Hyundai Robex 140LS SMART Service Manual
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Hyundai Robex 140LS SMART Service Manual

Hyundai Robex 140LS SMART Service Manual

Hydraulic excavator
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Summary of Contents for Hyundai Robex 140LS SMART

  • Page 1 140LS...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ------------------------------------------------------------------------------------------------------ 1-10 SECTION 2 STRUCTURE AND FUNCTION SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------- 2-1 Group 2 Main Control Valve ---------------------------------------------------------------------------------------------- 2-20 Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-43 Group 4 Travel Device ------------------------------------------------------------------------------------------------------- 2-55 Group 5 RCV Lever ----------------------------------------------------------------------------------------------------------- 2-80...
  • Page 3 Group 8 Anti-Restart System -------------------------------------------------------------------------------------------- 5-10 Group 9 Self-Diagnostic System --------------------------------------------------------------------------------------- 5-11 Group 10 Engine Control System ------------------------------------------------------------------------------------- 5-14 Group 11 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-20 Group 12 Monitoring System --------------------------------------------------------------------------------------------- 5-23 SECTION 6 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING Group 1 Before trobleshooting ----------------------------------------------------------------------------------------- 6-1 Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4 Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24 Group 4 Mechatronics System --------------------------------------------------------------------------------------- 6-39...
  • Page 4 SECTION 9 COMPONENT MOUNTING TORQUE SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide ----------------------------------------------------------------------------------------------- 9-1 Group 2 Engine system ---------------------------------------------------------------------------------------------------- 9-2 Group 3 Electric system ---------------------------------------------------------------------------------------------------- 9-4 Group 4 Hydraulic system ------------------------------------------------------------------------------------------------ 9-6 Group 5 Undercarriage ----------------------------------------------------------------------------------------------------- 9-9 Group 6 Structure -------------------------------------------------------------------------------------------------------------- 9-10 Group 7 Work equipment -------------------------------------------------------------------------------------------------- 9-14...
  • Page 5 This section shows bolt specifications and standard torque values needed when mounting components to the machine. The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 6 Revised edition mark( Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.

  • Page 7: Conversion Table

    3. CONVERSION TABLE 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Example Method of using the Conversion Table to convert from millimeters to inches...
  • Page 8 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
  • Page 9 Liter to U.S. Gallon Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454...
  • Page 10 kgf m to to lbf lbf ft ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2...
  • Page 11 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
  • Page 12 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 13: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...
  • Page 14 SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.

  • Page 15: Prepare For Emergencies

    PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...

  • Page 16: Move And Operate Machine Safely

    KEEP RIDERS OFF EXCAVATOR KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.

  • Page 17: Support Machine Properly

    SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under 13031GE10 continuous load.

  • Page 18: Beware Of Exhaust Fumes

    BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

  • Page 19: Stay Clear Of Moving Parts

    SERVICE MACHINE SAFELY SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

  • Page 20: Prevent Battery Explosions

    AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

  • Page 21: Prevent Acid Burns

    PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.

  • Page 22: Replace Safety Signs

    DISPOSE OF FLUIDS PROPERLY DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 23: Group 2 Specifications

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Tool box Fuel tank Hydraulic tank Main pump Engine Radiator Oil cooler Turning joint Tooth Swing motor Bucket Main control valve Arm cylinder Boom Boom cylinder Muffler Counterweight R140LSLS Swing bearing Bucket cylinder...
  • Page 24 2. SPEC SPECIFICA IFICATIO TIONS 1) R140LS ·4.60 m (15' 4.60 m (15' 1") BOOM and 2.10 m (6' 11") ARM 1") BOOM nd 2.10 m (6' 11") ARM I(I') R140LS B(L) 140D92SP02 Description Unit Specification Operating weight kg (lb) 13980 (30820) Bucket capacity (SAE heaped), standard 0.65 (0.85)
  • Page 25 3. 3. WORKING RANGE WORKING RANGE R140LSLS 1) 1) (1) (1) 4.60 4.60 m (15' 1") MONO (15' 1") MONO BOOM BOOM 14092SP06 Description 2.10 m (6' 11") Arm Max digging reach 7920 mm (25'11") Max digging reach on ground 7780 mm (25' 6") Max digging depth 5200 mm (17' 1")
  • Page 26 4. WEI WEIGHT 1) R140LSL R140LS Item Upper structure assembly 5630 12420 Main frame weld assembly 1120 2470 Engine assembly 1210 Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 1900 4190 Cab assembly Lower chassis assembly...
  • Page 27 5. LIFTIN G CAPA A CIT CITIES LIFTING CAP 1-14...
  • Page 31 6. B B UCKET SELE UCKET SELECTION GUIDE CTION GUIDE 1) R140LSLS Gener neral al b bu u c c k k e e t t 0.52 m 0.65 m 0.72 m heaped bucket heaped bucket heaped bucket 1-15...
  • Page 32 7. UNDERCARRIAGE 7. UNDERCARRIAGE 1) 1) TRACKS TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. 2) 2) TYPES OF SHOES TYPES OF SHOES...
  • Page 33 4) 4) SELECTION OF TRACK SHOE SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Method of selecting shoes Confirm the category from the list of applications in table table 2 2, then use table table 1 1 to select the shoe.
  • Page 34 8. SPECIFICATIONS FOR MAJOR COMPONENTS 8. SPECIFICATIONS FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification HM4.2 Model Type 4-cycle turbocharged diesel engine Cooling method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type Cylinder bore stroke 105 120 mm...

  • Page 35: Main Control Valve

    3) 3) GEAR PUMP GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 35 kgf/cm (500 psi) Rated oil flow 27.75 /min (7.3 U.S. gpm / 6.1 U.K. gpm) 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification...
  • Page 36 7) 7) CYLINDER CYLINDER Item Specification Bore dia Rod dia Stroke 75 1075 mm Boom cylinder Cushion Extend only Bore dia Rod dia Stroke 80 1138 mm Arm cylinder Cushion Extend and retract Bore dia Rod dia Stroke 70 840 mm Bucket cylinder Cushion Extend only...

  • Page 37: Recommended Oils

    9. RECOMMENDED OILS 9. RECOMMENDED OILS Use only oils listed below or equivalent. Use only oils listed below or equivalent. Do not mix different brand oil. Do not mix different brand oil. Ambient temperature C ( F) Capacity Service point Kind of fluid (U.S.

  • Page 38: Section 2 Structure And Function

    SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device Group 2 Main Control Valve 2-20 Group 3 Swing Device 2-43 Group 4 Travel Device 2-55 Group 5 RCV Lever 2-80 Group 6 RCV Pedal 2-87...
  • Page 39 SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. Port Port name Port size A1,2 Delivery port SAE6000psi 3/4" Suction port SAE2500psi 2 1/2" Drain port PF 1/2 - 19 Pn1,n2 Pilot port PF 1/4 - 15...
  • Page 40 MAIN PUMP(1/2) The main pump consists of two piston pumps(front & rear) and valve block. 789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113 153 156 124 312 114 466 885 467 141 981 271 401 04 Gear pump 261 Seal cover(F)
  • Page 41 REGULATOR(1/2) Port Port name port size Delivery port 3/4" Suction port 2 1/2" Pilot port PF 1/4-15 Qmax cut port PF 1/4-15...
  • Page 42 REGULATOR(2/2) 651 652 SECTION A-A 412 Hexagon socket screw 631 Sleeve, pf 730 O-ring 413 Hexagon socket screw 641 Pilot cover 732 O-ring 436 Hexagon socket screw 642 Pilot cover(QMC) 733 O-ring 438 Hexagon socket screw 643 Pilot piston 734 O-ring 735 O-ring 496 Plug 644 Spring seat(Q)
  • Page 43 GEAR PUMP 354 351 466, 725 307 Poppet 353 Drive gear 466 Plug 308 Seat 354 Driven gear 700 Ring 309 Spring seat 355 Filter 710 O-ring 310 Spring 361 Front case 725 O-ring 311 Screw 433 Flange socket 732 O-ring 312 Nut 434 Flange socket 850 Snap ring...
  • Page 44 2. FUNCTION MAIN PUMP The pumps may classified roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: the swash plate group that varies the delivery rates: and the valve cover group that changes over oil suction and discharge. Rotary group The rotary group consists of drive shaft (F)(111), cylinder block(141), piston...
  • Page 45 Valve block group The valve block group consists of valve block(312), valve plate(313) and valve plate pin(885). The valve plate having two melon-shaped ports is fixed to the valve block and feeds and collects oil to and from the cylinder block.
  • Page 46 REGULATOR Regulator consists of the negative flow control, total horse power control and power shift control function. Negative flow control By changing the pilot pressure Pn, the pump tilting angle(delivery flow) is regulated arbitrarily, as shown in the figure. This regulator is of the negative flow control in which the delivery flow Q decreases as the pilot pressure Pn rises.
  • Page 47 Flow reducing function B(E) Small diameter Servo piston Large diameter chamber chamber As the pilot pressure Pn rises, the pilot piston(643) moves to the right to a position where the force of the pilot spring(646) balances with the hydraulic force. The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613).
  • Page 48 Flow increasing function B(E) Small diameter Servo piston chamber Large diameter chamber As the pilot pressure Pn decreases, the pilot piston(643) moves to the left by the action of the pilot spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897) is pressed against the large hole section(C) of lever 2 by the action of the return spring(654) via the spool(652), pin(874), and feedback lever(611), the feedback lever rotates...
  • Page 49 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut(801) and by tightening(or loosening) the hexagonal socket head screw(924). Tightening the screw shifts the control chart to the right as shown in the figure. Adjusting values are shown in table.
  • Page 50 Total horsepower control The regulator decreases the pump tilting angle(delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump. (The input horsepower is constant when the speed is constant.) Since the regulator is of the simultaneous...
  • Page 51 Overload preventive function B(E) Large diameter Servo piston Small diameter chamber chamber When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston(621). It presses the compensating rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with the hydraulic force.
  • Page 52 Flow reset function B(E) Large diameter Small diameter chamber chamber Servo piston As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever 1(612) around point E.
  • Page 53 Low tilting angle(Low flow) command preferential function As mentioned above, flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However, since sections C and F have the pins( 4) protruding from the large hole( 8), only the lever lessening the tilting angle contacts the pin(897) ;...
  • Page 54 Adjustment of inner spring Adjust it by loosening the hexagon nut (801) and by tightening(or loosening) the adjusting screw QI(925). Tightening the screw increases the flow and then the input horsepower as shown in the figure. Adjusting valves are shown in table Adjustment of inner spring Speed Tightening...
  • Page 55 Power shift control B(E) Large diameter Small diameter chamber chamber Servo piston The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one proportional pressure reducing valve is provided. However, the secondary pressure Pf (power shift pressure) is admitted to the horsepower control section of each...
  • Page 56 Adjustment of maximum and minimum Adjust it by loosening the hexagon nut(808) and by tightening(or loosening) the set screw(954). The maximum flow only is adjusted without changing other control characteristics. Adjustment of max flow Speed Tightening Flow change amount of amount adjusting screw (954)
  • Page 57 (5) Qmax cut control The regulator regulates the maximum delivery flow by inputting the pilot pressure Pm. Since this is a 2-position control method, the maximum delivery flow may be switched in two steps by turning on/off the pilot pressure Pm.(The maximum control flow cannot be controlled in intermediate level.)
  • Page 58 GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE Mark Port name Port size Tightening torque Make up for swing motor Travel left pilot port(FW) Travel left pilot port(BW) Travel right pilot port(BW) Travel right pilot port(FW) Pa20 Boom up pilot port Pa21 Boom up confluence pilot port Pb21...
  • Page 59 15 91 90 3 77 87 58 82 80 72 55 56 16,91 15 91 20 18 81 21 30,31 Housing-P2 Stopper-lock valve Housing-P1 Spool-regen selector Spool-straight travel Spring-regeneration Spool-travel 1-RH Stopper-regeneration Spool-travel 2-LH Piston-cut off Spool-swing Poppet-signal 73 78 Spool-boom1 Spring-signal 32,74...

  • Page 60: Hydraulic Circuit

    2. HYDRAULIC CIRCUIT OPTION-C OPTION-B BUCKET Pc42 Pc41 OPTION-A & Pc40 Pd40 REGENERATION ARM 1 Pd41 Pc42 BOOM 2 & SWING ARM 2 Pd41 Pa21 PRIORITY Pb21 Pb20 Pa20 SWING Pa21 BOOM 1 TRAVEL(LH) TRAVEL(RH) STRAIGHT TRAVEL BLOCK 140V92MC04 2-22...
  • Page 61 3. FUNCTION CONTROL IN NEUTRAL FUNCTION P1 SIDE Straight travel spool P2 port Tank port T1 P1 port P1 Bypass passage P1 Parallel passage SECTION A-A P1 Bypass passage TRAVEL STRAIGHT TRAVEL(RH) SWING BOOM 2 & SW PRIORITY ARM 1 OPTION-B OPTION-C Tank passage...
  • Page 62 P2 SIDE Straight travel spool P2 port Tank port T1 P2 Bypass passage P2 Parallel passage SECTION A-A P2 Bypass passage TRAVEL(LH) BOOM 1 ARM 2 ARM REGEN & OPTION-A BUCKET Tank passage P2 Negative relief valve P1 Negative relief valve SECTION B-B 1607A2MC11 The hydraulic fluid from pump A2 flows into the main control valve through the inlet port "P2", pass the...
  • Page 63 EACH SPOOL OPERATION TRAVEL OPERATION Travel forward operation P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT From RCV Tank passage P2 Bypass passage 1607A2MC17A Travel backward operation P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT From RCV Tank passage P2 Bypass passage 1607A2MC18A During the travel operation, the hydraulic fluid of the pump A2 is supplied to the travel motor and the...
  • Page 64 TRAVEL STRAIGHT FUNCTION P1 Parallel passage P2 port Orifice P1 Bypass passage Check valve Straight travel spool P1 port P2 Bypass passage P2 Parallel passage 1607A2MC19A This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm, bucket, swing) during a straight travel.

  • Page 65: Boom Operation

    BOOM OPERATION Boom up operation P2 Bypass passage Tank passage Holding valve Boom 1 spool From RCV Boom summation passage P2 Parallel passage Cylinder head side Cylinder rod side P1 Parallel passage Arm summation passage P1 Bypass passage Swing priority spool Boom 2 spool From RCV...
  • Page 66 Boom down operation P2 Bypass passage Tank passage Boom 1 spool Holding valve From RCV P2 Parallel passage Cylinder head side Cylinder rod side 1607A2MC26 During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 and shift the boom 1 spool in the right direction.

  • Page 67: Bucket Operation

    BUCKET OPERATION Bucket roll in operation P2 Bypass passage Tank passage Bucket spool Check 2 From RCV Check 1 P2 Parallel passage Cylinder head side Cylinder rod side 1607A2MC34A Bucket roll out operation P2 Bypass passage Tank passage Bucket spool Check 2 From RCV Check 1...
  • Page 68 Bucket roll in operation During the bucket roll in operation, the pilot pressure from RCV is supplied to port Pa5 and shift the bucket spool in the left direction. The hydraulic fluid from pump A2 entered P2 parallel passage and is directed to the port A5 through the check 1.

  • Page 69: Swing Operation

    SWING OPERATION Swing left operation Tank passage Swing spool From RCV P1 Bypass passage P1 Parallel passage 1607A2MC32 Swing right operation Tank passage Swing spool From RCV P1 Bypass passage P1 Parallel passage 1607A2MC33 The pilot pressure from the RCV is supplied to the Pd2 and shift the swing spool in left direction. The hydraulic fluid from pump A1 flows into swing spool through the parallel passage.

  • Page 70: Arm Operation

    ARM OPERATION Arm roll in operation Cylinder rod side Cylinder head side Arm summation passage P1 Parallel passage Arm 1 spool Piston C Selector spool Arm regeneration Tank passage cut pilot pressure Arm roll in pilot pressure P1 Bypass passage Arm regeneration &...
  • Page 71 Arm regeneration : The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool through the arm holding valve and the arm 1 spool. It is suppled the arm cylinder head through internal passage.
  • Page 72 Arm roll out operation Cylinder rod side Cylinder head side Arm summation passage P1 Parallel passage Arm 1 spool Tank passage Arm roll out pilot pressure From RCV P1 Bypass passage Spool bypass notch Arm summation passage Boom 2 spool Arm 2 spool From RCV Arm roll out...
  • Page 73 SWING PRIORITY FUNCTION Swing priority spool Path "A" P1 Parallel passage Swing priority pilot pressure From RCV Boom 2 spool Arm 2 spool 1607A2MC27 During swing priority operation, the pilot pressure is supplied to the port Pc3 and shift swing priority spool in the right direction.
  • Page 74 HOLDING VALVE OPERATION Holding operation 14072SF30 At neutral condition, the pilot piston chamber is connected to drain port through the pilot port. And the piston "B" is supported with spring "B" and the pressured fluid from actuator entered to inside of the holding valve through the periphery hole of check, crevice of the check and the plug and the periphery hole of plug.
  • Page 75 Release holding operation PILOT PISTON CHAMBER TANK PATH PISTON "A" SPRING PISTON "B" SPRING "B" POPPET CHECK SPRING "C" PLUG SOCKET SPOOL POPPET SEAT PILOT PORT ACTUATOR PORT FOR RELEASE HOLDING VALVE DRAIN PORT 14072SF31 The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the left direction against the spring "B", and shifts the poppet in the left direction through piston "B"...
  • Page 76 NEGATIVE RELIEF VALVE CONTROL Negative Tank passage P2 Bypass passage P1 Bypass passage end control valve Bucket spool Tank passage P2 negative P1 negative relief valve relief valve Negative Orifice Pn2 port Pn1 port control spring 1607A2MC28 When no function is being actuated on P2 side, the hydraulic fluid from the pump A2, flows into the tank passage through the bypass passage and orifice.
  • Page 77 (10) OPERATION OF MAIN RELIEF VALVE The main relief valve is fitted to the straight travel valve block and functions as follows : The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the inside space, and seats the plunger against the housing securely.
  • Page 78 Opening the poppet causes the pressure in chamber A to fall and the plunger to open. As the result the pressurized oil at port P runs into tank passage (T). Plunger Poppet Tank passage 1607A2MC38 High pressure setting pilot signal (Pu) : ON When the power boost switch is ON, the pilot pressure enters through hole A.
  • Page 79 (11) OPERATION OF PORT RELIEF VALVE Function as relief valve The pressurized oil passes through the piston A and orifice is filled up in chamber A of the inside space and seat the plunger against the socket and the socket against the housing securely.
  • Page 80 Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As the result the pressurized oil at port P runs into tank passage (T). Tank passage Chamber A Poppet Housing Tank passage Plunger 1607A2MC41 Make-up function When negative pressure exists at port P, the oil is supplied through tank passage (T).

  • Page 81: Group 3 Swing Device

    GROUP 3 SWING DEVICE GROUP 3 SWING DEVICE 1. STRUCTURE 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Time delay valve Relief valve R/G grease fill port(PT 1/4) Oil level gauge &...
  • Page 82 1) 1) SWING MOTOR SWING MOTOR DETAIL K 11 10 9 22 7 32,33 37 30 8 13 12 15 14 17 2 3 4 14W92SM02 Body 16 Brake piston 31 Anti-rotating valve Oil seal 17 O-ring 32 Time delay valve Roller bearing 18 O-ring 33 Wrench bolt...

  • Page 83: Reduction Gear

    REDUCTION GEAR REDUCTION GEAR 23 5 1 16 10 11 9 21 12 24 Oil drain Grease port VIEW A 14W92SM03 Casing Pin No.2 assembly Stop ring Drive shaft Sun gear No. 2 Side plate No. 1 Cover plate Carrier No. 1 Ring gear Spacer Planet gear No.
  • Page 84 2. PRINCIPLE OF DRIVING 2. PRINCIPLE OF DRIVING 1) 1) GENERATING THE TURNING FORCE GENERATING THE TURNING FORCE The high hydraulic supplied from a hydraulic pump flows into a cylinder (9) through valve cover of motor (20), and valve plate (23). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston (13).
  • Page 85 MAKE UP VALVE MAKE UP VALVE In the system using this type of motor, there is no counter balance functioning valve and there happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency. A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action.

  • Page 86: Relief Valve

    3) 3) RELIEF VALVE RELIEF VALVE Body Seat Plunger Spring Adjusting screw Piston Bushing Spring seat Shim O-ring Back up ring O-ring 14007A2SM05 Construction of relief valve Construction of relief valve The valve casing contains two cartridge type relief valves that stop the regular and reverse rotations of the hydraulic motor.
  • Page 87 Ports (P,R) at tank pressure. 14007A2SM06 When hydraulic oil pressure (P A ) reaches the preset force (F ) of spring (4), the plunger (3) moves to the right as shown. Fsp+Pg A Fsp+Pg A 14007A2SM07 2-49...
  • Page 88 The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset force (F ) of spring (4), the piston (6) moves left and stop the piston (6) hits the bottom of bushing (7).
  • Page 89 4) 4) ANTI-INVERSION VALVE ANTI-INVERSION VALVE In the event of swing motor operates switch part to drive and stop the swing part. By the action of pump on motor, there is brake on both-side of port because of the block on both sides. Swing part is stopped by pressure of brake (in order words, 4-5 times of inversion) Under the operating condition, the side of anti-inversion blocks off both ports but bypassing compressed oil which is blocked in processing of anti-inversion fixed time and amount to inverse...

  • Page 90: Brake System

    5) 5) BRAKE SYSTEM BRAKE SYSTEM (1) (1) Control valve swing brake system Control valve swing brake system This is the brake system to stop the swing motion of the excavator during operation. In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance created by this throttling works as a brake force to slow down the swing motion.
  • Page 91 Operating principle Operating principle When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (3). This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump charged oil (P3) goes to the chamber G through port PG.
  • Page 92 When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right. Then, the piston (16) is moved lower by spring force and the return oil from the chamber G flows back to tank port. At this time, the brake works.

  • Page 93: Group 4 Travel Device

    GROUP 4 TRAVEL DEVICE (TYPE1) GROUP 4 TRAVEL DEVICE (TYPE1) 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.

  • Page 94: Basic Structure

    1) 1) BASIC STRUCTURE BASIC STRUCTURE Reduction gear Travel motor Brake valve Parking brake High/low speed changeover mechanism Main control valve Main pump 14092TM02 2-56...
  • Page 95 2) 2) STRUCTURE STRUCTURE 42 26 36 30 27 43 38,21 25 37 67 49 89,90 SECTION A - A 209 210 46 205 208 207 204 203 202 71 126 10 11 5 101 129 130 103 61 108 14092TM03 Rear flange 19 Valve...

  • Page 96: Hydraulic Motor Assembly

    2. 2. HYDRAULIC MOTOR ASSEMBLY HYDRAULIC MOTOR ASSEMBLY With brake valve, parking brake and high/low speed changeover mechanism. 1) 1) FUNCTION UNCTION Hydraulic motor Hydraulic motor This hydraulic motor is a swash plate type piston motor and converts the force of pressurized oil delivered from the pump into a rotational movement.

  • Page 97: Operating Principle

    OPERATING PRINCIPLE OPERATING PRINCIPLE 2) 2) Hydraulic motor Hydraulic motor (Y1) ( Y2) 14092TM05 The pressurized oil delivered from the hydraulic pump flows to rear flange (1) of the motor, passes through the brake valve mechanism and is introduced into cylinder block (4) via timing plate (9). This oil constructively introduced only to one side of (Y1) - (Y2) connecting the upper and lower dead points of stroke of piston (5).
  • Page 98 Brake valve Brake valve Brake released Brake released When the pressurized oil supplied from port (A), the oil opens valve (27) and fl ows into port (C) at the suction side of hydrau- lic motor to rotate motor. At the same time, the pressurized oil passes through pipe line (a) from a small hole in spool (23) and flow into chamber (b).
  • Page 99 ② Stopping and stalling Stopping and stalling (brake applied) When the pressurized oil supplied from port (A) is stopped during traveling, no hydraulic pressure is applied and spool (23) which has slid to the left will return on the right (neutral) via stopper (25, 26) by the force of spring (31).
  • Page 100 Parking brake Parking brake Running Running When the pressurized oil is supplied from 12 101 a 15 16 the valve, the spool of brake valve in the hydraulic motor assembly actuates to open the passage to the parking brake and the pressurized oil is introduced into cylinder chamber (a) which is composed of the spindle of reduction gear assembly and...
  • Page 101 High/low speed changeover mechanism High/low speed changeover mechanism At low speed At low speed - pilot pressure of less than 10 kgf/cm When no pilot pressure is supplied from (D) (at a pressure of 10 kgf/cm or less), valve (65) is pressed toward the top by the force of spring (66) and (A) port or (B) port, the pressurized oil supply port (C) is shut off, and oil in chamber (P) is released into the motor case via valve(65).

  • Page 102: Reduction Gear

    3. 3. REDUCTION GEAR REDUCTION GEAR The reduction gear is composed of a two-stage planetary gear mechanism shown in the following fi gure. Flange 14092TM12 The rotating motion of the hydraulic motor is transmitted to drive gear (121) of 1st stage, and the drive gear rotate planetary gears (R, 117).
  • Page 103 TRAVEL MOTOR (TYPE 2) TRAVEL MOTOR (TYPE 2) ■ 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Travel motor Reduction gear PF1/2 FILL LEVEL PF1/2 DRAIN PF1/2...
  • Page 104 1) 1) STRUCTURE STRUCTURE 2 4 6 9 15 17 18 19 20 21 22 24 45 23 52 50 61 32 33 34 31 27 28 26 30 29 60 25 5 A" B" 8 7 1 16 14 10 11 12 13 51 45 49 47 43 35 36 62 28 37 53 48 DETAIL T...
  • Page 105 1 2 3 4 5 6 7-1 7-2 7-3 7-5 7-4 7-6 10-2 10-4 10-1 10-5 10-6 10-3 145Z9A2TM02A Spindle 7-4 Washer 2 10-5 Bearing 1 Floating sesal 7-5 Bearing 2 10-6 Pin 1 Ball bearing 7-6 Pin 2 11 Sun gear 1 Housing Coupling 12 Plate 1...
  • Page 106 3. PRINCIPLE OF DRIVING 3. PRINCIPLE OF DRIVING Travel motor comprises with rotary, relief valve, parking brake, counterbalance valve and 2-speed control. 1) 1) WORKING OF ROTARY PART WORKING OF ROTARY PART In the figure below, axis directional force F1 occurs when the high pressure oil flows into the cylinder block through to the valve plate (1) port, and the piston moves to the left hand side.
  • Page 107 2) 2) WORKING OF RELIEF VALVE WORKING OF RELIEF VALVE When the control valve spool is returned to neutral, the circuit between control valve and motor is blocked, and traveling movement stops. However, motor continues rotating because of the traveling inertia of the excavator's heavy weight. Then the motor will act as a pump, and oil blocked between control valve and motor will be pressured sharply and the increased oil pressure will damage internal parts.
  • Page 108 AT THE BEGINNING OF TRAVELING AT THE BEGINNING OF TRAVELING RELIEF VALVE A RELIEF VALVE A When travel control lever moves, high pressure oil works to rise the pressure of RA port up. This pressurized oil press plunger to the right, and then sustain the power of the spring, the plunger moves to the right and release the pressure oil of RA port to RB port (Stage 1) The plunger moves slowly by the pressure oil which flows into chamber 1 through orifice 1.
  • Page 109 DURING TRAVELING OPERATION DURING TRAVELING OPERATION RELIEF VALVE B RELIEF VALVE B During traveling operation, RA port pressure goes up and RB port pressure goes down. Thus RA port pressure oil flows into chamber 3, and pushes plunger to the left with a high pressure and the power of the spring.
  • Page 110 3) 3) WORKING OF PARKING BRAKE WORKING OF PARKING BRAKE Parking brake system consists of a brake piston, springs, friction plates and separating plates, and some orifices to control responsibility of the brake piston. The brake is usually held with the force of compressed spring, and it is released automatically by traveling oil pressure coming from inlet A, or B when the motor starts to run.
  • Page 111 • • Parking brake ON Parking brake ON When the control lever is returned to neutral position, the circuit between control valve and motor is blocked. As oil pressure in spool chamber drops to zero and the counter balance spool returns to neutral position.

  • Page 112: Counterbalance Valve

    4) 4) COUNTERBALANCE VALVE COUNTERBALANCE VALVE (1) (1) Function Function Control oil flow in the action of mechanical parking brake operation. Prevent overrun while traveling on down slope. Work as a hydraulic brake when motor stops, and prevent motor not to slip on slope. (2) (2) NEUTRAL NEUTRAL...
  • Page 113 (3) (3) How to work How to work When motor travel When motor travel When operator moves a traveling control lever, pressurized oil flows from pump to motor inlet A, and passes into spool chamber through counter orifice, and hydraulic force moves counter balance spool to the right, it makes pump oil flow into cylinder block through check poppet and kidney port.
  • Page 114 When motor stop When motor stop When operator moves a travel control lever to neutral position, pump oil flow is blocked. It reduce oil pressure of supply line down to zero, and oil in the spool chamber moves back to oil tank through counter orifice by the return force of spring in opposite side, and then counter balance spool returns to neutral position.
  • Page 115 5) 5) TWO SPEED (LOW SPEED - HIGH SPEED) CHANGEOVER EQUIPMENT TWO SPEED (LOW SPEED - HIGH SPEED) CHANGEOVER EQUIPMENT Rotating speed of the motor depends on slope angle of swash plate (9). Motor rotates slow when the angle is large, and rotates fast when the angle is small. •...
  • Page 116 • • High speed High speed When pilot pressure signal Pi is activated on spool (31), the spool moves to left hand end, and high pressure oil from Port is transferred to S1 which is connected to chamber A. The high pressure transferred to chamber A lift the piston (5) up, then the swash plate (12) tilts to smaller angle, and the motor rotates higher speed.

  • Page 117: Reduction Gear

    4. REDUCTION GEAR 4. REDUCTION GEAR 1) 1) PLANETARY GEAR MECHANISM PLANETARY GEAR MECHANISM Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force. This reduction unit utilizes two stages, planetary reduction system. Planetary reduction system consists of sun gear, planetary gears, carriers and ring gear.
  • Page 118 TRAVEL MOTOR (TYPE 3, 4) TRAVEL MOTOR (TYPE 3, 4) ■ 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. (39Q4-40100BG/ P/No.(39Q4-40100, 38Q4-40100BG) 38Q4-40100) Reduction gear Travel motor VIEW A 145LCR2TM20...
  • Page 119 2. 2. STRUCTURE STRUCTURE 49 40 43 42 41 44 72 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 71 70 59 77 64 3 63 7 10 11 14 15 13 16 26 27 6 8 125LCR2TM21...
  • Page 120 3. 3. OPERATION OPERATION 1) 1) MOTOR MOTOR High pressure oil delivered form hydraulic pump is led to inlet port that is provided in the brake valve portion and, through the rear cover (30) and valve plate (24), led to cylinder block (12). The oil flow and direction of shaft rotation are indicated in table.

  • Page 121: Parking Brake

    2) 2) PARKING BRAKE PARKING BRAKE Parking brake is released when high pressure oil selected by the brake valve portion that is connected directly to the rear cover (30), is applied to the parking piston (19). Otherwise the braking torque is always applied. This braking torque is generated by the friction between the separated plates (18), inserted into the casing (1), and friction plates (17), coupled to cylinder block (12) by the outer splines.

  • Page 122: Capacity Control Mechanism

    3) 3) CAPACITY CONTROL MECHANISM CAPACITY CONTROL MECHANISM Figure typically shows the capacity control mechanism. When high speed pilot line is charged with the pressure P that overcome the spring (44), the spring (44) is compressed and spool (40) shifts to the right to connect the port P and port C. Then, the highest pressure is selected by the check valve (50) from inlet and outlet pressure of the motor and high speed pilot line pressure and pushes shifter piston (4).
  • Page 123 4) 4) OVERLOAD RELIEF VALVE OVERLOAD RELIEF VALVE (1) (1) Structure tructure This valve is screwed in the motor rear cover (30) and consists of : plug (38-1) that is screwed and fixed in the rear cover (30), poppet (38-8) and supports the poppet seat (38-9), spring (38-2) that is operating relief valve setting pressure and supports the spring seat (38-3), that is inserted in the sleeve (38-4), piston (38-5) that reduce the shock.
  • Page 124 (2) (2) Operation Operation Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and have the following functions : ① When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating, bypasses surplus oil to return line.

  • Page 125: Brake Valve

    5) 5) BRAKE VALVE BRAKE VALVE (1) (1) Structure Structure The brake valve portion mainly consists of the following parts: ① Spool Spool By shifting the spool (31), the discharged oil from hydraulic motor is automatically shut off or restricted according to the condition and give the effect of holding, accelerating, stopping and counterbalance operations.
  • Page 126 (2) (2) Operation Operation ① Holding operation Holding operation When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (33) located on both spool ends holds the spool (31) at central position. Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
  • Page 127 ② Accelerating operation Accelerating operation When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool (31), and oil flows to motor via MA port to rotate the motor. Therefore, the pressure increases and negative brake is released by the pressure supplied from pump.
  • Page 128 ③ Stopping operation Stopping operation Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends become equal, and the spool (31) returns to the neutral position by spring (33) force.
  • Page 129 ④ Counterbalance operation Counterbalance operation Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force. In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on MB to VB side decreases and the spring (33) force moves the spool (31) leftwards towards neutral position.
  • Page 130 6) 6) REDUCTION GEAR REDUCTION GEAR Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force. This reduction unit utilizes two stages, planetary reduction system. Planetary reduction system consists of sun gear, planetary gears, (planetary) carriers, and ring gear.

  • Page 131: Group 5 Rcv Lever

    GROUP 5 RCV LEVER 1. STRUCTURE The casing has the oil inlet port P(Primary pressure) and the oil outlet port T(Tank). In addition the secondary pressure is taken out through ports 1,2,3 and 4 provided at the bottom face. Single Simultaneous operation operation...

  • Page 132: Cross Section

    CROSS SECTION The construction of the pilot valve is shown in the attached cross section drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure, return spring(10), stopper(9), spring seat(8) and shim(6).
  • Page 133 CROSS SECTION 2-82...
  • Page 134 2. FUNCTIONS FUNDAMENTAL FUNCTIONS The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure(Secondary pressure) of the pilot valve to the other end.

  • Page 135: Operation

    OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. Pilot valve Main pump Hydraulic motor Pilot pump...
  • Page 136 Case where handle is in neutral position The force of the spring(7) that determines the output pressure of the pilot valve is not applied to the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1, 3) in the operation explanation drawing.
  • Page 137 Case where handle is tilted When the push rod(14) is stroked, the spool(5) moves downwards. Then port P is connected with port(1) and the oil supplied from the pilot pump flows through port(1) to generate the pressure. When the pressure at port(1) increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force.

  • Page 138: Group 6 Rcv Pedal

    GROUP 6 RCV PEDAL GROUP 6 RCV PEDAL 1. STRUCTURE 1. STRUCTURE The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size...
  • Page 139 CROSS SECTION CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool (8), spring (6) for setting secondary pressure, return spring (10), stopper (9), and spring seat (7).

  • Page 140: Fundamental Functions

    2. FUNCTION 2. FUNCTION FUNDAMENTAL FUNCTIONS FUNDAMENTAL FUNCTIONS 1) 1) The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the pilot valve to the other end.
  • Page 141 3) 3) OPERATION OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below ant the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 36072SF01 Pilot valve Main pump...
  • Page 142 (1) (1) Case where pedal is in neutral position Case where pedal is in neutral position 21092RP03 The force of the spring (6) that determines the output pressure of the pilot valve is not applied to the spool (8). Therefore, the spool is pushed up by the spring (10) to the position of port 2 in the operation explanation drawing.
  • Page 143 (2) (2) Case where pedal is tilted Case where pedal is tilted 21092RP04 When the push rod (14) is stroked, the spool (8) moves downwards. Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1 to generate the pressure.

  • Page 144: Section 3 Hydraulic System

    SECTION 3 HYDRAULIC SYSTEM SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1 Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-2 Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-5 Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-12 Group 5 Combined Operation ------------------------------------------------------------------------------------------ 3-22...

  • Page 145: Group 1 Hydraulic Circuit

    SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT O/R 380k P2(BW) P1(FW) P2(BW) P1(FW) O/R 380k Pc41 Pc40 Main pump Pd40 Main control valve Pc42 Swing motor Travel motor Pc3(Sh) RCV lever(LH) Pa21 Pd41 RCV lever(RH) RCV pedal Boom cylinder(L/H) Boom cylinder(R/H) Pb21 380k...

  • Page 146: Group 2 Main Circuit

    GROUP 2 MAIN CIRCUIT GROUP 2 MAIN CIRCUIT The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit. The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders and two travel motors. The swash plate type variable displacement axial piston pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
  • Page 147 2. RETURN CIRCUIT 2. RETURN CIRCUIT Check valve(2) 1.5 kgf/cm Full flow filter Oil cooler Main control valve Actuators Check valve(1) 3.0 kgf/cm Check valve (3) Check valve(3) 1.5 kgf/cm 1.5 kgf/cm 14093CI01 All oil returned from each actuator returns to the hydraulic tank through the main control valve. The bypass check valves are provided in the return circuit.

  • Page 148: Drain Circuit

    3. DRAIN CIRCUIT 3. DRAIN CIRCUIT Travel motor Swing motor Return line Turning Main joint pump dr #, DR # Return filter Hydraulic Drain filter oil tank Check valve 1.5 kgf/cm 14093CI02 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through drain filter.

  • Page 149: Group 3 Pilot Circuit

    GROUP 3 PILOT CIRCUIT GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve RCV pedal (RH lever) (LH lever) Safety lock Swing parking brake solenoid valve Travel speed solenoid valve Arm regeneration solenoid valve • • Power boost solenoid valve •...
  • Page 150 1. SUCTION, DELIVERY AND RETURN CIRCUIT 1. SUCTION, DELIVERY AND RETURN CIRCUIT Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 RCV PEDAL TRAVEL SWING ARM BUCKET BOOM (Pump) (Pump) (T/Joint) (MCV) Pd40 LINE FILTER Pc40 Pa20 Pb20 (MCV) RD14093HC02 The pilot pump receive oil from the hydraulic tank.
  • Page 151 2. SAFETY 2. SAFETY SOLENOID SOLENOID VALVE VALVE (SAFETY LEVER) Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 RCV PEDAL TRAVEL SWING ARM BUCKET BOOM (Pump) (Pump) (T/Joint) (MCV) Pd40 LINE FILTER Pc40 Pa20 Pb20 (MCV) RD14093HC03 When the lever of the safety solenoid valve is moved upward, oil flows into the remote control valve through solenoid valve and line filter.
  • Page 152 3. SWING PRIORITY SYSTEM 3. SWING PRIORITY SYSTEM Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 RCV PEDAL TRAVEL ARM BUCKET BOOM SWING (Pump) (Pump) (T/Joint) (MCV) Pd40 LINE FILTER Pc40 Pa20 Pb20 (MCV) RD14093HC04 When carrying out the combined operation of swing and boom or arm of the left control valve, the swing speed can be lowered than operating speed of boom or arm.
  • Page 153 4. TRAVEL SPEED CONTROL SYSTEM 4. TRAVEL SPEED CONTROL SYSTEM P2(BW) P1(FW) P1(FW) P2(BW) Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 RCV PEDAL TRAVEL SWING ARM BUCKET BOOM (Pump) (Pump) (T/Joint) (MCV) Pd40 LINE FILTER Pc40 Pa20 Pb20 (MCV) RD14093HC05...
  • Page 154 5. MAIN RELIEF PRESSURE CHANGE SYSTEM 5. MAIN RELIEF PRESSURE CHANGE SYSTEM Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 RCV PEDAL TRAVEL SWING ARM BUCKET BOOM (Pump) (Pump) (T/Joint) (MCV) Pd40 LINE FILTER Pc40 Pa20 Pb20 (MCV) RD14093HC06 When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve is actuated, the discharged oil from the pilot pump flows into Pu port of the main relief valve of main...
  • Page 155 6. SWING PARKING BRAKE RELEASE 6. SWING PARKING BRAKE RELEASE Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 A(ccw) B(cw) Pb21 Pb20 Pa20 RCV PEDAL TRAVEL SWING ARM BUCKET BOOM (Pump) (Pump) (T/Joint) (MCV) Pd40 LINE FILTER Pc40 Pa20 Pb20 (MCV) RD14093HC07 When the swing control lever is tilted, the pilot oil flow into SH port of shuttle valve, this pressure move spool so, discharged oil from pilot valve flow into PG port.

  • Page 156: Group 4 Single Operation

    GROUP 4 SINGLE OPERATION GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION 1. BOOM UP OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC10 When the right control lever is pulled back, the boom spools in the main control valve are moved to the up position by the pilot oil pressure from the remote control valve.
  • Page 157 2. BOOM DOWN OPERATION 2. BOOM DOWN OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC11 When the right control lever is pushed forward, the boom spools in the main control valve are moved to the down position by the pilot oil pressure from the remote control valve. The oil from the A2 pump flows into the main control valve and then goes to the small chamber of boom cylinders.
  • Page 158 3. ARM ROLL IN OPERATION 3. ARM ROLL IN OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC12 When the left control lever is pulled back, the arm spools in the main control valve are moved the to roll in position by the pilot oil pressure from the remote control valve.
  • Page 159 4. ARM ROLL OUT OPERATION 4. ARM ROLL OUT OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC13 When the left control lever is pushed forward, the arm spool in the main control valve are moved to the roll out position by the pilot oil pressure from the remote control valve. The oil from the A1 and A2 pump flows into the main control valve and then goes to the small chamber of arm cylinder.
  • Page 160 5. BUCKET ROLL IN OPERATION 5. BUCKET ROLL IN OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC14 When the right control lever is pulled left, the bucket spool in the main control valve is moved to the roll in position by the pilot oil pressure from the remote control valve.
  • Page 161 6. BUCKET ROLL OUT OPERATION 6. BUCKET ROLL OUT OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC15 When the right control lever is pushed right, the bucket spool in the main control valve is moved to the roll out position by the pilot oil pressure from the remote control valve. The oil from the A2 pump flows into the main control valve and then goes to the small chamber of bucket cylinder.
  • Page 162 7. SWING OPERATION 7. SWING OPERATION Pc41 Pc40 Pd40 Pc42 Pd41 Pa21 A(ccw) B(cw) Pb21 Pb20 Pa20 RCV PEDAL TRAVEL SWING ARM BUCKET BOOM (Pump) (Pump) (T/Joint) (MCV) Pd40 LINE FILTER Pc40 Pa20 Pb20 RD14093HC16 (MCV) When the left control lever is pushed left or right, the swing spool in the main control valve is moved to the left or right swing position by the pilot oil pressure from the remote control valve.
  • Page 163 SWING CIRCUIT OPERATION SWING CIRCUIT OPERATION SWING MOTOR DEVICE PARKING BRAKE BRAKE OFF BRAKE RELEASE VALVE BRAKE ON ANTI-INVERSION VALVE MOTOR BRAKE VALVE MAKE UP VALVE B(cw) A(ccw) MAKE UP PORT(Mu) TO / FROM MAIN CONTROL VALVE 14W93HC18A 1) 1) MOTOR BRAKE VALVE MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing...
  • Page 164 8. TRAVEL FORWARD AND RE 8. TRAVEL FORWARD AND REVERSE O VERSE OPERATION PERATION P2(BW) P1(FW) P1(FW) P2(BW) TURNING JOINT Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 RCV PEDAL TRAVEL SWING ARM BUCKET BOOM (Pump) (Pump) (MCV) (T/Joint) Pd40 LINE FILTER...
  • Page 165 TRAVEL CIRCUIT OPERATION TRAVEL CIRCUIT OPERATION TRAVEL MOTOR DEVICE P2(BW) P1(FW) P1(FW) P2(BW) COUNTER BALANCE OVERLOAD RELIEF TURNING VALVE VALVE JOINT TO/FROM MAIN CONTROL VALVE 14093HC19A Valves are provided on travel motors to offer the following functions. 1) 1) COUNTER BALANCE VALVE COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run.

  • Page 166: Group 5 Combined Operation

    GROUP 5 COMBINED OPERATION GROUP 5 COMBINED OPERATION 1. OUTLINE 1. OUTLINE Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC20 The oil from the A1 and A2 pump flows through the neutral oil passage, bypass oil passage and confluence oil passage in the main control valve.
  • Page 167 2. COMBINED SWING AND BOOM UP OPERATION 2. COMBINED SWING AND BOOM UP OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC21 When the swing and boom functions are operated, simultaneously the swing spool and boom spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 168 3. COMBINED SWING AND ARM OPERATION 3. COMBINED SWING AND ARM OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC22 When the swing and arm functions are operated, simultaneously the swing spool and arm spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 169 4. COMBINED SWING AND BUCKET OPERATION 4. COMBINED SWING AND BUCKET OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC23 When the swing and bucket functions are operated, simultaneously the swing spool and bucket spool in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 170 5. COMBINED SWING AND TRAVEL OPERATION 5. COMBINED SWING AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC24 When the swing, boom, arm and bucket functions are operated, simultaneously each spool in the main control valve is moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 171 6. COMBINED BOOM AND TRAVEL OPERATION 6. COMBINED BOOM AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC25 When the swing and travel functions are operated, simultaneously the swing spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and straight travel spool is pushed to the left by the pilot oil pressure from the pilot pump.
  • Page 172 7. COMBINED ARM AND TRAVEL OPERATION 7. COMBINED ARM AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC26 When the boom and travel functions are operated, simultaneously the boom spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
  • Page 173 8. COMBINED BUCKET AND TRAVEL OPERATION 8. COMBINED BUCKET AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC27 When the arm and travel functions are operated, simultaneously the arm spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
  • Page 174 9. COMBINED BUCKET AND TRAVEL OPERATION 9. COMBINED BUCKET AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 RD14093HC28 When the bucket and travel functions are operated, simultaneously the bucket spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve, and the straight travel spool is pushed to the left by the oil pressure from pilot pump.

  • Page 175: Section 4 Electrical System

    SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1 Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3 Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-21 Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-29...

  • Page 176: Group 1 Component Location

    SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 Switch panel CN-16&16A CN-16B 140V94EL01 19 Aircon switch Start switch 10 Power max switch Accel dial switch 11 One touch decel switch 20 Main light switch Horn switch 12 Fuse &...

  • Page 177: Solenoid Valve

    2. LOCATION 2 2. LOCATION 2 BOOM SOLENOID VALVE Patt MAIN CONTROL VALVE RD14094EL02 Lamp Horn 13 Travel alarm buzzer Fuel sender Screw coupling 14 Solenoid valve Fuel filler pump Heater relay 15 Pump EPPR valve Beacon lamp 10 Start relay 16 Travel pressure sensor Battery 11 Alternator...

  • Page 178: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT(1/2) COMP RY R/DRYER 5R 146 WASHER P/P 145 5W POWER MASTER SW CS-74A FUSE BOX CN-95 MASTER SW FUSIBLE LINK BATTERY FUEL HEATER CN-60 CR-1 12V X 2 1.2B 1.2G TO:STARTER "B" TERM. BATT RY DO-3 141E...
  • Page 179 ·ELECTRICAL CIRCUIT ELECTRICAL CIRCUIT(2/2) CN-21 CABIN LAMP QUICK COUPLING SW WIPER CUT THERMOCON CN-11 DESTINATION ACT (+) WIPER MOTOR MODE M- A/CON SW FUSE(IG) MODE M+ CN-141 TEMP M- FEED BACK TEMP M+ CN-17 MOTOR DRIVE SIG DPS(COMPRESSOR) MOTOR DRIVE- MOTOR DRIVE+ TAIL(-) ILLUMINATION...
  • Page 180 MEMORANDUM MEMORANDUM HYUNDAI HEAVY INDUSTRIES CO., LTD CONSTRUCTION EQUIPMENT DIV.

  • Page 181: Power Circuit

    1. POWER CIRCUIT 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis through master switch. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW OPERATING FLOW Battery...
  • Page 182 POWER CIRCUIT POWER CIRCUIT FUSE BOX POWER RY CS-74 MASTER SW CN-95 FUSIBLE LINK CN-60 BATT RY BATTERY (12VX2) MASTER SW CR-1 CS-74B DOOR SW CS-1 ROOM LAMP 0.8Y CL-1 START KEY SW WIPER MOTOR WIPER MOTOR CONTROLLER 140V94EL03...
  • Page 183 2. STARTING CIRCUIT 2. STARTING CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74] Fuse box [No.4] Master switch [CS-74B] I/conn [CN-8(12)] Start switch [CS-2(1)] When start key switch is in ON position When start key switch is in ON position Start switch ON [CS-2 (2)] I/conn [CN-8 (11)]...

  • Page 184: Starting Circuit

    STARTING CIRCUIT STARTING CIRCUIT FUSE BOX POWER RY CS-74 MASTER SW CN-95 FUSIBLE LINK ANTI-RESTART RY CN-60 0.8BOr 0.8Br CR-5 MASTER SW BATT RY 1.2B BATTERY (12VX2) 1.2G CS-74B CR-1 DIODE 0.8G 0.8B DO-3 ANTI-RESTART RY CN-50 START RY STARTER CN-3 0.8B 0.8W...

  • Page 185: Charging Circuit

    3. CHARGING CIRCUIT 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the battery relay [CR-1].
  • Page 186 CHARGING CIRCUIT CHARGING CIRCUIT FUSE BOX CS-74 MASTER SW CN-95 FUSIBLE LINK CN-60 BATT RY 1.2B BATTERY (12VX2) 1.2G CR-1 DIODE 0.8G 0.8B DO-3 CN-5 START RY STARTER CN-3 0.8B CLUSTER CN-56 POWER IG(24V) 0.8W CR-23 CN-45 ALTERNATOR CN-74 RESISTER 1.2W 0.8R RS-2...
  • Page 187 4. HEAD AND WORK LIGHT CIRCUIT 4. HEAD AND WORK LIGHT CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Fuse box (No.18) Head light relay [CR-13 (30,86)] Fuse box (No.15) Work light relay [CR-4 (30,86)] (1) (1) Head light switch ON Head light switch ON Head light relay [CR-13 (86) →...
  • Page 188 HEAD AND WORK LIGHT CIRCUIT HEAD AND WORK LIGHT CIRCUIT FUSE BOX CN-12 CL-5 CN-7 WORK LAMP ACCEL DIAL LED CL-6 CN-279 WORK LAMP RY 0.8RW 87 85 AC CONTROLLER 0.8VW ACT (+) CN-11 CR-4 MODE M- CL-3 MODE M+ 1.2B TEMP M- 1.2ROr...
  • Page 189 5. CAB LIGHT CIRCUIT 5. CAB LIGHT CIRCUIT OPERATING FLOW OPERATING FLOW 1) 1) Fuse box (No.16) Cab light relay [CR-9 (30, 86)] Cab light switch ON Cab light switch ON (1) (1) Cab light switch ON [CS-24 (2)] I/conn [CN-6 (4)] I/conn [CN-10 (11)] Cab light ON [CL-8 (2)] Cab light ON [CL-9 (2)]...
  • Page 190 CAB LIGHT CIRCUIT CAB LIGHT CIRCUIT FUSE BOX CS-24 CABIN LAMP SW CN-10 CL-8 CAB LIGHT CL-9 140V94EL07 4-15...
  • Page 191 6. WIPER AND WASHER CIRCUIT 6. WIPER AND WASHER CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Key switch ON Key switch ON Fuse box (No.6) I/conn [CN-5 (4)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)] Wiper motor [CN-21(4)] Fuse box (No.17) I/conn [CN-6 (5)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]...
  • Page 192 WIPER AND WASHER CIRCUIT WIPER AND WASHER CIRCUIT FUSE BOX WASHER PUMP 0.8GrW 0.8V CN-22 DO-5 0.8GrW 0.8V WIPER CUT SW WIPER & WASHER WIPER PUMP S/W WIPER MOTOR WIPER MOTOR CONTROLLER 140V94EL08 4-17...

  • Page 193: Controller Circuit

    CONTROLLER CIRCUIT CONTROLLER CIRCUIT FUSE BOX HOUR METER CN-5 CN-48 DC/DC CONVERTER CN-138 12V SOCKET CN-139 CN-7 ACCEL DIAL 0.8Gr 0.8W 0.8B CN-142 RH CONSOLE GOV. MOTOR CN-76 140V94EL09 4-18...

  • Page 194: Monitoring Circuit

    MONITORING MONITORING CIRCUIT CIRCUIT FUSE BOX CN-5 CLUSTER CN-56 POWER IG(24V) AIR CLEANER SW 1.2BW 1.2YOr CD-10 FUEL SENDOR 1.2BW 1.2YOr CD-2 HYD TEMP 1.2BW 1.2LOr CD-1 140V94EL10 4-19...
  • Page 195 ELECTRIC CIRCUIT FOR HYDRAULIC ELECTRIC CIRCUIT FOR HYDRAULIC QUICK COUPLING SW BREAKER SW FUSE BOX BREAKER CN-279 0.8B 0.8ROr CN-7 CN-6 ACCEL DIAL LED Brea CR-62 CS-26 Horn CS-5 BREAKER RY CN-142 CN-8 ACCEL DIAL CN-4 CN-68 SAFETY SOL CN-140 Power QUICK COUPLER CS-29...

  • Page 196: Group 3 Electrical Component Specification

    GROUP 3 ELECTRICAL COMPONENT SPECIFICATION GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check ※ Check specific gravity 12V × 80Ah 1.280 over : Over charged Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging Rated load : ※...
  • Page 197 Part name Symbol Specifications Check ※ Check resistance Tacho sensor 24V 20A Normal : 300Ω(For terminal 1, 2) CD-17 CD-2 ※ Check resistance Temperature 50˚C : 804Ω sensor (hydraulic, 80˚C : 310Ω coolant) 100˚C : 180Ω CD-8 CD-1 CD-8 ※ Check contact High level : ∞Ω...
  • Page 198 Part name Symbol Specifications Check ※ Check resistance 87 85 Normal : About 160 Ω Relay 24V 16A (for terminal 85-86) 0Ω(for terminal 30-87a) CR-4 CR-5 CR-7 CR-4 CR-7 CR-9 ∞Ω(for terminal 30-87) CR-13 CR-35 CR-46 CR-13 CR-35 CR-46 ※ Check resistance Solenoid valve Normal : 15~25Ω...
  • Page 199 Part name Symbol Specifications Check ※ Check disconnection Normal : 1.0Ω ON : 0Ω(For terminal 1-5, 2-6) Switch 24V 8A ∞Ω(For terminal 5-7, 6-8) OFF : ∞Ω(For terminal 1-5, 6-8) 0Ω(For terminal 5-7, 6-8) CS-67 ※ Check disconnection Normal : 1.0Ω Room lamp ON : 0Ω(For terminal 1-2) 24V 10W...
  • Page 200 Part name Symbol Specifications Check ※Check operation DC22~28V Horn Supply power(24V) to each terminal and connect ground. CN-20 CN-25 ※Check contact Normal : 0Ω(for terminal 1-2) 24V 15A ∞Ω(for terminal 1-3) Safety switch (N.C TYPE) Operating : ∞Ω(for terminal 1-2) 0Ω(for terminal 1-3) CS-4 CS-4...
  • Page 201 Part name Symbol Specifications Check ※Check disconnection Wiper motor 24V 2A Normal : 7Ω(for terminal 2-6) CN-21 24V (1-2) DC/DC 12V 3A Converter 12V (1-3) CN-138 ※Check coil resistance Normal : About 1MΩ ※Check contact Cigar lighter 24V 5A 1.4W Normal : ∞Ω...
  • Page 202 Part name Symbol Specifications Check ※Check contact Aircon 24V 79W compressor Normal : 13.4Ω CN-28 ※Check contact Start relay 24V 300A Normal : 0.94Ω(for terminal 1-2) CR-23 ※Check resistance Blower motor 24V 9.5A Normal : 2.5Ω(for terminal 1-2) ※Check resistance 1.12Ω(For terminal 4-2) Resistor 2.07Ω(For terminal 2-3)
  • Page 203 Part name Symbol Specifications Check ※Check disconnection Normal : 0Ω Fusible link (connect ring terminal and check resist between terminal 1 and 2) CN-60 CN-95 ※Check disconnection Master switch 6-36V Normal : 0.1Ω CS-74A CN-74B Socket 12V 10A CN-139 4-28...

  • Page 204: Group 4 Connectors

    GROUP 4 CONNECTORS GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Frame harness-Pump PS harness) S816-006002 S816-106002 CN-2 I/conn (Frame harness-Engine harness) 2-85262-1 S816-112002 CN-3 I/conn (Frame harness-Engine harness) S816-006002 S816-106002 CN-4...
  • Page 205 Connector part No. Connector No. of Type Destination number Female Male CN-74 Alternator "l" terminal S810-002200 CN-75 Pump EPPR S816-002002 CN-76 DEUTSCH Accel actuator DT06-6S-EP06 CN-81 DEUTSCH Travel buzzer solenoid DT06-2S-EP06 CN-88 DEUTSCH Power max solenoid DT06-2S-EP06 CN-95 YAZAKI Fusible link S813-130201 CN-125 Econoseal J...
  • Page 206 Connector part No. Connector No. of Type Destination number Female Male CS-26 DEUTSCH Breaker switch DT06-2S-EP06 CS-26A Breaker pedal switch S816-002002 S816-102002 CS-27 Breaker switch SWF 593757 CS-29 DEUTSCH Power max switch DT06-2S-EP06 CS-53 Wiper cut switch S822-014002 CS-54 Aircon switch SWF 593757 CS-67 Quick clamp switch...
  • Page 207 2. CONNECTION TABLE FOR CONNECTORS 2. CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR PA TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 3S811-109002 S811-011002 S811-111002 4 - 32...
  • Page 208 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4 - 33...
  • Page 209 J TYPE CONNECTOR J TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 4 - 34...
  • Page 210 SWP TYPE CONNECTOR SWP TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 4 - 35...
  • Page 211 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4 - 36...
  • Page 212 CN TYPE CONNECTOR CN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 4 - 37...
  • Page 213 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 4 - 38...
  • Page 214 375 FASTEN TYPE CONNECTOR 375 FASTEN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR AMP ECONOSEAL CONNECTOR No. of Receptacle connector (female) Plug connector (male) 344111-1 344108-1 AMP TIMER CONNECTOR AMP TIMER CONNECTOR No.
  • Page 215 AMP 040 MULTILOCK CONNECTOR AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 174045-2 AMP 070 MULTILOCK CONNECTOR AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 173852 AMP FASTIN - FASTON CONNECTOR AMP FASTIN - FASTON CONNECTOR No.
  • Page 216 KET 090 CONNECTOR KET 090 CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610070 KET 090 WP CONNECTORS KET 090 WP CONNECTORS No. of Receptacle connector (female) Plug connector (male) MG640605 MG640795 4 - 41...
  • Page 217 KET SDL CONNECTOR KET SDL CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610406 4 - 42...
  • Page 218 DEUTSCH DT CONNECTORS DEUTSCH DT CONNECTORS DT 06 - 3S - ★★★★ Modifications (see below) Number of contacts (P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connectors ※ Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
  • Page 219 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 4 - 44...
  • Page 220 MOLEX 2CKTS CONNECTOR MOLEX 2CKTS CONNECTOR No. of Receptacle connector (female) Plug connector (male) 35215-0200 35215-0200 ITT SWF CONNECTOR ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF593757 MWP NMWP CONNECTOR MWP NMWP CONNECTOR No. of Receptacle connector (female) Plug connector (male) NMWP01F-B 4 - 45...
  • Page 221 ECONOSEAL J TYPE CONNECTORS ECONOSEAL J TYPE CONNECTORS No. of Receptacle connector (female) Plug connector (male) S816-001002 S816-101002 S816-002002 S816-102002 S816-003002 S816-103002 S816-004002 S816-104002 4 - 46...
  • Page 222 No. of Receptacle connector (female) Plug connector (male) S816-006002 S816-106002 S816-008002 S816-108002 S816-010002 S816-110002 S816-012002 S816-112002 4 - 47...
  • Page 223 No. of Receptacle connector (female) Plug connector (male) 368301-1 2-85262-1 METRI-PACK TYPE CONNECTOR METRI-PACK TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) 12040753 DEUTSCH HD30 CONNECTOR DEUTSCH HD30 CONNECTOR No. of Receptacle connector (female) Plug connector (male) HD36-24-23SN HD34-24-23PN 4 - 48...
  • Page 224 DEUTSCH MCU CONNECTOR DEUTSCH MCU CONNECTOR No. of Receptacle connector (female) Plug connector (male) DRC26-40SA/B DEUTSCH SERVICE TOOL CONNECTOR DEUTSCH SERVICE TOOL CONNECTOR No. of Receptacle connector (female) Plug connector (male) HD10-9-96P AMP FUEL WARMER CONNECTOR FUEL WARMER CONNECTOR No. of Receptacle connector (female) Plug connector (male) 2-967325-3...
  • Page 225 DEUTSCH E DEUTSCH ENGINE NGINE ECM CONNECTOR ECM CONNECTOR No. of Receptacle connector (female) Plug connector (male) DRC26-50S-04 DEUTSCH DEUTSCH INTERMEDIATE INTERMEDIATE CONNECTOR CONNECTOR No. of Receptacle connector (female) Plug connector (male) DRB16-60SAE-L018 4 - 50...

  • Page 226: Section 5 Mechatronics System

    SECTION 5 MECHATRONICS SYSTEM SECTION 5 MECHATRONICS SYSTEM Group 1 Outline ---------------------------------------------------------------------------------------------------------------- 5-1 Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-3 Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-5 Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-6 Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-7 Group 6 Automatic Warming Up Function --------------------------------------------------------------------- 5-8 Group 7 Engine Overheat Prevention Function ------------------------------------------------------------- 5-9 Group 8 Anti-Restart System ----------------------------------------------------------------------------------------- 5-10...

  • Page 227: Group 1 Outline

    SECTION 5 MECHATRONICS SYSTEM SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE GROUP 1 OUTLINE The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration, power boost function, etc.

  • Page 228: System Diagram

    SYSTEM DIAGRAM SYSTEM DIAGRAM Travel motor Regulator Auto deceleration pressure switch Main control valve Extra C Bucket Extra B Extra A & Arm 1 Arm regen Power boost Boom 2 solenoid valve Arm 2 S/Priority Boom 1 Swing Travel speed solenoid valve Travel(RH) Travel(LH)

  • Page 229: Group 2 Mode Selection System

    GROUP 2 MODE SELECTION SYSTEM GROUP 2 MODE SELECTION SYSTEM 1. POWER MODE SELECTION SYSTEM 1. POWER MODE SELECTION SYSTEM Main control valve Engine speed sensor Engine Main pump Pilot pump Accel Fuel injection actuator pump EPPR valve Power mode switch signal Accel dial signal Accel dial Drive signal...
  • Page 230 2. WORK MODE SELECTION SYSTEM 2. WORK MODE SELECTION SYSTEM 2 work modes can be selected for the optional work speed of the machine operation. Main control valve Extra C Bucket Extra B Extra A & Arm 1 Arm regen Boom 2 Arm 2 S/Priority...

  • Page 231: Group 3 Automatic Deceleration System

    GROUP 3 AUTOMATIC DECELERATION SYSTEM GROUP 3 AUTOMATIC DECELERATION SYSTEM Work equipment Travel oil pressure switch pressure switch Accel Fuel injection actuator pump Main control valve Auto decel switch signal Pressure switch signal CPU controller Accel dial signal Accel dial 1.

  • Page 232: Group 4 Power Boost System

    GROUP 4 POWER BOOST SYSTEM GROUP 4 POWER BOOST SYSTEM Main control valve Extra C Bucket Extra B Extra A & Arm 1 Arm regen Boom 2 Arm 2 S/Priority Boom 1 Swing Travel(RH) Travel(LH) Straight Main relief Travel Power boost valve solenoid valve Engine speed...

  • Page 233: Group 5 Travel Speed Control System

    GROUP 5 TRAVEL SPEED CONTROL SYSTEM GROUP 5 TRAVEL SPEED CONTROL SYSTEM Travel motor Main control valve Extra C Bucket Extra B Regulator Regulator Extra A & Arm 1 Arm regen Boom 2 Arm 2 S/Priority Boom 1 Swing Travel(RH) Travel(LH) Straight Travel...

  • Page 234: Group 6 Automatic Warming Up Function

    GROUP 6 AUTOMATIC WARMING UP FUNCTION GROUP 6 AUTOMATIC WARMING UP FUNCTION Engine Coolant temp sensor Pilot pump Main pump Accel Max flow Fuel injection actuator CO valve pump EPPR valve Drive signal Warming up lamp signal Cluster RD14095MS04 The MCU reads engine coolant temperature through the temperature sensor, and if the coolant temperature is less than 30 C, it increases the engine speed from key start rpm to 1200rpm.
  • Page 235 GROUP 7 ENGINE OVERHEAT PREVENTION GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM SYSTEM Engine Coolant temp sensor Main pump Pilot pump Accel Fuel injection actuator Max flow pump CO valve EPPR valve Drive signal Overheat warming signal RD14095MS05 1. MCU reads engine coolant temperature through the temperature sensor and when the engine coolant boils up to 110 C, it sends overheat warning signal to the cluster and decrease the engine ˚...

  • Page 236: Group 8 Anti-Restart System

    GROUP 8 ANTI-RESTART SYSTEM GROUP 8 ANTI-RESTART SYSTEM Engine Starter Start safety relay Drive signal CPU controller CN-92a CN-92b 1. ANTI-RESTART FUNCTION 1. ANTI-RESTART FUNCTION After 10 seconds from the engine starts to run, MCU turns off the start safety relay to protect the starter from inadvertent restarting.

  • Page 237: Group 9 Self-Diagnostic System

    GROUP 9 SELF-DIAGNOSTIC SYSTEM GROUP 9 SELF-DIAGNOSTIC SYSTEM OUTLINE OUTLINE 1. 1. When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster and also stores them in the memory.

  • Page 238: Error Codes Table

    5. ERROR CODES TABLE 5. ERROR CODES TABLE Fault code No. Description Short circuit in governor motor system Potentiometer circuit is shorted to Vcc(5V) or battery + Short circuit in pump EPPR valve system Short circuit in boom down EPPR valve system Short circuit in travel speed solenoid system Short circuit in power boost solenoid system Short circuit in max flow solenoid system...
  • Page 239 Fault code No. Description Hydraulic oil temperature sensor circuit is shorted to ground Fuel level sensor circuit is shorted to ground Coolant temperature sensor circuit is shorted to ground Boom up pressure sensor circuit is shorted to power supply(24V) line Hydraulic oil temperature sensor circuit is open or shorted to battery + Fuel level sensor circuit is open or shorted to battery + Coolant temperature sensor circuit is open or shorted to battery +...

  • Page 240: Group 10 Engine Control System

    GROUP 10 ENGINE CONTROL SYSTEM 1. MCU MOUNTING Electric box Bolt(M8) 2. MCU ASSEMBLY Remove four pieces of bolt(3) of electric box(2). Disconnect 2 connectors from MCU. Remove 6 pieces of screw and open the cover of MCU. Inspection : Check PCB(Printed Circuit Board) If any damage is found, replace MCU assembly.
  • Page 241 3. EXCHANGE METHOD OF THE ROM Disassemble the ash tray(2). Disassemble the wiper motor cover(3). Disassemble the cluster(1). Loosen the screws(6EA) located back of the cluster. Then you can open the upper case of the cluster easily. Install the new ROM.(Be careful of direction and assmelbe the cluster in the reverse order to removal).

  • Page 242: Engine Throttle Lever

    4. ENGINE ACCEL ACTUATOR Accel actuator Push-pull cable for manual control ENGINE THROTTLE LEVER Throttle lever SL : Stopper, low idle SH : Stopper, high idle Accel actuator EMERGENCY CABLE (Push-pull cable) It controls engine speed by connecting onto the lever of the injection pump when the malfunction of the MCU or the accel actuator happen.
  • Page 243 ACCEL ACTUATOR DC motor Cable Ball joint Connector Connector Type 6P, female White(Potentiometer 5V) Blue(Potentiometer SIG) Black(Potentiometer GND) Line color & description Green(Motor+) Yellow(Motor -) Check resistance Inspection Spec : 1~2 (Between No.5-6) 0.8~1.2k (Between No.1-3) 5-17...

  • Page 244: Key Start

    ACCEL ACTUATOR CABLE SETTING PROCEDURE Key OFF Connect the ball joint of cable to engine throttle lever. Pull the cable to high stopper and put nut A edge to yoke of the bracket. Make throttle lever not contact to the edge of high stopper. Turn nut A to clockwise until touching to the edge of high stopper.

  • Page 245: Engine Speed Sensor

    5. ENGINE SPEED SENSOR DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER Gear teeth, flywheel Lock nut, speed sensor Clearance Flywheel housing INSTALLATION Clean contacting point of sensor. Loosen lock nut. Screw speed sensor into flywheel housing. Turn it back 135 when it contacts with gear teeth. Tight lock nut and connect wiring.

  • Page 246: Group 11 Eppr Valve

    GROUP 11 EPPR VALVE 1. COMPOSITION OF EPPR VALVE EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main hydraulic pump. ELECTRO MAGNET VALVE Receive electric current from MCU and move the spool proportionally according to the specific amount of electric current value.
  • Page 247 2. OPERATING PRINCIPLE STRUCTURE 5-22(1) Sleeve O-ring Solenoid valve Spring O-ring Connector Spool Pilot oil supply line(Pilot pressure) Return to tank Secondary pressure to flow regulator at hydraulic pump AT H MODE Pressure line is blocked and A oil returns to tank. AT S MODE Secondary pressure enters into A.
  • Page 248 3. EPPR VALVE CHECK PROCEDURE Spec : 200~500mA CHECK ELECTRIC VALUE AT EPPR VALVE Start engine. Set S-mode and cancel auto decel mode. Position the accel dial at 10. CN-75 If tachometer show approx 2000 50rpm, disconnect one wire harness from EPPR valve.

  • Page 249: Group 12 Monitoring System

    GROUP 12 MONITORING SYSTEM 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine. Various select switches are built into the monitor panel, which act as the control portion of the machine control system.
  • Page 250 CLUSTER CHECK PROCEDURE Start key : ON Check monitor initial 5 seconds All lamps light up. Buzzer sound. Check monitor after 5 seconds : Indicate cluster version and machine condition Cluster program version : 1.00 Indicates program version 1.00 for 5 seconds. Tachometer : 0rpm Fuel gauge : All light up below appropriate level Hydraulic temperature : All light up below appropriate level...
  • Page 251 3. CLUSTER CONNECTOR Signal Input / Output Power IG(24V) Input(20~32V) Cluster Input(0V) Serial-(RX) Input(Vpp=12V) Serial+(TX) Output(Vpp=4V) 21075MS16 5- 25...
  • Page 252 LCD main operation display Default screen Option screen Default screen Option screen Time display RPM display Hydraulic oil temperature gauge Fuel level gauge Engine coolant temperature gauge 1607A3CD02A 1607A3CD02B Time display This displays the current time. Refer to the page 5-36 to set time for details. 1607A3CD02C RPM display This displays the engine rpm.
  • Page 253 Warning of main operation screen Warning display Engine coolant temperature This lamp blinks and the buzzer sounds when the temperature of coolant is over the normal temperature 105 C 221 F) . Check the cooling system when the lamp blinks. Fuel level This lamp blinks and the buzzer sounds when the level of fuel is below 31...
  • Page 254 : LCD SYSTEM MENU Monitoring Diagnosis Management : Escape, Settings Display User Mode Return to the previous menu : Down/Left Direction : Up/Right Direction : Select(Enter) Activate the currently chosen item 2507A4OP95B Main menu : Menu information : Monitoring Equipment, Switch, Output : Diagnosis Current error, Recorded error : Maintenance...
  • Page 255 Display map Monitoring Diagnosis Protocol type 1 (Error display) (Recorded error delete) 5- 29...
  • Page 256 Protocol type 2 - If there are more than 2 error codes, each one can be displayed by pressing switch respectively. - 3 error codes ( SPN200200, FMI06, SPN6789, FMI04, 345) display. No change Maintenance Setting Time set : Adjusting : Setting System lock - Reserved 5- 30...
  • Page 257 Dual mode - Changing the MCU mode Display Operation skin Brightness Language User mode Usermode(U) is not selected. : Adjusting : Adjusting : Adjusting : Setting : Setting : Setting 5- 31...
  • Page 258 Warning and pilot lamp Engine oil pressure warning lamp This lamp blinks and the buzzer sounds after starting the engine because of the low oil pressure. If the lamp blinks during engine operation, shut OFF engine immediately. Check oil level. 21073CD07 Air cleaner warning lamp This lamp blinks and the buzzer sounds when the filter of air...
  • Page 259 Power max pilot lamp The lamp will be ON when pushing power max switch on the LH RCV lever. 21073CD11 Decel pilot lamp Operating auto decel or one touch decel makes the lamp ON. The lamp will be ON when pushing one touch decel switch on the LH RCV lever.

  • Page 260: Section 6 Troubleshooting

    SECTION 6 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting ------------------------------------------------------------------------------------- 6-1 Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------ 6-4 Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24 Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-39...

  • Page 261: Group 1 Before Trobleshooting

    SECTION 6 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION 1. INTRODUCTION When a trouble is occurred in the machine, this section will help an operator to maintain the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics system.
  • Page 262 2. DIAGNOSING PROCEDURE 2. DIAGNOSING PROCEDURE To carry out troubleshooting efficiently, the following steps must be observed. STEP 1. Study the machine system STEP 1. Study the machine system Study and know how the machine is operating, how the system is composing, what kinds of function are installed in the machine and what are specifications of the system components by the machine service manual.
  • Page 263 STEP 4. Inspect the trouble actually on the STEP 4. Inspect the trouble actually on the machine machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not.

  • Page 264: Group 2 Hydraulic And Mechanical System

    GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION MACHINE IN GENERAL If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration. Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look for the cause based on the troubleshooting principle and perform maintenance and adjustment to prevent major failure from occurring.
  • Page 265 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and check if rubber Replace hub or pieces or particles retighten are not present. setscrew. Coupling hub spline is worn or hub fastening...
  • Page 266 ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard Is oil level in level. Abnormal noise hydraulic oil comes out of Hydraulic pump is Disassemble tank within hydraulic pump broken. and repair. standard level? Do not hydraulic Abnormal noise...
  • Page 267 3. HYDRAULIC SYSTEM HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and Drop hydraulic oil dispose it or sample on hot plate and check if replace hydraulic foams come up. oil. Air is intruded. Check suction line and return line and eliminate...
  • Page 268 CAVITATION OCCURS WITH PUMP Cause Remedy Replenish specified oil to the standard level. Is hydraulic oil volume proper? Replace oil with one of proper Is not viscosity viscosity. of hydraulic oil too high? Clean suction Is not suction strainer. strainer clogged? Is not air intruding from pump Check for air...

  • Page 269: Swing System

    4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish specified oil to the Is safety solenoid standard level. valve pressure within standard? Safety valve faulty Repair or replace. Is gear pump pilot pressure within or not operated. standard level? Is oil in hydraulic tank within...
  • Page 270 SWING SPEED IS LOW Cause Remedy Swing port relief Disassemble and Does swing control valve is faulty. repair or replace. valve spool move smoothly by hand? Swing control valve Disassemble Is MCV pilot spool is stuck. and repair. pressure same on LH and RH Clogged or oil Clean pilot piping...
  • Page 271 SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble and change when LH valve is faulty. repair. and RH port relief valves are exchanged Shuttle valve is Disassemble and Does swing control faulty. repair. valve spool move smoothly by hand? Is MCV pilot...
  • Page 272 THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy Is swing shuttle valve normal? Disassemble Shuttle valve is and replace. faulty. Is brake spring normal? Is return spring of swing control Disassemble Brake spring is valve normal? and replace.

  • Page 273: Travel System

    5. TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause Remedy Does counterbalance spool in travel brake valve move lightly by hand? Disassemble Counter spool in Is travel brake valve pressure and repair or travel brake valve within standard replace.
  • Page 274 SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble Do LH and RH defective. and repair or travel speeds replace. change when LH and RH travel Relief valve built Disassemble Does the symptom brake valves are change when in travel motor is and repair.
  • Page 275 MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None friction plate Friction plate is Disassemble worn? Check if parking faulty. and repair. brake pilot line is not clogged.
  • Page 276 TRAVEL ACTION IS POWERLESS(Travel only) Cause Remedy Is travel motor's drain rate within standard level? Is travel brake Disassemble Travel motor is pressure within and repair. faulty. standard level? Is travel relief valve pressure Disassemble Travel brake within standard and repair or valve is defective.
  • Page 277 MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal. Is select valve normal? Select valve is Repair or Is pilot pressure faulty. replace. for travel select valve within standard level? Remove dirt on...
  • Page 278 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace. valve is replaced with other valve? Is MCV pilot pressure within standard level? Inspect if pilot piping is not...
  • Page 279 BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. Are other attachment speeds within Is combination Is speed low only standard levels? of oil streams in composite normal at boom operation? Flow summation Disassemble and hoisting and at Does spool of flow arm extrusion? check valve spool repair.
  • Page 280 BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the symptom faulty. and repair or change when port Normal replace. relief valve is replaced with Is control valve normal valve? return spring Is not hydraulic normal?
  • Page 281 BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder in Item "Speed is internal leakage within standard low". level? Is relief pressure in port relief Cylinder is faulty. Disassemble valve within and repair. standard level? Is relief pressure in main relief...
  • Page 282 BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil Is boom foot pin seal and boom greased proper. sufficiently? Frictional noise will disappear if they are kept used.
  • Page 283 HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full. Disconnect hose(A) from rod side of boom cylinder and drain oil from cylinders and hose.(Put cups on piping and hose ends) Raise bucket OFF the ground by retracting the arm cylinder rod.

  • Page 284: Group 3 Electrical System

    GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.8.
  • Page 285 2. COMMUNICATION ERROR "Co : Err" FLASHES ON THE CLUSTER Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU...
  • Page 286 BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU...

  • Page 287: Water Temperature Sensor

    WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Coolant overheat...
  • Page 288 WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Clogged air filter or...

  • Page 289: Engine Oil Pressure Switch

    WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Engine oil leakage,...
  • Page 290 WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy High temperature...
  • Page 291 8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Repair or replace...

  • Page 292: Fuel Sender

    9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Disconnection in...
  • Page 293 10. WHEN SAFETY SOLENOID DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 23. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Hydraulic...
  • Page 294 11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 8. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective hydraulic...
  • Page 295 12. WHEN ENGINE DOES NOT START Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. START SWITCH CN-8 Cause...
  • Page 296 13. WHEN STARTING SWITCH ON DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and master switch ON. START SWITCH CN-8 After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Disconnection in...
  • Page 297 14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.16. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 298 15. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.15. After checking, insert the disconnected connectors again immediately unless otherwise specified.

  • Page 299: Group 4 Mechatronics System

    GROUP 4 MECHATRONICS SYSTEM GROUP 4 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW 1. ALL ACTUATORS SPEED ARE SLOW Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. Spec : P-mode 2100 50 rpm S-mode 1950 50 rpm E-mode 1800...

  • Page 300: Test Procedure

    2) 2) TEST PROCEDURE TEST PROCEDURE (1) (1) Test 1 Test 1 : Check resistance at connector SPEC : 45~50 (20˚C) CN-75. CN-75 Starting key OFF. Multimeter Disconnect connector CN-75 from EPPR valve at main hydraulic pump. Check resistance between 2 lines as figure.
  • Page 301 2. ENGINE STALL 2. ENGINE STALL Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Not enough Contact cummins engine power engine dealer Check pressure at EPPR Valve Defective EPPR Replace SPEC : 4~20 kgf/cm...
  • Page 302 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : 160~440 mA CN-75 Multimeter Test 4 Test 4 : Check electric current at EPPR valve at S-mode Install multimeter as figure. Start engine. Set the accel dial at "10" (max) EPPR valve Set S-mode with 2000 50 rpm.
  • Page 303 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse the MCU See if all lamps...
  • Page 304 4. AUTO DECEL SYSTEM DOES NOT WORK 4. AUTO DECEL SYSTEM DOES NOT WORK Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE INSPECTION PROCEDURE 1) 1) Cause Remedy Defective MCU Replace Defective travel Replace Check voltage pressure switch...
  • Page 305 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 6 Test 6 : Check voltage at CN-51(13) and ground. Prepare 1 piece of thin sharp pin, steel or copper. CN-50 CN-51 Insert prepared pin to rear side of connectors : One pin to (13) of CN-51.
  • Page 306 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
  • Page 307 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 8 Test 8 : Check voltage at CN-51(10) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (10) of CN-51.
  • Page 308 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
  • Page 309 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 9 : Check voltage at CN-51(11) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (11) of CN-51. CN-50 CN-51 Starting key ON.
  • Page 310 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE INSPECTION PROCEDURE 1) 1) Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage...
  • Page 311 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 10 Test 10 : Check voltage at CN-51(12) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (12) of CN-51.
  • Page 312 8. MALFUNCTION OF BOOM UP PRESSURE SENSOR 8. MALFUNCTION OF BOOM UP PRESSURE SENSOR Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-51 Detective boom up Replace or repair...
  • Page 313 2) 2) TEST PROCEDURE TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 11 Test 11 : Check voltage at CN-51(36) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (36) of CN-51.
  • Page 314 9. MALFUNCTION OF POWER MAX 9. MALFUNCTION OF POWER MAX Before carrying out below procedure, check all the related connectors are properly inserted. 1) 1) INSPECTION PROCEDURE INSPECTION PROCEDURE Cause Remedy Check resistance Defective power Repair or replace between CN-88 (1) - (2) max.
  • Page 315 TEST PROCEDURE TEST PROCEDURE 2) 2) SPEC : Key ON : 24 1V Key OFF : 0V Test 12 Test 12: Check voltage between connector (1) (1) CN-88(2) - GND. Disconnect connector CN-88 from power max solenoid valve. Power max switch Start key ON.

  • Page 316: Section 7 Maintenance Standard

    SECTION 7 MAINTENANCE STANDARD SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test -------------------------------------------------------------------------- 7-1 Group 2 Major Components -------------------------------------------------------------------------------------------- 7-21 Group 3 Track and Work Equipment ------------------------------------------------------------------------------- 7-31...

  • Page 317: Group 1 Operational Performance Test

    Whenever a new machine is delivered in parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec. 2) 2) OPERATIONAL PERFORMANCE OF A OPERATIONAL PERFORMANCE OF A...

  • Page 318: Service Limit

    2. TERMINOLOGY 2. TERMINOLOGY STANDARD STANDARD Specifications applied to the brand-new machine, components and parts. 140LC7MS02 SERVICE LIMIT SERVICE LIMIT The lowest acceptable performance level. When the perfor mance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
  • Page 319 3. OPERATION FOR PERFORMANCE TESTS 3. OPERATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. (1) (1) The machine The machine Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

  • Page 320: Engine Speed

    2) 2) ENGINE SPEED ENGINE SPEED Measure the engine speed at each power mode The engine speed at each power mode must meet standard RPM; if not, all other operational performance data will be unreliable. It is essential to perform this test first.

  • Page 321: Travel Speed

    TRAVEL SPEED TRAVEL SPEED Measure the time required for the excavator to travel a 20 m test track. (2) (2) Preparation Preparation Adjust the tension of both tracks to be equal. Prepare a flat and solid test track 20m in length, with extra length of 3 to 5 m on 0.3~0.5m both ends for machine acceleration and...
  • Page 322 TRACK REVOLUTION SPEED TRACK REVOLUTION SPEED Measure the track revolution cycle time with the track raised off ground. (2) (2) Preparation Preparation Adjust the tension of both side tracks to 90 ~ 110 be equal. On the track to be measured, mark one shoe with chalk.

  • Page 323: Travel Deviation

    TRAVEL DEVIATION TRAVEL DEVIATION Measure the deviation by the tracks from a 20m straight line. (2) (2) Preparation Preparation Adjust the tension of both tracks to be equal. Provide a flat, solid test yard 20 m in length, with extra length of 3 to 5 m on 0.3~0.5m both ends for machine acceleration and deceleration.
  • Page 324 SWING SPEED SWING SPEED Measure the time required to swing three complete turns. (2) (2) Preparation Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes.
  • Page 325 SWING FUNCTION DRIFT CHECK SWING FUNCTION DRIFT CHECK Measure the swing drift on the bearing outer circumference when stopping after a 360 full speed swing. (2) (2) Preparation Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging.
  • Page 326 SWING BEARING PLAY SWING BEARING PLAY Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. (2) (2) Preparation Preparation Check swing bearing mounting cap screws for loosening. Check the lubrication of the swing bearing.
  • Page 327 9) 9) HYDRAULIC CYLINDER CYCLE TIME HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. (2) (2) Preparation Preparation To measure the cycle time of the boom Boom cylinder Raise cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown.
  • Page 328 Bucket cylinders Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.
  • Page 329 DIG FUNCTION DRIFT CHECK DIG FUNCTION DRIFT CHECK Measure dig function drift, which can be caused by oil leakage in the control valve and boom, standard arm, and standard bucket cylinders, with the loaded bucket. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to purge air.
  • Page 330 CONTROL LEVER OPERATING FORCE CONTROL LEVER OPERATING FORCE Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip. (2) (2) Preparation Preparation Keep the hydraulic oil temperature at 50 5˚C. Measurement Measurement (3) (3) Start the engine.
  • Page 331 CONTROL LEVER STROKE CONTROL LEVER STROKE Measure each lever stroke at the lever top using a ruler. When the lever has play, take a half of this value and add it to the measured stroke. Preparation Preparation (2) (2) Keep the hydraulic oil temperature at 50 5˚C.
  • Page 332 PILOT PRIMARY PRESSURE PILOT PRIMARY PRESSURE Preparation Preparation (1) (1) Stop the engine. Push the pressure release button to bleed air. Loosen and remove plug on the pilot pump delivery port and connect pressure gauge. Star t the engine and check for oil leakage from the port.
  • Page 333 FOR TRAVEL SPEED SELECTING PRESSURE: FOR TRAVEL SPEED SELECTING PRESSURE: (1) (1) Preparation Preparation Stop the engine. Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. To measure the speed selecting pressure: Install a connector and pressure gauge assembly to turning joint P port as shown.
  • Page 334 SWING PARKING BRAKE RELEAS SWING PARKING BRAKE RELEASING PILOT PR ING PILOT PRESSURE ESSURE (1) (1) Preparation Preparation Stop the engine. Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. The pressure release L wrench to bleed air.
  • Page 335 MAIN PUMP DELIVERY PRESSURE MAIN PUMP DELIVERY PRESSURE Preparation Preparation (1) (1) Stop the engine. Push the pressure release button to bleed air. To measure the main pump pressure. Install a connector and pressure gauge assembly main pump gauge port as shown.
  • Page 336 SYSTEM PRESSURE REGULATOR SYSTEM PRESSURE REGULATOR RELIEF SETTING RELIEF SETTING (1) (1) Preparation Preparation Stop the engine. Push the pressure release button to bleed air. To measure the system relief pressure. Install a connector and pressure gauge assembly main pump gauge port, as shown.

  • Page 337: Group 2 Major Components

    GROUP 2 MAJOR COMPONENT GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 1. MAIN PUMP 14097MP01 Recommended Standard Part name & inspection item replacement Counter measures dimension value Clearance between piston (1) & Replace piston or 0.028 0.056 cylinder bore (2) cylinder.

  • Page 338: Main Control Valve

    2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE Part name Inspection item Criteria & measure · Existence of scratch, rusting or corrosion. · In case of damage in following section, replace Casing part. - Sliding sections of casing fore and spool, especially land sections applied with holded pressure.
  • Page 339 3. SWING DEVICE WEARING PARTS Standard Standard Inspection item Counter measures dimension dimension Replace piston or Clearance between piston and cylinder block bore 0.028 0.058 cylinder block Replace assembly Play between piston and shoe caulking section ( ) of piston and shoe Replace assembly Thickness of shoe (t) of piston and shoe...

  • Page 340: Travel Motor

    4. TRAVEL MOTOR 4. TRAVEL MOTOR 1) 1) TYPE 1 TYPE 1 Problem Cause Remedy · · Does not Pressure is not Pump failure Check if action other than traveling is start developed available. If faulty, repair. · · Control valve malfunction Check if spool moves correctly.
  • Page 341 2) 2) TYPE 2 TYPE 2 Troubleshooting Troubleshooting ① The motor does not rotate The motor does not rotate Problem Cause Remedy The pressure of a motor · The oil is bypassed at relief valve - Fix or exchange relief valve does not increase ·...
  • Page 342 ④ Shortage of rotating force at the standard value Shortage of rotating force at the standard value Problem Cause Remedy Brake is released, but the · Excavator main relief valve is not set - Resetting the main relief valve turning force is low correctly ·...
  • Page 343 5. RCV LEVER 5. RCV LEVER Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage becomes Conditions : more than 1000 cc/m at neutral handle position, or more Primary pressure : 40 kgf/cm than 2000 cc/m during operation. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has worn...
  • Page 344 6. RCV PEDAL 6. RCV PEDAL Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage effect Conditions : to the system. For example, the primary pressure Primary pressure : 40 kgf/cm drop. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has...
  • Page 345 7. TURNING JOINT 7. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination. Replace sealing sections. ·Worn abnormality or damaged more than 0.1 mm Sliding surface Replace between body and (0.0039 in) in depth due to seizure contamination.
  • Page 346 8. CYLINDER 8. CYLINDER Part name Inspecting section Inspection item Remedy ·Neck of rod pin ·Presence of crack ·Replace Piston rod ·Weld on rod hub ·Presence of crack ·Replace · Stepped part to which piston ·Presence of crack ·Replace is attached. ·Threads ·Presence of crack ·Recondition or replace...

  • Page 347: Group 3 Track And Work Equipment

    GROUP 3 TRACK AND WORK EQUIPMENT GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK 1. TRACK 1) 1) TRACK ROLLER TRACK ROLLER 21037MS01 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø190 Rebuild or Ø150 Ø138 Outside diameter of tread...

  • Page 348: Carrier Roller

    2) 2) CARRIER ROLLER CARRIER ROLLER 21037MS02 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø175 Rebuild or Ø151 Ø141 Outside diameter of tread replace Width of tread 37.25 42.25 Width of flange 18.25 Standard size &...
  • Page 349 3) 3) IDLER IDLER 21037MS03 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø552 Ø507 Ø497 Outside diameter of tread Rebuild or replace Width of protrusion Total width Width of tread Standard size & Tolerance Standard Clearance clearance...
  • Page 350 4) 4) TRACK TRACK 21037MS04 Unit : mm Check item Criteria Remedy Standard size Repair limit Turn or Link pitch replace 171.45 175.65 Ø53.75 Ø43.95 Outside diameter of bushing Rebuild or Height of grouser replace Height of link 94.5 86.5 Tightening torque Initial tightening torque : 42±4 kgf·m Retighten...
  • Page 351 5) 5) TRACK FRAME AND RECOIL SPRING TRACK FRAME AND RECOIL SPRING 21037MS05 Unit : mm Check item Criteria Remedy Standard size Tolerance Repair limit Track frame Vertical width of idler guide Rebuild or Idler support - 0.5 replace Track frame Horizontal width of idler guide Idler support Standard size...

  • Page 352: Work Equipment

    2. WORK EQUIPMENT 2. WORK EQUIPMENT 14097MS01 Unit : mm Bushing Remedy Measuring point Normal Recomm. Recomm. Mark & Limit Limit (Pin and Bushing) service value service Remark of use of use limit limit Boom Rear 68.5 70.5 Replace 〃 Boom Cylinder Head 68.5 70.5...

  • Page 353: Section 8 Disassembly And Assembly

    SECTION 8 DISASSEMBLY AND ASSEMBLY SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 8-1 Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 8-4 Group 3 Pump Device ------------------------------------------------------------------------------------------------------ 8-7 Group 4 Main Control Valve --------------------------------------------------------------------------------------------- 8-29 Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 8-43 Group 6 Travel Device ------------------------------------------------------------------------------------------------------ 8-64 Group 7 RCV Lever ---------------------------------------------------------------------------------------------------------- 8-119 Group 8 Turning Joint ------------------------------------------------------------------------------------------------------- 8-134...

  • Page 354: Group 1 Precaution

    SECTION 8 DISASSEMBLY AND ASSEMBLY SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS GROUP 1 PRECAUTIONS 1. REMOVAL WORK 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
  • Page 355 2. INSTALL WORK 2. INSTALL WORK Tighten all bolts and nuts (sleeve nuts) to the specified torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive.
  • Page 356 3. COMPLETING WORK 3. COMPLETING WORK If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.

  • Page 357: Group 2 Tightening Torque

    GROUP 2 TIGHTENING TORQUE GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf m lbf ft Engine mounting bolt (engine-bracket, FR) Engine mounting bolt (engine-bracket, RR) 1.75 72.3 Engine mounting bolt (bracket-frame, FR) 25.3 Engine Engine mounting bolt (bracket-frame, RR) 25.3...

  • Page 358: Torque Chart

    2. TORQUE CHART 2. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT BOLT AND NUT 1) 1) Coarse thread Coarse thread (1) (1) Bolt size kgf m lbf ft kgf m lbf ft 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 1.25...
  • Page 359 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE TYPE) kgf m lbf ft Thread size (PF) Width across flat (mm) 28.9 1/4" 36.2 3/8" 68.7 1/2" 130.2 3/4" 151.9 1" 253.2 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS TYPE) Thread size (UNF) Width across flat (mm) kgf m...

  • Page 360: Group 3 Pump Device

    GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 361 INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level. Bleed the air from the hydraulic pump. Remove the air vent plug(2EA).
  • Page 362 2. MAIN PUMP(1/2) STRUCTURE 789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113 153 156 124 312 114 466 885 467 141 981 271 401 04 Gear pump 261 Seal cover(F) 717 O-ring 111 Drive shaft(F) 271 Pump casing 719 O-ring...
  • Page 363 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
  • Page 364 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 Material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug(Materal : S45C) PT1/16 0.16 Wind a seal tape 1 1/2 to 2...
  • Page 365 DISASSEMBLY Select place suitable to disassembling. Select clean place. Spread rubber sheet, cloth or so on on overhaul workbench top to prevent parts from being damaged. Remove dust, rust, etc, from pump surfaces with cleaning oil or so on. Remove drain port plug(468) and let oil out of pump casing(Front and rear pump).
  • Page 366 Pull cylinder block(141) out of pump casing(271) straightly over drive shaft(111). Pull out also pistons(151), set plate(153), spherical bush(156) and cylinder springs(157) simultaneously. Take care not to damage sliding surfaces of cylinder, spherical bushing, shoes, swash plate, etc. Remove hexagon socket head bolts(406) and then seal cover(F, 261).
  • Page 367 (12) Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports. (13) Remove valve plates(313, 314) from valve block(312). These may be removed in work(6). (14) If necessary, remove stopper(L, 534), stopper(S, 535), servo piston(532) and tilting pin(531) from pump casing(271), and needle bearing(124) and splined...
  • Page 368 ASSEMBLY reassembling reverse disassembling procedures, paying attention to the following items. Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. Clean each part fully with cleaning oil and dry it with compressed air. Do not fail to apply clean working oil to sliding sections, bearings, etc.
  • Page 369 Place pump casing with its regulator fitting surface down, fit tilting bush of swash plate to tilting pin(531) and fit swash plate (212) to swash plate support(251) correctly. Confirm with fingers of both hands that swash plate can be removed smoothly. Apply grease to sliding sections of swash plate and swash plate support, and drive shaft can be fitted easily.
  • Page 370 Fit valve plate(313) to valve block(312), entering pin into pin hole. Take care not to mistake suction / delivery directions of valve plate. Fit valve block(312) to pump casing(271) and tighten hexagon socket head bolts (401). At first assemble this at rear pump side, and this work will be easy.
  • Page 371 3. REGULATOR STRUCTURE(1/2) 8-18...
  • Page 372 REGULATOR(2/2) 651 652 SECTION A-A Hexagon socket screw Sleeve, pf O-ring Hexagon socket screw Pilot cover O-ring Hexagon socket screw Pilot cover(QMC) O-ring Hexagon socket screw Pilot piston O-ring Plug Spring seat(Q) O-ring Casing Adjust stem(Q) O-ring Feed back lever Pilot spring O-ring Lever(1)
  • Page 373 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
  • Page 374 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 Material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plut(Materal : S45C) PT1/16 0.16 Wind a seal tape 1 1/2 to 2...
  • Page 375 DISASSEMBLY Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
  • Page 376 After removing cover(C, 629) subassembly, take out outer spring(625), inner spring (626) and spring seat(C, 624) from compensating section. Then draw out adjusting ring(Q, 645), pilot spring(646) and spring seat(644) from pilot section. Adjusting ring(Q,645) can easily be drawn out with M4 bolt. Remove hexagon socket head screws (436, 438) and remove pilot cover(641).
  • Page 377 Remove lever(2, 613). Do not draw out pin(875). Work will be promoted by using pincers or so on. (10) Draw out pin(874) and remove feedback lever(611). Push out pin(874, 4mm in dia.) from above with slender steel bar so that it may not interfere with lever(1, 612).
  • Page 378 (11) Remove lever(1, 612). Do not draw out pin(875). (12) Draw out pilot piston(643) and spool(652). (13) Draw out piston case(622), compensating piston(621) and compensating rod(623). Piston case(622) can be taken out by pushing compensating rod(623) at opposite side of piston case. This completes disassembly.
  • Page 379 ASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following items. Always repair parts that were scored at disassembly. Get replacement parts ready beforehand. Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
  • Page 380 Fit feedback lever(611), matching its pin hole with pin hole in spool. Then insert pin(874). Insert pin in feedback lever a little to ease Lever (1) side Lever (2) side operation. (Fulcrum plug of Take care not to mistake direction of adjusting plug side) feedback lever.
  • Page 381 (11) Fit set spring(655) to spool hole and put compensating piston(621) and piston case(622) into compensating hole. Fit pilot cover(641) and tighten it with hexagonal socket head screws(436, 438). (12) Put spring seat(644), pilot spring(646) and adjusting ring(Q, 645) into pilot hole. Then fix spring seat(624), inner spring (626) and outer spring(625) into compensating hole.

  • Page 382: Group 4 Main Control Valve

    GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 383 2. STRUCTURE(1/4) DETAIL OF LOCK VALVE 1607A8MC04 Spring Plug Plug Poppet Filter Spring seat Spring Piston Restrictor Socket Spring Plug Poppet guide Plug Housing-P1 Pilot poppet Plug Spool assy Poppet seat Plug Spool assy Piston 1 Socket head bolt Spool assy Piston guide O-ring Spool assy...
  • Page 384 STRUCTURE(2/4) 1607A8MC05 18 Plug 25 Overload relief valve 78 O-ring 19 Poppet 1 27 Plug 80 O-ring 20 Spring 59 Plug 81 O-ring 21 Plug 61 Plug 84 O-ring 22 Poppet 2 68 Plug 86 Back-up ring 23 Spring 72 Plug 88 Back-up ring 24 Main relief valve 76 O-ring...
  • Page 385 STRUCTURE(3/4) 28 , DETAIL OF LOCK VALVE 81 86 1607A8MC06 Stopper Plug Plug Plug Plug Housing-P2 Holding block Plug Spool assy Poppet Socket head bolt Spool assy Restrictor O-ring Spool assy Spring O-ring Spool assy Poppet guide O-ring Spool assy Pilot poppet O-ring Spool assy...
  • Page 386 STRUCTURE(4/4) 1607A8MC07 18 Plug 26 Plug 77 O-ring 19 Poppet 1 55 Orifice 80 O-ring 20 Spring 56 Coin type filter 81 O-ring 21 Plug 58 Plug 82 O-ring 22 Poppet 2 59 Plug 83 O-ring 23 Spring 70 Plug 84 O-ring 25 Overload relief valve 72 Plug...
  • Page 387 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be remove from the machine, apply caps and masking seals to all ports.
  • Page 388 DISASSEMBLY Disassembly of spools without holding valve Loosen hexagon socket head bolts with washer (Hexagon wrench : 5mm) Remove the pilot cover. Pay attention not to lose the O-ring under the pilot cover. Remove the spool assembly from the body by hand slightly. When extracting each spool from its body, pay attention not to damage the body.
  • Page 389 Disassembly of spools with holding valve(Boom 1, Arm 1 spool) Loosen hexagon socket head bolts with washer (Hexagon wrench : 5mm) Remove the pilot cover with internal parts. Pay attention not to lose the O-ring and the poppet under the pilot cover. Pay attention not to damage the "piston A"...
  • Page 390 Disassembly of the holding valve Remove the pilot cover with the holding valve as described on previous page. Do not disassembled internal parts of the pilot cover. Loosen the poppet seat and remove the poppet, the spring seat, the spring and the check. (Spanner : 26 mm) Pay attention not to lose the poppet.
  • Page 391 Disassembly of the load check valve and the negative relief valve The load check valve Fix the body to suitable work bench. Pay attention not to damage the body. Loosen the plug (Hexagon wrench : 10mm). Remove the spring and the load check valve with pincers or magnet. The negative relief valve Loosen the socket (Hexagon wrench : 12mm).
  • Page 392 Disassembly of the main and overload relief valve Fix the body to suitable work bench. Remove the main relief valve. (Spanner : 32mm) Remove the overload relief valve. (Spanner : 32mm) When disassembled, tag the relief valve for identification so that they can be reassembled correctly.
  • Page 393 Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. Control valve Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
  • Page 394 ASSEMBLY General precaution In this assembly section, explanation only is shown. For further understanding, please refer to the figures shown in the previous structure & disassembly section. Pay close attention to keeping all seals free from handling damage and inspect carefully for damage before using them.
  • Page 395 Covers Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket head bolts to the specified torque. Hexagon wrench : 5mm Tightening torque : 1.0~1.1kgf m(7.2~7.9lbf ft) Confirm that O-rings have been fitted. Fit spring covers to the spring end for the spools, and tighten hexagon socket head bolts to the specified torque.

  • Page 396: Group 5 Swing Device

    GROUP 5 SWING DEVICE GROUP 5 SWING DEVICE 1. REMOVAL AND INSTALL OF MOTOR 1. REMOVAL AND INSTALL OF MOTOR REMOVAL REMOVAL 1) 1) Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 397 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE STRUCTURE 1) 1) DETAIL K 11 10 9 22 7 37 30 32,33 8 13 12 15 14 17 2 3 4 14W92SM02 Body 16 Brake piston 31 Anti-rotating valve Oil seal 17 O-ring...
  • Page 398 2) 2) DISASSEMBLY DISASSEMBLY Lift the motor out. Clean the motor in kerosene and dry with compressed air. ※ To avoid dust inside the motor, mask all the ports of the motor with tapes. 32038SM01 Loosen the drain plug to discharge oil in the body(1).
  • Page 399 Remove the relief valve (30) from rear cover (20). 32038SM05 Remove plug (25) from rear cover (20) and spring (28), check (29). ※ Be careful not to damage the check seat assembly. 32038SM06 Remove rear cover (20) from body (1). Then, remove the valve plate (23) from rear cover (20) with care.
  • Page 400 Remove brake piston (16) from body (1). 32038SM09 (10) Remove the cylinder (9) from the drive shaft (5) with the motor positioned horizontally. Remove ball guide (11), set plate (12), piston (13) and shoe plate (8). 32038SM10 (11) Remove friction plate (14) and separate plate (15) from body (1).
  • Page 401 (13) Remove the cone of roller bearing (3) by press. ※ Do not reuse bearings. Press Output shaft Roller bearing 32038SM15 (14) Remove bushing (6) and oil seal (2) from body (1). 25038SM05 (15) Remove the needle bearing (21) from the rear cover (20) by using slide hammer bearing puller.
  • Page 402 (16) When disassembling the relief valve, release the adjusting screw (5). Remove the piston (6), spring seat (8), spring (4) and plunger (3) with the body (1) downwards. 14007A2SM05 This completes disassembly. 8-49...
  • Page 403 3) 3) ASSEMBLY ASSEMBLY Do the reassembly in the reverse procedure of the disassembly. Apply three bond of white color on outer surface of oil seal (2) and insert it to the body (1). 11078SM22 Install the roller bearing (3) to the drive shaft (5).
  • Page 404 Insert the shoe plate (8) with the body (1) position horizontally. 32038SM28 Insert the ball guide (11) into the cylinder (9). 32038SM29 Install the piston sub-assembly (13) to the set plate (12). 32038SM30 Reassemble the piston assembly (9) to the body (1).
  • Page 405 Assembly friction plate (14) and separate plate (15) to the body (1). 11078SM26 (10) Insert O-ring (17) inside the body (1). 32038SM33 (11) Reassemble brake piston (16) to the body (1). 32038SM34 (12) Reassemble brake spring (19) to the brake piston (16).
  • Page 406 (13) When assembling the needle bearing (21), insert the needle bearing (21) into rear cover (20) by hammering. 32038SM36 (14) Reassemble valve plate (23) to the rear cover (20) and reassemble O-ring (18). 32038SM37 (15) Connect the rear cover (20) with the body (1) and tighten the wrench bolt (24).
  • Page 407 (17) Insert O-rings to the relief valve (30) and reassemble them to rear cover (20). This completes assembly. 32038SM42 8-54...
  • Page 408 3. REMOVAL AND INSTALL OF REDUCTION GEAR 3. REMOVAL AND INSTALL OF REDUCTION GEAR 1) 1) REMOVAL REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove mounting bolts (2). Remove the reduction gear assembly.
  • Page 409 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE STRUCTURE 1) 1) 23 5 1 16 10 11 9 21 12 24 Oil drain Grease port VIEW A 14W92SM03 Casing Pin No.2 assembly Stop ring Drive shaft Sun gear No.
  • Page 410 2) 2) DISASSEMBLY DISASSEMBLY Remove level gauge (38) from the swing motor casing. ※ Pour the gear oil out of reduction gear into the clean bowl to check out the friction decrease. 14W98SM05 Loosen the socket bolts (24) to separate swing motor from reduction gear.
  • Page 411 Disassembling carrier 1 (12) assembly. ① Remove stop ring (18). ② Remove thrust washer (15) and planet gear 1(13) from the carrier 1 (12). ③ Using M8 solid drill, crush spring pin (17) so that the pin 1 (14) can be removed by hammering.
  • Page 412 Disassembling carrier 2 (8) assembly. ① Using M8 solid drill, crush spring pin (17) so that the pin 2 (10) can be removed. ※ Do not reuse spring pin (17). ② Remove pin 2 (10) and planet gear 2 (9) from the carrier 2 (8).
  • Page 413 (12) Remove roller bearing (6) and oil seal (7) from the drive shaft (2). ※ Do not reuse oil seal (20) once removed. 14W98SM16 (13) Using the bearing disassembly tool, remove roller bearing (5). 14W98SM17 (14) Remove plugs (25, 26) from the casing (1).
  • Page 414 3) 3) ASSEMBLY ASSEMBLY Assemble roller bearing (5) inside the casing (1). 14W98SM17 Assemble the drive shaft (2) into the casing (1) and then install oil seal (7) and roller bearing (6). 14W98SM19 Install stop ring (19) on top of drive shaft (2).
  • Page 415 Assembling carrier 2 (8) assembly. ① Install the planet gear 2 (9) inside the carrier 2 (8). ② Assemble the pin 2 (10) to the carrier 2 (8) and then press the spring pin (17) by hammering. ③ Punch 2 points of the spring pin (17) lip. ※...
  • Page 416 (10) Assemble carrier 1 (12) assembly into the ring gear (21). 14W98SM20 (11) Hammer 4 knock pins (22) around the ring gear (21). (12) Assemble sun gear 1 (16) to the drive shaft of the swing reduction gear. 14W98SM21 (13) Apply loctite to the tapped holes of the ring gear (21) and then mount swing motor onto the ring gear (21).

  • Page 417: Group 6 Travel Device

    GROUP 6 TRAVEL DEVICE (TYPE1) GROUP 6 TRAVEL DEVICE (TYPE1) 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Swing the work equipment 90。and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 418 2. TRAVEL MOTOR 2. TRAVEL MOTOR STRUCTURE STRUCTURE 1) 1) 42 26 36 30 27 43 38,21 25 37 67 49 89,90 SECTION A - A 209 210 46 205 208 207 204 203 202 71 126 10 11 5 101 129 130 103 61 108 14092TM03...
  • Page 419 2) 2) TOOLS TOOLS (1) (1) Standard tools Standard tools Name Description/Size 6 (M8) (PT1/4), 8 (M10) each 1 Hexagon wrench 10 (M12) (PF1/2) each 1 (JIS B 4650) 4 (M6) Socket wrench Nominal 30 kgf · m dial type Torque wrench Nominal 90 kgf ·...
  • Page 420 (2) (2) Special tools Special tools ① Inversion working bench 25098TM101 ② Pressurize jig (Ⅰ) 14098TM90 ③ Pressurize jig (Ⅱ) 25098TM102 ④ Aluminum bar 14098TM91 ⑤ Steel bar 25098TM103 8-67...

  • Page 421: Tightening Torque

    ⑥ Sharp punch 14098TM92 ⑦ Draw bar 14098TM93 3) 3) TIGHTENING TORQUE TIGHTENING TORQUE Tightening torque Item No. Parts name Size kgf · m lbf · ft 10 ± 2 72.3 ± 14.5 Plug PF 3/8 M30 × 1.5 36 ± 7.2 260 ±...

  • Page 422: General Precautions

    3. DISASSEMBLY 3. DISASSEMBLY GENERAL PRECAUTIONS GENERAL PRECAUTIONS Spread rubber or vinyl cover on the work bench. When disassembling the travel motor, provide a match mark on the mating face or each part. Arrange the detached parts to prevent them from being damaged or lost. The disassembled seals must be replaced with new ones as a rule even if they are free from dam- age.
  • Page 423 Remove planetary gear R (117), needle bearing, inner race (119) and holder (116) from hub (105). 14098TM62 Remove sun gear (114), screw (110) and thrust plate F (113). 14098TM63 Remove the thrust washer (109), planetary gears F (108), needle bearings (111) and collar (112) from hub (105).
  • Page 424 Remove the nut ring (103) from hub (105). 14098TM66 Remove the spindle (101) from the hub (105). ※ Remove it using a crane after eye bolt is assem- bled at the hub (105). 14098TM67 (10) Remove the floating seal (102), seal ring (129), angular bearings (125, 2EA), snap ring (106) and O-ring (130) from the hub (105).
  • Page 425 (12) Remove the oil seal (32) from spindle (101). 14098TM70 2) 2) DISASSEMBLING THE HYDRAULIC MOTOR PART ISASSEMBLING THE HYDRAULIC MOTOR PART Remove the relief valve (70, 2EA) from rear fl ange (1). ※ Tools ·Hexagon socket ·Torque wrench 14098TM05 Remove hexagon socket head bolts (43, 8EA) from the rear fl...
  • Page 426 Remove the parallel pin (42) from the spindle (101). 14098TM08 Remove the O-ring (126) from the spindle (101). ※ Do not reuse the O-ring (126). 14098TM09 Disassembling the rear fl ange (1) part Disassembling the rear fl ange (1) part ①...
  • Page 427 ④ Remove the ball bearing (50) from the rear fl ange (1). 14098TM12 Disassembling the brake valve part Disassembling the brake valve part ① Remove two plugs (24) from the rear fl ange (1). ※ User can work easily if sub-disassembly was done on the reversal table.
  • Page 428 ⑤ Remove the springs (30, 2EA), valves (27, 2EA) from rear fl ange (1). 14098TM16 ⑥ Remove the O-ring (37) from plug (24). ※ Do not reuse the O-ring (37). 14098TM17 ⑦ Remove the O-ring (36) from plug (26). ※ Do not reuse the O-ring (36).
  • Page 429 ② Remove the spool (65) and spring (66) from rear fl ange (1). 14098TM20 (10) (10) Disassembling the plug (52). Disassembling the plug (52). ① Do not remove plug (52) if it not to be necessary. Disassembling the plug (52) if it was malfunction because of get mixed with dust.
  • Page 430 ③ Remove the valve seat (18) by injecting com- pressed air from the access hole in the spindle (101) after caulking the hole of valve seat (18). 14098TM23 ④ Remove the valve (19) and spring (20) from rear fl ange (1) downside hole with shaking lightly. 14098TM24 ⑤...
  • Page 431 ② Remove the O-rings (35, 39) and backup rings (47 , 48) from the piston (12). ※ Do not reuse O-rings (35, 39) and backup rings (47, 48) after removal. 14098TM27 Disassembling the hydraulic motor part Disassembling the hydraulic motor part (13) (13) ①...
  • Page 432 (14) (14) Disassembling the cylinder block kit Disassembling the cylinder block kit ① Piston assembly [piston (5), shoe (6)] from the removed cylinder block (4). 14098TM30 ② Piston (5) and shoe (6) from the removed retainer plate (7). 14098TM31 ③ Thrust ball (8) from the removed cylinder block (4).
  • Page 433 (15) (15) Disassembling the spring of the cylinder block Disassembling the spring of the cylinder block ① Put the cylinder block (4) on the pressurize jig. ② Press the washer (10) with pressurize jig, and re- move the spring (14) after snap ring (45) removed. ※...

  • Page 434: Reassembly Procedure

    4. REASSEMBLY 4. REASSEMBLY GENERAL PRECAUTIONS GENERAL PRECAUTIONS Reassemble in a work area that is clean and free from dust and dirt. Handle parts with bare hands to keep them free of linty contaminants. Repair or replace the damaged parts. Each parts must be free of burrs its corners.
  • Page 435 Reassembe the cylinder block kit Reassembe the cylinder block kit ① Install washer (10), spring (14, 9EA), washer (10) and snap ring (45) in that order, into the cylinder block (4) inner part. ② Put the cylinder block (4) on the pressurize jig. 14098TM35 ③...
  • Page 436 ⑤ Install cylinder block (4) assembly to the shaft (2). ※ After fi tting splines of both cylinder block (4) and shaft (2), assemble them. ※ After installing the cylinder (4), confi rm whether it revolves or not by turning using both hands. ※...
  • Page 437 ② Install spring (30) and valve (27) into the plug (26). ③ Install plug (26) into the rear fl ange (1). ※ Install spring (30) and valve (27) into the plug (26), and then grease the spring (30) and the valve (27) and hand-lock the former.
  • Page 438 ⑦ Install spring retainer (25) and spring (28) into the plug (24). ⑧ Install plug (24) into the rear fl ange (1). ⑨ Tighten the plug (24) to the required torque. ※ Tightening torque : 36 ± 5.4 kgf · m (260 ± 39 lbf · ft) ※...
  • Page 439 ② Mount the rear fl ange (1) on a working bench that the mounting side of the spindle (101) faces up- ward. ③ Install valve (19), spring (20) and valve seat (18) in that order. 14098TM49 ④ After new ring (22) bend somewhat and put the valve seat (18), then into the rear fl...
  • Page 440 ⑦ Install timing plate (9) into the rear fl ange (1). ※ Apply hydraulic oil to the contact surface of rear fl ange. 14098TM10 Reassembe the rear fl ange (1) and spindle (101) Reassembe the rear fl ange (1) and spindle (101) ①...
  • Page 441 ⑤ Tighten the socket bolt (43) into the spindle (101) to the required torque. ※ Tightening torque : 5.9 ± 1.0 kgf · m (42.7 ± 7.2 lbf · ft) ※ Tools · Adapter for hexagon wrench 8 · Torque wrench 14098TM06 ⑥...
  • Page 442 Install angular bearing (125) and snap ring (106) into the hub (105). ※ Be careful for the insert direction. 14098TM72 Insert the O-ring (130), the sealing (129) and fl oat- ing seal (102) in the hub (105). ※ Apply grease to the fl oating seal (102) thinly. 14098TM73 Install the spindle (101) into the hub (105) assem- bly.
  • Page 443 Install thrust washer (109) and collar (112) into the hub (105). 14098TM74 Install needle bearing (111) planetary gear F (108), thrust washer (109), thrust plate F (113) and screw (110) into the hub (105). ※ Tightening torque : 0.83 kgf · m (6.0 lbf · ft) ·Hexagon socket 5 ·Torque wrench 14098TM75...
  • Page 444 (10) Install cover (123), thrust plate (150), plug (301, 128) and socket bolt (124) into the hub (105). ※ Apply grease to the cover (123) after installed O-ring (127). 14098TM60 (11) (11) Pressing the oil seal Pressing the oil seal ①...
  • Page 445 TRAVEL MOTOR (TYPE 2) TRAVEL MOTOR (TYPE 2) ■ 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Swing the work equipment 90˚ and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 446 2. 2. SPECIFICATION SPECIFICATION 1) 1) STRUCTURE STRUCTURE 2 4 6 9 15 17 18 19 20 21 22 24 45 23 52 50 61 32 33 34 31 27 28 26 30 29 60 25 5 A" B" 8 7 1 16 14 10 11 12 13 51 45 49 47 43 35 36 62 28 37 53 48 DETAIL T...
  • Page 447 1 2 3 4 5 6 7-1 7-2 7-3 7-5 7-4 7-6 10-2 10-4 10-1 10-5 10-6 10-3 145Z9A2TM02A Spindle 7-4 Washer 2 10-5 Bearing 1 Floating sesal 7-5 Bearing 2 10-6 Pin 1 Ball bearing 7-6 Pin 2 11 Sun gear 1 Housing Coupling 12 Plate 1...
  • Page 448 2) 2) TOOL AND TIGHTENING TORQUE TOOL AND TIGHTENING TORQUE Tools Tools Name of tools B (mm) Name of part applied Plug (42, 45, 46, 47) Plug (43, 44) Hexagonal L-Wrench Plug (39) Plug (37, 57), Wrench bolt (53) Relief plug (48) Socket wrench/ spanner Main spool plug (32)
  • Page 449 3. DISASSEMBLING 3. DISASSEMBLING AND ASSEMBLING AND ASSEMBLING GENERAL INSTRUCTIONS GENERAL INSTRUCTIONS 1) 1) Generally, hydraulic equipment is precisely manufactured and clearances between each parts are very narrow. Therefore, disassembling and assembling works should be performed on the clean place where dusts hardly gather. Tools and kerosene to wash parts should also be clean and handled with great care.
  • Page 450 2) 2) DISASSEMBLING MOTOR UNIT DISASSEMBLING MOTOR UNIT Disassemble relief valve (48) from valve casing (25) using a torque wrench. 145Z9A8TM01 145Z9A8TM02 Disassemble wrench bolt (53) (M12 30) and take out valve casing sub assembly. 145Z9A8TM03 Remove parking spring (52) - 12EA. 145Z9A8TM04 Remove O-ring (23).
  • Page 451 Disassemble brake piston (20) using a jig. 145Z9A8TM06 145Z9A8TM07 Disassemble friction plate (19)-3EA, steel plate (18)-4EA. 145Z9A8TM08 145Z9A8TM09 145Z9A8TM10 Remove the cylinder block kit (II). ※ It is easier to work by placing the shaft casing (1) horizontal. 145Z9A8TM12 145Z9A8TM11 8-98...
  • Page 452 Disassemble cylinder block (10), ball guide (15), set plate (16), piston assy (17), pin (14) from cylinder block kit (II). Press spring (12) using a jig and take out snap ring (14) using a plier. Disassemble snap ring (13), spring seat (11), spring (12) from cylinder block kit (II).
  • Page 453 (11) Disassemble shaft (3) from shaft casing (1). 145Z9A8TM21 145Z9A8TM22 After disassembled shaft (3) is placed on a jig, top of shaft is pressed down using a press. It can remove ball bearing (4) portion. ※ Remove ball bearing (4) in case it is replaced only.
  • Page 454 (14) Disassemble valve plate (51) and ball bearing (49) from valve casing (25). 145Z9A8TM31 145Z9A8TM30 145Z9A8TM32 (15) Disassemble plug (47) from valve casing (25). 145Z9A8TM33 (16) Disassemble plug (37) from valve casing (25) using a torque wrench and disassemble two speed control spool (35), spring (36) in regular sequence.
  • Page 455 (18) Disassemble plug (43) from valve casing (25) and then disassemble orifice (42), steel ball (41) one by one. 145Z9A8TM38 145Z9A8TM39 (19) Disassemble plug (39), relief valve damping piston (38) from valve casing (25). 145Z9A8TM41 145Z9A8TM40 (20) Disassemble plug (43) from valve casing (25) and disassemble orifice (63).
  • Page 456 3) 3) ASSEMBLING MOTOR UNIT ASSEMBLING MOTOR UNIT Put oil seal into shaft casing (1) using a jig. ※ Caution direction of oil seal. 145Z9A8TM46 145Z9A8TM45 Assemble swash spring (8) into shaft casing (1) and put swash piston (7) into shaft casing (1).
  • Page 457 Assemble swash ball (6)-2EA. 145Z9A8TM54 Apply grease to swash plate (9) and assemble swash plate (9) into shaft casing (1). 145Z9A8TM56 145Z9A8TM55 Slant the shaft casing (1) and then assemble cylinder block kit (II). Assemble spring seat (11), spring (12), spring seat (11) into cylinder block kit (II) in regular sequence.
  • Page 458 Assemble friction plate (19), steel plate (18) into cylinder block in regular sequence. Friction plate : 3 EA Steel Plate : 4 EA 145Z9A8TM64 145Z9A8TM65 145Z9A8TM66 Assemble parking piston (20) into shaft casing (1) using a jig. 145Z9A8TM67 145Z9A8TM68 (10) Put O-ring (23) into shaft casing (1).
  • Page 459 (11) Put spring (36), two speed control spool (35) into valve casing (25) in regular sequence and assemble plug (37) into valve casing (25) using a torque wrench. Tighten torque : 10 kgf-m (72.3 lbf-ft) 145Z9A8TM70 145Z9A8TM71 (12) Assemble check (30), spring (29), plug (27) into main spool (26) in regular sequence.
  • Page 460 (15) Put steel ball (41), orifice (42) into valve casing (25) and tighten the plug (43). Tighten torque : 1.25 kgf-m (9.0 lbf-ft) 145Z9A8TM80 145Z9A8TM81 (16) Put steel ball (56) into valve casing (25) and tighten the plug (57). Tighten torque : 1.25 kgf-m (9.0 lbf-ft) 145Z9A8TM82 145Z9A8TM83 (17)
  • Page 461 (19) Assemble pin (50) into valve casing (25). 145Z9A8TM86 (20) Assemble pin (5) into valve casing (25). 145Z9A8TM87 (21) Assemble ball bearing (49) into valve casing (25). 145Z9A8TM88 (22) Apply grease on the face of valve plate and assemble valve plate (51) into valve casing (25).
  • Page 462 (23) Apply grease to brake spring (52)-12EA and assemble brake spring (52)-12EA into valve casing (25). 145Z9A8TM91 (24) Assemble valve casing (25) into shaft casing (1) and tighten the wrench bolt (53) using a torque wrench. Tighten torque : 10.4 kgf-m (75.2 lbf-ft) 145Z9A8TM92 (25) Assemble relief valve (48) into valve casing...
  • Page 463 4) 4) DISASSEMBLING REDUCTION GEAR DISASSEMBLING REDUCTION GEAR Loose plug (26)-3EA and drain reduction oil. 145Z9A8TR02 Loose wrench bolt (25) using a tool. 145Z9A8TR03 Disassemble end cover (24). 145Z9A8TR04 Disassemble trust plate (23). 145Z9A8TR06 145Z9A8TR05 8-110...
  • Page 464 Disassemble driver gear (16). 145Z9A8TR07 145Z9A8TR08 Disassemble carrier No.1 (17) sub assy. Assemble eyebolt into carrier No.1 tap hole and disassemble carrier No.1 (17) sub assy using a hoist. 145Z9A8TR09 Disassemble carrier No.1 sub assy. Remove spring pin No.1 (22) from carrier No.1 (17) and planetary gear No.1 (18), washer No.1 (19), needle bearing No.1 (20), carrier pin No.1 (21) in regular...
  • Page 465 Disassemble carrier No.2 (7) sub assy. Assemble eyebolt into carrier No.2 tap hole and disassemble carrier No.2 (7) sub assy using a hoist. 145Z9A8TR15 Disassemble carrier No.2 (7) sub assy. Remove spring pin No.2 (12) from carrier No.2 (7) and disassemble planetary gear No.2 (8), washer No.2 (9), needle bearing No.2 (10), carrier pin No.2 (11) in regular sequence.
  • Page 466 (11) Disassemble ring gear sub assy (4) into Ring gear motor assy. sub assy Assemble eye bolt into tap hole of ring gear sub assy (4) and disassemble ring gear sub assy (4) using a hoist. 145Z9A8TR23 (12) Disassemble floating seal (2) from ring gear sub assy (4).
  • Page 467 5) 5) ASSEMBLING REDUCTION GEAR SSEMBLING REDUCTION GEAR Before assembing please observe following item. • Wash all parts cleanly using solvent and dry all parts perfectly using compressed air. • Check metal dust in casing and cleansing solution. • Before application packing, please remove oil certainly. •...
  • Page 468 Press angular bearing (3) into ring gear Press (4) using a jig. 145Z9A8TR31 145Z9A8TR30 Assemble floating seal(2) into ring gear(4) using a jig. 145Z9A8TR33 145Z9A8TR32 Assemble ring gear sub assy (4) into Ring gear motor assy using a assembly epuipment. sub assy 145Z9A8TR34 Push down ring gear (4) using a jig and...
  • Page 469 Assemble carrier No.2 sub assy. Assemble planetary gear No.2 (8), washer No.2 (9), needle bearing No.2 (10) and carrier pin No.2 (11) into carrier No.2 (7) in regular sequence. Assemble spring pin No.2 (12). Assemble spring pin No.2 (12) and caulk spring pin into pin hole.
  • Page 470 Assemble carrier No.1 (17) sub assy. Assemble eyebolt into carrier No.1 and assemble carrier No.1 (17) sub assy into ring gear using hoist. 145Z9A8TR48 (10) Assemble driver gear(16). 145Z9A8TR50 145Z9A8TR49 (11) Assemble trust plate (23). 145Z9A8TR52 145Z9A8TR51 (12) Assemble end cover (24). 145Z9A8TR53 8-117...
  • Page 471 (13) Tighten wrench bolt (25) using a air impact. Tighten torque : 68 kgf-m (491.8 lbf-ft) 145Z9A8TR54 (14) Adjust control lever to be sunk the product under the test oil and then check the air leak. *TEST : Air pressure 0.7 kgf/cm ×...
  • Page 472 TRAVEL MOTOR (TYPE 3, 4) TRAVEL MOTOR (TYPE 3, 4) ■ 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Swing the work equipment 90˚and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 473 2. TRAVEL MOTOR 2. TRAVEL MOTOR 1) 1) STRUCTURE STRUCTURE 49 40 43 42 41 44 72 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 71 70 59 77 64 3 63 7 10 11 14 15 13 16 26 27 6 8 125LCR2TM21...
  • Page 474 2) 2) DISASSEMBLY DISASSEMBLY Choose a clean place, remove contaminants (dust, etc) and cleans motor before placing it on worktable. ※ Lay the rubber plate on worktable and take care not to damage the component. 125LCR8TM02 Remove the connector (45) using 21 mm socket wrench.
  • Page 475 Remove spring seat (42) and spool (40). 125LCR8TM06 Disassemble relief valve assembly (38) using 26 mm socket wrench. (2 sets) 125LCR8TM07 Disassemble cover (32) using 41 mm socket wrench. 125LCR8TM08 Disassemble spring seat (37) and spring (33). (2 sets) 125LCR8TM09 8-118-4...
  • Page 476 Separate main spool assembly (31) from rear cover. 125LCR8TM10 (10) Unscrew socket bolt (47) (1EA), (48) (3EA), (49) (6EA) from rear cover. 125LCR8TM11 (11) Remove parallel pin (29). 125LCR8TM12 (12) From rear cover, disassemble valve plate (24) and O-ring (27). ※...
  • Page 477 (13) Disassemble restrictor (55, 56) (2EA). ※ Mark the number on restrictor and its hole to avoid confusing (55) and (56). 125LCR8TM14 (14) Remove plug (52). 125LCR8TM15 (15) Remove restrictor (34) and spring (35). (2 sets) ※ Do not confuse restrictor (34) and check valve (50).
  • Page 478 (17) Remove check valve (50) and spring (51). (2 sets) ※ Do not confuse restrictor (34) and check valve (50). ※ Do not confuse spring (35) and spring (51). ※ Do not lose spring. ※ Do not mix spring with other springs. 125LCR8TM18 (18) From parking piston, remove spring (26) (12ea).
  • Page 479 (21) From parking piston separate O-ring (20) and back-up ring (21). 125LCR8TM22 (22) Lay casing down horizontally and remove cylinder block assembly, friction plate (17) (3EA) and separator plate (18) (4EA). 125LCR8TM23 (23) Separate retainer plate (15) and piston assembly (16).
  • Page 480 (25) Disassemble swash plate (11) and steel ball (10). ※ Take care not to damage sliding surface. 125LCR8TM26 (26) Disassemble shaft (6) and ball bearing (7). ※ Do not remove ball bearing unless malfunction is detected, since it is mounted by shrink fit. 125LCR8TM27 (27) Disassemble 1, 2 speed piston (4) and steel ball...
  • Page 481 (29) Turn casing (1) upside down and remove oil seal (3) using jig. 125LCR8TM30 8-118-10...
  • Page 482 3) 3) ASSEMBLY ASSEMBLY ※ Even though assembly is accomplished by reversing disassembly steps, be careful of the following. ① Repair the damaged part when disassemblying and prepare parts for exchange in advance. ② All parts should be cleaned with cleaner, dried with compressed air.
  • Page 483 After applying grease on steel ball (10), insert steel ball in casing. 125LCR8TM33 After assembling piston seal (5) and steel ball (9) in 1, 2 speed piston (4), insert piston in hole of casing. ※ Check whether piston sticks in hole. ※...
  • Page 484 Assemble spring (13) (9ea) and ball guide (14) in cylinder block (12) in that order. 125LCR8TM37 Insert piston assembly (16) in retainer plate (15) and assemble them in cylinder block. ※ Spread hydraulic oil on piston assembly. ※ Take care not to damage each component. ※...
  • Page 485 (11) Insert back-up ring & O-ring in parking piston. 125LCR8TM41 (12) Align the pin hole of parking piston (19) with oil hole of casing, assemble them using jig. ※ Spread grease on O-ring and back-up ring. ※ Take care not to damage components. 125LCR8TM42 (13) Insert spring (26) (12EA) in parking piston.
  • Page 486 (15) Assemble check valve (50) and spring (51) in order. ※ Do not confuse check valve (50) and restrictor (34). ※ Do not confuse spring (51) and spring (35) 125LCR8TM45 (16) Clamp plug (52) using 5 mm hexagon wrench. ※ Tightening torque : 1.5 kgf ·...
  • Page 487 (19) Clamp plug (54). ※ Tightening torque : 3 kgf · m (21.7 lbf · ft) 125LCR8TM49 (20) Assemble restrictor (55) and (56) in rear cover. ※ Check whether the restrictor is placed in exact hole. ※ Do not confuse (55) and (56). 125LCR8TM50 (21) Assemble ball bearing (8) in rear cover using jig.
  • Page 488 (23) After spreading grease sufficiently to the bottom side of valve plate (24), assemble valve plate in rear cover by matching its holes with pins. ※ Take care not to damage sliding surface. ※ Pay attention to the assembly direction. 125LCR8TM53 (24) Assemble O-ring (27) in rear cover.
  • Page 489 (27) Settle cover (32). ※ Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8TM57 (28) Insert relief valve (38) in rear cover. ※ Tightening torque : 15 kgf · m (108 lbf · ft) 125LCR8TM58 (29) After clamping connector (45) to rear cover, assemble spool (40).
  • Page 490 (31) After assembling spring (44) in order, clamp plug (41). ※ Tightening torque : 5 kgf · m (36 lbf · ft) 125LCR8TM61 8-118-19...
  • Page 491 3. 3. TRAVEL REDUCTION GEAR DISASSEMBLY TRAVEL REDUCTION GEAR DISASSEMBLY While travel reduction gear is tilted to one side disassemble PF3/8 plug (24), remove gear oil and place motor sideto the bench. 125LCR8TM70 Disassemble cover (22) by unscrewing the M10 bolts (23) (12 pcs).
  • Page 492 Carrier No. 1 sub assy disassembly Carrier No. 1 sub assy disassembly Disassemble M8 bolt (18) from the carrier assembly. (3 pcs) 125LCR8TM74 Disassemble thrust plate No.1 (17) from the carrier assembly. 125LCR8TM75 Disassemble planetary gear No.1 (14).(3 pcs) 125LCR8TM76 Disassemble needle bearing (15).(3 pcs) ※...
  • Page 493 Disassemble Sun gear No.2 (12). 125LCR8TM78 Disassemble M10 bolt (6).(4 pcs) 125LCR8TM79 Disassemble thrust washer No.2 (11).(4 pcs) 125LCR8TM80 Disassemble planetary gear No.2 (8).(4 pcs) 125LCR8TM81 8-118-22...
  • Page 494 Disassemble needle bearing No.2 (9).(4 pcs) 125LCR8TM82 Disassemble thrust plate No.2 (7).(4 pcs) ※ Do not disassemble inner race in the absence of abnormalities. 125LCR8TM83 Disassemble M10 bolt (6) and M8 screw bolt (19). 125LCR8TM84 Disassemble lock plate (5). 125LCR8TM85 8-118-23...
  • Page 495 Disassemble nut ring (4) by using the jig. 125LCR8TM86 Disassemble ring gear sun assembly from motor assembly. 125LCR8TM87 Disassemble folating seal assembly (3) from ring gear sun assembly and motor assembly. 125LCR8TM88 Disassemble bearing (2) (2ea) from ring gear assembly. ※...
  • Page 496 4. 4. TRAVEL REDUCTION GEAR ASSEMBLY TRAVEL REDUCTION GEAR ASSEMBLY ※ Even though assembly is accomplished by reversing disassembly steps, be careful of the following. ① Repair the damaged part when disassemblying and prepare parts for exchange in advance. ② All parts should be cleaned with cleaner, dried with compressed air.
  • Page 497 Assemble planetary gear No.1 (14) of which groove is faced downward. (3 places) 125LCR8TM92 Assemble thrust plate No.1(17). 125LCR8TM93 After spreading loctite #242, assemble the M8 bolt (18).(3 pcs) ※ Tightening torque : 2.7 ± 0.3 kgf · m ※ After the assembly, instantly check the noise and interference by rotatong the gear.
  • Page 498 After turning ring gear over, assemble bearing the same way. ※ Be care of nick and safety when turn ring gear over. 125LCR8TM96 Assemble folating seal assembly (3) by usingthe jig. ※ After assembling, wipe steel-lined section with alcohol. ※ Flatness deviation has to be less than 1 mm.
  • Page 499 After assembling nut ring (4) by using the jig, disassemble the clamping. ※ Tightening torque : 60 kgf · m (434 lbf · ft) 125LCR8TM100 Place lock plate (5) on the nut ring groove. ※ Select best position from one of 4 casing hole to assemble lock plate.
  • Page 500 Shrink fit the inner race No.2 (10).(4 pcs) 125LCR8TM104 Assemble thrust plate No.2 (7).(4 pcs) 125LCR8TM105 Assemble needle bearing No.2 (9).(4 pcs) 125LCR8TM106 Assemble planetary gear No.2 (8).(4 pcs) ※ Grooves of planetary gear will be facingup. 125LCR8TM107 8-118-29...
  • Page 501 Assemble thrust washer No.2 (11).(4 pcs) 125LCR8TM108 After spreading loctite #242, assemble the M10 bolt (6).(4 pcs) ※ Tightening torque : 5.5 ± 0.6 kgf · m (39.8 ± 4.3 lbf · ft) 125LCR8TM109 Assemble sun gear No.2 (12). 125LCR8TM110 Assemble carrier No.1 assembly.
  • Page 502 Assemble sun gear No.1 (20). 125LCR8TM112 Place steel ball (21) on the sun gear No.1. 125LCR8TM113 Spread the loctite #515 on the cover (22) with reference to the right detail view. Detail view 125LCR8TM114 Place cover (22) to fit the bolt holes. 125LCR8TM115 8-118-31...
  • Page 503 After spreading loctite #242, assemble the M10 bolt (23).(12 pcs) ※ Tightening torque : 6.3 ± 0.7 kgf · m (45.6 ± 5.1 lbf · ft) 125LCR8TM116 Inject the 2.5 ± 0.3 liter gear oil to PF3/8 tap section. 125LCR8TM117 After assembling the O-ring (25) to the plug (24), assemble it to the cover.(3 pcs) ※...

  • Page 504: Group 7 Rcv Lever

    GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 505 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 8-120...
  • Page 506 Case 11 Plug 21 O-ring Plug 12 Rod seal 22 Handle connector Plug 13 O-ring 23 Nut O-ring 14 Push rod 24 Insert Spool 15 Plate 25 Boot Shim 16 Bushing 26 Handle Spring 17 Joint assembly 27 Switch assembly Spring seat 18 Swash plate 28 Screw...
  • Page 507 TOOLS AND TIGHTENING TORQUE Tool name Remark Allen wrench Spanner (+) Driver Length 150 (-) Driver Width 4~5 Capable of tightening with the specified torques Torque wrench Tightening torque Torque Part name Item Size kgf m lbf ft Plug PT 1/8 21.7 Joint 25.3...
  • Page 508 DISASSEMBLY Clean pilot valve with kerosene. Put blind plugs into all ports Fix pilot valve in a vise with copper(or lead) sheets. Remove end of boot(26) from case(1) and take it out upwards. For valve with switch, remove cord also through hole of casing.
  • Page 509 Loosen adjusting nut(20) and plate(19) with spanners on them respectively, and remove them. Turn joint anticlockwise to loosen it, utilizing jig(Special tool). When return spring(10) is strong in force, plate(16), plug(11) and push rod(14, 15) will come up on loosening joint. Pay attention to this.
  • Page 510 Remove plate(16). When return spring(10) is weak in force, plug(11) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading. During taking out, plug may jump up due to return spring(10) force.
  • Page 511 (12) For disassembling reducing valve section, stand it vertically with spool(5) bottom placed on flat workbench. Push down spring seat(8, 31) and remove two pieces of semicircular stopper(9) with tip of small minus screwdriver. Pay attention not to damage spool surface.
  • Page 512 (16) Remove lock nut(21) and then boot(26). 8-127...
  • Page 513 (17) Cleaning of parts Put all parts in rough cleaning vessel filled with kerosene and clean them (Rough cleaning). If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil.
  • Page 514 ASSEMBLY Tighten hexagon socket head plug(2) to the specified torque. Tighten two bolts alternately and slowly. Put shim(6), springs(7, 30) and spring seat(8, 31) onto spool(5) in this order. Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper(9) on spring seat without piling them on.
  • Page 515 Assemble O-ring(13) onto plug(11). Assemble seal(12) to plug(11). Assemble seal in such lip direction as shown below. Assemble push rod(14, 15) to plug(11). Apply working oil on push-rod surface. Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring.
  • Page 516 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate(16), and tighten joint(18) temporarily. (10) Fit plate(16). (11) Tighten joint(18) with the specified torque to casing, utilizing jig. (12) Assemble plate(19) to joint(18). Screw it to position that it contacts with 4 push rods evenly.
  • Page 517 (14) Fit boot(40) to plate. (15) Fit boot(26) and lock nut(21), and handle subassembly is assembled completely. (16) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. 8- 132...
  • Page 518 (17) Assemble bushing(17) to plate and pass cord and tube through it. Provide margin necessary to operation. (18) Determine handle direction, tighten lock nut(21) to specified torque to fix handle. (19) Apply grease to rotating section of joint and contacting faces of disk and push rod. (20) Assemble lower end of bellows to casing.

  • Page 519: Group 8 Turning Joint

    GROUP 8 TURNING JOINT GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.

  • Page 520: Disassembly And Assembly

    2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY STRUCTURE STRUCTURE 1) 1) 14098TJ03 Shim 11 Wear ring Shaft Slipper seal 12 Retainer ring Cover O-ring 13 Plug Spacer O-ring 14 Hexagon bolt Shim 10 O-ring 15 Spring washer 8-135...
  • Page 521 2) 2) DISASSEMBLY DISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts (14), washer (15) and cover (3). 21078DA10 Remove shim (6) and O-ring (10). Remove retainer ring (12), spacer (4) and shim (5). 21078DA11 Place hub (1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out shaft Wooden block...
  • Page 522 3) 3) ASSEMBLY ASSEMBLY Clean all parts. As a general rule, replace oil seals and O-ring. Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix seven slipper seal (7) and O-ring (9), two wear ring (11) to hub (1). Fit O-ring (8) to shaft (2).
  • Page 523 Install cover (3) to body (1) and tighten bolts (14). Torque : 10~12.5 kgf m (72.3~90.4 lbf ft) 21078DA10 8-138...

  • Page 524: Group 9 Boom, Arm And Bucket Cylinder

    GROUP 9 BOOM, ARM AND BUCKET CYLINDERS GROUP 9 BOOM, ARM AND BUCKET CYLINDERS 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL BUCKET CYLINDER BUCKET CYLINDER Removal Removal (1) (1) Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine.
  • Page 525 Sling bucket cylinder assembly (8) and remove bolt (6) then pull out pin (5). Remove bucket cylinder assembly (8). Weight : 100 kg (220 lb) 21078DA17 (2) (2) Install Install Carry out installation in the reverse order to removal. When aligning the mounting position of When aligning the mounting position of the pin, do not insert your fingers in the the pin, do not insert your fingers in the...

  • Page 526: Arm Cylinder

    ARM CYLINDER ARM CYLINDER (1) (1) Removal Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 527 Sling arm cylinder assembly(8) and remove bolt (7) then pull out pin (6). Remove arm cylinder assembly (8). Weight : 160 kg (350 lb) 21098CY21 (2) (2) Install Install Carry out installation in the reverse order to removal. When aligning the mounting position When aligning the mounting position of the pin, do not insert your fingers in of the pin, do not insert your fingers in...

  • Page 528: Boom Cylinder

    BOOM CYLINDER BOOM CYLINDER Removal Removal (1) (1) Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 529 Disconnect boom cylinder hoses (7) and put plugs on cylinder pipe. 21078DA25 Remove bolt (9) and pull out pin (8). Remove boom cylinder assembly (6). Weight : 130 kg (285 lb) 21078DA26 Install Install (2) (2) Carry out installation in the reverse order to removal.
  • Page 530 2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY STRUCTURE STRUCTURE 1) 1) Bucket cylinder Bucket cylinder (1) (1) 9,10 6,7 8 4,5 22 11,12 2 13 14 17 15 18,19 20 21 Internal detail 23, 25 24, 25 14W98CY01 Tube assembly 11 O-ring 21 Hexagon socket set screw Rod assembly...
  • Page 531 (2) (2) Arm cylinder Arm cylinder 9,10 6,7 8 4,5 23 33 32 3 11,12 13 14 17 16 15 18,19 20 Internal detail 24, 25 24, 25 25,26,27,28 14W98CY02 Tube assembly 12 Back up ring 23 Hexagon socket head bolt Rod assembly 13 Cushion ring 24 Pin bushing...
  • Page 532 (3) (3) Boom cylinder Boom cylinder 13 14 17 16 15 18,19 20 21 9,10 6,7 8 4,5 22 29 28 3 11,12 Internal detail 23, 24 23, 24 14W98CY03 Tube assembly 11 O-ring 21 Hexagon socket set screw Rod assembly 12 Back up ring 22 Hexagon socket head bolt Gland...
  • Page 533 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE Tools Tools (1) (1) Tool name Remark Allen wrench Spanner (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Tightening torque (2) (2) Torque Part name Item...
  • Page 534 3) 3) DISASSEMBLY DISASSEMBLY Remove cylinder head and piston rod Remove cylinder head and piston rod Procedures are based on the bucket cylinder. Hold the clevis section of the tube in a vise. Use mouth pieces so as not to damage the machined surface of the cylinder tube.
  • Page 535 Note that the plated surface of rod assembly (2) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. Place the removed rod assembly on a wooden V-block that is set level.
  • Page 536 (3) (3) Disassemble the piston assembly Disassemble the piston assembly Remove wear ring (16). Remove dust ring (17) and piston seal (15). Exercise care in this operation not to damage the grooves. 14W98CY12 (4) (4) Disassemble cylinder head assembly Disassemble cylinder head assembly 9 6 7 8 12 11 Remove back up ring (12) and O-ring...
  • Page 537 3) 3) ASSEMBLY ASSEMBLY (1) (1) Assemble cylinder head assembly Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil stone. Coat the inner face of gland (3) with hydraulic oil. 21078DA37 Coat dust wiper (9) with grease and fit Press here dust wiper (9) to the bottom of the hole of (Straight down)
  • Page 538 Fit back up ring (12) to gland (3). Put the backup ring in the warm water of 30~50˚C . Fit O-ring (11) to gland (3). 21078DA39 (2) (2) Assemble piston assembly Assemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone.
  • Page 539 (3) (3) Install piston and cylinder head Install piston and cylinder head Cylinder head assembly Fix the rod assembly to the work bench. Apply hydraulic oil to the outer surface of Rod assembly rod assembly (2), the inner surface of piston and cylinder head.
  • Page 540 (3) (3) Overall assemble Overall assemble Fix with a bar Place a V-block on a rigid work bench. Mount the tube assembly (1) on it and Lift fix the assembly by passing a bar through the clevis pin hole to lock the Straight assembly.

  • Page 541: Group 10 Undercarriage

    GROUP 10 UNDERCARRIAGE GROUP 10 UNDERCARRIAGE 1. TRACK LINK 1. TRACK LINK REMOVAL REMOVAL Move track link until master pin is over front idler in the position put wooden Master pin block as shown. Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards.
  • Page 542 2. CARRIER ROLLER 2. CARRIER ROLLER Frame REMOVAL REMOVAL 1) 1) Grease Loosen tension of the track link. valve 8-162(1) Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller 8-162(2) Loosen the lock nut (1). Carrier roller Open bracket(2) with a screwdriver, push...
  • Page 543 3. TRACK ROLLER 3. TRACK ROLLER Frame REMOVAL REMOVAL 1) 1) Grease Loosen tension of the track link. valve 8-163(1) Using the work equipment, push up track frame on side which is to be removed. After jack up the machine, set a block under the unit.
  • Page 544 4. IDLER AND RECOIL SPRING 4. IDLER AND RECOIL SPRING REMOVAL REMOVAL 1) 1) Remove the track link. For detail, see removal of track link. 8-164(1) Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry.
  • Page 545 3) 3) DISASSEMBLY AND ASSEMBLY OF IDLER DISASSEMBLY AND ASSEMBLY OF IDLER (1) (1) Structure Structure 21078DA43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 8-160...
  • Page 546 Disassembly Disassembly (2) (2) Press Remove plug and drain oil. Draw out the spring pin (7), using a press. 8-166(1) Pull out the shaft (2) with a press. Press Remove seal (3) from idler (1) and bracket (5). Remove O-ring (6) from shaft. 8-166(2) Remove the bushing (4) from idler, using a special tool.
  • Page 547 Assembly Assembly Before assembly, clean the parts. Press Coat the sliding surfaces of all parts with oil. Cool up bushing (4) fully by some dry ice and press it into shell (1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
  • Page 548 Install bracket (5) attached with seal (3). 8-168(1) Knock in the spring pin (7) with a hammer. 8-168(2) Lay bracket (5) on its side. Supply engine oil to the specified level, and tighten plug. 8-168(3) 8-163...

  • Page 549: Disassembly And Assembly Of Recoil Spring

    4) 4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure Structure (1) (1) 7, 8 R210UCG01 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod assembly Spring Spring washer 13 Grease valve Bracket Rod seal Lock nut 10 Back up ring...
  • Page 550 Disassembly Disassembly Apply pressure on spring (3) with a press. The spring is under a large installed load. This is dangerous, so be sure to set properly. Spring set load : 11132 kg (24542 lb) 7, 8 Remove bolt (7), spring washer (8) and lock plate (6).
  • Page 551 Assembly Assembly Install dust seal (11), back up ring (10) 9 10 11 and rod seal (9) to body (1). ※ When installing dust seal (11) and rod seal (9), take full care so as not to damage the lip. R210UCG2(3) ②...
  • Page 552 Lighten the press load and confirm the set length of spring (3). After the setting of spring (3), install lock plate (6), spring washer (8) and bolt (7). 16078UC08 8-167...

  • Page 553: Group 11 Work Equipment

    GROUP 11 WORK EQUIPMENT GROUP 11 WORK EQUIPMENT 1. STRUCTURE 1. STRUCTURE SECTION A SECTION B SECTION C SECTION A SECTION B SECTION C 21078DA44 8-168...

  • Page 554: Bucket Assembly

    2. REMOVAL AND INSTALL 2. REMOVAL AND INSTALL BUCKET ASSEMBLY BUCKET ASSEMBLY 1) 1) (1) (1) Removal Removal Lower the work equipment completely to ground with back of bucket facing down. 36078AT04 Remove nut (1), bolt (2) and draw out the pin (B).

  • Page 555: Arm Assembly

    2) 2) ARM ASSEMBLY ARM ASSEMBLY Removal Removal Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can Escaping fluid under pressure can penetrated the skin causing serious penetrated the skin causing serious injury.

  • Page 556: Boom Cylinder

    3) 3) BOOM CYLINDER BOOM CYLINDER Removal Removal Remove arm and bucket assembly. For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly. 8-176(1) Disconnect head lamp wiring. Disconnect bucket cylinder hose (2) and arm cylinder hose (1).
  • Page 557 SECTION 9 COMPONENT MOUNTING TORQUE SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide ----------------------------------------------------------------------------------------------- 9-1 Group 2 Engine system ---------------------------------------------------------------------------------------------------- 9-2 Group 3 Electric system --------------------------------------------------------------------------------------------------- 9-4 Group 4 Hydraulic system ------------------------------------------------------------------------------------------------ 9-6 Group 5 Undercarriage ----------------------------------------------------------------------------------------------------- 9-9 Group 6 Structure -------------------------------------------------------------------------------------------------------------- 9-10 Group 7 Work equipment ------------------------------------------------------------------------------------------------- 9-14...

  • Page 558: Group 1 Introduction Guide

    This section shows bolt specifications and standard torque values needed when mounting components to the machine. Use genuine Hyundai spare parts. We expressly point out that Hyundai will not accept any responsibility for defects resulted from non-genuine parts. In such cases Hyundai cannot assume liability for any damage.

  • Page 559: Group 2 Engine System

    GROUP 2 ENGINE SYSTEM GROUP 2 ENGINE SYSTEM 1. ENGINE AND ACCESSORIES MOUNTING 1. ENGINE AND ACCESSORIES MOUNTING Accel actuator Muffler Engine Air cleaner RD14099CM01 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 8×1.25 2.5±0.5 18.1±3.6 M12×1.75...
  • Page 560 2. COOLING SYSTEM AND FUEL TANK MOUNTING 2. COOLING SYSTEM AND FUEL TANK MOUNTING Hyd tank Fuel tank Air compressor Air con Condenser idle pulley Reservoir tank Needle valve RD14099CM02 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 6 1.0...

  • Page 561: Group 3 Electric System

    GROUP 3 ELECTRIC SYSTEM GROUP 3 ELECTRIC SYSTEM 1. ELECTRIC COMPONENTS MOUNTING 1 1. ELECTRIC COMPONENTS MOUNTING 1 Work lamp Heater relay Battery Washer tank Battery relay Horn DETAIL C DETAIL B DETAIL A RD14099CM03 Tightening torque Item Size kgf m lbf ft Item Size...
  • Page 562 2. ELECTRIC COMPONENTS MOUNTING 2 2. ELECTRIC COMPONENTS MOUNTING 2 Work lamp Wiper motor VIEW A Electric box Cluster Fuse box Wiper motor cover RD14099CM04 Tightening torque Item Size kgf m lbf ft M 6 1.0 1.05 0.2 7.6 1.45 M 8 1.25 2.5 0.5 18.1 3.6...

  • Page 563: Group 4 Hydraulic System

    GROUP 4 HYDRAULIC SYSTEM GROUP 4 HYDRAULIC SYSTEM 1. HYDRAULIC COMPONENTS MOUNTING 1 1. HYDRAULIC COMPONENTS MOUNTING 1 Air breather Level gauge Solenoid valve Main pump Spin filter Hydraulic tank RCV-LH VIEW A RCV-RH Terminal Main pump housing Cross Coupling RCV-pedal RD14099CM05 Tightening torque...
  • Page 564 2. HYDRAULIC COMPONENTS MOUNTING 2 2. HYDRAULIC COMPONENTS MOUNTING 2 Attachment piping Travel motor(RH) Stop Bracket valve Cover Rubber Travel motor(LH) Turning joint D/acting 3 way joint D/acting hose joint RD14099CM06 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft...

  • Page 565: Bucket Cylinder

    3. HYDRAULIC COMPONENTS MOUNTING 3 3. HYDRAULIC COMPONENTS MOUNTING 3 BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER RD14099CM07 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 8×1.25 2.7±0.3 19.5±2.2 M12×1.75 9.3±1.9 67.3±13.7 M10×1.5 3.2±0.3 23.1±2.2 M14×2.0 15±2.0...

  • Page 566: Group 5 Undercarriage

    GROUP 5 UNDERCARRIAGE GROUP 5 UNDERCARRIAGE ADJUST COMPONENT Swing bearing Idler Idler Carrier roller Cover Track chain Cover Adjust component Track roller Track guard Travel motor Sprocket RD14099CM08 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 8×1.0 3.74±0.7...

  • Page 567: Group 6 Structure

    GROUP 6 STRUCTURE GROUP 6 STRUCTURE 1. CAB AND ACCESSORIES MOUNTING 1. CAB AND ACCESSORIES MOUNTING Sun roof Latch VIEW A Door latch Track guard RD14099CM09 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 6×1.0 1.44±0.3 10.4±2.2...
  • Page 568 2. CAB INTERIOR MOUNTING 2. CAB INTERIOR MOUNTING Seat Console box(RH) Seat base Console box(LH) Safety lever Slide rail Pedal Travel lever Viscous mount Foot rest Foot rest bracket Bottom plate RD14099CM10 Tightening torque Item Size kgf m lbf ft Item Size kgf m...
  • Page 569 3. COWLING MOUNTING 3. COWLING MOUNTING Engine hood Pump hood Support(RH) Tank cover MCV hood Radiator hood Screen assy Support assy(LH) Side cover(LH) RD14099CM11 Tightening torque Item Size kgf m lbf ft M 8×1.25 1.05±0.2 7.6±1.4 M12×1.75 12.8±3.0 92.6±21.7 9-12...
  • Page 570 4. COUNTERWEIGHT AND COVERS MOUNTING 4. COUNTERWEIGHT AND COVERS MOUNTING Handle pipe Counterweight Tool box Swing bearing grease drain cover Pump under cover H/tank under cover Engine under cover F/tank under cover Radiator under cover MCV under cover Cab under cover(C) Cab under cover(B) Cab under cover(A) RD14099CM12...

  • Page 571: Group 7 Work Equipment

    GROUP 7 WORK EQUIPMENT GROUP 7 WORK EQUIPMENT Boom pin Boom Arm cylinder rod pin Arm cylinder Arm cylinder Boom cylinder head pin head pin Boom cylinder rod pin Boom cylinder Arm pin Side cutter(RH) Bucket cylinder head pin Bucket cylinder Side cutter(LH) Bucket control link...

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