Hyundai Robex 130 SMART Service Manual
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Hyundai Robex 130 SMART Service Manual

Hyundai Robex 130 SMART Service Manual

Hydraulic excavators
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  • Page 2: Table Of Contents

    CONTENTS SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9 SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1...
  • Page 3 Group 9 Engine Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11 Group 10 EPPR(Electro Proportional Pressure Reducing) Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17 Group 11 Prolix Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-20 Group 12 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21...
  • Page 4 This section shows bolt specifications and standard torque values needed when mounting components to the machine. The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 5 Revised edition mark( Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.

  • Page 6: Conversion Table

    3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 7 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 8 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 9 kgf m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9...
  • Page 10 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 11 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 12: Section 1 General

    SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9...
  • Page 13 SECTION 1 GENERAL GROUP 1 SAFETY FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. 13031GE01 WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.
  • Page 14 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers doctors, ambulance service, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
  • Page 15 KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.
  • Page 16 SUPPORT MACHINE PROPERLY 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 17 BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
  • Page 18 SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
  • Page 19 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
  • Page 20 USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards. Use power tools only to loosen threaded tools and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.
  • Page 21 SPECIFICATIONS Tool box Fuel tank Hydraulic tank Main pump Engine Radiator Oil cooler Bucket Main control valve Swing motor Tooth Turning joint Arm cylinder Boom Boom cylinder Muffler Counterweight R130 Side cutter Idler Track roller Connecting link Travel motor Bucket cylinder Carrier roller Track Sprocket...
  • Page 22 2. SPECIFICATIONS I(I') R 130 B(L) D11072SP02 Description Unit Specification Operating weight kg(lb) 11800(26222) Bucket capacity(SAE heaped), standard (yd ) 0.60(0.78) Overall length 7240(23' 9") 2490( 8' 2") Overall width, with 500mm shoe Overall height 2550( 8' 4") Superstructure width 2475( 8' 1") Overall height of cab 2800( 9' 2")
  • Page 23 R130 4.3m(14' 1") MONO BOOM, 2.26m(7' 5") ARM AND REAR DOZER BLADE I(I') B(L) 11072SP02A Description Unit Specification Operating weight kg(lb) 11800(26222) Bucket capacity(SAE heaped), standard (yd ) 0.60(0.78) Overall length 7620(25' 0") Overall width, with 500mm shoe 2490( 8' 2") Overall height 2550( 8' 4") Superstructure width...
  • Page 24 3. WORKING RANGE R130 D11072SP03 Description m(6' 5") Arm 2.26m(7' 5") Arm 1.96 Max digging reach 7460mm (24' 6") 7740mm (25' 5") Max digging reach on ground 7320mm (24' 0") 7610mm (25' 0") Max digging depth 4770mm (15' 8") 5090mm (16' 8") Max digging depth (8ft level) 4510mm...
  • Page 25 1-13...
  • Page 26 4. WEIGHT 1) R130 Item Upperstructure assembly 3300 7280 Main frame weld assembly 1030 2270 Engine assembly 1210 Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 1450 3200 Cab assembly Lower chassis assembly 3990 8800...

  • Page 27: Lifting Capacities

    5. LIFTING CAPACITIES ROBEX 130 4.3m(14' 1") boom, 2.26m(7' 5") arm equipped with 0.45m (SAE heaped) bucket and 500mm(20") triple grouser shoe. : Rating over-front : Rating over-side or 360 degree Load radius At max. reach Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity...
  • Page 28 4.3m(14' 1") boom, 2.81m(9' 3") arm equipped with 0.45m (SAE heaped) bucket and 500mm(20") triple grouser shoe. Load radius At max. reach Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach height m(ft) 6.0m *1570 1290 6.66 (20ft) *3460 2840 (21.9) 4.5m *1640 1570...
  • Page 29 4.3m(14' 1") boom, 1.96m(6' 5") arm equipped with 0.45m (SAE heaped) bucket and 500mm(20") triple grouser shoe, and rear dozer blade down. Load radius At max. reach Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach height m(ft) 6.0m *1770 *1770 *1820 *1820 5.62...
  • Page 30 1-18...
  • Page 31 7. UNDERCARRIAGE TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. TYPES OF SHOES Triple grouser Model Shapes...
  • Page 32 1-20...
  • Page 33 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Kirlostar 4R1040T Type 4-cycle turbocharged 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 105 120mm(4.1"...

  • Page 34: Swing Motor

    GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 35kgf/cm (500psi) Rated oil flow 29.3 /min(7.7U.S.gpm/6.4U.K.gpm) MAIN CONTROL VALVE Item Specification Type 11 spools mono-block Operating method Hydraulic pilot system Main relief valve pressure 330kgf/cm (4695psi)[360kgf/cm (5120psi)]...

  • Page 35: Remote Control Valve

    REMOTE CONTROL VALVE Item Specification Type Pressure reducing type Minimum 6.5kgf/cm (92psi) Operating pressure Maximum 26kgf/cm (370psi) Lever 61mm(2.4in) Single operation stroke Pedal 123mm(4.84in) CYLINDER Specification Item Bore dia Rod dia Stroke 70 1015mm Boom cylinder Extend only Cushion Bore dia Rod dia Stroke 75 1070mm...

  • Page 36: Recommended Oils

    9. RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. 1-24...

  • Page 37: Section 2 Structure And Function

    SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-19 Group 3 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-42 Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-54...

  • Page 38: Group 1 Pump Device

    SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. Port Port name Port size A1,2 Delivery port SAE6000psi 3/4" Suction port SAE2500psi 2 1/2" Drain port PF 1/2 - 19 Pi1,i2 Pilot port PF 1/4 - 15...
  • Page 39 MAIN PUMP(1/2) The main pump consists of two piston pumps(front & rear) and valve block. 789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113 153 156 124 312 114 466 885 467 141 981 271 401 14072SF02 04 Gear pump...
  • Page 40 REGULATOR(1/2) SECTION B-B 722 496 VIEW C(FRONT) VIEW C(REAR) KR36-9N12(FRT) KR36-9N1S(RR) Port Port name port size Delivery port 3/4" Suction port 2 1/2" Pilot port PF 1/4-15 SECTION D-D Qmax cut port PF 1/4-15 11072PM03...
  • Page 41 REGULATOR(2/2) 651 652 140LC-7 SECTION A-A 405 Hexagon socket screw 629 Cover(C) 730 O-ring 412 Hexagon socket screw 630 Lock nut 732 O-ring 413 Hexagon socket screw 631 Sleeve, pf 733 O-ring 436 Hexagon socket screw 641 Pilot cover 734 O-ring 438 Hexagon socket screw 643 Pilot piston 735 O-ring...
  • Page 42 GEAR PUMP 354 351 466, 725 140LC-7 307 Poppet 353 Drive gear 466 Plug 308 Seat 354 Driven gear 700 Ring 309 Spring seat 355 Filter 710 O-ring 310 Spring 361 Front case 725 O-ring 311 Screw 433 Flange socket 732 O-ring 312 Nut 434 Flange socket...
  • Page 43 2. FUNCTION MAIN PUMP The pumps may classified roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: the swash plate group that varies the delivery rates: and the valve cover group that changes over oil suction and discharge. Rotary group The rotary group consists of drive shaft (F)(111), cylinder block(141), piston...
  • Page 44 Valve block group The valve block group consists of valve block(312), valve plate(313) and valve plate pin(885). The valve plate having two melon-shaped ports is fixed to the valve block and feeds and collects oil to and from the cylinder block.
  • Page 45 REGULATOR Regulator consists of the negative flow control, total horse power control and power shift control function. Negative flow control By changing the pilot pressure Pn, the pump tilting angle(delivery flow) is regulated arbitrarily, as shown in the figure. This regulator is of the negative flow control in which the delivery flow Q decreases as the pilot pressure Pn rises.
  • Page 46 Flow reducing function B(E) Servo piston Small diameter Large diameter chamber chamber 11072PM10 As the pilot pressure Pn rises, the pilot piston(643) moves to the right to a position where the force of the pilot spring(646) balances with the hydraulic force. The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613).
  • Page 47 Flow increasing function B(E) Small diameter Servo piston Large diameter chamber chamber 11072PM11 As the pilot pressure Pn decreases, the pilot piston(643) moves to the left by the action of the pilot spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897) is pressed against the large hole section(C) of lever 2 by the action of the return spring(654) via the spool(652), pin(874), and feedback lever(611), the feedback lever rotates...
  • Page 48 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut(801) and by tightening(or loosening) the hexagonal socket head screw(924). Tightening the screw shifts the control chart to the right as shown in the figure. Adjusting values are shown in table.
  • Page 49 Total horsepower control The regulator decreases the pump tilting angle(delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump. (The input horsepower is constant when the speed is constant.) Since the regulator is of the simultaneous...
  • Page 50 Overload preventive function B(E) Large diameter Servo piston Small diameter chamber chamber 140LC-7 2-14 When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston(621). It presses the compensating rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with the hydraulic force.
  • Page 51 Flow reset function B(E) Large diameter Small diameter chamber chamber Servo piston 140LC-7 2-15 As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever 1(612) around point E.
  • Page 52 Low tilting angle(Low flow) command preferential function As mentioned above, flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However, since sections C and F have the pins( 4) protruding from the large hole( 8), only the lever lessening the tilting angle contacts the pin(897) ;...
  • Page 53 Adjustment of inner spring Adjust it by loosening the hexagon nut (801) and by tightening(or loosening) the adjusting screw QI(925). Tightening the screw increases the flow and then the input horsepower as shown in the figure. Adjusting valves are shown in table Adjustment of outer spring Speed Tightenin...
  • Page 54 Power shift control B(E) Large diameter Small diameter chamber chamber Servo piston 140LC-7 2-18 The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one proportional pressure reducing valve is provided.
  • Page 55 Adjustment of maximum and minimum flows Adjust it by loosening the hexagon nut(808) and by tightening(or loosening) the set screw(954). The maximum flow only is adjusted without changing other control characteristics. 140LC-7 2-19(1) Adjustment of max flow Speed Tightening Flow change amount of amount adjusting screw...

  • Page 56: Group 2 Main Control Valve

    GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE Mark Port name Port size Tightening torque Make up for swing motor Travel left pilot port(FW) Travel left pilot port(BW) Travel right pilot port(BW) Travel right pilot port(FW) Pa20 Boom up pilot port Pa21 Boom up confluence pilot port Pb20...
  • Page 57 Body Stopper-regeneration Spool-straight travel Piston-cut off Spool-travel Poppet-signal Spool-swing Spring-signal Spool-boom Plug Spool-swing priority Orifice-signal Spool-boom2 Coin type filter Spool-arm2 Orifice-plug Spool-arm Plug Spool-arm regeneration Plug & breaker Plug Spool-option Plug-orifice Spool-bucket Poppet-negative control Cover-pilot A Coin type filter Cover-pilot B1 Spring seat Cover-Pilot B2 Spring-negative control...

  • Page 58: Hydraulic Circuit

    2. HYDRAULIC CIRCUIT 14072SF05 2-21...
  • Page 59 3. FUNCTION CONTROL IN NEUTRAL FUNCTION P1 SIDE 14072SF13 14072SF15 The hydraulic fluid from pump P1 flows into the main control valve through the inlet port "P1", pass the travel straight spool, into the P1 bypass passage and P1parallel passage. The hydraulic fluid from the pump P1 is directed to the tank through the bypass passage of spools : travel left, boom1, arm2, arm regeneration &...
  • Page 60 P2 SIDE 14072SF14 14072SF16 The hydraulic fluid from pump P2 flows into the main control valve through the inlet port "P2", pass the straight travel spool, into the P2 bypass passage and P2 parallel passage. The hydraulic fluid from the pump P2 is directed to the tank through the bypass passage of spools : travel right, swing, boom2 &...
  • Page 61 EACH SPOOL OPERATION TRAVEL OPERATION Travel forward operation 14072SF17 Travel backward operation 14072SF18 During the travel operation, the hydraulic fluid of the pump P1 is supplied to the travel motor and the hydraulic fluid of the pump P2 is supplied to the other travel motor. The pilot pressure from the pilot control valve is supplied to the spring side of pilot port (pa1, pd1).
  • Page 62 TRAVEL STRAIGHT FUNCTION 14072SF19 This function keeps straight travel in case of simultaneous operation of other actuators(boom, arm, bucket, swing) during a straight travel. 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 63: Boom Operation

    BOOM OPERATION Boom up operation 14072SF24 14072SF25 During boom up operation, the pilot pressure from RCV is supplied into the port Pa20 and shift the boom1 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 and boom holding valve then flows into the port A2.
  • Page 64 Boom down operation 14072SF26 During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 and shift the boom1 spool in the right direction. The hydraulic fluid from the pump P1 enters the parallel passage and is directed to the port B2 through the load check valve.

  • Page 65: Bucket Operation

    BUCKET OPERATION Bucket roll in operation 14072SF34 Bucket roll out operation 14072SF35 2-28...
  • Page 66 Bucket roll in operation During the bucket roll in operation, the pilot pressure from RCV is supplied to port Pa5 and shift the bucket spool in the left direction. The hydraulic fluid from pump P1 entered P1 parallel passage and is directed to the port A5 through the check1.

  • Page 67: Swing Operation

    SWING OPERATION Swing left operation 14072SF32 Swing right operation 14072SF33 The pilot pressure from the RCV is supplied to the Pd2 and shift the swing spool in left direction. The hydraulic fluid from pump P2 flows into swing spool through the parallel passage. Then it is directed to swing motor through the port D2.

  • Page 68: Arm Operation

    ARM OPERATION Arm roll in operation 14072SF21 14072SF20 Arm roll in operation : During arm roll in operation the pilot pressure from the RCV is supplied to the port Pc4 and Pb3 and shifts arm1 spool and arm2 spool in the right 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 C4.
  • Page 69 Arm regeneration : The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool through the arm holding valve and the arm1 spool. It is suppled the arm cylinder head through internal passage.
  • Page 70 Arm roll out operation 14072SF23 14072SF22 During arm roll out operation the pilot pressure from RCV is supplied to the port Pd40 and the Pd41 and shifts arm1 spool and arm2 spool in the right direction. The hydraulic fluid from pump P2 flows into arm1 spool through the parallel passage. Then it enters into the arm cylinder rod side through the load check valve, bridge passage, arm holding valve and the port D4.
  • Page 71 SWING PRIORITY FUNCTION 14072SF27 During swing priority operation, the pilot pressure is supplied to the port Pc3 and shift swing priority spool in the right direction. The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm1 side through swing priority spool and the passage "A"...
  • Page 72 HOLDING VALVE OPERATION Holding operation 14072SF30 At neutral condition, the pilot piston chamber is connected to drain port through the pilot port. And the piston "B" is supported with spring "B" and the pressured fluid from actuator entered to inside of the holding valve through the periphery hole of check, crevice of the check and the plug and the periphery hole of plug.
  • Page 73 Release holding operation 14072SF31 The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the left direction against the spring "B", and shifts the poppet in the left direction through piston "B" and piston "A"...
  • Page 74 NEGATIVE CONTROL 14072SF28 When no function is being actuated on P1 side, the hydraulic fluid from the pump P1, flows into the tank passage through the bypass passage and orifice. The restriction caused by this orifice thereby pressurizes. This pressure is transferred as the negative control signal pressure Pn1 to the pump P1 regulator.
  • Page 75 (10) OPERATION OF MAIN RELIEF VALVE The main relief valve is fitted to the straight travel valve block and functions as follows : The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the inside space, and seats the plunger against the housing securely.
  • Page 76 Opening the poppet causes the pressure in chamber A to fall and the plunger to open. As the result the pressurized oil at port P runs into tank passage (T) 14072SF38 High pressure setting pilot signal(Pu) : ON When the power boost switch is ON, the pilot pressure enters through hole A. It pushes the piston(B) in the left direction to increase the force of the spring and change the relief set pressure to the high pressure.
  • Page 77 (11) OPERATION OF PORT RELIEF VALVE Function as relief valve The pressurized oil passes through the piston A and orifice is filled up in chamber A of the inside space and seat the plunger against the socket and the socket against the housing securely.
  • Page 78 Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As the result the pressurized oil at port P runs into tank passage (T). 14072SF41 Make-up function When negative pressure exists at port P, the oil is supplied through tank passage (T). When the pressure at tank passage (T) becomes higher than that at port P, the socket moves in the right direction.

  • Page 79: Group 3 Swing Device

    GROUP 3 SWING DEVICE 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Time delay valve SH PG Oil gauge port Port Port name Port size Main port PF 3/4...
  • Page 80 SWING MOTOR 11072SM02 Body 16 Brake piston 31 Check Oil seal 17 O-ring 32 Relief valve assy Roll bearing 18 O-ring 33 Reactionless valve assy Snap ring 19 Spring 34 Time delay valve assy Shaft 20 Rear cover 35 Wrench bolt Bushing 21 Needle bearing 36 Plug...

  • Page 81: Reduction Gear

    REDUCTION GEAR 26 27 28 17 22 20 18 25 8 12 4 10 23 3 11072SM03 Casing 10 Pin No.2 assembly 21 Plug(B) Drive shaft 11 Pin No.1 22 Plug(A) Ring gear 12 Thrust washer(B) 23 Spring pin Planet gear No.2 13 Thrust washer(A) 24 Stop ring Sun gear No.2...
  • Page 82 2. FUNCTION ROTARY PART When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(1), hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the piston(2) upon the return plate(3) which acts upon the swash plate(4) via an hydrostatic bearing. Force F1 perpendicular to swash plate(4) and force F2 perpendicular to cylinder center.
  • Page 83 MAKE UP VALVE In the system using this type of motor, there is no counter balance functioning valve and there happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency. A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action.

  • Page 84: Relief Valve

    RELIEF VALVE Body Seat Plunger Spring Adjusting screw Piston Bushing Spring seat Shim 10 O-ring 11 Back up ring 12 O-ring Construction of relief valve The valve casing contains two cartridge type relief valves that stop the regular and reverse rotations of the hydraulic motor.
  • Page 85 Ports (P,R) at tank pressure. R140LC-7 2-49 When hydraulic oil pressure(P A ) reaches the preset force(F ) of spring(4), the plunger(3) moves to the right as shown. Fsp+Pg A Fsp+Pg A R140LC-7 2-49 2-48...
  • Page 86 The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset force(F ) of spring(4), the piston(6) moves left and stop the piston(6) hits the bottom of bushing(7). R140LC-7 2-49 When piston(6) hits the bottom of bushing(7), it stops moving to the left any further. As the result, the pressure in chamber(g) equals(Ps).

  • Page 87: Brake System

    BRAKE SYSTEM Control valve swing brake system This is the brake system to stop the swing motion of the excavator during operation. In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance created by this throttling works as a brake force to slow down the swing motion. Deceleration Stop Work...
  • Page 88 Operating principle When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control valve(2) and to S of the time delay valve(3) via the shuttle valve(4), this pressure move spool(5) to the leftward against the force of the spring(8), so pilot pump charged oil(P ) goes to the chamber G.
  • Page 89 Meantime, the oil pressure of port D balance with the preset force of spring(7), the pressure of chamber G keeps constant pressure. Swing control lever Swing control valve(MCV) Time delay valve Shuttle valve Spool Piston Brake spring Spring Pilot pump 11072SM07 2-52...
  • Page 90 When the swing control(1) lever is set the neutral position, the spool(5) returns right in the time delay valve(3). Then, the piston(6) is moved lower by spring force and the return oil from the chamber G flows back to tank. At this time, the poppet works to make a time lag for 5 seconds.

  • Page 91: Group 4 Travel Device

    GROUP 4 TRAVEL DEVICE 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Oil fill port(PF 1/2) 2 speed control port(PP3) Oil level Pressure gauge port(M1, M2) Drain port(PF 1/2) Port Port name...

  • Page 92: Basic Structure

    BASIC STRUCTURE Reduction gear Hydraulic motor Brake valve Parking brake High/low speed changeover mechanism Control valve Hydraulic pump 11072TM02 2-55...
  • Page 93 STRUCTURE 11072TM04 Shaft 20 Brake piston 37 Retainer 54 Plug 71 Sleeve 89 Carrier Cylinder barrel 21 Friction plate 38 Poppet 55 O-ring 72 Stopper 90 Sun gear B Ball retainer 22 Steel plate 39 Spring 56 Orifice 73 Spring 91 Planetary gear B Retainer 23 Disk spring...
  • Page 94 2. FUNCTION HYDRAULIC MOTOR Motoring function Valve plate Piston Sun gear(A) (for 1st stage of Planetary reduction gear) Shaft Spline Spline High Cylinder barrel pressure pressure 11072TM05 High-pressure oil is supplied to the left port of motor. The oil goes into the cylinder barrel through the valve plate. The high pressure pushes the piston to the left.
  • Page 95 Speed-shifting function The torque and speed generated by the motor depends on the displacement of the motor. And the displacement depends on Speed shifting piston the cam angle The bigger the cam angle is, the higher the torque is and the lower the speed is. The smaller the cam angle is, th lower Low speed mode...
  • Page 96 Parking brake function This travel drive is equipped with a parking brake. It gives parking brake torque to the motor when high pressure oil is NOT supplied to the motor and the motor is NOT traveling. Also, it releases parking Splined brake when high-pressure oil is supplied to the motor and the motor is traveling.

  • Page 97: Brake Valve

    BRAKE VALVE Counterbalance valve function Level travel GEAR When high pressure oil is NOT supplied Parking brake Relief valve to the brake valve, CBV spool is at the (Right) center because of two springs beside it. Relief valve Now oil flow passage from motor is (Left) closed.
  • Page 98 Down-slope travel If there is NOT a counterbalance valve equipped When the vehicle travels down a slope, GEAR gravity makes the travel drives rotate more speedily than you intended. The "overrunning" cannot be controlled by the supplying oil flow rate. Also, the pumps Outlet side Inlet side cannot maintain the oil supply to the...
  • Page 99 Crossover relief valve function Shockless piston High pressure Spring Poppet High pressure High pressure 11072TM10 This travel drive is equipped with a pair of shockless crossover relief valves. The purpose is as below : The relief valve prevents the ocurrence of a shock load while travel deceleration or stopping process.
  • Page 100 Function and mechanism of shock-less crossover relief valves Please refer to the figures in "2)-(1) counterbalance valve function" and on this page. The explanation below is described about relief valve(right). Firstly, the relief valve(right) is in condition (1) previous page. When a sudden pressure increase occurs in the outlet side of the motor in deceleration or stopping process, the shock of high pressure pushes down shockless piston in the relief valve as shown in (2), while relieving high pressure oil with poppet moving up.
  • Page 101 Automatic 2-speed shifting function Spool #2 for auto shifting "PP3" Inlet (Independent from Pilot pilot fluctuation) ON/OFF Load pressure Spool #1 for switching modes: Auto shifting mode Low fixed mode Speed P1 P2 shifting piston Selector valve (Light load) Load pressure For speed Speed shifting piston...
  • Page 102 Functions Please refer to (1) shown above. When the pilot pressure PP3 is NOT applied, SPOOL #1 is at the right position because of the spring behind the spool. Now the motor is always at low speed regardless of the position of SPOOL #2.
  • Page 103 REDUCTION GEAR Function Planetary reduction gear system A general construction of planetary reduction gear system is as shown right. The system mainly consists of these parts below. NAME Number of teeth Sun Gear Planetary gears Carrier Ring gear Planetary type Firstly, let's think about the case that Ring Gear is fixed and rotation is given to Sun gear.
  • Page 104 In the travel drive This travel drive is equipped with 2-stage planetary reduction gear system, which consists of mixture of PLANETARY TYPE and STAR TYPE. Input is given to sun gear of 1 stage and output is taken out at ring gear. Ring gear is commonly used in 1 stage and 2...

  • Page 105: Group 5 Rcv Lever

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

  • Page 106: Cross Section

    CROSS SECTION The construction of the pilot valve is shown in the attached cross section drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure, return spring(10), stopper(9), spring seat(8) and shim(6).
  • Page 107 CROSS SECTION 14072SF80 2-70...
  • Page 108 2. FUNCTIONS FUNDAMENTAL FUNCTIONS The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure(Secondary pressure) of the pilot valve to the other end.

  • Page 109: 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. 140LC-7 2-70 Pilot valve Main pump...
  • Page 110 Case where handle is in neutral position 25032RL03 The force of the spring(7) that determines the output pressure of the pilot valve is not applied to the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1, 3) in the operation explanation drawing.
  • Page 111 Case where handle is tilted 25032RL04 When the push rod(14) is stroked, the spool(5) moves downwards. Then port P is connected with port(1) and the oil supplied from the pilot pump flows through port(1) to generate the pressure. When the pressure at port(1) increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force.

  • Page 112: Group 6 Rcv Pedal

    GROUP 6 RCV PEDAL 1. STRUCTURE The casing(Spacer) has the oil inlet port P(Primary pressure), and the oil outlet port T(Tank). addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size Pilot oil inlet port...
  • Page 113 CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool(8), spring(6) for setting secondary pressure, return spring(10), stopper(9), and spring seat(7). The spring for setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/cm (depending on the type).
  • Page 114 2. FUNCTION FUNDAMENTAL FUNCTIONS The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure(Secondary pressure) of the pilot valve to the other end.
  • Page 115 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below ant the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 140LC-7 2-76 Pilot valve Main pump...
  • Page 116 Case where pedal is in neutral position 14072SF74 The force of the spring(6) that determines the output pressure of the pilot valve is not applied to the spool(8). Therefore, the spool is pushed up by the spring(10) to the position of port 2 in the operation explanation drawing.
  • Page 117 Case where pedal is tilted 14072SF75 When the push rod(14) is stroked, the spool(8) moves downwards. Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1 to generate the pressure. When the pressure at port 1 increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force.

  • Page 118: Section 3 Hydraulic System

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

  • Page 119: Group 1 Hydraulic Circuit

    SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT O/R 380k PUMP Pump MAIN CONTROL VALVE Main control valve O/R 380k SWING MOTOR Swing motor TRACK MOTOR RCV LEVER(L/H) Track motor Pc41 Pc40 RCV LEVER(R/H) P Dr Pd40 RCV Lever(L/H) RCV PEDAL Pc42 RCV Lever(R/H) BOOM CYLINDER(L/H)

  • Page 120: 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 121 2. RETURN CIRCUIT Full flow filter Oil cooler Check valve(2) 1.5kgf/cm Main control valve Actuators Check valve(1) 3.0kgf/cm Bypass relief valve 1.5kgf/cm 140LC-7 3-03 All oil returned from each actuator returns to the hydraulic tank through the control valve. The bypass check valves are provided in the return circuit. The setting pressure of bypass check valves are 1.5kgf/cm (21psi) and 3.0kgf/cm (43psi).

  • Page 122: Drain Circuit

    3. DRAIN CIRCUIT Travel motor Swing motor Main pump Turning joint Bypass valve 1.5kgf/cm Spin filter Hydraulic oil tank 140LC-7 3-04 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through spin filter. When the drain oil pressure exceed 1.5kgf/cm (21psi), the oil returns to the hydraulic tank directly.

  • Page 123: Group 3 Pilot Circuit

    GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve RCV pedal RCV dozer (LH lever) (RH lever) Safety lock Swing parking brake solenoid valve Control valve Travel speed solenoid valve Power boost solenoid valve Line filter Main pump Relief valve 35kgf/cm Pilot pump Suction filter...
  • Page 124 1. SUCTION, DELIVERY AND RETURN CIRCUIT Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC02 The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to the safety solenoid valve through the line filter.
  • Page 125 2. SAFETY VALVE(SAFETY LEVER) Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC03 When the lever of the safety solenoid valve is moved upward, oil flows into the remote control valve through solenoid valve and line filter.
  • Page 126 3. SWING PRIORITY SYSTEM Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC04 When carrying out the combined operation of swing and boom or arm of the left control valve, the swing speed can be lowered than operating speed of boom or arm.
  • Page 127 4. TRAVEL SPEED CONTROL SYSTEM P1 P2 P2 P1 Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC05 When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the discharged oil from the pilot pump flows to the Pk port of pilot valve in the travel motors.
  • Page 128 5. MAIN RELIEF PRESSURE CHANGE SYSTEM Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC06 When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve is actuated, the discharged oil from the pilot pump flows into Pu port of the main relief valve of main control valve;...
  • Page 129 6. SWING PARKING BRAKE RELEASE Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC07 When the swing control lever is tilted, the pilot oil flow into SH port of shuttle valve, this pressure move spool so, discharged oil from pilot valve flow into PG port.

  • Page 130: Group 4 Single Operation

    GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC10 When the right control lever is pulled back, the boom spools in the main control valve are moved to the up position by the pilot oil pressure from the remote control valve. The oil from the front and rear pump flows into the main control valve and then goes to the large chamber of boom cylinders.
  • Page 131 2. BOOM DOWN OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC11 When the right control lever is pushed forward, the boom spools in the main control valve are moved to the down position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the main control valve and then goes to the small chamber of boom cylinders.
  • Page 132 3. ARM ROLL IN OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC12 When the left control lever is pulled back, the arm spools in the main control valve are moved the to roll in position by the pilot oil pressure from the remote control valve. The oil from the front and rear pump flows into the main control valve and then goes to the large chamber of arm cylinder.
  • Page 133 4. ARM ROLL OUT OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC13 When the left control lever is pushed forward, the arm spool in the main control valve are moved to the roll out position by the pilot oil pressure from the remote control valve. The oil from the front and rear pump flows into the main control valve and then goes to the small chamber of arm cylinder.
  • Page 134 5. BUCKET ROLL IN OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC14 When the right control lever is pulled left, the bucket spool in the main control valve is moved to the roll in position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the main control valve and then goes to the large chamber of bucket cylinder.
  • Page 135 6. BUCKET ROLL OUT OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC15 When the right control lever is pushed right, the bucket spool in the main control valve is moved to the roll out position by the pilot oil pressure from the remote control valve. The oil from the front pump flows into the main control valve and then goes to the small chamber of bucket cylinder.
  • Page 136 7. SWING OPERATION D5 Pc5 Pc41 Pc40 Pd40 Pc42 Pd41 Pa21 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC16 When the left control lever is pushed left or right, the swing spool in the main control valve is moved to the left or right swing position by the pilot oil pressure from the remote control valve.

  • Page 137: Parking Brake

    SWING CIRCUIT OPERATION PARKING BRAKE BRAKE RELEASE VALVE BRAKE OFF BRAKE ON MOTOR BRAKE VALVE MAKE UP VALVE Mu(MAKE UP PORT) TO/FROM MAIN CONTROL VALVE 11073HC30 MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation.
  • Page 138 8. TRAVEL FORWARD AND REVERSE OPERATION P1 P2 P2 P1 Pc41 Pc40 Pd40 Pc42 (sh) Pa21 Pd41 Pb21 Pb20 Pa20 DOZER TRAVEL (1) (2) LINE FILTER Pa20 Pb20 Pd40 Pc40 11073HC17 When the travel levers are pushed forward or reverse position, the travel spools in the main control valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote control valve.

  • Page 139: Counter Balance Valve

    TRAVEL CIRCUIT OPERATION P1 P2 P2 P1 Check valve Counter balance valve Turning joing 11073HC17A Valves are provided on travel motors to offer the following functions. COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run. OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 365kgf/cm to prevent high pressure generated at at time...
  • Page 140 9. DOZER UP OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC18 When the dozer control lever is pulled back, the dozer spool in the main control valve is moved to the dozer up position by the pilot oil pressure from the remote control valve. The oil from the rear pump flows into the main control valve and then goes to the small chamber of dozer cylinders.
  • Page 141 10. DOZER DOWN OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC19 When the dozer control lever is pushed forward, the dozer spool in the main control valve is moved to the dozer down position by the pilot oil pressure from the remote control valve. The oil from the rear pump flows into the main control valve and then goes to the large chamber of dozer cylinders.

  • Page 142: Group 5 Combined Operation

    GROUP 5 COMBINED OPERATION 1. OUTLINE Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC20 The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and confluence oil passage in the main control valve. Then the oil goes to each actuator and operates them.
  • Page 143 2. COMBINED SWING AND BOOM OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC21 When the swing and boom functions are operated, simultaneously the swing spool and boom spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 144 3. COMBINED SWING AND ARM OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC22 When the swing and arm functions are operated, simultaneously the swing spool and arm spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 145 4. COMBINED SWING AND BUCKET OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC23 When the swing and bucket functions are operated, simultaneously the swing spool and bucket spool in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 146 5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC24 When the swing, boom, arm and bucket functions are operated, simultaneously each spool in the main control valve is moved to the functional position by the pilot oil pressure from the remote control valve.
  • Page 147 6. COMBINED SWING AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC25 When the swing and travel functions are operated, simultaneously the swing spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and straight travel spool is pushed to the left by the pilot oil pressure from the pilot pump.
  • Page 148 7. COMBINED BOOM AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC26 When the boom and travel functions are operated, simultaneously the boom spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
  • Page 149 8. COMBINED ARM AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC27 When the arm and travel functions are operated, simultaneously the arm spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
  • Page 150 9. COMBINED BUCKET AND TRAVEL OPERATION Pc41 Pc40 Pd40 Pc42 Pa21 Pd41 Pb21 Pb20 Pa20 11073HC28 When the bucket and travel functions are operated, simultaneously the bucket spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote control valve, and the straight travel spool is pushed to the left by the oil pressure from pilot pump.

  • Page 151: Section 4 Electrical System

    SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3 Group 3 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-23 Group 4 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35...

  • Page 152: Group 1 Component Location

    SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Switch panel TONE BAND SEEK push TUNE PROG SYNTH ESIZER TUNNIN SPARE CABIN LAMP SPARE WORK LAMP BEACON LAMP SPARE LAMP & HEATER FUEL F/PUMP HEAD MOTOR SOLENO BOOM LAMP WIPER SOL.
  • Page 153 2. LOCATION 2 EPPR VLV START MOTOR AIR HEATER CABLE A/C COMP. 11074EL02 Lamp Alternator Fuel filler pump Horn Battery 10 Beacon lamp Fuel sender Travel alarm buzzer 11 Heater relay Temp sender Battery relay 12 Air cleaner switch...

  • Page 154: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT INTAKE M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2) FUSE BOX BLOWER POWER RY AC COMP RY R/DRYER HORN RY BATTERY FUSIBLE LINK HARNESS FRAME HARNESS AIR-CON 12V X 2 MASTER SW CR-1 CN-11 DESTINATION TO:STARTER "B" TERM. DESTINATION CN-11 GND(CONTROLLER)

  • Page 155: 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 Battery Battery relay Fusible link (CN-60) Fuse box [No.1] I/conn [CN-8(12)] Start switch [CS-2(1)]...
  • Page 156 POWER CIRCUIT FUSE BOX POWER RY RELAY(M2) RELAY(HI) CN-11 RW/R CN-10 AC&HEATER CONTROLLER FUSIBLE LINK CN-27 S.R- CS-1 CR-1 S.R- S.L- CN-8 S.L- DOOR SW 12V X 2 MASTER SW BATTERY RY ILL+ S.R+ CL-1 S.R+ ROOM LAMP S.L+ S.L+ CN-17 CN-21 CN-5...
  • Page 157 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Battery relay[CR-1] Fusible link Fuse box No.1 I/conn CN-8(12) Start key CS-2(1) Start switch : ON Start switch ON CS-2(2) I/conn CN-8(11) Diode[DO-2] Battery relay [CR-1]:Battery relay operating(All power is supplied with the electric component) Start switch ON CS-2(3) I/conn CN-8(10) GPS Connector[CN-125(2)

  • Page 158: Starting Circuit

    STARTING CIRCUIT FUSE BOX POWER RY CN-8 FUSIBLE LINK BATTERY CR-1 12V X 2 MASTER SW BATTERY RY START KEY SW DO-3 DIODE CN-125 DO-2 DIODE DO-1 GPS CONN. DIODE CR-23 CN-45 CN-2 CR-5 B/OR 2 B/OR B/OR START RY STARTER ANTI-RESTART RY CN-74...

  • Page 159: 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). The current also flows from alternator to each electrical component and controller through the fuse box.
  • Page 160 CHARGING CIRCUIT FUSE BOX POWER RY CN-8 FUSIBLE LINK BATTERY CR-1 12V X 2 MASTER SW BATTERY RY START KEY SW DO-3 DIODE CN-125 DO-2 DIODE GPS CONN. DO-1 DIODE CR-23 CN-45 CN-2 B/OR 2 B/OR START RY STARTER CN-74 ALTERNATOR DO-4 DIODE...
  • Page 161 4. HEAD LAMP CIRCUIT OPERATING FLOW Fuse box (No.14) I/conn CN-5(15) Light switch[CS-21(1)] When lamp switch ON Light switch[CS-21(7)] I/conn[CN-6(12)] I/conn [CN-10(2)] Cassette radio illumination [CN-27(7)] I/conn [CN-11(8)] AC & Heater controller illumination Head lamp [CL-4(2)] : Head lamp ON I/conn[CN-6(8)] Cigarlight [CL-2] Light switch[CS-21(5)]...
  • Page 162 HEAD LAMP CIRCUIT FUSE BOX CN-11 CN-10 CN-27 CL-4 S.R- S.R- S.L- HEAD LAMP S.L- ILL+ CN-6 S.R+ S.R+ S.L+ S.L+ CL-2 CN-5 CIGARLIGHT CS-21 LIGHT SW 11074EL07 4-11...
  • Page 163 5. WORK LAMP CIRCUIT OPERATING FLOW Fuse box (No.15) I/conn CN-5(14) Light switch[CS-21(4)] When work lamp switch ON Work lamp switch ON CS-21(2) I/conn [CN-5(2)] Work lamp relay[CR-3(3) (4)] I/conn[CN-12(1)] Work lamp ON [CL-5(2), CL-6(2)] CHECK POINT Engine Key switch Check point Voltage - GND (Fuse box)
  • Page 164 WORK LAMP CIRCUIT FUSE BOX CN-12 CL-5 CR-3 WORK LAMP WORK LAMP RY CL-6 CN-5 CS-21 LIGHT SW 11074EL08 4-13...
  • Page 165 6. CAB LAMP CIRCUIT OPERATING FLOW Fuse box (No.15) I/conn CN-5(14) Light switch[CS-21(4)] When Lamp switch ON Lamp switch ON [CS-21(2)] I/conn [CN-5(2)] Work lamp relay[CR-3(3) (4)] I/conn [CN-10(11)] Cab light ON [CL-8(2), CL-9(2)] CHECK POINT Check point Voltage Engine Start switch - GND (Fuse box) - GND (Light switch input)
  • Page 166 CAB LAMP CIRCUIT FUSE BOX CN-10 CL-9 CABIN LIGHT CL-8 CN-7 SWITCH PANEL 14074EL09 4-15...
  • Page 167 7. BEACON LAMP CIRCUIT OPERATING FLOW Fuse box (No.16) I/conn CN-8(3) Beacon lamp switch CS-23(6) When lamp switch ON Beacon lamp switch ON CS-23(2) Switch lndicator lamp ON CS-23(9) l/conn CN-8(4) l/conn CN-10(10) Beacon lamp ON CL-7 CHECK POINT Voltage Engine Start switch Check point...
  • Page 168 BEACON LAMP CIRCUIT FUSE BOX CN-10 CL-7 BEACON LAMP CN-8 CS-23 BEACON LAMP SW 11074EL10 4-17...
  • Page 169 8. WIPER AND WASHER CIRCUIT OPERATING FLOW Key switch ON Fuse box (No.8) I/conn [CN-5(3)] Cluster[CN-56(1)] Fuse box (No.4) I/conn [CN-5(4)] I/conn [CN-17(5)] Wiper motor controller [CN-141(7)] Wiper motor [CN-21(4)] Fuse box (No.13) I/conn [CN-6(5)] l/conn [CN-17(4)] Wiper motor controller [CN-141(6)] Washer pump [CN-22(2)] Wiper switch ON(Intermittent) Wiper switch ON [CN-50(14)]...
  • Page 170 WIPER AND WASHER CIRCUIT FUSE BOX CN-21 WIPER CUT WIPER MOTOR CN-141 CN-6 FEED BACK CN-17 MOTOR DRIVE SIG MOTOR DRIVE- MOTOR DRIVE+ DO-5 GY/W GY/W GY/W GY/W GY/W GY/W CONTINUE 24V DIODE WASHER P/P WASHER SIG. INT. SIG CN-22 GY/W WIPER CUT SW WASHER PUMP...

  • Page 171: Controller Circuit

    CONTROLLER CIRCUIT FUSE BOX CN-5 W/OR CN-48 W/OR HOUR METER CN-2 CD-17 CN-19B CN-75 CN-19 CN-19A EPPR VLV CN-9 CN-142 G/OR G/OR ACCEL DIAL RESISTER CN-76 G/OR GOV MOTOR CPU CONTROLLER 11074EL13 4-20...

  • Page 172: Monitoring Circuit

    MONITORING CIRCUIT FUSE BOX CN-5 CN-56 POWER IG(24V) CLUSTER CN-2 CD-8 WATER TEMP SENDOR GY/W GY/W CD-18 GY/W ENG OIL PRESS CD-16 CD-10 AIR CLEANER SW WATER LEVEL CD-2 B/OR FUEL LEVEL RS232 CONN. CD-1 BR/OR HYD TEMP CPU CONTROLLER 11074EL12 4-21...
  • Page 173 ELECTRIC CIRCUIT FOR HYDRAULIC FUSE BOX CS-27 CN-8 CS-26 BREAKER CN-66 BREAKER SW BREAKER SOL. CN-116 HEAD LIGHT OUT WORK LIGHT OUT CS-67 WORK LIGHT OUT CN-7 WIPER MOTOR DRIVE PRE-HEAT POWER 24V CABIN LIGHT OUT CABIN LIGHT OUT HEAD LIHGT 24V WORK LIGHT 24V WORK LIGHT 24V WASHER SIG...

  • Page 174: Group 3 Electrical Component Specification

    GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specification Check Check specific gravity 1.280 over : Over charged 100Ah Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging Check coil resistance (M4 to M4) Rated load Normal : About 50 Battery relay 100A(continuity) Check contact...
  • Page 175 Part name Symbol Specification Check Check resistance Temperature 50 C : 804 sensor (Coolant, 80 C : 310 hydraulic) 100 C : 180 CD-1, CD-8 Pressure: Air cleaner Check contact 635mmH pressure switch Normal : (N.O TYPE) CD-10 Check contact Coolant level High level : 24V 0.5A...
  • Page 176 Part name Symbol Specification Check Check resistance Normal : About 160 (For terminal 85-86) Relay 24V 16A : 0 (For terminal 30-87a) CR-2 CR-35 (For terminal 30-87) CR-5 CR-36 CR-7 Check resistance Normal : 1-2 (For terminal 5-6) Accel actuator 0.8-1.2k (For terminal 1-3) CN-76...
  • Page 177 Part name Symbol Specification Check Check contact Normal Switch ON - 0 (For terminal 1-5,2-6) 24V 8A (Looking type) (For terminal 5-7,6-8) OFF - (For terminal 1-5,2-6) CS-23, CS-24, - 0 (For terminal 5-7,6-8) CS-27, CS-54 Check contact Normal ON - 0 (For terminal 1-5,2-6) Switch 24V 8A (For terminal 5-7,6-8)
  • Page 178 Part name Symbol Specification Check Check operation DC 22.0 ~ 28.0V Supply powe(24V) to each Horn terminal and connect ground. CN-20 CN-25 Check contact Normal : 0 (For terminal A-B) 24V 15A (For terminal A-C) Safety switch 1 (N.C TYPE) Operating : (For terminal A-B) : 0 (For terminal A-C)
  • Page 179 Part name Symbol Specification Check Check contact Washer pump 24V 3.8A Normal : 10.7 (For terminal 1-2) CN-22 Check coil resistance Normal : About 1M Check contact Cigar lighter 24V 5A 1.4W Normal : Operating time : 5~15sec CL-2 Switch Check resistance (Door, Safety, 24V 2W...
  • Page 180 Part name Symbol Specification Check Check contact Start relay 24V 300A Normal : 0.94 (For terminal 1-2) CR-23 Check contact Delco Remy Starter 28MT 24V Normal : 0.1 CN-45 Check contact Normal : 0 (For terminal B -1) Alternator 24V 60A Normal : 24 ~ 27.5V CN-74 Check contact...
  • Page 181 Part name Symbol Specification Check 24V(A-B) DC/DC 12V 3A Converter 12V(B-C) CN-138 Check resistance Blower motor 24V 9.5A 2.5 (For terminal 1-2) Check resistance 1.12 (For terminal 4-2) Resistor 2.07 (For terminal 2-3) 3.17 (For terminal 3-1) Check resistance 1 C OFF Duct sensor : 0 (For terminal 1-2, (Switch)
  • Page 182 Part name Symbol Specification Check Check contact Main light 24V 8A switch OFF : (For terminal 1-5, 2-4) CS-21 4-31...

  • Page 183: Group 4 Connectors

    GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION Connectorn No. of Connector part No. Type Destination umber Female Male CN-2 Engine harness 2-85262-1 S816-112002 CN-4 LH console wire harness S816-008002 S816-108002 CN-5 RH side harness 2-85262-1 S816-112002 CN-6 RH side harness S816-012002 S816-112002 CN-8 RH console wire harness...
  • Page 184 Connectorn No. of Connector part No. Type Destination umber Female Male CN-95 Fusible link S813-130200 CN-125 S816-004002 S816-104002 CN-126 DEUTSCH RS232C connector DT06-4S-P012 DT04-4P-E004 CN-138 DEUTSCH DC/DC converter DT06-3S DT04-3P CN-139 DEUTSCH 12V Socket DT04-2P CN-140 DEUTSCH Quick coupling DT06-2S-EP06 DT04-2P-E005 CN-141 Wiper motor control unit...
  • Page 185 Connectorn No. of Connector part No. Type Destination umber Female Male SENDER CD-1 Hydraulic Temp sender 963040-3 CD-2 DEUTSCH Fuel sender DT06-2S-EP06 CD-8 Water temp sender 85202-1 CD-10 RING TERM Air cleaner switch S820-104002 CD-11 Travel alarm pressure switch S816-102002 CD-12 Travel alarm pressure switch S816-102002...
  • Page 186 2. CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 3S811-109002 S811-011002 S811-111002 4-35...
  • Page 187 No. of Receptacle connector(Female) Plug connector(Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4-36...
  • Page 188 J TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 4-37...
  • Page 189 SWP TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 4-38...
  • Page 190 No. of Receptacle connector(Female) Plug connector(Male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4-39...
  • Page 191 CN TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 4-40...
  • Page 192 No. of Receptacle connector(Female) Plug connector(Male) S810-006202 S810-106202 S810-008202 S810-108202 4-41...
  • Page 193 375 FASTEN TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 344111-1 344108-1 AMP TIMER CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 85202-1 4-42...
  • Page 194 AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 174045-2 AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 173852 AMP FASTIN - FASTON CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 925276-0 480003-9 4-43...
  • Page 195 KET 090 CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) MG610070 KET 090 WP CONNECTORS No. of Receptacle connector(Female) Plug connector(Male) MG640605 MG640795 4-44...
  • Page 196 KET SDL CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) MG610406 4-45...
  • Page 197 DEUTSCH DT CONNECTORS No. of Receptacle connector(Female) Plug connector(Male) DT06-2S DT06-2P DT06-3S DT06-3P DT06-4S DT06-4P DT06-6S DT06-6P 4-46...
  • Page 198 No. of Receptacle connector(Female) Plug connector(Male) DT06-8S DT06-8P DT06-12S DT06-12P 4-47...
  • Page 199 MOLEX 2CKTS CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 35215-0200 ITT SWF CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) SWF593757 MWP NMWP CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) NMWP01F-B 4-48...

  • Page 200: Section 5 Mechatronics System

    SECTION 5 MECHATRONICS SYSTEM Group 1 Outline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Mode Selection System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3 Group 3 Power Boost System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4 Group 4 Travel Speed Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5...

  • Page 201: Group 1 Outline

    SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE The NEW CAPO(Computer Aided Power Optimization) system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, one touch deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.

  • Page 202: System Diagram

    SYSTEM DIAGRAM Travel motor Regulator Main control valve Extra C Extra B Bucket (Dozer) Extra A & Arm 1 Arm regen Power boost Boom 2 solenoid valve Arm 2 S/Priority Travel speed Boom 1 Swing solenoid valve Travel(RH) Travel(LH) Straight Main relief Travel valve...

  • Page 203: Group 2 Mode Selection System

    GROUP 2 MODE SELECTION SYSTEM 1. POWER MODE SELECTION SYSTEM Main control valve Engine speed sensor Engine Main pump Pilot pump Accel Fuel injection actuator pump EPPR valve CPU controller Power mode switch signal Accel dial signal Accel dial Drive signal Normal Emergency Battery...

  • Page 204: Group 3 Power Boost System

    GROUP 3 POWER BOOST SYSTEM Main control valve Extra C Extra B Bucket (Dozer) Extra A & Arm 1 Arm regen Boom 2 Arm 2 S/Priority Boom 1 Swing Travel(RH) Travel(LH) Straight Travel Main relief Power boost valve solenoid valve Engine speed sensor Engine...

  • Page 205: Group 4 Travel Speed Control System

    GROUP 4 TRAVEL SPEED CONTROL SYSTEM Travel motor Main control valve Extra C Extra B Bucket (Dozer) Regulator Regulator Extra A & Arm 1 Arm regen Boom 2 Arm 2 S/Priority Boom 1 Swing Travel(RH) Travel(LH) Straight Travel Travel spped solenoid valve Engine Main pump...

  • Page 206: Group 5 Automatic Warming Up Function

    GROUP 5 AUTOMATIC WARMING UP FUNCTION Engine Coolant temp sensor Main pump Pilot pump Accel Fuel injection actuator pump EPPR valve Drive signal Warming up lamp signal CPU controller RD11075MS05 CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant temperature is less than 30 C, it increases the engine speed from key start rpm to 1200rpm.

  • Page 207: Group 6 Engine Overheat Prevention Function

    GROUP 6 ENGINE OVERHEAT PREVENTION FUNCTION Engine Coolant temp sensor Main pump Pilot pump Accel Fuel injection actuator pump EPPR valve Drive signal Overheat warming signal CPU controller RD11075MS06 1. CPU controller reads engine coolant temperature through the temperature sensor and when the engine coolant boils up to 110 C, it sends overheat warning signal to the cluster and decrease the engine speed same as accel dial 7 position.

  • Page 208: Group 7 Anti-Restart System

    GROUP 7 ANTI-RESTART SYSTEM Engine Starter Start safety relay Drive signal CPU controller CN-92a CN-92b 21075MS10 1. ANTI-RESTART FUNCTION After 10 seconds from the engine starts to run, CPU controller turns off the start safety relay to protect the starter from inadvertent restarting. 2.

  • Page 209: Group 8 Self-Diagnostic System

    GROUP 8 SELF-DIAGNOSTIC SYSTEM 1. OUTLINE When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the cluster and also stores them in the memory. The current or recorded error codes are displayed at the error display mode selected by touching SELECT switch 2 times while pressing BUZZER STOP switch.

  • Page 210: Error Codes Table

    5. ERROR CODES TABLE Fault code No. Description No error Short circuit in accel actuator motor system Potentiometer circuit is shorted to Vcc(5V) or battery + Short circuit in pump EPPR valve system Short circuit in travel speed solenoid system Short circuit in hour-meter system Accel dial circuit is shorted to Vcc(5V) or battery + Accel actuator motor circuit is open or shorted to ground...

  • Page 211: Group 9 Engine Control System

    GROUP 9 ENGINE CONTROL SYSTEM 1. CPU CONTROLLER MOUNTING NE 1 SPARE CABIN LAMP SPARE LAMP LAMP SPARE WORK LAMP BEACON & HEATER FUEL F/PUMP START HEAD BOOM LAMP WIPER MOTOR HONE LIGHT SOLENO & HEATER SAFETY SOL. CIGAR SOLENO WIPER MOTOR SWITCH...
  • Page 212 3. EXCHANGE METHOD OF THE ROM Disassemble the ash tray(2). Disassemble the wiper motor cover(3). Disassemble the cluster(1). 21075MS12 Loosen the screws(6EA) located back of the cluster. Then you can open the upper case of the cluster easily. 21075MS13 Install the new ROM.(Be careful of direction and assmelbe the cluster in the reverse order to removal).

  • Page 213: Engine Throttle Lever

    4. ENGINE ACCEL ACTUATOR Accel actuator RD8075MS07 ENGINE THROTTLE LEVER SL : Stopper, low idle SH : Stopper, high idle Throttle lever Accel actuator 11075MS08 5-13...
  • Page 214 ACCEL ACTUATOR DC motor Cable Ball joint Connector 11075MS09 Connector Type 6P, female Green(Potentiometer 5V) White(Potentiometer SIG) Yellow(Potentiometer GND) Line color & description Red(Motor+) Blue(Motor -) Check resistance Inspection Spec : 10 (Between No.5-6) 5k (Between No.1-3) 5-14...
  • Page 215 ACCEL ACTUATOR CABLE SETTING PROCEDURE Key ON Set the engine control dial max position and the one touch decel switch OFF. Connect the ball joint of cable to engine throttle lever. Pull the cable to high stopper and put nut A edge to yoke of the bracket. Make throttle lever not contact to the edge of high stopper.

  • Page 216: Installation

    5. ENGINE SPEED SENSOR DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER Flywheel housing Gear teeth, flywheel Lock nut, speed sensor Clearance 11075MS10/R140LC-7 5-20 INSTALLATION Clean contacting point of sensor. Loosen lock nut. Screw speed sensor into flywheel housing. Turn it back 135 when it contacts with gear teeth.

  • Page 217: Group 10 Eppr(Electro Proportional Pressure Reducing) Valve

    GROUP 10 EPPR VALVE 1. COMPOSITION OF EPPR VALVE EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main hydraulic pump. ELECTRO MAGNET VALVE Receive electric current from CPU controller and move the spool proportionally according to the specific amount of electric current value.
  • Page 218 2. OPERATING PRINCIPLE STRUCTURE R140LC-7 5-22(1) Sleeve O-ring Solenoid valve Spring O-ring Connector Spool Pilot oil supply line(Pilot pressure) Return to tank Secondary pressure to flow regulator at hydraulic pump AT H MODE Pressure line is blocked and A oil returns to tank. AT S MODE Secondary pressure enters into A.
  • Page 219 3. EPPR VALVE CHECK PROCEDURE Spec : 200~500mA CHECK ELECTRIC VALUE AT EPPR VALVE Start engine. Set S-mode and cancel auto decel mode. CN-75 Position the accel dial at 10. If tachometer show approx 1950 50rpm, disconnect one wire harness from EPPR valve.
  • Page 220 GROUP 11 PUMP PROLIX Its the conversion connector to manual control temporarily when the electronic control system is out of order, until repair work be done. Normal Emergency CN-47 CN-47 CN-19&19A CN-19&19B CN-19B CN-19A CN-96A CN-96A CN-96B CN-96B 16075MS12 1. OPERATING PRINCIPLE WIRING DIAGRAM 16075MS30 NORMAL EPPR valve supply specified amount of pilot pressure to the flow regulator of hydraulic pump and...

  • Page 221: Group 12 Monitoring System

    GROUP 12 MONITORING SYSTEM 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine. Various select switches are built into the monitor panel, which act as the control portion of the machine control system.
  • Page 222 CLUSTER CHECK PROCEDURE Start key : ON Check monitor initial 5 seconds All lamps light up. Buzzer sound. Check monitor after 5 seconds : Indicate cluster version and machine condition Cluster program version : CL : 2.0 Indicates program version 2.0 for 2 seconds. Tachometer : 0rpm Fuel gauge : All light up below appropriate level Hydraulic temperature : All light up below appropriate level...
  • Page 223 3. CLUSTER CONNECTOR Signal Input / Output Input(20~32V) Power IG(24V) Cluster Input(0V) Serial-(RX) Input(Vpp=12V) Output(Vpp=4V) Serial+(TX) 21075MS16 5-23...

  • Page 224: Fuel Gauge

    4. CLUSTER FUNCTION MONITORING DISPLAY This displays the current time and machine information such as engine rpm, coolant/hydraulic oil temperature, hydraulic oil pressure and also error codes. Refer to the page 5-24 for details. 14073CD03 FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the white range or warning lamp blinks.

  • Page 225: Engine Oil Pressure Warning Lamp

    FUEL LOW LEVEL WARNING LAMP This lamp blinks and the buzzer sounds when the level of fuel is below 21.5 (5.7U.S. gal). Fill the fuel immediately when the lamp blinks. 21073CD04A HYDRAULIC OIL TEMPERATURE WARNING LAMP This warning lamp operates and the buzzer sounds when the temperature of hydraulic oil is over 105 C 221 F) .
  • Page 226 COOLANT LEVEL WARNING LAMP This lamp blinks and the buzzer sounds when the coolant is below LOW in the reservoir tank of radiator. Check the reservoir tank when the lamp blinks. 21073CD09 CPU CONTROLLER CHECK WARNING LAMP Communication problem with CPU controller makes the lamp blinks and the buzzer sounds.

  • Page 227: Power Mode Switch

    WARMING UP PILOT LAMP This lamp is turned ON when the coolant temperature is below 30 C 86 F). The automatic warming up is cancelled when the engine coolant temperature is above 30 C, or when 10 minutes have passed since starting. 21073CD18 PREHEAT PILOT LAMP This lamp is turned ON when the preheating function is...

  • Page 228: Preheat Switch

    PREHEAT SWITCH This switch is used for starting the engine in cold weather. If pressed, grid heater is activated to get easier engine starting. Never hold the push button switch in for more than 30 seconds, as this can damage the grid heater. The indicator lamp is turned ON when operating this switch.
  • Page 229 5. MONITORING DISPLAY OUTLINE Information of machine performance as monitored by the CPU controller can be displayed on the cluster when the operator selects a display mode by touching switch alone or with SELECT switch on the cluster as below. BUZZER STOP How to select display mode Display group...
  • Page 230 DESCRIPTION OF MONITORING DISPLAY Group Display Description Name It displays current engine speed detected by engine speed Engine speed sensor from 500 to 3000rpm. 2200 rpm Range : 500~3000rpm by 10rpm It displays current time(12 is hour and 30 is minute) Time Group 0 TIME 12 : 30...
  • Page 231 Group Display Description Name One touch Shows that one touch decel switch is pressed. od : on od : on or oFF decel switch Shows that one touch decel switch is released. od : oFF Shows that preheat switch is pressed. PH : on PH : on or oFF Preheat switch...

  • Page 232: Monitoring System

    MONITORING SYSTEM 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine. Various select switches are built into the monitor panel, which act as the control portion of the machine control system.
  • Page 233 CLUSTER CHECK PROCEDURE Start key : ON Check monitor initial 5 seconds All lamps light up. Buzzer sound. Check monitor after 5 seconds : Indicate cluster version and machine condition Cluster program version : 1.00 Indicates program version 1.00 for 5 seconds. Tachometer : 0rpm Fuel gauge : All light up below appropriate level Hydraulic temperature : All light up below appropriate level...
  • Page 234 3. CLUSTER CONNECTOR Signal Input / Output Input(20~32V) Power IG(24V) Cluster Input(0V) Serial-(RX) Input(Vpp=12V) Output(Vpp=4V) Serial+(TX) 21075MS16 5-34...
  • Page 235 4. LCD main operation display Default screen Option screen Default screen Option screen Time display RPM display Hydraulic oil temperature gauge Fuel level gauge Engine coolant temperature gauge 1607A3CD02A 1607A3CD02B Time display This displays the current time. Refer to the page 5-34 to set time for details. 1607A3CD02C RPM display This displays the engine rpm.
  • Page 236 5. Warning of main operation screen Warning display Engine coolant temperature This lamp blinks and the buzzer sounds when the temperature of coolant is over the normal temperature 105 C 221 F) . Check the cooling system when the lamp blinks.
  • Page 237 : LCD SYSTEM MENU Monitoring Diagnosis Management : Escape, Settings Display User Mode Return to the previous menu : Down/Left Direction : Up/Right Direction : Select(Enter) Activate the currently chosen item RD8075MS10 Main menu : Menu information : Monitoring Equipment, Switch, Output : Diagnosis Current error, Recorded error : Maintenance...
  • Page 238 Display map Monitoring Diagnosis Protocol type 1 (Error display) (Recorded error delete) 5-38...
  • Page 239 Protocol type 2 - If there are more than 2 error codes, each one can be displayed by pressing switch respectively. - 3 error codes ( SPN200200, FMI06, SPN6789, FMI04, 345) display. No change Maintenance Setting Time set : Adjusting : Setting System lock - Reserved 5-39...
  • Page 240 Dual mode - Changing the MCU mode Display Operation skin Brightness Language 5- 40...
  • Page 241 Warning and pilot lamp Engine oil pressure warning lamp This lamp blinks and the buzzer sounds after starting the engine because of the low oil pressure. If the lamp blinks during engine operation, shut OFF engine immediately. Check oil level. 21073CD07 Air cleaner warning lamp This lamp blinks and the buzzer sounds when the filter of air...
  • Page 242 Decel pilot lamp Operating auto decel or one touch decel makes the lamp ON. The lamp will be ON when pushing one touch decel switch on the LH RCV lever. 21073CD17 Warming up pilot lamp This lamp is turned ON when the coolant temperature is below 30 C 86 F).

  • Page 243: Switch Panel

    SWITCH PANEL Work mode switch Power mode switch Travel speed switch Wiper switch Buzzer stop switch Washer switch Select switch RD8075MS11 Power mode switch This switch is to select the machine power mode, which shifts from high power work to standard power work and light power work in a raw by pressing the switch.
  • Page 244 Washer switch The washer liquid is sprayed and the wiper is operated only while pressing this switch. The indicator lamp is turned ON when operating this switch. 1107A3CD22 Travel speed control switch 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.

  • Page 245: Section 6 Troubleshooting

    SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4 Group 3 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24 Group 4 Mechatronics System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-41...

  • Page 246: Group 1 Before Trobleshooting

    GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help an operator to maintain the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics system.
  • Page 247 2. DIAGNOSING PROCEDURE To carry out troubleshooting efficiently, the following steps must be observed. STEP 1. Study the machine system Study and know how the machine is operating, how the system is composing, what kinds of function are installed in the machine and what are specifications of the system components by the machine service manual.
  • Page 248 STEP 4. Inspect the trouble actually on the machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not. R140LC-7 6-3(1) STEP 5.

  • Page 249: Group 2 Hydraulic And Mechanical System

    GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION MACHINE IN GENERAL If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration. Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look for the cause based on the troubleshooting principle and perform maintenance and adjustment to prevent major failure from occurring.
  • Page 250 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and check if rubber Replace hub or pieces or particles retighten are not present. setscrew. Coupling hub spline is worn or hub fastening...
  • Page 251 ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard Is oil level in level. Abnormal noise hydraulic oil comes out of Hydraulic pump is Disassemble tank within hydraulic pump broken. and repair. standard level? Do not hydraulic Abnormal noise...
  • Page 252 3. HYDRAULIC SYSTEM HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and Drop hydraulic oil dispose it or sample on hot plate and check if replace hydraulic foams come up. oil. Air is intruded. Check suction line and return line and eliminate...
  • Page 253 CAVITATION OCCURS WITH PUMP Cause Remedy Replenish specified oil to the standard level. Is hydraulic oil volume proper? Replace oil with one of proper Is not viscosity viscosity. of hydraulic oil too high? Clean suction Is not suction strainer. strainer clogged? Is not air intruding from pump Check for air...
  • Page 254 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish specified oil to the Is safety solenoid standard level. valve pressure within standard? Safety valve faulty Repair or replace. Is gear pump pilot pressure within or not operated. standard level? Is oil in hydraulic tank within...
  • Page 255 SWING SPEED IS LOW Cause Remedy Swing port relief Disassemble and Does swing control valve is faulty. repair or replace. valve spool move smoothly by hand? Swing control valve Disassemble Is MCV pilot spool is stuck. and repair. pressure same on LH and RH Clogged or oil Clean pilot piping...
  • Page 256 SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble and change when LH valve is faulty. repair. and RH port relief valves are exchanged Shuttle valve is Disassemble and Does swing control faulty. repair. valve spool move smoothly by hand? Is MCV pilot...
  • Page 257 THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy Is swing shuttle valve normal? Disassemble Shuttle valve is and replace. faulty. Is brake spring normal? Is return spring of swing control Disassemble Brake spring is valve normal? and replace.
  • Page 258 5. TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause Remedy Does counterbalance spool in travel brake valve move lightly by hand? Disassemble Counter spool in Is travel brake valve pressure and repair or travel brake valve within standard replace.
  • Page 259 SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble Do LH and RH defective. and repair or travel speeds replace. change when LH and RH travel Relief valve built Disassemble Does the symptom brake valves are change when in travel motor is and repair.
  • Page 260 MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None friction plate Friction plate is Disassemble worn? Check if parking faulty. and repair. brake pilot line is not clogged.
  • Page 261 TRAVEL ACTION IS POWERLESS(Travel only) Cause Remedy Is travel motor's drain rate within standard level? Is travel brake Disassemble Travel motor is pressure within and repair. faulty. standard level? Is travel relief valve pressure Disassemble Travel brake within standard and repair or valve is defective.
  • Page 262 MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal. Is select valve normal? Select valve is Repair or Is pilot pressure faulty. replace. for travel select valve within standard level? Remove dirt on...
  • Page 263 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace. valve is replaced with other valve? Is MCV pilot pressure within standard level? Inspect if pilot piping is not...
  • Page 264 BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. Are other attachment speeds within Is combination Is speed low only standard levels? of oil streams in composite normal at boom operation? Flow summation Disassemble and hoisting and at Does spool of flow arm extrusion? check valve spool repair.
  • Page 265 BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the symptom faulty. and repair or change when port Normal replace. relief valve is replaced with Is control valve normal valve? return spring Is not hydraulic normal?
  • Page 266 BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder in Item "Speed is internal leakage within standard low". level? Is relief pressure in port relief Cylinder is faulty. Disassemble valve within and repair. standard level? Is relief pressure in main relief...
  • Page 267 BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom Is boom foot pin greased proper. sufficiently? Frictional noise will disappear if they are kept used.
  • Page 268 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. 14076BY01 Disconnect hose(A) from rod side of boom cylinder and drain oil from cylinders and hose.(Put cups on piping and hose ends) R140LC-7 6-20(2)

  • Page 269: Group 3 Electrical System

    GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.8.
  • Page 270 2. COMMUNICATION ERROR "Co : Err" FLASHES ON THE CLUSTER Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective controller...
  • Page 271 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 controller...
  • Page 272 WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Coolant overheat...
  • Page 273 WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Clogged air filter or...
  • Page 274 WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Engine oil leakage,...
  • Page 275 WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy High temperature...
  • Page 276 WHEN COOLANT LEVEL WARNING LAMP LIGHTS UP(Engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Insufficient coolant...
  • Page 277 9. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Repair or replace...
  • Page 278 10. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Disconnection in...
  • Page 279 11. WHEN SAFETY SOLENOID DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.24. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Hydraulic...
  • Page 280 12. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.22 . After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective hydraulic...
  • Page 281 13. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.14. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 282 14. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.15. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 283 15. WHEN ENGINE DOES NOT START START SWITCH 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. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 284 16. WHEN STARTING SWITCH ON DOES NOT OPERATE START SWITCH Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and master switch ON. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy CN-8...
  • Page 285 17. 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.4, 8 and 13 is not blown out. After checking, insert the disconnected connectors again immediately unless otherwise specified.

  • Page 286: Group 4 Mechatronics System

    GROUP 4 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. Spec : H-mode 2050 50rpm S-mode 1950 50rpm L-mode 1850 50 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy...

  • Page 287: Test Procedure

    TEST PROCEDURE SPEC : 17.5 1 (20 C ) Test 1 : Check resistance at connector CN-2(12)-(13). CN-2 Starting key OFF. 15 13 12 Disconnect connector CN-2. Check resistance between pin and at connector CN-2(12)-(13). Multimeter 11076TS31 Test 2 : Check resistance at connector SPEC : 17.5 1 (20 C ) CN-75.
  • Page 288 Test 4 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm (70~280psi) Remove plug and connect pressure gauge as figure. Gauge capacity : 0 to 40~50kgf/cm (0 to 570~710psi) Start engine. Supply line, pilot press Set the accel dial at "10"(Max) Set S-mode and cancel auto decel mode.
  • Page 289 2. ENGINE SPEED IS SLOW AT ALL MODE Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Good If test 7 is good, Check tachometer check TEST 1~4 work properly or not by changing Misalignment Clean speed the mode.
  • Page 290 TEST PROCEDURE SPEC : 1~2 Test 5 : Check resistance between CN-50 Y R G (12)-(23). CONTROLLER Starting key OFF. CN-50 Disconnect connector CN-50 from CPU CN-51 controller. Check resistance as figure. CN-50 Multimeter R29076MS04 Unit : rpm Test 6 : Check tachometer(Work properly Spec Remark or not)
  • Page 291 Test 8 : Check resistance at speed SPEC : 0.2~0.4k sensor. Starting key OFF. Speed sensor Disconnect connector CD-17 of speed sensor at engine flywheel housing. Check resistance as figure. CD-17 CD-17 Engine flywheel Multimeter R140LC-7 6-42(1) 6-46...
  • Page 292 3. ENGINE STALL Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Not enough engine Contact cummins power engine dealer Check pressure at EPPR Valve Defective EPPR Replace SPEC:5~20kgf/cm valve See TEST 10 Check electric current at EPPR Defective CPU...
  • Page 293 TEST PROCEDURE SPEC : 200~550mA Test 9 : Check electric current at EPPR valve at S-mode CN-75 Install multimeter as figure. Start engine. Set the accel dial at "10"(max) Set S-mode with 1950 50rpm. Check electric current. EPPR VALVE Multimeter R140LC-7 6-44(1) Test 10 : Check pressure at EPPR valve...
  • Page 294 4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse the CPU controller See if all lamps off in the CPU controller case CPU failure Replace...
  • Page 295 5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Slow action of Check and repair engine speed control due to interference Check interference between Defective CPU...
  • Page 296 TEST PROCEDURE SPEC : 1~2 Test 11 : Check resistance. Y R G Starting key OFF. Disconnect connector CN-50 from CPU CONTROLLER controller. CN-50 Check resistance between CN-50(12)- CN-51 (23) as figure. CN-50 Multimeter R29076MS04 6-51...
  • Page 297 Test 12 : Check voltage and resistance. SPEC : 0.1~0.9k Check resistance between CN-51(20)- Y R G (22). CONTROLLER Starting key OFF. Disconnect connector CN-51 from CPU CN-51 CN-50 controller. Check resistance value with multimeter as figure. CN-51 Multimeter R29076MS08 Check voltage between CN-51(20) and SPEC : 5 1V CN-51(21).
  • Page 298 6. MALFUNCTION OF WARMING UP Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective cluster or Repair or Replace CPU controller or Check resistance between CN-51 CD-8(Sensor) (31) - CD-8(2) Poor connection Repair SPEC : Below10 Check resistance...
  • Page 299 7. MALFUNCTION OF POWER MAX Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Check resistance between CN-88 Defective power Repair or replace (1) - (2) max. solenoid valve Resistance between CN-51 SPEC: 15-30 (2)-GND normal? See TEST 13...
  • Page 300 TEST PROCEDURE SPEC : Key ON : 24 1V Key OFF : 0V Test 13: Check voltage between connector Resistance : 15~30 CN-88 - GND. Start key ON. Disconnect connector CN-88 from power Power max. switch max solenoid valve. Check voltage as figure. LH RCV-lever CN-88 CN-88...

  • Page 301: Section 7 Maintenance Standard

    SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21 Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28...

  • Page 302: Group 1 Operational Performance Test

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

  • Page 303: Service Limit

    2. TERMINOLOGY STANDARD Specifications applied to the brand-new machine, components and parts. SERVICE LIMIT The lowest acceptable performance level. When the performance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
  • Page 304 3. OPERATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. The machine Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. Test area Select a hard, flat surface.

  • Page 305: Engine Speed

    ENGINE SPEED Measure the engine speed at each power mode The engine speed at each power mode must meet standard RPM; if not, all other operational performance data will be unreliable. It is essential to perform this test first. Preparation Warm up the machine, until the engine coolant temperature reaches 50 C or more, and the hydraulic oil is 50 5 C.

  • Page 306: Travel Speed

    TRAVEL SPEED Measure the time required for the excavator to travel a 20m test track. Preparation Adjust the tension of both tracks to be equal. Prepare a flat and solid test track 20m in length, with extra length of 3 to 5m on 0.3~0.5m both ends for machine acceleration and deceleration.
  • Page 307 TRACK REVOLUTION SPEED Measure the track revolution cycle time with the track raised off ground. Preparation Adjust the tension of both side tracks to be equal. On the track to be measured, mark one shoe with chalk. 90 ~ 110 Swing the upperstructure 90 and lower the bucket to raise the track off ground.

  • Page 308: Travel Deviation

    TRAVEL DEVIATION Measure the deviation by the tracks from a 20m straight line. Preparation Adjust the tension of both tracks to be equal. Provide a flat, solid test yard 20m in length, with extra length of 3 to 5m on 0.3~0.5m both ends for machine acceleration and deceleration.
  • Page 309 SWING SPEED Measure the time required to swing three complete turns. Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom...
  • Page 310 SWING FUNCTION DRIFT CHECK Measure the swing drift on the bearing outer circumference when stopping after a 360 full speed swing. Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes.
  • Page 311 SWING BEARING PLAY Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. Preparation Check swing bearing mounting cap screws for loosening. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise.
  • Page 312 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. Preparation Boom cylinder To measure the cycle time of the boom Raise cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown.
  • Page 313 Bucket cylinders Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.
  • Page 314 DIG FUNCTION DRIFT CHECK Measure dig function drift, which can be caused by oil leakage in the control valve and boom, standard arm, and standard bucket cylinders, with the loaded bucket. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to purge air.
  • Page 315 CONTROL LEVER OPERATING FORCE Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip. Preparation Keep the hydraulic oil temperature at 50 5 C. Measurement Start the engine. Select the following switch positions. Mode selector : H mode Operate each boom, arm, bucket and swing lever at full stroke and measure the...
  • Page 316 CONTROL LEVER STROKE Measure each lever stroke at the lever top using a ruler. When the lever has play, take a half of this value and add it to the measured stroke. Preparation Keep the hydraulic oil temperature at 50 5 C. Measurement Stop the engine.
  • Page 317 PILOT PRIMARY PRESSURE Preparation Stop the engine. Push the pressure release button to bleed air. Loosen and remove plug on the pilot pump delivery port and connect pressure gauge. Start the engine and check for oil leakage from the port. Keep the hydraulic oil temperature at 50 5 C.
  • Page 318 FOR TRAVEL SPEED SELECTING PRESSURE: Preparation Stop the engine. Push the pressure release button to bleed air. To measure the speed selecting pressure: Install a connector and pressure gauge assembly to turning joint P port as shown. Start the engine and check for on leakage from the adapter.
  • Page 319 SWING PARKING BRAKE RELEASING PRESSURE Preparation Stop the engine. Push the pressure release button to bleed air. Install a connector and pressure gauge assembly to swing motor SH port, as shown. Start the engine and check for oil leakage from the adapter. Keep the hydraulic oil temperature at 50 5 C.
  • Page 320 MAIN PUMP DELIVERY PRESSURE Preparation Stop the engine. Push the pressure release button to bleed air. To measure the main pump pressure. Install a connector and pressure gauge assembly main pump gauge port as shown. Start the engine and check for oil leakage from the port.
  • Page 321 SYSTEM PRESSURE REGULATOR RELIEF SETTING Preparation Stop the engine. Push the pressure release button to bleed air. To measure the system relief pressure. Install a connector and pressure gauge assembly main pump gauge port, as shown. Start the engine and check for oil leakage from the port.

  • Page 322: Group 2 Major Components

    GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 140LC-7 7-21 Recommended Standard replacement Part name & inspection item Counter measures dimension value Clearance between piston(1) & cylinder Replace piston 0.028 0.056 bore(2) or cylinder. (D-d) Play between piston(1) & shoe caulking 0-0.1 section(3) Replace...

  • Page 323: Main Control Valve

    2. MAIN CONTROL VALVE Part name Inspection item Criteria & measure Casing Existence of scratch, rusting or corrosion. In case of damage in following section, replace part. - Sliding sections of casing fore and spool, especially land sections applied with holded pressure.
  • Page 324 3. SWING DEVICE Part name Inspection item Remedy Shoe of piston Sliding surface has a damage. Lapping assembly Sliding surface depression( Replace parts or motor dimension less than 0.45mm or has a large damage. Piston of piston Sliding surface has a seizure(Even though Replace motor assembly small).
  • Page 325 4. TRAVEL DEVICE Maximum Standard allowable value Part name Check point Remedy dimension (Criteria) Piston assy(7) Play between piston Replace 9 sets of = 0.1mm < 0.5mm and slipper piston assy Piston assy(7) and cylinder Clearance/diameter 0.03mm < 0.07mm Replace the set of barrel (3) between piston diamet- 1 cylinder barrel...
  • Page 326 Maximum Standard allowable value Part name Check point Remedy dimension (Criteria) Shaft(2) Spline sections(con- No abnormality Replace nected to cylinder such as crack, barrel, and bear part) chipping, nonuni- formly wear-ing out, etc. Bearings(1-3), (1-8), (1-13), Rolling surface No flaking or other Replace (11), (12) abnormal damage...
  • Page 327 5. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination. Replace sealing sections. Sliding surface Worn abnormality or damaged more than 0.1mm Replace between body and (0.0039in) in depth due to seizure contamination. stem other than Body, Damaged more than 0.1mm(0.0039in) in depth.
  • Page 328 6. CYLINDER Part name Inspecting section Inspection item Remedy Piston rod Neck of rod pin Presence of crack Replace Weld on rod hub Presence of crack Replace Stepped part to which piston Presence of crack Replace is attached. Threads Presence of crack Recondition or replace Plated surface Plating is not worn off to base...

  • Page 329: Group 3 Track And Work Equipment

    GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK TRACK ROLLER 21037MS01 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread 39.5 45.5 Width of flange tolerance Standard Standard...

  • Page 330: Carrier Roller

    CARRIER ROLLER 32077MS02 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread 35.5 39.5 Width of flange Standard size & Tolerance Standard Clearance Clearance between shaft clearance limit Shaft...
  • Page 331 IDLER 21037MS03 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of protrusion Outside diameter of tread Rebuild or replace Width of protrusion Total width Width of tread Standard size & tolerance Standard Clearance Clearance between shaft clearance limit Replace...
  • Page 332 TRACK 21037MS04 Unit : mm Check item Criteria Remedy Standard size Repair limit Turn or Link pitch replace 171.45 175.45 Outside diameter of bushing 50.6 40.8 Rebuild or Height of grouser replace Height of link Tightening torgue Initial tightening torque : 42 4kgf m Retighten 7 - 31...
  • Page 333 TRACK FRAME AND RECOIL SPRING 21037MS05 Unit : mm Check item Criteria Remedy Standard size Tolerance Repair limit Track frame Vertical width of idler guide Rebuild or Idler support - 0.5 replace Track frame Horizontal width of idler guide Idler support Standard size Repair limit Free...

  • Page 334: Work Equipment

    2. WORK EQUIPMENT 11077MS15 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 68.5 70.5 Replace Boom Cylinder Head 68.5 70.5 Boom Cylinder Rod 68.5...

  • Page 335: Section 8 Disassembly And Assembly

    SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-29...

  • Page 336: Group 1 Precaution

    SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil.
  • Page 337 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 338 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 339: Group 2 Tightening Torque

    GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf m lbf ft Engine mounting bolt(Engine-Bracket) 1.75 10.0 72.3 Engine mounting bolt(Bracket-Frame, FR) 25.3 Engine Engine mounting bolt(Bracket-Frame, RR) 25.3 Radiator mounting bolt, nut 1.75 12.2 88.2 Coupling mounting bolt 22.0 Main pump mounting bolt 22.1...

  • Page 340: Torque Chart

    2. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf m lbf ft kgf m lbf ft 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8...
  • Page 341 PIPE AND HOSE Thread size Width across flat mm kgf m lbf ft 1/4" 21.7 3/8" 28.9 1/2" 36.2 3/4" 86.8 1" FITTING Thread size Width across flat mm kgf m lbf ft 1/4" 28.9 3/8" 36.2 1/2" 43.4 3/4" 94.0 1"...

  • Page 342: Group 3 Pump Device

    GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 343 INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level. Bleed the air from the hydraulic pump. Remove the air vent plug(2EA).
  • Page 344 2. MAIN PUMP(1/2) STRUCTURE 789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113 153 156 124 312 114 466 885 467 141 981 271 401 14072SF02 04 Gear pump 271 Pump casing 719 O-ring 111 Drive shaft(F) 312 Valve block 724 O-ring...
  • Page 345 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
  • Page 346 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 Material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug(Materal : S45C) PT1/16 0.16 Wind a seal tape 1 1/2 to 2...
  • Page 347 DISASSEMBLY Select place suitable to disassembling. Select clean place. Spread rubber sheet, cloth or so on on overhaul workbench top to prevent parts from being damaged. Remove dust, rust, etc, from pump surfaces with cleaning oil or so on. Remove drain port plug(468) and let oil out of pump casing(Front and rear pump).
  • Page 348 Pull cylinder block(141) out of pump casing(271) straightly over drive shaft(111). Pull out also pistons(151), set plate(153), spherical bush(156) and cylinder springs(157) simultaneously. Take care not to damage sliding surfaces of cylinder, spherical bushing, shoes, swash plate, etc. R140LC-7 MP03 Remove hexagon socket head bolts(406) and then seal cover(F, 261).
  • Page 349 (12) Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports. R140LC-7 MP07 (13) Remove valve plates(313, 314) from valve block(312). These may be removed in work(6). R140LC-7 MP08 (14) If necessary, remove stopper(L, 534), stopper(S, 535), servo piston(532) and tilting pin(531) from pump casing(271),...
  • Page 350 ASSEMBLY For reassembling reverse the disassembl- ing procedures, paying attention to the following items. Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. Clean each part fully with cleaning oil and dry it with compressed air. Do not fail to apply clean working oil to sliding sections, bearings, etc.
  • Page 351 Place pump casing with its regulator fitting surface down, fit tilting bush of swash plate to tilting pin(531) and fit swash plate (212) to swash plate support(251) correctly. Confirm with fingers of both hands that swash plate can be removed smoothly. Apply grease to sliding sections of swash plate and swash plate support, and drive shaft can be fitted easily.
  • Page 352 Fit valve plate(313) to valve block(312), entering pin into pin hole. Take care not to mistake suction / delivery directions of valve plate. R140LC-7 MP14 Fit valve block(312) to pump casing(271) and tighten hexagon socket head bolts (401). At first assemble this at rear pump side, and this work will be easy.
  • Page 353 3. REGULATOR STRUCTURE(1/2) SECTION B-B 722 496 VIEW C(FRONT) VIEW C(REAR) KR36-9N12(FRT) KR36-9N1S(RR) SECTION D-D 11072PM03 8-18...
  • Page 354 REGULATOR(2/2) 651 652 SECTION A-A R140LC-7 405 Hexagon socket screw 629 Cover(C) 730 O-ring 412 Hexagon socket screw 630 Lock nut 732 O-ring 413 Hexagon socket screw 631 Sleeve, pf 733 O-ring 436 Hexagon socket screw 641 Pilot cover 734 O-ring 438 Hexagon socket screw 643 Pilot piston 735 O-ring...
  • Page 355 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
  • Page 356 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 Material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plut(Materal : S45C) PT1/16 0.16 Wind a seal tape 1 1/2 to 2...
  • Page 357 DISASSEMBLY Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
  • Page 358 After removing cover(C, 629) subassembly, take out outer spring(625), inner spring (626) and spring seat(C, 624) from compensating section. Then draw out adjusting ring(Q, 645), pilot spring(646) and spring seat(644) from pilot section. Adjusting ring(Q,645) can easily be drawn out with M4 bolt. R140LC-7 REG03 Remove hexagon socket head screws...
  • Page 359 R140LC-7 REG07 Remove lever(2, 613). Do not draw out pin(875). Work will be promoted by using pincers or so on. R140LC-7 REG08 (10) Draw out pin(874) and remove feedback lever(611). Push out pin(874, 4mm in dia.) from above with slender steel bar so that it may not interfere with lever(1, 612).
  • Page 360 (11) Remove lever(1, 612). Do not draw out pin(875). (12) Draw out pilot piston(643) and spool(652). (13) Draw out piston case(622), compensating piston(621) and compensating rod(623). Piston case(622) can be taken out by pushing compensating rod(623) at opposite side of piston case. This completes disassembly.
  • Page 361 ASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following items. Always repair parts that were scored at disassembly. Get replacement parts ready beforehand. Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
  • Page 362 Fit feedback lever(611), matching its pin hole with pin hole in spool. Then insert pin(874). Insert pin in feedback lever a little to ease Lever (1) side Lever (2) side operation. (Fulcrum plug of Take care not to mistake direction of adjusting plug side) feedback lever.
  • Page 363 (11) Fit set spring(655) to spool hole and put compensating piston(621) and piston case(622) into compensating hole. Fit pilot cover(641) and tighten it with hexagonal socket head screws(436, 438). R140LC-7 REG02 (12) Put spring seat(644), pilot spring(646) and adjusting ring(Q, 645) into pilot hole. Then fix spring seat(624), inner spring (626) and outer spring(625) into compensating hole.

  • Page 364: Group 4 Main Control Valve

    GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 365 2. STRUCTURE(1/4) 1408DA13 Body Cover-pilot Valve-check Spool Holder-spring Spring-check valve Spool Holder-spring Plug Spool End-spool O-ring Spool Spring O-ring Spool Spring O-ring Spool Stopper Bolt-socket head Spool Stopper Bolt-socket head Cover-pilot Holder-spring 101 Lock-valve Cover-pilot 8-30...
  • Page 366 STRUCTURE(2/4) 1408DA14 Spool Spring O-ring Spool Spool-selector O-ring Spool Spring O-ring Spool Stopper O-ring Spool Piston Back-up ring Cover-pilot Restrictor Back-up ring Cover-pilot Plug O-ring Cover-pilot Plug Bolt-socket head Holder-spring Restrictor Bolt-socket head Holder-spring Plug-socket head Bolt-socket head End-spool\ Plug-socket head 101 Lock-valve Spring Plug...
  • Page 367 STRUCTURE(3/4) 1408DA15 Plug Plug O-ring Valve-check Plug O-ring Spring-check valve Plug O-ring Plug Plug O-ring Valve-check O-ring O-ring Spring-check valve O-ring Back-up ring 8-32...
  • Page 368 STRUCTURE(4/4) 1408DA16 Cover-pilot Spring-check valve O-ring Valve-lock Plug O-ring Restrictor-lock valve Restrictor O-ring Spring-lock valve Filter-coin type O-ring Holder-spring Poppet-negative O-ring Poppet Filter-coin type O-ring Seat-poppet Holder-spring O-ring Piston Spring-negative Back-up ring Guide-piston Piston-negative Back-up ring Spring-lock valve Socket-negative Relief valve-main Piston Plug Bolt-socket head...
  • Page 369 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be remove from the machine, apply caps and masking seals to all ports.
  • Page 370 DISASSEMBLY Disassembly of spools without holding valve Loosen hexagon socket head bolts with washer (Hexagon wrench : 5mm) Remove the pilot cover. Pay attention not to lose the O-ring under the pilot cover. Remove the spool assembly from the body by hand slightly. When extracting each spool from its body, pay attention not to damage the body.
  • Page 371 Disassembly of spools with holding valve(Boom 1, Arm 1 spool) Loosen hexagon socket head bolts with washer (Hexagon wrench : 5mm) Remove the pilot cover with internal parts. Pay attention not to lose the O-ring and the poppet under the pilot cover. Pay attention not to damage the "piston A"...
  • Page 372 Disassembly of the holding valve Remove the pilot cover with the holding valve as discribed on previous page. Do not disassembled internal parts of the pilot cover. Loosen the poppet seat and remove the poppet, the spring seat, the spring and the check. (Spanner : 32mm) Pay attention not to lose the poppet.
  • Page 373 Disassembly of the load check valve and the negative relief valve The load check valve Fix the body to suitable work bench. Pay attention not to damage the body. Loosen the plug (Hexagon wrench : 10mm). Remove the spring and the load check valve with pincers or magnet. The negative relief valve Loosen the socket (Hexagon wrench : 12mm).
  • Page 374 Disassembly of the main and overload relief valve Fix the body to suitable work bench. Remove the main relief valve. (Spanner : 32mm) Remove the overload relief valve. (Spanner : 32mm) When disassembled, tag the relief valve for identification so that they can be reassembled correctly.
  • Page 375 Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. Control valve Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
  • Page 376 ASSEMBLY General precaution In this assembly section, explanation only is shown. For further understanding, please refer to the figures shown in the previous structure & disassembly section. Pay close attention to keeping all seals free from handling damage and inspect carefully for damage before using them.
  • Page 377 Covers Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket head bolts to the specified torque. Hexagon wrench : 5mm Tightening torque : 1~1.1kgf m(7.2~7.9lbf ft) Confirm that O-rings have been fitted. Fit spring covers to the spring end for the spools, and tighten hexagon socket head bolts to the specified torque.

  • Page 378: Group 5 Swing Device

    GROUP 5 SWING DEVICE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 379 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE 11072SM02 Body 16 Brake piston 31 Check Oil seal 17 O-ring 32 Relief valve assembly Roll bearing 18 O-ring 33 Reactionless valve assembly Snap ring 19 Spring 34 Time delay valve assembly Shaft 20 Rear cover 35 Wrench bolt...
  • Page 380 DISASSEMBLY Lift the motor out. Clean the motor in kerosene and dry with compressed air. To avoid dust inside the motor, mask all the ports of the motor with tapes. 32038SM01 Loosen the drain plug to discharge oil in the body(1). 32038SM02 Fix the drive shaft(5) on the workbench with the end of output shaft down.
  • Page 381 Remove the relief valve(32) from rear cover(20). 32038SM05 Remove plug(27) from rear cover(20) and spring(30), check(31). Be careful not to damage the check seat assembly. 32038SM06 Remove rear cover(20) from body(1). Then, remove the valve plate(23) from rear cover(20) with care. 32038SM07 Remove the brake spring(19) from brake piston(16).
  • Page 382 Remove brake piston(16) from body(1). 32038SM09 (10) Remove the cylinder(9) from the output shaft(5) with the motor positioned horizontally. Remove ball guide(11), set plate(12), piston(13) and shoe plate(8). 32038SM10 (11) Remove friction plate(14) and separate plate(15) from body(1). 32038SM11 (12) Remove snap ring(4) and remove drive shaft(5) from body(1).
  • Page 383 (13) Remove the cone of roller bearing(3) by press. Do not reuse bearings. Press Output shaft Roller bearing 32038SM15 (14) Remove bushing(6) and oil seal(2) from body(1). 25038SM05 (15) Remove the needle bearing(21) from the rear cover(20) by using slide hammer bearing puller.
  • Page 384 (16) When disassembling the relief valve, release the plug(3). Remove the piston(7), spring seat(9), spring(8) and plunger(6) with the body(1) downwards. Do not release the lock nut(15). 29078SM04 This completes disassembly. 8-49...
  • Page 385 ASSEMBLY Do the reassembly in the reverse procedure of the disassembly. Apply three bond of white color on outer surface of oil seal(2) and insert it to the body(1). 11078SM22 Install the roller bearing(3) to the drive shaft(5). 11078SM21 Insert the drive shaft(5) into the body(1) with the plastic hammer lightly.
  • Page 386 Insert the shoe plate(8) with the body(1) position horizontally. 32038SM28 Insert the ball guide(11) into the cylinder (9). 32038SM29 Install the piston sub-assembly(13) to the set plate(12). 32038SM30 Reassemble the piston assembly(9) to the body(1). 32038SM31 8-51...
  • Page 387 Assembly friction plate(14) and plate(15) to the body(1). 11078SM26 (10) Insert O-ring(17) inside the body(1). 32038SM33 (11) Reassemble brake piston(16) to the body (1). 32038SM34 (12) Reassemble brake spring(19) to the brake piston(16). 32038SM35 8-52...
  • Page 388 (13) When assembling the needle bearing(21), insert the needle bearing(21) into rear cover(20) by hammering. 32038SM36 (14) Reassemble valve plate(23) to the rear cover(20) and reassemble O-ring(18). 32038SM37 (15) Connect the rear cover(20) with the body (1) and tighten the wrench bolt(26). 32038SM38 (16) Insert check(31) and spring(30) in the...
  • Page 389 (17) Insert O-rings to the relief valve (32) and reassemble them to rear cover(20). This completes assembly. 32038SM42 8-54...
  • Page 390 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly(1) and remove mounting bolts(2). Remove the reduction gear assembly. Reduction gear device weight : 95kg (209lb) 13031GE18 INSTALL...
  • Page 391 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE 26 27 28 17 22 20 18 25 8 12 4 10 23 3 11072SM03 Casing 10 Pin No.2 assembly 21 Plug(B) Drive shaft 11 Pin No.1 22 Plug(A) Ring gear 12 Thrust washer(B) 23 Spring pin Planet gear No.2 13 Thrust washer(A)
  • Page 392 DISASSEMBLY Remove gauge bar(14) and gauge pipe (15) from the swing motor casing. Pour the gear oil out of reduction gear into the clean bowl to check out the friction decrease. 14078DA79F Loosen the socket bolts(19) to separate swing motor from reduction gear. 14078DA79E Remove stop ring(24) and then sun gear1(7).
  • Page 393 Disassembling carrier1(9) assembly. Remove stop ring(24). Remove thrust washer(12), planet gear1 (6), needle cage(29), and thrust washer(12) from the carrier. Using M8 solid drill, crush spring pin(23) so that the pin1(11) can be removed by hammering. Do not reuse spring pin(23). 14078DA72 Do not remove pin1(11), carrier1(9) and spring pin(23) but in case of replacement.
  • Page 394 Disassembling carrier2(8) assembly Using M8 solid drill, crush spring pin(23) so that the pin2(10) can be removed. Do not reuse spring pin(23). Remove pin2(10), planet gear2(4) and thrust washer(12) from the carrier2(8). Put matching marks on the planet gear2 (4) and the pin2(23) for easy reassembly. Do not disassemble pin2(23), carrier2(8) 14078DA75 and spring pin(23) but in case of...
  • Page 395 (12) Remove the roller bearing(17), the cover plate(27) and the spacer(26) from the drive shaft(2). 11078RD07 Using the bearing disassembly tool, (13) remove roller bearing(18). 11078RD08 (14) Remove the oil seal(20). 11078RD09 (15) Remove plugs(21, 22) from the casing(1). 14078DA79B 8-60...
  • Page 396 ASSEMBLY Assemble the space(26), the cover plate(27) and the roller bearing(17) on the drive shaft(2). 11078RD07 Assemble the drive shaft sub assembly(2) into the casing(1) and tighten the bolt(28) with loctite No.262. 26,27 11078RD07 Install the oil seal(20) and the roller bearing(18).
  • Page 397 Apply loctite to the tapped holes of casing (1). Tighten 2 M16 eye bolts to the ring gear(3) and lift up and then assemble it onto the casing(1). Don't fail to coincide the knock pin(16) holes. 14078DA76 Assembling carrier2(8) assembly. Install thrust washer(12) and the planet gear2(4) inside the carrier2(8).
  • Page 398 (10) Assembling carrier1(9) assembly. Assemble the pin1(11) to the carrier1(9) and then press the spring pin(23) by hammering. Punch 2 points of the spring pin's(23) lip. Install needle cage(29) into the planet gear1(6). Assemble thrust washer(12), planet gear1(6), and then stop ring(24) to the 14078DA72 pin1(11).
  • Page 399 (16) Assemble plugs(21, 22), gauge bar(14) and gauge pipe(15). 11078RD11 8-64...

  • Page 400: Group 6 Travel Device

    GROUP 6 TRAVEL DEVICE 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90 and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 401 2. TRAVEL MOTOR STRUCTURE 11072TM04 Shaft 20 Brake piston 37 Retainer 54 Plug 71 Sleeve 89 Carrier Cylinder barrel 21 Friction plate 38 Poppet 55 O-ring 72 Stopper 90 Sun gear B Ball retainer 22 Steel plate 39 Spring 56 Orifice 73 Spring 91 Planetary gear B Retainer...
  • Page 402 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench 5, 6, 8, 10, 14 22, 30, 32, 41 Socket OSocket for socket wrench, spanner 5, 6, 8, 10, 14, 19 Torque wrench Capable of tightening with the specified torques Pliers (-) Driver 150mm...
  • Page 403 3. DISASSEMBLY GENERAL PRECAUTIONS Before disassembling the motor, 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. To disassemble the motor, use the disassembling procedures described in section 2) and select a clean place.

  • Page 404: Disassembling Procedure

    DISASSEMBLING PROCEDURE Clean the outside of the travel motor completely before disassembling. Be aware that in re-assembling, the parts must be installed in the original locations. For this purpose, it is strongly recomm- ended to record the original positions of the parts before and during disassembling process.
  • Page 405 It would be easier to remove motor cover if you temporarily replace two bolts with two "tool" bolts(4) of yours as shown. (You don't have to use them necessarily). Bolt thread size = M12 P1.75 Bolt length = about 70mm(for example) 11078TM13 Place brake valve(3) on wood blocks(5) as shown.
  • Page 406 Remove two diagonal bolts(8) on one side as shown. Then, loosen the two remaining bolts little by little alternately until they are removed completely. Remove cover(9) from the brake valve. There is strong spring pressure under the cover(9). For your safety and preventing damage, be sure to loosen the bolts carefully so that spring 11078TM16...
  • Page 407 (10) Remove stopper(15), spring(16), and spool(17) located behind plug(14), from the brake valve. 11078TM19 (11) Remove two plugs(18). 11078TM20 (12) Remove O-ring(19) from each plug. Remove steel balls(20) from the brake valve. 11078TM21 Remove one relief valve(21) shown in the (13) picture.
  • Page 408 (14) Remove back-up ring(22) and O-ring(23) from the relief valve. 11078TM23 (15) Remove plug assembly(24) from the brake valve. Don't disassemble plug assembly(24). The screw setting must be kept at the original condition. 11078TM24 (16) Remove plug(25). 11078TM25 Remove spring(26), spring guide(27) and (17) rod(28) behind plug assembly(24).
  • Page 409 You don't have to remove sleeve inside the brake valve if the speed-shifting is functioning in order. 11078TM27 (18) Remove four bolts(31) and remove cover (32). Refer to step 7. 11078TM28 (19) Place the brake valve upside-down as shown. Remove valve plate(33) from the brake valve.
  • Page 410 (21) Remove three O-rings(36)(37)(38), two disk springs(39), and shim(40) from the body casing. 11078TM31 (22) Install tooling "Brake piston puller" as shown. a. Screw-in two bolts to the brake piston. b. Turn the center bolt little by little and let the center bolt push the shaft.
  • Page 411 (24) Remove two friction plates(46) and two steel plates(47) from the body casing, using a steel wire, a magnet, etc. Don't pull off the cylinder barrel compon- ent yet. 11078TM34 11078TM35 (25) Position the travel motor as shown on a wood block and apply wood wedges that prevent the travel drive from rolling around.
  • Page 412 (26) Be aware that in re-assembling, retainer(49), piston assemblies(50) and cylinder barrel(51) must be installed in the original locations. For this purpose, it is strongly recomm- ended to record the original positions of the parts before and during disassembling process. (27) Remove retainer(49) and piston assembli- es(50) from barrel(51).
  • Page 413 (30) Give a slight amount of compression on plate(54) with a press machine using a suitable size diameter jig. Remove snap ring(55). Remove plate(54) spring(56) and plate(57) from the cylinder barrel(51). There is strong spring force behind plate (54). For your safety and avoid-ing damage, a press machine 11078TM41 should be used to hold spring...
  • Page 414 (31) Remove cam(58) from the body casing. 11078TM44 11078TM45 (32) Remove two steel balls(59) and piston(60) from the body casing. Remove the spring(61) behind the piston. 11078TM46 11078TM47 8-79...
  • Page 415 (33) Place the travel motor on wood blocks as shown. Remove sixteen bolts(62) and washers(63). To avoid damaging shaft, don't put the traval motor directly on a flat ground but use blocks. 11078TM48 11078TM49 (34) With a soft-faced hammer, break the seal between cover(64) and gear casing(65).
  • Page 416 (35) Remove three bolts(66) and a thrust plate(67). 11078TM52 (36) Remove sun gear(68), three planetary gears(69) and three bearings(70). 11078TM53 11078TM54 (37) Remove carrier(71). 11078TM55 8-81...
  • Page 417 (38) If necessary, remove three inner races(72) from the carrier shaft. 11078TM56 (39) Remove sun gear(73). 11078TM57 (40) Remove snap ring(74) from sun gear(73). 11078TM58 (41) Remove four bolts(75) and a thrust plate (76). 11078TM59 8-82...
  • Page 418 (42) Remove four planetary gears(77), four bearings(78), four bushes(79) and four plates(80). 11078TM60 11078TM61 (43) Remove bolt(81) and washer(82). 11078TM62 (44) Remove pin(83) with a magnet. If it is difficult, follow the procedure below. Put a cover plate over the tap hole as shown.
  • Page 419 (46) Remove the gear casing(65) from the body casing with a hoist. 11078TM64 (47) Remove an angular bearing(85) from the gear casing. 11078TM65 (48) Put the gear casing upside-down. Remove a floating seal(86) and another angular bearing(87) from the gear casing. 11078TM66 (49) Remove another floating seal(88) from...
  • Page 420 (50) If necessary, remove a bearing(91) from the body casing. Remove an oil seal(92) from the body casing. 11078TM68 (51) If necessary, remove a bearing(91) from the shaft(90). If necessary, remove an inner race(93) from the shaft(90). This is the end of disassembling process. 11078TM69 8-85...
  • Page 421 4. ASSEMBLY GENERAL PRECAUTIONS Reassemble in a work area that is clean and free from dust and grit. Handle parts with bare hands to keep them free of linty contaminats. Repair or replace the damaged parts. Each parts must be free of burrs its corners. Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.

  • Page 422: Assembling Procedure

    ASSEMBLING PROCEDURE Make sure that all the parts are complete- ly clean and free of dirt and debris before assembling. Check the condition of all O-rings, back- up rings, and oil seal used in the travel motor. If any of them have any damage, replace them with new ones.
  • Page 423 Install floating seal(88) in the body casing, using tool "Floating seal installer". Then, put clean SAE30 engine oil or gear oil 80W-90 on the contact surface(flat surface) of the metal seal. 11078TM73 11078TM74 Install an angular bearing(85) to the gear casing.
  • Page 424 Install another floating seal(86) in the gear casing, using tooling "Floating seal installer". Then, put clean SAE30 engine oil or gear oil 80W-90 on the contact surface(flat surface) of the metal seal. Be careful and don't scratch or damage the floating seals before and during assembling the two components.
  • Page 425 Use the following procedure to make a preload adjustment of bearings(85) and (87) as follows : Tighten the ring nut(84) strongly enough until there is no gap among body casing, two bearings, gear casing, and ring nut. Rotate gear casing(65) several turns. Turn the ring nut(84) forward/backward and adjust the tightening position of the 11078TM80...
  • Page 426 (12) Apply Thread Lock "THREE BOND 2403" to bolt(81). Install bolt(81) and washer(82) to the body casing. Tighten the bolt to a torque of 68.6 4.9 N m(50.6 3.6lbf ft). 11078TM83 (13) Position the travel motor as shown. Install two steel balls(59), spring(61) and piston assembly(60) in the body casing.
  • Page 427 (15) Install plate(57), spring(56) and plate(54) in cylinder barrel(51). Use a press machine on plate(54), and compress spring(56). Install snap ring(55). 11078TM86 11078TM86 (16) Install three pins(53) in the cylinder barrel. 11078TM88 (17) Install retainer ball(52) to the cylinder barrel. Put clean hydraulic oil on retainer ball(52).
  • Page 428 (18) Install piston assemblies(50) in their original holes of retainer(49). (19) Put clean hydraulic oil in the bores of the cylinder barrel and piston assemblies(50). Install the piston assemblies with the retainer in their original bores in cylinder barrel(51). 11078TM90 (20) Put clean hydraulic oil on the sliding surfaces of the cam, nine piston shoe...
  • Page 429 (22) Make sure brake piston(41) is completely clean and free of dirt and debris. Check the condition of back-up rings(44)(45) and O-rings(42)(43). If any of them have any damage, replace them with new ones. Install back up rings(44)(45) and O- rings(42)(43) on brake piston(41) as shown.
  • Page 430 (25) Install bearing(34) and location pin(35) in the brake valve. 11078TM98 (26) Put the motor cover upside-down on wood blocks. Put some clean hydraulic oil on spool assembly(12), and install it in the valve body. Install washer(11) and then spring(10) in the valve body. Install O-ring(94) as shown.
  • Page 431 (28) Put O-ring(30) on plug(25). Install plug (25) to the brake valve. Tighten the plug(25) to a torque of 78.5 7.8N m (57.9 5.8lbf ft). 11078TM104 (29) Install rod(28), spring guide(27) and spring(26) to the brake valve. 11078TM102 11078TM103 (30) Put O-ring(29) on plug assembly(24).
  • Page 432 (31) Install back-up ring(22) and O-rings(23) on the relief valve as shown. 11078TM106 (32) Install relief valve(21) in the travel brake valve body as shown. Tighten the relief valve body to a torque of 196 19.6N m (145 14.5lbf ft). 11078TM107 (33) Install two balls(20) in the brake valve.
  • Page 433 (34) Put spool(17), spring(16), and stopper(15) in the brake valve body. Put the O-ring on plug(14). Install plug(14) to the travel brake valve. Tighten the plug to a torque of 49 4.9N m (36.1 3.6lbf ft). Put O-ring(13) on the brake valve body. 11078TM110 11078TM111 (35)
  • Page 434 (36) Put the brake valve upside-down. Install valve plate(33) in its original position on the brake valve. Put some clean hydralulic oil on the valve plate surface. 11078TM114 (37) Position brake valve(3) on the body casing. Install ten bolts(2) that hold it. Tighten the bolts to a torque of 191 14.7 N m (141 10.8lbf ft).
  • Page 435 (40) Place the travel motor with brake valve upside down as shown. Apply torque to shaft(90) to confirm the parking brake torque. If the shaft starts rotating by a torque of more than 239N m (176lbf ft), it satisfies the spec. If the motor output shaft rotates at a less torque than above, shim(40) needs to be replaced with thicker one in order to get a higher parking brake...
  • Page 436 (43) Put thrust plate(76) as shown. Apply Thread Lock "THREE BOND 2403" to bolts(75). Install four bolts(75). Tighten the bolts to a torque of 68.6 4.9 N m (50.6 3.6lbf ft). Then install sun gear(73). 11078TM121 (44) Install three inner races(72) on the carrier shaft.
  • Page 437 (47) Put thrust plate(67) on the carrier. Apply Thread Lock "THREE BOND 2403" to bolts(66). Install three bolts(66) that hold plate(67) to the planetary carrier. Tighten the bolts to a torque of 68.6 4.9 N m (50.6 3.7lbf ft). 11078TM125 (48) Make sure the machined surface of gear casing(65) and cover(64) is completely...

  • Page 438: Group 7 Rcv Lever

    GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 439 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 14072SF80 8-104...
  • Page 440 Case 12 Rod seal 22 Handle connector Plug 13 O-ring 23 Nut Plug 14 Push rod 24 Insert O-ring 15 Plate 25 Boot Spool 16 Bushing 26 Handle Shim 17 Joint assembly 27 Switch assembly Spring 18 Swash plate 28 Screw Spring seat 19 Adjusting nut 29 Switch assembly...
  • Page 441 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanner (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Plug PT 1/8 21.7 Joint...
  • Page 442 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. 14078DA62 For valve with switch, remove cord also through hole of casing.
  • Page 443 Loosen adjusting nut(20) and plate(19) with spanners on them respectively, and remove them. R140LC-7 RE04 R140LC-7 RE05 Turn joint anticlockwise to loosen it, utilizing jig(Special tool). When return spring(10) is strong in force, plate(16), plug(11) and push rod(14, 15) will come up on loosening joint. Pay attention to this.
  • Page 444 Remove plate(16). R140LC-7 RE08 When return spring(10) is weak in force, plug(11) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
  • Page 445 (12) For disassembling reducing valve section, stand it vertically with spool(5) bottom placed on flat workbench. Push down spring seat(8, 31) and remove two pieces of semicircular stopper(9) with tip of small minus screwdriver. Pay attention not to damage spool surface.
  • Page 446 R140LC-7 RE18 (16) Remove lock nut(21) and then boot(26). R140LC-7 RE19 25038RL02(4) 8-111...
  • Page 447 (17) Cleaning of parts Put all parts in rough cleaning vessel filled with kerosene and clean them (Rough cleaning). If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil.
  • Page 448 ASSEMBLY Tighten hexagon socket head plug(2) to the specified torque. Tighten two bolts alternately and slowly. R140LC-7 RE29 Put shim(6), springs(7, 30) and spring seat(8, 31) onto spool(5) in this order. R140LC-7 RE30 Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper(9) on spring seat without piling them on.
  • Page 449 Assemble O-ring(13) onto plug(11). R140LC-7 RE33 Assemble seal(12) to plug(11). Assemble seal in such lip direction as shown below. R140LC-7 RE34 Assemble push rod(14, 15) to plug(11). Apply working oil on push-rod surface. R140LC-7 RE35 Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring.
  • Page 450 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate(16), and tighten joint(18) temporarily. R140LC-7 RE37 (10) Fit plate(16). (11) Tighten joint(18) with the specified torque to casing, utilizing jig. R140LC-7 RE38 Assemble plate(19) to joint(18). (12) Screw it to position that it contacts with 4 push rods evenly.
  • Page 451 (14) Fit boot(40) to plate. 1408DA61 Fit boot(26) and lock nut(21), and handle (15) subassembly is assembled completely. 25038RL02(4) R140LC-7 RE48 (16) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. 1408DA66 8- 116...
  • Page 452 (17) Assemble bushing(17) to plate and pass cord and tube through it. Provide margin necessary to operation. 1408DA67 (18) Determine handle direction, tighten lock nut(21) to specified torque to fix handle. 1408DA68 (19) Apply grease to rotating section of joint and contacting faces of disk and push rod.

  • Page 453: Group 8 Turning Joint

    GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 454 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 21078DA09 Shim Wear ring Shaft Slipper seal Retainer ring Cover O-ring Plug Spacer O-ring Hexagon bolt Shim O-ring Spring washer 8-119...
  • Page 455 DISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts(14), washer(15) and cover(3). 21078DA10 Remove shim(6) and O-ring(10). Remove retainer ring(12), spacer(4) and shim(5). 21078DA11 Place hub(1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out Wooden block shaft(2) to about 1/2 from the body with a hammer.
  • Page 456 ASSEMBLY Clean all parts. As a general rule, replace oil seals and O- ring. Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix seven slipper seal(7) and O-ring(9), two ring wear(11) to hub(1). Fit O-ring(8) to shaft(2). 21078DA12 Set shaft(2) on block, tap hub(1) with a plastic hammer to install.
  • Page 457 Install cover(3) to body(1) and tighten bolts(14). Torque : 10~12.5kgf m(72.3~90.4lbf ft) 21078DA10 8-122...

  • Page 458: Group 9 Boom, Arm And Bucket Cylinder

    GROUP 9 BOOM, ARM AND BUCKET CYLINDER 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 459 Sling bucket cylinder assembly(8) and remove bolt(6) then pull out pin (5). Remove bucket cylinder assembly(8). Weight : 90kg(200lb) 1408DA83 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.

  • Page 460: Arm Cylinder

    ARM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. 13031GE18 Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 461 Sling arm assembly(7) and remove bolt (6) then pull out pin(5). Remove arm cylinder assembly(7). Weight : 140kg(310lb) 11078CY03 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.

  • Page 462: Boom Cylinder

    BOOM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release 13031GE18 the pressure inside the hydraulic tank.
  • Page 463 Disconnect boom cylinder hoses(7) and put plugs on cylinder pipe. 1408DA90 Remove bolt(9) and pull out pin(8). Remove boom cylinder assembly(6). Weight : 115kg(255lb) 1408DA91 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
  • Page 464 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder 9,10 6,7 8 21 3 11,12 5 30 28 11,12 15,16 14 17 18 19 20 Internal detail 22,24 23,24 11078CY05 Tube assembly 11 O-ring 21 Hexagon socket head bolt Rod assembly 12 Back up ring 22 Pin bush Gland 13 Cushion ring...
  • Page 465 Arm cylinder 9,10 4,5 3 11,12 15,16 17 18 19 23 20,21,22 29,31 32,33,34,35 11078CY07 Tube assembly Cushion ring Pin bush Rod assembly Piston Dust seal Gland O-ring Band assembly DD2 Bush Back up ring Pipe assembly(R) Snap ring Piston seal O-ring Rod seal Wear ring...
  • Page 466 Boom cylinder 9,10 6,7 8 3 11,12 5 27 28 11,13 15,16 14 17 18 19 25 26 27,29 22,23 11078CY06 Tube assembly O-ring Hexagon socket head bolt Rod assembly Back up ring Pin bush Gland Cushion ring Dust seal DD2 bush Piston Band assembly...
  • Page 467 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanner (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Bucket cylinder 9.4 1 68.0 7.2 Gland mounting bolt Boom cylinder...
  • Page 468 DISASSEMBLY Remove cylinder head and piston rod Procedures are based on the bucket cylinder. Hold the clevis section of the tube in a vise. Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means.
  • Page 469 Note that the plated surface of rod assembly(2) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. Place the removed rod assembly on a wooden V-block that is set level.
  • Page 470 Disassemble the piston assembly Remove wear ring(18). 19 18 17 18 19 Remove dust ring(19) and piston seal (17). Exercise care in this operation not to damage the grooves. 11078CY23 Disassemble cylinder head assembly Remove back up ring(11) and O-ring 9 10 7 6 8 4 12 11 5 (12).
  • Page 471 ASSEMBLY Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil stone. Coat the inner face of gland(3) with hydraulic oil. 1408DA119 Coat dust wiper(9) with grease and fit dust wiper(9) to the bottom of the hole of dust seal.
  • Page 472 Fit back up ring(12) to gland(3). Put the backup ring in the warm water of 12 11 30~50 C. Fit O-ring(11) to gland(3). 11078CY25 Assemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone. Coat the outer face of piston(14) with hydraulic oil.
  • Page 473 Install piston and cylinder head Fix the rod assembly to the work bench. Apply hydraulic oil to the outer surface of rod assembly(2), the inner surface of piston and cylinder head. Insert cylinder head assembly to rod assembly. 1408DA124 Insert cushion ring(13) to rod assembly. Note that cushion ring(13) has a direction in which it should be fitted.
  • Page 474 Overall assemble Place a V-block on a rigid work bench. Mount the tube assembly(1) on it and fix the assembly by passing a bar through the clevis pin hole to lock the assembly. Insert the rod assembly in to the tube assembly, while lifting and moving the rod assembly with a crane.

  • Page 475: Group 10 Undercarriage

    GROUP 10 UNDERCARRIAGE 1. TRACK LINK REMOVAL Move track link until master pin is over Master pin front idler in the position put wooden block as shown. Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards.
  • Page 476 2. CARRIER ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve R140LC- 7 8-162(1) Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller R140LC- 7 8-162(2) Loosen the lock nut (1). Carrier roller Open bracket(2) with a screwdriver, push out from inside, and remove carrier roller...
  • Page 477 3. TRACK ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve R140LC- 7 8-163(1) Using the work equipment, push up track frame on side which is to be removed. After jack up the machine, set a block under the unit. 90 ~ 110 Mark 11078TR01...
  • Page 478 4. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link. R140LC- 7 8-164(1) Sling the recoil spring(1) and pull out idler and recoil spring assembly from track frame, using a pry. Weight : 215kg(474lb) R140LC- 7 8-164(2) Remove the bolts(2), washers(3) and...
  • Page 479 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 21078DA43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 8-144...
  • Page 480 Disassembly Press Remove plug and drain oil. Draw out the spring pin(7), using a press. R140LC- 7 8-166(1) Pull out the shaft(2) with a press. Press Remove seal(3) from idler(1) and bracket (5). Remove O-ring(6) from shaft. R140LC- 7 8-166(2) Remove the bushing(4) from idler, using a special tool.
  • Page 481 Assembly Before assembly, clean the parts. Press Coat the sliding surfaces of all parts with oil. Cool up bushing(4) fully by some dry ice and press it into shell(1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
  • Page 482 Install bracket(5) attached with seal(3). R140LC- 7 8-168(1) Knock in the spring pin(7) with a hammer. R140LC- 7 8-168(2) Lay bracket(5) on its side. Supply engine oil to the specified level, and tighten plug. R140LC- 7 8-168(3) 8-147...
  • Page 483 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure 7, 8 R210UCG1 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod assembly Spring Spring washer 13 Grease valve Bracket Rod seal Lock nut 10 Back up ring 8-148...
  • Page 484 Disassembly Apply pressure on spring(3) with a press. The spring is under a large installed load. This is dangerous, so be sure to set properly. Spring set load : 8497kg(18733lb) Remove bolt(7), spring washer(8) and 7, 8 lock plate(6). Remove lock nut(5). Take enough notice so that the press which pushes down the spring, should not be slipped out in its operation.
  • Page 485 Assembly Install dust seal(11), back up ring(10) and 9 10 11 rod seal(9) to body(1). When installing dust seal(11) and rod seal(9), take full care so as not to damage the lip. R210UCG2(3) Pour grease into body(1), then push in rod(12) by hand.
  • Page 486 Lighten the press load and confirm the Press set length of spring(3). After the setting of spring(3), install lock plate(6), spring washer(8) and bolt(7). 11078UC01 8-151...

  • Page 487: Group 11 Work Equipment

    GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A SECTION B SECTION C 21078DA44 8-152...
  • Page 488 2. REMOVAL AND INSTALL BUCKET ASSEMBLY Removal Lower the work equipment completely to ground with back of bucket facing down. R140LC- 7 8-174(1) Remove nut(1), bolt(2) and draw out the pin(A). R140LC- 7 8-174(2) Remove nut(3), bolt(4) and draw out the pin(B).

  • Page 489: Arm Assembly

    ARM ASSEMBLY Removal Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury. Remove bucket assembly. For details, see removal of bucket assembly. Disconnect bucket cylinder hose(1). Fit blind plugs(5) in the piping at the chassis end securely to prevent oil from spurting out when the...

  • Page 490: Boom Assembly

    BOOM ASSEMBLY Removal Remove arm and bucket assembly. For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly. Disconnect head lamp wiring. Disconnect bucket cylinder hose(2) and arm cylinder hose(1).

  • Page 491: Section 9 Component Mounting Torque

    SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1 Group 2 Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2 Group 3 Electric system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-4 Group 4 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-6...

  • Page 492: Group 1 Introduction Guide

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

  • Page 493: Group 2 Engine System

    GROUP 2 ENGINE SYSTEM 1. ENGINE AND ACCESSORIES MOUNTING Muffler Engine Throttle lever Accel actuator Air cleaner 11079CM01 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 6 1.0 1.1 0.2 7.95 1.45 M8 1.25 2.5 0.5 18.1 3.6 M 8 1.25...
  • Page 494 2. COOLING SYSTEM AND FUEL TANK MOUNTING Air conditioner idle pulley Cooler & radiator Air compressor Water separator Hyd tank Fuel tank Receiver drier U I D L I Q Condenser VIEW A Radiator Oil cooler Needle valve Shroud Fan guard 11079CM02 Tightening torque kgf m...

  • Page 495: Group 3 Electric System

    GROUP 3 ELECTRIC SYSTEM 1. ELECTRIC COMPONENTS MOUNTING 1 Fuel filler pump Work lamp EPPR VLV START MOTOR AIR HEATER CABLE A/C COMP. Travel alarm buzzer Horn Battery Washer tank Battery relay Fuse box 11079CM03 Tightening torque kgf m lbf ft kgf m lbf ft Item...
  • Page 496 2. ELECTRIC COMPONENTS MOUNTING 2 Beacon lamp Wiper motor VIEW A Prolix Electric box resistor controller Cluster Wiper motor cover 11079CM04 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 6 1.0 1.05 0.2 7.6 1.45 M10 1.5 6.9 1.4...

  • Page 497: Group 4 Hydraulic System

    GROUP 4 HYDRAULIC SYSTEM 1. HYDRAULIC COMPONENTS MOUNTING 1 Air breather Hydraulic tank Main pump Level gauge Spin filter Solenoid valve Main control valve Swing motor VIEW A RCV-LH Main pump housing RCV-RH Terminal Coupling Cross 11079CM05 Tightening torque kgf m lbf ft kgf m lbf ft...
  • Page 498 2. HYDRAULIC COMPONENTS MOUNTING 2 Travel motor(RH) Turning joint Travel motor(LH) RCV-pedal Boom safety lock system Arm safety lock system Boom safety lock valve Arm safety lock valve Arm cylinder Boom cylinder 11079CM06 Tightening torque kgf m lbf ft kgf m lbf ft Item Size...
  • Page 499 3. HYDRAULIC COMPONENTS MOUNTING 3 Solenoid valve Check valve Cartridge Coil BOOM CYLINDER BUCKET CYLINDER ARM CYLINDER 11079CM07 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size 14.5 M 8 1.25 2.7 0.3 19.5 2.2 M10 1.5 3.2 0.3 23.1 2.2...

  • Page 500: Group 5 Undercarriage

    GROUP 5 UNDERCARRIAGE ADJUST COMPONENT Swing bearing Idler Idler Carrier roller Track chain Cover Adjust component Track roller Travel motor Track guard Sprocket 11079CM08 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size 1.25 3.43 0.7 24.8 5.1 M16 2.0 29.6 3.2...

  • Page 501: Group 6 Structure

    GROUP 6 STRUCTURE 1. CAB AND ACCESSORIES MOUNTING Sun roof Sun visor Latch Air vent cover VIEW A Door latch Striker 11079CM09 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 6 1.0 0.49 0.1 3.5 0.7 M10 1.5 6.9 1.4...
  • Page 502 2. CAB INTERIOR MOUNTING Seat Storage box cover Aircon upper cover Console box(RH) Storage Wiper motor cover Defroster Aircon lower hose cover cover Console box(LH) Travel Safety lever lever Slide rail Seat base Pedal bracket Viscous mount Foot rest Bottom plate 14079CM10 Tightening torque kgf m...
  • Page 503 3. COWLING MOUNTING Counterweight screen Engine hood Side cover-RH Tank cover Radiator hood Support-RH MCV hood Aircleaner hood Support-LH 11079CM11 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 6 1.0 0.49 0.1 3.5 0.7 M12 1.75 12.8 3.0 92.6 21.7...
  • Page 504 4. COUNTERWEIGHT AND COVERS MOUNTING Handle pipe Counterweight Fuel tank Tool box Upper frame Pump under cover Engine under cover Hyd tank under cover Radiator under cover MCV under cover Swing bearing grease drain cover under cover(C) Cab under cover(B) Cab under cover(A) 11079CM12 Tightening torque...

  • Page 505: Group 7 Work Equipment

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

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