Case cx36b compact hydraulic excavator service repair manual by 163561

CX31B CX36B Compact Hydraulic Excavator CX31B - PIN PW14-46519 - and higher CX36B - PIN PX15-21105 - and higher

SERVICE MANUAL

Part number S5PW0032E02 English August 2010

model

CX31B CX36B

INDEX 1 SPECIFICATIONS SECTION 2 MAINTENANCE SECTION

SYSTEM

SHOP MANUAL

MAINTENANCE SPECIFICATIONS

COMPACT HYDRAULIC EXCAVATOR

5 TROUBLESHOOTING 6 ENGINE SECTION

OPT.

OF INSTALLING 7 PROCEDURE OPTIONS SECTION

E / G TROUBLESHOOTING

4 DISASSEMBLY SECTION

DISASSEMBLING

3 SYSTEM SECTION

Book Code No.S5PW0032E02 0-1

GENERAL SAFETY INFORMATION

3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as follows:

Do not operate or perform any maintenance on this machine until all instructions found in the OPERATORâ&#x20AC;&#x2122;S MANUAL and this MANUAL have been thoroughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death. Always keep the manual in storage. If it is missing or damaged, place an order with an authorized our Distributor for a replacement. If you have any questions, please consult an authorized our Distributor.

(4) It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur. (6) Continue studying the manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

(1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read and understood by all personnel before starting any work with or on the machine. (2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. (3) Messages of safety appear in the manual and on the machine : All messages of safety are identified by either word of "DANGER", "WARNING" and "CAUTION". 1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:

0-2

SAFETY PRECAUTIONS

stands, capable of supporting the machine, before performing any disassembly.

The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATORâ&#x20AC;&#x2122;S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.

Do not operate this machine unless you have read and understand the instructions in the OPERATORâ&#x20AC;&#x2122;S MANUAL. Improper machine operation is dangerous and could result in injury or death. (6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.

(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section ; SPECIFICATIONS.

(8) Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face to the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

The following is a list of basic precautions that must always be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine.

(9) To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

(2) Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.

(10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely.

(3) Disconnect the battery and hang a "Do Not Operate" tag in the Operators Compartment. Remove ignition keys. (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not roll while working on or under the machine. Hang a "Do Not Operate" tag in the Operators Compartment.

(12)Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

(5) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack

0-3

(21)Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

(13)Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work. (14)Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

(22)Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.

(15)Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted. (16)Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. (17)Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Donâ&#x20AC;&#x2122;t fail to lower the attachment and place the bucket to the ground before starting the work. (19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

0-4

INDEX

CASE-NA

CX31B CX36B

S5PW2232E02 2010-06 S5PW2332E02 2010-06 S5PW2432E02 2010-06

SYSTEM

S5PA0105E01 2010-03 S5PW0232E02 2010-06 S5PW0332E02 2010-06 S5PW1131E02 2010-06 S5PW1231E02 2010-06 S5PW1332E02 2010-06 _

MAINTENANCE SPECIFICATIONS

Book Code No. Distribution Yearâ&#x20AC;&#x201C;Month

Title

Index No.

OUTLINE

SPECIFICATIONS

ATTACHMENT DIMENSIONS

TOOLS

STANDARD MAINTENANCE TIME TABLE MAINTENANCE STANDARD AND TEST PROCEDURE

HYDRAULIC SYSTEM

ELECTRIC SYSTEM

COMPONENTS SYSTEM

GENERAL DISASSEMBLY & ASSEMBLY

ATTACHMENT

UPPER SLEWING STRUCTURE

TRAVEL SYSTEM

HYDRAULIC SYSTEM

ELECTRICAL SYSTEM

ENGINE

33 1

2 42 34

11 3 43 51

44 12

S5PA3105E01 2010-03 S5PW3232E02 2010-06 S5PW3332E02 2010-06 S5PW3432E02 2010-06

DISASSEMBLING

E / G TROUBLESHOOTING

S5PW4231E02 2010-06 S5PW4331E02 2010-06 S5PW4431E02 2010-06 S5PW5131E02 2010-06 _

31 23

32 24

_ _

PW14-46519~ PX15-21105~

APPLICABLE MACHINES

0-5

NOTE:

This Manual may be revised due to the improvement of products, modification of specifications, etc. There may be cases where the system on the actual machine may differ with the manual - this may be due to variation of specifications by countries. Contact your local distributor if you need clarification.

This manual contains information necessary for the maintenance and repair of hydraulic excavators. It is categorized into seven chapters: Specification, Maintenance, System, Disassembly, Troubleshooting, Engine and Installation Procedures for Optional Attachment. •

The Chapter "Specification" describes the specifications for the entire machine and replacement and repairing of attachments.

•

The Chapter "Maintenance" contains material for service and adjustment of the entire machine.

•

The Chapter "System" describes the operating system, including the hydraulic system, electric system, components, etc.

•

The Chapter "Disassembly" describes the removal and installation of assemblies mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment.

•

The Chapter "Troubleshooting" describes how to find the faults in equipment.

•

The Chapter "Engine" contains the complete "Maintenance Manual" provided by the engine supplier.

•

The Chapter "Installation Procedures for Optional Attachment" describes the supplements added on request as required.

When ordering replacement or service parts, refer to the most recent Parts Catalog for the machine to get the correct replacement/service part number.

0-6

1. OUTLINE

1. OUTLINE TABLE OF CONTENTS

1.1 GENERAL PRECAUTIONS FOR REPAIRS ........................................................1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING ..............................................1-3 1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING ...................................1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ..........1-4 1.1.4 ELECTRICAL EQUIPMENT ........................................................................1-6 1.1.5 HYDRAULIC PARTS ....................................................................................1-7 1.1.6 WELDING REPAIR ......................................................................................1-7 1.1.7 ENVIRONMENTAL MEASURES .................................................................1-7 1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS' STANDARD HANDBOOK FOR MECHANICAL ENGINEERS) ................................................1-8

Book Code No. S5PA0105E01 1-1

1. OUTLINE

Issue

Date of Issue

First Edition

June, 2009

E10SR : PA03-05001~

S5PA0105E01 (NHK-EUR)

↑

E10SR : PA03-05001~

↑ (NHK-AUS)

↑

SK10SR-2 : PA03-05001~

↑

July, 2009

SK10SR-2 : PA03-05001~

↑

Applicable Machines

December, 2009 E18SR : PU09-08001~

Remarks

↑ (AUS) ↑ (KOR) ↑ (NHK-EUR) ↑

↑

January, 2010

SK17SR-3 : PU09-08001~

↑ (Oceania)

↑

SK30SR-5 : PW14-45964~ SK35SR-5 : PX15-20658~

↑ (KCM North America)

↑

CX17B : PU09-08001~

↑ (CASE AUS)

↑

E18SR : PU09-08001~

↑ (NH AUS)

↑

CX31B : PW14-45964~ CX36B : PX15-20658~

↑ (CASE-NA)

↑

E30B : PW14-45964~ E35B : PX15-20658~

(NH-NA)

↑

SK17SR-3 : PU09-08001~

↑

SK50SR-5 : PJ06-08890~

↑

February, 2010

SK30SR-5 : PW14-45001~ SK35SR-5 : PX15-20001~

↑ (KCM S.E.ASIA&OCE)

↑

CX31B : PW14-45001~ CX36B : PX15-20001~

↑ (CASE-AUS)

↑

CX50B : PJ06-08890~

↑ (CASE-NA)

↑

E50B : PJ06-08890~

↑

E30B : PW14-45001~ E35B : PX15-20001~

↑

SK27SR-5 : PV13-33292~

↑

March, 2010

SK30SR-5 : PW14-46519~ SK35SR-5 : PX15-21105~

↑ (KCM North America)

↑

CX31B : PW14-46519~ CX36B : PX15-21105~

↑ (CASE-NA)

SK17SR-3K : PU09-08001~

1-2

(KOR)

↑ ↑ (NA) ↑ (NA)

↑ (NH-NA) ↑ (NH-AUS) ↑ (NA)

1. OUTLINE

1.1

GENERAL PRECAUTIONS FOR REPAIRS

1.1.1

PREPARATION BEFORE DISASSEMBLING

Read Operator's Manual before disassembling

(1) Understanding operating procedure Read OPERATOR'S MANUAL carefully to understand the operating procedure. (2) Cleaning machines Remove soil, mud, and dust from the machine before bringng it into the service shop to prevent loss of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while reassembling. (3) Inspecting machines Identify the parts to be disassembled before starting work. Determine the disassembling procedure, considering the workshop situations etc., and order necessary parts in advance. (4) Recording Record the following items for communication and prevention of recurring malfunction. 1. 2. 3. 4. 5. 6.

Inspection date and place. Model name, applicable machine number, and hour meter read. Trouble condition, place and cause. Visible oil leakage, water leakage and damage. Clogging of filters, oil level, oil quality, oil contamination and loosening of connections. Result of consideration if any problem exists based on the operation rate per month calculated from hour meter indication after the last inspection date.

(5) Arrangement and cleaning in service shop 1. Tools required for repair work. 2. Prepare space to place the disassembled parts. 3. Prepare oil containers for draining oil etc.

1.1.2

SAFETY IN DISASSEMBLING AND ASSEMBLING

WARNING

(1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses. (2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work. (3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine. (4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency. (5) Choose a hard, level and safe place, and place the attachment on the ground securely. (6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. (7) Use proper tools, and replace or repair defective tools. (8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

1-3

1. OUTLINE 1.1.3

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

(1) Removing hydraulic equipment 1. Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter. 2. Carefully drain oil of the removed pipes into a containers without spilling on the floor. 3. Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion. 4. Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench. (2) Disassembling hydraulic equipment 1. Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after modification. 2. When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training. 3. Provide matching marks to facilitate reassembling work. 4. Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself. 5. Use the special jig and tools without fail if they are specified. 6. If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause. 7. Place the removed parts in order and attach tags to facilitate the reassembling. 8. Note the location and quantity of parts commonly applied to multiple locations. (3) Inspecting parts 1. Ensure that the disassembled parts are free from seizure, interference and uneven contact. 2. Measure and record wear condition of parts and clearance. 3. If the problem is found in a part, repair or replace it with a new one. (4) Reassembling hydraulic equipment 1. Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts. 2. Perform rough and finish cleaning before assembling. 3. Remove washing oil by air and apply clean hydraulic or gear oil for assembling. 4. Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance. 5. Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied. 6. Remove rust preventive agent from the new parts before use. 7. Fit bearings, bushings and oil seals using special jigs. 8. Assemble the parts utilizing matching marks. 9. Ensure all the parts are completely assembled after the work.

1-4

1. OUTLINE (5) Installing hydraulic equipment 1. Ensure hydraulic oil and lubricant are properly supplied. 2. Perform air bleeding when : a. Hydraulic oil changed b. Parts of suction side piping replaced c. Hydraulic pump installed d. Slewing motor installed e. Travel motor installed f. Hydraulic cylinder installed 3. Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug, starting the engine and keep it in low idle condition. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug. 4. Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more than 5 minutes at low speed without load. 5. Perform air bleeding of pilot line by performing a series of digging, slewing and travel. 6. Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

Level gauge Oil level lines (Level located between the two lines shows appropriate amount of oil)

Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment.

Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.

1-5

1. OUTLINE 1.1.4

ELECTRICAL EQUIPMENT

(1) Do not disassemble electrical equipment. (2) Handle electrical equipment carefully - be careful not to drop. Exposure to electrical current can cause electrical shock. (3) Turn the key OFF prior to connecting and disconnecting work. (4) Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion. (5) Connect the connector and ensure it is completely locked. (6) Turn the key OFF prior to touching the terminal of starter or generator. (7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay. (8) Do not splash water on the electrical equipment and connectors during machine washing. (9) Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector. If moisture adhesion is found, dry it completely before the connection.

Battery electrolyte is hazardous. Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or loss of eyesight. If the exposure occurs, take the following emergency measures and seek the advice of a medical specialist. -When skin exposed : Wash with water and soap sufficiently. -When eyes exposed : Immediately wash away with city water continuously for more than 10 minutes. -When a large amount of the liquid flows out : Neutralize with sodium bicarbonate or wash away with city water. -When swallowed : Drink a large amount of milk or water. -When clothes exposed: Immediately undress and wash.

1-6

1. OUTLINE 1.1.5

HYDRAULIC PARTS

1 (1) O-ring • Ensure O-rings have elasticity and are not damaged before use. • Use the appropriate O-rings. O-rings are made of various kinds of materials having different hardness to apply to a variety of parts, such as the part for moving or fixed portion, subjected to high pressure, and exposed to corrosive fluid, even if the size is same. • Fit the O-rings without distortion and bend. • Always handle floating seals as a pair. (2) Flexible hose (F hose) • Use the appropriate parts. Different parts are used depending on the working pressure even the size of fitting and the total length of the hose is same. • Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized.

1.1.6

WELDING REPAIR

(1) Refer repair welding to qualified personnel according to the appropriate procedure. (2) Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment. (3) Move away the articles in advance that may cause fire if exposed to sparks. (4) Before starting the repair of the attachment, do not fail to cover the plated surface of the piston rod with flameproof sheet to prevent it from being exposed to sparks.

1.1.7

ENVIRONMENTAL MEASURES

(1) Run the engine at the place that is sufficiently ventilated. (2) Industrial waste disposal Dispose of the following parts according to the relevant regulations : Waste oil and waste container Battery (3) Precautions for handling hydraulic oil Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures : -When an eye exposed : Immediately wash away with city water sufficiently till stimulative feeling vanishes. -When swallowed : Do not let vomit, and receive medical treatment immediately. -When skin exposed: Wash with water and soap sufficiently. (4) Others Use replacement parts and lubricants authorized as the manufacturer's genuine parts.

1-7

1. OUTLINE

1.2

INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS' STANDARD HANDBOOK FOR MECHANICAL ENGINEERS)

Introduction Although this manual includes International System of Unit and Foot-Pound System of Units, if you need SI unit, refer to the following international system of units. Given hereinafter is an excerpt of the units that are related to this manual. 1. Etymology of SI Unites French: Le Systeme International d' Unites English: International System of Units 2. Construction of SI Unit System

Base units Table 1-1

SI unit system

Derived units of base units Table 1-3

Supplemen tary units Table 1-2

SI units

Derived units bearing peculiar designations Table 1-4

Derived units

Prefixes of SI (n-th power of 10, where n is an integer) Table 1- 5

(4) Derived Units bearing Peculiar Designations

(1) Base units

Table 1-4

Table 1-1 QUANTITY

UNIT

SYMBOL

QUANTITY

Length

meter

Frequency

Mass

kilogram

Force

Time

second

Electric current

ampere

Thermodynamic temperature

kelvin

Amount of substance

mol

Luminous intensity

candela

UNIT

Plane angle

radian

Solid angle

steradian

rad sr

Table 1-3 UNIT

1/s

kg • m/s 2

N/m2

N•m

watt

J/s

coulomb

A•s

Electric potential difference, volt Voltage, and Electromotive force

W/A

Quantity of static electricity farad and Electric capacitance

C/V

Quantity of electricity

(3) Derived Units

QUANTITY

Power

SYMBOL

Electric resistance

SYMBOL

Area

square meter

Volume

cubic meter

Velocity

meter per second

m/s

ohm

Acceleration meter per second squared

m/s2

celcius Celcius degree or temperature degree

Density

kg/m3

Illuminance

kilogram per cubic meter

1-8

FORMULA

hertz

Energy, Work and Quantity of joule heat

Table 1-2

SYMBOL

newton

Pressure and pascal Stress

(2) Supplementary units

QUANTITY

UNIT

lux

V/A

(t+273.15)K

l m/m2

1. OUTLINE (6) Unit Conversion

(5) Prefixes of SI

Table 1-6

Table 1-5 PREFIX SYMBOL

MULTIPLICATION FACTORS

QUANTITY Gravitational

giga

Mass

mega

106

Force

kgf

kilo

Torque

kgf•m

hecto

Pressure

kgf/cm

deca

deci

Motive Power

centi

10–2

Revolution

rpm

milli

10–3

micro

10–6

nano

10–9

pico

10–12

3 2

–1

CONVERSION FACTOR 1 kgf=9.807 N

N•m kgf•m=9.807 N•m 2

MPa 1 kgf/cm2=0.09807 MPa kW 1 PS=0.7355 kW min–1 r/min *1

*1 Units that are allowed to use.

1-9

1. OUTLINE

1-10

2. SPECIFICATIONS

2. SPECIFICATIONS TABLE OF CONTENTS

2.1 COMPONENTS NAME ........................................................................................2-3 2.2 MACHINE DIMENSIONS .....................................................................................2-4 2.3 SPECIFICATIONS AND PERFORMANCE ..........................................................2-6 2.4 MACHINE & COMPONENTS WEIGHT (DRY) ....................................................2-8 2.5 TRANSPORTATION .............................................................................................2-10 2.6 TYPE OF CRAWLER SHOES .............................................................................2-13 2.7 TYPE OF BUCKET ..............................................................................................2-14 2.8 ENGINE SPECIFICATIONS .................................................................................2-15 2.8.1 SPECIFICATIONS .......................................................................................2-15 2.8.2 ENGINE PERFORMANCE CURVE .............................................................2-16

Book Code No. S5PW0232E02 2-1

2. SPECIFICATIONS

Issue

Date of Issue

First Edition

March, 2010

Revision

June, 2010

Applicable Machines

Remarks

CX31B : PW14CX36B : PX15-

S5PW0232E01 (CASE-NA)

CX31B : PW14-46519~ CX36B : PX15-21105~

S5PW0232E02 (CASE-NA)

2-2

2. SPECIFICATIONS

2.1

COMPONENTS NAME

ARM CYLINDER LIGHT BOOM

BOOM CYLINDER

BUCKET CYLINDER

CANOPY OPERATING LEVER

ARM

DOZER OPERATING LEVER HYDRAULIC TANK

LINK CONTROL VALVE BUCKET

TRAVEL LEVER

MONITOR PANEL (GAUGE CLUSTER) RADIATOR AIR CLEANER

SWING CYLINDER

RESERVOIR TANK

DOZER CYLINDER

MUFFLER

BATTERY

ENGINE

FUEL TANK DOZER RUBBER CRAWLER SHOE IDLER ASSY LOWER ROLLER

OIL FILTER

UPPER ROLLER

SLEWING MOTOR

SLEWING BEARING

SWIVEL JOINT

TRAVEL MOTOR

2-3

HYDRAULIC PUMP

2. SPECIFICATIONS

2.2

MACHINE DIMENSIONS Unit: mm (ft-in)

R775 {2'6.5"}

85 {3.3"}

50 {2.0"}

1550 {5'1.0"} 660 {2'2.0"} 660 {2'2.0"}

185 {7.28"}

(1) CX31B (CANOPY)

4470 {14'8.0"} 1840 {6'0.44"} 1380 {4'6.3"} 775 {2'6.5"}

300 {11.8"}

345 {13.6"}

570 {1'10.4"}

2570 {8'5.2"}

1550 {5'1.0"}

1250 {4'1.2"} 1550 {5'1.0"}

1550 {5'1.0"} 1700 {5'6.9"} 2150 {7'0.6"} 2630 {8'7.5"}

R775 {2'6.5"}

85 {3.3"}

50 {2.0"}

1550 {5'1.0"}

660 {2'2.0"} 660 {2'2.0"}

185 {7.28"}

(2) CX31B (CAB)

4470 {14'8.0"} 1840 {6'0.44"} 1380 {4'6.3"}

1550 {5'1.0"}

300 {11.8"}

345 {13.6"}

570 {1'10.4"}

2570 {8'5.2"}

775 {2'6.5"}

1250 {4'1.2"} 1550 {5'1.0"}

2-4

1550 {5'1.0"} 1700 {5'6.9"} 2150 {7'0.6"} 2630 {8'7.5"}

2. SPECIFICATIONS Unit:mm(ft-in)

1700 {5'6.9"} 660 {2'2.0"} 660 {2'2.0"} 50 {2.0"}

160{6.3"}

(3) CX36B (CANOPY)

R850 {2'9.5"}

60 {2.4"}

2 4710 {15'5.4"} 1910 {6'3.2"} 1460 {4'9.5"} 850 {2'9.5"}

570 {1'10.4"}

330 {13.0"}

345 {13.6"}

2570 {8'5.2"}

1550 {5'1.0"}

1600 {5'3.0"} 300 {11.8"}

1700 {5'6.9"} 2150 {7'0.6"} 2680 {8'9.5"}

1400 {4'7.1"} 1700 {5'6.9"}

R850 {2'9.5"}

60 {2.4"}

50 {2.0"}

1700 {5'6.9"} 660 {2'2.0"} 660 {2'2.0"}

160{6.3"}

(4) CX36B (CAB)

4710 {15'5.4"} 1910 {6'3.2"} 1460 {4'9.5"} 850 {2'9.5"}

570 {1'10.4"}

345 {13.6"}

330 {13.0"}

2610 {8'6.8"}

1550 {5'1.0"}

1600 {5'3.0"} 300 {11.8"}

1700 {5'6.9"} 2150 {7'0.6"} 2680 {8'9.5"}

1400 {4'7.1"} 1700 {5'6.9"}

2-5

2. SPECIFICATIONS

2.3

SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY Model Applicable Machines Shoe Type

CX31B

CX36B

PW14-46519~

PX15-21105~

Rubber shoe

Slewing Speed

min -1 {rpm}

Travel Speed

km/h (mph)

Gradeability

Iron shoe (OPT)

Rubber shoe

8.9 (8.9)

Iron shoe (OPT)

8.9 (8.9)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

2.5

4.5

2.5

4.5

2.5

4.5

2.5

4.5

% (degree)

58(30)

ENGINE Model (YANMAR)

3TNV88-BPYB

Type

Water-cooled, 4-cycle type Swirl chamber type diesel engine

Number of cylinders-Bore X Stroke

3 - 88 dia. mm X 90 mm (3.46 in X 3.54 in)

Total Displacement

L kW/min-1 {PS/rpm}

Output Rating Maximum Torque

1.642 (100.2 cu-in)

N-m/min

-1

21.2/2,400 (29/2,400)

(lbf-ft/rpm)

Starting Motor Generator

98.0/1,440 (72.3/1,440)

V X kW

12 X 1.7

VXA

12 X 55

HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gear pump

Hydraulic Motor

Axial piston

Hydraulic Motor w/Reducer (Travel)

2-Axial piston, 2-Speed motor

Control Valve

10-spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer) Double action cylinder Return Filter

Safety valve containing/Filter Type (30Î¼)

SIDE DIGGING & DOZER Type Boom Swing Angle

Stroke of Dozer (above/below)

Boom swing by hydraulic cylinder Right

60 degrees

Left

70 degrees

mm (in)

560 / 410 (22.0/16.1)

2-6

540 / 440 (21.3/17.3)

2. SPECIFICATIONS WEIGHT Rubber shoe

Iron shoe

Rubber shoe

Iron shoe

3,200 (7050)

3,340 (7360)

3,580 (7900)

3,700 (8160)

kg (lb)

1,600 (3530)

<--

1,900 (4190)

<--

Travel system

kg (lb)

1,120 (2470)

1,230 (2710)

Attachment (Boom+STD Arm+STD Bucket)

kg (lb)

400 (880)

460 (1020)

Oil & Water

kg (lb)

80 (175)

<--

Machine Weight

kg (lb)

Upper slewing body

This figure is calculated with Japanese standard bucket.

2-7

1,140 (2520)

1,260 (2780)

2. SPECIFICATIONS

2.4

MACHINE & COMPONENTS WEIGHT (DRY) Unit ; kg (lb) CX31B

MODEL

RUBBER SHOE

IRON SHOE

CANOPY

CAB

CANOPY

CAB

COMPLETE MACHINE

3,200 (7050)

3,340 (7360)

3,310 (7300)

3,450 (7600)

UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) UPPER FRAME CANOPY / CAB ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK FUEL TANK SWING BRACKET SWING CYLINDER SLEWING MOTOR CONTROL VALVE COUNTERWEIGHT GUARD - BONNET BOOM CYLINDER

1,600 (3530)

1,740 (3840)

1,600 (3530)

1,740 (3840)

348 (767) 85 (187) 155 (340) 28 (60) 3 (7) 42 (93) 4 (9) 82 (181) 37 (82) 38 (84) 25 (55) 370 (815) 92 (203) 35 (77)

<-220 (485) <-<-<-<-<-<-<-<-<-<-<-<--

<-85 (187) <-<-<-<-<-<-<-<-<-<-<-<--

<-220 (485) <-<-<-<-<-<-<-<-<-<-<-<--

LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME SLEWING BEARING TRAVEL MOTOR LOWER ROLLER FRONT IDLER IDLER ADJUSTER SPROCKET RUBBER CRAWLER SHOE 300mm (11.8") IRON SHOE SWIVEL JOINT DOZER DOZER CYLINDER

1,120 (2470)

<--

1,230 (2710)

<--

350 (771) 42 (93) 42X2 (93X2) 6X 8 (13X 8) 22X2 (49X2) 16X2 (35X2) 9X2 (20X2) 141X2 (311X2) 22 (49) 140 (310) 27 (60)

<-<-<-<-<-<-<-<-<-<-<--

<-<-<-<-<-<-<-190X2 (420X2) <-<-<--

<-<-<-<-<-<-<-<-<-<-<--

ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY ARM BUCKET CYLINDER BUCKET LINK IDLER LINK BUCKET ASSEMBLY (STD)

400 (880)

<--

220 (485) 130 (286) 30 (66) 120 (265) 70 (155) 20 (44) 10 (22) 4X2 (9X2) 81 (180)

<-<-<-<-<-<-<-<-<--

FLUIDS HYDRAULIC OIL FUEL COOLANT

80 (176) 42 (93) 32 (70) 4 (9)

<-<-<-<--

Bucket weight is shown with Japanese standard bucket weight.

2-8

2. SPECIFICATIONS Unit ; kg (lb) CX36B MODEL

RUBBER SHOE

IRON SHOE

CANOPY

CAB

CANOPY

CAB

COMPLETE MACHINE

3,580 (7890)

3,720 (8200)

3,700 (8160)

3,840 (8470)

1,900 (4190)

2,040 (4500)

1,900 (4190)

2,040 (4500)

348 (767) 85 (187) 155 (340) 28 (60) 3 (7) 42 (93) 4 (9) 82 (181) 37 (82) 38 (84) 25 (55) 665 (1470) 92 (203) 35 (77)

<-220 (485) <-<-<-<-<-<-<-<-<-<-<-<--

<-85 (187) <-<-<-<-<-<-<-<-<-<-<-<--

<-220 (485) <-<-<-<-<-<-<-<-<-<-<-<--

1,140 (2520)

<--

1,260 (2780)

<--

370 (815) 42 (93) 42X2 (93X2) 6X8 (13X8) 22X2 (49X2) 16X2 (35X2) 9X2 (20X2) 141X2 (311X2) 22 (49) 150 (330) 27 (60)

<-<-<-<-<-<-<-<-<-<-<--

<-<-<-<-<-<-<-190X2 (420X2) <-<-<--

<-<-<-<-<-<-<-<-<-<-<--

460 (1020)

<--

190 (420) 140 (310) 34 (75) 140 (310) 80 (175) 20 (44) 10 (22) 4X2 (9X2) 89 (196)

<-<-<-<-<-<-<-<-<--

80 (176) 42 (93) 32 (70) 4 (9)

<-<-<-<--

ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY ARM BUCKET CYLINDER BUCKET LINK IDLER LINK BUCKET ASSEMBLY (STD) FLUIDS HYDRAULIC OIL FUEL COOLANT

Bucket weight is shown with Japanese standard bucket weight.

2-9

2. SPECIFICATIONS

2.5

TRANSPORTATION

(1) LOADING MACHINE ON A TRAILER 1. Keep trailer bed clean. Put chocks against truck wheels. 2. Use a ramp or loading deck. Ramps must be strong enough, have a low angle, and correct height. Load and unload machine on a level surface. 3. Travel machine onto ramps slowly. Center the machine over the trailer. 4. Lower all attachment. 5. Stop engine. Remove key from switch.

Do not put chains over or against hydraulic lines or hoses. 6. Fasten machine to trailer with chains or cables. During transportation, the bucket or attachments may hit the canopy or the cab. Therefore, set the machine in the transporting position by observing following points: a. Extend the bucket cylinder fully. b. Extend the arm cylinder fully. c. Lower the boom. d. If machine cannot be transported with arm cylinder fully extended, remove bucket or attachment and extend arm cylinder. (2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT 1. BOOM WITH ARM CYLINDER Model

CX31B

CX36B

LXHXW mm(ft-in)

2,390 X 870 X 320 (7'10.1") (2'10.2") (12.6")

2,590 X 810 X 320 (8'6.0") (2'7.9") (12.6")

Weight w/Arm cyl. kg (lb)

163 (360)

184 (405)

2-10

2. SPECIFICATIONS 2.

ARM & BUCKET (Japanese standard bucket) Model

CX31B

CX36B

LXHXW mm (ft-in)

2,190 X 450 X 500 (7'2.2") (17.7") (19.7")

2,360 X 450 X 600 (7'8.9") (17.7") (1'11.6")

Weight kg (lb)

198 (435)

219 (485)

2 H

L 3.

ARM Model

CX31B

CX36B

LXHXW mm (ft-in)

1,520 X 430 X 280 (4'11.8") (16.9") (11.0")

1,690 X 430 X 280 (5'6.5") (16.9") (11.0")

Weight kg (lb)

112 (245)

123 (270)

H L

BUCKET (Japanese standard bucket) Model

CX31B

CX36B

Heaped capacity m3(cu-yd)

0.09 (0.118)

0.11 (0.144)

LXHXW mm (ft-in)

670 X 620 X 500 (2'2.4") (2'0.4") (19.7")

670 X 620 X 600 (2'2.4") (2'0.4") (1'11.6")

Weight kg (lb)

81 (180)

89 (196)

2-11

2. SPECIFICATIONS 5.

DOZER w/o cylinder weight Model

CX31B

CX36B

LXHXW mm (ft-in)

1,230 X 330 X 1,550 (4'0.4") (13.0") (5'1.0")

1,280 X 330 X 1,700 (4'2.4") (13.0") (5'6.9")

Weight kg (lb)

142 (315)

150 (330)

H L

2-12

2. SPECIFICATIONS

2.6

TYPE OF CRAWLER SHOES

Type

Model

Shoe width mm (in)

Total Crawler width mm (ft•in)

Number of Link

Ground pressure kPa (psi) CANOPY

CAB

Rubber shoe CX31B

300 (11.8") 1,550 (5’1.0")

27 (3.9)

28 (4.1)

CX36B

300 (11.8") 1,700 (5’6.9")

31 (4.5)

32 (4.6)

CX31B

300 (11.8") 1,550 (5’1.0")

28 (4.1)

29 (4.2)

CX36B

300 (11.8") 1,700 (5’6.9")

32 (4.6)

33 (4.8)

Iron shoe (option)

2-13

2. SPECIFICATIONS

2.7

TYPE OF BUCKET

Type

Model

Heaped capacity m3 (cu.yd)

CX31B

0.09 (0.118)

Outer width mm (in) with side without cutter side cutter

Number of tooth

Weight kg (lb)

81 (179)

Remarks

Back hoe bucket 500 (1’7.7")

430 (1’4.9")

Standard size CX36B

0.11 (0.144)

600 (1’11.6")

This table shows Japanese standard bucket.

2-14

530 (1’8.9")

89 (196)

2. SPECIFICATIONS

2.8

ENGINE SPECIFICATIONS

2.8.1

SPECIFICATIONS CX31B, CX36B

Model Engine Model

3TNV88-BPYB

Type

Vertical, 4-cycle water-cooled diesel engine

No. of cylinders - Bore × Stroke

3 - 88 mm (3.46 in) × 90 mm (3.54 in)

Total displacement

1.642 liter (100 cu•in)

Compression ratio

19.1

Rated output

21.2 kW (28.8 PS) at 2400 rpm

Maximum torque

98 ~ 106.8 N•m (72.3 ~ 78.8 lbf•ft) at 1440 rpm

Low idling

1250±25 rpm

High idling

2590±25 rpm

Fuel consumption rate

245 g / kW•h (180 g / PS•h) LESS THAN

Allowable tilting angles

Continuous ; 30° for all direction

Rotating direction

Counterclockwise as seen from flywheel side

Firing order

1-3-2-1

Fuel injection timing (b.T.D.C.)

(FIT) 15.0±1 / (FIR) 5.0±1

Fuel injection pressure Valve action

Valve clearance

200

+10 0

kg / cm2 (2840

+140 0

psi)

Open

Intake valve

b.T.D.C. 15±5

a.B.D.C. 45±5

Exhaust valve

b.B.D.C. 56±5

a.T.D.C. 18±5

Intake valve

0.2 mm (0.008 in) in cold condition

Exhaust valve

0.2 mm (0.008 in) in cold condition

Thermostat action

Start 71 ± 1.5 C (160 ± 3 F) / Full open 85 C (185 F)

Compression pressure

3.43 ± 0.1 MPa (500 ± 14 psi) at 250 rpm

Lubrication oil pressure

0.392 MPa (57 psi) at 2400 rpm

Dimensions L × W × H

585 × 539 × 648 mm (23.0 × 21.2 × 25.5 in)

Dry weight

155 kg (342 lb)

Governor

Mechanical centrifugal governor (All speed type)

Fuel filtration

cartridge type paper filter

Lubrication system

Forced lubrication with trochoid pump

Cooling system

Liquid cooling / Radiator

Starter capacity

12 V × 1.7 kW 12 V × 55 A

Generator capacity Starting aid

Glow plug (12 V - 300 W)

Cooling water capacity : Max / Engine

4.0 / 2.0 liter (1.06 / 0.53 gal)

Engine oil volume : High / Low

6.7 / 3.9 liter (1.77 / 1.03 gal)

2-15

2. SPECIFICATIONS 2.8.2

ENGINE PERFORMANCE CURVE

CX31B, CX36B Model : 3TNV88-BPYB Rated Output : 21.2 kW / 2400 min-1 (28.8 PS / 2,400 rpm)

N.m (lbf.ft)

(34)

100

(74)

(59)

(44)

(30)

[T]

kW (20)

15 g/kWh (g/psh) [F]

(14)

(7)

1000

1500

2000

Engine speed

Fuel consumption volume =

F XPX X 1000

280

(206)

260

(191)

240

(176)

220

(162)

200

(147)

2500

min 1{rpm}

kWh kW

245 X 21.2 X 0.835 X 1000 3.73 ~ 4.35 L / h (load factor : (0.60 ~ 0.70))

= 6.22

2-16

FUEL CONSUMPTION RATE

POWER OUTPUT

(27)

(89)

SHAFT TORQUE

(PS)

120

3. ATTACHMENT DIMENSIONS

3. ATTACHMENT DIMENSIONS 3

TABLE OF CONTENTS

3.1 BOOM .................................................................................................................. 3-3 3.1.1 BOOM DIMENSIONAL DRAWINGS ........................................................... 3-3 3.1.2 BOOM MAINTENANCE STANDARDS ........................................................ 3-4 3.2 ARM ..................................................................................................................... 3-8 3.2.1 ARM DIMENSIONAL DRAWINGS .............................................................. 3-8 3.2.2 ARM MAINTENANCE STANDARDS ........................................................... 3-10 3.3 BUCKET .............................................................................................................. 3-15 3.3.1 BUCKET DIMENSIONAL DRAWINGS ........................................................ 3-15 3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION .......................... 3-16 3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION ........................ 3-16 3.4 DOZER ................................................................................................................ 3-17 3.4.1 DOZER DIMENSIONAL DRAWINGS .......................................................... 3-17 3.4.2 DOZER MAINTENANCE STANDARDS ...................................................... 3-18 3.5 SWING ................................................................................................................. 3-20 3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ........................................ 3-20 3.5.2 SWING PORTION MAINTENANCE STANDARDS ..................................... 3-21

Book Code No. S5PW0332E02 3-1

3. ATTACHMENT DIMENSIONS

Issue

Date of Issue

First Edition

March, 2010

Revision

June, 2010

Applicable Machines

Remarks

CX31B : PW14CX36B : PX15-

S5PW0332E01 (CASE-NA)

CX31B : PW14-46519~ CX36B : PX15-21105~

S5PW0332E02 (CASE-NA)

3-2

3. ATTACHMENT DIMENSIONS

3.1

BOOM

3.1.1

BOOM DIMENSIONAL DRAWINGS

Boom Dimensional Drawings

No.

DIMENSIONS [mm(ft-in)]

NAME

A B C D E

Boom length Distance between pins of boss Distance between pins of bracket Height of boom cylinder rod pin Height of arm cylinder (head side) pin

F G H J K

Boom foot width Inner width of bracket for boom cylinder (rod side) mounting Boom end inner width Boom end outer width Inner width of bracket for arm cylinder (head side)

Boom foot pin dia. [Bushing outer dia.] Boom cylinder (rod side) pin dia. Pin dia. of arm end Arm cylinder (head side) pin dia.

d2 d3 d4

CX31B

CX36B

2300 (7'6.55") R1217.5 (3'11.93") R1130.5 (3'8.51") 420.5 (1'4.56") 764 (2'6.08")

2500 (8'2.43") R1210 (3'11.64") R1157 (3'9.55") 385.5 (1'3.18") 708 (2'3.87")

178 (7.01") 61 (2.40") 150 (5.91") 235 (9.25") 61 (2.40")

<-<-<-<-<--

45 dia. [55 dia. 45 dia. 45 dia. 45 dia.

3-3

(1.77") (2.17")] (1.77") (1.77") (1.77")

<-<-<-<--

3. ATTACHMENT DIMENSIONS 3.1.2

BOOM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing on boom section

Clearance of pin and bushing on boom section

Unit : mm (in) Standard dimensions Pos.

Item

Pin part No.

Pin dia.

Clearance

Tolerance Standard Tolerance Standard Serviceabi Remedy on bushing value for on pin dia. value lity limit bore dia. repair +0.10 +0.05 (+0.0039) (+0.0020)

0.070.15 (0.00280.0059)

Boom foot

PX02B01299P1

–0.02 –0.05 (-0.0008) (-0.0020)

Boom cylinder PX02B01263P1 (Head side)

–0.02 –0.08 (-0.0008) (1.7717) (-0.0031)

+0.12 +0.06 (+0.0047) (+0.0024)

0.080.20 (0.00310.0079)

Boom cylinder (Rod side)

Arm cylinder (Head side)

–0.02 –0.05 (-0.0008) (-0.0020)

+0.13 +0.07 (+0.0051) (+0.0028)

0.090.23 (0.00350.0091)

PW02B01306P1

0.7 (0.028)

-The tolerance for bushing inside diameter means the dimension after fitting of it into place. -The part number for pins may be changed owing to improvement, use them only for reference.

3-4

1.0 (0.039)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS

This page is blank for editing convenience.

3-5

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on boom and cylinder installation section

PL2

Clearance in thrust direction on boom section

3-6

3. ATTACHMENT DIMENSIONS Unit : mm (in) Standard dimensions Sec.

Item

Standard No. Dimensions value

A-A Boom foot

L1 Swing bracket

Boom cylinder C-C (Rod side)

(7.008

L2 Swing bracket

0.2-0.6 (0.0080.024)

PL1

297 (11.69)

PL2

178 (7.01)

0.5-0.9 (0.0200.035)

PL3

151 (5.94)

0.1-0.5 (0.0040.020)

PL4

151 (5.94)

)

(2.362

)

61 (2.402

0.1-0.5 (0.0040.020)

)

1.0 (0.039)

Boom cylinder L3

(2.362

)

1.5 (0.059)

Adjusted with shim

)

Arm cylinder L4 Boom

Remedy Standard Serviceabili No. Dimensions value for ty limit repair

Boom cylinder

(2.402

Arm cylinder (Head side)

)

178

Boom

D-D

Pin length

178

Boom

Boom cylinder B-B (Head side)

Clearance X adjusted with shim (total of both sides)

(2.165

)

61 (2.205

)

3-7

3. ATTACHMENT DIMENSIONS

3.2

ARM

3.2.1

ARM DIMENSIONAL DRAWINGS

Arm dimensional drawings

3-8

3. ATTACHMENT DIMENSIONS

No.

Dimensions [mm(ft-in)]

Name

CX31B

CX36B

Arm length

1180(3'10.46")

1320(4'3.97")

Distance between pins of boss and bracket

R304.5(11.99")

R314(1'0.36")

Distance between pins of boss and bracket

R1036(3'4.79")

Distance between pins of boss and boss

R190(7.48")

Height between pins of boss and bracket

332(1'1.07")

Height between pins of boss and bracket

180(7.09")

149.5(5.89")

Height between pins of boss and center

8(0.31")

Boss width

140(5.51")

Boss width

150(5.91")

Bracket inner width

56(2.20")

Bracket inner width

61(2.40")

Idler link dimension

310(1'0.20")

Bucket link dimension

285(11.22")

I.D. of boss

50 dia.(1.97")

I.D. of boss

50 dia.(1.97")

I.D. of boss

55 dia.(2.17")

Pin dia.

40 dia.(1.57")

Pin dia.

40 dia.(1.57")

Pin dia.

45 dia.(1.77")

Pin dia.

40 dia.(1.57")

Pin dia.

45 dia.(1.77")

3-9

3. ATTACHMENT DIMENSIONS 3.2.2

ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

Clearance of pin and bushing on arm section • CX31B

Unit : mm (in) Standard dimensions

Clearance

Tolerance on bushing bore dia.

Standard value

+0.11 +0.06 (+0.0043) (+0.0024)

0.080.16 (0.00310.0063)

Bucket link (Bucket side)

+0.11 +0.05 (+0.0043) (+0.0020)

0.070.16 (0.00280.0063)

Idler link (Connected part of arm)

+0.08 +0.03 (+0.0031) (+0.0012)

0.050.13 (0.00200.0051)

+0.09 +0.03 (+0.0035) (+0.0012)

0.05-0.14 (0.00200.0055)

+0.25 +0.05 (+0.0098) (+0.0020)

0.070.30 (0.00280.0118) 0.090.18 (0.00350.0071)

Pos.

Item

Arm point (Connected part of bucket)

Pin part No.

Pin dia.

Tolerance on pin dia.

PW12B01351P1

PW12B01311P1 ø40 (1.575)

Bucket link (Idler link side)

–0.02 –0.05 (-0.0008) (-0.0020)

PX12B01319P1 D’

Bucket cylinder (Rod side)

Bucket cylinder (Head side)

PW12B01220P1

+0.13 +0.07 (+0.0051) (+0.0028)

Arm foot (Connected PX12B01370P1 part of boom)

+0.10 +0.05 (+0.0039) (+0.0020)

0.070.15 (0.00280.0059)

+0.13 +0.07 (+0.0051) (+0.0028)

0.090.18 (0.00350.0071)

ø45 (1.772)

Arm cylinder PW02B01306P1 (Rod side)

3-10

Standard value for repair

0.7 (0.028)

Serviceabili Remedy ty limit

1.0 (0.039)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS

• CX36B

Unit : mm (in) Standard dimensions

Clearance

Tolerance on bushing bore dia.

Standard value

+0.11 +0.06 (+0.0043) (+0.0024)

0.080.16 (0.00310.0063)

Bucket link (Bucket side)

+0.11 +0.05 (+0.0043) (+0.0020)

0.070.16 (0.00280.0063)

Idler link (Connected part of arm)

+0.08 +0.03 (+0.0031) (+0.0012)

0.050.13 (0.00200.0051)

+0.09 +0.03 (+0.0035) (+0.0012)

0.05-0.14 (0.00200.0055)

+0.25 +0.05 (+0.0098) (+0.0020)

0.070.30 (0.00280.0118) 0.090.18 (0.00350.0071)

Pos.

Item

Arm point (Connected part of bucket)

Pin part No.

Pin dia.

Tolerance on pin dia.

PW12B01351P1

PW12B01311P1 ø40 (1.575)

Bucket link (Idler link side)

–0.02 –0.05 (-0.0008) (-0.0020)

PX12B01319P1 D’

Bucket cylinder (Rod side)

Bucket cylinder (Head side)

PX12B01206P1

+0.13 +0.07 (+0.0051) (+0.0028)

Arm foot (Connected PX12B01370P1 part of boom)

+0.10 +0.05 (+0.0039) (+0.0020)

0.070.15 (0.00280.0059)

+0.13 +0.07 (+0.0051) (+0.0028)

0.090.18 (0.00350.0071)

ø45 (1.772)

Arm cylinder PX12B01320P1 (Rod side)

Standard value for repair

Serviceabili Remedy ty limit

0.7 (0.028)

-The tolerance for bushing inside diameter means the dimension after fitting of it into place. -The part number for pins may be changed owing to improvement, use them only for reference.

3-11

1.0 (0.039)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on arm and cylinder installation section

3-12

3. ATTACHMENT DIMENSIONS Clearance in thrust direction on arm section

• CX31B

Unit : mm (in) Standard dimensions

Sec.

Clearance X adjusted with shim (total of both sides)

Item No.

Arm A-A Arm point

Bucket

Link side B-B Bucket link Bucket Idler link C-C (Connected part of arm)

L3 Link side

140 (5.512)

140 (5.551)

(2.165

(2.205

D-D

—

(5.512

)

— (—)

Idler link

Less than 0.5 (0.020)

1.0 (0.039)

PL2

268 (10.55)

PL3

204.5 (8.05)

PL5

204.5 (8.05)

PL6

153 (6.02)

PL7

234.5 (9.23)

PL8

151 (5.94)

1.5 (0.059)

)

140

Bucket link

0.1-0.5 (0.0040.020)

Adjusted with shim

—

Head side L6

(2.165

)

Arm

(2.205

0.5-0.9 (0.0200.035)

)

150

Arm F-F Arm foot

)

Link side

Bucket cylinder E-E (Head side)

268 (10.55)

See "NOTE"

0.1-0.5 (0.0040.020)

— (—)

PL1

Rod side

Bucket link (Idler link side)

Standard Servicea Remedy Standard bility No. Dimensions value for value limit repair

141±0.7 (5.551±0.028) 0.5-2.1 (0.020140 0.083) ) L2 (5.512 141±0.7 (5.551±0.028)

Arm

Bucket link (Rod side)

Dimensions

Pin length

(5.906

)

150

Boom

Less than 0.5 (0.020)

1.0 (0.039)

1.5 (0.059)

(5.906) 60

Rod side Arm cylinder G-G (Rod side)

L8 Arm

(2.362

)

61 (2.402

0.5-0.9 (0.0200.035)

)

Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

3-13

3. ATTACHMENT DIMENSIONS • CX36B

Unit : mm (in) Standard dimensions

Sec.

Item No.

Arm A-A Arm point

Bucket

Link side B-B Bucket link Bucket Idler link C-C (Connected part of arm)

L3 Link side

140 (5.551) — (—)

(2.165

(2.205

D-D

—

(5.512

Less than 0.5 (0.020)

1.0 (0.039)

268 (10.55)

PL2

268 (10.55)

PL3

204.5 (8.05)

PL5

204.5 (8.05)

PL6

157 (6.18)

PL7

234.5 (9.23)

PL8

160 (6.30)

1.5 (0.059)

)

— (—)

Idler link

0.1-0.5 (0.0040.020)

Adjusted with shim

—

Head side L6

(2.165

)

Arm

(2.205

0.5-0.9 (0.0200.035)

)

150

Arm F-F Arm foot

)

140

Bucket link

Bucket cylinder (Head side)

PL1

See "NOTE"

0.1-0.5 (0.0040.020)

Link side

E-E

140 (5.512)

Rod side

Bucket link (Idler link side)

Pin length

Standard Servicea Remedy Standard bility No. Dimensions Dimensions value for value limit repair

141±0.7 (5.551±0.028) 0.5-2.1 (0.020140 0.083) (5.512 ) L2 141±0.7 (5.551±0.028)

Arm

Bucket link (Rod side)

Clearance X adjusted with shim (total of both sides)

(5.906

)

150

Boom

Less than 0.5 (0.020)

1.0 (0.039)

1.5 (0.059)

(5.906) 60

Rod side Arm cylinder G-G (Rod side)

L8 Arm

(2.362

)

61 (2.402

0.5-0.9 (0.0200.035)

)

Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

3-14

3. ATTACHMENT DIMENSIONS

3.3

BUCKET

3.3.1

BUCKET DIMENSIONAL DRAWINGS

Bucket dimensional drawings No.

Model

CX31B

CX36B

Heaped Capacity m3 (cu.yd)

0.09 (0.118)

0.11 (0.144)

200 (7.87") R712 (2'4.03") 430 (1'4.93") 193 (7.60")

<-<-530 (1'8.87") <--

A B C D

Distance between pin and bracket Distance between bucket pin and tooth end Inner width of bucket top end Inner width of lug

E F G H J

Inner width of bracket Outer width of side cutter Outer width of bucket bottom plate Outer tooth distance Pitch between teeth

141 (5.55") 500 (1'7.69") 405 (1'3.94") 367 (1'2.45") 122 (4.80")

<-600 (1'11.62") 505 (1'7.88") 468 (1'6.43") 156 (6.14")

J0 d1 d2

Pitch between teeth Pin dia. Pin dia.

123 (4.83") 40 dia.(1.57") 40 dia.(1.57")

156 (6.14") <-<--

1. Japanese standard bucket.

3-15

3. ATTACHMENT DIMENSIONS 3.3.2

DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION

Dimension of lug section

Unit : mm (in) Portion

Plate outer dia. øA

Boss thickness B

ø85 (3.35)

26 (1.02)

Dimensions

3.3.3

Pin bore dia. øC

Lug plate thickness D

ø40 (1.578

14 (0.551)

)

DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION

Dimension of boss section

Unit : mm (in) Portion Dimensions

øA

øB

øC

øD

øG

65 (2.56)

43 (1.69)

60 (2.36)

63 (2.48)

12 (0.472)

24 (0.945)

11 (0.433)

3-16

3. ATTACHMENT DIMENSIONS

3.4

DOZER

3.4.1

DOZER DIMENSIONAL DRAWINGS

Dozer dimensional drawings

No.

Dimensions [mm(ft-in)]

NAME

CX31B

CX36B

A B C D E

Blade width Blade height Distance from dozer attaching pin center to cutting edge end Inner width of dozer attaching bracket Width of dozer attaching bracket

1550 (5'1.02") 346 (1'1.62") R1187 (3'10.73") 500 (1'7.69") 60 (2.36")

1700 (5'6.93") 345 (1'1.58") R1232 (4'0.50") <-<--

R608 (1'11.94")

R626 (2'0.65")

G H J d1

Distance from dozer attaching pin center to attaching pin on dozer cylinder head side Attaching bracket inner width on dozer cylinder head side Horizontal distance from dozer attaching pin center to edge end Vertical distance from dozer attaching pin center to edge end Dozer attaching pin dia.

62 (2.44") 1144 (3'9.04") 315 (1'0.40") 40 dia.(1.57")

<-1192 (3'10.93") 310 (1'0.20") <--

Attaching pin dia. on dozer cylinder head side

45 dia.(1.77")

<--

3-17

3. ATTACHMENT DIMENSIONS 3.4.2

DOZER MAINTENANCE STANDARDS

Dozer maintenance standards (1) Clearance of pin and bushing

Unit : mm (in) Standard dimension Pin part No.

Tolerance Tolerance Standard Standard Serviceabi Remedy Pin dia. on pin dia. on bushing value for value lity limit bore dia. repair

Pos.

Item

Dozer blade cylinder (Head side)

Dozer blade cylinder (Rod side)

Dozer blade ø40 PW51B01028P1 foot (1.575)

PH12B01009P1

Clearance

ø45 (1.772)

–0.06 –0.11 (-0.0024) (-0.0043)

+0.20 +0.05 (+0.0079) (+0.0020)

0.110.31 (0.00430.0122)

–0.06 –0.09 (-0.0024) (-0.0035)

+0.22 +0.12 (+0.0087) (+0.0047)

0.180.31 (0.00710.0122)

3-18

0.7 (0.028)

1.0 (0.039)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS

-The tolerance for bushing inside diameter means the dimension after fitting of it into place. -The part number for pins may be changed owing to improvement, use them only for reference.

(2) Clearance in thrust direction on the dozer and cylinder installation section

Unit : mm (in) Standard dimensions Pos.

Item

Dozer blade cylinder (Head side)

No.

Dimensions

Dozer blade cylinder (Rod side)

Dozer blade foot

(2.362

)

PL1

137 (5.39)

PL2

137 (5.39)

PL3

127 (5.00)

)

Rod side L2 Lower frame

Lower frame

No. Dimensions

Dozer blade

(2.362

)

62 (2.441

0.6-2.0 (0.023-0.079) After shim adjustment

When clearance X exceeds 3.5 mm, adjust it with shim.

)

60Âą0.3 (2.362Âą0.012)

Dozer blade C

Remedy

Head side

(2.441

Clearance X (total of both sides)

Pin length

62 (2.441

)

3-19

3. ATTACHMENT DIMENSIONS

3.5

SWING

3.5.1

SWING BRACKET DIMENSIONAL DRAWINGS

H d3

D B

C F1 d4 F J

Swing bracket dimensional drawings No.

NAME

DIMENSION [mm(in)]

A B C D E

Distance between swing center pin and boom foot pin Distance between boom foot pin and boom cylinder pin - ditto Distance between swing center pin and swing cylinder pin - ditto -

96 (3.78) 176.8 (6.96) 266.9 (10.51) R264 (10.39) 257 (10.12)

F F1 F2 G H

Inside width of swing center - ditto - ditto Inside width of boom foot Inside width for installing boom cylinder

303.7 (11.96) 75.7 (2.98) 73.5 (2.89) 178 (7.01) 61 (2.40)

J d1 d2 d3 d4

Inside width for installing swing cylinder Pin dia. of swing center Pin dia. of boom foot Pin dia. of boom cylinder Pin dia. of swing cylinder

67 (2.64) 65 dia.(2.56) 45 dia.(1.77") 45 dia.(1.77") 45 dia.(1.77")

3-20

3. ATTACHMENT DIMENSIONS 3.5.2

SWING PORTION MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

Clearance of pin and bushing on swing portion

Unit : mm (in) Standard dimension Pos.

Item

Pin part No.

Swing cylinder (Rod side)

PX02B01241P1

Swing cylinder (Head side)

PW02B01271P1

Swing center PX02B01239P1 (Upper side)

Swing center PX02B01275P1 (Lower side)

Clearance

Tolerance Standard Tolerance Standard Serviceabi Remedy Pin dia. on bushing value for on pin dia. value lity limit bore dia. repair

ø45 (1.772)

ø65 (2.559)

–0.02 –0.05 (-0.0008) (-0.0020)

+0.20 +0.05 (+0.0079) (+0.0020)

0.070.25 (0.00280.0098)

+0.07 +0.02 (+0.0028) (+0.0008)

0.040.12 (0.00160.0047)

0.7 (0.028)

-The tolerance for bushing inside diameter means the dimension after fitting of it into place. -The part number for pins may be changed owing to improvement, use them only for reference.

3-21

1.0 (0.039)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on swing bracket and cylinder installation section

Clearance in thrust direction on swing portion

3-22

3. ATTACHMENT DIMENSIONS Unit : mm (in) Standard Dimension Sec.

Item No.

Swing A-A cylinder (Rod side)

Dimensions

(2.559

0.5-0.9 (0.0200.035)

PL1

123 (4.84)

PL2

128 (5.04)

—

Replace PL3 washer

153.5 (6.04)

1.5 (0.059)

Adjusted with PL4 shim

134 (5.28)

1.5 (0.059)

— Adjusted with shim

)

(2.559

)

67 (2.638

Upper frame L3

75.7±1 (2.98 ±0.039)

Upper frame

71.5±0.5 (2.815 ±0.020)

0.1-0.5 (0.0040.020)

73.5±1 (2.894 ±0.039)

1.0 (0.039)

—

)

71±0.5 (2.795 ±0.020)

Bracket

Remedy Standard Serviceability value for No. Dimensions limit repair

Cylinder

Swing center D-D (Lower side)

)

Bracket

Swing B-B cylinder (Head side) Upper frame

Standard value

Pin length

Cylinder

(2.638

Swing center C-C (Upper side)

Clearance X adjusted with shim (total of both sides)

0.5-0.9 (0.0200.035)

3-23

—

3. ATTACHMENT DIMENSIONS

3-24

11. TOOLS

11. TOOLS 11

TABLE OF CONTENTS

11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS .............................. 11-3 11.1.1 Metric Coarse Thread Standard Tightening Torque Values ....................... 11-3 11.1.2 Metric Fine Thread Standard Tightening Torque values ............................. 11-4 11.2 SCREW AND TOOL SIZES ............................................................................... 11-5 11.2.1 CAPSCREW .............................................................................................. 11-5 11.2.2 CAPSCREW (SOCKET BOLT) .................................................................. 11-5 11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ................................ 11-6 11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) ..................................... 11-6 11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ........................................... 11-6 11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS ............... 11-7 11.4.1 SLEEVE TYPE TUBE FITTINGS .............................................................. 11-7 11.4.2 PART NO. .................................................................................................. 11-7 11.5 PLUGS ............................................................................................................... 11-8 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................... 11-8 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................... 11-9 11.6 SPECIAL SPANNERS FOR TUBES .................................................................. 11-10 11.7 SPECIAL TOOLS ............................................................................................... 11-11 11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ............ 11-12 11.9 COUNTERWEIGHT LIFTING JIG ..................................................................... 11-13 11.10 UPPER FRAME LIFTING JIG ............................................................................ 11-14

Book Code No. S5PW1131E02 11-1

11. TOOLS

Issue

Date of Issue

First Edition

March, 2010

↑

Applicable Machines

Remarks

SK30SR-5 : PW14SK35SR-5 : PX15-

S5PW1131E01 (KCM North America)

↑

CX31B : PW14CX36B : PX15-

↑ (CASE-NA)

↑

E30B : PW14E35B : PX15-

(NH-NA)

Revision

June, 2010

SK30SR-5 : PW14-46519~ SK35SR-5 : PX15-21105~

S5PW1131E02 (KCM North America)

↑

CX31B : PW14-46519~ CX36B : PX15-21105~

↑ (CASE-NA)

↑

E30B : PW14-46519~ E35B : PX15-21105~

(NH-NA)

↑

11-2

↑

11. TOOLS

11.1

TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS

The following Torque Specifications are provided for use when actual torque value of a fastener is not known. Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance. Retighten the loosened ones, and install new ones for the dropped off. For the new machine, the check and retightening of them must be carried out at first 50 hours operation. For the replacement of them, make sure to use the same size of manufacturer's genuine parts. Refer to the table below for the tightening and retightening of capscrews. • The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening torque for such capscrews, consult with an authorized our distributor. Over-tightening may cause damages on the parts to be fixed. • In case that the tightening torque is specified in the manual, use such torque values regardless to the table below. • Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is provided for smaller size of capscrews, M 5 or less. Make certain to tighten all capscrews and nuts to proper torque values.

11.1.1 Metric Coarse Thread Standard Tightening Torque Values Torque value Unit : N•m (lbf•ft) Classification Nominal size

4.8T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

P=1

4.4±0.5 (3.2±0.4)

3.7±0.4 (2.7±0.3)

9.6±1.0 (7.1±0.7)

8.1±0.8 (6.0±0.6)

17.4±1.8 (12.8±1.3)

14.7±1.5 (10.8±1.1)

P=1.25

10.7±1.1 (7.9±0.8)

9.0±0.9 (6.6±0.7)

23.5±2.0 (17.3±1.5)

19.6±2.0 (14.5±1.5)

42.2±3.9 (31.1±2.9)

35.3±3.9 (26.0±2.9)

M10

P=1.5

21.6±2.0 (15.9±1.4)

17.9±1.8 (13.2±1.3)

46.1±4.9 (34.0±3.6)

39.2±3.9 (28.9±2.9)

83.4±8.8 (61.5±6.5)

70.6±6.9 (52.1±5.1)

M12

P=1.75

36.3±3.9 (26.8±2.9)

31.4±2.9 (23.2±2.1)

79.4±7.8 (58.6±5.8)

66.7±6.9 (49.2±5.1)

143±15 (105±11)

121±12 (89.2±8.9)

M14

P=2

57.9±5.9 (42.7±4.4)

49.0±4.9 (36.1±3.6)

126±13 (92.9±9.6)

106±10 (78.2±7.4)

226±20 (167±15)

191±19 (141±14)

M16

P=2

88.3±8.8 (65.1±6.5)

74.5±6.9 (55.0±5.1)

191±20 (141±15)

161±16 (119±12)

343±39 (253±29)

284±29 (209±21)

M18

P=2.5

122±12 (90.0±8.9)

103±10 (75.8±7.2)

265±29 (195±21)

226±20 (167±15)

481±49 (355±36)

402±39 (297±29)

M20

P=2.5

172±17 (127±13)

144±14 (106±10)

373±39 (275±29)

314±29 (232±21)

667±69 (492±51)

559±59 (412±44)

11-3

11. TOOLS Torque value Unit : N•m (lbf•ft) Classification Nominal size

4.8T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M22

P=2.5

226±20 (167±15)

192±20 (142±15)

500±49 (369±36)

422±39 (311±29)

902±88 (665±65)

755±78 (557±58)

M24

P=3

294±29 (217±21)

235±29 (173±21)

637±69 (470±51)

520±49 (383±36)

1160±118 (856±87)

941±98 (694±72)

M27

P=3

M30

P=3.5

431±39 (318±29) 588±59 (434±44)

353±39 (260±29) 490±49 (361±36)

941±98 (694±72) 1285±127 (948±94)

765±78 (564±58) 1079±108 (796±80)

1700±167 (1250±123) 2300±235 (1700±173)

1370±137 (1010±101) 1940±196 (1430±145)

M33

P=3.5

794±78 (586±58)

667±69 (492±51)

1726±177 (1270±131)

1451±147 (1070±108)

3110±314 (2290±232)

2610±265 (1930±195)

M36

P=4

1030±98 (760±72)

863±88 (637±65)

2226±226 (1640±167)

1863±186 (1370±137)

4010±402 (2960±297)

3360±333 (2480±246)

11.1.2 Metric Fine Thread Standard Tightening Torque values Torque value Unit : N•m (lbf•ft) Classification Nominal size

4.8T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

P=1.0

11.3±1.1 (8.3±0.8)

9.5±1.0 (7.0±0.7)

24.5±2.0 (18.1±1.5)

20.6±2.0 (15.2±1.5)

44.1±3.9 (32.5±2.9)

37.3±3.9 (27.5±2.9)

M10

P=1.25

22.6±2.0 (16.7±1.5)

18.7±1.9 (13.8±1.4)

48.1±4.9 (35.5±3.6)

41.2±3.9 (30.3±2.9)

87.3±8.8 (64.4±6.5)

73.5±6.9 (54.2±5.1)

M12

P=1.25

39.2±3.9 (28.9±2.9)

33.3±2.9 (24.6±2.1)

85.3±8.8 (62.9±6.5)

71.6±6.9 (52.8±5.1)

154±16 (114±12)

129±13 (95.2±9.6)

M16

P=1.5

92.2±8.8 (68.0±6.5)

77.5±7.8 (57.2±5.8)

196±20 (145±15)

169±17 (125±13)

363±39 (268±29)

304±29 (224±21)

M20

P=1.5

186±19 (137±14)

155±16 (114±12)

402±39 (297±29)

333±29 (246±21)

726±69 (535±51)

608±59 (448±44)

M24

P=2

314±29 (232±21)

265±29 (195±21)

686±69 (506±51)

569±59 (420±44)

1240±118 (915±87)

1030±98 (760±72)

M30

P=2

637±59 (470±44)

530±49 (391±36)

1390±137 (1030±101)

1157±118 (853±87)

2500±255 (1840±188)

2080±206 (1530±152)

M33

P=2

853±88 (629±65)

706±70 (521±52)

1860±186 (1370±137)

1550±155 (1140±114)

3350±334 (2470±246)

2790±275 (2060±203)

M36

P=3

1070±108 (789±80)

892±88 (658±65)

2330±226 (1720±167)

1940±196 (1430±145)

4200±422 (3100±311)

3500±353 (2580±260)

11-4

11. TOOLS

11.2

SCREW AND TOOL SIZES

11.2.1 CAPSCREW Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm

Tool size

M24

M30

M10

M36

M12

M42

M16

M48

M20

11.2.2 CAPSCREW (SOCKET BOLT) Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm

Tool size

M20

M24

M10

M30

M12

M36

M14

M42

M16

M48

(M18)

11-5

11. TOOLS

11.3

TORQUE SPECIFICATIONS FOR JOINTS AND HOSES

11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) Nominal screw size (PF)

Spanner size (mm)

Tightening torque N•m (lbf•ft)

1/8

17±2 (12±1)

1/4

36±2 (27±1)

3/8

74±5 (54±4)

1/2

108±9.8 (80±7)

3/4

162±9.8 (119±7)

255±9.8 (188±7)

11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) Nominal screw size (PF)

Spanner size (mm)

Tightening torque N•m (lbf•ft)

1/8

15±2.0 (11±1)

1/4

29±4.9 (22±4)

3/8

49±4.9 (36±4)

1/2

78±4.9 (58±4)

3/4

118±9.8 (87±7)

137±15 (101±11)

NOTE : The application of the tightening torque is subject to a dry condition.

11-6

11. TOOLS

11.4

TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS

11.4.1 SLEEVE TYPE TUBE FITTINGS Tube size OD × Thickness (mm)

Spanner size (mm)

Tightening Torque N•m (lbf•ft)

10 × 1.5

44±4.9 (33±4)

15 × 2.0

147±20 (110±14)

18 × 2.5

177±20 (130±14)

22 × 3.0

216±20 (160±14)

28 × 4.0

275±29 (200±22)

35 × 5.0

441±44 (330±33)

11 11.4.2 PART NO. SLEEVE

NUT B

Part NO. Nippon A.M.C

Tube size ød

Opposing flats(HEX) B

ZF93S06000

—

ZF93S08000

—

ZF93S10000

ZA93S10000

ZF93S12000

—

ZF93S15000

ZA93S15000

ZF93S18000

ZA93S18000

ZF93S22000

ZF93S28000

Tube size ød

Ihara Koatu

Part NO. Ihara Koatu

Nippon A.M.C

ZF93N06000

—

ZF93N08000

—

ZF93N10000

ZA93N10000

ZF93N12000

—

ZF93N15000

ZA93N15000

ZF93N18000

ZA93N18000

ZA93S22000

ZF93N22000

ZA93N22000

ZA93S28000

ZF93N28000

ZA93N28000

ZF93S32000

—

ZF93N32000

—

ZF93S35000

ZA93S35000

ZF93N35000

ZA93N35000

ZF93S38000

—

ZF93N38000

—

11-7

11. TOOLS

11.5

PLUGS

11.5.1 PLUG FOR HYDRAULIC PIPE JOINT

(1) Cap nut (Joint plug)

T screw

Applicable tube O. D : A 6 8 10 12 15 18 22 28

Opposing flats

Cap nut parts No.

T screw

ZF83H06000 ZF83H08000 ZF83H10000 ZF83H12000 ZF83H15000 ZF83H18000 ZF83H22000 ZF83H28000

M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5

Applicable tube O. D : A

Plug parts No.

6 8 10 12 15 18 22 28

ZF83P06000 ZF83P08000 ZF83P10000 ZF83P12000 ZF83P15000 ZF83P18000 ZF83P22000 ZF83P28000

H1 14 17 17 19 24 27 32 38

H 14 17 19 22 27 32 36 41

(2) Plug (Tube plug)

Sleeve Type joint body

Nut

D Screw

(3) Nut

Applicable tube O. D : A 6 8 10 12 15 18 22 28 32 35 38 11-8

Nut parts No. ZF93N06000 ZF93N08000 ZF93N10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000

D screw Opposing flats M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5 M42 X 1.5 M45 X 1.5 M48 X 1.5

14 17 19 22 27 32 36 41 50 55 60

11. TOOLS 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT (1) PF screw

O-ring

B PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring 19 PF1/4 ZE72X04000 ZD12P01100 1B P11 22 PF3/8 ZE72X06000 ZD12P01400 1B P14 27 PF1/2 ZE72X08000 ZD12P01800 1B P18 36 PF3/4 ZE72X12000 ZD12P02400 1B P24 41 PF1 ZE72X16000 ZD12P02900 1B P29

PF screw (2) PT screw

B PT screw

PT screw Plug parts No. ZE82T02000 PT1/8 ZE82T04000 PT1/4 ZE82T06000 PT3/8 ZE82T08000 PT1/2 ZE82T12000 PT3/4 ZE82T16000 PT1 ZE82T20000 PT1 1/4 ZE82T24000 PT1 1/2

B mm 5 6 8 10 14 17 22 22

(3) Plug for(F)flare hose

PF screw

PF screw Plug parts No. 2444Z2728D1 PF1/4 2444Z2728D2 PF3/8 2444Z2728D3 PF1/2 2444Z2728D4 PF3/4 2444Z2728D5 PF1

Opposing flats B

PF screw PF1/4 PF3/8 PF1/2 PF3/4 PF1 PF1 1/4

PF screw

Opposing flats F

Opposing flats E

11-9

Plug parts No. 2444Z2729D1 2444Z2729D2 2444Z2729D3 2444Z2729D4 2444Z2729D5 2444Z2729D6

E mm 14 17 23 27 36 40

B mm 14 17 22 27 36

F mm 19 22 27 36 41 50

11. TOOLS

11.6

SPECIAL SPANNERS FOR TUBES

Applicable tube diameter mm (in)

Part No.

HEX mm

Dimensions of a special spanner mm (in) 70(2.76)

15 (0.591)

2421T160

(0.630)

(0.866)

(0.315)

12.7

40(1.57)

(0.500

)

70(2.76) 42(1.65)

18 (0.709)

2421T138

(0.866)

(0.748) 22(0.866)

48(1.89)

22 (0.866)

2421T130

12.7

(0.866)

(0.906)

60(2.36)

2421T115

(0.500

)

109(4.29) 14.5(0.571) (0.866)

(1.142) 12.7

11-10

)

70(2.76) 11.5(0.453)

12.7

28 (1.102)

(0.500

)

11. TOOLS

11.7

SPECIAL TOOLS

No.

Tools name

Torx driver (with tamper proof) T25 (for M5)

Tools No.

Shape

Use.

4.4 (0.17")

â&#x20AC;&#x201D;

Nose shape

For instrument R.H cover

11-11

11. TOOLS

11.8

APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS

Service

Screw locking compound Sealing compound

Manufacturer

Features

Loctite

Three-Bond

#242

1360K

Low strength

#262

1374

Middle strength

#271

1305

High strength

#515

1215

Sealing

11-12

11. TOOLS

11.9

COUNTERWEIGHT LIFTING JIG

Counterweight lifting jig

11-13

11. TOOLS

11.10 UPPER FRAME LIFTING JIG

5 (0.20")

20 C (0 .7

(1.97")

) 9"

40(2)-100 (1.58"(0.079")-3.94")

24( 0.9 5")

Q'ty : 2 sets Material : Mild steel Unit : mm (in)

244 (9.61")

16 (0.63")

300 (11.8")

100 (3.94")

15 (0.59")

1. 0(

40(4)-120 {1.58"(0.16")-4.72"}

12 (0.47")

420 (16.5")

536 (21.1")

167 (6.58") 50 (1.97")

0 R3 8") .1 (1

5 (0.20")

Upper frame lifting jig

11-14

0 R2 9") .7 (0

C1 .3 0 9" )

(1.97")

5 ) C2 .98" (0

12 (0.47")

470 (18.5")

5 (0.20")

16 (0.63")

12. STANDARD MAINTENANCE TIME TABLE

12. STANDARD MAINTENANCE TIME TABLE TABLE OF CONTENTS

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR 12-4

Book Code No. S5PW1231E02 12-1

12. STANDARD MAINTENANCE TIME TABLE

Issue

Date of Issue

First Edition

March, 2010

↑

Applicable Machines

Remarks

SK30SR-5 : PW14SK35SR-5 : PX15-

S5PW1231E01 (KCM North America)

↑

CX31B : PW14CX36B : PX15-

↑ (CASE-NA)

↑

E30B : PW14E35B : PX15-

(NH-NA)

Revision

June, 2010

SK30SR-5 : PW14-46519~ SK35SR-5 : PX15-21105~

S5PW1231E02 (KCM North America)

↑

CX31B : PW14-46519~ CX36B : PX15-21105~

↑ (CASE-NA)

↑

E30B : PW14-46519~ E35B : PX15-21105~

(NH-NA)

↑

12-2

↑

12. STANDARD MAINTENANCE TIME TABLE PREFACE (1) Working Conditions 1. Technicians : One more technicians who are qualified by Manufacturer are needed. The technicians need five of more years of experience, and they have to complete the training in the operation of this machine. 2. Facilities : General jigs, tools, apparatus, testers to be provided. The maintenance workshop to be equipped with a good enough capacity of building with crane and inspection instruments necessary for specific self inspection activities. 3. Place : The workshop should have a level surface where work can be performed with access to a lift crane. (2) Applicable Range of Standard Maintenance Time 1. Standard maintenance time : Direct maintenance time plus spare time. 2. Direct maintenance time : Net time actually spent for maintenance. 3. Spare time : Time for transportation of the machine for maintenance, preparation for safety work, meetings, lunch and breaks for the technician. (3) Excluded Time (not included in the standard maintenance time) 1. Repairing time : Time for machining, sheet metal processing, welding, gas cutting, removing broken parts and painting. 2. Items excluded from maintenance time because of uncertainty in time : Receiving the vehicle into shop, transportation, delivery, final inspection and investigation of causes for trouble, diagnosis and inspection. 3. Indirect time : Time for field work, preparation of required parts, etc., before starting work, going to and from the site, waiting due to user's convenience at the site and paper work for reports, bills, etc. 4. Special time : Working time at early morning, at mid night and on holidays shall be separately calculated. 5. Separate calculation : The cost for service cars, trucks with crane and truck cranes shall be separately calculated. (4) Applicable Machine for Estimation of Standard Maintenance Time 1. Standard machine. 2. A well maintained machine combined with standard attachments which has operated in a normal circumstances.

12-3

12. STANDARD MAINTENANCE TIME TABLE

12.1

STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR

(1) Standard maintenance time table 1. Units of working time : 6 minutes = 0.1 hour 2. Calculating method of standard maintenance time : Maintenance time = Working time X Number of workers (Working time = Maintenance time / Number of workers) 3. When more than one work are done, a. Add each standard maintenance time b. A net time (readily starting) is given except covers easily removed by hand. c. Assy works include the following works marked with black dot Âˇ 4. O / H : The removing and installing time are not included. 5. Abbreviations in the table. ASSY

; Assembly

SOL

; Solenoid

Rem.

; Removal

ATT

; Attachment

; Switch

Inst.

; Installation

BRG

; Bearing

; Valve

O/H

; Overhaul

C/V

; Control valve

F hose

; Flexible hose

Cyl

; Cylinder

E/G

; Engine

(2) Classification of work code No.

GROUP

01 02 03 04

Attachment Canopy and Guard Upper Structure Under carriage

REMARKS To indicate removing, installing, replacement and overhaul.

01 Attachment(1/2) No.

EQUIPMENT PORTION

Bucket portion

01 02 03 04 05 06 07

Bucket ASSY -Bucket removing / installing position -Bucket installing pin -Bucket drive pin -Bucket sling and transfer Bucket (Single) -Bushing

Arm portion

Arm ASSY

-Bucket cylinder removing / installing position and piping -Bucket cylinder rod pin -Bucket cylinder head pin -Bucket cylinder assy -Arm cylinder rod pin -Boom top pin -Arm sling and transfer

13 14 15 16 17 18

WORK TO BE DONE

UNIT

REMARKS

UNIT: HOUR

Refer to 32.1.2 Rem./Inst. Preparation Rem./Inst. - ditto Preparation O/H Replace

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

Include adjustment Include stopper pin.

Not include removal / inst.

0.4 0.1 0.1 0.1 0.1 0.6 0.5

Refer to 32.1.3 Rem./Inst.

1 pc.

0.8

Preparation

1 pc.

0.2

Rem./Inst. - ditto - ditto - ditto - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

12-4

Include stopper pin. Include stopper pin. Include stopper pin.

0.1 0.1 0.1 0.1 0.1 0.1

12. STANDARD MAINTENANCE TIME TABLE 01 Attachment(2/2) No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

REMARKS

UNIT: HOUR

Boom portion

21 22 23 24 25 26 27 28 29

Boom ASSY -Boom removing / installing position -Boom cylinder temporary slinging -Boom cylinder rod pin -Boom cylinder piping -Arm & Bucket piping -Boom assy temporary slinging -Boom foot pin -Boom assy slinging

Rem./Inst. Preparation - ditto Rem./Inst. - ditto - ditto Rem./Inst. - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

30 31 32 33 40 41 42 43

Arm cylinder removing / installing -Arm cylinder piping -Arm cylinder head pin -Arm cylinder slinging Boom cylinder removing / installing -Boom cylinder piping -Boom cylinder head pin -Boom cylinder slinging

- ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

50 51 60 61 70 71

Bucket cylinder -Pin bushing Arm cylinder -Pin bushing Boom cylinder -Pin bushing

O/H Replace O/H Replace O/H Replace

1 pc. 1 set 1 pc. 1 set 1 pc. 1 set

Swing portion

81 82 83 84

Swing bracket assy -Swing cylinder rod pin -Swing bracket slinging -Swing center pin

Rem./Inst. - ditto - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc.

After removing boom.

0.4 0.1 0.1 0.1

85 86 87 88 89

Swing cylinder removing / installing -Swing cylinder hose -Swing cylinder head pin Swing cylinder -Pin bushing Other necessary works

- ditto Rem./Inst. - ditto O/H Replace Rem./Inst.

1 pc. 2 pcs. 1 pc. 1 pc. 1 pc. 1 set

After removing swing bracket.

0.3 0.2 0.1 2.5 1.0 0.1

Dozer portion

91 92 93 94 95 96

Dozer ASSY -Dozer cylinder hose -Dozer cylinder rod pin -Dozer installing pin Dozer cylinder -Pin bushing

Refer to 32.1.4

Include stopper pin.

Include seal. Include seal. Include seal.

1.0 0.1 0.1 0.1 0.1 0.2 0.1 0.1 0.1 0.3 0.1 0.1 0.1 0.3 0.1 0.1 0.1 2.5 1.0 2.5 1.0 2.5 1.0

Refer to 32.1.5

Include seal. Panel assy (3) Refer to 32.1.6

Rem./Inst. - ditto - ditto - ditto O/H Replace

12-5

1 pc. 2 pcs. 1 pc. 2 pcs. 1 pc. 1 set

Include seal.

0.6 0.2 0.1 0.2 2.5 1.0

12. STANDARD MAINTENANCE TIME TABLE 02 Canopy & Guard (1/1) No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

Canopy portion

01 02

Canopy assy -Hand rail

Cab portion

11 12

Cab assy -Harness

Bonnet & Guard

21 22 23 24 25

Cover assy (1) Bonnet assy (2) Cover assy (3) Cover assy (4) Cover assy (5)

Control stand portion

31 32 33 34 35 36 37

Control stand ASSY -Air cleaner -E / G control cable -Deceleration motor (OPT) -Filler neck -Fuel air bleed hose -Harness

Rem./Inst. - ditto - ditto - ditto - ditto - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 set

Other necessary works

Rem./Inst. - ditto - ditto - ditto - ditto -

1 set 1 set 1 set 1 pc. 1 pc.

Floor plate portion

Floor plate assy Other necessary works

Counterweight portion

51 52 53 54

Counterweight ASSY -Lifting tools -Slinging -Counterweight fixing bolt Other necessary works

REMARKS

UNIT: HOUR

Refer to 33.1.1 Rem./Inst. - ditto -

1 pc. 1 pc.

0.2 0.1 Refer to 33.1.1

Rem./Inst. - ditto -

1 pc. 1 pc.

0.4 0.1 Refer to 33.1.2

Rem./Inst. - ditto - ditto - ditto Rem./Inst.

0.1 0.1 0.1 0.1 0.1

1pc. 1pc. 1pc. 1pc. 1pc. Refer to 33.1.15

1.0 0.1 0.2 0.1 0.1 0.1 0.3 Canopy Floor cover Guard (Cover, support) Counterweight Negative terminal of battery

0.2 0.1 0.4 0.4 0.1

Refer to 33.1.3 Rem./Inst. - ditto -

1 set 1 pc.

Canopy removal / inst

0.5 0.2

Refer to 33.1.5 Rem./Inst. Preparation Rem./Inst. - ditto - ditto -

12-6

1 pc. 1 set 1 pc. 1 set 3 pcs.

Guards

0.4 0.1 0.1 0.1 0.3

12. STANDARD MAINTENANCE TIME TABLE 03 Upper structure (1/4) No.

EQUIPMENT PORTION

Control portion

E / G control cable

Other necessary works

Intake portion

11 12 13 14

Air cleaner ASSY -Hose (1) -Hose (2) -Element

Exhaust portion

21 22 23 24

Muffler ASSY -Clamp -Exhaust manifold attaching nuts -Muffler fixing bolt Other necessary works

WORK TO BE DONE

UNIT

Rem./Inst.

1 pc.

- ditto -

1 set

Rem./Inst. - ditto - ditto Replace

Rem./Inst. - ditto - ditto - ditto - ditto -

1 pc. 1 pc. 4 pcs. 4 pcs. 1 set

Generator -Connector -Generator fixing bolt -V-belt Other necessary works

Rem./Inst. - ditto - ditto - ditto - ditto - ditto -

1 pc. 1 pc. 2 pcs. 1 pc. 1 set 1 pc.

36 37 38 39

Starter -B-terminal -S-terminal connector -Starter fixing bolt Other necessary works

Rem./Inst. - ditto - ditto - ditto - ditto - ditto - ditto -

1 pc. 1 pc. 1 pc. 2 pcs. 1 set 1 set 1 pc.

Fuel tank ASSY -Fuel -Hose (Supply ; water separator side) -Hose (Return ; filter side) -Level sensor connector -Fuel tank fixing bolt Other necessary works

Cover and Hose

0.4

0.3 0.1 0.1 0.1 Refer to 33.1.14

31 32 33 34

41 42 43 44 45 46

0.2

1 pc. 1 pc. 1 pc. 1 pc.

E / G Accessory portion

Fuel portion

UNIT: HOUR

Refer to 33.1.12

REMARKS

Heat insulation cover

0.4 0.1 0.1 0.1 0.1

Refer to 33.1.13 & 33.1.16

Include tension adjusting Covers Negative terminal of battery

Cover and Floor plate Seat and Stand cover Negative terminal of battery

0.6 0.1 0.1 0.3 0.1 0.1 0.5 0.1 0.1 0.2 0.1 0.3 0.1

Refer to 33.1.10 Rem./Inst. Replace Rem./Inst. - ditto - ditto - ditto - ditto -

12-7

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 4 pcs. 1 pc.

Covers

0.6 0.2 0.1 0.1 0.1 0.1 0.2

12. STANDARD MAINTENANCE TIME TABLE 03 Upper structure (2/4) No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

Hydraulic oil tank portion

51 52

Hydraulic oil tank ASSY -Return filter

Rem./Inst. Replace

1 pc. 1 pc.

53 54

-Hydraulic oil -Suction hose

- ditto Rem./Inst.

1 pc. 1 pc.

55 56 57 58

-Strainer -Pilot return hose -Swivel drain hose -SOL. valve return hose

Replace Rem./Inst. - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc.

59 60

-Slewing, C / V return hose -Tank fixing bolt Other necessary works

- ditto - ditto - ditto - ditto - ditto Preparation

2 pcs. 4 pcs. 1 pc. 1 pc. 1 pc. 1 pc.

Pump portion

Pump ASSY

Rem./Inst.

1 pc.

72 73 74

-Hydraulic oil -Pilot delivery oil hose -Suction hose

Replace Rem./Inst. - ditto -

1 pc. 1 pc. 1 pc.

75 76 77 78

-Suction tube (pump side) -Main pump delivery hose -Pump fixing bolt Pump ASSY Other necessary works

- ditto - ditto - ditto O/H Feed Preparation

1 pc. 3 pcs. 2 pcs. 1 pc. 1 pc. 1 pc.

Radiator portion

81 82 83 84 85

Radiator ASSY -Coolant (LLC) --Coolant density -Reserve tank hose -Radiator hose

86 87 88

-Cooler hose -Radiator fixing bolt -Radiator lifting or slinging Other necessary works

UNIT: HOUR

Refer to 33.1.11

REMARKS

After removing fuel tank ; Include pressure releasing & replacing O-ring

1.6 0.2 0.2 0.2

Include replacing O-ring

Covers Control valve Solenoid valve Hyd. oil tank pressurizing

0.1 0.1 0.1 0.1 0.2 0.2 0.2 1.6 0.1 0.1

Refer to 33.1.6 After removing counterweight Include pressure releasing

Hyd. oil in pump Hyd. oil tank pressurizing

1.2 0.2 0.1 0.2 0.2 0.2 0.2 3.0 0.1 0.1

Refer to 33.1.17 Rem./Inst. Replace Measuring Rem./Inst. - ditto -

1 pc. 1 pc. 1 pc. 1 pc. 2 pcs.

1.2 0.2 (0.2) 0.1 0.2

- ditto - ditto - ditto - ditto - ditto - ditto -

2 pcs. 3 pcs. 1 pc. 1 pc. 1 set 1 pc.

0.2 0.1 0.1 0.4 0.2 0.1

12-8

Counterweight Covers Duct

12. STANDARD MAINTENANCE TIME TABLE 03 Upper structure (3/4) WORK TO BE DONE

UNIT

REMARKS

UNIT: HOUR

No.

EQUIPMENT PORTION

Engine (E / G) Installing portion

91 92

Engine ASSY -Fuel hose

Rem./Inst. - ditto -

1 pc. 4 pcs.

93 94 95

-Harness, connector and cable -Engine fixing nut -Engine slinging

Rem./Inst. - ditto - ditto -

1 set 1 pc. 1 set

Other necessary works

- ditto - ditto - ditto - ditto - ditto -

1 set 1 pc. 1 set 1 pc. 1 pc.

Covers Canopy Control stand Counterweight Air cleaner

0.2 0.2 1.0 0.4 0.2

11 12 13 14

Air cleaner ASSY •Hose (1) •Hose (2) •Element

- ditto - ditto - ditto - ditto -

1 pc. 1 pc. 1 pc. 1 pc.

Muffler Pump Radiator Battery negative terminal

0.4 1.2 1.0 0.1

100

Control valve portion

101 102

Control valve ASSY -Piping connector, hose

104 105

-Fixing bolt Control valve ASSY Other necessary works

110

Slewing motor portion

111 112

Slewing motor ASSY -Piping connector, hose

113 114

-Fixing bolt Slewing motor ASSY Other necessary works

120

Swivel joint portion

121

Swivel joint ASSY

122 123 124 125 126

Refer to 33.1.18 1.0 0.2 0.3 0.2 0.2

Refer to 33.1.7 Rem./Inst. - ditto -

1 pc. 1 set

- ditto O/H

1 set 1 pc.

Rem./Inst. - ditto -

1 set 1 set

Include attaching hose's tag and plug

1.6 1.0 0.1 3.0

Covers Hoses

0.1 0.2

Refer to 33.1.20 Rem./Inst. - ditto -

1 pc. 7 pcs.

- ditto O/H

1 pc. 1 pc.

Rem./Inst. Feed

1 set 1 pc.

Include attaching hose's tag and plug

1.0 0.5 0.3 3.0

Floor plate, Covers Hyd. oil in motor

0.2 0.1

Refer to 33.1.21 Rem./Inst.

1 pc.

-Under cover -Piping connector, hose

- ditto - ditto -

1 pc. 1 set

-Stopper -Fixing bolt Swivel joint ASSY

- ditto - ditto O/H

1 pc. 1 set 1 pc.

Preparation

1 pc.

Other necessary works

For injection pump - 2 pcs. & For feed pump - 2 pcs.

1 pc. 1 pc.

12-9

After removing slewing motor Include attaching hose's tag and plug

2.5 0.1 1.5 0.1 0.2 2.0

Removal / Inst. position. (Secure working space.) Canopy removal / inst. (for easy working) Floor plate cover (2) removal / inst.

0.1 0.2 0.1

12. STANDARD MAINTENANCE TIME TABLE 03 Upper structure(4/4) No.

EQUIPMENT PORTION

130

Upper frame portion

131 132 133 134

Upper frame ASSY -Fixing bolt -Upper frame slinging -Cleaning Other necessary works

WORK TO BE DONE

UNIT

REMARKS

UNIT: HOUR

Refer to 33.1.22 Rem./Inst. - ditto - ditto Cleaning

1 pc. 1 set 1 pc. 1 pc.

Rem./Inst. - ditto - ditto Drain / Feed Rem./Inst. - ditto -

1 pc. 1 pc. 1 pc. 1 pc. 1 set 1 set

12-10

Apply sealant

Canopy Guard (Cover, support) Counterweight Hydraulic oil Swivel joint hose Boom, Swing bracket

1.0 0.3 0.3 0.2 0.2 1.5 0.4 0.2 0.5 1.5

12. STANDARD MAINTENANCE TIME TABLE 04 Under carriage No.

EQUIPMENT PORTION

Travel portion

01 02 03 04

Rubber crawler -Rubber shoe removing / inst. position. -Tension adjusting -Crawler shoe

Upper roller portion

11 12

Upper roller ASSY Upper roller

Lower roller portion

21 22

Lower roller ASSY Lower roller

Front idler & Idler adjuster portion

31 32 33 34

Idler & Idler adjuster ASSY Idler & Idler adjuster ASSY Idler ASSY Idler adjuster ASSY

Sprocket portion

Sprocket

Travel motor portion

51 52 53

Travel motor ASSY -Motor cover -Hydraulic connector, hose

54 55 56 57

-Motor fixing bolt -Motor slinging Travel motor Travel reduction unit Other necessary works

Slewing bearing portion

61 62 63 64

Slewing bearing ASSY -Slewing bearing fixing bolt -Slewing bearing -Slewing bearing slinging

WORK TO BE DONE

UNIT

REMARKS

UNIT: HOUR

Refer to 34.1.2 Rem./Inst. Preparation Adjusting Rem./Inst.

One side One side One side One side

0.6 0.1 0.2 0.2 Refer to 34.1.3

Rem./Inst. O/H

1 pc. 1 pc.

After removing crawler shoe

0.2 1.0

Refer to 34.1.4 Rem./Inst. O/H

1 pc. 1 pc.

0.2 1.0 Refer to 34.1.5 & 34.1.6

Rem./Inst. O/H O/H - ditto -

One side One side One side One side

After removing crawler shoe

0.5 0.1 1.0 0.5

Refer to 34.1.7 Replace

One side

After removing crawler shoe

0.5

Refer to 34.1.8 Rem./Inst. - ditto - ditto -

One side One side One side

- ditto - ditto O/H - ditto Feed

One side One side One side One side One side

After removing crawler shoe Include attaching hose's tag and plug

Hyd. oil in motor

1.0 0.1 0.6 0.3 0.1 3.0 3.0 0.1

Refer to 34.1.9 Rem./Inst. - ditto Cleaning Rem./Inst.

12-11

1 pc. 1 pc. 1 pc. 1 pc.

After removing upper frame Decreasing / Replenishment

0.6 0.3 0.1 0.2

12. STANDARD MAINTENANCE TIME TABLE

12-12

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13. MAINTENANCE STANDARD AND TEST PROCEDURE TABLE OF CONTENTS

13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS ...............13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE ........................................13-5 13.2.1 STANDARD VALUE TABLE .......................................................................13-5 13.3 MEASURING ENGINE SPEED ..........................................................................13-7 13.3.1 ENGINE SPEED MEASUREMENT ...........................................................13-7 13.4 MEASURING HYDRAULIC OIL PRESSURE ....................................................13-9 13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT ........13-9 13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT ................................13-9 13.5 MEASURING TRAVEL PERFORMANCES .......................................................13-13 13.5.1 TRAVEL .....................................................................................................13-13 13.5.2 TRAVEL DEVIATION .................................................................................13-13 13.5.3 MOVEMENT DRIFT DUE TO GRAVITY ....................................................13-14 13.5.4 DRAIN RATE OF TRAVEL MOTOR ..........................................................13-14 13.6 MEASURING SLEW PERFORMANCES ...........................................................13-16 13.6.1 SLEW TIME ...............................................................................................13-16 13.6.2 OVERRUN WHEN SLEWING STOPS ......................................................13-16 13.6.3 SLEW DRIFT DUE TO GRAVITY ..............................................................13-16 13.6.4 DRAIN RATE OF TRAVEL MOTOR ..........................................................13-17 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES .......................13-18 13.7.1 CYLINDER SPEED ....................................................................................13-18 13.7.2 GRAVITY DRIFT OF CYLINDERS ............................................................13-19 13.8 MEASURING SLEW BEARING PERFORMANCES ..........................................13-20 13.8.1 SLEW BEARING-BUCKET TIP PLAY .......................................................13-20 13.8.2 SLEW BEARING PLAY ..............................................................................13-20 13.9 MEASURING CRAWLER TENSION ..................................................................13-22 13.9.1 CRAWLER TENSION ................................................................................13-22

Book Code No. S5PW1332E02 13-1

13. MAINTENANCE STANDARD AND TEST PROCEDURE

Issue

Date of Issue

First Edition

March, 2010

Revision

June, 2010

Applicable Machines

Remarks

CX31B : PW14CX36B : PX15-

S5PW1332E01 (CASE-NA)

CX31B : PW14-46519~ CX36B : PX15-21105~

S5PW1332E02 (CASE-NA)

13-2

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1

HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

(1) Application 1. For New Machine; This manual is to be used to compare actual performance and functions of the machine with performance standards. 2. At Specific Self-Inspection (as per LOCAL RULES); The maintenance standards are criteria to determine time needed for reconditioning, adjustment and replacement. 3. At Deterioration of Performance; This manual provides the criteria for safe and economical judgment on whether the deterioriation of performance on the machine is caused by a fault or normal 4. For Replacement of Major Components; This manual is the standard to determine the time for replacement to maintain the performance of major components such as pump, etc (2) Terminology 1. Standard Values : These are the standard values to assemble and regulate a new machine. Where special notes are not given, these values are based on the machine with standard structure (machine with standard attachments and shoes). 2. Standard Values for Repair : These are of the values at which the reconditioning is required. In order to ensure the performance and safety, it is strictly prohibited to use the machine with the parts and components over the standard values. 3. Serviceability Limit : This is of the service limit for each part and component at which reconditioning is impossible and the part must be replaced with a new one. All the parts and components which are estimated to exceed the serviceability limit up to the next periodic inspection and maintenance, should be also be replaced. Operating the machine with parts and components that have exceeded the serviceability limit is unsafe and could result in equipment failuer and down time. (3) Precautions for Judgment : 1. Evaluation for Measured Data : Some variation on the measured data is inevitable, due to differences between old and new versions of the machine and measurement conditions. Measured data should be judged comprehensively, taking into consideration the level and extent of measurement, rather than merely compared with standard values. 2. Determination for Reconditioning, Adjustment or Replacement : There are two kinds of deterioration of machine performance; one is due to normal wear over time, and the other is recoverable to the standard values with the adjustment for presssure, etc. Therefore, the determination for reconditioning, adjustment or replacement should be conducted taking various factors into consideration such as operating hours, working conditions and maintenance conditions of the machine, so that the machine is able to be operated at the optimum performance level.

13-3

13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Other Precautions 1. Parts with Aging Effect : The rubber products such as hydraulic hoses, O-rings, oil seals, etc. will deteriorate with age. It is necessary to replace them to new ones at periodic intervals or at every overhaul. 2. Parts required Periodical Replacement : It is recommended to designate the important hoses critical for safety as Very Important Parts (V.I.P.), and periodically replace them with new ones. 3. Inspection & Replacement of Lubricants : The machine operator should become familiar with the procedures and precautions for safe handling and maintenance of the machine, including procedures for inspection and lubrication. Refer to the OPERATOR'S MANUAL.

13-4

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2

PERFORMANCE INSPECTION STANDARD TABLE

13.2.1 STANDARD VALUE TABLE Model Applicable machines Unit

Standard value

Repairable value

Standard value

Repairable value

Hyd. oil cleanliness

Class

8±1

—

8±1

—

50~60 (122~140)

—

50~60 (122~140)

—

60~90 (140~194)

—

60~90 (140~194)

—

1200±25

—

1200±25

—

2550±25

—

2550±25

—

1200±25

—

1200±25

—

Coolant temperature (Radiator surface)

Main relief valve pressure

C ( F)

Low idle

Engine speed

Measuring condition

Hyd. oil temperature (Tank surface)

High idle

rpm

Deceleration Boom • Bucket • Travel (LH)

Arm • Swing • Travel (RH) • Service

Dozer • *1 Slew

Pilot relief valve Pilot Line pressure *2 Port (Over load) relief valve pressure

CX36B PX15-21105~

Item

Div.

23.0

(3340

)

—

23.0

(3340

)

—

23.0

(3340

)

—

23.0

(3340

)

—

20.0

(2900

)

—

20.0

(2900

)

—

3.5

—

3.5

Boom

Head Rod

Arm

Head Rod

MPa (psi)

(508

)

(508

—

)

27.5

(3990

)

—

27.5

(3990

)

—

25.5

(3700

)

—

25.5

(3700

)

—

25.5

(3700

)

—

25.5

(3700

)

—

Bucket

Head

Dozer

Head

27.5

(3990

)

—

27.5

(3990

)

—

*1 Slew

LH/RH

20.0

(2900

)

—

20.0

(2900

)

—

Crawler Speed (5 rev.) Travel

CX31B PW14-46519~

Travel Speed 10 m (32.8 ft)

Rubber crawler

Low

33.2±1.6

high

18.9±0.9

34.0±1.7

Low

sec.

Iron crawler

High

19.3±0.9

Rubber crawler

Low

14.5±0.7

High

8.3±0.4

14.9±0.7

8.5±0.4

Iron crawler

Low

sec.

High

Travel deviation Drift due to gravity

w / P.B. (5 min)

140

(5.5

)

280 (11.0)

140

(5.5

)

280 (11.0)

mm (in) 0 (0)

1 (0.04)

*1. The pressure for slew is controlled by the relief valve attached to the slew motor. *2. Reference value for checking of pressure (tighten up the adjusting nut of main relief valve. Refer to item 13.4.2.1)

13-5

0 (0)

1 (0.04)

13. MAINTENANCE STANDARD AND TEST PROCEDURE

Model Applicable machines

Slew

Div.

CX31B

Item

Unit

Slew time per 2–revolution

sec.

Overrun when slewing stops

mm (in)

Drift due to gravity Canopy Boom Cylinder speed

Cab Arm

Cylinders C yl i n d e r G r a v i t y m o v e

Dozer

(10 min)

Crawler Slew bearing

18 95

Ext.

2.4±0.4

3.1

2.3±0.4

2.9

Ret.

2.4±0.4

3.1

2.3±0.4

2.9

Ext.

2.0±0.4

2.6

2.0±0.4

2.6

Ret.

2.1±0.4

2.7

2.0±0.4

2.6

Ext.

2.6±0.4

3.3

3.1±0.3

4.0

1.6±0.3

2.1

2.0±0.3

2.6

2.8±0.4

3.6

2.8±0.4

3.6

Ret.

1.8±0.3

2.3

1.8±0.3

2.3

Ext.

5.4±0.9

6.9

5.4±0.9

6.9

Ret.

4.0±0.7

5.1

4.0±0.7

5.1

Ext.

3.9±0.5

5.0

3.9±0.5

5.0

Ret.

3.0±0.4

3.8

3.0±0.4

3.8

sec.

Boom

Arm

(0.20

3 3

Bucket

mm (in)

24 (0.94)

)

10 (0.39)

(0.20

)

10 (0.39)

(0.12

)

6 (0.24)

(0.12

)

6 (0.24)

(0.12

)

6 (0.24)

(0.12

)

6 (0.24)

300 (12)

150

)

12 (0.47)

)

120 (4.7)

0.6~1.8 (0.024~0.071) 70~80 (2.76~3.15)

Bucket tip

150

Swing

Slew bearing play Rubber Iron

13.8±0.7

—

Bucket tip play

Crawler tension

Dozer

(5 min)

13.8±0.7

PX15-21105~ Repairable Standard value value

—

Ext.

Swing

PW14-46519~ Repairable Standard value value

Ret.

Bucket

CX36B

mm (in)

)

(5.9 (0.24

60 mm (in)

(0.47

(2.4

115~130 (4.53~5.12)

13-6

)

(0.47

)

(5.9

)

24 (0.94)

300 (12)

)

12 (0.47)

)

120 (4.7)

2.6 (0.10)

0.6~1.8 (0.024~0.071)

2.6 (0.10)

—

70~80 (2.76~3.15)

—

115~130 (4.53~5.12)

—

(0.24 (2.4

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3

MEASURING ENGINE SPEED

13.3.1 ENGINE SPEED MEASUREMENT (1) Measuring Instruments 1. Diesel Speedometer (Measuring engine speed by means of applying a pick-up to one of injection pipes) 2. Surface Thermometer (Measuring the surface temperature getting contact of the probe with the surface of hydraulic oil tank and radiator)

Engine Speed measurement (The above figure shows concept) (2) Engine Warming up Operation Start up the engine, and make the coolant temperature within the range of 60 to 90C degrees (140 to 194F degrees). Check the coolant temperature with the coolant thermometer on the monitor panel. The white color zone shows approx. 67 to 105Â°C (153 to 221Â°F degrees) of temperature range. Therefore, when the indicator is located at around center of the white zone, it is suitable for the engine operation. (3) Engine Speed Measurement 1. Apply the pick up of speedometer to one of convenient injection pipes. (Refer to Fig. "Engine Speed measurement") 2. Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD VALUE TABLE.

13-7

13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Speed Adjustment 1. Low / High Idling Speed is low ; The proper engine speed is obtained with the length of accelerator wire as shown in the right sketch. When the engine speed is lower than the standard speed, adjust the length of wire with loosening the capscrew (9) of throttle lever side.

DETAIL Z [WITH DECEL]

Accelerator wire adjustment

However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer.

13-8

13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4

MEASURING HYDRAULIC OIL PRESSURE

13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT (1) Hydraulic Instruments -6.86 MPa (1000 psi) pressure gauge : 1 set -49 MPa (7100 psi) pressure gauge : 3 sets -Surface Thermometer : 1 set -Pressure Measuring Kit and Oil Analyzing Equipment : 1 set (2) Measuring cleanliness of hydraulic oil

After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is over the standard value, replace the return filter and/or change the hydraulic oil.

13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT 13.4.2.1 MAIN CIRCUIT PRESSURE (1) Measuring Conditions Engine speed : High idling Hydraulic oil temperature : 50 to 60째C (122 to 140째F) Coolant temperature (on radiator surface) : 60 to 90째C (140 to 194째F)

13-9

13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pressure Measuring Procedures 1. After releasing pressure in the hydraulic oil tank, and setting a 49 MPa (7100 psi) pressure gauge to either of pressure detecting ports (G1, G2 or G3, PF1/4 with plug), operate the circuit to be measured to measure the relief pressure. 2. When the main relief pressure is being within the standard range, the measurement for the overload relief pressure may be omitted. 3. If the main relief pressure is lower than the standard range, tighten up the main relief valve by half turn [pressure increase by 12.2 MPa (1770 psi)], then measure the pressure at overload relief valve. 4. After adjustment for the overload relief pressure, return back the main relief pressure within the standard range.

Operating Circuit

Main hydraulic oil pressure measurement (1/2)

Press. Detecting Port Relief Valve Port Location Size

Boom, Bucket & Travel (left)

Arm, Travel (right) Swing & Service

Dozer & Slew

MR1 PF1/4

MR2 MR3

Attaching position of overload relief valve Main hydraulic oil pressure measurement (2/2)

OR1 BUCKET DIGGING OR6 DOZER DOWN OR2 BOOM UP

OR7 SLEW RIGHT

OR3 BOOM DOWN

OR8 SLEW LEFT

OR4 ARM IN OR5 ARM OUT

(3) Pressure Adjustment 1. Control Valve : Main Relief Valve and Overload Relief Valve a. Loosen the lock nut (2), and adjust the setting pressure turning the setscrew (1). Roughly with one full turn : Main relief valve & Overload relief valve : Approximately 12.2 MPa (1770 psi) CW turning : Increasing setting pressure CCW turning : Decreasing setting pressure b. After the adjustment, tighten up the lock nut holding the setscrew not to turn around. c. Again activate the relief valve to check the stable setting pressure. Tightening torque for nut (2) : 19.6 N-m (14.5 lbf-ft)

13-10

MAIN RELIEF VALVE OVERLOAD RELIEF VALVE Relief valve

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