Hyundai HX140L Manual

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

Group 2 Specifications ------------------------------------------------------------------------------------------------------ 1-10

SECTION 2 STRUCTURE AND FUNCTION

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

Group 2 Main Control Valve --------------------------------------------------------------------------------------------- 2-19

Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-46

Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-57

Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-78

Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-85

SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit -------------------------------------------------------------------------------------------------- 3-1

Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-2

Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-5

Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-15

Group 5 Combined Operation ------------------------------------------------------------------------------------------ 3-27

SECTION 4 ELECTRICAL SYSTEM

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

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3

Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-22

Group 4 Connectors ---------------------------------------------------------------------------------------------------------- 4-33

SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline ----------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode selection System ------------------------------------------------------------------------------------- 5-3

Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6

Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7

Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-8

Group 6 Automatic Warming Up Function ---------------------------------------------------------------------- 5-9

Group 7 Engine Overheat Prevention Function ------------------------------------------------------------- 5-10

Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-11

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Summary of Contents for Hyundai HX140L

Page 1: Table Of Contents
CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ------------------------------------------------------------------------------------------------------ 1-10 SECTION 2 STRUCTURE AND FUNCTION SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1 Group 2 Main Control Valve --------------------------------------------------------------------------------------------- 2-19 Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-46 Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-57 Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-78...
Page 2 Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12 Group 10 Boom Floating Control System------------------------------------------------------------------------- 5-13 Group 11 Intelligent Power Control System---------------------------------------------------------------------- 5-14 Group 12 Anti-Restart System ------------------------------------------------------------------------------------------ 5-16 Group 13 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-17 Group 14 Engine Control System ------------------------------------------------------------------------------------- 5-53 Group 15 EPPR Valve ------------------------------------------------------------------------------------------------------- 5-54 Group 16 Monitoring System --------------------------------------------------------------------------------------------- 5-59 Group 17 Fuel Warmer System ---------------------------------------------------------------------------------------- 5-95...
Page 3 SECTION 9 COMPONENT MOUNTING TORQUE SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide ---------------------------------------------------------------------------------------------- 9-1 Group 2 Engine system --------------------------------------------------------------------------------------------------- 9-2 Group 3 Electric system --------------------------------------------------------------------------------------------------- 9-4 Group 4 Hydraulic system ----------------------------------------------------------------------------------------------- 9-6 Group 5 Undercarriage ---------------------------------------------------------------------------------------------------- 9-9 Group 6 Structure ------------------------------------------------------------------------------------------------------------- 9-10 Group 7 Work equipment ------------------------------------------------------------------------------------------------- 9-14...
Page 4 This section shows bolt specifications and standard torque values needed when mounting components to the machine. The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 5 Revised edition mark(①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 6 3. CONVERSION TABLE 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Example Method of using the Conversion Table to convert from millimeters to inches...
Page 7 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
Page 8 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
Page 9 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
Page 10 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
Page 11 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 12: Section 1 General
SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...
Page 13 SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
Page 14 PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
Page 15 KEEP RIDERS OFF EXCAVATOR KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.
Page 16 SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under 13031GE10 continuous load.
Page 17 BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
Page 18 SERVICE MACHINE SAFELY SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
Page 19 AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Page 20 PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.
Page 21 DISPOSE OF FLUIDS PROPERLY DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Page 22: Group 2 Specifications
GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT Tool box DEF/AdBlue DEF/AdBlue® tank tank Fuel tank Hydraulic tank Main pump After treatment device Engine Oil cooler Charge air cooler Radiator Tooth Bucket Turning joint Swing motor Main control valve Arm cylinder Boom Boom cylinder Guardrail Counterweight...
Page 23 2. SPECIFICATIONS HX140 L 4.60 m (15' 1") BOOM and 2.50 m (8' 2") ARM I(I') B(L) 140F2SP02 Description Unit Specification Operating weight kg (lb) 14200 (31310) Bucket capacity (SAE heaped), standard 0.58 (0.76) Overall length 7820 (25' 8") Overall width, with 600 mm shoe 2600 (8' 6") Overall height of boom 2780 (9' 1")
Page 24 HX140 L, 4.90 m (16' 1") HYDRAULIC ADJUSTABLE BOOM and 2.10 m (6' 11") ARM I(I') B(L) 140F2SP03 Description Unit Specification Operating weight kg (lb) 14550 (32080) Bucket capacity (SAE heaped), standard 0.58 (0.76) Overall length 7820 (25' 8") Overall width, with 600 mm shoe 2600 (8' 6") Overall height of boom 2940 (9' 8")
Page 25 HX140 L DOZER BLADE I(I') B(L) 140F2SP04 Description Unit Specification Operating weight kg (lb) 15020 (33110) Bucket capacity (SAE heaped), standard 0.58 (0.76) Overall length 7820 (25' 8") Overall width, with 600 mm shoe 2600 (8' 6") Overall height of boom 2780 (9' 1") Superstructure width 2475 (8' 1")
Page 26 HX140 HW I(I') B(L) 140F2SP05 Description Unit Specification Operating weight kg (lb) 17100 (37700) Bucket capacity (SAE heaped), standard 0.58 (0.76) Overall length 7790 (25' 6") Overall width, with 800 mm shoe 2840 (9' 4") Overall height of boom 2830 (9' 3") Superstructure width 2475 (8' 1") Overall height of cab...
Page 27 3. WORKING RANGE HX140 L 4.60 m (15' 1") MONO BOOM 140F2SP06 Description 1.90 m (6' 3") Arm 2.10 m (6' 11") Arm 2.50 m ( 8' 2") Arm 3.00 m ( 9' 10") Arm Max digging reach 7750 mm (25' 5") 7920 mm (25'11") 8330 mm (27' 4") 8790 mm (28'10")
Page 28 4.10 m (13' 5") MONO BOOM 140F2SP06 Description 1.90 m (6' 3") Arm 2.10 m (6' 11") Arm Max digging reach 7260 mm (23' 10") 7420 mm (24' 4") Max digging reach on ground 7090 mm (23' 3") 7260 mm (23'10") Max digging depth 4540 mm (14' 11") 4740 mm (15' 7")
Page 29 4.90 m (16' 1") ADJUST BOOM 140F2SP08 Description 1.90 m (6' 3") Arm 2.10 m (6' 11") Arm 2.50 m ( 8' 2") Arm Max digging reach 8140 mm (26' 8") 8320 mm (27' 4") 8720 mm (28' 7") Max digging reach on ground 8000 mm (26' 3") 8180 mm (26'10") 8590 mm (28' 2")
Page 30 HX140 HW 4.6 m (15' 1") MONO BOOM 140F2SP09 Description 1.90 m (6' 3") Arm 2.10 m (6' 11") Arm 2.50 m ( 8' 2") Arm 3.00 m ( 9' 10") Arm Max digging reach 7750 mm (25' 5") 7920 mm (26' 0") 8330 mm (27' 4") 8790...
Page 31 4. WEIGHT HX140 L HX140 L HX140 L DOZER BLADE Item Upper structure assembly 5760 12500 Main frame weld assembly 1120 2470 Engine assembly 1230 Aftertreatment Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 2000...
Page 32 HX140 HW HX140 HW Item Upper structure assembly 5760 12500 Main frame weld assembly 1120 2470 Engine assembly 1230 Aftertreatment Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 2000 4410 Cab assembly 1060 Lower chassis assembly...
Page 33 Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
Page 34 4.60 m (15' 1") boom, 1.90 m (6' 3") arm equipped with 0.58 m (SAE heaped) bucket and 600 mm (24") triple grouser shoe. Load radius At max. reach 1.5 m (5 ft) 3.0 m (10 ft) 4.5 m (15 ft) 6.0 m (20 ft) Capacity Reach...
Page 35 HX140 L, ADJUST BOOM 4.90 m (16' 1") adjust boom, 1.90 m (6' 3") arm equipped with 0.58 m (SAE heaped) bucket and 600 mm (24") triple grouser shoe. : Rating over-front : Rating over-side or 360 degree Load radius At max.
Page 36 Work tools and ground conditions have effects on machine performance. Select an optimum combination according to the working conditions and the type of work that is being done. Consult your Hyundai dealer for information on selecting the correct boom-arm-bucket combination. 1-24...
Page 37 Special bucket Ditch cleaning bucket Slope finishing bucket 0.45 m 0.55 m heaped bucket heaped bucket Recommendation Capacity Width 4.6 m (15' 1") boom 4.1 m (13' 5") boom Weight CECE Without With 1.9 m arm 2.1 m arm 2.5 m arm 3.0 m arm 1.9 m arm 2.1 m arm...
Page 38 HX140 L, ADJUST BOOM General bucket 0.23 m 0.40, 0.46 m 0.52, 0.58, 0.65, 0.71 m heaped bucket heaped bucket heaped bucket Recommendation Capacity Width 4.9 m (16' 1") adjust boom Weight CECE Without With 1.9 m arm 2.1 m arm 2.5 m arm heaped heaped...
Page 39 Special bucket Ditch cleaning bucket Slope finishing bucket 0.45 m 0.55 m heaped bucket heaped bucket Recommendation Capacity Width 4.9 m (16' 1") boom Weight CECE Without With 1.9 m arm 2.1 m arm 2.5 m arm heaped heaped side cutter side cutter (6' 3") (6' 11")
Page 40 HX140 HW General bucket 0.23 m 0.40, 0.46 m 0.52, 0.58, 0.65, 0.71 m heaped bucket heaped bucket heaped bucket Recommendation Capacity Width 4.6 m (15' 1") boom Weight CECE Without With 1.9 m arm 2.1 m arm 2.5 m arm 3.0 m arm heaped heaped...
Page 41 Special bucket Ditch cleaning bucket Slope finishing bucket 0.45 m 0.55 m heaped bucket heaped bucket Recommendation Capacity Width 4.9 m (16' 1") boom Weight CECE Without With 1.9 m arm 2.1 m arm 2.5 m arm heaped heaped side cutter side cutter (6' 3") (6' 11")
Page 42 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 Model Shapes...
Page 43 SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Confirm the category from the list of applications in table 2, then use table 1 to select the shoe. Wide shoes (categories B and C) have limitations on applications. Before using wide shoes, check the precautions, then investigate and study the operating conditions to confirm if these shoes are suitable.
Page 44 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Perkins 1204F Type 4-cycle turbocharged charge air cooled diesel engine Cooling method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type Cylinder bore stroke 105 127 mm (4.1"...
Page 45 GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 40 kgf/cm (570 psi) Rated oil flow 29.2 /min (7.7 U.S. gpm / 6.4 U.K. gpm) MAIN CONTROL VALVE Item Specification Type 11 spools Operating method Hydraulic pilot system Main relief valve pressure 350 kgf/cm...
Page 46 CYLINDER Item Specification Bore dia Rod dia Stroke 75 1290 mm Boom cylinder Cushion Extend only Bore dia Rod dia Stroke 80 1510 mm Arm cylinder Cushion Extend and retract Bore dia Rod dia Stroke 70 1055 mm Bucket cylinder Cushion Extend only Bore dia...
Page 47 ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
Page 48: Section 2 Structure And Function
SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1 Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-19 Group 3 Swing Device ----------------------------------------------------------------------------------------------------- 2-46 Group 4 Travel Device ----------------------------------------------------------------------------------------------------- 2-57 Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-78 Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-85...
Page 49: Group 1 Pump Device
SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. 326 414 Qmax adjusting screw EPPR valve Qmin adjusting screw Qmin adjusting screw a1 a2 Regulator Regulator VIEW A A1 pump A2 pump Gear pump...
Page 50 MAIN PUMP The main pump consists of two piston pumps (front & rear) and valve block. 116 885 314 141 981 271 401 153 156 157 467 14092MP02 04 Gear pump 312 Valve block 717 O-ring 111 Drive shaft (F) 313 Valve plate (R) 719 O-ring 113 Drive shaft (R)
Page 51 REGULATOR (1/2) 876 874 641 730 643 708 644 645 646 728 924 801 SECTION B-B VIEW C (FRONT) VIEW C (REAR) 14092MP04 KR38-9N62 (FRONT) KR38-9N61 (REAR) 722 466 Port Port name Port size Delivery port SAE6000 psi 3/4" Suction port SAE2500 psi 2 1/2"...
Page 52 REGULATOR (2/2) 653 654 836 651 652 601 629 630 SECTION A-A 14W92MP05 079 EPPR valve assembly 629 Cover (C) 733 O-ring 405 Hexagon socket screw 630 Lock nut 734 O-ring 412 Hexagon socket screw 631 Sleeve, Pf 735 O-ring 413 Hexagon socket screw 641 Pilot cover 753 O-ring...
Page 53 GEAR PUMP 354 351 307 310 308 434 466,725 14092MP06 307 Poppet 353 Drive gear 466 Plug 308 Seat 354 Driven gear 700 Ring 309 Ring 355 Filter 710 O-ring 310 Spring 361 Front case 725 O-ring 311 Screw 433 Flange socket 732 O-ring 312 Nut 434 Flange socket...
Page 54 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 55 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 56 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 57 Flow reducing function B(E) Pi(From MCV) Large diameter Servo piston Small diameter chamber chamber 14W92MP12 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 58 Flow increasing function 651 652 B(E) Pi(From MCV) Large diameter Servo piston Small diameter chamber chamber 14W92MP13 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 59 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut (801) and by tightening (or loosening) the hexagonal socket head screw (924). Tightening the screw shifts the control chart to the right as shown in the figure.
Page 60 Total horsepower control The regulator decreases the pump tilting angle (delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump.
Page 61 Overload preventive function B(E) Small diameter Large diameter Servo piston chamber chamber 14W92RG03 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 62 Flow reset function B(E) Small diameter Large diameter Servo piston chamber chamber 14W92RG04 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 63 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 64 Adjustment of inner spring 625 626 Adjust it by loosening the hexagon nut (802) and by tightening (or loosening) the adjusting stem C (627). Tightening the screw increases the flow and then the input horsepower as shown in the figure. Adjusting value Adjustment of input horsepower Speed...
Page 65 Power shift control B(E) Small diameter Large diameter Servo piston chamber chamber 14W92RG05 The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one propor tional pressure reducing valve is provided.
Page 66 Adjustment of maximum and minimum flows Adjustment of maximum flow Adjust it by loosening the hexagon nut (808) and by tightening (or loosening) the set screw (954). The maximum flow only is adjusted w i t h o u t c h a n g i n g o t h e r c o n t r o l characteristics.
Page 67: Group 2 Main Control Valve
GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE (TYPE 1) Mark Port name Port size Tightening torque Make up for swing motor UNF 1 3/16 18 kgf m (130 lbf ft) Travel left pilot port (BW) Travel left pilot port (FW) Travel right pilot port (FW) Travel right pilot port (BW) Pa20...
Page 68 STRUCTURE (TYPE 2) Mark Port name Port size Tightening torque Travel left pilot port (BW) Travel left pilot port (FW) Travel right pilot port (FW) Travel right pilot port (BW) Boom up pilot port Pa21 Boom up confluence pilot port Boom down pilot port Pb21 Pb21...
Page 69 TYPE 1 53 56 77 34 65 62 31 49 48 46 47 50 56 53 61 30 50 53 56 69 11 43 79 72 28 63 29 80 44 26 Housing-P1 Load check-poppet Housing-P2 Load check-poppet Spool-straight travel Signal-poppet Spool-travel (LH, RH) Travel straight-sleeve...
Page 70 TYPE 2 48 53 72 73 42 53 48 42 48 53 59 11 40 45 28 46 41 Housing-P1 Signal-poppet Housing-P2 Orifice signal Spool-straight travel Load check poppet Spool-travel (LH, RH) Load check poppet Spool-swing Spool cap-A Spool-boom 1 Spool cap-B1 Spool-swing priority Spool cap-B2...
Page 71 2. HYDRAULIC CIRCUIT (TYPE 1) OPTION C (DOZER) BUCKET OPTION B B4(Breaker) Pc41(Unlock signal) Pb4(Regeneration cut) Pc40 Pa4(Breaker) ARM 1 Pd40 ARM REGENERATION Pd41 & OPTION B (BREAKER) Pc42(Arm crowd pilot) Pc40 V3(Carry over port) Pc41 Pc3(Swing priority) (Arm dump pilot) Pa21(Boom up pilot) Pa20 BOOM 2...
Page 72 HYDRAULIC CIRCUIT (TYPE 2) OPTION C (DOZER) BUCKET OPTION B B4(Breaker) Pc41(Unlock signal) Pb4(Regeneration cut) Pc40 Pd40 Pa4(Breaker) ARM 1 ARM REGENERATION & OPTION B (BREAKER) Pc42(Arm crowd pilot) V3(Carry over port) Pc3(Swing priority) (Arm dump pilot) Pa21(Boom up pilot) BOOM 2 Pd41 SWING...
Page 73 3. FUNCTION CONTROL IN NEUTRAL P1 SIDE (TYPE 1) The hydraulic fluid from pump A2 flows into the main control valve through the inlet port "P1", pass the straight travel spool into the P1 bypass passage and P1parallel passage. The hydraulic fluid from the pump A2 is directed to the tank through the bypass passage of spools : travel left, boom 1, arm 2, arm regeneration &...
Page 74 P1 SIDE (TYPE 2) The hydraulic fluid from pump A2 flows into the main control valve through the inlet port "P1", pass the straight travel spool into the P1 bypass passage and P1parallel passage. The hydraulic fluid from the pump A2 is directed to the tank through the bypass passage of spools : travel left, boom 1, arm 2, arm regeneration &...
Page 75 P2 SIDE The hydraulic fluid from pump A1 flows into the main control valve through the inlet port "P2", into the P2 bypass passage and P2 parallel passage. The hydraulic fluid from the pump A1 is directed to the tank through the bypass passage of spools : travel right, swing, boom 2 &...
Page 76 TRAVEL OPERATION TRAVEL FORWARD OPERATION P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT From RCV Tank passage P2 Bypass passage 14092MC18 TRAVEL BACKWARD OPERATION P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT From RCV Tank passage P2 Bypass passage 14092MC17 During the travel forward operation, the hydraulic fluid of the pump A2 is supplied to the travel left motor and the hydraulic fluid of the pump A1 is supplied to the other travel right motor.
Page 77 TRAVEL STRAIGHT FUNCTION P2 Parallel passage P1 port Orifice P2 Bypass passage Check valve Tank port T1 Straight travel spool P2 port P1 Bypass passage P1 Parallel passage 14092MC19 This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm, bucket, swing) during a straight travel.
Page 78 BOOM OPERATION BOOM UP OPERATION During boom up operation, the pilot secondary pressure from RCV is supplied to the port Pa20 of the spring side and shifts the boom 1 spool in the left direction. The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic oil fluid from pump A2 is entered P1 parallel passage and then passes through the load check, bridge passage and boom holding valve then flows into the port A2.
Page 79 BOOM DOWN OPERATION (TYPE 1) During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 of the spring opposite side and shifts the boom 1 spool in the right direction. The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic fluid from the pump A2 enters the parallel passage and is directed to the port B2 through the load check.
Page 80 BOOM DOWN OPERATION (TYPE 2) During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb2 of the spring opposite side and shifts the boom 1 spool in the right direction. The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic fluid from the pump A2 enters the parallel passage and is directed to the port B2 through the load check.
Page 81 HOLDING VALVE OPERATION HOLDING OPERATION At neutral condition, the pilot piston chamber is connected to drain port through the pilot port. And the piston "B" is supported with spring "B". Also, the pressured fluid from actuator entered to inside of the holding valve through the periphery hole of check, crevice of the check and the plug and the periphery hole of plug.
Page 82 RELEASE HOLDING OPERATION The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the left direction against the spring "B", and shifts the poppet in the left direction through piston "B" and piston "A" against spring "B" and shifts the spool in the left side. At same time, the return fluid from actuator returns to the drain port through the periphery hole of check, crevice of the check and the plug, the periphery hole of the plug, in side of holding valve, crevice of the poppet and the poppet seat, the periphery hole of the poppet seat, crevice of...
Page 83 BUCKET OPERATION BUCKET IN OPERATION (TYPE 1) During the bucket in operation, the pilot secondary pressure from RCV is supplied to port Pa5 of the spring side and shifts the bucket spool in the left direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port A5 through the check 1 of bucket logic valve.
Page 84 BUCKET IN OPERATION (TYPE 2) During the bucket in operation, the pilot secondary pressure from RCV is supplied to port Pa5 of the spring side and shifts the bucket spool in the left direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port A5 through the check 1.
Page 85 BUCKET OUT OPERATION (TYPE 1) During the bucket out operation, the pilot secondary pressure from RCV is supplied to port Pb5 of the spring opposite side and shifts the bucket spool in the right direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port B5 through the check 1 of bucket logic valve.
Page 86 BUCKET OUT OPERATION (TYPE 2) During the bucket out operation, the pilot secondary pressure from RCV is supplied to port Pb5 of the spring opposite side and shifts the bucket spool in the right direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port B5 through the check 1.
Page 87 BUCKET IN OPERATION WITH BOOM OPERATION (TYPE 1) When combined operation, mostly same as previous page but the fluid from P1 bypass passage is empty. So only the fluid from P1 parallel passage is supplied to the bucket cylinder. Also, parallel passage is installed the orifice of bucket logic valve for supplying the fluid from pump A2 to the boom operation prior to the bucket operation.
Page 88 BUCKET IN OPERATION WITH BOOM UP OPERATION (TYPE 2) When combined operation, mostly same as previous page but the fluid from P1 bypass passage is empty. When the boom up and bucket in combined operation, the boom up pilot pressure is supplied the pilot port (P04) of bucket spool stroke limit and the piston is shifted to the right and then the bucket in spool stroke is limited and the open of the bucket in spool is reduced.
Page 89 SWING OPERATION SWING LEFT & RIGHT OPERATION During the swing left operation, the pilot secondary pressure from the RCV is supplied to the port Pd2 of the spring side and shift the swing spool in left direction. The bypass passage is shut off by the movement of the swing spool and the hydraulic fluid from pump A1 flows into swing spool through the P2 parallel passage.
Page 90 SWING LEFT OPERATION WITH ARM OR BOOM OPERATION When combined operation, mostly same as previous page but the fluid from P2 bypass passage is empty. So only the fluid from parallel passage is supplied to the swing motor. Also, parallel passage is installed the orifice of swing logic valve for supplying the fluid from pump A1 to the boom or the arm operation prior to the swing operation.
Page 91 ARM OPERATION ARM IN OPERATION During arm in operation, the pilot secondary pressure from the RCV is supplied to the port Pc40 of spring opposite side and shifts arm 1 spool in the right direction. The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic oil from the pump A1 flows into the arm cylinder head side through P2 parallel passage, the load check valve, bridge passage and the port C4.
Page 92 ARM REGENERATION The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool through the arm holding valve and the arm 1 spool. It is supplied the arm cylinder head through internal passage.
Page 93 ARM OUT OPERATION During arm out operation, the pilot secondary pressure from RCV is supplied to the port Pd40 of spring side and shifts arm 1 spool in the left direction. The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic fluid from pump A1 flows into arm 1 spool through the P2 parallel passage.
Page 94 SWING PRIORITY FUNCTION During swing priority operation, the pilot secondary pressure is supplied to the port Pc3 of the spring side of the swing priority spool and shift swing priority spool in the right direction. The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm 1 side through swing priority spool and the path "A"...
Page 95 DOZER OPERATION Dozer down operation P2 Parallel passage Dozer spool From dozer RCV DOZER Tank passage 14W92MC30 Dozer up operation P2 Parallel passage Dozer spool DOZER From dozer RCV Tank passage 14W92MC31 During the dozer down operation, the pilot pressure from the dozer control valve is supplied into the port Pc6 of the spring side and it shifts the dozer spool in the left direction.
Page 96 NEGATIVE RELIEF VALVE OPERATION (TYPE 1) When no function is being actuated on P1 side, the hydraulic fluid from the pump A2, flows into the tank passage through the P1 bypass passage and orifice. The restriction caused by this orifice thereby pressurizes.
Page 97 NEGATIVE RELIEF VALVE OPERATION (TYPE 2) When no function is being actuated on P1 side, the hydraulic fluid from the pump A2, flows into the tank passage through the P1 bypass passage and orifice. The restriction caused by this orifice thereby pressurizes.
Page 98 OPERATION OF MAIN RELIEF VALVE The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the inside space, and seats the plunger against the housing securely. Socket Poppet Hole A Spring Piston B Chamber A Piston A Housing Tank...
Page 99 The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by spring force. Then the pressure at port P becomes equal to set pressure of the spring and the plunger is seated to the socket. Socket Poppet Spring...
Page 100 OPERATION OF OVERLOAD RELIEF VALVE FUNCTION AS RELIEF VALVE The pressurized oil passes through the piston A and orifice A is filled up in chamber A of the inside space and seat the plunger against the socket and the socket against the housing securely. Poppet Piston A Socket Chamber A...
Page 101 Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As the result the pressurized oil at port P runs into tank passage (T). Tank passage Chamber A Poppet Housing Tank passage Plunger 14W92MC43 The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by spring force.
Page 102 MAKE-UP FUNCTION When negative pressure exists at port P, the oil is supplied through tank passage (T). When the pressure at tank passage (T) becomes higher than that of at port P, the socket moves in the right direction. Then, sufficient oil passes around the socket from tank passage (T) to port P and fills up the space.
Page 103: Group 3 Swing Device
GROUP 3 SWING DEVICE (TYPE 1) 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Reduction gear Relief valve Oil level gauge & oil supply port Oil level &...
Page 104 SWING MOTOR 3 2 11 10 1 16 19 18 44 17 36 37 44 39 40 38 18 21 20 29 30 42 25 26 24 23 47 31 46 23 24 26 25 42 VIEW X 125LCR2SM22 Casing 17 Spring pin 33 Plug Oil seal...
Page 105 REDUCTION GEAR 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 17 24 22 125LCR2SM23 Ring gear 11 Planetary gear No. 2 21 Carrier pin No. 1 Drive shaft 12 Needle bearing No.
Page 106 2. PRINCIPLE OF DRIVING GENERATING THE TURNING FORCE The high hydraulic supplied from a hydraulic pump flows into a cylinder block (8) through valve casing of motor (22), and valve plate (20). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston (12).
Page 107 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 108 RELIEF VALVE Sleeve Poppet Poppet seat Spring Spring seat Shim Piston Stopper Plug O-ring O-ring 145WF2SM25 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 109 Ports (P,R) at tank pressure. A2 m h 145WF2SM26 When hydraulic oil pressure (P A ) reaches the preset force (F ) of spring (4), the poppet (2) moves to the right as shown. Fsp+Pg A Fsp+Pg A 145WF2SM27 2-52...
Page 110 The oil flows into chamber (g) via orifice (m) and (n). When the pressure of chamber (g) reaches the preset force (F ) of spring (4), the piston (7) moves left and stop the piston (7) hits the bottom of stopper (8). 145WF2SM28 When piston (7) hits the bottom of stopper (8), it stops moving to the left any further.
Page 111 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 112 Operating principle When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (35). This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump charged oil (P3) goes to the chamber G through port PG.
Page 113 When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right. Then, the parking piston (15) is moved lower by spring force and the return oil from the chamber G flows back to tank port. At this time, the brake works.
Page 114 SWING MOTOR (TYPE 2) 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. Relief valve Time delay valve R/G grease fill port(PT 1/4) Oil level gauge & Oil supply port R/G Oil drain port(PT 1/2) R/G Air bleed port(PT 1/4)
Page 115 SWING MOTOR DETAIL K 11 10 9 22 7 32,33 37 30 130ZF2SM02 2 3 4 8 13 12 15 14 17 Body 16 Brake piston 31 Anti-rotating valve Oil seal 17 O-ring 32 Time delay valve Roller bearing 18 O-ring 33 Wrench bolt Snap ring 19 Brake spring...
Page 116 REDUCTION GEAR 29 5 1 10 27 12 13 Oil drain Grease port VIEW A 130ZF2SM03 Casing 12 No.2 pin 23 Stop ring Drive shaft 13 No.2 bushing 24 No. 1 sun gear Cover plate 14 No.2 sun gear 25 Stop ring Spacer 15 No.1 carrier assy 26 Side plate No.1...
Page 117 2. PRINCIPLE OF DRIVING Descriptions are based on the type 1 of the swing motor. 1) GENERATING THE TURNING FORCE The high hydraulic supplied from a hydraulic pump flows into a cylinder block (8) through valve casing (22) of motor and valve plate (20). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston (12).
Page 118 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 119 RELIEF VALVE Sleeve Poppet Poppet seat Spring Spring seat Shim Piston Stopper Plug O-ring O-ring 145WF2SM25 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 120 Ports (P,R) at tank pressure. A2 m h 145WF2SM26 When hydraulic oil pressure (P A ) reaches the preset force (F ) of spring (4), the poppet (2) moves to the right as shown. Fsp+Pg A Fsp+Pg A 145WF2SM27 2-56-7...
Page 121 The oil flows into chamber (g) via orifice (m) and (n). When the pressure of chamber (g) reaches the preset force (F ) of spring (4), the piston (7) moves left and stop the piston (7) hits the bottom of stopper (8). 145WF2SM28 When piston (7) hits the bottom of stopper (8), it stops moving to the left any further.
Page 122 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 123 Operating principle When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (35). This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump charged oil (P3) goes to the chamber G through port PG.
Page 124 When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right. Then, the parking piston (15) is moved lower by spring force and the return oil from the chamber G flows back to tank port. At this time, the brake works.
Page 125: Group 4 Travel Device
GROUP 4 TRAVEL DEVICE (TYPE 1) 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. P/No.(38Q3-40100) P/No.(38Q4-40100) Reduction gear Travel motor VIEW A 125LCR2TM20 Port Port name Port size VA, VB Valve port...
Page 126 2. STRUCTURE 49 40 43 42 41 44 72 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 71 70 59 77 64 3 63 7 10 11 14 15 13 16 26 27 6 8 125LCR2TM21 Casing...
Page 127 3. OPERATION MOTOR High pressure oil delivered form hydraulic pump is led to inlet port that is provided in the brake valve portion and, through the rear cover (30) and valve plate (24), led to cylinder block (12). The oil flow and direction of shaft rotation are indicated in table. Shaft rotation Left Shaft rotation Right (Counterclockwise)
Page 128 PARKING BRAKE Parking brake is released when high pressure oil selected by the brake valve portion that is connected directly to the rear cover (30), is applied to the parking piston (19). Otherwise the braking torque is always applied. This braking torque is generated by the friction between the separated plates (18), inserted into the casing (1), and friction plates (17), coupled to cylinder block (12) by the outer splines.
Page 129 CAPACITY CONTROL MECHANISM Figure typically shows the capacity control mechanism. When high speed pilot line is charged with the pressure P that overcome the spring (44), the spring (44) is compressed and spool (40) shifts to the right to connect the port P and port C. Then, the highest pressure is selected by the check valve (50) from inlet and outlet pressure of the motor and high speed pilot line pressure and pushes shifter piston (4).
Page 130 OVERLOAD RELIEF VALVE Structure This valve is screwed in the motor rear cover (30) and consists of : plug (38-1) that is screwed and fixed in the rear cover (30), poppet (38-8) and supports the poppet seat (38-9), spring (38-2) that is operating relief valve setting pressure and supports the spring seat (38-3), that is inserted in the sleeve (38-4), piston (38-5) that reduce the shock.
Page 131 Operation Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and have the following functions : When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating, bypasses surplus oil to return line. When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under the predetermined value to stop the inertial force.
Page 132 BRAKE VALVE Structure The brake valve portion mainly consists of the following parts: Spool By shifting the spool (31), the discharged oil from hydraulic motor is automatically shut off or restricted according to the condition and give the effect of holding, accelerating, stopping and counterbalance operations.
Page 133 Operation Holding operation When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (33) located on both spool ends holds the spool (31) at central position. Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
Page 134 Accelerating operation When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool (31), and oil flows to motor via MA port to rotate the motor. Therefore, the pressure increases and negative brake is released by the pressure supplied from pump.
Page 135 Stopping operation Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends become equal, and the spool (31) returns to the neutral position by spring (33) force.
Page 136 Counterbalance operation Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force. In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on MB to VB side decreases and the spring (33) force moves the spool (31) leftwards towards neutral position.
Page 137 REDUCTION GEAR Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force. This reduction unit utilizes two stages, planetary reduction system. Planetary reduction system consists of sun gear, planetary gears, (planetary) carriers, and ring gear.
Page 138 TRAVEL DEVICE (TYPE 2, HIGH WALKER) 1. CONSTRUCTION Hydraulic motor includes followings. Part of rotary generating turning force Part of a valve of relief Part of Brake Part of a valve of counterbalance Part of flowing changeover Part of auto changeover Reduction gear Travel motor Port...
Page 139 2. STRUCTURE 81 82 20 19 22,23 26 27 24,25 71 76 40 91-9 91-6 91-8 90-3 90-4 90-6 90-1 9 17 18 36 35 32 31 30 64 90-5 90-2 91-4 91-6 90-7 91-1 91-7 91-5 90-7 91-3 91-2 85 84 49,50 51,52...
Page 140 3. OPERATION Generating the turning force The high hydraulic supplied from a hydraulic pump flows into a cylinder block (10) through rear cover (29) of motor, and valve plate (70). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston assy (18).
Page 141 Working of relief valve Relief valve carries on two functions of followings. It standardizes a pressure in case of driving a hydraulic motor ; bypasses and extra oil in a motor inlet related to acceleration of an inertia to an outlet. In case of an inertia stopped, it forces an equipment stopped, according to generating the pressure of a brake on the projected side.
Page 142 Working of negative brake When the operating pressure is supplied to the brake piston (21) through the spool (simultaneous peripheral operation online) built in the shaft casing (1), the negative brake is released. When the pressure does not work, the brake always runs. The force of a brake is generated by the frictional force among a separate plate (20) fixed by shaft casing, parking piston (21) and a frictional plate (19) connected through spline outside a cylinder block (10).
Page 143 Counterbalance valve Av port is connected to a hydraulic pump; Bv port is connected to a tank. An oil supplied from a hydraulic pump presses check valve and flows into L port. It makes a hydraulic motor circulated. The oil pressure out of a pump is increased and transferred to spring room M through the path G because negative brake is working on.
Page 144 Working description of automatic switch (at normal speed) Due to no pressure on pilot now, spool (47) is not working. 2 Speed line 2 Speed line 2 Speed changeover pressure port (Normal speed) (Normal Speed) 21078TM09 2-76...
Page 145 Working description of automatic switch (at high speed) At normal speed, once the hydraulic oil which is through the inner path of spool (47) flows into high speed switching pressure port (the pressure of external pilot : Pi = 35 kgf/cm ) spool (47) moves from right to left.
Page 146: Group 5 Rcv Lever
GROUP 5 RCV LEVER 1. STRUCTURE The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face. Refer to the parts manual for the types of the RCV lever.
Page 147 TYPE M2, M4, M6, M9 Null Null TYPE L2, L4 TYPE L6 TYPE M2, M4, M9 TYPE M6 Switches Type Single One touch decel Horn M2, M4 Simultaneous operation operation Power boost Breaker One touch decel Horn Power boost Null CCW rotation Close CW rotation...
Page 148 CROSS SECTION Case Bushing Spool Shim Spring Spring seat Spring Plug Push rod 10 O-ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut 23 Boot...
Page 149 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 apply- ing the output pressure (secondary pressure) of the pilot valve to the other end.
Page 150 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 2-70 Pilot valve Main pump Hydraulic motor...
Page 151 Case where handle is in neutral position Port 1 Port 3 300L2RL03 The force of the spring (5) that determines the output pressure of the pilot valve is not applied to the spool (3). Therefore, the spool is pushed up by the spring (7) to the position of port (1, 3) in the operation explanation drawing.
Page 152 Case where handle is tilted Port 1 Port 3 300L2RL04 When the push rod (9) is stroked, the spool (3) moves downwards. Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port (1) to generate the pressure.
Page 153: Group 6 Rcv Pedal
GROUP 6 RCV PEDAL ( -#0293) 1. STRUCTURE The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size...
Page 154 CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool (8), spring (6) for setting secondary pressure, return spring (10), stopper (9), and spring seat (7).
Page 155 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 156 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. 36072SF01 Pilot valve Main pump Hydraulic motor...
Page 157 Case where pedal is in neutral position 21092RP03 The force of the spring (6) 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 (10) to the position of port 2 in the operation explanation drawing.
Page 158 Case where pedal is tilted 21092RP04 When the push rod (14) is stroked, the spool (8) moves downwards. Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1 to generate the pressure. 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 159 RCV PEDAL ( #0294-) 1. STRUCTURE The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size...
Page 160 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 (7), spring (5) for setting secondary pressure, return spring (9), stopper (8), and spring seat (6).
Page 161 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 162 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 36072SF01 Pilot valve Main pump Hydraulic motor...
Page 163 Case where pedal is in neutral position 130ZF2RP03 The force of the spring (5) that determines the output pressure of the pilot valve is not applied to the spool (7). Therefore, the spool is pushed up by the spring (9) to the position of 1 and port 2. Then, since the output port is connected to tank port T only, the output port pressure becomes equal to tank pressure.
Page 164 Case where pedal is tilted 130ZF2RP04 When the push rod (13) is stroked, the spool (7) 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 165: Section 3 Hydraulic System
SECTION 3 HYDRAULIC SYSTEM SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1 Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-2 Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-5 Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-15 Group 5 Combined Operation ------------------------------------------------------------------------------------------ 3-27...
Page 166: Group 1 Hydraulic Circuit
SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT GROUP 1 HYDRAULIC CIRCUIT <BOOM SAFETY LOCK> <ARM SAFETY LOCK> <PROPOTIONAL RCV DOUBLE ACTING & ROTATING> ( 25 ,e1) ( 59 ,C) ( 2 ,Po5) ( 21 ,P4) SPRING 4k [PEDAL [BREAKER] [FLOW ( 21 ,A1) SAFETY]...
Page 167: Group 2 Main Circuit
GROUP 2 MAIN CIRCUIT GROUP 2 MAIN CIRCUIT The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit. The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders and two travel motors. The swash plate type variable displacement axial piston pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
Page 168 2. RETURN CIRCUIT 2. RETURN CIRCUIT 140L3CI02 All oil returned from each actuator returns to the hydraulic tank through the main control valve. The bypass check valves are provided in the return circuit. The setting pressure of bypass check valves are 3.0 kgf/cm (43 psi) and 6.0 kgf/cm (85 psi).
Page 169 3. DRAIN CIRCUIT 3. DRAIN CIRCUIT Travel motor Swing motor Main pump From return line Turning joint Dr#, dr# Drain filter Hydraulic oil tank Check valve 1.5 kgf/cm 140L3CI03 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through drain filter.
Page 170: Group 3 Pilot Circuit
GROUP 3 PILOT CIRCUIT GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve RCV pedal (RH lever) (LH lever) One pedal straight travel solenoid valve (opt) Safety lock solenoid valve Swing parking brake Travel speed solenoid valve Arm regeneration cut solenoid valve Power boost solenoid valve...
Page 171 1. SUCTION, DELIVERY AND RETURN CIRCUIT 1. SUCTION, DELIVERY AND RETURN CIRCUIT Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL...
Page 172 2. SAFETY VALVE 2. SAFETY VALVE (SAFETY LEVER) Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL...
Page 173 3. BOOM PRIORITY SYSTEM 3. BOOM PRIORITY SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL...
Page 174 4. TRAVEL SPEED CONTROL SYSTEM 4. TRAVEL SPEED CONTROL SYSTEM Pi1(Pump) Pi2(Pump) P2(BW) P1(FW) P1(BW) P2(FW) OPTION C (DOZER) TURNING JOINT OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt...
Page 175 5. MAIN RELIEF PRESSURE CHANGE SYSTEM 5. MAIN RELIEF PRESSURE CHANGE SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL...
Page 176 6. ARM REGENERATION CUT SYSTEM 6. ARM REGENERATION CUT SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN ARM REGEN VALVE Pa21 Arm regeneration BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1...
Page 177 7. SWING PARKING BRAKE RELEASE 7. SWING PARKING BRAKE RELEASE Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET SPRING 4k Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 VB(CCW) VA(CW) Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt...
Page 178 8. SWING PRIORITY SYSTEM 8. SWING PRIORITY SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL...
Page 179 9. 9. BOOM FLOATING BOOM FLOATING SYSTEM SYSTEM Pi1(Pump) Pi2(Pump) Boom safety lock valve Head to Rod to tank solenoid tank solenoid TURNING OPTION C JOINT (DOZER) Boom floating OPTION B BUCKET solenoid valve Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40...
Page 180: Group 4 Single Operation
GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 BOOM Pa21 HOLDING Pa20 VALVE BOOM 2 ARM 2 Pd41 Pb21 SWING RELIEF Pb20 VALVE...
Page 181 2. BOOM DOWN OPERATION 2. BOOM DOWN OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 RELIEF VALVE Pa20 BOOM 1 Patt...
Page 182 3. ARM IN OPERATION 3. ARM IN OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET MAKE UP VALVE RELIEF VALVE Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20...
Page 183 4. ARM OUT OPERATION 4. ARM OUT OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET RELIEF VALVE MAKE UP VALVE Pc41 Pc40 Pd40 Pd41 ARM 1 HOLDING Pc42 VALVE REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING...
Page 184 5. BUCKET IN OPERATION 5. BUCKET IN OPERATION Pi1(Pump) Pi2(Pump) RELIEF TURNING VALVE JOINT OPTION C MAKE UP (DOZER) VALVE OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20...
Page 185 6. BUCKET OUT OPERATION 6. BUCKET OUT OPERATION Pi1(Pump) Pi2(Pump) MAKE UP RELIEF TURNING VALVE VALVE OPTION C JOINT (DOZER) BUCKET OPTION B Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20...
Page 186 7. DOZER UP OPERATION 7. DOZER UP OPERATION Pi1(Pump) Pi2(Pump) MAKE UP VALVE TURNING RELIEF OPTION C JOINT VALVE (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20...
Page 187 8. DOZER DOWN OPERATION 8. DOZER DOWN OPERATION Pi1(Pump) Pi2(Pump) RELIEF VALVE MAKE UP TURNING VALVE OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20...
Page 188 9. SWING OPERATION 9. SWING OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET SPRING 4k Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 VB(CCW) VA(CW) Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 189 SWING CIRCUIT OPERATION SWING CIRCUIT OPERATION PARKING BRAKE BRAKE OFF BRAKE RELEASE VALVE BRAKE ON SPRING 4k MAKE UP VALVE MOTOR BRAKE VALVE MAKE UP PORT(MU) ANTI-INVERSION VALVE VB(CCW) VA(CW) TO / FROM MAIN CONTROL VALVE 140L3HC18A 1) 1) MOTOR BRAKE VALVE MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation and controls the swing motor operating pressure.
Page 190 10. TRAVEL FORWARD AND RE 10. TRAVEL FORWARD AND REVERSE O VERSE OPERATION PERATION Pi1(Pump) Pi2(Pump) P2(BW) P1(FW) P1(BW) P2(FW) OPTION C (DOZER) TURNING JOINT OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING...
Page 191 TRAVEL CIRCUIT OPERATION TRAVEL CIRCUIT OPERATION OVERLOAD RELIEF VALVE TRAVEL MOTOR DEVICE COUNTER BALANCE VALVE TURNING JOINT TO/FROM MAIN CONTROL VALVE 140L3HC19A Valves are provided on travel motors to offer the following functions. 1) 1) COUNTER BALANCE VALVE COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run.
Page 192: Group 5 Combined Operation
GROUP 5 COMBINED OPERATION 1. OUTLINE Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 193 2. COMBINED SWING AND BOOM UP OPERATION 2. COMBINED SWING AND BOOM UP OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING...
Page 194 3. COMBINED SWING AND ARM OPERATION 3. COMBINED SWING AND ARM OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) BUCKET OPTION B Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20...
Page 195 4. COMBINED SWING AND BUCKET OPERATION 4. COMBINED SWING AND BUCKET OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20...
Page 196 5. COMBINED SWING AND TRAVEL OPERATION 5. COMBINED SWING AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20...
Page 197 6. COMBINED BOOM AND TRAVEL OPERATION 6. COMBINED BOOM AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20...
Page 198 7. COMBINED ARM AND TRAVEL OPERATION 7. COMBINED ARM AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20...
Page 199 8. COMBINED BUCKET AND TRAVEL OPERATION 8. COMBINED BUCKET AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20...
Page 200 9. COMBINED BOOM UP AND BUCKET OPERATION 9. COMBINED BOOM UP AND BUCKET OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING...
Page 201: Section 4 Electrical System
SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1 Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3 Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-22 Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-33...
Page 202: Group 1 Component Location
SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Switch panel 140L4EL101 Cigar lighter Power max switch 17 Speaker Radio & USB player 10 Emergency engine stop switch 18 Rear view camera Haptic controller 11 One touch decel switch 19 Quick clamp switch Horn switch 12 RS232 &...
Page 203 2. LOCATION 2 BOOM SOLENOID VALVE MAIN PUMP BOOM SAFETY VALVE Patt SHUTTLE BLOCK MAIN CONTROL VALVE AIR CLEANER 140L4EL102 Lamp 11 Overload pressure sensor 21 Attach pressure sensor Fuel sender 12 Start relay 22 Travel pressure sensor Fuel filler pump 13 Heater relay 23 Air cleaner sensor Beacon lamp...
Page 204: Group 2 Electrical Circuit
GROUP 2 ELECTRICAL CIRCUIT ELECTRICAL CIRCUIT (1/5, SERIAL NO. : -#0610) CN-126 CS-74A 8R 146 0.8G 1.2V IG 24V AC COMP RY 145 15W 0.8G 0.8Y CAN2_Lo R/DRYER 0.8G 0.8L 2-PCS CAN2_Hi WASHER P/P 0.8G WASHER P/P(LOW) 0.8G SOL.V/V BEACON LAMP RY MASTER SW 139 1.2Gr CN-95...
Page 205 ELECTRICAL CIRCUIT (2/5, SERIAL NO. : -#0610) CS-67 DC/DC CONVERTER 12V SOCKET HOUR METER 0.8B 0.8ROr 0.8ROr CN-21 0.8ROr WIPER CUT SW QUICK CLAMP SW CN-113 1.2B 0.8Or CS-33 BUZZER CN-56B WIPER MOTOR 0.8B CS-1 CAM 6.5V 0.8L 1.2Gr 11 0.8G CAM GND 0.8Br...
Page 206 ELECTRICAL CIRCUIT (3/5, SERIAL NO. : #0611-) <HARNESS TWOWAY> PUMP HARNESS ATT. BOOM BOOM BOOM SWING SWING SWING BOOM CYL. ATT. SAFETY BREAKER PRESS PRESS PRESS PRESS PRESS MAIN DOWN PARK PARK PARK DOWN TANK COOLANT ATT. PS ROD PS CONFLUX TRAVEL STRAIGHT PUMP...
Page 207 ELECTRICAL CIRCUIT (4/5, SERIAL NO. : #0611-) CS-67 DC/DC CONVERTER 12V SOCKET HOUR METER 0.8B 0.8ROr 0.8ROr CN-21 0.8ROr WIPER CUT QUICK COUPLING SW CN-113 1.2B 0.8Or HARNESS CABIN CS-33 BUZZER CN-56B WIPER MOTOR 0.8B CS-1 CAM 6.5V 1.2Gr 11 0.8L 0.8G CAM GND...
Page 208 ELECTRICAL CIRCUIT (5/5, SERIAL NO. : #0611-) TAIL OUT TURBO OUT TEMP TEMP NOX SENSOR DEF ID MODULE NOX SENSOR INLET INLET TEMP TEMP CN93-J1 REGEN READINESS STG RETURN CN-3 ID DEF/SCR 2.0R BATTERY(+) AIR TEMP SENSOR ANALOGUE RETURN BATTERY(+) BATTERY(+) BATTERY(+) BATTERY(-)
Page 209 MEMORANDUM...
Page 210 1. POWER CIRCUIT (SERIAL NO. : -#0610) The negative terminal of battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW Battery Battery relay Circuit breaker [CN-60]...
Page 211 POWER CIRCUIT (SERIAL NO. : -#0610) 1.2Gr FUSE BOX POWER RY CS-74 MASTER SW CN-95 CL-40 CN93-J1 CIRCUIT BREAKER REGEN READINESS DEF LAMP STG RETURN ID DEF/SCR CN-60 CN-3 AIR TEMP SENSOR BATTERY(+) CR-101 BATTERY(+) BATTERY(+) 85 87 87a BATTERY(-) BATTERY(-) BATTERY(-) DCU RY...
Page 212 2. STARTING CIRCUIT (SERIAL NO. : -#0610) OPERATING FLOW Battery(+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74A] Fuse box [No.6] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2A (1)] When start key switch is in ON position Start switch ON [CS-2A (2)] I/conn [CN-5 (39)] Battery relay [CR-1]...
Page 213 STARTING CIRCUIT (SERIAL NO. : -#0610) 1.2Gr FUSE BOX POWER RY CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 PTC POWER CS-74 CR-1 MASTER SW 1.2B 1.2G BATTERY (12VX2) BATT RY DO-3 0.8G 0.8B CR-36 0.8BOr 0.8ROr 0.8L 0.8GrW AIR HEAT RY CR-5 0.8Br 1.2BOr...
Page 214 3. CHARGING CIRCUIT (SERIAL NO. : -#0610) 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].
Page 215 CHARGING CIRCUIT (SERIAL NO. : -#0610) FUSE BOX CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 PTC POWER CR-1 1.2B BATTERY (12VX2) BATT RY DO-3 0.8B CN-56A 0.8RW BATT.24V 0.8VOr IG 24V 0.8B CAN1 HI CAN1 LO CN-2 CAN2 HI CAN2 LO RS-232 RX RS-232 TX AUX LEFT...
Page 216 4. HEAD AND WORK LIGHT CIRCUIT (SERIAL NO. : -#0610) OPERATING FLOW Fuse box (No.20) Head light relay [CR-13 (30, 86)] Fuse box (No.17) Work light relay [CR-4 (30, 86)] Head light switch ON Head light switch ON [CN-376 (13)] Head light relay [CR-13 (85) (87)] Head light ON [CL-3 (2), CL-4 (2), CL-24 (2)]...
Page 217 HEAD AND WORK LIGHT CIRCUIT (SERIAL NO. : -#0610) FUSE BOX CR-13 1.2Br CN-376 0.8Br IG 24V 1.2ROr TRAVEL ALARM 0.8BrW WIPER WORK LIGHT HEAD LAMP RY CABIN LIGHT CL-4 1.2B 1.2ROr CAN HI HEAD LAMP WASHER CL-24 CL-24 INT.WIPER 1.2B 1.2B HEAD LIGHT...
Page 218 5. BEACON LAMP AND CAB LIGHT CIRCUIT (SERIAL NO. : -#0610) OPERATING FLOW Fuse box (No.29) Beacon lamp relay [CR-85 (2, 3)] Fuse box (No.18) Cab light relay [CR-9 (30, 86)] Beacon lamp switch ON Beacon lamp switch ON [CN-376 (15)] Beacon lamp relay [CR-85 (1) (5)] I/conn [CN-5 (50)]...
Page 219 BEACON LAMP AND CAB LIGHT CIRCUIT (SERIAL NO. : -#0610) FUSE BOX CR-85 0.8BOr 0.8ROr 0.8L 0.8GrW BEACON LAMP RELAY CN-376 IG 24V CR-9 TRAVEL ALARM 0.8R 87 85 WIPER WORK LIGHT 0.8Gr CABIN LIGHT CABIN LAMP RELAY CAN HI WASHER INT.WIPER HEAD LIGHT...
Page 220 6. WIPER AND WASHER CIRCUIT (SERIAL NO. : -#0610) OPERATING FLOW Key switch ON Fuse box (No.13) Membrane controller [CN-376 (1)] Fuse box (No.8) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141 (7)] Wiper motor [CN-21 (4)] Fuse box (No.19) I/conn [CN-5 (16)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]...
Page 221 WIPER AND WASHER CIRCUIT (SERIAL NO. : -#0610) FUSE BOX CN-407 CN-376 1.2BOr IG 24V 1.2GrW TRVEL ALARM 1.2B WIPER 1.2Br WORK LIGHT LOW WIPER MOTOR CABIN LIGHT OVERLOAD SW CN-408 0.8GrW CAN_HI(2) 0.8V WASHER WASHER PUMP INT WIPER DO-5 HEAD LIGHT 0.8GrW 0.8V...
Page 222 CONTROLLER CIRCUIT (SERIAL NO. : -#0610) FUSE BOX DEF FULL WARNING PURGING LAMP LAMP PUMP CN-J7A J1939 HI J1939 LO CR-101 ADDRESS SELEC 0.8L 85 87 87a J1939- BATT+ 1.2Br TAIL OUT NOX SENSOR CN-J7B DCU RY J1939 HI CD-16 0.8 B J1939 LO SIGNAL...
Page 223 MONITORING CIRCUIT (SERIAL NO. : -#0610) FUSE BOX CD-16 CN-3 0.8 B SIGNAL 3W 120? 0.8 Gr RETURN(29) 0.8 R CN-429 SUPPLY POWER 5V(72) WATER LEVEL SENSOR CN-126A 0.8G 5V SUPPKY CAN-A_Hi 0.8G DEF ID MODULE CAN-A_Lo CN93-J1 CDL- CDL+ REGEN READINESS STG RETURN ID DEF/SCR...
Page 224 ELECTRIC CIRCUIT FOR HYDRAULIC (1/2, SERIAL NO. : -#0610) FUSE BOX CN-5 CD-6 SUPPLY RETURN TRAVEL CD-7 SEE : 140L4EL14 SUPPLY RETURN WORK CN-263 CD-35 SUPPLY RETURN AIR COMP RY ARM IN_OUT BUCKET IN CD-24 SUPPLY CD-70 SUPPLY RETURN SWING RETURN CD-31 N1 PRESSURE...
Page 225 ELECTRIC CIRCUIT FOR HYDRAULIC (2/2, SERIAL NO. : -#0610) FUSE BOX CN-5 SWING SWING SWING 2-PCS PARKING PARKING PARKING SOL.VLV CN-3A SEE : 140L4EL13 CS-52 CN-7 CS-73 EPPR EPPR VALVE VALVE P/P VALVE (PVG 32) CONNECTOR 2(C2_BLACK) CONNECTOR 1(C1_GREY) PROPORTIONAL VALVE & LEVER SWING LOCK &...
Page 226 1. POWER CIRCUIT (SERIAL NO. : #0611-) The negative terminal of battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW Battery Battery relay [CR-1] Circuit breaker [CN-60]...
Page 227 POWER CIRCUIT (SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) POWER RY CN-263 CN-258 CL-40 2.0W CN93-J1 AIR COMP 2.0Gr POWER REGEN READINESS CS-74B DEF LAMP STG RETURN 5.0R ID DEF/SCR 5.0R CN-3 AIR TEMP SENSOR 2.0R CN-245 CS-74A BATTERY(+) CR-101...
Page 228 2. STARTING CIRCUIT (SERIAL NO. : #0611-) OPERATING FLOW Battery (+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74A] Fuse box [No.6] Master switch [CS-74B] I/conn [CN-5 (36)] Start switch [CS-2A (1)] When start key switch is in ON position Start switch ON [CS-2A (2)] I/conn [CN-5 (39)] Battery relay [CR-1]...
Page 229 STARTING CIRCUIT (SERIAL NO. : #0611-) IG (BATTERY RY) IG (POWER RY) POWER RY CN-263 CN-258 2.0W AIR COMP 2.0Gr POWER CS-74B 5.0R 5.0R CN-245 CS-74A CN-95 PTC POWER CIRCUIT BREAKER CN-60 CR-1 1.2B 1.2G BATTERY (12VX2) BATT RY DO-3 1.2G 1.2B CR-36...
Page 230 3. CHARGING CIRCUIT (SERIAL NO. : #0611-) When the starter is activated and the engine is started, the operator releases the start switch to the ON position. Charging current generated by operating alternator flows into the battery through the battery relay [CR-1].
Page 231 CHARGING CIRCUIT (SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) CN-263 CN-258 AIR COMP 2.0Gr POWER CS-74B 5.0R 5.0R CN-245 CS-74A CN-95 PTC POWER CIRCUIT BREAKER CN-60 CR-1 1.2B BATTERY (12VX2) BATT RY DO-3 1.2B CN-56A 0.75BW BATT.24V 0.75VBr IG 24V 0.75B...
Page 232 4. HEAD AND WORK LIGHT CIRCUIT (SERIAL NO. : #0611-) OPERATING FLOW Fuse box (No.21) Head light relay [CR-13 (30, 86)] Fuse box (No.34) Work light relay [CR-4 (30, 86)] Fuse box (No.14) RDU membrane controller [CN-376 (1)] Head light switch ON Head light switch ON [CN-376 (13)] Head light relay [CR-13 (85) (87)]...
Page 233 HEAD AND WORK LIGHT CIRCUIT (SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) CR-13 1.5VW CN-376 0.75GL IG 24V 1.5LY 0.75Br WIPER 0.75W WORK LIGHT HEAD LAMP RY CABIN LIGHT CL-4 1.5B 1.5R CAN 2_HI HEAD LAMP-RH WASHER CL-24 CL-24 INT.WIPER...
Page 234 5. BEACON LAMP AND CAB LIGHT CIRCUIT (SERIAL NO. : #0611-) OPERATING FLOW Fuse box (No.30) Beacon lamp relay [CR-85 (2, 3)] Fuse box (No.36) Cab light relay [CR-9 (30, 86)] Fuse box (No.14) RDU membrane controller [CR-376 (1)] Beacon lamp switch ON Beacon lamp switch ON [CN-376 (15)] Beacon lamp relay [CR-85 (1) (5)]...
Page 235 BEACON LAMP AND CAB LIGHT CIRCUIT (SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) CR-85 0.75GR 1.5BrG 0.75BrG 1.58GrW BEACON LAMP RELAY CN-376 IG 24V CR-9 2.0R 0.75R 87 85 WIPER 2.0V WORK LIGHT 0.75G 0.75G CABIN LIGHT CABIN LAMP RELAY CAN 2_HI WASHER...
Page 236 6. WIPER AND WASHER CIRCUIT (SERIAL NO. : #0611-) OPERATING FLOW Key switch ON Fuse box (No.13) RDU membrane controller [CN-376 (1)] Fuse box (No.8) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141 (7)] Wiper motor [CN-21 (4)] Fuse box (No.19) I/conn [CN-5 (16)] l/conn [CN-17 (4)]...
Page 237 WIPER AND WASHER CIRCUIT (SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) CN-376 0.75WBr IG 24V 0.75Y WIPER WORK LIGHT CABIN LIGHT OVERLOAD SW CAN 2_HI 0.75Or WASHER 0.75L INT WIPER HEAD LIGHT BEACON LAMP SW CN-22 0.75ROr CAN 2_LO 0.75V WASHER PUMP...
Page 238 CONTROLLER CIRCUIT (SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) DEF FULL WARNING PURGING LAMP LAMP PUMP CN-J7A J1939 HI J1939 LO CR-101 ADDRESS SELEC 85 87 87a J1939- BATT+ TAIL OUT NOX SENSOR CN-J7B DCU RY J1939 HI CD-16 J1939 LO RETURN(29)
Page 239 MONITORING CIRCUIT (SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) 5.0ROr 1.0WB CD-16 CN-3 2.0ROr 2.0R RETURN(29) 3W 120 SIGNAL CN-429 SUPPLY POWER 5V(72) WATER LEVEL SENSOR 2.0ROr 2.0R CN-126A 5V SUPPKY CAN-A_Hi DEF ID MODULE CAN-A_Lo 2.0ROr 2.0R CN93-J1 CDL-...
Page 240 ELECTRICAL CIRCUIT FOR HYDRAULIC (1/2, SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) CN-5 CD-6 SUPPLY RETURN TRAVEL CD-7 SUPPLY RETURN WORK CN-263 CD-35 SUPPLY RETURN AIR COMP RY ARM IN_OUT BUCKET IN CD-24 SUPPLY CD-70 SUPPLY RETURN SWING RETURN CD-31...
Page 241 ELECTRICAL CIRCUIT FOR HYDRAULIC (2/2, SERIAL NO. : #0611-) IG (POWER RY) IG (BATTERY RY) CN-5 2-PCS SOL.VLV CS-107 CN-3A SWING SWING SWING PARKING PARKING PARKING CS-52 CN-7 CS-73 EPPR EPPR VALVE VALVE P/P VALVE (PVG 32) CONNECTOR 2(C2_BLACK) CONNECTOR 1(C1_GREY) PROPORTIONAL VALVE &...
Page 242: Group 3 Electrical Component Specification
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check Check specific gravity 1.280 over : Over charged 100Ah Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging Rated load Check coil resistance(M4 to M4) Normal : About 50 Battery relay 100A (continuity) Check contact...
Page 243 Part name Symbol Specifications Check Check resistance Glow plug 24V 200A 0.25~0.12 CN-80 Check resistance Temperature 50˚C : 804 sensor 80˚C : 310 (hydraulic) 100˚C : 180 CD-8 CD-1 Air inlet temperature sensor CD-98 CD-98A Check contact Air cleaner N.O TYPE High level : pressure switch Low level : 0...
Page 244 Part name Symbol Specifications Check Check resistance Normal : About 160 Relay 24V 16A (for terminal 1-2) 0 (for terminal 3-4) CR-2 CR-5 CR-36 CR-2 CR-5 CR-36 (for terminal 3-5) CR-45 CR-62 CR-85 CR-95 Check resistance 87 85 Normal : About 160 Relay 24V 16A (for terminal 85-86)
Page 245 Part name Symbol Specifications Check Check disconnection Normal : 1.0 ON : 0 (For terminal 1-2) Room lamp 24V 10W (For terminal 1-3) OFF : (For terminal 1-2) CL-1 0 (For terminal 1-3) Head lamp, 24V 65W Check disconnection Work lamp, (H3 Type) Normal : 1.2 Cab lamp...
Page 246 Part name Symbol Specifications Check Check contact Normal : 1.0 ON : 0 (for terminal A-B) 24V 15A Safety switch (N.C TYPE) (for terminal A-C) OFF : (for terminal A-B) CS-20 CS-4 0 (for terminal A-C) Wiper cut Check contact switch (N.O TYPE) Normal : 0 (one pin to ground)
Page 247 Part name Symbol Specifications Check Check voltage DC/DC 12V 3A 24V (for terminal 1-2) Converter 12V (for terminal 1-3) CN-138 Low wiper motor Pf 1 CN-407 Check coil resistance Normal : About 1M Cigar lighter 24V 5A 1.4W Check contact Normal : Operating time : 5~15sec CL -...
Page 248 Part name Symbol Specifications Check Check contact Air conditioner 24V 79W compressor Normal : 13.4 CN-28 Check contact Start relay 24V 300A Normal : 0.94 (for terminal 1-2) CR-23 Check resistance Blower motor 24V 9.5A Normal : 2.5 (for terminal 1-2) Check resistance 1˚C OFF Normal : 0 (for terminal 1-2),...
Page 249 Part name Symbol Specifications Check Check disconnection Normal : 0 CN-60 : 60A Circuit breaker CN-95 : 90A (connect ring terminal and check CS-60 CS-95 CN-60 CN-95 resist between terminal 1 and 2) Check disconnection Master switch 6-36V Normal : 0.1 CS-74A CS-74B Breaker switch CS-26A...
Page 250 Part name Symbol Specifications Check Check contact Normal Switch 24V 8A OFF : (for terminal 2-1, 2-3, 5-4, 5-6) CS-79 CS-100 CS-100 Check contact Normal Switch 24V 8A OFF : (for terminal 2-1, 2-3, 5-4, 5-6) CS-73 LINE HEATER 3 HS DEF/AdBlue®...
Page 251 Part name Symbol Specifications Check DEF/AdBlue® full lamp CL-41 Temperature sensor (A/C incar, A/C ambient) CN-429 VALVE HS Coolant diverter valve VALVE LS CN-384 CN-J31 SIG. V(Us) SIG. V(Udc) Proportional valve sensor ERROR CN-308 Check resistance Dozer act N.O type pressure switch Normal : (open)
Page 252 Part name Symbol Specifications Check LVDS POS LVDS NEG POWER 24V Camera ADJUST SIGNAL CN-402 CN-403 CN-402 J1939 HI J1939 LO NOx sensor ADDRESS SELEC (tail out, J1939- turbo out) BATT+ CN-J7A CN-J7B 4-32...
Page 253: Group 4 Connectors
GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION (SERIAL NO. : -#0610) Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002 CN-2 I/conn (Frame harness-Engine harness) 936777-2 936780-2 CN-3 I/conn (Frame harness-Engine harness) 1897009-2 1897013-2 CN-3A...
Page 254 (SERIAL NO. : -#0610) Connector part No. Connector No. of Type Destination number Female Male CN-56A Cluster 174663-2 CN-56B Cluster 174984-2 CN-60 Circuit breaker S813-130201 CN-61 DEUTSCH Fuel filler pump DT06-2S-EP06 DT04-2P-E005 CN-66 DEUTSCH Breaker solenoid DT06-2S-EP06 CN-68 DEUTSCH Safety solenoid DT06-2S-EP06 CN-70 DEUTSCH...
Page 255 (SERIAL NO. : -#0610) Connector part No. Connector No. of Type Destination number Female Male CN-261 Siren AMP MG610047 CN-262 DEUTSCH Straight travel solenoid DT06-2S-EP06 DT04-2P-E005 CN-263 DEUTSCH 2 Piece solenoid DT06-2S-EP06 DT04-2P-E005 CN-305 DEUTSCH To PVG controller DTM06-12SA CN-306 DEUTSCH To PVG controller DTM06-12SB...
Page 256 (SERIAL NO. : -#0610) Connector part No. Connector No. of Type Destination number Female Male CN-423 DEUTSCH Tank header unit DT06-4S CN-424 DEF/AdBlue® injector temperature sensor 2098557-1 CN-425 SCR temperature sensor 282080-1 CN-426 DOC temperature sensor 282080-1 CN-427 MOLEX Reader-RMS 039012040 026013096 CN-429...
Page 257 (SERIAL NO. : -#0610) Connector part No. Connector No. of Type Destination number Female Male CS-74A Master switch S813-030201 CS-74B DEUTSCH Master switch DT06-2S-EP06 CS-78 CARLING Lower wiper switch VC2-01 CS-79 CARLING Lower wiper switch VC2-01 CS-83 CARLING Spare switch VC2-01 CS-99 CARLING...
Page 258 (SERIAL NO. : -#0610) Connector part No. Connector No. of Type Destination number Female Male CD-45 WIF sensor 776429-3 CD-50 Dozer pressure sensor MG640795 CD-69 DEUTSCH Attach pressure sensor DT06-3S-EP06 CD-70 DEUTSCH N1 pressure sensor DT06-3S-EP06 CD-71 DEUTSCH N2 pressure sensor DT06-3S-EP06 CD-85 DEUTSCH...
Page 259 CONNECTOR DESTINATION (SERIAL NO. : #0611-) Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002 CN-2 I/conn (Frame harness-Engine harness) 936777-2 936780-2 CN-3 I/conn (Frame harness-Engine harness) 1897009-2 1897013-2 CN-3A PVG harness 174661-2 368537-1...
Page 260 (SERIAL NO. : #0611-) Connector part No. Connector No. of Type Destination number Female Male CN-56A Cluster 174663-2 CN-56B Cluster 174984-2 CN-60 Circuit breaker S813-130201 CN-61 DEUTSCH Fuel filler pump DT06-2S-EP06 DT04-2P-E005 CN-66 DEUTSCH Breaker solenoid DT06-2S-EP06 CN-68 DEUTSCH Safety solenoid DT06-2S-EP06 CN-70 DEUTSCH...
Page 261 (SERIAL NO. : #0611-) Connector part No. Connector No. of Type Destination number Female Male CN-261 Siren AMP MG610049 CN-262 DEUTSCH Straight travel solenoid DT06-2S-EP06 DT04-2P-E005 CN-263 DEUTSCH 2 Piece solenoid DT06-2S-EP06 DT04-2P-E005 CN-263 DEUTSCH Air compressor relay DT06-2S-EP06 CN-305 DEUTSCH To PVG controller DTM06-12SA...
Page 262 (SERIAL NO. : #0611-) Connector part No. Connector No. of Type Destination number Female Male CN-424 DEF/AdBlue® injector temperature sensor 2098557-1 CN-425 SCR temperature sensor 282080-1 CN-426 DOC temperature sensor 282080-1 CN-427 MOLEX Reader-RMS 039012040 026013096 CN-429 DEF/AdBlue® ID module sensor 776433-3 CN-J7A DOC NOx sensor...
Page 263 (SERIAL NO. : #0611-) Connector part No. Connector No. of Type Destination number Female Male CS-74B DEUTSCH Master switch DT06-2S-EP06 CS-78 CARLING Lower wiper switch VC2-01 CS-79 CARLING Lower wiper switch VC2-01 CS-83 CARLING Spare switch VC2-01 CS-99 CARLING Air compressor switch VC2-01 CS-100 CARLING...
Page 264 (SERIAL NO. : #0611-) Connector part No. Connector No. of Type Destination number Female Male CD-50 Dozer pressure sensor MG640795 CD-69 DEUTSCH Attach pressure sensor DT06-3S-EP06 CD-70 DEUTSCH N1 pressure sensor DT06-3S-EP06 CD-71 DEUTSCH N2 pressure sensor DT06-3S-EP06 CD-85 DEUTSCH Boom down pressure sensor DT06-3S-EP06 CD-90...
Page 265 2. CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 3S811-109002 S811-011002 S811-111002 4 - 39...
Page 266 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4 - 40...
Page 267 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 - 41...
Page 268 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 - 42...
Page 269 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 - 43...
Page 270 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 - 44...
Page 271 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 4 - 45...
Page 272 375 FASTEN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR No. of Receptacle connector (female) Plug connector (male) 344111-1 344108-1 AMP TIMER CONNECTOR No. of Receptacle connector (female) Plug connector (male) 85202-1 4 - 46...
Page 273 AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 174045-2 AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 173852 AMP FASTIN - FASTON CONNECTOR No. of Receptacle connector (female) Plug connector (male) 480003-9 925276-0 4 - 47...
Page 274 KET 090 CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610070 KET 090 WP CONNECTORS No. of Receptacle connector (female) Plug connector (male) MG640605 MG640795 4 - 48...
Page 275 KET SDL CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610406 4 - 49...
Page 276 DEUTSCH DT CONNECTORS DT 06 - 3S - Modifications (see below) Number of contacts (P : Pin, S : Socket) 06 : Receptacle, 04 : Plug Deutsch connectors Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 277 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 4 - 51...
Page 278 MOLEX 2CKTS CONNECTOR No. of Receptacle connector (female) Plug connector (male) 35215-0200 35215-0200 ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF593757 MWP NMWP CONNECTOR No. of Receptacle connector (female) Plug connector (male) NMWP01F-B 4 - 52...
Page 279 ECONOSEAL J TYPE CONNECTORS No. of Receptacle connector (female) Plug connector (male) S816-001002 S816-101002 S816-002002 S816-102002 S816-003002 S816-103002 S816-004002 S816-104002 4 - 53...
Page 280 No. of Receptacle connector (female) Plug connector (male) S816-006002 S816-106002 S816-008002 S816-108002 S816-010002 S816-110002 S816-012002 S816-112002 4 - 54...
Page 281 No. of Receptacle connector (female) Plug connector (male) 368301-1 2-85262-1 METRI-PACK TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) 12040753 DEUTSCH HD30 CONNECTOR No. of Receptacle connector (female) Plug connector (male) HD36-24-23SN HD34-24-23PN 4 - 55...
Page 282 (SERIAL NO. : -#0610) DEUTSCH MCU CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-40SA/B DEUTSCH SERVICE TOOL CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) HD10-9-96P AMP FUEL WARMER CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) 2-967325-3 4 - 56...
Page 283 DEUTSCH ENGINE ECM CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-50S-04 DEUTSCH INTERMEDIATE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRB16-60SAE-L018 4 - 57...
Page 284 TE MCU CONNECTOR (SERIAL NO. : #0611-) No. of Receptacle connector (Female) Plug connector (Male) 1473416-1 1473416-1 4-1437290-0 4-1437290-1 4 - 57-1...
Page 285: Section 5 Mechatronics System
SECTION 5 MECHATRONICS SYSTEM Group 1 Outline ---------------------------------------------------------------------------------------------------------------- 5-1 Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-3 Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6 Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7 Group 5 Travel Speed Control System -------------------------------------------------------------------------- 5-8 Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-9 Group 7 Engine Overheat Prevention System -------------------------------------------------------------- 5-10 Group 8 Variable Power Control System ----------------------------------------------------------------------- 5-11 Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12...
Page 286: Group 1 Outline
SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
Page 287 SYSTEM DIAGRAM Attachment pilot Work Travel Work tool pressure pressure pressure Option Bucket (Dozer) SOLENOID VALVE EPPR VALVE Option Arm regen Attachment Travel speed Arm 1 Arm 2 pressure(opt) Attachment Boom priority Boom 1 Power boost Boom 2 conflux(opt) EPPR Travel(LH) Swing Attachment...
Page 288: Group 2 Mode Selection System
GROUP 2 MODE SELECTION SYSTEM 1. POWER MODE SELECTION SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Cluster Drive signal Haptic controller Power mode pilot lamp Emergency CN-16B Power mode switch signal CN-16A CN-16 CAN #2 CAN #1 &...
Page 289 2. WORK MODE SELECTION SYSTEM Work mode consists of the general operation (bucket) and the optional attachment (breaker, crusher). Attachment pilot pressure sensor Main control valve Work tool Option Bucket (Dozer) SOLENOID VALVE Option Arm regen Breaker Arm 1 Arm 2 Attachment Boom 1 Boom 2...
Page 290 3. USER MODE SELECTION SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Cluster Drive signal Haptic controller User mode pilot lamp Emergency CN-16B User mode switch signal CN-16A CN-16 CAN #1 & #2 CAN #2 Normal 140L5MS104 High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode.
Page 291: Group 3 Automatic Deceleration System
GROUP 3 AUTOMATIC DECELERATION SYSTEM Work Travel pressure pressure Main control valve Engine Pilot pump Main pump Cluster Pressure signal Haptic controller Auto idle pilot lamp Emergency CN-16B CN-16A Auto idle switch signal CN-16 CAN #2 CAN #1 & #2 Normal 140L5MS55 1.
Page 292: Group 4 Power Boost System
GROUP 4 POWER BOOST SYSTEM Main control valve Option Bucket (Dozer) Option Arm regen Arm 1 Arm 2 Boom 1 Boom 2 Swing Travel(LH) Travel(RH) Main relief valve pressure pressure Power boost solenoid valve Engine Pilot pump Main pump Power boost Pump power button shift EPPR...
Page 293: Group 5 Travel Speed Control System
GROUP 5 TRAVEL SPEED CONTROL SYSTEM Main control valve Option Travel motor Bucket (Dozer) Option Arm regen Arm 1 Arm 2 Regulator Boom 1 Boom 2 Swing Travel(LH) Travel(RH) Travel speed solenoid valve Engine Main pump Pilot pump Cluster Drive signal Travel speed pilot lamp Travel speed switch signal...
Page 294: Group 6 Automatic Warming Up System
GROUP 6 AUTOMATIC WARMING UP SYSTEM Main control valve Engine Main pump Pilot pump Pump power shift EPPR Cluster Hydraulic temp sensor Drive signal Haptic controller Emergency CN-16B Warming up pilot lamp signal CN-16A CN-16 Warming up CAN #1 & #2 CAN #2 Normal pilot lamp...
Page 295: Group 7 Engine Overheat Prevention System
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM Main control valve Engine Main pump Pilot pump Pump power shift EPPR Emergency warning lamp Cluster Hydraulic temp signal Hydraulic temp sensor Drive signal Haptic controller Emergency CN-16B Overheat warning signal CN-16A CN-16 CAN #2 CAN #1 &...
Page 296: Group 8 Variable Power Control System
GROUP 8 VARIABLE POWER CONTROL SYSTEM Travel pressure Main control valve Engine Main pump Pilot pump Pump power shift EPPR Signal Switch signal Pressure signal Pressure signal RH control LH control lever lever CN-16A CN-16 CAN #2 Normal CN-16B Emergency Haptic controller Cluster Power mode switch signal...
Page 297: Group 9 Attachment Flow Control System
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM Attachment pilot pressure sensor Main control valve Work tool Option Bucket (Dozer) SOLENOID VALVE Option Arm regen Breaker Arm 1 Arm 2 Attachment Boom 1 Boom 2 conflux Attachment Swing Travel(LH) safety Travel(RH) Engine Pilot pump Main pump Attachment...
Page 298: Group 10 Boom Floating Control System
GROUP 10 BOOM FLOATING CONTROL SYSTEM Boom cylinder Rod pressure Head pressure Head to tank Rod to tank solenoid solenoid Boom down pilot Boom 1 spool cutoff solenoid Main control valve RH control LH control lever lever Breaker Pilot pump Main pump button Signal...
Page 299: Group 11 Intelligent Power Control System
GROUP 11 INTELLIGENT POWER CONTROL SYSTEM Travel pressure Main control valve Option Bucket (Dozer) Option Arm regen Arm 1 Arm 2 Boom 1 Boom 2 Swing Travel(LH) Travel(RH) Attach flow EPPR 1 Engine Pilot pump Main pump Power boost Pump power button shift EPPR One touch...
Page 300 IPC MODE SELECTION IPC mode ON/OFF and the levels of flow rate limit can be selected at "Mode setup > IPC mode" Q(cc/rev) Balance mode IPC mode 1 Efﬁ ciency mode IPC mode 2 Pi(bar) 290F3CD311 IPC mode Description Balance mode (default) IPC mode ON, limit level 1 Efficiency mode IPC mode ON, limit level 2...
Page 301: Group 12 Anti-Restart System
GROUP 12 ANTI-RESTART SYSTEM Engine Starter Anti-restart relay Drive signal 140L5MS12 1. ANTI-RESTART FUNCTION After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the starter from inadvertent restarting. 5-16...
Page 302: Group 13 Self-Diagnostic System
GROUP 13 SELF-DIAGNOSTIC SYSTEM OUTLINE When any abnormality occurs in the ADVANCED CAPO system caused by electric parts malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster and also stores them in the memory. MONITORING Active fault 290F3CD120...
Page 303 3. MACHINE ERROR CODES TABLE (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.8V 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Hydraulic oil temperature display failure 2.
Page 304 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V £ Main Pump 1 (P1) Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage <...
Page 305 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Negative 1 Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 306 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (when you had conditions mounting pressure sensor) 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement Voltage > 5.2V (when you had conditions mounting pressure sensor) 10 seconds continuous, 0.3V£ Boom Down Pilot Press. Sensor Measurement Voltage <...
Page 307 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Swing Pilot Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 308 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Detection) (When Pump EPPR Current is more than 10 mA) 10 seconds continuous, Pump EPPR drive current < 0 mA (Cancellation) (When Pump EPPR Current is more than 10 mA) 3 seconds continuous, Pump EPPR drive current ³10 mA (Detection) 10 seconds continuous, Pump EPPR drive current >...
Page 309 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel EPPR Current is more than 10 mA) 10 seconds continuous, Travel EPPR drive current = 0 mA (Cancellation) (When Travel EPPR Current is more than 100 mA) 3 seconds continuous, Travel EPPR drive current ³ 10 mA (Detection) 10 seconds continuous, Travel EPPR drive current >...
Page 310 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Detection) (When Working Cutoff Relay is Off) 10 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage £ 3.0V (Cancellation) (When Working Cutoff Relay is Off) 3 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage >...
Page 311 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel Speed Solenoid is Off) 10 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Travel Speed Solenoid is Off) 3 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage >...
Page 312 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(breaker / crusher) (Detection) (When Attachment Conflux Solenoid is Off) 10 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Attachment Conflux Solenoid is Off) 3 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage >...
Page 313 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When Attachment Safety Solenoid is Off) 10 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Attachment Safety Solenoid is Off) 3 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage >...
Page 314 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Model Parameter) mounting Reverse Cooling Fan Solenoid (Detection) (When Reverse Cooling Fan Solenoid is Off) 10 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Reverse Cooling Fan Solenoid is Off) 3 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage >...
Page 315 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Detection) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 10 seconds continuous, Attachment Flow EPPR drive current < 100 mA (Cancellation) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 3 seconds continuous, Attachment Flow EPPR drive current ³...
Page 316 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement Voltage > 5.2V (Mounting pressure sensor) 10 seconds continuous, 0.3V£ Boom Cylinder Rod Press. Sensor Measurement Voltage < 0.8V (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press.
Page 317 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI Mounting pressure sensor (HCESPN 128 or 205) (Detection) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 10 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 3 seconds continuous,...
Page 318 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 10 seconds continuous, ATT Relief Setting EPPR 2 drive current = 0 mA (Cancellation) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 3 seconds continuous, ATT Relief Setting EPPR 2 drive current ³...
Page 319 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Transmission Oil Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage <...
Page 320 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Detection) (When Parking Relay is Off) 10 seconds continuous, Parking Relay drive unit Measurement Voltage £ 3.0V (Cancellation) (When Parking Relay is Off) 3 seconds continuous, Parking Relay drive unit Measurement Voltage > 3.0V (Detection) (When Parking Relay is On) 10 seconds continuous, Parking Relay drive current >...
Page 321 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Detection) (When Ram Lock Solenoid is Off) 10 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Ram Lock Solenoid is Off) 3 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage >...
Page 322 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Travel Forward Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage <...
Page 323 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage > 5.2V (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 324 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, ECM Communication Data Error (Results / Symptoms) 1. Control Function – ECM operation failure (Checking list) 1. CN-93 (#22) – CN-51 (#21) Checking Open/Short 2. CN-93 (#46) – CN-51 (#31) Checking Open/Short (When mounting the I/O Controller 1) 60 seconds continuous, I/O Controller 1 Communication Data Error (Results / Symptoms)
Page 325 (SERIAL NO. : -#0610) Application Diagnostic Criteria HCESPN FMI (When mounting the AAVM) 60 seconds continuous, AAVM communication Data Error (Results / Symptoms) 1. Control Function – AAVM operation failure (Checking list) 1. CN-401 (#86) – CN-51 (#22) Checking Open/Short 2.
Page 326 MACHINE ERROR CODES TABLE (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.8V 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Hydraulic oil temperature display failure 2.
Page 327 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V £ Main Pump 1 (P1) Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage <...
Page 328 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Negative 1 Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 329 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (when you had conditions mounting pressure sensor) 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement Voltage > 5.2V (when you had conditions mounting pressure sensor) 10 seconds continuous, 0.3V£ Boom Down Pilot Press. Sensor Measurement Voltage <...
Page 330 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Swing Pilot Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 331 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Detection) (When Pump EPPR Current is more than 10 mA) 10 seconds continuous, Pump EPPR drive current < 0 mA (Cancellation) (When Pump EPPR Current is more than 10 mA) 3 seconds continuous, Pump EPPR drive current ³10 mA (Detection) 10 seconds continuous, Pump EPPR drive current >...
Page 332 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel EPPR Current is more than 10 mA) 10 seconds continuous, Travel EPPR drive current = 0 mA (Cancellation) (When Travel EPPR Current is more than 100 mA) 3 seconds continuous, Travel EPPR drive current ³ 10 mA (Detection) 10 seconds continuous, Travel EPPR drive current >...
Page 333 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Detection) (When Working Cutoff Relay is Off) 10 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage £ 3.0V (Cancellation) (When Working Cutoff Relay is Off) 3 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage >...
Page 334 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel Speed Solenoid is Off) 10 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Travel Speed Solenoid is Off) 3 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage >...
Page 335 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(breaker / crusher) (Detection) (When Attachment Conflux Solenoid is Off) 10 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Attachment Conflux Solenoid is Off) 3 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage >...
Page 336 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When Attachment Safety Solenoid is Off) 10 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Attachment Safety Solenoid is Off) 3 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage >...
Page 337 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Model Parameter) mounting Reverse Cooling Fan Solenoid (Detection) (When Reverse Cooling Fan Solenoid is Off) 10 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Reverse Cooling Fan Solenoid is Off) 3 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage >...
Page 338 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Detection) (When pump P2 regulator EPPR current is equal or more than 300 mA) 10 seconds continuous, pump P2 regulator EPPR drive current < 100 mA (Cancellation) (When pump P2 regulator EPPR current is equal or more than 300 mA) 3 seconds continuous, pump P2 regulator EPPR drive current ³...
Page 339 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement Voltage > 5.2V (Mounting pressure sensor) 10 seconds continuous, 0.3V£ Boom Cylinder Rod Press. Sensor Measurement Voltage < 0.8V (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press.
Page 340 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI Mounting pressure sensor (HCESPN 128 or 205) (Detection) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 10 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 3 seconds continuous,...
Page 341 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 10 seconds continuous, ATT Relief Setting EPPR 2 drive current = 0 mA (Cancellation) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 3 seconds continuous, ATT Relief Setting EPPR 2 drive current ³...
Page 342 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Transmission Oil Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage <...
Page 343 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Detection) (When Parking Relay is Off) 10 seconds continuous, Parking Relay drive unit Measurement Voltage £ 3.0V (Cancellation) (When Parking Relay is Off) 3 seconds continuous, Parking Relay drive unit Measurement Voltage > 3.0V (Detection) (When Parking Relay is On) 10 seconds continuous, Parking Relay drive current >...
Page 344 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Detection) (When Ram Lock Solenoid is Off) 10 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage £ 3.0V (Cancellation) (When Ram Lock Solenoid is Off) 3 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage >...
Page 345 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V£ Travel Forward Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage <...
Page 346 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage > 5.2V (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 347 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, ECM Communication Data Error (Results / Symptoms) 1. Control Function – ECM operation failure (Checking list) 1. CN-93 (#25) – CN-52 (#02) Checking Open/Short 2. CN-93 (#26) – CN-52 (#01) Checking Open/Short (When mounting the Haptic Controller) 60 seconds continuous, Haptic Controller Communication Data Error (Results / Symptoms)
Page 348 (SERIAL NO. : #0611-) Application Diagnostic Criteria HCESPN FMI 60 seconds continuous, Switch Controller communication Data Error (Results / Symptoms) 1. Control Function – Switch Controller operation failure (Checking list) 1. CN-56A (#7) – CN-51 (#08) Checking Open/Short 2. CN-56A (#6) – CN-51 (#09) Checking Open/Short (When mounting the BKCU) 60 seconds continuous, BKCU communication Data Error (Results / Symptoms)
Page 349 4. ENGINE FAULT CODE J1939 Code Description Effect and Action Engine Exhaust Gas Recirculation The Electronic Control Module (ECM) detects the following Valve Position Sensor : Voltage conditions: Above Normal The signal voltage from the position sensor on the NOx Reduction System (NRS) valve is greater than 4.8 VDC for 0.1 seconds.
Page 350 J1939 Code Description Effect and Action Accelerator Pedal Position 2 : Voltage The ECM detects one of the following conditions: Below Normal (Engines equipped The ECM has been powered for 3 seconds. with an analog throttle) Diagnostic code 168-4 is not active. 3510 (2131) codes are not active.
Page 351 J1939 Code Description Effect and Action Accelerator Pedal Position 1 : Voltage The Electronic Control Module (ECM) detects the following Above Normal (Engines equipped conditions: with a digital throttle) The ECM has been powered for 3 seconds. Diagnostic code 168-4 is not active. There are no active 678 or 41 codes.
Page 352 J1939 Code Description Effect and Action Water In Fuel Indicator : High - Water has been detected in the fuel that is contained in the moderate severity (2) fuel/water separator bowl. The water has been present for at least 60 minutes. 97-16 The warning lamp will come on.
Page 353 J1939 Code Description Effect and Action Engine Intake Manifold #1 Pressure : This pressure is a variable value that is calculated by the High - moderate severity (2) ECM. The resulting value is dependent on the operating 102-16 conditions of the engine. Intake Manifold Air Pressure Is High Engine Intake Manifold #1 Pressure : This pressure is a variable value that is calculated by the...
Page 354 J1939 Code Description Effect and Action Engine Intake Manifold #1 The engine has been running for 3 minutes. Temperature : High - least severe (1) No other 105 (172) codes are active. 168 codes are not active. Code 412-16 (E1092 (2)) is not active. The intake manifold air temperature exceeds the value that 105-15 is programmed into the ECM for 8 seconds.
Page 355 J1939 Code Description Effect and Action Barometric Pressure : Data Drifted 108-21 5 V Sensor Supply Circuit - Test Engine Coolant Temperature : The coolant temperature has been at 114 (237 ) for 10 High - most severe (3) seconds. The ECM has been powered for at least 2 seconds.
Page 356 J1939 Code Description Effect and Action Engine Coolant Level : Low - most The engine has been running for 60 seconds. The engine severe (3) coolant level has fallen below the coolant level sensor for 111-1 the speciﬁ ed delay time. Engine power is derated.
Page 357 J1939 Code Description Effect and Action Battery Potential / Power Input 1 : The ECM detects voltage that is below the acceptable 168-4 Voltage Below Normal value. Ignition Keyswitch Circuit and Battery Supply Circuit - Test Engine Air Inlet Temperature : Voltage The ECM detects the following conditions: Above Normal The signal voltage from the air inlet temperature sensor is...
Page 358 J1939 Code Description Effect and Action Engine Speed : Abnormal Frequency, The Electronic Control Module (ECM) detects the following Pulse Width or Period conditions : An intermittent loss of signal or a complete loss of signal from the primary speed/timing sensor for 2 seconds. The engine has been running for more than 3 seconds.
Page 359 J1939 Code Description Effect and Action Engine Exhaust Gas Recirculation Engines equipped with a Diesel Particulate Filter (DPF): Temperature : High - least severe (1) The exhaust gas temperature in the NRS has reached (352 ) for 8 seconds. Engines not equipped with a DPF : The exhaust gas temperature in the NRS has reached 198 (388 ) for 8 412-15...
Page 360 J1939 Code Description Effect and Action Engine Timing Sensor : Other Failure The Electronic Control Module (ECM) detects the following Mode conditions: The outputs from the primary speed/timing sensor and the secondary speed/timing sensor differ by more than 8 degrees of crankshaft rotation. 637-11 The engine has been running for more than 5 seconds.
Page 361 J1939 Code Description Effect and Action Engine Injector Cylinder #01 : Erratic, The Electronic Control Module (ECM) detects an injector Intermittent or Incorrect code that is incorrect for the engine. 651-2 The warning lamp will come on. Injector Data Incorrect - Test Engine Injector Cylinder #01 : Current These diagnostic codes indicate an open circuit (Iow Below Normal...
Page 362 J1939 Code Description Effect and Action Engine Injector Cylinder #02 : Current These diagnostic codes indicate an open circuit (Iow Below Normal current) in either the solenoid or the wiring for the electronic unit injector. The EIectronic Control Module (ECM) detects the following conditions: A low c:urrent condition (open circuit) for each of ﬁ...
Page 363 J1939 Code Description Effect and Action Engine Injector Cylinder #03 : Current These diagnostic codes indicate an open circuit (Iow Below Normal current) in either the solenoid or the wiring for the electronic unit injector. The EIectronic Control Module (ECM) detects the following conditions: A low c:urrent condition (open circuit) for each of ﬁ...
Page 364 J1939 Code Description Effect and Action Engine Injector Cylinder #04 : Current These diagnostic codes indicate an open circuit (Iow Below Normal current) in either the solenoid or the wiring for the electronic unit injector. The EIectronic Control Module (ECM) detects the following conditions: A low c:urrent condition (open circuit) for each of ﬁ...
Page 365 J1939 Code Description Effect and Action Engine Injector Cylinder #06 : Current 656-6 Above Normal (1206E-E66 Engine Injector Solenoid Circuit - Test Only) Engine Glow Plug Relay : Current The EIectronic Control Module (ECM) detects the following Below Normal conditions: The engine is not cranking.
Page 366 J1939 Code Description Effect and Action ECU 8 Volts DC Supply : Voltage The ECM detects the following conditions: Below Normal The 8 VDC supply is less than 7.2 VDC for more than one second. The ECM has been powered for more than 3 seconds. Diagnostic code 168-4 is not active.
Page 367 J1939 Code Description Effect and Action Engine Fuel Injection Pump Fuel TheEIectronic Control Module (ECM) detects the following Control Valve : Current Below Normal conditions: Low Current in the output from the ECM to the fuel pump solenoid for 0.6 seconds. There are no active 168 diagnostic codes.
Page 368 J1939 Code Description Effect and Action Engine Turbocharger 1 Wastegate The ECM detects the following conditions: Drive : Current A high current condition in the output from the ECM to the Above Normal solenoid in the wastegate regulator. There are no active 168 diagnostic codes. The ECM has been powered for at least 2 seconds.
Page 369 J1939 Code Description Effect and Action Aftertreatment #1 DEF/AdBlue® Tank The level ﬂ uid in the Diesel Exhaust Fluid (DEF) tank is Volume : Low - least severe (1) less than 14%. 1761-17 The Emissions System Malfunction lamp comes on. The code is logged.
Page 370 J1939 Code Description Effect and Action Engine Alternate Rating Select : The Electronic Control Module (ECM) detects a Erratic, Intermittent, or Incorrect combination of switch positions for the mode switches that has not been deﬁ ned. If equipped, the warning lamp will come on and the ECM will log the diagnostic.
Page 371 J1939 Code Description Effect and Action Aftertreatment #1 Intake NOx : The data received from the NOx sensor is out of range. Failure The code is logged. 3216-12 The warning lamp is illuminated. Sensor (Data Link Type) - Test Aftertreatment #1 Intake O2 : High - The Engine Out NOx Sensor is reading a higher than 3217-16 moderate Severity (2)
Page 372 J1939 Code Description Effect and Action Particulate Trap Intake Gas The temperature at the intake of the DPF is below the Temperature : Low - least severe (1) trip point that is calculated by the ECM. The trip point varies depending on engine operating conditions. 3242-17 The code is logged.
Page 373 J1939 Code Description Effect and Action Aftertreatment #1 DEF/AdBlue® The ECM detects the following conditions: Dosing Unit : Current Below Normal A low current condition in the output from the DCU to the solenoid in the DEF. There are no active 168 diagnostic codes. 3361-5 The warning lamp will come on.
Page 374 J1939 Code Description Effect and Action Sensor Supply Voltage 1 : Voltage The ECM detects the following conditions: Below Normal The 5 VDC supply for the sensors is less than 4.84 VDC for more than one second. The ECM has been powered for at least 3 seconds. 3509-4 Diagnostic code 168-4 is not active.
Page 375 J1939 Code Description Effect and Action Aftertreatment #1 DEF/AdBlue® The Diesel Emissions Fluid (DEF) concentration cannot be Concentration : Failure determined. 3516-12 The engine warning lamp will come on. DEF/AdBlue® Concentration Is Incorrect Aftertreatment #1 DEF/AdBlue® The Diesel Emissions Fluid (DEF) has a high Concentration : High - moderate concentration.
Page 376 J1939 Code Description Effect and Action Aftertreatment #1 DEF/AdBlue® #1 There is excessive voltage on the signal wire between the Pressure (absolute) : Voltage Above Diesel Exhaust Fluid Controller (DCU) and the DEF pump. Normal 4334-3 There is an open circuit on the supply, signal, or return wire. The code is logged.
Page 377 J1939 Code Description Effect and Action Aftertreatment #1 SCR Catalyst The ECM detects the following conditions: Intake Gas Temperature : Voltage The signal voltage from the SCR inlet temperature sensor Below Normal is less than 0.2 VDC for more than 8 seconds. An active diagnostic code will be generated after 8 4360-4 seconds.
Page 378 J1939 Code Description Effect and Action Aftertreatment #1 Outlet NH3 Gas The ECM detects that the power supply to the ammonia 4380-2 Sensor Power In Range : Erratic, (NH3) sensor is not stable. Intermittent or Incorrect Electrical Power Supply - Test Aftertreatment #1 Diesel Oxidation The ECM detects the following conditions: Catalyst Intake Gas Temperature :...
Page 379 J1939 Code Description Effect and Action Diesel Particulate Filter #1 Mean 4783-19 Soot Sensor - Test Soot Signal : Data Error Diesel Particulate Filter #1 Mean The ECM detects the following conditions: Soot Signal : Data Drifted Low The soot sensor has not received a valid signal from the soot antenna for at least 60 seconds.
Page 380 J1939 Code Description Effect and Action High Pressure Common Rail Fuel 3509-XX or 262-XX codes are not active. Pressure Relief Valve : High - most 3510-XX or 2131-XX codes are not active. severe (3) The pressure limiting valve in the fuel rail is open. 5571-0 This code is a calculated parameter.
Page 381 J1939 Code Description Effect and Action Particulate Trap Active Regeneration 5629-31 Inhibited Due To Low Exhaust Gas Diesel Particulate Filter Collects Excessive Soot Pressure - least severe (1) Aftertreatment #1 Diesel Exhaust This code indicates low current to the DEF pump motor. 5706-5 Fluid Pump Heater : Current Below The code is logged.
Page 382 J1939 Code Description Effect and Action Aftertreatment Ambient Air The ECM detects the following conditions: Temperature : Voltage Below Normal The signal voltage from the aftertreatment ambient air temperature sensor is less than 0.2 VDC for more than 8 seconds. An active diagnostic code will be generated after 8 seconds.
Page 383 5. AAVM FAULT CODE Fault Code Description AAVM Communication Error -AAVM AAVM Communication Error -Front Camera AAVM Communication Error -Rear Camera AAVM Communication Error -Left Camera AAVM Communication Error -Right Camera Manual Setting Fail No MCU CID MCU CID Format Error AAVM Hardware Error -AAVM AAVM Hardware Error -Front Camera AAVM Hardware Error -Rear Camera...
Page 384: Group 14 Engine Control System
GROUP 14 ENGINE CONTROL SYSTEM (SERIAL NO. : -#0610) 1. MCU and ENGINE ECM ECM (Engine control module) Bolt (M8) 140L5MS52 2. MCU ASSEMBLY To match the pump absorption torque with the engine torque, MCU varies EPPR valve output pressure, which control pump discharge amount whenever feedbacked engine speed drops under the reference rpm of each mode set.
Page 385 (SERIAL NO. : #0611-) 1. UNITED MCU and ENGINE ECM ECM (Engine control module) United MCU Bolt (M8) 140L5MS152 2. UNITED MCU ASSEMBLY To match the pump absorption torque with the engine torque, united MCU varies EPPR valve output pressure, which control pump discharge amount whenever feedbacked engine speed drops under the reference rpm of each mode set.
Page 386: Group 15 Eppr Valve
GROUP 15 EPPR VALVE 1. PUMP EPPR VALVE COMPOSITION EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main pump. Electro magnet valve Receive electric current from MCU and move the spool proportionally according to the specific amount of electric current value.
Page 387 OPERATING PRINCIPLE (pump EPPR valve) Structure 5-22(1) Sleeve O-ring Solenoid valve Spring O-ring Connector Spool Pilot oil supply line (pilot pressure) Return to tank Secondary pressure to flow regulator at main pump Neutral Pressure line is blocked and A oil returns to tank.
Page 388 EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA Check electric current value at EPPR valve Adapter(P/no.:21Q6-50410) Disconnect connector CN-75 from EPPR EPPR valve valve. Multimeter CN-75 Insert the adapter to CN-75 and install multimeter as figure. Valve casing Start engine. Set S-mode and cancel auto decel mode.
Page 389 2. BOOM PRIORITY EPPR VALVE COMPOSITION The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil. This EPPR valve installed under the solenoid valve. CONTROL The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is supplying the coil with a current 580 mA at 30 and 24 V.
Page 390 EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA (combined boom up and swing operation) Check electric current value at EPPR valve Disconnect connector CN-133 from Solenoid valve EPPR valve. Insert the adapter to CN-133 and install Boom priority multimeter as figure. EPPR valve Start engine.
Page 391: Group 16 Monitoring System
GROUP 16 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 392 Start key : ON Check monitor Buzzer sounding for 4 seconds with HYUNDAI logo on cluster. If the ESL mode is set to the enable, enter the password to start engine. After initialization of cluster, the operating screen is displayed on the LCD.
Page 393 3. CLUSTER CONNECTOR (SERIAL NO. : -#0610) CN-56A Name Signal Battery 24V 20~32V Power IG (24V) 20~32V CN-56B CN-56A CAN 1 (H) 0~5V CAN 1 (L) 0~5V CAN 2 (H) 20~32V CAN 2 (L) 20~32V RS-232 (RX) ±15V Cluster RS-232 (TX) ±15V Aux left 0~5V...
Page 394 CLUSTER CONNECTOR (SERIAL NO. : #0611-) CN-56A Name Signal Battery 24V 20~32V Power IG (24V) 20~32V CN-56B CN-56A CAN 1 (H) 0~5V CAN 1 (L) 0~5V CAN 2 (H) 0~5V CAN 2 (L) 20~32V Cluster Aux left 0~5V Aux right 0~5V Aux GND CN-56A...
Page 395 GAUGE Operation screen When you first turn starting switch ON, the operation screen will appear. Default Option 290F3CD51 RPM / Speed gauge DEF/AdBlue® level gauge Engine coolant temperature gauge Tripmeter display Hydraulic oil temperature gauge Eco guage Fuel level gauge Accel dial gauge Operation screen type can be set by the screen type menu of the display.
Page 396 Hydraulic oil temperature gauge This gauge indicates the temperature of hydraulic oil. White range : 40-105˚C(104-221˚F) Red range : Above 105˚C(221˚F) If the indicator is in the red range or lamp pops up and the buzzer sounds reduce the load on the system. If the gauge stays in the red range, stop the machine and check the cause of the problem.
Page 397 Eco gauge This gauge indicates the fuel consumption rate and machine load status. So that operators can be careful with fuel econo- The fuel consumption rate or machine load is higher, the number of segment is increased. The color of Eco gauge indicates operation status. White : Idle operation 290F3CD58 Green : Economy operation...
Page 398 WARNING LAMPS Check engine warning lamp Battery charging warning lamp Engine oil pressure warning lamp Air cleaner warning lamp Emergency warning lamp Overload warning lamp Engine stop warning lamp Water in fuel warning lamp Engine coolant Fuel level warning lamp temperature warning lamp DEF/AdBlue level warning lamp...
Page 399 Engine coolant temperature warning lamp Engine coolant temperature warning is indicated two steps. 103˚C over : The lamp pops up and the buzzer sounds. 107˚C over : The lamp pops up and the buzzer sounds. The pop-up lamps move to the original position and blinks when the buzzer stop switch is pushed.
Page 400 Engine oil pressure warning lamp This warning lamp pops up and the buzzer sounds when the engine oil pressure is low. If the lamp blinks, shut OFF the engine immediately. Check oil level. 290F3CD65 Check engine warning lamp This warning lamp pops up and the buzzer sounds when the communication between MCU and engine ECM on the engine is abnormal, or if the cluster received specific fault code from engine ECM.
Page 401 Battery charging warning lamp This warning lamp pops up and the buzzer sounds when the battery charging voltage is low. Check the battery charging circuit when this lamp blinks. 290F3CD67 Air cleaner warning lamp This warning lamp pops up and the buzzer sounds when the filter of air cleaner is clogged.
Page 402 (10) Engine stop warning lamp This warning lamp pops up and the buzzer sounds when 30 minutes elapsed with empty condition of the DEF/AdBlue® tank, stop the engine immediately and check the DEF/ AdBlue® tank. Fill the DEF/AdBlue® immediately in the DEF/AdBlue® tank. 290F3CD252 Refer to page 5-70.
Page 403 (12) DEF/AdBlue® level warning lamp This warning lamp indicates when ON or blinking, that the DEF/AdBlue® level is low as table below. It is recommended that the DEF/AdBlue® tank be filled completely full of the DEF/AdBlue® in order to correct any fault conditions.
Page 404 PILOT LAMPS Warming up pilot lamp Decel pilot lamp Preheat pilot lamp Power max pilot lamp Fuel warmer pilot lamp Maintenance pilot lamp Power/User mode pilot mode lamp Auto idle pilot lamp Work tool mode pilot lamp Travel speed pilot lamp Smart key pilot lamp Entertainment pilot lamp Entertainment pilot lamp...
Page 405 Preheat pilot lamp Turning the start key switch ON position starts preheating in cold weather. Start the engine after this lamp is OFF. 290F3CD79 Warming up pilot lamp This lamp is turned ON when the coolant temperature is below 30˚C (86˚F ). The automatic warming up is cancelled when the engine cool- ant temperature is above 30˚C, or when 10 minutes have passed since starting the engine.
Page 406 Entertainment pilot lamp This lamp is on when audio or video files are playing. Refer to the page 5-88. 290F3CD84 Smart key pilot lamp (opt) This lamp is ON when the engine is started by the start button. This lamp is red when the a authentication fails, green when succeeds.
Page 407 SWITCHES Aircon quick Entertainment touch switch quick touch switch Main menu quick touch switch Work mode Travel speed pilot lamp pilot lamp Auto idle pilot lamp Power/User mode pilot lamp User mode switch Travel speed switch Auto idle/Buzzer stop switch Power mode switch Work mode switch Escape(previous or parent menu)
Page 408 User mode switch This switch is used to memorize the current machine operating status in the MCU and activate the memorized user mode. Memory : Push more than 2 seconds. Action : Push within 2 seconds. Cancel : Push this switch once more within 2 seconds. Refer to the page 5-79 for another set of user mode.
Page 409 Head light switch This switch is used to operate the head light. The pilot lamp is turned ON when operating the switch. 290F3CD94 Intermittent wiper switch This switch is used to wipe operates intermittently. The pilot lamp is turned ON when operating the switch. 290F3CD95 (10) Wiper switch...
Page 410 (13) Beacon switch This switch turns ON the rotary light on the cab. The pilot lamp is turned ON when operating the switch. 290F3CD97 (14) Overload switch When this switch turned ON, buzzer makes sound and over- load warning lamp comes ON in case that the machine is overload.
Page 411 MAIN MENU You can select or set the menu by the haptic controller or touch screen. On the operation screen, tap MENU to access the main menu screen. On the sub menu screen, you can tap the menu bar to access functions or applications. Operation screen Main menu screen Sub menu screen...
Page 412 Mode setup Work tool 210WF3CD108 290F3CD253 290F3CD254 Select on installed optional attachment A : It can set the user's attachment. It is available in setting #1~#10. B : Max ﬂ ow - Set the maximum ﬂ ow for the attachment. Relief pressure - Set the relief pressure.
Page 413 Auto power boost 210WF3CD118 290F3CD117 The power boost function can be activated or cancelled. Enable - The digging power is automatically increased as working conditions by the MCU. It is operated max 8 seconds. Disable - Not operated. 290F3CD310 290F3CD311 290F3CD304 290F3CD312 290F3CD305...
Page 414 Automatic engine shutdown (option) 210WF3CD11 210WF3CD12 210WF3CD13 The automatic engine shutdown function can be set by this menu. One time Always Disable Wait time setting : Max 40 minutes, min 2 minutes Initial mode 290F3CD122 290F3CD119 Key on initial mode Selected the power mode is activated when the engine is started.
Page 415 Monitoring Active fault 290F3CD120 290F3CD121 290F3CD125 The active faults of the MCU, engine ECM or air conditioner can be checked by this menu. Logged fault 290F3CD128 290F3CD123 290F3CD124 The logged faults of the MCU, engine ECM or air conditioner can be checked by this menu. Delete logged fault 290F3CD134 290F3CD126...
Page 416 Management Fuel rate information 210WF3CD14 210WF3CD15 General record (A) Average fuel rate (left) (from "Reset" to now) Fuel consumption devided by engine run time (service meter time). A days fuel used (right) Fuel consumption from 24:00 (or "Reset" time) to now (MCU real time).
Page 417 Maintenance information 210WF3CD131 290F3CD132 290F3CD133 Alarm lamp ( ) is ON when oil or ﬁ lter needs to be changed or replaced. Replacement : The elapsed time will be reset to zero (0). Change interval : The change or replace interval can be changed in the unit of 50 hours. Change or relpace interval Item Interval...
Page 418 Machine security 210WF3CD190 290F3CD135 290F3CD136 ESL mode setting ESL : Engine Starting Limit ESL mode is desingned to be a theft deterrent or will pre- vent the unauthorized operation of the machine. If the ESL mode was selected Enable, the password will be required when the start switch is turned ON.
Page 419 Machine Information 290F3CD144 290F3CD145 This can confirm the identification of the model information (ECU), MCU, monitor, haptic controller, switch controller, RMCU, relay driver unit, FATC (air conditioner controller), AAVM (opt). Contact (A/S phone number) 290F3CD146 290F3CD147 290F3CD148 Enter the new A/S phone number Service menu 290F3CD149 290F3CD250...
Page 420 Update (cluster & ETC devices) 210WF3CD17 210WF3CD18 210WF3CD19 380F3CD06 380F3CD04 ETC devices and cluster can be updated through CAN 2 network. Insert USB memory stick which includes program ﬁ les, start download. 5-85...
Page 421 Display Display item 290F3CD154 290F3CD155 290F3CD156 The center display type of the LCD can be selected by this menu. The engine speed or each of the tripmeter (A,B,C) is displayed on the center display. Clock 290F3CD157 290F3CD158 The ﬁ rst line's three spots " "...
Page 422 Unit 290F3CD161 210WF3CD162 290F3CD193 Temperature : ˚C ˚F Pressure : bar kgf/cm Volume Flow : lpm Distance : km mile Date format : yy/mm/dd mm/dd/yy dd-mm-yy Language 290F3CD163 290F3CD164 User can select preferable language and all displays are changed the selected language. Screen type 290F3CD165 290F3CD166...
Page 423 Utilities Entertainment 290F3CD195 290F3CD196 210WF3CD219 290F3CD197 210WF3CD220 290F3CD198 210WF3CD199 210WF3CD22 Video (A) : This menu operates the video play function. mp4, mkv, avi ﬁ les and so on. Audio (B) : This menu operates the play music. mp3, mp4 ﬁ les and so on. Smart terminal (C) : The menu features a smartphone and operates the miracast.
Page 424 Tripmeter 290F3CD168 290F3CD169 Maximum 3 kinds of tripmeters can be used at the same time. Each tripmeter can be turned on by choosing "Start" while it also can be turned off by choosing "Stop". If the tripmeter icon is activated in the operation screen, it can be controlled directly there. Camera setting If the rear camera is not installed on the machine, set disable.
Page 425 AAVM (All Around View Monitoring, option) The AAVM buttons of the cluster consist of ESC/CAM and AUTO IDLE/Buzzer stop. Buzzer stop switch Escape switch 290F3CD244 Escape button It will enter into the AAVM mode from the beginning screen if the AAVM is installed. While in the AAVM mode, select the ESC button to return to the beginning screen.
Page 426 AIR CONDITIONER AND HEATER Full auto air conditioner and heater system automatically keeps the optimum condition in accor- dance with operator's temperature conﬁ guration sensing ambient and cabin inside temperature. Location of air flow ducts Cluster : Haptic controller : Setting temperature Power switch Temperature switch...
Page 427 Power switch This switch makes the system ON/OFF. Just before the power OFF, set values are stored. Default setting values Function Air conditioner In/outlet LCD Temperature Mode Previous sw Previous sw 290F3CD251 Value Inlet Air conditioner switch This switch turns the compressor ON/OFF. Air conditioner operates to remove vapor and drains water through a drain hose.
Page 428 Fan speed switch Fan speed is controlled automatically by setted temperature. This switch controls fan speed manually. · There are 8 up/down steps to control fan speed. · The maximum step or the minimum step beeps 5 times. 290F3CD226 Fan speed Steps 1 through 8 to display the amount of wind.
Page 429 SELF DIAGNOSIS FUNCTION Diagnostic methods : Diagnostic information window, select Diagnostic indication (Displays fault) Fault code Description Fail safe function Ambient temperature sensor open 20˚C alternate value control Ambient temperature sensor short Cab inside temperature sensor open 25˚C alternate value control Cab inside temperature sensor short Evaporate temperature sensor open 0˚C alternate value control...
Page 430: Group 17 Fuel Warmer System
GROUP 17 FUEL WARMER SYSTEM (SERIAL NO. : -#0610) 1. SPECIFICATION Operating voltage : 24 4 V Power : 350 50 W Current : 15 A Filter head & 2. OPERATION fuel warmer T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s automatically controlled without thermostat according to fuel temperature.
Page 431 (SERIAL NO. : #0611-) 1. SPECIFICATION Operating voltage : 24 4 V Power : 350 50 W Current : 15 A Filter head & 2. OPERATION fuel warmer T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s automatically controlled without thermostat according to fuel temperature.
Page 432: Section 6 Troubleshooting
SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1 Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4 Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24 Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-40...
Page 433: Group 1 Before Trobleshooting
SECTION 6 TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help an operator to maintain the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics system.
Page 434 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 435 STEP 4. Inspect the trouble actually on the machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not. (210-7) 6-3(1) STEP 5.
Page 436: Group 2 Hydraulic And Mechanical System
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION MACHINE IN GENERAL If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration. Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look for the cause based on the troubleshooting principle and perform maintenance and adjustment to prevent major failure from occurring.
Page 437 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and Replace hub or check if rubber pieces or particles retighten are not present. setscrew. Coupling hub spline is worn or hub fastening...
Page 438 ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard Is oil level in level. Abnormal noise hydraulic oil comes out of Hydraulic pump is Disassemble tank within hydraulic pump broken. and repair. standard level? Do not hydraulic Abnormal noise...
Page 439 3. HYDRAULIC SYSTEM HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and Drop hydraulic oil dispose it or sample on hot plate and check if replace hydraulic foams come up. oil. Air is intruded. Check suction line and return line and eliminate...
Page 440 CAVITATION OCCURS WITH PUMP Cause Remedy Replenish specified oil to the standard level. Is hydraulic oil volume proper? Replace oil with one of proper Is not viscosity viscosity. of hydraulic oil too high? Clean suction strainer. Is not suction strainer clogged? Is not air intruding Check for air from pump...
Page 441 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish Does safety specified oil to the solenoid valve standard level. operation Safety solenoid Repair or replace. Is gear pump pilot normal? pressure within valve faulty or not standard level? Is oil in hydraulic operated.
Page 442 SWING SPEED IS LOW Cause Remedy Swing port relief Disassemble and valve is faulty. repair or replace. Does swing spool move? Swing control valve Disassemble Is MCV pilot spool is stuck. and repair. pressure same on LH and RH Clogged or oil Clean pilot piping sides? leak.
Page 443 SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble change when LH valve is faulty. and repair. and RH port relief valves are exchanged? Shuttle valve is Disassemble Does swing control faulty. and repair. valve spool move? Swing control valve Disassemble...
Page 444 THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy Is swing shuttle valve normal? Shuttle valve is Disassemble faulty. and replace. Is brake spring normal? Is return spring of swing spool Brake spring is Disassemble normal? faulty.
Page 445 5. TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause Remedy Does counterbalance spool move lightly by hand? Counter spool is Disassemble Is travel brake valve pressure stuck. and repair or within standard replace. Does the symptom level? change when relief valves in...
Page 446 SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble Do LH and RH defective. and repair or travel speeds replace. change when LH and RH travel Relief valve built Disassemble Does the symptom brake valves are change when in travel motor is and repair.
Page 447 MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None Friction plate is Disassemble friction plate worn? Check if parking faulty. and repair. brake pilot line is clogged.
Page 448 TRAVEL ACTION IS POWERLESS (travel only) Cause Remedy Is travel motor's drain rate within standard level? Is travel brake Travel motor is Disassemble pressure within faulty. and repair. standard level? Is travel relief valve pressure Travel brake valve Disassemble within standard is defective.
Page 449 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 straight spool normal? Straight spool is Repair or Is pilot pressure faulty. replace. for travel straight spool within standard level? Remove dirt on...
Page 450 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace. valve is replaced with other valve? Is MCV pilot pressure within standard level? Inspect if pilot See Note 3, 4...
Page 451 BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. Are other attachment speeds within Is combination Is speed low only standard levels? of oil streams in composite normal at boom operation? Replace spring up and at arm Does spool of flow extrusion? summation check valve move lightly...
Page 452 BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the symptom faulty. and repair or change when port Normal replace. relief valve is replaced with Is control valve normal value? return spring Is not hydraulic normal?
Page 453 BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder in Item "Speed is internal leakage within standard low". level? Is relief pressure in port relief Cylinder is faulty. Disassemble valve within and repair. standard level? Is relief pressure in main relief...
Page 454 BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom Is boom foot pin greased proper. sufficiently? Frictional noise will disappear if they are kept used.
Page 455 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. 300L6TS01 Disconnect hose (A) from rod side of boom cylinder and drain oil from cylinders and hose.
Page 456: Group 3 Electrical System
GROUP 3 ELECTRICAL SYSTEM (SERIAL NO. : -#0610) 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 457 (SERIAL NO. : -#0610) COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective cluster...
Page 458 (SERIAL NO. : -#0610) BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU...
Page 459 (SERIAL NO. : -#0610) WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
Page 460 (SERIAL NO. : -#0610) WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Clogged air filter or...
Page 461 (SERIAL NO. : -#0610) WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective circuit,...
Page 462 (SERIAL NO. : -#0610) WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy High temperature...
Page 463 (SERIAL NO. : -#0610) 8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
Page 464 (SERIAL NO. : -#0610) 9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 465 (SERIAL NO. : -#0610) 10. WHEN SAFETY SOLENOID DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 25. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 466 (SERIAL NO. : -#0610) 11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 467 (SERIAL NO. : -#0610) 12. WHEN ENGINE DOES NOT START ( lights up condition) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 3, 6, 10, 12, 21, 22. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 468 (SERIAL NO. : -#0610) 13. WHEN STARTING SWITCH ON DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted, master switch ON and check open circuit of circuit breaker (CN-60, CN-95). After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 469 (SERIAL NO. : -#0610) 14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.
Page 470 (SERIAL NO. : -#0610) 15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.20.
Page 471 (SERIAL NO. : -#0610) 16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.17.
Page 472 ELECTRICAL SYSTEM (SERIAL NO. : #0611-) 1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER DISPLAY DOES NOT APPEAR Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 473 (SERIAL NO. : #0611-) COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective cluster...
Page 474 (SERIAL NO. : #0611-) BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU...
Page 475 (SERIAL NO. : #0611-) WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
Page 476 (SERIAL NO. : #0611-) WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Clogged air filter or...
Page 477 (SERIAL NO. : #0611-) WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective circuit,...
Page 478 (SERIAL NO. : #0611-) WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy High temperature...
Page 479 (SERIAL NO. : #0611-) 8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
Page 480 (SERIAL NO. : #0611-) 9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 481 (SERIAL NO. : #0611-) 10. WHEN SAFETY SOLENOID DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 26. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 482 (SERIAL NO. : #0611-) 11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 483 (SERIAL NO. : #0611-) 12. WHEN ENGINE DOES NOT START ( lights up condition) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 1, 6, 12, 13, 23. After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 484 (SERIAL NO. : #0611-) 13. WHEN STARTING SWITCH ON DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted, master switch ON and check open circuit of circuit breaker (CN-60, CN-95). After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 485 (SERIAL NO. : #0611-) 14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.
Page 486 (SERIAL NO. : #0611-) 15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.14 &...
Page 487 (SERIAL NO. : #0611-) 16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.14 &...
Page 488: Group 4 Mechatronics System
GROUP 4 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW (SERIAL NO. : -#0610) Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. Spec : P-mode 1850 50 rpm S -mode 1750 50 rpm E-mode 1650 50 rpm Before carrying out below procedure, check all the related connectors are properly inserted and fault code on the cluster.
Page 489 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : 15~25 (20˚C) Test 1 : Check resistance at connector CN-75 EPPR valve CN-75. Starting switch OFF. Disconnect connector CN-75 from EPPR Multimeter valve at main hydraulic pump. Valve casing Check resistance between 2 lines as figure.
Page 490 2. ENGINE STALL (SERIAL NO. : -#0610) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Not enough Check engine engine power fault Check pressure Contact cummins at EPPR valve SPEC:2~25 kgf/cm Defective EPPR Replace See TEST 5...
Page 491 (SERIAL NO. : -#0610) TEST PROCEDURE Spec : 100~700 mA Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410) valve. EPPR valve Disconnect connector CN-75 from EPPR Multimeter CN-75 valve. Insert the adapter to CN-75 and install multimeter as figure. Valve casing Start engine.
Page 492 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM (SERIAL NO. : -#0610) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse No.5 the MCU See if all lamps off in the MCU case MCU failure...
Page 493 4. AUTO DECEL SYSTEM DOES NOT WORK (SERIAL NO. : -#0610) Fault code : HCESPN 105, FMI 0~4 (work pressure sensor) HCESPN 108, FMI 0~4 (travel oil pressure sensor) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy...
Page 494 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 7 : Check voltage at CN-52 (38) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of CN-51 CN-52 connectors : One pin to (38) of CN-52.
Page 495 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 120, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
Page 496 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 9 : Check voltage at CN-52 (29) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (29) of CN-52.
Page 497 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 121, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
Page 498 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 10 : Check voltage at CN-52 (12) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (12) of CN-52.
Page 499 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR (SERIAL NO. : -#0610) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52- between (32)-CN-1(7)
Page 500 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 11 : Check voltage at CN-52 (32) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (32) of CN-52.
Page 501 8. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 123, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
Page 502 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 12 : Check voltage at CN-52 (33) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (33) of CN-52.
Page 503 9. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 124, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
Page 504 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 13 : Check voltage at CN-52 (17) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (17) of CN-52.
Page 505 10. MALFUNCTION OF SWING PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 135, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective swing Replace or repair (36) - GND...
Page 506 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 14 : Check voltage at CN-52 (36) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (36) of CN-52.
Page 507 11. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 133, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52...
Page 508 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 15 : Check voltage at CN-52 (14) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (14) of CN-52.
Page 509 12. MALFUNCTION OF BOOM UP PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 127, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective boom up Replace or repair...
Page 510 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 16 : Check voltage at CN-52 (19) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (19) of CN-52.
Page 511 13. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR (SERIAL NO. : -#0610) Fault code : HCESPN 128, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-53 Detective boom up Replace or repair...
Page 512 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 17 : Check voltage at CN-53 (23) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (23) of CN-53.
Page 513 14. MALFUNCTION OF POWER MAX (SERIAL NO. : -#0610) Fault code : HCESPN 166, FMI 4 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between Check resistance CN-88(1)-CN-52 (2)
Page 514 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Starting switch ON : 24 1V Starting switch OFF : 0V Test 18: Check voltage between connector CN-88 (2) - GND. Disconnect connector CN-88 from power max solenoid valve. Power max switch Start switch ON.
Page 515 15. MALFUNCTION OF BOOM PRIORITY EPPR VALVE (SERIAL NO. : -#0610) Fault code : HCESPN 141, FMI 5 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between CN-52(35)-CN-133...
Page 516 16. MALFUNCTION OF ARM REGENERATION SOLENOID (SERIAL NO. : -#0610) Fault code : HCESPN 170, FMI 4 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Short circuit or Replace or repair...
Page 517 (SERIAL NO. : -#0610) TEST PROCEDURE SPEC : Starting switch ON : 24 2 V Test 20 : Check voltage at CN-52 (1) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (1) of CN-52.
Page 518 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW (SERIAL NO. : #0611-) Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. Spec : P-mode 1850 50 rpm S -mode 1750 50 rpm E-mode 1650 50 rpm Before carrying out below procedure, check all the related connectors are properly inserted and fault code on the cluster.
Page 519 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : 15~25 (20˚C) Test 1 : Check resistance at connector CN-75 EPPR valve CN-75. Starting switch OFF. Disconnect connector CN-75 from EPPR Multimeter valve at main hydraulic pump. Valve casing Check resistance between 2 lines as figure.
Page 520 2. ENGINE STALL (SERIAL NO. : #0611-) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Not enough Check engine engine power fault Check pressure Contact Perkins at EPPR valve SPEC:2~25 kgf/cm Defective EPPR Replace See TEST 5...
Page 521 (SERIAL NO. : #0611-) TEST PROCEDURE Spec : 100~700 mA Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410) valve. EPPR valve Disconnect connector CN-75 from EPPR Multimeter CN-75 valve. Insert the adapter to CN-75 and install multimeter as figure. Valve casing Start engine.
Page 522 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM (SERIAL NO. : #0611-) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse No.2 the united MCU See if all lamps off in the united MCU case United MCU failure...
Page 523 4. AUTO DECEL SYSTEM DOES NOT WORK (SERIAL NO. : #0611-) Fault code : HCESPN 105, FMI 0~4 (work pressure sensor) HCESPN 108, FMI 0~4 (travel oil pressure sensor) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy...
Page 524 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 7 : Check voltage at CN-52 (27) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of CN-51 CN-52 CN-53 CN-54...
Page 525 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 120, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Short circuit or Replace or repair poor connection Check voltage...
Page 526 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 9 : Check voltage at CN-52 (22) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (22) of CN-52.
Page 527 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 121, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Short circuit or Replace or repair poor connection Check voltage...
Page 528 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 10 : Check voltage at CN-51 (14) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (14) of CN-51.
Page 529 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR (SERIAL NO. : #0611-) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Short circuit or Replace or repair poor connection Check voltage between CN-51- between (13)-CN-1 (7)
Page 530 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 11 : Check voltage at CN-51 (13) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (13) of CN-51.
Page 531 8. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 123, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Short circuit or Replace or repair poor connection Check voltage...
Page 532 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 12 : Check voltage at CN-51 (22) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Inser t prepared pin to rear side of connectors : One pin to (22) of CN-51.
Page 533 9. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 124, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Short circuit or Replace or repair poor connection Check voltage...
Page 534 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 13 : Check voltage at CN-51 (28) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (28) of CN-51.
Page 535 10. MALFUNCTION OF SWING PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 135, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Replace or repair Check voltage between CN-52 Detective swing...
Page 536 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 14 : Check voltage at CN-52 (18) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (18) of CN-52.
Page 537 11. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 133, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Check voltage between CN-52...
Page 538 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 15 : Check voltage at CN-52 (24) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (24) of CN-52.
Page 539 12. MALFUNCTION OF BOOM UP PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 127, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Check voltage between CN-52 Detective boom up Replace or repair...
Page 540 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 16 : Check voltage at CN-52 (23) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (23) of CN-52.
Page 541 13. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR (SERIAL NO. : #0611-) Fault code : HCESPN 128, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective united Replace Check voltage between CN-52 Replace or repair Detective boom up...
Page 542 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 17 : Check voltage at CN-52 (31) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (31) of CN-52.
Page 543 14. MALFUNCTION OF POWER MAX (SERIAL NO. : #0611-) Fault code : HCESPN 166, FMI 4 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between Check resistance CN-88 (1)-CN-53...
Page 544 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Starting switch ON : 24 1V Starting switch OFF : 0V Test 18: Check voltage between connector CN-88 (2) - GND. Disconnect connector CN-88 from power max solenoid valve. Start switch ON. Power max switch Check voltage as figure.
Page 545 15. MALFUNCTION OF BOOM PRIORITY EPPR VALVE (SERIAL NO. : #0611-) Fault code : HCESPN 141, FMI 5 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between CN-54 (04)-CN-133...
Page 546 16. MALFUNCTION OF ARM REGENERATION SOLENOID (SERIAL NO. : #0611-) Fault code : HCESPN 170, FMI 4 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective Replace united MCU Check voltage between CN-52 Short circuit or...
Page 547 (SERIAL NO. : #0611-) TEST PROCEDURE SPEC : Starting switch ON : 24 2 V Test 20 : Check voltage at CN-52 (07) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (07) of CN-52.
Page 548: Section 7 Maintenance Standard
SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1 Group 2 Major Components -------------------------------------------------------------------------------------------- 7-21 Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-30...
Page 549: Group 1 Operational Performance Test
Whenever a new machine is delivered in parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec. OPERATIONAL PERFORMANCE OF A WORKING MACHINE With the passage of time, the machine's...
Page 550 2. TERMINOLOGY STANDARD Specifications applied to the brand-new machine, components and parts. 140LC7MS02 SERVICE LIMIT The lowest acceptable performance level. When the perfor mance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
Page 551 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 552 ENGINE SPEED Measure the engine speed at each power mode CLUSTER 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 553 TRAVEL SPEED Measure the time required for the excavator to travel a 20 m 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 5 m on 0.3~0.5m both ends for machine acceleration and deceleration.
Page 554 TRACK REVOLUTION SPEED Measure the track revolution cycle time with the track raised off ground. Preparation Adjust the tension of both side tracks to 90 ~ 110 be equal. On the track to be measured, mark one shoe with chalk. Swing the upperstructure 90 and lower Mark the bucket to raise the track off ground.
Page 555 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 20 m in length, with extra length of 3 to 5 m on 0.3~0.5m both ends for machine acceleration and deceleration.
Page 556 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 557 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 558 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 559 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. Preparation To measure the cycle time of the boom Boom cylinder Raise cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown.
Page 560 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 561 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 562 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. Power mode switch: P mode Operate each boom, arm, bucket and swing lever at full stroke and measure the...
Page 563 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 564 PILOT PRIMARY PRESSURE Main pump Preparation Keep the hydraulic oil temperature at 50 5˚C. Pressure sensor Measurement Select the following switch positions. Power mode switch : P mode Monitoring Auto decel switch : OFF (analog) Measure the primary pilot pressure by the monitoring menu of the cluster.
Page 565 FOR TRAVEL SPEED SELECTING PRESSURE: Preparation Stop the engine. Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. To measure the speed selecting pressure: Install a connector and pressure gauge assembly to turning joint P port as shown. Star t the engine and check for on leakage from the adapter.
Page 566 SWING PARKING BRAKE RELEASING PILOT PRESSURE Preparation Stop the engine. Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. The pressure release L wrench to bleed air. Install a connector and pressure gauge assembly to swing motor SH port, as shown.
Page 567 MAIN PUMP DELIVERY PRESSURE Main pump Preparation Keep the hydraulic oil temperature at 50 5˚C. Pressure sensor Measurement Select the following switch positions. Power mode switch : P mode Monitoring Measure the main pump deliver y (analog) pressure in the P mode (high idle). Cluster 140L7MS03 Evaluation...
Page 568 SYSTEM PRESSURE REGULATOR RELIEF SETTING Preparation Keep the hydraulic oil temperature at 50 5˚C. Main pump Measurement Select the following switch positions. Pressure sensor Power mode switch : P mode Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and measure the Monitoring pressure.
Page 569: Group 2 Major Components
GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 14097MP01 Recommended Standard Part name & inspection item replacement Counter measures dimension value Clearance between piston (1) & Replace piston or 0.028 0.056 cylinder bore (2) cylinder. (D-d) Play between piston (1) & shoe caulking 0-0.1 section (3) Replace...
Page 570 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.
Page 571 3. SWING DEVICE WEARING PARTS Standard Standard Inspection item Counter measures dimension dimension Replace piston or Clearance between piston and cylinder block bore 0.028 0.058 cylinder block Replace assembly Play between piston and shoe caulking section ( ) of piston and shoe Replace assembly Thickness of shoe (t) of piston and shoe...
Page 572 4. TRAVEL MOTOR TYPE 1 Problem Cause Remedy · · Does not Pressure is not Pump failure Check if action other than traveling is start developed available. If faulty, repair. · · Control valve malfunction Check if spool moves correctly. Repair if necessary.
Page 573 TYPE 2 Recommended Standard Inspection item replacement Counter measures dimension value Replace piston or Clearance between piston and cylinder block bore 0.025 0.050 cylinder block Replace assembly Play between piston and shoe caulking section (T) of piston and shoe Replace assembly Thickness of shoe (t) of piston and shoe Replace set of set...
Page 574 5. RCV LEVER Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage becomes Conditions : more than 1000 cc/m at neutral handle position, or more Primary pressure : 40 kgf/cm than 2000 cc/m during operation. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has worn...
Page 575 6. RCV PEDAL Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage effect Conditions : to the system. For example, the primary pressure Primary pressure : 40 kgf/cm drop. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has The leakage at the left condition is...
Page 576 7. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination. Replace sealing sections. Sliding surface Worn abnormality or damaged more than 0.1 mm Replace between body and (0.0039 in) in depth due to seizure contamination. stem other than Body, Damaged more than 0.1 mm (0.0039 in) in depth.
Page 577 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 base...
Page 578: Group 3 Track And Work Equipment
GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK TRACK ROLLER 21037MS01 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread 36.5 42.5 Width of flange 26.5 tolerance Standard...
Page 579 CARRIER ROLLER 21037MS02 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread 37.25 42.25 Width of flange 18.25 Standard size & Tolerance Standard Clearance clearance limit Clearance between shaft...
Page 580 IDLER 21037MS03 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Outside diameter of tread Rebuild or replace Width of protrusion Total width Width of tread Standard size & Tolerance Standard Clearance clearance limit Clearance between shaft Replace Shaft...
Page 581 TRACK 21037MS04 Unit : mm Check item Criteria Remedy Standard size Repair limit Turn or Link pitch replace 171.45 175.65 Outside diameter of bushing 53.75 43.95 Rebuild or Height of grouser replace Height of link 94.5 86.5 Tightening torque Initial tightening torque : 42 4 kgf m Retighten (Tightening angle method) Additional tightening angle : 32˚...
Page 582 TRACK FRAME AND RECOIL SPRING 21037MS05 Unit : mm Check item Criteria Remedy Standard size Tolerance Repair limit Track frame Vertical width of idler guide Rebuild or Idler support - 0.5 replace Track frame Horizontal width of idler guide Idler support Standard size Repair limit Free...
Page 583 2. WORK EQUIPMENT 14097MS01 Unit : mm Bushing Remedy Measuring point Normal Recomm. Recomm. Mark & Limit Limit (Pin and Bushing) service value service Remark of use of use limit limit Boom Rear 68.5 70.5 Replace Boom Cylinder Head 68.5 70.5 Boom Cylinder Rod 68.5...
Page 584: Section 8 Disassembly And Assembly
SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 8-1 Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 8-4 Group 3 Pump Device ------------------------------------------------------------------------------------------------------ 8-7 Group 4 Main Control Valve --------------------------------------------------------------------------------------------- 8-29 Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 8-43 Group 6 Travel Device ------------------------------------------------------------------------------------------------------ 8-59 Group 7 RCV Lever ---------------------------------------------------------------------------------------------------------- 8-123 Group 8 Turning Joint ------------------------------------------------------------------------------------------------------- 8-137 Group 9 Boom, Arm and Bucket Cylinder ---------------------------------------------------------------------- 8-142...
Page 585 SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
Page 586 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 587 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 588: Group 2 Tightening Torque
GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf m lbf ft Engine mounting bolt (engine-bracket, FR) 1.75 11.2 Engine mounting bolt (engine-bracket, RR) 1.75 57.1 14.5 Engine mounting bolt (bracket-frame, FR) 34.0 28.9 Engine Engine mounting bolt (bracket-frame, RR) 34.0 28.9 Radiator mounting bolt...
Page 589 2. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8 8.7 ~ 13.0 1.5 ~ 2.1 10.9 ~ 15.1 M 8 ×...
Page 590 PIPE AND HOSE (FLARE TYPE) kgf m lbf ft Thread size (PF) Width across flat (mm) 28.9 1/4" 36.2 3/8" 68.7 1/2" 130.2 3/4" 151.9 1" 253.2 1-1/4" PIPE AND HOSE (ORFS TYPE) Thread size (UNF) Width across flat (mm) kgf m lbf ft 9/16-18...
Page 591: Group 3 Pump Device
GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 592 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 593 2. MAIN PUMP (1/2) STRUCTURE 116 885 314 141 981 271 401 153 156 157 467 14092MP02 04 Gear pump 312 Valve block 717 O-ring 111 Drive shaft (F) 313 Valve plate (R) 719 O-ring 113 Drive shaft (R) 314 Valve plate (L) 724 O-ring 116 1st Gear 326 Cover...
Page 594 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 595 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug (material : S45C) PT1/16 0.16 Wind a seal tape 1 1/2 to 2...
Page 596 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 (468) and let oil out of pump casing (front and rear pump).
Page 597 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.
Page 598 (12) Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports. (210-7) MP07 (13) Remove valve plates (313, 314) from valve block (312). These may be removed in work (6). (210-7) MP08 (14) If necessary, remove stopper (L, 534),...
Page 599 ASSEMBLY F o r r e a s s e m b l i n g r e v e r s e t h e disassembling procedures, paying attention to the following items. Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance.
Page 600 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 suppor t (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 (210-7) MP10...
Page 601 Fit valve plate (313) to valve block (312), entering pin into pin hole. Take care not to mistake suction / delivery directions of valve plate. (210-7) MP14 Fit valve block (312) to pump casing (271) and tighten hexagon socket head bolts (401).
Page 602 3. REGULATOR STRUCTURE (1/2) 876 874 641 730 643 708 644 645 646 728 924 801 SECTION B-B VIEW C (FRONT) VIEW C (REAR) KR38-9N62 (FRONT) KR38-9N61 (REAR) 722 466 SECTION D-D(REAR) 14092MP04 8-18 8-18...
Page 603 REGULATOR (2/2) 653 654 836 651 652 601 629 630 SECTION A-A 14092MP05 079 EPPR valve assembly 629 Cover (C) 733 O-ring 405 Hexagon socket screw 630 Lock nut 734 O-ring 412 Hexagon socket screw 631 Sleeve, Pf 735 O-ring 413 Hexagon socket screw 641 Pilot cover 753 O-ring...
Page 604 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 605 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug (material : S45C) PT1/16 0.16 Wind a seal tape 1 1/2 to 2...
Page 606 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 607 After removing cover (C, 629) subassembly, take out outer spring (625), inner spring (626) and spring seat (C, 624) from compensating section. Then draw out adjusting ring (Q, 645), pilot spring (646) and spring seat (644) from pilot section. Adjusting ring (Q,645) can easily be drawn out with M4 bolt.
Page 608 (210-7) REG07 Remove lever (2, 613). Do not draw out pin (875). Work will be promoted by using pincers or so on. (210-7) REG08 (10) Draw out pin (874) and remove feedback lever (611). Push out pin (874, 4 mm in dia.) from above with slender steel bar so that it may not interfere with lever (1, 612).
Page 609 (11) Remove lever 1 (612). Do not draw out pin (875). (12) Draw out pilot piston (643) and spool (652). (13) D r a w o u t p i s t o n c a s e ( 6 2 2 ) , c o m p e n s a t i n g p i s t o n ( 6 2 1 ) a n d compensating rod (623).
Page 610 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 611 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 612 (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). (210-7) REG14 (12) Put spring seat (644), pilot spring (646) and adjusting ring (Q, 645) into pilot hole.
Page 613: Group 4 Main Control Valve
GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 614 2. STRUCTURE (1/4, TYPE 1) 140L8MC04 Housing-P1 Regeneration block Socket head bolt Spool assy-travel(LH) Plug Plain washer Spool assy-boom 1 Plug O-ring Spool assy-arm 2 Orifice plug O-ring Spool assy-arm regen Plug O-ring Spool assy-bucket Signal poppet O-ring Nega con relief valve Signal orifice Check spring Bucket stroke limiter...
Page 615 STRUCTURE (2/4, TYPE 1) 140L8MC05 16 Main relief valve 42 Plug 71 O-ring 17 Overload relief valve 43 Poppet 1 72 O-ring 28 Plug 44 Poppet 2 74 Back up ring 29 Plug 59 O-ring 75 Back up ring 31 Plug 61 O-ring 76 Back up ring 32 Plug...
Page 616 STRUCTURE (3/4, TYPE 1) REAR FRONT 140L8MC06 Housing-P2 Lock valve kit B Socket head bolt Spool assy-straight travel Plug Socket head bolt Spool assy-travel(RH) Plug Plain washer Spool assy-swing Plug Spring washer Spool assy-swing priority T/straight sleeve O-ring Spool assy-boom 2 T/straight piston O-ring Spool assy-arm 1...
Page 617 STRUCTURE (4/4, TYPE 1) REAR HOUSING-P2 FRONT REAR HOUSING-P2 FRONT 140L8MC07 17 Overload relief valve 37 Plug 67 O-ring 18 Overload relief valve 43 Poppet 1 68 O-ring 21 Swing logic valve 44 Poppet 2 72 O-ring 23 ON/OFF valve-option 48 Signal orifice 73 O-ring 28 Plug...
Page 618 STRUCTURE (1/4, TYPE 2) 140L8MC104 Housing-P1 24 Pilot cover assy 43 Pilot cover B1 Spool assy-travel(LH) 25 Arm regeneration block 47 Signal spring Spool assy-boom 1 27 Plug 48 Socket head bolt 10 Spool assy-arm 2 32 Plug 53 Spring washer 12 Spool assy-arm regen 37 Plug 59 O-ring...
Page 619 STRUCTURE (2/4, TYPE 2) 140L8MC105 16 Main relief valve 30 Plug 45 Load check poppet 17 Overload relief valve 31 Plug 46 Load check poppet 26 Overload plug 34 Plug 65 Dust cap 27 Plug 35 Plug 66 Dust cap 28 Plug 40 Load check poppet 67 Dust cap...
Page 620 STRUCTURE (3/4, TYPE 2) REAR FRONT 140L8MC106 Housing-P2 15 Option C spool assy 51 Socket head bolt Straight travel spool assy 28 Plug 52 Socket head bolt Travel spool assy 29 Plug 53 Spring washer Swing spool assy 36 Plug 59 O-ring Swing priority spool assy 42 Pilot cover A...
Page 621 STRUCTURE (4/4, TYPE 2) REAR HOUSING-P2 (4075 ITEM 2) FRONT REAR HOUSING-P2 (4075 ITEM 2) FRONT 140L8MC07 17 Overload relief valve assy 32 Plug 62 Spring seal 2 18 Overload relief valve assy 39 Signal orifice 65 Dust cap 21 Swing logic valve 40 Load check poppet 66 Dust cap 22 Option logic valve...
Page 622 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be remove from the machine, apply caps and masking seals to all ports.
Page 623 DISASSEMBLY Disassembly of spools without holding valve (travel right, travel left) Loosen hexagon socket head bolts with washer. (hexagon wrench : 5 mm) Remove the pilot cover. Pay attention not to lose the O-ring under the pilot cover. Remove the spool assembly from the body by hand slightly. When extracting each spool from its body, pay attention not to damage the body.
Page 624 Disassembly of spools with holding valve (boom 1, Arm 1 spool) Loosen hexagon socket head bolts with washer. (hexagon wrench : 5 mm) Remove the pilot cover with internal parts. Pay attention not to lose the O-ring and the poppet under the pilot cover. Pay attention not to damage the "piston A"...
Page 625 Disassembly of the holding valve Remove the pilot cover with the holding valve as described on previous page. Do not disassembled internal parts of the pilot cover. Loosen the poppet seat and remove the poppet, spring seat, spring and check. (spanner : 26 mm) Pay attention not to lose the poppet.
Page 626 Disassembly of the load check valve and the negative relief valve The load check valve Fix the body to suitable work bench. Pay attention not to damage the body. Loosen the plug (hexagon wrench : 10 mm). Remove the spring and the load check valve with pincers or magnet. The negative relief valve Loosen the socket (spanner : 32 mm).
Page 627 Disassembly of the main and overload relief valve Fix the body to suitable work bench. Remove the main relief valve. (spanner : 32 mm) Remove the overload relief valve. (spanner : 32 mm) When disassembled, tag the relief valve for identification so that they can be reassembled correctly.
Page 628 Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. Control valve Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
Page 629 ASSEMBLY General precaution In this assembly section, explanation only is shown. For further understanding, please refer to the figures shown in the previous structure & disassembly section. Pay close attention to keeping all seals free from handling damage and inspect carefully for damage before using them.
Page 630 Pilot covers Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket head bolts to the specified torque. Hexagon wrench : 5 mm Tightening torque : 1.0~1.1 kgf m (7.2~7.9 lbf ft) Confirm that O-rings have been fitted. Fit spring covers to the spring end for the spools, and tighten hexagon socket head bolts to the specified torque.
Page 631: Group 5 Swing Device
GROUP 5 SWING DEVICE (TYPE 1) 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 632 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE 3 2 11 10 1 16 19 18 44 17 36 37 44 39 40 38 18 21 20 29 30 42 25 26 24 23 47 31 46 23 24 26 25 42 VIEW X 125LCR2SM22 Casing...
Page 633 DISASSEMBLY For easy assembly, put motor on worktable with the spline side of shaft (3) facing downwards. Lay rubber plate on worktable and take care not to damage the components. Remove snap ring (4) using snap ring plier. Disassemble level gauge assembly (41) using pipe wrench.
Page 634 Unscrew socket bolt (42) (4EA) using 12 mm hexagon wrench. 125LCR8SM07 Remove valve plate (20) from valve casing. Take care not to drop the valve plate (20). 125LCR8SM08 Remove O-ring (18) from valve casing. 125LCR8SM09 Remove plug (33) using 10 mm hexagon wrench and take out anti-rotating valve assembly (32).
Page 635 Remove plug (29) (1EA), plug (27) (2EA) using 4 mm, 6 mm hexagon wrench. 125LCR8SM11 (10) Remove plug (25) using 32 mm socket wrench and separate spring ; spring (24) and check valve (23). (same for the set on opposite side) 125LCR8SM12 (11) Separate each one of O-ring (40) and spring...
Page 636 (13) Remove spring (16) (24EA) from parking piston. 125LCR8SM15 (14) Disassemble parking piston (15) from casing using air gun. 125LCR8SM16 (15) Lay casing down horizontally and remove cylinder block assembly from shaft. And remove all friction plate (13) and separator plate (14).
Page 637 (17) Remove O-ring (19) from casing. 125LCR8SM19 (18) Use a magnet to separate swash plate (7) from casing. Sliding surface should be carefully treated to avoid scratches and damage. 125LCR8SM20 (19) Disassemble shaft (3) and cylinderical roller bearing (5). Do not remove cylinderical roller bearing (5) unless malfunction is detected, since it is mounted by shrink fit.
Page 638 ASSEMBLY Even though assembly is accomplished by reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried with compressed air. Sliding surface, O-ring, bearing and oil seal should be lubricated with clean hydraulic oil, prior to final assembly.
Page 639 Assemble shaft assembly in casing using urethane hammer. Take care not to damage oil seal. 125LCR8SM25 Insert swash plate (7). Take care not to damage sliding surface. 125LCR8SM26 After applying grease on O-ring (19), insert O-ring in casing (1). 125LCR8SM27 Assemble spring (9) (9EA) in cylinder block (8).
Page 640 Assemble ball guide (10) in cylinder block. Take care not to damage sliding surface of cylinder block. 125LCR8SM29 Insert piston assembly (12) in retainer plate (11). Do not mix piston with other piston (9EA/1set). Spread sufficient amount of hydraulic oil on piston assembly.
Page 641 (11) Put friction plate (13) in casing. 125LCR8SM33 (12) Put separator plate (14) in casing. Put friction plate and separator plate alternately. 125LCR8SM34 (13) Assemble O-ring (18) in parking piston (15). Apply grease on O-ring. 125LCR8SM35 (14) Assemble parking piston (15) in casing using jig. Pay attention to the hole location of parking piston.
Page 642 (15) Put spring (16) (24EA) in each hole of parking piston. 125LCR8SM37 (16) Assemble restrictor (39) in spool (36). Spread loctite #242. 125LCR8SM38 (17) Place spool in casing. 125LCR8SM39 (18) Assemble spring (38) & spring seat (37) in casing. 125LCR8SM40 8-54...
Page 643 (19) Assemble plug (27) using 6 mm hexagon wrench. Tightening torque : 4.5 kgf · m (32.5 lbf · ft) 125LCR8SM41 (20) Assemble plug (29) using 4 mm hexagon wrench. Tightening torque : 3 kgf · m (21.7 lbf · ft) 125LCR8SM42 (21) Assemble anti-rotating valve assembly (32) in...
Page 644 (23) Caulk check valve (23) using jig. (same for the set on opposite side) 125LCR8SM45 (24) Assemble spring (24), plug (25). (in that order) (same for the set on opposite side) Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8SM46 (25) Assemble spring pin (21) in valve casing using...
Page 645 (27) Apply grease on steel side of valve plate (20) to prevent plate from sliding. Assemble valve plate with the copper side facing upwards. Pay attention to the assembly direction. Take care not to damage sliding surface. 125LCR8SM49 (28) Assemble valve casing by matching its holes and pins of casing and parking piston.
Page 646 (31) Wrap teflon tape 2 or 3 times around the tap part of level gauge assembly (41). And assemble it using pipe wrench. 125LCR8SM53 8-58...
Page 647 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove mounting bolts (2). Remove the reduction gear assembly. Reduction gear device weight : 75 kg (165 lb) 13031GE18 INSTALL...
Page 648 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 17 24 22 125LCR2SM23 Ring gear 11 Planetary gear No. 2 21 Carrier pin No.
Page 649 DISASSEMBLY Remove the swing motor, and then place swing reduction gear on the bench. 125LCR8SM60 Disassemble sun gear No.1 (22). 125LCR8SM61 Disassemble carrier No.1 sub assembly. 125LCR8SM62 Carrier No.1 sub assy disassembly Put carrier No.1 sub assembly on the bench, then remove the snap ring (23).
Page 650 Disassemble thrust washer No.1 (upper) (32).(3 pcs) 125LCR8SM64 Disassemble planetary gear No.1 (18). (3 pcs) 125LCR8SM65 Disassemble thrust plate (24). 125LCR8SM66 Disassemble needle bearing No.1 (19). (3 pcs) 125LCR8SM67 8-58-4...
Page 651 Disassemble thrust washer No.1 (lower) (20). (3 pcs) 125LCR8SM68 (10) After placing spring pin (15) to center of carrier pin No.1 (21) with a jig, disassemble it. (3 pcs) Do not reuse spring pin, carrier and carrier pin. 125LCR8SM69 (11) Disassemble sun gear No.2 (16).
Page 652 Carrier No.2 sub assy disassembly (13) After placing spring pin (15) to center of carrier pin No.2 (14) with a press machine, disassemble it.(3 pcs) Do not reuse spring pin. 125LCR8SM72 (14) Disassemble planetary gear No.2.(3 pcs) 125LCR8SM73 (15) Disassemble thrust plate (24). 125LCR8SM74 (16) Disassemble thrust washer No.2 (13).(6 pcs)
Page 653 (17) Disassemble needle bearing No.2 (12). (3 pcs) 125LCR8SM76 (18) Separate ring gear (1) from casing (8). 125LCR8SM77 (19) Loosen a bolt (7) (4 pcs), and disassemble lock plate (6). 125LCR8SM78 (20) Disassemble nut ring (5) by using the jig. 125LCR8SM79 8-58-7...
Page 654 Drive shaft sub assy disassembly (21) Separate drive shaft sub assembly from casing (8). 125LCR8SM80 (22) Disassemble taper bearing (3) and oil seal (27) by using a press machine. 125LCR8SM81 (23) Disassemble sleeve (25) and O-ring (26). 125LCR8SM82 (24) Disassemble the outer ring of taper bearing (3) in casing (8) by using the jig.
Page 655 ASSEMBLY Even though assembly is accomplished by reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried with compressed air. Sliding surface, O-ring, bearing and oil seal should be lubricated with clean hydraulic oil, prior to final assembly.
Page 656 Caulking is performed on the assembled spring pin unit. Caulking To cover pins, implement the caulking in two two places places that are located direction of 180 degrees around assembled spring pin. 125LCR8SM86 Assemble thrust washer No.1 (lower) (20). (3 pcs) 125LCR8SM87 Assemble needle bearing No.1 (19).(3 pcs) 125LCR8SM88...
Page 657 Assemble planetary gear No.1 (18) of which groove is faced downward.(3 pcs) 125LCR8SM90 Assemble thrust washer No.1 (upper) (32). (3 pcs) 125LCR8SM91 Assemble snap ring (23) (3 pcs), complete carrier No.1 sub assembly. Gear rotation state should be smooth. 125LCR8SM92 Carrier No.2 sub assy assembly (10) Assemble needle bearing No.2 (12) in the...
Page 658 After spreading grease on thrust washer (11) No.2 (13), assemble it on both upper side and lower side of planetary gear No.2. 125LCR8SM94 (12) Assemble thrust plate (24). 125LCR8SM95 (13) Assemble planetary gear No.2 in the carrier No.2 (10).(3 pcs) Thrust washer No.2 should notseparated.
Page 659 Assemble spring pin (15).(3 pcs) (15) 125LCR8SM98 (16) Caulking is performed on the assembled spring pin unit. Caulking To cover pins, implement the caulking in two two places places that are located direction of 180 degrees around assembled spring pin. 125LCR8SM99 Drive shaft sub assy assembly (17)
Page 660 (19) Shrink fit taper bearing (3) on drive shaft, complete drive shaft sub assembly. 125LCR8SM102 Casing assembly (20) Press outer ring of the taper bearing in the casing (8) by using the jig. 125LCR8SM103 (21) Press in oil seal (27) by using the jig. Be careful of the direction of the assembly.
Page 661 (23) After fixing drive shaft so that it does not fall, and then turn it over, press taper bearing (4). 125LCR8SM106 (24) Assemble nut ring (5) by using the jig. Tightening torque : 3.5 0.4 kgf · m (25.3 2.9 lbf · ft) 125LCR8SM107 (25) Place lock plate (6) on the nut ring.
Page 662 (27) Press parallel pin (31) by using press machine. 125LCR8SM110 (28) Spread the loctite #515 on the casing with Loctite #515 reference to the right detail view. Loctite should not flow into casing. Detail view 125LCR8SM111 (29) Assemble ring gear (1) in accordance with a pin hole on casing.
Page 663 (31) Assemble sun gear No.2 (16). 125LCR8SM114 (32) Assemble carrier No.1 sub assembly. 125LCR8SM115 (33) Assemble sun gear No.1 (22) of which grinding surface is faced downward. 125LCR8SM116 (34) Fill with gear oil 3.5 liter. 125LCR8SM117 8-58-17...
Page 664 SWING DEVICE (TYPE 2) 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 665 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE DETAIL K 11 10 9 22 7 37 30 32,33 130ZF2SM02 2 3 4 8 13 12 15 14 17 Body 16 Brake piston 31 Anti-rotating valve Oil seal 17 O-ring 32 Time delay valve Roller bearing 18 O-ring 33 Wrench bolt...
Page 666 DISASSEMBLY Lift the motor out. Clean the motor in kerosene and dry with compressed air. To avoid dust inside the motor, mask all the ports of the motor with tapes. 32038SM01 Loosen the drain plug to discharge oil in the body(1).
Page 667 Remove the relief valve (30) from rear cover (20). 32038SM05 Remove plug (25) from rear cover (20) and spring (28), check (29). Be careful not to damage the check seat assembly. 32038SM06 Remove rear cover (20) from body (1). Then, remove the valve plate (23) from rear cover (20) with care.
Page 668 Remove brake piston (16) from body (1). 32038SM09 (10) Remove the cylinder (9) from the drive shaft (5) with the motor positioned horizontally. Remove ball guide (11), set plate (12), piston (13) and shoe plate (8). 32038SM10 (11) Remove friction plate (14) and separate plate (15) from body (1).
Page 669 (13) Remove the cone of roller bearing (3) by press. Do not reuse bearings. Press Output shaft Roller bearing 32038SM15 (14) Remove bushing (6) and oil seal (2) from body (1). 25038SM05 (15) Remove the needle bearing (21) from the rear cover (20) by using slide hammer bearing puller.
Page 670 (16) When disassembling the relief valve, release the adjusting screw (5). Remove the piston (6), spring seat (8), spring (4) and plunger (3) with the body (1) downwards. 14007A2SM05 This completes disassembly. 8-58-24...
Page 671 ASSEMBLY Do the reassembly in the reverse procedure of the disassembly. Apply three bond of white color on outer surface of oil seal (2) and insert it to the body (1). 11078SM22 Install the roller bearing (3) to the drive shaft (5).
Page 672 Insert the shoe plate (8) with the body (1) position horizontally. 32038SM28 Insert the ball guide (11) into the cylinder (9). 32038SM29 Install the piston sub-assembly (13) to the set plate (12). 32038SM30 Reassemble the piston assembly (9) to the body (1).
Page 673 Assembly friction plate (14) and separate plate (15) to the body (1). 11078SM26 (10) Insert O-ring (17) inside the body (1). 32038SM33 (11) Reassemble brake piston (16) to the body (1). 32038SM34 (12) Reassemble brake spring (19) to the brake piston (16).
Page 674 (13) When assembling the needle bearing (21), insert the needle bearing (21) into rear cover (20) by hammering. 32038SM36 (14) Reassemble valve plate (23) to the rear cover (20) and reassemble O-ring (18). 32038SM37 (15) Connect the rear cover (20) with the body (1) and tighten the wrench bolt (24).
Page 675 (17) Insert O-rings to the relief valve (30) and reassemble them to rear cover (20). This completes assembly. 32038SM42 8-58-29...
Page 676 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove dowel pin (3) and mounting bolts (2). Remove the reduction gear assembly. Reduction gear device weight : 60 kg (132 lb) 13031GE18...
Page 677 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE 29 5 1 10 27 12 13 Oil drain Grease port VIEW A 130ZF2SM03 Casing 12 No.2 pin 23 Stop ring Drive shaft 13 No.2 bushing 24 No. 1 sun gear Cover plate 14 No.2 sun gear 25 Stop ring Spacer...
Page 678 DISASSEMBLY Remove level gauge (38) from the swing motor casing. Pour the gear oil out of reduction gear into the clean bowl to check out the friction decrease. 14W98SM05 Loosen the socket bolts (30) to separate swing motor from reduction gear. 130ZF8SM06 Remove sun gear 1 (24).
Page 679 Disassembling carrier 1 assembly (15). Remove stop ring (23). Remove planet gear 1(17) from the carrier 1 (16). Using M8 solid drill, crush spring pin (22) so that the pin 1 (19) can be removed by hammering. Remove thrust washer (21). Do not reuse spring pin (22).
Page 680 Disassembling carrier 2 assembly (8). Using M8 solid drill, crush spring pin (22) so that the pin 2 (12) can be removed. Do not reuse spring pin (22). Remove pin 2 (12), planet gear 2 (10) and thrust washer (21) from the carrier 2 (9). Put matching marks on the planet gear 2 (10) and the pin 2 (22) for easy reassembly.
Page 681 (12) Remove roller bearing (6) and oil seal (7) from the drive shaft (2). Do not reuse oil seal (7) once removed. 14W98SM16 (13) Using the bearing disassembly tool, remove roller bearing (5). 14W98SM17 (14) Remove plugs (31, 32) from the casing (1).
Page 682 ASSEMBLY Assemble roller bearing (5) inside the casing (1). 14W98SM17 Assemble the drive shaft (2) into the casing (1) and then install oil seal (7) and roller bearing (6). 14W98SM19 Install stop ring (25) on top of drive shaft (2). 130ZF8SM14 Apply loctite to the tapped holes of casing (1).
Page 683 Assembling carrier 2 assembly (8). Install the planet gear 2 (10) and thrust washer inside the carrier 2 (9). Assemble the pin 2 (12) to the carrier 2 (9) and then press the spring pin (22) by hammering. Punch 2 points of the spring pin (22) lip. Take care not to mistake the matching marks of each part.
Page 684 (10) Assemble carrier 1 assembly (12) into the ring gear (27). 130ZF8SM20 (11) Hammer 4 knock pins (28) around the ring gear (27). (12) Assemble sun gear 1 (24) to the drive shaft of the swing reduction gear. 130ZF8SM26 (13) Apply loctite to the tapped holes of the ring gear (27) and then mount swing motor onto the ring gear (27).
Page 685: Group 6 Travel Device
GROUP 6 TRAVEL DEVICE (TYPE 1) 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90˚and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 686 2. TRAVEL MOTOR STRUCTURE 49 40 43 42 41 44 72 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 71 70 59 77 64 3 63 7 10 11 14 15 13 16 26 27 6 8 125LCR2TM21...
Page 687 DISASSEMBLY Choose a clean place, remove contaminants (dust, etc) and cleans motor before placing it on worktable. Lay the rubber plate on worktable and take care not to damage the component. 125LCR8TM02 Remove the connector (45) using 21 mm socket wrench.
Page 688 Remove spring seat (42) and spool (40). 125LCR8TM06 Disassemble relief valve assembly (38) using 26 mm socket wrench. (2 sets) 125LCR8TM07 Disassemble cover (32) using 41 mm socket wrench. 125LCR8TM08 Disassemble spring seat (37) and spring (33). (2 sets) 125LCR8TM09 8-62...
Page 689 Separate main spool assembly (31) from rear cover. 125LCR8TM10 (10) Unscrew socket bolt (47) (1EA), (48) (3EA), (49) (6EA) from rear cover. 125LCR8TM11 (11) Remove parallel pin (29). 125LCR8TM12 (12) From rear cover, disassemble valve plate (24) and O-ring (27). Take care not to damage assembly surface of rear cover.
Page 690 (13) Disassemble restrictor (55, 56) (2EA). Mark the number on restrictor and its hole to avoid confusing (55) and (56). 125LCR8TM14 (14) Remove plug (52). 125LCR8TM15 (15) Remove restrictor (34) and spring (35). (2 sets) Do not confuse restrictor (34) and check valve (50).
Page 691 (17) Remove check valve (50) and spring (51). (2 sets) Do not confuse restrictor (34) and check valve (50). Do not confuse spring (35) and spring (51). Do not lose spring. Do not mix spring with other springs. 125LCR8TM18 (18) From parking piston, remove spring (26) (12ea).
Page 692 (21) From parking piston separate O-ring (20) and back-up ring (21). 125LCR8TM22 (22) Lay casing down horizontally and remove cylinder block assembly, friction plate (17) (3EA) and separator plate (18) (4EA). 125LCR8TM23 (23) Separate retainer plate (15) and piston assembly (16).
Page 693 (25) Disassemble swash plate (11) and steel ball (10). Take care not to damage sliding surface. 125LCR8TM26 (26) Disassemble shaft (6) and ball bearing (7). Do not remove ball bearing unless malfunction is detected, since it is mounted by shrink fit. 125LCR8TM27 (27) Disassemble 1, 2 speed piston (4) and steel ball...
Page 694 (29) Turn casing (1) upside down and remove oil seal (3) using jig. 125LCR8TM30 8-68...
Page 695 ASSEMBLY Even though assembly is accomplished by reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried with compressed air. Sliding surface, O-ring, bearing and oil seal should be lubricated with clean hydraulic oil, prior to final assembly.
Page 696 After applying grease on steel ball (10), insert steel ball in casing. 125LCR8TM33 After assembling piston seal (5) and steel ball (9) in 1, 2 speed piston (4), insert piston in hole of casing. Check whether piston sticks in hole. Use piston seal jig.
Page 697 Assemble spring (13) (9ea) and ball guide (14) in cylinder block (12) in that order. 125LCR8TM37 Insert piston assembly (16) in retainer plate (15) and assemble them in cylinder block. Spread hydraulic oil on piston assembly. Take care not to damage each component. Check cylinder block and piston assembly runs properly.
Page 698 (11) Insert back-up ring & O-ring in parking piston. 125LCR8TM41 (12) Align the pin hole of parking piston (19) with oil hole of casing, assemble them using jig. Spread grease on O-ring and back-up ring. Take care not to damage components. 125LCR8TM42 (13) Insert spring (26) (12EA) in parking piston.
Page 699 (15) Assemble check valve (50) and spring (51) in order. Do not confuse check valve (50) and restrictor (34). Do not confuse spring (51) and spring (35) 125LCR8TM45 (16) Clamp plug (52) using 5 mm hexagon wrench. Tightening torque : 1.5 kgf · m (10.9 lbf · ft) 125LCR8TM46 (17) Assemble restrictor (34) and spring (35) in order.
Page 700 (19) Clamp plug (54). Tightening torque : 3 kgf · m (21.7 lbf · ft) 125LCR8TM49 (20) Assemble restrictor (55) and (56) in rear cover. Check whether the restrictor is placed in exact hole. Do not confuse (55) and (56). 125LCR8TM50 (21) Assemble ball bearing (8) in rear cover using jig.
Page 701 (23) After spreading grease sufficiently to the bottom side of valve plate (24), assemble valve plate in rear cover by matching its holes with pins. Take care not to damage sliding surface. Pay attention to the assembly direction. 125LCR8TM53 (24) Assemble O-ring (27) in rear cover.
Page 702 (27) Settle cover (32). Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8TM57 (28) Insert relief valve (38) in rear cover. Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8TM58 (29) After clamping connector (45) to rear cover, assemble spool (40).
Page 703 (31) After assembling spring (44) in order, clamp plug (41). Tightening torque : 5 kgf · m (36 lbf · ft) 125LCR8TM61 8-77...
Page 704 TRAVEL REDUCTION GEAR DISASSEMBLY While travel reduction gear is tilted to one side disassemble PF3/8 plug (24), remove gear oil and place motor sideto the bench. 125LCR8TM70 Disassemble cover (22) by unscrewing the M10 bolts (23) (12 pcs). 125LCR8TM71 Disassemble sun gear No.1 (20), steel ball (21). 125LCR8TM72 Disassemble carrier No.1 assembly.
Page 705 Carrier No. 1 sub assy disassembly Disassemble M8 bolt (18) from the carrier assembly. (3 pcs) 125LCR8TM74 Disassemble thrust plate No.1 (17) from the carrier assembly. 125LCR8TM75 Disassemble planetary gear No.1 (14).(3 pcs) 125LCR8TM76 Disassemble needle bearing (15).(3 pcs) Do not disassemble inner race in the absence of abnormalities.
Page 706 Disassemble Sun gear No.2 (12). 125LCR8TM78 Disassemble M10 bolt (6).(4 pcs) 125LCR8TM79 Disassemble thrust washer No.2 (11).(4 pcs) 125LCR8TM80 Disassemble planetary gear No.2 (8).(4 pcs) 125LCR8TM81 8-80...
Page 707 Disassemble needle bearing No.2 (9).(4 pcs) 125LCR8TM82 Disassemble thrust plate No.2 (7).(4 pcs) Do not disassemble inner race in the absence of abnormalities. 125LCR8TM83 Disassemble M10 bolt (6) and M8 screw bolt (19). 125LCR8TM84 Disassemble lock plate (5). 125LCR8TM85 8-81...
Page 708 Disassemble nut ring (4) by using the jig. 125LCR8TM86 Disassemble ring gear sun assembly from motor assembly. 125LCR8TM87 Disassemble folating seal assembly (3) from ring gear sun assembly and motor assembly. 125LCR8TM88 Disassemble bearing (2) (2ea) from ring gear assembly. Do not disassemble bearing in the absence of abnormalities.
Page 709 TRAVEL REDUCTION GEAR ASSEMBLY Even though assembly is accomplished by reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried with compressed air. Sliding surface, O-ring, bearing and oil seal should be lubricated with clean hydraulic oil, prior to final assembly.
Page 710 Assemble planetary gear No.1 (14) of which groove is faced downward. (3 places) 125LCR8TM92 Assemble thrust plate No.1(17). 125LCR8TM93 After spreading loctite #242, assemble the M8 bolt (18).(3 pcs) Tightening torque : 2.7 0.3 kgf · m After the assembly, instantly check the noise and interference by rotatong the gear.
Page 711 After turning ring gear over, assemble bearing the same way. Be care of nick and safety when turn ring gear over. 125LCR8TM96 Assemble folating seal assembly (3) by usingthe jig. After assembling, wipe steel-lined section with alcohol. Flatness deviation has to be less than 1 mm. 125LCR8TM97 Place folating seal assembly on the motor assem- bly then assemble it.
Page 712 After assembling nut ring (4) by using the jig, disassemble the clamping. Tightening torque : 60 kgf · m (434 lbf · ft) 125LCR8TM100 Place lock plate (5) on the nut ring groove. Select best position from one of 4 casing hole to assemble lock plate.
Page 713 Shrink fit the inner race No.2 (10).(4 pcs) 125LCR8TM104 Assemble thrust plate No.2 (7).(4 pcs) 125LCR8TM105 Assemble needle bearing No.2 (9).(4 pcs) 125LCR8TM106 Assemble planetary gear No.2 (8).(4 pcs) Grooves of planetary gear will be facingup. 125LCR8TM107 8-87...
Page 714 Assemble thrust washer No.2 (11).(4 pcs) 125LCR8TM108 After spreading loctite #242, assemble the M10 bolt (6).(4 pcs) Tightening torque : 5.5 0.6 kgf · m (39.8 4.3 lbf · ft) 125LCR8TM109 Assemble sun gear No.2 (12). 125LCR8TM110 Assemble carrier No.1 assembly. 125LCR8TM111 8-88...
Page 715 Assemble sun gear No.1 (20). 125LCR8TM112 Place steel ball (21) on the sun gear No.1. 125LCR8TM113 Spread the loctite #515 on the cover (22) with reference to the right detail view. Detail view 125LCR8TM114 Place cover (22) to fit the bolt holes. 125LCR8TM115 8-89...
Page 716 After spreading loctite #242, assemble the M10 bolt (23).(12 pcs) Tightening torque : 6.3 0.7 kgf · m (45.6 5.1 lbf · ft) 125LCR8TM116 Inject the 2.5 0.3 liter gear oil to PF3/8 tap section. 125LCR8TM117 After assembling the O-ring (25) to the plug (24), assemble it to the cover.(3 pcs) Tightening torque : 5 0.5 kgf ·...
Page 717 TRAVEL DEVICE (TYPE 2, HIGH WALKER) 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90 and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 718 2. TRAVEL MOTOR STRUCTURE 81 82 20 19 22,23 26 27 24,25 71 76 40 91-9 91-6 91-8 90-3 90-4 90-6 90-1 9 17 18 36 35 32 31 30 64 91-4 90-5 90-2 91-6 90-7 91-1 91-7 91-5 90-7 91-3 91-2 85 84...
Page 719 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench 2, 5, 4, 6, 10 Socket for socket wrench, spanner Socket 8, 14, 24, 27 Torque wrench Capable of tightening with the specified torques Pliers Plastic and iron hammer Wooden hammer allowed. Normal 1 or so Monkey wrench Oil seal inserting jig Bearing pliers...
Page 720 3. OUTLINE OF DISASSEMBLING GENERAL SUGGESTIONS Select a clean place for dismantling. Spread a rubber plate on a working table in order to prohibit the damage of parts. Clean a deceleration equipment and a motor part, washing out dirt and unnecessary substances. Without any damage of O-ring, oil seal, the adhered surface of other seals, a gear, a pin, the adhered surface of other bearings, and the surface of moisturized copper, treat each parts.
Page 721 Unloosing wrench bolt (M12 35L, 16 EA) and disassemble rear cover assembly from motor assembly. 21078TM23 21078TM24 Dismantle packing piston (21) using compressed air. 21078TM25 Disassembly rotary kit from motor assembly (cylinder block assembly, piston assembly, ball guide, set plate, friction plate, steel plate...) 21078TM26 8-95...
Page 722 Using a jig, disassemble swash plate (9) from shaft casing. 21078TM27 Using compressed air, disassemble piston swash (4) piston ring (5), respectively. 21078TM28 21078TM29 Using a hammer, disassemble shaft (6) from shaft casing (1). 21078TM30 8-96...
Page 723 Disassemble cylinder sub. Disassemble cylinder block assembly, piston assembly (9) and seat plate (M). 21078TM31 21078TM32 Disassemble ball guide (16), ring and pin (15) from cylinder block, respectively. 21078TM33 21078TM34 8-97...
Page 724 21078TM35 Pushing spring (12) by an assembling jig, disassemble snap ring (14), spring seat (13), spring (12) and spring seat (11), respectively. 21078TM36 21078TM37 Disassemble valve casing sub. Using an hexagon wrench, unloosing wrench bolt (45) and disassemble cover (37), spring (38), spool (39), spring seat (43), spring (36) and spring seat (35), respectively.
Page 725 21078TM39 Disassemble spool (59), spool (47), O-ring (51), guide (48) and snap ring (53) on rear cover, respectively. 21078TM40 21078TM41 Using a torque wrench, disassemble relief valve assembly (46) on rear cover. 21078TM42 8-99...
Page 726 4. OUTLINE FOR ASSEMBLING GENERAL SUGGESTIONS After washing each parts cleanly, dry it with compressed air. Provided that you do not wash friction plate with treated oil. In bonding each part, fasten bond torque. When using a hammer, do not forget to use a plastic hammer. 4.1 ASSEMBLING Assemble the sub of turning axis Using a jig, assemble oil seal (3) into shaft...
Page 727 21078TM46 Using a jig, assemble shaft assembly into shaft casing (1). 21078TM47 After spreading grease on steel ball (8) assemble into shaft casing (1). 21078TM48 Assemble swash piston assembly (4, 5) into shaft casing (1). 21078TM49 8-101...
Page 728 Assemble swash plate (9) into shaft casing (1). 21078TM50 Assemble cylinder block sub. Assemble spring seat (13), spring (12), spring seat (11) into cylinder block (10) respectively, pushing spring (12) using by a jig, assemble snap ring (14) with a snap ring (14).
Page 729 Assemble ring, pin (15) on cylinder block (10) ball guide (16) respectively. 21078TM53 21078TM54 21078TM55 Assemble cylinder block assembly, piston assembly (9), seat plate (17). 21078TM56 8-103...
Page 730 21078TM57 Assemble cylinder block assembly (9) into shaft casing (1). 21078TM58 Assemble friction plate (19) and plate (20) into shaft casing (1) respectively, prepare 6 set. 21078TM59 21078TM59-1 8-104...
Page 731 Assemble O-ring (22, 23) into packing piston (21). 21078TM60 21078TM60-1 After spreading grease on packing piston (21) bond wrench bolt and assemble shaft casing (1). 21078TM61 Assemble rear cover sub. Using a jig, assemble bearing (69) into rear cover (29). 21078TM62 8-105...
Page 732 After assembling spool (59), spool (47), O-ring (51), guide (48) and snap ring (53) respectively into rear cover (29). Using torque wrench, assemble it. 21078TM63 21078TM64 21078TM65 8-106...
Page 733 Assemble spring seat (35), spring (36), spring seat (43), spool (39), spring (38), cover (37) respectively and assemble wrench bolt (45). (same balance on both sides) 21078TM66 21078TM67 21078TM67-1 8-107...
Page 734 Assemble plug (2). Plug (NPT1/16) - 11 EA 21078TM68 21078TM69 21078TM70 21078TM71 8-108...
Page 735 Assemble plug (64). Plug (PT3/8) - 11 EA 21078TM72 Assemble plug (62, 63) into rear cover (29) and assemble relief valve assembly. 21078TM73 21078TM74 Put spring (67, 68) together into rear cover (29), prepare 6 set. 21078TM75 8-109...
Page 736 21078TM76 Assemble valve plate (70) into rear cover (29). 21078TM77 After assembling shaft casing (1) and rear cover (29). Assemble spool assembly (30), spring (38), spool (39), cover (37) after then complete assembly with wrench bolt (45). 21078TM78 Finish assembly. 21078TM79 8-110...
Page 737 5.1 DISASSEMBLING REDUCTION UNIT Preparation for disassembling The reduction units removed from excavator are usually covered with mud. Wash outside of propelling unit and dry it. Locate reducer in order for drain port to be at the lowest level loosen taper screw plug of drain port, and drain oil from reduction gear.
Page 738 Removing No.1 carrier sub assembly Screw three M10 eye-bolt in No.1 carrier and lift up and remove No.1 carrier assy. 21078TM83 Remove No.1 sun gear Be sure to maintain it vertical with the ground when disassembling No.1 sun gear. 21078TM84 Removing No.2 carrier sub assembly Screw three M10 eye-bolt in No.2 carrier and lift up and remove No.2 carrier assy.
Page 739 Removing ring gear As the ring gear (88) is adhered to housing (81), disassemble ring gear (88) and housing (81) by lightly hammering slantwise upward using sharpen punch inserted between the ring gear and housing. Carefully disassembling ring gear not to make scratch on it.
Page 740 Removing floating seal Lift up a piece of floating seal of motor side. 21078TM91 Disassembling housing assembly After turning housing, lift up a piece of floating seal from housing and then remove it. Don't disassemble angular bearing. 21078TM92 Disassembling No.1 carrier Remove thrust ring (90-7) from carrier.
Page 741 21078TM95 Disassembling No.2 carrier Disassemble No.2 carriers, using the same method for No.1 carrier assembly. 21078TM96 21078TM97 8-115...
Page 742 6.1 ASSEMBLY REDUCTION GEAR General notes Clean every part by kerosene and dry them by air blow. Surfaces to be applied by locktite must be decreased by solvent. Check every part for any abnormals. Each hexagon socket head bolt should be used with locktite No. 262 applied on its threads.
Page 743 Install No.1 pin (91-5) into No.1 carrier where the holes for No.1 pin (91-5) are to be in line with those of No.1 carrier, and then, install spring pins into the holes. 21078TM100 Caulk carrier holes as shown on the picture.
Page 744 Caulk carrier holes as shown on the picture. Assembly thrust ring (90-7) into carrier. 21078TM104 Assembling floating seal (83) and main bearing (82) Assemble floating seal into motor by use of pressing jig. Grease the contact parts for floating seal which is assembled into motor.
Page 745 Installing housing assembly Install 2 EA of M12 eye-bolt into housing assembly. Assemble housing into motor by use of hoist and eye-bolt. Be sure to tighten eye-bolt deep enough. 21078TM108 Installing main bearing (82) Heat main bearing at 60~70 C and then, install.
Page 746 Installing ring gear Apply three bone #1104 (loctite #515) on housing for ring gear without gap. Insert lock pin into housing hole. Install M14 eye-bolt on the tap of ring gear. Lift ring gear and then, assemble into housing in order for hole of ring gear and 21078TM112A parallel pin of housing to be in line.
Page 747 Installing No.2 sun gear (91-2) Install No.2 sun gear on the spline of No.2 carrier and No.2 planetary gear, matching teeth of them. 21078TM115 Install No.2 sun gear on the spline of No.2 carrier and No.2 planetary gear, matching teeth of them. 21078TM116 Installing No.1 carrier sub assembly Install M10 eye-bolt on No.2 carrier...
Page 748 Installing cover (93) Beat pad (94) with plastic hammer, and press it into the center of cover. Apply three bond #1104, loctite (#515) on the ring gear for cover without gap. Put cover on ring gear, apply loctite (#262) on M12 hexagon socket head bolt, and then, bolt.
Page 749: Group 7 Rcv Lever
GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 750 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 300L2RL06 Case Plug 15 Joint assembly 22 Nut Bushing Push rod 16 Swash plate 23 Boot Spool 10 O-ring 17 Adjusting nut 24 Last guard filter Shim 11 Rod seal 18 Bushing 25 O-ring Spring 12 Plate 19 Plug 26 O-ring...
Page 751 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanne (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Joint 25.3 Swash plate 5.0 0.35...
Page 752 DISASSEMBLY Procedures are based on the type M1. Clean pilot valve with kerosene. Put blind plugs into all ports Fix pilot valve in a vise with copper (or lead) sheets. Remove end of boot (23) from case (1) and take it out upwards. 300E8RL01 For valve with switch, remove cord also through hole of casing.
Page 753 Loosen adjusting nut (17) and swash plate (16) with spanners on them respectively, and remove them. 36078RL01 36078RL02 Turn joint anticlockwise to loosen it, utilizing jig (Special tool). When return spring (7) is strong in force, plate (12), plug (8) and push rod (9) will come up on loosening joint.
Page 754 Remove plate (12). 36078RL05 When return spring (7) is weak in force, plug (8) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
Page 755 Take push rod (9) out of plug (8). (12) 36078RL11 (13) Remove O-ring (10) and seal (11) from plug (8). Use small minus screwdriver or so on to remove this seal. 36078RL12 36078RL13 8-129...
Page 756 (14) Remove lock nut (22) and then boot (23). 36078RL14 2507ARL10 8-130...
Page 757 (15) Cleaning of parts Put all parts in rough cleaning vessel filled with kerosene and clean them (rough cleaning). If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil.
Page 758 ASSEMBLY Put shim (4), springs (5) and spring seat (6) onto spool (3) in this order. 36078RL16 Assemble spring (7) into casing (1). Assemble reducing valve subassembly into casing. Assemble them to their original positions. 36078RL18 Assemble O-ring (10) onto plug (8). 36078RL19 Assemble seal (11) to plug (8).
Page 759 Assemble push rod (9) to plug (8). Apply working oil on push-rod surface. 36078RL21 Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring. 36078RL22 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate (12), and tighten joint (15) temporarily.
Page 760 (10) Assemble swash plate (16) to joint (15). Screw it to position that it contacts with 4 push rods evenly. Do not screw it over. 36078RL25 (11) Assemble adjusting nut (17), apply spanner to width across flat of plate (16) to fix it, and tighten adjusting nut to the specified torque.
Page 761 (13) Fit boot (23) and lock nut (22), and handle subassembly is assembled completely. 2507ARL10 36078RL27 (14) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. 1408DA66 (15) Assemble bushing (18) to plate and pass cord and tube through it.
Page 762 Determine handle direction, tighten lock (16) nut (22) to specified torque to fix handle. 300E8RL05 (17) Apply grease to rotating section of joint and contacting faces of disk and push rod. 300E8RL06 (18) Assemble lower end of bellows to casing. (19) Inject volatile rust-preventives through all ports and then put blind plugs in ports.
Page 763: Group 8 Turning Joint
GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 764 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 14098TJ03 Shim 11 Wear ring Shaft Slipper seal 12 Retainer ring Cover O-ring 13 Plug Spacer O-ring 14 Hexagon bolt Shim 10 O-ring 15 Spring washer 8-138...
Page 765 DISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts (14), washer (15) and cover (3). 21078DA10 Remove shim (6) and O-ring (10). Remove retainer ring (12), spacer (4) and shim (5). 21078DA11 Place hub (1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out shaft Wooden block...
Page 766 ASSEMBLY Clean all parts. As a general rule, replace oil seals and O-ring. Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix seven slipper seal (7) and O-ring (9), two wear ring (11) to hub (1). Fit O-ring (8) to shaft (2).
Page 767 Install cover (3) to body (1) and tighten bolts (14). Torque : 10~12.5 kgf m (72.3~90.4 lbf ft) 21078DA10 8-141...
Page 768 GROUP 9 BOOM, ARM, BUCKET AND DOZER CYLINDERS 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 769 Sling bucket cylinder assembly (8) and remove bolt (6) then pull out pin (5). Remove bucket cylinder assembly (8). Weight : 100 kg (220 lb) 145WF8DA17 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
Page 770 ARM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 771 Sling arm cylinder assembly(8) and remove bolt (7) then pull out pin (6). Remove arm cylinder assembly (8). Weight : 160 kg (350 lb) 145WF8CY21 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 772 BOOM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 773 Disconnect boom cylinder hoses (7) and put plugs on cylinder pipe. 145WF8DA25 Remove bolt (9) and pull out pin (8). Remove boom cylinder assembly (6). Weight : 130 kg (285 lb) 145WF8DA26 Install Carry out installation in the reverse order to removal.
Page 774 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder 9,10 6,7 8 4,5 22 3 11,12 2 13 14 17 15 18,19 20 21 Internal detail 23, 25 24, 25 145WF8CY01 Tube assembly 11 O-ring 21 Hexagon socket set screw Rod assembly 12 Back up ring 22 Hexagon socket head bolt Gland...
Page 775 Arm cylinder , 9 , 10 11 , 12 18 , 19 23 33 13 14 17 16 15 Internal detail 24 , 25 24 , 25 25 , 26 , 27 , 28 145WF8CY02 Tube assembly 12 Back up ring 23 Hexagon socket head bolt Rod assembly 13 Cushion ring...
Page 776 Boom cylinder 6,7 8 4,5 22 29 13 14 17 16 15 18,19 20 21 9,10 11,12 Internal detail 23, 24 23, 24 145WF8CY03 Tube assembly 11 O-ring 21 Hexagon socket set screw Rod assembly 12 Back up ring 22 Hexagon socket head bolt Gland 13 Cushion ring 23 Pin bushing...
Page 777 Dozer cylinder 26,27 26,27 16,17 10,11 18,19 14098CY05 Tube assembly 10 O-ring 19 Set screw Rod assembly 11 Back up ring 20 Pipe assembly Gland 12 O-ring 21 Hexagon socket head bolt Dust wiper 13 Piston 22 O-ring Retainer ring 14 Piston seal 23 Check valve assembly Rod seal...
Page 778 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanner (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Bucket cylinder ( 1) 15 2.0 108 14.5 Socket head bolt...
Page 779 DISASSEMBLY Remove cylinder head and piston rod Procedures are based on the bucket cylinder. Hold the clevis section of the tube in a vise. Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means.
Page 780 Note that the plated surface of rod assembly (2) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. Place the removed rod assembly on a wooden V-block that is set level.
Page 781 Disassemble the piston assembly Remove wear ring (16). Remove dust ring (17) and piston seal (15). Exercise care in this operation not to damage the grooves. 14W98CY12 Disassemble cylinder head assembly 9 6 7 8 12 11 Remove back up ring (12) and O-ring (11).
Page 782 ASSEMBLY Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil stone. Coat the inner face of gland (3) with hydraulic oil. 21078DA37 Coat dust wiper (9) with grease and fit Press here dust wiper (9) to the bottom of the hole of (Straight down) dust seal.
Page 783 Fit back up ring (12) to gland (3). Put the backup ring in the warm water of 30~50˚C . Fit O-ring (11) to gland (3). 21078DA39 Assemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone. Coat the outer face of piston (14) with hydraulic oil.
Page 784 Install piston and cylinder head Cylinder head assembly Fix the rod assembly to the work bench. Apply hydraulic oil to the outer surface of Rod assembly rod assembly (2), the inner surface of piston and cylinder head. Insert cylinder head assembly to rod assembly.
Page 785 Overall assemble Fix with a bar Place a V-block on a rigid work bench. Mount the tube assembly (1) on it and Lift fix the assembly by passing a bar through the clevis pin hole to lock the Straight assembly. Insert the rod assembly in to the tube assembly, while lifting and moving the Appply liquid packing...
Page 786: Group 10 Undercarriage
GROUP 10 UNDERCARRIAGE 1. TRACK LINK REMOVAL Move track link until master pin is over front idler in the position put wooden Master pin block as shown. Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards.
Page 787 2. CARRIER ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-162(1) Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller 8-162(2) Loosen the lock nut (1). Carrier roller Open bracket(2) with a screwdriver, push out from inside, and remove carrier roller assembly.
Page 788 3. TRACK ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-163(1) Using the work equipment, push up track frame on side which is to be removed. After jack up the machine, set a block under the unit. 90 ~ 110 14098UC05 Remove the mounting bolt (1) and draw...
Page 789 4. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link. 8-164(1) Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry. Weight : 192 kg (423 lb) 8-164(2) Remove the bolts (2), washers (3) and separate ilder from recoil spring.
Page 790 DISASSEMBLY AND ASSEMBLY OF IDLER Structure (type 1) 21078DA43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 8-164...
Page 791 Structure (type 2 & 3, high walker) 140L8DA143 Shell Bushing Spring pin Shaft Bracket Hex Plug Seal assy O-ring 8-164-1...
Page 792 Disassembly Press The illustrations are base on the type 1. Remove plug and drain oil. Draw out the spring pin (7), using a press. 8-166(1) Pull out the shaft (2) with a press. Press Remove seal (3) from idler (1) and bracket (5).
Page 793 Assembly Before assembly, clean the parts. Press Coat the sliding surfaces of all parts with oil. Cool up bushing (4) fully by some dry ice and press it into shell (1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
Page 794 Install bracket (5) attached with seal (3). 8-168(1) Knock in the spring pin (7) with a hammer. 8-168(2) Lay bracket (5) on its side. Supply engine oil to the specified level, and tighten plug. 8-168(3) 8-167...
Page 795 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure (type 1) 7, 8 130ZF8UC30 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod assembly Spring Spring washer 13 Grease valve Bracket Rod packing 14 Spring pin Lock nut 10 Back up ring 8-168...
Page 796 Structure (type 2 and 3, high walker ) 7, 8 9, 10 140L8UC130 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod assembly Spring Spring washer 13 Grease valve Bracket Rod seal 14 Spring pin Lock nut 10 Back up ring 15 Spacer 8-168-1...
Page 797 Disassembly Press The illustrations are base on the type 1. Apply pressure on spring (3) with a press. The spring is under a large installed load. This is dangerous, so be sure to set properly. 7, 8 Remove bolt (7), spring washer (8) and lock plate (6).
Page 798 Assembly Install dust seal (11), back up ring (10) and rod seal (9) to body (1). When installing dust seal (11) and rod seal (9), take full care so as not to damage the lip. 130ZF8UC33 Pour grease into body (1), then push in rod (12) by hand.
Page 799 Lighten the press load and confirm the Press set length of spring (3). - Type 1 : 405 ± 1.5 mm - Type 2 & 3 : 420 ± 1.5 mm After the setting of spring (3), install lock 7, 8 plate (6), spring washer (8) and bolt (7).
Page 800: Group 11 Work Equipment
GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A SECTION B SECTION C SECTION A SECTION B SECTION C 21078DA 44 8-172...
Page 801 2. REMOVA L A ND INSTA LL B UCKET A SSEMB LY Removal Lower the work equipment completely to ground with back of bucket facing down. 36078A T04 Remove nut (1), bolt (2) and draw out the pin (B ). 145WF8A T01 Remove nut (3), bolt (4) and draw out the pin (A ) then remove the bucket assembly.
Page 802 A RM A SSEMB LY Removal Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury. Remove bucket assembly. For details, see removal of bucket 8-175(1) assembly. Disconnect bucket cylinder hose (1).
Page 803 B OOM CYLINDER Removal Remove arm and bucket assembly. For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly. 8-176(1) Disconnect head lamp wiring. Disconnect bucket cylinder hose (2) and arm cylinder hose (1).
Page 804 SECTION 9 COMPONENT MOUNTING TORQUE SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide ----------------------------------------------------------------------------------------------- 9-1 Group 2 Engine system ---------------------------------------------------------------------------------------------------- 9-2 Group 3 Electric system --------------------------------------------------------------------------------------------------- 9-4 Group 4 Hydraulic system ------------------------------------------------------------------------------------------------ 9-6 Group 5 Undercarriage ----------------------------------------------------------------------------------------------------- 9-9 Group 6 Structure -------------------------------------------------------------------------------------------------------------- 9-10 Group 7 Work equipment ------------------------------------------------------------------------------------------------- 9-14...
Page 805: Group 1 Introduction Guide
This section shows bolt specifications and standard torque values needed when mounting components to the machine. Use genuine Hyundai spare parts. We expressly point out that Hyundai will not accept any responsibility for defects resulted from non-genuine parts. In such cases Hyundai cannot assume liability for any damage.
Page 806: Group 2 Engine System
GROUP 2 ENGINE SYSTEM GROUP 2 ENGINE SYSTEM 1. ENGINE AND ACCESSORIES MOUNTING 1. ENGINE AND ACCESSORIES MOUNTING Engine Spacer Fan clutch Air cleaner 140L9CM01 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 8×1.25 2.5±0.5 18.1±3.6 M12×1.75 7.9±2.0 57.1±14.5 M10×1.5...
Page 807 2. COOLING SYSTEM AND FUEL TANK MOUNTING 2. COOLING SYSTEM AND FUEL TANK MOUNTING Engine oil filter Secondary fuel filter Hyd tank Primary fuel filter Block Fuel tank Air conditioner idle pulley Air compressor Condenser Coolant valve DEF/AdBlue® Needle valve tank Fuel cooler DEF/AdBlue®...
Page 808: Group 3 Electric System
GROUP 3 ELECTRIC SYSTEM GROUP 3 ELECTRIC SYSTEM 1. ELECTRIC COMPONENTS MOUNTING 1 1. ELECTRIC COMPONENTS MOUNTING 1 ELECTRIC COMPONENTS MOUNTING 1 DETAIL D BOOM Travel buzzer Battery Washer tank Battery relay DETAIL A DETAIL B 140L9CM03 ·Tightening torque Item Size kgf·m lbf·ft...
Page 809 2. ELECTRIC COMPONENTS MOUNTING 2 2. ELECTRIC COMPONENTS MOUNTING 2 ELECTRIC COMPONENTS MOUNTING 2 VIEW A RMS bracket Electric box Camera Work lamp Fuse box Remote control unit DC/DC converter Warning buzzer Smart key reader Smart key DETAIL A control unit 140L9CM04 ·Tightening torque Item...
Page 810: Group 4 Hydraulic System
GROUP 4 HYDRAULIC SYSTEM GROUP 4 HYDRAULIC SYSTEM 1. HYDRAULIC COMPONENTS MOUNTING 1 1. HYDRAULIC COMPONENTS MOUNTING 1 HYDRAULIC COMPONENTS MOUNTING 1 Main pump 5 cartridge valve 3 way solenoid valve Main control valve Swing motor Upper frame Cross Terminal assy RCV-RH VIEW A RCV-LH...
Page 811 2. HYDRAULIC COMPONENTS MOUNTING 2 2. HYDRAULIC COMPONENTS MOUNTING 2 HYDRAULIC COMPONENTS MOUNTING 2 S & D/acting attachment piping Single acting main piping Double acting main piping Pro relief Pro relief valve valve Hose joint block Upper Solenoid frame Hose joint Stop valve block...
Page 812 3. HYDRAULIC COMPONENTS MOUNTING 3 3. HYDRAULIC COMPONENTS MOUNTING 3 Solenoid valve Accumulator Check valve Check valve EPPR valve Cartridge BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER 140L9CM07 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 8×1.25 2.7±0.3 19.5±2.2 M10×1.5 5.0±1.0...
Page 813: Group 5 Undercarriage
GROUP 5 UNDERCARRIAGE GROUP 5 UNDERCARRIAGE ADJUST COMPONENT Idler Swing bearing Track chain Travel motor Sprocket Carrier roller Cover Adjust component Track guard Cover 140L9CM08 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M10×1.5 6.9±1.4 49.9±10.1 M16×2.0 29.7±3.0 215±23.1 M12×1.75 12.8±3.0...
Page 814 UNDERCARRIAGE MOUNT UNDERCARRIAGE MOUNTING (HIGH WALKER) ING (HIGH WALKER) UNDERCARRIAGE MOUNTING (HIGH WALKER) ADJUST COMPONENT Idler Roller Sprocket Roller Track guard Adjust component Idler Full track guard 140L9CM09 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M10×1.5 6.9±1.4 49.9±10.1 M20×2.5 57.9±6.0...
Page 815: Group 6 Structure
GROUP 6 STRUCTURE GROUP 6 STRUCTURE 1. CAB AND ACCESSORIES MOUNTING 1. CAB AND ACCESSORIES MOUNTING CAB AND ACCESSORIES MOUNTING Sun roof assy Back latch Side door Nonslip plate Striker 140L9CM10 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 6×1.0 1.05±0.2...
Page 816 2. CAB INTERIOR MOUNTING 2. CAB INTERIOR MOUNTING CAB INTERIOR MOUNTING Seat Console box(RH) Console box(LH) Safety lever Travel lever Bottom plate Viscous Foot rest mount 140L9CM11 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 6×1.0 1.05±0.2 7.6±1.45 M 8×1.25 4.05±0.8...
Page 817 3. COWLING MOUNTING 3. COWLING MOUNTING Engine hood Side cover (RH) Air cleaner Side cover (LH) 140L9CM12 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 8×1.25 2.5±0.5 18.1±3.6 M12×1.75 12.8±3.0 92.6±21.7 M10×1.5 6.9±1.4 49.9±10.1 M16×2.0 29.7±4.5 215±32.5 9-13...
Page 818 4. COUNTERWEIGHT AND COVERS MOUNTING 4. COUNTERWEIGHT AND COVERS MOUNTING COUNTERWEIGHT AND COVERS MOUNTING Counterweight DEF/AdBlue® tank cover Upper frame Pump under cover Hyd tank under cover Engine under cover Fuel tank under cover Radiator under cover DEF/AdBlue® tank under cover Tool box MCV under cover Cab under cover...
Page 819: Group 7 Work Equipment
GROUP 7 WORK EQUIPMENT GROUP 7 WORK EQUIPMENT WORK EQUIPMENT Boom pin Boom cylinder Boom rod pin Boom Arm cylinder cylinder Arm cylinder head pin Boom cylinder head pin Arm cylinder rod pin Arm pin Bucket cylinder Bucket cylinder head pin Side cutter(LH) Bucket Bucket...

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