Hyundai R60CR-9 Manual
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Hyundai R60CR-9 Manual

Hyundai R60CR-9 Manual

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Summary of Contents for Hyundai R60CR-9

  • Page 11: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints ---------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-9...
  • Page 12 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 13: 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 14: 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 15: 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 work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.

  • Page 16: 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 17: 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 18: 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 19: Replace Safety Signs

    USE TOOLS PROPERLY USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards. Use power tools only to loosen threaded tools and fasteners. For loosening and tightening hardware, use the c o r r e c t s i ze t o o l s. D O N OT u s e U. S. measurement tools on metric fasteners.
  • Page 20 GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Oil cooler Engine Engine hood Radiator Main pump Muffler Swing motor Hydraulic tank Fuel tank Tooth Bucket Turning joint Main control valve Arm cylinder Boom Boom cylinder Swing post Counterweight Side cutter Track...

  • Page 21: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) 2.9 m ( 9' 6") MONO BOOM, 1.48 m ( 4' 10") ARM, WITH BOOM SWING 2.9 m ( 9' 6") MONO BOOM, 1.48 m ( 4' 10") ARM, WITH BOOM SWING SYSTEM SYSTEM I(I') B(L) 55Z9SP02...

  • Page 22: Working Range

    3. WORKING RANGE 3. WORKING RANGE 1) 1) 2.9 m (9' 6") MONO BOOM WITH BOOM SWING SYSTEM (9' 6") MONO BOOM WITH BOOM SWING SYSTEM 60CR92SP03 Description 1.48 m (4' 10") Arm 6150 mm (20' 2") Max digging reach 6010 mm (19' 9") Max digging reach on ground 3570 mm (11' 9")
  • Page 23 4. WEIGHT Item Upperstructure assembly 2895 6380 Main frame weld assembly 1260 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Boom swing post Counterweight 1040 Cab assembly Lower chassis assembly 2275 5020 Track frame weld assembly...

  • Page 24: Lifting Capacities

    5. LIFTING CAPACITIES 5. LIFTING CAPACITIES 2.9 m ( 9' 6") boom, 1.48 ( 9' 6") boom, 1.48 m m ( 4' 10") arm equipped with 0.18 ( 4' 10") arm equipped with 0.18 m (SAE heaped) bucket and 380 (SAE heaped) bucket and 380 mm (15") triple grouser shoe, the dozer blade down with 470 (15") triple grouser shoe, the dozer blade down with 470 kg kg (1040...
  • Page 25 2) 2) 2.9 m ( 9' 6") boom, 1.48 m ( 4' 10") arm equipped with 0.18 ( 9' 6") boom, 1.48 m ( 4' 10") arm equipped with 0.18 m (SAE heaped) bucket and 380 (SAE heaped) bucket and 380 mm (15") triple grouser shoe, the dozer blade up with 470 kg (1040 lb) counterweight.
  • Page 26 6. BUCKET SELECTION GUIDE 6. BUCKET SELECTION GUIDE GENERAL BUCKET GENERAL BUCKET 1) 1) 0.07m 0.18 m heaped bucket heaped bucket Recommendation Capacity Width 2.9 m (9' 6") boom Weight CECE Without With 1.48 m (4' 10") arm heaped heaped side cutter side cutter 0.07 m...
  • Page 27 Rubber track Model Shapes Shoe width mm (in) 380 (15) 400 (16) Operating weight kg (lb) 5900 (13010) 5800 (12790) R60CR-9 Ground pressure kgf/cm (psi) 0.36 (5.12) 0.34 (4.83) Overall width mm (ft-in) 2000 (6' 7") 2000 (6' 7") 3) 3)
  • Page 28 8. SPECIFICATIONS FOR MAJOR COMPONENTS 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE ENGINE 1) 1) Item Specification Model Yanmar 4TNV98-EPHYBU Type 4-cycle diesel engine, low emission 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...
  • Page 29 3) 3) GEAR PUMP (P3, P4) GEAR PUMP (P3, P4) Item Specification Type Fixed displacement gear pump double stage Capacity 18.3/4.5 cc/rev Maximum pressure 220/30 kgf/cm (3130/430 psi) Rated oil flow 38.4/9.5ℓ/min (10.2/2.5 U.S. gpm / 8.4/2.1 U.K. gpm) 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item...
  • Page 30 Discoloration does not cause any harmful effect on the cylinder performance. 8) 8) SHOE SHOE Item Width Ground pressure Link quantity Overall width R60CR-9 380 mm (15") 0.36 kgf/cm (5.12 psi) 2000 mm (6' 7") 9) 9) BUCKET BUCKET Capacity...

  • Page 31: Recommended Oils

    ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
  • Page 32 SECTION 2 STRUCTURE AND FUNCTION SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device -------------------------------------------------------------------------------------------------- 2-1 Group 2 Main Control Valve ---------------------------------------------------------------------------------------- 2-9 Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-31 Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-38 Group 5 RCV Lever ------------------------------------------------------------------------------------------------------ 2-47...

  • Page 33: Section 2 Structure And Function

    SECTION 2 STRUCTURE AND FUNCTION SECTION 2 STRUCTURE AND FUNCTION GROUP 1 HYDRAULIC PUMP GROUP 1 HYDRAULIC PUMP 1. GENERAL 1. GENERAL This is a variable displacement double-piston pump for discharge with equal displacements from one cylinder block. This pump is so compact as to appear a single pump though this is actually a double pump.
  • Page 34 2. PRINCIPAL COMPONENTS AND FUNCTIONS 2. PRINCIPAL COMPONENTS AND FUNCTIONS R5572SF02 Drive shaft Control spring Hanger Control piston Rotary group Gear pump Cover Housing SPECIFICATIONS SPECIFICATIONS ● Capacity : 2×27.5+18.3+4.5 cc/rev ● Rated oil flow : 2×57.8+38.4+9.5 ℓ /min ● Rated pressure : 3×220+30 kgf/cm This is a variable displacement double-piston pump for discharge with two equal displacements from one cylinder block.

  • Page 35: Principle Of Operation

    PRINCIPLE OF OPERATION PRINCIPLE OF OPERATION Function of pump Function of pump Piston Lower dead point Hanger (Swash plate) Cylinder block Control plate Discharge port Upper dead point Discharge process Suction process Suction port R5572SF03 The cylinder block is connected via spline and can rotate together with the drive shaft. The piston assembled into the cylinder block performs reciprocal operation while following the swash plate on the hanger.

  • Page 36: Control Functions

    CONTROL FUNCTIONS CONTROL FUNCTIONS Spring A Spring B Hanger Piston Piston Piston for P3 shift Shifting line Piston Q max Flow rate Section D-D R5572SF04 The discharge pressures P1 and P2 are directed to the pistons of equal area act on the hanger. The spring is provided to act against the discharge pressure.
  • Page 37 CONTROL / ADJUSTMENT PROCEDURE CONTROL / ADJUSTMENT PROCEDURE Loosen the hexagonal nut. Tighten or loosen the adjusting screw to set the power shifting line. Spring seat Cover Adjusting screw Tighten Loosen Q max Flow rate Loosen Tighten R5572SF05...

  • Page 38: Installation

    3. ADJUSTMENT 3. ADJUSTMENT This hydraulic pump has been set and inspected according to your specified input power and control. Readjustment of all the adjusting portions may lead to the loss of functions specified for each control and the pump proper may be excluded from the scope of guarantee. Never attempt operating the adjusting screw, etc.

  • Page 39: Maintenance

    (14) When the motor has reached the operation speed, check the operation while applying the load to the actuator. (15) Check the monitoring or measuring instrument if installed. (16) Check the noise level. (17) Check the oil level in the tank. Supply the oil. If required. (18) Check the setting of the pressure control valve while applying the load to the actuator.
  • Page 40 Changing the hydraulic oil Changing the hydraulic oil ① After 2000 hours of operation. ② Every 2000 hours of operation or once a year after that. The change interval may have to be shortened depending on the degree of fouling and the thermal load condition of the hydraulic oil.
  • Page 41 GROUP 2 MAIN CONTROL VALVE GROUP 2 MAIN CONTROL VALVE 1. OUTLINE 1. OUTLINE Gauge Ai Pp 55Z92MC01 Port Tightening Port Tightening Mark Port name Mark Port name size torque size torque B10 Bucket in port P1 P1 pump port 6.0~7.0 B11 Arm 2 port P2 P2 pump port...
  • Page 42 2. STRUCTURE (1/4) 2. STRUCTURE (1/4) 5-15 5-101 5-11 5-102 4-111 4-112 4-113 4-101 4-15 4-102 3-111 3-112 5-121 3-113 5-122 3-101 3-15 3-102 4-13 4-12 5-15 2-101 2-102 2-15 4-14 3-12 3-13 4-15 2-112 3-14 2-12 2-111 3-15 2-13 2-14 2-15 55Z92MC02...
  • Page 43 STRUCTURE (2/4) STRUCTURE (2/4) 9-15 9-101 9-102 8-15 8-11 8-101 8-102 9-12 7-15 9-11 7-101 7-11 7-102 8-11 9-13 9-15 8-12 6-15 9-11 6-101 6-11 8-13 6-102 7-13 7-123 7-122 8-15 7-121 7-14 7-15 6-11 6-1 6-13 6-12 6-15 55Z92MC03 2 Way block 7-1 Work block (Ba3) 7-14 O-ring...
  • Page 44 STRUCTURE (3/4) STRUCTURE (3/4) 12-4 12-19 12-5 12-3 12-6 12-91 12-2 12-10 12-92 12-8 12-17 11-4 12-7 11-17 11-5 11-3 11-6 11-101 12-18 11-2 11-102 10-8 12-13 11-9 10-9 12-12 11-8 10-12 12-14 10-3 10-61 10-11 12-1 12-16 12-15 11-13 10-151 12-3 10-10...
  • Page 45 STRUCTURE (4/4) STRUCTURE (4/4) 14-4 14-15 14-5 14-3 14-6 14-2 14-91 14-81 13-4 14-92 14-82 13-14 13-5 13-151 13-11 13-3 13-6 13-151 13-152 14-102 13-152 13-16 14-101 13-16 13-18 13-17 14-1 13-2 14-3 14-11 14-15 13-11 14-7 14-6 14-5 13-1 13-12 13-13 13-3...
  • Page 46 3. HYDRAULIC CIRCUIT (boom swing, 2-way) 3. HYDRAULIC CIRCUIT (boom swing, 2-way) Swing Dozer Boom swing (2-WAY) Breaker Travel (LH) Travel (RH) Boom Bucket 55Z92MO02 2-14...
  • Page 47 4. FUNCTION 4. FUNCTION 1) 1) CONTROL IN NEUTRAL FUNCTION CONTROL IN NEUTRAL FUNCTION Gauge GAUGE 555C92MC07 In neutral, spring sets the spool at the neutral position, the hydraulic oil from pumps flows to the tank through the center bypass. 2-15...
  • Page 48 (1) (1) The oil discharged from the hydraulic pump flows into control valve P1 port, and then flows the right side travel valve through the travel straight valve. In neutral, the oil flows through the center bypass passage in the direction of right travel → boom 1 → bucket → arm 2 spool, and then flows from the center bypass passage to the tank port T1 and T2.
  • Page 49 2) 2) EACH SPOOL OPERATION EACH SPOOL OPERATION (1) (1) Travel operation Travel operation (forward / backward) (forward / backward) ARM1 Arm 1 BREAKER Breaker Center bypass passage Tank TANK Check poppet Gauge GAUGE Boom ⇒ bucket BOOM BUCKET ⇒ Arm 2 ARM1 555C92MC08 ·...
  • Page 50 (2) (2) Boom operation Boom operation ① Boom up operation Boom up operation (P1 and P2 summation) Load check valve Parallel passage TS Ai GAUGE Gauge 555C92MC09 2-18...
  • Page 51 · During boom up operation, the pilot pressure from RCV is supplied into the port a9 and shift the boom 1 spool in the left direction. The hydraulic oil fluid from pump P1 is entered P1 parallel passage and then passes through the load check valve then flows into the port A9. Following this, it flows into the head side of the boom cylinder.
  • Page 52 ② Boom down operation Boom down operation TS Ai Gauge GAUGE Load check valve Parallel passage 555C92MC10 · During the boom lowing operation, the pilot pressure from RCV is supplied to the port b9 and shift the boom 1 spool in the right direction. The hydraulic fluid from the pump P1 enters the parallel passage and is directed to the port B9 through the load check valve.
  • Page 53 (3) (3) Bucket operation Bucket operation ① Bucket roll in operation Bucket roll in operation GAUGE Gauge Load check valve 555C92MC11 · During the bucket roll in operation, the pilot pressure from RCV is supplied to port b10 and shift the bucket spool in the right direction.
  • Page 54 ② Bucket roll out operation Bucket roll out operation Gauge GAUGE 555C92MC12 · In case of the bucket roll out operation, the operation is similar. · The hydraulic oil flow from the Pp port is same as the bucket in operation. 2-22...
  • Page 55 ③ Bucket load check valve operation Bucket load check valve operation PLUNGER Plunger ORIFICE Orifice 555C92MC13 · This function is used to speed up of the boom or arm by reducing the bucket speed when bucket operation with boom or arm operation simultaneously. ·...
  • Page 56 (4) (4) Arm operation Arm operation ① Arm roll in operation Arm roll in operation (P1 and P2 summation) GAUGE Gauge 555C92MC14 2-24...
  • Page 57 · During arm roll in operation the pilot pressure from the RCV is supplied to the port b6 and b11 and shifts arm 1 spool and arm 2 spool in the direction. The hydraulic oil from the pump P2 flows into the arm cylinder head side through P2 parallel passage, the load check valve and the port B6.
  • Page 58 ② Arm roll out operation Arm roll out operation Gauge GAUGE 555C92MC15 · During arm roll out operation the pilot pressure from RCV is supplied to the port a6 and the a11 and shifts arm 1 spool and arm 2 spool in the left direction. The hydraulic fluid from pump P2 flows into arm 1 spool through the parallel passage.
  • Page 59 (5) (5) Swing operation Swing operation Swing SWING 555C92MC16 · The pilot pressure from the RCV is supplied to the a1 and shift the swing spool in left direction. The hydraulic fluid from pump P3 flows into swing spool through the parallel passage. Then it is directed to swing motor through the port A1.
  • Page 60 (6) (6) Travel straight function Travel straight function Parallel passage Center bypass passage Gauge GAUGE Cut off when the boom, BOOM or ARM or BUCKET arm and bucket operation 555C92MC17 2-28...
  • Page 61 · This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm, bucket, swing, woodgrab) during a straight travel. ① During travel only : The hydraulic fluid of the pump P1 is supplied to the travel motor and the pump P2 is supplied to the other motor.
  • Page 62 (7) (7) Holding valve operation Holding valve operation ① Holding operation Holding operation Pilot piston chamber Actuator port Check Spring Drain port Pilot port Boom holding valve Boom 1 spool Plug Poppet Poppet seat Piston A Spring B Piston B 55W72MC16 At neutral condition, the pilot piston chamber is connected to drain port through the pilot port.

  • Page 63: Swing Motor

    GROUP 3 SWING DEVICE 1. STRUCTURE Swing device consists swing motor, swing reduction gear. SWING MOTOR Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. 60CR92SM01 Port Port name Port size Main port PF 3/8 Main port PF 3/8 Drain port...
  • Page 64 2) 2) SWING MOTOR/REDUCTION GEAR (1/2) SWING MOTOR/REDUCTION GEAR (1/2) 55Z9SM001 T01 Casing T15 Separation plate T43 Socket bolt R13 Neddle bearing T02 Valve casing T16 Brake piston R01 Gear casing R14 Neddle bearing T03 Drive shaft T17 Brake spring R02 Pinion shaft R15 Planet gear No.2 T04 Roller bearing...
  • Page 65 SWING MOTOR/REDUCTION GEAR (2/2) SWING MOTOR/REDUCTION GEAR (2/2) 55Z9SM002 T19 Plunger T33 Filter T20 Check spring T34 Bush T21 Plug T35 Spacer T27 O-ring T36 Throttle plate T28 O-ring T37 Spring T30 Spool T38 RO Plug T31 Spring T40 Plug T32 Plunger A T44 Relief valve 2-33...

  • Page 66: Principles Of Working

    2. PRINCIPLES OF WORKING 2. PRINCIPLES OF WORKING 1) 1) MOTOR PART MOTOR PART High pressure oil from the control valve is routed through valve casing and valve plate to pistons. When the oil enters the cylinder bores through port, it forces the pistons against the fixed inclined swash plate (F1,F2).

  • Page 67: Control Valve

    VALVE CASING PART VALVE CASING PART Anticavitation nticavitation check valve check valve The motor can be rotated faster than supplied oil flow because there is no counter-balancing valve to prevent over speed ; in order to prevent cavitation of the motor, oil compensation insufficient flow is drawn through the anti-cavitation check valve.
  • Page 68 HYD.AREA A2 SPRING(321) PISTON(302) (PRESSURE;Pg) R PORT P PORT (PRESSURE;P1) ADJUSTMENT HYD.AREA A1 PLUNGER(301) PLUG(401) PRESSURE;Ps PRESSURE;Ps Relief valve working description 55Z9SM004 2-36...
  • Page 69 3) 3) BRAKE PART BRAKE PART The swing brake is spring applied and hydraulically released. Friction plate (T14) are splined to and rotate with cylinder block. Separation plates (T15) are splined to the motor casing (T01). When the swing controller blocks pilot pressure at port (SH), the brake springs (T17) force on brake piston (T16) squeeze the separation and friction plates together to prevent the upper structure from swinging.
  • Page 70 GROUP 4 TRAVEL DEVICE (TYPE 1) GROUP 4 TRAVEL DEVICE (TYPE 1) 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 Supply port PT 3/8 FILL...

  • Page 71: Basic Structure

    1) 1) BASIC STRUCTURE BASIC STRUCTURE Reduction gear Hydraulic motor Brake valve Parking brake High/low speed changeover mechanism Control valve Pump 5592TM02 2-39...
  • Page 72 2) 2) STRUCTURE STRUCTURE 37 39,40 30 31 56 57 23 22 20 19 18 17 10 9 16 64 1 5 59 82 83 52,53 87,88 48 50 51 41 42 46 45 43 44 32 33 24 34 27 35 25 14,13,12,11 63 15 62 61 65 3 67 68 66...
  • Page 73 2. PRINCIPLE OF DRIVING 2. PRINCIPLE OF DRIVING GENERATING THE TURNING FORCE GENERATING THE TURNING FORCE The high hydraulic supplied from a hydraulic pump flows into a cylinder (11) through valve casing of motor (26), and valve plate (56). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston (18).
  • Page 74 2) 2) WORKING OF RELIEF VALVE WORKING OF RELIEF VALVE Relief valve carries on two functions of followings. It standardizes a pressure in case of driving a hydraulic motor ; bypasses and extra oil in a motor inlet related to acceleration of an inertia to an outlet. In case of an inertia stopped, it forces an equipment stopped, according to generating the pressure of a brake on the projected side.
  • Page 75 3) 3) WORKING OF BRAKE WORKING OF BRAKE Brake operates the pressure supplied through SPOOL (simultaneous peripheral operation online) installed in valve casing (26) to the part of parking piston (21) and releases a brake. When the pressure does not work, the brake always runs. The force of a brake is generated by the frictional force among a plate (20), brake piston (21) and a cylinder block (11) that is connected through spline which are fixed by shaft casing (1) with friction plate (19).

  • Page 76: Counterbalance Valve

    4) 4) COUNTERBALANCE VALVE COUNTERBALANCE VALVE Av port is connected into a hydraulic pump and Bv port is into a tank. Hydraulic pump supplying oil is come into Av → Cv room. In accordance with spring force (43) that is working on the spool's side it moves to the spool (41) on the right side which is medium position and that time motor is turning.
  • Page 77 4) 4) HIGH/LOW SPEED CHANGEOVER MECHANISM HIGH/LOW SPEED CHANGEOVER MECHANISM (1) (1) At low speed-at pilot pressure of less than 10 At low speed-at pilot pressure of less than 10 kgf/cm kgf/cm (0.98 (0.98 Mpa Mpa) Holder flange Spring Case of motor 5592TM05 When no pilot pressure is supplied from port (A) at a pressure of 10 kgf/cm (0.98 Mpa) or less,...

  • Page 78: Reduction Gear

    2. REDUCTION GEAR 2. REDUCTION GEAR FUNCTION FUNCTION The reduction gear unit consists of a combination of simple planetaly gear mechanism. This mechanism reduce the high speed rotation from the hydraulic motor and convert it into low speed, high torque to rotate the hub (or case), which in turn rotates the sprocket. 2) 2) OPERATING PRINCIPLE OPERATING PRINCIPLE...
  • Page 79 TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #1488-) TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #1488-) 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 Supply port PF 1/2...
  • Page 80 2) 2) STRUCTURE STRUCTURE 307 301 305 406 303 106 119 109 618 112 113 617 622 115 410 625 611 605 615 HX60A2TM51 124,123135 136 432 503 433 302 405 404 202 107 101 105 102 626 111 626 405 409 401 114 511 601 118 Friction plate...

  • Page 81: Major Component

    2) 2) MAJOR COMPONENT MAJOR COMPONENT This product is only composed of hydraulic motor. Reduction parts are not composed. This hydraulic motor is variable swash plate axial piston motor. It is composed of 4 parts. - Rotary part which makes rotatory power - Traveling brake valve part - Parking brake part - Switching the tilting angle part (auto 1/2 speed control part)
  • Page 82 3) 3) BASIC STRUCTURE BASIC STRUCTURE Rotary part Relief valve part Counterbalance valve part Check valve part Parking brake part Switching the tilting angle part 559A2TM53 2-46-4...
  • Page 83 2. WORKING PRINCIPLE 2. WORKING PRINCIPLE HYDRAULIC MOTOR SECTION HYDRAULIC MOTOR SECTION When high pressure oil passes from pump through the inlet port of the valve plate(108) and flows into the cylinder (104) as shown in figure, the oil pressure acts upon the piston (101) to generate the axial force "F".
  • Page 84 2) 2) TRAVELING BRAKE VALVE TRAVELING BRAKE VALVE Traveling brake valve is composed of relief valve, counterbalance valve and check port A is connected with hydraulic pump and port B is connected with tank. (1) (1) In case of traveling In case of traveling When the compressed oil, which is supplied along the inlet port, exceeds certain pressure, it pushes cap (509).
  • Page 85 (2) (2) In case of stop In case of stop If the pressure supplied along the port to the inlet breaks while traveling, the pressure applied to the section of the main spool (501) is removed. Therefore, the main spool (501), which was pushed to the right, returns to neutral due to the spring elasticity force of the main spool spring (505).
  • Page 86 (2) (2) In case of stop In case of stop If the pressure supplied along the port to the inlet breaks while traveling, the pressure applied to the section of the main spool (501) is removed. Therefore, the main spool (501), which was pushed to the right, returns to neutral due to the spring elasticity force of the main spool spring (505).
  • Page 87 (3) (3) In case of overrun In case of overrun Overrun is when the excavator's speed is increased by the it's gravity (inertia), such as when an excavator is going downhill, causing the hydraulic motor to rotate above the supply flow of the hydraulic pump.

  • Page 88: Parking Brake

    3) 3) PARKING BRAKE PARKING BRAKE The parking brake is wet-type multiple disk brakes. It is a negative brake system which is released when the brake release pressure enters the brake piston chamber. The internal structure of parking brake is shown in figure. Friction plate (118) and separator plate (119) are alternately stacked, and acting on springs to produce brake torque with friction forces.
  • Page 89 (2) (2) In case of stop In case of stop If the pressurized oil supplied by the inlet is cut off during stop, the pressurized oil supplied to the brake piston chamber (c) will also be blocked. (below brake release pressure) If the spring elasticity force F3 of the brake spring (117) is greater than the hydraulic force F4 of the brake piston chamber (c), then brake piston (114) move to casing by spring elasticity force.
  • Page 90 1/2 SPEED SWITCHING OPERATION (AUTOMATIC 1/2 SPEED CONTROL PART) 1/2 SPEED SWITCHING OPERATION (AUTOMATIC 1/2 SPEED CONTROL PART) (1) (1) Low speed traveling Low speed traveling If pilot pressure is not supplied on pilot port (port S), 2 speed spool (502) is pushed in the direction of the port S by spring elasticity of 2 speed spool spring (506).
  • Page 91 (2) (2) High speed traveling High speed traveling If the pilot pressure (20~50 kgf/cm ) is supplied to the port (port S), the pilot pressure overcomes the oil pressure in the main port and the spring elasticity force of the 2 speed spool spring (506). and it pushes the 2 speed spool (502) to the 2 speed plug (308) direction.
  • Page 92 (3) (3) Automatic 1/2 speed control part Automatic 1/2 speed control part If the load is increased during the 2-speed driving, the hydraulic pressure on the main port is increased. The pressure (△P) of main port and spring elasticity force of 2 speed spool spring (506) will overcome the pressure of pilot, 2 speed spool (502) is pushed in port S direction.
  • Page 93 REDUCTION GEAR REDUCTION GEAR 559A2TM63 Refer to the section drawing for the basic construction. The reduction gear consists of two stage planetary gears. The reduction ratio is determined by the number of teeth of the gear, and the reduction ratio is 42.439.
  • Page 94 GROUP 5 RCV LEVER GROUP 5 RCV LEVER 1. STRUCTURE 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. Switches One touch decel Horn Breaker...

  • Page 95: Cross Section

    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 (4), spring (6) for setting secondary pres- sure, return spring (10), stopper (8), spring seat (7, 13) and shim (5).
  • Page 96 CROSS SECTION CROSS SECTION Port 1,3 Port 2,4 21092RL02 Case Stopper 15 O-ring 22 Lock nut Plug Push rod 16 Rod seal 23 Handle assembly Bushing 10 Spring 17 Plate 24 Handle bar Spool 11 Push rod 18 Boot 25 Nut Shim 12 Spring 19 Joint assembly...
  • Page 97 2. FUNCTIONS 2. FUNCTIONS FUNDAMENTAL FUNCTIONS FUNDAMENTAL FUNCTIONS 1) 1) The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and apply- ing the output pressure (secondary pressure) of the pilot valve to the other end.

  • Page 98: Operation

    3) 3) 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. 2-70 Pilot valve Main pump...
  • Page 99 Case where handle is in neutral position Case where handle is in neutral position 21092RL03 The force of the spring (6) that determines the output pressure of the pilot valve is not applied to the spool (4). Therefore, the spool is pushed up by the spring (10) to the position of port (1, 3) in the operation explanation drawing.
  • Page 100 Case where handle is tilted Case where handle is tilted 21092RL04 When the push rod (11) is stroked, the spool (4) 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 101: Table Of Contents

    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 --------------------------------------------------------------------------------------------- 3-10 Group 5 Combined Operation -------------------------------------------------------------------------------------- 3-22...

  • Page 102: Group 1 Hydraulic Circuit

    SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT GROUP 1 HYDRAULIC CIRCUIT T/MOTOR LH T/MOTOR RH ARM CYLINDER BOOM SWING CYLINDER QUICK COUPLER DOZER CYLINDER BUCKET CYLINDER BOOM CYLINDER (2-WAY) BREAKER Main pump (FW)P2 P1(BW) (FW)P1 P2(BW) Main control valve Swing motor Travel motor RCV lever (LH)

  • Page 103: 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 104 2. RETURN CIRCUIT 2. RETURN CIRCUIT Full flow filter Oil cooler Check valve (2) 1.5 kgf/cm Main control valve Actuators Check valve (1) 3.0 kgf/cm Bypass relief valve 1.5 kgf/cm 3-03 (140-7 TIER) All oil returned from each actuator returns to the hydraulic tank through the control valve. The bypass check valves are provided in the return circuit.

  • Page 105: Drain Circuit

    3. DRAIN CIRCUIT 3. DRAIN CIRCUIT Travel motor Swing motor Return line Turning joint Return filter Hydraulic oil tank R5573CI02 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. TRAVEL MOTOR DRAIN CIRCUIT TRAVEL MOTOR DRAIN CIRCUIT Oil leaked from the right and left travel motors comes out of the drain ports provided in the respective motor casing and join with each other.

  • Page 106: Group 3 Pilot Circuit

    GROUP 3 PILOT CIRCUIT GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve Dozer lever (RH lever) (LH lever) Safety lock Swing parking brake solenoid valve Control valve Travel speed solenoid valve Breaker solenoid valve Boom solenoid valve Line filter Relief valve 30kgf/cm Pilot pump...
  • Page 107 1. SUCTION, DELIVERY AND RETURN CIRCUIT 1. SUCTION, DELIVERY AND RETURN CIRCUIT T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...

  • Page 108: Safety Valve

    2. SAFETY VALVE 2. SAFETY VALVE (SAFETY LEVER) T/MOTOR LH T/MOTOR RH BOOM SWING BUCKET BOOM DOZER (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
  • Page 109 3. TRAVEL SPEED CONTROL SYSTEM 3. TRAVEL SPEED CONTROL SYSTEM T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
  • Page 110 4. SWING PARKING BRAKE RELEASE 4. SWING PARKING BRAKE RELEASE T/MOTOR LH T/MOTOR RH BOOM SWING BUCKET BOOM DOZER (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...

  • Page 111: Group 4 Single Operation

    GROUP 4 SINGLE OPERATION GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION 1. BOOM UP OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING BOOM DOZER BUCKET (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor)
  • Page 112 2. BOOM DOWN OPERATION 2. BOOM DOWN OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
  • Page 113 3. ARM ROLL IN OPERATION 3. ARM ROLL IN OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P2 P1(BW) (FW)P1 P2(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
  • Page 114 4. ARM ROLL OUT OPERATION 4. ARM ROLL OUT OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING BOOM DOZER BUCKET (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
  • Page 115 5. BUCKET ROLL IN OPERATION 5. BUCKET ROLL IN OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING BOOM DOZER BUCKET (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
  • Page 116 6. BUCKET ROLL OUT OPERATION 6. BUCKET ROLL OUT OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING BOOM DOZER BUCKET (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...

  • Page 117: Swing Operation

    7. SWING OPERATION 7. SWING OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING BOOM DOZER BUCKET (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV) (2-WAY)
  • Page 118 SWING CIRCUIT OPERATION SWING CIRCUIT OPERATION PARKING BRAKE BRAKE RELEASE VALVE BRAKE OFF BRAKE ON MOTOR BRAKE VALVE MAKE UP VALVE (CW) (CCW) TO/FROM MAIN CONTROL VALVE 55Z93HC40 1) 1) MOTOR BRAKE VALVE MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation.
  • Page 119 8. TRAVEL FORWARD AND RE 8. TRAVEL FORWARD AND REVERSE O VERSE OPERATION PERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P2 P1(BW) (FW)P1 P2(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4...
  • Page 120 TRAVEL CIRCUIT OPERATION TRAVEL CIRCUIT OPERATION Travel motor Overload relief valve Counter balance valve Turning joint Main control valve 5593HC15 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. OVERLOAD RELIEF VALVE OVERLOAD RELIEF VALVE 2) 2)
  • Page 121 9. DOZER UP OPERATION 9. DOZER UP OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
  • Page 122 10. DOZER DOWN OPERATION 10. DOZER DOWN OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)

  • Page 123: Group 5 Combined Operation

    GROUP 5 COMBINED OPERATION GROUP 5 COMBINED OPERATION 1. OUTLINE 1. OUTLINE T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P2 P1(BW) (FW)P1 P2(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 124 2. COMBINED SWING AND BOOM OPERATION 2. COMBINED SWING AND BOOM OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 125 3. COMBINED SWING AND ARM OPERATION 3. COMBINED SWING AND ARM OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 126 4. COMBINED SWING AND BUCKET OPERATION 4. COMBINED SWING AND BUCKET OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 127 5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION 5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P2 P1(BW) (FW)P1 P2(BW) (CW) (CCW) Dr(Swing motor)
  • Page 128 6. COMBINED SWING AND TRAVEL OPERATION 6. COMBINED SWING AND TRAVEL OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 129 7. COMBINED BOOM AND TRAVEL OPERATION 7. COMBINED BOOM AND TRAVEL OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 130 8. COMBINED ARM AND TRAVEL OPERATION 8. COMBINED ARM AND TRAVEL OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 131 9. COMBINED BUCKET AND TRAVEL OPERATION 9. COMBINED BUCKET AND TRAVEL OPERATION T/MOTOR LH T/MOTOR RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (FW)P1 P2(BW) (FW)P2 P1(BW) (CW) (CCW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
  • Page 132 SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location -------------------------------------------------------------------------------------- 4-1 Group 2 Monitoring system ------------------------------------------------------------------------------------------ 4-3 Group 3 Electrical Circuit ---------------------------------------------------------------------------------------------- 4-16 Group 4 Electrical Component Specification -------------------------------------------------------------- 4-32 Group 5 Connectors ------------------------------------------------------------------------------------------------------ 4-39...

  • Page 133: Section 4 Electrical System

    SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 Switch panel 2 Switch panel 1 55Z94EL02 Head light switch Breaker operation switch 15 Fuse box Work light switch Accel dial switch 16 Cigar lighter Travel alarm switch...
  • Page 134 2. LOCATION 2 2. LOCATION 2 Cabin room 55Z94EL03 Lamp Fuel filler pump 11 Engine oil pressure switch Horn Washer pump 12 Start relay Master switch Fuel sender 13 Travel alarm buzzer Battery Temperature sender 14 MCU Battery relay 10 Air clearer switch 15 ECU...
  • Page 135 GROUP 2 MONITORING SYSTEM GROUP 2 MONITORING SYSTEM 1. OUTLINE 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 136 CLUSTER CHECK PROCEDURE CLUSTER CHECK PROCEDURE Start key : ON Start key : ON ① Check monitor initial 6 seconds Check monitor initial 6 seconds All lamps light up. Buzzer sound. ② Check monitor after 3 seconds : Indicate machine condition Check monitor after 3 seconds : Indicate machine condition Tachometer : 0 rpm Fuel gauge : Pointed at appropriate level...
  • Page 137 3. CLUSTER CONNECTOR 3. CLUSTER CONNECTOR CN-56 CONNECTOR CN-56 CONNECTOR Input/ Signal Output CN-56 Null 10 9 8 7 6 5 4 3 2 1 Null 19 18 17 15 14 13 12 11 Alternator signal Input Over heat signal Input Tacho signal Input...

  • Page 138: Gauges And Displays

    4. CLUSTER FUNCTION 4. CLUSTER FUNCTION 1) 1) GAUGES AND DISPLAYS GAUGES AND DISPLAYS LCD display LCD display (1) (1) ① Service meter Service meter : This meter shows the total operation hours of Service meter the machine. ※ Always ensure the operating condition of the meter during the machine operation.
  • Page 139 2) 2) WARNING AND PILOT LAMPS WARNING AND PILOT LAMPS (1) (1) Fuel low level warning lamp Fuel low level warning lamp ① This lamp blinks and the buzzer sounds when the level of fuel is below 18ℓ(4.8 U.S. gal). ②...
  • Page 140 (6) (6) Battery charging warning lamp ① This lamp blinks and the buzzer sounds when the starting switch is ON, it is turned OFF after starting the engine. ② Check the battery charging circuit when this lamp blinks during engine operation. R5573CD16 (7) (7) Warming up pilot lamp...
  • Page 141 (11) (11) Auto idel pilot lamp Auto idel pilot lamp ① If the control lever and pedal are not moved for several seconds with auto idle switch pressed, the indicator illuminates and engine speed is decelerated. ② If the auto idle switch is pressed once more or the control lever or pedal is moved, the indicator turns off and the number of engine revolution is turned to the previous condition.
  • Page 142 (6) (6) Menu and enter switch Menu and enter switch ① Menu Enter These switches are used to set time or set ESL (Engine Start Limit) function. The Enter button ( ) is used to select a function. The Menu button ( ) is used to select a menu or return to the time display menu.
  • Page 143 ⑤ Change password Change password Select ESL function to YES and press the Menu button ( the display is shifted to the password change menu. · Input a new password (Sn : - - - -) after enter the current password successfully (SC : - - - -).
  • Page 144 ⑦ Machine fault code Machine fault code Fault code Description HCESPN Working pressure sensor data above normal range (or open circuit) Working pressure sensor data below normal range Working pressure sensor data error Working pressure sensor circuit - voltage below normal, or shorted to low source Working pressure sensor circuit - special instructions Working pressure sensor circuit - voltage valid but above normal operational range Working pressure sensor circuit - voltage valid but below normal operational range...
  • Page 145 ⑧ Engine fault code Engine fault code Fault code Description YANMAR SPN FMI Engine fuel rack position sensor : shorted to low source 1210 Engine fuel rack position sensor : shorted to high source Accelerator pedal position sensor “A” : shorted to low source Accelerator pedal position sensor “A”...
  • Page 146 3) 3) SWITCHES SWITCHES Travel speed control switch Travel speed control switch (1) (1) ① This switch is to control the travel speed which is changed to high speed (rabbit mark) by pressing the switch and low speed (turtle mark) by pressing it again. 555C93CD15 (2) (2) Auto idle switch...
  • Page 147 Fault code Description YANMAR SPN FMI Cold start device : open circuit 522242 Cold start device : short circuit Cold start device : intermittent fault EGR stepping motor “A” : open circuit 522251 EGR stepping motor “A” : short circuit EGR stepping motor “B”...
  • Page 148 GROUP 3 ELECTRICAL CIRCUIT GROUP 3 ELECTRICAL CIRCUIT CABIN LAMP BEACON ROOM LH,RH LAMP LAMP CONSOLE BOX CIRCUIT BREAKER START SW BOOM SWING SW BOOM SWING CIGAR LIGHTER MANUL RESET BR ACC ST C WIPER SW WIPER MOTOR WASHER SW WIPER RY ACCEL DIAL SEAT HEATER...
  • Page 149 MEMORANDUM MEMORANDUM 4-17...

  • Page 150: Power Circuit

    1. POWER CIRCUIT 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW OPERATING FLOW Battery Battery relay (CR-1) Fusible link (CN-60)
  • Page 151 POWER CIRCUIT POWER CIRCUIT CR-68 ECU MAIN POWER RY CR-45 ECU IG POWER RY CR-23 START RY CR-24 CN-3 CN-19 AIR HEATER RY CN-95 CIRCUIT BREAKER CS-74 MANUL RESET CN-60 CN-2 MASTER SW RELAY (HI) CR-1 BATTERY BATT RY RELAY (M2) CN-6 BATTERY(+) CL-1...

  • Page 152: Starting Circuit

    2. STARTING CIRCUIT 2. STARTING CIRCUIT OPERATING FLOW OPERATING FLOW Battery (+) terminal Battery relay [CR-1] Fusible link [CN-60] I/conn [CN-3 (2)] Master switch [CS-74] Fuse box No.1 Start key [CS-2 (1)] ※ Start switch : ON Start switch ON [CS-2 (2)] ECU IG power relay [CR-45 (86)] I/conn [CN-5 (9)] Battery relay [CR-1]:Battery relay operating (all power is supplied with the electric component)
  • Page 153 STARTING CIRCUIT STARTING CIRCUIT BATTERY START ECU IG POWER RY AIR-HEATER RY MOTOR START SW START RY BR ACC ST C PRE-HEATER 0, I CN-5 CN-14 CN-170 SEAT HEATER CR-5 CN-4 CN-17 ANTI-RESTART RY CR-36 PRE-HEAT RY CN-3 CN-19 CN-60 CN-36 CAB LAMP/FUEL FEED P/P CIRCUIT BREAKER...

  • Page 154: 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 155 CHARGING CIRCUIT CHARGING CIRCUIT BATTERY START ECU IG POWER RY AIR-HEATER RY MOTOR START SW START RY BR ACC ST C PRE-HEATER 0, I CN-5 CN-14 CN-170 SEAT HEATER CR-5 CN-4 CN-17 ANTI-RESTART RY CR-36 PRE-HEAT RY CN-3 CN-19 CN-60 CN-36 CAB LAMP/FUEL FEED P/P CIRCUIT BREAKER...
  • Page 156 4. HEAD AND WORK L 4. HEAD AND WORK LAMP AMP CIRCUIT CIRCUIT OPERATING FLOW OPERATING FLOW 1) 1) Head lamp relay [CR-13 (86) → (85)] Fuse box (No.10) Switch panel [CN-116 (1)] Work lamp relay [CR-3 (86) → (85)] Fuse box (No.11) Switch panel [CN-116 (2)] (1) (1)
  • Page 157 HEAD AND WORK LAMP CIRCUIT HEAD AND WORK LAMP CIRCUIT CN-116 CN-2 POWER IG 12V BREAKER TRAVEL ALARM CABIN LIGHT OUT BEACON ILLUMINATION AC & HEATER WORK LIGHT OUT CONTROLLER ILL LAMP OUT SWITCH PANEL CN-7 CR-3 WORK LAMP RY CR-13 CL-2 CN-15...
  • Page 158 5. BEACON 5. BEACON LAMP AND CAB LAMP LAMP AND CAB LAMP CIRCUIT CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Fuse box (No.18) Beacon lamp relay [CR-85(30) (85)] Switch panel [CN-116 (6)] Fuse box (No.20) Cab lamp relay [CR-9 (30) (85)] Switch panel [CN-116 (7)] (1) (1)
  • Page 159 BEACON LAMP CIRCUIT BEACON LAMP CIRCUIT CR-85 CL-7 CN-6 BEACON LAMP BEACON LAMP RY CL-9 CR-9 CABIN LAMP CABIN LAMP RY CL-10 CN-116 POWER IG 12V BREAKER TRAVEL ALARM CABIN LIGHT OUT BEACON WORK LIGHT OUT ILL LAMP OUT SWITCH PANEL 55Z94EL08 4-27...
  • Page 160 6. WIPER AND WASHER CIRCUIT 6. WIPER AND WASHER CIRCUIT OPERATING FLOW OPERATING FLOW 1) 1) Key switch ON Key switch ON Fuse box (No.13) Wiper relay [CR-4 (86)] Int wiper relay [CR-6 (4)] Wiper switch [CS-3 (11)] Wiper motor [CN-21 (3)] I/conn [CN-5 (11)] I/conn [CN-14 (11)] Washer pump [CN-22 (2)]...
  • Page 161 WIPER AND WIPER AND WASHER CIRCUIT WASHER CIRCUIT CS-3 WIPER SW CR-6 CN-5 CN-14 INT. WIPER RY CR-4 CN-22 WIPER RY WASHER P/P CN-21 Pf 1 WIPER MOTOR DO-1 CS-30 WASHER SW 55Z94EL09 4-29...

  • Page 162: Monitoring Circuit

    MONITORING CIRCUIT MONITORING CIRCUIT CN-13 CN-1 CD-2 FUEL SENDOR CD-30 WATER TEMP CD-1 HYD OIL TEMP CD-10 AIR CLEANER SW CLUSTER SWITCH MP3 & RADIO PANEL PLAYER 55Z94EL10 4-30...
  • Page 163 ELECTRIC CIRCUIT FOR HYDRAULIC ELECTRIC CIRCUIT FOR HYDRAULIC FUSE BOX CN-36 BOOM BREAKER HORN SWING CN-5 CN-14 CS-4 CN-68 SAFETY SW SAFETY SOL CN-116 HEAD LIGHT OUT WORK LIGHT PUT CN-13 BEACON CABIN LIGHT OUT CN-121 TRAVEL ARARM CN-15 BREAKER POWER 12V(IG) CN-121 SWITCH PANEL...
  • Page 164 GROUP 4 ELECTRICAL COMPONENT SPECIFICATION GROUP 4 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specification Check ※ Check specific gravity 1.280 over : over charged 12V × 100Ah Battery 1.280 ~ 1.250 : normal 1.250 below : recharging ※ Check coil resistance Rated load : 12V Normal : about 12Ω...
  • Page 165 Part name Symbol Specification Check ※ Restriction limits Air cleaner 12-24V pressure switch Max. Load : 6W 6.2 kPa±8% at 23˚C CD-10 ※ Check resistance Full : 100Ω Fuel sender Low : 500Ω Empty warning :700Ω CD-2 ※ Check resistance Normal : about 200Ω...
  • Page 166 Part name Symbol Specification Check ※ Check contact Normal Boom swing 12V 16A OFF - ∞Ω (for terminal 1-5,2-6) switch - 0Ω (for terminal 5-7,6-8) CS-47 ※ Check contact Normal Quick clamp 12V 16A OFF - ∞Ω (for terminal 1-5,2-6) switch - 0Ω...
  • Page 167 Part name Symbol Specification Check ※ Check contact Normal : 0Ω(for terminal A-B) : ∞Ω(for terminal A-C) Safety switch Micro Operating : ∞Ω(for terminal A-B) : 0Ω(for terminal A-C) CS-4 DC24V 2A ※ Check contact Pressure switch 10bar Normal : 0.1Ω (N.O type) CD-11 CD-12...
  • Page 168 Part name Symbol Specification Check ※Check coil resistance Normal : about 1MΩ ※ Check contact Cigar lighter 12V 10A 1.4W Normal : ∞Ω CL-2 CL-2 Operating time : 5~15sec ※Check contact Wiper motor 12V 3A Normal : 6Ω(for terminal 2-6) 1 Pf CN-21 DC 14.4V...
  • Page 169 Part name Symbol Specification Check Travel buzzer 107±4dB at 4ft CN-81 Compressor 12V 38W CN-28 Air con 12V 8.5A fan motor CN-83 Fuel feed pump Max. 20A CN-145 180A Master switch (In Countinous capaty) 1000A (In rush) 4-37...
  • Page 170 Part name Symbol Specification Check Preheater 12V 42A 500W CN-80 12V socket 12V 120W CN-139 ※ Check resistance Normal : 0Ω 1˚C OFF Duct sensor (for terminal 1-2) 4˚C ON the atmosphere temp : over 4˚C ※ Check resistance Normal : about 5kΩ Input voltage : (for terminal A-C) 5Vdc±2%...
  • Page 171 GROUP 5 CONNECTORS GROUP 5 CONNECTORS 1. CONNECTOR DESTINATION 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 Cabin room harness - Main harness S816-012002 174663-2 CN-2 Aircon harness - Cabin room harness S816-012002 174663-2 CN-3 YAZAKI...
  • Page 172 Connector part No. Connector No. of Type Destination number Female Male CN-76 DC motor MG640515-4 CN-79 YAZAKI Fuel cut-off solenoid S813-060300 CN-80 Pre heater ST710384-2 CN-81 DEUTSCH Travel buzzer DT06-2S-EP06 DT04-2P-E005 CN-83 Air-con fan MG640188-5 CN-92 Anti-restart relay S814-001100 CN-95 YAZAKI Fusible link S813-130201...
  • Page 173 Connector part No. Connector No. of Type Destination number Female Male CR-9 HELLA Cabin lamp SJA003526-001 CR-12 HELLA Travel relay SJA003526-001 CR-13 HELLA Head lamp SJA003526-001 CR-23 Start relay S814-002001 CR-24 Air heater relay S814-002001 CR-33 Air-con fan relay S810-004002 CR-36 HELLA Pre-heater relay...
  • Page 174 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 S811-109002 S811-011002 S811-111002 4-42...
  • Page 175 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4-43...
  • Page 176 J TYPE CONNECTOR J TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S816-002001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 4-44...
  • Page 177 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 4-45...
  • Page 178 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4-46...
  • Page 179 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 4-47...
  • Page 180 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 4-48...
  • Page 181 375 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 182 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 183 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 4-51...
  • Page 184 KET SDL CONNECTOR KET SDL CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610406 4-52...
  • Page 185 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 186 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT06-6P DT06-8S DT06-8P DT06-12S DT06-12P 4-54...
  • Page 187 MOLEX 2CKTS CONNECTOR MOLEX 2CKTS CONNECTOR No. of Receptacle connector (female) Plug connector (male) 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 4-55...

  • Page 188: Section 5 Troubleshooting

    SECTION 5 TROUBLESHOOTING SECTION 5 TROUBLESHOOTING Group 1 Before Troubleshooting --------------------------------------------------------------------------------- 5-1 Group 2 Hydraulic and Mechanical System -------------------------------------------------------------- 5-4 Group 3 Electrical System ------------------------------------------------------------------------------------------- 5-24...
  • Page 189 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 and Electrical system system. At each system part, an operator can check the machine according to the troubleshooting process diagram.
  • Page 190 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 191 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 192 GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION 1. INTRODUCTION MACHINE IN GENERAL 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.

  • Page 193: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION UNUSUAL NOISE COMES OUT OF PUMP CONNECTION 1) 1) 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...
  • Page 194 2) 2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL 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...
  • Page 195 3. HYDRAULIC SYSTEM 3. HYDRAULIC SYSTEM 1) 1) HYDRAULIC OIL IS CLOUDY 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.
  • Page 196 CAVITATION OCCURS WITH PUMP 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.

  • Page 197: Swing System

    4. SWING SYSTEM 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE 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.
  • Page 198 SWING SPEED IS LOW SWING SPEED IS LOW Cause Remedy Does swing Swing port relief Disassemble and control valve valve is faulty. repair or replace. spool move smoothly by Swing control valve Disassemble hand? Is MCV pilot spool is stuck. and repair.
  • Page 199 3) 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble change when LH valve is faulty. and repair. and RH port relief valves are exchanged Shuttle valve is Disassemble Does swing control faulty.
  • Page 200 5) 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy ⓐ Is swing shuttle Shuttle valve is Disassemble faulty. and replace. Is brake spring normal? Is return spring...

  • Page 201: Travel System

    5. TRAVEL SYSTEM 5. TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE 1) 1) Cause Remedy ⓐ Does counterbalance spool in travel brake valve move lightly by hand? Counter spool in Disassemble Is travel brake...
  • Page 202 2) 2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES 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...
  • Page 203 3) 3) MACHINE DOES NOT STOP ON A SLOPE MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None friction plate Friction plate is...
  • Page 204 5) 5) TRAVEL ACTION IS POWERLESS TRAVEL ACTION IS POWERLESS (travel only) Cause Remedy ⓐ Is travel motor's drain rate within standard level? Is travel brake Travel motor is Disassemble pressure within faulty. and repair. standard level? Is travel relief valve pressure Travel brake valve Disassemble...
  • Page 205 7) 7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal.
  • Page 206 6. ATTACHMENT SYSTEM 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL 1) 1) Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace.
  • Page 207 2) 2) BOOM, ARM OR BUCKET SPEED IS LOW BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. ⓐ Are other attachment speeds within Is combination ⓑ Is speed low only of oil streams in composite normal at boom operation? Flow summation Disassemble...
  • Page 208 3) 3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the faulty. and repair or symptom change Normal replace.
  • Page 209 4) 4) BOOM, ARM OR BUCKET POWER IS WEAK 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.
  • Page 210 6) 6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom Is boom foot pin greased proper.
  • Page 211 ※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE 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. R5575BY01 Disconnect hose(A) from rod side of boom cylinder and drain oil from cylinders and hose.(Put cups on piping and hose ends) R5575BY02...
  • Page 212 GROUP 3 ELECTRICAL SYSTEM GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR 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.2 and No.5.
  • Page 213 BATTERY CHARGING WARNING LAMP LIGHTS UP 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 cluster...

  • Page 214: Water Temperature Sensor

    WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started) (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.
  • Page 215 WHEN AIR CLEANER WARNING LAMP LIGHTS UP 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.

  • Page 216: Engine Oil Pressure Switch

    WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP 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.
  • Page 217 6. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP 6. 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.
  • Page 218 7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE 7. 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 219: Fuel Sender

    8. WHEN FUEL GAUGE DOES NOT OPERATE 8. 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.

  • Page 220: Safety Switch

    9. WHEN SAFETY SOLENOID DOES NOT OPERATE 9. 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.14. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 221 10. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE 10. 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.15.
  • Page 222 11. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE 11. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.13 is not blown out.

  • Page 223: Switch Panel

    12. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP 12. 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.10.
  • Page 224 13. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP 13. 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.11.
  • Page 225 14. WHEN ENGINE DOES NOT START 14. WHEN ENGINE DOES NOT START CIRCUIT BREAKER MANUL RESET ·Check supply of the power at engine stop solenoid while starting switch is ON. ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted.
  • Page 226 15. WHEN STARTING SWITCH ON DOES NOT OPERATE 15. WHEN STARTING SWITCH ON DOES NOT OPERATE CIRCUIT BREAKER MANUL RESET ·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.

  • Page 227: Section 6 Maintenance Standard

    SECTION 6 MAINTENANCE STANDARD SECTION 6 MAINTENANCE STANDARD Group 1 Operational Performance Test ----------------------------------------------------------------------- 6-1 Group 2 Major Components ----------------------------------------------------------------------------------------- 6-21 Group 3 Track and Work Equipment ---------------------------------------------------------------------------- 6-35...

  • Page 228: New Machine

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

  • Page 229: Service Limit

    2. TERMINOLOGY 2. TERMINOLOGY STANDARD STANDARD Specifications applied to the brand-new machine, components and parts. 55Z96MC02 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 230 3. OPERATION FOR PERFORMANCE 3. OPERATION FOR PERFORMANCE TESTS 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 231: Engine Speed

    ② Set the M mode at the cluster ③ Measure the engine RPM. Evaluation Evaluation The measured speeds should meet the following specifications. Unit : rpm Model Engine speed Standard Remark Low idle 1000±50 R60CR-9 High idle 2200±50 M mode...

  • Page 232: Travel Speed

    Repeat steps ④ and ⑤ three times in each direction and calculate the average 555C96MC05 values. Evaluation Evaluation The average measured time should meet the following specifications. Unit : Seconds / 20m Model Travel speed Standard Maximum allowable Remarks 1 Speed 32.7±2.0 R60CR-9 2 Speed 18.0±1.0...
  • Page 233 Repeat steps ③ and ④ three times and calculate the average values. Evaluation Evaluation The revolution cycle time of each track should meet the following specifications. Unit : Seconds / 3 revolutions Model Travel speed Standard Maximum allowable 1 Speed 27.5±1.5 33.1 R60CR-9 2 Speed 14.5±1.5 18.3...

  • Page 234: Travel Deviation

    ⑤ Repeat steps ③ and ④ three times and 7-7(2) 140-7 calculate the average values. (4) (4) Evaluation Evaluation Mistrack should be within the following specifications. Unit : mm / 20m Model Standard Maximum allowable Remarks R60CR-9 200 below...
  • Page 235 Repeat steps ① and ② three time and calculate the average values. (4) (4) Evaluation Evaluation The time required for 2 swings should meet the following specifications. Unit : Seconds / 2 revolutions Model Standard Maximum allowable Remarks R60CR-9 12.8±0.4...
  • Page 236 ④ Repeat steps ② and ③ three times each R5576MC08 and calculate the average values. (4) (4) Evaluation Evaluation The measured drift angle should be within the following specifications. Unit : Degree Model Standard Maximum allowable Remarks R60CR-9 40 below...
  • Page 237 Record the dial gauge reading (h2). Calculate bearing play (H) from this data (h1 and h2) as follows. H=h2-h1 Evaluation 55Z96MC10 The measured drift should be within the following specifications. Unit : mm Model Standard Maximum allowable Remarks R60CR-9 0.5 ~ 1.2 6-10...
  • Page 238 9) 9) HYDRAULIC CYLINDER CYCLE TIME HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, Boom cylinder standard arm, and standard bucket Raise cylinders. (2) (2) Preparation Preparation ① To measure the cycle time of the boom Lower cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the...
  • Page 239 Standard Maximum allowable Remarks Boom raise 2.6±0.4 Boom lower 2.7±0.4 Arm in 2.1±0.4 Arm out 2.0±0.3 Bucket load 3.6±0.4 R60CR-9 Bucket dump 2.3±0.3 Boom swing (LH) 6.4±0.4 Boom swing (RH) 6.4±0.4 Dozer up (raise) 4.2±0.3 Dozer down (lower) 3.4±0.3 6-12...
  • Page 240 The measured drift should be within the following specifications. Unit : mm / 5min Model Drift to be measured Standard Maximum allowable Remarks Boom cylinder 10 below R60CR-9 Arm cylinder 20 below Bucket cylinder 20 below 6-13...
  • Page 241 The measured operating force should be within the following specifications. Unit : kgf Model Kind of lever Standard Maximum allowable Remarks Boom lever 1.4 or below Arm lever 1.4 or below R60CR-9 Bucket lever 1.4 or below Swing lever 1.4 or below Travel lever 2.0 or below 6-14...
  • Page 242 Evaluation Evaluation The measured drift should be within the following specifications. Unit : mm Model Kind of lever Standard Maximum allowable Remarks Boom lever 87±10 Arm lever 87±10 R60CR-9 Bucket lever 87±10 Swing lever 87±10 Travel lever 86±10 6-15...
  • Page 243 Keep the hydraulic oil temperature at 50±5˚C. (2) (2) Measurement Measurement ① Measure the primary pilot pressure in the R55NN7MA14 M mode. Evaluation Evaluation The average measured pressure should meet the following specifications: Unit : kgf / cm Model Standard Remarks R60CR-9 30±5 6-16...
  • Page 244 Repeat steps ② and ③ three times and calculate the average values. (3) (3) Evaluation Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Travel speed mode Standard Maximum allowable Remarks 1 Speed R60CR-9 2 Speed 30±5 6-17...
  • Page 245 ② Repeat three times and calculate the average values. (3) (3) Evaluation Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Description Standard Remarks Brake disengaged 30±5 R60CR-9 Brake applied 6-18...
  • Page 246 Measure the main pump deliver y R55NN7MA17 pressure at high idle. (3) (3) Evaluation Evaluation The average measured pressure should meet the following specifications. Unit : kgf / cm Model Engine speed Standard Allowable limits Remarks R60CR-9 High idle 20±5 6-19...
  • Page 247 (3) (3) Evaluation Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Function to be tested Standard Boom, Arm, Bucket 220±10 R60CR-9 Travel 220±10 Swing 200±10 6-20...
  • Page 248 GROUP 2 MAJOR COMPONENT GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 1. MAIN PUMP Before inspection, wash the parts well and dry them completely. Inspect the principal parts with care and replace them with new parts when any abnormal wear exceeding the allowable limit or damage considered harmful is found.

  • Page 249: Control Plate

    CONTROL PLATE CONTROL PLATE Check the slide surface for any damage. When the damage is large, replace the plate with new one. R55NM7PH48 GUIDE AND RETAINER GUIDE AND RETAINER Check for scouring or stepped wear. If this can not be corrected, replace the guide and retainer with new full-set.

  • Page 250: 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, Block replace part. - Sliding sections of casing fore and spool, especially land sections applied with holded pressure.

  • Page 251: General Cautions

    3. SWING DEVICE 3. SWING DEVICE 1) 1) GENERAL CAUTIONS GENERAL CAUTIONS Here, counter-measures to be taken when troubles have happened while the motor is in operation are described. As for general precaution. Consider a cause of the trouble before repairing Before setting to work, think whether the same thing has happened before or not.
  • Page 252 CONDITION & COUNTERMEASURES OF TROUBLES CONDITION & COUNTERMEASURES OF TROUBLES Motor does not rotation Motor does not rotation Condition Cause Remedy ·Setting pressure of relief valve ·Reset the pressure to correct The pressure of the circuit is not increasing is incorrect value ·Working defectiveness of relief valve...
  • Page 253 Brake torque is not sufficient Brake torque is not sufficient Condition Cause Remedy ·Friction plates are worn ·Disassembly or inspection. Brake torque is not suffi cient When it is worn more than standard, replace it ·Brake piston is becoming stick ·Disassembly or inspection ·Brake releasing pressure is not working...
  • Page 254 4. MAINTENANCE STANDARDS 4. MAINTENANCE STANDARDS 1) 1) PART REPLACEMENT STANDARDS FOR HYDRAULIC MOTOR PART REPLACEMENT STANDARDS FOR HYDRAULIC MOTOR If the various parts of the motor have been worn out beyond the following standard values, please replace them. But this shall apply only to those cases when is no remarkable outside damage. Recommended Standard Inspection item...
  • Page 255 2) 2) PART REPLACEMENT STANDARDS FOR REDUCTION GEAR PART REPLACEMENT STANDARDS FOR REDUCTION GEAR Standard Recommended Item dimension value for replacement Remedy (mm) (mm) Replace if pitting or Pitting or crack of gear Pitting area rate : 10% crack is found Motor driving shaft external Overpin : 28.194 (Ø3.048) 27.594...
  • Page 256 3) 3) STANDARD FOR CORRECTING SLIDING SURFACES STANDARD FOR CORRECTING SLIDING SURFACES If the surface roughness of the sliding surface of a part exceeds the following standards, correct it or replace the part. Table 5. Standards Item Surface roughness Roughness requiring correction 0.8 - Z (Ra=0.2) Shoe 3 - Z (Ra=0.8)
  • Page 257 5. TRAVEL DEVICE (TYPE 1) 5. TRAVEL DEVICE (TYPE 1) Disassembling and inspection of the motor must be done in strict accordance with the servicing standards described here. During servicing, handle each part very carefully not to damage them, especially for their movable or sliding sections. SEALS SEALS 1) 1)
  • Page 258 Item Maximum allowable Part name Situation Standard dimension value (criteria) ·The sliding surface is damaged. Distance piece ·The sliding surface is excessively worn out. ·Dents are present. Ball bearing ·Flaking develops. ·Nonuniform wear is present. ·The movable section contacting Rear flange kit Rear flange kit Linear clearance : Linear clearance :...
  • Page 259 Item Maximum allowable Part name Situation Standard dimension value (criteria) ·The spherical sliding section that Thrust ball contacts the retainer plate (107) is nonuniformly worn out. ·The sliding surface has the Timing plate traces of seizure or nonuniformly wear. ·Both edges are nonuniformly Friction plate Braking torque 40.6 Braking torque 40.6...
  • Page 260 TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #1488-) TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #1488-) Disassembling and inspection of the motor must be done in strict accordance with the servicing standards described here. During servicing, handle each part very carefully not to damage them, especially for their movable or sliding sections.
  • Page 261 6. TURNING JOINT 6. TURNING JOINT Part name Maintenance standards Remedy ·Plating worn or peeled due to seizure or contamination. Body, Sliding surface with Replace Stem 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 262 7. CYLINDER 7. 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 263: Track Shoe

    GROUP 3 TRACK AND WORK EQUIPMENT GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK SHOE 1. TRACK SHOE STEEL SHOE SPEC STEEL SHOE SPEC R5576MC16 Unit : mm Criteria Check item Remedy Standard size Repair limit Replace bushing Link pitch 138.6 and pin and link Outside diameter of bushing...
  • Page 264 RUBBER SHOE SPEC RUBBER SHOE SPEC SECTION B-B SECTION A-A R5576MC17 Unit : mm Criteria Check item Remedy Standard size Tolerance Repair limit ±1.0 Link pitch Height of grouser Replace Width of link 6-36...
  • Page 265 2. IDLER 2. IDLER R5576MC18 Unit : mm Criteria Check item Remedy Standard size Repair limit Steel Outside diameter of flange Rebuild Rubber Outside diameter of thread or replace Width of flange 6-37...
  • Page 266 3. TRACK/CARRIER ROLLER 3. TRACK/CARRIER ROLLER R5576MC15 Unit : mm Criteria Check item Remedy Standard size Repair limit Steel Outside diameter of flange Rebuild Rubber Outside diameter of thread or replace Width of flange 6-38...
  • Page 267 4. TENSION CYLINDER 4. TENSION CYLINDER STEEL SHOE SPEC STEEL SHOE SPEC R5576MC19 Unit : mm Criteria Check item Remedy Standard size Repair limit Track frame Rebuild Outside diameter of flange Idler support Rebuild or replace Track frame Rebuild Outside diameter of thread Idler guide Rebuild or replace Standard size...
  • Page 268 RUBBER SHOE SPEC RUBBER SHOE SPEC R5576MC20 Unit : mm Criteria Check item Remedy Standard size Repair limit Track frame Vertical width of idler guide Rebuild Idler support Track frame Rebuild or replace Horizontal width of idler guide Idler guide Rebuild Standard size Repair limit...
  • Page 269 5. SPROCKET 5. SPROCKET R5576MC21 Unit : mm Criteria Check item Remedy Standard size Repair limit Wear out of sprocket tooth 418.6 lower side diameter Wear out of sprocket tooth upper side diameter Repair or Replace Wear out of sprocket tooth 33.5 upper side width Wear out of sprocket tooth...

  • Page 270: Work Equipment

    6. WORK EQUIPMENT 6. WORK EQUIPMENT 5596MC01 Unit : mm Bushing Remedy Normal Measuring point Recomm. Recomm. Mark & Limit Limit (pin and bushing) value service service Remark of use of use limit limit Boom Rear 53.5 55.5 Replace 〃 Boom Cylinder Head 58.5 60.5...
  • Page 271 SECTION 7 DISASSEMBLY AND ASSEMBLY SECTION 7 DISASSEMBLY AND ASSEMBLY Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 7-1 Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 7-4 Group 3 Pump Device ----------------------------------------------------------------------------------------------------- 7-7 Group 4 Main Control Valve -------------------------------------------------------------------------------------------- 7-38 Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 7-51 Group 6 Travel Device ----------------------------------------------------------------------------------------------------- 7-74 Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 7-102 Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 7-116...

  • Page 272: Section 7 Disassembly And Assembly

    SECTION 7 DISASSEMBLY AND ASSEMBLY SECTION 7 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 273 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 274 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 275: 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 M10 × 1.5 Engine mounting bolt(Engine-Bracket) 6.9±1.0 50±7.2 M16 × 2.0 Engine mounting bolt(Bracket-Frame) 25±2.5 181±18.1 Engine M12 × 1.75 Radiator mounting bolt, nut 9.3±1.9 67.3±13.7...

  • Page 276: Torque Chart

    2. TORQUE CHART 2. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread Bolt size kg·m lb·ft kg·m lb·ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25...
  • Page 277 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size (PF) Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size (UNF) Width across flat (mm) kgf·m lbf·ft...

  • Page 278: Group 3 Pump Device

    GROUP 3 PUMP DEVICE GROUP 3 PUMP DEVICE 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 Loosen the breather slowly to release the 13031GE18...
  • Page 279 2) 2) INSTALL 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.
  • Page 280 2. MAIN PUMP 2. MAIN PUMP 1) 1) STRUCTURE STRUCTURE 63 62 SECTION D-D SECTION C-C 37 38 39 DETAIL J 16 24 51 50 555C92SF06 Drive shaft 14 O-ring 27 Spring seat(1) 39 Shim 51 Valve plate 63 Snap ring Seal cover 15 Pivot 28 Spring seat(2)
  • Page 281 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Name Quantity Size (nominal) Hexagonal bar spanner One each 5, 6, 8, 10 Spanner 17, 24 Plastic hammer...
  • Page 282 (3) (3) Tightening torque Tightening torque Torque Wrench size Part name Bolt size kgf·m lbf·ft Hexagon socket head bolt 0.20 21.7 0.24 10.0 72.3 0.39 24.0 0.55 34.0 0.55 PT 1/16 0.16 PT Plug PF Plug PF 1/8 10.8 0.20 PF 1/4 21.7 0.24...

  • Page 283: Disassembly Procedure

    3. DISASSEMBLY PROCEDURE 3. DISASSEMBLY PROCEDURE DISASSEMBLING THE GEARED PUMP DISASSEMBLING THE GEARED PUMP ① Remove the hexagonal socket headed bolts (M10 × 25, 2 pieces). Hexagonal bar spanner (Hex. side distance : 8) ※ Be careful because the O-ring and filter are provided to the match surface of the geared pump.
  • Page 284 ③ This photo shows the state with the cover removed. R55NM7HP07 ④ Remove the O-ring from the cover. R55NM7HP08 The removal of the control spring The removal of the control spring ① Remove 2 springs (inner and outer). R55NM7HP09 ② Remove the spring seat.
  • Page 285 The removal of rotary group The removal of rotary group ① Lay the pump on the side and take out the rotary group from the shaft. R55NM7HP11 ② Remove the plate. R55NM7HP12 The removal of the shaft The removal of the shaft ①...
  • Page 286 ③ Remove the O-ring. R55NM7HP15 ④ Remove it while knocking the shaft rear and lightly with a plastic hammer. R55NM7HP16 The removal of the hanger The removal of the hanger ① Remove the hexagonal socket headed bolts (M6 × 16, 4pieces) and plate. Hexagonal bar spanner (Hex.
  • Page 287 ③ Remove the bearing. R55NM7HP19 ④ Remove the hanger. R55NM7HP20 The removal of the cover The removal of the cover ① Remove the control plate. R55NM7HP21 ② Remove the C-type stop ring. R55NM7HP22 7-16...
  • Page 288 ③ Remove the filter. R55NM7HP23 The removal of the control piston The removal of the control piston ① Remove the hexagonal socket headed bolts. (M8 × 25, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) The threaded portion of the bolt is coated with LOCTITE #270.
  • Page 289 ④ Take out three caned disk springs and spring seats. R55NM7HP27 The removal of the control spring The removal of the control spring ① Remove the hexagonal socket headed bolts (M8×30, 2pieces) and remove the cover. Hexagonal bar spanner (Hex. side distance : 6). R55NM7HP28 ②...
  • Page 290 The removal of the relief valve The removal of the relief valve ① Remove the hexagonal nuts. ※ Since the pressure has been set, this assembly must be made only when necessary. Spanner (Hex. side distance : 24). R55NM7HP30 ② Remove the adjusting screw.
  • Page 291 Disassembly of the shaft Disassembly of the shaft ① Remove the bearing. Remove the C-type stop ring. Snap ring pliers for shaft. R55NM7HP34 ② Remove it while knocking the rear end of shaft lightly with a plastic hammer. R55NM7HP35 7-20...
  • Page 292 DISASSEMBLING THE GEARED PUMP DISASSEMBLING THE GEARED PUMP Disassembling the P3 and P4 pump Disassembling the P3 and P4 pump ① Removed hexagonal socket head bolt and nut. Hexagonal socket wrench (8 mm). Hexagonal bar spanner (17 mm). R55NM7HP209 Disassembling the geared pump Disassembling the geared pump (P4) ①...
  • Page 293 Disassembling the geared pump Disassembling the geared pump (P3) ① Remove the square ring (10). R5577MP01 ② Remove the plate (5) and the guide ring (pieces). With O-ring (6, 8). Remove the O-ring (8) from guide ring (6). R5577MP02 ③ Remove the drive and idle gear (2, 3) and the side plate (4) assembly.

  • Page 294: Assembling Procedure

    4. ASSEMBLING PROCEDURE 4. ASSEMBLING PROCEDURE ASSEMBLING THE MAIN PUMP ASSEMBLING THE MAIN PUMP Assembling the hanger. R55NM7HP50 Install the bearing. R55NM7HP50A Install the distance piece. Confirm that pre-load is 0.1 ± 0.2. R55NM7HP51 Fix the plate with the hexagonal socket headed bolts (M6 ×...
  • Page 295 Assembling the shaft Assembling the shaft ① Fit the shaft into the bearing (with the bearing in the bottom) by using the press machine and jig. If the press is not available, use the jig in the similar manner and drive the shaft into the bearing by knocking with a plastic hammer.
  • Page 296 Install the case with oil seal vertically without tilting. ※ Apply grease to the oil seal lip beforehand. R55NM7HP57 Install the C-type stop ring to fix the shaft. R55NM7HP58 Assembling the rotary group. Install 10 (ten) pistons into the retainer. R55NM7HP59 (10) Apply grease to 3 parallel pins and...
  • Page 297 (11) Apply grease to the spherical portion of the guide. R55NM7HP61 (12) Insert the guide between the retainer and cylinder block and assemble the piston into the hole of cylinder block. R55NM7HP62 (13) Assembling the rotary group. To prevent dislodgement, apply grease to the back side of the plate and assemble it to the hanger.
  • Page 298 (15) Assembling the control spring. Apply grease to the spherical portion of the spring seat before assembling. R55NM7HP65 (16) Assemble 2 springs (inner and outer). R55NM7HP66 (17) Assembling the cover. Assemble the spring seats and coned disk springs (3 pieces). R55NM7HP67 (18) Assembling the control piston.
  • Page 299 (19) Apply grease to the O-rings (5.28×1.78, 1piece), (7.65×1.78, 1piece) and (15.6×1.78, 1piece) and assemble them to the cylinder. R55NM7HP69 (20) Apply grease to 3 parallel pins and assemble 3 pins into the cylinder. R55NM7HP70 (21) Fix the cylinder with the hexagonal socket headed bolts (M8×25, 2pieces).
  • Page 300 (23) Fix the cover with the hexagonal socket headed bolts (M8×30, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 2.9 ~ 3.5 kgf·m (21 ~ 25.3 lbf·ft) R55NM7HP73 (24) Apply grease to the back side of the control plate and assemble it to the cover while matching knock holes.
  • Page 301 (27) Fix the filter with the C-type stop ring. R55NM7HP77 (28) Assembling the relief valve. Assemble the spool. R55NM7HP78 (29) Assemble the spring. R55NM7HP79 (30) Insert the shim into the adjusting screw. R55NM7HP80 7-30...
  • Page 302 (31) Assemble the adjusting screw. R55NM7HP81 (32) Tighten the hexagonal nuts. After assembling, set the pressure and tighten the nuts. 1 kgf·m (7.2 lbf·ft) Spanner (Hex. side distance : 24) R55NM7HP82 (33) Install the cover in a parallel direction to the housing mounting surface.
  • Page 303 (35) Install the O-ring into the cover. R55NM7HP85 (36) Install the coupling to the shaft end of the main pump. R55NM7HP86 (37) Connect the main and geared pump. R55NM7HP87 (38) Fix the geared pump with the hexagonal socket headed bolts (M10×25, 2pieces). Hexagonal bar spanner (Hex.
  • Page 304 REASSEMBLING THE GEARED PUMP REASSEMBLING THE GEARED PUMP Reassembling the geared pump Reassembling the geared pump (P3) ① Insert the plate (5) to the pump housing. R5577MP03 ② Insert the square ring into the side plate. ※ Be careful to suction and discharge side. R55NM7HP210 ③...
  • Page 305 ⑤ Assemble the O-ring to the guide ring and assemble them to the plate. R55NM7HP213 ⑥ Assemble the guide ring assembly (6, 8) and plate (5) to the gear casing. R5577MP03 ⑦ Assemble the square ring (10) to the gear casing. R5577MP01 7-34...
  • Page 306 Reassembling the geared pump Reassembling the geared pump (P4) ① Insert the drive gear into the gear casing. R55NM7HP219 ② Insert the idle gear to into the gear casing. R55NM7HP220 ③ Insert the pins (2-pieces) to the center frame. R55NM7HP221 ④...
  • Page 307 ⑤ Assemble the center frame sub- assemble to the gear casing sub- assembly. R55NM7HP223 Reassembling the P3 and P4 pumps Reassembling the P3 and P4 pumps ① Insert the pins (2-pieces) into the center frame. R55NM7HP224 ② Insert coupling to the P3 geared pump. R55NM7HP225 ③...
  • Page 308 ④ Assemble the hexagonal socket bolts and nuts. · Size : M10×65L, 4pieces · Allen wrench : 8 mm · Spanner : 17 mm · Tightening torque : 580 kgf·cm (56.9 N·m) R55NM7HP227 ⑤ Assemble the O-ring to the pump housing.

  • Page 309: Group 4 Main Control Valve

    GROUP 4 MAIN CONTROL VALVE GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR 1. REMOVAL AND INSTALL OF MOTOR 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 310 2. STRUCTURE (1/4) 2. STRUCTURE (1/4) 5-15 5-101 5-11 5-102 4-111 4-112 4-113 4-101 4-15 4-102 3-111 3-112 5-121 3-113 5-122 3-101 3-15 3-102 4-13 4-12 5-15 2-101 2-102 2-15 4-14 3-12 3-13 4-15 2-112 3-14 2-12 2-111 3-15 2-13 2-14 2-15 55Z92MC02...
  • Page 311 STRUCTURE (2/4) STRUCTURE (2/4) 9-15 9-101 9-102 8-15 8-11 8-101 8-102 9-12 7-15 9-11 7-101 7-11 7-102 8-11 9-13 9-15 8-12 6-15 9-11 6-101 6-11 8-13 6-102 7-13 7-123 7-122 8-15 7-121 7-14 7-15 6-11 6-1 6-13 6-12 6-15 55Z92MC03 2 Way block 7-1 Work block (Ba3) 7-14 O-ring...
  • Page 312 STRUCTURE (3/4) STRUCTURE (3/4) 12-4 12-19 12-5 12-3 12-6 12-91 12-2 12-10 12-92 12-8 12-17 11-4 12-7 11-17 11-5 11-3 11-6 11-101 12-18 11-2 11-102 10-8 12-13 11-9 10-9 12-12 11-8 10-12 12-14 10-3 10-61 10-11 12-1 12-16 10-151 12-15 11-13 12-3 10-62...
  • Page 313 STRUCTURE (4/4) STRUCTURE (4/4) 14-4 14-15 14-5 14-3 14-6 14-2 14-91 14-81 13-4 14-92 14-82 13-14 13-5 13-151 13-11 13-3 13-6 13-151 13-152 14-102 13-152 13-16 14-101 13-16 13-18 13-17 14-1 13-2 14-3 14-11 14-15 13-11 14-7 14-6 14-5 13-1 13-12 13-13 13-3...

  • Page 314: Disassembly And Assembly

    3. DISASSEMBLY AND ASSEMBLY 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS GENERAL PRECAUTIONS 1) 1) 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 315 3) 3) DISASSEMBLY DISASSEMBLY (1) (1) Disassembly of spools Disassembly of spools (pilot type) ① Loosen hexagon socket head bolts (5) with washer (6). (Hexagon wrench : 5 mm) ② Remove the pilot cover (3). ※ Pay attention not to lose the O-ring (7) under the pilot cover.
  • Page 316 (3) (3) Disassembly of the load check valve Disassembly of the load check valve and the negative relief valve and the negative relief valve ① The load check valve Fix the body to suitable work bench. ※ Pay attention not to damage the body. Loosen the plug (10) (Hexagon wrench : 10 mm).
  • Page 317 (5) (5) Disassembly of the block assembly Disassembly of the block assembly ① Fix the body to suitable work bench. ② Remove the nut (20). (Spanner : 13 mm) ※ The work block is assembled by two sets of tie-bolts. ③...
  • Page 318 (6) (6) Inspection after disassembly 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. ① Control valve 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 319 4) 4) ASSEMBLY ASSEMBLY (1) (1) General precaution General precaution ① In this assembly section, explanation only is shown. For further understanding, please refer to the figures shown in the previous structure & disassembly section. ② Pay close attention to keeping all seals free from handling damage and inspect carefully for damage before using them.
  • Page 320 (3) (3) Main relief, port relief valves Main relief, port relief valves ① Install the main relief valve (5). ·Spanner : 30 mm ·Tightening torque : 6 kgf·m (43.4 lbf·ft) ② Install the over load relief valve (12). ·Spanner : 22 mm ·Tightening torque : 4 kgf·m (28.9 lbf·ft) R5577MCV09 R5577MCV10...
  • Page 321 Holding valve Holding valve (6) (6) ① Fit the holding valve to the body and tighten hexagon socket head bolt (7) to specified torque. ·Hexagon wrench : 5 mm ·Tightening torque : 1.1 kgf·m(7.9 lbf·ft) Holding valve R5577MCV14 R5577MCV13 7-50...

  • Page 322: 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 323 2) 2) SWING MOTOR/REDUCTION GEAR (1/2) SWING MOTOR/REDUCTION GEAR (1/2) 55Z9SM001 T01 Casing T15 Separation plate T43 Socket bolt R13 Neddle bearing T02 Valve casing T16 Brake piston R01 Gear casing R14 Neddle bearing T03 Drive shaft T17 Brake spring R02 Pinion shaft R15 Planet gear No.2 T04 Roller bearing...
  • Page 324 SWING MOTOR/REDUCTION GEAR (2/2) SWING MOTOR/REDUCTION GEAR (2/2) 55Z9SM002 T19 Plunger T33 Filter T20 Check spring T34 Bush T21 Plug T35 Spacer T27 O-ring T36 Throttle plate T28 O-ring T37 Spring T30 Spool T38 RO Plug T31 Spring T40 Plug T32 Plunger A T44 Relief valve 7-53...

  • Page 325: Disassembling And Assembling

    3. DISASSEMBLING & ASSEMBLING 3. DISASSEMBLING & ASSEMBLING 1) 1) TIGHTENING TORQUE OF BOLTS TIGHTENING TORQUE OF BOLTS In table 1 it is shown tightening torque of bolts used in motor. In case of reassembling, tighten accurately each bolt in accordance with table 1. Table 1 Bolt Size Name...
  • Page 326 Effectiveness screw length : 20 Special tool for removing the break piston Special tool for removing the break piston 55Z9SM009 7-55...

  • Page 327: Disassembly Of Motor

    DISASSEMBLY OF MOTOR DISASSEMBLY OF MOTOR Please use the following procedures for the inspection and repair of the motor. Numerals given in parentheses following the parts names indicate the items number shown by the drawing in page 7-52. Completely remove dirt and dust adhering to the outside. Discharge all hydrualic fluid in the motor casing and the port oil passage.
  • Page 328 Remove the valve plate (T18). 55Z9SM013 Remove the bearing (T05) and the pin (T22). 55Z9SM014 Remove brake springs (T17). 55Z9SM015 Remove the O-ring (T26, T27). 55Z9SM016 7-57...
  • Page 329 Remove brake piston (T16) from the casing (T01) by using the special tool for removing the brake piston. Lift it up straight by using the bolt hole in the brake piston. 55Z9SM017 (10) Pull out friction plate (T14, 2EA) and separation plate (T15, 1EA) from the casing (T01).
  • Page 330 (13) Remove the spherical bush (T11). 55Z9SM021 (14) Remove the cylinder spring (T12). 55Z9SM022 (15) Remove the drive shaft (T03). 55Z9SM023 (16) Remove the shoe plate (T07). 55Z9SM024 7-59...
  • Page 331 (17) Remove the bearing (T04). 55Z9SM025 (18) Remove the relief valve (T44). Do not disassemble the relief valve Do not disassemble the relief valve assembly because it is a functional assembly because it is a functional component. component. 55Z9SM026 (19) Remove the plug (T21), the spring (T20) and the plunger (T19).
  • Page 332 4) 4) ASSEMBLY OF MOTOR ASSEMBLY OF MOTOR Following are caution to be specially borne in mind. Rework damaged parts and before assembling and prepare all parts to be replaced. Clean all parts and dry with compressed air. Coat the sliding parts and bearing with clean hydraulic oil. Replace O-ring, oil seal.
  • Page 333 ④ Assemble the relief valve (T44). 55Z9SM032 ⑤ Assemble roller bearing (T04) in the casing (T01) with a using of tool. 55Z9SM033 ⑥ Apply grease to the back side of the shoe plate (T07) and assemble it. 55Z9SM034 ⑦ Assemble the drive shaft (T03) in the casing (T01).
  • Page 334 ⑧ Apply grease to the O-ring (T23, T24) and assemble it. 55Z9SM036 ⑨ Assemble the cylinder spring (T12). 55Z9SM037 ⑩ Assemble the spherical bush (T11). 55Z9SM038 ⑪ Set the piston assembly (T09, T10) on the retainer plate (T08) and assemble it in the cylinder block (T13).
  • Page 335 ⑫ Assemble the cylinder block (T13) and other associated parts. 55Z9SM040 ⑬ Assemble the friction plate (T14, 2EA) and separation plate (T15, 1EA). 55Z9SM041 ⑭ Assemble the brake piston (T16). 55Z9SM042 ⑮ Assemble the brake spring (T17). Confirm the springs are fitted to the brake piston completely.
  • Page 336 Assemble the O-ring (T26, T27). 55Z9SM044 Press-fit the ball bearing (T05). Assemble the pin (T22). 55Z9SM045 Assemble the valve plate (T18). Be careful to note the direction of the valve plate. Mount the valve plate with its round part toward the opposite side of the flange. Coat lightly with grease.
  • Page 337 Mount valve casing (T02) to casing (T01) and tighten hex socket bolts (T43) to specification. 55Z9SM048 7-66...
  • Page 338 DISASSEMBLY OF REDUCTION GEAR DISASSEMBLY OF REDUCTION GEAR Please use the following procedures for the inspection and repair of the reduction gear. Numerals given in parentheses following the parts names indicate the items number shown by the drawing in page 7-52. Wind the wire rope at reduction gear outside , lift up the reduction gear, and clean the reduction gear with cleaning oil.
  • Page 339 Remove the carrier No.2 sub-assembly (R08). 55Z9SM052 Remove the following parts. Snap ring R21 Thrust washer No2 R16 Planet gear No1 R14 Needle bearing R12 Inner ring No1 R19 Thrust washer No1 55Z9SM053 Secure the carrier No2 in a vice and loosen the screw (R22) to remove the thrust plate (R20).
  • Page 340 Remove the half collar (R07). 55Z9SM056 (10) Remove the pinion shaft (R02). ※ When removing the pinion shaft, be careful not to drop it. If it is hard to remove, lightly strike it with a plastic hammer. 55Z9SM057 (11) Remove the taper roller bearing (R04). 55Z9SM058 (12) Remove the oil seal (R05).
  • Page 341 6) 6) ASSEMBLY OF REDUCTION GEAR ASSEMBLY OF REDUCTION GEAR Following are caution to be specially borne in mind. Rework damaged parts before assembling and prepare all parts to be replaced. Clean all parts and dry with compressed air. Coat the sliding parts and bearing with clean hydraulic oil. Replace oil seal.
  • Page 342 ④ Install the pinion shaft (R02) and other associated parts. Prior to assembling the pinion shaft, Prior to assembling the pinion shaft, etc. apply grease slightly on the lip sur- etc. apply grease slightly on the lip sur- face to prevent any scratch when face to prevent any scratch when installing.
  • Page 343 ⑧ Install the following parts. Thrust plate Screw ※ Apply locite to the screw prior to tightening it. 55Z9SM067 ⑨ Install the carrier No.2 sub-assembly (R08). 55Z9SM068 ⑩ Install the sun gear No2 (R17). Be sure to check the direction of sun gear when assembling.
  • Page 344 ⑫ Install the carrier No.1 sub-assembly (R09). Turn the carrier slowly by hand to adjust the matching holes when assembling. 55Z9SM071 ⑬ Install the sun gear No1 (R18). Be sure to check the direction of sun gear when assembling. 55Z9SM072 ⑭...

  • Page 345: Group 6 Travel Device

    GROUP 6 TRAVEL DEVICE (TYPE 1) GROUP 6 TRAVEL DEVICE (TYPE 1) 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 346 3) 3) STRUCTURE STRUCTURE 37 39,40 30 31 56 57 23 22 20 19 18 17 10 9 16 64 1 5 59 82 83 87,88 52,53 48 50 51 SECTION A-A 41 42 46 45 43 44 32 33 24 34 27 35 25 14,13,12,11 63 15 62 61 65 3 67 68 66...
  • Page 347 2. DISASSEMBLY 2. DISASSEMBLY 1) 1) GENERAL PRECAUTIONS GENERAL PRECAUTIONS Before disassembling the travel motors, check the items to be inspected and, for remedy against trouble, closely examine the nature of the trouble, so that the motor can be disassembled effectively.
  • Page 348 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools Name of tools Size Name of applied parts Orifice (84) Plug (27) Hexagonal L-wrench Plug (49), wrench bolt (70, 83) Plug (81) Plug (38, 52, 50) Socket wrench / spanner Plug (44), Relief valve assembly (46) Snap-ring plier (for holes, axis)
  • Page 349 3. DISASSEMBLY 3. DISASSEMBLY 1) 1) GENERAL PRECAUTIONS GENERAL PRECAUTIONS Select a clean place for disassembling. Spread a rubber plate on a working table in order to prohibit the damage of parts. Clean a reduction gear and a motor part, washing out dirt and unnecessary substances. Without any damage of O-ring, oil seal, the adhered surface of other seals, a gear, a pin, the adhered surface of other bearings, and the surface of moisturized copper, treat each parts.
  • Page 350 ③ Dissemble plate spring (57) from shaft casing (1). 555K7TM03 ④ Using compression air, disassemble parking piston (21) from shaft casing (1) and dissemble O-ring (23), O-ring (22) and back up ring (85) in that order. 7078TM04/04A ⑤ Disassemble respectively 3 set of friction plate (19), parking plate (20) from shaft casing (1).
  • Page 351 (2) (2) Cylinder block Cylinder block ① Disassemble set plate (17), piston assembly (18) from cylinder block assembly (11). 7078TM07/07A ② Disassemble cylinder block (11), ball guide (16) and pin (15) in that order. 555K7TM08/08A ③ Put the cylinder block (11) on the air assembling jig and dissemble snap ring (14) by using a plier.
  • Page 352 ⑤ Disassemble steel ball (8) and swash plate (6) from shaft casing (1). 555K7TM11/11A/11B (3) (3) Rear cover Rear cover ① Disassemble valve plate (56) from rear cover (26). 555K7TM12/12A ② Using plier jig, disassemble snap ring (35), seat (34), O-ring (24), spring (33), check (32) from rear cover (26) and then disassemble snap ring (31), stopper (30), spr ing (29) and spool (28) same...
  • Page 353 ④ Using torque wrench, disassemble plug (44) and O-ring (45), spring (43), spring seat (42) and main spool (41) in that order. 7078TM15/15A ⑤ Disassembly make up valve Disassembly make up valve Using L-wrench, disassemble plug (38) and dissemble O-ring (36), back up ring (40) and spring (37) and then check (36) and spring (37) in that order.
  • Page 354 (4) (4) Reduction gear Reduction gear ① Using L-wrench, disassemble wrench bolt (83) and then ring gear cover (80), O-ring (82) from ring gear (59). 7078TM17/17A ② Disassemble thrust plate (79) from ring gear (59). 7078TM18/18A ③ Disassemble planetary gear (76), drive gear (78) in that order from ring gear (59).
  • Page 355 ⑤ Disassemble in order collar (75), carrier (73) from ring gear (59). 7078TM21/21A ⑥ Disassemble sun gear (71) from ring gear (59) and then disassemble snap ring (72) with a plier jig. 7078TM22/22A ⑦ Using a L-wrench, disassemble plate head bolt (70)-4EA from ring gear (59) and then disassemble plate (69).
  • Page 356 ⑨ Disassemble needle bearing (68)-4EA from ring gear (59). 7078TM25/25A ⑩ Disassemble collar (66)-4EA from ring gear (59). 7078TM26/26A ⑪ Disassemble washer (65)-4EA from ring gear (59). 7078TM27/27A ⑫ Using jig, disassemble nut (64) when inner pressed state with a L-wrench bolt from ring gear (59).
  • Page 357 ⑬ Put the reduction gear on the assembling jig and then disassemble ring gear (59). 555K7TM17 7-86 7-86...
  • Page 358 4. ASSEMBLY 4. ASSEMBLY GENERAL SUGGESTIONS GENERAL SUGGESTIONS 1) 1) After washing each parts cleanly, dry it with compressed air. Provided that you do not wash friction plate with treated oil. In bonding each part, fasten bond torque. When using a hammer, do not forget to use a plastic hammer. 2) 2) ASSEMBLING ASSEMBLING...
  • Page 359 ④ Assemble swash plate (9) to the shaft casing (1). 555K7TM20 ⑤ Assemble shoe plate (10) to the shaft casing (1). 555K7TM21 ⑥ Assemble shaft (4) to the shaft casing (1). 555K7TM22/22A (2) (2) Cylinder block sub assembly Cylinder block sub assembly ①...
  • Page 360 ② Assemble pin (15), ball guide (16) in that order to the cylinder block (11). 555K7TM08/08A ③ Assemble piston (18) to the set plate (17, 9 set). 555K7TM23 ④ Assemble sub-assembled piston (17, 18) to the cylinder block (9). 7078TM60 ⑤...
  • Page 361 ⑥ Assemble friction plate (19), parking plate (20) (respectively 3 EA) to the shaft casing (1). 555K7TM05 ⑦ Assemble back up ring (86), O-ring (23, 22), back up ring (85) in that order to the parking piston (21). 7078TM04/04A ⑧ Using a jig, insert the parking piston to the shaft casing (1) and assemble.
  • Page 362 ⑩ Assemble O-ring (25) to the shaft casing (1). 555K7TM02 ⑪ Assemble pin (55), O-ring (24) in that order to the shaft casing (1). 555K7TM25 (3) (3) Rear cover assembly Rear cover assembly ① Using a L-wrench, assemble plug (27)- 9EA to the rear cover (26).
  • Page 363 ③ Assemble the make up check valve Assemble the make up check valve Assemble check (36), spring (37) to rear cover (26) and assemble plug (38) with back up ring (40) and O-ring (39) to rear cover (26) by using a L-wrench. 7078TM16/16A ④...
  • Page 364 ⑦ Fit O-ring (51) to plug (49) and O-ring (53) to plug (52) and then assemble them to rear cover (26) by a torque wrench. 555K7TM26/26A ⑧ Assemble 2 plug (50) to rear cover (26) by a torque wrench. 555K7TM27 ⑨...
  • Page 365 ⑪ Assemble rear cover (26) to shaft casing (1). 555K7TM29 ⑫ Combine rear cover assembly and shaft casing assembly with 8 bolt (58). 555K7TM30 ⑬ Motor pressure test Motor pressure test Check the oil leak for one minute by appearance test at air pressure 5 kgf/cm (43 psi).
  • Page 366 (4) (4) Travel reduction gear Travel reduction gear ① Before assemble nut (64) to the motor. Remove burr and alien substances ready for assembling. 7078TM77/28A ② Insert ring gear (59) to the spray washing machine and heat up 69~70 ˚C for one minute.
  • Page 367 ⑤ Assemble floating seal (63) to ring gear (59) and motor part with a jig. 7078TM81/81A/82 ⑥ Upset the ring gear (59) and assemble with motor. 7078TM83 ⑦ Combine nut (64) to the ring gear (59) and pressing use a jig and then assemble with a torque-wrench.
  • Page 368 ⑨ Assemble washer (65)-4EA to the ring gear (59). 7078TM27 ⑩ Assemble collar (66)-4EA to the ring gear (59). 7078TM26 ⑪ Assemble needle bearing (68)-4EA to the ring gear (59). 7078TM25 ⑫ Assemble planetary gear (67)-4EA to the ring gear (59). 7078TM24 7-97 7-97...
  • Page 369 ⑬ Assemble plate (69)-1EA to the ring gear (59) and then tighten flat head bolt (70)- 4EA with a L-wrench. (after paste loctite and then tighten the flat head bolt). 7078TM23 ⑭ Assemble snap ring (72) to the sun gear (71) with a plier jig.
  • Page 370 Assemble carrier sub assembly to the ring gear (59). 7078TM87 Assemble needle bearing (77)-3EA to the ring gear (59). 7078TM20 Assemble in order planetary gear (76), drive gear (78) to the ring gear (59). 7078TM19 Assemble thrust plate (79) to the ring gear (59).
  • Page 371 Assemble in order ring gear cover (80) with O-ring (82) and then assemble wrench bolt (83) with a torque-wrench. 7078TM17/17A Roll the teflon tape to the ring gear (59) and then combine with a L-wrench (after test of drain part water pressure and capacity and then assemble plug PT3/8).
  • Page 372 (5) (5) Test Test ① Motor pressure test Motor pressure test Check the oil leak for one minute by appearance test at air pressure 5 kgf/cm (71 psi). 7078TM89 ② Performance test Performance test Pour the gear oil (85W-140) by beaker at the reduction gear.
  • Page 373 TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #1488-) TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #1488-) 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 374: Parts List

    2. DISASSEMBLY AND ASSEMBLY OF MOTOR UNIT 2. DISASSEMBLY AND ASSEMBLY OF MOTOR UNIT PARTS LIST (1/2) PARTS LIST (1/2) Rear flange assy 110 111 559A7TM05 110 Swash piston 119 Separator plate 101 Piston 111 Swash shoe 202 Reducer casing 102 Shoe 112 Pivot 401 O-ring...
  • Page 375 PARTS LIST (2/2) PARTS LIST (2/2) 559A7TM06 309 Set plug 503 Steel ball 30 Relief valve assy 310 Restrictor 504 Plunger 201 Valve casing 403 O-ring 505 Main spool spring 301 Socket bolt 405 O-ring 506 2 speed spool spring 302 Plug 406 O-ring 507 Spring pin...
  • Page 376 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tightening torque Tightening torque This table shows the typical screw sizes and tightening torques used in the motor Tightening torque Item Part name Size kgf · m lbf · ft Relief valve assy G 1/2 11.2...
  • Page 377 (2) (2) Tools Tools ① Hexagon and socket wrench Hexagon and socket wrench Tools Item Part name B size Screw size 304, 310 NPTF plug, Restrictor R 1/16 626, 632 Pipe plug, ROH plug R 1/8 Hexagon wrench 302, 308 ROH plug, 2 speed plug G 1/4 Socket bolt...
  • Page 378 (3) (3) Special tools Special tools ① Brake piston disassembly jig Brake piston disassembly jig Base plate Guide nut Side bolt Center bolt M12 screw M5 tap, depth 5 Motor casing Brake piston 559A7TM05 7-101-6...
  • Page 379 ② Brake piston press jig Brake piston press jig The below dimensions are the reference dimensions. 155.5 Assembled status 559A7TM10 ③ Bearing press jig Bearing press jig The below dimensions are the reference dimensions. 33.3 Bearing assembly Bearing pressing jig for valve casing Roller bearing pressing jig for casing 559A7TM11 7-101-7...
  • Page 380 3) 3) DISASSEMBLY DISASSEMBLY When disassembling the motor, disassemble in the order shown below. The number in brackets after part name means item number of section drawing. (1) (1) Wrap a wire rope around the outer periphery of the motor, lift it with a crane, and wash it with white kerosene.
  • Page 381 Disassemble the spring cap (510) → → cap Disassemble the spring cap (510) (509). (509). 559A7TM14 Loosen the set plug (309), remove the Loosen the set plug (309), remove the plunger (504) and the main spool spring plunger (504) and the main spool spring (505).
  • Page 382 The following operations should be The following operations should be carried out if necessary. carried out if necessary. ① Loosen the ROH plug (302) and remove Loosen the ROH plug (302) and remove the restrictor (310). the restrictor (310). ※ If there is no problem with the 1st / 2nd If there is no problem with the 1st / 2nd speed switching, no special disassembly...
  • Page 383 559A7TM22 ■ DISASSEMBLY OF MOTOR BODY (10) Remove the brake spring (117) from the brake piston (114). 559A7TM25 (11) Using the jig, remove the brake piston (114) from the casing (202). No.16 ※ If you need to disassemble without jig, Fill the brake flow path hole with compressed air.
  • Page 384 (12) Put the motor horizontally. Disassemble cylinder block (104) from drive shaft (103). Also, disassemble piston assy (10), set plate (106), spherical bush (105), cylinder spring (107). 559A7TM31 ※ Mark each cylinder block bore, piston assy, and set plate bore in the assembled position so that the assembled position does not change.
  • Page 385 (13) Disassemble friction plate (118) and separator plate (119) in casing (202). 559A7TM35 (14) Disassemble the drive shaft (103) and swash plate (109). 559A7TM37 (15) Disassemble swash piston assy (20), swash piston spring (511), pivot (112), pivot pin (113). 559A7TM38 7-101-13...
  • Page 386 (16) Do not disassemble any further unless there is a specific problem. At this state, check bearing according to the following inspection instructions. ① Check the raceway surface, rollers or balls in the visible range, and make sure there are no pittings or cracks. ②...
  • Page 387 4) 4) ASSEMBLY ASSEMBLY The assembly way is the reverse of the disassembly way, but be careful of the following items. The assembly way is the reverse of the disassembly way, but be careful of the following items. ① Be sure to repair damaged parts during disassembly. Please prepare replacement parts in Be sure to repair damaged parts during disassembly.
  • Page 388 Assemble main spool (501), Plunger Assemble main spool (501), Plunger (504) → → main spool spring (505) main spool spring (505) → (504) O-ring (411) → Assemble set plug (309) O-ring (411) Assemble set plug (309) in order. in order. ※...
  • Page 389 ■ ASSEMBLY OF MOTOR BODY ASSEMBLY OF MOTOR BODY Place the casing (202) on the work Place the casing (202) on the work surface with the valve casing (201) surface with the valve casing (201) assembly surface facing up. assembly surface facing up. Insert the oil seal (408) into the casing Insert the oil seal (408) into the casing (202) using a jig.
  • Page 390 (13) Assemble swash piston spring (511) and swash piston assy (20) to casing (202). ※ It is advisable to apply grease thinly on the mating surface of swash piston spring to prevent falling off. When assembled normally, the pushed swash piston assy goes deeper than the casing stage.
  • Page 391 (16) Set the cylinder spring (107) and the spherical bush (105) into the cylinder block (107). and insert the piston assy. (10) to the bore of set plate (106). ※ Assemble the Larger outer diameter face of set plate and the sliding movement face of shoe in the same direction.
  • Page 392 (18) Place casing (202) with the valve casing (201) assembly surface of casing (202) facing up. Separator plate (119) and friction plate (118) are alternately assembled to casing (202). ※ Put the separator plate in arc groove of casing. ※ Please refer to the assembly drawing for the number of assembly of the separator 559A7TM30...
  • Page 393 ※ Pay attention to the assembly direction of the brake piston. The orifice of the brake piston is located downward on the same vertical line as the flow hole in casing. 559A7TM42 (21) Attach the brake spring (117) to the brake piston (114).
  • Page 394 (24) The valve plate (108) is installed in the valve casing (202) and the O-ring (401) is mounted. ※ Apply grease thinly to the joint surface of the valve plate. (prevention of dropout) 559A7TM23 559A7TM22 (25) Attach the valve casing (201) to the casing (202) and fasten it with a socket bolt (301).
  • Page 395 3. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR 3. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR PARTS LIST PARTS LIST 559A7TM49 610 Thrust plate R 621 Snap ring 202 Reducer casing 611 Thrust washer 622 Steel ball 601 Housing 613 Collar 623 Socket bolt 602 Cover 614 Inner race 624 Bolt...
  • Page 396 GENERAL PRECAUTIONS GENERAL PRECAUTIONS This reduction gear is designed to reduce the number of parts and balance the life of the parts. Therefore, all parts can be supplied separately, but when replacing, it is often necessary to replace them both structurally and functionally. Parts to be replaced at the same time Part number 617 618 611 613 615 605 612 609 624 603 620 614 616 606...
  • Page 397 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tightening torque Tightening torque This table shows the typical screw sizes and tightening torques used in the reduction gear. This table shows the typical screw sizes and tightening torques used in the reduction gear. Tightening torque Item Part name...
  • Page 398 (3) (3) Special tools Special tools Square part 1 inch 559A7TM50 7-101-26...
  • Page 399 4) 4) ASSEMBLY ASSEMBLY Disassembly and assembly tips Disassembly and assembly tips ① When disassembling, be careful not to damage the parts. When disassembling, be careful not to damage the parts. ② Wash each part with washing oil and dry it with compressed air. Wash each part with washing oil and dry it with compressed air.
  • Page 400 ※ Be careful not to damage the O-ring (619) Be careful not to damage the O-ring (619) of the cover during disassembly. of the cover during disassembly. 559A7TM54 Disassemble thrust plate R (610), drive Disassemble thrust plate R (610), drive gear (608).
  • Page 401 Disassembly of No.1 holder assy Disassembly of No.1 holder assy Do not disassemble the No.1 holder assy Do not disassemble the No.1 holder assy further. further. In this state, check the parts according to In this state, check the parts according to the inspection instructions shown in the inspection instructions shown in section 6.
  • Page 402 (10) Disassembly of No.2 holder assy Do not disassemble any more No.2 holder assy unless otherwise specified. In this state, check the parts according to the inspection instructions shown in section 6. As mentioned above, it is recommended to exchange No.2 holder assy as a set as much as possible.
  • Page 403 (12) Disassemble pipe plug (625). ※ When disassembling the pipe plug (625), Do not reuse. 559A7TM65 (13) Disassemble the nut ring (604). 559A7TM66 ※ Please disassemble the nut ring using the dedicated jig referring to the attachment. 559A7TM67 7-101-31...
  • Page 404 (14) Disassemble casing (202) from housing (601). 559A7TM68 559A7TM69 (15) After disassembling the pipe plug (626), remove the steel ball (622). ※ The number of steel ball is 105. When disassembling, be sure to check the number of balls. 559A7TM70 (16) Disassemble the floating seal kit (618).
  • Page 405 (17) Disassemble angular bearing (617). 559A7TM72 ※ Use a press for disassembly. 559A7TM73 ※ The disassembly process is finished. 7-101-33...
  • Page 406 5) 5) ASSEMBLY ASSEMBLY After placing angular bearing (617) on After placing angular bearing (617) on housing (601), press the angular bearing housing (601), press the angular bearing (617) using a press. (617) using a press. 559A7TM72 ※ Assemble the protrusion of the inner ring Assemble the protrusion of the inner ring face down.
  • Page 407 ※ Before assembling, check the metal Before assembling, check the metal surface of the floating seal for cracks, surface of the floating seal for cracks, dents, and O-ring damage. dents, and O-ring damage. Do not apply oil to the floating seal rubber Do not apply oil to the floating seal rubber part.
  • Page 408 ※ Caulking is performed to prevent looseni- Caulking is performed to prevent looseni- Caulking ng around the assembly. ng around the assembly. 3 places 559A7TM76 Assemble the No. 2 holder assy Assemble the No. 2 holder assy Assemble in the order of thrust washer Assemble in the order of thrust washer (611) →...
  • Page 409 Fasten snap ring (621) to sun gear (607) using snap ring pliers. And assemble in the center of planetary gear F. ※ Assemble R part of snap ring toward cover. Sun gear is assembled with the long end facing toward casing. 559A7TM78 (10) Assemble the No.1 holder assy.
  • Page 410 (12) Assemble drive gear (608) and thrust plate R (610). 559A7TM55 (13) Assemble the O-ring (619), side plate A (627) and side plate B (628) on the cover (602). ※ After assembling the side plate B, remove any debris from the side. 559A7TM82 (14) Assemble cover sub to housing.

  • Page 411: Group 7 Rcv Lever

    GROUP 7 RCV LEVER GROUP 7 RCV LEVER 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 412: Disassembly And Assembly

    2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY 1) 1) STRUCTURE STRUCTURE 555C92RL02 Case Stopper 15 O-ring 22 Lock nut Plug Push rod 16 Rod seal 23 Handle assembly Bushing 10 Spring 17 Plate 24 Handle bar Spool 11 Push rod 18 Boot 25 Nut Shim...
  • Page 413 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools Tool name Remark Allen wrench Spanner (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques (2) (2) Tightening torque Tightening torque Torque Part name...
  • Page 414 3) 3) DISASSEMBLY 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. 21098RL04 ※...
  • Page 415 Loosen adjusting nut (21) and plate (20) with spanners on them respectively, and remove them. 36078RL01 36078RL02 Turn joint anticlockwise to loosen it, utilizing jig (special tool). ※ When return spring (10) is strong in force, plate (17), plug (14) and push rod (11) will come up on loosening joint.
  • Page 416 Remove plate (17). 36078RL05 When return spring (10) is weak in force, plug (14) stays in casing because of sliding resistance of O-ring. ※ Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
  • Page 417 (12) For disassembling reducing valve section, stand it vertically with spool (4) bottom placed on flat workbench. Push down spring seat (7) and remove two pieces of semicircular stopper (8) with tip of small minus screwdriver. ※ Pay attention not to damage spool surface.
  • Page 418 36078RL13 (16) Remove lock nut (22) and then boot (26). 36078RL14 2507ARL10 7-109...
  • Page 419 (17) (17) Cleaning of parts Cleaning of parts ① 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.
  • Page 420 4) 4) ASSEMBLY ASSEMBLY Tighten hexagon socket head plug (2) to the specified torque. ※ Tighten two bolts alternately and slowly. 36078RL15 Put shim (5), springs (6) and spring seat (7) onto spool (4) in this order. 36078RL16 Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper (8) on spring seat...
  • Page 421 Assemble O-ring (15) onto plug (14). 36078RL19 Assemble seal (16) to plug (14). ※ Assemble seal in such lip direction as shown below. 36078RL20 Assemble push rod (11) to plug (14). ※ Apply working oil on push-rod surface. 36078RL21 Assemble plug subassembly to casing. ※...
  • Page 422 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate (17), and tighten joint (19) temporarily. 36078RL23 (10) Fit plate (17). (11) Tighten joint (19) with the specified torque to casing, utilizing jig. 36078RL24 (12) Assemble plate (20) to joint (19).
  • Page 423 (14) Fit boot (18) to plate. 1408DA61 (15) Fit boot (26) and lock nut (22), and handle subassembly is assembled completely. 2507ARL10 36078RL27 (16) Pull out cord and tube through adjusting nut hole provided in direction 60˚ to 120˚ from casing hole. 1408DA66 7-114...
  • Page 424 (17) Assemble bushing (27) to plate and pass cord and tube through it. ※ Provide margin necessary to operation. 21098RL07 (18) Determine handle direction, tighten lock nut (22) to specified torque to fix handle. 21098RL08 (19) Apply grease to rotating section of joint and contacting faces of disk and push rod.

  • Page 425: 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 426 2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY 1) 1) STRUCTURE STRUCTURE 12 13 555K7TJ03 Slipper seal 10 Plug Shaft O-ring 11 Plug Cover Retainer ring 12 Hexagon bolt O-ring O-ring 13 Spring washer Ring 7-117...
  • Page 427 2) 2) DISASSEMBLY DISASSEMBLY ※ Before the disassembly, clean the turning joint. Remove bolts (12), washer (13) and cover (3). R55NM7TJ02 Remove O-ring (7). Remove retainer ring (8) and ring (5). 555K7TJ04 Place hub (1) on a V-block and by using a wood buffer at the shaft end, hit out shaft Secure with hand Wooden block...
  • Page 428 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 eight slipper seal (6) and O-ring (4) to hub (1).
  • Page 429 Install cover (3) to body (1) and tighten bolts (12) with washer (13). R55NM7TJ02 7-120...

  • Page 430: 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 (1) (1) Removal Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine.
  • Page 431 ④ Sling bucket cylinder assembly (8) and remove bolt (6) then pull out pin (5). ⑤ Remove bucket cylinder assembly (8). ·Weight : 30 kg (70 lb) R5577CY05 Install Install (2) (2) ① Carry out installation in the reverse order to removal.

  • Page 432: 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. 13031GE18 Loosen the breather slowly to release Loosen the breather slowly to release...
  • Page 433 ⑤ Sling arm assembly (8) and remove bolt (7) then pull out pin (6). ⑥ Remove arm cylinder assembly (8). ·Weight : 50 kg (110 lb) R5577CY09 Install Install (2) (2) ① 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...

  • Page 434: Boom Cylinder

    BOOM CYLINDER BOOM 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. 13031GE18 Loosen the breather slowly to release Loosen the breather slowly to release...
  • Page 435 ⑤ Disconnect boom cylinder hoses (4) and put plugs on cylinder pipe. 60CR97CY13 ⑥ Remove bolt (6) and pull out pin (5). ⑦ Remove boom cylinder assembly (3). ·Weight : 70 kg (150 lb) 60CR97CY14 (2) (2) Install Install ① Carry out installation in the reverse order to removal.
  • Page 436 2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY STRUCTURE STRUCTURE 1) 1) (1) (1) Bucket cylinder Bucket cylinder R55Z97CY22 Tube assembly 10 O-ring 19 Steel ball Rod assembly 11 Back-up ring 20 Set screw Rod cover 12 O-ring 21 Du bushing Dust seal 13 Piston 22 Bushing...
  • Page 437 (2) (2) Arm cylinder Arm cylinder R55Z97CY24 Tube assembly 13 Cushion stopper 25 Spring Rod assembly 14 Piston 26 Support spring Rod cover 15 Piston seal 27 Plug Dust wiper 16 Wear ring 28 U-bolt Retaining ring 17 Dust ring 29 Hex nut U-packing 18 Wear ring...
  • Page 438 (3) (3) Boom cylinder Boom cylinder 555C97CY21 Tube assembly 11 Retaining ring 21 Dust ring Bushing 12 O-ring 22 O-ring Bushing 13 Back-up ring 23 Back-up ring Du bushing 14 O-ring 24 Piston nut Rod cover 15 Back-up ring 25 Set screw Rod bushing 16 O-ring 26 Dust seal...
  • Page 439 (4) (4) Dozer cylinder Dozer cylinder R55Z97CY23 Tube assembly 11 Back-up ring 21 Pipe Rod assembly 12 O-ring 22 Double pitot check valve Gland 13 Piston 23 O-ring Dust wiper 14 Piston seal 24 O-ring Retaining ring 15 Dust ring 25 Socket bolt Rod seal 16 Wear ring...
  • Page 440 (5) (5) Boom swing cylinder Boom swing cylinder R55Z96MC02 Tube assembly 10 O-ring 18 Back-up ring Rod assembly 11 Buck-up ring 19 Steel ball Gland 12 O-ring 20 Set screw Dust wiper 13 Piston 21 Pin bushing Retaining ring 14 Piston seal 22 Dust seal Rod seal 15 Dust ring...
  • Page 441 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools Name Specification Allen wrench Spanner Hook spanner Suitable size (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques (2) (2) Tightening torque Tightening torque Torque...
  • Page 442 3) 3) DISASSEMBLY DISASSEMBLY Remove cylinder head and piston rod Remove cylinder head and piston rod ① 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 443 Note that the plated surface of rod assembly (3) 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. ⑤ Place the removed rod assembly on a wooden V-block that is set level.
  • Page 444 (3) (3) Disassemble the piston assembly Disassemble the piston assembly ① Remove wear ring (17). ② Remove dust ring (18) and piston seal (16). ※ Exercise care in this operation not to damage the grooves. 555C97CY36 (4) (4) Disassemble gland assembly Disassemble gland assembly ①...
  • Page 445 4) 4) 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. ① Coat the inner face of rod cover (5) with hydraulic oil. 555C97CY38 ②...
  • Page 446 ⑤ Fit back up ring (12) to rod cover (5). ※ Put the backup ring in the warm water of 12,13 30~50˚C . ⑥ Fit O-ring (13) to rod cover (5). 555C97CY41 (2) (2) Assemble piston assembly Assemble piston assembly ※...
  • Page 447 (3) (3) Install piston and cylinder head Install piston and cylinder head ① Fix the rod assembly to the work bench. Gland assembly ② Apply hydraulic oil to the outer surface of Rod assembly rod assembly (3), the inner surface of piston and cylinder head.
  • Page 448 (3) (3) Overall assemble Overall assemble Fix with a bar ① Place a V-block on a rigid work bench. Mount the tube assembly (2) on it and Lift fix the assembly by passing a bar through the clevis pin hole to lock the Straight assembly.

  • Page 449: 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 block Master pin as shown. Loosen tension of the track link. ※...

  • Page 450: Carrier Roller

    2. CARRIER ROLLER 2. CARRIER ROLLER 1) 1) REMOVAL REMOVAL Loosen tension of the track link. Grease valve R5577TR05 Jack up the track link height enough to permit carrier roller removal. Carrier roller Jack R5577TR04 Remove bolt (1) at both side. Remove carrier roller (2).

  • Page 451: Track Roller

    3. TRACK ROLLER 3. TRACK ROLLER 1) 1) REMOVAL REMOVAL Loosen tension of the track link. Grease valve R5577TR05 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 452 4. IDLER AND RECOIL SPRING 4. IDLER AND RECOIL SPRING 1) 1) REMOVAL REMOVAL Remove the track link. For detail, see removal of track link. 8-164(1) 140-7 Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry.
  • Page 453 3) 3) DISASSEMBLY AND ASSEMBLY OF IDLER DISASSEMBLY AND ASSEMBLY OF IDLER (1) (1) Structure Structure 555K7ID43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 7-144...
  • Page 454 (2) (2) Disassembly Disassembly Press ① Remove plug and drain oil. ② Draw out the spring pin (7), using a press. 8-166(1) 140-7 ③ Pull out the shaft (2) with a press. Press ④ Remove seal (3) from idler (1) and bracket (5).
  • Page 455 Assembly Assembly ※ Before assembly, clean the parts. ※ Press Coat the sliding surfaces of all parts with oil. ① 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 456 ⑥ Install bracket (5) attached with seal (3). 8-168(1) 140-7 ⑦ Knock in the spring pin (7) with a hammer. 8-168(2) 140-7 ⑧ Lay bracket (5) on its side. Supply engine oil to the specified level, and tighten plug. 8-168(3) 140-7 7-147...

  • Page 457: Disassembly And Assembly Of Recoil Spring

    4) 4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure Structure (1) (1) R5577RS01 Spacer 16 Dust-seal Spring 11 Bracket 17 Spacer Lock washer 12 Piston 18 Retaining ring Hex-nut 13 Grease valve 21 Bolt Slotted hex-nut 14 O-ring 22 Washer...
  • Page 458 Disassembly Disassembly ① Apply pressure on spring (3) with a press. 5, 6 The spring is under a large installed load. ※ This is dangerous, so be sure to set properly. ·Spring set load : 3900 kg (8600 lb) ② Remove split pin (6) and nut (5).
  • Page 459 ⑧ Remove retaining ring (18), spacer (17), dust seal (16), back-up ring (15) and O-ring (14). R5577RS05 Assembly Assembly ① Install O-ring (14), back-up ring (15), dust seal (16), spacer (17) and retaining ring (18) to bracket (11). ※ When installing dust seal (16) take full care so as not to damage the lip.
  • Page 460 ⑤ Install spring (3) and bracket (4) to body (1). ⑥ Apply pressure to spring (3) with a press 5, 6 and tighten nut (4). ※ Apply sealant before assembling. ※ During the operation, pay attention specially to prevent the press from slipping out.

  • Page 461: Group 11 Work Equipment

    GROUP 11 WORK EQUIPMENT GROUP 11 WORK EQUIPMENT 1. STRUCTURE 1. STRUCTURE SECTION A-A SECTION B-B SECTION E-E SECTION C-C SECTION D-D 55Z97AT01 7-152...
  • Page 462 2. REMOVAL AND INSTALL 2. REMOVAL AND INSTALL 1) 1) BUCKET ASSEMBLY BUCKET ASSEMBLY (1) (1) Removal Removal ① Lower the work equipment completely to ground with back of bucket facing down. 55Z97AT02 ② Remove nut (1), bolt (2) and draw out the pin (4).

  • Page 463: 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 464: Boom Cylinder

    3) 3) BOOM CYLINDER BOOM CYLINDER Removal Removal ① Remove arm and bucket assembly. ② For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly. 55Z97AT08 ③ Disconnect head lamp wiring.
  • Page 465 SECTION 8 COMPONENT MOUNTING TORQUE SECTION 8 COMPONENT MOUNTING TORQUE Group 1 Introduction guide ------------------------------------------------------------------------------------------- 8-1 Group 2 Engine system ------------------------------------------------------------------------------------------------ 8-2 Group 3 Electric system ----------------------------------------------------------------------------------------------- 8-4 Group 4 Hydraulic system -------------------------------------------------------------------------------------------- 8-5 Group 5 Undercarriage ------------------------------------------------------------------------------------------------ 8-7 Group 6 Structure --------------------------------------------------------------------------------------------------------- 8-8 Group 7 Work equipment --------------------------------------------------------------------------------------------- 8-10...

  • Page 466: Section 8 Component Mounting Torque

    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 467: Group 2 Engine System

    GROUP 2 ENGINE SYSTEM GROUP 2 ENGINE SYSTEM 1. ENGINE AND ACCESSORIES MOUNTING 1. ENGINE AND ACCESSORIES MOUNTING Air cleaner Muffler REAR FRONT Engine 55Z98CM01 ·Tightening torque Item Size kgf·m lbf·ft M 8×1.25 3.4±0.7 24.6±5.0 M10×1.5 6.9±1.4 49.9±10.1 M16×2.0 29.7±4.5 214.8±32.5...
  • Page 468 2. COOLING SYSTEM AND FUEL TANK MOUNTING 2. COOLING SYSTEM AND FUEL TANK MOUNTING Air compressor Fuel tank Air con idle pulley Radiator and cooler 55Z98CM02 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 6×1.0 1.05±0.2 7.6±1.45 M12×1.75 12.8±3.0 92.6±21.7...

  • Page 469: Group 3 Electric System

    GROUP 3 ELECTRIC SYSTEM GROUP 3 ELECTRIC SYSTEM Fuel pump assy Starter & Heater relay Travel alarm buzzer Battery relay Battery Horn DETAIL A 55Z98CM03 ·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 M10×1.5 6.9±1.4 49.9±10...

  • Page 470: Group 4 Hydraulic System

    GROUP 4 HYDRAULIC SYSTEM GROUP 4 HYDRAULIC SYSTEM 1. HYDRAULIC COMPONENTS MOUNTING 1 1. HYDRAULIC COMPONENTS MOUNTING 1 Air breather Dozer lever Level gauge Block(A) Hydraulic tank Solenoid valve Swing motor Terminal Cross RCV-RH Main control valve Turning joint RCV-LH PUMP MOUNTING R.C.V Pedal Coupling...

  • Page 471: Bucket Cylinder

    2. HYDRAULIC COMPONENTS MOUNTING 2 2. HYDRAULIC COMPONENTS MOUNTING 2 ,3,4 BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER DOZER CYLINDER 55Z98CM07 ·Tightening torque Rod cover Rod cover (1) Piston nut Piston nut (3) Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft Boom cylinder M115 70±7.0...

  • Page 472: Group 5 Undercarriage

    GROUP 5 UNDERCARRIAGE GROUP 5 UNDERCARRIAGE ADJUST COMPONENT Swing bearing Idler Travel motor Sprocket TRACK CHAIN Idler Track guard 55Z98CM08 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M10×1.5 6.9±1.4 49.9±10.1 M18×2.0 41.3±6.2 298.7±44.8 M12×1.75 12.8±3.0 92.6±21.7 M24×3.0 100±15 723.3±108 M14×2.0...

  • Page 473: Group 6 Structure

    GROUP 6 STRUCTURE GROUP 6 STRUCTURE 1. CAB AND ACCESSORIES MOUNTING 1. CAB AND ACCESSORIES MOUNTING Console frame Cabin Seat base 55Z98CM09 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 6×1.0 1.44±0.3 10.4±2.1 M10×1.5 4.7±0.9 34.0±6.5 M 8×1.25 2.5±0.5 18.1±3.6 M12×1.75...
  • Page 474 2. COWLING MOUNTING 2. COWLING MOUNTING Fuel hood body Engine hood Frame cover-RH Counterweight Upper frame Frame cover-LH Under cover-Pump Under cover-H/Tank Under cover-Engine Under cover-F/Tank Under cover-Mcv 55Z98CM10 ·Tightening torque Item Size kgf·m lbf·ft M 8×1.25 2.5±0.5 18.1±3.6 M10×1.5 6.9±1.4 49.9±10.1...

  • Page 475: Group 7 Work Equipment

    GROUP 7 WORK EQUIPMENT GROUP 7 WORK EQUIPMENT 55Z98CM11 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M12×1.75 12.8±3.0 92.6±21.7 M16×2.0 29.7±4.5 215±32.5 8-10...

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