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Hyundai R 160 LC-3 Service Manual
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Hyundai R 160 LC-3 Service Manual

Hyundai R 160 LC-3 Service Manual

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FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component.
It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
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.
0-1

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Summary of Contents for Hyundai R 160 LC-3

  • Page 1 This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. 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 2 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 3 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 4 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 5 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 6 kg m to lb ft 1kg m = 7.233lb 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...
  • Page 7 kg/cm to lb/in 1kg / cm = 14.2233 lb / 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...
  • Page 8 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 10 SECTION 1 GENERAL GROUP 1 SAFETY FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.
  • Page 11 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
  • Page 12 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 13 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 14 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 15 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 16 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 17 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 18 GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT Tool box Fuel tank Hydraulic oil tank Main pump Engine Radiator Tooth Bucket Turning joint Swing motor Main control valve Oil cooler Arm cylinder Boom Boom cylinder Cab Muffler Counterweight Bucket cylinder Connecting link Idler Carrier roller Sprocket...
  • Page 19 2. SPECIFICATION ROBEX 160LC-3 I(I') B(L) Description Unit Specification Operating weight kg(lb) 16600(36600) Bucket capacity(PCSA heaped), standard 0.65(0.85) Overall length 8530(28' 0") Overall width, with 600mm shoe 2590( 8' 6") Overall height 2870( 9' 5") Superstructure width 2470( 8' 1") Overall height of cab 2850( 9' 4") Ground clearance of counterweight...
  • Page 20 3. WORKING RANGE 5.10m(16' 9") BOOM 2.25m(7' 5") Arm 2.60m(8' 6") Arm 3.10m(10' 2") Arm Description Max digging reach 8630mm (28' 4") 8950mm (29' 4") 9340mm (30' 8") 8470mm (27' 9") 8800mm (28'10") 9200mm (30' 2") Max digging reach on ground Max digging depth 5740mm (18'10")
  • Page 21 4. WEIGHT R160LC-3 R160LC-3 Item Upperstructure assembly 7220 15920 Main frame weld assembly 1210 2670 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 2900 6390 Cab assembly Lower chassis assembly 6450 14220 Track frame weld assembly...
  • Page 22 5. LIFTING CAPACITIES ROBEX 160LC-3 5.10m(16' 9") boom, 2.60m(8' 6") arm equipped with 0.65m (PCSA heaped) bucket and 600mm (24") triple grouser shoe. : Rating over-front : Rating over-side or 360 degree Load radius At max. reach Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft)
  • Page 23 5.10m(16' 9") boom, 2.25m(7' 5") arm equipped with 0.65m (PCSA heaped) bucket and 600mm (24") triple grouser shoe. Load radius At max. reach Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach height m(ft) 7.5m *3040 *3040 5.71 (25ft) *6700 *6700 (18.7) 6.0m *3020...
  • Page 24 6. BUCKET SELECTION GUIDE GENERAL BUCKET 0.65m PCSA 0.39m PCSA 0.57m PCSA 0.70m PCSA 0.80m PCSA heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket Recommendation Capacity Width 5.10m (16' 9") boom Weight PCSA CECE Without With 2.25m arm 2.60m arm 3.10m arm heaped...
  • Page 25 7. UNDERCARRIAGE TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. TYPES OF SHOES Triple grouser Shapes Model...
  • Page 26 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Cummins B3.9-C 4-cycle turbocharged, after cooled and low emission Type diesel engine Water cooling Cooling method Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type 4.72") Cylinder bore stroke...
  • Page 27 GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 10cc/rev Maximum pressure 40kgf/cm (570psi) Rated oil flow 22 /min(5.8U.S. gpm/4.8U.K. gpm) MAIN CONTROL VALVE Item Specification Type 9 spools two-block Operating method Hydraulic pilot system Main relief valve pressure 320kgf/cm (4550psi)[350kgf/cm (4980psi)]...
  • Page 28 REMOTE CONTROL VALVE Item Specification Type Pressure reducing type 5.5kgf/cm (78psi) Minimum Operating pressure 19.5kgf/cm (277psi) Maximum Lever 82.7mm(3.3in) Single operation stroke 123mm(4.8in) Pedal CYLINDER Specification Item Bore dia Rod dia Stroke 80 1180mm Boom cylinder Cushion Extend only Bore dia Rod dia Stroke 85 1320mm...
  • Page 29 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 11(2.9) oil pan...
  • Page 30 SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. Qmin Adjusting screw Qmax Adjusting screw Qmin Adjusting screw Regulator Regulator Front pump Valve block Rear pump Pilot pump Front Rear Port...
  • Page 31 MAIN PUMP The main pump consists of two piston pumps(Front & rear) and valve block. 214 548 531 724 534 901 808 153 156 158 157 141 271 401 Gear pump Seal cover(F) O-ring Drive shaft(F) Pump casing O-ring Drive shaft(R) Valve block O-ring Spline...
  • Page 32 REGULATOR(1/2) SECTION D-D KR36-9N1S 641 730 643 (KDRDE5K) SECTION B-B 699 413 Port Port name Port size Delivery port 3/4" Suction port 2 1/2" Pilot port PF 1/4-15 Powershift port PF 1/4-15 Companion delivery port VIEW C 2 - 3...
  • Page 33 REGULATOR(2/2) 653 654 836 651 652 624 629 SECTION A-A Hexagon socket screw Adjust screw(C) Hexagon socket screw Cover(C) O-ring Hexagon socket screw O-ring Hexagon socket screw Sleeve O-ring Hexagon socket screw Pilot cover O-ring Hexagon socket screw Pilot cover(QMC) O-ring Plug Pilot piston...
  • Page 34 GEAR PUMP 307 310 308 466,725 Poppet Drive gear Plug Seat Driven gear Ring Spring seat Filter O-ring Spring Front case O-ring Adjust screw Flange socket O-ring Lock nut Flange socket Snap ring Gear case Flange socket 2 - 5...
  • Page 35 2. FUNCTION MAIN PUMP The pumps may classified roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: The swash plate group that varies the delivery rates: And the valve cover group that changes over oil suction and discharge. Rotary group The rotary group consists of drive shaft (F)(111), cylinder block(141), piston...
  • Page 36 Valve block group The valve block group consists of valve block(312), valve plate(313) and valve plate pin(885). The valve plate having two melon-shaped ports is fixed to the valve block and feeds and collects oil to and from the cylinder block.
  • Page 37 REGULATOR Regulator consists of the negative flow control, total horse power control and power shift control function. Negative flow control By changing the pilot pressure Pi, the pump tilting angle(Delivery flow) is regulated arbitrarily, as shown in the figure. This regulator is of the negative flow control in which the delivery flow Q decreases as the pilot pressure Pi rises.
  • Page 38 Flow reducing function B(E) Small diameter Servo piston chamber Large diameter chamber As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the force of the pilot spring(646) balances with the hydraulic force. The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613).
  • Page 39 Flow increasing function B(E) Small diameter Servo piston chamber Large diameter chamber As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the pilot spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897) is pressed against the large hole section(C) of lever 2 by the action of the return spring(654) via the spool(652), pin(874), and feedback lever(611), the feedback lever rotates around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left.
  • Page 40 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut (801) and by tightening(Or loosening) the hexagonal socket head screw(924). Tightening the screw shifts the control chart to the right as shown in the figure. Adjusting values are shown in table Adjustment of flow control characteristic...
  • Page 41 Total horsepower control The regulator decreases the pump tilting angle(Delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump. (The input horsepower is constant when the speed is constant.) Since the regulator is of the simultaneous...
  • Page 42 Overload preventive function B(E) Large diameter Servo piston Small diameter chamber chamber When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston(621). It presses the compensating rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with the hydraulic force.
  • Page 43 Flow reset function B(E) Large diameter Small diameter chamber chamber Servo piston As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever 1(612) around point E.
  • Page 44 Low tilting angle(Low flow) command preferential function As mentioned above, flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However, since sections C and F have the pins( 4) protruding from the large hole( 8), only the lever lessening the tilting angle contacts the pin(897) ;...
  • Page 45 Adjustment of inner spring Adjust it by loosening the hexagon nut (801) and by tightening(Or loosening) adjusting screw QI(925). Tightening the screw increases the flow and then the input horsepower as shown in the figure. Adjusting valves are shown in table Adjustment of inner spring Speed Tightening...
  • Page 46 Power shift control B(E) Large diameter Small diameter chamber chamber Servo piston The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one proportional pressure reducing valve is provided. However, the secondary pressure Pf (power shift pressure) is admitted to the horsepower control section of each pump...
  • Page 47 Adjustment of maximum and minimum flows Adjustment of maximum flow Adjust it by loosening the hexagon nut(808) and by tightening(Or loosening) the set screw(954). The maximum flow only is adjusted without changing other control characteristics. Adjustment of max flow Speed Tightening amount Flow change of adjusting screw...
  • Page 48 GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE(1/2) 15 25 2 43 O-ring O-ring O-ring Housing Socket bolt O-ring Spring washer Spring Retainer Overload assy Spring guide Socket bolt O-ring Spring guide Plunger assy(TS) Orifice Plunger assy (TL, TR) Spring Plunger assy (SW) O-ring Check...
  • Page 49 STRUCTURE(2/2) 6 57 56 6 Spring Plunger assy(BM1) Spacer Spool Poppet Plunger assy(AM2) Cover Stopper Cover Piston Selector assy Manifold Back up ring O-ring O-ring Nylon chip Check O-ring Overload assy Spring guide Spring Spring Spring Spool Check Foot relief assy Poppet Plug O-ring...
  • Page 50 2. FUNCTION HYDRAULIC CIRCUIT XAk2 Pal dr8 XAah XAa1 XAa2 ARM1 XBa2 ARM2 XBa1 XBa2 XAas XAb1 XBb2 XBb1 BOOM2 BOOM1 XBb2 XAk2 BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) 320K(350K) 2 - 21...
  • Page 51 BASIC OPERATION (1) Bucket flow summation circuit Bucket flow summation circuit Oil from pump P2 is fed into cylinder port Ak1 by adding pressure to bucket plunger pilot port XAk and the oil from actuator flow tank through cylinder port Bk1. The center bypass valve is changeover by the pilot pressure XAk2 and the oil from center bypass passage flows to the...
  • Page 52 Swing priority circuit (2) Swing priority circuit Oil from pump P1 is fed into cylinder port Bs via center bypass passage by adding pressure to swing plunger pilot port XBs. In case of simultaneous operation of swing and arm, the delivery oil from P1 for swing is also supplied to arm cylinder port Aa1.
  • Page 53 OPERATIONAL DESCRIPTION OF CONTROL VALVE Plunger operation Neutral position of plunger Parallel feed passage Cylinder port B Cylinder port A Port relief valve Port relief valve Pilot port b Pilot port a Spring Center bypass passage Low pressure passage Low pressure passage High pressure feed passage In neutral, spring sets the plunger at the neutral position;...
  • Page 54 Operation of plunger Parallel feed passage Cylinder port B Cylinder port A Port relief valve Port relief valve Pilot port b Pilot port a Low pressure passage Center bypass passage Spring Low pressure passage High pressure feed passage When actuated(Pressure is applied to pilot port a), the plunger moves to the left, the center bypass is shut off;...
  • Page 55 Foot relief valve operation fp is lower than spring force Pressure signal sent out to the pump Spring Poppet From center bypass valve To tank passage Oil from the center bypass valve flows into the tank via orifice(A) of poppet. Pressure fp generated by orifice(A) is led to the pump, to control the pump delivery flow.
  • Page 56 Center bypass valve operation Pilot pressure signal : OFF From center bypass Spring(B) Spool(A) Drain line Pilot signal port(XAk2) To tank passage via foot relief valve Spring(B) sets spool(A) in position; Oil from center bypass flows into the tank passage via the foot relief valve.
  • Page 57 Main relief valve operation High pressure setting pilot signal : OFF Low pressure Passage Pilot poppet(D) Main poppet(A) Piston(E) Pilot From pump signal : OFF port side (Pz) Spring(B) Spring(C) This relief valve is built in between the pump port side(1) and low pressure passage. Piston(E) is seated right end by spring(C).
  • Page 58 Low pressure passage Main poppet(A) When the above oil flow is formed, pressure drops before and behind orifice(2) ; When pressure of chamber(1) x area d is large than pressure of chamber(3) x area d , main poppet(A) is opened and hydraulic oil flows into the low pressure passage. High pressure setting pilot signal : ON Piston(E) Pilot...
  • Page 59 Overload relief valve operation Overload working operation Pilot poppet(E) Poppet(C) Cylinder port Piston(A) Main poppet(B) Spring(D) Low pressure passage Hydraulic oil from cylinder port enters chamber(2) via orifice(3) of piston(A). Because d <d and d <d , main poppet(B) and poppet(C) are securely seated. Pilot poppet(E) Poppet(C) Cylinder port...
  • Page 60 Hydraulic oil from chamber(1) enters chamber(2) via throttle(6) at the tip of pilot poppet(E) ; It flows into the low pressure passage via side hole(4) and passage(5). Pilot poppet(E) Poppet(C) Cylinder port Piston(A) Spring(D) Main poppet(B) Low pressure passage Pressure drops before and behind throttle(6), making pressure of chamber(1) x area >pressure of chamber(2) x area d ;...
  • Page 61 Make up operation Pilot poppet(E) Poppet(C) Cylinder port Piston(A) Main poppet(B) Spring(D) Low pressure passage Poppet(C) is securely seated because the cylinder port pressure is normally higher than the tank pressure and d <d When the cylinder port pressure drops(Closer to negative pressure) until the cylinder port pressure is lower than the tank pressure, poppet(C) opens receiving the tank pressure for the difference in area between d and d...
  • Page 62 Arm regeneration operation Arm operation Parallel feed passage Low pressure passage Tank passage Pilot port XAa1 High pressure feed passage Center bypass passage Piston(A) Spool(B) Spring(C) When pressure is applied to pilot port XAa1 of the arm plunger, the plunger moves to right as shown ;...
  • Page 63 is higher than P Parallel feed passage Low pressure passage Tank passage Pilot port XAa1 High pressure feed passage Center bypass passage Piston(A) Spool(B) Spring(C) : Pressure of cylinder head side : Pressure of cylinder rod side Return oil from cylinder rod side opens check valve(C ) in the plunger ;...
  • Page 64 is higher than P Parallel feed passage Low pressure passage Tank passage Pilot port XAa1 High pressure feed passage Piston(A) Spool(B) Center bypass passage Spring(C) Return oil from cylinder rod side is shut off by check(C ) in the plunger and passage(2) is blocked from passage(1).
  • Page 65 Arm holding valve operation When the plunger is in neutral(4Pi pilot signal : OFF) Pilot signal port Piston(A) Tank passage Drain High pressure port feed passage Arm1 plunger To arm 3(Pv) cylinder rod (Ba1) 2(Pc) Piston(B) Poppet(E) Poppet(C) Check(D) VIEW Z Piston(A) is in the status as shown ;...
  • Page 66 When the plunger is in operation(4Pi pilot signal : OFF) If Pv is higher than Pc(In the case of arm out) Pilot signal port Piston(A) Tank passage Drain High pressure port feed passage To arm 3(Pv) cylinder rod (Ba1) 2(Pc) Piston(B) Poppet(E) Poppet(C)
  • Page 67 If Pc is higher than Pv(In the case of arm in operation) Pilot signal port Piston(A) Tank passage Drain High pressure port feed passage To arm 3(Pv) cylinder rod (Ba1) 2(Pc) Piston(B) Poppet(E) Poppet(C) Check(D) VIEW Z When the pressure of pilot signal enters, piston(A) moves to down. When the pressure signal(Pg2) enters to chamber(Y), piston(B) moves to left and poppet(C) opens ;...
  • Page 68 Boom holding valve operation When the plunger is in neutral(5Pi pilot signal : OFF) Spool(A) Pilot signal port To boom cylinder head Poppet(B) 2(Pc) 3(Pv) Boom1 High pressure Tank passage feed passage Spool(A) is in the status as shown ; Chamber(1) and drain port(dr4) are shut off by spool(A). Therefore, the pressure of chamber(1) becomes pressure Pc as it is connected with chamber(2) via orifice(4).
  • Page 69 When the plunger is in operation(5Pi pilot signal : OFF) If Pv is higher than Pc(In the case of boom raise) Spool(A) Pilot signal port To boom cylinder head Poppet(B) 2(Pc) 3(Pv) High pressure Tank passage feed passage When the plunger moves to right, the high pressure oil enters to chamber(3). Therefore, the pressure of chamber(1) becomes Pc as it is connected to chamber(2) via orifice(4) ;...
  • Page 70 If Pc is higher than Pv(In the case of boom down operation) Spool(A) Pilot signal port From boom cylinder head Poppet(B) 2(Pc) 3(Pv) High pressure Tank passage feed passage When plunger moves to left, chamber(3) is connected with tank passage. At the same time, spool(A) moves to right by the pressure of pilot signal ;...
  • Page 71 GROUP 3 SWING DEVICE 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Reduction gear Time delay valve Grease filling port Gear oil drain port Swing motor Relief valve View X Port...
  • Page 72 SWING MOTOR 116 118 114 031 031-1 706 707 702 712 472 981 438 303 469 488 355 351 400 400-2 400-1 051 051-1 993 SECTION A-A Time delay valve O-ring Plug 031-1 Plug O-ring Plug Relief valve assembly O-ring O-ring Hexagon socket bolt O-ring...
  • Page 73 REDUCTION GEAR Casing Hexagon socket bolt Drive shaft Side plate Seal Ring gear Side plate Plug Planetary gear 2 Side plate Plug Sun gear 2 Side plate Spring pin Planetary gear 1 Level bar Snap ring Sun gear 1 Pipe Snap ring Carrier 2 Roller bearing...
  • Page 74 2. FUNCTION ROTARY PART When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(131), hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the piston(121) upon the return plate(123) which acts upon the swash plate(124) via an hydrostatic bearing.
  • Page 75 MAKE UP VALVE In the system using this type of motor, there is no counter balance functioning valve and there happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency. A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action.
  • Page 76 RELIEF VALVE Plunger Piston Spring Spring Construction of relief valve The valve casing contains two cartridge type relief valves that stop the regular and reverse rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing motion and can control the relief pressure in two steps, high and low, in order to insure smooth operation.
  • Page 77 Ports(P,R) at tank pressure. When hydraulic oil pressure(P A ) reaches the preset force(F ) of spring(321), the plunger(301) moves to the right as shown. Also the oil flow chamber g via orifice m. Fsp+Pg A Fsp+Pg A P=P1 2-48...
  • Page 78 When the pressure of chamber g reaches the preset force(F ) of spring(321), the piston(320) moves right and stop the piston(320) hits the end of body. P=P2 When piston(320) hits the end of body, it stops moving to the right any further. As the result, the pressure in chamber g equals Ps.
  • Page 79 BRAKE SYSTEM Control valve swing brake system This is the brake system to stop the swing motion of the excavator during operation. In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance created by this throttling works as a brake force to slow down the swing motion. Deceleration Stop Work...
  • Page 80 Operating principle When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control valve(2) and to Sh of the time delay valve(3) via the shuttle valve(4), this pressure shift time delay vlave so, pilot pump charged oil(P ) go to the chamber G.
  • Page 81 When the swing control(1) lever is set the neutral position, the time delay valve(3) shifts the neutral position and the pilot oil blocked chamber G. Then, the piston(702) is moved lower by spring force and the return oil from the chamber G is drain.
  • Page 82 GROUP 4 TRAVEL DEVICE 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor include counter balance valve, cross over relief valve. Filling Level Drain VIEW A VIEW C Port Port name Port size Main port PT 3/4 T1(T2) Main port PT 3/4...
  • Page 83 TRAVEL MOTOR(1/2) 26 23 27 28 RELIEF VALVE DETAIL VIEW A Base plate Relief housing Plug Plunger Poppet Spool Check valve Poppet seat Spring Spring Spring seat Plug Plug Spring O-ring O-ring Plug Orifice O-ring Orifice O-ring Free piston O-ring Socket head bolt O-ring Plug...
  • Page 84 TRAVEL MOTOR(2/2) Casing Steel ball Spring Shaft Piston assembly Spring pin Roller bearing Spring Cylinder block Roller bearing Valve plate Piston assembly Spring pin Orifice Retainer plate Socket head bolt O-ring Retainer holder Oil seal O-ring Snap ring Disc plate Plug Collar Brake piston...
  • Page 85 2) REDUCTION GEAR 11 12 -6 -2 -4 -5 -7 -3 -8 -1 -1 -4 -3 -2 -5 -6 Holder A assembly Shim(0.1~0.05t) Planet gear C Holder A Roller bearing Socket head bolt Planet gear A Gear shaft C Socket head bolt Needle bearing Floating bushing Plate...
  • Page 86 2. FUNCTION HYDRAULIC MOTOR Rotary group Cylinder block Shaft Piston Valve plate The cylinder block contains nine pistons. The end face of the cylinder block is in contact with the valve plate that has two semicircular ports B and C(Distributor valve that changes over high and low pressures).
  • Page 87 COUNTER BALANCE VALVE Neutral position Control valve Counter balance valve controls according to oil supply so as to prevent reckless of running of the motor. When the control valve is in neutral position, oil does not supply the port P1 and P2. This blocks the motor port to prevent the motor from rotating.
  • Page 88 Counter balance function Control valve Oil discharged from main pump flows into the counter balance valve port P via control valve. The oil flows into piston motor via check valve and M port. Since the return oil from motor port M is blocked by check valve, the pressure of port P increased.
  • Page 89 Brake function When the travel lever return to neutral position, the oil from the main pump is blocked, and the plunger return the neutral position by spring force. But the motor is rotated by inertia, so the pressure at the output port of motor rises, then motor is braked.
  • Page 90 RELIEF VALVE Poppet Poppet seat Spring seat Piston stroke 11,12 10 15 Spring 13,14 Plug O-ring Shockless piston Adjust screw 10 Spring guide O-ring 12 Back up ring 13 O-ring 14 Back up ring 15 O-ring Construction of relief valve The release valve determines the drive force and the brake force of the machine during running and is mounted to the cross line.
  • Page 91 First stage At the beginning of the relief valve operation, the pressure in the spring chamber is held low by the shockless piston, with the result that the pressure receiving area of the poppet equals the area(S1) of the poppet seat.
  • Page 92 2-SPEED CONTROL The 2-speed mechanism consists of a 2-speed changeover valve(Hereinafter called valve), a two- speed control piston(Hereinafter called piston)and a swash plate. The swash plate, which has three faces A~C, is fixed to the motor case by two steel balls so that it can be tilted.
  • Page 93 (2) Low speed control 2 speed changeover valve Pilot pressure Ps 0kg/cm Side A Piston chamber Side C 2 speed control valve Steel ball High Side B pressure pressure Swash plate Swash face Valve plate If the changeover pilot pressure Ps is shut off, the valve is brought to the condition in Fig. As the result the piston chamber is connected with the drain line in the motor casing.
  • Page 94 PARKING BRAKE Parking(Neutral) Double counter balance valve Spring Piston Disc plate Brake release cylinder chamber Operation(Release) The parking brake is a negative brake consisting of a disc plate, brake piston and a spring. When pressurized oil runs into the motor, it then runs into port P3 via the double counter balance valve and is admitted into the brake release cylinder chamber.
  • Page 95 6) GEAR BOX Drive gear(1st sun gear) 2nd planetary gear Ring gear 1st planetary gear 2nd carrier 10 Casing 1st carrier 3rd sun gear 3rd carrier 2nd sun gear 3rd planetary gear (1) The reduction gear is composed of a three stage planetary gear mechanism shown in the figure. 2-66...
  • Page 96 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. Single Simultaneous operation operation...
  • 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(5), spring(7, 30) for setting secondary pressure, return spring(10), stopper(9), spring seat(8, 31) and shim(6).
  • Page 98 CROSS SECTION 7,30 Port 1, 3 Port 2, 4 2-69...
  • 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. Pilot valve Main pump Hydraulic motor Pilot pump...
  • Page 101 Case where handle is in neutral position The force of the spring(7) that determines the output pressure of the pilot valve is not applied to the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1,3) in the operation explanation drawing.
  • Page 102 Case where handle is tilted When the push rod(15) is stroked, the spool(5) moves downwards. Then port P is connected with port(1) and the oil supplied from the pilot pump flows through port(1) to generate the pressure. When the pressure at port(1) increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force.
  • Page 103 GROUP 6 RCV PEDAL 1. STRUCTURE The casing(Spacer) has the oil inlet port P(Primary pressure), and the oil outlet port T(Tank). addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size Pilot oil inlet port...
  • Page 104 CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool(8), spring(11) for setting secondary pressure, return spring(18), stopper(13), spring seat(12) and shim(9). The spring for setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/cm (Depending on...
  • Page 105 2. FUNCTION FUNDAMENTAL FUNCTIONS The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure(Secondary pressure) of the pilot valve to the other end.
  • Page 106 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below ant the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. Pilot valve Main pump Hydraulic motor Pilot pump...
  • Page 107 Case where pedal is in neutral position The force of the spring(11) that determines the output pressure of the pilot valve is not applied to the spool(8). Therefore, the spool is pushed up by the spring(18) to the position of port 2 in the operation explanation drawing.
  • Page 108 Case where pedal is tilted When the push rod(19) is stroked, the spool(8) moves downwards. Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1 to generate the pressure. When the pressure at port 1 increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force.
  • Page 109 SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT XAk2 Pal dr8 XAah XAa1 XAa2 Main pump XBa2 XBa1 XBa2 Main control valve XAas XAb1 Swing motor Travel motor XBb2 XBb1 Solenoid valve XBb2 Pk dr1 RCV lever XAk2 RCV pedal Boom cylinder(RH) Boom cylinder(LH) XAtl...
  • Page 110 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 variable displacement open loop bent axis double pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
  • Page 111 2. RETURN CIRCUIT Full flow filter Oil cooler Check valve(2) 1.5kg/cm Actuators Main control valve Check valve(1) 3.0kg/cm Bypass relief valve 3.0kg/cm 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 1.5kg/cm (21psi) and 3.0kg/cm (43psi).
  • Page 112 3. DRAIN CIRCUIT Travel motor Swing motor Main pump Turning joint Bypass valve 1.5kg/cm Spin filter Hydraulic oil tank Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through spin filter. When the drain oil pressure exceed 1.5kg/cm (21psi), the oil returns to the hydraulic tank directly.
  • Page 113 GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve RCV pedal (LH lever) (RH lever) Safety lock Swing parking brake solenoid valve Control valve Travel speed solenoid valve Arm half flow solenoid valve Power boost solenoid valve Line filter Main pump Relief valve 40kg/cm...
  • Page 114 1. SUCTION, DELIVERY AND RETURN CIRCUIT ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR ARM1 ARM2 BOOM2 BOOM1 SWING MOTOR SWING BUCKET OPTION TRAVEL(RH) TRAVEL(RH) RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM SPIN FILTER TANK SAFETY SOLENOID VALVE PILOT PUMP LINE STRAINER...
  • Page 115 2. SAFETY SOLENOID VALVE(SAFETY LEVER) ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR ARM1 ARM2 BOOM2 BOOM1 SWING MOTOR SWING BUCKET OPTION TRAVEL(RH) TRAVEL(RH) RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM SPIN FILTER TANK LEVER DOWN SAFETY SOLENOID VALVE LEVER UP PILOT PUMP...
  • Page 116 3. MAIN RELIEF PRESSURE CHANGE CIRCUIT ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR ARM1 ARM2 BOOM2 BOOM1 SWING MOTOR SWING BUCKET OPTION TRAVEL(RH) TRAVEL(RH) MAIN RELIEF VALVE RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM SPIN FILTER TANK POWER MAX SOLENOID VALVE...
  • Page 117 4. SWING PARKING BRAKE RELEASE ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR ARM1 ARM2 SWING MOTOR DEVICE BOOM2 BOOM1 SWING BUCKET OPTION TRAVEL(RH) TRAVEL(RH) RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM SPIN FILTER TANK SAFETY SHUTTLE VALVE SOLENOID VALVE PILOT PUMP LINE...
  • Page 118 5. ARM HALF FLOW SYSTEM ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAa1 XAa2 XAah ARM1 ARM2 BOOM2 BOOM1 SWING MOTOR SWING BUCKET OPTION TRAVEL(RH) TRAVEL(RH) RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM XAa1 ARM HALF SPIN SOLENOID FILTER...
  • Page 119 6. TRAVEL SPEED CONTROL PRESSURE TRAVEL MOTOR DEVICE ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL SPEED CHANGE OVER VALVE ARM1 ARM2 BOOM2 BOOM1 SWING MOTOR SWING BUCKET OPTION TRAVEL(RH) TRAVEL(RH) RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM TRAVEL SPEED SPIN SOLENOID VALVE...
  • Page 120 GROUP 4 SINGLE OPERATION 1. BOOM RAISE OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR BOOM HOLDING VALVE XAb1 XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR MAKE UP VALVE RELIEF VALVE FRONT REAR PILOT TANK PUMP PUMP PUMP When the right control lever is pulled back, the boom spools in the main control valve are moved to the raise position by the pilot oil pressure from the remote control valve.
  • Page 121 2. BOOM DOWN OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR RELIEF VALVE MAKE UP VALVE XAb1 XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BOOM HOLDING VALVE FRONT REAR PILOT TANK PUMP PUMP PUMP When the right control lever is pushed forward, the boom spools in the main control valve are moved to the lower position by the pilot oil pressure from the remote control valve.
  • Page 122 3. ARM ROLL IN OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR MAKE UP RELIEF VALVE VALVE XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 SWING MOTOR ARM HALF SOLENOID VALVE XAa2 FRONT REAR PILOT TANK PUMP PUMP PUMP XAah When the left control lever manually is placed in the arm roll in position.
  • Page 123 4. ARM ROLL OUT OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR MAKE UP RELIEF VALVE VALVE XAah XAa1 XAa2 ARM2 ARM1 XBa2 XBa1 XBa2 SWING MOTOR FRONT REAR PILOT TANK PUMP PUMP PUMP When the left control lever manually is placed in the arm roll out position. Then the oil flows from pilot pump through the remote control valve to arm sections of the main control valve.
  • Page 124 5. BUCKET ROLL IN OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 CENTER BYPASS VALVE RELIEF VALVE MAKE UP VALVE SWING MOTOR XAk2 BUCKET FRONT REAR PILOT TANK PUMP PUMP PUMP When the right control lever is manually placed in the bucket roll in position. Then the oil flows from pilot through the pilot valve to bucket section of the main control valve.
  • Page 125 6. BUCKET ROLL OUT OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 CENTER BYPASS VALVE SWING MOTOR XAk2 BUCKET MAKE UP VALVE RELIEF VALVE FRONT REAR PILOT TANK PUMP PUMP PUMP When the right control lever is manually placed in the bucket roll out position. Then the oil flows from pilot pump through the pilot valve to bucket section of the main control valve.
  • Page 126 7. SWING OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR SWING MOTOR SWING RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM SPIN TANK FILTER SAFETY FRONT REAR PILOT SOLENOID VALVE PUMP PUMP PUMP LINE STRAINER FILTER When the left control lever is manually placed in the left(Right) swing position. Then the oil flows from front pump through the swing section of the main control valve to swing motor to left(Right) swing the superstructure.
  • Page 127 SWING CIRCUIT OPERATION PARKING BRAKE SWING MOTOR DEVICE BRAKE RELEASE VALVE BRAKE OFF BRAKE ON MAKE UP PORT(Mu) MAKE UP VALVE MOTOR BRAKE VALVE TO/FROM MAIN CONTROL VALVE MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation.
  • Page 128 8. TRAVEL FORWARD AND REVERSE OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR TURNING JOINT SWING MOTOR XAtl XBtl TRAVEL(LH) XAtr XBtr TRAVEL(RH) STRAIGHT TRAVEL SPOOL PILOT VALVE RCV PEDAL RCV LEVER(LH) RCV LEVER(RH) TRAVEL SWING BUCKET BOOM XAtl XBtl XAtr XBtr SPIN...
  • Page 129 TRAVEL CIRCUIT OPERATION TRAVEL MOTOR DEVICE a1 a2 OVERLOAD RELIEF VALVE COUNTER CHECK TURNING JOINT BALANCE VALVE VALVE TO/FROM MAIN CONTROL VALVE Valves are provided on travel motors to offer the following functions. COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run. OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 350kgf/cm to prevent high pressure generated at at time...
  • Page 130 GROUP 5 COMBINED OPERATION 1. OUTLINE ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 XAb1 XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) STRAIGHT TRAVEL SPOOL PILOT VALVE...
  • Page 131 2. COMBINED SWING AND BOOM OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 XAb1 XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) FRONT REAR PILOT...
  • Page 132 3. COMBINED SWING AND ARM OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM2 ARM1 XBa2 XBa1 XBa2 XAb1 XAas XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) ARM HALF SOLENOID VALVE XAa2...
  • Page 133 4. COMBINED SWING AND BUCKET OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 XAb1 XAas XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) FRONT REAR...
  • Page 134 5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 XAb1 XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR SWING BUCKET XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) ARM HALF SOLENOID VALVE...
  • Page 135 6. COMBINED SWING AND TRAVEL OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 XAb1 XAas XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR SWING BUCKET XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) STRAIGHT CHECK...
  • Page 136 7. COMBINED BOOM AND TRAVEL OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM2 ARM1 XBa2 XBa1 XBa2 XAb1 XAas XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) STRAIGHT CHECK...
  • Page 137 8. COMBINED ARM AND TRAVEL OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 XAb1 XAas XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) STRAIGHT CHECK...
  • Page 138 9. COMBINED BUCKET AND TRAVEL OPERATION ARM CYLINDER BOOM CYLINDER BUCKRT CYLINDER TRAVEL MOTOR XAk2 XAah XAa1 XAa2 ARM1 ARM2 XBa2 XBa1 XBa2 XAb1 XAas XBb2 XBb1 BOOM2 BOOM1 XBb2 SWING MOTOR BUCKET SWING XAtl XBtl OPTION TRAVEL(LH) XAtr XBtr TRAVEL(RH) STRAIGHT CHECK...
  • Page 139 SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Horn switch Arm half switch Resistor Cluster Aircon switch CPU controller Starting switch Main light switch Emergency engine starting connector Cigar lighter Wiper & washer switch Prolix switch Breaker switch Cassette &...
  • Page 140 2. LOCATION 2 Alternator Hyd temperature sender Accel actuator Start relay Engine speed sensor Battery Air cleaner switch Engine oil pressure switch Connector plate Fuel sender Water temperature sender Battery relay Fuel filler pump Heater valve Lamp Heater adapter 4 - 2...
  • Page 141 GROUP 2 ELECTRICAL CIRCUIT TO : STARTER CPU CONTROLLER 4 -3...
  • Page 142 4 -4...
  • Page 143 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis through master switch. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW Battery Battery relay Fusible link CN-60(1) Fuse box(No.11)
  • Page 144 POWER CIRCUIT FUSE BOX CN-36 MASTER SW BATTERY RELAY CN-27 CN-6 CASSETTE RADIO CS-2 CL-1 ROOM LAMP START KEY SW CPU CONTROLLER 4 - 6...
  • Page 145 2. STARTING CIRCUIT OPERATING FLOW Battery relay(M8, B + terminal) Battery(+) terminal Fusible link CN-60(1) Fuse box(No.11) I/conn CN-1(N) Start switch CS-2(1) When start key switch is in ON position Start switch ON CS-2(2) I/conn CN-1(M) Battery relay M4 terminal Battery relay operating(All power is supplied with the electric component) Start switch ON CS-2(3) I/conn CN-1(L)
  • Page 146 STARTING CIRCUIT FUSE BOX CN-36 MASTER SW CR-5 START SAFETY RY CN-7 CN-8 CN-51 CPU CONTROLLER CN-45 START RY CN-3 CR-23 STARTER CN-74 ALTERNATOR CN-79 FUEL CUT OFF START KEY SW 4 - 8...
  • Page 147 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 148 CHARGING CIRCUIT FUSE BOX CN-36 MASTER SW CN-45 START RY CN-3 CR-23 STARTER CN-74 CN-51 ALTERNATOR CN-50 CPU CONTROLLER CLUSTER 4 - 10...
  • Page 149 4. HEAD AND WORK LIGHT CIRCUIT OPERATING FLOW Fuse box(No.16) I/conn CN-1(R) Main light switch CS-21(1) Fuse box(No.17) Work light relay CR-3(2, 3) Head light switch ON : 1st step Head light switch ON CS-21(5) I/conn CN-1(O) Head light ON CL-3(2) Cluster illumination lamp CN-52(4) Switch indicator lamp ON CS-21(9) Work light switch ON : 2nd step...
  • Page 150 HEAD AND WORK LIGHT CIRCUIT MAIN LIGHT SW CN-36 CN-1 FUSE BOX CN-52 CPU CONTROLLER CR-3 CN-2 WORK LAMP RY CN-10 CL-6 WORK LAMP CL-5 WORK LAMP CL-3 HEAD LAMP 4 - 12...
  • Page 151 5. BEACON LAMP CIRCUIT OPERATING FLOW Fuse box(No.10) I/conn CN-1(X) Beacon lamp switch CS-23(2) When Lamp switch ON Beacon lamp switch ON CS-23(6) Switch indicator lamp ON CS-23(9) I/conn CN-6(6) I/conn CN-14(3) Beacon lamp ON CL-7 CHECK POINT Engine Start switch Check point Voltage - GND(Fuse box)
  • Page 152 BEACON LAMP CIRCUIT CN-1 CN-36 CS-23 BEACON LAMP SW FUSE BOX CN-6 CN-2 CN-14 CL-7 BEACON LAMP 4 - 14...
  • Page 153 6. WIPER AND WASHER CIRCUIT OPERATING FLOW Wiper motor switch ON : 1st step Fuse box(No.5) I/conn CN-1(V) Wiper and washer switch CS-3(1) I/conn CN-6(1) I/conn CN-13(1) Wiper motor operation CN-21(1) Washer switch ON : 2nd step Fuse box(No.5) I/conn CN-1(V) Wiper and washer switch CS-3(1) I/conn CN-1(U) Washer tank CN-22(2)
  • Page 154 WIPER AND WASHER CIRCUIT WIPER & WASHER SW CN-36 CN-1 FUSE BOX CN-2 CN-6 CN-22 WASHER TANK WIPER MOTOR CN-21 CN-13 4 - 16...
  • Page 155 CONTROLLER CIRCUIT FUSE BOX CN-36 CN-53 CN-76 CN-52 DC MOTOR CN-47 RESISTOR CN-51 CS-7 PROLIX SW(EPPR) CN-3 CN-50 CPU CONTROLLER EPPR VALVE TACHO SENSOR 4 - 17...
  • Page 156 ELECTRIC CIRCUIT FOR HYDRAULIC PEDAL BREAKER SW TRAVEL ALARM TRAVEL BUZZER SAFETY SOL ARM HALF BREAKER SOL FUSE BOX CN-1 CN-2 POWER MAX TRAVEL CPU CONTROLLER ARM HALF SW POWER MAX SAFETY SW 4 -18...
  • Page 157 MONITORING CIRCUIT FUSE BOX WATER TEMP ENG OIL PS AIR FILTER WATER LEVEL CN-1 CD-1 HYD TEMP CD-2 CN-56 CN-9 CN-2 FUEL SENDER CLUSTER CN-48 HOUR METER CPU CONTROLLER 4 -19...
  • Page 158 GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check Check specific gravity 160Ah 1.280 over : Over charged Battery (2EA) 1.280~1.250 : Normal 1.250 below : Recharging Check coil resistance(M4 to M4) Rated load : 24V Normal : About 50 100A(Continuity) Battery relay Check contact...
  • Page 159 Part name Symbol Specifications Check Pressure switch Check resistance 0.5kg/cm (For engine oil) (N. C TYPE) Normal 0 (CLOSE) CD-18 Check resistance Coolant 50 C : 800 temperature 80 C : 310 sensor 100 C: 180 CD-8 Pressure:635mm Air cleaner Check contact pressure switch Normal...
  • Page 160 Part name Symbol Specifications Check Check resistance Normal : About 200 Relay 24V 20A (For terminal 1-3) (For terminal 2-4) CR-2, CR-3, CR-5 Check resistance Normal : 1~2 (For terminal 5-6) Accel actuator 0.8~1.2k (For terminal 1-3) CN-76 Check resistance 24V 1A Solenoid valve Normal : 15~25...
  • Page 161 Part name Symbol Specifications Check Check contact 10 9 8 7 6 5 4 3 2 1 Normal ON : 0 (For terminal 1-5, 2-6) Switch 24V 8A (Locking type) (For terminal 5-7, 6-8) OFF : (For terminal 1-5, 2-6) CS-16, CS-23, CS-27, 0 (For terminal 5-7, 6-8) CS-50, CS-54...
  • Page 162 Part name Symbol Specifications Check Check operation Supply power(24V) to Hour meter terminal (+) and connect terminal (-) to ground. CN-48 Check operation DC 22.0~28.0V Supply power(24V) to each Horn terminal and connect ground. CN-20, CN-25 Check contact Normal : 0 (For terminal 1-2) 24V 15A (For terminal 1-3) Safety switch...
  • Page 163 Part name Symbol Specifications Check Check disconnection Beacon lamp 24V 70W Normal : 1.1 CL-7 Check contact Power boost 24V 6A switch Normal : 15M CS-29 Check contact Horn switch 24V 6A Normal : 15 M CS-5 Check contact Ether 24V 15A Normal : 1.1 CN-78...
  • Page 164 Part name Symbol Specifications Check Check coil resistance Normal : About 1M Check contact Cigar lighter 24V 5A 1.4W Normal : Operating time : 5 ~15sec CL-2 Check resistance Door switch 24V 20W Normal : About 5M CS-1 Check contact Normal : 10.5 (For terminal 1-2) Washer spray : 0.2 (For terminal 1-4)
  • Page 165 Part name Symbol Specifications Check DELCO REMY Check contact Starter 28MT 24V Normal : 0.1 CN-45 Check contact Ι Normal : 0 (For terminal B + - 24V 60A Alternator Normal : 24~27.5V CN-74 Check contact 24V 0.5A Travel alarm Normal : 5.2 CN-65 Check contact...
  • Page 166 Part name Symbol Specifications Check Check contact Normal : 0.9 (For terminal 2-4) : 3.3 (For terminal 1-3) Aircon resistor 24~28V : 5.4 (For terminal 1-4) : 5.7 (For terminal 1-2) Mode actuator 9~16V & 300mA MAX Temp actuator Working temperature of contact point : AC ON 4.5 C AC OFF...
  • Page 167 GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION Destination Connector No. of Type Destination number Female Male CN-1 DEUTSCH I/conn(Frame harness-main harness) HD36-24-23SE HD34-24-23PE CN-2 DEUTSCH I/conn(Frame harness-main harness) HD36-24-23SE HD34-24-23PE CN-3 DEUTSCH I/conn(Engine harness-frame harness) HD36-24-23SE HD34-24-23PE CN-4 I/conn(Engine harness) S814-004001 CN-6 I/conn(Cabin harness-main harness) S814-008001...
  • Page 168 Destination Connector No. of Type Destination number Female Male CN-66 Breaker solenoid S814-002000 S814-102001 CN-68 Safety solenoid S814-002000 S814-102001 CN-70 Travel solenoid S814-002000 S814-102001 CN-74 RING-TERM Alternator "I" term S820-104000 CN-75 EPPR valve 174354-2 174352-2 CN-76 DEUTSCH DC motor DT06-6S-E003 CN-78 Ether S822-014000...
  • Page 169 Destination Connector No. of Type Destination number Female Male Light CL-1 Room lamp MG610392 CL-2 Cigar lighter S822-014000 S822-114000 CL-3 Head lamp S814-002001 S814-102001 CL-5, 6 Work lamp S814-002000 S814-102000 CL-7 Beacon lamp S822-014000 S822-114000 Sensor, sendor CD-1 Hydraulic oil temp sender 85202-1 CD-2 Fuel sender...
  • Page 170 2. CONNECTION TABLE FOR CONNECTORS 58-L TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S813-030100 S813-130100 S813-030200 S813-130200 4 - 32...
  • Page 171 MULTILOCK TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S817-020105 4 - 33...
  • Page 172 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 - 34...
  • Page 173 No. of Receptacle connector(Female) Plug connector(Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4 - 35...
  • Page 174 58-X TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S813-060100 S813-160100 S813-060200 S813-160200 S813-060300 S813-160300 S813-060400 S813-160400 4 - 36...
  • Page 175 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 176 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 177 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 178 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 179 No. of Receptacle connector(Female) Plug connector(Male) S810-006202 S810-106202 S810-008202 S810-108202 4 - 41...
  • Page 180 BS TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S812-002001 S812-102001 S812-003001 S812-103001 S812-004001 S812-104001 S812-006001 S812-106001 4 - 42...
  • Page 181 LC TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S815-010000 S815-012000 S815-016000 S815-018000 4 - 43...
  • Page 182 No. of Receptacle connector(Female) Plug connector(Male) S815-024000 4 - 44...
  • Page 183 375 FASTEN TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S810-002402 S810-102402 4 - 45...
  • Page 184 SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE The CAPO(Computer Aided Power Optimization)- system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
  • Page 185 SYSTEM DIAGRAM Travel motor Regulator Regulator Auto deceleration pressure switch Main control valve Arm 2 Arm 1 Boom 2 Boom 1 Bucket Swing Arm half flow Drive signal Service LH travel solenoid valve RH travel Power boost solenoid valve Main relief valve Travel spped solenoid valve...
  • Page 186 GROUP 2 MODE SELECTION SYSTEM Main control valve Engine Engine speed sensor Pilot pump Main pump Accel Fuel injection actuator pump EPPR valve POWER MODE Mode switch signal CPU controller ENGINE SPEED Drive signal Engine speed switch signal Normal Emergency Prolix Resistor Battery...
  • Page 187 2. PUMP CONTROL BY ENGINE SPEED SENSING Engine Torque If any engine speed drops under the reference rpm of each mode set caused by the pump load are detected by the engine speed sensor, CPU controller sends calculated current signal to EPPR(Electro Proportional Pressure Reducing) valve to match engine torque with pump torque optimally by controlling the pump...
  • Page 188 Engine Torque 3. MAXIMUM POWER OF "H" MODE When H mode is selected in the cluster, CPU controller moves the engine accel actuator to set the throttle lever to the full position and sends initial current signal to the EPPR valve to set the pump absorption torque high.
  • Page 189 Engine Torque 4. GENERAL STANDARD POWER OF "S" MODE When S mode is selected in the cluster, CPU controller moves the engine accel actuator to set the throttle lever to the partial position and sends power shift current to EPPR valve which reduces the pump discharge.
  • Page 190 Engine Torque 5. ENERGY SAVING AND LIGHT POWER OF "L" MODE When L mode is selected in the cluster, CPU controller moves the engine accel actuator to set the throttle lever to the partial position and it sends large amount of power shift current to EPPR valve, which reduces the pump absorption horsepower 30 So, at this mode it is useful for light work...
  • Page 191 6. FINISHING WORK OF "F" MODE Engine Torque When F mode is selected in the cluster, CPU controller moves the engine accel actuator to set the throttle lever to the partial position and it sends large amount of power shift current to EPPR valve to reduce the pump absorption horsepower to 50 of full horsepower.
  • Page 192 Power boost switch OFF Power boost switch ON Other functions Mode Power Power Auto Overheat Level of achievement Level of achievement decel prevention Full power used by engine Full power used by engine speed sensing. speed sensing. Power increased by power boost solenoid valve.
  • Page 193 GROUP 3 AUTOMATIC DECELERATION SYSTEM Auto deceleration pressure switch Accel actuator Fuel injection pump Main control valve AUTO Auto decel switch signal Pressure switch signal DECEL CPU controller 1. WHEN AUTO DECEL LAMP ON If all the work equipment control levers including swing and travel levers are at neutral for at least 4 seconds, CPU controller drives the accel actuator to reduce the engine speed to 1200rpm.
  • Page 194 GROUP 4 POWER BOOST SYSTEM Main control valve Arm 2 Arm 1 Boom 1 Boom 2 Bucket Swing Service LH travel RH travel Main relief Power boost valve solenoid valve Engine speed sensor Engine Main pump Pilot pump Accel Fuel injection actuator pump EPPR valve...
  • Page 195 GROUP 5 TRAVEL SPEED CONTROL SYSTEM Travel motor Main control valve Arm 2 Arm 1 Regulator Regulator Boom 2 Boom 1 Swing Bucket Service LH travel RH travel Main relief Power boost solenoid valve valve Travel spped solenoid valve Engine Pilot pump Main pump EPPR valve...
  • Page 196 GROUP 6 AUTOMATIC WARMING UP FUNCTION Engine Coolant temp sensor Pilot pump Main pump Accel Fuel injection actuator pump EPPR valve TIME Drive signal Warming up lamp signal CPU controller POWER MODE AUTO SELECT DECEL TRAVEL SPEED ENGINE SPEED CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant temperature is less than 30 C, it increases the engine speed from key start rpm to 1200rpm.
  • Page 197 GROUP 7 ENGINE OVERHEAT PREVENTION FUNCTION Engine Coolant temp sensor Main pump Pilot pump Accel Fuel injection actuator pump EPPR valve TIME Drive signal Overheat warning signal CPU controller POWER MODE AUTO SELECT DECEL TRAVEL SPEED ENGINE SPEED 1. CPU controller reads engine coolant temperature through the temperature sensor and when the engine coolant boils upto 110 C, it sends overheat warning signal to the cluster and changes mode set to F mode.
  • Page 198 GROUP 8 ARM HALF FLOW SYSTEM LH control lever Main control valve Arm 2 Arm 1 Boom 2 Boom 1 Bucket Swing Service LH travel RH travel Arm half flow solenoid valve Arm half Main relief flow switch valve Engine Pilot pump Main pump When arm half flow switch is turned ON, the arm half flow solenoid valve is switched to ON and it...
  • Page 199 GROUP 9 ANTI-RESTART SYSTEM Starter Start safety relay Drive signal CPU controller CN-7 CN-8 1. ANTI-RESTART FUNCTION After 10 seconds from the engine starts to run, CPU controller turns off the start safety relay to protect the starter from inadvertent restarting. 2.
  • Page 200 GROUP 10 SELF-DIAGNOSTIC SYSTEM OUTLINE When any abnormality occurs in the CAPO- system caused by electric parts malfunction and by open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the cluster and also stores them in the memory. The current or recorded error codes are displayed at the error display mode selected by touching SELECT switch 2 times while pressing BUZZER STOP switch.
  • Page 201 5. ERROR CODES TABLE Display Problems Current error Recorded error Err : 00 TIME Err : 00 No problem Err : 01 TIME Err : 01 Short circuit in accel actuator 2 lines Err : 02 TIME Err : 02 Potentiometer is shorted to Vcc(5V) or battery(+) Err : 03 TIME Err : 03...
  • Page 202 GROUP 11 ENGINE CONTROL SYSTEM 1. CPU CONTROLLER MOUNTING CPU controller Electric box Bolt(M8) 2. CPU CONTROLLER ASSEMBLY Remove 4 CPU controller mounting bolt(3). Disconnect 4 connectors from CPU controller. CN-50 Remove 6 pieces of screw and open the CN-51 cover of CPU controller.
  • Page 203 3. ENGINE GOVERNOR MOTOR Accel actuator Push-pull cable for manual control ENGINE THROTTLE LEVER Throttle lever SL : Stopper, low idle SH : Stopper, high idle Accel actuator EMERGENCY CABLE (Push-pull cable) It controls engine speed by connecting onto the lever of the injection pump when the malfunction of the CPU controller or the accel actuator happen.
  • Page 204 ACCEL ACTUATOR DC motor Cable Ball joint Connector Connector Type 6P, female White(Potentiometer 5V) Blue(Potentiometer SIG) Black(Potentiometer GND) Line color & description Green(Motor+) Yellow(Motor -) Check resistance Inspection Spec : 1~2 (Between No.5-6) 0.8~1.2k (Between No.1-3) 5 - 21...
  • Page 205 4. ENGINE SPEED SENSOR DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER Gear teeth, flywheel Lock nut, speed sensor Flywheel housing Clearance INSTALLATION Clean contacting point of sensor. Loosen lock nut. Screw speed sensor into flywheel housing. Turn it back 135 when it contacts with gear teeth. Tight lock nut and connect wiring.
  • Page 206 GROUP 12 EPPR VALVE 1. COMPOSITION OF EPPR VALVE EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main hydraulic pump. ELECTRO MAGNET VALVE Receive electric current from CPU controller and move the spool proportionally according to the specific amount of electric current value.
  • Page 207 2. OPERATING PRINCIPLE STRUCTURE Sleeve O-ring Solenoid valve Spring O-ring Connector Spool Pilot oil supply line(Pilot pressure) Return to tank Secondary pressure to flow regulator at hydraulic pump AT H MODE Pressure line is blocked and A oil returns to tank. AT S, L, F MODE Secondary pressure enters into A.
  • Page 208 3. EPPR VALVE CHECK PROCEDURE Spec : 200~400mA CHECK ELECTRIC VALUE AT EPPR VALVE Start engine. Set S-mode and cancel auto decel mode. If tachometer show approx 2250 50rpm, CN-75 disconnect one wire harness from EPPR valve. Install multimeter as figure. Check electric current at bucket circuit EPPR VALVE relief position.
  • Page 209 GROUP 13 PROLIX SWITCH Is the conversion switch to manual control temporarily when the electronic control system is out of order, until repair work be done. Emergency Electric box Normal Never place this switch in EMERGENCY position when the CPU is in normal operation. 1.
  • Page 210 GROUP 14 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 211 CLUSTER CHECK PROCEDURE Start key : ON Check monitor initial 2 seconds All lamps light up. Buzzer sound. Check monitor after 2 seconds : Indicate cluster version and machine condition Cluster program version : CLS : 11 Indicates program version 1.1 for 2 seconds. Tachometer : 0rpm Fuel gauge : All light up below appropriate level Engine coolant temperature gauge : All light up below appropriate level...
  • Page 212 3. CLUSTER CONNECTOR CONNECTOR Signal Input / Output Power IG(24V) Input(20~32V) Cluster Input(0V) Serial-(RX) Input(Vpp=12V) Serial+(TX) Output(Vpp=4V) CN-56 5- 29...
  • Page 213 4. CLUSTER FUNCTION TACHOMETER Tachometer displays the number of engine revolutions. Refer select switch for the selection and adjustment. CLOCK Clock displays the current time by electric digital timer. Refer select switch for the selection and adjustment. TIME FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank.
  • Page 214 COOLANT LEVEL WARNING LAMP This lamp is turned ON when the coolant is below LOW in the reservoir tank of radiator. Check if the coolant level is between FULL and LOW in the reservoir tank located at the side of radiator after opening the engine cover, and check if there is mixture of oil and coolant.
  • Page 215 AIR CLEANER WARNING LAMP This lamp is turned on when the filter in the air cleaner is clogged. Check the filter and wash or replace it when the lamp is ON. OVERHEAT WARNING LAMP This lamp is turned ON when the temperature of coolant is over the normal temperature(110 C) and lose the cooling function.
  • Page 216 ENGINE SPEED CONTROL SWITCH This switch is to control the engine speed, which is increased by pressing switch and decreased by pressing switch. ENGINE SPEED At each pressing of the switches, a short term beep sounds. SELECTION SWITCH(Tachometer and clock) This switch is used to select the tachometer or clock.
  • Page 217 5.MONITORING DISPLAY OUTLINE Information of machine performance as monitored by the CPU controller can be displayed on the cluster when the operator selects a display mode by touching switch alone or with SELECT BUZZER switch on the cluster as below. STOP How to select display mode Display group...
  • Page 218 DESCRIPTION OF MONITORING DISPLAY Group Display Description Name It displays current engine speed detected by engine speed 2450 rpm Engine speed sensor from 500 to 3000rpm. Range : 500~3000rpm by 10rpm It displays current time(12 is hour and 30 is minute) TIME 12 : 30 Time Range : Hour(1~12), minute(00~59)
  • Page 219 Group Display Description Name PP : on Shows that pump prolix switch is turned on(At Pump prolix emergency position). PP : on or oFF switch PP : oFF Shows that pump prolix switch is turned off(At normal position). dP : on Shows that auto decel pressure switch is pressed on Auto decel (Operation of control lever).
  • Page 220 SECTION 6 TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help an operator to maintain the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics system.
  • Page 221 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 222 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. STEP 5.
  • Page 223 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 224 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble and is broken. 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 225 ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard level. Is oil level in Abnormal noise hydraulic oil Hydraulic pump is Disassemble and comes out of tank within hydraulic pump broken. repair. standard level? Do not hydraulic Abnormal noise...
  • Page 226 3. HYDRAULIC SYSTEM HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and dispose Drop hydraulic oil sample on hot it or replace plate and check hydraulic oil. if foams come up. Air is intruded. Check suction line and return line and eliminate...
  • Page 227 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 of viscosity. hydraulic oil too high? Clean suction strainer. Is not suction Is not air intruding strainer clogged? Check for air from pump suction...
  • Page 228 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish specified oil to the Is safety valve pressure within standard level. standard? Safety valve faulty Is gear pump pilot pressure within or not operated. Repair or replace. standard level? Is oil in hydraulic tank within...
  • Page 229 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 and Is MCV pilot spool is stuck. repair. pressure same on Clogged or oil leak.
  • Page 230 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 valve spool faulty.
  • Page 231 THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy Is swing shuttle valve normal? Disassemble and Shuttle valve is faulty. replace. Is brake spring normal? Is return spring of swing control Disassemble and Brake spring is valve normal? faulty.
  • Page 232 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? Counter spool in Disassemble and Is travel brake valve pressure travel brake valve repair or replace. within standard is stuck.
  • Page 233 SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble and Do LH and RH travel defective. repair or replace. speeds change when LH and RH Relief valve built in Disassemble and travel brake valves Does the symptom travel motor is repair.
  • Page 234 MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy None Is parking brake Friction plate is Disassemble and friction plate worn? Check if parking faulty. repair. brake pilot line is not clogged.
  • Page 235 TRAVEL ACTION IS POWERLESS(Travel only) Cause Remedy Is travel motor's drain rate within standard level? Disassemble and Travel motor is Is travel brake pressure within faulty. repair. standard level? Is travel relief valve Travel brake valve Disassemble and pressure within is defective.
  • Page 236 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 Is pilot pressure for Repair or replace. travel select valve faulty.
  • Page 237 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL Cause Remedy Does the symptom Port relief valve is Disassemble and change when port faulty. repair or replace. relief valve is replaced with other valve? Is MCV pilot pressure within standard level? Inspect if pilot piping is not...
  • Page 238 BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. Are other attachment speeds within standard Is combination of levels? Is speed low only oil streams normal in composite at boom hoisting operation? Flow summation Disassemble and and at arm Does spool of flow extrusion? check valve spool...
  • Page 239 BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble and Does the symptom faulty. repair or replace. change when port Normal relief valve is replaced with normal valve? Is control valve return spring Is not hydraulic oil normal?
  • Page 240 BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder internal in Item "Speed is leakage within low". standard level? Is relief pressure in port relief valve Cylinder is faulty. Disassemble and within standard repair.
  • Page 241 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 proper. greased Frictional sufficiently? noise will disappear if they are kept used.
  • Page 242 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. Disconnect hose(A) from rod side of boom cylinder and drain oil from cylinders and hose.(Put cups on piping and hose ends) Raise bucket OFF the ground by retracting the arm cylinder rod.
  • Page 243 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.3.
  • Page 244 2. COMMUNICATION ERROR "Co : Err" FLASHES ON THE CLUSTER Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective controller...
  • Page 245 BATTERY CHARGING 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 controller...
  • Page 246 WHEN COOLANT OVERHEAT 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 247 WHEN AIR CLEANER 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...
  • Page 248 WHEN ENGINE OIL PRESSURE 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 249 WHEN HYDRAULIC OIL TEMPERATURE 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 High temperature...
  • Page 250 WHEN COOLANT LEVEL 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 Insufficient coolant...
  • Page 251 9. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Repair or replace...
  • Page 252 10. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check and repair...
  • Page 253 11. WHEN SAFETY SOLENOID DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.8. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Hydraulic malfunction...
  • Page 254 12. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.6. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective...
  • Page 255 13. WHEN ENGINE DOES NOT START Check supply of the power at engine stop solenoid while starting switch is ON. START SWITCH 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 256 14. WHEN STARTING SWITCH ON DOES NOT OPERATE START SWITCH 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 wiring...
  • Page 257 15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.5 is not blown out. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 258 16. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.16. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 259 17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.17. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 260 GROUP 4 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. Spec : H-mode 2450 50rpm S-mode 2250 50rpm L-mode 2250 50rpm F-mode 1750 50rpm Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy...
  • Page 261 TEST PROCEDURE SPEC : 17.5 1 (20 C) Test 1 : Check resistance at connector CN-52(1)-(7). CN-52 Starting key OFF. 1 2 3 Disconnect connector CN-52. CONTROLLER Check resistance between pin and at 8 9 10 CN-50 CN-51 CN-52 CN-53 connector CN-52(1)-(7).
  • Page 262 Test 4 : Check pressure at EPPR valve. SPEC : 2~10kgf/cm (30~140psi) Remove plug and connect pressure gauge as figure. Gauge capacity : 0 to 40~50kgf/cm (0 to 570~710psi) Start engine. Supply line, pilot press Set S-mode and cancel auto decel mode. If tachometer show approx 2250 50rpm, CN-75 check pressure.
  • Page 263 2. ENGINE SPEED IS SLOW AT ALL MODE Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Good If test 7 is good, check TEST 1~4 Check tachometer work properly or not by changing Misalignment Clean speed the mode.
  • Page 264 TEST PROCEDURE SPEC : 1~2 Test 5 : Check resistance between CN-53 (1)-(13). CONTROLLER Starting key OFF. CN-50 CN-51 CN-52 CN-53 Disconnect connector CN-53 from CPU controller. Check resistance as figure. CN-53 1 2 3 4 5 6 11 12 13 14 15 16 17 18 Multimeter...
  • Page 265 Test 8 : Check resistance at speed sensor. SPEC : 0.2~0.4k Starting key OFF. Disconnect connector CD-17 of speed sensor at engine flywheel housing. Speed sensor Check resistance as figure. CD-17 CD-17 Engine flywheel Multimeter 6 - 46...
  • Page 266 3. ENGINE STALL Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Not enough engine Contact cummins power engine dealer Check pressure at EPPR Valve Defective EPPR Replace SPEC:10~20kgf/cm valve Check electric See TEST 10 current at EPPR valve...
  • Page 267 TEST PROCEDURE SPEC : 400~500mA Test 9 : Check electric current at EPPR valve at F-mode Install multimeter as figure. CN-75 Start engine. Set F-mode with 1750 50rpm. Check electric current. EPPR VALVE Multimeter Test 10 : Check pressure at EPPR valve SPEC : 15~25kgf/cm (218~363psi) at F-mode...
  • Page 268 4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse the CPU controller See if all lamps off in the CPU controller case CPU failure Replace...
  • Page 269 5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Slow action of Check and repair engine speed control due to interference Check interference between Defective CPU...
  • Page 270 TEST PROCEDURE SPEC : 1~2 Test 11 : Check resistance. Starting key OFF. Disconnect connector CN-53 from CPU CONTROLLER controller. CN-50 CN-51 CN-52 CN-53 Check resistance between CN-53(1)-(13) as figure. CN-53 1 2 3 4 5 6 11 12 13 14 15 16 17 18 Multimeter 6 - 51...
  • Page 271 Test 12 : Check voltage and resistance. SPEC : 0.1~0.9k Check resistance between CN-50(14)- (22). CONTROLLER Starting key OFF. Disconnect connector CN-50 from CPU CN-50 CN-51 CN-52 CN-53 controller. Check resistance value with multimeter as figure. CN-50 1 2 3 4 5 6 13 14 17 18 19...
  • Page 272 6. AUTO DECEL SYSTEM DOES NOT WORK Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective CPU Replace Check voltage controller between CN-50(3) - GND, CN-50(11)-GND Defective pressure Replace SPEC : Check resistance switch Actuator operating :...
  • Page 273 TEST PROCEDURE SPEC : Actuator stop : 4.5~5.5V Actuator operating : 0~2V Test 13 : Check voltage at CN-51(3) and ground. Prepare 1 piece of thin sharp pin, steel or CONTROLLER copper. Starting key ON. CN-50 Insert prepared pin to rear side of connectors : One pin to (3) of CN-50.
  • Page 274 7. MALFUNCTION OF WARMING UP Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective cluster or Repair or Replace CPU controller or Check resistance between CN- CD8(Sensor) 50(15) - (24) Check resistance Defective Replace See TABLE...
  • Page 275 8. MALFUNCTION OF POWER MAX Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Check resistance between CN-88 Defective power Repair or replace (1) - (2) max. solenoid valve Resistance between CN-50 SPEC: 15-30 (21) -GND normal? See TEST 14...
  • Page 276 TEST PROCEDURE SPEC : Key ON : 24 1V Key OFF : 0V Test 14 : Check voltage between connector Resistance : 15~30 CN-88 - GND. Start key ON. Disconnect connector CN-88 from power Power max. switch max solenoid valve. Check voltage as figure.
  • Page 277 Maintenance record meets Hyundai spec. OPERATIONAL PERFORMANCE OF A WORKING MACHINE With the passage of time, the machine's operational performance deteriorates, so...
  • Page 278 2. TERMINOLOGY STANDARD Specifications applied to the brand-new machine, components and parts. 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 279 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 280 ENGINE SPEED Measure the engine speed at each power mode. The engine speed at each power mode must meet standard RPM ; If not, all other operational performance data will be unreliable. It is essential to perform this test first. Preparation Warm up the machine, until the engine coolant temperature reaches 50 C or...
  • Page 281 TRAVEL SPEED Measure the time required for the excavator to travel a 20m test track. Preparation Adjust the tension of both tracks to be equal. Prepare a flat and solid test track 20m in length, with extra length of 3 to 5m on both ends for machine acceleration and 0.3~0.5m deceleration.
  • Page 282 TRACK REVOLUTION SPEED Measure the track revolution cycle time with the track raised off ground. Preparation Adjust the tension of both side tracks to be equal. On the track to be measured, mark one 90~110 shoe with chalk. Swing the upperstructure 90 and lower the bucket to raise the track off ground.
  • Page 283 TRAVEL DEVIATION Measure the deviation by the tracks from a 20m straight line. Preparation Adjust the tension of both tracks to be equal. Provide a flat, solid test yard 20m in 0.3~0.5m length, with extra length of 3 to 5m on both ends for machine acceleration and deceleration.
  • Page 284 SWING SPEED Measure the time required to swing three complete turns. Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom...
  • Page 285 SWING FUNCTION DRIFT CHECK Measure the swing drift on the bearing outer circumference when stopping after a 360 full speed swing. Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes.
  • Page 286 SWING BEARING PLAY Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. Preparation Check swing bearing mounting cap screws for loosening. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise.
  • Page 287 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. Preparation Boom cylinder Raise To measure the cycle time of the boom cylinders. With the arm rolled out and the empty Lower bucket rolled out, lower the bucket to the ground, as shown.
  • Page 288 Bucket cylinders. Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.
  • Page 289 DIG FUNCTION DRIFT CHECK Measure dig function drift, which can be caused by oil leakage in the control valve and boom, standard arm, and standard bucket cylinders, with the loaded bucket. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to purge air.
  • Page 290 CONTROL LEVER OPERATING FORCE Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip. Preparation Keep the hydraulic oil temperature at 50 5 C. Measurement Start the engine. Select the following switch positions. Mode selector : H mode Operate each boom, arm, bucket and swing lever at full stroke and measure...
  • Page 291 CONTROL LEVER STROKE Measure each lever stroke at the lever top using a ruler. When the lever has play, take a half of this value and add it to the measured stroke. Preparation Keep the hydraulic oil temperature at 50 5 C. Measurement Stop the engine.
  • Page 292 PILOT PRIMARY PRESSURE Preparation Stop the engine. Remove the top cover of the hydraulic tank oil supply port with a wrench. Loosen and remove plug on the pilot pump delivery port and connect pressure gauge. Start the engine and check for oil leakage from the port.
  • Page 293 FOR TRAVEL SPEED SELECTING PRESSURE Preparation Stop the engine. Push the pressure release button to bleed air. To measure the speed selecting pressure. Install a connector and pressure gauge assembly to turning joint E port as shown. Start the engine and check for on leakage from the adapter.
  • Page 294 Power boost pressure Preparation Stop the engine. Remove the top cover of the hydraulic tank oil supply port with wrench. Turn the pressure release L wrench to bleed air. To measure the power boost pressure. Install a connector and pressure gauge assembly to main relief valve, as shown.
  • Page 295 SWING PARKING BRAKE RELEASING PRESSURE Preparation Stop the engine. The pressure release L wrench to bleed air. Install a connector and pressure gauge assembly to swing motor SH port, as shown. Start the engine and check for oil leakage from the adapter. Keep the hydraulic oil temperature at 50 5 C.
  • Page 296 MAIN PUMP DELIVERY PRESSURE Preparation Stop the engine. Remove the top cover of the hydraulic tank oil supply port with a wrench. Push the pressure release button to bleed air. To measure the main pump pressure. Install a connector and pressure gauge assembly main pump gauge port as shown.
  • Page 297 SYSTEM PRESSURE REGULATOR RELIEF SETTING Preparation Stop the engine. Remove the top cover of the hydraulic tank oil supply port with a wrench. Push the pressure release button to bleed air. To measure the system relief pressure. Install a connector and pressure gauge assembly main pump gauge port, as shown.
  • Page 298 GROUP 2 MAJOR COMPONENT 1. MAIN PUMP Recommended Standard replacement Part name & inspection item Counter measures dimension value Clearance between piston(1) & Replace piston 0.028 0.056 cylinder bore(2) or cylinder (D-d) Play between piston(1) & shoe caulking 0-0.1 section(3) Replace assembly of piston &...
  • Page 299 2. MAIN CONTROL VALVE Part name Inspection item Criteria & measure Casing Existence of scratch, rusting or corrosion In case of damage in following section, replace part - Sliding sections of casing fore and spool, especially land sections applied with holded pressure - Seal pocket section where spool is inserted...
  • Page 300 3. SWING DEVICE Recommended Standard replacement Part name & inspection item Counter measures dimension value Clearance between piston(1) & Replace piston 0.028 0.058 cylinder bore(2) or cylinder (D-d) Play between piston(1) & shoe caulking section(3) Replace assembly of piston & shoe Thickness of shoe Thickness of friction Replace...
  • Page 301 4. TRAVEL DEVICE MOTOR Standard Recommended Part name General view Remedy dimension replacement value Piston Replace cylinder Sliding surface has a deep subassembly(159) block kit score or is roughened. The clearance between the piston and the cylinder block 0.035 0.050 bore is large.
  • Page 302 Standard Recommended Part name General view Remedy dimension replacement value Free piston(136) Replace valve The clearance between the subassembly piston and base plate(103) is large. Sliding surface is deeply scored or roughened. Relief housing Replace valve Sliding surface of free piston is subassembly(122) subassembly deeply scored or roughened.
  • Page 303 REDUCTION GEAR Replace parts according to the standards of the below table : Handle parts with care so that too face and the sliding surface of bearings may not be scored. Do not reuse seals once used after disassembly, but replace all of them with new ones. Recommended Standard Parts replacement standard...
  • Page 304 5. RCV LEVER Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage becomes Conditions : more than 1000cc/m at neutral handle position, or more Primary pressure : 30kgf/cm than 2000cc/m during operation. Oil viscosity : 23cSt Spool This is to be replaced when the sliding surface has The leakage at the left condition is...
  • Page 305 6. RCV PEDAL Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage effect to Conditions : the system. For example, the primary pressure drop. Primary pressure : 30kgf/cm Oil viscosity : 23cSt Spool This is to be replaced when the sliding surface has The leakage at the left condition is worn more than 10 m, compared with the non-sliding estimated to be nearly equal to the...
  • Page 306 7. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination Replace sealing sections Worn abnormality or damaged more than 0.1mm Sliding surface 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 307 8. 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...
  • Page 308 GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK TRACK ROLLER Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread 46.5 51.5 Width of flange Tolerance Standard Clearance...
  • Page 309 CARRIER ROLLER Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread 45.7 50.7 Width of flange Standard size &Tolerance Standard Interference Clearance between shaft Shaft Bearing Replace...
  • Page 310 IDLER Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of protrusion Outside diameter of tread Rebuild or replace Width of protrusion Total width Width of tread Standard size & Tolerance Standard Clearance clearance limit Replace Clearance between shaft and Shaft Hole...
  • Page 311 TRACK Unit : mm Check item Criteria Remedy Standard size Repair limit Link pitch Turn or 201.2 replace Outside diameter of bushing 54.4 Height of grouser Replace Height of link Standard size & Tolerance Standard Interference Interference between bushing interference limit Shaft Hole...
  • Page 312 TRACK FRAME AND RECOIL SPRING Unit : mm Check item Criteria Remedy Standard size Tolerance Repair limit Track frame Vertical width of idler guide - 0.5 Rebuild or Idler support - 1.0 replace Track frame Horizontal width of idler guide Idler support Standard size Repair limit...
  • Page 313 2. WORK EQUIPMENT 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 73.5 75.5 Replace Boom cylinder head 68.5 70.5 Boom cylinder rod 73.5 75.5...
  • Page 314 SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil.
  • Page 315 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 316 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 317 GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf m lbf ft 14.4 Engine mounting bolt, nut 1.75 12.8 92.6 21.7 Radiator mounting bolt Engine Coupling mounting socket bolt 49.9 Main pump housing mounting bolt 22.1 17.4 Main pump mounting socket bolt 1.75 12.2...
  • Page 318 2. TORQUE CHART The torques given are standard figures. Any figures specifically described in this manual has priority. METRIC BOLT - Coarse thread Bolt size lbf ft kgf m kgf m lbf ft 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 0.85 ~ 1.25 1.25 14.5 ~ 21.7...
  • Page 319 PIPE AND HOSE Thread size Width across flat mm kgf m lbf ft 1/4" 21.7 3/8" 28.9 1/2" 36.2 3/4" 86.8 1" FITTING Thread size Width across flat mm lbf ft kgf m 1/4" 28.9 3/8" 36.2 1/2" 43.4 3/4" 94.0 1"...
  • Page 320 GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 321 INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level. Bleed the air from the hydraulic pump. Remove the air vent plug(2EA).
  • Page 322 2. MAIN PUMP STRUCTURE 214 548 531 724 534 901 808 153 156 158 157 141 271 401 Gear pump Seal cover(F) O-ring Drive shaft(F) Pump casing O-ring Drive shaft(R) Valve block O-ring Spline Valve plate(R) O-ring Roller bearing Valve plate(L) O-ring Needle bearing Hexagon socket bolt...
  • Page 323 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
  • Page 324 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 (Material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 115.7 0.47 24.0 173.6 0.55 34.0 245.9 0.55 44.0 318.3 0.67 PT plug(Material : S45C) PT 1/16...
  • Page 325 DISASSEMBLY Select place suitable to disassembling. Select clean place. Spread rubber sheet, cloth or so on on overhaul workbench top to prevent parts from being damaged. Remove dust, rust, etc. from pump surfaces with cleaning oil or so on. Remove drain port plug(467) and let oil out of pump casing.(Front and rear pump) Remove hexagon socket head bolts(412, 413) and remove regulator.
  • Page 326 Pull cylinder block(141) out of pump casing(271) straightly over drive shaft(111). Pull out also pistons(151), set plate(153), spherical bush(156) and cylinder springs(157) simultaneously. Take care not to damage sliding surfaces of cylinder, spherical bushing, shoes, swash plate, etc. Remove hexagon socket head bolts(406) and then seal cover(F, 261).
  • Page 327 (12) Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports. (13) Remove valve plates(313, 314) from valve block(312). These may be removed in work(6). (14) If necessary, remove stopper(L, 534), stopper(S, 535), servo piston(532) and tilting pin(531) from pump casing(271), and needle bearing(124) and spline...
  • Page 328 ASSEMBLY reassembling reverse disassembling procedures, pay attention to the following items. Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. Clean each part fully with cleaning oil and dry it with compressed air. Do not fail to apply clean working oil to sliding sections, bearings, etc.
  • Page 329 Place pump casing with its regulator fitting surface down, fit tilting bush of swash plate to tilting pin(531) and fit swash plate (212) to swash plate support(251) correctly. Confirm with fingers of both hands that swash plate can be removed smoothly. Apply grease to sliding sections of swash plate and swash plate support, and drive shaft can be fitted easily.
  • Page 330 Fit valve plate(313) to valve block(312), entering pin into pin hole. Take care not to mistake suction / delivery directions of valve plate. Fit valve block(312) to pump casing(271) and tighten hexagon socket head bolts (401). At first assemble this at rear pump side, and this work will be easy.
  • Page 331 3. REGULATOR STRUCTURE(1/2) SECTION D-D 641 730 643 SECTION B-B 699 413 VIEW C 8 - 18...
  • Page 332 REGULATOR(2/2) 654 836 651 652 SECTION A-A Proportional reducing valve Adjust screw(C) O-ring Hexagon socket screw Cover(C) O-ring Hexagon socket screw O-ring Hexagon socket screw Sleeve O-ring Hexagon socket screw Pilot cover O-ring Hexagon socket screw Pilot piston O-ring Plug Spring seat(Q) O-ring Plug...
  • Page 333 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
  • Page 334 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 (Material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 115.7 0.47 24.0 173.6 0.55 34.0 245.9 0.55 44.0 318.3 0.67 PT Plug(Material : S45C) PT 1/16...
  • Page 335 DISASSEMBLY Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
  • Page 336 After removing cover(C, 629) subassembly, take out outer spring(625), inner spring (626) and spring seat(C, 624) from compensating section. Then draw out adjusting ring(Q, 645), pilot spring(646) and spring seat(644) from pilot section. Adjusting ring(Q,645) can easily be drawn out with M4 bolt. Remove hexagon socket head screws (436, 438) and remove pilot cover(641).
  • Page 337 Remove lever(2, 613). Do not draw out pin(875). Work will be promoted by using pincers or so on. (10) Draw out pin(874) and remove feedback lever(611). Push out pin(874, 4mm in dia.) from above with slender steel bar so that it may not interfere with lever(1, 612).
  • Page 338 (11) Remove lever(1, 612). Do not draw out pin(875). (12) Draw out pilot piston(643) and spool(652). (13) Draw out piston case(622), compensating piston(621) and compensating rod(623). Piston case(622) can be taken out by pushing compensating rod(623) at opposite side of piston case. This completes disassembly.
  • Page 339 ASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following items. Always repair parts that were scored at disassembly. Get replacement parts ready beforehand. Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
  • Page 340 Fit feedback lever(611), matching its pin hole with pin hole in spool. Then insert pin(874). Insert pin in feedback lever a little to ease Lever (1) side Lever (2) side operation. (Fulcrum plug of Take care not to mistake direction of adjusting plug side) feedback lever.
  • Page 341 (11) Fit set spring(655) to spool hole and put compensating piston(621) and piston case(622) into compensating hole. Fit pilot cover(641) and tighten it with hexagonal socket head screws(436, 438). (12) Put spring seat(644), pilot spring(646) and adjusting ring(Q, 645) into pilot hole. Then fix spring seat(624), inner spring (626) and outer spring(625) into compensating hole.
  • Page 342 GROUP 4 MAIN CONTROL VALVE 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 pressure inside the hydraulic tank.
  • Page 343 2. STRUCTURE(1/2) 15 25 2 43 O-ring O-ring O-ring Housing Socket bolt O-ring Spring washer Spring Retainer Overload assy Spring guide Socket bolt O-ring Spring guide Plunger assy(TS) Orifice Plunger assy (TL, TR) Spring Plunger assy (SW) O-ring Check Plunger assy Cover Plunger assy Socket bolt...
  • Page 344 STRUCTURE(2/2) 6 57 56 6 Spring Plunger assy(BM1) Spacer Spool Poppet Plunger assy(AM2) Cover Stopper Cover Piston Selector assy Manifold Back up ring O-ring O-ring Nylon chip Check O-ring Overload assy Spring guide Spring Spring Spring Spool Check Foot relief assy Poppet Plug O-ring...
  • Page 345 3. DISASSEMBLY AND ASSEMBLY PRECAUTION Disassembly Handle the components carefully not to drop them or bump them with each other as they are made with precision. Do not force the work by hitting or twisting as burred or damaged component may not be assembled or result in oil leakaged or low performance.
  • Page 346 MOUNTING AND DISMOUNTING VALVES Disassembly Remove socket bolts and separate 4 spool valve and 5 spool valve. Assembly Valves should be mounted after making sure that all O-rings and caps are placed on the assembling faces of 4 plunger valve. Carry out assembly in the reverse manner of disassembly.
  • Page 347 PLUNGER 3 2 1 Loosen socket bolt(1) and remove cover (2). Tightening torque : 3kgf m(21.7lbf ft) Install cover (2) after making sure that O- ring is placed on the edge of the valve hole. Tools Hexagon socket : 6mm Torque wrench Pull the plunger out while holding the spring.
  • Page 348 Arm plunger only (Remove check). Remove cap(6) and disassemble spring (7) and check(8). Tightening torque : 3kgf m(21.7lbf ft) Tools Hexagon socket : 6mm Torque wrench MAIN RELIEF ASSEMBLY Relief assy is assembled into a single block as a cartridge. Do not disassemble the relief assembly as a rule.
  • Page 349 OVERLOAD RELIEF VALVE ASSEMBLY Relief assembly is assembled into a single block as a cartridge. Do not disassemble the relief assembly as a rule. Loosen the relief sleeve (1) and remove the cartridge. Tightening torque : 4kgf m(29lbf ft) Tools Hexagon socket : 27mm Torque wrench Loosen the relief seat (2) and remove the...
  • Page 350 FOOT RELIEF ASSEMBLY Loosen cap(1) and remove poppet (2). Tightening torque : 6kgf m(43.4lbf ft) Tools Hexagon socket : 30mm Torque wrench Remove cap (3) and take off shim (4) and spring (5). Tightening torque : 6kgf m(43.4lbf ft) Make sure adjust shim quantity. Tools Hexagon socket : 30mm Torque wrench...
  • Page 351 BOOM HOLDING VALVE ASSEMBLY Loosen the socket bolt(1) and remove the cover assy(2). Tightening torque : 5kgf m(36.2lbf ft) Install cover assy(2) after making sure that O-ring is placed on the edge of the Overload relief valve valve hole. Remove the spring guide(3), spring(4) and poppet(5).
  • Page 352 CENTER BYPASS VALVE ASSEMBLY Remove cap (1). Tightening torque : 8kgf m(57.9lbf ft) Tools Hexagon socket : 36mm Torque wrench Remove spool (2) and spring (3). 8-39...
  • Page 353 ARM REGENERATION VALVE Remove cap(1) and take off spring(2), spring guide(3), check(4) and sleeve(5). Tightening torque : 10kgf m(72.3lbf ft) Tools Hexagon socket : 27mm Torque wrench Remove cap(6) and spring guide(7). Tightening torque : 6kgf m(43.4lbf ft) Tools Hexagon socket : 10mm Torque wrench 8-40...
  • Page 354 ARM STROKE LIMIT ASSEMBLY Loosen the socket bolt(1) and remove cover(2). Tightening torque : 3kgf m(21.7lbf ft) Tools Hexagon socket : 6mm Torque wrench Remove piston(3) and take off O-ring(4), spacer(5) from the valve hole. Make sure inserting direction of the spacer.
  • Page 355 Selector unit Remove cap (5). Take off piston(6) and spring(7). Tightening torque : 3kgf m(21.7lbf ft) Tools Hexagon socket : 6mm Torque wrench Cover assembly Remove cap(14). Take off spring(15) and check valve(16). Tightening torque : 5kgf m(36.2lbf ft) Tools Hexagon socket : 8mm Torque wrench Remove cap (13) and take off piston (12).
  • Page 356 BOOM FLOW SUMMATION CHECK Remove the cap(1) and take off spring(2) and check(3). Tightening torque : 10kgf m(72.3lbf ft) Boom flow summation check Tools Hexagon socket : 12mm Torque wrench BUCKET FLOW SUMMATION CHECK Remove the cap(1) and take off check(2) and spring(3).
  • Page 357 CHECK ASSEMBLY(BOOM1, 2, BUCKET, OPT, SWING, ARM-1) Remove cap(1). Tools Hexagon socket : 12mm Torque wrench Remove spring(2) and check(3). Tightening torque : 10kgf m(72.3lbf ft) CHECK ASSEMBLY(ARM 2) Remove cap(1). Tools Hexagon socket : 12mm Torque wrench Remove spring(2) and check(3, 4). Tightening torque : 10kgf m(72.3lbf ft) 8-44...
  • Page 358 CHECK ASSEMBLY(TR) Remove cap(1). Tightening torque : 10kgf m(72.3lbf ft) Tools Hexagon socket : 12mm Torque wrench Take off spring(2) and check(3). CHECK ASSEMBLY(P1) Remove cap(1). Tightening torque : 10kgf m(72.3lbf ft) Tools Hexagon socket : 12mm Torque wrench Remove spring(2) and check(3). 8-45...
  • Page 359 CHECK ASSEMBLY(TL) Remove cap(1) and spacer(2). Tightening torque : 10kgf m(72.3lbf ft) Tools Hexagon socket : 32mm Torque wrench Remove cap(3) and take off spring(4) and check(5). Tightening torque : 4kgf m(29lbf ft) Tools Hexagon socket : 8mm Torque wrench SELECTOR VALVE ASSEMBLY Remove cap(1) and take off spring(2) and spool(3).
  • Page 360 GROUP 5 SWING DEVICE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious in injury.
  • Page 361 2. SWING MOTOR STRUCTURE 116 118 114 031 031-1 706 707 702 712 472 981 438 303 469 488 355 351 400 400-2 400-1 051 051-1 993 SECTION A-A Time delay valve O-ring Plug 031-1 Plug O-ring Plug Relief valve assembly O-ring O-ring O-ring...
  • Page 362 DISASSEMBLY Lift the motor out. Clean the motor in kerosene and dry with compressed air. To avoid dust inside the motor, mask all the ports of the motor with tapes. Loosen the drain plug to discharge oil in the casing(301). Fix the output drive shaft(101) on the workbench with the end of output shaft down.
  • Page 363 Remove the relief valve(051) from valve casing(303). Remove the anti rotation valve(052) from valve casing(303). Remove RO plug(469) from valve casing(303) and take off spring(355) and plunger(351). Be careful not to damage the plunger seat assembly. Loosen the socket bolt(401) and remove valve casing(303) from casing(301).
  • Page 364 Remove the brake spring(712) from brake piston(702). (10) Remove brake piston(702) from casing(301). Remove the cylinder(111) from the drive (11) shaft (101) with the motor positioned horizontally. Remove piston(121), pushing plate(123), spherical bush(113) and spacer(117). If shoe plate would not removed easily, try again after procedure(15).
  • Page 365 (13) Remove snap ring(437) with plier and remove the seal cover(305) from casing(301). Seal cover could be removed with sliding shaft if necessary. (14) Remove drive shaft(101) from casing(301). (15) Remove the shoe plate(124) from casing(301). (16) Proceed with following job only when necessary.
  • Page 366 Remove oil seal(491) from seal cover(305). Remove the roller bearing(444) from the valve casing(303) by using slide hammer bearing puller. When disassembling the relief valve, release the plug(201) and remove the bush(343), spring(322), and spring seat(333) from the rod(303) of the body(101).
  • Page 367 ASSEMBLY Do the reassembly in the reverse procedure of the disassembly. Place the casing(301) on the workbench with the valve casing(303) downward. Install the cone of roller bearing(443) to the output drive shaft(101). Pay attention to roller bearing(443) direction. Output side Insert the drive shaft(101) into the casing(301) with the end of output shaft upward and tap the outer race of roller...
  • Page 368 Insert the output drive shaft(101) in the casing. Tack oil seal(491) to the casing(301). Reassemble the seal cover(305) to the casing(301). Apply grease to the rib of oil seal to avoid damage to the rib. Install the snap ring(437) to the casing(301).
  • Page 369 Insert the shoe plate(124) with the casing(301) position horizontally. Insert the push rod(116) into the cylinder(111). Place the spherical bush(113) assembled with spacer(117) onto the cylinder. Insert two push rods in each hole. (10) Install the piston sub-assembly(121, 122) to the push plate(123). (11) Reassemble the piston assembly(121, 122) to the cylinder(111).
  • Page 370 (12) Place the casing(301) under the seal cover(305) and reassemble 3 sheets of separate plate(743) and then 2 sheets of friction plate(742) to the casing(301). (13) Insert O-ring(706, 707) in the casing (301). (14) Reassemble brake piston(702) to the casing (301). (15) Reassemble brake spring(712) to the brake piston(702).
  • Page 371 (16) When the roller bearing(444) is removed. Insert the roller bearing(444) into valve casing(303) with hammering. (17) Reassemble valve plate(131) to the valve casing(303) and reassemble O-ring(472). (18) Connect the valve casing(303) with the casing(301) and tighten the hex socket bolt(401).
  • Page 372 (20) Connect the anti-rotation valve(052) with the casing(303) and tighten the hex socket bolt(171). Tightening torque : 3kgf m(21.7lbf ft) (21) Insert back-up ring(162) and O-ring(161) to the relief valve(051), and reassemble them to valve casing(303). Tightening torque : 18kgf m(130.2lbf ft) (22) Connect the time delay valve(031) with the casing(301) and tighten the hex bolt.
  • Page 373 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Slide reduction gear assembly(1) and remove mounting bolts(2). Remove the reduction gear assembly. Reduction gear device weight : 150kg(330lb) INSTALL Carry out installation in the reverse order to removal.
  • Page 374 4. REDUCTION GEAR STRUCTURE Casing Hexagon socket bolt Drive shaft Side plate Seal Ring gear Side plate Plug Planetary gear 2 Side plate Plug Sun gear 2 Side plate Spring pin Planetary gear 1 Level bar Snap ring Sun gear 1 Pipe Snap ring Carrier 2...
  • Page 375 INSPECTIONS Precautions This assembly is designed to balance the life time of each part. Therefore, when replacing the parts, some parts could require another part's replacement at the same time because of their structural or functional correlations. Inspections replacement When the pitting happens on a tooth of sun gear, planetary gear or ring gear, replace the gear.(When a pit size is bigger than 1mm(0.04") or the pits are more than 5 percent of the tooth.)
  • Page 376 ASSEMBLY Reassemble the drive shaft assembly. Insert the bearing seal(915) in the drive shaft(201). Install the roller bearing(401) in the drive shaft(201) after warming it up for about 10 minutes in the oil can at 80~100 C(176~ 212 F). Insert the oil seal(801) in the casing(102). Insert the roller bearing(402) with snap ring(913).
  • Page 377 GROUP 6 TRAVEL DEVICE 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90 and lower it completely to the ground. Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrate the skin causing serious in injury. When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.
  • Page 378 TRAVEL MOTOR(1/2) 26 23 27 28 RELIEF VALVE DETAIL VIEW A Base plate Relief housing Plug Plunger Poppet Spool Check valve Poppet seat Spring Spring Spring seat Plug O-ring Plug Spring O-ring Plug Orifice O-ring Orifice O-ring Free piston O-ring Socket head bolt O-ring Plug...
  • Page 379 TRAVEL MOTOR(2/2) Casing Steel ball Spring Shaft Piston assembly Spring pin Roller bearing Spring Cylinder block Roller bearing Valve plate Piston assembly Spring pin Orifice Retainer plate Socket head bolt O-ring Retainer holder Oil seal O-ring Snap ring Disc plate Plug Collar Brake piston...
  • Page 380 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Socket for socket wrench Spanner Capable of tightening with the specified torques Torque wrench Pliers (-) Driver 6 100 Hammer Steel and plastic Eye bolt M10, M16 Tightening torque Torque Wrench size Part name Item...
  • Page 381 3) DISASSEMBLY (1) Fixed the motor Direct the output shaft up and fix the base plate (3) in a vise. (2) Disassembling the base plate assembly Disassembling the relief valve assembly. Loosen plug(21) and remove the relief assembly(15). The plug(21) is lightly pressed into the relief housing(16), but in case it comes off, hold and turn the outer periphery of the relief housing(16) to separate them.
  • Page 382 Remove spring seat(10) and spring(11). Draw out the plunger assembly(4). Draw it out, turning it slowly. Disassembling the 2-speed control valve. Loosen plugs(36) and remove spring (35) and spool(34). Draw out it, by turning is slowly. (3) Disassembling the base plate Loosen socket bolts(66).
  • Page 383 Remove socket bolts(66) and take off base plate assembly(3), using a screwdriver. Do not pry the base plate assembly gerkily with a screwdriver. Remove O-ring(79, 80) from casing(1). 8-70...
  • Page 384 Separate valve plate(77), pins(75), O- ring(79, 80) and spring(74) from base plate(3). (4) Disassembling the brake piston Separate brake piston(69) from casing (1), using jet air and utilizing the pilot port hole of the casing(1). Remove disc plate(68). Brake piston(69) may pop up by air pressure.
  • Page 385 Remove snap ring(55) using a jig and separate collar(56), spring(57) and collar(58). (6) Separate shaft(40) from casing(1). Separate swash plate(60) from casing(1) and then take off steel ball(61), spring (76) and piston assembly(62). Steel balls(61) can easily be taken out if a magnet is used.
  • Page 386 Disassembling the plunger assembly Fit round bar( 10) into plunger(5) and fix in a vise and then remove plug(8). Separate spring(7) and check valve(6). This completes disassembly. 8-73...
  • Page 387 ASSEMBLY Precautions Clean parts with clean washing oil and blow it with jet air. Handle cleaned parts with care to be free from dust and scoring. Replace seals, bearings and pins with new ones. Tighten the fastening parts to specified torques.
  • Page 388 Fix piston assembly(52) to retainer plate(53) and fit it into cylinder block (51). Fix the retainer plate so the small diameter part of the retainer plate bore taper comes in contact with the flange of the piston shoe. Fix it after coating the piston hole with hydraulic oil.
  • Page 389 Fix shaft(40) to casing(1). Fix swash plate(60) to casing(1). Insert the cylinder block assembly(50) into casing(1) and assemble them together. Insert the cylinder block so piston assembly(62) and retainer holder(54) may not come off. Fix disc plate(68) to casing(1) 8-76...
  • Page 390 Fix O-ring(70, 72) and back up ring(71, 73) to brake piston(69). Fix brake piston(69) to casing(1). Place a suitable jig on the brake piston and insert brake piston by tapping with plastic hammer. 8-77...
  • Page 391 Fix O-ring(79, 80) to casing(1). Fix spring(74) to brake piston(69). (4) Assembling the base plate Place a suitable jig on a work bench and mount base plate(3) on it. Fix the out race of roller bearing(64) to base plate(3). Fix pin(75), spring pin(65) and valve plate(77) to the base plate(3).
  • Page 392 Tighten socket bolts(66). Tightening torque : 10~11kgf m (6) Assembling the plunger Fix round bar( 10) into plunger(4) and fix it in a vise. Fix check valve(6) and spring(7) to plunger(5). Fix O-ring(9) and plug(8) to plunger(5). Fix plunger(4) to base plate(3). Before assembling, applying hydraulic oil to sliding surface of plunger.
  • Page 393 Fit spring seat(10) and spring(11). Fit flange(12) to base plate(3) and fasten them with socket bolts(13) together. Since it is pushed by spring(11), tighten socket bolts(13), holding it down by hand. (7) Fit relief valve(15) to base plate(3) and tighten specified torque. 8-80...
  • Page 394 (8) Fit spool(34), spring(35) to base plate(3) and tighten plug(36). Pay attention to spool direction. 8-81...
  • Page 395 3. TRAVEL REDUCTION GEAR STRUCTURE 11 12 -6 -2 -4 -5 -7 -3 -8 -1 -1 -4 -3 -2 -5 -6 Shim(0.1~0.05t) Holder A assembly Planet gear C Holder A Roller bearing Planet gear A Gear shaft C Socket head bolt Socket head bolt Needle bearing Floating seal...
  • Page 396 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Socket for socket wrench Spanner Torque wrench Capable of tightening with the specified torques Pliers (-) Driver 6 100 Hammer Steel and plastic Eye bolt M10, M16 Tightening torque Torque Wrench size Part name Item...
  • Page 408 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 pressure inside the hydraulic tank.
  • Page 409 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 7,30 Port 1, 3 Port 2, 4 8 - 96...
  • Page 410 Case Rod seal O-ring Plug O-ring Handle connector Plug Push rod O-ring Push rod Insert Spool Plate Boot Shim Bushing Handle Spring Joint assembly Switch assembly Spring seat Swash plate Screw Stopper Adjusting nut Spring Spring Lock nut Spring seat Plug 8 - 97...
  • Page 411 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanner (+) Driver Length 150 (-) Driver Width 4~5 Capable of tightening with the specified torques Torque wrench Tightening torque Torque Part name Item Size kgf m lbf ft Plug PT 1/8 21.7 Joint...
  • Page 412 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(26) from case(1) and take it out upwards. For valve with switch, remove cord also through hole of casing.
  • Page 413 Loosen adjusting nut(20) and plate(19) with spanners on them respectively, and remove them. Turn joint anticlockwise to loosen it, utilizing jig(Special tool). When return spring(10) is strong in force, plate(16), plug(11) and push rod(14, 15) will come up on loosening joint. Pay attention to this.
  • Page 414 Remove plate(16). When return spring(10) is weak in force, plug(11) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading. During taking out, plug may jump up due to return spring(10) force.
  • Page 415 (11) For disassembling reducing valve section, stand it vertically with spool(5) bottom placed on flat workbench. Push down spring seat(8, 31) and remove two pieces of semicircular stopper(9) with tip of small minus screwdriver. Pay attention not to damage spool surface.
  • Page 416 (15) Remove lock nut(21) and then boot(26). 8 - 103...
  • Page 417 (16) 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 418 ASSEMBLY Tighten hexagon socket head plug(2) to the specified torque. Tighten two bolts alternately and slowly. Put shim(6), springs(7, 30) and spring seat(8, 31) onto spool(5) in this order. Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper(9) on spring seat without piling them on.
  • Page 419 Assemble O-ring(13) onto plug(11). Assemble seal(12) to plug(11). Assemble seal in such lip direction as shown below. Assemble push rod(14, 15) to plug(11). Apply working oil on push-rod surface. Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring.
  • Page 420 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate(16), and tighten joint(18) temporarily. (10) Fit plate(16). (11) Tighten joint(18) with the specified torque to casing, utilizing jig. (12) Assemble plate(19) to joint(18). Screw it to position that it contacts with 4 push rods evenly.
  • Page 421 (14) Fit boot(26) and lock nut(21), and handle subassembly is assembled completely. (15) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. (16) Assemble bushing(17) to plate and pass cord and tube through it. Provide margin necessary to operation.
  • Page 422 (17) Determine handle direction, tighten lock nut(21) to specified torque to fix handle. (18) Apply grease to rotating section of joint and contacting faces of disk and push rod. (19) Assemble lower end of bellows to casing. (20) Inject volatile rust-preventives through all ports and then put blind plugs in ports.
  • Page 423 GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 424 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Shim Retaining ring Shaft assembly Sipper seal Plug Cover O-ring Plug Spacer O-ring Hexagon head bolt Shim O-ring Spring washer 8 - 111...
  • Page 425 DISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts(14), washer(15) and cover (3). Remove shim(6) and O-ring(10). Remove retainer ring(11), spacer(4) and shim(5). Place hub(1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out Wooden block shaft(2) to about 1/2 from the hub with a hammer.
  • Page 426 ASSEMBLY Clean all parts. As a general rule, replace oil seals and O- ring. Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix seven slipper seal(7) and O-ring(9) to hub(1). Fit O-ring(8) to shaft(2). Set shaft(2) on block, tap hub(1) with a plastic hammer to install.
  • Page 427 Install cover(3) to hub(1) and tighten bolts(14). Torque : 5.5 ~ 12.5kgf m(40 ~ 90lbf ft) 8 - 114...
  • Page 428 GROUP 9 BOOM, ARM AND BUCKET CYLINDER 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 429 Sling bucket cylinder assembly(9), and remove nut(8), bolt(7), then pull out pin(6). Remove bucket cylinder assembly(9) Weight : 125kg(276lb) 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 430 ARM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 431 Sling arm cylinder assembly(10), and remove nut(9), bolt(8), then pull out pin(7). Remove arm cylinder assembly(10). Weight : 183kg(403lb) 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 432 BOOM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 433 Disconnect boom cylinder hoses(6), and put plugs on cylinder pipe. Remove spring(9), pin stopper(8), then pull out pin(7). Remove boom cylinder assembly(5). Weight : 135kg(298lb) 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 434 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder 10,11 33,34 10,12 15,16 17 18 19 Internal detail 35,36 35,36 23-6 23-3 Tube assembly Back up ring 23-3 Hexagon bolt Rod assembly Cushion ring 23-6 Hexagon bolt Gland Piston Pipe assembly(R) Du bushing O-ring Pipe assembly(B) Rod seal...
  • Page 435 Arm cylinder 10,11 36,37 35 10,12 15,16 18 14 17 19 22 21 20 Internal detail 38,39 25-4 38,39 25-5 Tube assembly Cushion ring 25-4 Hexagon bolt Rod assembly Piston 25-5 Hexagon nut Gland O-ring Band assembly(B) Du bushing Back up ring Pipe assembly(R) Rod seal Piston seal...
  • Page 436 Boom cylinder 10,11 32,33 10,12 15,16 17 18 19 Internal detail 34,36 23-5 23-4 35,37 Tube assembly Back up ring 23-4 Hexagon bolt Rod assembly Cushion ring 23-5 Hexagon nut Gland Piston Pipe assembly(R) Du bushing O-ring Pipe assembly(B) Rod seal Back up ring O-ring Back up ring...
  • Page 437 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanner (-)Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Socket head bolt Bucket cylinder 23 2 166.4 14.5 Boom cylinder...
  • Page 438 DISASSEMBLY 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. Pull out piston rod(2) about 200mm(8in).
  • Page 439 Note that the plated surface of piston rod(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 piston rod assembly on a wooden V-block that is set level.
  • Page 440 Disassemble the piston assembly Remove wear ring(18). 19 18 17 18 19 Remove dust ring(19) and piston seal(17). Exercise care in this operation not to damage the grooves. Disassemble cylinder head assembly 9 8 6 5 7 11 10 12 10 Remove back up ring(12) and O-ring (10).
  • Page 441 ASSEMBLY Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil stone. Coat the inner face of gland(3) with hydraulic oil. Coat dust wiper(8) with grease and fit Press here (Straight down) dust wiper(8) to the bottom of the hole of Metal dust wiper.
  • Page 442 Fit back up ring(11,12) to gland(3). Put the backup ring in the warm water of 30~50 C Fit O-rings(10) to gland(3). Assemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone. Coat the outer face of piston(14) with hydraulic oil.
  • Page 443 Install piston and cylinder head Fix the piston rod assembly to the work Gland assembly bench. Piston rod Apply hydraulic oil to the outer surface of piston rod(2), the inner surface of piston and cylinder head. Insert cylinder head assembly to piston rod.
  • Page 444 Overall assemble Fix with a bar Place a V-block on a rigid work bench. Mount the cylinder tube assembly(1) on it Lift and fix the assembly by passing a bar through the clevis pin hole to lock the assembly. Insert the piston rod assembly in to the Straight cylinder tube assembly, while lifting and Oil pan...
  • Page 445 GROUP 10 UNDERCARRIAGE 1. TRACK LINK REMOVAL Move track link until master pin is over front idler in the position put wooden Master pin block as shown. Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards.
  • Page 446 2. CARRIER ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller Loosen the lock nut (1). Carrier roller Open bracket(2) with a screwdriver, push out from inside, and remove carrier roller assembly.
  • Page 447 3. TRACK ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 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 Remove the mounting bolt(1) and draw out the track roller(2).
  • Page 448 4. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link Sling the adjust component(1) and pull out idler and recoil spring assembly from track frame, using a pry. Weight : 270kg (595lb) Remove the bolts(2), washers(3) and separate idler from recoil spring.
  • Page 449 DISASSEMBLY AND ASSEMBLY OF IDLER Structure Shaft O-ring Idler Seal assembly Bracket Bushing O-ring Dowel pin Plug 8 - 136...
  • Page 450 Disassembly Press Remove plug and drain oil. Draw out the dowel pin(8), using a press. Pull out the shaft(4) with a press. Press Remove seal assembly(5) from idler(1) and bracket(8). Remove O-ring(6) from shaft. Remove the bushing(2) from idler, using a special tool. Only remove bushing if replacement is necessity.
  • Page 451 Assembly Before assembly, clean the parts. Press Coat the sliding surfaces of all parts with oil. Cool up bushing(2) fully by some dry ice and press it into shell(1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
  • Page 452 Install bracket(7) attached with seal assembly(5). Knock in the dowel pin(8) with a hammer. Lay bracket(7) on its side. Supply engine oil to the specified level, and tighten plug. 8 - 139...
  • Page 453 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure Packing Spring Packing Plug Cylinder Fork Piston Tie rod 8 - 140...
  • Page 454 Disassembly Press Apply pressure on spring(1) with a press. The spring is under a large installed load. This is dangerous, so be sure to set properly. Spring set load : 11000kg(24250lb) Remove lock nut(4). Take enough notice so that the press which pushes down the spring, should not be slipped out in its operation.
  • Page 455 Assembly Install packings(5,7) to cylinder liner(2). When installing packing(5,7) take full care so as not to damage the lip. Pour grease into cylinder liner(2), then push in piston(6) by hand. After take grease out of plug mounting hole, let air out. If air letting is not sufficient, it may be difficult to adjust the tension of crawler.
  • Page 456 GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A SECTION B SECTION C 8 - 143...
  • Page 457 2. REMOVAL AND INSTALL BUCKET ASSEMBLY Removal Lower the work equipment completely to ground with back of bucket facing down. GROUND Remove nut(4), bolt(3), and draw out the pin(1). Remove nut(4), bolt(3), and draw out the pin(2). Install Carry out installation in the reverse order to removal.
  • Page 458 ARM ASSEMBLY Removal Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury.
  • Page 459 BOOM ASSEMBLY 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 boom cylinder assembly. Disconnect head work wiring. Disconnect bucket cylinder hose(2) and arm cylinder hose(1).