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Hyundai R60CR-9A Manual

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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

Group 2 Main Control Valve ----------------------------------------------------------------------------------------- 2-9

Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-31

Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-38

Group 5 RCV Lever ------------------------------------------------------------------------------------------------------ 2-47

SECTION 3 HYDRAULIC SYSTEM

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

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

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

Group 4 Single Operation -------------------------------------------------------------------------------------------- 3-10

Group 5 Combined Operation ------------------------------------------------------------------------------------- 3-22

SECTION 4 ELECTRICAL SYSTEM

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

Group 2 Monitoring system ------------------------------------------------------------------------------------------ 4-3

Group 3 Electrical Circuit ---------------------------------------------------------------------------------------------- 4-59

Group 4 Electrical Component Specification ------------------------------------------------------------- 4-75

Group 5 Connectors ----------------------------------------------------------------------------------------------------- 4-82

Group 6 Fault codes ----------------------------------------------------------------------------------------------------- 4-100

SECTION 5 TROUBLESHOOTING

Group 1 Before Troubleshooting ---------------------------------------------------------------------------------- 5-1

Group 2 Hydraulic and Mechanical System --------------------------------------------------------------- 5-4

Group 3 Electrical System ------------------------------------------------------------------------------------------- 5-24

SECTION 6 MAINTENANCE STANDARD

Group 1 Operational Performance Test ----------------------------------------------------------------------- 6-1

Group 2 Major Components ---------------------------------------------------------------------------------------- 6-21

Group 3 Track and Work Equipment ---------------------------------------------------------------------------- 6-35

CONTENTS

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Page 1: 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 Group 2 Main Control Valve ----------------------------------------------------------------------------------------- 2-9 Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-31 Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-38 Group 5 RCV Lever ------------------------------------------------------------------------------------------------------ 2-47 SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit --------------------------------------------------------------------------------------------- 3-1...
Page 11: Section 1 General
SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints ---------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-9...
Page 12 SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
Page 13: Prepare For Emergencies
PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
Page 14: Move And Operate Machine Safely
KEEP RIDERS OFF EXCAVATOR KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.
Page 15: Support Machine Properly
SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.
Page 16: Beware Of Exhaust Fumes
BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
Page 17: Stay Clear Of Moving Parts
SERVICE MACHINE SAFELY SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
Page 18: Prevent Battery Explosions
AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Page 19: Replace Safety Signs
USE TOOLS PROPERLY USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards. Use power tools only to loosen threaded tools and fasteners. For loosening and tightening hardware, use the c o r r e c t s i ze t o o l s. D O N OT u s e U. S. measurement tools on metric fasteners.
Page 20: Group 2 Specifications
GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Oil cooler Engine Engine hood Radiator Main pump Muffler Swing motor Hydraulic tank Fuel tank Tooth Bucket Turning joint Main control valve Arm cylinder Boom Boom cylinder Swing post Counterweight Carrier roller Side cutter...
Page 21: Specifications
2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) 2.9 m ( 9' 6") MONO BOOM, 1.48 m ( 4' 10") ARM, WITH BOOM SWING 2.9 m ( 9' 6") MONO BOOM, 1.48 m ( 4' 10") ARM, WITH BOOM SWING SYSTEM SYSTEM I(I') B(L) 60CR9A2SP02...
Page 22: Working Range
3. WORKING RANGE 3. WORKING RANGE 1) 1) 2.9 m (9' 6") MONO BOOM WITH BOOM SWING SYSTEM (9' 6") MONO BOOM WITH BOOM SWING SYSTEM 8 ft 60CR92SP03 Description 1.48 m (4' 10") Arm Max digging reach 6150 mm (25' 5") Max digging reach on ground 6010 mm (24' 11") 3570 mm (11' 9")
Page 23 4. WEIGHT Item Upperstructure assembly 2895 6380 Main frame weld assembly 1260 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Boom swing post Counterweight 1040 Cab assembly Lower chassis assembly 2275 5020 Track frame weld assembly...
Page 24: Lifting Capacities
5. LIFTING CAPACITIES 2.9 m ( 9' 6") boom, 1.48 m ( 4' 10") arm equipped with 0.18 m (SAE heaped) bucket and 380 mm (15") triple grouser shoe, the dozer blade down with 470 kg (1040 lb) counterweight. : Rating over-front : Rating over-side or 360 degree Load radius At max.
Page 25: Angle Dozer Blade
Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Please be aware of the local regulations and instructions for lifting operations.
Page 26 2.9 m ( 9' 6") boom, 1.48 m ( 4' 10") arm equipped with 0.18 m (SAE heaped) bucket and 380 mm (15") triple grouser shoe, the dozer blade up with 470 kg (1040 lb) counterweight. : Rating over-front : Rating over-side or 360 degree Load radius At max.
Page 27 Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Please be aware of the local regulations and instructions for lifting operations.
Page 28 6. BUCKET SELECTION GUIDE 6. BUCKET SELECTION GUIDE GENERAL BUCKET GENERAL BUCKET 1) 1) 0.07m 0.18 m heaped bucket heaped bucket Recommendation Capacity Width 2.9 m (9' 6") boom Weight CECE Without With 1.48 m (4' 10") arm heaped heaped side cutter side cutter 315 mm...
Page 29 Shapes Shoe width mm (in) 380 (15) 450(18) 400 (16) Operating weight kg (lb) 5900 (13010) 5960(13140) 5800 (12790) R60CR-9A Ground pressure 0.36 (5.12) 0.31(4.41) 0.34 (4.83) kgf/cm (psi) Overall width mm (ft-in) 1980 (6' 6") 2050 (6' 9") 2000 (6' 7")
Page 30 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Yanmar 4TNV98C Type 4-cycle diesel engine, low emission Cooling method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type Cylinder bore×stroke 98×110 mm (3.85"×4.33") Piston displacement 3319 cc (203 cu in)
Page 31: Swing Motor
3) 3) GEAR PUMP (P3, P4) GEAR PUMP (P3, P4) Item Specification Type Fixed displacement gear pump double stage Capacity 18.3/4.5 cc/rev Maximum pressure 220/30 kgf/cm (3130/430 psi) Rated oil flow 36.6/9ℓ/min (9.7/2.4 U.S. gpm / 8.1/2.0 U.K. gpm) 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item...
Page 32 Discoloration does not cause any harmful effect on the cylinder performance. 8) 8) SHOE SHOE Item Width Ground pressure Link quantity Overall width R60CR-9A 380 mm (15") 0.36 kgf/cm (5.12 psi) 1980 mm (6' 6") R60CR-9A 450 mm (18") 2050 mm (6' 9") 0.31 kgf/cm (4.41 psi)
Page 33: Recommended Oils
※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
Page 34: Section 2 Structure And Function
SECTION 2 STRUCTURE AND FUNCTION SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device -------------------------------------------------------------------------------------------------- 2-1 Group 2 Main Control Valve ---------------------------------------------------------------------------------------- 2-9 Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-31 Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-38 Group 5 RCV Lever ------------------------------------------------------------------------------------------------------ 2-47...
Page 35 SECTION 2 STRUCTURE AND FUNCTION SECTION 2 STRUCTURE AND FUNCTION GROUP 1 HYDRAULIC PUMP GROUP 1 HYDRAULIC PUMP 1. GENERAL 1. GENERAL This is a variable displacement double-piston pump for discharge with equal displacements from one cylinder block. This pump is so compact as to appear a single pump though this is actually a double pump.
Page 36 2. PRINCIPAL COMPONENTS AND FUNCTIONS 2. PRINCIPAL COMPONENTS AND FUNCTIONS R5572SF02 Drive shaft Control spring Hanger Control piston Rotary group Gear pump Cover Housing SPECIFICATIONS SPECIFICATIONS ● Capacity : 2×27.5+18.3+4.5 cc/rev ● Rated oil flow : 2×57.8+38.4+9.5 ℓ /min ● Rated pressure : 3×220+30 kgf/cm This is a variable displacement double-piston pump for discharge with two equal displacements from one cylinder block.
Page 37: Principle Of Operation
PRINCIPLE OF OPERATION PRINCIPLE OF OPERATION Function of pump Function of pump Piston Lower dead point Hanger (Swash plate) Cylinder block Control plate Discharge port Upper dead point Discharge process Suction process Suction port R5572SF03 The cylinder block is connected via spline and can rotate together with the drive shaft. The piston assembled into the cylinder block performs reciprocal operation while following the swash plate on the hanger.
Page 38: Control Functions
CONTROL FUNCTIONS CONTROL FUNCTIONS Spring A Spring B Hanger Piston Piston Piston for P3 shift Shifting line Piston Q max Flow rate Section D-D R5572SF04 The discharge pressures P1 and P2 are directed to the pistons of equal area act on the hanger. The spring is provided to act against the discharge pressure.
Page 39 CONTROL / ADJUSTMENT PROCEDURE CONTROL / ADJUSTMENT PROCEDURE Loosen the hexagonal nut. Tighten or loosen the adjusting screw to set the power shifting line. Spring seat Cover Adjusting screw Tighten Loosen Q max Flow rate Loosen Tighten R5572SF05...
Page 40: Installation
3. ADJUSTMENT 3. ADJUSTMENT This hydraulic pump has been set and inspected according to your specified input power and control. Readjustment of all the adjusting portions may lead to the loss of functions specified for each control and the pump proper may be excluded from the scope of guarantee. Never attempt operating the adjusting screw, etc.
Page 41: Maintenance
(14) When the motor has reached the operation speed, check the operation while applying the load to the actuator. (15) Check the monitoring or measuring instrument if installed. (16) Check the noise level. (17) Check the oil level in the tank. Supply the oil. If required. (18) Check the setting of the pressure control valve while applying the load to the actuator.
Page 42 Changing the hydraulic oil Changing the hydraulic oil ① After 2000 hours of operation. ② Every 2000 hours of operation or once a year after that. The change interval may have to be shortened depending on the degree of fouling and the thermal load condition of the hydraulic oil.
Page 43: Group 2 Main Control Valve
GROUP 2 MAIN CONTROL VALVE GROUP 2 MAIN CONTROL VALVE 1. OUTLINE 1. OUTLINE Gauge Ai Pp 559A2MC01 Port Tightening Port Tightening Mark Port name Mark Port name size torque size torque B10 Bucket in port P1 P1 pump port PF1/2 6~7 kgf·m B11 Arm 2 port P2 P2 pump port...
Page 44 2. STRUCTURE (1/4) 2. STRUCTURE (1/4) 5-15 5-101 5-11 5-102 4-111 4-112 4-113 4-101 4-15 4-102 3-111 3-112 5-121 3-113 5-122 3-101 3-15 3-102 4-13 4-12 5-15 2-101 2-102 2-15 4-14 3-12 3-13 4-15 2-112 3-14 2-12 2-111 3-15 2-13 2-14 2-15 55Z92MC02...
Page 45 STRUCTURE (2/4) STRUCTURE (2/4) 9-15 9-101 9-102 8-15 8-11 8-101 8-102 9-12 7-15 9-11 7-101 7-11 7-102 8-11 9-13 9-15 8-12 6-15 9-11 6-101 6-11 8-13 6-102 7-13 7-123 7-122 8-15 7-121 7-14 7-15 6-11 6-1 6-13 6-12 6-15 55Z92MC03 2 Way block 7-1 Work block (Ba3) 7-14 O-ring...
Page 46 STRUCTURE (3/4) STRUCTURE (3/4) 12-4 12-19 12-5 12-3 12-6 12-91 12-2 12-10 12-92 12-8 12-17 11-4 12-7 11-17 11-5 11-3 11-6 11-101 12-18 11-2 11-102 10-8 12-13 11-9 10-9 12-12 11-8 10-12 12-14 10-3 10-61 10-11 12-1 12-16 12-15 11-13 10-151 12-3 10-10...
Page 47 STRUCTURE (4/4) STRUCTURE (4/4) 14-4 14-15 14-5 14-3 14-6 14-2 14-91 14-81 13-4 14-92 14-82 13-14 13-5 13-151 13-11 13-3 13-6 13-151 13-152 14-102 13-152 13-16 14-101 13-16 13-18 13-17 14-1 13-2 14-3 14-11 14-15 13-11 14-7 14-6 14-5 13-1 13-12 13-13 13-3...
Page 48 3. HYDRAULIC CIRCUIT (boom swing, 2-way) 3. HYDRAULIC CIRCUIT (boom swing, 2-way) Swing Dozer Boom swing (2-WAY) Breaker Travel (LH) Travel (RH) Boom Bucket 55Z92MO02 2-14...
Page 49 4. FUNCTION 4. FUNCTION 1) 1) CONTROL IN NEUTRAL FUNCTION CONTROL IN NEUTRAL FUNCTION Gauge GAUGE 555C92MC07 In neutral, spring sets the spool at the neutral position, the hydraulic oil from pumps flows to the tank through the center bypass. 2-15...
Page 50 (1) (1) The oil discharged from the hydraulic pump flows into control valve P1 port, and then flows the right side travel valve through the travel straight valve. In neutral, the oil flows through the center bypass passage in the direction of right travel → boom 1 → bucket → arm 2 spool, and then flows from the center bypass passage to the tank port T1 and T2.
Page 51 2) 2) EACH SPOOL OPERATION EACH SPOOL OPERATION (1) (1) Travel operation Travel operation (forward / backward) (forward / backward) ARM1 Arm 1 BREAKER Breaker Center bypass passage Tank TANK Check poppet Gauge GAUGE Boom ⇒ bucket BOOM BUCKET ⇒ Arm 2 ARM1 555C92MC08 ·...
Page 52 (2) (2) Boom operation Boom operation ① Boom up operation Boom up operation (P1 and P2 summation) Load check valve Parallel passage TS Ai GAUGE Gauge 555C92MC09 2-18...
Page 53 · During boom up operation, the pilot pressure from RCV is supplied into the port a9 and shift the boom 1 spool in the left direction. The hydraulic oil fluid from pump P1 is entered P1 parallel passage and then passes through the load check valve then flows into the port A9. Following this, it flows into the head side of the boom cylinder.
Page 54 ② Boom down operation Boom down operation TS Ai Gauge GAUGE Load check valve Parallel passage 555C92MC10 · During the boom lowing operation, the pilot pressure from RCV is supplied to the port b9 and shift the boom 1 spool in the right direction. The hydraulic fluid from the pump P1 enters the parallel passage and is directed to the port B9 through the load check valve.
Page 55 (3) (3) Bucket operation Bucket operation ① Bucket roll in operation Bucket roll in operation GAUGE Gauge Load check valve 555C92MC11 · During the bucket roll in operation, the pilot pressure from RCV is supplied to port b10 and shift the bucket spool in the right direction.
Page 56 ② Bucket roll out operation Bucket roll out operation Gauge GAUGE 555C92MC12 · In case of the bucket roll out operation, the operation is similar. · The hydraulic oil flow from the Pp port is same as the bucket in operation. 2-22...
Page 57 ③ Bucket load check valve operation Bucket load check valve operation PLUNGER Plunger ORIFICE Orifice 555C92MC13 · This function is used to speed up of the boom or arm by reducing the bucket speed when bucket operation with boom or arm operation simultaneously. ·...
Page 58 (4) (4) Arm operation Arm operation ① Arm roll in operation Arm roll in operation (P1 and P2 summation) GAUGE Gauge 555C92MC14 2-24...
Page 59 · During arm roll in operation the pilot pressure from the RCV is supplied to the port b6 and b11 and shifts arm 1 spool and arm 2 spool in the direction. The hydraulic oil from the pump P2 flows into the arm cylinder head side through P2 parallel passage, the load check valve and the port B6.
Page 60 ② Arm roll out operation Arm roll out operation Gauge GAUGE 555C92MC15 · During arm roll out operation the pilot pressure from RCV is supplied to the port a6 and the a11 and shifts arm 1 spool and arm 2 spool in the left direction. The hydraulic fluid from pump P2 flows into arm 1 spool through the parallel passage.
Page 61 (5) (5) Swing operation Swing operation Swing SWING 555C92MC16 · The pilot pressure from the RCV is supplied to the a1 and shift the swing spool in left direction. The hydraulic fluid from pump P3 flows into swing spool through the parallel passage. Then it is directed to swing motor through the port A1.
Page 62 (6) (6) Travel straight function Travel straight function Parallel passage Center bypass passage Gauge GAUGE Cut off when the boom, BOOM or ARM or BUCKET arm and bucket operation 555C92MC17 2-28...
Page 63 · This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm, bucket, swing, woodgrab) during a straight travel. ① During travel only : The hydraulic fluid of the pump P1 is supplied to the travel motor and the pump P2 is supplied to the other motor.
Page 64 (7) (7) Holding valve operation Holding valve operation ① Holding operation Holding operation Actuator port Check Spring Pilot piston chamber Drain port Pilot port Boom holding valve Boom 1 spool Plug Poppet Poppet seat Spring B Piston A Piston B 55W72MC16 At neutral condition, the pilot piston chamber is connected to drain port through the pilot port.
Page 65: Group 3 Swing Device
GROUP 3 SWING DEVICE 1. STRUCTURE Swing device consists swing motor, swing reduction gear. SWING MOTOR Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. 60CR92SM01 Port Port name Port size Main port PF 3/8 Main port PF 3/8 Drain port...
Page 66 2) 2) SWING MOTOR/REDUCTION GEAR (1/2) SWING MOTOR/REDUCTION GEAR (1/2) 55Z9SM001 T01 Casing T15 Separation plate T43 Socket bolt R13 Neddle bearing T02 Valve casing T16 Brake piston R01 Gear casing R14 Neddle bearing T03 Drive shaft T17 Brake spring R02 Pinion shaft R15 Planet gear No.2 T04 Roller bearing...
Page 67 SWING MOTOR/REDUCTION GEAR (2/2) SWING MOTOR/REDUCTION GEAR (2/2) 55Z9SM002 T19 Plunger T33 Filter T20 Check spring T34 Bush T21 Plug T35 Spacer T27 O-ring T36 Throttle plate T28 O-ring T37 Spring T30 Spool T38 RO Plug T31 Spring T40 Plug T32 Plunger A T44 Relief valve 2-33...
Page 68: Principles Of Working
2. PRINCIPLES OF WORKING 2. PRINCIPLES OF WORKING 1) 1) MOTOR PART MOTOR PART High pressure oil from the control valve is routed through valve casing and valve plate to pistons. When the oil enters the cylinder bores through port, it forces the pistons against the fixed inclined swash plate (F1,F2).
Page 69: Control Valve
VALVE CASING PART VALVE CASING PART Anticavitation nticavitation check valve check valve The motor can be rotated faster than supplied oil flow because there is no counter-balancing valve to prevent over speed ; in order to prevent cavitation of the motor, oil compensation insufficient flow is drawn through the anti-cavitation check valve.
Page 70 HYD.AREA A2 SPRING(321) PISTON(302) (PRESSURE;Pg) R PORT P PORT (PRESSURE;P1) ADJUSTMENT HYD.AREA A1 PLUNGER(301) PLUG(401) PRESSURE;Ps PRESSURE;Ps Relief valve working description 55Z9SM004 2-36...
Page 71 3) 3) BRAKE PART BRAKE PART The swing brake is spring applied and hydraulically released. Friction plate (T14) are splined to and rotate with cylinder block. Separation plates (T15) are splined to the motor casing (T01). When the swing controller blocks pilot pressure at port (SH), the brake springs (T17) force on brake piston (T16) squeeze the separation and friction plates together to prevent the upper structure from swinging.
Page 72: Group 4 Travel Device
GROUP 4 TRAVEL DEVICE (TYPE 1) GROUP 4 TRAVEL DEVICE (TYPE 1) 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Travel motor Reduction gear Supply port PT 3/8 FILL...
Page 73: Basic Structure
1) 1) BASIC STRUCTURE BASIC STRUCTURE Reduction gear Hydraulic motor Brake valve Parking brake High/low speed changeover mechanism Control valve Pump 5592TM02 2-39...
Page 74 2) 2) STRUCTURE STRUCTURE 37 39,40 30 31 56 57 23 22 20 19 18 17 10 9 16 64 1 5 59 82 83 52,53 87,88 48 50 51 41 42 46 45 43 44 32 33 24 34 27 35 25 14,13,12,11 63 15 62 61 65 3 67 68 66...
Page 75 2. PRINCIPLE OF DRIVING 2. PRINCIPLE OF DRIVING GENERATING THE TURNING FORCE GENERATING THE TURNING FORCE The high hydraulic supplied from a hydraulic pump flows into a cylinder (11) through valve casing of motor (26), and valve plate (56). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston (18).
Page 76 2) 2) WORKING OF RELIEF VALVE WORKING OF RELIEF VALVE Relief valve carries on two functions of followings. It standardizes a pressure in case of driving a hydraulic motor ; bypasses and extra oil in a motor inlet related to acceleration of an inertia to an outlet. In case of an inertia stopped, it forces an equipment stopped, according to generating the pressure of a brake on the projected side.
Page 77 3) 3) WORKING OF BRAKE WORKING OF BRAKE Brake operates the pressure supplied through SPOOL (simultaneous peripheral operation online) installed in valve casing (26) to the part of parking piston (21) and releases a brake. When the pressure does not work, the brake always runs. The force of a brake is generated by the frictional force among a plate (20), brake piston (21) and a cylinder block (11) that is connected through spline which are fixed by shaft casing (1) with friction plate (19).
Page 78: Counterbalance Valve
4) 4) COUNTERBALANCE VALVE COUNTERBALANCE VALVE Av port is connected into a hydraulic pump and Bv port is into a tank. Hydraulic pump supplying oil is come into Av → Cv room. In accordance with spring force (43) that is working on the spool's side it moves to the spool (41) on the right side which is medium position and that time motor is turning.
Page 79 4) 4) HIGH/LOW SPEED CHANGEOVER MECHANISM HIGH/LOW SPEED CHANGEOVER MECHANISM (1) (1) At low speed-at pilot pressure of less than 10 At low speed-at pilot pressure of less than 10 kgf/cm kgf/cm (0.98 (0.98 Mpa Mpa) Holder flange Spring Case of motor 5592TM05 When no pilot pressure is supplied from port (A) at a pressure of 10 kgf/cm (0.98 Mpa) or less,...
Page 80: Reduction Gear
2. REDUCTION GEAR 2. REDUCTION GEAR FUNCTION FUNCTION The reduction gear unit consists of a combination of simple planetaly gear mechanism. This mechanism reduce the high speed rotation from the hydraulic motor and convert it into low speed, high torque to rotate the hub (or case), which in turn rotates the sprocket. 2) 2) OPERATING PRINCIPLE OPERATING PRINCIPLE...
Page 81 TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #2118-) TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #2118-) 1. CONSTRUCTION 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Travel motor Reduction gear Supply port PF 1/2...
Page 82 2) 2) STRUCTURE STRUCTURE 307 301 305 406 303 106 119 109 618 112 113 617 622 115 410 625 611 605 615 HX60A2TM51 124,123135 136 432 503 433 302 405 404 202 107 101 105 102 626 111 626 405 409 401 114 511 601 118 Friction plate...
Page 83: Major Component
2) 2) MAJOR COMPONENT MAJOR COMPONENT This product is only composed of hydraulic motor. Reduction parts are not composed. This hydraulic motor is variable swash plate axial piston motor. It is composed of 4 parts. - Rotary part which makes rotatory power - Traveling brake valve part - Parking brake part - Switching the tilting angle part (auto 1/2 speed control part)
Page 84 3) 3) BASIC STRUCTURE BASIC STRUCTURE Rotary part Relief valve part Counterbalance valve part Check valve part Parking brake part Switching the tilting angle part 559A2TM53 2-46-4...
Page 85 2. WORKING PRINCIPLE 2. WORKING PRINCIPLE HYDRAULIC MOTOR SECTION HYDRAULIC MOTOR SECTION When high pressure oil passes from pump through the inlet port of the valve plate(108) and flows into the cylinder (104) as shown in figure, the oil pressure acts upon the piston (101) to generate the axial force "F".
Page 86 2) 2) TRAVELING BRAKE VALVE TRAVELING BRAKE VALVE Traveling brake valve is composed of relief valve, counterbalance valve and check port A is connected with hydraulic pump and port B is connected with tank. (1) (1) In case of traveling In case of traveling When the compressed oil, which is supplied along the inlet port, exceeds certain pressure, it pushes cap (509).
Page 87 (2) (2) In case of stop In case of stop If the pressure supplied along the port to the inlet breaks while traveling, the pressure applied to the section of the main spool (501) is removed. Therefore, the main spool (501), which was pushed to the right, returns to neutral due to the spring elasticity force of the main spool spring (505).
Page 88 (2) (2) In case of stop In case of stop If the pressure supplied along the port to the inlet breaks while traveling, the pressure applied to the section of the main spool (501) is removed. Therefore, the main spool (501), which was pushed to the right, returns to neutral due to the spring elasticity force of the main spool spring (505).
Page 89 (3) (3) In case of overrun In case of overrun Overrun is when the excavator's speed is increased by the it's gravity (inertia), such as when an excavator is going downhill, causing the hydraulic motor to rotate above the supply flow of the hydraulic pump.
Page 90: Parking Brake
3) 3) PARKING BRAKE PARKING BRAKE The parking brake is wet-type multiple disk brakes. It is a negative brake system which is released when the brake release pressure enters the brake piston chamber. The internal structure of parking brake is shown in figure. Friction plate (118) and separator plate (119) are alternately stacked, and acting on springs to produce brake torque with friction forces.
Page 91 (2) (2) In case of stop In case of stop If the pressurized oil supplied by the inlet is cut off during stop, the pressurized oil supplied to the brake piston chamber (c) will also be blocked. (below brake release pressure) If the spring elasticity force F3 of the brake spring (117) is greater than the hydraulic force F4 of the brake piston chamber (c), then brake piston (114) move to casing by spring elasticity force.
Page 92 1/2 SPEED SWITCHING OPERATION (AUTOMATIC 1/2 SPEED CONTROL PART) 1/2 SPEED SWITCHING OPERATION (AUTOMATIC 1/2 SPEED CONTROL PART) (1) (1) Low speed traveling Low speed traveling If pilot pressure is not supplied on pilot port (port S), 2 speed spool (502) is pushed in the direction of the port S by spring elasticity of 2 speed spool spring (506).
Page 93 (2) (2) High speed traveling High speed traveling If the pilot pressure (20~50 kgf/cm ) is supplied to the port (port S), the pilot pressure overcomes the oil pressure in the main port and the spring elasticity force of the 2 speed spool spring (506). and it pushes the 2 speed spool (502) to the 2 speed plug (308) direction.
Page 94 (3) (3) Automatic 1/2 speed control part Automatic 1/2 speed control part If the load is increased during the 2-speed driving, the hydraulic pressure on the main port is increased. The pressure (△P) of main port and spring elasticity force of 2 speed spool spring (506) will overcome the pressure of pilot, 2 speed spool (502) is pushed in port S direction.
Page 95 REDUCTION GEAR REDUCTION GEAR 559A2TM63 Refer to the section drawing for the basic construction. The reduction gear consists of two stage planetary gears. The reduction ratio is determined by the number of teeth of the gear, and the reduction ratio is 42.439.
Page 96: Group 5 Rcv Lever
GROUP 5 RCV LEVER GROUP 5 RCV LEVER 1. STRUCTURE 1. STRUCTURE The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face. Switches One touch decel Horn Breaker...
Page 97: Cross Section
CROSS SECTION CROSS SECTION The construction of the pilot valve is shown in the attached cross section drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool (4), spring (6) for setting secondary pres- sure, return spring (10), stopper (8), spring seat (7, 13) and shim (5).
Page 98 CROSS SECTION CROSS SECTION Port 1,3 Port 2,4 21092RL02 Case Stopper 15 O-ring 22 Lock nut Plug Push rod 16 Rod seal 23 Handle assembly Bushing 10 Spring 17 Plate 24 Handle bar Spool 11 Push rod 18 Boot 25 Nut Shim 12 Spring 19 Joint assembly...
Page 99 2. FUNCTIONS 2. FUNCTIONS FUNDAMENTAL FUNCTIONS FUNDAMENTAL FUNCTIONS 1) 1) The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and apply- ing the output pressure (secondary pressure) of the pilot valve to the other end.
Page 100: Operation
3) 3) OPERATION OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 2-70 Pilot valve Main pump...
Page 101 Case where handle is in neutral position Case where handle is in neutral position 21092RL03 The force of the spring (6) that determines the output pressure of the pilot valve is not applied to the spool (4). Therefore, the spool is pushed up by the spring (10) to the position of port (1, 3) in the operation explanation drawing.
Page 102 Case where handle is tilted Case where handle is tilted 21092RL04 When the push rod (11) is stroked, the spool (4) moves downwards. Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port (1) to generate the pressure.
Page 103: Section 3 Hydraulic System
SECTION 3 HYDRAULIC SYSTEM SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit ---------------------------------------------------------------------------------------------- 3-1 Group 2 Main Circuit ----------------------------------------------------------------------------------------------------- 3-2 Group 3 Pilot Circuit ------------------------------------------------------------------------------------------------------ 3-5 Group 4 Single Operation --------------------------------------------------------------------------------------------- 3-10 Group 5 Combined Operation -------------------------------------------------------------------------------------- 3-22...
Page 104: Group 1 Hydraulic Circuit
SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT (1/3) GROUP 1 HYDRAULIC CIRCUIT (1/3) (BREAKER) ,P3) (TANK "4") [cw] [ccw] ,T2) (FW)P2 P1(BW) (FW)P1 P2(BW) [LH-BW] [RH-BW] [Bucket IN] [Boom Down] ,b6) [BREAKER] [DOZER UP] [SWING CW] ,b11) ,Pi) ,T2) ,A3) [B/SWING R] [ARM IN]...
Page 105 HYDRAULIC CIRCUIT (2/3) HYDRAULIC CIRCUIT (2/3) DOUBLE ACTING PIPING ROTATING WITH PROPORTIONAL (ENGINE PTO PUMP) PATTERN CHANGE (LH LOCK) (RH LOCK) (ROTATOR) ARM OUT BOOM DOWN BOOM DOWN ARM OUT J1 J2 J3 J4 J1-M1 J2-M2 J1-M2 J2-M1 (2WAY) M1M2 M3 M4 <MCV SPOOL ARRANGEMENTS>...
Page 106 HYDRAULIC CIRCUIT (3/3) HYDRAULIC CIRCUIT (3/3) ANGLE DOZER BLADE Proportional valve Gear pump Angle dozer cylinder Turning joint Dozer lever [CW] Dozer RCV [CCW] G.P1 G.P2 <DOZER RCV LEVER> LH RH (ANGLE DOZER (ANGLE DOZER CCW) LH-RCV LEVER (MODULATION) (30, C1) (30, D1) ( 33, F) OUTLET DOWN...
Page 107: Group 2 Main Circuit
GROUP 2 MAIN CIRCUIT GROUP 2 MAIN CIRCUIT The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit. The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders and two travel motors. The swash plate type variable displacement axial piston pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
Page 108 2. RETURN CIRCUIT 2. RETURN CIRCUIT Full flow filter Oil cooler Check valve (2) 1.5 kgf/cm Main control valve Actuators Check valve (1) 3.0 kgf/cm Bypass relief valve 1.5 kgf/cm 3-03 (140-7 TIER) All oil returned from each actuator returns to the hydraulic tank through the control valve. The bypass check valves are provided in the return circuit.
Page 109: Drain Circuit
3. DRAIN CIRCUIT 3. DRAIN CIRCUIT Travel motor Swing motor Return line Turning joint Return filter Hydraulic oil tank R5573CI02 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. TRAVEL MOTOR DRAIN CIRCUIT TRAVEL MOTOR DRAIN CIRCUIT Oil leaked from the right and left travel motors comes out of the drain ports provided in the respective motor casing and join with each other.
Page 110: Group 3 Pilot Circuit
GROUP 3 PILOT CIRCUIT GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve Dozer lever (RH lever) (LH lever) Safety lock Swing parking brake solenoid valve Control valve Travel speed solenoid valve Breaker solenoid valve Boom solenoid valve Line filter Relief valve 30kgf/cm Pilot pump...
Page 111 1. SUCTION, DELIVERY AND RETURN CIRCUIT 1. SUCTION, DELIVERY AND RETURN CIRCUIT T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A1 B1 Gauge Pp(MCV)
Page 112: Safety Valve
2. SAFETY VALVE 2. SAFETY VALVE (SAFETY LEVER) T/MOTOR,RH T/MOTOR,LH BOOM SWING BOOM DOZER BUCKET (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV) BOOM...
Page 113 3. TRAVEL SPEED CONTROL SYSTEM 3. TRAVEL SPEED CONTROL SYSTEM T/MOTOR,LH T/MOTOR,RH BOOM SWING BUCKET BOOM DOZER (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
Page 114 4. SWING PARKING BRAKE RELEASE 4. SWING PARKING BRAKE RELEASE T/MOTOR,LH T/MOTOR,RH BOOM SWING BOOM DOZER BUCKET (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
Page 115: Group 4 Single Operation
GROUP 4 SINGLE OPERATION GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION 1. BOOM UP OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P2 P1(BW) (FW)P1 P2(BW) Dr(Swing motor) xb9 A9 A5 B4...
Page 116 2. BOOM DOWN OPERATION 2. BOOM DOWN OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING BUCKET BOOM DOZER (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV) BOOM...
Page 117 3. ARM ROLL IN OPERATION 3. ARM ROLL IN OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
Page 118 4. ARM ROLL OUT OPERATION 4. ARM ROLL OUT OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P2 P1(BW) (FW)P1 P2(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
Page 119 5. BUCKET ROLL IN OPERATION 5. BUCKET ROLL IN OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P2 P1(BW) (FW)P1 P2(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
Page 120 6. BUCKET ROLL OUT OPERATION 6. BUCKET ROLL OUT OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P2 P1(BW) (FW)P1 P2(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV)
Page 121: Swing Operation
7. SWING OPERATION 7. SWING OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P2 P1(BW) (FW)P1 P2(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV) BOOM SWING D/BLADE...
Page 122 SWING CIRCUIT OPERATION SWING CIRCUIT OPERATION PARKING BRAKE SWING MOTOR BRAKE RELEASE VALVE BRAKE OFF BRAKE ON B(CW) A(CCW) MOTOR BRAKE VALVE MAKE UP VALVE TO/FROM MAIN CONTROL VALVE 559A3HC40 1) 1) MOTOR BRAKE VALVE MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation.
Page 123 8. TRAVEL FORWARD AND RE 8. TRAVEL FORWARD AND REVERSE O VERSE OPERATION PERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1...
Page 124 TRAVEL CIRCUIT OPERATION TRAVEL CIRCUIT OPERATION Travel motor (FW)P1 P2(BW) (FW)P2 P1(BW) Counter balance valve Overload relief valve Turning joint Main control valve 60CR9A3HC15 Valves are provided on travel motors to offer the following functions. 1) 1) COUNTER BALANCE VALVE COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run.
Page 125 9. DOZER UP OPERATION 9. DOZER UP OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV) BOOM...
Page 126 10. DOZER DOWN OPERATION 10. DOZER DOWN OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge Pp(MCV) BOOM...
Page 127: Group 5 Combined Operation
GROUP 5 COMBINED OPERATION GROUP 5 COMBINED OPERATION 1. OUTLINE 1. OUTLINE T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 128 2. COMBINED SWING AND BOOM OPERATION 2. COMBINED SWING AND BOOM OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 129 3. COMBINED SWING AND ARM OPERATION 3. COMBINED SWING AND ARM OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 130 4. COMBINED SWING AND BUCKET OPERATION 4. COMBINED SWING AND BUCKET OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 131 5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION 5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING BUCKET BOOM DOZER (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4...
Page 132 6. COMBINED SWING AND TRAVEL OPERATION 6. COMBINED SWING AND TRAVEL OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 133 7. COMBINED BOOM AND TRAVEL OPERATION 7. COMBINED BOOM AND TRAVEL OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 134 8. COMBINED ARM AND TRAVEL OPERATION 8. COMBINED ARM AND TRAVEL OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 135 9. COMBINED BUCKET AND TRAVEL OPERATION 9. COMBINED BUCKET AND TRAVEL OPERATION T/MOTOR,LH T/MOTOR,RH BOOM SWING DOZER BUCKET BOOM (2-WAY) CYLINDER SWING MOTOR BREAKER CYLINDER CYLINDER CYLINDER CYLINDER QUICK COUPLER (CW) (CCW) (FW)P1 P2(BW) (FW)P2 P1(BW) Dr(Swing motor) xb9 A9 A5 B4 A1 B1 Gauge...
Page 136: Section 4 Electrical System
SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location -------------------------------------------------------------------------------------- 4-1 Group 2 Monitoring system ------------------------------------------------------------------------------------------ 4-3 Group 3 Electrical Circuit ---------------------------------------------------------------------------------------------- 4-59 Group 4 Electrical Component Specification -------------------------------------------------------------- 4-75 Group 5 Connectors ------------------------------------------------------------------------------------------------------ 4-82 Group 6 Fault codes ------------------------------------------------------------------------------------------------------ 4-100...
Page 137: Group 1 Component Location
SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 Switch panel 2 Switch panel 1 60CR9A4EL03 Illumination switch Accel dial switch 17 Horn switch 18 Radio & USB player Work light switch 10 Quick clamp switch Travel alarm switch...
Page 138 2. LOCATION 2 2. LOCATION 2 60CR9A4EL031 Water temp sender Back buzzer Washer tank assy Fuel filler pump Battery Power relay Battery relay Engine control unit Horn...
Page 139: Group 2 Monitoring System
GROUP 2 MONITORING SYSTEM GROUP 2 MONITORING SYSTEM (machine serial No.: ~#1865) (machine serial No.: ~#1865) 1. OUTLINE 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine.
Page 140 2) 2) GAUGE GAUGE (1) (1) Operation screen Operation screen When you first turn starting switch ON, the operation screen will appear. Default (A type) Option (B type) Option (C type) 559A3CD07A 559A3CD07B 559A3CD07C Engine coolant temp gauge Fuel level gauge Accel dial Hydraulic oil temp gauge Engine rpm...
Page 141 (4) (4) Fuel level gauge Fuel level gauge ① This gauge indicates the amount of fuel in the fuel tank. ② Fill the fuel when the red range, or lamp lights ON in red. ※ If the gauge indicates the red range or If the gauge indicates the red range or lamp lights ON in lamp lights ON in...
Page 142: Warning Lamps
WARNING LAMPS WARNING LAMPS 4) 4) HEST warning lamp DPF regeneration acknowledge warning lamp DPF regeneration inhibit warning lamp Battery charging warning lamp Emergency warning lamp PF warning lamp (-#1279) (#1280-) DPF warning lamp Overload warning lamp Air cleaner warning lamp Engine stop warning lamp Check engine warning lamp Engine oil pressure warning lamp...
Page 143 (4) (4) Emergency warning lamp Emergency warning lamp ① This lamp pops up and the buzzer sounds when each of the below warnings are happened. Engine coolant overheating (over 115˚C) Hydraulic oil overheating (over 105˚C) MCU input voltage abnormal Accel dial circuit abnormal or open 21093CD30 ※...
Page 144 Engine power may be reduced automatically (soot medium) Soot midium Blink · Engine power and speed will be reduced Soot high automatically · Initiate a manual regeneration · Stop the engine immediatary. Stop · Please contact your Hyundai service center or local dealer.
Page 145 DPF systems. diagsis DPF systems. ※ Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer.
Page 146 If the lamp lights ON, stop the engine immediately and check the engine. ② Check the fault codes on the monitor. STOP ※ Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer. 4-10...
Page 147: Pilot Lamps
PILOT LAMPS PILOT LAMPS 5) 5) Preheat pilot lamp Maintenance pilot lamp (#1280-) Power mode pilot lamp Travel speed pilot lamp (#1280-) Auto idle mode pilot lamp Warming up pilot lamp Auto idle status pilot lamp 559A3CD02E ※ When the pilot lamps light ON more than 3, you can check all lamps with next page button When the pilot lamps light ON more than 3, you can check all lamps with next page button Mode pilot lamps Mode pilot lamps...
Page 148 (4) (4) Auto idle status/ mode pilot lamp Auto idle status/ mode pilot lamp ① The auto idle pilot lamp will be ON when the idle mode is selected. ② The auto idle status pilot lamp will be ON when all levers and AUTO pedals are at neutral position, and the auto idle mode is n/min...
Page 149 6) 6) SWITCHES SWITCHES Main menu quick touch switch Power mode pilot lamp Travel speed pilot lamp Auto idle pilot lamp Escape(previous or parent menu) Power mode switch Rear camera(option) Travel speed switch Auto idle/Buzzer stop switch Select switch 559A3CD47 ※...
Page 150 (3) (3) Auto idle/ buzzer stop switch Auto idle/ buzzer stop switch ① This switch is used to activate or cancel the auto idle function. ※ Refer to the page 4-12 for details. Refer to the page 4-12 for details. ②...
Page 151 7) 7) MAIN MENU MAIN MENU · Operation screen Operation screen 559A3CD32A Main menu screen Main menu screen Sub menu screen Sub menu screen Press Press 559A3CD32B 559A3CD32D 559A3CD32E 559A3CD32C ※ Please refer to select switch, page 4-13 for selection and change of menu and input value. Please refer to select switch, page 4-13 for selection and change of menu and input value.
Page 152 (2) (2) Monitoring Monitoring ① Active fault - Machine Active fault - Machine 559A3CD50 559A3CD50A · The active faults of the MCU can be checked by this menu. ② Active fault - Engine Active fault - Engine 559A3CD50B 559A3CD50C · The active faults of engine ECU can be checked by this menu.
Page 153 ⑤ Monitoring Monitoring (Digital) - Input Input 559A3CD53 559A3CD53A · The switch status can be conﬁ rmed by this menu. · The activated switchs are blue light ON. ⑥ Monitoring Monitoring (Digital) - Output Output 559A3CD54 559A3CD54A · The output status can be conﬁ rmed by this menu. ·...
Page 154 (3) (3) Management Management ① ESL mode setting ESL mode setting 559A3CD55 559A3CD55A 559A3CD55B · ESL mode setting ESL mode setting ESL : Engine Starting Limit ESL mode is desingned to be a theft deterrent or will prevent the unauthorized operation of the machine.
Page 155 ③ Maintenance information Maintenance information 559A3CD57 559A3CD57A 559A3CD57B · Elapse : Maintenance elapsed time. · Interval : The change or replace interval can be changed in the unit of 50 hours. · History-Hour : Maintenance replacement history. · Replacement : The elapsed time will be reset to zero (0). ·...
Page 156 ⑤ A/S phone number A/S phone number 559A3CD59 559A3CD59A 559A3CD59B · The A/S phone number can be checked and changed. ⑥ Service menu Service menu 559A3CD60 Enter the password 559A3CD60A 559A3CD60B · Delete logged fault : Logged faults of MCU or engine ECU can be deleted. ·...
Page 157 ② Screen type Screen type 559A3CD62 559A3CD62A · The screen type (A,B,C) of the LCD can be selected by this menu. ③ Brightness setting calibration Brightness setting calibration 559A3CD63 559A3CD63A Manual (1st~10th step) 559A3CD63B 559A3CD63C Auto (day/night) Auto (time) · If "Auto"...
Page 158 ⑤ Language Language 559A3CD65 559A3CD65A · User can select preferable language and all displays are changed the selected language. ⑥ Calibration Calibration · When touch awareness goes wrong, this function use. Fall in the next step if touches the middle point of cross with ﬁ ngernail. If touches total ﬁ...
Page 159 (5) (5) Utilities Utilities ① Camera setting Camera setting · Three cameras can be installed on the machine and the display order can be set by this menu. · If the camera was not equipped, this menu is not useful. 559A3CD67 559A3CD67A ·...
Page 160 ③ Video Video · Play MP4 or codec ﬁ le of external hard disk through USB port. · The USB port is located under the cluster. 559A3CD70 559A3CD70A Touch Press 559A3CD70C 559A3CD70B · Over 1100 engine rpm, the screen turns into the operation screen with MP4 or codec ﬁ le playing for the safety.
Page 161: Monitoring System
MONITORING SYSTEM MONITORING SYSTEM (machine serial No.: #1866~) (machine serial No.: #1866~) STRUCTURE STRUCTURE 1) 1) The cluster consists of LCD and switches as shown below. The LCD is to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. Also, The LCD is to set and display for modes, monitoring and utilities with the switches.
Page 162 GAUGE GAUGE 2) 2) (1) (1) Operation screen Operation screen When you first turn starting switch ON, the operation screen will appear. HX60A3CD101A Engine coolant temp gauge Fuel level gauge Accel dial Hydraulic oil temp gauge Engine rpm Clinometer ※ Operation screen type can be set by the screen type menu of the display.
Page 163 (4) (4) Fuel level gauge Fuel level gauge ① This gauge indicates the amount of fuel in the fuel tank. ② Fill the fuel when the red range, or lamp lights ON in red. ※ If the gauge indicates the red range or If the gauge indicates the red range or lamp lights ON in lamp lights ON in...
Page 164 4) 4) WARNING LAMPS WARNING LAMPS Battery charging Emergency warning lamp Emission system fail warning lamp warning lamp Air cleaner warning lamp Check engine Overload warning lamp warning lamp Engine coolant temp warning lamp Engine oil pressure warning lamp DPF regeneration inhibit warning lamp Engine stop DPF regeneration acknowledge warning lamp...
Page 165 (4) (4) Emergency warning lamp Emergency warning lamp ① This lamp pops up and the buzzer sounds when each of the below warnings are happened. Engine coolant overheating (over 115˚C) Hydraulic oil overheating (over 105˚C) MCU input voltage abnormal 290F3CD64 Accel dial circuit abnormal or open ※...
Page 166 Engine power may be reduced automatically (soot medium) Soot midium Blink · Engine power and speed will be reduced Soot high automatically · Initiate a manual regeneration · Stop the engine immediatary. Stop · Please contact your Hyundai service center or local dealer. 4-30...
Page 167 ※ Manual regeneration method of DPF Manual regeneration method of DPF ※ Manual regeneration applies if the machine is in a fireproof Manual regeneration applies if the machine is in a fireproof Safety button area and there is no plan to turn off the maching during the area and there is no plan to turn off the maching during the regeneration.
Page 168 DPF systems. diagsis DPF systems. ※ Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer. (13) (13) DPF regeneration inhibit warning lamp DPF regeneration inhibit warning lamp ①...
Page 169 PILOT LAMPS PILOT LAMPS 5) 5) Maintenance pilot lamp Engine preheat pilot lamp Power mode pilot lamp Auto idle mode pilot lamp Fuel warmer pilot lamp Travel speed pilot lamp Optional flow control pilot lamp Auto idle status pilot lamp HX60A3CD112C and ▶) are activated when nine indicator or more ※...
Page 170 (3) (3) Warming up pilot lamp Warming up pilot lamp ① This lamp is turned ON when the coolant temperature is below 30˚C (86˚F ). ② The automatic warming up is cancelled when the engine coolant temperature is above 30˚C, or when 10 minutes have passed since starting the engine.
Page 171 (6) (6) Fuel warmer pilot lamp Fuel warmer pilot lamp ① This lamp is turned ON when the coolant temperature is below 10˚C (50˚F ) or the hydraulic oil temperature 20˚C ( 68˚F ). ② The automatic fuel warming is cancelled when the engine coolant temperature is above 60˚C, and the hydraulic oil temperature is above 45˚C since the start switch was ON HX60A3CD111...
Page 172 6) 6) SWITCHES SWITCHES Power mode switch Escape switch Travel speed switch Camera switch Auto idle switch Buzzer stop switch Select switch HX60A3CD117D ※ Selecting the switch displays the indicator on LCD. See Page 4-34 for further information. Selecting the switch displays the indicator on LCD. See Page 4-34 for further information. Power mode switch Power mode switch ①...
Page 173 Auto idle switch Auto idle switch ① This switch is used for operating or canceling the auto idle function. ※ See Page 4-34 for further information. See Page 4-34 for further information. HX60A3CD120 Buzzer stop switch Buzzer stop switch ① The buzzer sounds when the system fails.
Page 174 7) 7) MAIN MENU MAIN MENU Main menu screen Main menu screen Sub menu screen Sub menu screen or or Press Press Press Press HX60A3CD124A HX60A3CD125A ※ See “Selection Switch” on page 4-36 for further information on selection and change of the menus See “Selection Switch”...
Page 175 Monitoring Monitoring ① Active fault - system Active fault - system HX60A3CD130A HX60A3CD131A · You may use this menu to check active fault of MCU. ② Active fault - engine Active fault - engine HX60A3CD130A HX60A3CD133A · You may use this menu to check active fault of engine ECM. ③...
Page 176 ④ Delete logged fault Delete logged fault HX60A3CD143A HX60A3CD144A HX60A3CD145A HX60A3CD146A HX60A3CD147A · Delete logged fault: You are allowed to delete fault logged on system MCU or engine ECM. (Deletion can be deleted only while the engine is kept stopped.) ⑤...
Page 177 ⑦ Monitoring (output conditions) Monitoring (output conditions) HX60A3CD137A HX60A3CD142A · You may use this menu to check digital output information of the system. · Output lights blue. 4-41...
Page 178 Management Management ① Maintenance info. Maintenance info. HX60A3CD158A HX60A3CD157A HX60A3CD159A · Elapsed: Time elapsed since inspection and maintenance is displayed. · Change interval: You are allowed of changing exchange cycle in 50 hours. · History-Hourmeter: History of inspection, maintenance and exchange is displayed. ·...
Page 179 Proportional ﬂ ow control setting Proportional ﬂ ow control setting You may use this menu to set the values of individual option attachments. Rotary setup Rotary setup ·Rotary selecting RCV, button, and ﬂ ow setup. HW60A3CD42O HW60A3CD51OA ·RCV setup - It is possible to set operating RCV for rotary operation to LH or RH .
Page 180 Grapple setting Grapple setting ·Grapple selection RCV, button and flow setup HW60A3CD42O HW60A3CD61OA ·RCV setup - It is possible to set RCV for grapple operation to LH or RH. - Selecting grapple RCV to RH au- tomatically sets rotary RCV to LH. HW60A3CD62OA ·Button setup (Close)
Page 181 c) Checking settings c) Checking settings HX60A3CD81OA HW60A3CD71OA ※ Operating optional attachment function activates the symbol Operating optional attachment function activates the symbol on the bottom of the main screen. on the bottom of the main screen. ※ You are allowed of checking settings as follows in the course of Menu - Administrator Functions - You are allowed of checking settings as follows in the course of Menu - Administrator Functions - Optional Attachment.
Page 182 ④ Changing password Changing password The length of the password is between 5 and 10 digits. HX60A3CD151A HX60A3CD153A HX60A3CD149A Selecting Change Password Entering current password HX60A3CD156A HX60A3CD155A HX60A3CD149A Storing new password in MCU Entering new password again Entering new password ⑤...
Page 183 ⑦ Cluster update Cluster update HX60A3CD169A HX60A3CD170A HX60A3CD149A Selecting Cluster Update Entering user’s password · It is possible to update the cluster and CAN. ※ Do not turn power off while updating. Do not turn power off while updating. a. a. Application update Application update HX60A3CD172A...
Page 184 System update System update HX60A3CD177A HX60A3CD174A HX60A3CD173A Selecting OK Selecting system items Selecting ﬁ les to update HX60A3CD176 HX60A3CD175A Completed In progress 4-48...
Page 185 ⑧ Service menu Service menu HX60A3CD165A HX60A3CD144A HX60A3CD168A Entering service password · Power shift : Set the power shift mode (default/option). · Operating hours : You may check operating hours of the system in individual modes after acceptance of the system. ·...
Page 186 Display Display ① Clock adjust Clock adjust HX60A3CD191A HX60A3CD192A · "****-**-**” on the ﬁ rst line indicates year/month/day. · The second line indicates current time (00:00 - 12:59 am/pm) ② Brightness setting Brightness setting HX60A3CD193A HX60A3CD194A HX60A3CD195A Manual (Level 1 to 10) HX60A3CD197A HX60A3CD196A Auto (day/night)
Page 187 ③ Unit setting Unit setting HX60A3CD198A HX60A3CD199A Metric: Units are changed to metric units. U.S. units: Units are changed to U.S. units. User setting : Units are changed to user setting. Item Metric system U.S. unit User’s setup Temperature ˚ ˚...
Page 188 Utilities Utilities ① Entertainment Entertainment HX60A3CD70A HX60A3CD208A HX60A3CD209A · You may play MP4 or CODEC ﬁ les of detachable hard disk through USB port. · USB port is on the left of the instrument panel. · When engine rotation rate exceeds 1100 rpm or higher, the screen is switched to the operation screen even while MP4 or CODEC ﬁ...
Page 189 ③ Clinometer setting Clinometer setting HX60A3CD210A HX60A3CD211A · Pressing “Default” when the system is kept on ﬂ at surface resets X and Y values to zero. · You may check gradient of the system on the operating screen of the instrument panel. ④...
Page 190: Starting Switch
3. SWITCHES 3. SWITCHES Quick clamp switch(opt) Wiper switch Illumination switch Washer switch Boom offset switch(-#0014) Work light switch DPF switch Travel alarm switch Overload switch(opt) Cab light switch Beacon switch(opt) Breaker selection switch(opt) Start switch Switch panel 2 Switch panel 1 Breaker operation switch Accel dial switch...
Page 191: Work Light
2) 2) ACCEL DIAL ACCEL DIAL There are 10 dial setting. Setting 1 is low idle and setting 10 is high idle. Increase ·By rotating the accel dial to right : Engine speed increased. ·By rotating the accel dial to left : Engine speed decreased. Decrease 235Z93CD46A 3) 3)
Page 192: Beacon Switch
7) 7) BEACON SWITCH BEACON SWITCH (option) This switch turns ON the rotary light on the cab. The below indicator lamp is turned ON when operating this switch. 555C93CD30 8) 8) BREAKER SELECTION SWITCH BREAKER SELECTION SWITCH (option) This switch is used to operate breaker. ※...
Page 193: Master Switch
BOOM OFFSET SWITCH ( BOOM OFFSET SWITCH (machine serial NO:-#0014 machine serial NO:-#0014) This switch is used to swing the boom to the right or left direction. The indicator lamp turned ON when selected this switch. ※ Refer to the Refer to the operator's manual operator's manual page 4-7 for the operation.
Page 194 DPF (diesel particulate filter) SWITCH SWITCH This switch is used to select the regeneration function of the DPF. Safety button (2) (2) Inhibit position Inhibit position (①) ① The inhibit position disallows any automatic or manual regeneration of the DPF. ②...
Page 195: Group 3 Electrical Circuit
GROUP 3 ELECTRICAL CIRCUIT GROUP 3 ELECTRICAL CIRCUIT ·ELECTRICAL CIRCUIT (1/3) ELECTRICAL CIRCUIT (1/3) - MACHINE SERIAL NO. : -#2023 - MACHINE SERIAL NO. : -#2023 21ML-41301 HARNESS EXT. EPPR (2WAY) CONSOLE BOX LH,RH RCV-RH CIGAR LIGHTER CIGAR LIGHTER SAFETY SW FUSIBLE LINK BOOM ACCEL DIAL...
Page 196 - MACHINE SERIAL NO. : #2024-#2076 - MACHINE SERIAL NO. : #2024-#2076 (OPTION) CONSOLE BOX LH,RH BREAKER CIGAR LIGHTER RETURN SOL FUSIBLE LINK TO EPPR SAFETY SW BOOM ACCEL DIAL HARNESS BREAKER HORN SWING CR-1 BATTERY G 0.8B 42 0.8Br TO:STARTER "B"...
Page 197 - MACHINE SERIAL NO. : #2077- - MACHINE SERIAL NO. : #2077- CONSOLE BOX LH,RH CIGAR LIGHTER SAFETY SW (OPTION) BOOM Q/C DISENGAGEMENT ACCEL DIAL BREAKER HORN SWING BREAKER RETURN SOL FUSIBLE LINK TO EPPR HARNESS CR-1 BATTERY G 0.8B 42 0.8Br TO:STARTER "B"...
Page 198 ·ELECTRICAL CIRCUIT (2/3) ELECTRICAL CIRCUIT (2/3) - MACHINE SERIAL NO. : -#2023 - MACHINE SERIAL NO. : -#2023 CABIN LAMP CAMERA BEACON ROOM LH,RH LAMP LAMP Àü¿ø START SW BOOM SWING SW BOOM SWING RY. BR ACC ST C WIPER SW WASHER SW WIPER MOTOR OVERLOAD SW...
Page 199 - MACHINE SERIAL NO. : #2024-#2076 - MACHINE SERIAL NO. : #2024-#2076 CABIN LAMP CAMERA BEACON ROOM LH,RH LAMP LAMP Àü¿ø BOOM SWING SW START SW BOOM SWING RY. BR ACC ST C WASHER SW WIPER SW OVERLOAD SW WIPER MOTOR WIPER RY MASTER SW INT.WIPER RY...
Page 200 - MACHINE SERIAL NO. : #2077- - MACHINE SERIAL NO. : #2077- CABIN LAMP CAMERA BEACON ROOM LH,RH LAMP LAMP Àü¿ø BOOM SWING SW START SW BOOM SWING RY. BR ACC ST C WASHER SW WIPER SW OVERLOAD SW WIPER MOTOR WIPER RY MASTER SW INT.WIPER RY...
Page 201 ·ELECTRICAL CIRCUIT (3/3) ELECTRICAL CIRCUIT (3/3) - MACHINE SERIAL NO. : -#2023 - MACHINE SERIAL NO. : -#2023 CN-305(Gray) CN-306(Black) RCV RH RCV LH ANGLE DZ(RH) CN-305(Gray) CN-306(Black) CN-241 CN-242 CN-240A HARNESS-EXT RCV RH RCV LH HARNESS-EXT SPARE BREAKER SPARE SPARE HORN PVG ON/OFF...
Page 202 - MACHINE SERIAL NO. : #2024- - MACHINE SERIAL NO. : #2024- CN-305(Gray) CN-306(Black) RCV RH RCV LH ANGLE DZ(RH) CN-305(Gray) CN-306(Black) CN-241 CN-242 CN-240A HARNESS-EXT RCV RH RCV LH HARNESS-EXT SPARE BREAKER SPARE SPARE HORN PVG ON/OFF CIGAR LIGHTER SPARE BREAKER SPARE SPARE HORN...
Page 203 MEMORANDUM MEMORANDUM 4-61...
Page 204: Power Circuit
1. POWER CIRCUIT 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW OPERATING FLOW Battery Battery relay (CR-1) Fusible link (CN-60)
Page 205 POWER CIRCUIT POWER CIRCUIT 1.2Y CR-80 1.25 EGR VALVE RY CR-45 ECU IG POWER RY CR-23 START RY CR-24 CN-3 CN-19 AIR HEATER RY CN-95 CIRCUIT BREAKER CS-74 MANUAL RESET CN-60 CN-31 MASTER SW RELAY (HI) CR-1 BATTERY BATT RY RELAY (M2) CN-6 BATTERY(+)
Page 206: Starting Circuit
2. STARTING CIRCUIT 2. STARTING CIRCUIT OPERATING FLOW OPERATING FLOW Battery (+) terminal Battery relay [CR-1] Fusible link [CN-60] I/conn [CN-3 (2)] Master switch [CS-74] Fuse box No.1 Start key [CS-2 (1)] ※ Start switch : ON Start switch ON [CS-2 (2)] ECU IG power relay [CR-45 (86)] I/conn [CN-5 (9)] Battery relay [CR-1]:Battery relay operating (all power is supplied with the electric component)
Page 207 STARTING CIRCUIT STARTING CIRCUIT BATTERY START ECU IG POWER RY AIR-HEATER RY MOTOR START SW START RY BR ACC ST C PRE-HEATER 0, I CN-5 CN-18 0.85Br 0.85Br CN-170 CN-4 SEAT HEATER 0.8Y 0.8Y CR-5 0.8Gr 0.8RW 0.8Y 0.8G CN-10 CN-14 ANTI-RESTART RY CR-36...
Page 208: Charging Circuit
3. CHARGING CIRCUIT 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the Battery relay (CR-1).
Page 209 CHARGING CIRCUIT CHARGING CIRCUIT BATTERY START ECU IG POWER RY AIR-HEATER RY MOTOR START SW START RY BR ACC ST C PRE-HEATER 0, I CN-5 CN-18 0.85Br 0.85Br CN-170 CN-4 SEAT HEATER 0.8Y 0.8Y CR-5 0.8Gr 0.8RW 0.8Y 0.8G CN-10 CN-14 ANTI-RESTART RY CR-36...
Page 210 4. ILLUMINATION AND WORK L 4. ILLUMINATION AND WORK LAMP AMP CIRCUIT CIRCUIT OPERATING FLOW OPERATING FLOW 1) 1) Fuse box (No.10) Illumination lamp relay [CR-13 (30), (86)] Fuse box (No.11) Work lamp relay [CR-3 (30), (86)] (1) (1) Illumination Illumination lamp switch ON lamp switch ON Illumination lamp relay [CR-13 (85) →...
Page 211 ILLUMINATION AND WORK LAMP CIRCUIT ILLUMINATION AND WORK LAMP CIRCUIT SWITCH PANEL 0.8L POWER IG 12V BREAKER CN-1 TRAVEL ALARM CABIN LIGHT OUT BEACON 0.8Y WORK LIGHT OUT CN-6 0.8W ILL LAMP OUT CN-116 CAMERA WORK LAMP RY 0.8Gr 0.8L 0.8Y 0.8W 0.8V...
Page 212 5. BEACON 5. BEACON LAMP AND CAB LAMP LAMP AND CAB LAMP CIRCUIT CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Fuse box (No.18) Beacon lamp relay [CR-85 (30), (86)] Fuse box (No.20) Cab lamp relay [CR-9 (30), (86)] (1) (1) Beacon lamp switch ON Beacon lamp switch ON Beacon lamp switch ON [CN-116 (6)]...
Page 213 BEACON LAMP AND CAB LAMP CIRCUIT BEACON LAMP AND CAB LAMP CIRCUIT CR-85 0.8L CL-7 CN-6 1.2Y 1.2Y 0.8V 0.8V 0.8GW 0.8B 0.8GW BEACON LAMP 1.2L 0.8W BEACON LAMP RY CL-9 1.2L 1.2B CR-9 0.8G CABIN LAMP 0.8W 0.8VW 1.2L 0.8VW 1.2B CABIN LAMP RY...
Page 214 6. WIPER AND WASHER CIRCUIT 6. WIPER AND WASHER CIRCUIT OPERATING FLOW OPERATING FLOW 1) 1) Key switch ON Key switch ON Fuse box (No.13) Wiper relay [CR-4 (86)] Int wiper relay [CR-6 (4)] Wiper switch [CS-3 (11)] Wiper motor [CN-21 (3)] I/conn [CN-5 (11)] I/conn [CN-14 (11)] Washer pump [CN-22 (2)]...
Page 215 WIPER AND WIPER AND WASHER CIRCUIT WASHER CIRCUIT CS-3 WIPER SW CR-6 CN-5 CN-14 0.85G INT. WIPER RY CR-4 CN-22 0.8RW WIPER RY WASHER P/P CN-21 Pf 1 WIPER MOTOR DO-1 CS-30 WASHER SW 60CR9A4EL10 4-72...
Page 216: Monitoring Circuit
MONITORING CIRCUIT MONITORING CIRCUIT CN-116 0.8L POWER IG 12V BREAKER CN-1 TRAVEL ALARM CABIN LIGHT OUT BEACON WORK LIGHT OUT CN-6 ILL LAMP OUT SWITCH PANEL CN-249 0.8Gr 0.8L 0.8W 0.8Br CAMERA CN-15 CN-259 1.2B MAIN_GND 1.2R POWER_IG 0.8ROr CAMERA_2 CAMERA_3 0.8Gr SHIELD...
Page 217 ELECTRIC CIRCUIT FOR HYDRAULIC ELECTRIC CIRCUIT FOR HYDRAULIC SAFETY SW BREAKER CS-50 CN-5 CN-14 CN-68 CN-116 HEAD LIGHT OUT SAFETY SOL WORK LIGHT PUT CN-13 BEACON CABIN LIGHT OUT CN-121 TRAVEL ARARM CN-15 BREAKER CN-1 POWER 12V(IG) CN-121 SWITCH PANEL BOOM SWING CN-4 CN-17...
Page 218: Group 4 Electrical Component Specification
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION GROUP 4 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specification Check ※ Check specific gravity 1.280 over : over charged 12V × 100Ah Battery 1.280 ~ 1.250 : normal 1.250 below : recharging ※ Check coil resistance Rated load : 12V Normal : about 12Ω...
Page 219 Part name Symbol Specification Check ※ Restriction limits Air cleaner 12-24V pressure switch Max. Load : 6W 6.2 kPa±8% at 23˚C CD-10 ※ Check resistance Full : 100Ω Fuel sender Low : 500Ω Empty warning :700Ω CD-2 ※ Check resistance Normal : about 200Ω...
Page 220 Part name Symbol Specification Check ※ Check contact Boom swing Normal 12V 16A OFF - ∞Ω (for terminal 1-5,2-6) Overload switch - 0Ω (for terminal 5-7,6-8) CS-47 CS-50 ※ Check contact Normal Quick clamp 12V 16A OFF - ∞Ω (for terminal 1-5,2-6) switch - 0Ω...
Page 221 Part name Symbol Specification Check ※ Check contact Normal : 0Ω(for terminal A-B) : ∞Ω(for terminal A-C) Safety switch Micro Operating : ∞Ω(for terminal A-B) : 0Ω(for terminal A-C) CS-4 DC12V 2A ※ Check contact Pressure switch 10bar Normal : 0.1Ω (N.O type) CD-11 CD-12...
Page 222 Part name Symbol Specification Check ※Check coil resistance Normal : about 1MΩ ※ Check contact Cigar lighter 12V 10A 1.4W Normal : ∞Ω CL-2 CL-2 Operating time : 5~15sec ※Check contact Wiper motor 12V 3A Normal : 6Ω(for terminal 2-6) 1 Pf CN-21 ※...
Page 223 Part name Symbol Specification Check Travel buzzer 107±4dB at 4ft CN-81 Compressor 12V 38W CN-28 Air con 12V 17A fan motor CN-83 Fuel feed pump Max. 20A CN-61 180A Master switch (In Countinous capaty) 1000A (In rush) DPF switch 12V 16A CS-100 ※...
Page 224 Part name Symbol Specification Check Preheater 12V 42A 500W CN-80 12V socket 12V 120W CN-139 ※ Check resistance Normal : 0Ω 1˚C OFF Duct sensor (for terminal 1-2) 4˚C ON the atmosphere temp : over 4˚C ※ Check resistance Normal : about 5kΩ Input voltage : (for terminal A-C) 5Vdc±2%...
Page 225: Group 5 Connectors
GROUP 5 CONNECTORS GROUP 5 CONNECTORS 1. CONNECTOR DESTINATION 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 Cabin room harness - Bottom harness S816-012002 174663-2 CN-2 Cabin room harness - Aircon harness S816-012002 S816-012002 CN-3 YAZAKI...
Page 226 Connector part No. Connector No. of Type Destination number Female Male CN-61 TERM Fuel filler pump S822-014000 S822-114000 CN-66 DEUTSCH Breaker solenoid DT06-2S-EP06 DT04-2P-E005 CN-68 DEUTSCH Safety solenoid DT06-2S-EP06 CN-70 DEUTSCH Travel HI-LO solenoid DT06-2S-EP06 CN-74 Alternator MG640188-5 CN-76 DC motor MG640515-4 CN-79 YAZAKI...
Page 227 Connector part No. Connector No. of Type Destination number Female Male ·LAMP CL-1 Room lamp MG610392 CL-2 Cigar light S810-003202 CL-3 DEUTSCH Head lamp DT06-2S-EP06 DT04-2P-E005 CL-4 DEUTSCH Head lamp DT06-2S-EP06 DT04-2P-E005 CL-5 DEUTSCH Work lamp DT06-2S-EP06 CL-6 DEUTSCH Work lamp DT06-2S-EP06 CL-7 Beacon lamp...
Page 228 Connector part No. Connector No. of Type Destination number Female Male CD-30 Water temp 85202-1 CD-31 DEUTSCH Overload pressure switch DT06-3S-EP006 CD-32 DEUTSCH Boom up pressure switch DT06-3S-EP006 CD-45 WIF sensor S816-102003 DO-1 Diode 21EA-50570 DO-2 Diode 21EA-50570 DO-3 Diode 21EA-50570 ·SWITCH CS-2...
Page 229 2. CONNECTION TABLE FOR CONNECTORS 2. CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR PA TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 S811-109002 S811-011002 S811-111002 4-86...
Page 230 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4-87...
Page 231 J TYPE CONNECTOR J TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S816-002001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 4-88...
Page 232 SWP TYPE CONNECTOR SWP TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 4-89...
Page 233 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4-90...
Page 234 CN TYPE CONNECTOR CN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 4-91...
Page 235 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 4-92...
Page 236 375 FASTEN TYPE CONNECTOR 375 FASTEN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR AMP ECONOSEAL CONNECTOR No. of Receptacle connector (female) Plug connector (male) 344111-1 344108-1 AMP TIMER CONNECTOR AMP TIMER CONNECTOR No.
Page 237 AMP 040 MULTILOCK CONNECTOR AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 174045-2 AMP 070 MULTILOCK CONNECTOR AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 173852 AMP FASTIN - FASTON CONNECTOR AMP FASTIN - FASTON CONNECTOR No.
Page 238 KET 090 CONNECTOR KET 090 CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610070 KET 090 WP CONNECTORS KET 090 WP CONNECTORS No. of Receptacle connector (female) Plug connector (male) MG640605 MG640795 4-95...
Page 239 KET SDL CONNECTOR KET SDL CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610406 4-96...
Page 240 DEUTSCH DT CONNECTORS DEUTSCH DT CONNECTORS DT 06 - 3S - Modifications (see below) Number of contacts (P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connectors ※ Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 241 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT06-6P DT06-8S DT06-8P DT06-12S DT06-12P 4-98...
Page 242 MOLEX 2CKTS CONNECTOR MOLEX 2CKTS CONNECTOR No. of Receptacle connector (female) Plug connector (male) 35215-0200 ITT SWF CONNECTOR ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF593757 MWP NMWP CONNECTOR MWP NMWP CONNECTOR No. of Receptacle connector (female) Plug connector (male) NMWP01F-B 4-99...
Page 243: Group 6 Fault Codes
GROUP 6 FAULT CODES GROUP 6 FAULT CODES 1. MACHINE FAULT CODE 1. MACHINE FAULT CODE Fault code Description HCESPN Hydraulic oil temperature - voltage above normal, or shorted to high source Hydraulic oil temperature - voltage below normal, or shorted to low source Working pressure - data valid but above normal operational range Working pressure - data valid but below normal operational range Working pressure - data erratic, intermittent, or incorrect...
Page 244 Fault code Description HCESPN (MCU Input) Battery voltage - data valid but above normal operational range (MCU Input) Battery voltage - data valid but below normal operational range Alternator voltage - data valid but below normal operational range Acceleration dial voltage - voltage above normal, or shorted to high source Acceleration dial voltage - voltage below normal, or shorted to low source Cluster communications status - data erratic, intermittent, or incorrect ECM communication status - data erratic, intermittent, or incorrect...
Page 245 2. ENGINE FAULT CODE 2. ENGINE FAULT CODE Fault code Description YANMAR SPN FMI Area Status Crankshaft signal error 522400 Crankshaft speed sensor No signal from crankshaft Camshaft signal error 522401 Camshaft speed sensor No signal from camshaft Angle offset error Crankshaft speed sensor, Crankshaft/camshaft, speed sensor non-input 523249...
Page 246 Fault code Description YANMAR SPN FMI Area Status Fuel temperature sensor error (voltage high) Fuel temperature sensor Fuel temperature sensor error (voltage low) Fuel temperature high Rail pressure sensor error (voltage high) Rail pressure sensor Rail pressure sensor error (voltage low) DPF differential pressure sensor error (excessive sensor output) DPF differential pressure sensor abnormal rise in...
Page 247 Fault code Description YANMAR SPN FMI Area Status Starting aid relay disconnection 522243 Starting aid relay Starting aid relay relay GND short circuit Disconnection (injector-speciﬁ c) Injector (No.1 cylinder) Coil short circuit Short circuit Disconnection (injector-speciﬁ c) Injector (No.2 cylinder) Coil short circuit Short circuit Disconnection (injector-speciﬁ...
Page 248 Fault code Description YANMAR SPN FMI Area Status Overspeed Overspeed No-load of throttle valve drive H bridge circuit Power short circuit of throttle valve drive H bridge output 1 2950 GND short circuit of throttle valve drive H bridge output 1 Overload on the drive H bridge circuit of throttle valve Intake throttle drive circuit VB power short circuit of throttle valve drive H bridge...
Page 249 Fault code Description YANMAR SPN FMI Area Status EEPROM memory deletion error 522576 EEPROM EEPROM memory reading error 522578 EEPROM memory writing error 522585 CY 146 SPI communication fault 522588 Excessive voltage of supply 1 522589 Insufﬁ cient voltage of supply 1 522590 Sensor supply voltage error 1 522591...
Page 250 Fault code Description YANMAR SPN FMI Area Status Ash cleaning request 1 3720 Ash cleaning request 2 Stationary regeneration standby 3719 DPF OP interface Backup mode 3695 Reset regeneration is inhibited Regeneration faulure (recovery regeneration failure) 3719 Recovery regeneration is inhibited 4-107...
Page 251: Section 5 Troubleshooting
SECTION 5 TROUBLESHOOTING SECTION 5 TROUBLESHOOTING Group 1 Before Troubleshooting --------------------------------------------------------------------------------- 5-1 Group 2 Hydraulic and Mechanical System -------------------------------------------------------------- 5-4 Group 3 Electrical System ------------------------------------------------------------------------------------------- 5-24...
Page 252: Group 1 Before Troubleshooting
GROUP 1 BEFORE TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION 1. INTRODUCTION When a trouble is occurred in the machine, this section will help an operator to maintain the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system and Electrical system system. At each system part, an operator can check the machine according to the troubleshooting process diagram.
Page 253 2. DIAGNOSING PROCEDURE 2. DIAGNOSING PROCEDURE To carry out troubleshooting efficiently, the following steps must be observed. STEP 1. Study the machine system STEP 1. Study the machine system Study and know how the machine is operating, how the system is composing, what kinds of function are installed in the machine and what are specifications of the system components by the machine service manual.
Page 254 STEP 4. Inspect the trouble actually on the STEP 4. Inspect the trouble actually on the machine machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not.
Page 255: Group 2 Hydraulic And Mechanical System
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION 1. INTRODUCTION MACHINE IN GENERAL MACHINE IN GENERAL If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration.
Page 256: Drive System
2. DRIVE SYSTEM 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION UNUSUAL NOISE COMES OUT OF PUMP CONNECTION 1) 1) Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and check if rubber Replace hub or pieces or particles retighten...
Page 257 2) 2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard Is oil level in level. Abnormal noise hydraulic oil comes out of Hydraulic pump is Disassemble tank within...
Page 258 3. HYDRAULIC SYSTEM 3. HYDRAULIC SYSTEM 1) 1) HYDRAULIC OIL IS CLOUDY HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and Drop hydraulic oil dispose it or sample on hot plate and check if replace hydraulic foams come up.
Page 259 CAVITATION OCCURS WITH PUMP CAVITATION OCCURS WITH PUMP Cause Remedy Replenish specified oil to the standard level. Is hydraulic oil volume proper? Replace oil with one of proper Is not viscosity viscosity. of hydraulic oil too high? Clean suction Is not suction strainer.
Page 260: Swing System
4. SWING SYSTEM 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish ⓐ specified oil to the Is safety solenoid standard level. valve pressure within standard? Safety valve faulty Repair or replace.
Page 261 SWING SPEED IS LOW SWING SPEED IS LOW Cause Remedy Does swing Swing port relief Disassemble and control valve valve is faulty. repair or replace. spool move smoothly by Swing control valve Disassemble hand? Is MCV pilot spool is stuck. and repair.
Page 262 3) 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble change when LH valve is faulty. and repair. and RH port relief valves are exchanged Shuttle valve is Disassemble Does swing control faulty.
Page 263 5) 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy ⓐ Is swing shuttle Shuttle valve is Disassemble faulty. and replace. Is brake spring normal? Is return spring...
Page 264: Travel System
5. TRAVEL SYSTEM 5. TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE 1) 1) Cause Remedy ⓐ Does counterbalance spool in travel brake valve move lightly by hand? Counter spool in Disassemble Is travel brake...
Page 265 2) 2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble Do LH and RH defective. and repair or travel speeds replace. change when LH and RH travel Relief valve built Disassemble...
Page 266 3) 3) MACHINE DOES NOT STOP ON A SLOPE MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None friction plate Friction plate is...
Page 267 5) 5) TRAVEL ACTION IS POWERLESS TRAVEL ACTION IS POWERLESS (travel only) Cause Remedy ⓐ Is travel motor's drain rate within standard level? Is travel brake Travel motor is Disassemble pressure within faulty. and repair. standard level? Is travel relief valve pressure Travel brake valve Disassemble...
Page 268 7) 7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal.
Page 269 6. ATTACHMENT SYSTEM 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL 1) 1) Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace.
Page 270 2) 2) BOOM, ARM OR BUCKET SPEED IS LOW BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. ⓐ Are other attachment speeds within Is combination ⓑ Is speed low only of oil streams in composite normal at boom operation? Flow summation Disassemble...
Page 271 3) 3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the faulty. and repair or symptom change Normal replace.
Page 272 4) 4) BOOM, ARM OR BUCKET POWER IS WEAK BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder in Item "Speed is internal leakage within standard low". level? Is relief pressure in port relief Cylinder is faulty.
Page 273 6) 6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom Is boom foot pin greased proper.
Page 274 ※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full. R5575BY01 Disconnect hose(A) from rod side of boom cylinder and drain oil from cylinders and hose.(Put cups on piping and hose ends) R5575BY02...
Page 275: Group 3 Electrical System
GROUP 3 ELECTRICAL SYSTEM GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR APPEAR ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.2 and No.6.
Page 276 BATTERY CHARGING WARNING LAMP LIGHTS UP BATTERY CHARGING WARNING LAMP LIGHTS UP (starting switch : ON) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective cluster...
Page 277 WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started) (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 278 WHEN AIR CLEANER WARNING LAMP LIGHTS UP WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 279: Engine Oil Pressure Switch
WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 280 6. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP 6. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 281 7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE 7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Repair or replace...
Page 282: Fuel Sender
(1) and (2) down at lamp Defective fuel Replace check? Disconnect CD-2 sensor See Table Starting switch : ON Defective cluster Replace Check Table HYUNDAI Level Empty Full Item Unit Resistance (Ω) ~100 ±5 ±8 ±5 Tolerance (%) Red range...
Page 283: Safety Switch
9. WHEN SAFETY SOLENOID DOES NOT OPERATE 9. WHEN SAFETY SOLENOID DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.17. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 284 10. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE 10. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.15.
Page 285 11. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE 11. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.13 is not blown out.
Page 286: Switch Panel
12. WHEN STARTING SWITCH IS TURNED ON, 12. WHEN STARTING SWITCH IS TURNED ON, ILLUMINATION LAMP ILLUMINATION LAMP DOES NOT LIGHTS UP DOES NOT LIGHTS UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.10.
Page 287 13. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP 13. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.11.
Page 288 14. WHEN ENGINE DOES NOT START 14. WHEN ENGINE DOES NOT START CIRCUIT BREAKER MANUL RESET ·Check supply of the power at engine stop solenoid while starting switch is ON. ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted.
Page 289 15. WHEN STARTING SWITCH ON DOES NOT OPERATE 15. WHEN STARTING SWITCH ON DOES NOT OPERATE CIRCUIT BREAKER MANUL RESET ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and master switch ON.
Page 290: Section 6 Maintenance Standard
SECTION 6 MAINTENANCE STANDARD SECTION 6 MAINTENANCE STANDARD Group 1 Operational Performance Test ----------------------------------------------------------------------- 6-1 Group 2 Major Components ----------------------------------------------------------------------------------------- 6-21 Group 3 Track and Work Equipment ---------------------------------------------------------------------------- 6-35...
Page 291: Group 1 Operational Performance Test
Whenever a new machine is delivered in condition parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec. OPERATIONAL PERFORMANCE OF A OPERATIONAL PERFORMANCE OF A 2) 2) WORKING MACHINE...
Page 292: Service Limit
2. TERMINOLOGY 2. TERMINOLOGY STANDARD STANDARD Specifications applied to the brand-new machine, components and parts. 55Z96MC02 SERVICE LIMIT SERVICE LIMIT The lowest acceptable performance level. When the perfor mance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
Page 293 3. OPERATION FOR PERFORMANCE 3. OPERATION FOR PERFORMANCE TESTS TESTS Observe the following rules in order to carry out performance tests accurately and safely. (1) (1) The machine The machine Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.
Page 294: Engine Speed
Evaluation The measured speeds should meet the following specifications. Unit : rpm Model Engine speed Standard Remark Start idle 1000±50 P mode 1900±50 R60CR-9A S mode 1750±50 Auto decel 1100±50 Condition : Set the accel dial at 10 (Max) position.
Page 295: Travel Speed
Repeat steps ④ and ⑤ three times in each direction and calculate the average 555C96MC05 values. Evaluation Evaluation The average measured time should meet the following specifications. Unit : Seconds / 20m Model Travel speed Standard Maximum allowable Remarks 1 Speed 32.7±2.0 R60CR-9A 2 Speed 18.0±1.0...
Page 296 Repeat steps ③ and ④ three times and calculate the average values. Evaluation Evaluation The revolution cycle time of each track should meet the following specifications. Unit : Seconds / 3 revolutions Model Travel speed Standard Maximum allowable 1 Speed 26.5±1.5 33.1 R60CR-9A 2 Speed 14.6±1.5 18.3...
Page 297: Travel Deviation
⑤ Repeat steps ③ and ④ three times and 7-7(2) 140-7 calculate the average values. (4) (4) Evaluation Evaluation Mistrack should be within the following specifications. Unit : mm / 20m Model Standard Maximum allowable Remarks R60CR-9A 200 below...
Page 298 Repeat steps ① and ② three time and calculate the average values. (4) (4) Evaluation Evaluation The time required for 2 swings should meet the following specifications. Unit : Seconds / 2 revolutions Model Standard Maximum allowable Remarks R60CR-9A 13.6±0.4...
Page 299 ④ Repeat steps ② and ③ three times each R5576MC08 and calculate the average values. (4) (4) Evaluation Evaluation The measured drift angle should be within the following specifications. Unit : Degree Model Standard Maximum allowable Remarks R60CR-9A 40 below...
Page 300 Record the dial gauge reading (h2). Calculate bearing play (H) from this data (h1 and h2) as follows. H=h2-h1 Evaluation 55Z96MC10 The measured drift should be within the following specifications. Unit : mm Model Standard Maximum allowable Remarks R60CR-9A 0.5 ~ 1.2 6-10...
Page 301 9) 9) HYDRAULIC CYLINDER CYCLE TIME HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, Boom cylinder standard arm, and standard bucket Raise cylinders. (2) (2) Preparation Preparation ① To measure the cycle time of the boom Lower cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the...
Page 302 Standard Maximum allowable Remarks Boom raise 2.4±0.4 Boom lower 2.7±0.4 Arm in 2.3±0.4 Arm out 2.3±0.3 Bucket load 3.8±0.4 R60CR-9A Bucket dump 2.4±0.3 Boom swing (LH) 4.9±0.4 Boom swing (RH) 6.4±0.4 Dozer up (raise) 2.8±0.3 Dozer down (lower) 3.8±0.3 6-12...
Page 303 The measured drift should be within the following specifications. Unit : mm / 5min Model Drift to be measured Standard Maximum allowable Remarks Boom cylinder 10 below R60CR-9A Arm cylinder 20 below Bucket cylinder 20 below 6-13...
Page 304 The measured operating force should be within the following specifications. Unit : kgf Model Kind of lever Standard Maximum allowable Remarks Boom lever 1.4 or below Arm lever 1.4 or below R60CR-9A Bucket lever 1.4 or below Swing lever 1.4 or below Travel lever 2.0 or below 6-14...
Page 305 Evaluation Evaluation The measured drift should be within the following specifications. Unit : mm Model Kind of lever Standard Maximum allowable Remarks Boom lever 87±10 Arm lever 87±10 R60CR-9A Bucket lever 87±10 Swing lever 87±10 Travel lever 86±10 6-15...
Page 306 Keep the hydraulic oil temperature at 50±5˚C. (2) (2) Measurement Measurement ① Measure the primary pilot pressure in the R55NN7MA14 M mode. Evaluation Evaluation The average measured pressure should meet the following specifications: Unit : kgf / cm Model Standard Remarks R60CR-9A 30±5 6-16...
Page 307 Repeat steps ② and ③ three times and calculate the average values. (3) (3) Evaluation Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Travel speed mode Standard Maximum allowable Remarks 1 Speed R60CR-9A 2 Speed 30±5 6-17...
Page 308 ② Repeat three times and calculate the average values. (3) (3) Evaluation Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Description Standard Remarks Brake disengaged 30±5 R60CR-9A Brake applied 6-18...
Page 309 Measure the main pump deliver y R55NN7MA17 pressure at high idle. (3) (3) Evaluation Evaluation The average measured pressure should meet the following specifications. Unit : kgf / cm Model Engine speed Standard Allowable limits Remarks R60CR-9A High idle 20±5 6-19...
Page 310 (3) (3) Evaluation Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Function to be tested Standard Boom, Arm, Bucket 220±10 R60CR-9A Travel 220±10 Swing 220±10 6-20...
Page 311: Group 2 Major Components
GROUP 2 MAJOR COMPONENT GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 1. MAIN PUMP Before inspection, wash the parts well and dry them completely. Inspect the principal parts with care and replace them with new parts when any abnormal wear exceeding the allowable limit or damage considered harmful is found.
Page 312: Control Plate
CONTROL PLATE CONTROL PLATE Check the slide surface for any damage. When the damage is large, replace the plate with new one. R55NM7PH48 GUIDE AND RETAINER GUIDE AND RETAINER Check for scouring or stepped wear. If this can not be corrected, replace the guide and retainer with new full-set.
Page 313: Main Control Valve
2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE Part name Inspection item Criteria & measure ·Existence of scratch, rusting or corrosion. · In case of damage in following section, Block replace part. - Sliding sections of casing fore and spool, especially land sections applied with holded pressure.
Page 314: General Cautions
3. SWING DEVICE 3. SWING DEVICE 1) 1) GENERAL CAUTIONS GENERAL CAUTIONS Here, counter-measures to be taken when troubles have happened while the motor is in operation are described. As for general precaution. Consider a cause of the trouble before repairing Before setting to work, think whether the same thing has happened before or not.
Page 315 CONDITION & COUNTERMEASURES OF TROUBLES CONDITION & COUNTERMEASURES OF TROUBLES Motor does not rotation Motor does not rotation Condition Cause Remedy ·Setting pressure of relief valve ·Reset the pressure to correct The pressure of the circuit is not increasing is incorrect value ·Working defectiveness of relief valve...
Page 316 Brake torque is not sufficient Brake torque is not sufficient Condition Cause Remedy ·Friction plates are worn ·Disassembly or inspection. Brake torque is not sufﬁ cient When it is worn more than standard, replace it ·Brake piston is becoming stick ·Disassembly or inspection ·Brake releasing pressure is not working...
Page 317 4. MAINTENANCE STANDARDS 4. MAINTENANCE STANDARDS 1) 1) PART REPLACEMENT STANDARDS FOR HYDRAULIC MOTOR PART REPLACEMENT STANDARDS FOR HYDRAULIC MOTOR If the various parts of the motor have been worn out beyond the following standard values, please replace them. But this shall apply only to those cases when is no remarkable outside damage. Recommended Standard Inspection item...
Page 318 2) 2) PART REPLACEMENT STANDARDS FOR REDUCTION GEAR PART REPLACEMENT STANDARDS FOR REDUCTION GEAR Standard Recommended Item dimension value for replacement Remedy (mm) (mm) Replace if pitting or Pitting or crack of gear Pitting area rate : 10% crack is found Motor driving shaft external Overpin : 28.194 (Ø3.048) 27.594...
Page 319 3) 3) STANDARD FOR CORRECTING SLIDING SURFACES STANDARD FOR CORRECTING SLIDING SURFACES If the surface roughness of the sliding surface of a part exceeds the following standards, correct it or replace the part. Table 5. Standards Item Surface roughness Roughness requiring correction 0.8 - Z (Ra=0.2) Shoe 3 - Z (Ra=0.8)
Page 320 5. TRAVEL DEVICE (TYPE 1) 5. TRAVEL DEVICE (TYPE 1) Disassembling and inspection of the motor must be done in strict accordance with the servicing standards described here. During servicing, handle each part very carefully not to damage them, especially for their movable or sliding sections. SEALS SEALS 1) 1)
Page 321 Item Maximum allowable Part name Situation Standard dimension value (criteria) ·The sliding surface is damaged. Distance piece ·The sliding surface is excessively worn out. ·Dents are present. Ball bearing ·Flaking develops. ·Nonuniform wear is present. ·The movable section contacting Rear flange kit Rear flange kit Linear clearance : Linear clearance :...
Page 322 Item Maximum allowable Part name Situation Standard dimension value (criteria) ·The spherical sliding section that Thrust ball contacts the retainer plate (107) is nonuniformly worn out. ·The sliding surface has the Timing plate traces of seizure or nonuniformly wear. ·Both edges are nonuniformly Friction plate Braking torque 40.6 Braking torque 40.6...
Page 323 TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #2188-) TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #2188-) Disassembling and inspection of the motor must be done in strict accordance with the servicing standards described here. During servicing, handle each part very carefully not to damage them, especially for their movable or sliding sections.
Page 324 6. TURNING JOINT 6. TURNING JOINT Part name Maintenance standards Remedy ·Plating worn or peeled due to seizure or contamination. Body, Sliding surface with Replace Stem sealing sections. ·Worn abnormality or damaged more than 0.1 mm Sliding surface Replace between body and (0.0039 in) in depth due to seizure contamination.
Page 325 7. CYLINDER 7. CYLINDER Part name Inspecting section Inspection item Remedy ·Neck of rod pin ·Presence of crack ·Replace Piston rod ·Weld on rod hub ·Presence of crack ·Replace · Stepped part to which piston ·Presence of crack ·Replace is attached. ·Threads ·Presence of crack ·Recondition or replace...
Page 326: Group 3 Track And Work Equipment
GROUP 3 TRACK AND WORK EQUIPMENT GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK SHOE 1. TRACK SHOE STEEL SHOE SPEC STEEL SHOE SPEC R5576MC16 Unit : mm Criteria Check item Remedy Standard size Repair limit Replace bushing Link pitch 138.6 and pin and link Outside diameter of bushing...
Page 327 RUBBER SHOE SPEC RUBBER SHOE SPEC SECTION B-B SECTION A-A R5576MC17 Unit : mm Criteria Check item Remedy Standard size Tolerance Repair limit ±1.0 Link pitch Height of grouser Replace Width of link 6-36...
Page 328 2. IDLER 2. IDLER R5576MC18 Unit : mm Criteria Check item Remedy Standard size Repair limit Steel Outside diameter of flange Rebuild Rubber Outside diameter of thread or replace Width of flange 6-37...
Page 329 3. TRACK/CARRIER ROLLER 3. TRACK/CARRIER ROLLER R5576MC15 Unit : mm Criteria Check item Remedy Standard size Repair limit Steel Outside diameter of flange Rebuild Rubber Outside diameter of thread or replace Width of flange 6-38...
Page 330 4. TENSION CYLINDER 4. TENSION CYLINDER STEEL SHOE SPEC STEEL SHOE SPEC R5576MC19 Unit : mm Criteria Check item Remedy Standard size Repair limit Track frame Rebuild Outside diameter of flange Idler support Rebuild or replace Track frame Rebuild Outside diameter of thread Idler guide Rebuild or replace Standard size...
Page 331 RUBBER SHOE SPEC R5576MC20 Unit : mm Criteria Check item Remedy Standard size Repair limit Track frame Vertical width of idler guide Rebuild Idler support Track frame Rebuild or replace Horizontal width of idler guide Idler guide Rebuild Standard size Repair limit Free Installed...
Page 332 5. SPROCKET 5. SPROCKET R5576MC21 Unit : mm Criteria Check item Remedy Standard size Repair limit Wear out of sprocket tooth 418.6 lower side diameter Wear out of sprocket tooth upper side diameter Repair or Replace Wear out of sprocket tooth 33.5 upper side width Wear out of sprocket tooth...
Page 333: Work Equipment
6. WORK EQUIPMENT 6. WORK EQUIPMENT 60CR9A6MC01 Unit : mm Bushing Remedy Normal Measuring point Recomm. Recomm. Mark & Limit Limit (pin and bushing) value service service Remark of use of use limit limit Boom Rear 53.5 55.5 Replace 〃 Boom Cylinder Head 58.5 60.5...
Page 334 SECTION 7 DISASSEMBLY AND ASSEMBLY SECTION 7 DISASSEMBLY AND ASSEMBLY Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 7-1 Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 7-4 Group 3 Pump Device ----------------------------------------------------------------------------------------------------- 7-7 Group 4 Main Control Valve -------------------------------------------------------------------------------------------- 7-38 Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 7-51 Group 6 Travel Device ----------------------------------------------------------------------------------------------------- 7-74 Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 7-102 Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 7-116...
Page 335: Section 7 Disassembly And Assembly
SECTION 7 DISASSEMBLY AND ASSEMBLY SECTION 7 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS GROUP 1 PRECAUTIONS 1. REMOVAL WORK 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
Page 336 2. INSTALL WORK 2. INSTALL WORK Tighten all bolts and nuts(Sleeve nuts) to the specified torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive.
Page 337 3. COMPLETING WORK 3. COMPLETING WORK If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Page 338: Group 2 Tightening Torque
GROUP 2 TIGHTENING TORQUE GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf·m lbf·ft M10 × 1.5 Engine mounting bolt (engine-bracket) 6.9±1.0 50±7.2 M16 × 2.0 Engine mounting bolt (bracket-frame) 25±2.5 181±18.1 Engine M12 × 1.75 Radiator mounting bolt, nut 12.8±3.0 92.6±21.7...
Page 339: Torque Chart
2. TORQUE CHART 2. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread Bolt size kg·m lb·ft kg·m lb·ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25...
Page 340 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size (PF) Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size (UNF) Width across flat (mm) kgf·m lbf·ft...
Page 341: Group 3 Pump Device
GROUP 3 PUMP DEVICE GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18...
Page 342 2) 2) INSTALL INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level.
Page 343 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Name Quantity Size (nominal) Hexagonal bar spanner One each 5, 6, 8, 10 Spanner 17, 24 Plastic hammer...
Page 344 (3) (3) Tightening torque Tightening torque Torque Wrench size Part name Bolt size kgf·m lbf·ft Hexagon socket head bolt 0.20 21.7 0.24 10.0 72.3 0.39 24.0 0.55 34.0 0.55 PT 1/16 0.16 PT Plug PF Plug PF 1/8 10.8 0.20 PF 1/4 21.7 0.24...
Page 345: Disassembly Procedure
3. DISASSEMBLY PROCEDURE 3. DISASSEMBLY PROCEDURE DISASSEMBLING THE GEARED PUMP DISASSEMBLING THE GEARED PUMP ① Remove the hexagonal socket headed bolts (M10 × 25, 2 pieces). Hexagonal bar spanner (Hex. side distance : 8) ※ Be careful because the O-ring and filter are provided to the match surface of the geared pump.
Page 346 ③ This photo shows the state with the cover removed. R55NM7HP07 ④ Remove the O-ring from the cover. R55NM7HP08 The removal of the control spring The removal of the control spring ① Remove 2 springs (inner and outer). R55NM7HP09 ② Remove the spring seat.
Page 347 The removal of rotary group The removal of rotary group ① Lay the pump on the side and take out the rotary group from the shaft. R55NM7HP11 ② Remove the plate. R55NM7HP12 The removal of the shaft The removal of the shaft ①...
Page 348 ③ Remove the O-ring. R55NM7HP15 ④ Remove it while knocking the shaft rear and lightly with a plastic hammer. R55NM7HP16 The removal of the hanger The removal of the hanger ① Remove the hexagonal socket headed bolts (M6 × 16, 4pieces) and plate. Hexagonal bar spanner (Hex.
Page 349 ③ Remove the bearing. R55NM7HP19 ④ Remove the hanger. R55NM7HP20 The removal of the cover The removal of the cover ① Remove the control plate. R55NM7HP21 ② Remove the C-type stop ring. R55NM7HP22 7-16...
Page 350 ③ Remove the filter. R55NM7HP23 The removal of the control piston The removal of the control piston ① Remove the hexagonal socket headed bolts. (M8 × 25, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) The threaded portion of the bolt is coated with LOCTITE #270.
Page 351 ④ Take out three caned disk springs and spring seats. R55NM7HP27 The removal of the control spring The removal of the control spring ① Remove the hexagonal socket headed bolts (M8×30, 2pieces) and remove the cover. Hexagonal bar spanner (Hex. side distance : 6). R55NM7HP28 ②...
Page 352 The removal of the relief valve The removal of the relief valve ① Remove the hexagonal nuts. ※ Since the pressure has been set, this assembly must be made only when necessary. Spanner (Hex. side distance : 24). R55NM7HP30 ② Remove the adjusting screw.
Page 353 Disassembly of the shaft Disassembly of the shaft ① Remove the bearing. Remove the C-type stop ring. Snap ring pliers for shaft. R55NM7HP34 ② Remove it while knocking the rear end of shaft lightly with a plastic hammer. R55NM7HP35 7-20...
Page 354 DISASSEMBLING THE GEARED PUMP DISASSEMBLING THE GEARED PUMP Disassembling the P3 and P4 pump Disassembling the P3 and P4 pump ① Removed hexagonal socket head bolt and nut. Hexagonal socket wrench (8 mm). Hexagonal bar spanner (17 mm). R55NM7HP209 Disassembling the geared pump Disassembling the geared pump (P4) ①...
Page 355 Disassembling the geared pump Disassembling the geared pump (P3) ① Remove the square ring (10). R5577MP01 ② Remove the plate (5) and the guide ring (pieces). With O-ring (6, 8). Remove the O-ring (8) from guide ring (6). R5577MP02 ③ Remove the drive and idle gear (2, 3) and the side plate (4) assembly.
Page 356: Assembling Procedure
4. ASSEMBLING PROCEDURE 4. ASSEMBLING PROCEDURE ASSEMBLING THE MAIN PUMP ASSEMBLING THE MAIN PUMP Assembling the hanger. R55NM7HP50 Install the bearing. R55NM7HP50A Install the distance piece. Confirm that pre-load is 0.1 ± 0.2. R55NM7HP51 Fix the plate with the hexagonal socket headed bolts (M6 ×...
Page 357 Assembling the shaft Assembling the shaft ① Fit the shaft into the bearing (with the bearing in the bottom) by using the press machine and jig. If the press is not available, use the jig in the similar manner and drive the shaft into the bearing by knocking with a plastic hammer.
Page 358 Install the case with oil seal vertically without tilting. ※ Apply grease to the oil seal lip beforehand. R55NM7HP57 Install the C-type stop ring to fix the shaft. R55NM7HP58 Assembling the rotary group. Install 10 (ten) pistons into the retainer. R55NM7HP59 (10) Apply grease to 3 parallel pins and...
Page 359 (11) Apply grease to the spherical portion of the guide. R55NM7HP61 (12) Insert the guide between the retainer and cylinder block and assemble the piston into the hole of cylinder block. R55NM7HP62 (13) Assembling the rotary group. To prevent dislodgement, apply grease to the back side of the plate and assemble it to the hanger.
Page 360 (15) Assembling the control spring. Apply grease to the spherical portion of the spring seat before assembling. R55NM7HP65 (16) Assemble 2 springs (inner and outer). R55NM7HP66 (17) Assembling the cover. Assemble the spring seats and coned disk springs (3 pieces). R55NM7HP67 (18) Assembling the control piston.
Page 361 (19) Apply grease to the O-rings (5.28×1.78, 1piece), (7.65×1.78, 1piece) and (15.6×1.78, 1piece) and assemble them to the cylinder. R55NM7HP69 (20) Apply grease to 3 parallel pins and assemble 3 pins into the cylinder. R55NM7HP70 (21) Fix the cylinder with the hexagonal socket headed bolts (M8×25, 2pieces).
Page 362 (23) Fix the cover with the hexagonal socket headed bolts (M8×30, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 2.9 ~ 3.5 kgf·m (21 ~ 25.3 lbf·ft) R55NM7HP73 (24) Apply grease to the back side of the control plate and assemble it to the cover while matching knock holes.
Page 363 (27) Fix the filter with the C-type stop ring. R55NM7HP77 (28) Assembling the relief valve. Assemble the spool. R55NM7HP78 (29) Assemble the spring. R55NM7HP79 (30) Insert the shim into the adjusting screw. R55NM7HP80 7-30...
Page 364 (31) Assemble the adjusting screw. R55NM7HP81 (32) Tighten the hexagonal nuts. After assembling, set the pressure and tighten the nuts. 1 kgf·m (7.2 lbf·ft) Spanner (Hex. side distance : 24) R55NM7HP82 (33) Install the cover in a parallel direction to the housing mounting surface.
Page 365 (35) Install the O-ring into the cover. R55NM7HP85 (36) Install the coupling to the shaft end of the main pump. R55NM7HP86 (37) Connect the main and geared pump. R55NM7HP87 (38) Fix the geared pump with the hexagonal socket headed bolts (M10×25, 2pieces). Hexagonal bar spanner (Hex.
Page 366 REASSEMBLING THE GEARED PUMP REASSEMBLING THE GEARED PUMP Reassembling the geared pump Reassembling the geared pump (P3) ① Insert the plate (5) to the pump housing. R5577MP03 ② Insert the square ring into the side plate. ※ Be careful to suction and discharge side. R55NM7HP210 ③...
Page 367 ⑤ Assemble the O-ring to the guide ring and assemble them to the plate. R55NM7HP213 ⑥ Assemble the guide ring assembly (6, 8) and plate (5) to the gear casing. R5577MP03 ⑦ Assemble the square ring (10) to the gear casing. R5577MP01 7-34...
Page 368 Reassembling the geared pump Reassembling the geared pump (P4) ① Insert the drive gear into the gear casing. R55NM7HP219 ② Insert the idle gear to into the gear casing. R55NM7HP220 ③ Insert the pins (2-pieces) to the center frame. R55NM7HP221 ④...
Page 369 ⑤ Assemble the center frame sub- assemble to the gear casing sub- assembly. R55NM7HP223 Reassembling the P3 and P4 pumps Reassembling the P3 and P4 pumps ① Insert the pins (2-pieces) into the center frame. R55NM7HP224 ② Insert coupling to the P3 geared pump. R55NM7HP225 ③...
Page 370 ④ Assemble the hexagonal socket bolts and nuts. · Size : M10×65L, 4pieces · Allen wrench : 8 mm · Spanner : 17 mm · Tightening torque : 580 kgf·cm (56.9 N·m) R55NM7HP227 ⑤ Assemble the O-ring to the pump housing.
Page 371: Group 4 Main Control Valve
GROUP 4 MAIN CONTROL VALVE GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR 1. REMOVAL AND INSTALL OF MOTOR REMOVAL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 372 2. STRUCTURE (1/4) 2. STRUCTURE (1/4) 5-15 5-101 5-11 5-102 4-111 4-112 4-113 4-101 4-15 4-102 3-111 3-112 5-121 3-113 5-122 3-101 3-15 3-102 4-13 4-12 5-15 2-101 2-102 2-15 4-14 3-12 3-13 4-15 2-112 3-14 2-12 2-111 3-15 2-13 2-14 2-15 55Z92MC02...
Page 373 STRUCTURE (2/4) STRUCTURE (2/4) 9-15 9-101 9-102 8-15 8-11 8-101 8-102 9-12 7-15 9-11 7-101 7-11 7-102 8-11 9-13 9-15 8-12 6-15 9-11 6-101 6-11 8-13 6-102 7-13 7-123 7-122 8-15 7-121 7-14 7-15 6-11 6-1 6-13 6-12 6-15 55Z92MC03 2 Way block 7-1 Work block (Ba3) 7-14 O-ring...
Page 374 STRUCTURE (3/4) STRUCTURE (3/4) 12-4 12-19 12-5 12-3 12-6 12-91 12-2 12-10 12-92 12-8 12-17 11-4 12-7 11-17 11-5 11-3 11-6 11-101 12-18 11-2 11-102 10-8 12-13 11-9 10-9 12-12 11-8 10-12 12-14 10-3 10-61 10-11 12-1 12-16 10-151 12-15 11-13 12-3 10-62...
Page 375 STRUCTURE (4/4) STRUCTURE (4/4) 14-4 14-15 14-5 14-3 14-6 14-2 14-91 14-81 13-4 14-92 14-82 13-14 13-5 13-151 13-11 13-3 13-6 13-151 13-152 14-102 13-152 13-16 14-101 13-16 13-18 13-17 14-1 13-2 14-3 14-11 14-15 13-11 14-7 14-6 14-5 13-1 13-12 13-13 13-3...
Page 376: Disassembly And Assembly
3. DISASSEMBLY AND ASSEMBLY 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS GENERAL PRECAUTIONS 1) 1) All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be remove from the machine, apply caps and masking seals to all ports.
Page 377 3) 3) DISASSEMBLY DISASSEMBLY (1) (1) Disassembly of spools Disassembly of spools (pilot type) ① Loosen hexagon socket head bolts (5) with washer (6). (Hexagon wrench : 5 mm) ② Remove the pilot cover (3). ※ Pay attention not to lose the O-ring (7) under the pilot cover.
Page 378 (3) (3) Disassembly of the load check valve Disassembly of the load check valve and the negative relief valve and the negative relief valve ① The load check valve Fix the body to suitable work bench. ※ Pay attention not to damage the body. Loosen the plug (10) (Hexagon wrench : 10 mm).
Page 379 (5) (5) Disassembly of the block assembly Disassembly of the block assembly ① Fix the body to suitable work bench. ② Remove the nut (20). (Spanner : 13 mm) ※ The work block is assembled by two sets of tie-bolts. ③...
Page 380 (6) (6) Inspection after disassembly Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. ① Control valve Control valve Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
Page 381 4) 4) ASSEMBLY ASSEMBLY (1) (1) General precaution General precaution ① In this assembly section, explanation only is shown. For further understanding, please refer to the figures shown in the previous structure & disassembly section. ② Pay close attention to keeping all seals free from handling damage and inspect carefully for damage before using them.
Page 382 (3) (3) Main relief, port relief valves Main relief, port relief valves ① Install the main relief valve (5). ·Spanner : 30 mm ·Tightening torque : 6 kgf·m (43.4 lbf·ft) ② Install the over load relief valve (12). ·Spanner : 22 mm ·Tightening torque : 4 kgf·m (28.9 lbf·ft) R5577MCV09 R5577MCV10...
Page 383 Holding valve Holding valve (6) (6) ① Fit the holding valve to the body and tighten hexagon socket head bolt (7) to specified torque. ·Hexagon wrench : 5 mm ·Tightening torque : 1.1 kgf·m(7.9 lbf·ft) Holding valve R5577MCV14 R5577MCV13 7-50...
Page 384: Group 5 Swing Device
GROUP 5 SWING DEVICE GROUP 5 SWING DEVICE 1. REMOVAL AND INSTALL OF MOTOR 1. REMOVAL AND INSTALL OF MOTOR REMOVAL REMOVAL 1) 1) Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 385 2) 2) SWING MOTOR/REDUCTION GEAR (1/2) SWING MOTOR/REDUCTION GEAR (1/2) 55Z9SM001 T01 Casing T15 Separation plate T43 Socket bolt R13 Neddle bearing T02 Valve casing T16 Brake piston R01 Gear casing R14 Neddle bearing T03 Drive shaft T17 Brake spring R02 Pinion shaft R15 Planet gear No.2 T04 Roller bearing...
Page 386 SWING MOTOR/REDUCTION GEAR (2/2) SWING MOTOR/REDUCTION GEAR (2/2) 55Z9SM002 T19 Plunger T33 Filter T20 Check spring T34 Bush T21 Plug T35 Spacer T27 O-ring T36 Throttle plate T28 O-ring T37 Spring T30 Spool T38 RO Plug T31 Spring T40 Plug T32 Plunger A T44 Relief valve 7-53...
Page 387: Disassembling And Assembling
3. DISASSEMBLING & ASSEMBLING 3. DISASSEMBLING & ASSEMBLING 1) 1) TIGHTENING TORQUE OF BOLTS TIGHTENING TORQUE OF BOLTS In table 1 it is shown tightening torque of bolts used in motor. In case of reassembling, tighten accurately each bolt in accordance with table 1. Table 1 Bolt Size Name...
Page 388 Effectiveness screw length : 20 Special tool for removing the break piston Special tool for removing the break piston 55Z9SM009 7-55...
Page 389: Disassembly Of Motor
DISASSEMBLY OF MOTOR DISASSEMBLY OF MOTOR Please use the following procedures for the inspection and repair of the motor. Numerals given in parentheses following the parts names indicate the items number shown by the drawing in page 7-52. Completely remove dirt and dust adhering to the outside. Discharge all hydrualic fluid in the motor casing and the port oil passage.
Page 390 Remove the valve plate (T18). 55Z9SM013 Remove the bearing (T05) and the pin (T22). 55Z9SM014 Remove brake springs (T17). 55Z9SM015 Remove the O-ring (T26, T27). 55Z9SM016 7-57...
Page 391 Remove brake piston (T16) from the casing (T01) by using the special tool for removing the brake piston. Lift it up straight by using the bolt hole in the brake piston. 55Z9SM017 (10) Pull out friction plate (T14, 2EA) and separation plate (T15, 1EA) from the casing (T01).
Page 392 (13) Remove the spherical bush (T11). 55Z9SM021 (14) Remove the cylinder spring (T12). 55Z9SM022 (15) Remove the drive shaft (T03). 55Z9SM023 (16) Remove the shoe plate (T07). 55Z9SM024 7-59...
Page 393 (17) Remove the bearing (T04). 55Z9SM025 (18) Remove the relief valve (T44). Do not disassemble the relief valve Do not disassemble the relief valve assembly because it is a functional assembly because it is a functional component. component. 55Z9SM026 (19) Remove the plug (T21), the spring (T20) and the plunger (T19).
Page 394 4) 4) ASSEMBLY OF MOTOR ASSEMBLY OF MOTOR Following are caution to be specially borne in mind. Rework damaged parts and before assembling and prepare all parts to be replaced. Clean all parts and dry with compressed air. Coat the sliding parts and bearing with clean hydraulic oil. Replace O-ring, oil seal.
Page 395 ④ Assemble the relief valve (T44). 55Z9SM032 ⑤ Assemble roller bearing (T04) in the casing (T01) with a using of tool. 55Z9SM033 ⑥ Apply grease to the back side of the shoe plate (T07) and assemble it. 55Z9SM034 ⑦ Assemble the drive shaft (T03) in the casing (T01).
Page 396 ⑧ Apply grease to the O-ring (T23, T24) and assemble it. 55Z9SM036 ⑨ Assemble the cylinder spring (T12). 55Z9SM037 ⑩ Assemble the spherical bush (T11). 55Z9SM038 ⑪ Set the piston assembly (T09, T10) on the retainer plate (T08) and assemble it in the cylinder block (T13).
Page 397 ⑫ Assemble the cylinder block (T13) and other associated parts. 55Z9SM040 ⑬ Assemble the friction plate (T14, 2EA) and separation plate (T15, 1EA). 55Z9SM041 ⑭ Assemble the brake piston (T16). 55Z9SM042 ⑮ Assemble the brake spring (T17). Confirm the springs are fitted to the brake piston completely.
Page 398 Assemble the O-ring (T26, T27). 55Z9SM044 Press-fit the ball bearing (T05). Assemble the pin (T22). 55Z9SM045 Assemble the valve plate (T18). Be careful to note the direction of the valve plate. Mount the valve plate with its round part toward the opposite side of the flange. Coat lightly with grease.
Page 399 Mount valve casing (T02) to casing (T01) and tighten hex socket bolts (T43) to specification. 55Z9SM048 7-66...
Page 400 DISASSEMBLY OF REDUCTION GEAR DISASSEMBLY OF REDUCTION GEAR Please use the following procedures for the inspection and repair of the reduction gear. Numerals given in parentheses following the parts names indicate the items number shown by the drawing in page 7-52. Wind the wire rope at reduction gear outside , lift up the reduction gear, and clean the reduction gear with cleaning oil.
Page 401 Remove the carrier No.2 sub-assembly (R08). 55Z9SM052 Remove the following parts. Snap ring R21 Thrust washer No2 R16 Planet gear No1 R14 Needle bearing R12 Inner ring No1 R19 Thrust washer No1 55Z9SM053 Secure the carrier No2 in a vice and loosen the screw (R22) to remove the thrust plate (R20).
Page 402 Remove the half collar (R07). 55Z9SM056 (10) Remove the pinion shaft (R02). ※ When removing the pinion shaft, be careful not to drop it. If it is hard to remove, lightly strike it with a plastic hammer. 55Z9SM057 (11) Remove the taper roller bearing (R04). 55Z9SM058 (12) Remove the oil seal (R05).
Page 403 6) 6) ASSEMBLY OF REDUCTION GEAR ASSEMBLY OF REDUCTION GEAR Following are caution to be specially borne in mind. Rework damaged parts before assembling and prepare all parts to be replaced. Clean all parts and dry with compressed air. Coat the sliding parts and bearing with clean hydraulic oil. Replace oil seal.
Page 404 ④ Install the pinion shaft (R02) and other associated parts. Prior to assembling the pinion shaft, Prior to assembling the pinion shaft, etc. apply grease slightly on the lip sur- etc. apply grease slightly on the lip sur- face to prevent any scratch when face to prevent any scratch when installing.
Page 405 ⑧ Install the following parts. Thrust plate Screw ※ Apply locite to the screw prior to tightening it. 55Z9SM067 ⑨ Install the carrier No.2 sub-assembly (R08). 55Z9SM068 ⑩ Install the sun gear No2 (R17). Be sure to check the direction of sun gear when assembling.
Page 406 ⑫ Install the carrier No.1 sub-assembly (R09). Turn the carrier slowly by hand to adjust the matching holes when assembling. 55Z9SM071 ⑬ Install the sun gear No1 (R18). Be sure to check the direction of sun gear when assembling. 55Z9SM072 ⑭...
Page 407: Group 6 Travel Device
GROUP 6 TRAVEL DEVICE (TYPE 1) GROUP 6 TRAVEL DEVICE (TYPE 1) 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Swing the work equipment 90˚ and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 408 3) 3) STRUCTURE STRUCTURE 37 39,40 30 31 56 57 23 22 20 19 18 17 10 9 16 64 1 5 59 82 83 87,88 52,53 48 50 51 SECTION A-A 41 42 46 45 43 44 32 33 24 34 27 35 25 14,13,12,11 63 15 62 61 65 3 67 68 66...
Page 409 2. DISASSEMBLY 2. DISASSEMBLY 1) 1) GENERAL PRECAUTIONS GENERAL PRECAUTIONS Before disassembling the travel motors, check the items to be inspected and, for remedy against trouble, closely examine the nature of the trouble, so that the motor can be disassembled effectively.
Page 410 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools Name of tools Size Name of applied parts Orifice (84) Plug (27) Hexagonal L-wrench Plug (49), wrench bolt (70, 83) Plug (81) Plug (38, 52, 50) Socket wrench / spanner Plug (44), Relief valve assembly (46) Snap-ring plier (for holes, axis)
Page 411 3. DISASSEMBLY 3. DISASSEMBLY 1) 1) GENERAL PRECAUTIONS GENERAL PRECAUTIONS Select a clean place for disassembling. Spread a rubber plate on a working table in order to prohibit the damage of parts. Clean a reduction gear and a motor part, washing out dirt and unnecessary substances. Without any damage of O-ring, oil seal, the adhered surface of other seals, a gear, a pin, the adhered surface of other bearings, and the surface of moisturized copper, treat each parts.
Page 412 ③ Dissemble plate spring (57) from shaft casing (1). 555K7TM03 ④ Using compression air, disassemble parking piston (21) from shaft casing (1) and dissemble O-ring (23), O-ring (22) and back up ring (85) in that order. 7078TM04/04A ⑤ Disassemble respectively 3 set of friction plate (19), parking plate (20) from shaft casing (1).
Page 413 (2) (2) Cylinder block Cylinder block ① Disassemble set plate (17), piston assembly (18) from cylinder block assembly (11). 7078TM07/07A ② Disassemble cylinder block (11), ball guide (16) and pin (15) in that order. 555K7TM08/08A ③ Put the cylinder block (11) on the air assembling jig and dissemble snap ring (14) by using a plier.
Page 414 ⑤ Disassemble steel ball (8) and swash plate (6) from shaft casing (1). 555K7TM11/11A/11B (3) (3) Rear cover Rear cover ① Disassemble valve plate (56) from rear cover (26). 555K7TM12/12A ② Using plier jig, disassemble snap ring (35), seat (34), O-ring (24), spring (33), check (32) from rear cover (26) and then disassemble snap ring (31), stopper (30), spr ing (29) and spool (28) same...
Page 415 ④ Using torque wrench, disassemble plug (44) and O-ring (45), spring (43), spring seat (42) and main spool (41) in that order. 7078TM15/15A ⑤ Disassembly make up valve Disassembly make up valve Using L-wrench, disassemble plug (38) and dissemble O-ring (36), back up ring (40) and spring (37) and then check (36) and spring (37) in that order.
Page 416 (4) (4) Reduction gear Reduction gear ① Using L-wrench, disassemble wrench bolt (83) and then ring gear cover (80), O-ring (82) from ring gear (59). 7078TM17/17A ② Disassemble thrust plate (79) from ring gear (59). 7078TM18/18A ③ Disassemble planetary gear (76), drive gear (78) in that order from ring gear (59).
Page 417 ⑤ Disassemble in order collar (75), carrier (73) from ring gear (59). 7078TM21/21A ⑥ Disassemble sun gear (71) from ring gear (59) and then disassemble snap ring (72) with a plier jig. 7078TM22/22A ⑦ Using a L-wrench, disassemble plate head bolt (70)-4EA from ring gear (59) and then disassemble plate (69).
Page 418 ⑨ Disassemble needle bearing (68)-4EA from ring gear (59). 7078TM25/25A ⑩ Disassemble collar (66)-4EA from ring gear (59). 7078TM26/26A ⑪ Disassemble washer (65)-4EA from ring gear (59). 7078TM27/27A ⑫ Using jig, disassemble nut (64) when inner pressed state with a L-wrench bolt from ring gear (59).
Page 419 ⑬ Put the reduction gear on the assembling jig and then disassemble ring gear (59). 555K7TM17 7-86 7-86...
Page 420 4. ASSEMBLY 4. ASSEMBLY GENERAL SUGGESTIONS GENERAL SUGGESTIONS 1) 1) After washing each parts cleanly, dry it with compressed air. Provided that you do not wash friction plate with treated oil. In bonding each part, fasten bond torque. When using a hammer, do not forget to use a plastic hammer. 2) 2) ASSEMBLING ASSEMBLING...
Page 421 ④ Assemble swash plate (9) to the shaft casing (1). 555K7TM20 ⑤ Assemble shoe plate (10) to the shaft casing (1). 555K7TM21 ⑥ Assemble shaft (4) to the shaft casing (1). 555K7TM22/22A (2) (2) Cylinder block sub assembly Cylinder block sub assembly ①...
Page 422 ② Assemble pin (15), ball guide (16) in that order to the cylinder block (11). 555K7TM08/08A ③ Assemble piston (18) to the set plate (17, 9 set). 555K7TM23 ④ Assemble sub-assembled piston (17, 18) to the cylinder block (9). 7078TM60 ⑤...
Page 423 ⑥ Assemble friction plate (19), parking plate (20) (respectively 3 EA) to the shaft casing (1). 555K7TM05 ⑦ Assemble back up ring (86), O-ring (23, 22), back up ring (85) in that order to the parking piston (21). 7078TM04/04A ⑧ Using a jig, insert the parking piston to the shaft casing (1) and assemble.
Page 424 ⑩ Assemble O-ring (25) to the shaft casing (1). 555K7TM02 ⑪ Assemble pin (55), O-ring (24) in that order to the shaft casing (1). 555K7TM25 (3) (3) Rear cover assembly Rear cover assembly ① Using a L-wrench, assemble plug (27)- 9EA to the rear cover (26).
Page 425 ③ Assemble the make up check valve Assemble the make up check valve Assemble check (36), spring (37) to rear cover (26) and assemble plug (38) with back up ring (40) and O-ring (39) to rear cover (26) by using a L-wrench. 7078TM16/16A ④...
Page 426 ⑦ Fit O-ring (51) to plug (49) and O-ring (53) to plug (52) and then assemble them to rear cover (26) by a torque wrench. 555K7TM26/26A ⑧ Assemble 2 plug (50) to rear cover (26) by a torque wrench. 555K7TM27 ⑨...
Page 427 ⑪ Assemble rear cover (26) to shaft casing (1). 555K7TM29 ⑫ Combine rear cover assembly and shaft casing assembly with 8 bolt (58). 555K7TM30 ⑬ Motor pressure test Motor pressure test Check the oil leak for one minute by appearance test at air pressure 5 kgf/cm (43 psi).
Page 428 (4) (4) Travel reduction gear Travel reduction gear ① Before assemble nut (64) to the motor. Remove burr and alien substances ready for assembling. 7078TM77/28A ② Insert ring gear (59) to the spray washing machine and heat up 69~70 ˚C for one minute.
Page 429 ⑤ Assemble floating seal (63) to ring gear (59) and motor part with a jig. 7078TM81/81A/82 ⑥ Upset the ring gear (59) and assemble with motor. 7078TM83 ⑦ Combine nut (64) to the ring gear (59) and pressing use a jig and then assemble with a torque-wrench.
Page 430 ⑨ Assemble washer (65)-4EA to the ring gear (59). 7078TM27 ⑩ Assemble collar (66)-4EA to the ring gear (59). 7078TM26 ⑪ Assemble needle bearing (68)-4EA to the ring gear (59). 7078TM25 ⑫ Assemble planetary gear (67)-4EA to the ring gear (59). 7078TM24 7-97 7-97...
Page 431 ⑬ Assemble plate (69)-1EA to the ring gear (59) and then tighten flat head bolt (70)- 4EA with a L-wrench. (after paste loctite and then tighten the flat head bolt). 7078TM23 ⑭ Assemble snap ring (72) to the sun gear (71) with a plier jig.
Page 432 Assemble carrier sub assembly to the ring gear (59). 7078TM87 Assemble needle bearing (77)-3EA to the ring gear (59). 7078TM20 Assemble in order planetary gear (76), drive gear (78) to the ring gear (59). 7078TM19 Assemble thrust plate (79) to the ring gear (59).
Page 433 Assemble in order ring gear cover (80) with O-ring (82) and then assemble wrench bolt (83) with a torque-wrench. 7078TM17/17A Roll the teflon tape to the ring gear (59) and then combine with a L-wrench (after test of drain part water pressure and capacity and then assemble plug PT3/8).
Page 434 (5) (5) Test Test ① Motor pressure test Motor pressure test Check the oil leak for one minute by appearance test at air pressure 5 kgf/cm (71 psi). 7078TM89 ② Performance test Performance test Pour the gear oil (85W-140) by beaker at the reduction gear.
Page 435 TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #2118-) TRAVEL DEVICE (TYPE 2, MACHINE SERIAL NO. : #2118-) 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Swing the work equipment 90˚ and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 436: Parts List
2. DISASSEMBLY AND ASSEMBLY OF MOTOR UNIT 2. DISASSEMBLY AND ASSEMBLY OF MOTOR UNIT PARTS LIST (1/2) PARTS LIST (1/2) Rear flange assy 110 111 559A7TM05 110 Swash piston 119 Separator plate 101 Piston 111 Swash shoe 202 Reducer casing 102 Shoe 112 Pivot 401 O-ring...
Page 437 PARTS LIST (2/2) PARTS LIST (2/2) 559A7TM06 309 Set plug 503 Steel ball 30 Relief valve assy 310 Restrictor 504 Plunger 201 Valve casing 403 O-ring 505 Main spool spring 301 Socket bolt 405 O-ring 506 2 speed spool spring 302 Plug 406 O-ring 507 Spring pin...
Page 438 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tightening torque Tightening torque This table shows the typical screw sizes and tightening torques used in the motor Tightening torque Item Part name Size kgf · m lbf · ft Relief valve assy G 1/2 11.2...
Page 439 (2) (2) Tools Tools ① Hexagon and socket wrench Hexagon and socket wrench Tools Item Part name B size Screw size 304, 310 NPTF plug, Restrictor R 1/16 626, 632 Pipe plug, ROH plug R 1/8 Hexagon wrench 302, 308 ROH plug, 2 speed plug G 1/4 Socket bolt...
Page 440 (3) (3) Special tools Special tools ① Brake piston disassembly jig Brake piston disassembly jig Base plate Guide nut Side bolt Center bolt M12 screw M5 tap, depth 5 Motor casing Brake piston 559A7TM05 7-101-6...
Page 441 ② Brake piston press jig Brake piston press jig The below dimensions are the reference dimensions. 155.5 Assembled status 559A7TM10 ③ Bearing press jig Bearing press jig The below dimensions are the reference dimensions. 33.3 Bearing assembly Bearing pressing jig for valve casing Roller bearing pressing jig for casing 559A7TM11 7-101-7...
Page 442 3) 3) DISASSEMBLY DISASSEMBLY When disassembling the motor, disassemble in the order shown below. The number in brackets after part name means item number of section drawing. (1) (1) Wrap a wire rope around the outer periphery of the motor, lift it with a crane, and wash it with white kerosene.
Page 443 Disassemble the spring cap (510) → → cap Disassemble the spring cap (510) (509). (509). 559A7TM14 Loosen the set plug (309), remove the Loosen the set plug (309), remove the plunger (504) and the main spool spring plunger (504) and the main spool spring (505).
Page 444 The following operations should be The following operations should be carried out if necessary. carried out if necessary. ① Loosen the ROH plug (302) and remove Loosen the ROH plug (302) and remove the restrictor (310). the restrictor (310). ※ If there is no problem with the 1st / 2nd If there is no problem with the 1st / 2nd speed switching, no special disassembly...
Page 445 559A7TM22 ■ DISASSEMBLY OF MOTOR BODY (10) Remove the brake spring (117) from the brake piston (114). 559A7TM25 (11) Using the jig, remove the brake piston (114) from the casing (202). No.16 ※ If you need to disassemble without jig, Fill the brake flow path hole with compressed air.
Page 446 (12) Put the motor horizontally. Disassemble cylinder block (104) from drive shaft (103). Also, disassemble piston assy (10), set plate (106), spherical bush (105), cylinder spring (107). 559A7TM31 ※ Mark each cylinder block bore, piston assy, and set plate bore in the assembled position so that the assembled position does not change.
Page 447 (13) Disassemble friction plate (118) and separator plate (119) in casing (202). 559A7TM35 (14) Disassemble the drive shaft (103) and swash plate (109). 559A7TM37 (15) Disassemble swash piston assy (20), swash piston spring (511), pivot (112), pivot pin (113). 559A7TM38 7-101-13...
Page 448 (16) Do not disassemble any further unless there is a specific problem. At this state, check bearing according to the following inspection instructions. ① Check the raceway surface, rollers or balls in the visible range, and make sure there are no pittings or cracks. ②...
Page 449 4) 4) ASSEMBLY ASSEMBLY The assembly way is the reverse of the disassembly way, but be careful of the following items. The assembly way is the reverse of the disassembly way, but be careful of the following items. ① Be sure to repair damaged parts during disassembly. Please prepare replacement parts in Be sure to repair damaged parts during disassembly.
Page 450 Assemble main spool (501), Plunger Assemble main spool (501), Plunger (504) → → main spool spring (505) main spool spring (505) → (504) O-ring (411) → Assemble set plug (309) O-ring (411) Assemble set plug (309) in order. in order. ※...
Page 451 ■ ASSEMBLY OF MOTOR BODY ASSEMBLY OF MOTOR BODY Place the casing (202) on the work Place the casing (202) on the work surface with the valve casing (201) surface with the valve casing (201) assembly surface facing up. assembly surface facing up. Insert the oil seal (408) into the casing Insert the oil seal (408) into the casing (202) using a jig.
Page 452 (13) Assemble swash piston spring (511) and swash piston assy (20) to casing (202). ※ It is advisable to apply grease thinly on the mating surface of swash piston spring to prevent falling off. When assembled normally, the pushed swash piston assy goes deeper than the casing stage.
Page 453 (16) Set the cylinder spring (107) and the spherical bush (105) into the cylinder block (107). and insert the piston assy. (10) to the bore of set plate (106). ※ Assemble the Larger outer diameter face of set plate and the sliding movement face of shoe in the same direction.
Page 454 (18) Place casing (202) with the valve casing (201) assembly surface of casing (202) facing up. Separator plate (119) and friction plate (118) are alternately assembled to casing (202). ※ Put the separator plate in arc groove of casing. ※ Please refer to the assembly drawing for the number of assembly of the separator 559A7TM30...
Page 455 ※ Pay attention to the assembly direction of the brake piston. The orifice of the brake piston is located downward on the same vertical line as the flow hole in casing. 559A7TM42 (21) Attach the brake spring (117) to the brake piston (114).
Page 456 (24) The valve plate (108) is installed in the valve casing (202) and the O-ring (401) is mounted. ※ Apply grease thinly to the joint surface of the valve plate. (prevention of dropout) 559A7TM23 559A7TM22 (25) Attach the valve casing (201) to the casing (202) and fasten it with a socket bolt (301).
Page 457 3. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR 3. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR PARTS LIST PARTS LIST 559A7TM49 610 Thrust plate R 621 Snap ring 202 Reducer casing 611 Thrust washer 622 Steel ball 601 Housing 613 Collar 623 Socket bolt 602 Cover 614 Inner race 624 Bolt...
Page 458 GENERAL PRECAUTIONS GENERAL PRECAUTIONS This reduction gear is designed to reduce the number of parts and balance the life of the parts. Therefore, all parts can be supplied separately, but when replacing, it is often necessary to replace them both structurally and functionally. Parts to be replaced at the same time Part number 617 618 611 613 615 605 612 609 624 603 620 614 616 606...
Page 459 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tightening torque Tightening torque This table shows the typical screw sizes and tightening torques used in the reduction gear. This table shows the typical screw sizes and tightening torques used in the reduction gear. Tightening torque Item Part name...
Page 460 (3) (3) Special tools Special tools Square part 1 inch 559A7TM50 7-101-26...
Page 461 4) 4) ASSEMBLY ASSEMBLY Disassembly and assembly tips Disassembly and assembly tips ① When disassembling, be careful not to damage the parts. When disassembling, be careful not to damage the parts. ② Wash each part with washing oil and dry it with compressed air. Wash each part with washing oil and dry it with compressed air.
Page 462 ※ Be careful not to damage the O-ring (619) Be careful not to damage the O-ring (619) of the cover during disassembly. of the cover during disassembly. 559A7TM54 Disassemble thrust plate R (610), drive Disassemble thrust plate R (610), drive gear (608).
Page 463 Disassembly of No.1 holder assy Disassembly of No.1 holder assy Do not disassemble the No.1 holder assy Do not disassemble the No.1 holder assy further. further. In this state, check the parts according to In this state, check the parts according to the inspection instructions shown in the inspection instructions shown in section 6.
Page 464 (10) Disassembly of No.2 holder assy Do not disassemble any more No.2 holder assy unless otherwise specified. In this state, check the parts according to the inspection instructions shown in section 6. As mentioned above, it is recommended to exchange No.2 holder assy as a set as much as possible.
Page 465 (12) Disassemble pipe plug (625). ※ When disassembling the pipe plug (625), Do not reuse. 559A7TM65 (13) Disassemble the nut ring (604). 559A7TM66 ※ Please disassemble the nut ring using the dedicated jig referring to the attachment. 559A7TM67 7-101-31...
Page 466 (14) Disassemble casing (202) from housing (601). 559A7TM68 559A7TM69 (15) After disassembling the pipe plug (626), remove the steel ball (622). ※ The number of steel ball is 105. When disassembling, be sure to check the number of balls. 559A7TM70 (16) Disassemble the floating seal kit (618).
Page 467 (17) Disassemble angular bearing (617). 559A7TM72 ※ Use a press for disassembly. 559A7TM73 ※ The disassembly process is finished. 7-101-33...
Page 468 5) 5) ASSEMBLY ASSEMBLY After placing angular bearing (617) on After placing angular bearing (617) on housing (601), press the angular bearing housing (601), press the angular bearing (617) using a press. (617) using a press. 559A7TM72 ※ Assemble the protrusion of the inner ring Assemble the protrusion of the inner ring face down.
Page 469 ※ Before assembling, check the metal Before assembling, check the metal surface of the floating seal for cracks, surface of the floating seal for cracks, dents, and O-ring damage. dents, and O-ring damage. Do not apply oil to the floating seal rubber Do not apply oil to the floating seal rubber part.
Page 470 ※ Caulking is performed to prevent looseni- Caulking is performed to prevent looseni- Caulking ng around the assembly. ng around the assembly. 3 places 559A7TM76 Assemble the No. 2 holder assy Assemble the No. 2 holder assy Assemble in the order of thrust washer Assemble in the order of thrust washer (611) →...
Page 471 Fasten snap ring (621) to sun gear (607) using snap ring pliers. And assemble in the center of planetary gear F. ※ Assemble R part of snap ring toward cover. Sun gear is assembled with the long end facing toward casing. 559A7TM78 (10) Assemble the No.1 holder assy.
Page 472 (12) Assemble drive gear (608) and thrust plate R (610). 559A7TM55 (13) Assemble the O-ring (619), side plate A (627) and side plate B (628) on the cover (602). ※ After assembling the side plate B, remove any debris from the side. 559A7TM82 (14) Assemble cover sub to housing.
Page 473: Group 7 Rcv Lever
GROUP 7 RCV LEVER GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 474: Disassembly And Assembly
2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY 1) 1) STRUCTURE STRUCTURE 555C92RL02 Case Stopper 15 O-ring 22 Lock nut Plug Push rod 16 Rod seal 23 Handle assembly Bushing 10 Spring 17 Plate 24 Handle bar Spool 11 Push rod 18 Boot 25 Nut Shim...
Page 475 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools Tool name Remark Allen wrench Spanner (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques (2) (2) Tightening torque Tightening torque Torque Part name...
Page 476 3) 3) DISASSEMBLY DISASSEMBLY Clean pilot valve with kerosene. ※ Put blind plugs into all ports Fix pilot valve in a vise with copper (or lead) sheets. Remove end of boot (26) from case (1) and take it out upwards. 21098RL04 ※...
Page 477 Loosen adjusting nut (21) and plate (20) with spanners on them respectively, and remove them. 36078RL01 36078RL02 Turn joint anticlockwise to loosen it, utilizing jig (special tool). ※ When return spring (10) is strong in force, plate (17), plug (14) and push rod (11) will come up on loosening joint.
Page 478 Remove plate (17). 36078RL05 When return spring (10) is weak in force, plug (14) stays in casing because of sliding resistance of O-ring. ※ Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
Page 479 (12) For disassembling reducing valve section, stand it vertically with spool (4) bottom placed on flat workbench. Push down spring seat (7) and remove two pieces of semicircular stopper (8) with tip of small minus screwdriver. ※ Pay attention not to damage spool surface.
Page 480 36078RL13 (16) Remove lock nut (22) and then boot (26). 36078RL14 2507ARL10 7-109...
Page 481 (17) (17) Cleaning of parts Cleaning of parts ① Put all parts in rough cleaning vessel filled with kerosene and clean them (rough cleaning). ※ If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged.
Page 482 4) 4) ASSEMBLY ASSEMBLY Tighten hexagon socket head plug (2) to the specified torque. ※ Tighten two bolts alternately and slowly. 36078RL15 Put shim (5), springs (6) and spring seat (7) onto spool (4) in this order. 36078RL16 Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper (8) on spring seat...
Page 483 Assemble O-ring (15) onto plug (14). 36078RL19 Assemble seal (16) to plug (14). ※ Assemble seal in such lip direction as shown below. 36078RL20 Assemble push rod (11) to plug (14). ※ Apply working oil on push-rod surface. 36078RL21 Assemble plug subassembly to casing. ※...
Page 484 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate (17), and tighten joint (19) temporarily. 36078RL23 (10) Fit plate (17). (11) Tighten joint (19) with the specified torque to casing, utilizing jig. 36078RL24 (12) Assemble plate (20) to joint (19).
Page 485 (14) Fit boot (18) to plate. 1408DA61 (15) Fit boot (26) and lock nut (22), and handle subassembly is assembled completely. 2507ARL10 36078RL27 (16) Pull out cord and tube through adjusting nut hole provided in direction 60˚ to 120˚ from casing hole. 1408DA66 7-114...
Page 486 (17) Assemble bushing (27) to plate and pass cord and tube through it. ※ Provide margin necessary to operation. 21098RL07 (18) Determine handle direction, tighten lock nut (22) to specified torque to fix handle. 21098RL08 (19) Apply grease to rotating section of joint and contacting faces of disk and push rod.
Page 487: Group 8 Turning Joint
GROUP 8 TURNING JOINT GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
Page 488 2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY 1) 1) STRUCTURE STRUCTURE 12 13 555K7TJ03 Slipper seal 10 Plug Shaft O-ring 11 Plug Cover Retainer ring 12 Hexagon bolt O-ring O-ring 13 Spring washer Ring 7-117...
Page 489 2) 2) DISASSEMBLY DISASSEMBLY ※ Before the disassembly, clean the turning joint. Remove bolts (12), washer (13) and cover (3). R55NM7TJ02 Remove O-ring (7). Remove retainer ring (8) and ring (5). 555K7TJ04 Place hub (1) on a V-block and by using a wood buffer at the shaft end, hit out shaft Secure with hand Wooden block...
Page 490 3) 3) ASSEMBLY ASSEMBLY ※ Clean all parts. ※ As a general rule, replace oil seals and O-ring. ※ Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix eight slipper seal (6) and O-ring (4) to hub (1).
Page 491 Install cover (3) to body (1) and tighten bolts (12) with washer (13). R55NM7TJ02 7-120...
Page 492: Group 9 Boom, Arm And Bucket Cylinder
GROUP 9 BOOM, ARM AND BUCKET CYLINDERS GROUP 9 BOOM, ARM AND BUCKET CYLINDERS 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL BUCKET CYLINDER BUCKET CYLINDER (1) (1) Removal Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine.
Page 493 ④ Sling bucket cylinder assembly (8) and remove bolt (6) then pull out pin (5). ⑤ Remove bucket cylinder assembly (8). ·Weight : 30 kg (70 lb) R5577CY05 Install Install (2) (2) ① Carry out installation in the reverse order to removal.
Page 494: Arm Cylinder
ARM CYLINDER ARM CYLINDER (1) (1) Removal Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. ※ Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. 13031GE18 Loosen the breather slowly to release Loosen the breather slowly to release...
Page 495 ⑤ Sling arm assembly (8) and remove bolt (7) then pull out pin (6). ⑥ Remove arm cylinder assembly (8). ·Weight : 50 kg (110 lb) R5577CY09 Install Install (2) (2) ① Carry out installation in the reverse order to removal. When aligning the mounting position When aligning the mounting position of the pin, do not insert your fingers in...
Page 496: Boom Cylinder
BOOM CYLINDER BOOM CYLINDER (1) (1) Removal Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. ※ Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. 13031GE18 Loosen the breather slowly to release Loosen the breather slowly to release...
Page 497 ⑤ Disconnect boom cylinder hoses (4) and put plugs on cylinder pipe. 60CR97CY13 ⑥ Remove bolt (6) and pull out pin (5). ⑦ Remove boom cylinder assembly (3). ·Weight : 70 kg (150 lb) 60CR97CY14 (2) (2) Install Install ① Carry out installation in the reverse order to removal.
Page 498 2. DISASSEMBLY AND ASSEMBLY 2. DISASSEMBLY AND ASSEMBLY STRUCTURE STRUCTURE 1) 1) (1) (1) Bucket cylinder Bucket cylinder R55Z97CY22 Tube assembly 10 O-ring 19 Steel ball Rod assembly 11 Back-up ring 20 Set screw Rod cover 12 O-ring 21 Du bushing Dust seal 13 Piston 22 Bushing...
Page 499 (2) (2) Arm cylinder Arm cylinder R55Z97CY24 Tube assembly 13 Cushion stopper 25 Spring Rod assembly 14 Piston 26 Support spring Rod cover 15 Piston seal 27 Plug Dust wiper 16 Wear ring 28 U-bolt Retaining ring 17 Dust ring 29 Hex nut U-packing 18 Wear ring...
Page 500 (3) (3) Boom cylinder Boom cylinder 555C97CY21 Tube assembly 11 Retaining ring 21 Dust ring Bushing 12 O-ring 22 O-ring Bushing 13 Back-up ring 23 Back-up ring Du bushing 14 O-ring 24 Piston nut Rod cover 15 Back-up ring 25 Set screw Rod bushing 16 O-ring 26 Dust seal...
Page 501 (4) (4) Dozer cylinder Dozer cylinder R55Z97CY23 Tube assembly 11 Back-up ring 21 Pipe Rod assembly 12 O-ring 22 Double pitot check valve Gland 13 Piston 23 O-ring Dust wiper 14 Piston seal 24 O-ring Retaining ring 15 Dust ring 25 Socket bolt Rod seal 16 Wear ring...
Page 502 (5) (5) Boom swing cylinder Boom swing cylinder R55Z96MC02 Tube assembly 10 O-ring 18 Back-up ring Rod assembly 11 Buck-up ring 19 Steel ball Gland 12 O-ring 20 Set screw Dust wiper 13 Piston 21 Pin bushing Retaining ring 14 Piston seal 22 Dust seal Rod seal 15 Dust ring...
Page 503 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools Name Specification Allen wrench Spanner Hook spanner Suitable size (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques (2) (2) Tightening torque Tightening torque Torque...
Page 504 3) 3) DISASSEMBLY DISASSEMBLY Remove cylinder head and piston rod Remove cylinder head and piston rod ① Hold the clevis section of the tube in a vise. ※ Use mouth pieces so as not to damage the machined surface of the cylinder tube.
Page 505 Note that the plated surface of rod assembly (3) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. ⑤ Place the removed rod assembly on a wooden V-block that is set level.
Page 506 (3) (3) Disassemble the piston assembly Disassemble the piston assembly ① Remove wear ring (17). ② Remove dust ring (18) and piston seal (16). ※ Exercise care in this operation not to damage the grooves. 555C97CY36 (4) (4) Disassemble gland assembly Disassemble gland assembly ①...
Page 507 4) 4) ASSEMBLY ASSEMBLY (1) (1) Assemble cylinder head assembly Assemble cylinder head assembly ※ Check for scratches or rough surfaces if found smooth with an oil stone. ① Coat the inner face of rod cover (5) with hydraulic oil. 555C97CY38 ②...
Page 508 ⑤ Fit back up ring (12) to rod cover (5). ※ Put the backup ring in the warm water of 12,13 30~50˚C . ⑥ Fit O-ring (13) to rod cover (5). 555C97CY41 (2) (2) Assemble piston assembly Assemble piston assembly ※...
Page 509 (3) (3) Install piston and cylinder head Install piston and cylinder head ① Fix the rod assembly to the work bench. Gland assembly ② Apply hydraulic oil to the outer surface of Rod assembly rod assembly (3), the inner surface of piston and cylinder head.
Page 510 (3) (3) Overall assemble Overall assemble Fix with a bar ① Place a V-block on a rigid work bench. Mount the tube assembly (2) on it and Lift fix the assembly by passing a bar through the clevis pin hole to lock the Straight assembly.
Page 511: Group 10 Undercarriage
GROUP 10 UNDERCARRIAGE GROUP 10 UNDERCARRIAGE 1. TRACK LINK 1. TRACK LINK REMOVAL REMOVAL Move track link until master pin is over front idler in the position put wooden block Master pin as shown. Loosen tension of the track link. ※...
Page 512: Carrier Roller
2. CARRIER ROLLER 2. CARRIER ROLLER 1) 1) REMOVAL REMOVAL Loosen tension of the track link. Grease valve R5577TR05 Jack up the track link height enough to permit carrier roller removal. Carrier roller Jack R5577TR04 Remove bolt (1) at both side. Remove carrier roller (2).
Page 513: Track Roller
3. TRACK ROLLER 3. TRACK ROLLER 1) 1) REMOVAL REMOVAL Loosen tension of the track link. Grease valve R5577TR05 Using the work equipment, push up track frame on side which is to be removed. ※ After jack up the machine, set a block under the unit.
Page 514 4. IDLER AND RECOIL SPRING 4. IDLER AND RECOIL SPRING 1) 1) REMOVAL REMOVAL Remove the track link. For detail, see removal of track link. 8-164(1) 140-7 Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry.
Page 515 3) 3) DISASSEMBLY AND ASSEMBLY OF IDLER DISASSEMBLY AND ASSEMBLY OF IDLER (1) (1) Structure Structure 555K7ID43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 7-144...
Page 516 (2) (2) Disassembly Disassembly Press ① Remove plug and drain oil. ② Draw out the spring pin (7), using a press. 8-166(1) 140-7 ③ Pull out the shaft (2) with a press. Press ④ Remove seal (3) from idler (1) and bracket (5).
Page 517 Assembly Assembly ※ Before assembly, clean the parts. ※ Press Coat the sliding surfaces of all parts with oil. ① Cool up bushing (4) fully by some dry ice and press it into shell (1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
Page 518 ⑥ Install bracket (5) attached with seal (3). 8-168(1) 140-7 ⑦ Knock in the spring pin (7) with a hammer. 8-168(2) 140-7 ⑧ Lay bracket (5) on its side. Supply engine oil to the specified level, and tighten plug. 8-168(3) 140-7 7-147...
Page 519: Disassembly And Assembly Of Recoil Spring
4) 4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure Structure (1) (1) R5577RS01 Spacer 16 Dust-seal Spring 11 Bracket 17 Spacer Lock washer 12 Piston 18 Retaining ring Hex-nut 13 Grease valve 21 Bolt Slotted hex-nut 14 O-ring 22 Washer...
Page 520 Disassembly Disassembly ① Apply pressure on spring (3) with a press. 5, 6 The spring is under a large installed load. ※ This is dangerous, so be sure to set properly. ·Spring set load : 3900 kg (8600 lb) ② Remove split pin (6) and nut (5).
Page 521 ⑧ Remove retaining ring (18), spacer (17), dust seal (16), back-up ring (15) and O-ring (14). R5577RS05 Assembly Assembly ① Install O-ring (14), back-up ring (15), dust seal (16), spacer (17) and retaining ring (18) to bracket (11). ※ When installing dust seal (16) take full care so as not to damage the lip.
Page 522 ⑤ Install spring (3) and bracket (4) to body (1). ⑥ Apply pressure to spring (3) with a press 5, 6 and tighten nut (4). ※ Apply sealant before assembling. ※ During the operation, pay attention specially to prevent the press from slipping out.
Page 523: Group 11 Work Equipment
GROUP 11 WORK EQUIPMENT GROUP 11 WORK EQUIPMENT 1. STRUCTURE 1. STRUCTURE SECTION A-A SECTION B-B SECTION E-E SECTION C-C SECTION D-D 55Z97AT01 7-152...
Page 524 2. REMOVAL AND INSTALL 2. REMOVAL AND INSTALL 1) 1) BUCKET ASSEMBLY BUCKET ASSEMBLY (1) (1) Removal Removal ① Lower the work equipment completely to ground with back of bucket facing down. 55Z97AT02 ② Remove nut (1), bolt (2) and draw out the pin (4).
Page 525: Arm Assembly
2) 2) ARM ASSEMBLY ARM ASSEMBLY Removal Removal ※ Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can Escaping fluid under pressure can penetrated the skin causing serious penetrated the skin causing serious injury.
Page 526 3) 3) BOOM CYLINDER BOOM CYLINDER Removal Removal ① Remove arm and bucket assembly. ② For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly. 55Z97AT08 ③ Disconnect head lamp wiring.
Page 527 SECTION 8 COMPONENT MOUNTING TORQUE SECTION 8 COMPONENT MOUNTING TORQUE Group 1 Introduction guide ------------------------------------------------------------------------------------------- 8-1 Group 2 Engine system ------------------------------------------------------------------------------------------------ 8-2 Group 3 Electric system ----------------------------------------------------------------------------------------------- 8-4 Group 4 Hydraulic system -------------------------------------------------------------------------------------------- 8-5 Group 5 Undercarriage ------------------------------------------------------------------------------------------------ 8-7 Group 6 Structure --------------------------------------------------------------------------------------------------------- 8-8 Group 7 Work equipment --------------------------------------------------------------------------------------------- 8-10...
Page 528: Section 8 Component Mounting Torque
This section shows bolt specifications and standard torque values needed when mounting components to the machine. Use genuine Hyundai spare parts. We expressly point out that Hyundai will not accept any responsibility for defects resulted from non-genuine parts. In such cases Hyundai cannot assume liability for any damage.
Page 529: Group 2 Engine System
GROUP 2 ENGINE SYSTEM GROUP 2 ENGINE SYSTEM 1. ENGINE AND ACCESSORIES MOUNTING 1. ENGINE AND ACCESSORIES MOUNTING Air cleaner Engine 60CR9A8CM01 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 8×1.25 3.0±2.0 21.7±14.5 M12×1.75 10±1.0 72.3±7.2 M10×1.5 6.9±1.0 49.9±7.2 M16×2.0...
Page 530 2. COOLING SYSTEM AND FUEL TANK MOUNTING 2. COOLING SYSTEM AND FUEL TANK MOUNTING Air compressor Air con idle pulley Fuel tank Radiator and cooler 60CR9A8CM02 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 6×1.0 1.05±0.2 7.6±1.45 M12×1.75 12.8±3.0 92.6±21.7...
Page 531: Group 3 Electric System
GROUP 3 ELECTRIC SYSTEM GROUP 3 ELECTRIC SYSTEM ELECTRIC COMPONENTS MOUNTING ELECTRIC COMPONENTS MOUNTING Fuel filler pump Power relay Travel alarm buzzer Battery relay Battery Horn DETAIL A 60CR9A8CM03 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 6×1.0 1.05±0.2 7.6±1.45 M10×1.5...
Page 532: Group 4 Hydraulic System
GROUP 4 HYDRAULIC SYSTEM GROUP 4 HYDRAULIC SYSTEM 1. HYDRAULIC COMPONENTS MOUNTING 1 1. HYDRAULIC COMPONENTS MOUNTING 1 Dozer lever Air breather Level gauge Block(A) Hydraulic tank Swing motor Terminal Solenoid valve Cross Shuttle valve RCV-RH Turning joint Main control valve Select valve RCV-LH Solenoid...
Page 533 2. HYDRAULIC COMPONENTS MOUNTING 2 2. HYDRAULIC COMPONENTS MOUNTING 2 ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER DOZER CYLINDER 60CR9A8CM06 ·Tightening torque Rod cover (1) Rod cover (1) Piston nut (3) Piston nut (3) Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft Boom cylinder M115...
Page 534: Group 5 Undercarriage
GROUP 5 UNDERCARRIAGE GROUP 5 UNDERCARRIAGE ADJUST COMPONENT Swing bearing Idler Travel motor Sprocket TRACK CHAIN Idler Track guard 60CR9A8CM07 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M10×1.5 6.9±1.4 49.9±10.1 M18×2.0 41.3±6.2 298.7±44.8 M12×1.75 12.8±3.0 92.6±21.7 M20×2.5 100±15 723.3±108 M14×2.0...
Page 535: Group 6 Structure
GROUP 6 STRUCTURE GROUP 6 STRUCTURE 1. CAB AND ACCESSORIES MOUNTING 1. CAB AND ACCESSORIES MOUNTING Console frame Cabin Seat base 60CR9A8CM08 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 6×1.0 1.44±0.3 10.4±2.1 M10×1.5 4.7±0.9 4.0±6.5 M 8×1.25 2.5±0.5 18.1±3.6 M12×1.75...
Page 536 2. COWLING MOUNTING 2. COWLING MOUNTING Fuel hood body Engine hood Frame cover-RH Counterweight Upper frame Frame cover-LH Under cover-Pump Under cover-H/Tank Under cover-Engine Under cover-F/Tank Under cover-MCV 60CR9A8CM09 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M 8×1.25 2.5±0.5 18.1±3.6 M24×3.0...
Page 537: Group 7 Work Equipment
GROUP 7 WORK EQUIPMENT GROUP 7 WORK EQUIPMENT 60CR9A8CM10 ·Tightening torque Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft M12×1.75 12.8±3.0 92.6±21.7 M16×2.0 29.7±4.5 215±32.5 8-10...