 11. O-ring 19. Snap Ring 4. O-ring 12. O-ring 20. Selector Assembly 5. O-ring 13. Backup Ring 21.
Page 227 DISASSEMBLY AND ASSEMBLY SWIVEL JOINT DISASSEMBLY AND ASSEMBLY General Cautions • Carry out disassembly and assembly operations in • Replace all seals with new ones each time the a clean place and provide clean containers to place hydraulic units is disassembled. the disassembled parts in.
Page 228 DISASSEMBLY AND ASSEMBLY SWIVEL JOINT Swivel Joint 1. Take out the bolts and remove the spring washers, then remove the ﬂange (1) from the hub. Bolt: 27.5 N·m • During assembly, place a pipe on the stopper pin of the shaft and check if the shaft rotates. Cap Screw: 6.9 N·m(5.1 ft-lb.) 2.
Page 229 DISASSEMBLY AND ASSEMBLY SWIVEL JOINT 5. Remove the seals from the inside diameter of the hub. • Check the positions of the seals in the struc- tural drawing. • Use an O-ring tooth or eyeleteer with a sharp point on the end, etc. •...
Page 231 DISASSEMBLY AND ASSEMBLY SWIVEL JOINT Inspection after assembly After assembly, perform an oil leak test on each circuit using the apparatus shown in the ﬁgure. 4O0AF08Z 1. Connect the pipe (3) from the hydraulic pump (2) to the shaft (1) side port. 2.
Page 232 TROUBLESHOOTING...
Page 233 TROUBLESHOOTING ABOUT THE TROUBLESHOOTING SECTION ABOUT THE TROUBLESHOOTING SECTION This “Troubleshooting” section describes the fault diagnosis and corrective actions mainly for hydraulic systems. The cause of the problem can be investigated by following the steps in the chart shown at the beginning of each item. Notes on troubleshooting and servicing 1.
Page 234 TroubleshooTing Overall machine Overall machine No operation is possible. insufficient check the hydraulic oil Add hydraulic oil. level sufficient • Repair or replace the hy- Faulty check hydraulic draulic pump. pump • Replace the coupling. 1. check the hydraulic oil level. check the hydraulic oil tank level. “4.
Page 235 TroubleshooTing Overall machine All systems working, but insufficient force. insufficient check the hydraulic oil Add hydraulic oil. level sufficient Abnormal noise from the Replace the seal tape, O-ring suction line faulty piston pump and hose. Action appropriate to the Frothing in the tank cause of the frothing. Faulty check the main relief repair or replace the main re- valve lief valve.
Page 236 TroubleshooTing Overall machine 4. check the main relief valve. measure the relief pressure of the main relief valve. • If the measured value is within specifications, the valve is normal. “2. Service data, Performance criteria” if the pressure of the main relief valve is low, adjust it to the set pressure by gradually tightening the set- screw.
Page 237 TroubleshooTing Overall machine Boom, bucket, slew and arm fail to move or are too slow. • Repair or replace the gear Faulty Check the gear pump pump (P4) • Replace the coupling normal Faulty check the fuse replace the fuse normal Faulty Adjust or replace the limit check the limit switch switch...
Page 238 TroubleshooTing Overall machine 2. check the fuse check the fuse in the power supply circuit that oper- ates the pilot solenoid valve. 3. check the limit switch Turn the limit switch on, by moving the lever stand to the driving position. Then check the voltage at the lever lock solenoid valve with a tester. If there is voltage, the switch works normally. 4. check the lever lock solenoid valve Check according to the following procedure.
Page 239 TroubleshooTing Traveling Traveling No travel is possible check the supply pres- sure for the travel lever lock cylinder normal Faulty repair or replace the faulty Check the linkage part(s) normal Faulty check the travel lever lock replace the travel lever lock cylinder cylinder 1.
Page 240 TroubleshooTing Traveling Right or left travel is impossible check the operation of actuators other than of the travel motor normal Faulty check the spool opera- Repair or replace the housing tion block normal Faulty Check the linkage Adjust, repair or replace normal Faulty repair or replace the swivel check the swivel joint joint normal...
Page 241 TroubleshooTing Traveling 3. check the linkage To check the linkage, remove the R pin (2) and pin (3) which connect the spool and the yoke (1), and then inspect the yoke (1) movement. 4. check the swivel joint • Disconnect the hose connecting the swivel joint and the counter balance valve from the counter balance valve. Fit the pressure gauge to the hose just dis- connected.
Page 242 TroubleshooTing Traveling Right or left travel speed decelerates, causing the machine to veer to one side Within specs Is the veering within Problem is caused by the normal specs? combination of devices out-of-specs check the crawler belt Adjust to the specified crawler Faulty tension. check for for- tension and remove the for- eign matter caught in the eign matter...
Page 243 TroubleshooTing Traveling 1. is the veering within specs? If the veering is within specifications, the machine is normal. Problem is caused by the combination of de- vices. “2. Service data, Performance criteria” 2. check the crawler tension “2. Service data, Performance criteria” 3. check the spool operation “No travel is possible, 2. Check the linkage.” 4. Switch the discharge hoses between the pumps Switch the discharge hoses between the pumps P1 and P2. If the veering direction is changed to the op- posite side, the pumps are faulty.
Page 244 TroubleshooTing Traveling 2nd speed travel is not possible Faulty Repair or replace the gear Check the gear pump (4) pump normal Faulty check the fuse replace the fuse normal check the 2nd speed Faulty replace the 2nd speed switch, switch, harness and con- harness and controller troller normal Faulty...
Page 245 TroubleshooTing Traveling 3. check the 2nd speed switch, harness and control- a. Press the switch to turn it on. Use a tester to check if a voltage is applied. The switch is normal if a voltage is applied. b. check the harness continuity. c. check the switch. d. check the controller. “2. Service data, Electric circuit diagram” 5C0AQ03Z 4. check the 2nd speed solenoid valve a. Turn the starter switch to the on position. b. Lightly press down the protruding part on the sole- noid end.
Page 246 TroubleshooTing Slewing Slewing No slewing is possible check the operation of actuators other than of the slew motor normal Faulty repair or replace the pilot check the pilot valve valve normal Faulty check the spool opera- Repair or replace the housing tion block normal Pressure too low Adjust the pressure of the check the slew pressure...
Page 247 TroubleshooTing Slewing 2. check the pilot valve Disconnect the hose connecting the pilot valve and the control valve (slew block) from the control valve. Fit the pressure gauge to the hose just disconnected. • Insert a plug into the control valve port. • Operate the lever (slew) and measure the pressure. • If the pressure is between 0 and 3.4 MPa (0 to 493 PSI) depending on the lever angle, the pilot valve is normal. 3. check the spool operation Disconnect the hose connecting the control valve (slew block) and the slew motor from the control valve. Fit the pressure gauge to the discharge port on the con- trol valve. • Operate the lever (slew) and measure the pressure. • If the measured value is as below, the spool is nor- mal.
Page 248 TroubleshooTing Slewing Slew right or left is not possible Faulty repair or replace the pilot check the pilot valve valve normal Faulty check the spool opera- Repair or replace the housing tion block normal Faulty check the slew relief repair or replace the slew re- valve lief valve normal...
Page 249 TroubleshooTing Slewing Slewing is slow or lacks force Within specs is the time needed for normal slewing within specs? slow Faulty repair or replace the pilot check the pilot valve valve normal Faulty check the spool opera- Repair or replace the housing tion block normal Pressure too low Adjust the slew relief valve check the slew pressure Adjust to set pressure...
Page 250 TroubleshooTing Slewing The machine slews, but overruns a lot when slewing stops, or slewing cannot be stopped is the amount of overrun Within specs when slewing stops with- normal in specs? out-of-specs Faulty repair or replace the pilot check the pilot valve valve normal Faulty check the spool opera-...
Page 251 TroubleshooTing Slewing 3. check the spool operation Check if the spool of the control valve (slew block) re- turns to the neutral position when the operation lever (slew) is released after operation. Disconnect the hose connecting the control valve (slew block) and the slew motor from the control valve. Fit the pressure gauge to the discharge port on the control valve. • Operate the lever (slew) and then release it to read the pressure gauge. • If the pressure is zero, the spool is normal. 4. check the slew pressure “No slewing is possible, 4. Check the slew pres- sure” sleWing 5D0AX00...
Page 252 TroubleshooTing Slewing When stopped on a slope, the upperstructure cannot maintain its posture Within specs is the slew spontaneous normal drop within specs? out-of-specs Adjust the relief valve Pressure too low check the slew pressure pressure of the slew brake Adjust to set pressure valve normal Pressure does not rise...
Page 253 TROUBLESHOOTING BOOM BOOM The boom cylinder does not move Check the operation of actuators other than of the boom cylinder. Normal Faulty Repair or replace the pilot Check the pilot valve. valve. Normal Faulty Check the spool opera- Repair or replace the housing tion.
Page 254 TROUBLESHOOTING BOOM 2. Check the pilot valve. Disconnect the hose connecting the pilot valve and the control valve (boom block) from the control valve. Fit the pressure gauge to the hose just disconnected. • Operate the lever (boom) and measure the pres- sure.
Page 255 TROUBLESHOOTING BOOM Boom cylinder operation is slow or lacks force. Within specs Is the speed of the boom Normal cylinder within specs? Out-of-specs Faulty Repair or replace the pilot Check the pilot valve. valve. Normal Faulty Check the spool opera- Repair or replace the housing tion.
Page 256 TROUBLESHOOTING BOOM 5. Check the boom cylinder. Check for leakage inside the boom cylinder (1) a. With the bucket cylinder fully retracted and the arm cylinder extended slightly from the fully re- tracted position, lower the bucket tip to the ground.
Page 257 TROUBLESHOOTING BOOM b. Disconnect hose (B) from the head side only and drain oil from the cylinder piping. Insert a plug (2) into the disconnected hose. c. Operate the bucket to raise the machine body. If oil leaks from the cylinder piping from which the hose was disconnected and the boom cylinder rod extends, the cylinder is leaking internally.
Page 258 TROUBLESHOOTING BOOM When the control lever is pulled slowly, the boom drops temporarily. Faulty Check the load check Repair or replace the housing valve in the control valve. block. Normal Faulty Check for leakage inside Repair or replace the boom the boom cylinder.
Page 259 TROUBLESHOOTING BOOM Spontaneous drop of the boom cylinder is too large. Is the spontaneous drop Within specs of the boom cylinder with- Normal in specs? Out-of-specs Faulty Check for leak inside the Repair or replace the boom boom cylinder. cylinder. Normal Problem solved Test by replacing the port...
Page 260 TroubleshooTing Arm cylinder does not move check the operation of actuators other than of the arm cylinder normal Faulty repair or replace the pilot check the pilot valve valve normal Faulty check the spool opera- Repair or replace the housing tion block normal Problem solved Test by replacing the port The port relief valve is repair or replace the port re-...
Page 261 TroubleshooTing 3. check the spool operation Disconnect the arm hose connected to the pipe at the boom foot, then install a pressure gauge in the discon- nected hose. • Operate the lever (arm) and measure the pressure. • If the measured value is within the specifications, the spool is normal. Supply pressure: 21.0 MPa (3046 PSI) 4. Test by replacing the port relief valve replace the port relief valve in question with a normal port relief valve.
Page 262 TroubleshooTing Arm cylinder operation is slow or lacks force Within spec is the speed of the arm normal cylinder within spec? out-of-spec Faulty repair or replace the pilot check the pilot valve valve. normal Faulty check the spool opera- Repair or replace the housing tion block.
Page 263 TroubleshooTing 5. check for leak inside the arm cylinder a. Fully retract the bucket cylinder and the arm cylin- der, and then lower the bucket to the ground. b. Disconnect the two hoses connected to the cylin- der. Insert plugs (1) into the disconnected hoses and the cylinder piping. c. raise the boom and lift the hoe attachment off the ground. If the arm drops, the cylinder is faulty. If not, there is a leak inside the control valve.
Page 264 TroubleshooTing Spontaneous drop of the arm is too large is the spontaneous drop Within specs of the arm cylinder within normal specs? out-of-specs Faulty repair or replace the arm cyl- check the arm cylinder inder 1. is the spontaneous drop of the arm cylinder within specs? “2. Service data, Performance criteria”...
Page 265 TroubleshooTing BuckeT BuckeT Bucket cylinder does not move or lacks force check the operation of actuators other than of the bucket cylinder normal Faulty repair or replace the pilot check the pilot valve valve normal Faulty check the spool opera- Repair or replace the housing tion block...
Page 266 TroubleshooTing BuckeT 4. Test by replacing the port relief valve replace the port relief valve in question with a port re- lief valve used for a normal boom. if the bucket cylinder operates normally with the replacement valve, the port relief valve used on the bucket side is faulty.
Page 267 TroubleshooTing BuckeT Spontaneous drop of the bucket is too large is the spontaneous drop Within specs of the bucket cylinder normal within specs? out-of-specs Faulty check the bucket cylin- repair or replace the bucket cylinder normal Oil is leaking inside the control Replace the housing block valve 1. is the spontaneous drop of the bucket cylinder within specs? “2. Service data, Performance criteria”...
Page 268 TROUBLESHOOTING BOOM SWING BOOM SWING Swing cylinder does not move. Check the operation of actuators other than of the swing cylinder. Normal Faulty Check the spool opera- Repair or replace the housing tion. block. Normal Faulty Check the linkage. Adjust, repair or replace. Normal Faulty Check the anti-cavitation...
Page 269 TroubleshooTing BOOm Swing 3. check the linkage To check the linkage, remove the R pin (2) and pin (3) used to connect the spool and the yoke (1) , and then inspect the yoke (1) movement. 4. check the anti-cavitation valve If only the right swing is inoperable, it is likely that for- eign matter is caught in the anti-cavitation valve or the valve is sticking. 5. check the swing cylinder Disconnect the hose connecting the swing cylinder and the control valve from the control valve and mea- sure the supply pressure in the control valve.
Page 270 TROUBLESHOOTING DOZER BLADE DOZER BLADE Dozer blade cylinder does not move or lacks force. Check the operation of actuators other than of the dozer blade cylinder. Normal Faulty Check the spool opera- Repair or replace the housing tion. block. Normal Faulty Check the linkage.
Page 271 TROUBLESHOOTING DOZER BLADE 4. Check the supply pressure of the control valve. Disconnect one of the hoses connected to the con- trol valve housing block (blade). Fit the pressure gauge to the hose just disconnected. Operate the le- ver (blade) and check the supply pressure of the valve.
Page 272 TROUBLESHOOTING DOZER BLADE The spontaneous drop of the dozer blade is too large, or the dozer blade cannot support the machine. Is the spontaneous drop Within specs of the dozer blade within Normal specs? Out-of-specs Faulty Check for leakage inside Repair or replace the housing the dozer blade cylinder.
Page 273 TROUBLESHOOTING DOZER BLADE c. Raise the dozer boom and apply a load on the blade. • If the machine drops while oil drains from the cylinder’s piping, the cylinder is faulty. If the machine drops even though no oil drains out, the control valve or the swivel joint is faulty.
Page 274 TroubleshooTing auxiliary hyDraulicS (1ST) auxiliary hyDraulicS (1ST) Prescribed pressure is not supplied to the auxiliary lines. check the operation of actuators other than the auxiliary lines normal Faulty check the spool opera- Repair or replace the housing tion block normal Faulty Check the linkage Adjust, repair or replace normal Faulty check the supply pres-...
Page 275 TroubleshooTing SPanner Spanner Spanner cylinder does not move or lacks force check the operation of actuators other than the spanner cylinder normal Faulty check the spool opera- Repair or replace the housing tion block normal Faulty Check the linkage Adjust, repair or replace normal Faulty check the supply pres- Repair or replace the housing sure of the control valve block...
Page 276 TroubleshooTing SPanner 5. check the swivel joint a. inspect the spool stroke “A” of the selector on the swivel joint, and check if the spool is correctly switched to the blade side. • Spool stroke “A”..6 mm (0.2 in.) b. Disconnect the hose between the swivel joint and the spanner cylinder from the cylinder side.
Page 277 TROUBLESHOOTING PISTON PUMP PISTON PUMP Symptoms Major causes Remedies Noise is too loud, unusual • Suction hose is crushed or suction filter • Remove the dirt and correct the crushing. sound is heard is clogged. • Joint in the suction side is loose and •...
Page 278 TROUBLESHOOTING GEAR PUMP GEAR PUMP “4. Disassembly and assembly, Gear pump” Symptoms Major causes Remedies No discharging operation • Direction of rotation is incorrect. • Rotate in the rated direction. • Hydraulic oil tank level is too low. • Add oil to the specified level. •...
Page 279 TROUBLESHOOTING CONTROL VALVE CONTROL VALVE “4. Disassembly and assembly, Control valve” The problems are listed individually in the table below, but in reality, many problems have multiple causes. Therefore, try to check and eliminate each possible cause one at a time. Symptoms Major causes Remedies...
Page 280 TROUBLESHOOTING CONTROL VALVE Symptoms Major causes Remedies Spool’s neutral position • There are cases of a large oil leak in- • Check if the cylinder drops spontaneously cannot be maintained side the cylinder. when it is held. If the cylinder is faulty, dis- (cylinder drops) assemble and repair it.
Page 281 TROUBLESHOOTING PILOT VALVE PILOT VALVE “4. Disassembly and assembly, Pilot valve” Symptoms Major causes Remedies The secondary pressure • Primary pressure is insufficient. • Keep the primary pressure. is too low • The spring is broken or worn out. • Replace •...
Page 282 TROUBLESHOOTING SOLENOID VALVE SOLENOID VALVE “4. Disassembly and assembly, solenoid valve” Symptoms Major causes Remedies Solenoid valve does not • Wiring short-circuit or wire break. • Replace operate • Coil assembly short-circuit or wire • Replace break. • Foreign matter is caught in the spool. •...
Page 283 TROUBLESHOOTING CYLINDERS CYLINDERS “4. Disassembly and assembly, Cylinders” Symptoms Major causes Remedies Oil is leaking from the pis- • Foreign matter is trapped in the inside • Remove the foreign matter. ton rod sliding surface (oil diameter of the rod packing or dust forms a ring on the piston seal.
Page 284 TROUBLESHOOTING TRAVEL MOTOR TRAVEL MOTOR “4. Disassembly and assembly, Travel motor” Hydraulic motor Symptoms Major causes Remedies Motor fails to start • All the devices other than the motor and • Check whether the specified pressure is the reduction gears are not working generated in the inlet port, and then check correctly.
Page 285 TROUBLESHOOTING TRAVEL MOTOR Parking brake Symptoms Major causes Remedies Braking force is insuffi- • Disc surface is faulty. • Repair or replace cient or not evenly applied • Spring is damaged. • Replace the spring. • Bolt for manual releasing is being fitted. • Remove the bolt for manual release, and fit the plug.
Page 286 TroubleshooTing Slew mOTOr Slew mOTOr If you notice that the noise or heat becomes unusually high, it is likely that there is a fault in the machine. If it occurs, stop the machine immediately and try to locate the faulty section. The table below shows the cause of the general problem and action to be taken when such problem occurs in the hydraulic circuits. hydraulic motor, brake valve symptoms how/Where? major causes remedies motor fails to start • No pressure at the motor’s inlet • Set pressure of relief valve is too • Set correctly port • Pump faulty...
Page 287 Other...
Page 288 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) Monochrome LCD Cluster Panel Display and LCD Specifications (Without a CAN) 6S3AY00...
Page 289 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) CONTENTS CONTENTS Contents Normal Panel Display/LCD Screen Panel Display: Water Temperature Gauge Panel Display: Fuel Gauge Panel Display: Function/Warning Lamps Normal Screen Main Menu Screen Data Selection Screen Data Screen (TRIP METER) 10 Data Screen (WATER TEMP.) 11 Settings Selection Screen 12 Setting Screen (CLOCK)
Page 290 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) NORMAL PANEL DISPLAY/LCD SCREEN NORMAL PANEL DISPLAY/LCD SCREEN Off States for Function and On States for Function and Warning Display Indicators Warning Display Indicators Panel Display Panel Display 1 Water temperature 1 Water temperature gauge 2 Fuel gauge gauge...
Page 291 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) PANEL DISPLAY: WATER TEMPERATURE GAUGE PANEL DISPLAY: WATER TEMPERATURE GAUGE Resistance characteristics Temp. Resistance Ω [°C (°F)] -30 (-22) 25.4 -20 (-4) 15.04 -10 (14) 9.16 0 (32) 5.74 5 (41) 4.72 10 (50)
Page 292 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) PANEL DISPLAY: FUEL GAUGE PANEL DISPLAY: FUEL GAUGE Resistance characteristics Float position FULL EMPTY Ω Resistance ( 17.7 (38) 61.7 Ω Allowable error ( – – – * Average values are used for the output values. (The average amount of movement over a span of 120 seconds mea- sured in 100-ms intervals.) Ω...
Page 293 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) PANEL DISPLAY: FUNCTION/WARNING LAMPS PANEL DISPLAY: FUNCTION/WARNING LAMPS Overheating warning light Ω Lamp ON conditions: Flashes when the temperature rises above 110°C (230°F)(Resistance: 0.1417 k Turns on solid for 0.5 s then goes out for 0.5 s and repeats in a flashing pattern. Engine oil pressure warning light Flashes when the oil pressure switch is ON (while set to LO).
Page 294 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) NORMAL SCREEN NORMAL SCREEN 1 Hour meter • The hour meter begins counting when the input terminal voltages of the alternator and trip meter rise above +3 V. • Pressing and holding down Button [2] for 2 seconds switches the display to the trip meter.
Page 295 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) MAIN MENU SCREEN MAIN MENU SCREEN Normal Screen Main Menu Screen • Pressing Button [3] on the Normal screen for a short while moves the display to the Main Menu screen. •...
Page 296 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) DATA SELECTION SCREEN DATA SELECTION SCREEN Main Menu Screen Data Selection Screen • Pressing Button [1] while [DATA] is highlighted moves the display to the Data Selection screen. • Pressing Button [3] on the Data Selection screen for a short while moves the display to the Main Menu screen. •...
Page 297 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) DATA SCREEN (TRIP METER) DATA SCREEN (TRIP METER) Data Selection Screen DATA Screen (TRIP METER) • Pressing Button [1] for a short amount of time while [TRIP METER] is highlighted moves the display to the DATA screen (TRIP METER). •...
Page 298 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) DATA SCREEN (WATER TEMP.) DATA SCREEN (WATER TEMP.) Resistance characteristics Data Selection Screen DATA Screen (WATER TEMP.) Temp. Resistance Ω [°C (°F)] -30 (-22) 25.4 -20 (-4) 15.04 -10 (14) 9.16 0 (32) 5.74...
Page 299 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) SETTINGS SELECTION SCREEN SETTINGS SELECTION SCREEN Main Menu Screen Settings Selection Screen • Pressing Button [1] while [SETTING] is highlighted moves the display to the Settings Selection screen. • Pressing Button [3] on the Settings Selection screen for a short while moves the display to the Main Menu screen. •...
Page 300 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) SETTING SCREEN (CLOCK) SETTING SCREEN (CLOCK) Settings Selection Screen Setting Screen (CLOCK) • Pressing Button [1] for a short amount of time while [CLOCK] is highlighted moves the display to the Setting screen (Clock Settings). •...
Page 301 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) SETTING SCREEN (ALARM)-1 SETTING SCREEN (ALARM)-1 Settings Selection Screen Setting Screen (ALARM) • Pressing Button [1] for a short amount of time while [ALARM] is highlighted moves the display to the Setting screen (Alarm Settings).
Page 302 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) SETTING SCREEN (ALARM)-2 SETTING SCREEN (ALARM)-2 Setting Screen (ALARM) • Pressing Button [2] on the Setting screen for a short while moves the bar to the next option. • Pressing and holding down Button [2] on the Setting screen for 3 seconds moves the bar to the ALARM TIME screen.
Page 303 MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS (WITHOUT A CAN) SETTING SCREEN (CONTRAST ADJ.) SETTING SCREEN (CONTRAST ADJ.) Settings Selection Screen Setting Screen (CONTRAST ADJ.) • Pressing Button [1] for a short amount of time while [CONTRAST] is highlighted moves the display to the Setting screen (CONTRAST ADJ.). •...

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