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New Holland E265B Shop Manual

Hydraulic excavator
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SHOP
MANUAL
INDEX
1
2
3
4
5
6
7
HYDRAULIC EXCAVATOR
model
SPECIFICATIONS SECTION
MAINTENANCE SECTION
SYSTEM SECTION
DISASSEMBLY SECTION
TROUBLESHOOTING
ENGINE SECTION
PROCEDURE OF INSTALLING
OPTIONS SECTION
0-1
E265B
E265B
LC
87731201
Book Code No.

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Summary of Contents for New Holland E265B

  • Page 1 HYDRAULIC EXCAVATOR SHOP E265B E265B MANUAL model INDEX SPECIFICATIONS SECTION MAINTENANCE SECTION SYSTEM SECTION DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION PROCEDURE OF INSTALLING OPTIONS SECTION 87731201 Book Code No.
  • Page 2 GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in mi- nor or moderate injury. It may also be used to alert against possible damage to the machine Do not operate or perform any maintenance on this and its components and is represented as fol- machine until all instructions found in the OPERA- lows:...
  • Page 3 SAFETY PRECAUTIONS stands, capable of supporting the machine, before performing any disassembly. The proper and safe lubrication and maintenance Do not operate this machine unless you have for this machine, recommended by Manufacturer, read and understand the instructions in the OP- are outlined in the OPERATOR’S MANUAL for the ERATOR’S MANUAL.
  • Page 4 (13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera- you understand how to use them before performing tion.
  • Page 5 E265B NDEX NHK Russia E265BLC Book Code No. Index Title Distribution Year–Month S5YN0118E01 OUTLINE 2007-7 S5LQ0218E01 SPECIFICATIONS 2007-7 S5LQ0318E01 ATTACHMENT DIMENSIONS 2007-7 S5LQ1114E01 TOOLS 2007-7 S5LQ1218E01 STANDARD MAINTENANCE 2007-7 TIME SCHEDULE S5LQ1314E01 MAINTENANCE STANDARD 2007-7 AND TEST PROCEDURE S5LQ2118E01 MECHATRO CONTROL...
  • Page 6 NOTE: This Manual is prepared as a technical material in This Manual may be properly revised due to the im- which the information necessary for the maintenance provement of products, modification of specifications, and repairing services of our hydraulic excavators are etc.
  • Page 7 1. OUTLINE TABLE OF CONTENTS GENERAL PRECAUTIONS FOR MAKING REPAIRS ............1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING ............1-3 1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......1-3 1.1.4 ELECTRICAL EQUIPMENT ..................1-4 1.1.5 HYDRAULIC PARTS ....................1-5 1.1.6 WELD REPAIR ......................1-5 1.1.7 ENVIRONMENTAL ISSUES..................1-5 INTERNATIONAL UNIT SYSTEM ..................1-6...
  • Page 8 SK225SR : YB05-03001~ ↑ ↑ SK225SRLC : LA05-02001~ (OCE) ↑ SK460-8: LS10-02001~ ↑ ↑ SK480LC–8 : YS10-01501~ (ASIA, OCE) ↑ E215B : YN11-45001~ ↑ ↑ E215BLC : YQ11-06001~ (NHK Middle East) ↑ E265B : LQ12-06001~ ↑ ↑ E265BLC : LL12-05001~ (NHK Russia)
  • Page 9 1. OUTLINE GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work. MAKING REPAIRS 3) Before starting inspection and maintenance 1.1.1 PREPARATION BEFORE stop the engine. DISASSEMBLING 4) Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to Read Operator's Manual...
  • Page 10 1. OUTLINE 5) For parts which are required to use jig and tools, don’t fail to use the specified jig and tools. 6) For parts which can not be removed in the If hydraulic oil and lubricating oil are not specified procedure, never force removal.
  • Page 11 1. OUTLINE (6) Engine key off before touching terminals of starter (2) Flexible hose (F hose) and alternator. • Even if the connector and length of hose are the (7) Remove battery grounding terminal before same, the parts differ according to the beginning work close to battery and battery relay withstanding pressure.
  • Page 12 1. OUTLINE INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations Table1-4 Introduction Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA of SI units system is described here. Frequency hertz 1Hz=1/s Given hereinunder are an excerpt of the units that are Force newton kg •...
  • Page 13 1. OUTLINE (6) Unit Conversion Table QUANTITIES REMARKS Mass Force 1kgf=9.807N Torque kgf•m N•m 1kgf•m=9.807N•m Pressure kgf/cm 1kgf/cm =0.098MPa Motive power 1PS=0.7355kW Revolution r.p.m 1r.p.m=1min –1 –1...
  • Page 14 1. OUTLINE [MEMO]...
  • Page 15 2. SPECIFICATIONS TABLE OF CONTENTS NAME OF COMPONENTS....................2-3 GENERAL DIMENSIONS ....................2-4 2.2.1 E265B/E265BLC ..2-4 [6.02m (19ft-9in) Boom+2.98m (9ft-9in) Standard Arm+1.0m (1.3cu•yd) Bucket Shoe] 2.2.2 E265B/E265BLC [6.02m (19ft-9in)+2.5m (8ft-2in) Short Arm+1.2m (1.57cu•yd) Bucket Shoe] ..2-4 2.2.3 E265B/E265BLC ..2-5 [6.02m (19ft-9in) Boom+3.66m (12ft-0in) Long Arm+0.81m (1.06cu•yd) Bucket Shoe]...
  • Page 16 2. SPECIFICATIONS Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ0218E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia)
  • Page 17 2. SPECIFICATIONS NAME OF COMPONENTS ARM CYLINDER BOOM BUCKET BOOM CYLINDER CYLINDER SLEWING BEARING SWIVEL JOINT SLEWING MOTOR IDLER LINK FUEL TANK CONTROL VALVE BUCKET LINK HYDRAULIC TANK MUFFLER GUARD HYDRAULIC PUMP BUCKET MONITOR PANEL SHOE AND TRACK LINK FRONT IDLER IDLER ADJUST ENGINE UPPER ROLLER...
  • Page 18 2. SPECIFICATIONS GENERAL DIMENSIONS 2.2.1 E265B/E265BLC [6.02m (19ft-9in) Boom+2.98m (9ft-9in) Standard Arm+1.0m (1.3cu•yd) Bucket Shoe] Unit : mm (ft-in) 10,120 (33'2") 2,970 (9'9") Lower roller Q'ty : 8 pcs or [9 pcs ] 4,260 (13'12") [4,640 (15'3")] (23.6") 2,990 (9'10") [3,190 (10'6")]...
  • Page 19 2. SPECIFICATIONS 2.2.3 E265B/E265BLC [6.02m (19ft-9in) Boom+3.66m (12ft-0in) Long Arm+0.81m (1.06cu•yd) Bucket Shoe] Unit : mm (ft-in) 10,130 (33'3") 4,120 (13'6") 2,970 (9'9") Lower roller Q'ty : 8 pcs. or [9 pcs.] Lower roller Q'ty : 8 pcs. or [9 pcs.] 4,260 (13'12") [4,640 (15'3")]...
  • Page 20 2. SPECIFICATIONS WEIGHT OF COMPONENTS Unit ; kg (lb) Model E265B E265BLC Item Machine complete 24,400 (53,800) 24,900 (54,900) ← 1. Upper frame assy (Assembly of following :) 11,380 (25,100) ← 1.1 Upper frame 2,200 (4,850) ← 1.2 Counter weight (Semi-weighted) 5,820 (12,830) ←...
  • Page 21 2. SPECIFICATIONS Unit ; kg (lb) Model E265B E265BLC Item ← 4. Lubricant and water (Assembly of following :) 590 (1,300) ← 4.1 Hydraulic oil 160 (350) ← 4.2 Engine oil 20 (44) ← 4.3 Fuel 380 (840) ← 4.4 Water 30 (66) Marks * show dry weight.
  • Page 22 2. SPECIFICATIONS TRANSPOTATION 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER (1) 6.02m (19ft-9in) Boom+2.98m (9ft-9in) Arm+1.00m (1.3cu•yd) Bucket Model E265B E265BLC Item Width 600mm (23.6in) shoes 2,990 (9ft-10in) 3,190 (10ft-6in) Weight 24,700kg (54,460 lbs) 25,200kg (55,570 lbs) Unit : mm (ft-in) 10,120 (33'2")
  • Page 23 2. SPECIFICATIONS 2.4.2 DIMENSIONS OF ATTACHMENT (1) BOOM Type 6.02m (19ft-9in) Boom Item 6.25 × 1.71 × 0.75 Length×Height×Width m (ft-in) L×H×W (20'6"× 5'7"× 29.5") Weight kg (lbs) 2,140 (4,720) (2) ARM AND BUCKET Type 2.5m (8ft-2in) Arm + 2.98m (9ft-9in) Arm + 3.66m (12ft) Arm + 1.2m (1.57cu•yd) Bucket...
  • Page 24 2. SPECIFICATIONS (4) Bucket Type Hoe bucket 1.48 × 1.34× 1.06 1.47 × 1.34× 1.27 1.47 × 1.34× 1.44 Length×Height×Width m (ft-in L×H×W (4'10"×4'5"×3'6") (4'10"×4'5"×4'2") (4'10"×4'5"×4'9") Weight kg (lbs) 700 (2,955) 810 (1,790) 850 (1,870) Bucket capacity 0.81 (1.06) STD 1.0 (1.3) 1.2 (1.57) cu•yd Type...
  • Page 25 2. SPECIFICATIONS SPECIFICATIONS AND PERFORMANCE 2.5.1 SPEED AND CLIMBING CAPABILITY Area & Model E265B E265BLC Item Swing speed min- {rpm} 11.0 {11.0} Travel speed (1-speed/2- km/h (mile/h) 3.6 / 5.8 (2.2 / 3.6) speed) Gradeability % (degree) 70 (35) 2.5.2...
  • Page 26 2. SPECIFICATIONS TYPE OF CRAWLER Overall width of crawler Ground pressure Shape Shoe width mm (in) mm (ft-in) kPa (psi) 2,790 (9'10") 53 (7.69) 600 (23.6) Grouser shoe 3,190 (10'6") 49 (7.11) 3,090 (10'2") 46 (6.67) 700 (27.6) 3,290 (10'9") 43 (6.24) 3,190 (10'6") 41 (5.95)
  • Page 27 Prohibited combination : There are problems from the view points of strength and stability. • Use the attachments recommended by NEW HOLLAND KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our...
  • Page 28 2. SPECIFICATIONS ENGINE SPECIFICATIONS 2.9.1 SPECIFICATIONS Applicable machine E265B, E265BLC Engine model HINO J05E-TB Water-cooled, 4 cycle 4 cylinder direct injection type Type diesel engine with inter cooler turbo-charger 4 × 112 × 130 (4.41 × 5.12) Number of cylinder×Bore×Stroke...
  • Page 29 2. SPECIFICATIONS 2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J05E-TB) Condition to be measured: The net value is indicated, measuring with cooling fan. marks show the rated point ENGINE SPEED (min Fuel consumption volume Fuel consumption rate X kW X Load factor ( ) 0.835 X 1000 211g/kW .
  • Page 30 2. SPECIFICATIONS [MEMO] 2-16...
  • Page 31 3. ATTACHMENT DIMENSIONS TABLE OF CONTENTS BOOM ..........................3-3 3.1.1 BOOM DIMENSIONAL DRAWING................3-3 3.1.2 BOOM MAINTENANCE STANDARD ...............3-4 ARM ...........................3-6 3.2.1 ARM DIMENSIONAL DRAWING................3-6 3.2.2 ARM MAINTENANCE STANDARD ................3-7 BUCKET ..........................3-10 3.3.1 BUCKET DIMENSIONAL DRAWING ...............3-10 3.3.2 BUCKET DIMENSIONAL TABLE ................3-10 3.3.3 LUG SECTION DIMENSIONAL DRAWING .............3-11 3.3.4...
  • Page 32 3. ATTACHMENT DIMENSIONS Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ0318E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia)
  • Page 33 3. ATTACHMENT DIMENSIONS BOOM 3.1.1 BOOM DIMENSIONAL DRAWING SECTION X-X Fig. 3-1 Boom dimensional drawing Unit : mm (ft-in) — 6.02M (19ft-9in) BOOM LQ02B00251F1 — NAME DIMENSION Boom length 6,020 (19'9") — Boom foot width 752 (29.6") — Boom end inner width 380 (15.0") —...
  • Page 34 3. ATTACHMENT DIMENSIONS 3.1.2 BOOM MAINTENANCE STANDARD (1) Clearance of pin and bushing on boom section Fig. 3-2 Clearance of pin and bushing on boom section Unit : mm (in) Standard value Clearance Sym- Bushing Repaira Item Pin part No. Pin dia.
  • Page 35 3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom cylinder installation section SECTION C-C SECTION D-D SECTION A-A SECTION B-B Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section Unit : mm (in) Clearance X adjusted with shim Basic size Pin length (total of both sides)
  • Page 36 3. ATTACHMENT DIMENSIONS 3.2.1 ARM DIMENSIONAL DRAWING VIEW J SECTION X-X SECTION Z-Z SECTION Y-Y Fig. 3-4 ARM DIMENSIONAL DRAWING 2.98m (9ft-9in) ARM LQ12B00530F1 (01) Unit : mm (ft-in) Code NAME DIMENSION Code NAME DIMENSION Arm length 2,980 (9'9") Arm cyl. rod inner width 136 (5.35") Distance between pins of boss R930.5 (36.6")
  • Page 37 3. ATTACHMENT DIMENSIONS 3.2.2 ARM MAINTENANCE STANDARD (1) Clearance of pin and bushing D, D' Fig. 3-5 Clearance of pin and bushing on arm section Unit : mm (in) Standard dimensions Clearance Item Pin part No. Remedy Pin dia. Bushing i.d. Standard Service Repairable...
  • Page 38 3. ATTACHMENT DIMENSIONS (2) Clearance of arm and cylinder installing sections in thrust direction D, D' D, D' SECTION A-A SECTION C-C SECTION F-F SECTION E-E X4' L4' SECTION B-B SECTION D-D SECTION G-G Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction...
  • Page 39 3. ATTACHMENT DIMENSIONS Unit : mm (in) Clearance X adjusted with shim Basic size Pin length (total of both sides) Sec. Item Remedy Standard Repairable Size Service limit No. Length value level (12.79) 1.0 (0.04) A-A Arm point or less (0.08) Bucket (12.83)
  • Page 40 3. ATTACHMENT DIMENSIONS BUCKET 3.3.1 BUCKET DIMENSIONAL DRAWING (1) Hoe bucket Fig. 3-7 Bucket dimensional drawing NAME NAME Distance between pin and bracket Inner width of bucket bottom Distance between bucket pin and tooth end Bucket outer width of front side Inner width of bucket top end Pitch between teeth Inner width of lug...
  • Page 41 3. ATTACHMENT DIMENSIONS 3.3.3 LUG SECTION DIMENSIONAL DRAWING BOSS 2416P26834 (1.10) Apply rust prevention oil (0.748) BOSS SHIM LQ61B01016P1 Insert this pin flush with surface Five shims are installed SECTION X-X at shipping DETAIL B Fig. 3-8 Dimension of lug section Unit : mm (ft-in) Capacity of Type of...
  • Page 42 3. ATTACHMENT DIMENSIONS 3.3.4 BOSS SECTION DIMENSIONAL DRAWING (0.197") 15 (0.591") Fig. 3-9 Dimension of boss section Unit : mm (ft-in) Type Capacity of Part No. of Part No. øA øB øC øD øG bucket bucket of boss bucket (cu•yd) 0.81 (1.06) LQ61B00170F1 [STD]...
  • Page 43 11. TOOLS TABLE OF CONTENTS 11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ..........11-3 11.2 SCREW SIZE........................11-5 11.2.1 CAPSCREW (BOLT) ....................11-5 11.2.2 CAPSCREW (SOCKET BOLT) ................11-5 11.2.3 SOCKET SET SCREW...................11-5 11.3 TIGHTENING TORQUE FOR HOSE AND FITTING ............11-6 11.3.1 JOINT (O-RING TYPE)...................11-6 11.3.2 HYDRAULIC HOSE (30°...
  • Page 44 Issue Date of Issue Applicable Machines Remarks SK250-8: LQ12-06001~ S5LQ1114E01 First edition October, 2006 SK260LC–8 : LL12-05001~ (ASIA, OCE) ↑ ↑ ↑ May, 2007 ASIA (HS Engine) ↑ E265B : LQ12-06001~ ↑ July, 2007 E265BLC : LL12-05001~ (NHK Russia) 11-2...
  • Page 45 11. TOOLS 11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS Tables Table11-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given. Overtightening of bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques. Table11-1 Tightening torque for metric coarse threads (not plated) Unit : N•m (lbf•ft) Classification...
  • Page 46 11. TOOLS Table11-2 Tightening torques for metric fine threads (not plated) Torque value Unit : N•m (lbf•ft) Classification 4.8T 10.9T Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication 11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9 P=1.0 (8.3±0.8) (7.0±0.7)
  • Page 47 11. TOOLS 11.2 SCREW SIZE 11.2.1 CAPSCREW (BOLT) Nominal B mm Nominal B mm screw size screw size Tool size Tool size (M14) (M60) (M18) (M68) (M22) (M27) 11.2.2 CAPSCREW (SOCKET BOLT) Nominal B mm Nominal B mm screw size screw size Tool size Tool size...
  • Page 48 11. TOOLS 11.3 TIGHTENING TORQUE FOR HOSE AND FITTING 11.3.1 JOINT (O-RING TYPE) Size Wrench Tightening torque -RING -RING (PF) (mm) N•m (lbf•ft) 1 / 8 17±2 (13±1.5) 1 / 4 36±2 (27±1.5) 3 / 8 74±5 (55±4) 1 / 2 108±9.8 (80.0±7) 3 / 4 162±9.8 (119±7)
  • Page 49 11. TOOLS 11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES Table11-3 indicates standard tightening torques applicable to cases where no particular note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections. Always tighten nuts and sleeves to proper torques.
  • Page 50 11. TOOLS 11.5 PLUG 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT (1) Cap nut (Joint plug) Applicable Opposing flats Cap nut parts T screw tube O. D : A ZF83H06000 ZF83H08000 ZF83H10000 ZF83H12000 T screw ZF83H15000 ZF83H18000 ZF83H22000 ZF83H28000 (2) Plug (Tube plug) Applicable tube Plug parts No.
  • Page 51 11. TOOLS 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT (1) PF screw O-ring PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring PF1/4 ZE72X04000 ZD12P01100 1B P11 PF3/8 ZE72X06000 ZD12P01400 1B P14 PF1/2 ZE72X08000 ZD12P01800 1B P18 PF3/4 ZE72X12000 ZD12P02400 1B P24 ZE72X16000...
  • Page 52 11. TOOLS (4) Plug for ORS joints Male -RING Screw size Applicable -ring Nominal pposing Plug parts No. hose .D parts No. -ring flats (HEX) YN01H01001P1 1-14UNS o21.7 ZD12A01600 1B A16 1 3/16-12UN o27.2 YN01H01002P1 ZD12A01800 1B A18 1 7/16-12UN o34.0 YN01H01003P1 ZD12A02100...
  • Page 53 11. TOOLS 11.6 SPECIAL SPANNER FOR TUBE Applicable tube diameter Part No. HEX (mm) Drawing of a special spanner mm (in) mm (in) 70(2.76) 15 (0.591) 2421T160 (0.630) (0.866) (0.315) 12.7 (0.500 40(1.57) 70(2.76) 42(1.65) 18 (0.709) 2421T138 (0.866) (0.748) 12.7 (0.500 22(0.866)
  • Page 54 11. TOOLS 11.7 SPECIAL TOOLS Table11-4 Tools name Tools No. Shape Applicable Allen wrench ZT22A10000 Pump Nominal suction B : 10, C : 11.3 Commercial tool length (L1) - cut length = Required length 40 (1.57") - 10 (0.39") = 30 (1.18") Spanner or Pump socket...
  • Page 55 11. TOOLS Table11-4 M8 Eye bolt M8 X 18 Additional Plug YN01H01001P1 threading Nominal 1-14UNS Flare hose HEX 27 ZS91C00800 Eye bolt 1-14UNS M8 Eye bolt M8 X 18 Additional Plug YN01H01002P1 threading Nominal HEX 36 Flare hose 1 3/16-12UN ZS91C00800 Eye bolt 1 3/16-12UN...
  • Page 56 11. TOOLS 11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND (1) For general use Manufacturer Service Features Loctite Three-Bond #242 1360K strength Screw locking Middle #262 1374 compound strength High #271 1305 strength Sealing #515 1215 Sealing compound (2) For specific location Manufacturer Name Equivalent...
  • Page 57 11. TOOLS 11.9 SUCTION STOPPER 11.9.1 COMPONENTS NAME PARTS No. Q'TY 24100P978F2 SUCTION STOPPER ASSY 2420T4660D1 ZN16C08007 COVER 2414T2123D2 O-RING 45Z91D6 Cover O-ring Fig. 11-1 Components of suction stopper 11.9.2 DIMENSION (1.97") O113 (4.45") M8 NUT O8 (1.315") +0.5 O100 +0.0197 (3.94 O108...
  • Page 58 11. TOOLS 11.10 COUNTER WEIGHT LIFTING JIG (1) Standard eye bolt Size Vertical Part No. lifting load kg (lbs) ZS91C00800 80 (176) ZS91C01000 150 (331) ZS91C01200 220 (485) ZS91C01600 450 (992) ZS91C02000 630 (1390) ZS91C02400 950 (2090) ZS91C03000 1500 (3310) ZS91C03600 2300 (5070) ZS91C04200...
  • Page 59 11. TOOLS 11.11 UPPER FRAME LIFTING JIG N A M E Q'TY TYPE MASTER LINK L KITO HL050 HIGH COUPLING HC KITO HC020 CHAIN 8 4.4m(14' 5") CHAIN 8 1.5m(4' 11") GRAB HOOK H KITO HH020 HOOK KITO HJ050 Fig. 11-4 Upper frame lifting jig 11-17...
  • Page 60 11. TOOLS 11.12 ENGINE MOUNTING PEDESTAL Material : Wood 245 (9.65) Unit ; mm (inch) 744 (29.3) (3.94) 945 (37.2) (10.8) (11.8) 2 X 1 piece 4 X 1 piece 1 X 1 piece 400 (15.7) 670 (26.4) 200 (7.9) 430 (16.9) (0.98) 120 (2.2)
  • Page 61 11. TOOLS 11.13 TRACK SPRING SET JIG Retainer nut Retainer plate Stand Hydraulic jack Base Fig. 11-6 Track spring set jig 11-19...
  • Page 62 11. TOOLS [MEMO] 11-20...
  • Page 63 12. STANDARD MAINTENANCE TIME TABLE TABLE OF CONTENTS 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4 12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) ....................12-15 12.2.1 MEASURING METHOD ..................12-15 12.2.2 WORKING CONDITION ..................12-15 12.2.3 STANDARD TIME CONSTITUENT ................12-15 12.2.4 MEANING OF WORDS IN USE ................12-17 Book Code No.
  • Page 64 12. STANDARD MAINTENANCE TIME TABLE Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ1218E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia) 12-2...
  • Page 65 12. STANDARD MAINTENANCE TIME TABLE PREFACE (1) Working Conditions 1) Workers : More than one worker shall be 1st class service technician (having five years or more of field experience and having received training in the operation). 2) Equipment : Jigs, tools, apparatuses and testers used in field service work shall be available commercially.
  • Page 66 12. STANDARD MAINTENANCE TIME TABLE 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR (1) Standard maintenance time table 1) Units of working time : 6 minutes = 0.1 hour 2) Calculating method of standard maintenance time : Maintenance time=Working time×Number of workers (Working time=Maintenance time÷Number of workers) 3) When more than one operation is going on : Add each standard service time.
  • Page 67 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour 00 Bucket relation See 32.1.2 01 Bucket ASSY 1 pc. Include adjustment. Detach/attach Preparation 1 pc. • Bucket attaching and detaching position 03 • Bucket attaching pin Include stopper pin.
  • Page 68 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour 71 • Pin bushing Replace 1 set Include seal. 80 Boom cylinder 81 • Pin bushing Replace 1 set Include seal. 10 Cab relation See 33.1.2 Cab ASSY 1 pc.
  • Page 69 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour 50 Under cover relation See 33.1.5 51 Cover (1) 1 pc. Detach/attach 52 Cover (2) 1 pc. Detach/attach 53 Cover (3) 1 pc. Detach/attach 54 Cover (4) 1 pc.
  • Page 70 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour 44 • Inter cooler hose & tube Detach/attach 2 pcs. (E/G to inter cooler) 45 • Radiator lifting or hoisting 1 pc. Detach/attach Cleaning 1 pc.
  • Page 71 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour 96 Swing motor 1 pc. 97 Swing reduction gear 1 pc. 100 Swivel joint relation See 33.1.20 101 Swivel joint ASSY Detach/attach 102 • Piping (Top part only) 1 set Detach/attach 103 •...
  • Page 72 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour Other necessary works 1 set Removing and installing guard Detach/attach 1 set Detach/attach Removing and installing Counterweight 1 set Removing and installing pump Detach/attach 1 set Removing and installing air cleaner 0.4 Detach/attach...
  • Page 73 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour 50 Travel motor relation See 34.1.7 51 Travel motor ASSY One side After removing track link Detach/attach 52 • Motor cover One side Detach/attach 53 •...
  • Page 74 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour Electric equipments E-1 Fuse & relay box Replace E-2 Alternator Replace E-3 Hour meter Replace E-5 Horn (High) Replace E-6 Horn (Low) Replace E-7 Tuner Replace E-8 Speaker left Replace...
  • Page 75 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour P1 pump proportional valve Replace PSV-P1 P2 pump proportional valve Replace PSV-P2 Relay R-1 Battery relay Replace R-2 Starter relay Replace R-3 Glow relay Replace R-4 Safety relay Replace...
  • Page 76 12. STANDARD MAINTENANCE TIME TABLE Work to be Unit : Group Location Unit Remarks done Hour SV-3 2-speed travel SOL Replace Include proportional valve block removing and installing. SV-4 Safety lever lock SOL Replace Include proportional valve block removing and installing. Switch SW-1 Key switch Replace...
  • Page 77 12. STANDARD MAINTENANCE TIME TABLE 12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) Preface This standard working time is based on the work time required for service of engine like disassembly, check, adjustment and assembly and so on under a following condition. This standard working time is provided under the following conditions.
  • Page 78 12. STANDARD MAINTENANCE TIME TABLE 12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME 12.2.3.2.1 HINO allowance rate (0.15~0.75) (1) Basic rate : 0.10 (2) Working posture allowance (Fatigue coefficient) : Take any one of the followings according to the work contents. Standing work : 0.05 Work in bent posture : 0.10 Work while lying : 0.15 (3) Difficult work allowance : 0.30...
  • Page 79 12. STANDARD MAINTENANCE TIME TABLE 12.2.4 MEANING OF WORDS IN USE • Completed machine : When detaching, replacing and adjusting the specified parts, it means the time which is determined by addition of the preparation time, net working time and standard allowance time of the work. •...
  • Page 80 12. STANDARD MAINTENANCE TIME TABLE SK200-8, SK250-8 SK330-8 Q'ty Work No. Work Work unit Works Adding hour Adding hour by 1 each by 1 each Timing adjustment Completed 00101 Engine adjustment A set machine Valve clearance adjustment Completed 00103 Engine adjustment B set A set and nozzle adjustment —...
  • Page 81 12. STANDARD MAINTENANCE TIME TABLE SK200-8, SK250-8 SK330-8 Q'ty Work No. Work Work unit Works Adding hour Adding hour by 1 each by 1 each Include; Valve lapping Exclude; Replacing of valve guide, Completed 00324 Overhaul of cylinder head 13.3 18.8 machine water pressure test and replacing...
  • Page 82 12. STANDARD MAINTENANCE TIME TABLE SK200-8, SK250-8 SK330-8 Q'ty Work No. Work Work unit Works Adding hour Adding hour by 1 each by 1 each 00552 Replacing crank shaft rear oil seal From fly wheel is removed condition Single unit 00613 Replacing intake manifold One set Include;...
  • Page 83 12. STANDARD MAINTENANCE TIME TABLE SK200-8, SK250-8 SK330-8 Q'ty Work No. Work Work unit Works Adding hour Adding hour by 1 each by 1 each From timing gear cover is removed 00739 Replacing cam idle gear shaft Single unit condition From timing gear cover is removed 00731 Replacing camshaft...
  • Page 84 12. STANDARD MAINTENANCE TIME TABLE SK200-8, SK250-8 SK330-8 Q'ty Work No. Work Work unit Works Adding hour Adding hour by 1 each by 1 each Include; Checking for temperature at 01049 Checking thermostat One set valve start opening 01053 Replacing coolant hose One set 01054 Replacing radiator hose...
  • Page 85 12. STANDARD MAINTENANCE TIME TABLE SK200-8, SK250-8 SK330-8 Q'ty Work No. Work Work unit Works Adding hour Adding hour by 1 each by 1 each 01901 Replacing main engine speed sensor One set Include; Function check 01902 Replacing sub engine speed sensor One set Include;...
  • Page 86 12. STANDARD MAINTENANCE TIME TABLE [MEMO] 12-24...
  • Page 87 13. MAINTENANCE STANDARD AND TEST PROCEDURE TABLE OF CONTENTS 13.1 ..13-3 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED 13.2 PERFORMANCE INSPECTION STANDARD TABLE .............13-4 13.3 MEASUREMENT OF ENGINE SPEED ................13-6 13.3.1 MEASUREMENT OF ENGINE SPEED ..............13-6 13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............13-7 13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE ........13-7...
  • Page 88 Issue Date of Issue Applicable Machines Remarks SK250-8: LQ12-06001~ S5LQ1314E01 First edition October, 2006 SK260LC–8 : LL12-05001~ (ASIA, OCE) ↑ ↑ ↑ May, 2007 ASIA (HS Engine) ↑ E265B : LQ12-06001~ ↑ July, 2007 E265BLC : LL12-05001~ (NHK Russia) 13-2...
  • Page 89 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED (1) Application 1) When the machine is new ; Confirm that the performances are in accordance with standard specifications as compared to the performance standards.
  • Page 90 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.2 PERFORMANCE INSPECTION STANDARD TABLE The mode is already "S" mode when power is thrown. Unless otherwise specified, measure it on "H" mode. Table13-1 Measuring Position Tolerance Measuring Standard Adjusting Inspection Item Unit value Point condition Position...
  • Page 91 13. MAINTENANCE STANDARD AND TEST PROCEDURE Standard Inspection item Unit value 1st speed 32.7 ~ 29.5 Sprocket revolution (RH,LH) 2nd speed 52.9 ~ 47.9 2.8 ~ 3.4 Boom Down 2.3 ~ 2.9 3.2 ~ 3.8 Operating time of (At no load) cylinder 2.6 ~ 3.2 Digging...
  • Page 92 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.3 MEASUREMENT OF ENGINE SPEED 13.3.1 MEASUREMENT OF ENGINE SPEED (1) Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90°C (140 to 194°F) at surface of radiator upper tank.
  • Page 93 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4 MEASUREMENT OF HYDRAULIC PRESSURE 13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE (1) Hydraulic equipment 6.9 MPa (1000psi) pressure gauge : 1unit 49 MPa (7100psi) pressure gauge : 2 units Pressure measuring equipment and instrument for analysis : 1 set (A1) PSV2...
  • Page 94 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.3 PRESSURE ADJUSTMENT POSITION (1) Main control valve PLUG FOR OPTIONAL RELIEF OR8 : ARM (R) MACHINE FRONT MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R) (ATT & TRAVEL) VIEW FROM THE TOP OF THE MACHINE OR4 : BOOM (R) OR1 : BUCKET (H) MACHINE...
  • Page 95 13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pilot relief valve The pilot relief valve PR1 is located on the gear pump that is attached to the main pump. PR1 ADJUST SCREW FOR PILOT RELIEF Fig. 13-5 Pilot relief valve position (3) Swing over load relief The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is carried out using gauge ports (a1) and (a2).
  • Page 96 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE (1) Pilot relief valve Adjust it with adjust screw (311). : 24 mm, Tightening torque : 29.4 N•m (22 lbf•ft) : 6 mm No. of turns of adjust screw Pressure change MPa (psi) OCK NUT HEX24 1 turn...
  • Page 97 13. MAINTENANCE STANDARD AND TEST PROCEDURE HIM FOR ADJU TING (4) Over load relief valve (Swing) This valve was adjusted by valve maker. If adjustment is required, adjust with shim thickness. When you cannot perform a check of setting HEX14 pressure, do not adjust pressure by any means.
  • Page 98 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5 MEASURING TRAVEL PERFORMANCES 13.5.1 TRAVEL SPEED (1) Purposes Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system. (2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Crawler on the right and left sides are tensioned evenly.
  • Page 99 13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Preparation 1) Straight course more than 30m (108ft) 2) Travel position in which the bottom of the bucket is lifted by about 30cm (1ft). (4) Measurement 20m (66ft) 1) Measure the max. deviation distance of the circular arc in the 20m (66ft) length, excluding Fig.
  • Page 100 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5.4 DRAIN RATE OF TRAVEL MOTOR (1) Purpose o 10 FORWARD (0.394") (3.54") To measure the drain rate of the travel motor and to o 22 PIPE confirm the performances of the travel motor. (0.866") (1.57") (2) Conditions...
  • Page 101 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.6 MEASURING SWING PERFORMANCES 13.6.1 SWING SPEED (1) Purpose Measure the swing time and confirm the performances between the hydraulic pump and the swing motor of the swing drive system. (2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground Engine revolution;...
  • Page 102 13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Measurement MEASURING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE 1) When operating in regular swing speed, by MATCHING MARKS ON shifting lever to neutral position at pole position OUTER RACE the swing operation stops.
  • Page 103 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.6.4 DRAIN RATE OF SWING MOTOR (1) Purpose Measure the drain rate of the swing motor and confirm the performances of the swing motor. (2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground Engine revolution;...
  • Page 104 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES 13.7.1 OPERATING TIME OF CYLINDERS (1) Purpose Measure the operating time of the boom, arm and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system.
  • Page 105 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.7.2 OIL TIGHTNESS OF CYLINDERS (1) Purpose Confirm that the cylinder oil tight by checking the OOM FOOT PIN moving length of the cylinder rods. (2) Condition Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground ARM TOP PIN After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness.
  • Page 106 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.8 MEASURING PERFORMANCES OF SWING BEARING (1) Purpose LOCATION OF BEARING Measure the gap between the lower frame and the MOUNTING BOLTS bottom face of the swing bearing and estimate the degree of wear of the swing bearing. SWING BEARING (2) Condition Firm, level ground...
  • Page 107 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9 MECHATRO CONTROLLER 13.9.1 ENGINE CONTROL INPUT / OUTPUT E-27: EMERGENCY C-8: ACCEL ENGINE CONTROLLER INJECTOR E-1: FUSE&RELAY C-2: GAUGE CLUSTER ENGINE ENGINE SPEED SENSOR PUMP PROPORTIONAL VALVE C-1: STARTER MECHATRO CONTROLLER ACCEL SWITCH POTENTIO METER Fig.
  • Page 108 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.3 PREPARATION (1) Raise the oil temperature to about 50°C (122°F) to warm up the engine. (2) Turn the air-con OFF. (3) Turn the starter key switch OFF to stop the engine. When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered.
  • Page 109 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.4 ADJUSTING PROCEDURE MULTI DISPLAY WORK MODE SELECT SWITCH BUZZER STOP SWITCH WASHER SWITCH WIPER SWITCH SELECT SWITCH Fig. 13-35 Gauge cluster (1) Adjustment of engine ("A" adjustment) Procedure 1) Turn starter key switch ON keeping the work mode selector switch on the MULTI DISPLAY (EXAMPLE) gauge cluster pressed, and hold it for 5~10 seconds, and then release it.
  • Page 110 13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Adjustment of pump ("B" adjustment) Procedure E ORY PU P 1) The adjustment automatically shifts from engine to pump, the speed shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the ENGINE SPEED 2000rpm PU P PRESSURE...
  • Page 111 13. MAINTENANCE STANDARD AND TEST PROCEDURE 2) In cases where the adjustment of pump can not be performed; And "ERROR RROR PUMP PUMP" is displayed. NGIN SP D 2000rpm Judging condition 1: PUMP PR SSUR C-1 35.0M C-2 35.0M PROPO-VALV P1 and P2 average pump pressure at the time when the adjustment is -1 300mA -2 300mA...
  • Page 112 13. MAINTENANCE STANDARD AND TEST PROCEDURE (6) When the adjustment of unloading valve only is performed; ("C" adjustment) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only. Procedure 1) Turn starter switch ON keeping the work mode selector switch on the gauge MULTI DISPLAY (EXAMPLE) cluster pressed, and hold it for 5~10 seconds, and then release it.
  • Page 113 13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER (1) Engine emergency mode When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating emergency acceleration (E-27) provided on the seat rear side.
  • Page 114 13. MAINTENANCE STANDARD AND TEST PROCEDURE [MEMO] 13-28...
  • Page 115 21. MECHATRO CONTROL SYSTEM TABLE OF CONTENTS 21.1 SUMMARY OF MECHATRO CONTROL SYSTEM............21-4 21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..........21-4 21.1.2 UNLOAD VALVE CONTROL..................21-6 21.1.3 POSITIVE CONTROL & P-Q CONTROL ...............21-7 21.1.4 BOOM UP CONFLUX CONTROL ................21-9 21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL..........21-10 21.1.6 ARM-IN ANTI-CAVITATION CONTROL ..............21-12 21.1.7...
  • Page 116 21. MECHATRO CONTROL SYSTEM Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ2118E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia) 21-2...
  • Page 117 21. MECHATRO CONTROL SYSTEM PREFACE This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system. 21-3...
  • Page 118 21. MECHATRO CONTROL SYSTEM 21.1 SUMMARY OF MECHATRO CONTROL SYSTEM 21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ELECTRIC CONTROLLER INPUT IGNAL HYDRAULIC VOLTAGE OUTPUT PILOT ECONDARY PRE URE OLENOID PROPORTIONAL VALVE ECONDARY PRE URE OLENOID PROPORTIONAL VALVE PRIMARY PRE URE MAIN CIRCUIT OPTION PILOT VALVE PILOT VALVE PILOT VALVE...
  • Page 119 21. MECHATRO CONTROL SYSTEM MAIN CONTROL VALVE SE-29 ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT SV-13 P1 P2 DIGGING REVERSE REVERSE RIGHT ARM IN SOLENOID VALVE SWING MOTOR PARKING RELEASE TRAVEL MOTOR 1,2 SPEED SELECT BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX ARM CYLINDER ARM OUT CONFLUX...
  • Page 120 21. MECHATRO CONTROL SYSTEM 21.1.2 UNLOAD VALVE CONTROL N&B SELECTOR VALVE SOLENOID PILOT PILOT (LEFT) (RIGHT) VALVE VALVE OPTIONAL PILOT VALVE PILOT VALVE FOR TRAVEL PRESSURE PRESSURE SE-11 SENSOR SENSOR SE-10 SE-9 SE-1~4 SE-5,7,8 PILOT SIGNAL PROCESS P2 UNLOAD PROPORTIONAL VALVE PSV-B PILOT SECONDARY PRESSURE PILOT SIGNAL...
  • Page 121 21. MECHATRO CONTROL SYSTEM 21.1.3 POSITIVE CONTROL & P-Q CONTROL N&B SELECTOR VALVE SOLENOID OPTIONAL PILOT VALVE SE-23 SE-22 SE-11 PILOT PILOT (LEFT) (RIGHT) VALVE VALVE PILOT VALVE FOR TRAVEL PRESSURE PRESSURE SENSOR SENSOR SE-10 SE-9 SE-1~4 SE-5,7,8 PILOT SIGNAL P2 PUMP P2 PUMP PROCESS...
  • Page 122 21. MECHATRO CONTROL SYSTEM (1) Positive control 1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
  • Page 123 21. MECHATRO CONTROL SYSTEM 21.1.4 BOOM UP CONFLUX CONTROL N&B SELECTOR VALVE SOLENOID PILOT VALVE PRESSURE SENSOR SE-3 PILOT SIGNAL P2 PUMP PROCESS PROPORTIONAL VALVE PSV-P2 BOOM UP PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS P1 PUMP PROPORTIONAL VALVE PSV-P1 BOOM UP PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS P2 UNLOAD...
  • Page 124 21. MECHATRO CONTROL SYSTEM 21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL N&B SELECTOR VALVE SOLENOID PILOT VALVE PRESSURE PRESSURE SENSOR SENSOR SE-1~6 SE-7 CONTROL PROCESS FOR 2 SPEED PILOT SIGNAL PROCESS P2 PUMP PROPORTIONAL VALVE PSV-P2 ARM IN PILOT SECONDARY PRESSURE P1 PUMP PROPORTIONAL VALVE PSV-P1...
  • Page 125 21. MECHATRO CONTROL SYSTEM (1) Recirculation and conflux (Low loading) 1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
  • Page 126 21. MECHATRO CONTROL SYSTEM 21.1.6 ARM-IN ANTI-CAVITATION CONTROL N&B SELECTOR VALVE SOLENOID PILOT VALVE ACCEL PRESSURE POTENTIO SENSOR SE-7 PILOT SIGNAL P2 PUMP PROCESS PROPORTIONAL VALVE PSV-P2 ARM IN PILOT SECONDARY PRESSURE PILOT SIGNAL REVERSE PROPORTIONAL PROCESS VALVE CONTROL PROCESS FOR ARM 2 SPOOL PSV-B ARM IN PILOT SECONDARY PRESSURE REVERSE PROPORTIONAL...
  • Page 127 21. MECHATRO CONTROL SYSTEM 21.1.7 ARM-OUT CONFLUX CONTROL N&B SELECTOR VALVE SOLENOID PILOT VALVE PRESSURE SENSOR SE-8 PILOT SIGNAL P2 PUMP PROCESS PROPORTIONAL VALVE PSV-P2 ARM OUT PILOT SECONDARY PRESSURE P1 PUMP PROPORTIONAL VALVE PSV-P1 ARM OUT PILOT SECONDARY PRESSURE P2 UNLOAD PROPORTIONAL VALVE PSV-B...
  • Page 128 21. MECHATRO CONTROL SYSTEM 21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL N&B SELECTOR VALVE SOLENOID PILOT VALVE PRESSURE SENSOR SE-1(2) PILOT SIGNAL P2 PUMP PROCESS PROPORTIONAL VALVE PSV-P2 BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE PILOT SIGNAL P1 PUMP PROCESS PROPORTIONAL VALVE PSV-P1 BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE PILOT SIGNAL P2 UNLOAD...
  • Page 129 21. MECHATRO CONTROL SYSTEM 21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL N&B SELECTOR VALVE SOLENOID PILOT VALVE PRESSURE SENSOR SE-1 (2) PILOT SIGNAL PROCESS P2 PUMP PROPORTIONAL VALVE PSV-P2 BUCKET DIGGING PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS P1 PUMP PROPORTIONAL VALVE PSV-P1 BUCKET DIGGING PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS...
  • Page 130 21. MECHATRO CONTROL SYSTEM (1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and is input to low pressure sensor. (2) The engine speed command output by accel potentiometer is input to mechatro controller. (3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve.
  • Page 131 21. MECHATRO CONTROL SYSTEM 21.1.10 SWING PRIORITY CONTROL PILOT VALVE N&B SELECTOR VALVE SOLENOID PRESSURE SENSOR PILOT SIGNAL PROCESS P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL ARM IN PILOT SECONDARY PRESSURE VALVE PSV-P1 PILOT SIGNAL PROCESS P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL...
  • Page 132 21. MECHATRO CONTROL SYSTEM 21.1.11 TRAVEL STRAIGHT CONTROL OPTIONAL N&B PILOT VALVE SELECTOR VALVE SOLENOID (LEFT) (RIGHT) PILOT PILOT VALVE VALVE PILOT VALVE FOR TRAVEL SE-11 SE-9 SE-10 PRESSURE SENSOR TRAVEL STRAIGHT SIGNAL PILOT SIGNAL TRAVEL STRAIGHT PROCESS PROPORTIONAL VALVE PSV-C PILOT SECONDARY PRESSURE PILOT SIGNAL P2 PUMP...
  • Page 133 21. MECHATRO CONTROL SYSTEM (1) Judgment travel straight 1) During travel operation (right and left), pilot pressure switches each spool and is input to low pressure sensor on carrying out attachment system operation. 2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on.
  • Page 134 21. MECHATRO CONTROL SYSTEM 21.1.12 PRESSURE RELEASE CONTROL N&B SELECTOR VALVE SOLENOID GAUGE CLUSTER PILOT VALVE SE-22 SE-23 ENGINE PRESSURE RELEASE ENGINE SPEED CONTROL CONTROL PILOT SIGNAL P2 PUMP PROCESS PROPORTIONAL VALVE PSV-P2 PILOT SIGNAL P1 PUMP PROCESS PROPORTIONAL VALVE PSV-P1 PILOT SIGNAL PROCESS P2 UNLOAD...
  • Page 135 21. MECHATRO CONTROL SYSTEM 21.1.13 N&B SWITCH CONTROL (OPTION) PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE SOLENOID A MODE B MODE GAUGE CLUSTER B MODE SWITCH MECHATRO CONTROLLER pi : OUTPUT OF N&B SELECTOR SOLENOID (1) Nibbler circuit 1) Select A mode through gauge cluster. 2) Nibbler display appears on gauge cluster.
  • Page 136 21. MECHATRO CONTROL SYSTEM 21.1.14 OPTION CONFLUX CONTROL (OPTION) N&B SELECTOR VALVE SOLENOID PILOT VALVE SINGLE / CONFLUX SWITCH PRESSURE SENSOR SE-11 PILOT SIGNAL P2 PUMP PROCESS PROPORTIONAL VALVE PSV-P2 OPTION PILOT SECONDARY PRESSURE PILOT SIGNAL P1 PUMP PROCESS PROPORTIONAL VALVE PSV-P1 OPTION PILOT SECONDARY PRESSURE PILOT SIGNAL...
  • Page 137 21. MECHATRO CONTROL SYSTEM 21.2 MECHATRO CONTROLLER 21.2.1 SUMMARY OF MULTI DISPLAY Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. (1) Controls EMERGECY ACCEL DIAL SWING PARKING BRAKE RELEASE SWITCH GAUGE CLUSTER SAFETY LOCK LEVER RIGHT CONTROL LEVER...
  • Page 138 21. MECHATRO CONTROL SYSTEM (3) Screen selection by work mode select switch After starting engine, "S" mode is usually set. The work modes "S","H","B" and "A" are selected in order every time ( ) is pressed. Select efficient work mode according to the working condition and the purpose from the following table. The selected mode is displayed on the left lower corner on multi display.
  • Page 139 21. MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode) Switches Screen change switch Buzzer stop switch KPSS work mode select switch Washer switch Wiper switch Travel speed select switch Auto accel switch Select switch Fig. 21-1 According to some kind of attachment, it is required to change the flow rate for service circuit.
  • Page 140 21. MECHATRO CONTROL SYSTEM (4) MAINTENANCE SCREEN DISPLAYS This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. For the initial set value of recommenced replacement/change time, see the following table. Replacement interval Item Default Engine oil 500 Hr...
  • Page 141 21. MECHATRO CONTROL SYSTEM (5) Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The display functions of multi display are explained below. CLOCK DISPLAY SELF DIAGNOSIS / WARNING MACHINE CONDITION MULTI DISPLAY INDICATIONS 1) Display function for operator ..
  • Page 142 21. MECHATRO CONTROL SYSTEM 21.2.2 SELF DIAGNOSIS DISPLAY (1) Outline This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector No.
  • Page 143 21. MECHATRO CONTROL SYSTEM Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine. 21-29...
  • Page 144 21. MECHATRO CONTROL SYSTEM 21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes according to the conditions like engine speed, attachment position, etc.
  • Page 145 21. MECHATRO CONTROL SYSTEM (2) Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.) 1) Service diagnosis mode No.1 Displays Contents Displays Contents...
  • Page 146 21. MECHATRO CONTROL SYSTEM NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR C-1 PUMP P1 B-11 3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value C-2 PUMP P2 B-12 3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value C-3 BOOM-HEAD...
  • Page 147 21. MECHATRO CONTROL SYSTEM Displays Contents Displays Contents NO.23 DIGITAL OUTPUT NO.27 MERIT SYSTEM DO15 COMP. OFF Set value in computer MEAS. OFF Measured value COMMUNICATION Status of communication in MERIT controller DO16 COMP. OFF Set value in computer MEAS. OFF Measured value DO17 COMP.
  • Page 148 21. MECHATRO CONTROL SYSTEM 3) Service diagnosis mode No.3 Displays Contents Displays Contents NO.1 NO.43 MACHINE-INFORM. MAIN CONT. P/N HOUR METER 3550 Hour meter of controller YN22E00001F1 P/No. indication TRIP METER 3500 Trip meter of controller PROGRAM VERSION OPERATION 3300 All accumulated operating time 1-VER 11.11 Program version indication...
  • Page 149 21. MECHATRO CONTROL SYSTEM (3) Service diagnosis data list Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use these data to decide normal/abnormal status. • The values in following display are reference values with standard attachment attached machine. •...
  • Page 150 21. MECHATRO CONTROL SYSTEM Operation No.5 : Boom down in full lever operation & in operation H mode Hi idle No.31 BOOM P1-PRES 10.5~14.0 M P2-PRES 0.7~2.0 M P1-PSV 585~605 mA P2-PSV 350 mA P1-UL(BPC) 435~485 mA P2-UL(BPC) 750 mA BOOM RAISE 0.0 M BOOM LOWER...
  • Page 151 21. MECHATRO CONTROL SYSTEM Operation No.9 : Operation No.8 : Arm-out in full lever operation & in operation Arm-out in full lever operation & relief H mode Hi idle H mode Hi idle No.32 ARM, SWING No.32 ARM, SWING P1-PRES 33.0~35.8 M P1-PRES 15.0~22.0 M...
  • Page 152 21. MECHATRO CONTROL SYSTEM Operation No.12 : Operation No.13 : Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation H mode Hi idle H mode Hi idle No.33 BUCKET No.33 BUCKET P1-PRES 33.0~35.8 M P1-PRES 3.5~7.5 M...
  • Page 153 21. MECHATRO CONTROL SYSTEM Operation No.16 : Operation No.17 : P2 side option in full lever operation & relief P2 side option in full lever operation & relief A mode Hi idle B mode Hi idle No.35 OPT No.35 OPT P1-PRES 22.5~26.0 M P1-PRES...
  • Page 154 21. MECHATRO CONTROL SYSTEM 21.2.4 TROUBLE HISTORY DIAGNOSIS The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one of history. And the errors are able to be indicated on the multi display. The warning content is record partially in "Travel history screen".
  • Page 155 21. MECHATRO CONTROL SYSTEM 21.2.5 TROUBLE DIAGNOSIS MODE The recent control system includes many electrical systems and it makes troubleshooting very difficult. The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be detected through the use of self diagnosis function (the failure can be specified through the use of error code) like disconnection and abnormal output.
  • Page 156 21. MECHATRO CONTROL SYSTEM 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/ change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc.
  • Page 157 21. MECHATRO CONTROL SYSTEM 21.2.7 ADJUSTING PROCEDURE OF DISPLAY (1) For operator 1) Auto idling stop Switchs Screen change switch Buzzer stop switch KPSS work mode select switch Washer switch Wiper switch Travel speed select switch Auto accel switch Select switch Fig.
  • Page 158 21. MECHATRO CONTROL SYSTEM 2) Clock Adjustment Switches Switches Screen Change Switch Buzzer Stop Switch KPSS Work Mode Select Switch Washer Switch Wiper Switch Travel Speed Select Switch Auto Accel Switch Select Switch Main screen SWITCH STATUS 10:25 13:15 CLOCK/CONTRAST Enter SWITCH STATUS ADJUST CLOCK...
  • Page 159 21. MECHATRO CONTROL SYSTEM 3) Contrast Adjustment Switches Switches Screen Change Switch Buzzer Stop Switch KPSS Work Mode Select Switch Washer Switch Wiper Switch Travel Speed Select Switch Auto Accel Switch Select Switch Main screen SWITCH STATUS 10:25 CLOCK/CONTRAST SWITCH STATUS ADJUST CLOCK 10:25 CLOCK/CONTRAST...
  • Page 160 21. MECHATRO CONTROL SYSTEM (2) Function for service Following items are provided for adjustment of service function. Item CONTENTS Language Language selection Rise-up wiper Wiper control change (When cab is changed) Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor P2 option pressure sensor...
  • Page 161 21. MECHATRO CONTROL SYSTEM 21.2.8 MECHATRO CONTROL EQUIPMENT (1) C-1 Mechatro controller 1) Outside view 2 1 4 2 1 16 12 CN101 CN102 CN103 CN104 CN105 CN106 CN107 CN108 CN109 2) List of connectors Connector No. Pin No. Port name Function Signal level Input/putput...
  • Page 162 21. MECHATRO CONTROL SYSTEM Connector No. Pin No. Port name Function Signal level Input/putput CN102 Travel right Input 0.5~4.5V +5VA Power output 5V +5VA Power output 5V Travel left Input 0.5~4.5V Accelation Input 0.5~4.5V +5VA Power output 5V +5VA Power output 5V P1 option Input 0.5~4.5V...
  • Page 163 21. MECHATRO CONTROL SYSTEM Connector No. Pin No. Port name Function Signal level Input/putput CN104 Boom head Input 0.5~4.5V +5VA Power output 5V +5VA Power output 5V Boom rod Input 0.5 4.5V Extra pressure source Input 0.5~4.5V +5VA Power output 5V +5VA Power output 5V Spare...
  • Page 164 21. MECHATRO CONTROL SYSTEM Connector No. Pin No. Port name Function Signal level Input/putput CN106 +24V 20~32V Battery relay secondary side SHGF Shield GND Output +24V 1.5A Accel motor A phase (spare) Output +24V 1.5A Accel motor A phase (spare) Output +24V 1.5A Accel motor B phase (spare)
  • Page 165 21. MECHATRO CONTROL SYSTEM Connector No. Pin No. Port name Function Signal level Input/putput CN108 DI 2 Key switch (ON) Input +24V / OPEN DI 4 Spare Input +24V / OPEN DI 5 Swing P/B release Input GND / OPEN DI 6 E/G start Input...
  • Page 166 21. MECHATRO CONTROL SYSTEM (2) Gauge cluster (symbol C-2) 1) General view MULTI DISPLAY LCD COOLANT TEMPERATURE GAUGE FUEL LEVEL GAUGE MATED SIDE AMP 040 HOUSING : 174044-2 TERMINAL : 173681-2 SCREEN CHANGE SWITCH ETC. BUZZER STOP SWITCH WORK MODE SWIHCH 2) Connector CN-600 (Harness side) Item name Wire color...
  • Page 167 21. MECHATRO CONTROL SYSTEM (3) Relay & fuse box (symbol E-1) 1) General view (Overhead view of box) LABEL INSIDE Note) These circles indicate the parts which are used in standard specification CN16 CN17 CN4-1 CN2-2 CN2-1 CN14 CN15 CN4-2 CN4-2 CN3-1 CN3-2...
  • Page 168 21. MECHATRO CONTROL SYSTEM 2) Circuit diagram 21-54...
  • Page 169 21. MECHATRO CONTROL SYSTEM 21-55...
  • Page 170 21. MECHATRO CONTROL SYSTEM 21-56...
  • Page 171 21. MECHATRO CONTROL SYSTEM (4) High pressure sensor : YN52S00048P1 SPECIFICATION : ECONOSEAL SERIES MARK (+)> 3POLES CAP PRESSURE RANGE : 0 50 MPa MATING HOUSING174357-2 POWER SOURCE VOLTAGE : 5.0+0.5V DC OUTPUT : 1/10Vs-9/10Vs COMMON (Vs=5V DC 0.5 4.5V DC) OUTPUT (+) INSURANCE RESISTANCE : 100M OR MORE...
  • Page 172 21. MECHATRO CONTROL SYSTEM [MEMO] 21-58...
  • Page 173 22. HYDRAULIC SYSTEM TABLE OF CONTENTS Paste here Book Code No. S5LQ2218E01 22-1...
  • Page 174 22. HYDRAULIC SYSTEM Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ2218E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia) 22-2...
  • Page 175 22. HYDRAULIC SYSTEM 22.1 SUMMARY The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass volume handling and low fuel consumption. Table22-1 Perfor- Device Function Features mance Travel straight Travel straight at combined operation Travel 2-speed change &...
  • Page 176 22. HYDRAULIC SYSTEM 22.2 HYDRAULIC CIRCUITS AND COMPONENTS STD. SCHEMATIC HYD. LINES LQ01Z00052P1 Item Component name Part No. Model No. LQ10V00018F1 K3V112DTP (STD : without PTO.) Hyd. pump assy LQ10V00019F1 K3V112DTP (OPT. : with PTO.) Control valve (main) LQ30V00024F1 KMX15YD Swing motor unit LQ15V00021F1 MFC160...
  • Page 177 22. HYDRAULIC SYSTEM 22.2.1 STANDARD SE22 SE23 A2 a2 SWING MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 RIGHT LEFT 28.5MPa TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa 37.8MPa...
  • Page 178 22. HYDRAULIC SYSTEM 22.2.2 N&B SPECIFICATION (OPTION) N&B specification YN01Z00162P1 PARTS PART No. MODEL No. SELECTOR VALVE YN30V00104F1 VBY-174B STOP VALVE 24100P3133F1 PILOT VALVE YN30V00080F1 16030-00000 YN22V00002F1 KRX16EK22 RELIEF VALVE NOTE: 1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT. TRAVEL 2.
  • Page 179 22. HYDRAULIC SYSTEM This page is blank for editing convenience. 22-7...
  • Page 180 22. HYDRAULIC SYSTEM 22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly, when the servo piston moves rightward, the FOR HYDRAULIC CIRCUITS (1) Type : This section describes the following. spool (652) is moved leftward by the feedback Electric flow controlled variable displacement Blue...
  • Page 181 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 182 22. HYDRAULIC SYSTEM 22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN This section describes the following. FUNCTION (1) Travel forward pilot simultaneous operation circuit (1) Purpose : (2) 2 speed travel solenoid command circuit and auto Change travel motor speed with switch.
  • Page 183 22. HYDRAULIC SYSTEM SE22 SE23 A2 a2 SWING MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 184 22. HYDRAULIC SYSTEM 22.6 BUCKET CIRCUIT 5) The secondary pressure delivered in travel 3) With the function of pilot circuit, the oil flow is straight proportional valve (PSV-C) is led to switched from bucket spool, and is fed into This section describes the following. PTb port provided in control valve (2) and shifts bucket cylinder head side through AC port of C/ (1) Bucket digging pilot circuit...
  • Page 185 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 186 22. HYDRAULIC SYSTEM 22.7 BOOM CIRCUIT This section describes the boom raise conflux operation. (1) Boom up pilot circuit (2) Boom up 2 pumps conflux main circuit in C/V 22.7.1 BOOM RAISE PILOT CIRCUIT (1) Operation : 1) If boom up operation is performed, the secondary pilot proportional pressure from the right pilot valve (10) gets out of port 3 and acts upon the low pressure sensor (SE3).
  • Page 187 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 188 22. HYDRAULIC SYSTEM This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION OF BOOM DOWN MAIN CIRCUIT (1) Boom down pilot circuit (1) Purpose : (2) Prevention of natural fall by lock valve and Prevention of cavitation during boom actuation at lowering lowering motion.
  • Page 189 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 190 22. HYDRAULIC SYSTEM 22.8 SWING CIRCUIT 22.8.2 SWING AUTO PARKING BRAKE (1) Purpose : This section describes the following operations. Swing lock in neutral position and parking (1) Swing left pilot circuit (2) Principle : (2) Swing auto parking brake Release mechanical brake only when required to (3) Swing main circuit operate swing and arm in.
  • Page 191 22. HYDRAULIC SYSTEM SE22 SE23 A2 a2 SWING MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 192 22. HYDRAULIC SYSTEM 22.9 ARM CIRCUIT with P2 pump delivery oil in the valve section, and then is flowed into arm cylinder head (H) This section describes the following operations. side through Aa port of C/V (2). (1) Arm in, light-load operating pilot circuit 3) The return oil from arm cylinder (R) side flows (2) Arm in, light-load variable normal recirculation main in Ba port of C/V (2) and passes through the Ba...
  • Page 193 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 194 22. HYDRAULIC SYSTEM This section describes the following operations. 4) The return oil returns directly into tank circuit because arm 2 spool is switched to (3) Arm in, heavy load operating pilot circuit recirculation cut position. (recirculation cut) (4) Arm in, heavy load operating sequence confluxed Position of arm 2 spool main circuit Neutral position...
  • Page 195 22. HYDRAULIC SYSTEM SE22 SE23 A2 a2 SWING MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 196 22. HYDRAULIC SYSTEM This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE (5) Arm out pilot circuit (1) Purpose : (6) Arm out 2 pumps conflux main circuit To prevent the arm from falling naturally by the (7) Natural fall protection with arm lock valve weight of the arm and bucket.
  • Page 197 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 198 22. HYDRAULIC SYSTEM 22.10 COMBINED CIRCUIT 22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT (1) Purpose : This section describes only the difference in combined To insure straight travel movement during travel operation. operation even if the attachment is operated. (1) Boom up / travel, pilot circuit (2) Principle : (2) Boom up / travel, main circuit The travel action and the attachment action are...
  • Page 199 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 200 22. HYDRAULIC SYSTEM In this section, the independent operation is omitted 22.10.4 SWING / ARM IN, SWING PRIORITY MAIN and describes difference in combined operation. CIRCUIT (3) Swing / Arm in light load, pilot circuit (1) Purpose : Stable swing speed. (4) Swing / Arm in, swing priority main circuit (2) Principle : 22.10.3...
  • Page 201 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 202 22. HYDRAULIC SYSTEM 22.11 PRESSURE DRAINING (3) Operation : (RELEASING) CIRCUIT 1) Pump proportional valve reduces the pump flow rate to the minimum. This section describes the following operations. 2) Unloading proportional valves (PSV-D, PSV-B) (1) Pressure drain (releasing) pilot circuit output secondary pressure and the secondary (2) Pressure drain (releasing) main circuit pressure flows in PCb, PCa ports of C/V(2) and...
  • Page 203 22. HYDRAULIC SYSTEM SE22 SE23 SWING A2 a2 MAIN PUMP PSV1 PSV2 PH1 PH2 PSV-P1 PSV-P2 28.5MPa RIGHT LEFT TRAVEL TRAVEL B D E E F F C A 5.0MPa 136kw /2100min- B3 Dr3 (OPT) MAIN CONTROL VALVE SWING RIGHT 34.3MPa SWING LEFT 37.8MPa...
  • Page 204 22. HYDRAULIC SYSTEM [MEMO] 22-32...
  • Page 205 23. ELECTRIC SYSTEM TABLE OF CONTENTS Paste here Book Code No. S5LQ2318E01 Book Code No. S5XX230XJ0X 23-1...
  • Page 206 23. ELECTRIC SYSTEM Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ2318E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia) 23-2...
  • Page 207 23. ELECTRIC SYSTEM 23.1 ELECTRIC CIRCUIT DIAGRAM APPLICABLE YN11-45001- MACHINE No. YQ11-06001- LC10-07001- ENG. HARNESS C-8 : ENGINE CONTROLLER YC10-03501- LQ12-06001- LL12-05001- ENG. SPEED SENSOR FOR ECU SH7 SHIELD E-1 : FUSE & RELAY BOX EGR VALVE 1 R-26 : LEVER LOCK RELAY EGR VALVE 2 SK330...
  • Page 208 23. ELECTRIC SYSTEM C-1 : MECHATRO CONTROLLER (TCO-60-2) FROM 1/4 SE-16 : ACCEL POTENTIO PRESS. SENSOR SE-1 : BUCKET DIGGING C-8 : ENG. CONTROLLER SE-2 : BUCKET DUMP ENG. HARNESS SE-3 : BOOM UP INJECTOR 1 SE-4 : BOOM DOWN SW-4 : SWING PARKING BRAKE RELEASE SW.
  • Page 209 23. ELECTRIC SYSTEM C-1 : MECHATRO CONTROLLER (TCO-60-2) FROM 2/4 R-17 : EXTRA RELEASE RELAY SW-7 : ENG. OIL PRESS SW. SV-11 : SW-8 : AIR FILTER CLOGGING SW. EXTRA RELEASE SOL R-5 : HORN RELAY E-5 : HORN HIGH E-5 : HORN LOW SW-10 : HORN SW.
  • Page 210 23. ELECTRIC SYSTEM C-1 : MECHATRO CONTROLLER (TCO-60-2) C-1 : MECHATRO CONTROLLER (TCO-60-2) FROM 3/4 C-6 : AUTO GREASE CONTROLLER R-26 : SV-6 : LEVER LOCK RELAY SW-33 : REVOLUTION SE-24 : REVOLUTION RIGHT SOL R-12 : PRESS SENSOR : BOOM HEAD RIGHT SW.
  • Page 211 23. ELECTRIC SYSTEM 23.2 ELECTRICAL EQUIPMENT LIST GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. MECHATRO CONTROLLER YN22E00214F1 BOOM WORK LIGHT (LH) YW80S00001F1 PRESSURE SENSOR : LC52S00019P1 SE-1 (TCO-60-2) (HARD) BOOM WORK LIGHT (RH) YT80S00002F2 BUCKET DIGGING GAUGE CLUSTER...
  • Page 212 23. ELECTRIC SYSTEM 23.3 HARNESS 23.3.1 HARNESS LIST DIVISION DRAWING No. HARNESS REMARKS ITEM NAME ASSEMBLY No. CODE No. NAME DRAWING No. POSITION INSTRUMENT PANEL ASSY YN17M00058F1 CONTROLLER INSTALL (ENGINE) YN22E00220F1 CONTROLLER INSTALL YN22E00219F1 CONVERTER YN77S00028F1 UPPER ELEC ASSY LC03E00008F1 UPPER HARNESS ASSY LQ13E00042F1 HARNESS...
  • Page 213 23. ELECTRIC SYSTEM 23.3.2 INSTRUMENT PANEL ASSY TIGHTENING TORQUE INSTRUMENT PANEL ASSY YN17M00058F1 (03) 1.5N . m (1.1lbf . ft) TIGHTENING TORQUE TIGHTENING TORQUE SEMS BOLT ITEM PART NAME PART No. Q'TY REMARKS 5.2N . m (3.8lbf . ft) 5.2N . m (3.8lbf . ft) 2 PLACES INSTALL TO CAB POTENTIO METER...
  • Page 214 23. ELECTRIC SYSTEM 23.3.3 CONTROLLER INSTALL CONTROLLER INSTALL(ENGINE) YN22E00220F1 CONVERTER YN77S00028F1 (03) (01) ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS CONTROLLER C8:ECU CONVERTER YT77S00001P1 ENGINE ACSSESSORY TIGHTENING TORQUE 1.7N . m (1.3lbf . ft) CONTROLLER C5:COOLANT LEVEL ENGINE ACSSESSORY...
  • Page 215 23. ELECTRIC SYSTEM 23.3.4 UPPER ELECTRIC ASSY UPPER ELECTRIC ASSY LC03E00008F1 (02) ITEM PART NAME PART No. Q'TY REMARKS BATTERY RELAY YN24S00008F1 HORN LC53S00001D1 HIGH HORN LC53S00001D2 AFTER INSTALLING GLOW RELAY AND STARTER RELAY TO BRACKET (A), ASSEMBLE THIS BRACKET TIGHTENING TORQUE SEMS BOLT 23.5N .
  • Page 216 23. ELECTRIC SYSTEM 23.3.5 UPPER HARNESS ASSY (1/6) CLIP : NOTES: UPPER HARNESS ASSY LQ13E00042F1 (03) FIX WHITE TAPING POSITION CLIP (1) TIGHTENING TORQUE OF BATTERY TERMINALS ARE 3.4N . m (2.5 lbf . ft). ITEM PART NAME PART No. Q'TY REMARKS (2) TIGHTENING TORQUE OF...
  • Page 217 23. ELECTRIC SYSTEM 23.3.5 UPPER HARNESS ASSY (2/6) REST SOL. SIDE HARNESS IS FIX WHITE TAPING BUNDLED THIS POSITION SV-11 : POSITION AND FASTEN WITH CONNECTOR EXTRA PRESS SOL. (OPT) CLIP CLIP L-2 : FRAME WORKING LIGHT RIGHT E-13 : SE-15 : TRAVEL ALARM (OPT) UPP FRAME...
  • Page 218 23. ELECTRIC SYSTEM 23.3.5 UPPER HARNESS ASSY (3/6) C-8 : ENG. CONTROLLER E-1 : 34P CONNECTOR 35P(A) CONNECTOR 32P CONNECTOR 35P(B) CONNECTOR 31P CONNECTOR FUSE & RELAY BOX WITH "CN-1F"TAG WITH "CN-2F"TAG WITH "CN-3F"TAG WITH "CN-4F"TAG WITH "CN-5F"TAG C-1 : VIEW MECHATRO CONNECT CONNECTOR...
  • Page 219 23. ELECTRIC SYSTEM 23.3.5 UPPER HARNESS ASSY (4/6) SW.-8 : SV-1 : FIX A HARNESS PART SV-4 : AIR FILTER RESTRICTION SW. SV-3 : SV-2 : SW.ING PARKING OPERATING OF COULGATED OF TWO-SPEED POWER BOOST SOL. BRAKE SOL. CLIP TO SW. LEVER LOCK SOL.
  • Page 220 23. ELECTRIC SYSTEM 23.3.5 UPPER HARNESS ASSY (5/6) TIGHTENING TORQUE 3.43N . m (2.53 lbf . ft) F TERMINAL USE NUT OF ATTACHED S TERMINAL GLOW RELAY GROW RELAY CONNECT TO 2P CONNECTOR 9 GLOW RELAY - STARTER RELAY FOR HARNESS OF ATTACHED HARNESS TIGHTENING TORQUE GLOW RELAY...
  • Page 221 23. ELECTRIC SYSTEM 23.3.5 UPPER HARNESS ASSY (6/6) TO HARNESS OF ATTACHED ENG. ALTERNATOR(B) TIGHTENING TORQUE ALTERNATOR (B) 3.3~4.4N . m(2.4~3.2lbf . ft) GLOW ENG. SUB HARNESS CLIP FIX WITH ENG. ENG. SUB HARNESS SUB HARNESS PART OF ALTERNATOR B TERMINAL UPP HARNESS CLIP SEAMS BOLT...
  • Page 222 23. ELECTRIC SYSTEM 23.3.5-1 UPPER HARNESS (1/4) : LQ13E01144P5 SEALING PLUG TO BE SEALING PLUG TO BE SE-15 : INSERTED IN TO ALL INSERTED IN TO ALL FUEL SENSOR TO BE INSTALLED SUPPLY SUPPLY ITEM 2 CAP WITH WITH E-6 : HORN LOW SV-5 : SV-11 :...
  • Page 223 23. ELECTRIC SYSTEM 23.3.5-1 UPPER HARNESS (2/4) : LQ13E01144P5 WHITE TAPING CAP TO BE INSTALLED 7034-1279 GLOW RELAY ; PSV-P2 : (COMMON) CAP TO BE DOUBLE PUMP P2 PROPORTIONAL SOL. INSTALLED TAPING AFTER SPLICE TAPING AFTER WHITE TAPING 7034-1279 BUNDLED BUNDLED E-10 : GLOW RELAY ;...
  • Page 224 23. ELECTRIC SYSTEM 23.3.5-1 UPPER HARNESS (3/4) : LQ13E01144P5 WHITE TAPING WHITE TAPING R-19 : FLASHER RELAY DOUBLE SPLICE TO HARNESS (CAB) TO HARNESS (CAB SUB) DOUBLE SPLICE SUPPLY WITH SUMITOMO 6409-0075 DOUBLE SPLICE C-5 : RADIATOR COOLANT LEVEL CONTROLLER TAPING DOUBLE SPLICE...
  • Page 225 23. ELECTRIC SYSTEM 23.3.5-1 UPPER HARNESS (4/4) : LQ13E01144P5 CONNECTORS SELECTION TABLE WIRE WIRE WIRE WIRE NO WIRE SIZE FROM CONNECTION WIRE NO WIRE SIZE FROM CONNECTION WIRE NO WIRE SIZE FROM CONNECTION COLOR COLOR COLOR CONNECTIOR PART NUMBER MANUFUC. NAME HOUSING TERMINAL...
  • Page 226 23. ELECTRIC SYSTEM 23.3.5-2 ECU HARNESS (1/2) : LQ13E01137P1 SEALING PLUG DOUBLE DOUBLE DOUBLE SPLICE SPLICE SPLICE ACCEL WHITE TAPING REDUNDANT TO FUSE & RELAY BOX TO ENGINE CONTROL WHITE TAPING HARNESS WHITE TAPING INSTALL DOUBLE CORRUGATE SEALING PLUG HARNESS (FLOOR) SEALING TAPING PLUG...
  • Page 227 23. ELECTRIC SYSTEM 23.3.5-2 ECU HARNESS (2/2) : LQ13E01137P1 23.3.5-3 BATTERY GROUNDING CABLE : LC13E01144P1 WIRE WIRE WIRE NO WIRE SIZE FROM CONNECTION WIRE NO WIRE SIZE FROM CONNECTION COLOR COLOR SHIELDED CABLE (2 CORE) SHIELDED CABLE (2 CORE) SHIELDED CABLE (2 CORE) 23.3.5-4...
  • Page 228 23. ELECTRIC SYSTEM 23.3.5-6 STARTER CABLE : LQ13E01145P1 23.3.5-8 AIR CLEANER HARNESS : LC13E01193P1 TERMINAL INSTALL DOUBLE CORRUGATE SW-8 : AIR FILTER CLOGGING TERMINAL SWITCH WHITE TAPING INSTALL WHITE TAPING YAZAKI 7034-1283 CORRUGATE TUBE CAP TO BE INSTALLED TERMINAL SUPPLY WIRE No.35 YAZAKI 7034-1283 WITH...
  • Page 229 23. ELECTRIC SYSTEM 23.3.6 ENGINE HARNESS ASSY E-11 : HARNESS (ECU) ENGINE HARNESS ASSY LQ16E00010F1 (03) AIR COMPRESSOR ENGINE ACCESORY CLUTCH ITEM PART NAME PART No. Q'TY REMARKS HARNESS LQ16E01015P1 ENGINE SUB M-1 : STARTER CABLE STARTER MOTOR TIGHTENING TORQUE 23.5N .
  • Page 230 23. ELECTRIC SYSTEM 23.3.6-1 ENGINE SUB-HARNESS : LQ16E01015P1 E-2 : AL ERNA OR SW-7 : ENGINE OIL PRESS. SW. SEALING PLUG ENGINE COOLAN HERMO SENSOR (FOR ECU) WHI E APING SEALING PLUG O UPP HARNESS 23-26...
  • Page 231 23. ELECTRIC SYSTEM 23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) SE-3 : UPPER HARNESS ASSY LC13E00032F1 NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS (10) PRESS SENSOR : SE-4 : MADE INTO THE FOLLOWING. BOOM RAISING ITEM PART NAME PART No.
  • Page 232 23. ELECTRIC SYSTEM 23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) (2/2) SW-10 : E-1 : HORN SW. LEFT (OPT) (BLUE TAPING) FUSE & RELAY SW-21 : C-1 : POWER BOOST SW. LEFT (OPT) MECHATRO (YELLOW TAPING) CONNECT THE "CNT-2" TAGGED C-8 : ENG. CONTROLLER CONTROLLER CONNECTOR WITH "UPPER HARNESS"...
  • Page 233 23. ELECTRIC SYSTEM 23.3.7-1 FLOOR HARNESS (1/3) : YN13E01449P3 SE-9 : PRESS SENSOR : TRAVEL RIGHT SW-1 : KEY SW. WHITE TAPING SUPPLY WITH SW-39 : AMP 1565123-1 NIBBLER OPEN WHITE TAPING PRESSURE SW. SUPPLY WITH TAPING AFTER TAPING AFTER SUPPLY BUNDLED BUNDLED...
  • Page 234 23. ELECTRIC SYSTEM 23.3.7-1 FLOOR HARNESS (2/3) : YN13E01449P3 S -12 : DOUBLE SPLICE OVER LOAD S -36 : S -18 : S -40 : ALARM INDEPENDENT LMN / BH SELECT S . ROTARY LIGHT SELECT S . TRAVEL S . S -35 : TAPING AFTER TAPING AFTER...
  • Page 235 23. ELECTRIC SYSTEM 23.3.7-1 FLOOR HARNESS (3/3) : YN13E01449P3 23-31...
  • Page 236 23. ELECTRIC SYSTEM 23.3.7-4 CAB SUB-HARNESS : LC13E01186P1 TO HARNESS (UPPER) E-1 : FUSE & RELAY BOX TO CAB HARNESS 23.3.7-9 FLOOR GROUNDING CABLE : LE13E01005P1 1PAF YAZAKI 7123-3010 23-32...
  • Page 237 23. ELECTRIC SYSTEM 23.3.8 CAB HARNESS ASSY CAB HARNESS ASSY LC14E00023F1 (07) ITEM PART NAME PART No. Q'TY REMARKS E-1 : HARNESS YN14E01102P3 FUSE & RELAY BOX C-1 : HARNESS YN14E01106P1 KEY S/W GROUND MECHATRO CONTROLLER CAB SUB HARNESS E-23 : 12V SOCKET E-9 : SPEAKER RIGHT...
  • Page 238 23. ELECTRIC SYSTEM 23.3.8.1 CAB HARNESS (1/2) : YN14E01102P3 E-8 : SPEAKER LEF DOUBLE SPLICE WHI E APING DOUBLE APING AF ER SPLICE BUNDLED O CAB WORKING LIGH O CAB WORKING LIGH DOUBLE E-9 : SPLICE DOUBLE SPEAKER RIGH SPLICE WHI E APING O ROOF WIPER E-23 :...
  • Page 239 23. ELECTRIC SYSTEM 23.3.8.2 CAB HARNESS (2/2) : YN14E01102P3 23.3.8-6 KEY SWITCH GROUND HARNESS : YN14E01106P1 23-35...
  • Page 240 23. ELECTRIC SYSTEM 23.3.9 BOOM HARNESS ASSY 23.3.10 INSTALLING BOOM LIGHT LC80E00004F1 BOOM HARNESS ASSY LQ15E00025F1 INSTALLING BOOM LIGHT (04) (01) ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS LIGHT YW80S00001F1 2 HARNESS LQ15E01009P1 BOOM LIGHT FIX WHITE CLIP TO THE...
  • Page 241 23. ELECTRIC SYSTEM 23.3.11 INSTALLING UPPER LIGHT 23.3.12 INSTALLING CAB LIGHT INSTALLING UPPER LIGHT YN80E00049F1 INSTALLING CAB LIGHT YN80E00072F1 (01) (01) ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS LIGHT YT80S00002F2 HARNESS YN02C01760P1 SWITCH YN50S00040D4 RELAY YN24S00010P1...
  • Page 242 23. ELECTRIC SYSTEM 23.3.12-5 CAB LIGHT HARNESS : YN02C01760P1 23.3.13 FUEL PUMP ASSY FUEL PUMP ASSY YN22P00024F1 (01) ITEM PART NAME PART No. Q'TY REMARKS FUEL PUMP ASSY YF22P00008F1 LEVEL SENSOR YF52S00004P1 TIGHTENING TORQUE 147N . m (108 lbf . ft) HOSE SECTION CC CLIP...
  • Page 243 23. ELECTRIC SYSTEM 23.3.13-1 FUEL PUMP ASSY FUEL PUMP ASSY YF22P00008F1 (01) ITEM PART NAME PART No. Q'TY REMARKS FUEL PUMP YF22P00009P1 RUBBER PLUG : AMP 172888-2 HOUSING : AMP 174259-2 BLACK GREEN WHITE LOCK PLUG : AMP 174260-7 CONTACT : AMP 173706-1 PF3/4 NOTE : 1) MAKER : JABSCO CO.
  • Page 244 23. ELECTRIC SYSTEM [MEMO] 23-40...
  • Page 245 24. COMPONENTS SYSTEM TABLE OF CONTENTS 24.1 HYDRAULIC COMPONENTS ..................24-3 24.1.1 HYDRAULIC PUMP • REGULATOR ..............24-3 24.1.2 CONTROL VALVE....................24-21 24.1.3 PILOT VALVE (ATT)....................24-59 24.1.4 PILOT VALVE (TRAVEL) ..................24-63 24.1.5 SWING MOTOR UNIT ....................24-65 24.1.6 TRAVEL MOTOR ....................24-73 24.1.7 SWIVEL JOINT.......................24-90 24.1.8 CYLINDER......................24-92 24.2 ELECTRIC EQUIPMENT....................24-97...
  • Page 246 24. COMPONENTS SYSTEM Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ2418E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia) 24-2...
  • Page 247 24. COMPONENTS SYSTEM 24.1 HYDRAULIC COMPONENTS 24.1.1 HYDRAULIC PUMP • REGULATOR 24.1.1.1 SUMMARY (1) Outside view and Hydraulic port EYE BOLT (M10) 2X4-M12 Depth 22 VIEW MAX. FLOW RATE ADJUSTING SCREW MIN. FLOW RATE MIN. FLOW ADJUSTING SCREW RATE ADJUSTING SCREW Hydraulic ports Q'TY...
  • Page 248 24. COMPONENTS SYSTEM (2) Hydraulic circuit diagram (FRONT) (REAR) (KDRDE5K) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K) Solenoid proportional Solenoid proportional reducing valve (PSV-2) reducing valve (PSV-1) Regulator Regulator Engine Gear pump for pilot Main pump PTO gear case Fig. 24-2 Hydraulic circuit diagram of pump (3) Specifications Main pump Item...
  • Page 249 24. COMPONENTS SYSTEM 24.1.1.2 HYDRAULIC PUMP 24.1.1.2.1 CONSTRUCTION (1) Main pump 953 806 Apply adhesive (Three Bond No.1305N) 901 808 954 401 251 490 271 313 124 710 116 312 885 314 141 153 156 157 Tightening torque Tightening torque Item number Thread size N .
  • Page 250 24. COMPONENTS SYSTEM (2) Gear pump (For pilot) Suction port : PF3/4 Tightening torque : 73.5N . m (54.2 lbf . ft) Delivery port : PF1/2 Tightening torque : 53N . m (39.1 lbf . ft) Drain port : PF3/8 Tightening torque : 34.3N .
  • Page 251 24. COMPONENTS SYSTEM (3) PTO gear case (OPT.) Parts Q’ty Parts Q’ty 115 Idle shaft 435 Flange socket ; M10×20 117 2nd gear 468 VP plug ; PF3/4 118 3rd gear 710 O-ring ; 1B G80 125 Ball bearing 711 O-ring ; 1B G85 126 Roller bearing 728 O-ring ;...
  • Page 252 24. COMPONENTS SYSTEM 24.1.1.2.2 OPERATION The pump assy is equipped with two pumps arranged on the same axis that are connected with gear (116) and distribute the rotating power to the REGULATOR gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the auxiliary pump (OPT) arranged on another shaft.
  • Page 253 24. COMPONENTS SYSTEM (1) Swash plate group The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), tilting pin (531), and servo 214 211 piston (532). The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support.
  • Page 254 24. COMPONENTS SYSTEM 24.1.1.3 REGULATOR 24.1.1.3.1 CONSTRUCTION 543 755 545 541 724 466, 755 644 646 645 VIEW C SECTION B-B SECTION A-A At start and emergency mode Tightening torque Tightening torque Item No. Thread size N . m (lbf . ft) 29 (21.4) 412,413 At normal...
  • Page 255 24. COMPONENTS SYSTEM Parts Q'ty Parts Q'ty Parts Q'ty Socket bolt ; M8X50 Adjusting screw (C) O-ring ; 1B P16 Socket bolt ; M8X70 Cover (C) O-ring ; 1B P20 Socket bolt ; M5X12 Lock nut ; M30X1.5 O-ring ; 1B G25 Socket bolt ;...
  • Page 256 24. COMPONENTS SYSTEM 24.1.1.3.2 OPERATION (1) Control function Control function …… Electric flow control. •Positive flow control. •Total horsepower control. Emergency mode control. •Hydraulic positive control. •Hydraulic total horsepower control (2) Summary The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control mechanism as mentioned below: 1) Electric flow control and positive flow control The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the...
  • Page 257 24. COMPONENTS SYSTEM a. Flow rate increase (See Fig. 24-11) CL port : As the command current value I rises, the Connect with large diameter chamber of secondary pressure P2 of electromagnetic servo piston proportional pressure-reducing valve rises, and by pressing pilot piston (643) in (A) direction it stops at the position the secondary pressure P2 balances the pilot spring force (646).
  • Page 258 24. COMPONENTS SYSTEM b. Flow rate decrease (See Fig. 24-12) CL port : As the command current value I is reduced, the Connect with large diameter chamber of secondary pressure P2 of electromagnetic servo piston proportional pressure-reducing valve is reduced, and by pressing pilot piston (643) in (G) direction it stops at the position the pilot spring force (646) L 897...
  • Page 259 24. COMPONENTS SYSTEM a. Overload prevention operation (See Fig. 24-14) Because the delivery pressure Pd1 acts on the CL port : Connect with large compensating rod stepped section with the rise diameter chamber of servo piston of self pump delivery pressure Pd1 the compensating rod (623) is pushed towards (M), and moves to the position the delivery pressure Pd1 balances the spring force of outer spring...
  • Page 260 24. COMPONENTS SYSTEM b. Flow rate recovery operation (See Fig. 24-15) Because the compensating rod (623) is pushed CL port : towards (S) with the force of outer spring (625) Connect with large diameter chamber of and inner spring (626) with reduction of self servo piston pump delivery pressure Pd1, and moves to the position the spring force of outer spring (625)
  • Page 261 24. COMPONENTS SYSTEM 4) Power shift control As shown in Fig. 24-16, the pump set power is controlled according to the movement of control by power shift pressure Pf. As power pressure Pf rises, the compensating rod (623) moves rightward through pin (898) and compensating piston (621).
  • Page 262 24. COMPONENTS SYSTEM (3) Adjusting the input horsepower (At emergency mode) Since the regulator is of total horsepower control type, turn the adjust screws of both the front (No.1) and rear (No.2) pumps when changing horsepower set values. Adjust the horsepower settings of both pumps to a same level.
  • Page 263 24. COMPONENTS SYSTEM 24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter YN33-II" (1) When the engine is overloaded, Load every unit of pump, and check on pumps on the right and left sides for possible damages.
  • Page 264 24. COMPONENTS SYSTEM 24.1.1.4 CONTROL CURVE OF PUMP 2100min 300mA (H mode) [1] 136kW E/G horse power [3] 126kW H mode at traveling or optional working 1900min [4] 98kW H mode at operating attachment S mode [5] 89kW S mode at operating attachment Input revolution ;2100 min Input horse power ;136 kW...
  • Page 265 24. COMPONENTS SYSTEM 24.1.2 CONTROL VALVE 24.1.2.1 SPECIFICATIONS 24.1.2.1.1 OUTSIDE VIEW P1 unload Travel left Travel P2 unload straight CMR1 CMR2 CMR1 CMR2 Travel Boom conflux right (HEAD) (HEAD) Swing Boom (ROD) (ROD) PBa1 PBa1 Bucket PLc2 PLc2 (HEAD) (HEAD) Arm 1 PAa1 PBa1...
  • Page 266 24. COMPONENTS SYSTEM 24.1.2.1.2 PORTS Port size Tightening torque Ports Description PF3/4 150~180 N•m (111~133 lbf•ft) (T3) Pluged PF1/2 98~120 N•m (72~89 lbf•ft) (P3) Pluged (P4) Pluged PF3/8 69~78 N•m (51~58 lbf•ft) PAa1 Arm 1 (in) pilot port PBa1 Arm 1 (out) pilot port Boom (up) pilot port Boom (down) pilot port Bucket (digging) pilot port...
  • Page 267 24. COMPONENTS SYSTEM Port size Tightening torque Ports Description Optional pilot port Optional pilot port 24.1.2.1.3 SPECIFICATIONS Item Specifications Model KMX15YD/B44011 Maximum flow rate [L/min (gal/min)] 246 (65)×2 Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port) Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 85×2L/min (22.5×2gal/min)] When power boost pressure...
  • Page 268 24. COMPONENTS SYSTEM 24.1.2.2 CONSTRUCTION AND OPERATION 24.1.2.2.1 CONSTRUCTION (1) Control valve PAa1 PBa1 (P4) 162 163 169 155 SECTION A-A PAa2 PBa2 (P3) SECTION B-B Fig. 24-23 Section (1/6) 24-24...
  • Page 269 24. COMPONENTS SYSTEM 273x10 273x10 P1 unload Travel left (Travel straight) Boom conflux Travel right (P2 unload) 978x2 Boom Swing PBa1 PBa1 Bucket Arm 1 PBa2 PBa2 Arm 2 Option PBp1 PBp1 PBp2 PBp2 (P3) (P3) PBa2 PBa2 PBp1 PBp1 PBp2 PBp2 274x4...
  • Page 270 24. COMPONENTS SYSTEM P1 unload Travel left CMR2 CMR1 ECTION C-C Travel straight Travel right Boom conflux (T3) ECTION D-D P2 unload Fig. 24-25 Section (3/6) 24-26...
  • Page 271 24. COMPONENTS SYSTEM Swing Boom SECTION E-E 164 551 Bucket Arm 1 PBa1 PAa1 SECTION F-F Fig. 24-26 Section (4/6) 24-27...
  • Page 272 24. COMPONENTS SYSTEM Arm 2 Option PBa2 LCAT2 LCAP2 PAa2 SECTION G-G SECTION H-H Fig. 24-27 Section (5/6) 24-28...
  • Page 273 24. COMPONENTS SYSTEM PBp1 PBp2 278x5 SEC ION J-J SEC ION K-K Fig. 24-28 Section (6/6) 24-29...
  • Page 274 24. COMPONENTS SYSTEM Tightening torque Tightening torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 101 Casing A 321 Spring 102 Casing B 322 Spring 154 Plug PF3/4 323 Spring 220~250 (162~184) 155 Plug PF1/2 324 Spring 110~130 (81~96) 325 Spring 20~24 (15~18) Plug PT1/4 MEC (Pre-coat bolt) 326 Spring...
  • Page 275 24. COMPONENTS SYSTEM (2) Main relief valve (Two step relief) (601) Fig. 24-29 Main relief valve (Two step relief) Tightening torque Tightening torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 69~78 (51~58) 103 Plug ; M27 562 Back up ring 104 Adjust screw 611 Poppet 121 C-ring...
  • Page 276 24. COMPONENTS SYSTEM (3) Over load relief valve (602,603,605) Fig. 24-30 Over load relief valve Tightening Tightening torque Parts Q’ty torque Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 69~78 (51~58) 101 Body ; M27 541 Seat 69~78 (51~58) 102 Plug ; M27 561 O-ring 161 O-ring 562 Backup ring...
  • Page 277 24. COMPONENTS SYSTEM (4) Arm 2 spool (308) 371 361 340 319 Fig. 24-31 Arm 2 spool Tightening Tightening torque torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 308 Spool 16~18 (33~35) Loctite #638 350 Plug 317 Plunger 16~18 (33~35) Loctite #638 351 Plug 319 Plunger 361 O-ring...
  • Page 278 24. COMPONENTS SYSTEM (6) Lock valve selector (211) Fig. 24-33 Lock valve selector Tightening Tightening torque torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 101 Casing 10~14 (7.4~10.3) 171 Socket bolt 161 O-ring 49~59 (36~44) 201 Plug 164 O-ring 321 Spring 166 O-ring 511 Spool...
  • Page 279 24. COMPONENTS SYSTEM (7) Bypass cut valve (606) " " Fig. 24-34 Bypass cut valve Tightening torque Tightening torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 98~120 (72~89) 101 Plug 301 Plunger 102 O-ring 302 Spring 201 Poppet 69~78 (51~58) 401 Plug 202 Spring 402 O-ring...
  • Page 280 24. COMPONENTS SYSTEM (8) Swing shuttle valve cover (204) G1/4 SECTION B-B G3/8 SECTION A-A Fig. 24-35 Swing shuttle valve cover Tightening Tightening torque torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 166 O-ring 542 Seat 202 Cover 25~29 (18~21) 554 Plug 541 Steel ball 7.9~9.8 (5.9~7.2) 555 Plug...
  • Page 281 24. COMPONENTS SYSTEM (9) Boost check valve (517) Fig. 24-36 Boost check valve Tightening Tightening torque torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) 101 Poppet 20~29 (15~21) Loctite #262 104 Plug 102 Poppet 107 Spring 24-37...
  • Page 282 24. COMPONENTS SYSTEM 24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM CMR1 CMR2 Travel straight Travel left P1 unload Boom conflux (T3) Travel right P2 unload CP 1 Swing Boom D ) Bb PBa1 AD) Ab Arm 1 PAa1 Aa (H LC c Bucket PLc2 (ROD) B (HEA...
  • Page 283 24. COMPONENTS SYSTEM 24.1.2.2.3 OPERATION (1) In neutral position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.
  • Page 284 24. COMPONENTS SYSTEM (2) Actuation in travel operation 1) In travel independent operation On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310).
  • Page 285 24. COMPONENTS SYSTEM 2) In travel straight operation When actuator other than travel operation and the travel operation are operated simultaneously in the said item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward.
  • Page 286 24. COMPONENTS SYSTEM (3) Actuation in bucket operation 1) In bucket digging operation On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309).
  • Page 287 24. COMPONENTS SYSTEM 2) In bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc).
  • Page 288 24. COMPONENTS SYSTEM (4) Boom 1) In boom up operation On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCa and switches unloading spool (309).
  • Page 289 24. COMPONENTS SYSTEM 2) In boom up conflux operation The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side.
  • Page 290 24. COMPONENTS SYSTEM 3) In boom down operation On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches unloading spool (309).
  • Page 291 24. COMPONENTS SYSTEM (5) Arm operation 1) In arm out operation On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
  • Page 292 24. COMPONENTS SYSTEM 2) In arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
  • Page 293 24. COMPONENTS SYSTEM 3) In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR].
  • Page 294 24. COMPONENTS SYSTEM (6) Swing operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
  • Page 295 24. COMPONENTS SYSTEM (7) Spool actuation for operation in option This spool is used to control the attachment in option like Nibbler (Crusher), etc. Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (323) (324), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
  • Page 296 24. COMPONENTS SYSTEM (8) Lock valve operation The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder.
  • Page 297 24. COMPONENTS SYSTEM 2) In boom down operation ((In arm in operation) Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the Fig. 25-52. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).
  • Page 298 24. COMPONENTS SYSTEM (9) By-pass cut valve This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each center by-pass passage to low pressure passage (D).
  • Page 299 24. COMPONENTS SYSTEM 2) At the time when failure occurred When the electric system is failed and consequently the secondary pressure of solenoid proportional valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other.
  • Page 300 24. COMPONENTS SYSTEM (10)Boost check valve, By-pass check valve 1) Boost check valve The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage. a. In normal operation The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1.
  • Page 301 24. COMPONENTS SYSTEM 2) By-pass check valve Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage.
  • Page 302 24. COMPONENTS SYSTEM This page is blank for editing convenience. 24-58...
  • Page 303 24. COMPONENTS SYSTEM 24.1.3 PILOT VALVE (ATT) 24.1.3.1 OUTLINE (1) Outside view 5-PF3/8 Single operating angle Single operating angle T=49.0 (36.1) (Port 2, 4) (Port 1, 3) The adjust nut (opposing flats : 22) : Fix adjust nut (opposing flats : 22) PF1/4 when the lever is installed by T=29.4 (21.7)
  • Page 304 24. COMPONENTS SYSTEM 24.1.3.2 CONSTRUCTION Apply Loctite #277 Apply grease on rotating and sliding sections. Be careful the Apply grease on top section assembling direction *246 *218-2 *218-1 216-2 216-1 241-2 241-1 201-2 201-1 Secondary pressure adjusting shim PORT 1,3 PORT 2,4 Fig.
  • Page 305 24. COMPONENTS SYSTEM 24.1.3.3 OPERATION (1) Lever in neutral (See Fig. 24-58) The action of spring (509) (for secondary pressure setting) that determines the output pressure of the pilot valve does not act upon spool (201). Therefore, spool (201) (for return) is pushed up by spring (221) [spring seat (216)].
  • Page 306 24. COMPONENTS SYSTEM (4) Operation in the area where the tilting angle of the lever is large. (varies with the model) If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts the bottom of the bore of the push rod.
  • Page 307 24. COMPONENTS SYSTEM 24.1.4 PILOT VALVE (TRAVEL) 24.1.4.1 OUTLINE (1) Outside view Tightening torque Function Port size Port name N . m (lbf . ft) LH travel forward port LH travel reverse port PF3/8 30 (22) RH travel forward port RH travel reverse port Tank port LH travel pressure sensor port...
  • Page 308 24. COMPONENTS SYSTEM 24.1.4.2 Construction and operation The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve. The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6).
  • Page 309 24. COMPONENTS SYSTEM 24.1.5 SWING MOTOR UNIT 24.1.5.1 SPECIFICATION (1) General view Port Tightening torque Port name Symbol N . m (lbf . ft) size Main port PF3/4 162 (119.5) THREAD FOR Drain port PF3/8 74 (55) EYE BOLT 2-M12 DEPTH 24 Make-up port 255 (188) PF1/4...
  • Page 310 24. COMPONENTS SYSTEM (2) Specifications Swing motor unit part No. LQ15V00021F1 Type MFC160-065 Part No. LQ15V00015F2 Displacement 151 (9.2) Working pressure MPa (psi) 28.5 (4,130) Max. flow L/min (gal/min) 253 (66.8) Braking torque N•m (lbf•ft) 685~891 (505~657) Release pressure MPa (psi) 3.1 (450) Relief set pressure MPa (psi)
  • Page 311 24. COMPONENTS SYSTEM 24.1.5.2 CONSTRUCTION (1) Swing motor SECTION A-A 15,16 A PORT SIDE RELIEF VALVE A PORT TOP DEAD POINT BOTTOM DEAD POINT B PORT B PORT SIDE RELIEF VALVE DRAIN PORT 39 38 37 MAKEUP PORT MECHANICAL BRAKE RELEASE CHAMBER 24-67...
  • Page 312 24. COMPONENTS SYSTEM Tightening Tightening torque torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) INNER RING 22 NEEDLE BEARING OIL SEAL 23 SNAP RING TAPERED ROLLER 24 CYLINDER BEARING BACKING SPRING 25 HOUSING CAM PLATE 26 COLLAR RETURN PLATE 27 SNAP RING PISTON ASSY 78 (58)
  • Page 313 24. COMPONENTS SYSTEM (2) Swing reduction unit Caulk these 2 places with punch. Be careful about installation direction of retaining ring. OIL FILLING PORT PT3/4 LEVEL PORT PT1/2 Tightening torque Be careful about 181 + - 20 N . m (134 + - 15 lbf . ft) installation direction Be careful about Apply Three Bond #1360.
  • Page 314 24. COMPONENTS SYSTEM 24.1.5.3 OPERATION 24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR (1) Swing motor The pressure oil fed by the pump via the control valve, etc. enters the motor through port A (or port B) installed on cover (32), and is discharged from port B (or port A). Also the oil leaking through the sliding section or clearance returns to the tank through drain port Dr installed on cover (32).
  • Page 315 24. COMPONENTS SYSTEM (3) Explanation of ultra shockless relief operation The high-pressure oil flowing in the front chamber of poppet (104) flows in the front chamber of poppet (109) through peripheral orifice of poppet (104) in the pressure-up process. The poppet (109) equipped with orifice "k" is pressed onto the end face of piston (106) with shoulder due to the load of spring (110).
  • Page 316 24. COMPONENTS SYSTEM 24.1.5.3.2 SWING REDUCTION UNIT The swing reduction unit is used to reduce the rotating RING GEAR (FIXED) PLANETARY SHAFT speed which is transmitted by the hydraulic motor and to convert it to the strong turning force (torque). This swing speed reduction unit is equipped with SPIDER planetary speed reducing mechanism.
  • Page 317 24. COMPONENTS SYSTEM 24.1.6 TRAVEL MOTOR 24.1.6.1 SPECIFICATIONS 24.1.6.1.1 General view SPROCKET INSTALLING FACE LUBRICATION PORT Tightening torque PORT PORT NAME PORT SIZE N . m SYMBOL (lbf . ft) Motor drive port 255 (188) Motor drive port LEVEL CHECK PORT PF1/2 108 (79.7) Drain port...
  • Page 318 24. COMPONENTS SYSTEM 24.1.6.2 CONSTRUCTION 19,20 SECTION Z6-Z6 (1 place) 67 30 SECTION Z5-Z5 (3 places) 33 34 15 14 14 15 34 33 SECTION Z4-Z4 SECTION 1- 1 Fig. 24-65 Construction of travel motor (1/2) 24-74...
  • Page 319 24. COMPONENTS SYSTEM SECTION 2- 2 SECTION 3- 3 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96 Fig. 24-66 Construction of travel motor (2/2) 24-75...
  • Page 320 24. COMPONENTS SYSTEM PARTS Q'TY PARTS Q'TY PARTS Q'TY FLANGE 36 SHAFT 68 PLUG BASE PLATE 37 CYLINDER BLOCK 69 PLUG (SPOOL) PLUNGER 38 PISTON ASSY 70 FLOATING SEAL CHECK VALVE 39 PLATE 71 ANGULAR BEARING SPRING 40 HOLDER HOUSING (RING GEAR) PLUG 41 SNAP RING 73 SHIM...
  • Page 321 24. COMPONENTS SYSTEM 24.1.6.3 OPERATION 24.1.6.3.1 SUMMARY The hydraulic circuit diagram for piston motor is shown EDUCTION UNIT in Fig. 24-67. PA KING B AKE This travel motor is made up of the following units, and PISTON MOTO AUTO those functions are described below. 2-SPEED CHANGE (1) Piston motor...
  • Page 322 24. COMPONENTS SYSTEM 24.1.6.3.2 PISTON MOTOR The construction drawing of piston motor is shown in Fig. 24-69. Nine pistons (38) are placed in the cylinder block (37), the end face of cylinder block is in contact with valve plate (62) in the two ports B and C (shaped somewhat like crescent). The hydraulic pump oil delivered flows into the piston through P1 or P2 port and flows out through P2 or P1 port while having the piston motor rotated.
  • Page 323 24. COMPONENTS SYSTEM 24.1.6.3.3 DOUBLE COUNTERBALANCE VALVE (1) Functions The function of double counter balance valve is described below. 1) Overrun prevention function to control the speed of piston motor to the speed corresponding to the supply flow rate when the piston motor speed is higher than the speed decided by the supply flow rate (hereinafter called pumping action) due to the outer load.
  • Page 324 24. COMPONENTS SYSTEM 2) When motor starts rotating (SeeFig. 24-71) When the oil delivered from the hydraulic pump is led into P1 port of the double counter balance valve, check valve (4) moves leftward resisting to the spring (5) force and oil passage C1 opens, and the oil delivered flows into the piston motor through M1 port and tries to rotate the piston motor.
  • Page 325 24. COMPONENTS SYSTEM 4) Braking of piston motor (SeeFig. 24-72) The double counter balance valve composes the brake circuit with the crossover relief valve. By returning the control valve to the neutral position, the pressure oil from the hydraulic pump is cut, and the pressure of P1 and P2 becomes equal.
  • Page 326 24. COMPONENTS SYSTEM 5) Shuttle valve function for high pressure selection (See Fig. 24-73) The double counter balance valve contains the high pressure select shuttle valve function for the release of parking brake self-pressure additionally. When the pressure oil is supplied through P1 port, plunger (3) moves rightward to the position shown in Fig. 24-73.
  • Page 327 24. COMPONENTS SYSTEM 24.1.6.3.4 CROSSOVER RELIEF VALVE The construction of relief valve is shown in Fig. 24-74. This relief valve is the differential area direct driven type. (1) Operation and function of relief valve After starting the control valve, and if the piston motor is started or braked, the pressure on the front side of poppet (17-2) rises to the set pressure or Fig.
  • Page 328 24. COMPONENTS SYSTEM 24.1.6.3.5 AUTO 2-SPEED CHANGE OVER (1) 2-Speed change over mechanism Fig. 24-77 shows the function when the motor capacity is low (at high speed). Swash plate (46) has three faces A to C. This swash plate (46) is installed on flange holder (1) with two steel balls (47) in the condition where the tilt rotation is possible.
  • Page 329 24. COMPONENTS SYSTEM 2) When switching the motor capacity to large capacity (low speed mode), (See Fig. 24-78) With turning the speed control switch to low speed, by returning the pilot pressure oil acting on Ps port into the tank, 2-speed control valves (19,20) is moved rightward by the spring (21) force until it comes into contact with plug (22).
  • Page 330 24. COMPONENTS SYSTEM (2) Auto 2-speed change over operation This piston motor is available to select the position where the motor capacity is fixed to the low speed (large capacity) and the position auto 2-speed position containing the motor capacity section function corresponding to the load pressure of the motor.
  • Page 331 24. COMPONENTS SYSTEM 4) Low speed (large capacity) position (See Fig. 24-80) The motor low speed condition at auto 2-speed position is shown in Fig. 24-80. When load pressure Pin to the motor is raised higher than the auto 1st speed return pressure, the motor capacity control valve moves rightward, and is switched to the motor low speed (large capacity) mode, that is, the motor low speed operation.
  • Page 332 24. COMPONENTS SYSTEM 24.1.6.3.6 PARKING BRAKE The construction of parking brake section is shown in Fig. 24-81. The parking brake is made up of disk plate (54) linked with the cylinder block, friction plate (55) and brake CYLINDER CYLINDER piston (56) located between disks and spring (59) BL CK BL CK which transmits the force to the brake piston.
  • Page 333 24. COMPONENTS SYSTEM 24.1.6.3.7 REDUCTION UNIT The reduction unit is constructed so that simple SPROCKET MOUNTING planetary gear reduction units which are made up of FIXED ON THE 83 85 2 drive gear, sun gear, holder, planetary gear and ring FRAME OF gear (tooth is cut inside of the housing.) are combined MACHINE...
  • Page 334 24. COMPONENTS SYSTEM 24.1.7 SWIVEL JOINT 24.1.7.1 GENERAL VIEW IEW Y IEW Z Fig. 24-84 General view of swivel joint 24.1.7.2 SPECIFICATIONS Item Specifications Assy parts No. YN55V00053F1 Working pressure 34.3 MPa (4970 psi) High pressure ports Max. impact pressure 51.5 MPa (7470 psi) A, B, C, D Rated flow...
  • Page 335 24. COMPONENTS SYSTEM 24.1.7.3 CONSTRUCTION 2 places Apply Three Bond #1805 to stem 2 places IEW Y 5 places Tightening torque 30.4 N . m (22.4 lbf . ft) Apply Loctite #242 SECTION HH Tightening torque 30.4 N . m (22.4 lbf . ft) Apply Loctite #242 Fig.
  • Page 336 24. COMPONENTS SYSTEM 24.1.8 CYLINDER 24.1.8.1 SPECIFICATIONS (1) General view Part No. and Manufacturing No. Stamp position Fig. 24-86 General view of cylinder (2) Specifications Unit : mm (ft-in) Center distance of pins Part No. of Cylinder bore / Dry weight Stroke Cushion Full extend B / Full...
  • Page 337 24. COMPONENTS SYSTEM 24.1.8.2 CONSTRUCTION AND FUNCTION 24.1.8.2.1 CONSTRUCTION (1) Boom cylinder T= Tightening torque ; N . m (lbf . ft) T=367 (271) PS1/8 PT1/4 With hole DETAIL B DETAIL C (1 place) T=7750 (5716) T=56.9 (42) 20 21 SLIT Orientation of cut off part of cushion bearing (13)
  • Page 338 24. COMPONENTS SYSTEM (2) Arm cylinder T= Tightening torque ; N . m (lbf . ft) T=56.9 (42) T=13600 (10031) 115 T=520 (384) 9 7,8 6 4 5 3 12 10,11 2 1 13 15 16 2725 24 14 17 18 20 Hole 1 place Location of the slit is shown in the drawing...
  • Page 339 24. COMPONENTS SYSTEM (3) Bucket cylinder T= Tightening torque ; N . m (lbf . ft) T=267 (197) PS1/8 PS1/8 With hole DETAIL B (1 place) DETAIL C T=6,860 (5,060) T=56.9 (42) 19 20 Orientation of cut off part of cushion bearing (13) Fig.
  • Page 340 24. COMPONENTS SYSTEM HYDRAULIC CYLINDER CONSTRUCTION (See Fig. 24-87) By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out the motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide. Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts.
  • Page 341 24. COMPONENTS SYSTEM 24.2 ELECTRIC EQUIPMENT 24.2.1 ELECTRIC EQUIPMENT LIST Group Code Name Parts No. C - 1 Mechatro controller YN22E00214F1 C - 2 Gauge cluster YN59S00021F1 C - 4 Air-con controler (including panel) YN20M01468P1 C - 5 Engine coolant level controller VHS834701230 C - 8 Engine controller VH89661E0010...
  • Page 342 24. COMPONENTS SYSTEM Group Code Name Parts No. Arm 2 speed inverse propo. YN35V00049F1 PSV - A valve (YN35V00047F1) P2 unload propo. valve YN35V00048F1 PSV - B Solenoid valve assy ↑ Travel straight propo. valve PSV - C ↑ P1 unload propo. valve PSV - D P1 pump propo.
  • Page 343 24. COMPONENTS SYSTEM Group Code Name Parts No. SV - 1 Swing parking brake SOL. YN35V00051F1 SV - 2 Power boost SOL YN35V00050F1 (YN35V00047F1) ↑ Solenoid valve assy SV - 3 Two speed select SOL ↑ SV - 4 Safety lock lever SOL SW - 1 Key switch YN50S00026F1 SW - 4 Swing parking brake release switch...
  • Page 344 24. COMPONENTS SYSTEM 24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS File No. Name of part Part No. Specification Description Applicable Machine C - 1 Maker Sinko Electric Co. Ltd Controller Rated voltage DC24V YN22E00214F1 Weight 4.2 kg (9.3 lbs) Mechatro controller YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~...
  • Page 345 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine C - 5 Rated voltage DC24V Controller S8347-01230B Maker's (Hino) P/No. VHS834701230 Controller YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ LQ12 - 06001 ~ LL12 - 05001 ~ Hino P/No.
  • Page 346 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine E - 1 Fuse capacity and circuit Fuse & Relay box YN24E00016F1 Fuse & Relay YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ LQ12 - 06001 ~ LL12 - 05001 ~...
  • Page 347 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine E - 5, 6 Bottom L : Low sound Type Horn H : High sound Rated voltage DC24V STAMP LC53S0001D1 (High) DC20~30V Operating voltage range LC53S0001D2 (Low) Sound level 113+5dB(A)/2m Warning sound...
  • Page 348 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine E - 11 aker's part No. 7360-6000 Air-con compressor Rated voltage DC24V YX91V00001F1 ax. revolution 4000rpm Air-con V belt Type B YX03 - 01601 ~ Refregerant R-134a YX04 - 01773 ~ SP-20:135cc...
  • Page 349 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine E - 13 GND AV 0.5 Black Model BA3111A Alarm Rated voltage DC 12V~36V Power AV 0.5 Red / Green YN53S00004F1 AMP Econoseal J series Mark II water-proof Travel alarm Housing : 174354-2 Harness seal : 172888-2...
  • Page 350 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine E - 23 Power supply For 12V 12V socket Max. current Less than 10A YN81S00001P1 Insulation resistance More than 10M /500v megger Power socket YN11 - 45001 ~ GROUND TERMINAL YQ11 - 06001 ~ LQ12 - 06001 ~...
  • Page 351 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine L - 5 Body Bulb 24V,5W Light Lens Note) Equivalent to 2456Z322F1 YT80S00001P1 Room light YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ Bulb YC10 - 03501 ~ LQ12 - 06001 ~...
  • Page 352 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine R - 1 At start 24V2000A(0.1 sec) Terminal A VIEW A Rated voltage / current Relay At charge 28V120A(Continuous) YN24S00008F1 Exciting current 0.4A or less / 24V Lock section Battery relay 37.2N {8.4 lb} or more...
  • Page 353 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine R - 3 Hino P/No. S2862-01420A Relay Rated voltage DC 24V VHS286201420A Rated load 100A flow Glow relay DC 18V or less Min. operating voltage YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ S terminal...
  • Page 354 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine R - 29,30,31,32 Maker's P/No. V23134-A0053-C643 Relay Parts name Relay YN24S00012P2 Rated voltage DV 24V Wiper motor relay Contact Washer motor relay * Accessory of relay box YN11 - 45001 ~ YQ11 - 06001 ~ Pin assignment...
  • Page 355 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine SE - 15 Float operation Fuel sending unit Float Resistance YN52S00045F1 +0.1 FULL -0.6 Fuel level (19) YN11 - 45001 ~ 32+5 YQ11 - 06001 ~ (49.5) LC10 - 07001 ~ EMPTY...
  • Page 356 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine PSV - A, B, C, D Proportional solenoid valve Hydraulic solenoid valve Hydraulic symbol A5 to A8 (YN35V00047F1) YN35V00048F1 YN35V00049F1 YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ LQ12 - 06001 ~...
  • Page 357 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine SW - 1 Auto return Switch Connection YN50S00026F1 Terminal Position Starter switch Auto return YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ VIEW A Terminal arrangement...
  • Page 358 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine SW - 8 aker's P/No. REX018171 Switch Air cleaner LC11P00018F1 YR11P00008S005 Inlet Air cleaner Connection port Clogging switch YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ Outlet YC10 - 03501 ~...
  • Page 359 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine SW - 17 Rated voltage DC 24V Switch Single pole single throw Type YN50S00040D9 (alternate) More than 1M / Roof window wiper Insulation resistance DC500V megger switch (OPT) YN11 - 45001 ~ Terminal connector...
  • Page 360 24. COMPONENTS SYSTEM File No. Name of part Part No. Specification Description Applicable Machine SW - 28 Switch VHS233002800A Fuel filter YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ Fuel outlet Fuel inlet YC10 - 03501 ~ LQ12 - 06001 ~ LL12 - 05001 ~ Deposit container...
  • Page 361 25. AIR-CONDITIONER SYSTEM TABLE OF CONTENTS 25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)......25-3 25.1.1 AIR CYCLE......................25-3 25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ............25-4 25.2 COMPONENT AND CONSTRUCTION ................25-5 25.2.1 COMPONENT ......................25-5 25.2.2 CONSTRUCTION ....................25-6 25.3 PIPING..........................25-9 25.3.1 AIR CONDITIONER....................25-9 25.3.2 AIR DRYER ASSY....................25-11 25.4 FUNCTION ........................25-12...
  • Page 362 25. AIR-CONDITIONER SYSTEM Issue Date of Issue Applicable Machines Remarks SK250-8: LQ12-06001~ S5LQ2514E01 First edition October, 2006 SK260LC–8 : LL12-05001~ (ASIA, OCE) ↑ E265B : LQ12-06001~ ↑ July, 2007 E265BLC : LL12-05001~ (NHK Russia) 25-2...
  • Page 363 25. AIR-CONDITIONER SYSTEM 25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside / outside air switching unit. And this unit changes hot air to cool air. 25.1.1 AIR CYCLE •...
  • Page 364 25. AIR-CONDITIONER SYSTEM 25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE AIR CONDITIONER CONTROL PANEL COMPRESSOR COMPRESSOR DRIVE SOURCE SOLAR RADIATION SENSOR REFRIGERANT PRESSURE SWITCH AIR MIXED DAMPER SIGNAL BLOWER REVOLUTION SIGNAL AIR-CON AIR OUTLET SWITCHING SIGNAL CONTROLLER INNER AIR SENSOR EVAPORATION SENSOR INNER AIR AND OUTER AIR SWITCHING SIGNAL OUTER AIR...
  • Page 365 25. AIR-CONDITIONER SYSTEM 25.2 COMPONENT AND CONSTRUCTION 25.2.1 COMPONENT 27-1 27-6 27-3 27-5 27-2 35-6 35-7 35-1 35-5 35-2 35-8 35-9 35-10 Fig. 25-1 Air-conditioner group A/C ASSY LQ20M00046F1 (01) Parts Q’ty Parts Q’ty Parts Q’ty 27 Air-conditioner assy 32 Compressor 35–6 D hose 27–1 Air-conditioner unit 33 Pulley...
  • Page 366 25. AIR-CONDITIONER SYSTEM 25.2.2 CONSTRUCTION (1) Air conditioner unit Fig. 25-2 Air conditioner unit (1/2) 25-6...
  • Page 367 25. AIR-CONDITIONER SYSTEM Fig. 25-3 Air conditioner unit (2/2) 25-7...
  • Page 368 25. AIR-CONDITIONER SYSTEM Parts Q’ty Parts Q’ty Parts Q’ty Screw M5×16 19 Relay 40 KK-box lower packing Main harness 20 Evaporator 41 Vent lever MA air mix 21 Expansion valve 42 Face lever Blower controller 22 O-ring 43 Foot joint lever Upper casing 23 O-ring 44 MA mode lever...
  • Page 369 25. AIR-CONDITIONER SYSTEM 25.3 PIPING 25.3.1 AIR CONDITIONER NOTE 1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings. 2. Refrigerant volume : 900 50g 3. T : Tightening torque N . m(lbf . ft) JAM NUT FOR TENSION PULLEY T=46.1(33) INITIAL BELT TENSION...
  • Page 370 25. AIR-CONDITIONER SYSTEM Air conditioner LQ20M00046F1 (01) Tightening Tightening torque Parts Q’ty torque Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) Hose : L = 3550 24 Clip Hose : L = 2950 25 Clip Bracket 27 Air conditioner assy V-belt 30 Panel 3.92~4.9 (2.9~3.6) Clip 32 Compressor assy...
  • Page 371 25. AIR-CONDITIONER SYSTEM 25.3.2 AIR DRYER ASSY " " Fig. 25-6 Air dryer assy LQ96V00021F1 (02) Tightening Tightening torque Parts Q’ty torque Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) Receiver dryer D hose Bracket L hose Capscrew L hose Capscrew S tube S hose 10 L tube 25-11...
  • Page 372 25. AIR-CONDITIONER SYSTEM 25.4 FUNCTION 25.4.1 MECHANISM OF COOLING CIRCUIT (2) Mechanism of Cooling Item HFC-134a (R134a) In the cooling process, the refrigerant that flows Chemical formula through the cooling circuit changes its phases from Molecular weight 102.03 Boiling point -26.19 (-15.14 liquid to gas and vice versa during which process...
  • Page 373 25. AIR-CONDITIONER SYSTEM (3) Characteristics of Refrigerant (Fig. 25-7) PRESSURE In general, the fluid (general term of gas and liquid) MPa(psi) R134a has the following qualities: 4(580) 1) As a gas under certain pressure is cooled down, 3(435) it begins to condensate at a certain temperature LIQUID to take a liquid state.
  • Page 374 25. AIR-CONDITIONER SYSTEM 25.4.2 COOLING CIRCUIT Fig. 25-8 illustrates the cooling circuit of the car air- conditioner. In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB) the compartment is the evaporator. The object air is cooled off by utilizing the fact that the refrigerant takes heat off the surrounding area as evaporation heat as it EVAPORATOR...
  • Page 375 25. AIR-CONDITIONER SYSTEM 25.4.3 COMPONENT PARTS (1) Evaporator (See Fig. 25-9.) The evaporator is an important heat exchanger that EVAPORATOR absorbs the heat of the compartment air (object) by the utilization of the latent vaporization heat of the low-temperature, low-pressure liquid-state refrigerant.
  • Page 376 25. AIR-CONDITIONER SYSTEM Fig. 25-10 shows how the block type expansion valve is constructed. The temperature sensing DIAPHRAGM part is provided in the shaft of the expansion valve to directly detect the refrigerant temperature at the outlet of the evaporator. The diaphragm contains R134a in saturated REFRIGERANT OUTLET...
  • Page 377 25. AIR-CONDITIONER SYSTEM (3) Compressor (See Fig. 25-12.) D HOSE The compressor performs the following three functions in the cooling circuit: 1) Suction action S HOSE 2) Pumping action 3) Compressive action 1) The suction action, as combined with the throttling action, works to decrease the refrigerant pressure in the evaporator.
  • Page 378 25. AIR-CONDITIONER SYSTEM (5) Receiver dryer ( See Fig. 25-14.) SIGHT GLASS REFRIGERANT 1) Receiver Tank INLET On the air-conditioner, the revolution of the REFRIGERANT compressor varies greatly which causes the OUTLET proper flow of refrigerant in the cooling circuit to vary.
  • Page 379 25. AIR-CONDITIONER SYSTEM 25.5 DISASSEMBLY AND ASSEMBLY 25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION (1) Special Refrigerator Oil Unit : N . m (lbf . ft) This air-conditioner uses special refrigerator oil SP20 for use with new refrigerant R134a. Oils other PIPE FASTENING PART TIGHTENING TORQUE than SP20 may not be used.
  • Page 380 25. AIR-CONDITIONER SYSTEM 25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT UNIT (1) Removing inner air filter ARNESS CLAMP Slide the inner air filter leftward and remove it from the unit. INNER AIR FILTER Fig. 25-15 (2) Removing selector box PLUS SCREW MODE ACTUATOR MAIN HARNESS Remove 6 plus screws, remove connector...
  • Page 381 25. AIR-CONDITIONER SYSTEM (5) Replacing blower controller UPPER UNIT CASING 1) Remove 2 plus screws and remove the blower controller from the upper unit casing. 2) Install new blower controller by the reverse procedure of removal. * Do not disassemble the blower controller. PLUS SCREW BLOWER CONTROLLER Fig.
  • Page 382 25. AIR-CONDITIONER SYSTEM 4) Remove 2 socket bolts M5×40 with Allen wrench (4mm) and remove the expansion valve from the EVAPORATOR evaporator. 5) Fit O-ring (NF O-ring 5/8 and 1/2 one each) to new evaporator. * When assembling again, fit O-ring paying attention so as not to be caught with others.
  • Page 383 25. AIR-CONDITIONER SYSTEM 3) Replacing inner and outer air switching actuator MA NTAKE LEVER a) Disconnect connector connected to the motor actuator. NTAKE ROD PLUS SCREW b) Remove intake rod from MA intake lever. (3PCS.) c) Remove 3 plus screws and remove the motor actuator with MA intake lever from the CONNECTOR unit.
  • Page 384 25. AIR-CONDITIONER SYSTEM 25.6 CHARGING REFRIGERANT 25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION (1) Always assign a person in charge of handling refrigerant. Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar with how work is done for handling refrigerant. •...
  • Page 385 25. AIR-CONDITIONER SYSTEM 25.6.2 OPERATING PROCEDURE (1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas charge operation". 1) The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water remains in the circuit, the small holes of the expansion valve are frozen during operation.
  • Page 386 25. AIR-CONDITIONER SYSTEM 25.6.3 CHARGING PROCEDURE 25.6.3.1 VACUUM MAKING OPERATION (1) Connecting gauge manifold (See Fig. 25-25) HIGH 1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE GAUGE pressure valve (LO) of the gauge manifold. GAUGE MANIFOLD (CLOSED)LOW HIGH PRESSURE...
  • Page 387 25. AIR-CONDITIONER SYSTEM (2) Vacuum making (See Fig. 25-27) LOW PRESSURE VALVE(OPEN) (CLOSE) 1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE) pressure valve (LO) of the gauge manifold. 30 min 2) Turn on the switch of the vacuum pump and make vacuum for more than 30 minutes.
  • Page 388 25. AIR-CONDITIONER SYSTEM 25.6.3.2 GAS CHARGING OPERATION (1) Charging from high pressure side (See Fig. 25-28.) 1) After making vacuum repeatedly, change the charging hose (yellow) of the gauge manifold from the vacuum pump to the service can. 2) Air purge Open the service can valve.
  • Page 389 25. AIR-CONDITIONER SYSTEM (3) Charging from low pressure side (See Fig. 25-30) 1) Make sure that the high-pressure and low- pressure valves of the gauge manifold and the LOW PRESSURE HIGH PRESSURE service can valve are closed. VALVE VALVE(CLOSE) OPEN CLOSE 2) Start the engine and run the revolution to (CLOSE SECURELY)
  • Page 390 25. AIR-CONDITIONER SYSTEM (4) Criterion for checking the amount of refrigerant filled in JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER After A/C is turned on, only a little bubbles are seen and thereafter light PROPER LEVEL milky white is seen.
  • Page 391 25. AIR-CONDITIONER SYSTEM This page is blank for editing convenience. 25-31...
  • Page 392 25. AIR-CONDITIONER SYSTEM 25.7 ELECTRIC CIRCUIT 25.7.1 WIRING DIAGRAM AND CONNECTORS JAE : JAPAN AVIATION ELECTRONICS INDUSTRY, LTD. HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1 TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000 MAKER : YAZAKI CORP. HOUSING No. : 7122-6060 MAKER : YAZAKI CORP. REAR HOLDER : 7157-6260-30 HOUSING No.
  • Page 393 25. AIR-CONDITIONER SYSTEM CCU (OPERATION PANEL + CONTROLLER) EVA SENSOR AIR INLET SENSOR SUN SENSOR MOTOR ACTUATER (FOR AIR MIX) MOTOR ACTUATER (FOR MODE) BLOWER OFF RELAY BLOWER MOTOR BLOWER AMP MOTOR ACTUATER (REC/FRESH) COMPRESSOR RELAY AIR CONDITIONER SIDE IN THE CAB WIRING (PARTS) Fig.
  • Page 394 25. AIR-CONDITIONER SYSTEM 25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION (1) Control panel and control unit The control unit is integrated into control panel, and processes the signal input by each sensor, etc. and the signal input by each switch through control panel with the function of the built-in micro Fig.
  • Page 395 25. AIR-CONDITIONER SYSTEM (3) Relay Four-electrode relay is used for the blower OFF relay and compressor relay. 1) Blower OFF relay The blower OFF relay turns on after receiving the signal from the control amplifier. When the blower OFF relay turns on, the source voltage is supplied to the blower motor and the blower motor starts running.
  • Page 396 25. AIR-CONDITIONER SYSTEM (5) The actuator for inner and outer The actuator for inner and outer air flow select is installed on the blower intake unit, and opens and closes inner and outer air damper through the link. The actuator for inner and outer air flow select contains position detection switch which is switched with the movement of shaft of the actuator.
  • Page 397 25. AIR-CONDITIONER SYSTEM 25.8 TROUBLESHOOTING Air temperature does not fall. Note : M/A is motor actuator is any of the numbers 0 ~ 9. If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel. "HL.
  • Page 398 25. AIR-CONDITIONER SYSTEM Air temperature does not rise. Note : is any of the numbers 0 ~ 9. HL.E is shown on the set temp. display of the panel. "HL. " is shown on the set temp. Connector for air mix M/A is display of the panel.
  • Page 399 25. AIR-CONDITIONER SYSTEM Blower motor does not run. At air flow HI, battery voltage acts across Note 1) both terminals (+) and ( - ) of blower motor. Battery voltage acts across red Blower motor fails. (+) and body of blower motor. Replace.
  • Page 400 25. AIR-CONDITIONER SYSTEM Blower motor speed does not change. CASE (1) Note) is any of the "HL. " is shown on the set temp. display of the panel. numbers 0 ~ 9. Replace blower Inner air sensor or harness is disconnected or shorted. amplifier controller.
  • Page 401 25. AIR-CONDITIONER SYSTEM Magnet clutch does not engage. Snow mark ( ) lights if A/C switch is pressed. Snow mark ( ) flickers and E is Voltage acts upon clutch. shown on panel display. Voltage is applied to To A On page 25-37. Clutch faulty.
  • Page 402 25. AIR-CONDITIONER SYSTEM Modes do not change. Mode display (Mark of person) on operating panel is flickering. Mode M/A connector is M/A rod does not disengage. disconnected or in poor contact or M/A failed or main harness is faulty. Repair. Each damper lever does not disengage. Inspect or replace.
  • Page 403 25. AIR-CONDITIONER SYSTEM Trouble with refrigeration cycle. Both high and low pressures are lower. Low pressure is higher. Air bubbles are seen in sight glass. Air bubbles are seen in High pressure sight glass. is lower. Cooling does not work Oil comes out from Compressor cylinder Compressor cylinder...
  • Page 404 25. AIR-CONDITIONER SYSTEM 25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL The failure of motor actuator and each sensor can be identified on the display of panel. 25.9.1 POSITION OF INDICATION FOR FAILURE. The error is indicated on 3 digits segment. 25.9.2 EXPLANATION OF INDICATION FOR FAILURE.
  • Page 405 25. AIR-CONDITIONER SYSTEM (2) Failures of sensors 1) HL.* is indicated on 3 digits segment. Check the inner air sensor or the harness for disconnection and short circuit, and also connectors for disconnection. (* is any of the numbers 0 to 9.) 2) **E and mark are flickering.
  • Page 406 25. AIR-CONDITIONER SYSTEM 25.9.3 EXPLANATION OF MONITOR MODE When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition (disconnection, short circuit). (1) Position of monitor mode indication SEGMENT FOR ONLY MONITOR INDICATION 3 DIGITS SEGMENT (2) Operation of monitor mode SPEED UP AND DOWN...
  • Page 407 25. AIR-CONDITIONER SYSTEM (3) Contents of monitor mode display Refer to the list of segment display exclusively used for monitor and the list of segments in three digits. Example 1 THIRD SEGMENT SECOND SEGMENT When the segment exclusively used for monitor indicates 0 (displays the inner air sensor condition), since the segment indicates 3F, the sensor is in normal operating condition according to the list of 3 segments.
  • Page 408 25. AIR-CONDITIONER SYSTEM [MEMO] 25-48...
  • Page 409 31. DISASSEMBLING AND ASSEMBLING TABLE OF CONTENTS 31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ......31-3 31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ........31-3 31.1.2 INDICATION OF TIGHTENING TORQUE .............31-3 Book Code No. S5YN3118E01 31-1...
  • Page 410 ↑ ↑ SK225SRLC : LA05-02001~ (OCE) ↑ SK460-8: LS10-02001~ ↑ ↑ SK480LC–8 : YS10-01501~ (ASIA, OCE) ↑ E215B : YN11-45001~ ↑ ↑ E215BLC : YQ11-06001~ (NHK Middle East) ↑ E265B : LQ12-06001~ ↑ ↑ E265BLC : LL12-05001~ (NHK Russia) 31-2...
  • Page 411 31. DISASSEMBLING AND ASSEMBLING 31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY 31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY This chapter is consist of 3-Section as follows. (1) ATTACHMENTS ..............Chapter 32 1) Removing and Installing 2) Disassembling and Assembling a.
  • Page 412 31. DISASSEMBLING AND ASSEMBLING [MEMO] 31-4...
  • Page 413 32. ATTACHMENT TABLE OF CONTENTS 32.1 REMOVING AND INSTALLING..................32-3 32.1.1 ATTACHMENT ASSY.....................32-3 32.1.2 BUCKET .........................32-3 32.1.3 ARM........................32-6 32.1.4 BOOM........................32-9 32.2 DISASSEMBLING AND ASSEMBLING................32-13 32.2.1 CYLINDER......................32-13 Book Code No. S5LQ3214E01 32-1...
  • Page 414 (ASIA, OCE) ↑ ↑ ↑ May, 2007 ASIA (HS Engine) ↑ E265B : LQ12-06001~ ↑ July, 2007 E265BLC : LL12-05001~ (NHK Russia) PREFACE (1) This Manual describes all the procedures from removing to attaching, arranging them by item. (2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
  • Page 415 32. ATTACHMENT 32.1 REMOVING AND INSTALLING 32.1.1 ATTACHMENT ASSY (C) BOOM CYLINDER ROD PIN (D) ARM CYLINDER HEAD PIN (A) BOOM FOOT PIN 4. BOOM ARM CYLINDER (F) BOOM TOP PIN (E) ARM CYLINDER ROD PIN 2. BUCKET 3. ARM (G) BUCKET CYLINDER HEAD PIN BUCKET CYLINDER...
  • Page 416 32. ATTACHMENT (3) Removing bucket attaching pin (K) Lift up bucket, position it so that bucket attaching pin (K) is not loaded, adjust bucket link, and pull out bucket attaching pin (K). Fig. 32-4 Removing bucket attaching pin (4) Removing bucket drive pin (J) Put bucket on the ground, position it so that the bucket drive pin (J) is not loaded, adjust bucket link, and pull out pin (J).
  • Page 417 32. ATTACHMENT 32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE Adjustment of clearance between bucket and arm +1.0 +0.039" Apply rust preventive oil (12.84 -0.5 -0.020" New bucket (1) Shift O-ring (3) toward the bucket boss, using a spatula. (a→b) 3 : O-RING 12 : WASHER 11 : CAPSCREW (2) When adjusting clearance (B), bring the non-...
  • Page 418 32. ATTACHMENT 32.1.3 32.1.3.1 REMOVING ARM (1) Put the machine in position to remove arm. Extend the arm cylinder, retract the bucket cylinder and bring the arm down on the ground. Fig. 32-8 Position to remove arm (2) Disconnecting piping of bucket cylinder Release pressure of hydraulic tank, place oil pan to prepare for oil leaking, and disconnect pipes.
  • Page 419 32. ATTACHMENT (5) Removing bucket cylinder Sling tube of bucket cylinder with nylon sling, and remove it. Bucket cylinder weight : 192 kg (423 lbs) Fig. 32-12 Slinging bucket cylinder (6) Removing arm cylinder rod pin (E) Apply grease to inner wall Put a wooden block between the arm cylinder and of bushing the boom.
  • Page 420 32. ATTACHMENT (8) Slinging arm assy Sling arm with nylon sling and remove it. Arm weight : 880 kg (1,940 lbs) Fig. 32-15 Slinging arm assy 32.1.3.2 ATTACHING ARM Instal the arm in the reverse order of removing, paying attention to the following : 1) When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
  • Page 421 32. ATTACHMENT 32.1.4 BOOM 32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM When removing and attaching boom in the position shown in Fig. 32-16, to remove and attach boom foot pin (A), removing and attaching of cab and guard are required. 32.1.4.2 REMOVING BOOM (1) Put the machine in position to remove boom.
  • Page 422 32. ATTACHMENT (5) Disconnecting the arm cylinder and bucket cylinder pipings Release pressure from arm and bucket circuit and bleed air in hydraulic tank, and then disconnect pipe at (A1), (A2), (A3), (A4) and hose (B1), (B2), (B3), (B10). : 36, 41 mm After disconnection of pipe, plug every pipe.
  • Page 423 32. ATTACHMENT (8) Hoisting boom assy Hoist and remove boom assy. Weight of single boom : 1,980 kg (4,360 lbs) Boom assy hoisting procedure (9) Completion of removal of front attachments When the removing and attaching of cylinder are not required, the work is finished. (10)Removing and installing arm cylinder 1) Lift up arm cylinder (2) with nylon sling so that the head of cylinder is not loaded.
  • Page 424 32. ATTACHMENT (11)Removing and installing boom cylinder 1) Release pressure from boom circuit and bleed air in hydraulic tank. 2) Sling boom cylinder (2) using nylon sling temporally not to act the weight of cylinder upon the cylinder head. 3) Disconnect each two hoses (C2) and (C3). And plug their both ends.
  • Page 425 32. ATTACHMENT 32.2 DISASSEMBLING AND ASSEMBLING 32.2.1 CYLINDER 32.2.1.1 PREPARATION BEFORE DISASSEMBLY Before assembly, secure a dustfree workshop and necessary equipment and facilities. 32.2.1.1.1 WORK AREA The following working area is required for disassembly: (1) Ample space For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this reason, the first condition is that the working area is long enough for the work.
  • Page 426 32. ATTACHMENT 32.2.1.1.3 NECESSARY TOOLS Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table32-1 as a guideline. Table32-1 List of Tools and Jigs Tool / Jig Remarks Tool / Jig Remarks Hammer 1.
  • Page 427 32. ATTACHMENT 32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER) PS1/8 PT1/4 SLIT ONE HOLE DETAIL 6 DETAIL B DETAIL C Piston with piston nut type 11 10 13 14 17 16 18 19 *20 *21 22 23 SLIT Fig. 32-27 Construction of general cylinder Parts name Q’ty Parts name...
  • Page 428 32. ATTACHMENT 32.2.1.3 DISASSEMBLY • When disassembling and servicing the cylinder, check the construction and the availability of service parts as well as necessary tools and jigs on separate Parts Manual. • The figures in parentheses after part names correspond to those in Fig. 32-27. •...
  • Page 429 32. ATTACHMENT • At this time, the weight of piston rod (2) is loaded KNOCK THIS EDGE WITH A PLASTIC MALLET. on rod cover (3). Therefore, lift the top end of the LIFT HERE. piston rod with a hoist to the extent that only the rod weight may be held.
  • Page 430 32. ATTACHMENT 32.2.1.3.2 REMOVING PISTON ASSY (1) Fix piston rod (2) by holding its clevis section in a WOODEN BLOCK vise. Fix the piston rod (2) securely as piston nut (21) is tightened to a high torque. • Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston (15), though the rod diameter remains the same.
  • Page 431 32. ATTACHMENT (5) After removing cushion bearing (13) and cushion LIFT WITH A HOIST. STRIKE WITH seal (14), separate rod cover (3) from piston rod (2). A PLASTIC MALLET. If it is too hard to slide it, knock the flanged part of PULL STRAIGHT.
  • Page 432 32. ATTACHMENT 32.2.1.3.4 DISASSEMBLING ROD COVER ASSY (1) Remove O-ring (10) and back-up ring (11). SPATULA Remove back-up ring (11) and O-ring (10) in that order. Remove back-up ring (11) and O-ring (10) by pulling and stretching them with an spatula like earpick.
  • Page 433 32. ATTACHMENT 32.2.1.3.5 REMOVING PIN BUSHING USH WITH A RESS. (1) Apply driver to wiper ring (25) of cylinder tube (1) and piston rod (2), and strike it by hammer lightly. JIG J (2) Push out pin bushing (24) press fitted in cylinder tube (1) and piston rod (2) with press.
  • Page 434 32. ATTACHMENT 32.2.1.5.2 ASSEMBLING OF PISTON ASSY (1) The fitting of seal ring (16) requires special tool as PRESS HERE METAL (G) shown in Fig. 32-46. Seal ring (16) is pushed in by PRESS JIG (E) press, etc. with pushing in tool as shown in the figure.
  • Page 435 32. ATTACHMENT (3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in INSERT U-RING INTO GROOVE FROM THIS SIDE. their grooves in that order. Before setting packings, coat them with hydraulic oil (or vaseline if not available). If you forget the coating, the packings may be scored.
  • Page 436 32. ATTACHMENT 32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD (1) Install cushion on the extraction side, cushion PISTON bearing (13) and cushion seal (14) by the following procedure. 1) Put cushion seal (14) on it, directing the slit machined side toward the piston side. 2) Fit cushion bearing (13) on it directing the flattening side as shown in Fig.
  • Page 437 32. ATTACHMENT (3) Insert shim (20), and tighten piston nut (21) or [piston (15)] till it gets tight. Always tighten the piston nut (21) or [piston (15)] of each piston to specified torque EYE WRENCH (Refer to 32.2.1.7.3). • In case that piston and piston nut are combined, the Fig.
  • Page 438 32. ATTACHMENT 32.2.1.5.6 OVERALL ASSEMBLY (1) Place a V-block on a work bench (A wooden V- block is preferable.). Place the cylinder tube assy (1) on it and fix the assy by passing a wooden bar LIFT through the clevis pin hole to lock the assy. (2) Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy with a hoist.
  • Page 439 32. ATTACHMENT 32.2.1.6 INSPECTION AFTER ASSEMBLY (1) No-load functional test Place the cylinder level at no load, operate the piston rod 5 to 6 strokes by the directional valve and DIRECTIONAL VALVE PUMP make sure that it operates without failure. •...
  • Page 440 32. ATTACHMENT 32.2.1.7 MAINTENANCE STANDARDS 32.2.1.7.1 INSPECTION AFTER DISASSEMBLY Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to use are not present. (1) Inspection Item Table32-2 Part Name Inspecting Section Inspection Item Remedy 1.
  • Page 441 32. ATTACHMENT 32.2.1.7.2 LIMIT OF SERVICEABILITY Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod that have no such damage as may degrade the sealing effect. (1) Clearance between piston rod and rod bushing Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm (0.01in).
  • Page 442 32. ATTACHMENT 32.2.1.8 TROUBLESHOOTING Table32-4 Trouble Failed Parts Cause Remedy 1. Oil leak through sliding 1. Back-up ring 1. Foreign matter is trapped in the 1. Remove foreign matter. surface of piston rod. Oil bore of back-up ring ring is formed on piston 2.
  • Page 443 32. ATTACHMENT 32.2.1.9 JIGS LIST 32.2.1.9.1 SPECIAL JIG LIST (POSSIBLE TO SUPPLY) When assembling, the following jigs are required. Table32-5 Described Application Shape paragraph For removing and press 32.2.1.3.4, fitting bushing 32.2.1.5.2 EDGE OF CHUCK For press fitting wiper 32.2.1.5.2 ring For correcting seal ring 32.2.1.5.2...
  • Page 444 32. ATTACHMENT Special Jig No. List (1) For jigs for rod cover, select jig corresponding to respective rod diameter. (2) For jigs for piston, select jig corresponding to the cylinder bore. Table32-6 Application rod diameter (mm) Kit No. of maker 3006J-56001 3007J-06001 3007J-56001...
  • Page 445 32. ATTACHMENT 32.2.1.9.2 OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP) (1) Bushing removing jig (Symbol J) MATERIAL : Mild steel Unit : mm (inch) Cylinder Used Bucket R0.2 12-S Boom, Arm 25-S Fig. 32-63 Bushing removing jig (2) Wrench for piston nut or [piston] Unit : mm (inch) Cylinder Used Boom...
  • Page 446 32. ATTACHMENT 32.2.1.9.3 SPECIAL JIG HANDLING PROCEDURE (1) How to remove bushing from rod cover. 1) Attaching chuck assy tool Insert tool in rod cover slowly until the edge top end of chuck assy reaches to the end of bushing (4).
  • Page 447 32. ATTACHMENT 3) Attaching tools for retainer Put retainer on the press bench directing the wiper ring fitting section of rod cover upward, then put retainer tool (D) on the rod cover. LANGE • Fit retainer tool as shown in the right figure directing large diameter section (flange section) upward.
  • Page 448 32. ATTACHMENT 5) Setting of tools for block Prepare block (C), and put rod cover (3) on it aligning them. Select corresponding block (C) in shape, dimensions, etc. from the table shown below. Unit : mm (inch) Class (Nominal size) o55 (2.17) 62 (2.44) 88 (3.46)
  • Page 449 32. ATTACHMENT 7) Removing of rod cover a. Remove block (C) with rod cover (3) near side, remove retainer tool (D) from rod cover (3), and then move rod cover (3) to other place. b. Take out the chuck tool (A) with bushing from block (C).
  • Page 450 32. ATTACHMENT 9) Tightening of adjuster bolt Tighten the chuck tool (A) the bushing (4) is DJUST BOLT removed to the extent that there is no gap between the chuck and the wedge upper face, turning the adjuster bolt by hand. WEDGE •...
  • Page 451 32. ATTACHMENT (2) Rod cover bushing press-fitting procedure 1) Temporary setting of head bushing Put rod cover (3) on the press-working bench directing the tube connection upward. Set bushing (4) on the inner surface of rod cover (3) temporarily. • Make sure that the inner and outer surfaces of bushing (4) are free from foreign matter.
  • Page 452 32. ATTACHMENT 3) Attaching retainer tool Put retainer tool (D) on the wedge stepped section of chuck assy tool (A) slowly directing the flange upward. • Align chuck assy (A) and the wedge. TEP OF WEDGE 4) Preparation for press-fitting PRESS RAM Move the rod cover on which chuck tool (A) and retainer tools are attached under the press.
  • Page 453 32. ATTACHMENT 5) Press-fitting of bushing Push the head of retainer (D) with press, and press fit bushing (4) to the specified position of rod cover (3) slowly. • The pressing force should be held 5 tons STEP OF WEDGE (11025 lbs) or less, keeping the required force for the press-fitting.
  • Page 454 32. ATTACHMENT [MEMO] 32-42...
  • Page 455 33. UPPER STRUCTURE TABLE OF CONTENTS 33.1 REMOVING AND INSTALLING..................33-3 33.1.1 OPERATOR SEAT ....................33-3 33.1.2 CAB ........................33-4 33.1.3 BATTERY .......................33-6 33.1.4 GUARD........................33-7 33.1.5 UNDER COVER .....................33-13 33.1.6 FUEL TANK ......................33-14 33.1.7 HYDRAULIC TANK ....................33-16 33.1.8 HYDRAULIC PUMP....................33-20 33.1.9 AIR CLEANER......................33-25 33.1.10 MUFFLER.......................33-26 33.1.11 COUNTERWEIGHT....................33-28 33.1.12 RADIATOR &...
  • Page 456 33. UPPER STRUCTURE Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ3318E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia) PREFACE (1) This Manual describes all the procedures from removing to installing, arranging them by item. (2) This Manual consists [Removing and installing], and [Disassembling and assembling].
  • Page 457 33. UPPER STRUCTURE 33.1 REMOVING AND INSTALLING 33.1.1 OPERATOR SEAT 33.1.1.1 REMOVAL (1) Preparation for removal 1) Remove the head rest (A1-1) of the operator’s A1-1 seat (A1) to ease handling. 2) Move the whole control stand to its foremost position.
  • Page 458 33. UPPER STRUCTURE 33.1.2 33.1.2.1 REMOVAL (1) Remove floor mat. (2) Remove cover (A7) Lift cover (A7) upwards and remove it. (Fixed with 2 clips) (3) Remove cover assy (A1) 1) Loosen 4 sems bolts (A22) M6×16 and lift cover assy (A1) up.
  • Page 459 33. UPPER STRUCTURE RELAY BOX ASSY Fig. 33-5 Move switch cover assy (7) Remove cab attaching bolt 1) 5 capscrews (A1) M12×65 and 1 capscrew (A3) M12×30. (Mark 2) 2 nuts (B4) M16 (Mark (8) Slinging cab 1) Remove two plastic plugs at the front of the ceiling of the cab.
  • Page 460 33. UPPER STRUCTURE 33.1.3 BATTERY 33.1.3.1 REMOVING (1) Open left panel assy (21). 1) Open it with starter key. 2) Open left panel assy (21). 3) Fix it with stay. (2) Remove battery cover (1) Loosen nut (6) M10 and remove battery cover (1). : 17 mm (3) Remove battery cable 1) Remove cable (A4) [between the earth and...
  • Page 461 33. UPPER STRUCTURE 33.1.4 GUARD 33.1.4.1 PREPARATION FOR REMOVAL (1) Remove guard in the following procedure. Remove the guards in the order of (31)→(5)→(6)→(7)→(2)→(21)→(23)→(3)→(4)→ (22) and (1). (2) All the locked cover, open them using starter key. Fig. 33-10 Arrangement of guard assy 33.1.4.2 REMOVE GUARD (1) Remove bonnet assy (31)
  • Page 462 33. UPPER STRUCTURE (3) Remove guard (6) and guard assy (3). 1) Remove 3 sems bolts (35) M12×30. 2) Remove a sems bolt (43a) M12×25. 3) Remove guard (6). 4) Remove a sems bolt (43b) M12×25. 5) Remove guard assy (3). : 19 mm Fig.
  • Page 463 33. UPPER STRUCTURE (7) Remove panel assy (23) 1) Remove 4 nuts (4) M10. 2) Remove panel assy (23). : 17 mm Weight : 10kg (22 lbs) Fig. 33-17 Removing panel assy (23) (8) Remove panel assy (22) 1) Unlock and open panel assembly (22). 2) Remove 4 nuts (4) M10.
  • Page 464 33. UPPER STRUCTURE (11)Remove beam (4) 1) Loosen 6 sems bolts (43) M12×25. 2) Remove beam (4). : 19 mm Weight : 18kg (40 lbs) Fig. 33-21 Removing and installing of beam (4) (12)Remove pillar (10), (12) Remove battery relay box in advance and remove pillar (10).
  • Page 465 33. UPPER STRUCTURE (15)Remove cover assy (1) 1) While air cleaner is removed, loosen hose clamp of engine intake and disconnect the hose. 2) Loosen 5 sems bolts (6) M12×30, and remove cover assy (1). : 19 mm (16)Remove guard assy (2) Loosen 4 sems bolts (6) M12×30, and remove guard assy (2).
  • Page 466 33. UPPER STRUCTURE (19)Remove cover assy (1) 1) Unlock the locks and open cover (1-2). 2) Remove 4 sems bolts (43) M12×25. 3) Remove cover assy (1). : 19 mm Weight : 30kg (66 lbs) (20)Remove other brackets, as required. Fig.
  • Page 467 33. UPPER STRUCTURE 33.1.5 UNDER COVER 33.1.5.1 REMOVAL (1) Remove under cover (1,2,3,4,5,6,7,8) 1) Remove attaching sems bolts (9) M12×30. 2) Remove covers. : 19 mm Fig. 33-27 Under cover assy 33.1.5.2 INSTALLATION (1) Install under cover (1,2,3,4,5,6,7,8) : 19 mm Tightening torque : 80.0 N•m (59.0 lbf•ft) 33-13...
  • Page 468 33. UPPER STRUCTURE 33.1.6 FUEL TANK 33.1.6.1 PREPARATION FOR REMOVAL (1) Draining fuel. (See Fig. 33-30) 1) Unlock cap (B2) with a starter key and open it. 2) Loosen valve (A8) under the tank. 3) Draining fuel Capacity of tank : 460L (122gal) (2) Remove stay (7) and guard (2).
  • Page 469 33. UPPER STRUCTURE 33.1.6.2 REMOVAL (1) Remove 4 capscrews (A1) M16×45. : 24 mm (2) Hook the wire to the lifting eye on the fuel tank assy (C1) and remove the fuel tank. Weight : 184kg (406 lbs) (3) Remove shim (A3). Record the shim locations.
  • Page 470 33. UPPER STRUCTURE 33.1.7 HYDRAULIC TANK 33.1.7.1 PREPARATION FOR REMOVAL (1) Remove panel assy (2), guard (6) and other guards necessary to remove the hydraulic oil tank. (See 33.1.4 GUARD.) Fig. 33-31 Remove guard (2) Release internal pressure of tank Remove cap on air breather and push valve (head Air breather of bolt) by your finger.
  • Page 471 33. UPPER STRUCTURE 33.1.7.2 REMOVAL (1) Draw out the suction hose (A3) Remove 2 clips (A19) of the tank side and pull out hose (A3). 2 : Flat-blade screwdriver At installing suction hose, apply PERMATEX to the inner end of both hoses. Fig.
  • Page 472 33. UPPER STRUCTURE (7) Remove hydraulic tank attaching bolt Remove 4 capscrews (A1) M20×40. : 30 mm (8) Slinging hydraulic oil tank Place a wire sling, using the lifting plate on top of the tank. Tank weight : Approx : 165kg (364 lbs) (9) Remove shim (A3).
  • Page 473 33. UPPER STRUCTURE (5) Connection of suction hose (A3)(See Fig. 33-34) O-RING 1) Apply PERMATEX on pipe side of hose connection and insert it. 2) Put the hose with clip (A13). Tightening torque : 5.39 N•m (4.0 lbf•ft) (6) Assembling return element Assemble filter element by the use of element kit (B-100).
  • Page 474 33. UPPER STRUCTURE 33.1.8 HYDRAULIC PUMP 33.1.8.1 PREPARATION FOR REMOVAL (1) Release pressure in hydraulic oil tank. (See 33.1.7HYDRAULIC TANK) (2) Remove six capscrews (C5) M10×25. (3) Remove cover (C2) uction stopper : 17 mm (4) Take out suction strainer. (5) Install suction stopper.
  • Page 475 33. UPPER STRUCTURE 33.1.8.2 REMOVAL (1) Loosen sems bolts (A15) M12×40 and remove half clamp (A4). And disconnect 2 hoses (A1), (A2) from the delivery side. : 19 mm (2) Remove pilot pump suction hose (1) (See Fig. 33-43) : 36 mm (3) Remove suction hose (A3) and drain hose (6) 1) Remove 4 capscrews (B2) M12×30.
  • Page 476 33. UPPER STRUCTURE (5) Remove connector Tightening torque 25.5N . m PSV-P1: (19 lbf . ft) Remove 4 connectors of all pressure sensors and SEMS BOLT P1 pump proportional valve proportional valves. PSV-P2: Engine P2 pump side proportional valve CLIP SE-22: Using Zip-tie, clamp Pressure sensor :...
  • Page 477 33. UPPER STRUCTURE 33.1.8.3 INSTALLATION Installing is done in the reverse order of removing. (1) Installing bracket (1) Tighten bracket (1) with capscrew (3) and install bracket temporarily. : 17 mm Tightening torque : 431 N•m (318lbf•ft) Apply Loctite #262 (2) Installing hub (2-2) Put hub (2-2) into the pump spline till it enters 1mm (0.04in) from the end face of the spline (See Fig.
  • Page 478 33. UPPER STRUCTURE (6) Installing the pump (See Fig. 33-45,Fig. 33-46) Lift the pump with bracket (1). Place coupling (2) in the groove of element (2-1) so as to receive insert NA (2-3). (7) Coat 8 capscrews (4) M10×35 with Loctite #262 and put them in place.
  • Page 479 33. UPPER STRUCTURE 33.1.9 AIR CLEANER 33.1.9.1 PREPARATION FOR REMOVAL (1) Opening bonnet assy (21) and (23). (See 33.1.4 GUARD) (2) Open bonnet assy (31). (See 33.1.4 GUARD) (3) Remove Panel assy (3). (See 33.1.4 GUARD) (4) Unplug terminals on indicator (1-8) wiring. (See Fig.
  • Page 480 33. UPPER STRUCTURE 33.1.10 MUFFLER 33.1.10.1 PREPARATION FOR REMOVAL (1) Remove bonnet assy (31) and guard (5). (2) Remove panel assy (22). (3) Remove guard (14), (15) and guard assy (16). (See Fig. 33-19) Fig. 33-50 Preparation for removal 33.1.10.2 REMOVAL (1) Remove U bolt (4).
  • Page 481 33. UPPER STRUCTURE 33.1.10.3 INSTALLATION Installing is the reverse order of removing with attention paid to the following items: (1) Procedure of fastening U bolt (4) (See Fig. 33-51) 1) Tighten 4 nuts (A) till there is no space and make sure that the dimension C is even all around.
  • Page 482 33. UPPER STRUCTURE 33.1.11 COUNTERWEIGHT 33.1.11.1 PREPARATION FOR REMOVAL Remove plug (A3) on the counterweight and attach 2 M36 eye bolts (See chapter 11) to the counterweight. : 55 mm Fig. 33-52 Lifting up counterweight 33.1.11.2 REMOVAL (1) Lifting up counterweight temporarily Hook wire rope to slinging jig, and lift it and stretch wire rope to the degree where it is providing no slack temporarily.
  • Page 483 33. UPPER STRUCTURE 33.1.12 RADIATOR & OIL COOLER 33.1.12.1 PREPARATION FOR REMOVAL (1) Bleed air from the hydraulic tank and install the suction stopper.(See 33.1.7 and 33.1.8) (2) Remove bonnet assy (31) (See 33.1.4 GUARD) (3) Remove battery (See 33.1.3 BATTERY) (4) Remove beam (4).
  • Page 484 33. UPPER STRUCTURE 33.1.12.2 REMOVAL (1) Remove radiator stay (A1). 1) Remove a sems bolt (A2) M12×35 and 3 sems bolts (A3) M12×30. : 19 mm 2) Remove 2 stays (A1). (2) Remove water hose (2),(3) 1) Loosen the hose bands (30) for water hose (2). : Flat-blade screwdriver 2) Remove hose (2).
  • Page 485 33. UPPER STRUCTURE (5) Disconnecting hydraulic oil hose (1), (2) 1) Loosen 2 capscrews (20) M12×55 for attaching clamp (15). C / V 2) Place an oil pan under the hose joint. Loosen 4 C / V sems bolts (18) M12×35, and remove hoses (1) and (2).
  • Page 486 33. UPPER STRUCTURE 33.1.12.3 INSTALLATION (1) Installing is done in the reverse order of removing. And removed clips of hose should be clamped at original position. (2) Install radiator assy Place a wire sling in the lifting eyes of the radiator Insert width Insert width and move it to original position temporally.
  • Page 487 33. UPPER STRUCTURE 33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE (1) Preparation for disassembly and assembly 14 15 1) Remove one under cover at the bottom of the radiator. 2) Wait till the engine coolant cools down so you do not get burned.
  • Page 488 33. UPPER STRUCTURE 10) Disconnection of oil cooler hose Disconnect hose (1), (2) from upper and lower of cooler, and drain hydraulic oil. (See Fig. 33-60) 11) Lift cooler temporally using cooler head flange for slinging. 12) Loosen 4 bolts (15) M8×25 attaching oil cooler. 13) Lift the oil cooler.
  • Page 489 33. UPPER STRUCTURE 33.1.13 ENGINE 33.1.13.1 PREPARATION FOR REMOVING (1) Remove battery ground (See 33.1.3 BATTERY) (2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER) (3) Remove air cleaner hose (See 33.1.9 AIR CLEANER) (4) Remove counterweight (See 33.1.11 COUNTERWEIGHT) (5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR &...
  • Page 490 33. UPPER STRUCTURE 33.1.13.2 REMOVAL Fig. 33-65 Dismantling and mounting engine (1) Remove hose of engine oil filter Place oil pan under the connection of filter (1), and disconnect hoses (2), (6), (7) at positions. : 17 mm, 41 mm (2) Plug connector of filter side and hose.
  • Page 491 33. UPPER STRUCTURE 33.1.13.3 INSTALLATION Installing is done in the reverse order of removing. (1) Tightening torque Tightening torque Name Remarks N . m (lbf . ft) Bolt 26.5 (20) Apply Loctite Sems bolt 64.7 (48) #262 Apply Loctite Sems bolt 79.4 (59) #262 Apply Loctite...
  • Page 492 33. UPPER STRUCTURE 33.1.14 CONSOLE COVER 33.1.14.1 REMOVAL (1) Removing right-hand console cover 1) During pushing 4 locked claws of boot retaining plate (4) with flat-blade screw driver, lift the plate (4) and remove it. : Flat-blade screwdriver 2) Loosen 3 sems bolts (10D) M6×16. Push : Plus screw driver 3) During lifting right upper console cover (9D) up;...
  • Page 493 33. UPPER STRUCTURE 33.1.15 CONTROL VALVE 33.1.15.1 PREPARATION FOR REMOVING (1) Remove guard (6) (See 33.1.4 GUARD) (2) Remove under cover (5). (See 33.1.5 UNDER COVER) (3) Install the suction stopper to the hydraulic oil tank. (4) Remove the hoses in Fig. 33-70 and Fig. 33-71. Tightening torque Mark each hose with a port name before removing it.
  • Page 494 33. UPPER STRUCTURE Functions Ports Ports on upper sides Ports Functions LEFT RIGHT P2 bypass cut PBp2 PBp1 P1 bypass cut PBa2 Arm 2 in Option Make-up line Arm (R) relief valve Bucket (R)relief valve Arm 1 out PBa1 Boom down Swing (LH) Boom (H) relief valve Boom conflux...
  • Page 495 33. UPPER STRUCTURE Function orts orts on left side (on machine) orts Function LOWER U ER SIDE SIDE Option Option Arm 1 out Arm 1 in Arm in lock release Swing left Swing low pressure sensor Travel left reverse Swing right Travel left forward Tank return orts on lower side (on machine)
  • Page 496 33. UPPER STRUCTURE 33.1.16 PILOT VALVE (FOR ATT) 33.1.16.1 PREPARATION FOR REMOVING The removing procedure for right and left is the same, so the preparation for left side is described here. (1) Put attachment on ground, stop engine and release pressure in tank.
  • Page 497 33. UPPER STRUCTURE 33.1.17 PILOT VALVE (FOR TRAVEL) 33.1.17.1 PREPARATION FOR REMOVING (1) Release pressure in hydraulic oil tank (See 33.1.7 HYDRAULIC TANK) (2) Remove under cover (1) (See 33.1.5 UNDER COVER) (3) Remove floor mat (B1). Fig. 33-75 Removing floor mat, pedal and and lever 33.1.17.2 REMOVAL (1) Separate the two pressure sensors SE-9 (A9) and...
  • Page 498 33. UPPER STRUCTURE 33.1.17.3 INSTALLATION Install it in the reverse order of removal and tighten it. Sems bolt (A11) : 17 mm T = 37 N•m (27.3 lbf•ft) Sems bolt (A7) : 17 mm T = 46.1 N•m (34.0 lbf•ft) Sems bolt (A8) : 13 mm T = 23.5 N•m (17.3 lbf•ft) Pressure sensor...
  • Page 499 33. UPPER STRUCTURE 33.1.18 SWING MOTOR UNIT 33.1.18.1 PREPARATION FOR REMOVING (1) Park machine on firm level ground and place attachment on ground. (2) Remove the guard (6). (See 33.1.4 GUARD) (3) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure in circuit by operating control lever.
  • Page 500 33. UPPER STRUCTURE (2) Removing the swing unit Remove 14 capscrews (1) M20×65. : 30 mm 1) Remove two plastic caps (2) M12 at the top of the swing motor and install eye bolts. : Flat-blade screwdriver 2) Put a wire sling in the eye bolts and remove the swing motor unit.
  • Page 501 33. UPPER STRUCTURE 33.1.19 SWIVEL JOINT 33.1.19.1 PREPARATION FOR REMOVING Remove boom piping hose 33.1.19.2 REMOVAL (1) Remove travel motor hose and tube 1) Remove 2 hoses (A16). (E port : PF1/2) : 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft) 2) Remove tubes (A1), (A2).
  • Page 502 33. UPPER STRUCTURE (2) Disconnecting the hoses on the top part of swivel joint 1) Remove drain hose (4). (E port : PF1/2) : 27 mm Tightening torque : 78 N•m (58 lbf•ft) 2) Remove hoses (A8), (A6). (A, CÉ|Å[Ég : 1-3/16-12UN) : 36 mm Tightening torque : 177 N•m (130 lbf•ft) 3) Remove hoses (A9), (A25).
  • Page 503 33. UPPER STRUCTURE (6) Remove capscrew for installation Attach eye bolt, lift it up temporarily, and remove 3 capscrews (C2) M12×25. EYE BOLT : 19 mm (See 11.7 SPECIAL TOOLS No.9 Plug) LOWER FRAME APS REW M12 25 Loctite #262 T=108N .
  • Page 504 33. UPPER STRUCTURE 33.1.20 UPPER FRAME 33.1.20.1 PREPARATION FOR REMOVING (1) Remove attachment (See chapter 32) (2) Remove cab (See 33.1.2 CAB) (3) Remove guard (See 33.1.4 GUARD) (4) Remove counterweight (See 33.1.11 COUNTERWEIGHT) (5) Remove swivel joint (See 33.1.19 SWIVEL JOINT) Fig.
  • Page 505 33. UPPER STRUCTURE 33.1.20.3 INSTALLATION (1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface over the whole circumference (shaded area) (2) Cleaning mating surfaces of upper frame and swing on the inside of capscrew. bearing.
  • Page 506 33. UPPER STRUCTURE 33.2 DISASSEMBLING AND ASSEMBLING 33.2.1 HYDRAULIC PUMP • REGULATOR 33.2.1.1 HYDRAULIC PUMP 33.2.1.1.1 Structural exploded view (1) Main pump 531 . 151 . Fig. 33-90 Structural exploded view of main pump 33-52...
  • Page 507 33. UPPER STRUCTURE Marks in Fig. 33-109 show the position where regulator is installed. Name Q'ty Name Q'ty Name Shaft(F) Valve plate (L) O-ring ; 1B P8 Shaft(R) Sensor block O-ring ; 1B P11 1st gear Cover O-ring ; 1B P14 Roller bearing Socket bolt ;...
  • Page 508 33. UPPER STRUCTURE (2) Gear pump (For pilot) Suction port : PF3/4 Tightening torque : 73.5N . m (54.2 lbf . ft) Delivery port : PF1/2 Tightening torque : 53N . m (39.1 lbf . ft) Drain port : PF3/8 Tightening torque : 34.3N .
  • Page 509 33. UPPER STRUCTURE 33.2.1.1.2 Disassembly and assembly of main pump (1) Tools Part The right list shows the tools required for remove Name Size Item No. Size and install. 406, 412 (2) Disassembling procedure Allen wrench 1) Selecting a place for disassembly. •...
  • Page 510 33. UPPER STRUCTURE 6) Disassembling the pump casing and the valve block Place the pump level on a work bench with its mounting surface of the regulator facing down. Then separate pump casing (271) and valve block (312). • When facing the mounting surface of the regulator down, place a rubber sheet on a work bench so as not to score the mounting surface.
  • Page 511 33. UPPER STRUCTURE 9) Separating the swash plate support and the pump casing Knock lightly on the mounting flange of swash plate support (251) from the pump casing (271) side and separate the swash plate support from the pump casing. Fig.
  • Page 512 33. UPPER STRUCTURE 12) Remove valve plate Remove valve plate (313, 314) from valve block (312). • The valve plate may come off during the operation under 6). (313 : Opposite Side Fig. 33-99 Removing valve plates (313), (314) 13) Remove other parts If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271), and remove needle...
  • Page 513 33. UPPER STRUCTURE (3) Installing procedure 1) Precautions to be exercised in installation Assembly is a reverse order of disassembly, but notice the following. 1. Repair scored parts at disassembly. Get replacements ready beforehand. 2. Wash parts sufficiently in cleaning oil and dry them with jet air.
  • Page 514 33. UPPER STRUCTURE 4) Installing shaft Install shaft (111) fitted with bearing (123), bearing spacer (127) and snap ring (824), to swash plate support (251). • Do not knock on the shaft with a hammer or something. • Fix the bearing by lightly tapping the outer 1 7,8 4 race of it by means of a plastic hammer and set it exactly to the end by using a steel rod...
  • Page 515 33. UPPER STRUCTURE 8) Installing valve block Install valve block (312) to pump casing (271) and fasten them together with socket bolts (401). : 17 mm Tightening torque ; 430 N•m (320 lbf•ft) • Work will be promoted if assembly is started from the rear pump.
  • Page 516 33. UPPER STRUCTURE 33.2.1.1.3 Maintenance standards (1) Replacement standards for abrasive parts Replace or readjust parts that exceed the following standards of wear. However, always replace such parts that show excessive damage on appearance. Recommended Standard Part name and inspection item value Remedy dimension...
  • Page 517 33. UPPER STRUCTURE 33.2.1.1.4 Troubleshooting (1) Locating causes of troubles The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location extremely difficult. However, faults would be found out easily if the following check items were attended to. 1) Inspecting the filter and drain oil Inspect the filter element to check for abnormal contaminations.
  • Page 518 33. UPPER STRUCTURE 3) Abnormal Sound and Vibration Cause Remedy Remarks 1. Cavitation 1) Prevent cavitation. 1-1) The boost pressure is low. Check that hydraulic oil is not 1-2) The attached pump is in trouble. clouded. 1-3) The suction pipe is inhaling air. 1-4) The suction resistance is high.
  • Page 519 33. UPPER STRUCTURE This page is blank for editing convenience. 33-65...
  • Page 520 33. UPPER STRUCTURE 33.2.1.2 REGULATOR 33.2.1.2.1 Structural exploded view 8-724 Fig. 33-109 Structural exploded view of regulator 33-66...
  • Page 521 33. UPPER STRUCTURE Marks in Fig. 33-90 show the position where regulator is installed. Name Q'ty Name Q'ty Name Socket bolt ; M8X50 Adjust screw (C) O-ring ; 1B P16 Socket bolt ; M8X70 Cover (C) O-ring Socket bolt ; M5X12 Lock nut ;...
  • Page 522 33. UPPER STRUCTURE 33.2.1.2.2 Disassembly and assembly (1) Tools Part The right list shows the tools required for remove Name Size mm Size Item No. and install. Allen wrench 438,439 (2) Disassembling procedure 412,413 1) Selecting a place for disassembly. Socket wrench PF1/4 Small size 1pc.
  • Page 523 33. UPPER STRUCTURE 6) Remove compensating parts M4 BOLT (See Fig. 33-109 (D) section, See Fig. 33-111, 44, 4 Fig. 33-112) After removing the cover (C) (629) sub assy, take out outer spring (625), inner spring (626) and spring seat (624) from the compensating part. Then take out adjust stem (645), pilot spring (646) and spring seat (644) from the pilot part.
  • Page 524 33. UPPER STRUCTURE " Fig. 33-116 Removing fulcrum plug (614) 10) Remove lever (Fig. 33-109 (G) section) Remove lever 2 (613). Do not draw out pin (875). • The work is eased if tweezers is used. !&%# Fig. 33-117 Removing lever 2 (613) 11) Remove feedback lever Draw out pin (874) and remove feedback lever %"...
  • Page 525 33. UPPER STRUCTURE 12)Remove lever (Fig. 33-109 (F) section) Remove lever 1 (612). &%" Do not draw out pin (875). &'% &%# &%# 13) Remove pilot piston and spool (Fig. 33-109 (C),(A) section) Draw out pilot piston (643) and spool (652). 14) Remove piston casing, compensating piston and compensating rod (Fig.
  • Page 526 33. UPPER STRUCTURE (3) Installing procedure : Assembly is the reverse order of disassembly. Do the work paying attention to the following : • Repair those parts that were damaged during disassembly and prepare replacement parts beforehand. • If foreign matter enters, it causes malfunction; clean parts thoroughly in cleaning oil, blow them with jet air and assemble parts in a clean place.
  • Page 527 33. UPPER STRUCTURE 5) Assembling pilot piston (See Fig. 33-109 (C) section) Assemble pilot piston (643) into the positive control hole of the casing. !&%# • Make sure that the pilot piston moves smoothly. 6) Assembling lever (See Fig. 33-109 (G) section) Place pin (875) pressed in lever 2 (613) into the groove of the pilot piston and assemble lever 2 (613).
  • Page 528 33. UPPER STRUCTURE 10) Assembling compensating parts (See Fig. 33- 109 (A),(B) section) Assemble set spring (655) into the spool hole. Place compensating piston (621) and piston casing (622) into the compensating hole and attach pilot cover (641). Then fasten them together with socket bolts (438), (439).
  • Page 529 33. UPPER STRUCTURE 33.2.1.3 PTO GEAR CASING (OPT.) 33.2.1.3.1 Structural exploded view Tightening torque Tightening torque Parts name Q’ty Parts name Q’ty N•m (lbf•ft) N•m (lbf•ft) 115 Idle shaft 33 (25) 435 Flange socket ; M10×20 117 2nd gear 74 (54) 468 VP plug ;...
  • Page 530 33. UPPER STRUCTURE 33.2.1.3.2 Disassembly and assembly (1) Tools Tool name Dimension The right list shows the tools required for remove Allen wrench Opposing flats 8,10mm and install. For snap ring RR-20 Plier (2) Disassembling procedure For snap ring RR-72 1) Selecting a place for disassembly.
  • Page 531 33. UPPER STRUCTURE 6) Removing the 2nd gear, the roller bearing and HOLE FOR the bearing spacer (115) IDLE SHAFT Draw out the spring pin (885) and remove idle shaft (115). Then draw out 2nd gear (117), roller bearing (126) and bearing spacer (128). 117 (126,128) •...
  • Page 532 33. UPPER STRUCTURE 33.2.2 CONTROL VALVE 33.2.2.1 SECTIONAL VIEW PBa1 PAa1 (P4) 162 163 169 155 SECTION A-A PBa2 PAa2 (P3) SECTION B-B Fig. 33-137 Section (1/6) 33-78...
  • Page 533 33. UPPER STRUCTURE 273x10 273x10 P1 unload Travel left (Travel straight) Boom conflux Travel right (P2 unload) 978x2 Boom Swing PBa1 PBa1 Bucket Arm 1 PBa2 PBa2 Arm 2 Option PBp1 PBp1 PBp2 PBp2 (P3) (P3) PBa2 PBa2 PBp1 PBp1 PBp2 PBp2 274x4...
  • Page 534 33. UPPER STRUCTURE P1 unload Travel left CMR2 CMR1 ECTION C-C Travel straight Travel right Boom conflux (T3) ECTION D-D P2 unload Fig. 33-139 Section (3/6) 33-80...
  • Page 535 33. UPPER STRUCTURE Swing Boom SECTION E-E 164 551 Bucket Arm 1 PBa1 PAa1 SECTION F-F Fig. 33-140 Section (4/6) 33-81...
  • Page 536 33. UPPER STRUCTURE Arm 2 Option PBa2 LCAT2 LCAP2 PAa2 SECTION G-G SECTION H-H Fig. 33-141 Section (5/6) 33-82...
  • Page 537 33. UPPER STRUCTURE PBp1 PBp2 278x5 SEC ION J-J SEC ION K-K Fig. 33-142 Section (6/6) 33-83...
  • Page 538 33. UPPER STRUCTURE Tightening torque Tightening torque Parts name Q’ty Parts name Q’ty N•m (lbf•ft) N•m (lbf•ft) 101 Casing A 321 Spring 102 Casing B 322 Spring 154 Plug PF3/4 323 Spring 220~250(162~184) 155 Plug PF1/2 324 Spring 110~130(81~96) 20~24(15~18) 325 Spring Plug PT1/4 (Capsule coating) 7.8~9.8(5.8~7.2) 160...
  • Page 539 33. UPPER STRUCTURE 33.2.2.2 PREPARATION FOR DISASSEMBLY (1) General precautions 1) As all the hydraulic components are precisely machined, it is essential to carry out disassembly and reassembly in an especially clean location. 2) When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or sand.
  • Page 540 33. UPPER STRUCTURE 33.2.2.3.1 Disassembling P1 unload spool (1) Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for P1 unload spool. Fig. 33-144 Removing spring cover (202) for P1 unload spring cover (2) Draw out, from casing B (102), as a assy of P1 unload spool (309), spring seat (331), springs (327), (329), stopper (336) and bolt (333).
  • Page 541 33. UPPER STRUCTURE 33.2.2.3.2 Disassembling the travel spool (left travel and right travel) (1) Loosen the socket bolts (273) and remove the spring cover (201) and the O-ring (261) for travel. Fig. 33-147 Removing spring cover (201) (2) Draw out the assy of travel spool (306), spring seat (331), springs (323), (324), stopper (336) and bolt (333) from casing A (101) or casing B (102).
  • Page 542 33. UPPER STRUCTURE 33.2.2.3.3 Disassembling the boom conflux spool (1) Loosen socket bolts (273) and remove spring cover (201) for boom conflux and O-ring (261). (2) Draw out the assy of boom conflux spool (305), spring seat (331), springs (325), (326), stopper (339) and bolt (333) from casing A (101).
  • Page 543 33. UPPER STRUCTURE (3) Fix the boom spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from boom spool (301). Do not disassemble boom spool (301) further unless there is special reason.
  • Page 544 33. UPPER STRUCTURE 33.2.2.3.6 Disassembling bucket spool (1) Loosen socket bolts (273) and remove bucket spring cover (209) and O-ring (261). Fig. 33-157 Removing spring cover (209) (2) Draw out the assy of bucket spool (304), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102).
  • Page 545 33. UPPER STRUCTURE 33.2.2.3.7 Disassembling arm 1 spool (1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 1 spool. (2) Draw out the assembly which is consist of arm 1 spool (302), spring seat (331), spring (321, 322), stopper (336) and bolt (333) from casing A (101).
  • Page 546 33. UPPER STRUCTURE 33.2.2.3.9 Disassembling option spool (1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of option spool. (2) Draw out the assembly which is consist of option spool (311), spring seat (331), spring (323, 324), stopper (336) and bolt (333) from casing A (101).
  • Page 547 33. UPPER STRUCTURE 33.2.2.3.11 Disassembling P2 unload spool (1) Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261). (2) Draw out the assembly which is consist of P2 unload spool (310), spring seat (331), spring (327, 329), stopper (336) and bolt (333) from casing A (101).
  • Page 548 33. UPPER STRUCTURE 33.2.2.3.13 Removing relief valve and plug assy for relief valve hole (1) Remove the main relief valve (601) and overload relief valve (602) and (603) from the casing. • Distinguish overload relief valve between (602) and (603) with a tag to prevent them from being confused during reassembly, as they are the same in appearance and shape but differ in pressure setting.
  • Page 549 33. UPPER STRUCTURE 33.2.2.3.14 Removing by-pass cut valve (1) Remove by-pass cut valve (606) from the casing. Remove the by-pass cut valve, giving particular attention to the poppet (606-201) and spring (606-202) which may be remained on the inside of casing. Fig.
  • Page 550 33. UPPER STRUCTURE (2) Remove springs (527), (528), boost check valve poppet sub (517) and by-pass check valve poppet (518) from the casing. The further disassembly of boost check valve poppet sub (517) is not allowed. Replace control valve so that the spool cover face directs downward.
  • Page 551 33. UPPER STRUCTURE 33.2.2.3.18 Removing check valve (1) Remove plugs of load check valve, conflux check valve, etc. and then remove poppet (511) and spring (521). (2) Load check valve on the swing section Remove plug (556) and then remove poppet (511) and spring (523).
  • Page 552 33. UPPER STRUCTURE 33.2.2.3.20 Inspection after disassembly Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet of paper or cloth for inspection. (1) Control valve 1) Inspect the entire surface of each part for burrs, scratches, cuts, and other defects. 2) Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
  • Page 553 33. UPPER STRUCTURE 33.2.2.4.1 Installing check valve (1) Load check valve, conflux check valve, and so on Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (9 places) (2) Load check valve of swing section Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them to the specified torque.
  • Page 554 33. UPPER STRUCTURE 33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly (1) Tighten main relief valve (601), port relief valves (602), (603) and relief valve hole plug assembly (604) in respective place to the specified torque. Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief valves (602), (603) are similar in shape.
  • Page 555 33. UPPER STRUCTURE 33.2.2.4.9 Assembling spool in option (1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque. •...
  • Page 556 33. UPPER STRUCTURE 33.2.2.4.12 Assembling bucket spool (1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque. •...
  • Page 557 33. UPPER STRUCTURE 33.2.2.4.14 Assembling boom spool (1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque. •...
  • Page 558 33. UPPER STRUCTURE 33.2.2.4.17 Assembling P1 unload spool (1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque. •...
  • Page 559 33. UPPER STRUCTURE 33.2.2.5 MAINTENANCE STANDARDS 33.2.2.5.1 Inspection of components Part name Inspection item Criterion and remedy Casing 1) Look for scratches, rusting and corrosion. 1) If any of the following parts are damaged, replace the casing. • Sliding part of casing hole and spool, particularly the land, to which holding pressure is applied.
  • Page 560 33. UPPER STRUCTURE 33.2.2.6 TROUBLESHOOTING (1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure, load pressure, etc.
  • Page 561 33. UPPER STRUCTURE Trouble Cause Remedy 3. Excessive natural 1) Excessive clearance between casing and 1) Replace spool. falls of attachment spool. under its own weight 2) Spool is not completely in neutral position. 2) Check secondary pilot pressure. when spool is in •...
  • Page 562 33. UPPER STRUCTURE Trouble Cause Remedy 6. Boom conflux does 1) Malfunctioning conflux valve. 1) Measure pilot pressure. not operate. • Excessive clearance between casing • Replace spool. and spool. • Disassemble and clean. • Foreign matter between casing and •...
  • Page 563 33. UPPER STRUCTURE 33.2.3 PILOT VALVE (ATT) 33.2.3.1 CROSS-SECTIONAL VIEW Apply grease on rotating and sliding sections. Apply grease on Be careful the top section assembling direction * 246 * 218-2 * 218-1 216-1 216-2 241-2 241-1 201-2 201-1 Secondary pressure adjusting shim Designed value...
  • Page 564 33. UPPER STRUCTURE 33.2.3.2 DISASSEMBLY (1) Plug each port of pilot valve, and clean it with kerosine. P port : PF1/4 1~4 and T port : PF3/8 (2) Fix pilot valve with vise via a protective plate (Alminum plate etc.), and remove boots (501). Fig.
  • Page 565 33. UPPER STRUCTURE Fig. 33-185 Installing Jig A (5) Turn joint (301) in counterclockwise with Jig A to remove. Jig A : See page 33-118. : 24mm When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out of plate (151), plug (211) and push rod (212).
  • Page 566 33. UPPER STRUCTURE (7) Remove push rod (212), plug (211), pressure reducing valve assy (spool), return springs (221) from casing (101). Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction. Fig. 33-189 Removing push rod, plug, pressure reducing valve and spring (8) Push springs (241-1), (241-2) in the range of 7mm 216-1...
  • Page 567 33. UPPER STRUCTURE (11)Pull out push rod (212) from plug (211). (12)Remove O-ring (214) from plug (211). Fig. 33-193 Removing push rod (212) (13)Remove inside seal (213) from plug (211) with small driver. Fig. 33-194 Removing seal (213) 33.2.3.3 CLEANING PARTS (1) Clean parts with wash oil roughly.
  • Page 568 33. UPPER STRUCTURE (2) Push spring (241-1), (241-2) in the range of that the 216-1 216-1 movement of spring seats (216-1), (216-2) in a side 216-2 216-2 direction, and install spools (201-1) through the larger hole of spring seat. (See Fig. 33-190) Never push down spring seat (216-1) in 7mm (0.276in) or more.
  • Page 569 33. UPPER STRUCTURE (6) Fit plug (211) assy to casing (101). 1) When the force of spring (211) is weak, it stops at the position where it is pushed in by the sliding resistance of O-ring (214). Fig. 33-200 Installing plug assy 2) When the force of spring (221) is strong, attach plate (151) and press 4 push rods by hand at the same time, and tighten joint (301) temporarily.
  • Page 570 33. UPPER STRUCTURE (8) Install circular plate (302) to joint (301) • Screw it in until it comes in contact with 4 push rods (212) equally. • The exceeding of screw in may cause malfunction of machine. (9) Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular plate returning.
  • Page 571 33. UPPER STRUCTURE 33.2.3.5 MAINTENANCE STANDARDS Check item Standard Remarks When leakage quantity reaches to 1000cc/ min. or more where handle is set in neutral position, Conditions or to 2000cc/min. or more in operation, replace Leakage Primary pressure 2.94 MPa (426 psi) spool with new one.
  • Page 572 33. UPPER STRUCTURE 33.2.3.7 (1) Jig for removing and installing joint (301) Material ; SCM415 (N) Carburizing and Quenching BUSHING Material ; S45C SECTION AA Installing condition on joint * (1) and (2) are tight fitted Sectional drawing of jig Material ;...
  • Page 573 33. UPPER STRUCTURE 33.2.4 PILOT VALVE (FOR TRAVEL) 33.2.4.1 CONSTRUCTION T=Tightening torgue N . m (lbf . ft) 12-o 12-o 12-o 12-y 12-y 12-x 12-x Loctite 262 T=5 (3.7) T=4 (3) T=30 (22) T=1.2 (0.9) T=4 (3) T=5 (3.7) Loctite 262 T=3~5 (2.2~3.7) Fig.
  • Page 574 33. UPPER STRUCTURE 33.2.4.2 DISASSEMBLY AND ASSEMBLY (1) Boot replacement witch plate The pilot control unit does not need to be removed from the machine to perform this operation. 1) Remove both faulty boots. (using a flat screw driver if necessary) 2) Replace both boots with a new one.
  • Page 575 33. UPPER STRUCTURE (3) Switch plate adjustment If the switch plate is replaced, it is necessary to adjust the regulation screws. crews locking the regulation 1) Unscrew the 2 locking screws using a 2,5mm screws socket wrench (See Fig. 33-208) * Reassembly : •...
  • Page 576 33. UPPER STRUCTURE 3) Lift the retaining plate to remove it. (See Fig. 33-211) * Reassembly : • Use the retaining plate to insert the 4 guides into the body simultaneously and perpendicularly. (See Fig. 33-211 left side) 4) Reassemble parts in reverse order. 5) Drain the pilot control unit (See 33.2.4.3).
  • Page 577 33. UPPER STRUCTURE • Squeeze the seal between your fingers to obtain a 8-shape. (See Fig. 33-215 No.5) • Insert the seal within the groove with your fingers (lip in bottom position). (See Fig. 33-215 No.6, 7) • Push the seal against the side using the round head of a small socket wrench.
  • Page 578 33. UPPER STRUCTURE 6) Guide/plunger and relulation unit replacement • Extract the regulation units from the body (using flat nose pliers). • Inspect the regulation units. If defects are detected on the parts, replace the 4 units. 7) Return spring replacement : •...
  • Page 579 33. UPPER STRUCTURE 2) Unscrew the screw using a 3mm socket wrench. (See Fig. 33-219) * Reassembly : • Apply a droplet of Loctite #262 on the screw thread • Screw on until it sets just above the body. (See Fig. 33-220) 3) Unscrew the throttle using a 3mm socket wrench.
  • Page 580 33. UPPER STRUCTURE 3) Put the body up-side-down to remove the shuttle valve and the ball. (See Fig. 33-224) 4) Unscrew the throttle using a 2,5mm socket wrench. * Reassembly: • Hand tighten. 5) Repeat the operation for the other subassemblies.
  • Page 581 33. UPPER STRUCTURE 33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT (1) When removing the retaining plate, the throttle kit or the shuttle valve kit, it is necessary to drain the pilot unit. (2) Reassemble the pilot unit control completely. (3) Install the pilot unit control in the machine. (4) Slightly unscrew the check valve plug using a 4mm socket wrench.
  • Page 582 33. UPPER STRUCTURE 33.2.5 SWING MOTOR UNIT 33.2.5.1 CONSTRUCTION (1) Swing motor SECTION A-A 15,16 A PORT SIDE RELIEF VALVE A PORT TOP DEAD POINT BOTTOM DEAD POINT B PORT B PORT SIDE RELIEF VALVE DRAIN PORT 39 38 37 MAKEUP PORT MECHANICAL BRAKE RELEASE CHAMBER...
  • Page 583 33. UPPER STRUCTURE Tightening Tightening torque torque Parts Q’ty Parts Q’ty N•m (lbf•ft) N•m (lbf•ft) INNER RING 22 NEEDLE BEARING OIL SEAL 23 SNAP RING TAPERED ROLLER 24 CYLINDER BEARING BACKING SPRING 25 HOUSING CAM PLATE 26 COLLAR RETURN PLATE 27 SNAP RING PISTON ASSY 78 (58)
  • Page 584 33. UPPER STRUCTURE (2) Swing reduction unit Caulk these 2 places with punch. Be careful about installation direction of retaining ring. OIL FILLING PORT PT3/4 LEVEL PORT PT1/2 Tightening torque Be careful about 181 + - 20 N . m (134 + - 15 lbf . ft) installation direction Be careful about Apply Three Bond #1360.
  • Page 585 33. UPPER STRUCTURE 33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR (1) Disassembly 1) Removal of relief valve assembly etc. Remove relief valve assembly (33), cap (38), spring (37) and check (36) from cover (32). : 14 mm, 10 mm Assemble removed parts to original state when reassembling.
  • Page 586 33. UPPER STRUCTURE Work carefully to avoid damaging the sliding face of the balance plate (21). Before removing, check and record location of balance plate (21) to prevent misassembling 5) Remove O-ring (12) from cover (32). Fig. 33-232 Removing O-ring 6) Remove bushing (20) with teflon ring (19) and scrowave (18).
  • Page 587 33. UPPER STRUCTURE 8) Removal of brake piston When removing piston (11) from housing (25), MONKEY there is a sliding resistance against tightening of WRENCH ETC. O-rings (10) (12). Use tap holes (M6) on piston (11) to take them out, as shown in the diagram. Remove O-rings (10) (12) from housing (25) and BLOCK piston (11).
  • Page 588 33. UPPER STRUCTURE 11) Separate outer race of taper roller bearing (3) from housing (25). Remove oil seal (2) from housing (25) with driver and hammer. Do not reuse oil seal (2) after removal. Fig. 33-238 Removing outer race & oil seal 12) Disassembly of the cylinder assembly 1.
  • Page 589 33. UPPER STRUCTURE 4. Remove backing spring (4) from cylinder (24). This completes disassembly. Fig. 33-242 Removing backing springs (2) Assembly 1) Preparation Before reassembling, perform below procedure. 1. Check each part for damage caused by using or disassembling. If damaged, remove scratches by rubbing with "wet and dry"...
  • Page 590 33. UPPER STRUCTURE 2) Assembling of cylinder assembly 1. Lubricate grease on round area (contacting area with spring (4)) of cylinder (24) and assemble spring (4). ROUND AREA Fig. 33-244 Assembling backing spring 2. Insert piston assembly (7) in hole of return plate (6).
  • Page 591 33. UPPER STRUCTURE 5. Assemble inner race of taper roller bearing (3) Jig 1 to cylinder (24). (Refer to (3) Tools) (INNER RACE) End surface of cylinder (24) is sliding face. So, protect the surface with a soft cloth against damage. Fig.
  • Page 592 33. UPPER STRUCTURE 4) Assembly outer race of taper roller bearing (OUTER RACE) Assemble outer race of taper roller bearing (3) into the housing (25). Fig. 33-251 Assembling outer race 5) Assembly of cylinder assembly The end of cylinder assy Hold the end of cylinder assembly (24) with hands and assemble cylinder assembly to housing (25).
  • Page 593 33. UPPER STRUCTURE 6) Assembly friction plate and lining plate Assemble friction plate (8) and lining plate (9). Apply hydraulic oil to each side. Fig. 33-253 Assembling friction plate & lining 7) Insert O-rings Insert O-rings (10) into housing (25). Insert O- ring (12) into piston (11).
  • Page 594 33. UPPER STRUCTURE 10) Assembly of balance plate Assemble scrowave (18) and bushing (20) with teflon ring (19) to bushing hole of cover (33). Grease teflon ring (42) and piston (14) (41). Assemble teflon ring (42) and piston (14) (41) to balance plate (21).
  • Page 595 33. UPPER STRUCTURE 13) Assembly of cover After cleaning the matching surface between cover (32) and housing (25) and degreasing it, assemble cover (32) to housing (25) lightly, holding them up with hands. Fit matching marks on housing (25) and cover (32) made before disassembling.
  • Page 596 33. UPPER STRUCTURE 16) Check of assembly Load pilot pressure of 3.2~4.9 MPa (464~711psi) to brake release port after opening inlet and outlet port. Check if output shaft is rotated smoothly around torque of 30~40 N•m (22~30 lbf•ft). P PORT If not rotated, disassemble and check.
  • Page 597 33. UPPER STRUCTURE 33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT 33.2.5.3.1 Tools Unit : mm (in) Code Tool name Remarks 450 (17.7) Material : Mild steel 330 (13.0) Stand 216 (8.5) Material : Mild steel 13- 24 Spherical bearing (13) (0.9) (Position removing jig (I)
  • Page 598 33. UPPER STRUCTURE Code Tool name Remarks Snap ring plier For shaft Torque wrench 200 N•m (148 lbf•ft) class Plastic hammer (Wooden mallet) Press 30 ton (66150 lb) class Flat-bladed screw driver General tools Allen wrench, Steel bar Thread sealant Three Bond #1360K Sealant Loctite #515...
  • Page 599 33. UPPER STRUCTURE 3) Removing ring gear (7) Attach eye bolts (M12) to the top surface of ring gear (7) and lift the ring gear lightly by a wire #2SPIDER ASSY sling. Put a flat-blade screwdriver (n) into the matching surface of ring gear (7) and housing (15) and remove ring gear (7) by lightly tapping the outer circumference of the ring gear with a plastic...
  • Page 600 33. UPPER STRUCTURE 6) Pulling out pinion shaft PRESS Pull pinion shaft (1), sleeve (17), oil seal (16) and spherical bearing (lower) (12) out by means of press while supporting housing (15) as shown in the figure. • Spherical bearing (upper) (13) and oil seal (14) are left in the housing.
  • Page 601 33. UPPER STRUCTURE 8) Removing spherical bearing (upper) HAMMER(k) Set housing (15) as shown in the figure, insert jig (d) between bearing (13) and oil seal (14) and FLAT-BLADE remove bearing (13) by striking from the upper SCREWDRIVER (n) STEEL BAR side.
  • Page 602 33. UPPER STRUCTURE 33.2.5.3.3 Assembly (1) Preparation 1) Sufficiently clean every part with wash oil and dry it with compressed air. 2) Check on every part for failure. (2) Assembling pinion shaft assy 1) Attaching oil seal JIG (e) Attach oil seal (16) to sleeve (17) by means of jig (e).
  • Page 603 33. UPPER STRUCTURE 5) Apply sufficient grease to the pinion shaft assy. Grease : Lithium extreme-pressure grease (SHELL Albania EP2 or equivalent) GREASE (3) Placing pinion shaft assy in 1) Place housing (15) on level bench. 2) Attach eye bolt to screw (M10) at the axis end of pinion shaft assy, and perpendicularly hang up pinion shaft assy and place it in the housing.
  • Page 604 33. UPPER STRUCTURE 5) Press fit spherical bearing (upper) (13) in pinion JIG (h) PRESS shaft (1) and housing (15) at the same time by means of jig (h). Fig. 33-280 Spherical bearing (upper) Press-fitting 6) Attach retaining ring (21). Fig.
  • Page 605 33. UPPER STRUCTURE (4) Assembling spider assy 1) Assembling #1 Spider assy a. Coat the bore surface of pinion (3) with grease. Put pinion (3) on thrust washer (18) and assemble needle bearing (10) into the bore surface Fig. 33-282 Assembling #1 spider assy b.
  • Page 606 33. UPPER STRUCTURE (6) Installing #2 sun gear (2) Install #2 sun gear (2) directing the spline upward. Fig. 33-286 Installing #2 sun gear (2) (7) Installing ring gear (7) Apply a thin film of sealant Loctite #515 to the matching surface of housing (15) and ring gear (7) #2 SPIDER ASSY and assemble them, aligning the gear teeth and...
  • Page 607 33. UPPER STRUCTURE 33.2.5.4 MAINTENANCE STANDARDS 33.2.5.4.1 SWING MOTOR Parts Name Check and Measuring Reference Value Measuring Instrument Correction Point (Allowable limit) Wear of shoe sliding Piston Assembly (7) Rmax 0.8μm Surface gauge surface Height of hollow of Min 0.4mm Dial depth gauge replace with new one shoe sliding surface...
  • Page 608 33. UPPER STRUCTURE 33.2.5.4.2 Swing reduction gear (1) Inspection at disassembly 1) Spacer and thrust washer a. Inspect that the parts are not seized or worn abnormally or unevenly. b. Inspect and measure the parts to see that the wear does not exceed the allowable values. 2) Gears a.
  • Page 609 33. UPPER STRUCTURE (3) Maintenance standards Lube oil level Unit : mm (in) Code Item Repairable level Service Limit Remedy Wear in #1 planetary shaft Replace entire spider assy. ø40 (1.57 -0.0004 No flaking Wear in #2 planetary shaft Replace four shafts as a set. ø40 (1.57 -0.0004...
  • Page 610 33. UPPER STRUCTURE 33.2.5.5 TROUBLESHOOTING 33.2.5.5.1 Swing motor Table A Symp-tom Cause External Inspection Action Repair Breakage of internal Measure the drain volume Where the motor supply volume See table B. parts largely equals the drain volume it is highly likely that a sliding part is broken so disassemble the motor to investigate.
  • Page 611 33. UPPER STRUCTURE Symp-tom Cause External Inspection Action Repair Seizure of the motor Look for metallic foreign bodies If you find a metallic foreign Repair or replace sliding surfaces in the in the motor drain oil or trapped bodies, or if the output shaft damaged parts.
  • Page 612 33. UPPER STRUCTURE 33.2.5.5.2 Reduction unit Remedy Trouble Cause 1) Reduction unit does not rotate. Hydraulic motor inlet pressure has risen. Overloaded Reduce the load of motor. Reduction unit is broken. Replace reduction unit. Parking brake of the hydraulic Inspect the release motor is not released.
  • Page 613 33. UPPER STRUCTURE 33.2.6 SWIVEL JOINT 33.2.6.1 CONSTRUCTION VIEW 2 places Apply Three Bond #1805 to stem 2 places IEW Y 5 places Tightening torque 30.4 N . m (22.4 lbf . ft) Apply Loctite #242 SECTION HH Tightening torque 30.4 N .
  • Page 614 33. UPPER STRUCTURE 33.2.6.2 DISASSEMBLY AND ASSEMBLY 33.2.6.2.1 Tools Tool Name Used for Remarks Hammer 1. Steel hammer 2. Wooden or plastic mallet Rubber mat 750 mm (30in) square or more Disassembly Wrench Assembly 1. Allen wrench 2. Double-ended and single-ended wrench 3.
  • Page 615 33. UPPER STRUCTURE 33.2.6.2.4 Disassembly The part numbers used in this disassembly procedure correspond to those of a construction drawing in Fig. 33-290. (1) Removing cover 1) Mark cover (4) and body (1) with matching marks for convenient reassembly. 2) Place a V-block on a work bench, place a swivel joint set on the side, fix it and loosen socket bolt LLEN WRENCH (9) by means of a pipe and wrench.
  • Page 616 33. UPPER STRUCTURE (4) Removing sealing parts SPATULA (f) 1) Remove rings (13) of seal assemblies (6) and (5) with spatula (f). Pay attention to the body (1) not to be damaged by the top edge of spatula (f). Fig. 33-295 Removing O-ring (13) 2) Pierce slipper ring of seal assemblies (6) and (5) with pin (e) and remove them from the seal SLIPPER RING...
  • Page 617 33. UPPER STRUCTURE 2) Slipper ring is assembled, after first inserting the backup ring, by slightly-distorting the shape as shown in Fig. 33-297. Also after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula. 3) Assemble seal (5) by the same procedure above mentioned.
  • Page 618 33. UPPER STRUCTURE (4) Assembling cover MATCHING MARK After installing O-ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (9) with Loctite #242 and tighten it which will then complete assembly. : 6 mm, Tightening torque : 30.4 N•m (22 lbf•ft) ALLEN WRENCH...
  • Page 619 33. UPPER STRUCTURE 33.2.6.3 MAINTENANCE STANDARDS 33.2.6.3.1 Inspection procedure and remedy Interval Check Item Checking Procedure Remedy Seal for oil leakage Replace O-ring or dust seal , if any oil 2,000hr Check oil leakage outside outside leakage can be found. 4,000hr All sealing parts Replace all sealing parts such as slipper...
  • Page 620 33. UPPER STRUCTURE Parts Maintenance Standards Remedy 1) Protruded excessively from seal groove. PROTRUSION Replace (With back-up ring) ACKUP RING 2) Slipper ring 1.5mm (0.06in) narrower than seal groove, or narrower than back-up ring. Replace Slipper ring (With back-up ring) 1.5mm (0.02in) (max.) BACKUP RING...
  • Page 621 33. UPPER STRUCTURE 33.2.6.3.3 Inspection after assembly After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in Fig. 33-301. (1) High pressure port (A,B,C,D and F port) Connect to Install a directional valve and pressure gauge to the body side stem side port and body side port respectively, and while watching the pressure gauge (for high...
  • Page 622 33. UPPER STRUCTURE [MEMO] 33-168...
  • Page 623 34. TRAVEL SYSTEM TABLE OF CONTENTS 34.1 REMOVING AND INSTALLING..................34-3 34.1.1 TRAVEL SYSTEM ....................34-3 34.1.2 CRAWLER......................34-3 34.1.3 UPPER ROLLER ....................34-7 34.1.4 LOWER ROLLER ....................34-13 34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ............34-21 34.1.6 SPROCKET ......................34-30 34.1.7 TRAVEL MOTOR ....................34-33 34.1.8 SWING BEARING ....................34-35 34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT ........34-38 34.2.1 CONSTRUCTION OF TRAVEL MOTOR ...............34-38...
  • Page 624 34. TRAVEL SYSTEM Issue Date of Issue Applicable Machines Remarks E265B : LQ12-06001~ S5LQ3418E01 First edition July, 2007 E265BLC : LL12-05001~ (NHK Russia) PREFACE (1) This Manual describes all the procedures from removing to attaching, arranging them by item. (2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
  • Page 625 34. TRAVEL SYSTEM 34.1 REMOVING AND INSTALLING 34.1.1 TRAVEL SYSTEM 8. SWING BEARING 2. CRAWLER 7. TRAVEL MOTOR 5. FRONT IDLER 6. SPROCKET GUARD LOWER FRAME 3. UPPER ROLLER GREASE NIPPLE OF THE TRACK SPRING ADJUSTER 4. LOWER ROLLER Fig. 34-1 Designation and location of undercarriage 34.1.2 CRAWLER 34.1.2.1...
  • Page 626 34. TRAVEL SYSTEM (3) Removing crawler REMOVING Put attachment on ground so that weight is not MASTER PIN loaded to the lower frame, and remove track link assy rotating sprocket. Crawler end section may fall on the ground just before extending it on the ground incurring danger of injury.
  • Page 627 34. TRAVEL SYSTEM (5) Adjusting crawler tension (See Fig. 34-8) After installing, adjust tension of crawler. : 19 mm tandard dimension A Dimension of iron crawler in 320~350mm (12.6~13.8in) a max. slackened condition Fig. 34-8 Adjusting crawler tension 34.1.2.3 CONSTRUCTION FLAT SHOE GROUSER SHOE Fig.
  • Page 628 34. TRAVEL SYSTEM 34.1.2.4 MAINTENANCE STANDARD Fig. 34-10 Unit : mm (in) REPAIRAB SERVICE ITEM STANDARD VALUE REMEDY LE LEVEL LIMIT Link pitch 190 ± 0.1 (7.4803 ± 0.0039) 194 (7.64) 198 (7.80) Replace the link O.D. of bushing ) ø 55 (2.17) ø 54 (2.13) assy if the service ø...
  • Page 629 34. TRAVEL SYSTEM 34.1.3 UPPER ROLLER 34.1.3.1 UPPER ROLLER ASSY UPPER ROLLER ASSY No. YN64D00032F1 ITEM NAME Q’TY REMARKS ROLLER ASSY YN64D01068F1 CAPSCREW (SEMS SCREW) M20×P2.5×100 WASHER 34.1.3.2 REMOVING (1) Preparation for removal Remove crawler (Above mentioned). (2) Removing upper roller (1) 1) Remove nuts on support tightening section, and also remove capscrew (2) M20×100.
  • Page 630 34. TRAVEL SYSTEM 34.1.3.4 CONSTRUCTION OLLE ASSY PA T NO. YN64D01068F1 Q'TY Q'TY NAME NAME OLLE FLOATING SEAL SHAFT O ING : 1A P65 COLLA SOCKET BOLT PLATE PLUG COVE SNAP ING BUSHING Fig. 34-13 Construction of upper roller 34.1.3.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly "...
  • Page 631 34. TRAVEL SYSTEM 7) Removing floating seal (7). Take out floating seal (7) from roller (1). Fig. 34-16 Taking out floating seal 8) Removing floating seal (7). Remove from collar (3), floating seal (7) that is located on the side from which shaft (2) was disassembled.
  • Page 632 34. TRAVEL SYSTEM 4) Installing floating seals (7) Two floating seals (7) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1). • Prior to placing floating seal (7) in, apply engine oil lightly to seal surface.
  • Page 633 34. TRAVEL SYSTEM 34.1.3.6 MAINTENANCE STANDARD Unit : mm (in) REPAIRABLE SERVICE ITEM STANDARD VALUE REMEDY LEVEL LIMIT Dia. ø 140 (6.30) — — Width 150 (5.91) — — Replace Tread dia. ø 120 (4.72) ø 107 (4.21) ø 105 (4.13) Tread width 33 (1.30) —...
  • Page 634 34. TRAVEL SYSTEM 34.1.3.7 TOOLS AND JIGS (1) Tightening tools Unit : mm NAME OPPOSING FLATS Socket Allen wrench (2) Jigs Unit : mm (in) NAME SHAPE 120 (4.72) 90 (3.54) Stand jig 52.5(2.07) For extruding bushing 49(1.93) For extruding shaft Bushing fixing (1.26)32...
  • Page 635 34. TRAVEL SYSTEM 34.1.4 LOWER ROLLER 34.1.4.1 LOWER ROLLER ASSY Apply Loctite #262 ROLLER LQ64D00028F1 T=397N . m (290 lbf . ft) LQ64D00030F1 ASSY NAME REMARKS ITEM Q'TY LQ64D00029F1 LOW ROLLER LQ64D00029F1 LOW ROLLER M18X80(P=1.5) CAPSCREW Apply Loctite #262 T=397N . m (290 lbf . ft) Fig.
  • Page 636 34. TRAVEL SYSTEM 34.1.4.3 INSTALLATION (1) Installation of lower roller Coat mounting capscrews (2) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified torque. : 27 mm, Tightening torque : 397N•m (290 lbf•ft) (2) Installation of track guide Capscrews (4) with Loctite #262 and fasten all 4 capscrews temporarily.
  • Page 637 34. TRAVEL SYSTEM 34.1.4.4 CONSTRUCTION 4 1 6 2 7 5 LQ64D00029F1 LOWER ROLLER REMARKS NAME Q'TY ROLLER COLLAR SHAFT BUSHING Fig. 34-27 Construction of lower roller FLOATING SEAL O RING 1A G60 PLUG PT1/4 34.1.4.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1) Drain oil Remove plug (8) and drain out oil.
  • Page 638 34. TRAVEL SYSTEM 5) Removing collar (2), O-ring (7) Remove O-ring (7) from shaft (3) that was drawn out in the previous paragraph. 6) Removing floating seal (6) Remove floating seal (6) from collar (2). 7) Removing floating seal (6) Remove floating seal (6) from roller (1).
  • Page 639 34. TRAVEL SYSTEM (2) Installing 1) Attach O-ring (7) to one side Install O-ring (7) to groove on shaft. • Grease O-ring. Fig. 34-33 Attach O-ring (7) to one side • Replace O-ring with new one without fail at reassembling. 2) Press fitting bushing (4) JIG Q Align inner hole of roller (1) and bushing (4) and...
  • Page 640 34. TRAVEL SYSTEM 5) Attach floating seal (6) to roller side Fit floating seal (6) to inner holes on both ends of roller (1). • Check that the seal surface is free from flaws, rusts, etc. before reusing the floating seal. 6) Inserting roller (1) Insert roller (1) from the side where collar (2), O-ring (7) is not press-fitted to the shaft (3).
  • Page 641 34. TRAVEL SYSTEM 34.1.4.6 MAINTENANCE STANDARD Fig. 34-40 Lower roller (Track roller) Unit : mm (in) REPAIRABLE SERVICE ITEM STANDARD VALUE REMEDY LEVEL LIMIT O.D. of flange ø 185 (7.28) — — Reinforcement weld, repair or replace Tread dia. ø 150 (5.91) ø...
  • Page 642 34. TRAVEL SYSTEM 34.1.4.7 TOOLS AND JIGS (1) Tightening tools Unit : mm NAME OPPOSING FLATS 19, 27 Socket Allen wrench (2) Jig Unit : mm (in) NAME SHAPE V-block 100(3.94) Pin (5) extrusion rod 200(7.87) Bushing extrusion rod 290(11.4) Stand jig 270(10.6) Shaft...
  • Page 643 34. TRAVEL SYSTEM 34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) 34.1.5.1 FRONT IDLER ASSY FRONT IDLER ASSY LQ52D00025F1 APPLY LOCTITE # 6 OR EQUIVALENT T= 79N . m ( 10 lbf . ft) NAME Q'TY REMARKS IDLER ASSY YN52D00009F1 IDLER ADJUSTER ASSY LQ54D00010F1 CAPSCREW M16X45...
  • Page 644 34. TRAVEL SYSTEM 34.1.5.3 IDLER ASSY 34.1.5.3.1 CONSTRUCTION IDLER ASSY YN52D00009F1 NAME Q'TY REMARKS IDLER YN52D01006P1 BUSHING COLLAR YN52D01011P1 FLOATING SEAL & SHAFT " O-RING 1A G70 PLUG PT1/8 Fig. 34-44 Idler assy 34.1.5.3.2 REMOVING AND INSTALLING (1) Removing 1) Drain oil Remove plug (8) on the side of collar (3) to drain.
  • Page 645 34. TRAVEL SYSTEM 5) Removing bushing (2) With idler (1) mounted on the stand, tap bushing (2) lightly by hammer, while placing the bushing drawing rod (T) against the end face of bushing (2) evenly all round, till it comes out. 6) Removing floating seals (4) Take out floating seals (4) from idler (1), collar (3).
  • Page 646 34. TRAVEL SYSTEM 7) Installing collar (3) Fit the half of floating seal (4) on the other collar (3), press fit it in shaft (6), and drive pin (5) in with hummer. 8) Filling oil•Inspection Fill in 200cc (12.2cu•in) of engine oil API grade CD #30 through the plug hole of collar (3), wind seal tape and tighten plug (8).
  • Page 647 34. TRAVEL SYSTEM 34.1.5.3.4 TOOLS AND JIGS (1) Tightening tools Unit : mm NAME OPPOSING FLATS Socket Allen wrench (2) Jigs Unit : mm (in) NAME SHAPE Pin striking jig (0.591) 105(4.13) 340 (13.4) Shaft push out jig 300(11.8) Bushing drawing rod pprox.150 (5.91) pprox.600...
  • Page 648 34. TRAVEL SYSTEM 34.1.5.4 IDLER ADJUSTER ASSY 34.1.5.4.1 CONSTRUCTION IDLER ADJUSTER ASSY LQ54D00010F1 NAME Q'TY REMARKS GREASE CYLINDER BRACKET SPRING PIN 8X80 SPRING PISTON COLLAR Fig. 34-54 Idler adjuster assy O-RING 1B G90 OIL SEAL COVER 34.1.5.4.2 DISASSEMBLY AND ASSEMBLY (1) Disassembly HOLDING-DOWN NUT 1) Spring set special jig...
  • Page 649 34. TRAVEL SYSTEM 6) Fixing idler adjuster assy Fit retainer plate to bracket (2), tighten holding- down nuts alternately, and secure idler adjuster assy. : 46 mm HOLDING-DOWN NUT RETAINER PLATE Fig. 34-57 Fixing idler adjuster assy 7) Compression of spring (5) Remove spring pin (4), press spring (5) lifting it with jack so that nut (3) can be turned freely, and remove nut (3).
  • Page 650 34. TRAVEL SYSTEM (2) Assembly Assembly is done in the reverse order of disassembly. 1) Installing spring (5), grease cylinder (1) Insert grease cylinder (1), collar (7) into spring (5) and attach lifting eye nut (W) to screw M56×P3 at the tip of the grease cylinder. Lift the grease cylinder by crane and erect it in the center of the jig stand upright.
  • Page 651 34. TRAVEL SYSTEM 6) Installing oil seal (9), O-ring (8) Fit oil seal (9) and O-ring (8) to grease cylinder (1). • Grease oil seal (9) and O-ring (8). 7) Filling grease cylinder (1) with grease. Fill up grease in cylinder (1), remove the grease nipple from piston (6) to discharge the inside air, and press in the piston by hand.
  • Page 652 34. TRAVEL SYSTEM 34.1.6 SPROCKET 34.1.6.1 REMOVING (1) Preparation for removal Remove crawler referring to "34.1.2 CRAWLER", lift up crawler frame with attachment, and put it on square timbers to float and stabilize. Fig. 34-66 Preparation for removal (2) Removing sprocket Loosen 30 capscrews (2) M16×50, for the attaching of the sprocket by means of a socket and remove the sprocket (1).
  • Page 653 34. TRAVEL SYSTEM 34.1.6.3 MAINTENANCE STANDARD (LQ51D01004P1) 96.07mm NUMBER OF PITCH (3.78in) TEETH SPECIFICATION ø58.72mm 644.602 ROLLER DIA. PITCH DIA. (2.31in) (25.333in) Fig. 34-69 Sprocket Unit:mm (in) REPAIRABLE SERVICE NAME STANDARD VALUE REMEDY LEVEL LIMIT Reinforcement weld, O.D. of sprocket ø...
  • Page 654 34. TRAVEL SYSTEM (2) Sprocket tooth profile gauge : W Unit : mm (in) Fig. 34-70 Tooth profile gauge (Full scale) 34-32...
  • Page 655 34. TRAVEL SYSTEM 34.1.7 TRAVEL MOTOR 34.1.7.1 TRAVEL MOTOR INSTALL ASSY LQ53D00010F1 NAME REMARKS Q'TY CAPSCREW M16X55 TRAVEL MOTOR ASSY LQ53D00011F1 APPLY LOCTITE #262 OR EQUIVALENT TIGHTENING TORQUE: 279 N . m(206 lbf . ft) Fig. 34-71 Installing travel motor 34.1.7.2 REMOVING (1) Preparation for removal...
  • Page 656 34. TRAVEL SYSTEM (5) Removing sprocket Removing thirty (one side) capscrews (3) M16×50. : 24 mm Fig. 34-74 Removing and installing sprocket (6) Loosening travel motor attaching bolts (3) REMOVE PIPES (DISCONNECT) Apply match marks on travel motor and crawler frame, and remove seventeen (one side) capscrews (3) M20×60.
  • Page 657 34. TRAVEL SYSTEM 34.1.8 SWING BEARING 34.1.8.1 SWING BEARING ASSY SWING BEARING ASSY LQ40F00013F1 NAME Q'TY REMARKS SWING BEARING LQ40F00014F1 CAPSCREW M20XP1.5X65 FRONT INNER S ZONE POSITION OF SWING BEARING SECTION AA Fig. 34-77 Swing bearing assy 34.1.8.2 REMOVING (1) Matchmarks WING BEARING Remove upper structure, apply matchmarks on OUTER RACE...
  • Page 658 34. TRAVEL SYSTEM 34.1.8.3 INSTALLING (1) Cleaning Clean it completely so that installing surfaces of swing bearing and lower frame are free from dust and dirt. (2) Installing Install swing bearing on lower frame meeting the FRONT matchmarks and positioning the S mark on inner race as shown in Fig.
  • Page 659 34. TRAVEL SYSTEM 4) While rotating outer race (1) little by little, take out ball (3) and retainer (4) through plug hole, in that order. " Fig. 34-84 Removing balls (3) and retainers (4) (2) Installing 1) Thoroughly degrease the groove for seal (6) located on the inner surface of outer race (1) and the groove for seal (5) located on the outer surface of inner race (2).
  • Page 660 34. TRAVEL SYSTEM 34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT 34.2.1 CONSTRUCTION OF TRAVEL MOTOR 34.2.1.1 CROSS-SECTIONAL VIEW OF TRAVEL MOTOR ASSEMBLY 19,20 SECTION Z6-Z6 (1 place) 67 30 SECTION Z5-Z5 (3 places) 33 34 15 14 14 15 34 33 SECTION Z4-Z4 SECTION 1- 1 Fig.
  • Page 661 34. TRAVEL SYSTEM SECTION 2- 2 SECTION 3- 3 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96 Fig. 34-88 Cross-sectional view of travel motor unit assembly (2/2) 34-39...
  • Page 662 34. TRAVEL SYSTEM Tightening Tightening Width Width NAME NAME torque Q’TY torque Q’TY across across N•m (lbf•ft) flats mm N•m (lbf•ft) flats mm FLANGE 44 COLLAR BASE PLATE 45 PIN 46 PLATE (SWASH PLATE) PLUNGER ; FOR BRAKE VALVE CHECK VALVE 47 BALL SPRING 48 PISTON ASSY...
  • Page 663 34. TRAVEL SYSTEM Tightening Tightening Width Width NAME NAME torque Q’TY torque Q’TY across across N•m (lbf•ft) flats mm N•m (lbf•ft) flats mm 84 SNAP RING 92 SCREW ; M10 58.8 (43) 85 HOLDER B 93 DRIVE GEAR 86 THRUST PLATE 94 THRUST PLATE 87 INNER RACE 95 COVER...
  • Page 664 34. TRAVEL SYSTEM 34.2.1.2 TOOLS (1) Standard tools (2) Materials APPLICATION APPLICATION TYPE . SIZE TOOLS NAME MATERIALS NAME DESCRIPTION ITEM (NO.) ITEM (NO.) Preset torque wrench Nominal 60 18,28,29,30 Sealing tape Nominal 230 Adhesive Locktite 76, 82, 14 Nominal 450 Gear oil GL-4#90 equiv.
  • Page 665 34. TRAVEL SYSTEM 34.2.1.3 DISASSEMBLY AND ASSEMBLY 34.2.1.3.1 DISASSEMBLY PROCEDURE (1) Removing cap (11) Fix the motor on a stable work bench, loosen eight socket bolts (13) and remove cap (11) with O-ring (12). 14,15,33,34 Next, remove spring seat (10), spring (9) and spring seat (8).
  • Page 666 34. TRAVEL SYSTEM (3) Removing relief valve assy (17) 17-3 Loosen plug (17-6) and remove relief valve assy (17). In that case, poppet seat (17-3) remains in base plate (2). : 27 mm 17-6 17-16 Relief valve assy (17) is set at certain pressure. The set 17-15 pressure of it determines the starting power and the braking power of the motor.
  • Page 667 34. TRAVEL SYSTEM If it gets stuck, do as below. Put spool (19) into base plate (2) once again by lightly tapping the end face of spool (19) with a plastic mallet. Then, make certain that spool (19) moves smoothly and draw it out, turning spool (19) by hand.
  • Page 668 34. TRAVEL SYSTEM (9) Removing O-rings, knock pin (60) and spring (59). Take off O-rings (63), (64), and knock pin (60). Then take off spring (59). (10)Removing brake piston (56) Attach a jet air nozzle to the oil path for the parking brake of flange (1), make brake piston (56) afloat by blowing jet air into the parking brake cylinder chamber and remove the brake piston.
  • Page 669 34. TRAVEL SYSTEM (11)Removing cylinder block (37) Take out cylinder block (37) from flange (1). When drawing out cylinder block (37), use care of the following : • Hold cylinder block (37) by both hands and take it out slowly, while turning it both ways lightly. •...
  • Page 670 34. TRAVEL SYSTEM 3) Separate retainer holder (40) from cylinder block (37). Then take off pin (45) from cylinder block (37). 4) Fix cylinder block (37) on a manual press bench so the moving surface faces upwards. Take off snap ring (41), push collar (44) with the jig, bend spring (43) and take off snap ring (41), using snap ring pliers.
  • Page 671 34. TRAVEL SYSTEM (13)Removing swash plate (46) Separate swash plate (46) from flange (1). Use care of the following when removing swash plate (46). • Take care so as not to score the sliding surface of swash plate (46). Desired performances will not be attainted if the surface is scored.
  • Page 672 34. TRAVEL SYSTEM (16)Draining lube oil from the reduction gear Next, before disassembling the reduction unit, put a screw in two tapped holes of flange (1) that are in diagonal positions and lift the reduction unit by crane. Remove two plugs (97) and drain lube oil from the reduction unit.
  • Page 673 34. TRAVEL SYSTEM (19)Removing drive gear (93) Remove drive gear (93) Fig. 34-112 Removing drive gear (93) (20)Removing the 1st stage holder assy Remove the 1st stage holder assy that consists of holder B (85), planetary gear B(89), needle bearing (88), inner race (87), thrust plate (86), thrust plate (90), thrust plate (91) and screw (92).
  • Page 674 34. TRAVEL SYSTEM (22)Removing sun gear C (83) Remove sun gear C (83). Fig. 34-115 Removing sun gear C (83) (23)Removing planetary gear C (80) Fix flange (1), loosen bolt (82) and remove it. Next, separate thrust plate (81), planetary gear C (80), needle bearing (79), inner race (78) and thrust plate (77), in that order.
  • Page 675 34. TRAVEL SYSTEM (25)Separating flange (1) from housing (72) Attach a jig to the end face on the outer flange of housing and separate flange (1) from housing (72) by pressing flange (1) by press. Fig. 34-118 Separating flange (1) from housing (72) (26)Removing floating seal (70) Remove floating seal (70) by pushing up the outer circumference of floating seal (70) with a flat-blade...
  • Page 676 34. TRAVEL SYSTEM 34.2.1.3.2 ASSEMBLING PROCEDURE <Reduction unit> (1) Assembling floating seal (70) into flange (1) Confirm the below items concerning floating seal (70). Then assemble floating seal (70) to flange (1), using the floating seal fixing jig. Make certain that there is no dust on the surface of flange (1) in contact with floating seal (70).
  • Page 677 34. TRAVEL SYSTEM (4) Assembling housing (72) into flange (1) Make sure of the below items and assemble housing (72) into flange (1), using a crane, so floating seal (70) of flange (1) matches floating seal (70) of housing (72) Make certain that there is no foreign matter on the moving surface of the seal ring located in floating seal (70).
  • Page 678 34. TRAVEL SYSTEM (6) Assembling holder C (74) Fix flange (1) and erect pins (99) [four places] upright on flange (1). Bring the shims selected under (5) in contact with holder C (74), using grease, match the pin holes in holder C (74) to the pins and press it in by press.
  • Page 679 34. TRAVEL SYSTEM (8) Assembling thrust plate (81) Install planetary gear C (80) so the chamfer side in the bolt hole of thrust plate (81) comes below the neck of bolt (82). After placing it, coat the screw threads of bolt (82) with Loctite, attach bolt (82) and tighten it to a specified torque.
  • Page 680 34. TRAVEL SYSTEM (11)Assembling planetary gear B (89) Assemble thrust plate (86) to planetary gear B (89). Next, attach needle bearing (88) to planetary gear B (89). Finally, attach inner race (87), engage the bore with the trunnions (3 places) of holder B (85), and assemble planetary gear B (89) into holder B (85).
  • Page 681 34. TRAVEL SYSTEM (13)Attaching thrust plate (94) Measure the step between the end face of housing (72) and thrust plate (94), using the thrust plate selecting jig, choose and attach thrust plate (94) according to the table below : Unit : mm (in) Shim Step dimension (T) Thrust plate code...
  • Page 682 34. TRAVEL SYSTEM <Motor> (1) Fitting oil seal (53) Make sure that flange (1) is equipped with oil seal (53). If not, press oil seal (53) into flange (1), using the oil seal fixing jig. OIL SEAL FIXING JIG Before attaching oil seal (53), apply grease to the bore surface of flange (1) (where the oil seal is placed) and outer diameter surface of oil seal (53).
  • Page 683 34. TRAVEL SYSTEM (4) Installing shaft (36) Press ball bearing (49) into shaft (36), using the bearing fixing jig. Then mount shaft (36) into the center of flange (1). BEARING FIXING JIG Assemble ball bearing (49) upright. • After mounting shaft (36), confirm that shaft (36) rotates smoothly.
  • Page 684 34. TRAVEL SYSTEM (6) Assembling cylinder block (37) 1) Place cylinder block (37) on a hand press bench so the sliding surface of valve plate (62) faces up. Assemble cylinder block (37) so the slope of spring seat (42) faces downward. Then mount spring (43) and collar (44) on spring seat (42), in that order.
  • Page 685 34. TRAVEL SYSTEM 4) Install retainer holder (40) to cylinder block (37). Fig. 34-143 Attaching retainer holder (40) 5) Attach piston assy (38) [9pcs.] to retainer plate (39) so the tapered face of retainer plate (39) faces downward. Fig. 34-144 Assembling retainer plate (39) 6) Install piston assy (38) to cylinder block (37).
  • Page 686 34. TRAVEL SYSTEM (7) Assembling cylinder block (37) Engage the inner tooth splines of retainer holder (40) and cylinder block (37) with the outer tooth spline of shaft (36) so the sliding surface of cylinder block (37) in contact with valve plate (62) faces upwards.
  • Page 687 34. TRAVEL SYSTEM (9) Installing brake piston (56) Attach O-rings (57), (58) to brake piston (56). Next, mount brake piston (56) to flange (1) so the larger diameter side of the brake piston faces upward. POSITIONING JIG Coat O-rings (57), (58) with sufficient grease, before fixing them.
  • Page 688 34. TRAVEL SYSTEM (12)Attaching base plate (2) Fit O-rings (64) and O-rings (63) [4 places] to the top face of flange (1). Fit knock pin (60) to base plate (2). Attach base plate (2) to flange (1) so the surface of valve plate (62) in contact with base plate (2) faces downward.
  • Page 689 34. TRAVEL SYSTEM (13)Assembling travel 2-speed select spool (19) Attach spring (21) to spool (19). Then attach them to base plate (2). After placing spool (19), make certain that O-ring 21 23 (23) is set in plug (22), fit plug (22) to base plate (2) and tighten it to a specified torque.
  • Page 690 34. TRAVEL SYSTEM (15)Assembling counterbalance valve plunger (3) Assemble plunger (3) to base plate (2). Assemble the plunger (3) to the base plate, while turning the plunger. • Install plunger (3) straight. • In case plunger (3) gets stuck, do not force it in, but tap it lightly with a plastic mallet.
  • Page 691 34. TRAVEL SYSTEM 34.2.1.4 MAINTENANCE STANDARD (1) Motor parts Parts Check point Tolerance Remedy Piston assy (38) 1.Sliding surface of shoe The roughness is 0.8a or the Lap the moving surface of surface is roughened or the shoe (#1000). scratch is deeper than If the scratch does not 0.02mm (0.0008in).
  • Page 692 34. TRAVEL SYSTEM Parts Check point Tolerance Remedy Swash plate (46) 3. Spherical hole in which a Ball depth : Replace swash plate. steel ball is placed 14.5mm (0.571in) Shaft (36) 1. O.D. of oil seal sliding The sliding surface shows a Replace shaft.
  • Page 693 34. TRAVEL SYSTEM Parts Check point Tolerance Remedy Plunger (3) 1. O.D. of plunger The roughness is 0.8a or the Replace base plate kit. surface shows a scratch deeper than 0.02mm (0.0008in) or is roughened. 2. O.D. and the bore dia. of Clearance: base plate 0.060mm (0.00236in)
  • Page 694 34. TRAVEL SYSTEM Parts Check point Tolerance Remedy Spring (21) 1. Appearance and Free length : dimension 28.3mm (1.11 in) 2. Appearance It is deformed or the coil surface is damaged. O-rings and oil seals At disassy Replace O-rings and oil seals.
  • Page 695 34. TRAVEL SYSTEM (2) Reduction unit parts Parts Check point Tolerance Remedy Planetary gear A (89) Tooth thickness Bridged dimension of 6 teeth : Replace planetary gear. 66.649mm (2.62397in) Tooth face Pitching or fracture is seen on 10% or more of the tooth face.
  • Page 696 34. TRAVEL SYSTEM Parts Check point Tolerance Remedy Housing (72) Tooth face Pitching or fracture is seen on Replace housing. 10% or more of the tooth face. Shim (73) At disassembly Replace shims. Flange (1) Bore dia. of the hole in 2- Clearance : Replace flange kit.
  • Page 697 34. TRAVEL SYSTEM Trouble Probable cause Remedy Rotating speed of motor Because of some trouble of hydraulic pump, Check that a required flow is supplied to the is low. pressure regulating valve, flow control valve inlet of piston motor. and the like, the piston motor does not Then check for the cause of the trouble, receive a required flow.
  • Page 698 34. TRAVEL SYSTEM Trouble Probable cause Remedy Abnormal sound and Motor is installed improperly or the location Confirm the motor orientation and if it is revolution and pressure of hydraulic oil tank is improper. wrong, correct it to the correct orientation. fluctuations occur due Therefore, hydraulic oil is discharged from Check that the oil level in the hydraulic oil...
  • Page 699 34. TRAVEL SYSTEM (2) Parking brake Trouble Probable cause Remedy If motor is rested under Parking brake torque is low as disk is worn. Disassemble and replace parking brake disk. external load, motor Clean parts and reassemble. rotates. Disk face deteriorated due to poor contact. Disassemble and replace disk.
  • Page 700 34. TRAVEL SYSTEM (3) Relief valve Trouble Probable cause Remedy Motor does not turn or Foreign matter is included between poppet Disassemble and remove foreign matter. revolution is low. seat and poppet of relief valve. This Clean parts and reassemble. developed poor seating, and high pressure oil is leaking toward the low pressure side.
  • Page 701 34. TRAVEL SYSTEM (4) Counterbalance valve Trouble Probable cause Remedy If motor makes pumping Plunger does not operate smoothly as Disassemble and remove the contamination. action as external load foreign matter is included in plunger. Then clean the plunger and reassemble it. acts on it, motor Wrong orifice size is used in pilot oil Replace with a correct orifice.
  • Page 702 34. TRAVEL SYSTEM (5) Auto 2-speed select function Trouble Probable cause Remedy High-speed rotation can Pilot pressure is not at Ps port. Check that pilot pressure is at Ps port, check not be selected for the cause, inspect and repair. Foreign matter is included between spool Disassemble, remove foreign matter, and and base plate, and spool does not change...
  • Page 703 34. TRAVEL SYSTEM (6) Reduction unit Trouble Probable cause Remedy Reduction unit does not Devices other than piston motor and Check that pressure is there at the motor rotate. reduction unit have trouble. inlet, check for the cause, inspect and repair. Motor except reduction unit failed.
  • Page 704 34. TRAVEL SYSTEM Trouble Probable cause Remedy Oil leakage occurs Reduction unit cover is slack and oil is Remove cover, reapply liquid packing and leaking. tighten cover to a specified torque. Then fill in lube oil to a specified level. Oil is leaking from leaked plugs in oil inlet, Retighten plugs to specified torque.
  • Page 705 46. TROUBLE SHOOTING (BY ERROR CODES) TABLE OF CONTENTS 46.1 JUDGMENT OF ACTUAL THING AT SITE ..............46-3 46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING ........46-4 46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ............46-4 46.4 TROUBLESHOOTING BY ERROR CODE..............46-4 Book Code No. S5YN4618E02 46-1...
  • Page 706 (NHK Russia) ↑ SK200-8 : YN11-45001~ ↑ April, 2007 SK210LC-8 : YQ11-06001~ ASIA (HS Engine) ↑ E215B : YN11-45001~ ↑ July, 2007 E215BLC : YQ11-06001~ (NHK Middle East) ↑ E265B : LQ12-06001~ ↑ ↑ E265BLC : LL12-05001~ (NHK Russia) 46-2...
  • Page 707 46. TROUBLE SHOOTING (BY ERROR CODES) Preface Troubleshooting provides process locating for the cause of trouble in the order that trouble occurred. This manual describes how to solve the specific phenomenon systematically as early as possible. For troubleshooting concerning the inside of equipment, refer to troubleshooting for each manual of equipment.
  • Page 708 46. TROUBLE SHOOTING (BY ERROR CODES) 46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING Classify failures into the following 3 types and carry out the troubleshooting. Classes of failure Troubleshooting When error code after self-diagnosis is displayed Carry out troubleshooting according to the error on gauge cluster code.
  • Page 709 46. TROUBLE SHOOTING (BY ERROR CODES) Error Code Trouble Described page B032 Incorrect output of arm out pressure sensor 46-14 B033 Disconnection of arm out pressure sensor 46-14 B034 Short-circuit of arm out pressure sensor 46-15 B042 Incorrect output of arm in pressure sensor 46-15 B043 Disconnection of arm in pressure sensor...
  • Page 710 46. TROUBLE SHOOTING (BY ERROR CODES) Error Code Trouble Described page E013 Disconnection of P1pump proportional valve 46-38 E022 Failure of output transistor ON at P2 pump proportional valve 46-38 E023 Disconnection of P2 pump proportional valve 46-39 F011 Failure of output transistor OFF and GND short of attachment boost SOL valve 46-39 F013 Failure of output transistor ON and disconnection of attachment boost SOL valve...
  • Page 711 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-1 Error code A015 Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment) Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting condition range.
  • Page 712 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-3 Error code A035 Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment) Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting condition range.
  • Page 713 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-5 Error code A225 Trouble The data of ROM adjustment is written incorrectly. Judging Check adjustment data, and judge the data is correct or not. condition Symptom It is not normal output, but no problem in normal operation Control in the Control can be done by default value.
  • Page 714 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-7 Error code A245 Trouble The data of ROM hourmeter is written incorrectly. Judging Check hourmeter memory, and judge the data is incorrect. condition Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation Control in the Normal control is available.
  • Page 715 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-9 Error code B012 Trouble Boom up pressure sensor outputs error Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after condition starter switch ON is in the range of 1.4V or more to less than 4.7V. Symptom The boom up operability becomes poor.
  • Page 716 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-11 Error code B014 Trouble Boom up pressure sensor’s power source is shortcut. Judging The input voltage from boom up pressure sensor is 4.7V or more. condition Symptom The boom up speed slows down. Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 717 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-13 Error code B023 Trouble Boom down pressure sensor’s wiring is disconnecting. Judging The input voltage from boom down pressure sensor is 0.1V or less. condition Symptom The boom down operability becomes poor. Set proportional valve output rate of P1 and P2 pumps to 0mA. Control in the (Hydraulic pump emergency mode) event of failure...
  • Page 718 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-15 Error code B032 Trouble Arm-in pressure sensor outputs error Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after condition starter switch ON is in the range of 1.4V or more to less than 4.7V. Symptom The arm-out operability becomes poor.
  • Page 719 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-17 Error code B034 Trouble Arm-out pressure sensor’s power source is shortcut. Judging The input voltage from arm-out pressure sensor is 4.7V or more. condition Symptom Shock at stopping of arm-out is great. Set proportional valve output rate of P1 and P2 pumps to 0mA. Control in the (Hydraulic pump emergency mode) event of failure...
  • Page 720 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-19 Error code B043 Trouble Arm-in pressure sensor’s wiring is disconnecting. Judging The input voltage from arm-in pressure sensor is 0.1V or less. condition Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done Symptom but if attachment is pulled in the air, arm falls first.
  • Page 721 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-21 Error code B052 Trouble Bucket digging pressure sensor outputs error Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V. Symptom The bucket digging operability becomes poor.
  • Page 722 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-23 Error code B054 Trouble Bucket digging pressure sensor’s power source is shortcut. Judging The input voltage from bucket digging pressure sensor is 4.7V or more. condition Symptom The bucket digging speed slows down a little. Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 723 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-25 Error code B063 Trouble Bucket dump pressure sensor’s wiring is disconnected. Judging The input voltage from bucket dump pressure sensor is 0.1V or less. condition Symptom The bucket dump speed slows down a little. Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 724 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-27 Error code B072 Trouble Swing pressure sensor outputs error Judging After starter switch ON and engine does not start yet. And the input voltage from the swing condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V. Symptom The swing operability becomes poor.
  • Page 725 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-29 Error code B074 Trouble Swing pressure sensor’s power source is shortcut. Judging The input voltage from swing pressure sensor is 4.7V or more. condition Symptom The swing operability becomes poor. Set proportional valve output rate of P1 and P2 pumps to 0mA. Control in the (Hydraulic pump emergency mode) event of failure...
  • Page 726 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-31 Error code B093 Trouble Travel right pressure sensor’s wiring is disconnected. Judging The input voltage from Travel right pressure sensor is 0.1V or less. condition Symptom The Travel right operability becomes poor. Set proportional valve output rate of P1 and P2 pumps to 0mA. Control in the (Hydraulic pump emergency mode) event of failure...
  • Page 727 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-33 Error code B102 Trouble Travel left pressure sensor outputs error Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V. Symptom The travel left operability becomes poor.
  • Page 728 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-35 Error code B104 Trouble Travel left pressure sensor’s power source is shortcut. Judging The input voltage from Travel left pressure sensor is 4.7V or more. condition Symptom The Travel left operability becomes poor. Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 729 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-37 Error code B114 Trouble Option selector position detect pressure sensor’s wiring is disconnected. Judging The input voltage from selector position detect pressure sensor is 4.7V or more. condition Symptom When B mode is selected, option selector valve error is indicated. Control in the Normal control event of failure...
  • Page 730 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-39 Error code B163 Trouble P1 side option pressure sensor’s wiring is disconnected. Judging The input voltage from P1 side option pressure sensor is 0.1V or less. condition Symptom The P1 side option does not work. Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 731 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-41 Error code B172 Trouble P2 side option pressure sensor outputs error Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V. Symptom The P2 side option operability becomes poor.
  • Page 732 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-43 Error code B174 Trouble P2 side option pressure sensor’s wiring is disconnected. Judging The input voltage from P2 side option pressure sensor is 4.7V or more. condition Symptom The selection of conflux does not work. Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 733 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-45 Error code C013 Trouble P1 pump pressure sensor’s wiring is disconnected. Judging The input voltage from P1 pump pressure sensor is 0.1V or less. condition Symptom The delicate operability of P1 pump related attachment becomes poor. Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 734 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-47 Error code C022 Trouble P2 pump pressure sensor outputs error. Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V. Symptom The P2 pump operability becomes poor.
  • Page 735 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-49 Error code C024 Trouble P2 pump pressure sensor’s power source is shortcut. Judging The input voltage from P2 pump pressure sensor is 4.7V or more. condition Symptom The delicate operability of P2 pump related attachment becomes poor. Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
  • Page 736 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-51 Error code C034 Trouble Boom head pressure sensor’s power source is shortcut. Judging The input voltage from boom head pressure sensor is 4.7V or more. condition Symptom Indication load value of High-reach crane becomes abnormal. Control in the Normal control event of failure...
  • Page 737 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-53 Error code C044 Trouble Boom rod pressure sensor’s power source is shortcut. Judging The input voltage from boom rod pressure sensor is 4.7V or more. condition Symptom Indication load value of High-reach crane becomes abnormal. Control in the Normal control event of failure...
  • Page 738 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-55 Error code D013 Trouble P1 unload proportional valve’s wiring is disconnected. Judging The feed-back value from proportional valve is 100mA or less. condition (If output is 100mA or less, judging is not done.) Symptom Option conflux can not be done.
  • Page 739 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-57 Error code D023 Trouble P2 unload proportional valve’s wiring is disconnected. Judging The feed-back value from proportional valve is 100mA or less. condition (If output is 100mA or less, judging is not done.) Symptom Independent operations of boom up and of bucket digging/dump become slow.
  • Page 740 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-59 Error code D033 Trouble Travel straight proportional valve’s wiring is disconnected. Judging The feed-back value from proportional valve is 100mA or less. condition (If output is 100mA or less, judging is not done.) Symptom Travel deviation occurs by combined operation of travel and attachment.
  • Page 741 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-61 Error code D063 Trouble Arm-in spool 2 proportional valve’s wiring is disconnected. Judging The feed-back value from proportional valve is 100mA or less. condition (If output is 100mA or less, judging is not done.) Symptom Operability of combined operation with arm-in becomes poor.
  • Page 742 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-63 Error code E013 Trouble P1 pump proportional valve’s wiring is disconnected. Judging The feed-back value from proportional valve is 100mA or less. condition (If output is 100mA or less, judging is not done.) Symptom The delicate operability of P2 pump related attachment becomes poor.
  • Page 743 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-65 Error code E023 Trouble P2 pump proportional valve’s wiring is disconnected. Judging The feed-back value from proportional valve is 100mA or less. condition (If output is 100mA or less, judging is not done.) Symptom The delicate operability of P2 pump related attachment becomes poor.
  • Page 744 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-67 Error code F013 Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection. Judging The feed-back signal is 24V level while exciting command is not output. condition Symptom ATT boost is not available or is leaving available. Control in the Normal control event of failure...
  • Page 745 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-69 Error code F023 Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection. Judging The feed-back signal is 24V level while exciting command is not output. condition Symptom Swing parking is not available or is leaving available. Control in the Normal control event of failure...
  • Page 746 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-71 Error code F033 Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection. Judging The feed-back signal is 24V level while exciting command is not output. condition Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
  • Page 747 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-73 Error code F043 Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection. Judging The feed-back signal is 24V level while exciting command is not output. condition Option selector valve does not change to breaker side or it does not change from breaker to Symptom nibbler.
  • Page 748 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-75 Error code G033 Trouble Mechatro controller direct input speed sensor, Disconnection Judging Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm. condition Symptom Operate without problem. Control in the Receive rpm from engine controller and control the rpm.
  • Page 749 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-77 G043 When cranking is executed for five seconds or more, this error code might be displayed. In case Error code that the engine does not start, check by the table of "Section 47.3 Engine related Troubleshooting".
  • Page 750 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-78 Error code H013 Trouble Accel potentiometer is disconnected. Judging The input voltage from accel potentiometer is 0.1V or less. condition Symptom LOW idling is fixed. Control in the LOW idling is fixed. event of failure Returned in It returns automatically in normal condition.
  • Page 751 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-80 Error code H023 Trouble Boom angle potentiometer’s wiring is disconnected. Judging The input voltage from boom angle potentiometer is 0.1V or less. condition Symptom Indications of rating load and working radius of High-reach crane become abnormal. Control in the Normal control event of failure...
  • Page 752 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-82 Error code H033 Trouble Arm angle potentiometer’s wiring is disconnected. Judging The input voltage from arm angle potentiometer is 0.1V or less. condition Symptom Indications of rating load and working radius of High-reach crane become abnormal. Control in the Normal control event of failure...
  • Page 753 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-84 Error code H091 Trouble Fuel sensor grounding is short-circuited. Judging The input voltage from fuel sensor is 0.1V or less. condition Symptom Warning for low fuel level is indicated. Control in the Fuel level becomes 0%. event of failure Returned in It returns automatically in normal condition.
  • Page 754 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-86 Error code I111 Trouble Reception of CAN1 communication is abnormal. (Passive error) Judging Reception from engine controller can not receive correctly. condition Symptom It has been affected little. Control in the Keep the last receiving condition. event of failure Returned in It returns automatically in normal condition.
  • Page 755 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-88 Error code I313 Trouble Reception of cluster communication is abnormal. (Time-out error) Judging Reception from gauge cluster can not receive correctly. condition Symptom Switch operation of gauge cluster can not be done. Control in the Keep the condition after immediately key-on is operated.
  • Page 756 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-90 Error code R014 Trouble Wiper motor arc prevention relay error Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the condition power source. Symptom Wiper does not move. Control in the Relay output is stopped.
  • Page 757 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-91 Error code R024 Trouble Wiper motor forward rotation relay error Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the condition power source. Symptom Wiper does not move. Control in the Relay output is stopped.
  • Page 758 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-92 Error code R034 Trouble Wiper motor reverse rotation relay error Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the condition power source. Symptom Wiper does not move after forward rotation. Control in the Relay output is stopped.
  • Page 759 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-93 Error code R044 Trouble Washer motor relay error Judging The mechatro controller output line to washer motor relay is short-circuited with the power source. condition Symptom Washer motor does not move. Control in the Relay output is stopped.
  • Page 760 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-95 Error code R144 Trouble Swing flasher relay error Judging The mechatro controller output line to swing flasher relay is short-circuited with the power source. condition Symptom Left swing flasher does not light. Control in the Relay output is stopped.
  • Page 761 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-97 Error code R164 Trouble Auto idle stop relay 2 relay error Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power condition source. Power source for mechatro controller often turns off. Symptom Auto idle stop relay 2 does not actuate.
  • Page 762 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-98 Error code R174 Trouble Engine forcibly stop relay error Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power condition source. When key switch is turned off but engine does not stop. Symptom Engine auto idle stop function does not actuate.
  • Page 763 46. TROUBLE SHOOTING (BY ERROR CODES) Table46-99 Error code R184 Trouble Safety lock lever relay error Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power condition source. Symptom Safety lock lever timer does not actuate. Control in the Relay output is stopped.
  • Page 764 46. TROUBLE SHOOTING (BY ERROR CODES) [MEMO] 46-60...
  • Page 765 47. TROUBLESHOOTING (BY TROUBLE) TABLE OF CONTENTS 47.1 HYDRAULIC SYSTEM ....................47-3 47.2 ELECTRIC SYSTEMS .....................47-27 47.2.1 WIRING CHECKING PROCEDURE ..............47-27 47.2.2 TROUBLE.......................47-30 47.3 ENGINE RELATED TROUBLESHOOTING ..............47-33 Book Code No. S5YN4718E01 47-1...
  • Page 766 July, 2007 E135BSRLC : YH05-07001~ (NHK) ↑ SK225SR : YB05-03001~ ↑ ↑ SK225SRLC : LA05-02001~ (OCE) ↑ E215B : YN11-45001~ ↑ ↑ E215BLC : YQ11-06001~ (NHK Middle East) ↑ E265B : LQ12-06001~ ↑ ↑ E265BLC : LL12-05001~ (NHK Russia) 47-2...
  • Page 767 47. TROUBLESHOOTING (BY TROUBLE) 47.1 HYDRAULIC SYSTEM Preface: The troubleshooting for the failures shown below is explained here. Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number. (1) All controls do not function/slow (2) Engine down/stalled (3) Move at lever neutral position (4) Poor fine operability...
  • Page 768 47. TROUBLESHOOTING (BY TROUBLE) (1) All controls do not function/slow Sections Contents/normal value Corrective action, others 1 Fuse Check fuse No.4 If the fuse is blown out, check on (10A) the short-circuited section. 2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by tester, switch...

  • Page 769: Secondary Pressure Of P1, P2 Pump Proportional Valve

    47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 14 Main relief pressure Carry out service •See Service Diagnosis Data List Measure the relief pressure diagnosis Operation No.3 Boom up full lever & relief actually Check set pressure Check that P1 and P2 pump pressures are Reset or replace 32MPa in boom up full lever, high idling and H mode operation.
  • Page 770 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 5 Lock valve poppet Check targeted poppet Seat is free from abnormality Replace (in case of boom and visually arm) 6 Lock valve selector Exchange lock valve Check that the trouble is reversed Replace (in case of boom and selector of boom/arm...

  • Page 771: Table Of Contents

    47. TROUBLESHOOTING (BY TROUBLE) (5) Slow boom up, insufficient power Sections Contents/normal value Corrective action, others 1 Boom up pressure Carry out service •See Service Diagnosis Data List Check and replace pressure sensor diagnosis Operation No.3 boom up full lever and sensor relief Check remote control valve...
  • Page 772 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 13 Boom spool Visual check When removing, free from abnormal Replace <Trouble> resistance against sliding (Check on the casing side for Only P1 pressure is Spring is free from breakage. damage) high.
  • Page 773 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 7 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of current value of travel diagnosis regardless of operation travel straight proportional •See Service Diagnosis Data List •In case where the reading is valve Operation No.

  • Page 774: Pump Pressure Sensor Carry Out Service

    47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump pump pressures in operation pressures, check high pressure...

  • Page 775: Actual Measuring

    47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 12 Remote control valve Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage 13 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace <Trouble>...
  • Page 776 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve P1, P2 unload proportional valve pressures are within the range of 0.5 to proportional valve secondary pressure 1.2MPa in arm out full lever and high directly at the ports A7 idling operation...

  • Page 777: And A5 Of 8 Sections Solenoid Block Carry Out Service

    47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 15 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly recirculation investigation (spring sliding <Trouble> side) Spring is free from breakage. Both P1, P2 pressures are low.

  • Page 778: Secondary Pressure Of

    47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 10 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is current value of travel diagnosis Operation No.12 Bucket digging full largely differed from the actually straight proportional lever &...
  • Page 779 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually unload proportional measured value, check...
  • Page 780 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 16 Over load relief valve Check targeted spool Free from dust entered in over load Replace visually relief valve. Seat is free from abnormality. (11)Swing does not move/slow Sections Contents/normal value Corrective action, others 1 Swing pressure sensor Carry out service •See Service Diagnosis Data List...
  • Page 781 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 12 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve travel straight proportional valve regardless of neutral/operation proportional valve secondary pressure at (Check this trouble by the ports A6 (travel only swing operation) straight) of 8 sections...
  • Page 782 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 7 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect swing reduction gear metal powder. reduction gear drain. 8 Swing reduction Visual check Tooth surface has no abnormally worn Replace...
  • Page 783 47. TROUBLESHOOTING (BY TROUBLE) (15)Travel speed is slow/poor Sections Contents/normal value Corrective action, others 1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure pressure sensor diagnosis Operation No.18 Travel right full lever sensor and idling Check remote control valve...
  • Page 784 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 10 Travel straight spool Visual check When removing, free from abnormal Replace <Trouble> resistance against sliding (Check on the casing side for P1 pressure is high. Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.
  • Page 785 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 5 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually unload proportional measured value, check...
  • Page 786 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 14 Travel motor Visual check Inner parts (piston, cylinder block, Replace valve plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc) 15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of...
  • Page 787 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 3 Parking brake in travel Visual check When removing, free from abnormal Replace motor resistance against sliding Spring free from breakage, damage, etc. 4 Orifice of passage for Visual check Free from entry of dust Remove dust or replace parking brake in travel...
  • Page 788 47. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action, others 6 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve travel straight proportional valve pressure is 2.7MPa or more in optional proportional valve secondary pressure at attachment full lever and high idling the ports A6 (travel operation...
  • Page 789 47. TROUBLESHOOTING (BY TROUBLE) (22)Selector valve for option malfunctions: Nibbler circuit is not obtained. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve") Sections Contents/normal value Corrective action, others 1 N&B selector spool Visual check When removing, free from abnormal Replace resistance against sliding...
  • Page 790 47. TROUBLESHOOTING (BY TROUBLE) Table47-1 Action of optional selector solenoid valve Optional Selector Safety lock Safety lock selector valve Engine Work Spool Failure diagnosis lever SW's lever relay's valve detecting Warning display condition mode position display input output COMP. pressure MEAS.
  • Page 791 47. TROUBLESHOOTING (BY TROUBLE) 47.2 ELECTRIC SYSTEMS 47.2.1 WIRING CHECKING PROCEDURE Check for continuity between connector terminals, CONNECTOR presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding. WIRE (1) Checking for disconnection between connectors. (When both ends measurement is easy because of TESTER short distance between connectors,)
  • Page 792 47. TROUBLESHOOTING (BY TROUBLE) (4) Checking connector terminal for contact INSERT Insert male terminal into female terminal unit, and then check that the inserting force is equivalent to other female terminals. MALE TERMINAL FEMALE TERMINAL If looseness is there, replace the female terminal with new one.
  • Page 793 47. TROUBLESHOOTING (BY TROUBLE) (7) When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations. a. Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine.
  • Page 794 47. TROUBLESHOOTING (BY TROUBLE) 47.2.2 TROUBLE (1) Engine does not stop. (2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display. (3) Auto accel does not actuate. (The engine speed does not automatically slow down.) (4) Auto accel does not actuate. (The engine speed does not automatically speed up.) (5) Wiper does not function.
  • Page 795 47. TROUBLESHOOTING (BY TROUBLE) (1) Engine does not stop. Sections Contents/normal value Corrective action, others 1 Starter key switch Check signal of starter No.4 K-3 Key switch Check continuity between key switch ON by OFF at starter key switch OFF position terminals of starter switch using carrying out service ON at starter key switch ON position...
  • Page 796 47. TROUBLESHOOTING (BY TROUBLE) (5) Wiper does not function Wiping range of forward and reverse movements Wiper motor Rise up limit switch's ON range Rise up (storing) position Reverse limit switch's ON range Upper reversing position Lower reversing position Sections Contents/normal value Corrective action, others 1 Fuse...
  • Page 797 47. TROUBLESHOOTING (BY TROUBLE) 47.3 ENGINE RELATED TROUBLESHOOTING Checking Filters Liquid Leak, clogging Factors Trouble Poor start ability (Take a long time) Faulty engine starting/engine does not rotate. Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Engine poor run-up (Low follow-up ability) Rotation in bad condition (hunting)
  • Page 798 47. TROUBLESHOOTING (BY TROUBLE) Checking Electric equipment Shovel side Shovel side Engine side Factors Trouble Poor start ability (Take a long time) Faulty engine starting/engine does not rotate. Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Engine poor run-up (Low follow-up ability) Rotation in bad condition (hunting)
  • Page 799 47. TROUBLESHOOTING (BY TROUBLE) Intake and Lubrication Cooling Fuel system exhaust system system system Factors Trouble Poor start ability (Take a long time) Faulty engine starting/engine does not rotate. Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Engine poor run-up (Low follow-up ability)
  • Page 800 47. TROUBLESHOOTING (BY TROUBLE) Engine body Factors Trouble Poor start ability (Take a long time) Faulty engine starting/engine does not rotate. Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Engine poor run-up (Low follow-up ability) Rotation in bad condition (hunting) Engine stalled during operation.
  • Page 801 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) TABLE OF CONTENTS 48.1 TROUBLE DIAGNOSIS MODE ..................48-3 Book Code No. S5YN4818E01 48-1...
  • Page 802 July, 2007 E135BSRLC : YH05-07001~ (NHK) ↑ SK225SR : YB05-03001~ ↑ ↑ SK225SRLC : LA05-02001~ (OCE) ↑ E215B : YN11-45001~ ↑ ↑ E215BLC : YQ11-06001~ (NHK Middle East) ↑ E265B : LQ12-06001~ ↑ ↑ E265BLC : LL12-05001~ (NHK Russia) 48-2...
  • Page 803 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) 48.1 TROUBLE DIAGNOSIS MODE The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output. (1) Function There are two types of trouble diagnosis mode.
  • Page 804 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) No.4 CASE OF DIAG MODE 2 START ENG DIAG MODE 2 SENSOR CHECK LOWER BOOM ENGINE SPEED START CHECK 0000 rpm TO GROUND PRESSURE 00.0M C-2 00.0M PROPO-VALVE 005mA E-2 005mA 300mA D-2 300mA Turn engine on Example: Case of boom up manually.
  • Page 805 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) Table48-1 Failure diagnosis Mode-1/Diagnosis item Display Contents of diagnosis Is normal pressure generated in the condition that P1 side flow rate is minimum, unload 13 1 TRAVEL-S valve is emergency position and travel straight is stroked fully? Is normal pressure generated in the condition that P2 side flow rate is minimum, unload 14 2 TRAVEL-S valve is emergency position and travel straight is stroked fully?
  • Page 806 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display) Possible cause Remedy Delivery rate is excessive large against the Check P2 pump regulator and replace command it if necessary. P2 PUMP NG Delivery rate is excessive small against the Check P2 pump and replace it if necessary.
  • Page 807 51. ENGINE PREFACE This service manual explains the single engine. Note that this manual is edited without modification by based on the service manual of HINO MOTOR. Book Code No. S5LQ5114E01 51-1...
  • Page 808 51. ENGINE Issue Date of Issue Applicable Machines Remarks SK250-8 : LQ12-06001~ First edition October, 2006 S5LQ5114E01 SK260LC-8 : LL12-05001~ ↑ E265B : LQ12-06001~ ↑ July, 2007 E265BLC : LL12-05001~ (NHK Russia) 51-2...
  • Page 809 HINO DIESEL ENGINE WORKSHOP MANUAL J05E-TB (25t) KSS-SMJ5-E102E 2006.10...
  • Page 811 GENERAL STANDARD VALUE PARTS TO BE PREPARED ENGINE ASSEMBLY/DISASSEMBLY FUEL SYSTEM EMISSION CONTROL ELECTRICAL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION STARTING AND CHARGING TURBOCHARGER AIR COMPRESSOR FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ENGINE DIAGNOSIS CODE For your information: This documentation does not contain any descriptions in regard to the hatched part "15.
  • Page 813 1–1 GENERAL ENGINE 1 GENERAL General General information Warning..............1-2 How to read this manual ........1-3 Precautions for work ..........1-7 Tightening of engine bolts and nuts ...... 1-10 Tightening of chassis bolts and nuts..... 1-12 Tightening of flare nuts and hoses......1-14 Taper thread sealant for piping ......
  • Page 814 1–2 GENERAL Warning JP31199010102001 Observe the following precautions to work safely and to prevent damage to customers' vehicles. This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who perform service with the way not specified in this manual may not only damage the vehicle, but also put service engineers and surrounding people in danger.
  • Page 815 1–3 GENERAL How to read this manual JP31199010102002 Scope of repair work Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement, assembly⋅disassembly and inspection⋅adjustment" and "Final inspection". This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement, assembly⋅disassembly and inspection⋅adjustment"...
  • Page 816 1–4 GENERAL How to read troubleshooting Failure diagnosis in this manual describes Step 2 and Step 3 below : Hear from customers for conditions and environments (1) Question "Step 1" of failures and check the fact. Perform diagnosis inspection, status inspection, (2) Pre-inspection function inspection and basic inspection.
  • Page 817 1–5 GENERAL How to read explanation details Part layout Example 9–17 ENGINE MECHANICAL [J08E] Timing Gear Cover and Flywheel Housing Part layout JP04117090402003 Part name code Part catalog Fig. No. SAPH041170900182 11308 Flywheel housing 11390 End plate Description of 11309 Oil seal retainer 9828A Front oil seal*...
  • Page 818 1–6 GENERAL Definition of terms Terms in this manual are defined as follows : Direction Individual unit Front/back direction The power input side is front and the output side is back. Rotating direction When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is left rotation.
  • Page 819 1–7 GENERAL Safety information Precautions for work JP31199010101001 General precautions To ensure safety in work and to prevent accidents, observe the following items : Appearance Wear safety goggles. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work. Bind long hair at the back.
  • Page 820 1–8 GENERAL Precautions for electric system Removal of battery cable In an electric system, remove the cable from the battery minus (-) terminal to prevent burnout due to short-circuit. When the battery cable is removed, the battery Loosen terminal may be damaged. Loosen the nut completely and never pry it for removal.
  • Page 821 1–9 GENERAL Handling of connector When a connector is removed, hold the connector (as shown by the arrow in the left) and pull it out. Do not pull the wire harness. Unlock the locking connector before pulling. Insert the locking connector completely until it clicks. To insert a test lead into the connector, insert it from the back of the connector.
  • Page 822 1–10 GENERAL Tightening of engine bolts and nuts JP31199010102003 Tightening torque of general standard bolts For bolts with seatings Unit : N⋅m{kgf⋅cm} Screw diameter x Pitch M8 x 1.25 (Coarse thread) 28.5{290} 36{370} M10 x 1.25 (Fine thread) 60{610} 74.5{760} M10 x 1.5 (Coarse thread) 55{560} 68.5{700}...
  • Page 823 1–11 GENERAL Precoated bolt Precoated bolt is the bolt with an application of a seal lock agent at the thread. When re-application of lock agent is required When precoated bolts are removed When precoated bolts are moved due to tightening Seal Lock Agent check (for loosening or tightening) •...
  • Page 824 1–12 GENERAL Tightening of chassis bolts and nuts JP31199010102004 Tightening torque of general standard bolts and nuts Selection method of tightening torque Find the applicable strength zone from the table below and select the bolt tightening torque from the table described later. Select the nut tightening torque from the mating bolt as described above.
  • Page 825 1–13 GENERAL Standard tightening torque table of general standard bolts and nuts (Representative standard seating is described) Unit : N⋅m{kgf⋅cm} Strength zone Bolt diameter (mm) 4.5±1.8{50±20} (Cab) 9.0±1.8{90±20} 11.5±2.0{117±23} 5.5±1.1{60±10} (Chassis) 14.0±3.5{140±40} (Cab) 22.0±4.0{220±40} 29.0±5.5{300±60} 17.0±3.0{170±30} (Chassis) 43.0±8.5{440±90} 57.0±11.0{580±110} (Cab) (Cab) 27.0±5.0{276±55} 51.5±10.0{530±100}...
  • Page 826 1–14 GENERAL Tightening of flare nuts and hoses JP31199010102005 Tightening torque of pipe flare nut Unit : N⋅m{kgf⋅cm} Pipe outer diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15 Material Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80} Tightening torque of hoses Unit : N⋅m{kgf⋅cm} Hose outer diameter Hose outer diameter...
  • Page 827 1–15 GENERAL Taper thread sealant for piping JP31199010102006 The taper thread of the air pipe joint has application of sealant [Loctite # 575 (by Japan Loctite)]. Follow the procedures below for connection or disconnection of pipes. For disconnection Removal of joint (Example: Use of magnetic valve) The sealant ( # Loctite 575) has strong sealing feature.
  • Page 828 1–16 GENERAL Assembly of joints and gaskets for piping JP31199010102007 Tightening torque of joints Unit : N⋅m{kgf⋅cm} Metal sealing method Sealing method (Flare pipe type, nipple connector type) Gasket sealing method (Aluminum + Rubber or Copper) Tightening screw Type A Type B size 13{130}...
  • Page 829 1–17 GENERAL Examples of joint methods in various pipes Metal sealing method Gasket sealing method Type A Type B (Flare pipe type) (Nipple connector type) Joint bolt Sealing surface: 3 places Flare pipe Gasket Connector Flare nut Connector nipple Joint bolt Sealing surface : 4 places Flare connector...
  • Page 830 1–18 GENERAL Handling of liquid gasket JP31199010102008 Application of liquid gasket and part assembly procedure Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent deposit of oil, moisture, dirt, etc. Be sure to overap parts at the beginning and at the end of application.
  • Page 831 1–19 GENERAL Failure diagnosis table for each problem JP31199010301001 Causes and actions are described for each item. Engine mechanical JP03Z01020601001 Status Cause Action Engine overheat (coolant) Insufficient coolant Replenish coolant Faulty thermostat Replace thermostat Water leak from cooling system Correction Faulty coolant pump Repair or replace Faulty head gasket...
  • Page 832 1–20 GENERAL Failure diagnosis using HinoDX JP31199010301002 • Hino–DX is used for inspection and ! CAUTION adjustment of the system in addition to failure diagnosis. Hino–DX With Hino–DX, failure of the common rail fuel injection system can be diagnosed. The interface box (Hino- Bowie) and the special cable are required for connection to the vehicle.
  • Page 833 1–21 GENERAL Deletion of past failures To delete past failures of the engine ECU, use Hino–DX on the PC. (Refer to "HinoDX operation manual".) SAPH311990100032 Connection of signal check harness To prevent damage to the ECU connector and to improve accessibility, connect the signal check harness and put a testing rod on the signal check connector of the signal check harness for meaurement.
  • Page 834 1–22 GENERAL Terminal No. For the signal check harness connector, the ECU terminal number in the text is treated as follows : ECU unit Signal check harness ECU side Vehicle side SAPH311990100038...
  • Page 835 1–23 GENERAL Connection method of HinoDX JP31199010301003 Connection of Hino–DX Remove the left side cover at the rear of the driver's seat and connect the failure diagnosis connector with a PC which installed Hino–DX through the interface box. Special tool : 09121-1040 Hino-Bowie (Interface box) 09042-1220 Connecting cable CD-ROM Hino–DX Engine ECU...
  • Page 837 2–1 STANDARD VALUE ENGINE 2 STANDARD VALUE Specification (performance) System drawing Engine Body..............2-2 Standard value............2-2 Tightening torque ............ 2-2 Fuel System ..............2-2 Tightening torque ............ 2-2 Emission Control............2-2 Tightening torque ............ 2-2 Electrical..............2-3 Standard value............2-3 Tightening torque ............
  • Page 838 2–2 STANDARD VALUE Engine Body Standard value JP31199020205001 MPa {kgf/cm , lbf/in. Repair Service Inspection item Standard value Action limit limit Compression pressure 3.4-3.7 — (Engine revolution per cylinder: 150 r/min) {35-38, 493-237} {28, 392} Tightening torque JP31199020205002 Unit:N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark...
  • Page 839 2–3 STANDARD VALUE Electrical Standard value JP31199020205018 Inspection item item item Standard value Remark 8 - 10mm {0.3152 - 0.394in.} Compression Deflection (Reference push force 98N gauge (09444- {10kgf, 22lbf}) 1210) is used. When installing Belt tension a new belt gauge (95506- 490 - 570 N Tension...
  • Page 840 2–4 STANDARD VALUE Engine Mechanical Standard value JP31199020205006 Unit : mm {in.} Inspection item Standard value Repair limit Service limit Action — — 0.30 {0.0118} Valve clearance (cold) — — 0.45 {0.0177} 0.01 - 0.08 — — Cylinder liner protrusion {0.003 - 0.003} —...
  • Page 841 2–5 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Approx. 11.5 — — {0.4527} Free joint clearance Approx. 14 — — Second {0.5512} 0.3 - 0.40 — 1.5 {0.0591} {0.0118 - 0.0157} Gap between ends 0.75 - 0.9 Replace —...
  • Page 842 2–6 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Replace piston pin 0.015 - 0.036 0.08 — Connecting rod bushing oil clearance {0.0006 - 0.0014} {0.0031} connecting rod bushing Replace the 63.8 — Crank pin outer diameter 65 {2.5590} crankshaft.
  • Page 843 2–7 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Replace 0.20 - 0.52 connecting — Connecting rod end play 1.0 {0.0394} {0.0079 - 0.0205} rod or crankshaft –0.15 Camshaft journal outer Replace — 40 {1.5748} diameter {–0.0059} camshaft Bearing Camshaft bearing inner...
  • Page 844 2–8 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action 30° Allowable angle 30° - 30°35' Valve seat angle 45° Allowable angle 45° - 30°30' Correction 30° Allowable angle 29°30 - 45° Valve face angle 45° Allowable angle 44°30 - 45° 44.8 —...
  • Page 845 2–9 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action 0.030 - 0.167 0.30 — Crank - Main idle {0.0012 - 0.0066} {0.0012} Main idle - Pump 0.032 - 0.096 0.10 — drive idle {0.0013 - 0.0038} {0.00393} Pump drive idle - 0.020 - 0.083 0.10...
  • Page 846 2–10 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action — — Shaft outer diameter 34 {1.3386} Bushing inner — — 34 {1.3386} diameter Replace Clearance between 0.025 - 0.075 0.20 — shaft or shaft and bushing {0.0002 - 0.0030} {0.0079} bushing idle...
  • Page 847 2–11 STANDARD VALUE Valve timing Exhaust valve open (before BDC) 54° Exhaust valve close (after BDC) 13° Intake valve open (before BTC) 14° Intake valve close (after BTC) 30° Tightening torque JP31199020205007 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Crankshaft pulley mounting bolt 118 {1,203, 87}...
  • Page 848 2–12 STANDARD VALUE Exhaust Tightening torque JP31199020205008 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Exhaust manifold mounting stud bolt 30 {300, 22} Exhaust manifold mounting nut 53 {540, 40} Cooling Standard value JP31199020205009 Standard Repair Service Inspection item Action value limit...
  • Page 849 2–13 STANDARD VALUE Repair Service Inspection item Standard value Action limit limit — — Outer diameter of drive gear 54 {2.1260} Cylinder block side — — 54 {2.1260} Oil pump chamber inner diameter Clearance between drive gear and 0.100 - 0.202 0.30 Replace drive —...
  • Page 850 2–14 STANDARD VALUE Tightening torque JP31199020205011 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Oil pan mounting bolt 30 {300, 22} Oil strainer 31 {320, 23} Oil pan drain cock 41 {420, 30} Oil pump mounting bolt 28.5 {290, 21} 24.5±4.9 {250±50, 18±4} 24.5±4.9 {250±50, 18±4} Oil circuit spring plug...
  • Page 851 2–15 STANDARD VALUE Tightening torque (Alternator 50A) JP31199020205013 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Bearing cover mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} Pulley mounting nut 127 - 157 {1, 300 - 1, 600, 94 - 116} Feed coil - Rear bracket 2.9 - 3.9 {30 - 39, 2 - 3} Heat sink mounting bolt...
  • Page 852 2–16 STANDARD VALUE Standard Inspection item Service limit Action value Metal bushing inner diameter of shaft Replace shaft 9 {0.3543} 9.2 {0.3622} assembly assembly Replace Bearing housing inner diameter of rear 28 {1.1024} 28.1 {1.1063} or more commutator end bracket frame Between C terminal and M Start...
  • Page 853 3–1 PARTS TO BE PREPARED ENGINE 3 PARTS TO BE PREPARED Special tool (SST) Special tool Engine Body..............3-2 Special tool ............. 3-2 Fuel System ..............3-2 Lubricant, etc............3-2 Electrical..............3-2 Special tool ............. 3-2 Engine Mechanical ............. 3-3 Special tool .............
  • Page 854 3–2 PARTS TO BE PREPARED Engine Body Special tool JP31199030901001 Shape Part No. Description Remark 09491–1010 Wire rope For engine lifting 09552–1030 Compression gauge adapter 09552–1060 Compression gauge adapter 09552–1110 Compression gauge adapter Fuel System Lubricant, etc. JP31199030901002 Name Remark Guide bolt (9069-08180) For supply pump positioning Electrical...
  • Page 855 3–3 PARTS TO BE PREPARED Engine Mechanical Special tool JP31199030901004 Shape Part No. Name Remark For crankshaft front oil seal 09420–1731 Oil seal puller removal For crankshaft front oil seal 09407–1030 Oil seal press press-fit For assembly/disassembly 09433–1070 Eye bolt of cylinder head For assembly/disassembly 09470–1170...
  • Page 856 3–4 PARTS TO BE PREPARED Shape Part No. Name Remark For valve stem seal 09472–2100 mounting For removal and inspection 09420–2100 Cylinder liner puller of cylinder liner For assembly/disassembly 09442–1011 Piston ring expander of piston ring For mounting of connecting rod small end bushing 9191–08252 Bolt...
  • Page 857 3–5 PARTS TO BE PREPARED Shape Part No. Name Remark 09441–1370 Piston ring holder For piston mounting For assembly/disassembly 09481–1340 Guide of flywheel For crankshaft rear oil seal 09420–1742 Oil seal puller removal 09420–1100 For main/sub idle gear Sliding hammer assembly and cam idle gear 09420–1442 shaft removal...
  • Page 858 3–6 PARTS TO BE PREPARED Shape Part No. Name Remark For cooling jet inspection 09470–1280 Tool assembly and adjustment Instruments JP31199030901005 Name Remark Micrometer For measurement of part outer diameter Cylinder gauge For measurement of part inner diameter Thickness gauge For measurement of each clearance Dial gauge For measurement of parts...
  • Page 859 3–7 PARTS TO BE PREPARED Starting and Charging Jig (reference dimensional drawing for manufacture) JP31199030901009 This is used for assembly of bearing. Reference dimensions are shown in the figures below: Jig B (Support jig) Unit : mm{in.} Jig A (Roller bearing insertion jig) φ23{20.827} φ25{0.984} 1C{0.039}...
  • Page 860 3–8 PARTS TO BE PREPARED Instruments JP31199030901010 Alternator Name Remark Circuit tester For measurement of parts Micrometer For measurement of parts Regulator checker (G&M Machinery ICD-101D or For inspection of regulator equivalent) Starter Name Remark Circuit tester For measurement of parts Micrometer For measurement of part outer diameter Growler tester...
  • Page 861 3–9 PARTS TO BE PREPARED Air compressor Special tool JP31199030901013 Shape Part No. Name Remark 09440-1060 Piston ring expander Remove the piston ring Supply pump side 09650-1101 Bearing puller For bearing and drain of drive gear Drive gear side 09650-1310 Puller assembly For drain of bearing Instruments...
  • Page 862 3–10 PARTS TO BE PREPARED Engine Failure Diagnosis Special tool JP31199030901016 Shape Part No. Name Remark • Operating system(OS):Windows95, Windows98(IE5.0 or later), Windows2000(SP3, IE5.0 or later), WindowsXP(SP1a, IE6.0 – Personal computer (DOS-V) or later) • CPU and memory: Conditions that assure operation of the above operating system •...
  • Page 863 4–1 ENGINE ASSEMBLY/DISASSEMBLY ENGINE 4 ENGINE ASSEMBLY/DISASSEMBLY Service procedure Overhaul item Inspection Before Service ......... 4-2 Measurement of compression pressure ....4-2 Engine Body..............4-4 Removal..............4-4 Installation............... 4-6 Work after installation ..........4-6...
  • Page 864 4–2 ENGINE ASSEMBLY/DISASSEMBLY Inspection Before Service Measurement of compression pressure JP31199040702001 • Measure the compression pressure before NOTICE disassembly of the engine and record the result. Regular measurement of the compression pressure can tell the engine status. Preparation before measurement Charge the battery completely.
  • Page 865 4–3 ENGINE ASSEMBLY/DISASSEMBLY Measure the compression pressure of each cylinder continuously. Engine revolution 150r/min {rpm} Compression pressure: Unit MPa {kgf/cm ,lbf/in. Standard value 3.4 - 3.7 {35 - 38 ,493 - 537} Service limit 2.7 {28, 392} Difference between 0.3{3, 44} or less cylinders If the compression pressure is the service limit or less or if the difference between cylinders is over the standard...
  • Page 866 4–4 ENGINE ASSEMBLY/DISASSEMBLY Engine Body Removal JP31199040702002 Preliminary work before removal of engine Place the vehicle on a level ground. Block tires with scotch. Remove the battery cable from the battery minus terminal. Drain of coolant and engine oil Right side of engine Drain coolant from the radiator drain cock and the oil cooler drain plug.
  • Page 867 4–5 ENGINE ASSEMBLY/DISASSEMBLY Disconnection of fuel hose Remove the fuel hoses (feed side and return side). Wrap the removed hose with a plastic sheet with its end facing upward to prevent spill of fuel. • Wipe spilled fuel with a rag. ! CAUTION SAPH311990400004 Disconnection of water, engine oil pipes, etc.
  • Page 868 4–6 ENGINE ASSEMBLY/DISASSEMBLY Installation JP31199040702003 Connection of fuel hose Insert a fuel hose and fix it with a hose band. Work after installation JP31199040702004 Inspection of engine oil Make sure that the drain cock is closed. Pour engine oil. Check the amount of oil with an oil level gauge. Engine oil amount (L{us gal}) Oil pan Oil filter and etc...
  • Page 869 5–1 FUEL SYSTEM ENGINE 5 FUEL SYSTEM Setup layout Layout Fuel System ..............5-2 Fuel system diagram..........5-2 Part layout .............. 5-3 Fuel filter drain (on machine main unit)....5-5 Replacement of fuel filter element (on machine main unit) ........... 5-6 Replacement of supply pump .........
  • Page 870 5–2 FUEL SYSTEM Fuel System Fuel system diagram JP31199050402001 Feed pipe Injection pipe Flow damper Injector Common rail Leakage pipe Pressure limiter Through feed pipe Overflow pipe Supply pump Fuel tank Fuel filter SAPH311990500001...
  • Page 871 5–3 FUEL SYSTEM Part layout JP31199050402003 SAPH311990500002 11195 Nozzle clamp holder 22760 Common rail assembly 11491A Common rail bracket 23910 Injector 13691 Bearing holder case 9645A O–ring* 22730 Supply pump 9851A O–ring* *Parts not to be reused. Tightening torque 22825 63.7N⋅m {650 kgf⋅cm, 47lbf⋅ft} 9068-08320 28.5N⋅m { 290kgf⋅cm, 21lbf⋅ft}...
  • Page 872 5–4 FUEL SYSTEM SAPH311990500003 23081 Leakage pipe 23766A Through feed pipe 23083 Through feed pipe 23783A Fuel pipe 23711 Injection pipe 9659B Gasket* 23712 Injection pipe 9659C Gasket* 23713 Injection pipe 9659D Gasket* 23714 Injection pipe 9659E Gasket* 23766 Through feed pipe *Parts not to be reused.
  • Page 873 5–5 FUEL SYSTEM Fuel filter drain (on machine main unit) JP31199050704001 Prepare a water container under the drain pipe. Air bleeding bolt Priming pump Loosen the fuel filter air bleeding bolt and the drain valve. Discharge water at the bottom of the fuel filter case. •...
  • Page 874 5–6 FUEL SYSTEM Replacement of fuel filter element (on machine main unit) JP31199050704002 Removal of water cup Refer to "Drain of the fuel filter" and discharge water from the fuel filter. Fuel filter element Fuel filter head Remove the water cup of the fuel filter. O-ring O-ring Removal of fuel filter element...
  • Page 875 5–7 FUEL SYSTEM Replacement of supply pump JP31199050704003 Compression upper dead center setting of No.1 cylinder Turn the crankshaft counterclockwise when viewed from the flywheel. Set the timing mark in the flywheel housing inspection window to "1". Flywheel Remove the inspection window plug in the bearing holder case of the supply pump.
  • Page 876 5–8 FUEL SYSTEM Secure the supply pump, install the injection pump drive gear on the shaft, and use a vice or similar to prevent turning while tightening the nut. Tightening torque : 63.7 N⋅m {650 kgf⋅cm, 47 lbf⋅ft} • Do not use the guide bolt for stopper key of ! CAUTION the shaft.
  • Page 877 5–9 FUEL SYSTEM Update of supply pump learning value When the supply pump is replaced, update the learning value memorized in the engine ECU with the failure diagnosis tool (HinoDX) using PC. (Refer to "HinoDX operation manual".) • If learning value is not updated, correct ! CAUTION common rail pressure is not controlled, resulting in engine stall or high common rail...
  • Page 878 5–10 FUEL SYSTEM Replacement of injector JP31199050704005 Removal of injector Remove the fixing bolt and remove the plate and the injection pipe oil seal. Remove the nozzle clamp holder and remove the injector. Installation of injector Attach a new O-ring to the groove of the cylinder head and insert the injector.
  • Page 879 5–11 FUEL SYSTEM Read the injector QR code with the scanner of the QR code reader and prepare the correction data file. Enter the injector correction value directly from the PC tools to the engine ECU. QR Code reader Hino-Bowie Engine-use code QR code Connector...
  • Page 880 5–12 FUEL SYSTEM Replacement of common rail JP31199050704007 Removal of common rail Remove the common rail together with the flow damper, pressure sensor and pressure limiter from the intake manifold. • Remove dirt around parts before removing ! CAUTION Pressure limiter the common rail Flow damper Pressure sensor...
  • Page 881 6–1 EMISSION CONTROL ENGINE 6 EMISSION CONTROL Setup layout Layout EGR................6-2 Part layout ............... 6-2 Overhaul of EGR valve and EGR cooler....6-3...
  • Page 882 6–2 EMISSION CONTROL Part layout JP31199060402001 SAPH311990600001 16691 Coolant pipe 900234 Coolant hose 16691A Coolant pipe 900234A Coolant hose 17104A Gasket* 900234B Coolant hose 17173 Gasket* 900234C Coolant hose 17308 EGR pipe 9659A Gasket* 17309 EGR cooler assembly 9659B Gasket* 17350 EGR valve *Parts not to be reused.
  • Page 883 6–3 EMISSION CONTROL Overhaul of EGR valve and EGR cooler JP31199060704001 Removal of EGR valve • Since burn may occur, replace the part after ! CAUTION cooling. (Leave it standing for 30 minutes or more after the starter key is turned OFF.) Remove the connector from the EGR valve.
  • Page 884 6–4 EMISSION CONTROL Installation of EGR cooler Install a new gasket and mount the EGR cooler on the exhaust manifold. Tightening torque : 68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft} SAPH311990600006 Connect the EGR pipe. Tightening torque : 29.5 N⋅m {300 kgf⋅cm, 22lbf⋅ft} Connect hoses to the EGR cooler.
  • Page 885 7–1 ELECTRICAL ENGINE 7 ELECTRICAL Setup layout Layout Electrical System............7-2 Part layout .............. 7-2 Layout of components..........7-5 Inspection of components ........7-8 Installation of component ........7-10 Installation of starter ..........7-10 Installation of alternator ........7-11...
  • Page 886 7–2 ELECTRICAL Electrical System Part layout JP31199070402001 SAPH311990700001 82030 Injector harness 89390 Boost pressure sensor 83420 Water temperature sender gauge 89410 Engine sub revolution sensor 83530 Oil pressure warning switch 89411 Engine main revolution sensor Tightening torque 9069C 4N⋅m{40kgf⋅cm, 3lbf⋅ft}...
  • Page 887 7–3 ELECTRICAL SAPH311990700002 12509 Alternator brace 9011-64410 Through bolt 12511 Alternator bracket 9241-10107 Fixing bolt at brace 27040 Alternator assembly 9189A Adjusting bolt 28100 Starter assembly Tightening torque 9069A 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft} 9241-10107 51N⋅m{520kgf⋅cm, 38lbf⋅ft} 9011-64401 83N⋅m{850kgf⋅cm, 61lbf⋅ft} 9241-14147 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft} 9189A 5.9N⋅m{60kgf⋅cm, 4lbf⋅ft}...
  • Page 888 7–4 ELECTRICAL SAPH311990700003 19110 Glow plug...
  • Page 889 7–5 ELECTRICAL Layout of components JP31199070402003 Fuel temperature sensor Boost pressure sensor Suction control valve (SCV) Common rail pressure sensor Left side view SAPH311990700004...
  • Page 890 7–6 ELECTRICAL Coolant temperature sender gauge Oil pressure warning switch Right side view SAPH311990700005...
  • Page 891 7–7 ELECTRICAL Engine sub revolution sensor Engine main revolution sensor Upper view SAPH311990700006 Service procedure Overhaul item...
  • Page 892 7–8 ELECTRICAL Inspection of components JP31199070702001 Inspection of oil pressure warning switch (Laid out on the oil filter) Apply pressure with air or oil and check continuity between terminals using a circuit tester. If it is faulty, replace it. At no load or less than 39kPa With continuity {0.4kgf/cm ,5.6565lbf/in.
  • Page 893 7–9 ELECTRICAL Inspection of glow plug Measure continuity between the body and the terminal using a circuit tester. If it is faulty, replace the glow plug. Standard value Resistance value : Ω(Normal temperature 2.59 - 3.29 20°C{68°F}) SAPH311990700010 Inspection of suction control valve SCV and fuel temperature sensor For inspection and replacement of the suction control valve (SCV) and the fuel temperature sensor, refer to the...
  • Page 894 7–10 ELECTRICAL Installation of component JP31199070702002 Installation of engine revolution sensor Confirm that there are O-rings on the sensors and then mount one sensor on top of the flywheel housing and one on the cam housing. • Since this sensor is a flange type, gap does O-ring NOTICE not have to be adjusted.
  • Page 895 7–11 ELECTRICAL Installation of alternator JP31199070702004 Installation of alternator Tighten the alternator temporarily using through bolts and nuts. Tighten the adjusting bolts and fixing bolts temporarily. V–belt tension adjustment Coolant Pump Pulley When installing a Item At the time of inspection new belt 8 - 10mm 10 - 12mm...
  • Page 897 8–1 INTAKE ENGINE 8 INTAKE Setup layout Layout Intake Manifold ............8-2 Part layout .............. 8-2 Replacement............8-3...
  • Page 898 8–2 INTAKE Intake Manifold Part layout JP31199080402001 SAPH311990800001 17103 Intake pipe 17113 Intake pipe 17111 Intake manifold 17171 Gasket* *Parts not to be reused. Tightening torque 9068-08320 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} 9240-08087 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} 9068-08550 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} Service procedure Replacement procedure item...
  • Page 899 8–3 INTAKE Replacement JP31199080704001 Removal of intake manifold Remove bolts and nuts and remove the intake manifold. Installation of intake manifold Clean inside of the intake manifold and the cylinder head. Assemble a new gasket. • Install the gasket so that the protrusion may ! CAUTION come at the rear end stud bolt of the cylinder head.
  • Page 901 9–1 ENGINE MECHANICAL ENGINE 9 ENGINE MECHANICAL Setup layout Layout Cylinder Head ............. 9-2 Part layout ............... 9-2 Replacement of cylinder head ........ 9-4 Liquid gasket application procedure for semicircular plug (only when semicircular plug is removed) ....9-7 Replacement of head cover ........9-7 Overhaul of cylinder head ........
  • Page 902 9–2 ENGINE MECHANICAL Cylinder Head Part layout JP31199090402001 SAPH311990900001 11101 Cylinder head assembly 11135 Exhaust valve seat 11122 Valve guide 11176 Nozzle seat 11131 Intake valve seat 900115 O-ring* *Parts not to be reused.
  • Page 903 9–3 ENGINE MECHANICAL SAPH311990900002 11115 Cylinder head gasket 12108 Oil filler cap 11188 Semicircular plug 12505 Silent block 11201 Cylinder head cover 23074 Injection pipe oil seal* 11213 Head cover gasket *Parts not to be reused. Tightening torque 11185 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+90° 9069A 59N⋅m{600kgf⋅cm, 44lbf⋅ft} 11185A...
  • Page 904 9–4 ENGINE MECHANICAL Replacement of cylinder head JP31199090704001 Removal of cylinder head and head gasket Loosen the head bolts from outside to inside gradually (1/ 4 turn for each) as shown in the order of the figure and remove them. No.4 - No.21 : M12 Bolts SAPH311990900003 Remove the cylinder head using a special tool and hoist.
  • Page 905 9–5 ENGINE MECHANICAL Installation of cylinder head gasket and liquid gasket application procedure Cut the rear end plate gasket to be flush with the surface Water hole seal ring of the cylinder block upper surface using a scraper. Install the cylinder head gasket on the cylinder block and the flywheel housing.
  • Page 906 9–6 ENGINE MECHANICAL Align the dowel pins of the cylinder block using a special tool and hoist and mount the cylinder head. Figure is an example of work. Special tool : 09433–1070 Eye bolt • Before mounting the cylinder head, make ! CAUTION sure that there is no foreign matter in the cylinder.
  • Page 907 9–7 ENGINE MECHANICAL (10) Tighten remaining head bolts (M10) in the order in the figure. This just 3 tighten Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft} SAPH311990900012 Liquid gasket application procedure for semicircular plug (only when semicircular plug is removed) JP31199090704002 Remove liquid gasket from the cylinder plug and the camshaft housing.
  • Page 908 9–8 ENGINE MECHANICAL Coat the semicircular plugs with liquid gasket (Three Bond TB 1207B-Black or equivalent) just before you install the cylinder head cover. • Install the oil cooler within 20 minutes after ! CAUTION application of the liquid gasket. SAPH311990900015 Put the cylinder head cover on the cylinder head and Cylinder...
  • Page 909 9–9 ENGINE MECHANICAL Replacement of valve seat • The valve seat replacement procedure below Backing Valve seat ! CAUTION metal may damage the cylinder head depending on the case. It is recommended that a request for replacement be made to a machining vendor. Electric welding Valve If the valve seat is replaced, use an out-of-use valve.
  • Page 910 9–10 ENGINE MECHANICAL After attaching a new O-ring into the nozzle seat hole of Cylinder head the cylinder head, apply the liquid gasket [Threebond TB1211 (white) or equivalent] at the lower part of a new O-ring nozzle seat and assemble it on the cylinder head. •...
  • Page 911 9–11 ENGINE MECHANICAL Cylinder Block Part layout JP31199090402002 SAPH311990900026 11401 Cylinder block assembly 11467 Cylinder liner 11408 Cooling jet Tightening torque 22N ⋅m{220kgf⋅cm, 16lbf⋅ft} 11521 69N⋅m{700kgf⋅cm, 51lbf⋅ft}+90°+45° 15605 Service procedure Overhaul item...
  • Page 912 9–12 ENGINE MECHANICAL Overhaul JP31199090702002 Replacement of cylinder liner Put match marks on the flange surfaces of the cylinder block and the cylinder liner using a oil based marker. • Store removed cylinder liners for each ! CAUTION Match mark cylinder number.
  • Page 913 9–13 ENGINE MECHANICAL • When a new cylinder liner is installed, install ! CAUTION Liner identification mark Engine type the cylinder liner with the same identification mark (A, B, C) stamped on the cylinder block. Block front Front of engine SAPH311990900030 Cylinder liner A, B and C marking...
  • Page 914 9–14 ENGINE MECHANICAL Connect the injection test oil hose from the lower part of the cylinder block to the special tool check bolt. • Use new engine oil for injection of oil. ! CAUTION Check bolt Oil hose SAPH311990900034 Set a special tool on the cylinder block. Special tool : 09470–1280 Tool assembly Special tool Tool assembly...
  • Page 915 9–15 ENGINE MECHANICAL If injection does not hit the target circle, correct it with a special tool. Special tool : 09472–1620 Tool If it cannot be corrected, install a new cooling jet for reinspection. Remove the check bolt and install the cooling jet on the cylinder block using the genuine oil check valve.
  • Page 916 9–16 ENGINE MECHANICAL Timing Gear Cover and Flywheel Housing Part layout JP31199090402003 SAPH311990900040 11309 Front oil seal retainer 11390 End plate 11351 Flywheel housing 9828A Front oil seal* 11357 Gasket* 9828B Rear oil seal* 11357A Gasket* *Parts not to be reused. Tightening torque 9068-08000 36N⋅m{370kgf⋅cm, 27lbf⋅ft}...
  • Page 917 9–17 ENGINE MECHANICAL Replacement of flywheel housing JP31199090702003 Removal of flywheel housing Remove bolts and remove the flywheel housing. • Remove bolts fixing the flywheel housing ! CAUTION from the cylinder block. SAPH311990900041 Installation of flywheel housing Liquid gasket Remove contamination from the joint surfaces of the flywheel housing and the end plate using a scraper.
  • Page 918 9–18 ENGINE MECHANICAL Installation of end plate Install the end plate and a new gasket with bolts. • Make sure that there is no dirt or foreign ! CAUTION matter on the installation surface of the cylinder block and the screw holes. Apply sealant (Super 5M or equivalent) to the thread of the Torx bolt.
  • Page 919 9–19 ENGINE MECHANICAL Remove two bolts which installed the plate of the special tool oil seal puller on the crankshaft. Attach the accompanying center bolt to the special tool oil seal puller and tighten it. Pull out the front oil seal. SAPH311990900048 Installation of front oil seal Guide...
  • Page 920 9–20 ENGINE MECHANICAL Replacement of crankshaft rear oil seal JP31199090704005 Removal of rear oil seal Install the plate of the special tool oil seal puller on the crankshaft using two flywheel assembly mounting bolts. Special tool : 09420–1742 Oil seal puller •...
  • Page 921 9–21 ENGINE MECHANICAL Remove contamination from the joint surface of the rear oil seal and the flywheel housing Apply small amount of engine oil to the seal area of the rear oil seal. Install the oil seal press guide inserting a new rear oil seal with accompanying guide bolts on the crankshaft.
  • Page 922 9–22 ENGINE MECHANICAL Main Moving Parts Part layout JP31199090402004 SAPH311990900059 11011 Thrust bearing 13260 Connecting rod assembly 11701 Main bearing 13271 Connecting rod bush 11703 Main bearing US 0.25 13411 Crankshaft 11704 Main bearing US 0.50 13450 Flywheel assembly 13005 Piston, Piston ring set 13453 Ring gear...
  • Page 923 9–23 ENGINE MECHANICAL Replacement of piston and connecting rod JP31199090702005 Removal of piston Figure is an Remove bolts and remove the connecting rod cap. example of work. • Insert a large flat tip screwdriver into the ! CAUTION flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft.
  • Page 924 9–24 ENGINE MECHANICAL Disassembly of piston and connecting rod Remove the retainer ring using snap ring pliers. Remove the piston pin using the brass bar and disconnect the piston from the connecting rod. SAPH311990900064 Remove the piston ring using a special tool. Special tool : 09442–1011 Piston ring expander •...
  • Page 925 9–25 ENGINE MECHANICAL Face the side with the piston ring identification print upward and install in the order of the oil ring, second ring and top ring using a special tool. • The identification print is present only on the NOTICE secondary ring and the top and bottom of the top ring and the oil ring are not identified.
  • Page 926 9–26 ENGINE MECHANICAL Insert the piston carefully so that the connecting rod may not come in contact with the cooling jet. • Face the "0" mark on the piston toward the ! CAUTION exhaust side for insertion. • Set the crankshaft of the cylinder as the top dead center for assembly.
  • Page 927 9–27 ENGINE MECHANICAL Tighten the connecting rod bolt and mark the bolt head in the same direction with paint. Paint mark Tightening torque : 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft} Connecting rod cap (10) Retighten the connecting rod bolt 90 °. (11) Retighten the connecting rod bolt further 45 °.
  • Page 928 9–28 ENGINE MECHANICAL Measure the piston ring groove using a thickness gauge. If it is out of the service limit, replace the piston. Standard value Service limit (mm{in.}) (mm{in.}) Top ring groove 2.5{0.0984} 2.70{0.1063} Second ring groove 2{0.0787} 2.20{0.0866} Oil ring groove 4{0.1575} 4.10{0.1614} SAPH311990900078...
  • Page 929 9–29 ENGINE MECHANICAL Replacement of connecting rod bushing JP31199090704006 Removal of connecting rod bushing Press Put the special tool press sub-assembly together with the Sub-assembly Wing nut special tool guide nut and fix them using the special tool wing nut. Guide Special tool : 09481–1130 Guide 09402–1530 Press sub-assembly...
  • Page 930 9–30 ENGINE MECHANICAL Chamfer one side of the connecting rod small end uniformly according to the figure. Chamfer • Remove burr completely. ! CAUTION • After chamfering, remove dirt from the inner surface at the small end and from the oil hole. SAPH311990900086 Installation of connecting rod bushing Install a new bushing on the special tool spindle and...
  • Page 931 9–31 ENGINE MECHANICAL Replacement of crankshaft JP31199090704007 Removal of crankshaft Remove the main bearing cap and the main shaft bearing. Remove the crankshaft using a hoist. • Since the part is heavy, be careful for ! CAUTION handling. • Store removed main bearing caps and main bearings for each cylinder number.
  • Page 932 9–32 ENGINE MECHANICAL Measure the underhead length of the bearing cap bolt using a vernier calipers. If it is out of the service limit, replace it with a new one. Service limit (mm{in.}) 108{4.252} Underhead length SAPH311990900073 Apply engine oil to the bolt seat and the bolt thread of the bearing cap bolt.
  • Page 933 9–33 ENGINE MECHANICAL Inspection of crankshaft JP31199090703002 Inspection of end play Measure the end play of the crankshaft using a dial gauge. If it is beyond the repair limit, replace the thrust bearing. If it is beyond the service limit, replace the crankshaft.
  • Page 934 9–34 ENGINE MECHANICAL Measure the crankshaft center journal width using a vernier calipers. If it is out of the service limit, replace the Figure is an example of work. crankshaft. Standard value (mm{in.}) Service limit (mm{in.}) 36{1.4173} 37.0{1.4567} SAPH311990900098 Inspection of crankshaft oil clearance Measure the outer diameter of the crankshaft journal using a micrometer.
  • Page 935 9–35 ENGINE MECHANICAL Dimension of fillet "R" Crank pin Radius is 2.5 to 3.0mm {0.0984 to 0.1181 in.} Radius is incomplete. Step Step small. Journal 2.5 to 3.0mm {0.0984 to 0.1181 in.} Good Poor SAPH311990900101 Inspection of crack and damage on crankshaft and of oil Figure is an hole example of work.
  • Page 936 9–36 ENGINE MECHANICAL Replacement procedure item Replacement of crankshaft pulley JP31199090704008 Removal of crankshaft pulley Remove bolts and remove the crankshaft pulley. • Insert a large flat tip screwdriver into the NOTICE flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft.
  • Page 937 9–37 ENGINE MECHANICAL Removal of ring gear Heat the entire ring gear circumference with a burner until it is about 200 °C(392°F). • Do not touch the ring gear and the flywheel ! CAUTION with bare hand while they are hot. SAPH311990900109 Hit the circumference of the ring gear gently using a backing rod to remove the ring gear from the flywheel.
  • Page 938 9–38 ENGINE MECHANICAL Installation of flywheel Make sure that there is no burr or dirt on the joint surface of the crankshaft and the flywheel and the screw hole. Install the special tool into the bolt hole of the crankshaft. Special tool : 09481–1340 Guide •...
  • Page 939 9–39 ENGINE MECHANICAL Camshaft and Idle Gear Part layout JP31199090402005 SAPH311990900117 13501 Camshaft assembly 13572B Idle gear thrust plate 13505 Cam idle gear 13581 Idle gear shaft 13505A Sub-idle gear 13581A Idle gear shaft 13505B Main idle gear 13581B Idle gear shaft 13520 Camshaft gear 9867A...
  • Page 940 9–40 ENGINE MECHANICAL Removal of camshaft JP31199090702006 Removal of rocker arm and camshaft assembly Loosen the lock nut and turn the adjusting screw completely. Rock nut • Removal without turning the adjusting screw ! CAUTION may bend the rocker shaft. SAPH311990900118 Loosen the rocker arm support bolts gradually from the center and remove the rocker arm and the rocker arm...
  • Page 941 9–41 ENGINE MECHANICAL Inspection of camshaft and camshaft bearing JP31199090702008 Inspection of cam height on camshaft Measure the cam height using a micrometer. If it is beyond the service limit, replace the camshaft. Standard value Service limit (mm{in.}) (mm{in.}) 50.067{1.9711} 49.987{1.9680} height 52.104{2.0513}...
  • Page 942 9–42 ENGINE MECHANICAL Assembly of camshaft JP31199090702009 Measure the camshaft mounting bolt using a vernier calipers. If it is out of the service limit, replace it with a new one. Service limit (mm{in.}) 31{1.2205} Underhead length SAPH311990900124 Fix the camshaft gear using a vice. Apply engine oil to the seat and the bolt thread of the camshaft gear mounting bolt.
  • Page 943 9–43 ENGINE MECHANICAL Installation of camshaft JP31199090702010 Align the No. 1 cylinder to the compression top dead center. Installation of camshaft and rocker arm. Place the camshaft so that two holes at 180 degrees from the three drilled holes of the camshaft gear may be Timing decision drill hole horizontal to the upper surface of the camshaft housing.
  • Page 944 9–44 ENGINE MECHANICAL Apply engine oil to the cam threads and set the rocker arm in position, making sure it is correctly laid on the crosshead. Then, tighten the bolts in the sequence shown in the figure, making several passes and gradually tightening them each time.
  • Page 945 9–45 ENGINE MECHANICAL Gear train layout JP31199090402006 SAPH311990900130 Service procedure Overhaul item Removal of timing gear JP31199090702011 Removal of main idle gear Remove the idle gear shaft mounting bolt and pull out the main idle gear assembly using a special tool. Special tool : 09420–1100 Sliding hammer 09420–1442 Sliding hammer Remove the idle gear thrust plate.
  • Page 946 9–46 ENGINE MECHANICAL Removal of sub-idle gear Remove the idle gear shaft mounting bolt and the idle gear thrust plate and pull out the sub-idle gear assembly using a special tool. Special tool : 09420–1100 Sliding hammer 09420–1442 Sliding hammer Remove the idle gear thrust plate.
  • Page 947 9–47 ENGINE MECHANICAL Installation of timing gear JP31199090702013 Installation of sub-idle gear Install the idle gear shaft on the sub-idle gear. Thrust plate Install the idle gear thrust plate. Provide the lubricating hole of the idle gear shaft in the vertical direction.
  • Page 948 9–48 ENGINE MECHANICAL Face the lubricating hole of the idle gear shaft toward the oil pan (downward). Install A in the figure by adjusting the timing of the crankshaft gear and the main idle gear as in Sub-idle gear the detailed drawing. Oil pump gear Main idle gear...
  • Page 949 9–49 ENGINE MECHANICAL Overhaul of sub-idle gear (bearing case side) JP31199090702014 Removal of bearing case assembly Remove the supply pump. "Reference : Replacement, Supply pump". Disconnect the bearing case assembly. • One bolt is tightened from the timing gear ! CAUTION case.
  • Page 950 9–50 ENGINE MECHANICAL Inspection of clearance between sub-idle gear shaft and sub-idle gear bushing Measure the outer diameter of the idle gear shaft. SAPH311990900142 Measure the inner diameter of the sub-idle gear. Calculate the clearance. If it is beyond the standard value, replace the shaft and the bushing.
  • Page 951 9–51 ENGINE MECHANICAL Inspection of installation status for each gear JP31199090703003 Inspection of backlash between camshaft gear and cam idle gear Insert a large flat tip screwdriver into the cam idle gear from the side of the camshaft gear of the camshaft housing to prevent turning of the cam idle gear.
  • Page 952 9–52 ENGINE MECHANICAL Measure backlash between the main idle gear and the air compressor idle gear using a dial gauge and a magnet stand. If it is beyond the service limit, replace each gear. • If the magnet stand is not stable, provide a NOTICE steel plate for measurement using bolt holes of the cylinder block.
  • Page 953 9–53 ENGINE MECHANICAL Inspection of backlash between sub-idle gear at cam idle gear and oil pump gear Insert a large flat tip screwdriver into the sub-idle gear to prevent turning of the sub-idle gear. SAPH311990900154 Measure backlash between the sub-idle gear and the oil pump gear using a dial gauge and a magnet stand.
  • Page 954 9–54 ENGINE MECHANICAL Measure backlash between the cam idle gear and the sub-idle gear using a dial gauge. If it is beyond the service limit, replace each gear. Standard value (mm{in.}) Service limit (mm{in.}) 0.050 - 0.218 0.30{0.0118} {0.0020 - 0.0086} Setup layout Layout SAPH311990900158...
  • Page 955 9–55 ENGINE MECHANICAL Valve System Part layout JP31199090402007 SAPH311990900159 13706 Crosshead assembly 13735 Valve spring upper seat 13709 Adjusting screw (rocker arm) 13787 Adjusting screw (cross head) 13711 Intake valve 13830 Rocker arm intake 13715 Exhaust valve 13840 Rocker arm (exhaust) 13719 Valve stem seal* 13901...
  • Page 956 9–56 ENGINE MECHANICAL Overhaul of valve system JP31199090702015 Inspection of rocker arm oil clearance Measure the outer diameter of the rocker shaft using a micrometer. Standard value (mm{in.}) Service limit (mm{in.}) 22{0.8661} 21.92{0.8630} Measure the rocker arm bushing inner diameter using a cylinder gauge.
  • Page 957 9–57 ENGINE MECHANICAL Replacement of valve stem seal Valve stem seal Special tool After removing the valve stem seal, assemble the valve spring lower seat. Apply engine oil to the lip and the inner Valve spring lower seat surface of the valve stem seal. Strike the valve guide using a special tool until the special tool comes in contact with the valve spring lower sea Special tool : 09472–2100 Bar...
  • Page 958 9–58 ENGINE MECHANICAL Inspection of valve spring Clearance A Measure squareness of the valve spring using a square or a thickness gauge. If it is beyond the service limit (clearance A), replace the valve spring. Clearance A (mm{in.}) 2.0{0.0787} SAPH311990900166 Measure the free length of the valve spring using a vernier calipers.
  • Page 959 9–59 ENGINE MECHANICAL Attachment procedure item Adjustment of valve clearance JP31199090706001 Precautions before adjustment • Before adjustment, make sure that bolts of ! CAUTION the cylinder head, rocker arm support, nozzle clamp, camshaft housing and camshaft bearing cap are tightened to the specified torque.
  • Page 960 9–60 ENGINE MECHANICAL Tighten the adjusting screw of the crosshead until the thickness gauge does not move. Close contact Close contact SAPH311990900173 While loosening the adjusting screw of the crosshead gradually, tighten the lock nut of the crosshead at the Start position where feel on the thickness gauge is appropriate.
  • Page 961 10–1 EXHAUST ENGINE 10 EXHAUST Setup layout Layout Exhaust Manifold............10-2 Part layout ............10-2 Replacement............10-3...
  • Page 962 10–2 EXHAUST Exhaust Manifold Part layout JP31199100402001 SAPH311991000001 17104 Gasket* 17141 Exhaust manifold *Parts not to be reused. Tightening torque 9209A 53 N⋅m {540 kgf⋅cm, 40lbf⋅ft} Service procedure Replacement procedure item...
  • Page 963 10–3 EXHAUST Replacement JP31199100704001 Removal of exhaust manifold Remove nuts and remove the exhaust manifold. Replacement of stud bolt Remove dirt (e.g. sealant) at the female thread of the cylinder head and clean the thread again with tap (M10 x 1.5).
  • Page 965 11–1 COOLING ENGINE 11 COOLING System drawing System drawing Cooling System ............11-2 Cooling system drawing........11-2 Part layout ............. 11-3 Replacement of thermostat case ......11-5 Inspection of thermostat ........11-6 Replacement of coolant pump ......11-7...
  • Page 966 11–2 COOLING Cooling System Cooling system drawing JP31199110803001 Reservoir Water temperature EGR cooler Thermostat case Cylinder head compressor Thermostat Cylinder block Turbo charger valve heater Oil cooler Coolant pump Drain cock Drain cock SAPH311991100001 Setup layout Layout...
  • Page 967 11–3 COOLING Part layout JP31199110402001 SAPH311991100002 16100 Coolant pump assembly 16323 Thermostat case cover 16173 coolant pump pulley 16325 Gasket* 16301 Thermostat case 9851A O–ring* 16302 Thermostat case cover *Parts not to be reused.
  • Page 968 11–4 COOLING SAPH311991100003 16100 Coolant pump assembly 16323 Thermostat case cover 16173 Coolant pump pulley 16325 Gasket* 16302 Thermostat case cover 16377 Fan spacer 16303 Thermostat case 9851A O–ring* 16306 Cooling fan *Parts not to be reused. Service procedure Replacement procedure item...
  • Page 969 11–5 COOLING Replacement of thermostat case JP31199110704001 Removal of thermostat case Remove the EGR cooler. Refer to "Inspection of EGR cooler, Emission control". Remove bolts and remove the thermostat case. Remove the O-ring from the groove on the coolant pump. SAPH311991100004 Installation of thermostat case Remove contamination on the joint between the...
  • Page 970 11–6 COOLING Inspection of thermostat JP31199110703001 Individual inspection of thermostat Wire Thermometer Put the thermostat in water as shown in the figure and heat it. • Support the thermostat in the center to ! CAUTION prevent approach to the heat source. •...
  • Page 971 11–7 COOLING Replacement of coolant pump JP31199110704002 Removal of coolant pump Remove bolts and remove the coolant pump. SAPH311991100010 Installation of coolant pump Liquid gasket Remove contamination on the joint surface between the coolant pump and the cylinder block using a scraper and degrease the surface.
  • Page 973 12–1 LUBRICATION ENGINE 12 LUBRICATION System drawing System drawing Oil Cooler, Oil Filter and Oil Pump......12-2 System drawing ............ 12-2 Part layout ............12-3 Replacement of oil cooler ........12-5 Overhaul of oil cooler ..........12-6 Replacement of oil pump ........12-9 Overhaul of oil pump...........
  • Page 974 12–2 LUBRICATION Oil Cooler, Oil Filter and Oil Pump System drawing JP31199120805001 Roller pin Roller Rocker Adjusting Valve Crosshead Rocker arm screw shaft Camshaft Cam idle gear shaft Sub-idle gear shaft Turbocharger Main Oil pump Oil filter Oil cooler oil hole Connecting Piston pin Crankshaft...
  • Page 975 12–3 LUBRICATION Part layout JP31199120402001 SAPH311991200002 15012 Oil pump cover assembly 15710 Oil cooler 15104 Oil strainer 9500-40400 Cotter pin* 15107 Driven gear 9851A O–ring* 15110 Oil pump assembly 9851B D–ring* 15119 Gasket* 15139 Seat2 15132 Relief valve spring 15139A Seat1 15135 Safety valve...
  • Page 976 12–4 LUBRICATION SAPH311991200003 15662 Drain plug 15720 Oil cooler case assembly 15675 Safety valve 9851A O–ring* 15701 Oil cooler case 9851B O–ring* 15710 Oil cooler assembly 9851C O–ring* 15712 Oil cooler element 9851D O–ring* 15717 Gasket* 9851E O–ring* *Parts not to be reused. Tightening torque 15662 44.1±4.9 N⋅m {450±50 kgf⋅cm, 33±4llbf⋅ft} 9201-10080...
  • Page 977 12–5 LUBRICATION Replacement of oil cooler JP31199120704001 Removal of oil cooler Remove bolts and remove the oil cooler. SAPH311991200004 If it is difficult to remove the oil cooler due to liquid gasket Figure is an sticking to the cylinder block, put a flat tip screwdriver at example of work.
  • Page 978 12–6 LUBRICATION Insert the positioning stud into the screw hole of the cylinder block and install the oil cooler. After temporary tightening with bolts, remove the positioning stud and tighten bolts. Tightening torque : 24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} •...
  • Page 979 12–7 LUBRICATION Remove the oil pressure warning switch. SAPH311991200012 Inspection of safety valve wear and damage If wear or damage is found, replace it. SAPH311991200013 Inspection of oil pressure warning switch For inspection of oil pressure warning switch, refer to "Inspection of components"- "Electrical".
  • Page 980 12–8 LUBRICATION Installation of oil cooler element Assemble new gasket and new O-ring and assemble the oil cooler element with nuts. Tightening torque : 24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} • In handling the oil cooler element, be careful ! CAUTION not to give damage to it.
  • Page 981 12–9 LUBRICATION Replacement of oil pump JP31199120704002 Removal of oil pump Dismount the engine from the machine. Remove the flywheel. Remove the flywheel housing. Remove the timing gear. Remove the oil pump. Installation of oil pump Apply engine oil to the pump case and the bearing (shaded area) of the cylinder block.
  • Page 982 12–10 LUBRICATION Overhaul of oil pump JP31199120702002 Remove the driven gear. SAPH311991200016 Remove the cotter pin and remove seat 2, seat 1, relief valve spring and safety valve. • When the cotter pin is removed, seat 2 and ! CAUTION the relief valve spring may eject out.
  • Page 983 12–11 LUBRICATION End play inspection between drive gear and cylinder block Measure the drive gear width and the pump chamber depth at the cylinder block using a depth gauge. Standard value Measuring area (mm{in.}) Width of drive gear 28.5{1.1220} Depth of pump chamber at 28.5{1.1220} cylinder block SAPH311991200020...
  • Page 984 12–12 LUBRICATION Inspection of clearance betweeen outer diameter of driven gear shaft and inner diameter of driven gear bushing Measure the outer diameter of the driven gear shaft using a micrometer and measure the inner diameter of the driven gear bushing using a cylinder gauge. Standard value Measuring area (mm{in.})
  • Page 985 12–13 LUBRICATION Inspection of drive gear backlash Fix the oil pump assembly with a vice. Measure backlash between the drive gear and the driven gear using a dial gauge. If it is beyond the service limit, replace the oil pump assembly. Standard value (mm{in.}) Service limit (mm{in.}) 0.072 - 0.277...
  • Page 986 12–14 LUBRICATION Oil Pan Part layout JP31199120402003 SAPH311991200029 12101 Oil pan assembly 12149 Drain plug 12151 Oil pan gasket* 9659A Gasket* *Parts not to be reused. Tightening torque 12149 30 N⋅m {300 kgf⋅cm, 22lbf⋅ft} 9068-08800 30 N⋅m {300 kgf⋅cm, 22lbf⋅ft} Service procedure Replacement procedure item...
  • Page 987 12–15 LUBRICATION Replacement JP31199120704004 Installation of oil pan Cut the gasket of the rear end plate to be flush to the cylinder block lower surface using a scraper. Make sure that there is no deformation, dirt or oil on the joint surface between the cylinder block and the oil pan.
  • Page 988 12–16 LUBRICATION Inspection of lubrication status JP31199120703001 Inspection of valve system • Perform inspection with the water ! CAUTION temperature at 60 °C{140°F}. Remove the head cover. • To prevent spread of engine oil, attach a jig ! CAUTION which cuts a head cover in half. Cut it to the degree that the camshaft is covered.
  • Page 989 13–1 STARTING AND CHARGING ENGINE 13 STARTING AND CHARGING Setup layout Layout Starter................ 13-2 Part layout (typical example)......... 13-2 Disassembly............13-3 Inspection of components ........13-9 Assembly ............13-14 Alternator (50A) ............13-21 Part layout (typical example of 50A) ....13-21 Circuit drawing (50A) ..........
  • Page 990 13–2 STARTING AND CHARGING Starter Part layout (typical example) JP31199130402001 SAPH311991300001 28011 Clutch assembly 28138 Packing* 28100 Starter 28140 Brush holder assembly 28111 Bushing 28142 Brush 28111A Bushing 28142A Brush 28113 Lever assembly 28143 Spring 28115 Start drive housing 28150 Center bracket 28117 Packing*...
  • Page 991 13–3 STARTING AND CHARGING Disassembly JP31199130702001 • Fix the starter on the working table to ease NOTICE M lead wire accessibility. M terminal MRemoval of lead wire Remove the cap of the M terminal. Remove nuts and remove the M lead wire. SAPH311991300002 Removal of commutator end frame Loosen and remove two through bolts.
  • Page 992 13–4 STARTING AND CHARGING Removal of brush holder assembly Brush holder Lift the spring using a flat tip screwdriver or pliers. Assembly Remove four brushes from the brush holder assembly. • Do not cut the brush lead fixing clamp. ! CAUTION Remove the brush holder assembly from the armature assembly.
  • Page 993 13–5 STARTING AND CHARGING Removal of armature assembly Remove the armature assembly by lifting. Armature • When the armature assembly is removed, the assembly ! CAUTION washer at the end of the gear may be dropped and lost. Be careful for handling. Center bracket assembly SAPH311991300008...
  • Page 994 13–6 STARTING AND CHARGING 10. Removal of internal gear Remove the internal gear from the center bracket. • Make sure that the gear is not damaged or ! CAUTION chipped. Internal gear Center bracket SAPH311991300012 11. Removal of shim washer Remove the shim washer from the center bracket.
  • Page 995 13–7 STARTING AND CHARGING 13. Removal of center bracket Center bracket Remove two set bolts at the switch using a box screwdriver or offset wrench. Lift and remove the center bracket. Clutch assembly SAPH311991300016 14. Removal of lever Hold the lever holder and press the entire lever to the clutch.
  • Page 996 13–8 STARTING AND CHARGING 15. Removal of brake plate Hold the clutch case outer diameter and slide the clutch assembly upward. Pinch the clip end fixing the brake plate and remove it by bending. SAPH311991300019 Remove the brake plate. Brake plate SAPH311991300020 16.
  • Page 997 13–9 STARTING AND CHARGING 18. Removal of packing Turn the center bracket upside down again and remove the packing. • Packing must not be reused. ! CAUTION Packing SAPH311991300023 Inspection procedure item Inspection of components JP31199130703001 Inspection of yoke assembly Make sure that the coil lead wire has electric continuity using a circuit tester.
  • Page 998 13–10 STARTING AND CHARGING Inspection of armature assembly Turn the armature assembly using a commercially Piece of steel available growler tester and put a piece of steel on the armature assembly. Make sure that the steel piece is not vibrating on the core circumference. Growler tester SAPH311991300027 Make sure that adjacent segments of the commutator...
  • Page 999 13–11 STARTING AND CHARGING Measure the undercut depth between segments. If the undercut depth is beyond the service limit, repair it. Standard value (mm{in.}) Service limit (mm{in.}) Undercut length: 0.5 - 0.8{0.0197 - 0.0315} 0.2{0.0079} or less 0.5 to 0.8 mm Segment {0.0197 - 0.0315} •...
  • Page 1000 13–12 STARTING AND CHARGING Inspection of shaft assembly Measure the outer diameter of the shaft using a micrometer If it is beyond the service limit, replace the shaft. Standard value Service limit Measuring area (mm{in.}) (mm{in.}) 25.90{1.0197} or Area 26{1.0236} less SAPH311991300035 12.04{0.4740} or...
  • Page 1001 13–13 STARTING AND CHARGING Measure the bearing metal inner diameter (3 in the figure) of the shaft assembly using a cylinder gauge. If it is beyond the service limit, replace the shaft assembly. Standard value (mm{in.}) Service limit (mm{in.}) 9{0.3543} 9.2{3.6220} Measure the bearing housing inner diameter (4 in the figure) of the commutator end frame using a cylinder...
  • Page 1002 13–14 STARTING AND CHARGING Push the end of the start magnet switch assembly (close the internal contact) and make sure that there is electric continuity between the B terminal and the M terminal using a circuit tester. SAPH311991300043 Overhaul item Assembly JP31199130702002 Installation of packing...
  • Page 1003 13–15 STARTING AND CHARGING Installation of brake plate Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the brake plate. Brake plate SAPH311991300045 Installation of lever Lubricate parts (refer to the lubrication point drawing and the lubrication list).
  • Page 1004 13–16 STARTING AND CHARGING Install the retainer clip using a tool such as snap ring pliers. Retainer clip Pinion stopper Pinion SAPH311991300014 Installation of shim washer Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the shim washer on the center bracket.
  • Page 1005 13–17 STARTING AND CHARGING 11. Installation of cover Install a new packing. Packing Cover Install the cover on the center bracket assembly. SAPH311991300010 12. Installation of rear bearing Install the bearing on the armature assembly using a press. • When the bearing is removed, replace it with ! CAUTION a new one.
  • Page 1006 13–18 STARTING AND CHARGING 16. Installation of brush holder assembly Brush holder Lift the spring using a flat tip screwdriver, long-nose pliers Assembly or pliers. Install four brushes on the brush holder assembly. Spring Brush Brush lead Clamp SAPH311991300005 17. Installation of commutator end frame Tighten the through bolt of the commutator end frame.
  • Page 1007 13–19 STARTING AND CHARGING 18. Installation of lead wire M lead wire Install the M lead wire. M terminal SAPH311991300002 19. Lubrication Refer to the following figure and table for lubricant to be applied. • There shall be no lubricant on the commutator surface, brush and contact. ! CAUTION SAPH311991300046...

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