Hitachi ex270 with hino h06cti service manual by engineparts2

H Hitachi EX270 Service Manual Note: the Hino H06CTI Engine Service Manual begins in section 11 on page EG12-1-1

HOW TO USE

, � CONTENTS

Group 1-SECTION & GROUP CONTENTS

HU10-1A-1-4

Group 2-INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 1. 2. 3.

HU3-2-1-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-2-1 Care of the Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-2-1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-2-2

Group 3-FEATURES OF THIS MANUAL 1. 2. 3. 4.

. . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-3-1-2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-3-1 Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-3-2 Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-3-2 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HU3-3-2

Group 4-SAFETY INFORMATIONS ........

HU3-4-1-4

HU10-1A-1

HOW TO USE

----------- SECTION & GROUP CONTENTS -----------

n !!

SECTION Group Group Group Group

1 1 2 3 4

SECTION Group Group Group Group Group

2 S PECIFI CATION S 1 General Specifications .................... SP84-1 2 Components Specifications ................ SP84-2A 3 Torque References ....................... SP84-3 4 Others ................................... SP81-4 5 Conversion Table ........................... CT-1

SECTION Group Group Group Group Group

3 GENERAL 1 Introduction 2 Construction ............................. 3 Hydraulic System ......................... 4 Electric System ........................... 5 Maintenance .............................

HOWTOUSE Section & Group Contents ................. HU10-1A Introduction ............................... HU3-2 Features of this Manual ..................... HU3-3 Safety informations ........................ HU3-4

GN10-1 GN10-2 GN10-3 GN10-4 GN10-5

SECTION 4 SUPER ST RUCTURE Group 1 Superstructure ............................. SS22 Group 2 Hydraulic Pump Device. Hydraulic Pump ......................... HYP-34A Regulator ................................ RE-28A Pump Transmission ........................ TM-5A Gear Pump ..... . ........................ HYP-36 Group 3 Control Valve .............................. CV-34A Group 4 Swing Device Swing Motor (MX 173 CAB Motor) ......... HYM-50 Swing Motor (M2X 170, 210 CAB Motor) ... HYM-58 Swing Reduction Device ................. SRD-9 Group 5 Pilot Valve Operational Plinciple, Disassembly & Assembly (For Front-End Attachment) ................... PV-9 Disassembly & Assembly (For Travel) ........ PV-10 Group 6 Control Neutralizer Valve ................... CNV-1 Group 7 Shockless Valve ........................... SHV-1

HU10-1A-2

HOW TO USE

----------- SECTION & GROUP CONTENTS ------------

Group 8 Accumulator .............................. ACC-4 Group 9 Solenoid Valve Operational Principle (Three spools) ......... SOV-9 Disassembly & Assembly (Three spools) ..... SOV-9 Operational Principle(One spool) ........... SOV-11 Disassembly & Assembly (One spool) ....... SOV-10 Group 10 Mode Selection Cylinder ................... CY-13

SECTION 5 UNDERCARRIAGE

Group 1 Undercarriage ............................ UC-25 Group 2 Travel Device Operational Principle of Travel Motor ...... HYM-48A Disassembly & Assembly of Travel Motor ... HYM-48A Disassembly & Assembly of Travel Device ... TD-18A Group 3 Center Joint ............................... CJ-10

SECTION 6 FRONT-END ATTACHMENTS

Group 1 Front-End Attachment ..................... Group 2 Hydraulic Cylinder Operational Principle ...................... Disassembly & Assembly ................... Group 3 Pin & Bushing ............................ Group 4 Point & Side Cutter ........................

SECTION 7 HYDRAULIC SYSTEM Group Group Group Group Group Group Group

1 2 3 4 5 6 7

Outline ................................... Main Hydraulic Circuit ...................... Pilot Circuit ............................... Single Operation .......................... Combined Operation ....................... Extra Control Circuit ........................ Hydraulic Circuit ...........................

FA15-1 CY-12 CY-19 FA15-3 FA15-4

HS-12A HS-12A HS-12A HS-12A HS-12A HS-12A HS-12A

HU10-1A-3

HOW TO USE

-----------

SECTION & GROUP CONTENTS -----------

SECTION 9 ELECTRICAL SYSTEM Group Group Group Group Group

1 2 3 4 5

Safety Precautions ........................ . Specifications ............................ Construction & Function ................... Circuit Operations ........................ Maintenance .............................

ES5-1 ES12-2 ES12-3 ES12-4 ES5-5A

SECTION 10 TROUBLESHOOTING Group Group Group Group Group

1 2 3 4 5

Introduction .............................. TS11-1 Diagnose Malfunctions ................... TS11-2A Excavator Performance Test ............... TS18-3A Components Performance Standard ........ TS18-48 Electrical System Test .................... TS18-5

SECTION 11 Hino H06 H06C H06CT H06CTI ENGINE Group Group Group Group Group Group Group

1 General Introduction ...................... 2 Engine ...... ............................ 3 Generator ............................... 4 Starter ................................... 5 Calibration ............................... 6 Turbocharger ............................ 7 Service Specifications .. . .................

EG12-1 EG12-2 EG12-3 EG12-4 EG12-5 EG12-6 EG12-7

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

HOW TO USE

HU3-2-1

INTRODUCTION-------------1.

INTRODUCTION

This service manual is for training new personnel and for reference by experienced service techni cian. It works to give you both the general background as a training text and technical details of shop service and field service. It is concise service guide for specific machine. It covers specifications construction, theory of operation, trouble shooting, removal and installation, disassembly and assembly, maintenance and repair. Using the service manual as a guide will reduce error and costly delay. It will also assure you the best in finished service work.

Note;

There are 3 types machines which are Super Deluxe type, Deluxe type and Standard type. In this service manual, Super Deluxe type machine is mentioned.

As supplied machines are different subject to territory and/or machine, please confirm which one is applicable and what equipments it has. All information, illustrations and specifications contained in this technical manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

2. CARE OF THE HANDLING----------------------2.1 PERSON IN CHARGE

Since the each service manual is serially numbered, please appoint personnel to be responsible for the care of this service manual and then inform us of his name with the kind of manual and serial no. If the person in charge is changed, please inform us promptly. 2.2 REVISIONS AND SUPPLEMENTS

This loose-leaf manual can be easily kept up-to-date by inserting or exchanging the revisions and supplements. The person in charge is responsible for updating the manual as soon as possible. Also, please dispose of the obsolete sheets to avoid confusion. 2.3 CONFIDENCE

This manual is strictly confidential. Thus, if the manual is lent or given to any third party, prior approval of Hitachi is required.

HOW TO USE

HU3-2-2

INTRODUCTION --------------

3. SYMBOLS----------------------------ln this manual, the following symbols are used to indicate important place for safety and quality.

3.1 SAFETY

CAUTION: This safety symbol is used for impor

3.2 NOTE:

tant safety messages. When you see this symbol, follow the safety mes sage to avoid personal injury.

Special technical notice or other notice for preserving standards are necessary when perfor ming the work.

HOW TO USE

HU3-3-1

----------- FEATURES OF THIS MANUAL -----------

1. CONSTRUCTI ON This manual is divided into eleven sections. The section names and its contents are as below. To fully use this service manual, understand how it is organized. Spend a minute reading this now and save many minutes of searching later.

Section 1 ------------------------------------------------------------------------------------------------------

Blue Tab

HOW TO USE

In the beginning, read this section for effective use of this manual.

Section 2 -------------------------------------------------------------------------------------------------------- Yellow Tab SPECIFICATIONS Specifications of machine and components and general service data are given in this section.

Section 3 -------------------------------------------------------------------------------------------------------- Yellow Tab GENERAL Use this section not only as a reference guide to maintenance or repair but also as a text book to train new personnel.

Section 4 ---------------------------------------------------------------------------------------------------SUPERSTRUCTURE Section 5 ·---------------------------------------------------------------------------------------------------

Green Tab

UNDERCARRIAGE Section 6 ----------------------------------------------------------------------------------------------------FRONT-END ATTACHMENTS Refer to each of these sections according to the component you need to know.

Section 7 HYDRAULIC SYSTEM Section 8 ---------------------------------------------------------------------------------------------------PNEUMATIC SYSTEM Delete this section for not using pheumatic system.

Section 9 --------------------------------------------------------------------------------------------------ELECTRICAL SYSTEM Refer to each of these sections according to the system you need to know. 'J

Gray Tab

HOW TO USE

HU3-3-2

----------- FEATURES OF THIS MANUAL-----------

Section 10 TROUBLESHOOTING

Red Tab

Section 11

Green Tab

Use to find out the causes relating troubled phenomena and to remove them.

ENGINE

Refer to this section according to the units you need to know.

2. TAB------------------------------------Five tab colors are used. Each color represents a different type of information. This is help you quickly locate the related information. The relations between tab colors and sections are as men tioned above.

3. PAGE-----------------------------------Each page is located on the right upper and has following meanings.

Example

GN 4- 3 - 1

T L--===: T

Consecutive page number for each group Group number '------------1� Numerical order of section or unit '----------Abbreviation of section or unit

4. CONTENTS--------------------------- Use the table of section & group contents to locate the information on the first section (HOW TO

USE).

------------ A SAFETY INFORMATION-----------

HOW TO USE

UNDERSTAND CORRECT MACHINE OPERATION AND SERVICE Only qualified people should operate the machine. Learn the location and purpose of all controls, instru ments, indicator lamps, and labels. Be sure you understand a service procedure before you work on the excavator. Do not run the engine while you service the excavator unless the procedure is approved. Keep hands away from moving parts. Unauthorized modifications to the excavator may impair the function and/or safety and affcect excavator life.

WEAR PROTECTIVE CLOTHING Wear fairly tight clothing ... and safety equipment.

USE SAFETY EQUIPMENT Fasten a first-aid kit and a fire extinguisher to the machine. Keep the extinguisher fully charged. Learn to use it correctly.

INSPECT EXCAVATOR

Inspect your excavator carefully each day before you start it. Use the check list which is printed on opera tion manual. Do not start or operate the excavator unless you are in the operator's seat. When you operate the excavator, do not let another person on the machine. When you get on or off the excavator, use hand rails and steps. Start the engine only in well-ventilated area. Before you move the excavator, be sure all persons are away from the excavator.

HU3-4-1

HU3-4-2

HOW TO USE

-------------

-SAFETY INFORMATION

CAUTIONS FOR INSPECTION AND MAINTENANCE Place a notice board "under inspection and mainte nance" on the cab door or control lever. Never get under the machine while it is jacked up by the boom and arm: When inspecting or servicing the machine with raised boom and arm, always use safety blocks, safety sup ports, etc.

SUPPORT RAISED EQUIPMENT Do not work under a raised bucket. Lower the bucket to ground or onto blocks. Do not work under a raised undercarriage.

SERVICE HYDRAULIC SYSTEM SAFELY The oil tank is always pressurized. Before you work on the hydraulic system: Take off the air breezer cap, and drain the air in the tank. Before you use the hydraulic system, be sure all connec tions are tight.

AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before discon necting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of carboard or paper to search for leaks. If ANY fluid is injected into the skin, it must be surgi cally removed within a few hours by a doctor familiar with this type injury or gangrene may result.

------------ A SAFETY INFORMATION-----------

HOW TO USE

Be careful not to touch hot surfaces or high temperature oil.

LOCK THE ENGINE HOOD Lock the engine hood after opening. Don't leave the hood open on slopes or in strong winds.

HANDLE FUEL SAFELY Be careful when you work with any kind of fuel. Do not fill the fuel tank when the engine is hot or running. Do not smoke while you fill the fuel or service the fuel system.

PROTECT EYES AGAINST FLYING DEBRIS When you drive connecting pins in or out, guard against injury from flying pieces of metal or debris. Wear goggles or safety glasses.

HU3-4-3

INDEX EX270-2A-1 A

SPECIFICATIONS

� CONTENTS

Group 1-GENERAL SPECIFICATIONS 1. 2. 3. 4. 5. 6.

.......................... SP84-1-1-6 Dimensions ....................................... SP84-1-1 Weights & Ground Pressure ........................ SP84-1-2 Backhoe Attachments ............................. SP84-1-2 Other Attachments ................................ SP84-1-3 Working Ranges .................................. SP84-1-4 Lifting Capacities .................................. SP84-1-5

Group 2-COMPONENTS SPECIFICATIONS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

................... SP84-2A-1 ,...,16 Engine ......................................... SP84-2A-1 Main Pump ..................................... SP84-2A-5 Pilot Pump .. : ................................... SP84-2A-6 Control Valve ................................... SP84-2A-7 Swing Motor ................................... SP84-2A-7 Travel Motor .................................... SP84-2A-8 Center Joint .................................... SP84-2A-8 Pilot Valve {for Travel} ........................... SP84-2A-8 Pilot Valve {for Swing, Boom, Arm, Bucket} ....... SP84-2A-9 Control Neutralizer Valve ........................ SP84-2A-9 Shockless Valve ................................. SP84-2A-9 Accumulator ................................... . SP84-2A-9 Hydraulic Tank .................................. SP84-2A-9 Suction Filter .................................. SP84-2A-10 Full-Flow Fiter ................................. SP84-2A-10 Air Breezer .................................... SP84-2A-10 Bypass Check Valve ............................ SP84-2A-10 Pilot Filter ..................................... SP84-2A-10 Oil Cooler ...................................... SP84-2A-10 Restriction Valve ............................... SP84-2A-10 Continued on next page

INDEX EX270-2A-2 A

CONTENTS (continued) 21. 22 . 23. 24� 25.

Solenoid Valve ................................. Mode Selection Cylinder ........................ Boom Cylinder ................................. Arm Cylinder .................................. Bucket Cylinder ...................• . • ..........

Group 3-TORQUE REFERENCE .............

SP84-2A-11 SP84-2A-11 SP84-2A-11 SP84-2A-11 SP84-2A-11 SP84-3-1-s

Group 4-0THERS .... . . . . . . ........... . ... . .... 1.

SP81-4-1-3 Maintenance Intervals ............................. SP81-4-1

Group 5-CONVERSION TABLE .................

CT-1-1-6

SPECIFICATIONS

SP84-1-1

------------ GENERAL SPECIFICATIONS----------1. DIMENSIONS---------------------------

,__ _

_ _ K -------, -

>----E-----1

>--

--------

L---------- - ---i

C -- --- J -

Distance between tumblers

Undercarriage length

,.._ - -B---

Counterweight clearance

3 710 mm (12'2") --- -- - - - - ---- ---- 4 580 mm (15'0") - ------- - - - - - - - - - - 1 130 mm (3'8") 3 030 mm (9'11")

Rear-end swing radius

Rear-end length

3 010 mm (9'11")

Overall width of superstructure

2 800 mm (9'2")

Overall height of cab

3 000 mm (9'10")

---

Min. ground clearance

Track gauge

Track shoe width Undercarriage width

Overall width

Overall length -

480 mm (1'7") 2 590 mm (8'6")

---

-A

600 mm (24")

800 mm (31")

910 mm (36")

3 190 mm (10'6")

3 390 mm (11'1 ")

3 500 mm (11 '6")

3 500 mm (11'6") 3 390 mm (11'1 ") 3 190 mm (10'6") - ----- - - -- -- - - - 10 570 mm (34'8") with 2.40 m (7'10") arm 1 0 450 mm (34'3") with 3.10 m (10'2") arm 10 470 mm (34'4'1 with 3.75 m (12'4") arm

- --- ---- - - -

Overall height of boom

3 350 mm (11'0") with 2.40 m (7'10") arm 3 170 mm (10'5") with 3.10 m (10'2") arm 3 250 mm (10'8'1 with 3.75 m (12'4") arm

Track height

1 000 mm (3'3"): triple grouser shoe, 1 170 mm (3'10"): triangular shoe

* Track shoe lug height not included.

SPECIFICATIONS

SP84-1-2

------------GENERAL SPECIFIC ATI ONS-----------2. WEIGHT AND GROUND PRESSURES------------------Equipped with 6.20 m (20'4") boom, 3.10 m (10'2") arm and 1.1 5 m3 (PCSA heaped) bucket I Shoetype Triple grouser

i [ Triangular

Shoewidlll

Openlllng weight

Ground pret19Ure

600mm (24") 800mm (31") 910mm (36")

26 000 kg (57 300 lb) 26 800 kg (59 000 lb) 27 300 kg (60 200 lb)

0.54 bar (0.54 kgf/cm 2, 7.68 psi) 0.42 bar (0.42 kgf/cm 2 , 5.97 psi) 0.38 bar (0.38 kgf/cm 2, 5.40 psi)

Basic machine weight with 5 400 kg (11 900 lb) counterweight and 600 mm (24") triple grouser shoes(without front-end attachment) 21 000 kg ( 46 300 lb)

3. BACKHOE ATTACHMENTS Boom and arms are of all-welded, low-stress, full-box section design. 6.20 m (20'4") boom, and 2.40 m (7'10"), 3.10 m ( 1 0 '2 ") and, 3. 7 5 m ( 12 '4 "). arms are available. Bucket of all-welded, high-strength steel structure. Side clear ance adjust mechanism is provided on the bucket joint brackets.

Digging Forces

Digging force due to bucket cylinder

----

Digging force due to arm cylinder

- - - - --

149 kN (15 200 kgf, 33 500 lbf)

138 kN (14 100 kgf, 31 000 lbf)

11 0 kN (11 200 kgf, 24 700 lbf)

-+---- - - - - -- - - - +--------------- ---�-----

---

1·

3.75 m (12'4") 149 kN (15 200 kgf, 33 500 lbf)

------ -- -

--�-� 2.40m (7'10") arm

96 kN (9 800 kgf, 21 60

----- -------- ------ -_____J______

3.10 m (10'2"} arm

3.75 m (12'4"} arm

___ __

SPECIFICATIONS

SP84-1-3

------------ GENERAL SPECIFICATIONS-----------��uckets

c...-,

PCM ........ 3

0.92 m (1.20 cu yd)

CECE ........ 0.80 m3

......... I ......... 1 120 (44")

0.90 m 3

1 160 (46")

1.15 m3 (1.50 cu yd)

1.00 m3

1 220 (48")

1.20 m 3

1 420 (56")

1.40 m3

1 620 (64")

1.62 m (2.12 cu yd)

0.92 m3 (1.20 cu yd) (PCSA heaped) bucket

willl

willlout

1.05 m3 (1.37 cu yd) 1.39 m 3 (1.82 cu yd)

..._

Widlh

985 kg (2 170 lb)

1 300 (51")

804 kg (1 770 lb)

1 350 (53")

880 kg (1 940 lb)

1 550 (61")

1 020 kg (2 250 lb)

---•

· IM•c ..

1 000 kg (2 200 lb)

0 0 □

lo.

-•

llillla••■---

3.10• .·

r=�o

0 □

lo.

3.75m 0

-�-o ___

I !

__ ,

□ ----�

• Heavy-duty service o Suitable for materials with density of 2 000 kg/ m3 (3 370 lb/ cu yd) or less □ Suitable for materials with density of 1 600 kg/ m3 (2 700 lb/ cu yd) or less 3 to. Suitable for materials with density of 1 100 kg/ m (1 850 lb/ cu yd) or less

1.05 m3 (1.37 cu yd) (PCSA heaped) bucket

1.15 m3 (1_50 cu yd) (PCSA heaped) bucket

1.39 m3 (1.82 cu yd) (PCSA heaped)

bucket

1.62 m3 (2.12 cu yd) (PCSA heaped) bucket

4. OTHER ATTACHMENTS------------------------

0.70 m 3 (0.92 cu yd) Ripper bucket for 2.40 m and 3. 10 m arms

One-point ripper"for 2.40 m and 3.10 m arms

0.6 m3 (0.78 cu yd) Clamshell bucket for 2.40 m and 3.10 m arms

Breaker

SPECIFICATIONS

SP84-1-4

------------ GENERAL SPECIFICATIONS----------5.

WORKING RANGES ------------------------ feet meter 35 11

1�

10 30 25

/i' � �It\

9 8

'i !

5 C 4

0 5

10 15 20 25

J, I I/;/

...f ')rn�! b

'1 ' \

5 i

7 i

I 13 12 11 10

..-.. --

Max. digging reach

,-?",,:--

;;,-, lU

A A

�,i""

.........__ I ... f-=f-R' R

.......

v�v� /

�

...

-' ';!.

;� i'l .. �! l l

I � \j I \ .\J\.; [k_1r

'\ \

I� �

I If

l \

\,\

'� �'ii\�,

.. ---�\ � \._� VJ.1//"i) l)\

�lill

�

i I

I /,

1;'(:llll

f, <, · '-- \\--�� - r-,;... }� • r\. (\ �

- �J I

[

�) � Ii

1 5

meter

feet

2AO• (7'10'")-

a..10111 {10'2")-

10 060 mm(33'0")

10 710 mm(35'2") 10 520 mm(34'6")

S.7Sa{12'4")11 320 mm (37'2") I

Max. digging reach (on ground)

9 860 mm(32'4")

Max. digging depth

6 540 mm(21'5")

7 230 mm(23'9")

7 870 mm(25'10")

Max. digging depth (8' level)

6 320 mm(20'9")

7 050 mm(23'2")

7 730 mm(25'4")

Max. cutting height

9 530 mm(31'3")

9 880 mm(32'5")

10 170 mm(33"4")

6 670 mm(21'11")

6 980 mm(22'11")

7 330 mm(24'1")

4 160 mm(13'8'1

4 150 mm(13'7")

6 100 mm(20'0")

6 740 mm(22"1")

Max. dumping height

Min. swing radius

Max. vertical wall

4 350 mm(14'3'1 5 260 mm(17'3")

11 150 mm(36'7")

SP84-1-5

SPECIF !CATIONS

------------ GENERAL SPECIFICATIONS-----------6. LIFTING CAPACITIES-----------------------

I METRIC MEASURE I

@i Rating Oller-side or 360 degrees 6.20mboom 2.40marm

Equipped with 1.15 m3 (PCSA heaped) bucket and 600 mm shoes.

i *6.93

5.58

6.37

9.85

0 (Ground)

6.76

*7.83

*5.86

4.69

*5.27

3.70

*4.96

2.61

3.93

9.57

4.33

6.47

3.48

5.21

2.46

3.76

9.68

5.28

8.04

4.19

6.31

3.39

5.10

2.49

3.81

9.55

5.16

7.91

4.08

6.20

3.31

5.03

2.59

3.96

9.29

3.27

4.98

3.13

4.74

8.33

-2m

10.0

*10.1

6.85

5.11

7.85

4.02

6.13

-4m

10.3

*10.8

7.05

*9.76

5.26

8.02

4.17

6.30

-Sm

*9.87

7.26

*8.31 !

5.48

' *6.69

...

... 0

6.20mboom 3.10marm

,....

*9.87

}�

! *10.4

o· --6 $11i-"

*3.91 *5.03

' *5.03

*4.63

4.38

*5.94

3.49

4.21

6.34

3.38

I *5.29

7.38

5.60

*7.04

7.03

*10.2

5.35

*7.92

6.84

10.7

5.18

7.93

4.07

6.75

10.6

5.04

7.78

3.95

: *10.4

5.11

7.86

4.01

6.12

*7.75

4.14

*6.24

-2m

*8.59:

-4m

10.1

-Sm

10.3

*8.59 •12.1 *11.4

6.20mboom 3.75 marm �<:-"' - -

Unit : 1 000 kg

Equipped with 1.15 m3 (PCSA heaped) bucket and 600 mm shoes.

0 (Ground)

Unit : 1 000 kg

*7.76

5.49

Rating Oller-front

6.88 7.03

*5.29 *9.00

*9.38

5.24

3.74

*3.91

*2.52

*4.40

*2.27

*2.58

5.23

2.14

*2.79

10.3

5.10

2.15

*2.96

, 10.2

9.67 ' 10.2

6.20

3.28

5.00

2.23

; *3.20

9.97

6.06

3.19

4.90

2.62

*3.98

9.09

3.75

, *5.45

7.47

Unit : 1 000 kg

Equipped with 1.05 m3 (PCSA heaped) bucket and 600 mm shoes.

--- :.:;,-fO..ft

10.7

*6.09 * 6.43

0 (Ground) -2m -4m -6m

*6.52 9.71 *13.5

*6.52 *9.71 *13.5

9.65 9.81 10.2

*3.16

*2.01

· 10.3

*4.09

3.83

*3.91

3.04

: *3.85

*2.05

10.8

5.73

*6.29

3.55

*4.83

2.86

4.31

1.93

•2.21

10.9

*6.09

5.44

*7.23

3.41

5.14

2.76

4.21

1.94

*2.34

10.8

*6.43

5.21

7.98

3.29

5.01

2.68

4.12

1.99

*2.52

10.6

4.98

7.72

3.15

4.86

2.59

4.02

2.29

*3.11

9.78

3.16

4.87

3.08

*4.33

3.08

*4.33

8.34

4m 2m

3.14 •11.0

•10.5 *12.9

4.99

7.73

*10.8

5.24

*7.23

Notes: 1. Ratings are based on SAE J1097. 2. Lifting capa.city of the EX Series does not exceed 75% of tipping load with the machine on firm, level ground or 87% of full hydraulic capa.city. 3. The load point is a hook (not standard equipment) located on the back of the bucket. 4. *Indicates load limited by hydraulic capacity.

SPECIFICATIONS

SP84-1-6

------------GENERAL SPECIFICATIONS------------

I ENGLISH MEASURE I :Q)c 20'4" boom 7'10" arm

15ft

10ft

15ft

Load radius 20ft

--+---

*11.7

______J_ _____ ___,_

; *11.7

10ft 13_.4 *1�1 _ · -- �, -- � ___ --�-·-----r5ft 17.5 11._13 -+------L 0 (Ground) 11.1 17.0

I tJ I

9.07

. *10.7 ---+

9.31

8.64

8.20

*10.1

- --

*12.1

12.3

7.89 --

17.5

20'4" boom 10'2" arm

15ft

----

0 (Ground) ------

-5ft

-10ft -15ft

-r--

�

- - -----+-- - -

20ft

-- -

---

*10.6

18.1 17.3

*22.7

17.8

17.4 --

-- 12.7 -11.8

*18.1

*23.1 -

---+--

*21.9

@i·7-i tJ-

At max. reach

� tJ 7------- : - -

6.91-

5.97

6.00

- ---+

i i

8.38 , 31'8" 8.31

5.44

5.71

11.8

8.73

---

10.9

*26.4

10.9 11.1

*23.7

*13.0

*11.7

8.29

10ft

(Q} ·

15ft

6 1� --

---•

-5ft

*11.7

-15ft

*24.7

*20.2

*28.9

*11.7

*20.2

+ .

*24.7 *28.9

*14.7 18.7 17.4

17.0

17.3

18.0

·-

*14.7 ·--

*21.6 - -

*25.8

27.2

*27.0 *25.2

20.9

-·

9.19 -- --

8.72 7.84

�

16.7

7.62

·-

6.40

*8.26

12.3

5.95

9.06

11.7

5.65

* 9.33 ----

*10.9

- --

11.7

*5.56 5.19

9.33

6.20

·-

5.75

11.9

7.63

Load radius 20ft

-·. '

*11.3

' -

12.0 11.2

� -

10.7 10.8

11.3

17.1

16.7

10.8

•

*11.3 -*14.7

16.5 16.7

15.3

24'7"

Unit : 1 000 lb

:� n

*8.45

17.1

17.0

� -+ -

- I

8.23

16.7

31'6"

30'5"

At max. reach ,_____. ·-�-------�·-

*16.2

11.1

*21.0 *22.8

9.86 ; 28'3" -

6.49

12.0

29'2"

8.95 ' 31'0"

5.53

9.10

oft in

*8.99

- + I

4.81 4.72

8.84

8.74

*5.56

* 5.61 *5.86

25ft

p} (

- *8.15 8.90

·--

8.35 ·-

7.87

7.57

+·-

-·

*11.7

12.0 11.6

11.7

6.02

5.75

33'9"

*8.25

30'7"

*7.05

6.74

10.3

ccy · 8 - -©} tJ 6.32

33'2"

32'7"

27'5"

At max. reach

30ft

*6.16

-- *6.16 +

31'6"

Unit: 1 000 lb

---

5.58

9.14

4.25 -

8.67

4.39

4.82 5.74

*9.05

8.85 8.66

5.57 -

*4.43

*4.47

6.57 ---� *8.23 *8.15, - ---

*9.77

11.5

7.47

7.60

•

@ftin

33'7"

4.91

5.49

*6.31

Equipped with 1.37 cu yd (PCSA heaped) bucket and 24" shoes.

5ft

-20ft

*18.1 --

17.2

10ft

-10ft

---•--- - ---

*10.6

15ft

0 (Ground)

---

20·4 boom 12·4· arm

Load point height

30ft

Load radius

20ft

5ft

Unit : 1 000 lb

Equipped with 1 .50 cu yd (PCSA heaped) bucket and 24" shoes.

Load point height

10ft

12.0

+-*19.1 �1 C>_ 16:9 7.77_ : _ ft i-:_23_._1_ 26.3 �26 11. 17:0 1.89 11.1 +_:-!_C>_ ____ _: �- _ � l 18.3 ! *21.5 11.5 *16.2 -15ft -5ft

--------·--· -- -<--

25ft

I @i I

----t-----+--------- ·-

- ----.--

- -

Equipped with 1.50 cu yd (PCSA heaped) bucket and 24" shoes.

Load point height 20ft

tJ Rating over-front

Rating over-side or 360 degrees

�-

4.35 --

7.75

*4.43

ft in

33'6"

*4.47

. 35'2" .

*5.56

34'7"

*4.65 35'8" ·--- - - t 35'7" *5.00' --

*6.46 -32'9" . *7.98. 29'9"

*11.0

25'5"

SPECIFICATIONS

SP84-2A-1

------------ EX270 SPECIFICATIONS------------

1. ENGINE ------------------------------------1.1

MAIN SPECIFICATIONS-------------------- ----------

>lodel Type

Cyl. nos.-bore x stroke

Piston displacement

Compression ratio

Engine performance

. Test condition Rated output

!\lax torque

Fuel consumption Y�te

\o load max. speed

\o load min. speed

Dry h·eight

H06C-TI

Water cooled, 4 cycle, 6 cylinder in line,

direct injection chamber type turbo

charged with inter cooler diesel engine

6 - 108mm x 118mm

6485 cm 3 17.7

In accordance with JIS. 01005 with 660mm dia. fan, generator

121 Kl\. (165±g PS) at 2100 min- 1 (rpm)

�lore than 589 N.m (60 kgf.m) at 1600 ·'"v 1800 min- 1 (rpm)

Less t:1an 228 g/ KW.h (168 g/PS.h) 2270 - 50 min- 1 (rpm) -'-

3-, r

_;:i

- 25 min-'

615 kg

(rpm)

Dimensions (Overall length x

1:21 mm x 796 mm x 1065 mm

Firing order

1-4-2-6-3-5

Overall width x Overall height) Rotation direction

Clockwise viewed from fan side

Fuel system

Injection pump

1'lodel

DIESEL KIKI

Type

Bosch AD type

Model

DIESEL KIKI

Governor

Type

Bosch "RSV" type

1'-lodel

RHC7

Turbo charger Type

Exhaust turbo supercharging h·ith inter

Lubrication type

Full-forced pressure feed

cooler

SP84-2A-2

SPECIFICATIONS

------------ EX270 SPECIFICATIONS------------

Lubrication system Type

Full-forced pressure feed

Oil cooler

Water-cooled

Oil pump

Gear pump

Oil filter

Full-flow type (Paper element)

Oil pan

Max: 201

Type

Water cooled cooling type

Water pump

Centrifugul type driven by V belt

Oil quantity Cooling system Cooling fan

Thermostat

Max: 271

Min: 231

Min: 161

Dia. 660 mm, 8 blades, draw-in type

Wax tottom by-pass type

Cracking temperature 82 ° C

Opening temperature 95 ° C

Water capacity

151

Type

Corrugated fin

Radiator

Water capacity

Model

FTGll

Model

170F51-MF

Air cleaner Battery

Capacity

Starting motor Type

Voltage

150AH x 2

Shift type

24 V

Output

6 kW

Type

AC generator belt driven

Output

25 A

Generator Voltage Regulator Type

24 V

Diode-rectified

SPECIFICATIONS

SP84-2A-3

------------ EX270 SPECIFICATIONS-----------1.2

ENGINE SERVICE DATA----------------------------

Valve clearance

Inlet 0.3 mm

Exhaust 0.45 mm

Valve timing

. Inlet valve

BTDC 16 °

Open

BBDC 51 °

Close ABDC 40 °

. Exhaust valve

Close ATDC 13 °

Injection timing

BTDC 16 °

Injection pressure

200 kgf/cm 2

Cylinder compression 1.3

Open

33 to 36 kgf/cm 2 (3200 to 3500 kpa) at 280 min.-1 (rpm)

INJECTION PUMP SERVICE DATA------------------------

Pump setting data

Adjusting Rack position point [mm] A

Pump speed [min.-1]

9.1

About 5.2

More than 14

Injection volume Variance [mm 3 /st] [%]

1050

98.2 to 100.2

±3.5

410

9.0 to 11.0

±10

RACK LIMIT B

IDLING SUB SPRING SET GOVERNOR SPRING SET

9.1

8.2 z 0 .......

....... 0 0.. ;,.:: u

Cf)

5.3 5.2

J I I

I I

- -1 -- - - - - - - I i H

I\ I \ I \ I \ I \ I

I 0

275

I I

I I I I I

L_I_ 410 510±20

PUMP SPEED min-1 (rpm)

1oso

�rn

1150±25

Remarks Basic

SP84-2A-4

SPECIFICATIONS

-------------EX270 SPECIFICATIONS------------1.4 0

ENGINE PERFORMANCE CURVE -------------------------

With 660 dia. x 8 blades cooling fan (rotating ration i = 0.84)

Data shows performance observed at following atmospheric condition. 20 ° C

Temperature:

Barometric pressure:

Water vapor pressure:

---

Torque

180

l----

100

11.4 mm Hg

In accordance with JIS. D1005

120

760 mm Hg

r----

L----

160

�v \

140

Hose power

600

500

400

kgf.m N.m

120 80 100

V 80

�

I�

Fuel consumption

_____.JD

,___

::: �:::

160

1000

1200

1400

1600

ENGINE SPEED min- 1 (rpm)

1800

2000

220

g/PS.h g/KW.h

SPECIFICATIONS

SP84-2A-5

-------------EX270 SPECIFICATIONS------------2. MAIN PUMP ---------------------------2.1

MAIN SPECIFICATIONS-----

-------- - ------------

Model

HPV145CW-26A

. Pump

Bent axis type variable displacement

Type

axial piston pump.

Operated by external pilot pressure

. Regulator

132 cm 3 /rev

Volumetric displacement Nos. of pistons

Rated pressure

325 kgf/cm 2 (31900 kpa)

Travel

285 kgf/cm 2 (28000 kpa)

Front

Max flow rate

262 £/min

Travel Front

252 £/min

Reduction ratio

0.9487

Weight

135 kg

Rotation direction

2.2

Counter clockwise (view from driven shaft)

PERFORMANCE DATA-----------------------------

PQ property

Test condition

Pump speed 1992 min-1 (rpm) Oil temperature 50�5 ° C 300

@ 262 1/min at

at llOkgf/cm 2

250 t::---------l 252 1/min at 50kgf/cm 2

100

@61 1/min at 294kgf/cm 2

50 I 'J

100

150

200

250

DELIVERY PRESSURE P kgf/cm 2

300

SPECIFICATIONS

SP84-2A-6

------------- EX270 SPECIFICATIONS-------------

FLOW RATE-PILOT PRESSURE 300

@ 250

�

� UJ u

<I'. ....l

B3 H Ci

150 100

0..

�

::i 0..

PILOT PRESSURE P kgf/cm 2

3. PILOT PUMP---------------------------Model Type

HY-ZFSll-16. SR Gear pump

Max flow rate

33.6/min

Volumetric displacement Rated pressure

16.8 cm 3 /rev

40 kgf/cm 2 (3900 kpa)

Rotating direction

ClockKise (view from driven shaft)

Weight

2.6 kg

Reduction ratio

1.0

SPECIFICATIONS

SP84-2A-7

------------- EX270 SPECIFICATIONS------------4. CONTROL VALVE--------------------------

Model

KVMG-270-HC

Type

Pilot operated, 9 spools, mono block type

Max flow rate

263 Q,/min

Relief valve set pressure For travel

Applicable Serial No.05001 'v 05377

Applicable Serial No.05378 'v

For boom, arm, bucket, swing

Overload relief valve set pressure Weight

2±0.5

27±1

325�1 kgf/cm 2 (31900��68 kpa) at 150 Q,/min 350:!:j kgf/cm 2 (34300��68 kpa) at 150 Q,/min 285:!:� kgf/cm 2 (28000:!:i58 kpa) at 170 Q,/min 300 + 5 ° kgf/cm 2 (29400 + 5 80 kpa) at 120 Q,/min

178 kg

�Smax w

Smax 10

8 n...

(/)

Pmox

PILOT PRESSURE kgf/cm2 --S ---------------------WING MOTOR5.

Applicable Serial No. 5.1 MOTOR

Model

Type

Displacement

Rated pressure

Output torque

Overload relief valve Set pressure

Cracking pressure Make-up valve

Cracking pressure

MX200CAB-IOA-OI/235

M2X210CAB-IOA-02/235

Swash plate type, axial piston motor

260 kgf/cm 2 (25500 kpa)

201 cm 3 /rev

210.1 cm 3 /rev

816 N.m (83.2 kgf.m) at 260 kgf/cm 2

852 N.m (86.9 kgf.m) at 260 kgf/cm 2

235�� kgf/cm 2 (23000�i68 kpa) at 160 Q,/min

235�i kgf/cm 2 (23000�i68 kpa) at 160 Q,/min

0.25 kgf/cm 2 (25 kpa)

More than 785 N.m (80 kgf.m)

More than 202 kgf/cm 2 (19800 kpa)

More than 197 kgf/cm 2 (19300 kpa)

5.2 PARKING BRAKE

Braking torque

32+ 6 k�f/cr./ (3140 + o 90 kpa)

32+ ci kgf/cm2 (3140 + 5 9 ° kpa)

Type

2 stage planetary gear

Weight

399 kg

Brake release pressure Weight

Ill kg (Swing motor assy) 71 kg (Swing motor assy)

5.3 REDUCTION DEVICE

Reduction ratio

18.347

399 kg

SP84-2A-8

SPECIFICATIONS

------------- EX270 SPECIFICATIONS------------6.

TRAVEL MOTOR--- - -----------------------

Applicable Serial �o.

EX270: 05001 '\, 05377

EX270: 05378 '\,

6.1 MOTOR

Model

HMT134CF-26A

Displacement

134 cm 3 /rev 1963 min - 1 (rpm)

Bent axis type, axial piston motor

Type

Rotation speed

Applicable max pressure

Output torque Weight

325 kgf/cm 2

(

H.t-lT134CF-26B

I Bent axis type, axial : piston motor 134 cm 3 /rev 1963 min-1 (rpm)

350 kgf/cm 2 (34300 kpa)

31900 kpa)

680 N.m (69.3 kgf.m) at 325 kgf/cm 2

70.9 kg

732 N.m (74.6 kgf.m) at 350 kgf/cm 2

I 6 7.8 kg

6.2 BRAKE VALVE

Overload relief valve Set pressure

Cracking pressure Counterbalance valve Cracking pressure

Weight

330 + 6 ° kgf/ cm 2 + (32400 6 80 kpa)

355 + 6o kgf/cm 2 + (34800 5 8 0 kpa)

More than 290 kgf/cm 2 (28400 kpa)

More than 310 kgf/cm 2 (30400 kpa)

11±1 kgf/cm 2 (1030±100 kpa)

27. 4 kg

27.4 kg

Type

3 stage planetary gear

Weight

428 kg

6.3 REDUCTION DEVICE

Reduction ratio

56.515

61.207

333 kg

CENTER JOINT-------------------------

Weight

33.9 kg

8. PILOT VALVE (FOR TRAVEL)-------------------HVP03A Model

Primary pressure

Weight

40 kgf/cm 2 (3900 kpa) 7.87 kg

'Eu 40.0

c,,

.:.c. 260 w

5.0 0 LO

STROKEmm

8.0 8.25

SPECIFICATIONS

SP84-2A-9

------------ EX270 SPECIFICATIONS-----------9.

PILOT VALVE (FOR SWING, BOOM, ARM BUCKET)------------Model

H\'P03B

Primary pressure

40 kgf/cm 2 (3900 kpa)

Weight

5.74 kg

FOR BUCKET AND ARM

E 400

I I w 26.0 ----------- I o:: I I � I I (JI

(J)

I I

1 I I I

� CL 1- 6.5 -

1 0.

I I I I

0 LO

STROKE mm

8.5 90

RC-40

Rated pressure

40 kgf/cm 2 (3900 kpa)

Weight

2.14 kg

Model

FR-05-2

Rated pressure

40 kgf/cm 2 (3900 kpa)

40 £/min.

SHOCKLESS VALVE ---------

Flow rate

Weight

10 £/min.

9.8 kg

ACCUMULATOR---------- �flJ70-300 Model Charging pressure of nitrogen gas

Capacity

Weight 13.

� 26.0------------- I: (/) I I (/) I I � n_ I : I I I- 6.5 -

CONTROL NEUTRALIZER VALVE ------------------

Flow rate

12.

I I I

70 75 STROKE mm

Model

11.

400

0 LO

FOR BOOM AND SWING

24±2 kgf/cm 2 (2350±200 kpa) at 20 ° C

300 cm 3 1.1 kg

HYDRAULIC TANK----------------------240£ at standard level Capacity Weight

184 kg

SPECIFICATIONS SP84-2A-10 ------------ EX270 SPECIFICATIONS------------

SUCTION FILTER-------------------------

14.

Model Type

Elements

15.

Weight

15.1

Type

Max filtration

80 meshes for outer

0. 7 kg

Y-2954

Paper element type with bypass valve

10 µ

2.0 kg BYPASS VALVE- ----------- -- ----------------

Weight

16.

Metal filter element

FULL-FLOW FILTER - ---------------------ELEMENT---------------------------------

Model

15.2

Y-1817

Cracking pressure

1.5±0.2 kgf/cm 2 (147±26 kpa) at 40 £/min.

Model

Y-3055

0.25 kg AIR BREEZER ------------------------- -

Weight

Max filtration

Valve set pressure Inlet-side

Exha.ust-side

0.04±0.01 kgf/cm 2 (4±1 kpa) at 1 £/min.

0.5±0.04 kgf/cm 2 (49±4 kpa) at 1 £/min.

0.6 kg 17. BYPASS CHECK VALVE--------------------3.0±0.3 kgf/cm 2 (290±30 kpa) at 5 £/min. Cracking pressure

Weight

Flow rate

200 £/min.

Relief pressure

3.5±0.5 kgf/cm 2 (340±50 kpa)

0.4 kg 18. PILOT FILTER------------------------Paper element with relief valve Type

Weight

Max filtration

26 µ

1.4 kg 19. OIL COOLER------------------------Corrugated fin Core type

Weight

Cooling capacity Oil capacity

50000 Kcal/hour

7.7 £

70 kg 20. RESTRICTION VALVE ---------------------1.5±0.3 kgf/cm 2 (150±29 kpa) at 5 £/min. Cracking pressure

Weight

0.11 kg

SPECIF I CATIONS

SP84-2A-11

------------EX270 SPECIFICATIONS-----------21.

SOLENOID VALVE-- - ------------------ - -

Model

Voltage

Max flow rate Relief valve

Set pressure

Cracking pressure Weight 22.

DV-04-H3

DC24V

50 £/min. 3 2 ,'900 40±1 kgf/cm (3900± 100Kpa) at 13 i;min.

More than 38 kgf/cm 2 (3700 kpa) at

0.5 £/min. 4 kg

MODE SELECTION CYLINDER--------------------

Applicable pressure

40 kgf/cm 2 (3900 kpa)

Rod dia.

16 mm

f\linimum length

81 mm

Stroke

Piston nut tightening torque

Weight

7 mm

9±1 kgf.m 0.3 kg

23. BOOM CYLINDER ------------------------

Bore

Rod dia.

1360 mm

Piston nut tightening torque

810±81 kgf-m (5856=586 ft.lbs)

1950 mm (pin to pin)

Weight

269 kg

Bore

150 mm

Stroke

1785 mm

AR M CYLINDER------------------------- -

Rod dia. Minimum length

Piston nut tightening torque

25.

95 mm

Stroke

f\linimum length

24.

145 mm

Weight

105 mm

2450 mm (pin to pin)

1530±153 kgf-m (11000±1106 ft.lbs) 377 kg

BUCKET CYLINDER------------------------

Bore

Rod dia.

145 mm

95 mm

Stroke

1080 mm

Piston nut tightening torque

980±98 kgf-m (7000±700 ft.lbs)

Minimum length Weight

1630 mm (pin to pin) 240 kg

SP84-3-1

SPECIFICATIONS

-------------TIGHTENING TORQUE-----------RETOROUE CHECK-Every 250 Hrs. (Initial 50 Hrs).

Retightening bolts and nuts.

The correct torque is essential for the proper fit of assembled parts.

The following bolts and nuts should be checked and retightend to the proper

torque after the first SO hrs. of operation, and then rechecked every 250 hrs.

or 30 days. Item

Items to be Retightened

Dia. mm

Q'ty Tool mm

N-m (kgf-m)ft.lbs

Engine Insulation

392

Engine Bracket Attaching Bolts

( 9)

Fuel Tank Mounting Bolts Hydraulic Hose Union

206

(21)

152

Pump-Transmission Attaching Bolts

36 41 17

177 206 49

(18) (21) ( 5)

130 152 36

Control Valve Attaching Bolts

206

(21) 152

Swing Device AU1ching Bolts

735.5(75)

Swing Motor Attaching Bolts

392

Battery Attaching Bolts

Cab Attaching Bolts

1. 2. 3.

7. 8. 9. 10.

11. 12.

13. 14.

15. 16. 17.

18. 19.

;,.I

The tightening torque of each bolt is shown in this table.

Rubber Attaching Bolts

Oil Tank Mounting Bolts

Swing Bearing Attaching Bolts (Track Frame) Swing Bearing Attaching Bolts (Main Frame) Propel Device Attaching Bolts

Sprocket Attaching Bolts

l-3/16-12UNF l-7/16-12UNF

206

(40) 289

(21)

152

543

(40) 289 ( 5)

152

206

735

(75) 543

637

(65)

470

539

(55)

398

539

265

(55) 398 (27) 195

(21)

Track Roller Attaching Bolts

539

(55)

398

Shoe Bolts

376

30 30

843

539

(86)

622

Track guard Attaching Bolts

Front Pin-Retaining Nuts

539

(55)

398

Carrier Roller Attaching Bolts

(55)

398

SP84-3-2

SPECIFICATIONS

-------------TIGHTENING TORQUE------------1. Retighten engine insulation rubber fixing bolts.

Tool

27 mm

Torque: 39 2 N·m (40 kgf·m) 289ft.lbs

2. Engine bracket mounting bolts.

Tool

19 mm

Torque: 88 N•m (9 kgf•) 65ft.lbs

3. 4.

Retighten hydraulic oil and fuel tank fixing bolts.

Tool

24 mm

Torque: 206 N·m (21 kgf-m) 152 ft-lbs

Retighten high-pressure hose unions.

Tool

36 mm

Tool

41 mm

Torque: 177 N•m (18 kgf•m) 130 ft·lbs Torque: 206 N·m (21 kgf·m) 152 ft•lbs

SP84-3-3

SPECIFICATIONS

-------------TIGHTENING TORQUE------------Retighten pump transmission attaching bolts.

Tool

17 mm

Torque: 49 N•m (5 kgf•m) 36 ft•lbs

Retighten control valve attaching bolts.

Tool

24 mm

Torque: 206 N•m (21 kgf·m) 152 ft·lbs

8. 9.

Retighten swing device and motor attaching bolts.

Tool

32 mm

Tool

30 mm

Torque: 735 N•m (75 kgf-m) 543 ft-lbs

Torque: 392 N·m (40 kgf·m) 289 ft·lbs

10.

Retighten battery attaching bolts.

Tool

17 mm

Torque: 49 N•m (5 kgf·m) 36 ft-lbs

11.

Retighten cab attaching bolts.

Tool

24 mm

Torque: 206 N·m (21 kgf•m) 152 ft·lbs

SPECIFICATIONS

SP84-3-4

------------- TIGHTENING TORQUE------------12.

Retighten swing bearing attaching bolts. (Track Frame)

Tool

32 mm

Torque: 735 N•m (75 kgf·m) 543 ft·lbs

(Main Frame)

Tool

32 mm

Torque: 637 N·m (65 kgf•m) 470 ft·lbs

13. Retighten propel device attaching bolts.

Tool

30 mm

Torque: 539 N·m (55 kgf•m) 398 ft·lbs

14. Retighten sprocket attaching bolts.

Tool

30 mm

Torque: 539 N·m (55 kgf•m) 398 ft·lbs

15.

Retighten carrier roller attaching bolts.

Tool

24 mm Torque: 265 N·m (27 kgf·m) 195 ft·lbs

SP84-3-5

SPECIFICATIONS

-------------TIGHTENING TORQUE-----------16.

Retighten track roller attaching bolts.

Tool

30 mm

Torque: 539 N·m (55 kgf·m) 398 ft-lbs

17.

Retighten shoe bolts.

Tool

30 mm

Torque: 843 N•m (86 kgf·m) 622 ft-lbs

18.

Retighten track guard attaching bolts.

Tool

30 mm

Torque: 539 �-m (55 kgf•m) 398 ft·lbs

SPBl-4-1

SPECIFICATIONS

OTHERS 1. MAINTENANCE INTERVALS 1.1

Greasing

Check the lubricating condition everyday. No. of parts (Quantity)

Parts

EX60

EX90

EX150 EX270 EX300

100

250

500

1000

2000

Soorr .::�,,,nde' ::,c::or"" Buck:e'.

Others 2. Swing bearing

8:'.::JM •ool

Front joint pins

Interval (Hours)

7 3

3. Swing gear 4. Propel levers

♦ After digging operation in water, apply grease to the pins which will get in or have been in water.

1.2

Engine oil No. of parts (Quantity)

Parts

EX60

EX90

(152)

Interval (Hours)

EX150 EX270 EX300

2. Engine oil filter replacement 3. Engine oil bypass filter replacement

1.3

Replacement

100

250

500

1000

2000

1000

2000

{\ff�� (

Oil level check 1. Engine oil

(152)

(272)

(282)

Replacement Replacement

Gear oil Interval (Hours)

No. of parts (Quantity) Parts

EX60

EX90

EX150 EX270 EX300

100

250

500

mmmrnmm

Oil level check

--------4-----1----1------+----l----+----+---+---+""" ·..:,·.,;· ·..:.· ,.:· "i" " f---t,-,-,.,..,-,.,..,-,t---t

Replacement

2. Swing mechanism

1.4

(1.4Q)

(102)

(10l2)

Oil level check Replacement Oil level check

3. Travel mechanism

(1.4Q)

Replacement

(2.32)

(3.22)

(5l2)

(2.52 X2)

(4.52 X2)

(4.02 X2)

(7.52 X2

(8.52 X2)

Hydraulic system Parts

No. of parts (Quantity) EX60

EX90

(852)

(1102)

Interval (Hours)

EX150 EX270 EX300

100

250

500

1000

1. Hydraulic oil level check 2. Hydraulic oil tank draining 3. Hydraulic oil replacement

4. Suction filter cleaning 5. Full-flow filter element replacement 6. Pilot filter element replacement

�

(1602)

(3002)

(3302) When replacing hydraulic oil

2000

SPECIFICATIONS

SP81-4-2

---------------OTHERS Fuel system

1.5

No. of parts (Quantity)

Parts EX60

EX90

Interval (Hours)

EX150 EX270 EX300

100

250

2000

1000

500

1. Fuel tank water draining 2. Water sedimenter checking 3. Fuel filter element replacement 4. Feed pump strainer cleaning 5. Fuel tank capacity

(1302) (2502)

(2502) (3102)

(5102)

Air cleaner

1.6

Interval (Hours)

No. of parts (Quantity) Parts

1. Air cleaner outer element 2. Air cleaner inner element

EX150 EX270 EX300

100

�mm�mrnm 250

500

1000

EX60

EX90

Cleaning

Replacement

After cleaning 6 times or 1 year

Replacement

At time of outer element

2000

(Or when warning lamp lit)

Cooling system

1.7

Interval (Hours)

No. of parts (Quantity) Parts

EX60

EX90

(12.52)

(152)

EX150 EX270 EX300

100

250

1000

500

2000

1. Water level check 2. Fan belt tension check 3. Cooling water replacement 4. Radiator core cleaning

(182)

(292)

(302)

Outside Inside

5. Oil cooler front net cleaning

Anti-freeze mixing ratio

EX90

EX60

Outside temperature

EX150 Anti-F(2)

EX270

EX300

[ F]

Anti-F(2)

Soft-W(2)

Anti-F(2}

Soft-W(2}

-1

30-2

3.8

8.7

4.5

10.5

2.7

15.3

8.7

20.3

9.0

21.0

-4

24.8

3.8

8.7

4.5

10.5

3.6

14.4

8.7

20.3

9.0

21.0

-7

19.4

3.8

8.7

4.5

10.5

4.5

13.5

8.7

20.3

9.0

21.0

-11

12.2

3.8

8.7

4.5

10.5

5.4

12.6

8.7

20.3

9.0

21.0

-15

5.0

4.4

8.1

5.3

9.7

6.3

11.7

10.4

18.6

10.8

19.2

-20

-4.0

5.0

7.5

6.0

9.0

7.2

10.8

11.6

17.4

12.0

18.0

-25

-13.0

5.6

6.9

6.8

8.2

8.1

9.9

12.8

16.2

13.2

16.8

-33

-27.4

6.3

6.2

7.8

7.2

9.4

8.6

14.5

15.0

-50

-58.0

7.5

5.0

9.0

6.0

10.8

7.2

17.4

11.6

18.0

12.0

[ C]

Anti-F; Anti-freeze (Ethyleneglycol)

Soft-W(Q}

Anti-F(2)

Soft-W; Soft water

Soft-W(2) Anti-F(2)

Soft-W(Q)

SP81-4-3

SPECIFICATIONS

----------------OTHERS---------------1.8

Others Interval (Hours)

No. of parts (Quantity)

Parts

EX60

EX150 EX270 EX300

When required

{�j(: -:-:-:-:-:-:-:-:

show on torque reference

5. Engine compression pressure

6. Engine valve clearance

Notes:

An lubricant name plate is affixed on the inside of the tool box cover.

[Mf��I Items to be done during under-water operation.

k�fJ

250

3. Bucket-fixing pin clearance adiustment 4. Bolt torque check

100

depend on bucket type

1. Bucket teeth loosening/wearing 2. Track tension check

EX90

Items to be done only first time check.

500

1000

2000

CT-1-1

CONVERSION TABLE LENGTH INCHES TO MILLIMETERS

MILLI�IBTERS TO INCHES mm

in.

0.0394

1.0236

2.0079

2.9921

0.0787

1.0630

2 0472

3.0315

0 1181

1.1024

2.0866

3.0709

0.1575

1.1417

2.1260

3.1102

0.1968

1.1811

2.1653

3.1496

0.2362

1 2205

2 2047

3.1890

0.2756

1.2598

2.2441

3.2283

0.3150

1.2992

2.2835

3.2677

0.3543

1.3386

2.3228

3.3071

0.3937

1.3779

2.3622

3.3464

0.4331

1.4173

2.4016

3.3858

0.4724

1.4567

2.4409

3.4252

0.5118

1.4961

2.4803

3.4646

0.5512

1.5354

2.5197

3.5039

0.5905

1.5748

2.5590

3.5433

0.6299

1.6142

2.5984

3.5827

0.6693

1.6535

2.6378

3.6220

0.7087

1.6929

2.677ti.

3.6614

0.7480

1.7323

2.7165

3.7008

0.7874

1.7716

2.7559

3.7401

0.8268

1.8110

2.7953

3.7795

0.8661

1.8504

2.8346

3.8189

0.9055

1.8898

2.8740

3.8583

0.9449

1.9291

2 9134

3.8976

0.9842

1.9685

2.9527

100

3.9370

in.

1/64

0.3969

3/64

1.1906

5164

1.9844

1.5875

1/16

7/64 9/64

4.3656

13/64

5.1594

4.7625

3/16

15/64 17/64 19/64 21/64 23/64 25/64 27164 29/64 31164

18.2562

49/64

19.4469

51/64

20.2406

19.8437 20.6375 53/64

21.0344 21.4312

27/32 55/64

21.8281

57/64

22.6219

22.2250

7/8 29/32

23.0187 59/64

10.7156

23.4156 23.8125

15/16

11.5094

12.7000

18.6531

13/16

9.9219

12.3062

47/64

25/32

9 1281

11.9062

15/32

17.8594

19.0500

8.3344

11.1125

7/16

45/64

16.6687

3/4

10.3187

13/32

17.0656 17.4625

1.5406

9.5250

3/8

43/64

23/32

8.7312

11/32

16.2719

11/16

6.7469

7.9375

5/16

41 /64 21/32

7.1437

9/32

15.4781 15.8750

518

5.9531 6.3500

1/4

14.6844 15.0812

39/64

5.5562

7/32

13.4937 14.2875

3.5719

11/64

13.8906

19/32

3 9687

5132

35/64 37/64

2.7781 3.1750

1/8

13.0969

9/16

2.3812

3132

33/64 17132

0.7937

1 /32

1/2

in.

61164

24.2094

63/64

25.0031

24.6062

31/32

CT-1-2

CONVERSION TABLE -

10 20 30 40 50 60 70 80 90 100

ft.

m 0.305 3.353 6.401 9.449 12.497 15.545 18.593 21 .641 24.689 27.737 30.785

3 048 6 096 9.1 44 1 2.1 92 1 5.240 1 8.288 21 .336 24.384 27.432 30.480

m 0.610 3.658 6.706 9 754 1 2.802 1 5.850 1 8.898 21 .946 24.994 28 042 31 090

FEET TO METERS 4

m 0.91 4 3.962 7 01 0 10.058 13.1 06 1 6.1 54 19.202 22.250 25.298 28.346 31.394

m 1.21 9 4 267 7.31 5 10 363 13.411 16.459 19 507 22.555 I 25.603 28 651 31 699

m 1 .524 4.572 7.620 10.668 I 1 3.716 1 6.764 ! 1 9.81 2 22.860 25.908 28 956 32 004

m 1 .829 4.877 7.925 1 0.973 1 4 021 17 069 20 1 17 23 165 26.21 3 29.261 32.309

m ,I 2.1 34 5.182 8.230 I 11 .278 14.326 17.374 20.422 23.470 26.51 8 29.566 32.614

m 2.438 5.486 8.534 11 .582 1 4.630 1 7.678 20.726 23.774 26.822 29.870 32.918

m 2.743 5.791 8.839 1 1.887 14.935 17.983 21 .031 24 079 27.1 27 30.1 75 33.223

8 ft

ft.

10 20 30 40 50 60 70 80 90 100

METERS TO FEET m

20 30 40 50 60 70 80 90 100

miles 10 20 30 40 50 60 70 80 90 100

093 32.1 87 48 280 64.374 80467 96 561 112.650 128 750 I ! 144.840 I 1 60.930

3.2808 6.561 7 36.0892 39.3701 72.1785 68.8976 1 01 .7060 1 04.9869 134.5144 1 37 7953 1 67.3228 1 70.6037 200.1 312: 20341 21 232.9396 236.2205 265.7480 269 0289 298.5564 301.8373 331.3648 334.6457

32.8084 65.61 68 98.4252 131 .2336 1 64 0420 1 96.8504 229.6588 2624672 295.2756 328 0840

ft.

1 609 17.703 33.796 49.890 65.983 82 077 98 1 70 11 4.260 1 30.360 146.450 162.540

4 ft

9.8425 1 3.1 234 45 931 8 42.6509 78 7402 75.4593 1 08.2677 1 11 5486 1 41 0761 1 44.3570 1 73.8845 1 77 1654 206.6929 209.9738 239 5013 242.7822 272.3097 275 5906 305.1 1811308.3990 337 9265 341 2074 i

4042 49 21 26 82 021 0 114.8294 1 47.6378 1 80.4462 213.2546 246 0630 278.871 4 311.6798 344 4882

22.9659 55.7743 885827 1 21 3911 1 54.1 995 1 87 0079 21 9.81 63 252.6247 285.4331 31 8.241 5 351 .0499

52.4934 85.301 8 11 8.11 02 1 50.91 86 183 7270 21 6.5354 249.3438 282.1 522 314.9606 347 7690

5 km

6.437 4 828 8 047 3.21 9 22 531 20 921 24 1 40 19 312 40 234 37 015 38.624 35406 I 54 71 8 56 327 51 499 53 108 72421 70 811 69.202 67 693 88 51 4 86.905 85.295 83 686 103.000 104.61 0 99.779 1 01 390 120 700 11 5.870 11 7 480 11 9 090 133 580 135.190 136 790 131 970 151.280 I 152 890 1 48 060 I 1 49.670 167 370 j 168 980 1 64 150 j 165 760

1 9.6850

MILES TO KILm!ETERS

6 ft

, I

9.656 25.750 41.843 57 S36 74.030 90.123 1 06 220 1 22.310 1 38 400 1 54 500 1 70 590

11 265 27.359 43.452 59.546 75 639 91 733 1 07 830 1 23.920 140 010 1 56 11 0 172.200

26.2467 59 0551 91.8635 1 24.671 9 1 75.4803 1 90.2887 223 0971 255.9055 28�71 39 321 5223 354.3307

29.5276 62.3360 95.1 444 127.9528 160.7612 193.5696 226.3780 259.1864 291 .9948 324.8032 357.611 6

1 4484 30.578 28 968 46.671 45 062 62.764 61 1 55 77.249 I 78.858 93.342 I 94.951 1 09 440 11 1.040 127.1 40 1 25.530 143.230 1 41 .620 157.720 1 59.330 1 75420 1 73.810 1 1 2.875

10 20 30 40 50 60 70 80 90 1 00

miles 10 20 30 40 50 60 70 80 90 1 00

KILm!ETERS TO :-II LES km

10 20 30 40 50 60 70 80 90 100

miles

6 21 4 12427 18 641 24.855 31.069 37.282 43 497 49 711 55 924 62.1 38

miles 0.621 6 835 13 049 1 9 263 25477 31 .690 37 904 44 118 50.332 56.545 62.759

miles 1 243 7457 13.670 19 884 26 098 32.31 1 38 525 44 739 50.953 57 166 63 380

miles 1.864 8 078 14.292 20 506 26 720 32.933 39.147 45.361 51 575 57.788 64 002

miles 2 486 i I 8 699 1 4 913 21 127 27.341 33 554 39 768 45 982 52 196 58 409 64.623

miles 3 107 9 321 15 534 21 748 27 962 34 1 75 I 40 389 I 46 603 52 817 59 030 65 244

i miles 3.728 9 942 1 6 156 I 22.370 I 28 584 I I 34 797 41 011 I 47 225 53439 59 652 65 866

miles 4 350 1 0.562 1 6 776 22 990 29 204 3541 7 41 631 47.845 54 059 60 272 66486

miles 4 971 11 1 85 17 399 23.61 3 29 827 36 040 42.254

48468

54.682 60.895 67.109

miles 5 592 11 805 1 8 019 24 233 30 447 36 660 42.874 49 088 55 302 61 515 67 729

km -

20 30

50 60 70 80 90 1 00

CT-1-3

CONVERSION TABLE AREA

SQUARE Il\CHES TO SQUARE CENTIMETERS

in 2

cm 2

64.516 129 032 193.548 258 064 322.580 387 096 451.612 516.128 580.644 645 160

6.452 70.968 135.484 200.000 264.516 329.032 393.548 458 064 522.580 587 096 651.612

10 20 30 40 50 60 70 80 90 100

in2

12.903 77.419 141.935 206.451 270.967 335.483 399.999 464 515 529.031 593.547 658 063

cm 2

19.355 83 871 148.387 212.903 277.419 341.935 406.451 470.967 535 483 599 999 664.515

25.806 90.322 154.838 219.354 283 870 348.386 412.902 477.418 541.934 606.450 670.966

32.258 96.774 161.290 225.806 290.322 354.838 419.354 483.870 548.386 612.902 677.418

cm'

38.710 103.226 167.742 232.258 296.774 361.290 425.806 490.322 554.838 619.354 683.870

cm2

45.161 109.677 174.193 238.709 303.225 367.741 432.257 496.773 561.289 625.805 690.321

in 2

8 cm2

cm'

51.613 116.129 180.645 245.161 309.677 374.193 438.709 503.225 567.741 632.257 696.773

58 064 122.580 187 096 251.612 316.128 380.644 445.160 509.676 574.192 638.708 703.224

10 20 30 40 50 60 70 80 90 100

in2

0.310 1 860 3.410 4.960 6.510 8.060 9.610 11 160 12.710 14.260 15.810

0 465 2.015 3.565 5.115 6.665 8.215 9.765 11.315 12.865 14.415 15.965

0 620 2.170 3.720 5 270 6 820 8 370 9.920 11.470 13.020 14.570 16.120

1n 2

in 2

0.775 2.325 3.875 5.425 6.975 8.525 10 075 11 625 I 13.175 I I 14.725 i 16.275

0.930 2.480 I 4.030 I 5 580 I 7.130 i 8 680 10.230 i 11.780 iI 13.330 14.880 16 430

in 2

cm'

1.085 2.635 4.185 5 735 7.285 8.835 10.385 11.935 13.485 15 035 16.385

1.240 2.790 4.340 5.890 7.440 8.990 10.540 12 090 13.640 15.190 16.740

1.395 2.945 4.495 6.045 7.595 9.145 10.695 12.245 13.795 15.345 16.895

10 20 30 40 50 60 70 80 90 100

CUBIC Il\CHES TO CUBIC CENTIMETERS 0

cm"(cc) 10 20 30 40 50 60 70 80 90 100

cm 2

in 2

VOLUME ,n'

cm'

SQUARE CENTIMETERS TO SQUARE I;1JCHES

0.155 1.705 1.550 i 3.255 3.100 : 4.805 4 650 6.355 6.200 ' 7.905 7.750 9.455 9 300 11005 10 850 12 555 12.400 I 13.950 I 14.105 ' 15 655 15 500 i

10 20 30 40 50 60 70 80 90 100

cm 2

I cm'(cc)

i 163.871 327 741 I 491 612 655.483 819.353 983.224 1147 094 1310.965 1474.836 1638 706 i

16.387 180.258 344 128 507.999 671.870 835.740 999.611 1163.482 1327 352 1491 223 1655 093

2 cm3(cc)

cm'(cc)

49 161 32 774 196.645 I 213 032 360 5151 376.902 524.386' 540 773 704 644 688.257 868.514 852.127 1015.998 1032 385 1179.869 1196 256 1343.739 1360 126 1507 610 1523.997 1671 48111687.868

5 cm3(cc)

4 cm3(cc)

81.935 65.548 245.806 229.419 209.677 393.290 573 547 557.160 737.418 121.031 I 901 289 884.901 1048.772 1065.159 1212.643 I 1229 030 13765'3 1392200 1540.384 1 1556 771 1704.255 1720 642

cm'(cc)

98.322 262.193 426 064 589.934 753.805 917.676 1081.546 1245.417 1409.288 1573.158 1737.029

7 cm3(cc)

114 709 278.580 442.451 606.321 770.192 934 063 1097.933 1261 804 1425 675 1589 545 1753.416

tn'

cm3(cc)

131097 294.967 458.838 622.708 786.579 950.450 1114.320 1278.191 1442 062 1605 932 1769.803

147.484 311.354 475.225 639 095 802.966 966.837 1130.707 1294.578 1458.449 1622.319 1786.190

10 20 30 40 50 60 70 80 90 100

cm3(cc)

0.5492 1.1595 1.7697 2.3799 2.9902 3.6004 4.2106 4.8209 5.4311 6.0414 6.6516

10 20 30 40 50 60 70 80 90 100

CUBIC CE'.\THIETERS TO CUBIC I;IJCl!ES cm3 (cc)

10 20 30 40 50 60 70 80 90 100

! i

in 3

' '

i 0.6102 I I

1 2205 1.8307 2.4409 3 0512 3.6614 4.2717 4.8819 5.4921 6.1024

0.0610 ! I 0.6713 1.2815 1.8917 2.5020 3.1122 3.7224 4.3327 4.9429 5.5532 6 1634

,n'

0 1220 0 7323 1.3425 1.9528 2.5630 3.1732 3.7835 4.3937 5.0039 5.6142 6.2244

0 1831 0.7933 1.4035 2.0138 2.6240 3.2343 3.8445 4.4547 5.0650 5.6752 6 2854

in'

0 3051 0.2441 0.9154 0.8543 1.5256 1.4646 2 1358 2.0748 2 7461 2.6850 3.2953 I 3.3563 3.9055 I 3.9665 4.5158 ! 4.5768 5 1260 I 5.1870 5.7973 5 7362 6 3465 I 6 4075

in'

0 3661 0 9764 1.5866 2.1969 2.8071 3.4173 4.0276 4 6378 5.2480 5 8583 6.4685

0.4272 1.0374 1.6476 2.2579 2.8681 3.4784 4.0886 4.6988 5.3091 5.9193 6 5295

0.4882 1 0984 1.7087 2.3189 2 9291 3.5394 4.1495 4.7599 5.3701 5 9803 6 5906

I I

CT-1-4

CONVERSION TABLE GALLONS (U.S.) TO LITERS U.S. gal.

10 20 30 40 50 60 70 80 90 100

liters

37.8543 75.7085 113.5528 151.4171 189.2713 227.1256 264.9799 302.8342 340.6884 378.5427

3.7854 41.6397 79.4940 117.3482 155.2025 193.0568 230.9110 268.7653 306.6196 344.4738 382.3281

7.5709 45.4251 83.2794 121.1337 158.9879 196.8422 234.6965 272.5507 310.4050 348.2593 386.1135

11.3563 49.2105 87 0648 124.9191 162.7734 200.6276 238.4819 276.3362 314.1904 352 0447 389.8990

15.1417 52.9960 90.8502 128.7045 166.5588 204.4131 242.2673 280.1216 317.9759 355.8301 393.6844

18.9271 56.7814 94.6357 132.4899 170.3442 208.1985 246 0527 283.9070 321.7613 359.6156 397.4698

22.7126 60.5668 98.4211 136.2754 174.1296 211.9839 249.8382 287.6924 325.5467 363.4010 401.2553

26.4980 64.3523 102.2065 140 0608 177.9151 215.7693 253.6236 291.4779 329.3321 367.1864 405.0407

30.2834 68.1377 105.9920 143.8462 181.7005 219.5548 257.4090 295.2633 333.1176 370.9718 408.8261

34.0'.:38 71.9231 109.7774 147.6316 185.4859 223.3402 261.1945 299 0487 336.9030 374.7573 412.6115

10 20 30 40 50 60 70 80 90 100

liters

U.S. gal.

LITERS TO GALLONS (U.S.) liters

10 20 30 40 50 60 70 80 90 100

gal.

2.6417 5.2834 7.9251 10.5668 13.2086 15.8503 18.4920 21.1337 23.7754 26.4171

0.2642 2.9059 5.5476 8.1893 10.8310 13.4727 16.1144 18.7561 21.3979 24.0396 26.6813

0.5283 3.1701 5.8118 8.4535 11.0952 13.7369 16.3786 19.0203 21.6620 24.3037 26.9454

0.7925 3.4342 6.0759 8.7176 11.3594 14.0011 16.6428 19.2845 21.9262 24.5679 27.2096

1 0567 3.6984 6.3401 8.9818 11.6235 14.2652 16.9069 19.5487 22.1904 24.8321 27.4738

1.3209 3.9626 6.6043 9.2460 11.8877 14.5294 17.1711 19 8128 22.4545 25 0962 27.7380

1.5850 4.2267 6.8684 9.5102 12.1519 14.7936 17.4353 20.0770 22.7187 25.3604 28.0021

1.8492 4.4909 7 1326 9.7743 12.4160 15 0577 17.6995 20.3412 22.9829 25.6246 28.2663

2.1134 4.7551 7.3968 10.0385 12.6802 15.3219 17.9636 20.6053 23.2470 25.8888 28.5305

2.3775 5 0192 7.6610 10.3027 12.9444 15.5861 18.2278 20.8695 23.5112 26.1529 28.7946

10 20 30 4G 50 60 70 80 90 100

Imp gal.

GALLONS (IMP.) TO LITERS Imp gal.

10 20 30 40 50 60 70 80 90 100

liters

45.4596 90.9192 136.3788 181.8384 227.2980 272.7576 318.2172 363.6768 409.1364 454.5960

4.5460 50.0056 95.4652 140.9248 186.3844 231.8440 277.3036 322.7632 368.2223 413.6824 459.1420

9 0919 54.5515 100.0111 145.4707 190.9303 236.3899 281.8495 327.3091 372.7687 418.2283 463.6879

13.6379 59.0975 104.5571 150.0167 195.4763 240.9359 286.3955 331.8551 377.3147 422.7743 468.2339

18.1838 63.6434 109.1030 154.5626 200.0222 245.4818 290.9414 336.4010 381.8606 427.3202 472.7798

22.7298 68.1894 113.6490 159.1086 204.5682 250.0278 295.4874 340.9470 386.4066 431.8662 477.3258

27.2758 72.2354 118.1950 163.6546 209.1142 254.5738 300.0334 345.4930 390.9526 436.4122 481.8718

31.8217 77.2813 122.7409 168.0005 213.6601 259.1197 304.5793 350.0389 395.4985 440.9581 486.4177

36.3677 81.8275 127.2869 172.7465 218.2061 263.6657 309.1253 354.5849 400 0445 445.9041 490.9637

40.9136 86.3732 131.8328 177.2924 222.7520 268.2116 313.6712 359.1308 404.5904 450.0500 495.5096

10 20 30 40 50 60 70 80 90 100

liters

LITERS TO GALLONS (IMP.) liters

10 20 30 40 50 60 70 80 90 100

gal.

1.3199 3.5196 5.7194 7.9191 10.9189 12.3187 14.5184 16.7182 18.9179 211177 23.3175

1.5398 3.7396 5.9394 8.1391 10.3389 12.5386 14.7384 16.9382 19.1379 21.3377 23.5374

1.7598 3.9596 6.1593 8.3591 10.5588 12.7586 14.9584 17.1581 19.3579 21.5576 23.7574

1.9798 4.1795 6.3793 8.5791 10.7788 12.9786 15.1783 17.3781 19.5779 21.7776 23.9774

gal.

2.1998 4.3995 6.5993 8.7990 10.9988 13.1986 15.3983 17.5981 19.7978 21.9976

0.2200 2.4197 4.6195 6.8193 9.0190 11.2188 13.4185 15.6183 17.8181 20.0178 22.2176

0.4400 2.6397 4.8395 7.0392 9.2390 11.4388 13.6385 15.8383 18.0380 20.2378 22.4376

0.6599 2.8597 5.0594 7.2592 9.4590 11.6587 13.8585 16.0582 18.2580 20.4578 22.6575

0.8799 3 0797 5.2794 7.4792 9.6789 11.8787 14.0785 16.2782 18.4780 20.6777 22.8775

1.0999 3.2996 5.4994 7.6992 9.8989 12.0987 14.2984 16.4982 18.6980 20.8977 23.0975

10 20 30 40 50 60 70 80 90 100

C T-1-5

CONVERSION TABLE MASS POUNDS TO KILOGRAMS

10 20 30 40 50 60 70 80 90 100

lbs.

kg 4.536 9.072 13.608 18.144 22.680 27.216 31.751 36.287 40.823 45.359

0.454 4.990 9.525 14 061 18.597 23.133 27.669 32 205 36.741 41.277 45 813

1 361 5.897 10.433 14.969 19.504 24.040 28.576 33.112 37 648 42.184 46 720

0.907 5.443 9.979 14.515 19.051 23.587 28.123 32.659 37.195 41.730 46.266

62.268 6.804 11.340 15.876 20.412 24.948 29.484 34 019 38.555 43 092 47.627

61.814 6.350 10.886 15.422 19.958 24 494 29 030 33.566 38.102 42.638 47.174

3.175 7.711 12.247 16.783 21.319 25.855 30.391 34.927 39.463 43.998 48.534

2.722 7.257 11.793 16.329 20.865 25.401 29 937 34 473 39 009 43.545 48 081

lbs.

3.629 8.165 12.701 17.237 21.772 26.308 30.844 35.380 39.916 44.453 48.988

4.082 8.618 13.154 17.690 22.226 26.762 31.298 35.834 40.370 44.906 49.442

10 20 30 40 50 60 70 80 90 100

19.842 41.888 63.934 85.980 108.030 130 070 152.120 174.170 196.210 218.260 240.300

KILOGRAMS TO POUNDS kg

10 20 30 40 50 60 70 80 90 100

lbs. 22.046 40 092 66.139 88.185 110.230 132.280 154.320 176.370 198.420 220.460

lbs

11.023 8.818 33 069 30.865 52.911 I 55.116 77.162 74.957 97 003 ' 99.208 ' 121.250 119 050 143.300 141 100 165.350 163.140 187.390 185.190 209.440 207.230 229.280 231.490

6.614 28.660 50.706 72.752 94.799 116.840 138.890 160 940 182.980 205.030 227 080

lbs

lbs.

lbs

4.409 26.455 48.502 70.548 92.594 114.640 136.690 158.730 180.780 202.830 224 870

2.205 24.251 46.297 68.343 90.389 112.440 134.480 156.530 178.570 200.620 222.670

lbs.

17 637 39.683 61.729 83.776 105.820 127.870 149.910 171.960 194.010 216 050 238.100

15.432 37.479 59.525 81.571 103.620 125.660 147.710 169.760 191.800 213.850 235.890

13.228 35 274 57.320 79 366 101.410 123.460 145.510 167.550 189.600 211.640 233 690

lbs.

10 20 30 40 50 60 70 80 90 100

PRESSURE POUNDS PER SQUARE INCHES TO KILOGRAM PER SQUARE CENTIMETERS lb!in 2

(psi)

kgicm

10 20 30 40 50 60 70 80 90 100

0.7031 1.4062 2.1092 2.8123 3.5154 4.2185 4 9216 5.6246 6 3277 7 0308

kg/cm'

0.0703 0.7734 1.4765 2.1795 2.8826 3.5857 4.2888 4.9919 5.6949 6.3980 7.1011

kgtcm'

0 1406 I I 0.8437 1.5468 2.2498 2.9529 3.6560 4.3591 5 0622 5.7652 I 6.4683 I 7 1714

kgCcm

i 2

0.2100 0.9140 1 6171 2.3202 3.0232 3 7263 4 4294 5.1325 II 5 8356 I 6 5386 I 7.2417

kgicm'

0.2812 0.9843 1.6874 2.3905 3 0935 3.7966 4.4997 5.2028 5.9059 ' 6 6089 7 3120

i I

kg ·cm'

0.3515 1.0546 1 7577 2 4608 3.1639 3 8669 4.5700 5.2731 5.9762 6 6793 7 3823

kg,cm

kg'cm'

0.4921 1 1952 1.8983 2.6014 3.3045 4 0072 4.7106 5.4137 6.1168 6.8199 7.5229

0.4218 1 1249 1.8280 2.5311 3 2342 3 9372 4 6403 5.3434 6.0465 6.7496 7 4526

kg/cm'

0.5625 1.2655 1.9686 2.6717 3.3748 4 0779 4.7809 5.4840 6.1871 6.8902 7 5933

lblin 2

kg/cm

0.6328 1.3358 2.0389 2.7420 3.4451 4.1482 4.8512 5.5543 6.2574 6.9605 7.6636

(ps,)

10 20 30 40 50 60 70 80 90 100

KILOGRAMS PER SQUARE CENTIMETERS TO POU NDS PER SQUARE INCHES kg,cm2

10 20 30 40 50 60 70 80 90 100

lb/in (psi) 2

14.22 156.45 142.23 298 69 284.46 440 92 426.70 568.93 583.15 i 711.16 I 725.38 I 867.61 853.39 1009.80 995.62 1152.10 1137.80 1280.10 1294.30

1422.30

1436.50

lbltn (psi) 2

28.45 170.68 312.91 455.14 597.37 739.61

881.84

1024.10 1166.30 1308.50 1450.80

lbiin (ps,I

lbi1n (psi)

lbiin (ps1) 2

71 12 56 89 42.67 213 35 199.12 184.90 355.58 341 36 327.13 497.81 483.59 469.36 640.04 625 82 611.60 782.28 768.05 753.83 924.51 910.28 896 06 1052.50 ! 1066 70 1038 30 1209.00 1180.50 I 1194.70 1337.00 I 1351.20 1322.10 1455_00 I 1479.20 J 1493 40

lb/in (psi)

lbiin 2 (ps1) 85.34 227.57 369.80 512.03 654.27 796.50 938.73 1081.00 1223.20 1365.40 1 507 70

99.56 241.79 384 03 526.26 668.49 810.72 952.95 1095.20 1237 40 1379.60 1521 90

113 78 256 02 398.25 540 48 682.71

824.94

967.18 1109.40 1251.60 1393.90 1536 10

lb/in (psi) 2

128 01 270.24 412.47 554.70 696.94 839.17 981.40

1123.60

1265.90 1408.10 1550.30

kg.,cm2

10 20 30

50 60 70 80 90 100

CT-1-6

CONVERTION TABLE TORQUE ft. lbs.

10 20 30 40 50 60 70 80 90 100

FOOT-POUNDS TO KILOGRAM-METERS 0

kg-m

1.382 2.764 4.146 5.528 6.910 8.292 9.674 11.056 12.438 13.820

0.138 1.520 2.902 4.284 5.666 7.048 8.430 9.812 11.194 12.576 13.958

0.276 1.658 3.040 4.422 5.804 7.186 8.568 9.950 11.332 12.714 14 096

0.415 1.796 3.178 4.560 5.942 7.324 8.706 10.088 11.470 12.855 14.235

0.553 1.934 3.316 4.698 6.080 7.462 8.844 10.227 11.609 12.991 14.373

0.691 2.073 3.455 4.837 6.219 7.601 8.983 10.365 11.747 13.129 14.511

0.829 2.211 3.593 4.975 6.357 7.739 9.121 10.503 11.885 13.267 14.649

0.967 2.349 3.731 5.113 6.495 7.877 9.259 10.641 12 023 13.405 14.787

1.106 2.487 3.869 5.251 6.633 8.015 9.397 10.779 12.161 13.544 14.925

1.244 2.625 4 007 5.389 6.771 8.153 9.535 10.918 12.300 13.682 14 064

10 20 30 40 50 60 70 80 90 100

kg-m

ft. lbs.

KILOGRAM-METERS TO FOOT-POUNDS kg-m

10 20 30 40 50 60 70 80 90 100

ft. lbs.

ft. lbs

ft. lbs.

ft. lbs

ft. lbs.

72.33 144.67 217.00 289.34 361.66 434.00 506.34 578.68 651.00 723.34

7.23 79.57 151.90 224.23 296.57 368.89 441.23 513.57 585.91 658.23 730.57

14.47 86.80 159.13 231.46 303.79 376.12 448.45 520.80 593.14 665.46 737.80

21.70 94.03 166.37 238.70 311.04 383.36 455.70 528.04 600.38 672.70 745 04

28.93 101.27 173.60 245.93 318.27 390.59 462.93 535.27 607.61 679.93 752.27

36.17 108.50 180.84 253.17 325.50 397.82 470.17 542.50 614.85 687.17 759.51

43.40 115.74 188.08 260.41 332.75 405.07 477.41 549.75 622 09 694.41 766.75

50.63 122.97 195.30 267.63 339.98 412.30 484.64 556.98 629.41 701.63 774.07

57.87 130.20 202.54 274.87 347.21 419.53 491.87 564.21 636.55 708.87 781.21

65.10 137.43 209.77 282.10 354.44 426.76 499.10 571.44 643.78 716.10 788.44

TEMPERATURE

CENTIGRADE TO FAHRENHEIT

FAHRENHEIT TO CENTIGRADE

-20 -15 -10 -5 0 1 2 3 4

5 10 15 20 25 30 35 40 45

50 55 60 65 70 75 80

-28.9 -26.1 -23.3 -20.6 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -12.2 -9.4 -6.7 -3.9 -1.1 1.7 4.4

7.2 10.0 12.8 15.6 18.3 21.1 23.9 26.7 29.4

90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 .185 190 195 200 205 210 212

32.2 35.0 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.8 65.6 68.3 71.1 73.9 76.7 79.4 82.2 85.0 87.8 90.6 93.3 96.1 98.9 100 0

□

-30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26

-22.0 -18.4 -14.8 -11.2 -7.6 -4.0 -0.4 3.2 6.8 10 4 14.0 17.6 21.2 24.8 28.4 32.0 35.6 39.2 42.8 46.4 50.0 53.6 57.2 60.8 64.4 68.0 71.6 75.2 78.8

28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 75 80 85 90 95 100

82.4 86.0 89.6 93.2 96.8 100.4 104.0 107.6 112.2 114.8 118.4 122 0 125.6 129.2 132.8 136.4 140.0 143.6 147.2 150.8 154.4 158.0 167.0 176.0 185.0 194.0 203.0 212.0

10 20 30 40 50 60 70 80 90 100

INDEX EX270-3-1

EmlmJ

GENERAL

CONTENTS Group 1-INTRODUCTION

GN10-1-1-2

Group 2-CONSTRUCTION ...................

GN10-2-1-4

Group 3-HYDRAULIC SYSTEM ............. 1. 2. 3.

GN10-3-1-10 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN"I0-3-1 Main Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN10-3-2 Pilot Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN10-3-6

Group 4-ELECTRIC SYSTEM ................ 1. 2. 3.

GN10-4-1-2 Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN10-4-1 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN10-4-2 Monitor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN10-4-2

Group 5-MAINTENANCE .................... 1.

2. 3.

GN10-s-1-32 Removal & lnstrallation (Cab, Front Attachment, Superstructure) . . . . . . . . . . . GN10-5-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN10-5-14 Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GN10-5-30

GNl0-1-1

GENERAL

EX270 INTRODUCTION 1. INTRODUCTION------------------------- The hydraulic excavator consists of three main conponents. They are the SUPERSTRUCTURE, the UNDERCARRIAGE, and the FRONT-END ATTACHMENTS.

This machine is driven completely by a hydraulic system and is totally differ

ent in its operation from other mechanical type machines.

from the engine is changed to hydraulic energy.

Mechanical energy

This hydraulic energy moves

cylinders and motors where it is reconverted to mechanical energy to do work.

In other words, travelling, swinging, digging and even more complex operations

like spin turns are all done by hydraulic power.

SUPERSTRUCTURE

FRONT-END ATTACHMENT

UNDERCARRIAGE

GENERAL

GN10-2-1

EX270 CONSTRUCTION 1. CONSTRUCTION

CI]

SUPERSTRUCTURE

• The superstructure consists of six main components.

They are the main frame, engine, fuel and hydraulic tank, hydraulic

system components and the counter weight.

• The main frame is a welded structure which holds the engine, the hydraulic system components, the fuel and hydraulic tank, the operator's cab and so on.

• The counter weight is bolted to the rear of the frame to balance the machine.

• The frame is bolted to the outer race of the swing bearing. The S\,ing bearing is mounted on the undercarriage.

UNDERCARRIAGE

• The undercarriage is a tractor type, which supports the superstructure and front-end attachments through the swing bearing.

The track frame is an all welded, stress-relieved structure.

• The front idler, track spring, track adjuster, rollers and travel unit are fixed to the track frame. Lifetime-lubricated track rollers, idlers and sprocket with floating seals. Track shoes of induction-hardened rolled

alloy with triple grousers.

FRONT-END ATTACHMENT

The front-end attachment mainly consists of six components.

They are the boom, arm, bucket, � boom c;:lindcrs, arm cylinder and bucket

[!]

cylinder.

HYDRAULIC SYSTEM -----------------------------

• :\11 operations of both the front-end attachments and main body are hydraulically powered.

• Hydraulic system mainly consi.sts of fi\·c circuit.

They arc the pump suction line, dcli\·cry line, return line, drain line

and pilot line.

• The oi-1 from the hydraulic tank floh·s to the three pumps Lfront, rear and pilot pump) through the pump suction line.

• The hydraulic pumps arc the heart of the hydraulic system and creates

the oil flow whi.ch supplied to all of the circuit through the deliYer:·

and pi lot 1 inc.

• Discharged oil from the control Yalve goes to the hydraulic tank through the return 1 inc.

• Internal leakage from the motors and brake \"al\"cs arc ncccssar\· because they act as luhri.cation. Lcakcu oil is returned to the hydraulic tank through the drain line.

GENERAL

GNl0-2-2

EX270 CONSTRUCTION

III

• The discharge oil from the pilot pump goes to the pilot valves and the pump's regulator and so on.

ELECTRICAL SYSTEM--- ----- --------------- - ----

I ts main functions are to start the engine, to charge the battery and to

supply current to E-P Control and Monitoring/alarm system, to supply

current to other electrical components such as lights.

• E-P Control System consists of Mode selection, Two-speed travel and Auto-idling.

Note: Mode selection is to control engine and hydraulic output for maximum productivity and fuel savings automatically by a microcomputer.

• Monitaring/alarm system consists of Meters, Warning lamps, Pilot lamps and Alarm buzzers.

• Starting system

It comprises mainly the battery, acting as a power source, and the

starting motor.

• Charging system

The battery should be charged as soon as practicable every time it is

used.

An alternator is provided to generate current.

The regulator and charging lamp are provided as auxiliaries.

G�NERAL

GN10 2 3

EX270 CONSTRUCTION ATTACHMENTS FRONIJ

26. 27. 28. 2 . 9 30 . 31. 32.

9. 1. CAB 10. SWING BEAR! NG 11. �-. CENTER JOINT 4. SWING MOTOR 12. 5. FUEL TANK 13. 14. 6. AIR CLEANER 7. HYDRAULIC OIL TANK 15. 16. B. RADIATOR

OIL COOLER ENGINE MUFFLER �� TRANSMISSION PUMPS (FRONT, REAR) PILOT PUM p CONTROL VAL VE (LEFT, RIGHT) BATTERY

BOOM CYLINDER HEAD LA MP BOOM ARM CYLINDER ARM BUCKET CYLINDER BUCKET

UNDERCARRIAGE

17 FRONT IDLER . 18. TRACK SPRING TRACK ADJUSTER 9. 210. UPPER ROLLER 21. LOWER ROLLER 22. TRACK LINK 23 TRAVEL REDUCTION DEVICE . 24. SHOE 25. TRAVEL MOTOR

GNl0-3-1

GENERAL

EX270 HYDRAULIC SYSTEM 1.

HYDRAULIC SYSTEM

Hydraulic system mainly consists of MAIN HYDRAULIC CIRCUIT and PILOT HYDRAULIC CIRCUIT. The below figure shows the hydraulic system outline.

�----i

I ,01 �ff! :

I I

: I

L-1-

@.i

r�

I I

: I

(J) @

I I

I l

L _____, 1

---------, I I

r------1}�-�

I L

L_ (8) "'-

L __ _

(�)

I I

: : 8:

CD ®

�

'• c••,;., v,1w }

(J)

@ ([j) @

@ @ (j] @ @ @ @

@ @ @ @

�Zl (1�

r----...1------,

___J

I I L---

Bucket cylinder Arm cylinder Boom cylinder Travel pilot valve Left pilot valve Right pilot valve Control neutraizer valve Shockless valve Restriction valve Check valve Oil tank Suction strainer Full flow filter Center joint Swing motor Parking brake release valve Bypass check valve Travel (left) Travel (right) Spare Bucket Boom Arm Swing

@ Control valve @ Front pump @ Rear pump ® Engine @ Radiator ® Oil cooler ® Accumulator @ Pilot pump @ Mode selection cylinder Solenoid valve @ Pilot filter

@ Travel motor

GENERAL

GN10-3-2 EX270 HYDRAULIC SYSTEM -----------

2. MAIN HYDRAULIC CIRCUIT

The main hydraulic circuit consists of a suction circuit, delivery circuit, return circuit and drain circuit.

The main hydraulic circuit is used to supply the oil to the actuators such as

cylinders and motors to move the machine for working. 2.1 SUCTION CIRCUIT

The circuit bet1,een the hydraulic tank and the main pumps is called as SUCTION CIRCUIT.

The hydraulic tank is provided with a suction filter. the suction filter and supplied· to the main pumps.

All oil is filtered by

2.2 DELIVERY CIRCUIT

The circuit between the main pumps and the control valve is called as DELIVERY CIRCUIT.

The oil discharged from the front pump flows to the right block of control valve.

The oi 1 discharged from the rear pump flows to the left block of

control valve.

The spools of control valve are moved by the

pilot pressure

act:vated by the pilot valve, and the oil from the main pumps flows to the actuators through the control valve.

2.3 RETURN CIRCUIT

The circuit between the control valve, and hydraulic tank is called as RETURJ\ CIRCUIT.

The oil from the actuators returns to the hydraulic tank through the control valve, oil cooler and full-flow filter.

The oil cooler cools the oil to proper temperature.

The restriction valves raises the return circuit pressure to improve the make-up performance.

The bypass check valve flows directly the return oil to the hydraulic tank in the conditions of low temperature and oil cooler clog.

The hydraulic oil is provided \\'ith full-fl01, filter and all return oil is filtered.

GENERAL

_:GN 10-_,_,3-3 :

______ ____ _ _ EX270 H YDRAULIC SYSTEM __

HYDRAULIC TANK

MAIN PUMP

GENERAL

EX270 H YDRAULIC SYSTEM

----

GNlQ.3.4

SWING MOTOR SWING MOTOR MAKE-UP LINE

CENTER JOINT

CONTROL VALVE

HYDRAULIC TANK

TRAVEL DRAIN LINE

TRAVEL MOTOR

GN10-3-5

GENERAL

EX270 HYDRAULIC SYSTEM 2.4 DRAIN CIRCUIT The circuit between the motors and the hydraulic tank is called as ORA.IN CIRCUIT. The motor has the internal leak and the oil must be fed back to the hydraulic tank.

2.5 MAKE-UP CIRCUIT The circuit between the swing motor and control valve is called as MAKE-UP CIRCUIT. The return circuit pressure is raised by the restriction valve, and the oil supplies to the swing motor from the return circuit through the control valve for preventing the cavitation of swing motor.

GENERAL

GN10-3-6

----------- EX270 HYDRAULIC SYSTEM 3. PILOT HYDRAULIC CIRCUIT

The pilot hydraulic circuit consists of the suction circuit,

elivery circuit,

pump and engine control circuit, swing parking brake circuit, return circuit

and relief pressure change circuit.

The pilot hydraulic circuit is mainly used for operating the control valve.

3.1

SUCTION CIRCUIT

The circuit between the hydraulic tank and the pilot pump is call as SUCTION

CIRCUIT.

The oil is supplied to the pilot pump from the hydraulic tank through the

suction fi 1 t er.

3.2 DELIVERY CIRCUIT

The circuit between the pilot pump and the pilot valves is called as DELIVERY

CIRCUIT.

The solenoid valve is provided with the relief valve for maintaining the

pilot circuit pressure.

The control neutralizer valve controls the oil supplying the pilot valve.

The oil from the pilot pump cannot be flow to the pilot valves in OFF position

of the valve.

In 0� position, the oil flows to the pilot valves.

3.3 PUMP AND ENGINE CONTROL CIRCUIT

The circuit between the solenoid valve and the main pump regulator is called

as Pm!P CO:HROL CIRCUIT.

The max. flow of main pumps is changed.

The circuit between the solenoid valve and two cylinders is called as ENGINE

CONTROL CIRCUIT.

The engine max. speed is changed.

3.4 PUMP INPUT TORQUE CONTROL CIRCUIT---------------------

The circuit between the solenoid valve and main pump regulator is called as PUMP INPUT TORQUE CONTROL CIRCUIT.

This is to prevent the engine stole owing to pump input torque exceeds engine

torque when the engine speed decreases.

GNl0-3-7

GENERAL

EX270 HYDRAULIC SYSTEM

RA L

G�� E � _ ___________________________ EX270

GNl0-3-8

HYDRAULIC SYSTEM

SWI N G MOTOR

SWING PARKING BRAKE LINE

CONTROL VALVE

HYDRAULIC TA N K

LI N E

HEAT-RUN LINE

SOLENOID VALVE

GNl0-3-9

GENERAL

EX270 HYDRAULIC SYSTEM 3.5 SWING PARKING BRAKE CIRCUIT

The circuit between the swing motor and the control valve is called as SWING PARKI\G BRAKE CIRCUIT.

When the control lever except travel is operated, the pilot oil is supplied to the brake release valve, and the parking brake is released.

3.6 RETURN CIRCUIT

The circuit beti-·een the control neutralizer valve and the hydraulic tank is

called as RETU�� CIRCUIT.

The oil released from the pilot relief valve is returned to the suction

circuit.

3.7 HEAT-RUN CIRCUIT

The circuit bet1,een the pilot relief valve and the shockless valve is called

as !!EAT-RU\ CIRCUIT.

This circuit is provided for quickly warming up the pilot line between the

pilot val\·es and shockless valve by using the oil which is warmed by the

pilot relief valve.

3.8 RELIEF PRESSURE CHANGE CIRCUIT

The circuit between the control valve and low-set pressure main relief valve

is called as RELIEF PRESSURE CHANGE CIRCUIT. This circuit is provided in the control valve for changing the circuit pressure in the main circuit.

GENERAL

GNl0-4-1 EX270 ELECTRIC SYSTEM

OUTLINE

EX-Series excavator is provided electrical system.

The electrical system

control and support the function of hydraulic excavator. This electrical

system is mainly consisted of Main circuit (Power line), Control system and Monitor system.

Q] MAIN CIRCUIT

Main circuit consists of starting sircuit, charging cir

cuit and lighting circuit. (1) Starting circuit

TI1e starting circuit converts electric energy from the

HEAD LAMP

batteries to mechanical energy by the starting motor.

(2) Charging circuit

The charging system recharges the battery after

FUEL METER SENSOR

current is used from the battery for starting or

electrical loads.

FUEL LEVEL WARNING SENSOR

If the electrical load constantly exceeds alternator

COOLING WATER LEVEL SENSOR

output, the battery will discharge. An alternator has a high current output at low engine rpms.

ALTERNATOR

ENGINE OIL PRESSURE SENSOR & HOUR METER SWITCH

MOTOR

AIR CLEANER FILTER CLOG SENSOR

HEATER RELAY

FUSIBLE LINK

GNl0-4-2

GENERAL

EX270 ELECTRIC SYSTEM

ll} CONTROL SYSTEM

Ill

(E-P Control System: Option)

Control system consists of mode selection

AUTO IDLING SWITCH

system, travel speed selection system and

auto idling system.

The E-P Control is a system that controls the engine and pump simultaneously.

TRAVEL SPEED

It selects and controls the engine speed

and the pump delivery to fit the current

working conditions and atmosphere through

mode selection, chargeover between 2-Speed

travel and auto-idling. I\IIONITOR SYSTEM

SWITCH

EX-Series are provided monitor system on the control box (Right side).

The monitor system to allow the operator to become aware of abnormality of the

machine as early as possible, various

gauges and alarm devices are provided.

SOLENLED VALVE A

PAE-HEAT TIMER

FUSE ENGINE STOP RELAY

DIODE RESISTOR

UNIT CONTROL HORN RELAY HOURMETER RELAY

CONTROL SYSTEM

GENERAL

GN10-5-1

-----------EX270. EX300 MAINTENANCE----------1. REMOVAL & INSTALLATION 1.1 CAB ------------------------------------

1.1.1 Removal of operator's cab

12} Remove 4 bolts from operator's seat. Remove operator's seat. 17 mm

fl]

Remove side cover from control box. ,

(..: 10mm

Disconnect wiring harness of wiper motor,

antenna, radio speaker, room lamp and so on.

'2]

Remove the nut for earth wiring.

--,�·: 17 mm

Disconnect earth wiring.

Remove 4 cab mounting bolts. 17 mm

8mm

GNl0-5-2

GENERAL

----------- EX270, EX300 MAINTENANCE-----------

II) Remove 4 U-nuts. -�

II)

24 mm

Fasten cab head with slings as shown.

� Lift cab. Weight: approx. 280 kg

GN10-5-3

GENERAL

-----------EX270, EX300 MAINTENANCE-----------1.1.2 Installation of operator's cab

(I}

Hook cab head with slings as shown.

ll]

Lift cab.

Set cab on the main frame.

Weight: approx. 280 kg

[I}

r= < ,":�

Install 4 cab mounting bolts. -�

17 mm

/.·--...... ..

8 mm

.-..:Skgf.m

\ -�-.I

ii)'

�

Bolt

Install 4 U-nuts. r

24 mm

.-..: 21 kgf.m

� Connect earth wiring.

Install the nut for earth wiring. 17 mm

��-��)

GNl0-5-4

GENERAL

-----------EX270, EX300 MAINTENANCE-----------

I!]

Connect wiring herness.

Install side cover to control box.

IZ)

(.,: 10mm

Set operator's seat.

Install 4 bolts to it. �

C,.:17mrn

... : 5 kgf.m

GENERAL

GN10-5-5

-----------EX270, EXJOO MAINTENANCE----------1.2 FRONT ATTACHMENT------------------------------

1.2.1 Removal of front attachment ass'y

� Place the excavator on level ground. Lower bucket to the ground.

Stop the engine.

Remove the air breezer cap, and drain the

air in the oil tank.

Disconnect lubrication hoses at adapters [) from boom cylinder rod ends.

�

tr: 19 mm

Remove bolts, nuts and stoppers of the pin

connecting with boom cylinder rod ends and boom.

13]

C,:

Fasten sling to boom cylinder.

Boom cylinder weight: Approx. 236 kg each

Push pin far enough to remove cylinder rod

with hummer.

!I)

Lower right boom cylinder to put it on

stand.

Fasten sling to other (left) boom cylinder. Push pin in other direction to remove

other (left) boom cylinder.

Lower other (left) boom cylinder.

GENERAL

GN10-5-6

-----------EX270, EX300 MAINTENANCE-----------

II) Disconnect 4 hoses of arm cylinder and bucket cylinder.

� : 41 , 50 mm

Close all openings with plug to keep clean.

[I)

Remove 2 bolts, 2 washers and plate of the

boom of the boom foot pin. RO

30 mm

(!) Fasten sling to the front end attachment.

(!)

Pull the boom foot pin with tool.

Remove the boom foot pin. mm Tool

ST-1953 Puller ass'y for EX270.

Note It is no need the special tool for EX300.

!ill

Remove the front end attachment.

GENERAL

GN10-5-7

-----------EX270, EX300 MAINTENANCE----------1.2.2 Installation of front attachment ass'y

� Fasten slign to the front attachment ass'y. Install dust seals to boom foot.

Align boom foot boss with the main frame boss.

Install boom foot pin with hummer.

I Install plate, nut and bolts. ,

t,: 30 mm 55 kgf.m

0 Remove the plugs to keep clean. . Connect the hydraulic hoses. �

,. '" [!)

�-

41, 50 mm --e'.;21 kgf.m for spanner 41 mm

---

: 26 kgf.m for spanner so mm

Fasten on side (left) boom cylinder.

Start engine.

Align the hole of boom cylinder rod end

with the hole of boom center by operating to extend or to retract the rod.

GENERAL

GN10-5-8

-----------EX270, EX300 MAINTENANCE----------

!!]

Install pin from one side (left side) with

hammer.

Fasten sling to the other (right) cylinder.

Align the hole of it's rod end with pin,

and then install pin with hammer.

Install stoppers, stopper bolts and nuts on both sides. �

...

C,: 30 mm :

55 kgf.m

I!} Connect lubrication hoses with boom cylind er rod ends. �

C, · 19 mm

__.: 3 kgf.m

GENERAL

GN10-5-9

-----------EX270, EX300 MAINTENANCE----------1.3 SUPERSTRUCTURE----- - ----------------------1.3.1 Removal of superstructure

II) Remove cab ass'y.

(Refer to 1.1.1 of this section removal of

operator's cab.)

[I}

Remove caps on counter weight.

11}

Install 2 eye-bolts at removing caps. Tool:

ST-9013 eye-bolt

� Fasten slings to counter weight. Counter weight's weight: approx. EX 270 EX 300

I!]

5400 kg 6200 kg

Remove 4 counter weight bolts and washers. ilO

: 46 mm

GENERAL

GN10-5-10

-----------EX270, EX300 MAINTENANCE-----------

[!]

II)

Lift counter weight, and remove and lower

it.

Remove front attachment ass'y.

(Refer to 1.2.1 of this section.

of front attachment ass'y)

II)

Removal

Drain the hydraulic oil from the oil tank. Disconnect 4 pipings at the top of center joint.

41 mm

11)

Disconnect lubricating hose.

Removal elbow from center joint. 22 mm

[ill

Fasten slings and lever-blocks to front

side and rear side of main frame.

Rear Side

GN10-5-11

GENERAL

-----------EX270, EX300 MAINTENANCE----------

G:2) Lift a

little bit till fastening slings.

Check rear slings do not touch on engine. Superstructure weight: approx. EX 270 EX 300

!ill

3900 kg 4500 kg

Remove the bolts of swing bearing.

32 mm

(EX 270) 36 mm ( EX 300 )

Note,;

Put a mating mark on outer race

and inner race.

(ill

Level main frame by adjusting with lever

blocks.

Li ft main frame.

Remove it from undercarriage. Lower it on the ground.

MARK

GENERAL

GN10-5-12

-----------EX270, EX300 MAINTENANCE-----------1.3.2

Installation of superstructure

II) Fasten slings and lever-blocks to front side and rear side of main frame.

Level main frame by adjusting with lever

blocks.

I]]

Lift super structure.

Set super structure on under carriage.

Connect super structure with undercarriage by inserting the bolts of swing bearing.

Tighten them temporarily. Note:

Align the outer race with the mating mark of inner race.-

[!)

Lower superstructure.

Install the bolts of swing bearing.

... '10 ,. ...

[!]

(EX 270)

65 kgf.m 36 mm (EX 300)

75 kgf.m

Connect elbow and lubricating hose.

Connect 4 pipings at the top of center

joint.

' II)

32 mm

.... ....

22 mm

lubricating hose side.

41 mm

4 pipings side

: 4 kgf.m : 21 kgf.m

Install front attachment ass'y.

(Refer to 1.2.2 of this section installa

tion of front attachment ass'y.) Fill the hydraulic oil.

GENERAL

GNl0-5-13

-----------EX270, EXJOO MAINTENANCE-----------

Lift counter weight.

Set it on main frame.

11) Tighten temporarily 4 counter weight bolts.

l!}

Lower counter weight.

Tighten 4 counter weight bolts.

...

195 kgf.m

� Remove eye-bolts. Install caps.

l!2)

Install cab ass'y.

(Refer to 1.1.2 of this section installa

tion of operator's cab.)

GENERAL

GNl0-5-14

-----------EX270, EX300 MAINTENANCE----------2. MAINTENANCE 2.1.1 Engine oil level check

Check the oil level before starting the

engine.

The oil level should be between

the cicle marks on the oil level gauge.

When the oil level is insufficient, refill

with recommended oil through the oil filter.

Then recheck the oil level.

2.1.2 Engine oil replacement

(1) Draining oil

Remove the drain plug from the engine oil

pan.

NOTE: Make sure you have a container cap-

able of holding 50 liters and a clean cloth.

Drain the oil through the clean

cloth into this container.

Check if there

is any foreign matter in the cloth such

as small pieces of metal.

(2) Filling

Make sure the drain plug is in and done up tightly.

Then remove the oil filter cap

and fill 28 liters of engine oil.

(3) Oil level check

The oil level should be between the "H"

and "L" marks on the dip-stick.

Run the engine for a few minutes at idling

speed then recheck the level after stopping

the engine.

2.1.3 Engine oil filter element replacement

(1) Loosen the drain plug at the bottom of the

cartridge filter, and drain the oil in the filter.

(2) Remove the cartridge element, and turn it counterclockwise with a tool.

(3) Apply engine oil lightly on the gasket sur face of a new cartridge element, and turn

it clockwise slowly by hand until it touches the seal surface.

Container

GENERAL

GN10-5-15

-----------EX270, EX300 MAINTENANCE ----------

(4) In this condition, fasten it further 3/4 � 1 turn by using a filter wrench.

Do not

fasten it too strongly, as it may crush the filter.

(5) When the oil filter warning lamp it on the monitor in operation, the filter element

is clogged.

In this case, replace the

element regardless of the replacement in

terval.

NOTE:

(1) Do not use cartridge element repeatedly.

(2) Be sure to replacement the gasket with a new one contained in the element kit.

(3) For installation, be careful not to twist and damage the gasket.

(4) Run the engine, and confirm no oil leak. 2.1.4 Engine oil bypass filter element replacement (1) Remove the upper and the lower plugs of the

bypass oil filter, and drain oil (apprxo.

4 lit.).

(2) Take off the clamp by loosening the fixing bolt, and remove the cover and the gasket.

(3) Remove the element by turning it counter clockwise.

(4) Clean the nozzle located at the screw that fixes the element.

(5) Reassemble a new element by following the above procedures in the reverse order.

NOTE:

(1) Assemble the parts with a proper tightening torque as follows: Part

Element

Clamp-fixing bolt Plug

Tightening torque (N-m)

(kgf.m)

To be fully turned by hand 17.6�22.5

1.8�2.3

14.7�20. 6

1.5�2.1

14.7�20.6

1.5�2.1

GENERAL

GN10-5-16

-----------EX270, EX300 MAINTENANCE-----------

(2) Make sure to replace the gasket and the 0rings of the plugs with new ones provided

in the element kit.

(3) For reassembly, never twist the gasket and

the 0-ring.

(4) When only the filter has been replaced,

confirm the oil level in the oil pan after

Drain Plug

Cover

0-ring

operating the engine for a few minutes.

If necessary, supply engine oil (Amount of

oil in the bypass oil filter:

lit.)

Approx. 4

(5) Start the engine, and check any oil leak.

(6) The case gets hot if the engine is in operation.

Wait until it cools down for

the replacement.

.�0-ring 'i) Oil inlet

-0,

Oil outlet

Plug

GENERAL

GN10-5-17

-----------EX270, EX300 MAINTENANCE-----------2.2. GEAR OIL 2.2.1

----------------------------------

Pump transmission-replacement

(1) Draining

Firstly, remove the plug at the top of the

transmission case.

Then remove the drain

plug at the bottom as shown.

NOTE: Make sure you have a container cap

able of holding 2 liters and a clean

cloth.

Drain the oil through the cloth into

this container.

Check the cloth carefully for foreign

matter such as small pieces of metal.

Container

(2) Supplying gear oil

1. Keep the machine body horizontal.

2. Remove the plug from the oil supply

pore, and supply gear oil about 1.4 lit.

3. Check the oil level.

4. Reinstall the level gauge and the plug.

(3) Checking oil level Check the oil level with the level gauge.

Oil level must be higher than low

level("L" mark) or between the lower end

of the stick and "H" mark.

Level gauge

GNl0-5-18

GENERAL

-----------EX270, EX300 MAINTENANCE----------2.2.2 Swing reduction unit oil level check and replacement

(1) Draining

Take off the top plug of the drain cock,

and open the cock to drain the oil.

(2) Filling

Make sure the drain plug is in and done up tightly.

Then fill 10 liters of gear oil.

(3) Oil level check

The oil level should be between the scales of the oil level gauge.

2.2.3 Travel reduction unit oil level check and replacement

(1) Oil replacement

Place the machine on level ground and set the

travel device as shown in the figure.

Slowly release the air with loosening the air

drain plug 2 or 3 turns.

Then remove the air drain plug and drain plug.

(2) Oil level check and refill

Place the machine on level ground and set the

travel device as shown in the figure.

Slowly release the air with loosening the air

drain plug 2 or 3 turns. Then remove the air

Air drain plug (oil supply plug)

drain plug and level check plug.

Refill oil up until the oil flows out from

the level check port. Retighten the plugs.

Tightening torque: 5 kgf•m (36 lbf•ft)

Drain plug Air drain plug (Oil supply plug) Oil level check plug

Horizontal oil level Drain plug

Serial no.5378~

GENERAL

GN10-5-19

-----------EX270, EX300 MAINTENANCE----------2.3 HYDRAULIC SYSTEM ----------------------------2.3.1

Oil level check

(1) Place the machine on firm and level ground, lower the bucket to the ground, with the

bucket cylinder extended fully and the arm cylinder retracted fully.

(2) Check the oil level in the oil level gauge on the side of the oil tank.

The oil level should be between the max.

and min. marks of the oil level gauge.

2.3.2 Oil tank draining

Loosen the drain plug at the bottom of the

tank to drain water and sediment.

2.3.3 Oil replacement

(1) Keep the front-end attachment in the pos ture indicated in the figure.

Cap

(2) Remove the air breezer cap, and release the air in the tank. How to remove air breezer cap.

1. Insert a hexagonal wrench (4 mm) through the hole provided on the lateral side of the side block.

Arrow (h) Projection

2. Turn the wrench clockwise, and turn the

cap counterclockwise about 30� at which

point stop the cap for a second to re lease the air.

Turn the cap further

until it stops, and take it off.

Side hole Hexagonal wrench 4 mm

GENERAL

GNl0-5-20

-----------EX270, EX300 MAINTENANCE------------

3. To reset the cap, align the projected

part of the cap with that of the case,

insert the cap, and turn it clockwise

until it locks.

For removing the cap, be sure to use a hexa

gonal wrench to release the lock. (3) Draining oil

1. Prepare a container with a 200 lit. capacity.

Remove the oil inlet cover, and drain

the hydraulic oil into the container by

using an oil pump.

2. Loosen the drain plug on the bottom of the oil tank, and drain the oil com pletely.

(4) Supplying oil

1. Take off the top cover of the hydraulic tank, and supply oil.

2. Release the air drain plugs on the top of the right and left pumps to drain

internal air, and supply hydrualic oil

in the pumps.

3. When the pumps are filled with hydrualic oil, temporarily fasten the plugs, start the engine, and keep it idling.

Loosen the air drain plugs a little, and

drain internal air until the hydraulic

oil leaks out from gaps.

After draining air, fasten the plugs

completely.

Be sure to supply hydraulic oil in the pumps,

as empty pumps will be broken by starting

the engine.

cover Filter case cover�"'..._

GENERAL

GN10-5-21

-----------EX270, EX300 MAINTENANCE----------(S) Drain air in hydraulic circuit

After refilling oil, drain the air in the

hydraulic circuit by running the cylinders and the swing motor uniformly for 10 � 15 minutes.

The pilot circuit is equipped with an air

drainer, and so the air can be drained in

S minutes by the above operation.

(6) Check oil level

1. Put back the front attachment to the

posture for checking.

2. Check the oil level. refi 11.

If it has lowered,

GENERAL

GN10-5-22

-----------EX270, EX300 MAINTENANCE----------2.3.4 Suction filter cleaning Cover

- When replacing hydraulic oil

A suction filter is provided at the bottom

of the tank.

It should be cleaned each

time the hydraulic oil is replaced.

After

draining the hydraulic oil, remove the

Support

cover attached to the air breezer, pull up

the rod and take out the filter.

Clean the

inside of the tank and the suction filter. For resetting, make sure that it is in

serted finnly into the pipe.

Before at

taching the cover, be sure to insert the

top edge of the rod through the hole of the cover support.

After confirmation, fix

the cover with bolts.

629 mm

Filter Inspection - IMPORTANT

When you change filter elements, inspect

the old element for foreign matters such

as debris of copper alloy, aluminum alloy, or others.

In this way, you can monitor waste content

and locate any malfunctions. 2.3.5 Full flow filter element replacement

(1) Remove the air breezer cap of the hydraulic oil tank, and drain the air.

For detaching/attaching the cap, refer to

the section of hydraulic oil replacement.

(2) Loosen the 6 bolts G), and take off the cover @ and the 0-ring @.

NOTE:

Never reverse these procedures, as it may cause the oil to pour out.

GENERAL

GN10-5-23

-----------EX270, EX300 MAINTENANCE----------(Caution)

The cover @ should be removed carefully

(3) Take out the spring

element

®·

©,

valve

@, and

( 4) Replace the element with a new one, to-

gether with the 0-ring

®·

(5) Fasten the bolt CD completely. 5 kgf.m

....

@--�

NEVER start the engine before filling up

both pumps with hydraulic oil.

If the pump

housings are empty, the pumps will be

damaged.

NOTE:

Cover

so as not to cause the spring @ to jump

out.

0-ring

Element

Bolt

GENERAL

GN10-5-24

-----------EX270, EX300 MAINTENANCE-----------2.3.6 Pilot filter element replacement

(1) For replacement, disassemble the element in the following procedures: (2) To detach the filter, loosen the case @ and take it out by pulling it downward. Detach ,the element @ by unscrewing it downward. (3) Before reassembly, replace the 0-ring @ with a new one.

--�©

Reassembly procedures (1) Insert a new 0-ring@ into the 0-ring groove on the head cover

CD .

(2) Assemble the element @ firmly with the head cover

by screwing it upward.

(3) Attach the case @ , and tighten the ele ment completely. r

_,. : 2 to 3 kgf. m

2.3. 7 Air breezer element replacement

(1) For replacement the element in the follow-

ing procedures: (2) Remove the bolt (3) Remove the cap

® ®·

of the cap ass'y. Remove the element

Cap Ass'y G)

Reassembly procedures (1) Put oil to 0-rings of the new element @. (2) Set the element

©.

(3) Fit the bayonet ass'y (z) and the cap@. (4) Install the bolt @. ,

.... : 0.7 to 0.9 kgf.m

--�

GNl0-5-25

GENERAL

- ----------EX270, EX300 MAINTENANCE----------2.4 2.4.1

FUEL SYSTEM Fuel tank drain

Remove the top plug of the drain valve

located at the bottom of the fuel tank,

and open the drain valve to drain water

and deposits.

The plug is attached to prevent vandalism.

2.4.2 Water sedimenter check

A water sedimenter separates the water mix

ed in fuel.

It is a case containing a

float, which comes up when water is accumu

lated.

When the float has reached the "Water-drain

level" indicated on the outside of the case, drain the water.

How to drain water

EX270

1'.E) ; Plug @ ; Water sedimenter @ ; Drain plug

Loosen the plug on the upper side of the

water sedimenter.

Then, loosen the lower

drain plug to discharge the water accumu

® ; Fuel cartridge filter

lated inside.

After the drainage, be sure to fasten the

��

both plugs.

NOTE: After draining water from the fuel, also

drain the air mixed in the fuel.

(See

"Air Bleeding" in the section of FUEL

SYSTEM)

Drain the water more often if it's content

is large in the fuel. 2.4.3

Fuel cartridge filter replacement

(1) Detach the cartridge filter by using a tool.

For safety and so as not to soil the ground,

make sure that the fuel is collected in a container.

(2) Apply fuel lightly on the gasket surface of a new cartridge filter.

EX 300

'p", · Plug �. @ ; Water sedimenter '� · Drain plug �· D

GENERAL

GN10-5-26

-----------EX270, EXJ00 MAINTENANCE---------(3) To reassemble the cartridge filter, turn

it slowly by hand until the gasket touches the seal surface.

(4) In this condition, turn it for more half by

hand.

Further tighten it by another 1/6 turn by

using a filter wrench.

Do not overtighten it, if not it will be

damaged.

(5) Draining air from fuel

After replacing the fuel filter element,

drain air contained in the fuel system.

(6) Start the engine and lock for any oil leak age from the seal surface.

2.4.4 Feed pump strainer cleaning

Loosen the joint bolt of the connecting

inlet hose of the feed pump.

Removed the joint bolt and loosen the

strainer from the inside of the joint bolt

with a screw driver.

Clean the inlet filter with diesel fuel. Point to NOTE Air bleeding

(1) Confirm no air inside the water sedimenter.

If air has entered during water drainage or

for any other reason, tighten both the air

bleed plug

and the drain plug, move the

primine pump up and down, and fill up the water sedimenter.

Joint bolt

(2) Then, loosen the air bleed plug

fuel filter, move the priming pump

of the

and down again until fuel containing no

foam flows out, and tighten the air bleed

plug.

(3) When the air bleeding is completed, wipe

out any leaked fuel, and check if fuel leaks out by running the engine.

If it leaks,

take thorough measures such as retighten the joints and replace parts.

L�

-------

�-�--

G) ; Air bleeding plug ® ; Air bleeding plug @ ; Priming pump Fuel cartridge filter ; Water sedimenter @

®;

GENERAL

GN10-5-27

-----------EX270, EX300 MAINTENANCE-----------

When supplying fuel, always put a container

to catch drops of fuel, to assure safety and avoid spots on the ground.

Ensure no fuel leakage (all parts including

pipes and joints), as it may cause a fire. If any abnormality is observed onthe fuel

injection pump or its parts, always contact

the distributor for inspection and adjust

ment.

2.5 FAN BELT--------------------------------2.5.1

Fan belt tension check

Check the belt's tension so that the fan

belts can be depressed about 10 'v 15 mm with

the thumb (with a force of 98N (lOkgf)) mid way between the fan pulley and alternator pulley.

Adjustment of the belts tension

I <

Lock Nut

I •

I I

,,.

can be done by pivoting- the alternator

pulley after the fixing bolts for alter

nator pulley adjusting plate and alternator

Bolt

pulley bracket have been loosed.

Check also the fan belt for any defect. If any defect is detected, replace it .

.rJ

Crank Pulley

GENERAL

GN10-5-28

----------- EX270, EXJOO MAINTENANCE---------2.6 BATTERY---------------------------------

(1) Cautions exercised in handing

A battery produced inflammable hydrogen gas and liable to cause ignition and

exposition.

Further, the battery is filled with sulfuric acid, which can eat

through clothing and burn flesh, even metals.

So, it must be handled with the

greatest possible care.

1. Never smoke or cause a spark near the battery.

2. If the battery acid gets on your skin or clothing, flush with cold water and then soap carefully.

If the battery acid gets into your eyes, flush

with fresh water immediately for about 15 minutes and the get medical atten

tion.

3. Don't finger the battery terminals immediately after the operation is finished.

It is dengerous.

Wait the battery for cooling moderately.

4. Prior to servicing and checking the battery turn off the load (engine key switch) to stop the engine and detach the vent plug.

S. When removing the battery terminals, be sure to do it from the earth side one

When attaching the other way, do the earth-side termi

terminal).

nal later.

If a tool comes in touch with

terminal and body (chassis)

in a condition where the lead wire of earth-side terminal is left connected, a spark occurs, which is dangerous.

6. Clamp the terminals securely.

If they are loose, a spark may occur.

7. When charging the battery, inflammable hydrogen gas is produced. the battery taking it off the machine and detach the vent plug.

So, charge

(2) Maintenance of MF (maintenance-free) battery

Since the battery performance has serious effect on the starting performance

of the engine, correct maintenance is required for the battery.

In MF battery,

the reduction in battery fluid during use and self-discharge are little com pared with general batteries.

the procedures below:

Perform the maintenance of the battery following

1. Since the specific gravity of the battery fluid differs depending on the fluid temperature, the specific gravity should be kept within the range shown in table below.

a.l

�

' �

20 C

Working range

I�

" r--.._

0 C

-20 C 1.21 1.22

1.23 1.24

1.25

"�

1.26

1.27 1.28

Specific gravity of battery fluid

1.29

1.30

1.31

�

1.32

GENERAL

GNl0-5-29

----------- EX270, EX300 MAINTENANCE-----------

£ CAUTION:

Measure the specific gravity of battery fluid when the fluid temperature has nearly become the atmospheric temperature, but not immediately after the

operation.

2. Check the terminals for looseness and rust.

Corrosion can be prevented by

applying 'grease or petroleum jelly to the terminals.

3. Always keep the battery surface (terminals and vent plugs) clean. preferably prevent the battery from getting exhausted up.

It can

4. When replacing the battery because it has become old, replace 2 batteries as a set.

It is because that when new and old batteries are used together,

the life of new battery will reduce.

5. Avoid using a general battery and MF battery together. advantage of MF battery being offset.

It results in t he

(3) Start-up by booster cable

When using a booster cable for a fead battery, observe the following instruc tions:

1. Stop the engine of the machine.

2. Connect one end of the booster cable (red to the

plus terminal of the

battery on the machine having trouble, and the other end to the same of the other machine.

3. The, connect one end of the other booster cable (black) to the

minus

terminal of the battery on the other machine, after that, the other end to the superstructure of the machine having trouble.

At that time, connect it to the point apart from the battery as far as

possible, because a spark is unavoida�le when the cable is connected at last.

4. After connecting them securely, start the engine on the machine having trouble.

5. After starting the engine, remove the booster cable with reverse order.

GN10-5-30

GENERAL

-----------EX270, EXJOO MAINTENANCE-----------3.

NAME PLATE

3.1

LOCATION OF NAME PLATE------------

(300) EX300 220

Left Side View of boom end

20 Right Side View

Detail@

Left Side View

[C 250 Front View of Control Box ( L l Inside View of Tool Box Cover

T�)

Upside View of Control Box(Rl

l� IJ Upside View of Oil Tank

Right Inside View of Cab

25 Upside View of Gauge Panel

Rear Inside View of Cab

GN 10-5-31

GENERAL

------------EX270, EX300 MAINTENANCE----------ITE�1

PART NAME

Q'TY 1

Machine MFG No.

Inspection manual

Control neutralizer lever

Lubrication

Caution for auto idle

Front window lock

Ty11e of machine

(screw)

1 4

Name of company

Accent stripe

Name of company

Accent stripe

Name of company

1 1

Accent stripe

(Plate)

Accent stripe Inspection

Key switch

Operation

Change of mode

Air vent

30 32

Buzzer cancel & level check

1 1 1 1

GENERAL

GNl0-5-32

-----------EX270, EXJOO MAINTENANCE----------3.2 MACHINE NUMBER PLATE --------------------------3.2.1 Machine model & serial number

Machine model and serial number are punched on the front-end side main frame, also are

shown by machine name plate as shown.

3.2.2 Engine type & serial number

Engine type and serial number are stamped

on the left side of the engine body.

EX270

H06C-TF10001 Engine model - Engine serial number

EX300

EP100-T13731 Engine model - Engine serial number

INDEX EX270-4A-1

SUPERSTRUCTURE

� CONTENTS

Group 1-SUPERSTRUCTURE .................

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

ss22-1-5s Main Frame & Counter-Weight ...................... 5S22-1 Engine ............................................ S522-2 Hydraulic Oil Tank ............. ..................... 5S22-8 Fuel Tank ......................................... S522-12 Swing Device ..................................... S522-14 Electric Parts................................. ..... S522-19 Cab Heater ....................................... S522-22 Engine Control Lever .............................. 5S22-24 Main Piping....................................... S522-25 Oil Cooler Piping .................................. S522-27 Cover ....................... ..................... 5S22-32 Pump Device...................................... S522-35 Control Box....................................... 5S22-42 Cab Group ....................................... . S522-44 Pilot Piping ....................................... S522-48 Control Lever .................... ................. S522-56

Group 2-HVDRAULIC PUMP DEVICE

■ ■ ■ ■ ■

OIP, Hydraulic Pump ..................... (OIP)HYP-34A-1-22 DI A, Main Pump ......................... (DIA)HYP-34A-1-22 DIA, Regulator............................. (DIA)RE-28 A-1-14 DIA, Pump Transmission ................... (DIA)TM-5A-1-14 DIA, HY-ZFS Gear Pump .................... (DIA)HYP-36 -1-10

Grouo 3-CONTROL VALVE

■ ■

OIP, KVMG-270-HC Control Valve......... DI A, KVMG-270-HC Control Valve ........

O/P: OPERATIONAL PRINCIPLE D/A: DISASSEMBLY & ASSEMBLY

(OIP)CV-34A-1-24 (DIA)CV-34-1-42

Continued on next page

INDEX EX270-4A-2

CONTENTS (continued) Group 4-SWING DEVICE

■ OIP, MX200 CAB Swing Motor............ ■ DIA, MX200 CAB Swing Motor............ ■ OIP, MX170,210 CAB Swing Motor........ ■ DIA, MX170,210 CAB Swing Motor........ ■ DIA, Swing Reduction Device.............

(OIP)HYM-50-1-10 (DIA)HYM-50-1-26 (OIP)HYM-58-1-10 (DIA)HYM-58-1-18 (DIA)SRD-9-1-14

Group 5-PILOT VALVE

■ OIP, Pilot Valve ...... . ....................... (OIP)PV-9-1-8 ■ DIA, HV Type Pilot-Valve (Front-End Attachment) ..................... (DIA)PV-9-1-14 ■ DIA, HV Type Pilot Valve(Travel) ............ (DIA)PV-10-1-14

Group 6-CONTROL NEUTRALIZER VALVE

■ ■

OIP, Control Neutralizer Valve ............... (OIP)CNV-1-1-2 DIA, Control Neutralizer Valve ............... (DIA)CNV-1-1-6

Group 7-SHOCKLESS VALVE

■ OIP, Shockless Valve ....................... (OIP)SHV-1-1-6 ■ DIA, Shockless Valve ...................... (DIA)SHV-1-1-10

Group 8-ACCUMULATOR

■

OIP, Accumulator ..........................

(OIP)ACC-4-1-2

Group 9-SOLENOID VALVE

■ OIP, Solenoid Valve(Three Spools) ......... . (OIP)SOV-9-1-6 ■ DIA, Solenoid Valve(Three Spools) ......... (DIA)SOV-9-1-10 ■ OIP, Solenoid Valve(One Spool) ........... (OIP)SOV-11-1-3 ■ DIA, Solenoid Valve(One Spool) ........... (DIA)SOV-10-1-8

Group 10-MODE SLECTION CYLINDER

■

DIA, Mode Selection Cylinder ................ (DIA)CY-13-1-4

SUPERSTRUCTURE

SS-22-1

-------------SUPE RSTRUCTURE------------1. MAIN FRAME & COUNTER WEIGHT-----------------1.1 CONSTRUCTION

Main frame consists of center frame, bed (right, left) and tail frame.

They are welded together.

Sw ing dev ice and control valve are installed to the center frame.

cab and hydraulic oil tank are mounted on the left bed.

on the r ight bed.

Operator's

Fuel tank is mount2d

Engine, pumps and counter weight are mounted on the tail frame.

COUNTER WEIGHT

BED (LI

SWING BEARING FIXING BOLT TAIL FRAME

1.2 SPECIFICATIONS-------- -

Main frame

Counter weight

--------- - ---- -- --1820 kg

5400 kg

SS-22-2

SUPERSTRUCTURE

--------------SUPERSTRUCTURE-------------2. ENGINE 2.1 CONSTRUCTION & FUNCTION 2.1.1

ENGINE

The Hino H06C-TI type engine is used in EX270.

This engine is a 6-cylinder, water-cooled, direct injection chamber with turbo

changer and inter cooler diesel engine, and with glow plug for in cold areas.

The engine ass'y consists of engine, radiator, muffler, air cleaner and others.

Note: For further paticulars on the H06C-TI engine, see Hino H06C-TI workshop manual.

BYPASS FILTEA

SS-22-3

SUPERSTRUCTURE

------------- SUPERSTRUCTURE------------2.1.2 RADIATOR

The radiator is installed in front of engine with the oil cooler, and it is

cooled by engine fan.

This machine is provided the water reserve tank to improve the ability and it

has level switch connecting to OK monitor in the cab.

RADIATOR

OIL COOLER

FAN GUARD

r::?

�/

SS-22-4

SUPERSTRUCTURE

------------- SUPERSTRUCTURE------------2.1.3 AIR CLEANER

Air cleaner consists of element, electric indicator and valve. This machine is provided with an air cleaner warning lamp which lights up in the monitor panel when the air cleaner's element becomes clogged.

Note: The additional element (for dusty condition) can be installed into the element (option).

ENGINE

I I I I I I I I I I

OPTION

L_ __________ ....J

�---SUPERSTRUCTURE

SS-22-5

SUPERSTRUCTURE

2.1.4 BYPASS FILTER The bypass filter is

provided

on the engine.

OIL FILTER

SUPERSTR UCTURE

SS-22-6

------------- SUPERSTRUCTURE------------2.2 MAINTENANCE STANDARD ---------------------------2.2.1

FUEL CONSUMPTION

(How to Calculate Fuel Consumption)

Estimating the precise fuel consumption of an actually working machine is

difficult.

A change in the engine speed will change the fuel consumption rate

and maximum output, as well as the current load or output power.

The fuel

consumption also depends on the maintenance of the engine and particularly

that of the fuel system. Measurement may be the best way, but we can also

evaluate the fuel consumption by the following calculation: F

where F:

Be/ 'Y X Le X 1/ 1,000

Amount of consumed fuel (£/h)

Be: Fuel consumption rate (g/PS h) at current engine speed (Read from engine performance curve)

Le: Shaft horsepower (PS) at current engine speed r:

(Read from engine performance curve)

Specific gravity of fuel (Light oil: 0.83 - 0.86)

Here, F represents a fixed value, and therefore should not be readily used as the actual fuel consumption that involves fluctuations of load and engine

output.

For adjustment, the calculated value F should be multiplied by one

of the following adjustment coefficients:

Light duty:

0.40

Heavy duty:

0.75 - 0.90

General:

(Reference)

Example:

0.60

0.60 - 0.75

Rated engine speed (H06C-TI)

F = 168/ 0.85

= 32.6 i/h

165

1/1,000

Light duty: F' = 32.6 x a.so = 16.3 t/h F' = 32.6 X 0.70 = 22.8 t/h General: Heavy duty: F' = 32.6

0.85 = 27.7 t/h

SUPERSTRUCTURE

SS-22-7

-------------SUPERSTRUCTURE------------2.3 SPECIFICATIONS----------------------------2.3.1

RADIATOR

Radiator

• Radiation area

. Exchange calorie Water flow rate

Water capacity

.. Weight 2.

Oil cooler

Radiation area

. Exchange calorie Oil flow rate

Oil capacity

. Weight 2.3.2

52. 72 m 2

More than 75000 Kcal/h 195 R,/min

11 fl

73 kg

32.33 m2

More than 50000 Kcal/h

280 fl/min 7. 7

70 kg

AIR CLEANER

. Filtration area . Air flow rate Weight

2.3.3

6.35 m 2

10.0 m 3 /min

12 kg

BY-PASS FILTER

• Filtration area Oil flow rate

Weight

1.8 m 2

6.0±3fl/min 7 kg

SS-22-8

SUPERSTRUCTURE

--------------SUPERSTRUCTURE------------3. HYDRAULIC OIL TANK

3.1 CONSTRUCTION & FUNCTION 3.1.1

OIL TANK

The oil tank acts as both a reservoir and an oil conditioner.

Its functions

are to dissipate heat from the oil, to separate out air from the oil and remove contaminants.

A full-flow filter and a suction filter are provided in the hydraulic oil tank.

They catch and remove dust and dirt particles from the oil.

SUCTION FILTER HYDRAULIC OIL TANK

LEVEL SWITCH

DRAIN PLUG PT 1/4

SS-22-9

SUPE RSTR UCTU RE

-------------SUPERSTRUCTURE------------3.1.2 FULL-FLOW FILTER

Full-flow filter means that the entire

�I

supply of oil is filtered each time the

oil circulates round the hydrualic system. The full-flow filter catches and removes

dust and dirt particles from the oil.

FILTER RELIEF VALVE

A full-flow filter is provided in the hydraulic oil tank.

As the filter element gets dirty, the pres

� I

sure difference between the inside and out

ELEMENT

side of the filter element increases

�

Filter relief valve is provided to prevent

K I ;

"i--�

because of the clogged element.

I;: I .

the filter element from break out.

: I

IMPORTANT: Immediately· replace the filter element when the relief valve

opens, or dirt in the oil will cause serious damage to

hydrualic components.

Fig. 5

(B) Hydraulic oil is not filtrated

(A) Hydraulic oil is filtered.

but released from relief vlave.

• FILTER ELEMENT

I f

SS-22-10

SUPE RSTR UCTU RE

--------------SUPERSTRUCTURE-------------3.1.3 SUCTION FILTER

Suction filter is provided to

take out foreign matter before

oil enters the pump.

·7 SUCTION /FILTER

J SUCTION PIPE

TO HYO. PUMPS

3.1.4 AIR BREATHER

The air breather consists of valves (intake and exhaust) and air breather cap. The intake and exhaust valves prevent destruction and pump cavitation by suck

ing or releasing air to the inside or outside of oil tank.

When the pressure is port A becomes higher than that of port B, the valve ex

haust will open to read the pressure to port B.

If the pressure in the port B becomes higher than that of port A, the valve

intake will open to read the pressure to port A.

B EXHAUST VALVE

SUPE RSTR UCTU RE

SS-22-11

------------- SUPERSTRUCTURE------------3.2 MAINTENANCE STANDAD

Refer to maintenance standard of Section 3 group 5.

3.3 SPECIFICATIONS 3.3.1 OIL TANK

Weight

149 kg

3.3.2 FULL-FLOW FILTER

Type

Filtration area

Max. filtration

Paper element

24,600 cm 2 10 M

Oi 1 flow rate

600 £/min

Weight

2.0 kg

Replacement interval

500 hrs

3.3.3 SUCTION FILTER 2

Filtration area

2,120 cm

Oi 1 flow rate

600 £/min

Max. filtration Weight

80 mesh 0. 7 kg

3.3.4 AIR BREATHER

Max. filtration Filtration area

Valve set: intak . Weight

1,3

exaust

10 i.i

240 cm

0.04±0.01 kgf/cm 2 at 1 ,Q,/min

0.5±0.04 kgf/cm 2 at 1 £/min 0.6 kg

SUPERSTRUCTURE

SS-22-12

-------------SUPERSTRUCTURE------------4. FUEL TANK 4.1 CONSTRUCTION & FUNCTION

Filter (fuel in port) and fuel level gauge are provided in the fuel tank.

Sensor of fuel gauge and fuel level warning lamp are also provided.

As to these sensors, see section 9 group 2.

@ �

CAP

FILTER

LEVEL GAUGE FUEL TANK

FLOAT

,__@'�

� from ENGINE to ENGINE

SUPE RSTRUCTU RE

SS-22-13

-------------SUPERSTRUCTURE------------4.2 MAINTENANCE STANDARD

Fill the fuel tank at the end of each day's operation.

Take off the drain cock plug on the bottom of the fuel tank, and open the drain cock to discharge water and deposits.

4.3 SPECIFICATIONS

Capacity

Weight

310

84.9 kg

SS-22-14

SUPERSTRUCTURE

-------------SUPERSTRUCTURE-------------5. SWING DEVICE -------------------------5.1 CONSTRUCTION & FUNCTION

Swing device consists of one swing motor and one s1ving reduction device.

swing motor is axial piston motor and swing reduction device is planetary

The

gear 2 stage type.

The swing motor and reduction device are mounted on the main frame.

SUN GEAR : FIRST HOUSING

PLANETARY GEA8 : FIRST

COVER

t · it-�Qlli

SUN GEAR:SECOND

��t

CARRIER: SECOND

�, . L-�r ,

F �-). �

DRIVE SHAFT

--{

::d

":&

l g

PLANETARY GEAR SECOND

'?,q.1w:rnm111,1i,.\ · J

:��)f ��

RING GEAR : SECOND

SS-22-15

SUPE RSTR UCTU RE

-------------SUPERSTRUCTURE------------5.1.1

SWING REDUCTION DEVICE

The swing reduction device is two stage planetary gear type.

The three first planetary gears fixed to a first carrier are driven by the

first sun gear on the output shaft of the swing motor.

As the planetary gears

mesh with the first ring gear, the first carrier rotates.

The second sun gear mesh with the first carrier and second carrier moving is

same as first carrier.

The drive shaft mesh with the second carrier, which meshes with the internal

gear of swing bearing.

The power from the motor is transmitted to the drive

shaft and thus the superstructure is rotated.

CARRIER: FIRST

SUN GEAR: FIRST

PLANET ALY GEAR: FIRST

PLANETARY GEAR: SECOND

DRIVE SHAFT

SS-22-16

SUPEASTA UCTU RE

-------------SUPERSTRUCTURE------------5.2 MAINTENANCE STANDARD 5.2.1

IJ:l

REMOVAL & INSTALLATION

(1) REMOVE SWING DEVICE Loosen the air breather cap to release the

ll}

compressed air in the hydraulic oil tank.

Remove cover. Remove hoses from the swing motor.

8mm

(!} Remove hoses from swing motor, install plugs.

�

then,

19 mm

22 mm

41 mm

I!} Remove bolts. 32 mm

I!] Remove swing device by using a eye bolts. Weight: 406 kg

SUPERSTRUCTURE

SS-22-17

------------- SUPERSTRUCTURE------------(2) INSTALL SWING DEVICE

Note: Before installing, clean the swing device.

IJ:) Install swing device to the main frame.

Install bolts Tightening torque: 75 kgf-m, 542 ft.lbs.

....

II{)

32 mm

(I} Install hoses Tightening torque: 5 kgf-m, 36 ft.lbs

8 mm

f!} Install hoses brake).

(drain, make-up and parking

Tightening torque (Brake) (Drain)

(make-up)

t,: 19mm, 22mm, 41mm

3 kgf-m,

22 ft.lbs 5 kgf-m, 36ft" lbs 21 kgf-m

152 ft.lbs

Install cover and air heather cap.

SUPE RSTR UCTU RE

SS-22-18

-------------SUPERSTRUCTURE------------5.3 SPECIFICATIONS 5.3.1 SWING REDUCTION DEVICE

Type

Two stage planetary gear type

Weight

406 kg

Reduction ratio

. Amount of gear oil

18.347

approx. 10

5.3.2 SWING MOTOR

Model

Type

. Displacement

Max. rotation speed Output torque

Relief set pressure

Parking brake release pressure

Weight

MX 200 CAB lOA

Swash plate type axial piston motor

201 cm 3 /rec 1500 rpm

83.2 kgf-m

235 kgf/cm 2

32 kgf/cm 2 111 kg

SUPERSTRUCTURE

SS-22-19

-------------SUPERSTRUCTURE------------6. ELEC TRIC PARTS-------------------------

6.1 CONSTRUCTION------------------------- ----6.1.1 ELECTRIC PARTS-1

Electric parts-1 consists of electric parts (radio, cigar lighter and etc.) and regulating parts (relay, switch and etc.).

They are installed in the right control box and operators cab.

WIPER-ARM

WIPER-MOTOR

AUTO IDLE SWITCH START SWITCH PANEL GAUGE

MODE CHANGE SWITCH LIGHT SWITCH WIPER SWITCH LIGHTER HEAT SWITCH CONTROLLER

HORN-RELAY

CONTROL UNIT

RESISTOR TIMER : AIR INTAKE HOURMETER-RELAY

SUPERSTR UOTU RE

SS-22-20

----- ----- --- SUPERSTRUCTURE-------------6.1.2 ELECTRIC PARTS-2 Electric parts-2 consists of electric parts (battery, head lamp and etc.) and regulating parts (switch, indicator, relay and etc.).

BATTERY

HEAD LAMP

PRESSURE SWITCH :FRONT

LEVEL SWITCH: OIL TANK PRESSURE SWITCH : TRAVEL

UNIT

INDICATOR: AIR CLEANER

SS-22-21

SUPERSTRUCTURE

--------------SUPERSTRUCTURE------------

-----6.2 SPECIFICATIONS -----------------------

(1) BATTERY

Model

180GS1-MF

Nominal voltage and capacity

12 V, 160 AH (5 Hr)

Discharge ampere

500 A

Quick discharge charactor

Voltage at just 30 sec

Weight

(2) HEADLIGHT

Halogen 24 V, 70 W

Voltage and watt

(3) ROOMLIGHT Model

174420-0007

24 V, 10 W

Voltage and watt (4) RADIO

Model

TM-430H

Voltage

24 V

(5) SPEAKER

. Allowable input (rated) (max)

(6) WIPER MOTOR

Rated voltage and ampere

(7) RELAY (horn) Model

Voltage

( 8) RELAY (Hourmeter) Rated voltage

(9) RELAY (battery)

40 kg

11CS60-0000

Model

Rated impedance

more than 9.1 V

Rated voltage and ampere

8 W

8 ohm

24 V, 1 A

HR-113

DC 24 V

DC 12 V-lA

DC 24 V - SO A

ss 22 2 2 �:- �- � --------SUPERSTRUCTURE -

SUPERSTRUCTURE

----7. CAB HEATER 7.1 CONSTRUCTION & FUNCTION

� __--=-=-=-=-=-=-=-=-=------

· machine is provided with a cab heater. C ab heater consists of heater u nit and h oses

Th·is

RESISTOR_/�

--�� \

SS-22-23

SUPERSTRUCTURE

-------------SUPERSTRUCTURE------------7.2 MAINTENANCE STANDARD

(OPERATION)

To operate the heater, open the heater

cock ( ® and @ ) on the engine, and turn

the heater switch in the cab on. When the heater is not in use, close the heater cock.

7.3 SPECIFICATIONS 7.3.1

HEATER

Model

Heating ability

CH230-HK

3,000 Kcal/min

Voltage and watt.

DC24 V, 90 W

Weight

5. 3 kg

Air flow rate

3.0 m 3 /min

SUPE RST RUCTU RE

SS-22-24

-------------SUPERSTRUCTURE------------8. ENGINE CONTROL LEVER---- ---- -- -----------8.1 CONSTRUCTION & FUNCTION --------------------------

Engine control lever is provided in the operator's control box for controlling

the engine.

The engine control lever is connected with a engine fuel lever through a push

pull type cable.

\·v \ -�

CONTROLBOX(RI

/I I

� --� --�--�\� CONTROL LEVER • \

��

,?�

,j..)

,.... �0,#-�o,•�

fi§f

CONTROL CABLE

I/�

SS-22-25

SUPERSTRUCTURE

-------------SUPERSTRUCTURE------------9. MAIN PIPING 9.1 CONSTRUCTION

Main piping consists of boom, arm, bucket, swing and center joint pipings and foses from the control valve.

BOOM CYLINDER (R)

BOOM CYLINDER (L) FRONT PIPINGS : BUCKET

p ROLL-OUT

� r

FRONT PIPINGS : ARM

% o

ffi

l�,j

-...

_;::: ,-o

�,,:cc::

ROLL-OUT

SUPERSTR UCTURE

SS-22-26

------------- SUPERSTRUCTURE------------9.2 MAINTENANCE STANDARD

Main and suction pipings are used ORS (O-ring Seal) joint for prevent oil leak.

Contruction

Adaptor

O-ring groove

O-ring

Seal surface

Union

Hose or pipe

CAUTION

(1) When removing the joint, replace O-ring.

(2) Make sure of the O-ring position before tightening.

(3) Be careful doesn't damage to the groove of O-ring and seal face.

(4) If there oil leak from the union, replace O-ring and make sure its position before tightening.

(5) Tightening torque. Width across flats mm

Tightening torque kgf.m (ft.lbs)

41. 46

14 (101)

13 (130)

21 ( 152)

26 (188)

SUPERSTRUCTURE

SS-22-27

-------------SUPERSTRUCTURE------------10. OIL COOLER PIPING

10.1 CONSTRUCTION -------------------------------

Oil cooler piping consists of pump suction line, pump delivery line, control valve return line, swing and travel motor drain line and control valve.

� �

DRAIN HOSE: TRAVEL MOTOR HOSE: SURGE MAKE-UP HOSE : SWING MOTOR

DRAIN HOSE : SWING MOTOR

BYPASS CHECK VALVE AIR RELEASE HOSES (3 kgf/cm 2 )

RETURN HOSE FROM CONTROL VALVE

RETURN PIPING FROM OIL COOLER

MANIFOLD

SUPERSTR UCTU RE

SS-22-28

-------------SUPERSTRUCTURE-------------- --- ---- ----- ---------10.2 MAINTENANCE STANDARD 10.2.1 REMOVAL & INSTALLATION

IJ:l

(1) REMOVE CONTROL VALVE

Remove cover ,

tv; 17mm

ll} Remove pilot hoses from the control valve. Note: Put matching number or tag on the hoses and control valve.

": 19 mm, 22 mm

Remove pump delivery hoses from the control valve.

10 mm

� Remove actuator's hoses from the control valve. Note: Put matching number or tag on the hoses and control valve.

8 mm

!!)Remove pilot hoses of control valve bottom side from the shockless valve. Note: Put matching number or tag on the hoses and shockless valve.

, . 19 mm, 22 mm

SUPERSTRUCTURE

SS-22-29

-------------SUPERSTRUCTURE-------------

I!} Remove wire from pressure switches.

Remove bolts ,

C,. : 24 mm

[!) Remove control valve by using a eye bolts.

(2) INSTALL CONTROL VALVE

CI] Install control valve to the main frame by using a eye bolts.

[I} Install

bolts

Tightening torque: 21 kgf-m, 174 ft.lbs

�

e,: 24 mm

SU PE RSTR UCTU RE

SS-22-30

-------------SUPERSTRUCTURE-------------

Install pilot hoses of control valve

bottom side to the shockless valve.

Tightening torque: 3 kgf-m, 22 ft.lbs

4 kgf-m, 29 ft.lbs

�

C, : 19 mm, 22 mm

(!) Install pump delivery hoses to the control valve.

Tightening torque: 9 kgf-m, 65 ft.lbs

10 mm

I!} Install actuator's hoses to the control valve.

Tightening torque: 5 kgf-m, 36 ft.lbs

8mm

[!} Install pilot hoses onto the control valve. Tightening torque: 3 kgf-m, 22 ft.lbs 4 kgf-m, 29 ft.lbs

�

t, : 19 mm, 22 mm

Install wire to the pressure switches.

SUPERSTRUCTURE

SS-22-31

--------------SUPERSTRUCTURE-------------

I!} Install cover.

Tightening torque: 5 kgf-m, 36 ft.lbs 17 mm

10.3 SPECIFICATIONS----------------------�-----

10.3.1 CONTROL VALVE

KVM-270-HC

Model

Pilot type

Type

Trave1 (spoo1)

Open center

Arm (spool)

Closed center

Boom (spool)

Closed center

. Bucket (spool)

Closed center

Swing (spool)

Max. oil flow rate

P-Port T-Port

(Front)

(Travel)

Main relief valve set pressure (Front)

(Travel)

Overload relief valve set pressure.

Arm, Boom, Bucket, Swing

Weight

252 t/min 263 9-/min

512 9-/min 285 325

-2

bar (kgf/cm2) at 170 9-/min

bar (kgf/ cm2) at 150 9-/min

300 ± o bar (kgf/ cm2) at 120 9-/min

178 kg

SUPEFISTR UCTU RE

SS-22-32

------------- SUPERSTRUCTURE------------11. COVER

11.1 CONSTRUCTION

(1) COVER

ENGINE COVER

The covers are installed on the superstructure to protect rain, dust and

damage from external obstruction for hydraulic components.

r( I TOOL BOX COVER

CONTROL VALVE COVER

FRONT DOOR OF RADIATOR

FRONT DOOR OF PUMP

SS-22-33

SUPE RSTR UCTU RE

SUPERSTRUCTURE (2) UNDER COVER

The under covers are in . stalled to Protect dust and damage from external obstruction for hYdraulic.

�-�

"_ "' ' / /\. /r< "

I J

t.\

-� CAB u ND E:o NTl COVER FI

�--�� 6! �

CAB UNDER COVER (REAR)

PUMP UNDER COVER

SS-22-34

SUPERSTRUCTURE

-------------SUPERSTRUCTURE------------(3) ENGINE COVER

The engine cover is installed to protect damage from external obstruction for

engine.

ENGINE COVER

11.2 SPECIFICATIONS

11.2.1 Engine cover . Weight

49.3 kg

11.2.2 Under cover . Weight

74.3 kg

SUPERSTRUCTURE

�: � =�=-� = ---====:� � � � � �- -� :�_ :�_ :�- � ;� ;� ; �; � �: SUPERSTRUCTURE

12. PUMP DEVICE 12·1

CONSTRUCTION

:... ;;

SS-22-35

. . . Pump device cons1sts of 2 main pumps, pilot pump and reduction device

ENGINE

TO REAR PUMP

Ofl!j

SS-22-36

SUPERSTRUCTURE

-------------SUPERSTRUCTURE------------(1) REDUCTION DEVICE The reduction device is one stage helical gear type.

Engine output is transmitted to the center shaft by the flexible coupling to

get smooth rotation.

ENGINE

DRIVE GEAR

(2) MAIN PUMP & PILOT PUMP The main pump is bent axis type variable displacement axial piston pump. Model name: HPV 14SC.

The pilot pump is a gear type pump.

Model name: HY-ZFS11-16.8R.

SUPERSTRUCTURE

SS-22-37

-------------SUPERSTRUCTURE------------12.2 MAINTENANCE STANDARD 12.2.1 REMOVAL & INSTALLATION

(1) REMOVE MAIN PUMP

Q] Place the machine on firm and level ground,

lower the bucket to the ground,

with the bucket cylinder extended fully and the arm cylinder retracted fully. Stop the engine, then, release the air pressure from the hydraulic tank.

I]] Remove the cover. �

(,: 19 mm

12] Remove suction piping from the pumps. I

10 mm

[!} Remove the suction hose from the pilot pump.

�

(,: 36

I!] Remove the delivery hoses from the main pumps.

I :

10 mm

SUPERSTRUCTURE

SS-22-38

--------------SUPERSTRUCTURE-------------

I!]

Remove the delivery hose from the pilot

pump. �

[ZJ

C,: 22 mm

Remove pilot pipings from the regulators. ,

19 mm ,22 mm

[!) Install wire to the pump device.

I!} Remove bolts . �

t,: 17 mm

[ill Remove pump device. Weight : 195 kg

SS-22-39

SUPE RSTR UCTU RE

--------------SUPERSTRUCTURE-------------(2) INSTALL MAIN PUMP

IJ:}

Install pump device to the engine. Tightening torque: 5 kgf-m, 36 ft.lbs Weight : 195 kg

[l]

'7 : 17 mm

Install delivery hose to the pilot pump. Tightening torque: 4 kgf-m, 29 ft.lbs mm

II)

Install delivery hoses to the main pump. Tightening torque: 9 kgf-m, 65 ft.lbs

10 mm

[!] Install suction hose to the pilot pump. Tightening torque: 18 kgf-m, 130 ft.lbs ,

36 mm

� Install suction piping to the pump. Tightening torque: 9 kgf-m, 6S ft.lbs

I 77

10 mm

SU PE RSTR UCTU RE

SS-22-40

-------------SUPERSTRUCTURE-------------

I!]

Install pilot pipings Tightening torque: 3 kgf-m, 22 ft.lbs 19 mm

4 kgf-m, 29 ft.lbs

22 mm

(I) Replenish the hydraulic oil into the tank. Note: Remove an air vent plug on the pump to release the air in the pump.

I!) Install cover Tightening torque: 9 kfg--m, 65 ft. lbs �

'7: 19 mm

SS-22-41

SUPERSTRUCTURE

------------- SUPERSTRUCTURE------------12.3 SPECIFICATIONS

12.3.1 MAIN PUMP

Model

HPV145CW-26A

Type

Bent axis type variable displacement

Displacement

132 cm 3 / rev x 2 252 £/min

axial piston pump

Max. discharge (Front) (Travel)

262 £/min

Driven ratio

0.9487

Rotating direction

Weight

Regulator

12.3.2 PILOT PUMP

Counter clockwise viewed from

shaft side.

67.5 kg

Operated by pilot pressure

Type

Gear pump

Driven gear ratio

1.0

Displacement Weight

16.8 cm 3 /rev

2.6 kg

:�=�=��_c_ _ _ ------� su PE RST R u

SS-22-42

Tu RE

SUPERSTRUCTURE

13. CONTROL BOX--------13.1

ONSTRUCTION

(1) C�NTROL BOX (R

; Con trol box (R consists of stan d , gauge panel an d covers.

COVER

PANEL

COVER STAND

COVER

SUPERSTRUCTURE

SS-22-43

SUPERSTRUCTURE-----------(2) CONTROL BOX (L)

COVER

STAND

SUPE RSTR UCTU RE

SS-22-44

------------SUPERSTRUCTURE-----------14. CAB GROUP ----------------------- 14.1 CONSTRUCTION -------------------- -- (1) GENERAL

Cab group consists of cab, seat, plate and floor mat.

FLOOR MAT

PLATE

GLASS WOOL

SUPERSTRUCTURE

SS-22-45

------------- SUPERSTRUCTURE------------(2) CAB

The new cab is totally human engineered to meet ISO standards.

The large, reinforced bronze-colored glass area assures good all-round

visibility.

SUPE RSTR UCTU RE

SS-22-46

-------------SUPERSTRUCTURE-------------(3) SEAT

The seat is reclining type with arm and head-rests and it can adjust the reclin

ing angle.

SEAT

ji-�,

,.,

KNOB

cy-GJ>--

►

STAND

14.2 SPECIFICATIONS 14.2.1

CAB

Weight

14.2.2

221 kg

SEAT

Weight

13 kg

SUPPORT

SUPE RSTR UCTU RE

SS-22-47

-------------SUPERSTRUCTURE------------14.2.3 DIMENSION OF THE GLASS

The glasses are all reinforced glass. Front glass (lower) : S mm thick, Except front glass (lower) 730

4 mm thick 514

432

(X)

N �

FRONT GLASS (LOWER)

794

618

382

'3-

327 0

491

�'

�

1)>o

�Ibo

914

R12000

874

□

!:::

752

□

756

(\J

368

»--I

•I

SUPERSTRUCTURE

SS-22-48

-------------SUPERSTRUCTURE------------15. PILOT PIPING

15.1 CONSTRUCTION 15.1.1 PILOT PIPING (1)

Pilot piping (1) consists of suction and delivery pipings of the pilot pump,

pilot, filter, solenoid valve, pressure switch and E.P mode control pipings.

The pressure switches are provided on the control valve and pick-up travel and front actions pressure.

The solenoid valve operates pump regulator, auto-idle cylinder and mode

change cylinder.

'} ,

-J-1-� '-:-'�,�

�-

d ·� l

LM O OE, OUTO IDLE CYL � �

�

��BSA

r==::S��

SHOCKLESS VALVE

•

PRESSURE SWITCH :FRONT

''--,,::1 �

�,-,,,/

; �

�

r l> l '�i J •

'-:(r�

PRESSU RE SWITCH : TRAVEL

�

PILOT � FILTER

SHOCKLESS VALVE

'a �

SU CTI ON HOSE

PIL OT RELIEF FALVE

ONTROL VALVE

SUPERSTRUCTURE

SS-22-49

-------------SUPERSTRUCTURE------------15.1.2 PILOT PIPING (2)

Pilot piping (2) consists of pump control piping, swing parking brake release

piping and accumulator piping.

n �

@ 0

'b,

ACCUMLATOR

SUPERSTRUCTURE

SS-22-50

-------------SUPERSTRUCTURE------------15.1.3 PILOT PIPING (3)

Pilot piping (3) consists of control neutralizer valve, shockless valve and these pipings.

OIL TANK

t·�.��

NEUTRALIZER ALVE •. ;

RETURN HOSE FOR QUICK HEAT CIRCUIT

® @ ® @ © G)

@ @ @ ® @ ®

(z) ®

Right travel motor reverse Left travel motor reverse Left travel motor forward Right travel motor toward Arm dump Boom rise Boom lower

@ (8)

® (D @ Q) @ ®

@ 8

9 ®

Extra Extra Bucket crowd Bucket dump Arm crowd Swing left Swing right

S_UPE RSTRUCTU RE

SS-22-51

--------------SUPERSTRUCTURE------------15.1.4 PILOT PIPING (4)

Pilot piping (4) consists of travel pilot valve piping and piping from pilot valve to shockless valve.

PILOT PRESSURE HOSE :TRAVEL

VALVE SHOCK LESS VALVE

SUPERSTRUCTURE

SS-22-52

--------------SUPERSTRUCTURE-------------15.1.5 PILOT PIPING (5)

Pilot piping (5) consists of front pilot valves (R and L) pipings aqd pipings

from pilot valves to shockless valve.

()

PILOT PRESSURE HOSE

�- >

PILOT

SHOCK LESS �- VALVE -

HOSE

<:) -

RETURN HOSE

- ',

�\)�

VALVE RETURN HOSE

SUPERSTRUCTURE

SS-22-53

------------- SUPERSTRUCTURE------------15.1.6 PILOT PIPING (6)

Pilot piping (6) consists of pump torque control piping, solenoid valve

and hoses.

io�

-�OP :::::=�

�©'

��o,,·-,_, ,

•_/2

, ' !I

�

PILOT FILTEA PUMP DEVICE �

SUPERSTRUCTURE

SS-22-54

-------------SUPERSTRUCTURE------------15.2 SPECIFICATIONS 15.2.1

SPECIFICATIONS (1 I

(1) SOLENOID VALVE Model

Type (Mode selection) (Pump regulator)

Rated voltage

DV-04-H3

Normal close type x 2

Normal open type 24 V

Allowable voltage

32 V

Relief valve set pressure

40 ± 1 kgf/cm 2 (3.922 kpa) at

Operated voltage

. Weight (2) PILOT FILTER

Type

23 V '\., 32 V 3

13 ,Q,/min

4 kg

Paper element with relief valve

Relief pressure

3.5 kgf/cm 2 (343 kpa)

Max. filtration

26 JJ

Filtration area

(3) PRESSURE SWITCH Model

Type

(4) PILOT PIPING (1) . Weight

(5) ACCUMULATOR Capacity

Charging pressure of nitrogen gas (6) PILOT PIPING (2)

. Weight

1.690 cm 2

52 PS

Normal open type

12 kg

300 cm 3

24 kgf/cm 2 (2.354 Kpa)

8.1 kg

SUPERSTR UCTURE

SS-22-55

-------------SUPERSTRUCTURE------------15.2.2 SPECIFICATIONS (2)

(1)

(2)

PILOT PIPING (3) . Weight NEUTRALIZER VALVE Type

Set pressure (3)

SHOCK LESS VALVE Model

Discharge (Free)

Max. pressure

Weight

25.8 kg

ROTARY type 40 kgf/crn 2 (3.922 Kpa)

FR-05-2

£/min 40 kgf/crn 2 (3.922 Kpa)

9. 8 kg

( 4)

PILOT PIPING ( 4) Weight

12.2 kg

(5)

PILOT PIPING (5) . Weight

4.1 kg

(6)

PILOT PIPING (6) . Weight

2.9 kg

SUPE RSTR UCTU RE

SS-22-56

-------------SUPERSTRUCTURE------------16. CONTROL LEVER 16.1

CONSTRUCTION

Control lever consists of pilot valve, lever and pedal.

The hydraulic pilot type control lever system can be easily changed to each

operation pattern by reconnecting the pilot hoses.

TRAVEL LEVER (L)

PEDAL

�PILOT VALVE (TRAVEL) DAMPER

PILOT VALVE (FRONT)

LEVER (L) : SWING,

NEUTRALIZER VALVE LEVER

SS-22-57

SUPERSTRUCTURE

-------------SUPERSTRUCTURE------------16.2 SPECIFICATIONS 16.2.1 TRAVEL PILOT VALVE

Model

HVP03A

Secondary pressure

40 kgf/cm 2 (3,924 kpa)

Primary pressure Stroke

40 kgf/cm 2 (3,924 kpa) 8.25 mm

16.2.2 FRONT PILOT VALVE

Model

HVP03B

Secondary pressure

40 kgf/cm 2 (3,924 kpa)

Primary pressure

Stroke:

1.3 port

2.4 port

40 kgf/cm 2 (3,924 kpa) 7 .5 mm

9.0 mm

OPERATIONAL PRINCIPLE

HYP-34A-1

l -----------HPV116C & 145C HYDRAULIC PUMP--------(O_IP__ 1. OUTL INE----------------------------Hydraulic pump consists of two bent-axis type variable displacement pumps

serving as main pump, 1 gear-type fixed displacement pump supplying hydraulic source for the main pump control and operation control, and a transmission

device.

These pumps are driven by one input shaft via the transmission gears.

BENT-AXIS PUMP

0 TRANSMISSION

HPV116CW HYDRAULIC PUMP

BENT-AXIS PUMP

GEAR PUMP

BENT-AXIS PUMP

TRANSMISSION

HPV145 CW HYDRAULIC PUMP

OPERATIONAL PRINCIPLE

HYP-34A-2 (0/P) ----------- HPV116C & 145C HYDRAULIC PUMP _______.......,__ MAIN PUMP (HPV116CW / HPV145CW)

The main pump is a variable displacement

type bent-axis piston pump.

It is equipped with a pilot operated

regulator.

REGULATOR (RH23A / RH25B, RH26A / RH28A)

The pump regulator is attached to each

main pump.

By changing rotor inclina

regulated.

Adjustment of the pump's

tion angle the pump's displacement is

displacement can be performed in two ways: • In accordance with the external pilot pressure from the pilot pressure source

line.

As the pilot pressure increases, the

pump's displacement is determined in an inverse proportion ratio to the pilot

pressure.

• In accordance with the main hydraulic system pressure.

When pressure increases, the regulator automatically decreases pump displace

ment, and vice versa. GEAR PUMP (HY-ZFS11-16.8Rl

The gear pump consists of two gears

closely fitted into a housing supplied

with inlet and outlet ports opposite each other.

TRANSMISSION

Three pumps are driven by the engine by

means of the pump transmission.

The main pumps are driven at 0.972 times (Model:HPV116C)/0.9487times(Model:HPV145C) the engine speed.

The gear pump is driven at the same speed as the engine.

RH23A / RH25B

OPERATIONAL PRINC IPLE

HYP-34A-3

l ----------- HPV116C & 145C HYDRAULIC PUMP---------(_O_/P.., _

2. FUNCTION----------------------------2.1 GEAR PUMP (HY-ZFS11-16.8R) -------------------------

One gear is driven by the engine by means

of the pump transmission, and in turning,

SUCTION

this gear drives the second one.

Oil is carried around the periphery of the revolving gears from the suction to the discharge side of the housing.

The teeth are tightly meshed between the two gears, thus preventing the return of

oil from the suction to the discharge side of the housing.

The discharge pressure is set at 40kgf/cm 2 (3923 kpa) by the relief valve.

This pump

DISCHARGE

suppies oil to the main pumps and to the

pilot circuit.

2.2 BENT-AXIS PUMP (HPV116C / HPV145C)---------------------

The following explanation refers to the single piston pump. The center shaft rotates the rotor with seven pistons.

The rotor rotates and slides along the surface of the valve plate.

SUCTION PORT

VALVE PLATE SURFACE DISCHARGE PORT

OPERATIONAL PRINCIPLE

HYP-34A-4 P) - ---------HPV116C & 145C HYDRAULIC PUMP--------(_O_I _ _

Inclining the rotor causes the pistons to reciprocate in their cylinder bores. Discharge oil is generated by the pistons reciprocating motion.

Therefore,

pump displacement is determined by the piston stroke length which varies in

proportion to the inclination angle of the cylinder. PISTON RECIPROCATION STROKE

CYLINDER BORE

Cylinder port (a) is located just between the discharge port and the suction

port, and the piston (A) reaches to the bottom dead center.

Cylinder ports

(e), (f), and (g) are located in the discharge port, and the respective pis

tons are in the discharge stroke for discharging the oil until they come to the bottom dead-center.

Cylinder ports (b), (c), and (d) are located in the suction port, and the

respective pistons are involved in the suction stroke.

.--VALVE PLATE

HYP-34A-5 OP ----------- HPV116C & 145C HYDRAULIC PUMP--------(_ _I _l _

OPERATIONAL PRINCIPLE

SHAFT

DISCHARGE PORT SUCTION PORT

After the rotor 1s rotated on the valve plate surface slightly, piston (D)

begins to move in the direction of the valve plate, and the oil is forced out

through the discharge port until the piston reaches its stroke-end.

DISCHARGE PORT

OPERATIONAL PRINCIPLE

-----------HPV116C & 145C HYDRAULIC PUMP

HYP-34A-6

(0/P)

The rotor inclination angle is varied from 2 to 24 degrees by the servo-piston

movement via the servo-pin and the valve plate.

OPERATIONAL PRINCIPLE

HYP-34A-7

-----------HPV116C & 145C HYDRAULIC PUMP--------O ( _I_Pl_ 2.3 REGULATOR

(RH23A / RH25B, RH26A / RH28A)-------------------

The major components of the pump regulator are the servo-piston, the feed back link, the piston, the spool, and the follow sleeve.

The servo-piston movement determines the rotor inclination angle. RH23A/RH2SB regulator is comprised of three mechanisms:

RH26A/RH28A regulator is comprised of four mechanismes:

Instruction mechanism (RH23A / RH25B, RH26A / RH28A)

This is activated by pilot pressure from the control valve and the solenoid

valve.

Pilot pressure from the control valve converts the pump displacement in an

inverse proportion ratio to the pressure.

Pilot pressure from the solenoid valve changes the set high and low pump

maximum displacement.

Compensation mechanism (RH23A / RH258, RH26A / RH28A)

This is activated by the hydraulic system pressure.

It automatically

varies the pump displacement according to the pressure in the hydraulic

system, preventing the engine from overloading. Compensation mechanism (RH26A / RH28A)

Pilot pressure from the solenoid valve changes the compensation

starting point of the P-Q line for preventing the engine from overloading at the low engine speed.

Feedback mechanism (RH23A / RH258, RH26A / RH28A)

This stops movement of the rotor after the signal from either of the above

mechanisms has been received.

OPERATIONAL PRINCIPLE

HYP-34A-8 O P

( -----------HPV116C & 145C HYDRAULIC PUMP--------..,/_,l_

3. OPERATION (HPV116C-RH23A / RH25B. HPV145C-RH26A / RH28A) -----------

HPV116C Hydraulic Pump is much about the same as HPV145C Hydraulic Pump. So,this paragraph discrives, for the most part, about HPV116C Hydraulic Pump.

3.1 NEUTRAL (ENGINE STOP STATUS)

In the engine stop condition, no discharge oil is generated and the rotor

inclination angle is kept to its minimum angle.

w :E w (.) <( ...J D.. en

D.. :E :J D..

z <i :E

PILOT PRESSURE

MAIN HYDRAULIC PRESSURE

OPERATIONAL PRINCIPLE

HYP-34A-9 OI_P l .,. ---------- HPV116C & 145C HYDRAULIC PUMP--- -----( _ 3.2 NEUTRAL (ENGINE FULL SPEED)

When the engine runs at full speed and the control lever is in neutral, the

external pilot pressure is at its maximum value. apllied to piston (17).

Therefore, oil pressure is

Piston (17) is pushed rightward with spool (24) until its stroke end against

spring (25) to open the passage to the large chamber.

As servo-pressure from the pilot pump acts on the large chamber, the servo

piston is thus pushed upward moving the rotor to its minimum inclination

angle.

This creates minimum pump displacement.

PILOT PRESSURE

EXTERNAL PILOT PRESSURE

SERVO-PRESSURE

�

OPERATIONAL PRINCIPLE

HYP-34A-10 Pl (O _I_ --_ ----------- HPV116C & 145C HYDRAULIC PUMP------3.3 INCREASING DISPLACEMENT

Here a contro.l lever has been operated to a point midway between the minimum

stroke and the maximum stroke.

When any control lever is operated, pilot pressure is decreased in accordance

with the lever stroke.

This pressure decrease allows the force of spring

(25) to overcome the oil pressure force acting on piston (17).

causes piston (17) and spool (24) to move leftward.

This movement

Movement of piston (17) opens the passage between the large chamber and the

tank port.

As the large chamber oil is released to the tank, the servo

piston moves downward, thus increasing the rotor's inclination angle.

increases pump displacement: operation.

an example of the instruction mechanism

This

As the rotor inclination angle increases, its movement is transmitted to the

sleeve (23) by the feedback mechanism.

left, blocks the tank passage. tank is blocked.

Hence oil flow from the large chamber to the

At this point, movement of the rotor stops, as oil in the

large chamber cannot escape.

operation.

The movement of the sleeve to the

This is an example of the feedback mechanism

EXTERNAL

PILOT PRESSURE

Pl LOT PRESSURE

MAIN HYDRAULIC PRESSUD<=

OPERATIONAL PRINCIPLE

HYP-34A-11 -----------HPV116C & 145C HYDRAULIC PUMP--------!_O_IP_l_ 3.4 MAXIMUM DISPLACEMENT --------------------------

Here the control lever has been moved to its full stroke position. Pilot pressure reaches its minimum value.

This decreased pilot pressure acts

on piston (17), pushing it to extreme left position and corning into contact

with the stopper.

This movement causes the spool (24) to move to the left,

and opens the passage between the large chamber and the tank port again,

allowing the large chamber oil to be released to the tank.

The rotor angle thus increases and approaches its maximum inclination.

�ow the rotor has reached its maximum inclination angle, so pump displacement is also at its maximum value.

The movement of the rotor is transmitted

through the feedback mechanism to the sleeve (23). left, blocking the tank passage.

The sleeve moves to the

As a result, movement of the rotor is stopped. 1-

z w

o,_� �w

=>U o,_ <(

z_.

_o,_

�a <( CJ)

Pl LOT PRESSURE

EXTERNAL PILOT PRESSURE

LARGE CHAMBER

OPERATIONAL PRINCIPLE

HYP-34A-12

----------- HPV116C & 145C HYDRAULIC PUMP ________(o_;_Pl_ 3.5 OVERLOAD PREVENTION---------------------------

Here the control lever is still at full stroke. applied to an actuator.

Now consider a load being

This increases the main hydraulic system pressure,

hence, the discharged oil pressure from the main pump. The system pressure always acts on piston (OS).

At a pre-set value, this

pressure overcomes the force of springs (08) (09) and pushes piston (05) and

spool (03) rightward, opening the passage between the servo-piston large chamber and the servo-pressure line.

pilot pump to the large chamber.

This permits the flow of oil from the

This in turn causes the servo-piston to

move upward, decreasing the pump displacement.

This is an example of the

compensation mechanism working in the overload prevention mode. As spool (03) is moved rightward, the force of springs (08)

(09) increases.

This causes piston (OS) and spool (03) to move leftward until the main system pressure equals the spring's force.

As in the previous examples, after each movement of the servo-piston, the feedback mechanism operates to complete the adjustment.

In this case sleeve

(02) closes the servo-pressure passage to stop the movement of the servo

piston.

The operation of this compensation mechanism maintains the P-Q line

of the pump below the engine output curve to prevent the pump from overloading

the engine.

Pl LOT PRESSURE 1-

z w � w u <{ ...J a.. en � ::, a.. z <{ �

MAIN HYDRAULIC

OPERATIONAL PRINCIPLE

HYP-34A-13 O IP l_ _... ----------- HPV116C & 145C HYDRAULIC PUMP ________(_

I-

z � w

z �

u <(

0..

CJ)

0..

�

:::>

0..

�

\L Pl LOT PRESSURE

0..

CJ)

0 0.. �

:::>

0..

�

MAIN HYDRAULIC PRESSURE

OPERATIONAL PRINCIPLE

HYP-34A-14 (0/P)

----------- HPV116C & 145C HYDRAULIC PUMP---------3.6 RECOVERY OPERATION

In this situation, the control lever is still at full stroke.

Hoi-·ever, con

sider the load on the actuator now decreasing, causing a pressure reduction

in the main hydraulic system.

This pressure drop allows the force of springs

(08) (09) to overcome the oil pressure force acting upon piston (OS).

This causes the piston and spool (03) to move leftward.

Movement of the spool

opens the passage between the large chamber and the tank, allm\·ing oil from the large chamber to flow to the tank.

increasing the pump displacement.

The servo-piston thus moves dmmward,

This is an example of the compensation mechanism working in the recovery mode.

1z w � w u <( ...J c.. CJ)

0 c.. � :::, c.. z <( �

Pl LOT PRESSURE z w � w u <( ...J a.. CJ)

c.. � :::, c.. z <( �

MAIN HYDRAULIC PRESSURE LARGE CHAMBER

As the spool is moved leftward, the spring's force decreases.

This causes

the piston and the spool to move leftward until the main system pressure equals the spring force.

When the forces are balanced, the passage to the tank is blocked. point.movement of the rotor stops.

At this

This is the feedback mechanism operating

to complete the instructions from the compensation mechanism.

makes optimum use of engine horsepower.

This feature

OPERATIONAL PRINCIPLE

HYP-34A-15

----------- HPV116C & 145C HYDRAULIC PUMP ________(_O_IP_l_ 3.7 DECREASING DISPLACEMENT

Here the control lever has been operated to a point midway of the lever stroke.

When any control lever is returned by a half lever stroke, pilot

pressure increases in accordance with the lever stroke.

This pressure

increase allows oil pressure force acting on piston (17) to overcome the force of spring (25).

This movement causes piston (17) and spool (24) to move rightward.

of piston (17) closes the tank passage.

Movement

Owing to flow of the servo-pressure oil to the large chamber, the servo-piston

moves upward, thus decreasing the rotor's inclination angle.

As the rotor inclination angle decreases, its movement is transmitted to sleeve (23) by the feedback mechanism.

The movement of the sleeve to the

right, blocks the passage between the large chamber and servo-pressure line.

Hence oil flow from the pilot pump to the large chamber is blocked.

At this point, movement of the rotor stops, as servo-pressure cannot flow

to the large chamber.

This is an example of the feedback mechanism operation.

LARGE CHAMBER

OPERATIONAL PRINCIPLE

HYP-34A-16 O Pl .:..;./ .:..-----------HPV116C & 145C HYDRAULIC PUMP-------.(� 3.8 MINIMUM DISPLACEMENT

Pilot pressure

Here the control lever has just been returned to neutral. reaches its maximum value.

This increased pilot pressure acts on piston (17)

pushing it to its extreme right position and bringing it into contact with the

stopper.

This movement causes the spool (24) to move to the right, and opens

the passage between the large chamber and the servo-pressure line again, allowing the servo-pressure oil to flow to the large chamber.

The rotor angle thus decreases and approaches its minimum inclination.

Now the rotor has reached its minimum inclination angle, so pump displacement

is also at its minimum value.

The movement of the rotor is transmitted

through the feedback mechanism to sleeve (23).

blocking the passage of the servo-pressure line.

The sleeve moves to the right,

As a result, movement of the rotor is stopped.

1z w

CL�

CL� �w :JU CL <t

�w

:::>U

CL <t

z--l _CL

<t�

�o

<t�

�o

MAIN HYDRAULIC PRESSURE

PILOT PRESSURE

LARGE CHAMBER

OPERATIONAL PRINCIPLE

HYP-34A-17

O... IP_l _ !_, ----------- HPV116C & 145C HYDRAULIC PUMP ________

3_9 SUMMATION CONTROL MECHANISM----------------------

In addition to the previously mentioned functions, a summation control

mechanism is provided as well.

The main system pressure from the other

(partner) pump is constantly applied to the stepped part of piston (05) to

prevent the pump from overloading the engine.

In other words, both main

pump's regulators have a common compensation circuit.

The operation is then exactly the same as described in the section entitled "OVERLOAD PREVE>JTION".

Pdl

Lt Pd2

OPERATIONAL PRINCIPLE

HYP-34A-18

----------- HPV116C & 145C HYDRAULIC PUMP--------(o_;_)_ P _ The following explains the part played b)· piston (05) in the functioning of

the summation control mechanism.

The ratio of the self-pump discharge pressure acting area of piston (05) and

the partner-pump discharge pressure acting area (stepped part) of the piston

is as follows:

Self-pump discharge pressure acting area

55%

Partner-pump discharge pressure acting area: 45%

Therefore, each pump's oil pressure force acting on the piston is as fol lows:

P = 0.55 x Pdl

Pdl: Self-pump discharge pressure

0.45 x Pd2 Pd2: Partner-pump discharge pressure

As mentioned above, when the Pdl is 100 kgf/cm 2 and Pd2 is 200 kgf/cm 2 , each

pump's displacement is as follows:

Pl's oil pressure force acting on the piston

0.55 x 100 + 0.45 x 200 = 145 kgf/cm 2

Pl's displacement corresponds to 145 kgf/cm 2 of the P-Q line

P2's oil pressure force acting on the piston

0.55 x 200 + 0.45 x 100 = 155 kgf/cm 2

P2's displacement corresponds to 155 kgf/cm 2 of the P-Q line

OPERATIONAL PRINCIPLE

HYP-34A-19

----------- HPV116C & 145C HYDRAULIC PUMP ________(_o_/Pl..,-

w � w

__J Cl

� w u <(

u <(

Pl LOT PRESSURE

145 P1 HYDRAULIC PRESSURE

SELF-PUMP

155

P2 HYDRAULIC PRESSURE

PARTNER-PUMP

OPERATIONAL PRINCIPLE

HYP-34A-20

-----------HPV116C & 145C HYDRAULIC PUMP ________(_o_;P_l_ 3.10 MAXIMUM OIL FLOW SELECTION MECHANISM

In addition to the previously mentioned functions, a maximum oil flow High/Low

position selection mechanism is provided.

pilot pressure from the solenoid valve.

This selection is determined by the

When the pilot pressure oil flows to act on spool (18), the spool is pushed rightward to its extreme right position.

leftward movement.

This movement restricts piston (17) 's

The rotor maximum inclination angle thus decreases and approaches its low

position, so pump maximum displacement is also at its low side value. This feature makes optimum use of the actuator speed.

z w � w (.) <( ..J c.. en � :::> c.. z <( � Pl LOT PRESSURE

Pl LOT PRESSURE

MAIN HYDRAULIC PRESSURE

HYP-34A-21

(0/P)

----------- HPV116C & 145C HYDRAULIC PUMP---------3.11

COMPENSATION STARTING POINT CHANGING MECHANISM (Model: RH26A/RH28A)

In addition to the previously mentioned function, a compensation starting point

changing mechanism is provided.

This is to prevent the engine stole owing to pump absotption torque exceeds

the engine output torque when the engine speed decreases.

This mechanism is determinded by the pilot pressure from the solenoid valve. When the oil from the solenoid valve flows to act on spool ( A ), the spool

is pushed leftward .

As aresult, the compensation mechanism starts earlier than usual. Other operation is then exactly the same as descrived in the section entitled "OVERLOAD PREVEN

TION".

(RH26A / RH28A)

Partner-Pump Pressure Receiving Chamber

elf-Pump Pressure Receiving Chamber

Pressure Receiving Chamber

Spool-A(three-stepped part type) is pushed leftward

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP

HYP-34A-1 (D/A)

1. DISASSEMBLY---------------------------

• Clean the outside of regulator. • Refer to Tl\1-5 for the single pump removal procedure from transmission. • The following pictures are HPV116C pump.

II)

Place a pump on the bed as shown. Remove a retaining ring using retaining pliers.

II)

Remove a drive gear using 2 jaws puller.

Place the pump on the working bench (ST-5050) as shown.

� Loosen 4 socket bolts L50) and washers (51) to remove regulator ass'y.

8 mm

HYP-34A-2

DISASSEMBLY and ASSEMBLY

(D/Al

HPV116C & 145C PUMP

I!}

I!]

Remove 5 0-rings (34), 0-ring (45) and 2 spring pins (46).

Loosen 8 socket bolts (35) and washers (36) to remove head cover (31).

10 mm

ll}

Remove 3 0-rings (34) from casing (01).

[!)

Place \·alve plate (19) on the casing as shown.

Remove retaining ring (13) using

wire or the like.

[!}

Remove rotor (08} and vahe plate Ll9i ass'y.

--,.'".,.,

h,\___�_ .. ··_.,·· -· ._" �

HYP-34A-3

DISASSEMBLY and ASSEMBLY

(D/A)

HPV116C & 145C PUMP

[ill Remove spring

(12) from casing.

Remove retaining ring (11) using screw

driver or the like. --«=I

..a.·/,

::,,--_ii:¥ ;-..,·_.{-�);

Remove center shaft ( 09) , using care that ball (10) and pin (14) from the center

shaft.

!ill

Remove 7 pistons (07) by placing pistion

horizontal position against drive disc (02) as shown.

Place casing on the bench as shown and

remove retaining ring (18) using retain

ing pliers.

DISASSEMBLY and ASSEMBLY

!ill

HPV116C & 145C PUMP

Place casing on the work bench and remove

seal cover (16) using 2 screw drivers as

shown.

!ill

Remove seal (15) using screw driver.

!ill

Remove 0-ring (17) using screw driver or

the like.

Place the casing on the press as shown

and remove drive disc (02) with bearings (03) using tool (ST-1239)

HYP-34A-4 (D/A)

HYP-34A-5

DISASSEMBLY and ASSEMBLY

1201

(D/A)

HPV116C & 145C PUMP Place drive disc (02) with bearings (03)

on the tool (ST-5905).

Install tool (ST-3054) on the spline of

drive disk to loosen bearing nut (06). Note:

ST-3054

--.. --'!f

Loosen the bearing nut by turning

the drive disk in the direction of clockwise.

Remove bearing nut (06)

Remove both bearings (04) with spacer

(OS) from the drive disk using pulling

attachments and puller.

1231

lrfi)

Remove cup of bearing (03).

HYP-34A-6 (D/A)

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP 1241

Remove cone of bearing (04) from spacer (05) using tool (ST-2315).

HPV116C

HPV145C

l2sl

Disk

ST-2315

ST-1271

Install tool (ST-1233) between drive

disk (02) and bearing (03), install and

tighten it with a vice until obtaining

clearance to facilitate, removal of bear

ing (03) .

HPV116C

!261

�

HPV145C

Puller

ST-1233 ST-1272

Romove bearings (03) from the dri\·e disk

using puller and pulling attachments.

Loosen 4 socket bolts ( 42) and washers (43) to remove stopper-S (40)

6 mm

( �

Remove O-ring ( 41) .

Ur--®

DISASSEMBLY and ASSEMBLY

HYP-34A-7

HPV116C & 145C PUMP � Loosen

--1-

(D/A)

socket bolts ( 42) and 1,ashers

(--1-3) to remove stopper-L (38).

Remove 0-ring (39).

r 1301

Loosen set screw (30) from sen·o piston

to remove servo pin (21).

@II

6 mm

5 mm

Remove sen·o piston (28) from large

chamber side of casing.

2. INSPECTION---------------------------

[I)

;-leasure the chordal thickness of the disk spline.

Unit

HPV116C HPV145C

Limit of use

Standard

3.5

4.9

il]

�leasure the diameter of the sleeve. l

l l HPV116C

HPV14SC

Standard

55.0 60.0

Unit

Limit of use

54.8 59.8

HYP-34A-8

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP

[!)

Move the piston up and down to measure

the clearance between the piston and the

drive disk.

Std.Clearance

Limit of use

0.055

0.4

0.049

HPV116C

HPV145C

(!}

Unit

Measure the diameter of the rotor piston

bore.

Measure the diameter of the piston.

Calculate the clearance between them.

Limit of use

Std.Clearance

0.08

0.043

HPV116C

0.08

0.044

HPV145C

II)

Unit : mm

Fix the piston with a vice.

Move the piston up and d01m to measure

the clearance between the connecting rod

and the positon.

HPV116C HPV145C

Standard clearance 0.1

I!}

Unit

Limit of use

0.4 mm

Move the shaft up and down to measure the

clearance between the shaft and the holder. HPV116C HPV145C Standard clearance 0.4

Unit

Limit of use 1.0

(D/A)

HYP-34A-9

DISASSEMBLY and ASSEMBLY

[!}

(D/A)

HPV116C & 145C PUMP

Measure the diamter of the valve plate

bore.

Measure the diameter of the center shaft. Calculate the clearance between them.

CENTER SHAFT

Std.Clearance HPV116C

0.078

HPV14SC

0.084

Unit

Limit of use

0.3 0.3

VALVE PLATE

[!)

bore and the diameter of the small servo

posi ton.

��

Calculate the clearance between them. Unit

HPV116C HPV14SC Standard clearance 0.089

I!}

•

Measure the diameter of the small chamber

Limit of use

0.2

Measure the diameter of the large chamber bore and the diameter of the large cham ber.

Calcuate the clearance between them.

....

.,¥�

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP Unit Std.Clearance

!ill

HYP-34A-10 (D/A)

Limit of use

HPV116C

0.089

0.2

HPV14SC

0.100

0.2

Measure the diameter of the servo pin bearing part and measure the diameter of the valve plate bore. Calculate the clearance betheen them.

Unit

HPV116C HPV14SC Standard clearance

Lmit of use

0.051

0 . .)

' 3. ASSEMBLY---------------------------- -

• Before assembling, clean all parts Kith pure oil and dry air, keeping them clean from dust. • Refer to TM-5 for the single pump install procedure to transmission.

IJl

Install servo piston (28) into head co\·er (31).

Install servo pin (29) into the

bore of the servo piston.

Install and

tighten set screw(30) to hold the sen-o pin.

:-..

Note:

2.5 kgf.m (18 ft.lbs) Apply the lock tight on the thread part of the screw.

DISASSEMBLY and ASSEMBLY

HYP-34A-11

HPV116C & 145C PUMP

(D/A)

Install 0-ring (-HJ on stopper-S (-HJ) and

install the stoppcr-S on head cover L31). Install and tighten 4 socket holts L42)

and washers (43) to hold the head cover.

! aot ·

12]

6 mm 2kgf.m (15 ft. lbs)

Temporarily install tool (ST-7922) with

2 socket bolts l42) to Keep servo pin at

c enter position of opening to facilitate assembling of the head cover onto the

casing.

Holder ass'y ST-7922

HPV116C

HPV14SC

ST-7923

[!) \farm up 3 bearing coans L03) (04) and _ casing (01) to 80 l50 ° C using a oil bath. J

[El

Install 2 bearings (03) on drive disk. Note:

• Use care not to scald yourself during assembling of bearing.

• Apply a few drops of lubricant oil on bearing coan.

[El

Install bearing cup (04) into spacer LO:=i)

using tool (ST-2316).

HPV116C

HPV145C

Disk ST-2316

ST-2408

......______ ST-7922

HYP-34A-12

DISASSEMBLY and ASSEMBLY

(D/A)

HPV116C & 145C PUMP

II)

Install bearing (04) with spacer (OS) on

drive disk (02). Note:

• Use care not to scald yourself

during assembling of bearing (04).

• Lower the temperature of bear ing after assembling.

Hit spacer lightly so bearing is tight

against its shoulder using tool (ST-7102).

I!)

Place the drive disk on tool (ST-5905). Install bearing nut (06) on drive disk

until bearing nut seats on bearing coan (04). Note:

Apply a few drops of lubricant oil

on bearing nut threaded part.

I!)

Install tools (ST-3054) (ST-502S)(ST-5026)

(ST-5024) to tighten bearing nut tempo rary.

Note :

Tighten bearing nut by turning the

drive disk in the direction of

counter clockwise. �

Install tool (ST-3055) to measure pre

load of the bearing.

Tool : Torque meter

Starting moment : 0.20±0.0Skgf.m ( 1. 45±0. 4ft. lbs) Note:

Rotate the torque meter two or three times both right and left direction before measurement.

-\ ST-5905

HYP-34A-13

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP

Use tool tST-7103), as required to back

off bearing during measurement. Tube HPV116C HPV14SC

ST-7103 ST-7105

Place casing (01} and apply grease as

sh01m. Note:

Use care not to scald yourself

during applying grease.

[ill Place casing

(01) as shown.

Install drive disc (02) into the casing.

Note:

Lower the temperature of casing

after assembling.

!ill

Install O-ring ( 17} into casing and apply

surfaces with grease.

Instal1 oil seal ( 15) into seal coyer (16}

using tool (ST-2284}.

HPV116C HPV14SC

Disk

ST-2284 ST-2409

(D/A)

HYP-34A-14

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP

[ill

Install tool (ST-2280) on the spline of

drive disk to prevent damage it during

assembling of seal cover (16). Install the seal cover into the casing. ll6C; ST-2280 145C ;ST-2410 Note: Seal cover must be installed e\'en with surface. Check to be sure the groove of the retaining ring is availabe.

Q]J

Install retaining ring (18) using retain

ing pliers. Note:

Make sure the retaining ring is

positioned in ring groove after in stalling using soft mallet and bar or the like.

GlJ

Turn the casing up side d01m on \\'Ork bench (ST-5050)

Install 7 pistons (07) into drive disc

(02) by placing piston hori:ontal position

against drive disc as shown. Note:

Apply a few drops hydraulic oil on

the hole of drive disc.

!ill

Install ball (10) and pin (14) on center

shaft (09) .

Apply ball and pin with grease not to drop

from center shaft.

{D/A)

HYP-34A-15 (D/A)

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP

� Install center shaft (09) on dri Ye disc

•

aligning ball and drive disk hole.

1201 Install retaining ring (11) on the driye disk to hold centr shaft.

ll!) Install spring

( 12) on center shaft.

� Install valve plate (19) and link (21) ass'y into the casing. Note:

Link end must be inserte d into

opening of casing.

j23I Install rotor (08) into the casing align

ing 7 rotor holes and - pistons, aligning

a groove in the rotor �ith a pin of center

shaft so rotor can be installed its cor

rect position.

HYP-34A-16

DISASSEMBLY and ASSEMBLY

(D/A)

HPV116C & 145C PUMP

j24I

Install retaining ring (l�J on

center shaft using retaining pliers.

1251 Place valve plate (19) on the rotor

aligning top of center shaft with

bushing (20) of valve plate. Note:

Apply hydraulic oil on sliding sur faces of valve plate and rotor. Make sure the deli very port is positioned rightward as viewed from head cover downward.

1261 Place pin (25) into mounting hole of

casing.

!ill

Install 3 0-rings (34) on the casing .

• l2al Temporarily install tool (ST-7089) into

drain port of casing to keep valve plate

(19) position to facilitate assembling of

the head cover on the casing. HPV116C

HPV145C

Guide

ST-7089

ST-7094

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP � Install head cover (31) on casing

(01) aligning servo pin with valve hole.

Apply liquid gasket to faying sur face of casing. Place head cover in casing, being careful to align valve in casing, being careful to align val\-e pl ate sliding surface properly with guide of head cover and to align spring pin with pin hole.

Note:

1301 Install 8 washers (36) and socket bolts

(35) and tighten evenly.

...

10 mm

llkgf.m (80ft.lbs)

@:I) Remove tools

(ST- 7922) (ST- 7089).

Install Stopper-1(38) with O-ring

(39), install and tighten 4 socket bolts (42) and washers (43).

...

Install plug (47).

,.r � ,. �:

HPV116C

6 mm 2fgf.m (lSft. lbs) 22 mm :kgf. m (Slft.lbs)

HPV145C j32I

Holder

Guide

ST-7923

ST-7094

ST-7922

ST-7089

Install 0-ring (45) and 5 0-rings (3·i).

1331 Install regulator (..J-4) aligning feed back

pin (26) with groove of regulator 2 sleeves. Note:

Remo\·e eyebolt and plug of regula

tor will ease assembling of regulator.

HYP-34A-17 (D/A)

HYP-34A-18

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP 1341 Install 4 washers (51) and socket bolts

(50), tighten evenly.

t: rs

8 mm

,... · 5 kgf.m (15ft. lbs)

1351 Place casing as shown.

Install drive gear.

Make sure dri ,:e gear

is tight against center shaft.

j361 Install retaining ring using retaining

pliers.

(D/A)

HYP-34A-19 (D/A)

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP

3. SPECIAL TOOLS--------------------------

ST-Number ST-5050 ST-9061

ST-9065

ST-1239

ST-5905 ST-3054

ST-2315

ST-1771

ST-1233

ST-1272 ST-7922

ST-7923 ST-2316

ST-2408

ST-7102

ST-3055

ST-7103 ST-7105 ST-2284

ST-2409

ST-2280

ST-2410

ST-7089

ST-7094

Pump

• • • • • • •

• • • • • •

116C 145C

• • • • • • • •

•

Q'ty

l\'ork bench

Bracket

Puller

Holder ass'y Adapter

Disk

• • • • • • • •

Tool name

Use To hold single pump

To lift single pump

To remove drive disc from pump casing

1 set To remove and install bearing nut and

set pre-load of bearing

1 1

To loosen and tighten bearinQ nut

To remove bearing

Puller

1 set To obtain clearance between drive disk

Holder ass'y

1 set To hold servo pin position when

and bearing

assembling headcover

Disk

To install bearing

Puller

To install bearing

Adapter

To set pre-load of bearin_g

Tube

To back off bearing (To set pre-load)

Disk

To install oil seal

Tube

To install seal cover

Guide

To hold rotor position when assembling head cover

e:Applicable Pump

DISASSEMBLY and ASSEMBLY

HYP-34A-20 (D/A)

HPV116C & 145C PUMP

ST-SOSO

ST-S90S

ST-9061

(HPV116C)

ST-906S

(HPV14SC)

ST-30SS

ST-3054

ST-1233

(HPV116C)

ST- 7089 (HPV116C) ST- 7922 (HPV116CJ

ST-1272

(HPV14SC)

ST- 7094 (HPV145C) ST-7923 (HPV14SC)

HYP-34A-21

DISASSEMBLY and ASSEMBLY

(D/A)

HPV116C & 145C PUMP

4. PARTS LIST----------------------------

Item 01

0.3

Part name

Casing

Drive disk

Bearing ass'y

Spacer

08 10 11 12

Q'tr 1

Item

1 set

,...,

� I

1 set

Part name

Retaining ring

Servo piston

Servo pin

Set screh:

Q'ty 8 1 1 1

Head cover

Piston ass'r

7 set

.33

Plug

Center shaft

Bolt

Plug

0-ring

Bearing nut Rotor

Ball

Spring

Retaining ring

.32

Spring pin

.34

0-ring

Spring washer

Stopper-L

Stopper-S

Oil seal

0-ring

Spring washer

Valve plate

0-ring

Link

Plug

Screw

18 20 22 7-

�.)

25 26

Seal cover

Retaining ring

Bushing

Lever

Feed back pin

Bolt

Regulator ass'y

Spring pin

\arne plate

Bolt

Spring washer

1 2

DISASSEMBLY and ASSEMBLY

HPV116C & 145C PUMP

HYP-34A-22 (0/A)

DISASSEMBLY and ASSEMBLY

RH23A RH25B RH26A RH28A REGULATOR

RE-28A-1 (D/A)

1. DISASSEMBLY • When disassemble the regulator, do not disassemble the adjusting part (10), (11), (14), (15), (16), (19), (21), (22), (28), (29) at the below figure except that you need to disassemble them. formance curve of the regulator is changed.

If disassemble them, the per So you must adjust the regula

tor refer to component performance test. • Refer to HYP-34A for Regulator removal procedure from pump casing.

RH23A,RH25B

RH26A,RH28A

• The following pictures are RH23A,RH25B type regulator.

[!]

Clean the outside of regulator. Hold cosing (01) of regulator with a vice.

Remove plug (34) with eyebolt (36) and 3 adapters of pilot piping. �

t, :

19 mm, 41 mm

RE-28A-2

DISASSEMBLY and ASSEMBLY

(D/A)

RH23A RH25B RH26A RH28A REGULATOR

I]]

Loosen 4 socket bolts (32) to remove the front cover ass'y.

6 mm

Note: Refer to RE-28A-4 for the front cover ass'y disassembly procedure.

I!]

Loosen 4 socket bolts (32) to remove the rear cover ass'y.

6 mm

Note: Refer to RE-28A-5 for the rear cover ass'y disassembly procedure.

I!)

I!]

(I)

Remove 2 springs (08) (09) from opening of casing rear side.

Remove cylinder (04) from opening of casing front side by pushing spool (03).

Remove piston (05), O-ring (06) and back up ring (07) from cylinder (04).

FRONT COVER ASS'Y

r-<l,.,..,• �•)

RE-28A-3 (D/A) RH23A RH25B RH26A RH28A REGULATOR --------

DISASSEMBLY and ASSEMBLY

I!}

Remove sleeve (02) with spool (03) from

opening of casing front side.

I!) Remove spool

!ill

(03) from sleeve (02).

Remove sleeve (26) and spring (2S) from

opening of casing rear side by pushing spool (24).

l2IJ

Remove piston (27) and 0-ring (12) from

sleeve (26).

� Remove sleeve (23) with spool (24) from opening of casing front side.

Remove spool (24) from sleeve (23).

,:' :--f:· ,,,._,,::,.

RE-28A-4

DISASSEMBLY and ASSEMBLY

RH23A RH25B RH26A RH28A REGULATOR --

DISASSEMBLY OF FRONT COVER ASS'Y

[I) Hold front cover

(30) with a vice.

Measure height (A) of stopper (16) and record it.

Turn front cover (30) upside doKn and

hold it with a vice.

Remove lock nut (22).

�

t,:

22 mm

Measure height (B) of set screw (19) and

record it.

12]

Remove lock nut (21). 32 mm

(!]

Remove stopper (16).

(D/A)

DISASSEMBLY and ASSEMBLY

RH23A RH25B RH26A RH28A REGULATOR

I!]

RE-28A-5 (D/A)

Hold the stopper with a vice.

Remove set screw (19) from stopper (16).

I!]

Remove spool (17) and 0-ring (12) from the

stopper.

fl)

Remove spool (18) from the stopper.

I!)

Remove 0-ring (20) from set screv, (19).

--DISASSEMBLY OF REAR COVER ASS'Y

[I)

Hold rear cover (31) with a vice.

Meausre height (C) of stopper (10) and

record it.

,::,,., 9

DISASSEMBLY and ASSEMBLY

llJ

(I)

RH23A RH25B RH26A RH28A REGULATOR

Remove 0-ring (12).

Turn rear cover (31) upside down and hold it with a vice. Remove lock nut (15) ,

(, :

13 mm

Meausre height (D) of stopper (10) and record it.

I!}

Remove lock nut (14) from the cover. 30 mm

I!)

Remove stopper (10) from the cover.

RE-28A-6 (D/A)

RE-28A-7

DISASSEMBLY and ASSEMBLY

(D/A) RH23A RH25B RH26A RH28A REGULATOR --------

I!]

Remove set screw (11) and O-ring (13) from stopper (10).

Note : • Wash all parts throughly using

clear solvent.

Dry the parts.

• Inspect all parts for \,·ear or damage.

11, !

' I h :::: : r-+j:;;y-=•:: : l:ffi-=• :.: : : : 0lni·

9···-· .· ··. ..·.·.·.·.· :;;2r::•:�_-:•:•_.::::_:•:•:•:

RH23A,RH25B

RH26A,RH28A

2. ASSEMBLY---------------------------• Use all new O-rings and seals when assembling regulator. • Apply clean hydraulic oil all parts.

[I}

tll

Hold casing (01) with a vice.

DISASSEMBLY and ASSEMBLY

RH23A RH258 RH26A RH28A REGULATOR

[I)

Install spool (03) into sleeve (02).

II)

Install sleeve (02) into casing rear side.

[!}

Install spool (24) into sleeve (23) and

RE-28A-8 (D/A)

install them into casing rear side.

I!)

Install p iston (27) into sleeve (26).

1--�@

·----® I!}

Install O-ring (12) on sleeve (26) and install them into casing rear side �ith s pring (25). Note: Put grease on O-ring.

RE-28A-9

DISASSEMBLY and ASSEMBLY

RH23A RH25B RH26A RH28A REGULATOR

(I)

Install rear cover ass'y with spring

Cos)

(09) in casing rear side.

Install and tighten 4 socket bolts (32)

and washers (33).

6 mm

2 kgf•m (15 ft.lbs)

Note: • Put grease on 0-ring.

• Refer to RE-28A-10 for the rear

cover ass'y assembly procedure.

[!)

Install 0-ring (06), back up ring (07) and

piston (05) in cylinder (04).

Install cylinder (04) into casing front

side.

Note: Put grease on 0-ring.

�

Install front cover ass'y in the casing.

Install and tighten 4 socket bolts (32) and

washers (33) .

r ....

6 mm

2 kgf·m (15 ft.lbs)

Note: • Put grease on 0-ring.

• Refer to RE-28A-llfor the front cover ass'y assembly procedure.

(D/A)

DISASSEMBLY and ASSEMBLY

RH23A RH25B RH26A RH28A REGULATOR

Install plug (34), eye bolts (36) and 3

adapters on the casing . .,

(,:

ant

41 mm

8 kgf.m (58 ft.lbs)

--REAR COVER ASSEMBLY PROCEDURE-----

IJ:]

Install O-ring (13) on set screw (11) and

O-ring (12) on stopper (10).

Install set screw (11) into stopper (10).

Hold cover (31) with a vice and install

stopper (10) in the cover.

Note: Measure dimension as shown.

Use stopper ( 10) , as required, to

adjust collect length to measurement dimension at disassembly. (Refer toRE-28A-5)

Turn the cover upside down and hold it

with a vice.

Install and tighten lock nut (14) securely. r

--«:

30 mm

3 kgf·m (22 ft. bls)

Note: Use caution not to change dimension

during tightening lock nut.

RE-28A-10 (D/A)

DISASSEMBLY and ASSEMBLY

RH23A RH25B RH26A RH28A REGULATOR

� Adjust set sere\, (11) l ength to obtain in the same dimension as that before disas

sembly.

Install l ock nut (15) on the set

13 mm

sere\,· and tighten it securely as shoM1. ,

(,:

-..:

1 kgf·m (7 ft.lbs).

Note : Refer to RE-28A-6.

-- FRONT COVER ASSEMBLY PROCEDURE-----

IJ]

Install 0-ring (12) on stopper (16) using

tool (ST-2281).

Install piston (18) into stopper (16).

Install 0-ring C20) on set sere\\' (19) and

install set screK into stopper (16).

Install piston (17) into stopper.

RE-28A-11 (D/A)

RE-28A-12

DISASSEMBLY and ASSEMBLY

RH23A RH25B RH26A RH28A REGULATOR

I!]

(D/A)

Hold cover (30) with a vice.

Install stopper (16) to obtain the same

dimension as that before dissasembly.

Refer to RE-28A-4.

I!]

Turn cover upside down and hold it with a

vice.

Install and tighten lock nut (21) securely.

-.. :

32 mm

4 kgf·m (29 ft. lbs)

Note : Use caution not to change dimension

llJ

during tightening lock nut.

Adjust set screw (19) length to obtain the same dimension as that before disassembly (Refer to RE-28-6).

Install lock nut (22)

on the set screw and tighten it securely as shown.

�

....

C,: :

22 mm

2 kgf•m (15 ft. lbs)

3. SPECIAL TOOL--------------------------

ST-Number

Tool name

ST-2281

Sleeve

Q'ty 1

Use To install O-ring

RE-28A-13 (D/A) RH23A RH25B RH26A RH28A REGULATOR --------

DISASSEMBLY and ASSEMBLY

4. PARTS LIST (RH23A,RH25B) ----------------------

Itern 01

Part name

Casing

Sleeve

Cylinder

08 09

Spool

Q'ty 1

'.'Jut

Stopper

Back up ring

Spring

Stopper

Set sere\\' 0-ring

0-ring

Spring

Part name

Piston

0-ring

Item

- .)

Spring

Piston

Sleeve

Nut

Rear cover

Spring washer

Spool

Nut

Piston

Part name

Set screw

Itern

Nut

Q'ty 3

0-ring

\ut

Sleeve Spool

1 1

28 30

32 34

Set screw Front cover

Q'ty 1 1

Socket bolt

Plug

0-ring

Eye bolt

1 1

RE-28A-14

DISASSEMBLY and ASSEMBLY

(D/A)

RH23A RH25B RH26A RH28A REGULATOR 4. PARTS LIST (RH26A, RH28A)

Item 01

08 09

Part name

Casing

Sleeve

Spool

Cylinder Piston

0-ring

Back up ring

Spring

Stopper

Set screw 0-ring

Q'ty l l

1 1

Item 13

l ..J. 15

Part name

0-ring

\ut

Q'tv 3 l

Item -,-

-:l

'"");

Stopper

Spool

0-ring

.)_

17 19

).)

Piston

Set screw

\ut

Sleeve Spool

Set screw

Front cover

Piston

Rear cover

.):J

34 36

.l.

31 -)

Qr ty

Sleeve

\ut

Sorina ' "'

Part na:ne

Socket bolt

Spring washer Plug

0-ring

1 8 8 1

TM-5A-1 (D/A)

DISASSEMBLY and ASSEMBLY

PUMP TRANSMISSION ------------I. DISASSEMBLY ·-------------------------- Cleane the outside of the pump device ass'y. The following pictures are pump transmission for EX200 and EX220.

[I} Loosen 4 socket bolts

( 46) and remove

element (49) from clamping hub (42).

Remove 2 clamping screws ( 43) to remove

clamping hub.

I (il

14 mm

8 mm

Remove clamping hub (42) with alminum

insert R (45) from center shaft (03)

using 2 jaws puller.

[!]

1,t

Remove plug (27) to drain oil from gear

casing.

DISASSEMBLY and ASSEMBLY

TM-5A-2 A

------------ PUMP TRANSMISSION ____________ (D_I_l...

l!l

I!]

[I)

I!)

Place the pump device ass'y on a 1wrking

bench (ST-

Remove bolt (36), nut (37) and washer (38)

to remove clamp (35) from the pipe.

Remove pipes (28), (32) and (33) from the

pump device ass'y.

Loosen lock nut to remove adapter (16)

from gear pump (12).

[!} Remove 2 bolts

(13) with each spring

washers (14) and plane washers (15) to

remove gear pump (12) from the casing.

8 mm

TM-5A-3

DISASSEMBLY and ASSEMBLY

II2J

(D/A)

PUMP TRANSMISSION Remove 4 bolts (20) \\·i th 2 seal washers (21) and spring washers (22) from the single pump casing. 24

Install a lifting too 1 ST-9061 with 2 bolts onto the suction port surface of the single pump (19). EX200.EX220 EX270,EX300

jill

!ill

G!)

,1 7

ST-9061 ST-9065

. .--)

�

Bolt si:e: m2 x 1. 7::i neck length 30 mm Remove single pump (19) from casing (01) using hoist.

To remove the other single pump, use this same procedure.

Remove retaining ring (18) from each pumps using retaining plieres.

,. ...!--

·�f'

ST-9061

TM-5A-4 (D/A)

DISASSEMBLY and ASSEMBLY

!ill

PUMP TRANSMISSION------------Remove drive gear (17) from each pumps

using 2 jaws puller.

Remove level gauge (26) and elbow (23)

from casing. �

[ill

!ill

(,: 22 mm

Turn casing (01) upside down and remove

retaining ring (11) from casing.

Remove seal cover (09) using 2 minus

screw drivers or the like.

Remove oi1 seal (08) from seal over (09)

using pusher (ST-1234)

TM-5A-5

DISASSEMBLY and ASSEMBLY

(DIA)

PUMP TRANSMISSION

j2ol

Remove 0-ring OllJ from casing (01)

. �,

Remove retaining ring (07) from center shaft (03) using retaining plieres.

...

( ��

@II

Turn casing (01) upside down and remo\-e center shaft (03) with bearing (06) using a press and tool (ST-1236).

� Remove center gear (02) from casing opening.

[ill

�) .. J

Remove bearing (06) from center shaft (03) using 2 jaws puller. Note: Use care to prevent damage to spline

part of center shaft when remo\·ing the bearing.

118'

• .�, J

TM-5A-6

DISASSEMBLY and ASSEMBLY

(D/A)

PUMP TRANSMISSION-------------

1 24 1

Remove bearing (05) from casing using

tool (ST-1235).

@�

2. INSPECTION--------------------------- Measure back lash of gear. Standard

0.48 mm

Limit of use 1.5 mm

Remedy

Exchange

TM-5A-7

DISASSEMBLY and ASSEMBLY

PUMP TRANSMISSION

(D/A)

3. ASSEMBLY---------------------------- Before attempting assembly, clean all parts with pure oil, and dry them by the compressed air. Then keep the parts clean, being free from dust.

always keep your hand clean.

[!}

Place casing (01) as shown.

Install bearing (OS) onto the casing using

disc (ST-2307).

Note: Make sure bearing is tight against

[I}

its shoulder.

Place center gear (02) in bearing (05) ,

being careful to align the center gear

hole properly with the bearing hole.

[I}

Place casing on a press.

Press fit center shaft (03) into bearing (05) aligning teeth on center gear with

spline on center shaft.

Note: Make sure center shaft is tight

against the bearing.

Use only clean tools and

TM-5A-8

DISASSEMBLY and ASSEMBLY

(D/A)

PUMP TRANSMISSION -------------

� Press fit bearing (06) with Tool lST-2308) between center shaft (03) and casing (01).

Note: Make sure bearing is tight against

its shoulder.

[) Place casing (01) on the working bench. Install 0-ring (10) on the casing and

retaining ring (07) on center shaft (03).

I!]

Install oil seal (08) into seal cover (09)

using disc (ST-2284).

Seal must be

installed even with surface.

lZ)

ST-2284

08 Install Tool (ST-2280) on the center shaft

to prevent damage on the lip of the seal cover.

Install seal cover (09) into the casing

using soft hammer.

Note: Seal must be installed even with sur

face.

Check to he sure the groove

of the retaining ring is available.

TM-5A-9

DISASSEMBLY and ASSEMBLY

(D/A)

PUMP TRANSMISSION-------------

I!)

Install retaining ring (11) into the

groove of the casing using retaining

plieres.

Note: Make sure the retaining ri�g is

positioned in ring groove after

installing.

I!)

Turn the casing upside down and place it

on the work bench (ST-5050) to hold it. Note: Apply Liquid gasket to mating

surfaces of the casing and the pumps.

� Install drive gear (17) and retaining

ring (18) to each pump center shaft (03).

ll!)

Install single pump on casing aligning

the teeth of the gear using Tool (ST-9061)

and hoist.

!2l)

Install 2 seal washers (21) and 2 spring

washers (22) under bolt (20) and tighten 4 bolts evenly.

To install the other pump, use this same

procedure.

Note: Seal \\'asher must be installed on the

inside of the casing.

/;,()

(, : 24 mm

-.f:l:ikgf•m(l08.5ft.lbs)

TM-5A-10

DISASSEMBLY and ASSEMBLY

------------

!ill

Install elbow (23) on the casing.

Note : Use sealing tape for threaded part.

II!)

Install gear pump (12) on the casing \,ith

2 bolts (13), 2 plane washers (14) and

2 spring washers (15). 8 mm

•,--•--•� : 5 kgf•m (36 ft-lbs)

Note: Position gear pump with delivery

!ill

port upward. Install adapter (16) to gear pump (12) with lock nut.

, ,-

lill

(,: 27 mm ,_.: 9.5 kgf•m (69 ft·lbs)

Install pipes (28)(29)(32)(33) and clamp (35) with bolt (36), nut (37) and washer (38) .

.... ' .... ' ....

�

,. F

13 mm

: 0.2 'v 0.3 kgf·m (2 ft-lbs)

(, : 17 mm : 3.5 kgf.m(25 ft. lbs)

(,:

(D/A)

PUMP TRANSMISSION -------------

19 mm

: 3.5 kgf.m(25 ft. lbs)

Install level gauge (26) and plug (27).

, (,: 22 mm •r--•--mt�: 7 kgf·m (51 ft-lbs)

TM-5A-11

DISASSEMBLY and ASSEMBLY

!ill

PUMP TRANSMISSION Place ass'y side ways using hoist.

Install clamping hub (42) to center shaft (03) and tighten clamping 2 scre\,s ( 43).

I "'

!ill

8 mm

11 kgf•m (80 ft-lbs)

Install element (49) on clamping hub.

Tighten 4 alminum insert R (45) with

4 bolts (46).

I "'

14 mm

_..

22 kgf-m (159 ft-lbs)

(EX200,EX220,EX270)

: 32 kgf.rn(231 ft.lbs) (EX300)

!201

While holding the ass'y hori=ontally, remove plug (25) to fill casing with specified gear oil.

Gear oil

EX200 EX220 EX270 EX300

about 1.2 1 about 1.4 1

Note:Check the oil level with the level gauge Oil level must be higher than low

level("L" mark) or between the lower end of the stick and "H" mark.

(D/A) -------------

TM-5A-12

DISASSEMBLY and ASSEMBLY

(D/A)

------------- PUMP TRANSMISSION ------------4. SPECIAL TOOLS---------------------- -----

Tool name

ST-Number

Work bench

ST-5050

Lifting tool - ditto -

ST-9061 ST-9065

Q'ty

Use

This is used for disassembl:- and assembl;· of Transmission

This lS used to lift single pump for EX200 and 220 This is used to lift single pump for EX270 and 300

ST-1234

Puller

This is used to remove Oil seal

ST-1235

Puller

This is used to remove Bearing

ST-1236

Puller

ST-2307

This is used to remove Bearing

Disc

This is used to install Bearing

Disc

This is used to install Oil seal

ST-230 8

Puller

ST-2280

Sleeve

ST-2284

This is used to install Bearing

This is used to install Seal cover

5. PARTS LIST

Item 01

Casing

Part name

Q'ty 1

Item

Part name

Q'ty 1

Level gauge

Pipe

Fitting

Pipe

Drain plug

Center gear

Spline sleeve

Pipe

Bearing

Fitting

Pipe

03 05

o-:-

10 11

Center shaft Bearing

Retaining ring

Oil seal

Seal cover 0-ring

Retaining ring

--, - '

1 1

---,

.:>..:

_),)

1 set

Gear pump ass'y

Spring washer

Adapter

Retaining ring

--,

Bolt

Plane washer Drive gear

Single pump ass'y

Seal 1,asher

--,

set

Bolt

,,, ..... .., -

Spring hasher

Reducer

'- _)

Elbow Plug

38 40

_)'

Fitting

1 set

Clamp

Bolt

'.'-:ut

Eye bolt

Sere\.;

Washer

\ame plate

Calmping hub

Calmping screw

Spring pin

Alminum insert R

4�

Alminum insert

Bolt

Element

\.-\

4 4

Dl S

SS t Mll L Y an d

TM-5A·l3

SSE M UL Y

:� A::::�::A==:::___________________

(D/AI

PUMP TRANSMISSION--------------------------

@®@ 35i--------i

p,l.

DISASSEMBLY and ASSEMBLY

------------- HY-ZFS GEAR PUMP

HYP-36-1 (D/A)

1. DISASSEMBLY-------------------------Note: Before disassembling clean the outside of the pump.

[!} Hold the flange part of the pump lightly by a vice.

ll]

Remove bolts (13).

[I)

Remove cover (06).

[!]

Remove 0-ring (09).

assembly

DISASSEMBLY and ASSEMBLY ____________ HY-ZFS GEAR PUMP

I!}

Remove flange (02).

I!)

Remove O-ring (09) •

[!}

Remove snap ring (04) •

I!)

Remove oil seal (03) •

Remove seal element (05) and back-up element (07) from the bushing of cover side.

HYP-36-2 (D/A)

DISASSEMBLY and ASSEMBLY

HYP-36-3 (D/A)

------------ HY-ZFS GEAR PUMP -------------

� Remove bushing (14) (15) of cover side. Note: Don't lose the key of bushing.

II!)

Remove seal element (OS) and back-up element (07) from the bushing of flange side.

!ill

!;If

Remove bushing (14) (15) of flange side.

Remove drive gear (11) and gear (10).

DISASSEMBLY and ASSEMBLY

HYP-36-4

------------- HY-ZFS GEAR PUMP ___________l_D_IA_l_ 2. INSPECTION

Check the disassembled parts for fouling and/or discoloration and then clean

them with light oil. Body (01)

Don't clean the rubber parts with light oil.

SUCTION SIDE

DISCHARGE SIDE

WORKI.\G LH!IT LENGTH SEMI-CIRCUMFERENCE The gear pump, in order to \\Ork efficiently, has been made so that it rotates

while the tooth crest is contacting the body somehhat.

Therefore, in the pump

operated once, a contact mark is found nearby the suction port

\ominal length

of the contact mark is about 1/3 of the inner circumference of body.

If the

contact mark is long and found over the half of the circumference, it 1s sus pected that the hushing or ge,u shaft is \\·orn heavily.

If dimension x shohn above is over 37.525 mm di::i. or the contact mark is m·er

semi-circumference, replace the body hith neh one. Bl!Slll\ G

It is a good condition if the inside

sliding face is not rough and about the

half part at the suction side is shohing 8

glossy contact face_

\ proper contact at the side is th::it con

tact at the suction side is strong some

\,·hat and that at the discharge side is found to he slight as shoh.

sucnor-:

SIDE

CO!\TACT MARK

GEAR SIDE

HYP-36-5 (D/A)

DISASSEMBLY and ASSEMBLY

------------- HY-ZFS GEAR PUMP-------------When the following conditions are found, replace the bushing with new one. 1)

2) 3)

When contact is found over the whole inside sliding face and so rough that

a nail gets caught.

When there arc found lots of contact trace in circumferential direction at

the side and the side is so rough that a nail gets caught.

hl1cn there is an evidence that any foreign substance has been caught in

the inside sliding face and side face.

When the hushing is in such conditions as mentioned above, the gear shaft and/

or side face must he rough or Korn heavily.

So, replace the gear, too.

(mm)

Limit of Use

>----

Bushing inside dia. I Overall length of bushing 18.134

18. 975

CEAR

In case Kherc the shaft or gear side face is so rough that a nail gets caught,

the tooth flank is found cracked or the tooth surface is found cracked or the

tooth surface is Korn unusually only at one side, replace the gear Kith neK one.

If the face 1s rough or discolored, the bushing and body must also be abnormal.

So, recheck the bushing and body.

Limit of Use (mm) 17. 968

SHAFT DIA.

/JS

HYP-36-6 (D/A)

DISASSEMBLY and ASSEMBLY

------------ HY-ZFS GEAR PUMP -------------

3. ASSEMBLY-----------------------------

Note: Clean all parts and apply clean hydraulic oil to all internal parts.

[I}

Install oil seal (03) into flange (02)

with special tool (ST-2290).

•''±�

�;;f:•: [l]

Install snap ring (04) into flange (02).

Install bushing (14) (15). Note: Don't mistake delivery side and suction side.

� Install drive gear (11).

DISASSEMBLY and ASSEMBLY

HYP-36-7

(D/A)

------------- HY-ZFS GEAR PUMP--------------

I!}

Install gear (10).

I!}

Install bushing (14) (15) of flange side.

(I)

Install seal element (OS) and back-up

I!)

element (07).

Install 0-ring (09).

I!} Install

flange (02).

DISASSEMBLY and ASSEMBLY

HYP-36-8 (D/A)

-------------HY-ZFS GEAR PUMP-------------

� Hold the flange part of the pump assembly lightly by a vice.

Install seal element (05) and back-up

element (07).

!ill

Install O-ring (09).

G:j

Install cover (06).

.. '

:t:1'

!ill

Install bolt (13) and washer (12). �

C,:17mm

Tighten torque: 4.5 kg·m (32.55 ft.lbs)

ST-NUMBER

TOOL NAME

Q'ty

USE

ST2290

Bushing driving guide

To install a bushing

� �,.,__,, ~, ·.'.· --,

DISASSEMBLY and ASSEMBLY

HYP-36-9 (D/A)

------------ HY-ZFS GEAR PUMP-------------

�@ �

�®

Q\@ e,

�

@)@)

Item 01 02

Housing Flange

Q'ty 1

Washer

Bushing

Knock pin

Seal element

07 08

Back-up element

Key

cover

0-ring

Q'ty

Part name

Oil seal

Snap ring

Item

03 04

,::,-J

Part name

...

11 13

Gear

Drive gear

Bolt

Bushing

1 1 4

CV-34A-1 (0/P)

OPERATIONAL PRINCIPLE

----------KVMG-270-HC CONTROL VALVE ----------1. GENERAL----------------------------The control valve regulates the pressure, direction and volume of oil flow in

the hydraulic circuit.

The KVMG-HC type control valve is a mono-block type control valve which is incorprated the right block consisting of 4 spools and the left block consisting of 5 spools as shown Fig. 2.

This valve consists of

spools, main relief valves, overload relief valves and make-up valves, pump

control relief valves, switch valves and housing.

Confluence oil passages

are provided on the contact surface between the right block and the left

block of the TRAVEL, BUCKET, BOOM and ARM sections, it can control the oil flows in both the single and combined operations as shown Fig. 1,2,3.

These valve spools are operated by pilot and connected in parallel and tandem circuits.

�

(.) 0 _J !D

I- I (!)

cc:

> _J

�

(.) 0 _J !D 1-

r I 1 I I I

_; I - _J TO TRAVEL MOTOR

RELIEF VALVE (300 kgf/cm')

Fig. 1

/.J..'J-

TO SWING MOTOR

�

HYD. TANK

f-'.J,

BUCKET

EXTRA

\___,<' � \_ __x

--;:_\_ _,/

xK �-

� i5

TRAVEL (R)

TRAVEL (L) /

0 -,:, m :I]

BOOM 1111

ARM (II)

ARM ill

�n:�Y

_,43 x� x- _j .· BOOM (1)

SWING

RIGHT BLOCK

SWITCH VALVE

-,:, :I]

("') -,:,

r m

s::

..:., .....

9 :::c

(")

n 0

-i :JJ

0 r-

r < m

MAIN RELIEF VALVE (HIGH-PRESSURE) 325 kgf/crn 2 OR 350 kgf/crn 2

PRESSURE

Applicable Serial No.

325 kgf/crn 2

EX270: 05001 ~ 05377

350 kgf/cm 2

EX270: 05378 ~ EX300: 02001 ~

("')

Fig. 2

-< O w· ---

-,:,.i:,. - )>

I',.)

OPERATIONAL PRINCIPLE

KVMG-270-HC CONTROL VALVE

TO RIGHI, TRAVEL OTOR

TO ARM (It) SECTION

,, I.

-. -·. ·-T .. u .

TO BUCKET CYLINDER

(' I I I I I

l�

:,_,,.,

�,i:, .,,o,

OVERLOAD RELIEF VA,LVE (300 kgf /cm I

W--'.

tr,.

TO BOOM CYLINDER

I I I I

... ......

.•� .

- - - - -- ·_· r - �·:;. • •· J.. . :·., ·.l·· :- .. . �..... .......

PORT: TJ;

·th .

FROM TRA VEL (RI SECTION

.........

......

...... ...... ......

......... ...

TO SWING Moron

... ... . ... /!!' .... ,,..> ... ...

, ........... ,,...

...... ...

......

...... ......

... ... ......

... ...

......

,,.._

...... POnT P2

P,Y

Fig. 3

/ ... ...

... ......

... ...

I I I I I I I I I I I I I

CV·34 A A (0/P)

P E R AT l0 N AL P R I c O::��:��=�N:�·: I �� -------------- KVMG-270-HC CONTROL VALVE -----------� P LE

NEUTRAL OIL PASSAGE

PORT, TJ;

PORT T1

,...... ',, /'

Fig. 4

',....._

______ _,

., .,

)

I I I I I I I I I I I I I

CV-34A-5 (0/P)

OPERATIONAL PRINCIPLE

---------- KVMG-270-HC CONTROL VALVE----------2. CONSTRUCTION AND FUNCTION 2-1

NEUTRAL OIL PASSAGE

Refer to Fig. 4 and 5.

When all spools are in the neutral position, the discharged oil from the pumps

are fed to the ports "Pl", "P2", and is returned to the tank through the

neutral oil passage of each section, pump control relief valve and port "T2"

or "T3".

When any control spool is operated, this neutral oil passage is

closed by it.

Therefore, the oil does not flo� to the next section.

P1 OIL PASSAGE

SWING

HYD. TANK

Fig. 5

OPERATIONAL PRINCIPLE

CV-34A-6 (0/P)

----------KVMG-270-HC CONTROL VALVE----------2-2 RETURN OIL PASSAGE

Refer to Fig. 6 and 7.

The return oil passage is communicating with each section as shown Fig. 6 and 7.

The oil returned from the main relief valve, overload relief valve and

each actuator is fed to the tank through the return oil passage and port "T2"

or "T3".

RETURN OIL PASSAGE T1

P1 , '

BOOM (I)

HYO. TANK

RETURN OIL PASSAGE Fig. 6

,,:�-,�•::\��u��'1�\�� - �:•: , ��• ------ --- --- - -------n

L f fl ll

CV-34A-7 (0/P)

1.,1t L

KVMG-270-HC CONTROL VALVE

RETURN OIL PASSAGE

PORT: Pl

PORT: TJ

f' I I I I I I I I I I I I I I

RETURN OIL PASSAGE

l..,

... .........

......

... ...

... ........ ...

......

... ... ... ...

PORT: Tl

...... ......

,.'., ;

�

11I

Fig. 7

CV-34A-8 (0/P)

OPERATIONAL PRINCIPLE

KVMG-270-HC CONTROL VALVE PARALLEL Oil PASSAGE

PARALLEL OIL PASSAGE

PORT: T1

Fig. 8

CV-34A-9 (0/P)

OPERATIONAL PRINCIPLE

----------KVMG-270-HC CONTROL VALVE----------2-3 PARALLEL 01 L PASSAGE

Refer to Fig. 8 and 9.

When any spool is operated, the oil from the main pump does not flow to the

next section of the spool from the neutral oil passage. To avoid this incon

venience, the parallel oil passages are provided.

These oil passages enable to make 2 or 3 combined oprations simultaneously.

-------'------- P ARALLEL OIL P ASSAGE

HYD.

TANK

Fig. 9

OPERATIONAL PRINCIPLE

CV-34A-10 (0/P)

-----------KVMG-270-HC CONTROL VALVE----------2-4 CONFLUENCE OIL PASSAGE -------------------------- (1) BUCKET CONTROL SECTION

When the bucket and the travel spools are operated simultaneously, the oil from

the PORT "Pl" .c;upply to the travel (R) section. flow to the bucket section.

Therefore, the oil does not

The oi 1 is fed to the bucket cylinder from the PORT

"P2" through the neutral oil passage of the EXTRA section and the check valve of the confluence oil passage.

BUCKET CYLINDER

Fig. 10

OPERATIONAL PRINCIPLE

CV-34A-11 (0/P)

-----------KVMG-270-HC CONTROL VALVE----------(2) BOOM CONTROL SECTION ■ BOOM SINGLE OPERATION (BOOM RAISE)

The oi 1 from the PORT "P:?" passes through the boom (TI) section, and the

confluence oil passage, then enters the hoom (I) section, and joins the oil from

the PORT "Pl".

Thus the confluenced oil is fed to the boom cylinders to

increase the BOml RAISE speed.

■ COMBINED BOOM AND TRAVEL OPERATION

IVhen the hoom and travel spools are operated simulaneously, the spool of

the travel (R) section is changed to the oil from the PORT "Pl" direct to only travel motor.

Therefore, the oil does not flow to the boom (I) section.

this time, only the oil from the PORT "P2" supply to the boom cylinders through

boom (II) section and confluence oil passage.

BOOM CYLINDER

CONFLUENCE OIL PASSAGE

FRONT PUMP

REAR PUMP P2

PORT: P2 Fig. 11

CV-34A-12 (0/P)

OPERATIONAL PRINCIPLE

----------- KVMG-270-HC CONTROL VALVE----------(3) ARM CONTROL SECTION ■ ARM ROLL-IN OPERATION

The oil from the PORT "Pl" through the neutral oil passage, arm

(I I)

section

and the confluence oil passage (A), then enters the arm (I) section, and joins the oil from the PORT "P2".

Thus the confluenced oil is fed to the arm cylinder

to increase the ARM ROLL-IN speed.

ARM CYLINDER

CONFLUENCE

ARM (I)

Fig. 12

CV-34A-13 (0/P)

OPERATIONAL PRINCIPLE

-----------KVMG-270-HC CONTROL VALVE----------■ ARM ROLL-OUT OPERATION

The oil from the PORT "P2" through the parallel oil passage and arm (I) section to arm cylinder.

The oil from the PORT "Pl" through the neutral oil passage,

arm (II) section and confluence oil passage (B), then enters the arm (I} section, and joins the oil from the PORT "P2".

Thus the confluenced oil is fed to the

arm cylinder to increase the AR1'I ROLL-OUT speed.

ARM CYLINDER

ARM (II) SECTION

FRONT PUMP

CONFLUENCE OIL PASSAGE (B)

Fig. 13

OPERATIONAL PRINCIPLE

CV-34A-14 (0/P)

-----------KVMG-270-HC CONTROL VALVE-----------■ COMBINED ARM, BOOM and BUCKET OPERATION

When the arm is operated and boom or bucket is operationed simultaneously, the arm operation speed is changed suddenly.

preventing from this phenomenon.

The bypass oil passage is provided for

This bypass oil passar,c flows the oil to the

arm cylinder from the front pump through the confluence oil passage (A).

At this time, the oil from the front pump dosen't flow the bucket and boom sections. So the bypass oil passage is not affected by the boom and bucket operations.

Consequently, even though the arm, boom and bucket are operated simultaneously,

the arm operation is smooth.

FROM ARM

CYLINDER

ARM (II)

CONFLUENCE

OIL PASSAGE (A)

REAR PUMP

Fig. 14

OPERATIONAL PRINCIPLE

CV-34A-15

---------------------------------KVMG-270-HC CONTROL VALVE-------------------------------(_o_;P_l_ 2-5

SWITCH VALVE

When the spool except travel is moved, the pilot oil from the pilot pump is closed by its spool.

TO LEFT

Consequently, the pilot pressure of pilot port "l'p" of the

switch valve is raised and its spool is moved.

TRAVEL SECT ION

And the oil flow from the front

pump "Pl" is changed from the right block to the left block of the' travel (I.) section, and the machine straight travelling.

-===• �:>:c: : -:.·:?.::'··.�·:··· •.-· �c:2:-:.:c: ·•.:.c:-·-�··=��

,,r-

Fig. 15

CV-34A-17 (0/P)

-----------KVMG-270-HC CONTROL VALVE----------2-6 MAIN RELIEF PRESSURE SELECT SYSTEM ---------------------

This valve for changing the circuit pressure in the main circuit.

pressure is 285 kgf/cm tion is 325 kgf/cm

(27930 kpa)

The circuit

in the all operation except travel opera

(31900 kpa) [or 350 kgf/cm 2 (34300 kpa)] in travel operation.

When the swing, boom, arm or bucket is operated, the pilot oil from the

pilot pump is returned to the tank through the left travel spool and right travel spool.

When any travel lever is operated, the pilot oil passage is

closed by the spool.

Consequently, the pilot pressure "SI" of low pressure

main relief valve is raised and the poppet is moved.

When the low pressure

passage to low-set pressure main relief valve is closed, which activates only the high-pressure set main relief valve to maintain a high pressure in

travelling.

... ...

...

MAIN RELIEF VALVE (HIGH-PRESSURE) 325 kgf/cm 2 OR 350 kgf/cm 2

PRESSURE

Applicable Serial No.

325 kgf/cm

EX270: 05001 ~ 05377

350 kgf/cm 2

I I I I

EX270: 05378 ~ EX300: 02001 ~

A I

�-PILOT UPUMP

Fig. 16

OPERATIONAL PRINCIPLE

CV·34A-19 (0/P)

--------------------------------KVMG-270-HC CONTROL VALVE-------------------------------FUNCTION

2-7 PUMP CONTROL RELIEF VALVE

(I) lvhcn spools arc nctural position

OUTLINE

When the all spools of the control valve arc in the netural position, the oil

from the pump through the netural oil passage makes this valve open, and return to the tank through the return oil passage. At this time, a signal pressure is generated by this valve, and is sent to the pump regulator to

The oi I from the net11ral oil passage opens the poppet (Al, and through th<'

orifice to the return oil passage,

fice as shown in rig. 20.

Control pressure is generated by the ori

control the delivery of the pump.

NEUTRAi. OIL PASSAGE

F;g. 20 SPOOL NEUTRAL POSITION

(2) When low-pressure relief valve is function.

PUMP CONTROL RELIEF VALVE

If too much oil has flow through the neutral oil passage, the poppet (A) opened, and oil to the return oil passage through the orifice. At the this time, the poppet (Bl set by the spring is opened, and oil flow

the return oil passage to prevent abnormal pressure as shown in rig. 21.

Fig. 21

...

Fig. 19

.......... .......... .. ',---------------------------------------------------------------------------------------J fl[GlJI ATOR

FUNCTION

OPERATIONAL PRINCIPLE

CV-34A-21 (0/P)

----------KVMG-270-HC CONTROL VALVE----------2-8 MAIN RELIEF VALVE and OVERLOAD RELIEF VALVE (SWING)

■ HIGH-PRESSURE SET MAIN RELIEF VALVE

(1) Oil flows to the chamber through the orifice of the main poppet

and the chamber is filled with oil.

The main poppet is securely

pressed against the seat of

check valve by force difference. 6P 1 = 2'._ (B2 - A 2 ) 4

Pkg

(2) When the pressure in the "HP" is

high enough to overcome the force of spring B, the pilot poppet is causing the oil escapes to the

low pressure side through around

the poppet and holes.

(3) The opening of the pilot poppet decreases the pressure in the chamber.

■ OVERLOAD RELIEF VALVE (FOR SWING)

So the main poppet is

moved to the right by force dif ference

6P 2 = ¾ (A 2

HP - B 2

LP).

CV-34A-22 (0/P)

OPERATIONAL PRINCIPLE

-----------KVMG-270-HC CONTROL VALVE----------■ LOW-PRESSURE SET MAIN RELIEF VALVE

(1) If the "Hp" pressure reaches a set spring force, the pilot poppet "F" will

open the same as the high-pressure set main relief valve.

The oil opens the poppet "D" and flows to the low-pressure passage "Lp"

through the passage "A" and "B".

If the pilot poppet "F" opens, the main poppet "C" open and the oil on

the high pressure side will flow to the low-pressure passage "Lp".

POPPET (D)

"Pp"

PASSAGE (B)

(2) The moves poppet "D" to the left side by the pilot pressure port "Pp" and the drain passage "A" and "B" is closed.

Since the pilot spring chamber is in closed condition, this low-pressure

relief valve will not operate this keeping the port "Hp" in closed condi tion.

MAIN POPPET(C)

POPPET (D)

PRESSURE "Pp"

OPERATIONAL PRINCIPLE

CV-34A-23 (0/P)

-----------KVMG-270-HC CONTROL VALVE----------2-9 OVERLOAD RELIEF and MAKE-UP VALVE

Overload relief valve in this control valve is a combination valve combining a relief valve and an make-up valve.

■ RELIEF OPERATION

(1) Oil enters through the hole of poppet valve into the chamber. The main poppet is securely

pressed against the stat of the check valve by force difference ,T

2 x Pkg �P 1 = 4 (B 2 - A)

......... Lp

(2) When the pressure in HP is high enough to overcome the force of

the pilot poppet spring, the

pilot poppet is opened causing

the oil escape to the LP side

through around the poppet and

holes.

(3) The opening of pilot poppet de creases the pressure in the chamber "C".

Then the poppet

valve moves to seat on the pilot

poppet to block the flow of oil into the chamber and decreases

the pressure in the chamber. (4) The main poppet is moved by Hp

.....

force difference �P 2 = � (A 2 4

HP - B 2

LP) kg

and the oil enters into the LP

side from the HP side.

OPERATIONAL PRINCIPLE

CV-34A-24 (0/P)

----------KVMG-270-HC CONTROL VALVE----------■ SUCTION OPERATION

(5) This valve, in operation, pre CHECK VALVE

SPRING

vents a condition - so called

cavitation - that arises in the

cylinder port where fluid is not

entirely filling out.

That is, this relief valve is

combined an make-up valve supply ing oil.

When the pressure of oil in the

port Hp is low than the pressure of oil in low pressure side Lp,

force difference fip = 21: ("0" 2 4

"C" 2 )

opens check valve against the force of the spring.

Oil enters into cylinder port

"Hp" from low pressure side "Lp", fills up a void.

CV-34-1 (D/A) ----------- KVM-270-HC CONTROL VALVE -----------DISASSEMBLY and ASSEMBLY

DISASSEMBLY CONTROL VALVE --------

12)

Clean the of outside of control valve. Then put the valve assembly on a clean work table.

DISASSEMBLY OF CAP

Loosen and remove the socket bolt (20).

I @]

8 mm

Remove the cap (03) (05) from the housing (01).

f!}

Remove the O-ring (07) from the cap.

DISASSEMBLY OF SPOOL

Remove the spool assembly (11) (12) (13) (14) (15) (16) (17) (18) (19) from the housing.

DISASSEMBLY and ASSEMBLY

CV-34-2

----------- KVM-270-HC CONTROL VALVE __________(D_I_A_l _

NOTE

r - -- -

I I 1

- - - ------ -,

PUT A TAG OR MARK TO THE SPOOLS SO THAT SPOOL CAN BE INSTALLED TO THE I ORIGINAL BORE IN THE HOUSING

'-- - - - - - - - -- - -

I!)

I!}

. I

Hold the spool assembly in a vice.

'I"'''

Loosen and remove the spool end (09) from

the spool.

Remove the spring seat (08) and spring (10) from the spool end.

-= · · � · = n � .,. o I @! · @)1 · @)/ •r��;; t�

�·."

DISASSEMBLY and ASSEMBLY

CV-34-3

----------- KVM-270-HC CONTROL VALVE __________(_o_lA_)_ DISASSEMBLY OF CHECK VALVE

[ill

Loosen and remove the plug (23) from the

housing.

!ill

19 mm

Remove the spring (7 4) and poppet (25).

� Loosen and remove the plug (42). �

,,/J

(, 36 mm

Remove the 0-ring (24) from the plug.

DISASSEMBLY and ASSEMBLY

CV-34-4 (D/A)

----------- KVM-270-HC CONTROL VALVE------------

jill

Remove the spring (44) and poppet (43).

� Remove the sleeve (49).

[ill

Remove the spring (46) and poppet (45).

� Loosen and remove check valve assembly (78). �

(, 36 mm

[ill Remove the 0-ring

(24) from the check valve.

CV-34-5 (D/A) ----------- KVM-270-HC CONTROL VALVE----------DISASSEMBLY and ASSEMBLY

1201 Hold the check valve assembly in a vice.

Then the loosen and remove the plug (A). �

@II

(, 22 mm

Remove the spring (B) and poppet (C).

<EXTRA SECTION> 1221 Loosen and remove plug (38).

(, 36 mm

l2sl Remove the 0-ring (24) from the plug.

1261 Remove the spring (40) and poppet (39).

r<fl

CV-34-6

DISASSEMBLY and ASSEMBLY

(0/A) ----------- KVM-270-HC CONTROL VALVE------------

[ill

<BUCKET, BOOM and SWING SECTIO�>

Loosen and remove the plug (23).

19 mm

l2al Remove the 0-ring (24) from the plug.

� Remove the spring (26) and poppet (25).

l3ol Loosen and remove the plug (42). �

@I)

(, 36 mm

Remove the O-ring (24) and spring (44).

••

DISASSEMBLY and ASSEMBLY

- -

CV-34-7 (D/A) ----------- KVM-270-HC CONTROL VALVE ------------

� Remove the poppet ( 43).

1331 Remove the s 1 eeve ( 4 7) .

1341 Remove the spring (70) and poppet (69)

from the sleeve.

1351 Loosen and remove the plug (71). 36 mm

1361 Remove the spring (77) and poppet (76).

! ¢}

CV-34-8

DISASSEMBLY and ASSEMBLY

----------- KVM-270-HC CONTROL VALVE __________!_D_IA_l _ DISASSEMBLY OF PUMP CONTROL VALVE

Remove the relief valve assembly (32) from

the housing. �

(, 36 mm

j3al

Remove the sleeve (03).

1391

Remove the plug (05) from the plug (01). �

j4ol

(, 32 mm

Remove the spring (06).

[ill

Remove the poppet (02) from the plug (01).

DISASSEMBLY and ASSEMBLY

CV-34-9 (D/A) ----------- KVM-270-HC CONTROL VALVE------------

1421

DISASSEMBLY OF SWITCH VALVE.

Loosen and remove the switch valve assem

bly (30) from the housing. SO mm

-�

1431

Remove the sleeve assembly (02), spool (03)

and spring (04) from the plug (01).

Then remove the poppet (OS), spring (06),

0-rings (10) (12), back-up rings (11) (13)

from the sleeve (02).

DISASSEMBLY OF MAIN RELIEF VALVE (HIGH-SET PRESSURE)

Loosen and remove the main relief valve

assembly (27). �

1451

32 mm

Remove the sleeve (03) from the pilot seat (OS).

Then remove the 0-ring (13) and back-up

ring (14) from pilot seat (OS).

1461

;,µ/.

Remove the spring (11) and main poppet (04)

from the sleeve (03).

DISASSEMBLY and ASSEMBLY

CV-34-10 (0/A)

----------- KVM-270-HC CONTROL VALVE------------

[!il

Loosen and remove the nut (17B). �

148

Remove the adjusting screw (17A) from the

plug (02).

t, 17 mm

6mm

49 Remove the spring (12) and pilot poppet

50 1

(06).

DISASSEMBLY OF MAIN RELIEF VALVE (LOW-SET PRESSURE)

Remove the sleeve (06) from pilot

seat (02).

Then remove the O-ring (04) and

back-up ring (OS).

@II Remove the spring

(08) and main

poppet (07) from the sleeve (06).

DISASS'=MBLY and ASSEMBLY -----------

CV-34-11 J KVM-270-HC CONTROL VALVE ____________ (D .;../A...;,:_.

� Loosen and remove plug (18).

1531 Loosen the nut (16).

I 541 kemove the adjuster (12) from plug (01).

1nen remove poppet (17), 0-ring (13) (15) and back-up ring (14) from adjuster (12).

� temove the spring (10) and

pilot poppet (09) from plug (01).

DISASSEMBLY OF OVERLOAD RELIEF VALVE

I 561 Hold the plug (02) in a vice. Then loosen the cap (01). 32 mm

DISASSEMBLY and ASSEMBLY

CV-34-12

----------- KVM-270-HC CONTROL VALVE __________ (D_IA_)_

� Remove the cap (01) from the plug (02).

1581 Remove the sleeve (03) from the plug (02).

@!I

Remove the spring (08), 0-rings (12) (14)

and back-puring (13) from the plug (02).

1so1

Remove the spring (07).

@I)

Remove the poppet (04) and piston (05) from the sleeve (03).

DISASSEMBLY and ASSEMBLY

CV-34-13 (D/A)

----------- KVM-270-HC CONTROL VALVE-----------

ls2I Remove the O-ring (16) and back-up ring (17) from the poppet (04).

1631 Loosen and remove nut (10B).

1641 Remove the screw (l0A) from the plug (02).

6 mm

lssl Remove the spring

(09) and poppet (06)

from the plug (02).

DISASSEMBLY and ASSEMBLY

CV-34-14

(D•Ai -----------KVM-270-HC CONTROL VALVE-----------DISASSEMBLY OF VALVE HOUSING

Loosen and remove the socket bolts (21).

r [ill

14 mm

Remove the housing (01) from the housing (02)

Then remove the 0-rings (36) (58) (63) (66) (73).

1681

Remove the spring (57) and poppet (56)

1691

Remove the spring (60) and poppet (59)

from the section 0-0.

. from the section E-E.

1101 Remove

the seat (72) from the section F-F.

DISASSEMBLY and ASSEMBLY

CV-34-15 (D/A)

-----------KVM-270-HC CONTROL VALVE-----------

fl!) Remove the spring (60)

and poppet (59).

[illLoosen and remove the cap (04) (06) from the housing.

1'1·7

8 mm

CV-34-16 (D/A)

DISASSEMBLY and ASSEMBLY

----------- KVM-270-HC CONTROL VALVE ------------

IJ:l

INSPECT CO NTROL VALVE

Clean all removed parts with solvent and

dry them with compressed air.

Check spools surface for abnormal wear or

its sliding.

Minor defects may be repair

ed by lapping or grinding with an oil

SPOOL

stone.

The spools are not available separately as

service parts for field replacement because

of selective fitting in the housing bore.

(I)

Check the contact point of the poppets (25) (39) (43) (45) (69) (76).

y "ll

CHECK VALVE

ll}

I!}

Check the contact point of poppet (02) and sleeve (03).

Check the sliding surface of spool (03).

Itu

l l

PUMP CONTROL RELIEF VALVE

SWITCH VALVE

. ·-

----

,...11,;•,,11• -

I!}

Check the contact point of main poppet

(04), pilot poppet (06), piston (05) and seat.

RELIEF VALVE

DISASSEMBLY and ASSEMBLY

CV-34-17 (D/A)

-----------KVM-270-HC CONTROL VALVE-----------ASSEMBLY CONTROL VALVE ------ <NOTE>

Clean all the internal parts before assem

ble them.

III

,t/-t

ASSEMBLY OF VALVE HOUSING --------

Install the spring (60) into section F-F.

[1}

Install the poppet (59).

llJ

Install the seat (72) to the poppet (59).

[!]

Install poppet (59) and spring (60) into

the section E-E.

DISASSEMBLY and ASSEMBLY

CV-34-18

(D/A) ----------- KVM-270-HC CONTROL VALVE ------------

I!)

Install the poppet (56) into the section

D-D.

I!}

Install the spring (57).

IZJ

Install the 0-rings (36) (58) (63) (66)

(!)

Install housing (01) to the housing (02).

(73) into the housing.

Then tighten the socket bolts (22). Tightening torque: 17 to 18 kgf.m

I 14 mm ' ....

I!}

(123 to 130 ft.lbs)

Install the cap (04) (06) to the housing.

Then tighten the socket bolts (20). Tightening torque: 4 to 4.5 kgf.m

(29 to 32 ft.lbs)

DISASSEMBLY and ASSEMBLY

CV-34-19

-----------KVM-270-HC CONTROL VALVE _________(_DI_A_l_

!ill

ASSEMBLY OF OVERLOAD RELIEF VALVE

Instal 1 the piston (OS) into the poppet (04).

spring (07) into the sleeve (03).

[ill

Install the 0-ring (12) (14), back-up ring

!ill

Install the sleeve assembly to the plug.

Install plug assembly into the cap (01).

Install the poppet (04), piston (05) and

(13) and spring (08) to the plug (02).

(02).

®--=i�· '

llf-7

• .

' .

-�,�, ,..

' ,<>:;%,..

CV-34-20

DISASSEMBLY and ASSEMBLY

(D/A) ----------- KVM-270-HC CONTROL VALVE ------------

G!J

Hold the plug (02) in a vice. Then the tighten cap (01).

Tightening torque: 8 to 9 kgf.m

llO

[ill

IJII

!ill

(58 to 65 ft.lbs)

32 mm

Install poppet (06) and spring (09) into

the plug (02).

Install the adjusting screw (17) into the

plug (02).

Install the overload relief valves (79)

to the swing section and overload relief

and make-up valves (28) to the bucket, boom

and arm sections.

!ill

Tighten the overload relief valve. Tightening torque: 8 to 9 kgf.m

llO

....

32 mm

(58 to 65 ft.lbs)

HSASSEMBLY and ASSEMBLY -----------

1201

ll!J

1221

ASSEMBLY OF MAIN RELIEF VALVE (HIGH-SET PRESSURE)

Install main poppet (04) and spring (11) into the sleeve (03).

Install pilot poppet (06) and spring (12)

into the plug (02).

Install the adjusting screw (17) into the

plug (02).

1231

6mm

Tighten the nut to screw. �

1241

KVM-270-HC CONTROL VALVE

17mm

Install the 0-ring (13) and back-up ring (14) into the pilot seat (05. )

CV-34-21 (D/A) ------------

DISASSEMBLY and ASSEMBLY

CV-34-22 (D/A) ----------- KVM-270-HC CONTROL VALVE ------------

� Install the sleeve assembly to the plug assembly.

j2sl Install the main relief valve assembly (27) (High-set pressure).

� Tighten the main relief valve assembly (27).

Tightening torque: 8 to 9 kgf.m

...

32 mm

(58 to 65 ft.lbs)

ASSEMBLY OF MAIN RELIEF VALVE (LOW-SET PRESSURE)

Install pilot poppet (09) and spring (10)

into the plug (01).

� Install poppet (17), 0-ring (13) (15) and back-up ring (14) into the

adjuster (12).

CV-34-23 (D/A) ----------- KVM-270-HC CONTROL VALVE ----------DISASSEMBLY and ASSEMBLY

1301

@II

Install adjuster (12) into the

plug (01).

Tighten the nut (16).

Tightening torque: 8 to 9 kgf.m (58 to 65 ft.lbs) -,

(, 32 mm

1321 Tighten the plug (18).

Tightening torque: S to 6 kgf.m (36 to 43.S ft.lbs) BO

.... n

1331 Install O-ring (04) and back-up

ring (OS) into the pilot seat (02).

1341 Install main poppet (07) and

spring (08) into the sleeve (06).

DISASSEMBLY and ASSEMBLY

CV-34-24 (D/A)

-----------KVM-270-HC CONTROL VALVE----------1351 Install sleeve (06) into the

pilot seat (02).

1361 Install main relief valve assembly (37)

(Low-set pressure).

� Tighten the main relief valve assembly (37). Tightening torque: 8 to 9 kgf.m (58 to 65 ft.lbs) mm

DISASSEMBLY and ASSEMBLY

CV-34-25

(D/A) -----------KVM-270-HC CONTROL VALVE----------ASSEMBLY OF SWITCH VALVE

1381

Install the poppet (OS), 0-rings (10) (12)

and back-up rings (11) (13) to the sleeve (02).

1391

Inst.all the spring (06) to the sleeve (OS).

Then isntall the sleeve assembly into the

housing.

• 1 4ol

Install the spool (03) and spring (04).

Install the 0-ring (08) and back-up ring (09) into the plug (01).

21 Tighten the plug (01). 14

Tightening torque: 10 to 12 kgf.m

IIO

__.

(72 to 87 ft.lbs)

CV-34-26 (D/A)

DISASSEMBLY and ASSEMBLY

-----------KVM-270-HC CONTROL VALVE-----------ASSEMBLY OF PUMP CONTROL VALVE

Install the poppet (02) and spring (06)

into the plug (01).

1441

Tighten the plug (05) into the plug (01).

1451

Install the sleeve (03) into the plug (01).

1461

Install the pump control relief valve as

sembly (32) to the housing.

1471

Tighten the relef valve. Tightening torque: 8 to 9 kgf.m

...

32 mm

(58 to 65 ft. lbs)

CV-34-27 (D/A) -----------KVM-270-HC CONTROL VALVE----------DISASSEMBLY and ASSEMBLY

ASSEMBLY OF CHECK VALVE <ARM (II) SECTION>

1481 Install poppet (76) and spring (77) into

the section F-F..

1491

Intall the plug (71).

lsol Tighten the plug (71). Tightening torque: 13 to 14 kgf.rn

36 mm

(94 to 101 ft.lbs}

<BUCKT, BOOM and SWING SECTION>

@:!) Install the poppet

(25) and spring (26).

ls2I Install the O-ring (24} to the plug (23).

CV-34-28

DISASSEMBLY and ASSEMBLY

----------- KVM-270-HC CONTROL VALVE _________,_o_JA_l_

1531

Tighten the plug (23). Tightening torque: 13 to 14 kgf.m

(94 to 101 ft.lbs)

---

19 mm

Seriai no.5378~: 16 to 17 kgf•m

(116 to 123 ft•lbs)

1541

Install the poppet (C) and spring (B).

1551

Tighten the plug (A).

j561

Tighten the check valve (78) to section

C-C.

Tightening torque: 13 to 14 kgf.m llO r EDI 36 mm

@!I

( 94 to 101 ft. lbs)

Intall the poppet (69) and spring (70)

into the section F-F.

r-•-

DISASSEMBLY and ASSEMBLY -----------

KVM-270-HC CONTROL VALVE

� Install the sleeve (47).

1551

16ol

@II

Install the poppet (43) and spring (44)

into the sleeve (47).

Install the 0-ring (24) to plug (42).

Tighten the plug (42). Tightening torque: 13 to 14 kgf.m IIO F

1621

11'l

_..

36 mm

(94 to 101 ft.lbs}

Install the poppet (39) and spring (40)

into the section D-D.

CV-34-29 (D/A) -----------

DISASSEMBLY and ASSEMBLY

CV-34-30 (D/A)

-----------KVM-270-HC CONTROL VALVE--.----------

1631

Install 0-ring (24) to plug (38).

1641

Tighten the plug (38). Tightening torque: 13 to 14 kgf.m

,. 1651

....

36 mm

(94 to 101 ft.lbs)

Install the poppet (45) and spring (46) to sleeve (49).

Then install the sleeve (49) into the

section C-C._

1661

Install the poppet (43) and spring (44).

1671

Install the plug (42).

l'I

DISASSEMBLY and ASSEMBLY

CV-34-31 (D/A)

----------- KVM-270-HC CONTROL VALVE ------------

j6al Tighten the plug (42).

•

Tightening torque: 13 to 14 kgf.m

....

36 mm

(94 to 101 ft.lbs)

<SWITCH VALVE SECTION> Install poppet (25) and spring (74) into 1691 the plug (23).

j1ol

ll!)

[ill

Install the 0-ring (24) to plug (23).

Install the check valve assembly into the

housing.

Tighten the plug (23). Tightening torque: 13 to 14 kgf.m

I ;tr-

19 mm

(94 to 101 ft.lbs)

CV-34-32

DISASSEMBLY and ASSEMBLY

----------- KVM-270-HC CONTROL VALVE ________....,;, _I_A_ASSEMBLY OF SPOOL

1131

Hold the spool in a vice.

1141

Install the spring seat (08) and spring

!ill

Apply a coat of LOCK TIGHTE to thread of

!ill

(10) to spool end (09).

the spool end.

Then install to the spool.

Tighten the spool end (09) to spool. Tightening torque: 1 to 1.2 kgf.m

(7 to 9 ft. 1 bs)

22 mm

!ill

Install the spool assembly into the bore of

housing.

NOTE

,-------------

---,

I INSTALL EACH SPOOL BY REFERING THE I LOCATION MARK WHICH HAS BEEN PROVIDED ON IT AT THE TIME OF DISASSEM I BLING. '- --- - - -

DISASSEMBLY and ASSEMBLY -----------

!1al

KVM-270-HC CONTROL VALVE

ASSEMBLY OF CAP

Install the 0-rings (07) to cap (03) (05).

1191 Install the cap (03), (05) to valve hous ing.

laol

Tighten the socket bolts (20). Tightening torque: 4 to 4.5 kgf.m

(29 to 33 ft.lbs)

.. ....

8 mm

CV-34-33 (D/A) -----------

CV-34-34

DISASSEMBLY and ASSEMBLY

-----------KVM-270-HC CONTROL VALVE __________(_DI_A_l_

Item 01

05 06

10 11

12 13

15 16

Housing

Part name

Housing

Cap Cap

Cap

Q-ring

Spring seat

Spool end

Spring

1 18

18 9

Spring

2 2 2

Poppet

Sleeve

Plate

Sleeve Bolt

1 1

Spring washer

Spool

O-ring

Spool

Poppet

O-ring

Spring

Spool

1 1

Spool

Socket bolt

55 57

Plug

:fame plate

Poppet

Main relief valve (high)

Switch valve

Pump control valve

0-ring

Spring

O-ring

Poppet

Washer

Spring

Plug

Back-up ring

Socket bolt

Plug

Poppet

Q'ty 1

Part name

Spool

Plug Plug

Spool

Item

Q'ty 1

O-ring O-ring

1 4

Drive screw

Spring

Seat

Plug

Overload relief valve

Pl ug

O-ring

Plug

Spring

Main relief valve ( Low)

Overload relief valve (swing)

Poppet

32 33

Plug

O-ring

2 4

Plug

Spring

Poppet

78 80

Check valve Plug

Plug

1 1

DI SASS EM BLY .ind ASS!cMBLY

CV-34-3o (D/A)

KVM-270-HC CONTROL VA LVE ------

VIEW

x-x

CV-34-37 (D/A)

DISASSEMBLY and ASSEMBLY

KVM-270-HC CONTROL VALVE--

SEC1l� 8-8

�

------------------------;;:

@ 31

® SECTl(X\! J-J

SEcnrn N-N

SE0110'/ M-M

CV-34-39

DISASSEMBLY and ASSEMBLY

!D -----------------------------KVM-270-HC CONTROL VALVE ___________________________.!.!;:.:,;/A:_:I_

SEC 1/{JII 0-0

SECl!CJ-1 , ,

SEC!IQ'II G-G

sccrrn c-c

SEC!ICJ-1 E-E

OISASSEMBL Y and ASSEMBLY

CV-34Al

KVM-270-HC CONTROL VALVE _____________________________..,:l�D::_: /A�):..._

Part name

l tcm

MAIN RELIEF VALVE (HIGHI

03 0/4 OS

0(1

Main poppet

Scat

Pi lot poppet

Spring

0-ring

MAIN RELIEF VALVE (LOW PRESSURE)

S lcevc

11 12

MAIN RELIEF VALVE (HIGH PRESSURE)

!'lug

Spring

l I

0-ring

l l

Plug

0-ring

Back-up ring

OVERLOAD RELIEF VALVE

08 09

Sleeve

Main poppet Spring

Pilot poppet Pilot spring

0-ring

Adjuster 0-ring

Back-up ring

1 1

Poppet

Plug

0-ring

1 l

PUMP CONTROL VALVE Ill

02 03

P lu_g

Poppet

Sleeve

l I

I I I

Plug

Sleeve

Spring

Spool

Poppet

Spring

0-ring

l l l

0-ring

Back-up ring

Cap

07 09

10 11

0-ring 0-ring

OVERLOAD RELIEF VALVE

Q' ty

0-ring

!'art name

SWITCH VALVE

Nut

0-ring

SWITCH VALVE

0-ring

PUMP CONTROL VALVE

Pilot seat

MAIN RELIEF VALVE (LOW)

Plug Spring

Nut

OS 06

Adj usting screw

17B

Item

0-ring

Back-up ring

17A

Q' ty

Plug

Main poppet Piston

Spring

08 09

Sleeve

Pilot poppet

Spring

lOA

Adjusting screw

0-ring

Back-up ring

108 12

Nut

0-ring

l I

1 I

l I

0-ring

HYM-50-1 (0/P)

OPERATION PRINCIPLE

SWING MOTOR-------------

1. OUTLINE (MX200 CAB)--------------------This swashplate type axial piston motor comprises fixed type swashplate,

cylinder block, pistons with shoes, valve plate, parking brake and casing.

The shoe is calked to the each piston and nine pieces of these assemblies are

inserted into the cylinder.

The shoes of nine pistons are so installed on the swashplate that they can

move along the inclined slide way of the swashplate.

They are reciprocated

in the cylinder by the actuating oil flow and slided on the swashplate to rotate the cylinder.

As the cylinder is installed and fixed on the output shaft by spline, its

rotation is transmitted to the output shaft.

The coupling is installed on the output shaft by spline, and cylinder block

and the friction plate is installed on the coupling also by spline.

VALVE COVER

VALVE PLATE

PARKING RELEASE VALVE

FRICTION PLATE

OUTPUT SHAFT

BRAKE PISTON

OPERATION PRINCIPLE

HYM-50-2 (0/P)

SWING MOTOR--------------

The valve plate is installed to the right end of output shaft with dowel pin,

further, the valve plate is pushed on it by the spring for preventing oil leakage.

CYLINDER BLOCK

SPRING

OUTPUT �---'---l-------------

VALVE COVER

PISTON

SHAFT

.. VALVE PLATE

If the pressure is increased due to increased

output torque, bearing force generated at the contact areas of piston and shoe, shoe and

swashplate are also increased.

The pressure oil in the piston is led to

their contact areas to be balanced with the bearing force, thus preventing them from

metal contact to decrease their frictions.

SHOE SHOE PLATE SWASHPLATE

PISTON

OPERATION PRINCIPLE

HYM-50-3

SWING MOTOR ___________io_;_Pl__ 2. FUNCTION 2.1 MOTOR

CLOCKWISE ROTATION

Pressure oil corning from the pump, after getting into port A of the valve plate

via, the control valve, flows into the right-side cylinders through a semicircular groove of the valve plate.

Then, pistons are pushed to slide on the swashplate,

and cylinder assembly and output shaft turn clockwise.

The left-side pistons are moved back to the inside as the cylinder assembly turns,

and oil in the cylinder is discharged through port B.

I I I I

Port B \

Port A

crn1NTER-CLOCKWISE ROTATION

Pressure oil corning from the pump, after getting into port-B of the valve plate

via the control valve, flows into the left-side cylinders through a semicircular groove of the valve plate.

Then, pistons are pushed to slide en the swashplate,

and the cylinder assembly and output shaft turn counter-clockwise.

The right-side pistons are moved back to the inside as the cylinder assembly turns, and oil in the cylinder is discharged through port (A).

ff;l

OPERATION PRINCIPLE

HYM-50-4 (0/P)

SWING MOTOR-------------2.2 CROSSCOVER RELIEF VALVE

The swing crossover relief valve is a direct acting relief valve.

The first

occurs when pressure at port AV suddenly becomes high as when starting to

swing.

The second occurs when pressure at AV suddenly switches from high

to low and BV pressure switches from low to high as when quick moving the

lever to neutral or to opposite direction. CHAMBER D

PISTON B

CHAMBER C

PISTON A

CHAMBER B

PLUNGER

0 SWING CONTROL LEVER IS NEUTRAL

With the swing control lever in neutral and no external loads on the swing,

pressure at AV and BV are both low.

low.

The plunger is closed.

Pressure in chambers B, C and D is also

HYM-50-5 (0/P)-

OPERATION PRINCIPLE

SWING MOTOR-----------SWING START MOTION CHAMBER D

ORIFICE H

CHAMBER C

PISTON A

CHAMBER B

PLUNGER

0 When the swing lever is quickly moved to full stroke, pressure AV increases. This pressure is also applied to chamber B through the orifice F and the piston A and B are moved to the left.

The effective area in chamber B holding

the plunger closed is smaller than the effective area of AV pushing the plunger open and orifice H is closed.

When AV pressure reaches the setting

of the relief valve, the plunger moves to the left and pressure oi 1 is crossed over to the return side of the motor (BV).

While the superstructure

rolating, pressure at AV wil 1 drop and the plunger will close.

OPERATION PRINCIPLE

HYM-50-6 (0/P)

SWING MOTOR-------------SWING STOP MOTION CHAMBER C

CHAMBER B

CHAMBER D

ORIFICE F

While the machine is swinging the crossover relief valve B has high pressure at AV and low· pressure at BV _

pressure is low.

Chamber C and D pressure are high, chamber B

0 CHAMBER C

ORIFICE F

CHAMBER B

PISTON A

PISTON B

CHAMBER D

When the control lever is returned to neutral or to the opposite direction,

AV pressure suddenly drops and BV increases due to the inertia of the machine. The plunger opens with low AV because chamber B pressure is low.

The piston

A and B slowly move to the right as B\' pressure oil flows through the orifice F until the piston A and B movement are stopped by the bushing.

Chamber B

pressure now increases to equal BV pressure and the plunger starts to close until pressure equals the setting of the relief valve.

smooth swing starting, stopping, and direction changes.

This operation gives

OPERATION PRINCIPLE

HYM-50-7

(0/P) SWING MOTOR------------2.3 MAKE-UP VALVE

In case of the control valve is set to its neutral position to out off the

circuit while the motor is rotating, the motor cannot stop abruptly and is still rotating.

of the motor.

In such a case, high pressure works at the side of port "B"

Then, the high pressure may be released by means of a relief valve fitted

inside the motor or an overload relief valve inside the control valve.

On the contrary the pressure at the side of port "A" drops to be negative pressure condition since the oil becomes short.

As the make-up valve is provided with oil passage hole to connect the port

"A" and chamber A, the make-up valve A is moved toward the left against

spring A.

The oil 1n the return circuit is drawn into the motor circuit

from the part "D" via port "C", preventing a cavitation from occuring in

the circuit.

The make-up valve B works in the same function of the above.

MAKE-UP VALVE A

PLUG

MAKE-UP VALVE B

FROM RETURN

CIRCUIT I

){

SPRING A PORT "D"

PORT PORT "E"

FROM

RETURN CIRCUIT

CONTROL VALVE

HYM-50-8 (0/P)

OPERATION PRINCIPLE

SWING MOTOR------------2.4 PARKING BRAKE

Fig. shows the construction of spring-set, hydraulically-released type disc brake. In the lever neutral condition, piston is kept pressed in upside direction by cone disc spring to press friction plate and coupling, thus

obtaining braking force.

In the lever operation, the pilot oil pressure is

applied to B-port through the parking release valve to move the piston to

the down ward against the force of the cone disc spring, thus releasing the

brake force.

PARKING RELEASE

VALVE

COUPLING

SPRING

PARKING RELEASE VALVE

OPERATION PRINCIPLE

HYM-50-9 (0/P)

SWING MOTOR-------------When the control lever is returned from operating to nutral position, the spool returns right in the parking re lease valve.

Then, the brake piston is

moved upper by spring force and the return oi 1 from the chamber B flows back to 0-port through the orifice.

At this time, the orifice works to make a time

lag for 4 second.

PARKING RELEASE VALVE

ORIFICE

SPRING

,�t

PISTON

DISASSEMBLY and ASSEMBLY

HYM-50-1 (D/A)

------------- MX200 CAB MOTOR ------------1. DISASSEMBLY-------------------------- Note: Before disassembling, throughly

clean the outside of the motor.

IJ:l

Lift the motor assembly and drain

hydraulic oil by removing plug (36).

27 mm

Set the motor assembly on the work-bench (ST-5058) then, put matching mark on the

casing (01), brake valve body (02) and

cover (10).

II)

Loosen socket bolts (44 and 45)

17 mm

[!] Remove brake valve assembly from the casing.

DISASSEMBLY and ASSEMBLY

HYM-50-2 (D/A)

-------------- MX200 CAB MOTOR --------------

I!)

I!]

Remove valve plate (05) from the motor

assembly.

Remove cylinder block (04) from the

casing.

[I) Remove piston assembly. piston (06), shoe (07), retainer plate (09), holder (08), spring (15) and

shim (16).

HYM-50-3 (D/A)

DISASSEMBLY and ASSEMBLY

------------- MX200 CAB MOTOR --------------

[!J

Turn the motor casing upside dm-.n. Remove socket bolts (30).

r I!}

!ill

10 mm

Remove cover (10) from the casing (01).

Remove spring (25) \,ashers (2<+) and o-rrng (31).

[II) Remove plug

(19).

6 mm

[ill Remove brake piston

(12) from the casing

hy using a bolt (10 mm).

DISASSEMBLY and ASSEMBLY

!ill

HYM-50-4 (D/A) MX200 CAB MOTOR -------------

Put matching mark on the piston and

casing (01).

G!J

Remove retaining ring (28).

!ill

Remove coupling (13).

!ill

Remove friction plate (14).

!ill

Remove spacer (18) .

HYM-50-5 (D/A)

DISASSEMBLY and ASSEMBLY

MX200 CAB MOTOR -------------

� Remove retaining rrng (32).

!ill

Turn the motor casing as shown.

Remove shaft (03) by using a plastic

hammer.

1201 Remove thrust plate (35).

•t

@2J Remove retaining ring ( 17)

I.e.•\.. (28) and spacer

HYM-50-6 (D/A)

DISASSEMBLY and ASSEMBLY

MX200 CAB MOTOR

� Remove bearing (33) from the shaft by using a press.

1231 Remove oil seal (27) from the cover (10)

by using a special tool (ST-1249).

1241 Remove parking release valve (34) from

the casing.

10 mm

I 251 Remove a-ring (38) and put brake valve assembly on t he work bench (ST-5059).

1261 Remove overload relief valve (SO) from

the brake valve. 27 mm

® A; ,

DISASSEMBLY and ASSEMBLY

!ill

MX200 CAB MOTOR

HYM-50-7 (D/A)

Remove plug (46) of the make up vahe.

14 mm

!2sl Remove spring (48) and pis ton ( 49) .

� Remove needle bearing ( 41) from the brake valve body (02) by using a puller.

1301 Disassembly overload relief valve (50).

Remove seat (05) and cartridge (02) from the body (01).

DISASSEMBLY and ASSEMBLY

MX200 CAB MOTOR

@II Remove piston

(03) and poppet (04).

1321 Remove springs (06 and 07).

1331 Remove piston (08), spring (12) and spring seats (09) from the body.

1341 Remove seat (11) with steel ball from the piston (08).

1351Put overload relief valve in a vice and to measure the mensions between the adjusting screw (13) and relief valve body (01)

HYM-50-8 (D/A)

HYM-50-9 (D/A)

DISASSEMBLY and ASSEMBLY

MX200 CAB MOTOR

1361 Remove lock-nut ( 14) and adjusting screi- ( 13) .

1371 Disassembly parking release valve (34).

Remove o-rings (38) and springs (03 and 37).

I I

�@

l3al Remove spool (32) from the casing (31).

13 1 Remove plunger (34) from the block. 9

0 l4ol Remove bushing (35) and filter (36) from the plunger.

HYM-50-10 (D/A)

DISASSEMBLY and ASSEMBLY

MX200 CAB MOTOR 2. INSPECTION �leasure between cylinder bore and piston

CI]

diameter.

Standard clearance Max. 0.032 mm

Limit of use 0.062 mm

ll] Move the piston up and down to measure

the clearance between the piston and shoe.

Standard clearance 0

f1J

Limit of use 0.3 mm

Measure the shoe diameter Standard 6.0 mm

I!} Measure the

Limit of use 5.8 mm

friction plate diamter.

Standard 3.78 mm

Limit of use 3.38 mm

DISASSEMBLY and ASSEMBLY ------------- MX200 CAB MOTOR

� '.',!easure the dimention (I) betKeen Yalve plate and casing.

Measure the dimention (L) the brake valve

body.

Frexure

L - .Q,

Standard

Limit of use

2.6 nun

2.1 mm

Less than 2.1 mm - add the shim (16) � Measure between the retainer plate (09) and the holder (08).

height Standard

H - h

Limit of use

23 mm

22.5 mm

Less than 22.5 mm

/?,

replace thrust plate and holder.

HYM-50-11 (D/A)

DISASSEMBLY and ASSEMBLY

HYM-50-12

(D/A)

------------- MX200 CAB MOTOR

3. ASSEMBLY----------------------------

Note: Before assembling, clean all parts and dry with compresed air. Apply clean hydraulic oil to all internal parts.

[I)

Install retaining ring (28) and spacer (17) to the shaft (03).

Install new bearing inner race (33) by using a press.

[I) Insert shaft with th e new bearing outer

race (33) to the casing by using a hammer and bar.

HYM-50-13 (D/A)

DISASSEMBLY and ASSEMBLY ------------- MX200 CAB MOTOR

[!]

Install retaining ring (32) to the

casing.

� Install spacer (18) and coupling (13).

I!] Install friction plate casing.

(14) to the

[:) Install retaining ring (28).

I!] Install a-rings

(21 and 22) to the brake

piston (12) and apply a grease to the a-rings.

t?l

HYM-!'}0-14 (D/A)

DISASSEMBLY and ASSEMBLY ------------

MX200 CAB MOTOR

� Install brake piston (12) to the casing.

I Note: Make sure the knock-pin position with the cover.

[ill Put the washer

(24), spring (25) and

washer (24) on the brake piston.

a !ill

Install o-ring (31) to the casing.

Install new oil seal (27) and a-ring (23)

into the cover (10).

Special tool (ST-2325)

I ,

HYM-50-15 (D/A)

DISASSEMBLY and ASSEMBLY

------------- MX200 CAB MOTOR

!ill

Apply grease thinly to the np of oi 1

seal (27) and o-ring (23), then, install cover (10) to the casing ( 01) .

Note: Make sure the pin position and

matching mark and take care not to

damage the seal rip.

Apply a Locktight to the socket bolts

after that tighten them.

Tightening torque: 10 kg-m, 70 ft.lbs

!ill

... ....

10 mm

Install thrust plate (35) into the casing.

Note: Big chamfered side should be casing

side.

!ill

Install shim (16), springs (15) into the

holder (08).

[ill Install pistons

(06) and holder sub

assembly to the retainer plate

l?J

(091.

...,.,, ,.

DISASSEMBLY and ASSEMBLY ------------- MX200 CAB MOTOR

[ill

!ill

Install piston assembly into the cylinder

block (04).

Install cylinder block assembly to the

shaft (03).

j2ol Assembly brake valve.

Install piston (49) and spring (48) into

the body.

Note: Make sure the piston moves smoothly.

ll!) Install and tighten plug

(46) ,,.-ith a-ring

( 47)

Tightening torque: 22 kg-m, 160 ft.lbs

! :

14 mm

l22IAssembly overload relief valve (SO) Put relief valve body in a vice.

Install adjusting screw (13) and lock-nut (14).

HYM-50-16 (D/A)

HYM-50-17 (D/A) ------------- MX200 CAB MOTOR -------------DISASSEMBLY and ASSEMBLY

Screw in adjusting screw to set the

original setting length as measured at disassembling step 34. Tighten lock-nut.

Tightening torque: 5 kg-m, 36 ft.lbs

! :

8 mm

1231 Install seat (11) with steel ball and

spring (12) into the piston (08).

1241 Instal1 bushing (10) with o-ring (19) and

back-up ring (20) into the body (01).

� Insert piston sub-assembly to the body.

!2sl Insert spring seat (09) and springs (06) and (07) to the body.

111/.

@@@

4:i'

DISASSEMBLY and ASSEMBLY

HYM-50-18 (D/A)

------------- MX200 CAB MOTOR --------------

� Install poppet (04) and piston (03) into the cartridge (02).

!2al Install cartridge sub-assembly to the body with c-ring (16).

� Install seat (OS) to the valve.

1301 Install overload relief valve assembly (50) into the brake valve body ( 02) .

Tightening torque: 15 kg-m, 110 ft.lbs 27 f

.... :

@I) Install cap valve.

(15) to the overload relief

DISASSEMBLY and ASSEMBLY

HYM-50-19 (D/A)

MX200 CAB MOTOR -------------J32I Install new needle bearing ( 41) into the

body by using a special tool (ST-2327).

1 331 Install nng (39) to the body.

1341 Apply a grease to the a-ring (38) and

install it to the brake valve body.

1351 Apply a grease to the valve plate (05) and

install it to the brake valve body.

1361 Apply clean hydraulic oil 2 x. to the motor

assembly.

DISASSEMBLY and ASSEMBLY

HYM-50-20 (D/A) MX200 CAB MOTOR -------------

� Install brake valve assembly to the motor casing. Note: Be careful fall down the valve

plate and align the matching mark.

jJal

Tighten socket bolts (44 and 45). Tightening torque: 44 kg-m. 320 ft.lbs

....

17 mm

� Assembly brake release valve (34).

Install filter (36) and bushing (35) into the plunger (34) then, insert plunger

sub-assembly to the casing (31).

l4ol Install spring (37) and o-ring (38) to the casing (31).

l!I)Install spool (32) into the casing.

®®@ ®

®@

DISASSEMBLY and ASSEMBLY

1421

1431

MX200 CAB MOTOR------------

Install spring (33) and o-ring (38) to

the casing.

Install brake release valve assembly (34)

to the casing (01).

Tightening torque: 1 kg-m, 7 ft.lbs

....

10 mm :

1441 Install plugs

(19 and 36) with o-rings

(20 and 37) to the casing.

Tightening torque: 1.1 kg-m, 8 ft.lbs

Tightening torque: 3.5 kg-m, 25 ft. 1 bs

--a:

27 mm

6 mm

HYM-50-21 (D/A)

HYM-50-22 (D/A)

DISASSEMBLY and ASSEMBLY

--------------

MX200 CAB MOTOR -------------

4. SPECIAL TOOLS -------------------------ST-No.

ST-5058

Title

Work bench

Q'ty 1

This

Use

used for disassembly and assembly motor.

ST-5059

Work bench

This is used for disassembly and assembly brake

ST-1249

Puller

This is used to remove oi1 seal.

ST-2325

ST-2327

Puller

ST-5058

1 1

valve.

This

used to install oil seal.

This is used to install bearing.

ST-5059

HYM-50-23 (D/A)

DISASSEMBLY and ASSEMBLY

------------- MX200 CAB MOTOR --------------

Item 01

06 07

10 11

14 15

17 18 19

20 21 22

7'--''

Casing

Part name

Brake \'alve bod y

Shaft

Cylinder block

Valve plate

Piston

Shoe

Holder

Socket bolt

Plug

Spring

Relief valve ass'y

1 9

Cover

Brake piston

Coupling

Spring

Friction plate

Shim

Spacer

1 1 1

Spacer

0-ring

Plug

0-ring

Washer Spring

1 2

Oi1 seal

Plug

Retaining ring

Socket bolt

Retaining ring

0-ring

Bearing

Thnist plate

Item

Retainer plate

Q' ty

Parking release valve

Plug

0-ring

Ring

1 1

45 47

Part name

�eedle bearing

Plug

Q'ty 1

0-ring

Socket bolt

0-ring

Piston

2 2

HYM-50-24 (D/A)

DISASSEMBLY and ASSEMBLY

---------- MX200 CAB MOTOR----------

,'.) \_/

@--t--� @--+--�lk

i---@

@@@

®@)

HYM-50-25 (D/A)

DISASSEMBLY and ASSEMBLY

------------- MX200 CAB MOTOR--------------

@@@)@@)

@@@

@ @

@)@) @@@@)@@@

@)@ @

50 Overload re1ie f valve Item 01 02

Cartridge

Piston

Poppet

Spring

Seat

Q' ty 1 1 1

1 1 1

Spring

Spring seat

10 11 12

Piston

Bushing

Seat Spring

1 1 1

Adjusting screw

Cap

0-ring

14 16

18 19

I?�

Body

Part name

34 Parking releas valve

l\ut

C-ring

Back-up ring 0-ring

Back-up ring

1 1 1 1 1

Item 31 32

33 34

Casing

Part name

Spool

Spring

Plunger

Q'ty 1 1 1 1

Bushing

Spring

0-ring

38 40

Filter

0-ring

Steel ball Bolt

1 2 1 1

HYM-58-1 (0/P)

OPERATION PRINCIPLE

------------M2X170, 210 CAB MOTOR------------

1. OUTLINE---------------------------- This swashplate type axial piston motor comprises fixed t�·pe S\,·ashplate,

cylinder block, pistons with shoes, valve nlate, parking brake and casing.

The shoe is calked to the each piston and nine pieces of these assemblies

are inserted into the cylinder.

The shoes of nine pistons are so installed on the swashplate that they can

move along the inclined slide way of the swashplate.

They are reciprocated

in the cylinder by the actuating oil flow and slided on the swashplate to rotate the cylinder.

As the cylinder is installed and fixed on the output shaft by spline, its

rotation is transmitted to the output shaft.

The coupling is installed on the output shaft by spline, and cylinder block

and the friction plate is installed on the cylinder block also by spline. VALVE COVER

VALVE PLATE

BRAKE PISTON CYLINDER BLOCK

OUTPUT SHAFT

BEARING

OPERATION PRINCIPLE

HYM-58-2 (0/P)

------------M2X170, 210 CAB MOTOR-----------The valve plate is installed to the right end of output shaft with dowel pin,

further, the valve plate is pushed on it by the spring for preventing oil

leakage.

CYLINDER BLOCK

PUSHER

000 /

OUTPUT SHAFT

PISTON

SPRING

If the pressure is increased due to in

creased output torque, bearing force gene

rated at the contact areas of piston and

shoe, shoe and swashplate are also increased.

The pressure oil in the piston is led to

their contact areas to be balanced with the

bearing force, thus preventing them from

metal contact to decrease their frictions.

SHOE PLATE SWASH PLATE

OPERATION PRINCIPLE

HYM-58-3 (0/P)

------------M2X170, 210 CAB MOTOR-----------2. 2.1

FUNCTION----------------------------MOTOR-----------------------------------

CLOCKWISE ROTATION

Pressure oil coming from the pump, after getting into port A of the valve plate

via, the control valve, flows into the right-side cylinders through a semi

circular groove of the valve plate.

Then, pistons are pushed to slide on the

swashplate, and cylinder assembly and output shaft turn clockwise.

The left-side pistons are moved back to the inside as the cylinder assembly

turns, and oil in the cylinder is discharged through port B.

1f I I I I

I PORTB

(;,

'°' I I

I PORT A

�

COU\TER-CLOCKWISE ROTATIO� Pressure oil coming from the pump, after getting into port-B of the valve plate

via the control valve, flows into the left-side cylinders through a semi circular groove of the valve plate.

Then, pistons are pushed to slide on the

swashplate, and the cylinder assembly and output shaft turn counter-clockwise.

The right-side pistons are moved back to the inside as the cylinder assembly turns, and oil in the cylinder is discharged through port A.

I 'j-0

HYM-58-4 (0/P)

OPERATION PRINCIPLE

------------M2X170, 210 CAB MOTOR-----------2.2

CROSSOVER RELIEF VALVE-- - - ----------------------

The swing crossover relief valve is a direct acting relief valve.

The first

occurs when pressure at port A\" suddenly becomes high as when starting to swing.

The second occurs when pressure at A\ suddenly switches from high

to low and BV pressure switches from low to high as when quick moving the

lever to neutral or to opposite direction.

This relief valve consists of body, plunger, piston, rod, springs, retainer, bushing, cap and adjusting screw. RETAINER

BUSHING

SPRING

ROD

B PORT

A PORT

SWING CONTROL LEVER IS '.'-IEUTRAL

With the swing control lever in neutral and no external loads on the swing, pressure at AV and BV are both low.

And plunger is closed.

OPERATION PRINCIPLE

HYM-58-5 (0/P)

------------M2X170, 210 CAB MOTOR-----------S\il \G START :IOTI o:-,,;

PLUNGER ORIFICE B

PORT B

PORT A

When the swing lever is quickly moved to full stroke, pressure AV increases. This pressure is also applied to chamber B through the orifice A and B and the rod is moved to the left.

Then, the piston moves smooth to the right

and also pressure oil increases smoothly by the chamber C.

When AV pressure reaches the setting of the relief valve, the plunger moves to the left and pressure oil is crossed over to the return side of the motor (BV).

While the superstructure rotating, pressure at AV will drop

and the plunger will close.

OPERATION PRINCIPLE

HYM-58-6 (0/P)

------------M2X170, 210 CAB MOTOR-----------SWING STOP MOTION

:-:-:-:-:-:-:-:-:-:-:-

CHAMBER B CHAMBER C ORIFICE C

While the machine is swinging the crossover relief valve B has high pressure at AV and low pressure at BV.

pressure are low.

Chamber D pressure is high, chamber B and C PORT B

PORT A

AV ····················••······

ORIFICE B

When the control lever is returned to neutral or to the opposite direction,

AV pressure suddenly drops and BV increases due to the inertia of the machine.

The plunger opens with low AV because chamber D pressure is low.

The rod

slowly move to the right as BV pressure oil flows through the orifice A until the piston movement is stopped by the body.

Chamber B pressure now increases

to equal BV pressure and the plunger starts to close until pressure equals the setting of the relief valve.

stopping, and direction changes.

This operation gives smooth swing starting,

HYM-58-7 (0/P)

OPERATION PRINCIPLE

------------M2X170, 210 CAB MOTOR-----------2.3

MAKE-UP VALVE -------------------------------

In case of the control valve is set to its neutral position to out off the circuit \,hile the motor is rotating, the motor cannot stop abruptly and is

still rotating.

of the motor.

In such a case, high pressure works at the side of port "B"

Then, the high pressure may be released by means of a relief valve fitted inside the motor or an overload relief valve inside the control valve.

·on the contrary the pressure at the side of port "A'' drops to be negative pressure condition since the oil becomes short.

As the make-up valve is provided with oil passage hole to connect the port

"A" and chamber A, the make-up valve A is moved toward the left against spring A.

The oil in the return circuit is drawn into the motor circuit

from the part "D" via port "C", preventing a cavitation from occuring in

the circuit.

The make-up valve B works in the same function of the above.

PORT B

PORT A

MAKE-UP VALVE A PLUG MAKE-UP VALVE B

,,.

'' PORT "C" SPRING A PORT "D"

PORT "E"

FROM RETURN---- CIRCUIT

CONTROL VALVE

FROM RETURN----� CIRCUIT

HYM-58-8 (0/P)

OPERATION PRINCIPLE

------------ M2X170, 210 CAB MOTOR-----------2.4

PARKING BRAKE---------------

---------------

Fig. shows the construction of spring-set, h:,draulical ly-released t)·pe disc

brake.

In the lever neutral condition, piston is kept pressed in down ward

direction by spring to press plates and friction paltes, thus obtaining

braking force.

In the lever operation, the pilot oil pressure is applied

to B-port through the parking release valve to move the piston to the up

ward against the force of the spring, thus releasing the brake force. SPRING

PARKING RELEASE VALVE

FRICTION PLATE

PARKING RELEASE VALVE

8-PORT

HYM-58-9 (0/P)

OPERATION PRINCIPLE

------------M2X170, 210 CAB MOTOR-----------When the control lever is returned from operating to neutral position, the spool returns right in the parking release valve.

Then, the brake piston is

moved lower by spring force and the return oil from the chamber B flows back

to 0-port through the orifice.

time lag for 4 second.

At this time, the orifice works to make a

D-PORT

\' ¥--Y, V / "' ' , .... -- -t" .,,, '

', ... __, -.,.,,.

PARKING RELEASE VALVE

CHAMBER B

DISASSEMBLY and ASSEMBLY

HYM-58-1 (D/A)

------------M2X170, 210 CAB MOTOR-----------1.

DISASSEMBLY--------------------------- Note: Before disassembling, throughly clean

the outside of the motor.

IJ]Lift the motor assembly and drain hydraulic oil from the drain port.

[I}set the motor assembly on the work bench, then put matching make on the casing (01) and brake valve body (02).

[I) RemoYe parking release valve casing (011.

(3-i) from the

� Remove the overload relief \·alve (:=ill) from the brake valve.

DISASSEMBLY and ASSEMBLY

HYM-58-2

(D/A) ------------M2X170, 210 CAB MOTOR------------

I!] Remove plug I:

(46) of the make uu val\'e.

14 mm

I!] Remove spring

(48) and piston (49).

12] Loosen socket bolts I: 17 mm

(44).

I!] Remove brake valve assembly and \·alve plate (OS).

[1} Remove brake springs

(25).

DISASSEMBLY and ASSEMBLY

HYM-58-3 (D/A)

------------M2X170, 210 CAB MOTOR-----------jillRemove brake piston (12) using a bolts (M8Xl.25).

llI)Lay the motor and remove cylinder block assembly.

[ill Remove plates

(13) and friction plates

(14) from the casing.

GlJ

Remove retaining ring (32) and cover (10).

Remove shaft (03) using a plastic hammer.

,lrf

DISASSEMBLY and ASSEMBLY

HYM-58-4

------------M2X170, 210 CAB MOTOR-----------(D_I_A_)

G:IJ Remove thrust plate

(35) as sho1m.

!ill

Remove retaining ring (28) and spacer (17).

[ill Remove bearing press.

G]J Remove oil as shown.

(33) from the shaft using a

seal (27) from the cover (10)

!ill

Remove bearing (41) from the brake valve

body (02) using a puller.

DISASSEMBLY and ASSEMBLY

HYM-58-5 (D/A)

------------M2X170, 210 CAB MOTOR-----------1201 Disassembly overload relief valve (50).

Remove plug (02) from the body (01). �

ll!J

(, : 36 mm

Remove busing (10), spring (07) and spring seat (12) from the rod (03).

Remove piston (11), rod (03), spring (06),

spring seat (09) and plunger (04) from the

body (01).

1221 To measure the dimensions bet,,·cen the

adjusting screw (13) and plug (02).

1231 Remove lock-nut C 14) and adjusting screw. t)

19 mm

10 mm

1241 Disassembly parking release valve (34).

Remove o-rings (40 and 41) and springs (33

and 39).

I I0

I �®

DISASSEMBLY and ASSEMBLY

HYM-58-6 (D/A)

------------M2X170, 210 CAB MOTOR------------

1251 Remove

spool (32) from the casing (31).

1261

Remove plunger (34).

( 0

1211

Remove bushing (35), filter (36), spacer (37) and orifice (38) from the plunger.

2. INSPECTION-------------------------- Measure between the retainer plate (09)

[!]

and the holder (08).

height = H - h Standard

Limit of use

23 mm

22.5 mm

Less than 22.5 mm replace thrust plate and holder.

DISASSEMBLY and ASSEMBLY

HYM-58-7 (D/A)

------------M2X170, 210 CAB MOTOR------------

Measure between cylinder bore and uiston

diameter.

Standard clearance Max. 0.028 mm

Limit of use

---- l

0.058 mm

ll] �-love the piston up and down to measure the clearance between the piston and shoe. Standard clearance 0

Limit of use 0.3 TTim

II} '.'-leasure the shoe diameter. Standard 5.S mm

Limit of use 5.3 mm

I!} '.vleasure the friction plate diameter. Standard 4.0 mm

Limit of use 3.6 mm

DISASSEMBLY and ASSEMBLY

HYM-58-8 (D/A)

------------M2X170, 210 CAB MOTOR------------

3. ASSEMBLY-----------------------------Note:

Before assembling, clean al1 parts and dry with compressed air. Apply clean hyclraulic oil to all internal parts.

!l) Install retaining ring

(28) and spacer

(17) to the shaft (03).

ll] Install new bearing inner race

(33) by

(I] Install new bearing inner race

( 41) as

using a press.

above, and install retaining ring (29).

DISASSEMBLY and ASSEMBLY

HYM-58-9 (D/Al

------------M2X170, 210 CAB MOTOR------------

� Insert shaft then, install new bearing

outer race (33) to the casing (01) using a hammer and bar.

I!) Install new oil seal

(27) into the cover

(10).

I!] Install a-ring

(31) to the casing.

11) Apply grease thinly to the rip of oil seal (27), then install cover tc the casing.

I!) Install

!P?

retaining ring (32).

DISASSEMBLY and ASSEMBLY

HYM-58-10 (D/A}

------------M2X170, 210 CAB MOTOR------------

[!} Lay the casing plate (35).

(01) and install thrust

G:2J Install push rods block (04).

(20) to the cylinder

Install spacer (18) to the holder (08)

then install it to the cylinder block.

llI) Install piston assembly retainer plate (09).

!ill

(06 and 07) to the

Install piston assembly into the cylinder

block.

Install cylinder block assembly to the

shaft (03).

DISASSEMBLY and ASSEMBLY

HYM-58-11 (D/A)

------------M2X170, 210 CAB MOTOR------------

Install plates (13) and friction vlates (14) alternately.

Note: Align the notches of friction plates.

lli)Apply grease to the o-rings (22 and 23) and install them to the casing.

!ill

Install brake piston (12) to the casing

using a plastic hammer.

Note: Align the slit of brake piston as shown.

Slit

piston

[ill Install springs

(25) to the brake piston.

DISASSEMBLY and ASSEMBLY

HYM-58-12

(D/A) ------------M2X170, 210 CAB MOTOR------------

'3Install bearing outer race (41) to the body (02).

[illApply grease to the valve plate (OS) and install it to the body.

Install a-ring (21).

I 201 Install body to the casing and tighten bolts ( 44).

Note: Be careful fall down the valve plate and align the matching mark.

Tightening torque: 44±6.6 kgf·m

...

I F

@:!J Install

17 mm

(318±48 ft. lbs)

piston ( 49) and spring ( 48) .

� Install plug (46) to the body. Tightening torque: 22.5±2.5 kgf·m

I: F

....

(163±18 ft.lbs)

14 mm

DISASSEMBLY and ASSEMBLY

HYM-58-13 (D/A}

------------M2X170, 210 CAB MOTOR------------

1231 Assembly

overload relief valve (50).

Install rod (03), spring (06), spring seat (09) and piston (11) to the plunger (04).

1241 Install

body (01) to the plunger.

1251 Install

spring seat (12) spring (07) and

bushing (10) to the body.

1261 Install adjusting screw (14) to the plug (02).

(13) and lock-nut

� Screw in adjusting screw to set the

original setting length as measured at

disassembling step Tighten lock-nut.

1221.

Tightening torque: 2.8 kgf·m, 20 ft.lbs

1'/C

....

10 mm

DISASSEMBLY and ASSEMBLY

HYM-58-14 (D/A)

------------M2X170, 210 CAB MOTOR-----------!2alrnstall o-ring (16) and back-up ring (18)

to the retainer (08), then install retainer to the plug (02).

�Install o-ring (17) to the plug, then install plug to the body (01). Tightening torque: 18±1 kgf·m

(130±7 ft. lbs}

.... t,

13olrnstall back-up ring (19) and o-ring (20)

to the overload relief valve.

@II Install overlo::id re.lief valve. Tightening torque: 18±1 kgf·m

(130±7 ft.lbs)

....

36 mm

l32lrnstall o-rings (39 and 37) to the plugs (30 and 36), then install plugs

to the body and casing.

Tightening torque: 3.7±2 kgf·m

...

(28±15 ft.lbs)

19 mm

DISASSEMBLY and ASSEMBLY

HYM-58-15 (D/A)

------------M2X170, 210 CAB MOTOR------------

1331 Assembly

brake release valve (34).

Install orifice (38), spacer (37), filter

(36) and bushing (35) into the plunger (34)

then, insert plunger sub-assembly to the casing (31).

1341 Install spring casing (31).

(39) and o-ring (41) to the

1351 Install

spool (32) into the casing.

1361 Install spring casing.

(33) and o-ring (41) to the

@zJ Install brake release valve assembly to the casing (01).

Tightening torque: 1 kgf·m, 7 ft.lbs

'10 :

10 mm

Note: Fill hydraulic oil to the motor after assembly.

191

1.0 1.5

,Q, ,Q,

(n2Xl70CAR)

(M2X210CAB)

(34)

DISASSEMBLY and ASSEMBLY

HYM-58-16 (D/A)

------------M2X170, 210 CAB MOTOR------------

Item 01

Casing

Part name

0-ring

Piston

Shoe

1 9

Holder

Cover

Brake piston

Friction plate

Retainer plate Pin

Plate

1 2

Spring

Spacer

16 18

Spacer

0-ring

Push rod

0-ring

Spring

0-ring

1 1

Oil seal

Retaining ring

0-ring

Bearing

Thrust plate

34 36

Retaining ring Plug

Retaining ring Parking release valve Plug

0-ring

Socket bolt

Valve plate

Bearing

n' 1 tv.

Cylinder block

..n

Part name

Shaft

Item

Brake valve body

03 04

Q'ty 1

Ring

1 1 '")

1 1

Plug

Spring

Relief valve ass'y

2 2

DISASSEMBLY and ASSEMBLY

HYM-58-17 (D/A)

---------M2X170, 210 CAB MOTOR---------

@-\.-,��b=-==-==='L @

�+ @

@ @®@

,,,,.,,-----

@ @ @ @ @

@ -----@) @ /

@ @®

DISASSEMBLY and ASSEMBLY

HYM-58-18 (D/A)

------------M2X170, 210 CAB MOTOR------------

@) @) @)@ @)@@) @@) @ @

® Item

50 Overload relief valve

Body

Rod

02 04

?art name

Plug

Plunger

Q'ty 1

Item 31

34 Parking release valve Casing

Part name

Spool

Plunger

Spring

@ Q'ty 1 1

Bushing

Spring

Spacer

Spring seat

Piston

Seat

Spring

Retainer

Bushing

Spring seat

Nut

0-ring

Adjusting screw

1 1

Cap

0-ring

18 20

Back-up ring

1 1 1 1

Filter

Orifice

0-ring

Steel ball Bolt

1 2

SRD-9-1 (D/A)

DISASSEMBLY and ASSEMBLY

----------- SWING REDUCTION DEVICE----------1.

DISASSEMBLY

Note: Before disassembling, throughly

clean the outside of the swing de vice.

IJ:} Hoist the swing device and drain gear oil from the reduction device.

fl] Put the swing device on the work bench and remove bolts (24). : 30 mm

ll}

Put identification marks on the outside

reduction device.

I!} Remove sun gear

(07).

.. \),- \,.

SRD-9-2

DISASSEMBLY and ASSEMBLY

(D/A) ------------SWING REDUCTION DEVICE------------

I!}

Remove first carrier (01).

I!]

Remove ring gear (19).

IZJ

Remove sun gear (08).

[!) Remove ring gear

(20) and knock pins

(54) from the housing (47).

DISASSEMBLY and ASSEMBLY

SRD-9-3

(D/A)

------------SWING REDUCTION DEVlce------------

[ill

Remove retaining ring (15) from the

drive shaft (22). �:

III) Turn the housing

up side down, and

remove bolts (31).

!ill

(, : 19 mm

Put the housing on a press.

Push out the drive shaft (22) by using

a press.

!ill

Push out the bearing (17), cover (55) and sleave (34) by using

a special tool (ST-1268).

Remove oil seal (36) and 0-ring (57) from the cover (55)

SRD-9-4

DISASSEMBLY and ASSEMBLY

(D/A)

-----------SWING REDUCTION DEVICE-----------

G!J

Remove retaining ring (59) and 0-ring (38)

from the sleave (34).

!ill

Remove magent (60) and screw (61).

!ill

Push out the bearing (16) from the

housing.

IJ!I

Disassembly the carrier.

Tap spring pin (06) out from first

carrier (01) using a punch.

@®

SRD-9-5

DISASSEMBLY and ASSEMBLY

(D/A)

----------- SWING REDUCTION DEVICE-----------

jill Remove pin

(04), planetary gear (09),

thrust plates (13) and needle bearing (11).

•

r);. @)

1201 Remove thrust plate (03) from the

carrier (01).

@I) Tap spring pin

(06) out from second

carrier (02) using a punch.

� Remove pin (OS), planetary gear (12), thrust plates (13) and bushing (10).

1231 Remove thrust plate (03) from the

carrier (02).

SRD-9-6 (D/A)

DISASSEMBLY and ASSEMBLY

------------SWING REDUCTION DEVICE -----------2. ASSEMBLY ----------------------------

Note: Before assembling, clean all parts

and dry with compressed air.

Apply clean hydraulic oil to all internal parts.

[!]

Assembly the carrier

Install needle bearing (11) into the

planetary gear (09).

Install thrust plate (03) into the

��

carrier (01).

The oil groove of thrust plate should be

toward the up side of carrier.

llJ

Install planetary gear (09) and thrust

plates (13) with the oil grooves of

thrust plates toward the planetary gear. The groove of planetary gear should be toward the up side of carrier.

� Install pin (04) aligning the hole in pin with hole in carrier.

DISASSEMBLY and ASSEMBLY

SRD-9-7 (D/A)

------------ SWING REDUCTION DEVICE ------------

[!}

Tap spring pin (06) into the hole of carrier.

The slit of spring pin should

be toward the up side of carrier.

I!]

(I)

Press bushing (10) into the planetary gear (12) using a press.

Install thrust plate (03) into the

carrier (02).

The oil groove of thrust plate should

be toward the up side of carrier.

I!)

Install pranetary gear (12) and thrust

plates (13) with oil groove of thrust plates toward the planetary gear.

The groove of planetary gear should be toward the up side of carrier.

� Install pin (05) aligning the hole in pin with hole in carrier.

DISASSEMBLY and ASSEMBLY

----------- SWING REDUCTION DEVICE

� Tap spring pin (06) into the hole of carrier.

The slit of spring pin should

be toward the up side of carrier.

[ill

!ill

Install magnet (60), screw (61) to

the sleave (34).

Install retaining ring (59) and O-ring (38).

Put shin grease on the O-ring.

[ill

Install oil seal (36) into the cover (55) using a special tool (ST-2328).

Put thin grease on the seal rip.

Install O-ring (57) in the groove on

cover.

SRD-9-8 (D/A)

DISASSEMBLY and ASSEMBLY

[ill

SRD-9-9

SWING REDUCTION DEVICE

Install cover (55) to the drive shaft.

Put the drive shaft (22) on a press.

Install cover sub-assembly to the drive

shaft.

Then, put thin grease on the

drive shaft.

GlJ

Heat bearing (17) in oil to temperature

of 110 ° C (212 ° F).

Install the bearing on the drive shaft (22) using a special tool (ST-1268).

[ill

Put the housing (47) on a press.

Install drive shaft sub-assembly into

the housing using a press.

Temporarily,

install and tighten bolts (31) with

washer (32).

Note: Be careful safely.

!ill

Heat bearing (16) in oil to temperature

of 110 ° C (212 ° F).

Turn the housing upside down on a press. Put thin grease on the bearing and

housing.

Install bearing into the drive shaft (22)

using a press.

177

(D/A)

DISASSEMBLY and ASSEMBLY

------------ SWING REDUCTION DEVICE

1201

Install retaining ring (15) in the

groove of drive shaft (22).

SRD-9-10 (D/A)

�:

!lll

Turn the housing upside drun. bolts (31) with washer (32).

Tightening torque: 19 mm

' 1221

1231

Tighten

9 kg-m. 65 ft. lbs

__.:

Apply liquid gasket to maching the

surfaces of ring gear and housing (47).

Install knock pin (54) and ring gear (20) to the housing.

Align the maching mark.

1241

Install second carrier assembly.

DISASSEMBLY and ASSEMBLY

SRD-9-11

----------- SWING REDUCTION DEVICE � Install sun gear (08) into the carrier.

j2sl Install ring gear (19). Align the maching mark.

Apply liquid gasket to maching surfaces

of ring gears (19 and 20).

� Install first carrier assembly.

� Install sun gear (07) into the carrier.

� Apply gear oil into the reduction device. Oil capacity:

10 liters.

\ �\�.--

(DIA)

DISASSEMBLY and ASSEMBLY

SR0-9-12

(0/A)

----------- SWING REDUCTION DEVICE

!Joi

@:!)

Apply liquid gasket to maching surfaces of motor (53) and ring gear.

Install the motor in position of the

reduction drvice with bolts (24) and

washers (25).

Tightening torque: go

....

30 mm

40 kg-m. 289 ft.lbs

3. SEPCIAL TOOLS --------------------------

ST No.

ST-1268

ST-2326

Puller

Title

Q'ty 1

Use

To remove bearing from drive shaft.

To install oil seal.

ST-1268

DISASSEMBLY and ASSEMBLY

SRD-9-13 (D/A)

----------- SWING REDUCTION DEVICE

Item 01

Carrier

Thrust plate

Carrier

Q'ty

Item

Part name

Spring

Oil seal

Sleave

0-ring

Spring pin

Level gauge

Sun gear

10 11

12 13

14 15

16 17

19 20

Pipe

Planetary gear

Housing

Spring washer

Motor

Cover

Retaining ring

Bushing

Planetary gear

'.\eedle bearing Thrust plate

Retaining ring

Retaining ring Bearing

Bearing

Ring gear

1 1

Bolt

Spring washer

Ring gear

12 10

Stop valve

Drive shaft

Sun gear

22 24

Q'ty 10 1

I 1J

Part name

Plug

Bolt

Knock pin

0-ring

12 2

1 1

Magnet

Plug

Screw

SR D -9-14 (D A / l _______.;,;;;;,;,;. �--------- SWING REDUCTION DEVICE D ISASSEMBLY

and ASSEMBLY

i-------@

,r-'-

----------1

, ____:__• � �1--------@ @ @)

�;F�iill�=== @ @) @ @ @ @ @ @ @ @ @

®@ ®

@ @)

OPERATIONAL PRINCIPLE

PV-9-1 (0/P)

-------------- PILOT VALVE

1. OUTLINE----------------------------

The pilot valve is provided for producing the secondary pilot pressure to

activate the spool in the control valve. It is divided in two different types:

One is one-lever type which is to

operate front attachment and swing, and the other is two-lever type which is to operate travel.

RETURN SPRING

T-PORT

P-PORT

Fig. 1

ONE-LEVER TYPE PILOT VALVE

Fig. 2 TWO-LEVER TYPE PILOT VALVE

OPERATIONAL PRINCIPLE

PV-9-2

(0/P)

--------------- PILOT VALVE ---------------

The oil passage of valve inside is as shown in Fig. 3.

FROM PILOT PUMP (PRESSURE PORT)

Fig. 3

PV-9-3

OPERATIONAL PRINCIPLE

(0/P)

--------------PILOT VALVE-------------2. FUNCTION---------------------------2-1. IN NEUTRAL RANGE (A-B)

When the lever is shifted into neutral

position, the spool is pushed up by the

return spring to block the port "I�" and

to connect ports "OUT" to "T".

-----CAM

Consequently, the pressure at delivery

port "OUT" becomes the same as that

at the port "T".

PUSHER

Within the stroke "A" of the pusher

BUSHING

the delivery pressure does not rise,

keeping the same pressure as that of

the tank.

The above neutral range is shown in Fig. 5 by A-Bline.

RETURN SPRING

® SPOOL

Fig. 4

A B

Pusher stroke

Fig. 5

�J

OPERATIONAL PRINCIPLE

PV-9-4 (0/P)

PILOT VALVE-------------2-2. PRESSURE FLASHING POINT (B-C)

When the pusher is further pushed down,

this movement is transmitted to the spool through the balance spring.

If the spool is positioned at the port

"IN", the port "T" is disconnected, thus applying the pressure to the port "OUT".

At the same time, this pressure is applied to a small piston in the spool through orifice to push the spool up so as to

close the port "IN".

Now the relation between the secondary

SPRING GUIDE

pressure "P2" and the spring force "F1"

is;

F1 = F2

BALANCE SPRING

F1: Present spring force

F2 = A

RETURN SPRING

If the upward force "F 2 " to the spool by the secondary pressure "P 2 " is larger than "F 1", the following equation is

OUT IN

established; F 1 < F2

F 1 = Present spring force

F2 = A X P 2 Then the spool is pushed up to connect

port "OUT" to "T", decreasing the second

ary pressure to be balanced with the force

PISTON

Fig. 6

The above operation range is shown in

Fig. 9 by B-C line.

Ax P2; F2

Fig. 7

Fig. 9

•

"F 1 " of the spring.

Pusher stroke

SPOOL

OUT

T Ax P2; F2

Fig. 8

PV-9-5 (0/P)

OPERATIONAL PRINCIPLE

PILOT VALVE-------------2-3. CONTROL RANGE (C-D)

When the pusher is pushed down, the

balance spring is compressed and its force "F 1 " is transmitted to the spool, connect ing the ports "IN" to "OUT" to release

the pilot pressure out of delivery port,

as shown in Fig. 11.

This delivery

pressure is applied to the piston in the spool, and

pushes the spool up until it

is balanced with the force F 1•

Consequently, the delivery pressure "P 2 "

(secondary pressure) is varied in propor

PUSHER

tion to the compressed force "F 1" of the

spring.

When the force "F i " is balanced with "F 2 ",

BALANCE SPRING

the spool is positioned at both ports;

"IN" and "T".

RETURN SPRING

There fore, both ports are

blocked and disconnected from the port

"OUT".

NOTE:

The piston in the spool is provided to decrease the pressure receiving area, so it is decreased upward force "F2".

Ax P2

A:PRESSURE RECEIVING AREA

Fig. 10

P2:SECO�DARY PRESSURE

Therefore, it can decrease spring force

T OUT

The above operation range is shown in Fig. 13.

D .., 0

Cl.

Pusher stroke Fig. 13

t F2

Fig. 11

Fig. 12

OPERATIONAL PRINCIPLE

PV-9-6 (0/P)

-------------- PILOT VALVE--------------2-4. CONTROL RANGE END (D-E)

When the pusher is further pressed down

to increase the secondary pilot pressure,

the clearance "@" will be decreased, and

the pusher finally gets in touch with the spool as shown in Fig. 14.

At this time,

the secondary pilot pressure is increased suddenly because the pusher directly

presses the spool down.

This operating range is shown in Fig. 16

by D-E line.

Fig. 14

OUT

T Pusher stroke

Fig. 15 Fig. 16

PV-9-7 (0/P)

OPERATIONAL PRINCIPLE

PILOT VALVE 2-5. DIRECT OPERATION RANGE (E-F)

With the pusher in touch with the spool

the movement of the pusher is transmitted directly to the spool.

Consequently, the primary pilot pressure

is automatically led to the delivery port "OUT".

Within this operation range, the secondary pilot pressure is equalized with the pilot

relief valve.

The above operation range is shown in

PUSHER

Fig. 19 by E-F line.

SPRING GUIDE BALANCE SPRING ��-RETURN SPRING

OUT

SPOOL

Fig. 17

T OUT

....0

T Pusher stroke Fig. 19

Fig. 18

DISASSEMBLY and ASSEMBLY

PV-9-1 (D/A)

--------- HV TYPE PILOT VALVE (FOR FRONT) ---------1. DISASSEMBLY---------------------------

Note: Before disassembling clean the all

parts.

II) Put a pilot valve assembly on a work bench.

I]]

Remove a lock nut.

llJ

Remove a rubber.

[!]

Remove joint screw (21). �

(,: 19, 24 mm

DISASSEMBLY and ASSEMBLY

PV-9-2 (D/A)

--------- HV TYPE PILOT VALVE (FOR FRONT) ----------

� Remove earn (20)

I!]

Remove universal joint (19). ,

17 mm

ll)

Tur n over casing (01).

I!)

Remove socket bolt (18).

r I!)

I� 10 mm

Remove plate (16) with bolt (Ml6 x P2).

PV-9-3 (D/A)

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR FRONT)----------

jill

Remove 0-ring (17) from the plate.

II!)

Remove 0-ring (15) from a casing.

!ill

Remove piston (14) from spool (02).

!ill

Turn over casing (01).

-----® II!)

Install a special tool (ST-7924) into the

casing.

DISASSEMBLY and ASSEMBLY

PV-9-4

(D/A) --------- HV TYPE PILOT VALVE (FOR FRONT) ----------

[ill

Remove socket bolt (22).

!ill

8mm

Loosen special tool (ST-7924) gradually,

until it has lost spring force.

III) Remove the special tool the casing.

(ST-7924) from

J [ill Remove plate

!ill

(13).

Remove four pusher assemblies.

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR FRONT)

1201

llIJ

Remove pusher (12) from bushing (08).

Remove 0-ring (11) from bushing (08).

1221

Remove dust seal (10) from bushing (08) .

!231

Remove oil seal (09) from bushing (08).

1241

Remove four spool assemblies. Note: Arrenge the parts disassembled to

each port with caution to do not

confuse.

PV-9-5 (D/A)

PV-9-6 (D/A) --- ------ HV TYPE PILOT VALVE (FOR FRONT) ---------DISASSEMBLY and ASSEMBLY

1251 Press spring (03) and remove spacer (04) from spool (02).

l2sl Remove spring (03) and shim (05) from spool (02).

� Remove four spring guides (07) and four springs (06).

DISASSEMLBY and ASSEMBLY

PV-9-7 (D/A)

HV TYPE PILOT VALVE (FOR FRONT) ---------2. ASSEMBLY-----------------------------

IJ:l

Clean all parts and apply clean hydraulic

oil to all internal parts.

P3 P4

ll)

Put casing (01) on the workbench.

[1]

Install the special tools (ST-7099) into

I!]

four holes in the casing.

Install shim (OS) and spring (03) into

spool (02).

Note: Number of shim are decided at

performance test, don't loose them.

I!]

Press spring (03) and install spacer (04)

between spool (02) and spring (03).

Note: Spacer h as both sides, face the

spring seat side to the spring.

o-·• '�

0 }\

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR FRONT)

11)

Install four springs (06) into the

casing.

®11}

Install four spring guides (07) on the

springs. Note:

Spring guide has both sides, face

the spring seat side to the spring.

I!)

Install four spool assemblies into spring

guides (07). Note:

Install spool assembly refer to

port number.

I!)

!ill

Install oil seal (09) with grease into

bushing (08).

Install dust seal (10) into bushing (08)

with special tool (ST-2292).

@) @

PV-9-8 (D/A)

PV-9-9 (D/A)

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR FRONT)

III)

Install 0-ring (11) into bushing (08). '•,

@ � Install pusher (12) into bushing (08) from oil seal side.

!ill

Install four pusher assemblies.

G!J

Install plate ( 13).

[ill

Install the special tool (ST-7924) into

the casing.

DISASSEMBLY and ASSEMBLY

HV TYPE PILOT VALVE (FOR FRONT)

[ill

Tighten special too 1 unti 1 under surface

of bushing (08) reach to upper surface of casing.

[!zJ

Remove four special tools (ST-7099) from

bottom of the casing.

[ill

Tighten the special tool (ST-7924) until

!ill

Install two socket bolts (22).

Plate (13) reach to upper surface of casing.

1201 Tighten two socket I:

bolts (22).

8mm

Tighten torque: 5 kg.m (36.17 ft.lbs)

PV-9-10 (D/A)

PV-9-11 (D/A)

DISASSEMBLY and ASSEMBLY

HV TYPE PILOT VALVE (FOR FRONT)

@II

Remove the special tool (ST-7924) from

the casing.

Turn over the casing.

1221

Install piston (14) into spool (02).

1231

Install O-ring (15) into the casing.

P '

1241

Install O-ring (17) into plate (16).

@ @ l2sl Install plate (16) into the casing. Note: Apply grease to O-ring (17).

:lOmm

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR FRONT) 1261 Install socket bolt (18).

.· r.

10 mm

Tighten torque: 5 kg.m (36.17 ft.lbs)

jill

Turn over the casing.

l2al Install universal joint (19) with lock tight. .,

Cr:17rnm

Tighten torque: 2.5 kg.m (18.08 ft.lbs)

1291 Apply grease to a pin of universal joint.

l3ol

Install cam (20).

Apply grease between cam (20) and

pusher.

PV-9-12 (D/A)

DISASSEMBLY and ASSEMBLY

PV-9-13 (DIA)

--------- HV TYPE PILOT VALVE (FOR FRONT)

@II

Adjust the clearance beb·een pusher ( 12) and cam (20). Install joint screw (21). mm

Clearance: 0 � 0.2 mm

Tighten torque: 9 kg.m (65.10 ft.lbs) 1321 Install the rubber.

1331 Install the lever into joint screw (21).

�

(, : 19, 22 mm

3. SPECIAL TOOLS--------------------------

ST7088 S17987

] ST7924 (Ass' y No. of

ST7099

and @)

ST2292

· .. .. \tY @

ST-I\UMBER

TOOL '.IJAME

Q'TY 1

ST7088

Valve holder

ST7924

Valve holder ass'y

Bushing driving guide

ST7987

ST7099

ST2292

Valve holder

Plate removing guide

iv , · n/ •Jl�n' @

USE

to remove and install plate

to keep straight the spool

Ass'y No. of ST7088 and ST7987

to install a bushing

DISASSEMBLY and ASSEMBLY

PV-9-14

(D/A)

HV TYPE PILOT VALVE (FOR FRONT)

®--------1 ®----� @)

@ @

Item

Part name

Item 12

Pusher

Q'ty 4 4

Part name

Casing

Q' ty 1

Spring

Piston

Shim

Plate

04 06

08 09

10 11

Spool

Spacer Spring

Spring guide

Plate

0-ring

Carn

Socket bolt

Universal joint

Dust seal

Joint screw

0-ring

20 22

Socket bolt

Bushing

Oil seal

PV-10-1

DISASSEMBLY and ASSEMBLY

(D/A)

--------- HV TYPE PILOT VALVE (FOR TRAVEL) --------1. DISASSEMBLY--------------- ----------- -

Note: Before disassembling clean the all

parts.

� Put a pilot valve assembly on a work-

bench.

Remove two spring pins.

ll)

llJ

Remove both right and left lever.

Remove bolt (24), plain washer (25) and

spring washer (26). �

[!]

�_,,

�

10 mm

Remove cover (23).

DISASSEMBL Y an dASSEMBLY

PV-10-2 (D/A)

HV TYPE PILOT VALVE (FOR TRAVEL) � Hold the pilot valve assembly b,_- a vice.

., �

Remove two plugs (l S) ·

6 mm

Remove four plugs (16).

8 mm

[!}

Remove 0-ring (17) from plug (16).

II)

Remove piston (15) from spo 0 1 (02).

DISASSEMBLY and ASSEMBLY

HV TYPE PILOT VALVE (FOR TRAVEL)

� Put the pi lot valve assembly on the workbench.

Remove socket bolt (14) from the casing.

r jill

[ill

Install a special tool (ST-7925) into

the casing.

Remove the other socket bolt (14) from the casing.

Gl}

ll!J

8 mm

Install the special tool (ST-7925) into

the casing.

Loosen both special tools (ST-7925)

gradually, until it has lost spring force.

PV-10-3 (D/A)

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR TRAVEL)

jill Remove the special tools the casing.

[ill

(ST-7925) from

Remove holder (13) and cam (20) assembly

-from the casing.

� Hold the holder (13) and cam (20) assembly by the vice.

� Remove spring pin (22) from pin (21) with a special tool (ST-1237).

!ill

Remove pin (21) and cam (20) from holder (13).

PV-10-4 (D/A)

DISASSEMBLY and ASSEMBLY

HV TYPE PILOT VALVE (FOR TRAVEL) 1201 Remove four pusher assemblies.

@II Remove pusher

(12) from bushing (08).

� Remove 0-ring (11) from bushing (08).

1231 Remove dust seal (10) from the bushing.

Remove oil seal (09) from the bushing. 12 41

PV-10-5 (D/A)

DISASSEMBLY and ASSEMBLY

PV-10-6 (D/A)

--------- HV TYPE PILOT VALVE (FOR TRAVEL)---------

l2sl Remove four spool assemblies.

l2sl Press spring (03) and remove spacer (04) from spool (02).

1211 Remove spring (03) and shim (05) from spool (02).

l2sl Remove four spring guides (07) and four springs (06).

PV-10-7 (D/A)

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE {FOR TRAVEL)---------

.. ..

2. ASSEMBLY----------------------------

Clean all parts and apply clean hydraulic [!] oil to all internal parts.

P3 P4

ll} Put casing (01) on the workbench.

12) Install a special tool holes in the casing.

[!] Install shim spool (02).

(ST-7099) into four

(05) and spring (03) into

Note: Number of shim are decided at performance test, don't loose them.

11] Press spring (03)

and install spacer (04)

between spool (02) and spring (03).

Note: Spacer has both sides, face the spring seat side to the spring.

�

' ..

�

;,,

PV-10-8 (D/A)

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR TRAVEL)---------

I!]

II)

Install four springs (06) into the

casing.

Install four spring guides (07) on the

springs.

Note: Spring guide has both sides, face

the spring seat side to the spring.

I!) Install four spool assemblies guides (07).

into spring

Note: Install spool assembly refer to port nwnber.

II) Install oil seal with grease.

!ill

(09) into bushing (08)

Install dust seal (10) into bushing (08)

with special tool (ST-2292).

PV-10-9 (D/A)

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR TRAVEL)---------

II!)

Install 0-ring (11) into bushing (08).

� Install pusher (12) into bushing (08) from oil seal side.

Note: Apply grease inside of bushing.

� Install four pusher assemblies.

Install holder (13).

!ill

Install the special tools (ST-7925) into

the casing.

I 1, ST-7925"

{

PV-10-10 (D/A)

DISASSEMBLY and ASSEMBLY

--------- HV TYPE PILOT VALVE (FOR TRAVEL)

jill

Tighten both special tools (ST-7925)

until under surface of bushing reach to

upper surface of casing.

!ill

Remove four special tools (ST-7099) from

bottom of the casing.

.• ('! • ,'· �no

/ �� , . e

�

��ST-7099

jill

Tighten both special tools (ST-7925)

until holder reach to upper surface of

casing.

� �move the special tool (ST-7925) of the left hand side.

Install socket bolt (14).

j2ol Remove the special tool (ST-7925) of the other side.

DISASSEMBLY and ASSEMBLY

PV-10-11

(D/A) --------- HV TYPE PILOT VALVE (FOR TRAVEL)---------

@II

Install socket bolt (14).

I :

8mm

Tighten torque: 5 kg.m (36.17 ft.lbs)

1221 Hold the casing assembly by the vice.

1231 Install piston (15) into spool (02).

1241 Install 0-ring (17) into plug (16).

� Install four plugs (16).

I :

8mm

Tighten torque: 5 kg.m (36.17 ft.lbs)

DISASSEMB LY and ASSEMBLY

PV-10-12 (D/A)

--------- HV TYPE PILOT VALVE (FOR TRAVEL)--------1261 Install ti,-o plugs (18).

6 mm

Tighten torque: 2 kg.m (14.17 ft.lbs)

� Put the casing assembly on the workbench. Apply grease to cam (20).

j2al

Install cam (20) and pin (21) into holder (13).

1291 Install spring pin (22) into cam (20) 1vith a hammer.

l3ol Install cover (23) into holder (13).

DISASSEMBLY and ASSEMBLY

PV-10-13 (D/A) --------- HV TYPE PILOT VALVE (FOR TRAVEL)---------

@I)

Install bolt (24), plain washer (25) and

spring washer (26). �

(,: 10mm

1321 Install both right and left levers.

, 1331 Install two spring pins.

3. SPECIAL TOOLS--------------------------

ST-7925 ST-7099

ST-2292

ST-1237

ST-:.JUMBER ST7925

TOOL NAME

Valve holder ass'y

ST7099

Holder removing guide

ST1237

Spring pin removing guide

ST2292

Bushing driving guide

Q'ty 2 4

USE

to remove and install holder to keep straight the spool to install the bushing

to remove the spring pin

DISASSEMBLY and ASSEMBLY

PV-10-14

(D/A)

---------HV TYPE PILOT VALVE (FOR TRAVEL)---------

@ Item 01

Part name

Casing

Q'ty 1

Item

Spring

Spool

Spacer

Shim

Spring

Spring guide

Bushing

Plug

Cam

Spring pin

Bolt

Spring washer

20 4

Oil seal

0-ring

13 14

Dust seal

Pusher

Holder

Socket bolt

Spring washer

Q'ty 2

Part name

0-ring

Cover

Plain washer

4 4

2 1

OPERATIONAL PRINCIPLE

CNV-1-1 (0/P) CONTROL NEUTRALIZER VALVE ----------

1. OUTLINE

Control neutraliser valve is provided to operate pilot pressure for pilot valve.

This valve is mainly composed of spool, Body and lever.

PILOT VALVE

(,;-:�

-\!�

SPOOL

LEVER CONTROL NEUTRALISER VALVE

Fig. 1

PILOT PUMP

CNV-1-2 {O/P)

OPERATIONAL PRINCIPLE

CONTROL NEUTRALIZER VALVE 2. FUNCTION

a. �eutral position (OFF) When lever is "OFF" position, pilot

pressure oil is cut and open the drain

line from pilot valve to tank.

So that machine can not operate.

HYO. TANK Fig. 2

b. Working position (O�) When lever is "ON" position, drain

PILOT

VALVE

line is cut and pilot pressure oil flows to pilot valves.

So that machine can operate.

PILOT PUMP Fig. 3

;:-).__ _____-_-_- __��--�===

Fig. 4

DISASSEMBLY and ASSEMBLY

CNV-1-1 (D/A)

CONTROL NEUTRALIZER VALVE ---------1. DISASSEMBLY NOTE: Before disassembling clean the all parts.

[!] Remove nut ,

(11)

, : 14 mm

ll)Remove spring washer (09) and lever (03).

0Loosen nut (10) and remove bolt (07) and (08).

4 mm

II)Remove seal plate (06).

DISASSEMBLY and ASSEMBLY

I!]

Remove spool (02), 0-ring (05) and

back-up ring (04).

I!} Remove I

CNV-1-2 (D/A) CONTROL NEUTRALIZER VALVE -----------

bolt (07). 4 mm

Remove seal plate (06), 0-ring (05)

and back-up ring (04).

DISASSEMBLY and ASSEMBLY

CNV-1-3 (D/A)

CONTROL NEUTRALIZER VAVLE ----------2. ASSEMBLY NOTE: Before assembling, clean all parts

and apply clean hydraulic oil to

all internal parts.

QJ Install spool

(02).

Install 0-ring (05) and back-up ring (04).

12) Install seal plate Tighten torque

(06) and bolt (07).

0.8 kg.m (5.78 ft.lbs)

�Install 0-ring (05) and back-up ring (04).

DISASSEMBLY and ASSEMBLY

CONTROL NEUTRALIZER VALVE

I!)' Install seal plate ( 08).

(06), bolt (07) and

Tighten nut (10). �

Cv :8mm

I!] Install spring washer

(09) and lever (03).

0Install nut (11). �

<, : 14 mm

Tighten torque

1.5 kg.m (10.85 ft.lbs)

CNV-1-4 (D/A)

DISASSEMBLY and ASSEMBLY

CONTROL NEUTRALIZER VALVE

Item 01

Q'ty

Body

Lever

Spool

Back-up ring

Seal plate

03 05

0-ring

Bolt

06 08 09

10 11

»-I

Part name

2 3

Bolt

Nut

Spring washer

Nut

CNV-1-5 (D/A) -----------

SHV-1-1 (0/P)

OPERATIONAL PRINCIPLE

------------- SHOCKLESS VALVE -------------

1. OUTLINE

".he shockless valve is provided in the

pilot circuit to privent shock for body :ind ,,1 ,=trm up for pilot circuit.

This valve is mainly composed of plunger,orifice, sleeve,and filter. BALL

PLUNGER

fig. 1

OPE RATIONAL PRINCIPLE

SHV-1-2

------------- SH (0/P) OCKLESS VALVE ------------

2. FUNCTION 2-1 SHOCKLESS SYSTEM

The shockless valve is provided shockless syste m that is to prevent to occur shock for body after each control lever operated. It is to restrict the return oil form the control valve to the pilot valve through orifice of shockless valve.

CONTROL NEUTRALISER VALVE PILOT VALVE

CHECK BLOCK

SOLENOID VALVE

, .....................

�-

_____ J

SHOCK LESS VALVE

PILOT FILTER

CONTROL VALVE

PILOT PUMP

SUCTION FILTER

Fig. 2

FULL-FLOW FILTER

SHV-1-3

OPERATIONAL PRINCIPLE

(0/P)

-------------SHOCKLESS VALVE

))

CONTROL VALVE

PILOT VALVE

SHOCKLESS VALVE

-SHOCKLESS CIRCUITFig. 3

SHV-1-4 (0/P)

OPERATIONAL PRINCIPLE ------------ SHOCKLESS VALVE 2-2 HEAT-RUN SYSTEM

The shock less valve is provided heat-run system that is to h·arm up the pilot

line.

The relief pressure oil flows to the pilot valve through filter and

check valve of shockless valve.

CONTROL NEUTRALISER VALVE

PILOT VALVE

CHECK BLOCK

SOLENOID VALVE

__J CONTROL VALVE

PILOT FILTER

PILOT PUMP

SUCTION FILTER

Fig. 4

FULL-FLOW FILTER

OPERATIONAL PRINCIPLE

SHV-1-5

-------------SHOCKLESS VALVE ___________ (o_J_P_l_

PILOT VALVE

)}

SOLENOID VALVE

PILOT PUMP

PILOT FILTER

- HEAT-RUN CIRCUIT Fig. 5

SHV-1-1 (D/Al

DISASSEMBLY and ASSEMBLY

------------- SHOCKLESS VALVE------------1. DISASSEMBLY

NOTE: Before disassembling clean the valve assembly.

----------- DISASSEMBLY OF FLOW CONTROL ASS'Y ------------

IJ:] Remove plug I:

(02)

• .&

8mm

Remove plug (06)

8mm

fl) Remove spring

(01)

�

13] Remove plunger ass'y

--...., 0

(12)

DISASSEMBLY and ASSEMBLY ------------- SHOCKLESS VALVE

I!)

SHV-1-2 (D/A)

Remove spring (01) and 0-ring (09) from the

plug.

---------- DISASSEMBLY OF Fl L TER AND CHECK ASS'Y - ---------

[II Remove plug I :

6 mm

(04).

Remove 0-ring (10).

12) Remove spring

(03) and steel ball (15D).

DISASSEMBLY and ASSEMBLY

SHV-1-3 (D/A)

------------- SHOCKLESS VALVE -------------

[!] Remove

sleeve (14B) with retaining plier.

IIIRemove 0-ring (08) from the sleeve.

DISASSEMBLY and ASSEMBLY -------------SHOCKLESS VALVE

SHV-1-4 (D/A)

2. INSPECTION ----------------------------

Q] Plunger

When plunger (12) stuck because of rust or

dust, check surface of plunger.

So if it has rust or flaw, clange the plunger.

Spring

When spring (01) was bended or broken, change the spring.

Check valve

When check valve was leaked, check spring (03) and valve seat.

DISASSEMBLY and ASSEMBLY

------------- SHOCKLESS VALVE 3. ASSEMBLY

------------ ASSEMBLY OF FLOW CONTROL ASS'Y

o:J

Before assembling clean the all parts.

Install 0-ring (09) into the plug.

(II Install plug I :

8 mm

(02).

Tighten torque : 4 kg.m (28.93 ft.lbs)

[llrurn the casing.

Install spring (01).

[!] Install plunger ass' y

(12) and spring (01).

SHV-1-5 (D/A)

DISASSEMBLY and ASSEMBLY ------------- SHOCKLESS VALVE

SHV-1-6 (D/A)

� Install plug (06).

8 mm

Tighten torque

4 kg.rn (28.93 ft.lbs)

------------ASSEMBLY OF Fl LTER AND CHECK ASS'Y ------------

Q] Before assembling clean the all parts.

Install 0-ring (08) into the sleeve and

0-ring (10) into the plug.

ll} Install sleeve

(14B).

@] Install steel ball

(15D).

DISASSEMBLY and ASSEMBLY

SHV-1-7 (D/A)

------------- SHOCKLESS VALVE -------------

[!]

Install spring (03).

� Install plug (04). 6 mm

Tighten torque : 2 kg.m (14.47 ft.lbs)

DISASSEMBLY and ASSEMBLY

SHV-1-8

-------------SHOCKLESS VALVE ___________!_o;_A_l_

SECTION-X

(6.7 PORT) (5 PORT) (1 - 4 PORT)

@ 0

SECTION-Y

o ; o 9

SHV-1-9 (D/A)

DISASSEMBLY and ASSEMBLY

-------------SHOCKLESS VALVE

Item

Part name

Spring

Plug

Q'ty 14 7 I

12A

Plunger

Q'ty 1

Orifice

Item

12B

Part name

Ring

Spring

12C

Name-Plate

13A

Plunger

Screw drive

13C

Orifice

O-ring

04 06

Plug

O-ring

14B

O-ring

llA

Plunger

Orifice

11B

llC 12

Plunger ass'y Ring

Plunger ass'y

13B

14A

Plunger ass'y

Ring

Filter ass'y

Sleeve

Filter

Body ass'y

lSB

Seal

15D

lSA

lSC

l l l l

Body

Seal

Steel ball

OPERATIONAL ORINCIPLE

AC0-4-1 (0/P)

ACCUMULATOR 1. OUTLINE

The accumulator mainly consists of the body, holder, bladder enclosed the nitrogen gas, and poppet.

Can not inject a accumulator with nitrogen gas, replace as an assembly.

BODY POPPET

HYD OIL

,,._,..,.__ ____ ___ 01 L PORT

PORT A

PILOT PUMP

PILOT FILTER

SUCTION FILTER

L-�

1,-

CHECK BLOCK

,--

-I

)( SOLENOID VALVE

ACC-4-2 (0/P)

OPERATIONAL PRINCIPLE

ACCUMULATOR

2. FUNCTION---------------------------

The hydraulic oil from the pilot pump is

regulated its pressure by the relief valve.

Since the nitrogen gas is enclosed inside of

the bladder, the hydraulic oil enters through

the port A into the body which is formed by

the body and bladder, and compresses the

bladder until its 1ressure is balanced with the inside nitrogen gas pressure of the

bladder, necessarily increasing gas pressure. PORT A

If the hydraulic oil in the circuit it cut

off by such phenomenon as the engine stop,

the inside nitrogen gas of the bladder acts to prevent sudden 0il pressure drop in the

circuit by pushing the accumulated oil through the port A out of the accumulator, expanding

the bladder and decreasing the gas pressure.

PORT A

SOV-9-1 (0/P)

OPERATIONAL PRINCIPLE

SOLENOID VALVE------------1. OUTLINE Solenoid valves are provided in the

pilot circuit to operate pump regu

lator, auto-idle cylinder and mode change cylinder.

This valve is mainly composed of spool, magnetic coil, plunger and body.

SOLENOID VALVE

PLUNGER

RELIEF VALVE

BODY

__ (7

TO PUMP REGULATOR

/�

TO CYLINDER (11)

Fig. 1

OPERATIONAL PRINCIPLE

SOV-9-2 (0/P)

SOLENOID VALVE------------2. FUNCTION 2.1

SOLENOID VALVE (N/C: Normal close type)

This valves are provided to operate cylinder (I) and (IT).

a. Neutral position When no electrical instruction is given, the valve is in neutral.

In this condition, pilot pressure line from pilot pump is cut, and allows the

pilot pressure oil in port S to flow

to the tank.

T (TO TANK)

Fig. 2

b. Working position When an electrical instruction is given,

the valve move to the downward.

Pilot

pressure oil from pilot pump flows to

the cylinder.

S (TO CYLINDER)

P (FROM Pl LOT PUMP)

Fig. 3

SOV-9-3 (0/P)

OPERATIONAL PRINCIPLE

SOLENOID VALVE 2.2 SOLENOID VALVE (N/O: Normal open type)

This valve is provided to operate pump regulator.

a. Neutral position When no electrical instruction is given, the valve is in neutral.

In this condition, pilot pressure oil from pilot pump flows to the pump

regulator.

P (FROM PILOT PUMP)

Fig. 4

b. Working position When an electrical instruction is given, the spool rrove to the downward.

Pilot

pressure line from pilot pump is cut,

and allows the pilot pressure oil in port S to flow to the tank.

T (TO TANK)

Fig. 5

OPERATIONAL PRINICPLE

SOV-9-4 (0/P)

-------------SOLENOED VALVE 2.3 PILOT RELIEF VALVE

This valve is provided to keep the pilot pressure at 40 kg/crn 2 •

a. Neutral position When engine is stopped, the valve

is in neutral.

In this condition, pilot pressure line is opened to the tank through control

neutraliser valve.

NOTE: If pilot pump is broken, the valve is in neutral.

b. Working position

TANK FROM PILOT PUMP

Fig. 6

When engine is started, the valve moves to the upward.

In this condition, pilot pressure

builds up at 40 kg/cm z and oil flows

to shockless valve.

TO SHOCK LESS VALVE

FROM PILOT PUMP

Fig. 7

SOV-9-5

OPERATIONAL PRINCIPLE

SOLENOID VALVE ____________(_o_;P_l

The oil passage of solenoid valve is as shown in Fig. 6 and 7.

CYLINDER 11

CYLINDER I REGULATOR CHECK VALVE

PILOT PUMP

PILOT FILTER

r-1

CONTROL NEUTRALISER VALVE TO SHOCKLESS VALVE Fig. 8

DISASSEMBLY and ASSEMBLY

SOV-9-1

-------------- SOLENOID VALVE ____________ (o_l_A_l 1. DISASSEMBLY--------------------------Note: Before disassembling clean the all parts.

IJ:}

Remove screw (20).

11}

Remove coil assembly (18) from screw (20).

Ill

[!}

Remove spacer(l 7) from coil assembly (18).

Remove inner housing (16) .

DISASSEMBLY and ASSEMBLY

-------------SOLENOID VALVE

I!)

I!]

Remove plunger(l3), spring(l2) and spring seat (11).

Remove pipe (10) and 0-ring (09) from inner housing (16) with nylon brush.

'2]

Remove stopper (14) and rod (15).

(!)

Remove spool (08) and (19).

[!) Remove spring

(03).

SOV-9-2 (D/A)

SOV-9-3 (D/A)

DISASSEMBLY and ASSEMBLY

-------------SOLENOID VALVE � Remove body (07).

!ill

Remove 0-ring(04), (05) and (06) from body (07)

Remove plug (02). �

'-: 22 mm

[ill Remove shim

(24) and relief spring (25).

!ill

Remove 0-ring (23).

DISASSEMBLY and ASSEMBLY

-------------SOLENOID VALVE

\ill

SOV-9-4 (D/A)

Remove relief valve assembly (21).

Remove gasket (22).

_;.,

DISASSEMBLY and ASSEMBLY

SOV-9-5 (D/A)

SOLENOID VALVE-------------

2. INSPECTION ---------------------------

[I}

Coil assembly

When coil assembly(@)short-circuited or disconnected, change coil assembly.

llJ

Plunger

When plunger(@) stuck because of rust or dust, check surface of plunger.

So if it has rust or flaw, change the plunger.

I]]

Spool

When spool(@)stuck because of rust or dust, check surface of spool.

So if it has rust or flaw, change the spoo 1 and body.

COIL ASSEMBLY

BODY

DISASSEMBLY and ASSEMBLY

SOV-9-6 (D/A)

SOLENOID VALVE ------------3. ASSEMBLY Note:

Before assembling clean all parts

and apply clean hydraulic oil to

all internal parts.

Install gasket (22).

ll]

Install relief valve assembly (21).

[!]

Install 0-ring (23).

� Install relief spring (25).

SOV-9-7 (D/A)

DISASSEMBLY and ASSEMBLY

------------- SOLENOID VALVE -------------

Install shim (24) .

Note: �umber of shim are decided at

performance test, don't loose them.

I!}

Install plug (02). �

, : 22 mm

Tighten torgue: 5 kg.m (36.17 ft. lbs)

IZJ

Install O-ring(04), (05) and (06) into body (07).

[!) Install body (07) and spring (03).

[!) Install spool (08)

and (09).

Note: Install spool refer to port number.

SOV-9-8

DISASSEMBLY and ASSEMBLY

-------------

� Install stopper (14) and rod (15).

!ill

Install plunger (13), spring (12) and

spring seat (11).

jill

Install 0-ring(09) into inner housing(l6).

!ill

Install pipe (10) into inner housing(l6).

Install inner housing (16).

(D/A)

SOLENOID VALVE -------------

SOV-9-9 (D/A)

DISASSEMBLY and ASSEMBLY

------------- SOLENOID VALVE -------------

!ill

Install spacer (17) into coil assembly (18) .

[ill

Install coil assembly (18) into screw (20).

!ill

Install screw (20). Note:

Apply lock tight to screw, 32 mm

Tighten torgue: 3 kg.m(21. 70 ft.lbs)

DISASSEMBLY and ASSEMBLY -------------

SOV-9-10 (D/A)

SOLENOID VALVE

®.

@ @ @

@---�

@------l'Ql-l�

@ Item

Part name

Casing

Q' ty 1

Item

Spring

0-ring

01 02

04 06

Plug

0-ring 0-ring Body

Spool

Pipe

09 11

13 H

1 3 3

3 3

Part name

Inner housing

Q'ty 3

Spacer

Spool

20 21 '11 -,

�.)

Coil assembly

Sere\\

Relief \·al\·e assembly

3 3

Gasket

0-ring

Shim

Spring seat

Tape L1\hite)

Spring

Plunger

Stopper Rod

Relief spring Tape (blue) Tape (red)

1 1 1

SOV-11-1

OPERATION PRINCIPLE

(0/P)

-------------- SOLENOID VALVE -------------1. OUTLINE ------------------------------

Solenoid valve is provided in the pilot

circuit to operate pump regulator.

This valve is mainly composed of plunger, magnetic coil, spool, spring and

body.

MAGNETIC COIL

SPOOL

SOV-11-2 (0/P)

OPERATION PRINCIPLE

---------------SOLENOID VALVE--------------2_ FUNCTION ------------------------------

(1) Neutr�l position When no electrical instruction is

given, the valve is in neutral posi tion.

In this condition, pilot pressure line

from pilot pump is cut, and allO\,s the

TANK ___

pilot pressure oil to the tank.

(2) Working position When electrical instruction is given, the valve move to the downward.

So that, the pilot pressure oil from

pilot pump flows to pump regulator and mode selection cylinder.

TO REGULATOR

SOV-11-3

OPERATION PRINCIPLE

(0/P)

SOLENOID VALVE

The oil passage of the solenoid valve is as shown below.

-------<►� SOLENOID (THREE ) VALVE SPOOLS SOLENOID (ONE ) VALVE SPOOL

PILOT PUMP

REGULATOR

L -J

TANK

(

SOLENOID ONE ( ) VALVE SPOOL

l <",-'�-\ = 1; 1 I j ;'., .j\ ,-- Jc

"l�)/1

i PILOT

=".

FILTER

SOV-10-1 (D/A)

DISASSEMBLY and ASSEMBLY

-------------- SOLENOID VALVE -------------

1. DISASSEMBLY Note:

12]

Remove screw (18) �

ll}

Before disassembling clean the outside of the solenoid valve.

<,:

32 mm

Remove coil assembly (17) from screw (18) .

Remove spacer (16) from coil assembly (17).

-� Remove inner housing (15) .

DISASSEMBLY and ASSEMBLY

SOV-10-2

(D/A)

-------------- SOLENOID VALVE -------------

I!]

Remove plunger (12), spring (11), and

spring seat (10) from inner housing (15}.

Remove pipe (09) and 0-ring (08) from the

inner housing.

Remove stopper (13) and rod (14).

Remove spool (07).

II)

Remove spring (02).

, '• • •

�

SOV-10-3 (D/A)

DISASSEMBLY and ASSEMBLY

-------------- SOLENOID VALVE -------------

[ill

Remove body (06). .,.,,

:;;.;-· -,

·� .;,,,.�.

.._ ,

[!II

Remove 0-ring (03) (04) (05).

SOV-10-4 (D/A)

DISASSEMBLY and ASSEMBLY -------------

SOLENOID VALVE

2. INSPECTION

II)

Coil assembly

When coil assembly (17) short-circuited

or disconnected, change coil assembly.

llJ

Plunger

When plunger (12) stuck because of rust or dust, check surface of plunger.

So if it has rust or flaw, change the

plunger.

II)

Spool

When spool (07) stuck because of rust or dust, check surface of spool.

So if it has rust or flaw, change the

spool and body.

COIL ASSEMBLY

PLUNGER

SPOOL

DISASSEMBLY and ASSEMBLY -------------

SOLENOID VALVE

SOV-10-5 (D/A)

3. ASSEMBLY Note:

Before assembling clean all parts and apply cle2n hydraulic oil to all internal parts.

Install 0-ring (03) (04) (05) into the body.

II)

Install spring (02).

Install spool (07).

� Install stopper (13) and rod (14).

• .

SOV-10-6 (D/A)

DISASSEMBLY and ASSEMBLY

--------------

SOLENOID VALVE -------------

Install plunger (12), spring (11) and

spring seat (10).

Install O-ring (08) into the inner

housing.

IZJ

Install pipe (09) into the inner housing.

[!}

Install inner housing (IS) into the body.

� Install spacer (16) into coil assembly ( 17) .

-.I

�

DISASSEMBLY and ASSEMBLY

--------------

[ill

SOLENOID VALVE -------------

Install screw (18) into coil assembly ( 17) .

[ill

Install screw (18). Note:

, ' ' ....

Apply locktight to screw. 32 mm

3 kgf.m (22 ft.lbs)

SOV-10-7 (D/A)

DISASSEMBLY and ASSEMBLY

SOV-10-8

-------------- SOLENOID VALVE ___________(_DI_A_l_

@ @)

@ @ @ @ �;j--------@

@)@)@ Item 01 02

Part name Housing Spring

0-ring 0-ring

Q'ty

Item

0-ring

Spool

Pipe

Body

0-ring

@ Part name

Q'ty

Spring seat

Plunger

Rod

Spring

Stopper

1 1

Inner housing

Coil assembly

Spacer

Screw

DISASSEMBLY and ASSEMBLY

CY-13-1 (D/Al

MODE SELECTION CYLINDER ----------1. DISASSEMBLY Note: Before disassembling clean the cylinder assembly.

[J:l

llJ

Hold cylinder assembly by a vice.

Remove nipp1e (02). ,

II)

(,: 32 mm

Remove 0-ring (08) from nipple (02).

� Remove piston rod (03) and washer (04) from plug (01).

CY-13-2 (D/A)

DISASSEMBLY and ASSEMBLY

----------- MODE SELECTION CYLINDER ------------

[!}

Remove seal (06) and wiper ring (07)

2. ASSEMBLY

Note: Before assembling clean the all

parts.

[!] Install seal

(I)

(06) and wiper ring (07).

Install piston rod (03) and washer (04).

C C:I

DISASSEMBLY and ASSEMBLY

CY-13-3

(D/A) ----------- MODE SELECTION CYLINDER ------------

ll}

Install 0-ring (08) into nipple (02).

[!]

Install nipple (02) into plug (01). 32 mm

Tighten torque: 9 kg•rn (65.10 ft.lbs)

DISASSEMBLY and ASSEMBLY

CY-13-4 (D/A)

----------- MODE SELECTION CYLINDER ------------

Item 01 02

Plug

Part name

Q'ty 1

Nipple

Washer

Seal

0-ring

05 07 08

Piston rod

Nut

Wiper ring

1 1

INDEX EX270-5A-1

L=mmmo

UNDERCARRIGE

CONTENTS Group 1-UNDERCARRIAGE ...................

uc2s-1-ss 1 . Track Frame ....... .................... . ........... UC25-1 2. Swing Bearing .... . ................................ UC25-3 3. Travel Device & Piping ............................. UC25-10 4. Front Idler ........................................ UC25-19 5. Adjuster ........... .......... ..................... UC25-26 6. Upper Roller & Lower Roller ........................ UC25-38 7. Track Link .................................... .... UC25-52 8. Center Joint ...... . .......................... ..... UC25-62

Group 2-TRAVEL DEVICE

■ ■ ■

O/P, Travel Motor ............................. HYM-48A-1-6 DIA, Travel Motor ............................ HYM-48A-1-38 DIA, Travel Device ............................. TD-18A-1-24

Group 3-CENTER JOINT

■ ■

O/P,Center Joint ................................. CJ-10-1-2 D/A,Center Joint ................................. CJ-10-1-8

0/P: OPERATIONAL PRINCIPLE 0/A: DISASSEMBLY & ASSEMBLY

UNDERCARRIAGE

UC-25-1

-------------UNDERCARRIAGE-------------1. TRACK FRAME 1.1 CONSTRUCTION & FUNCTION

The track frame is a welded one-construction and composed of center frame, right and left side frames.

The center frame is X of shape and has a centralized hole for the pipings to

improve the reliability.

can be easily eliminated.

mud fall off easily.

The side frame is convex of shape so that the mud

A hole is provided beneath the upper roller to make

The swing bearing "and the center joint are provided on the center frame, the

lower rollers and the center guards are under the side frames, the upper

rollers are on the side frames, the front idlers are at the front of the side frames and the travel devices are at the rear of the side frames.

CENTER FRAME

SIDE FRAME (R)

TRAVEL PIPING COVER

,,/

SIDE FRAME (L)

UNDERCARRIAGE

UC-25-2

-------------UNDERCARRIAGE------------1.2 SPECIFICATIONS- ------------- ----------- --

F----�1

EX270 A

B C D

E F

Weight

2590 mm

3188 mm

965 mm 785 mm

3710 mm

4140 mm

3060 kg

UNDERCARRIAGE

UC-25-3

-------------UNDERCARRIAGE-------------2. SWING BEARING 2.1 CONSTRUCTION & FUNCTION

The swing bearing supports the superstructure and makes rotation smooth. This swing bearing is a single row shear type ball bearing.

The major parts of the swing bearing are the outer race, the inner race with

internal gear, balls, supports and dust seals.

The outer race is bolted to the superstructure.

The inner race is bolted to the undercarriage.

The internal gear is incorporated in the inner ring and meshes with the pinion from the swing reduction device.

OUTER RACE

DUST SEAL ---1

DUST SEAL

UNDERCARRIAGE

UC-25-4

-------------UNDERCARRIAGE-------------2.2 MAINTENANCE

2.2.1 ASSEMBLY DRAWING

OU TER RACE

.-i

1416 1378 -1162(P.C.D)-1137 -

INNER RACE

�� :-(•

�1/

SEAL

I I

(:)--

f--

��

�� '-=u

.-j l-,b

�

SEAL

1300 SUPPORT A

SUPPORT B

NOTE

1) After cleaning the grooves of inner and outer races, apply adhesive liquid to seal A and B, and install them to the races.

2) Before installing swing-bearing to the machine, supply grease plenty Recommended grease:

3) Thrust clearance: 4) Radial clearance

EP2

0.15 � 0.35 mm 0.15 � 0.35 mm

UC-25-5

UNDERCARRIAGE

------------- UNDERCARRIAGE-------------The races, on which the steel balls run, are hardened by means of flame harden

ing which creates a soft zone at heat starting point.

On the inner race

(internal gear side), the soft zone is marked with "S" as shown below.

minimize loading on the soft zone, mark "S" should be placed on the righthand

side of the track frame as shown belm,·. Also, the softzone of outer race is

placed on the righthand side as same as inner race.

BALL

SOFT ZONE OF OUTER RACE

SOFT ZONE OF INNER RACE

UNDERCARRIAGE

l)C-25-6

-------------UNDERCARRIAGE--------------

2.2.2 REMOVAL (1) REMOVAL

INSTALLATION

Remove the superstructure

IJ:l ll}

Put a mating mark on swing bearing and

undercarriage.

Remove bolts (20). ,

C, 36

Hoist swing bearing (21) using special tool (ST-9050)

Weight: 309 kg

[!]

Remove swing bearing (21).

IJ:l

(2) INSTALLATION

Clean the mating faces of truck frame and

swing bearing.

ll} Install special tool ing bearing.

(ST-9050) to the sw

UNDERCARRIAGE

UC-25-7

-------------UNDERCARRIAGE--------------

Hois t the swing bearing.

Align the swing bearing with the mating

FRONT SOFT ZONE

mark of t ruck frame.

Weight: 309 kg

Outer race soft zone and

Inner race soft zone shoud

be place same position as shown.

[!]

Instal l bo lts (20). Tightening to rque: 95 kgf.m

...

(687 ft. lbs)

2.2.3 DISASSEMBLY � 1

Grind off calked part of taper pin.

Push the pin out from lower part.

UNDERCARRIAGE

UC-25-8

------------- UNDERCARRIAGE--------------

II)

Remove plug using a (10 mm, pitch 1. 5 mm)

bolt as shown.

1 2

Hoist the swing bearing outer race

slightly using special tool (ST-9050). Inspect the rotation of the bearing.

Note; If the rotation of the bearing is not smooth, remove seals.

[!]

I!)

Remove the steel ball using magnet as

shown.

Remove the support using wire as shown.

While rotating the inner race, remove

steel balls and supports.

UC-25-9

UNDERCARRIAGE

2.3 SPECIFICATIONS

Number of steel ball

Number of support B

Number of support A Number of tooth Weight

75 83

309 kg

UNDERCARRIAGE

UC-25-10

-------------UNDERCARRIAGE-------------3. TRAVEL DEVICE & PIPING 3.1 CONSTRUCTION & FUNCTION

The below figure shows the piping from center joint to travel motor.

This piping consists of one pipe for draining from the travel motor and four

piping for actuating the travel motor.

brake is supplied from the brake valve.

The oil for releasing the parking

JOINT

REVERSE

RIGHT TRAVEL MOTOR

TRAVEL MOTOR

UNDERCARRIAGE

UC-25-11

------------- UNDERCARRIAGE-------------3. 1. 1

TRAVEL DEVI CE

The travel device consists of travel motors, travel reduction device and

sprocket.

The spring-set hydraulically released type disc parking brake is provided

in the travel device.

DRUM !

HOUSING

HYDRAULIC MOTOR

// /c:RRIER ��-�--

SPROCKET

RING GEAR

UC-25-12

UNDERCARRIAGE

-------------UNDERCARRIAGE--------------

3.1.2 TRAVEL DEVICE FUNCTION

3rd STAGE

MOTOR

� G ili ru·· JJ.j 1z

�

T -----'-----

SPROCKET

1st STAGE

2nd STAGE

SUN GEAR

��

ETARY

RIN} GEAR

The travel reduction device is three stage planetary gear type.

If the motor rotates clockwise, propel shaft (35) does the same direction.

As ring gear (18) is being fixed, planetary gear (30) rotates counterclockwise

on its axis and moves around the propel shaft.

This orbital motion of the

planetary gears (30) rotate the carrier clockwise in the same direction of

the propel shaft.

The 2-stage carrier rotates the 3-stage planetary gear (13).

carrier is fixed by the housing, so the ring gear is rotated. is fixed to the sprocket with bolts.

The 3-stage

The ring gear

Consequently, the sprocket is rotated.

INPUT

FIX

I-stage

Sun gear

Ring gear

Carrier

2-stage

Sun gear

Ring gear

Carrier

3-stage

Sun gear

Carrier

Ring gear

OUTPUT

UNDERCARRIAGE

UC-25-13

-------------UNDERCARRIAGE-------------3.2 MAINTENANCE

3.2.1 REMOVAL

REMOVAL

ll)

INSTALLATION

Place unit on level ground.

Swing the

superstructure so that the operator's cab

side is travel device side as shown.

Disconnect track link.

Stop the engine and operate the control lever for releasing pressure in the hy

CAP

draulic system.

Remove the air breather cap and release

the air from the hydraulic tank.

[!]

r Remove the piping covers.

�

� Remove clamps '

(, 19

ARROW

UC-25-14

UNDERCARRIAGE

-------------UNDERCARRIAGE--------------

[!]

Disconnect the hose for releasing the air

from the control valve.

Set the vaccume pump and operate it.

IZJ

Disconnect travel pipings from the travel

motor.

r [!)

Lift the travel device. Weight: 427 kg

[!}

Remove bolts and separate the travel device

from the track frame using a bar. 30

INSTALLATION

[I} Lift the travel device and place it on the track frame.

Install bolts.

Tightening torque: 55 kgf.m

(400 ft.lbs)

UNDERCARRIAGE

UC-25-15

-------------UNDERCARRIAGE--------------

Install travel piping s to the motor.

.,, 22 ,...._,

4 kgf.m, 29 ft.lbs Tightening torque: 9 kgf.m, 65 ft.lbs

Install clamps and piping cover s.

�

Tightening torque: 9 kgf.m, 65 ft.lbs

[!}

Connect track link

I!]

Check the hydraulic oil level.

Supply the hydraulic oil at the level.

UNDERCARRIAGE

UC-25-16

--------------UNDERCARRIAGE--------------

3.2.2

MAINTENANCE STANDARD

(1) SPROCKET

j©

Unit: mm

EX270

Number of tooth

Weight

59. 8 kg ND

612

606

602

689. 4

704

698

694

203,2

ND:

Nominal Dimension

LU:

Limit of Use

RL:

Recommended Service Limit

UNDERCARRIAGE

UC-25-17

-------------UNDERCARRIAGE--------------

(2) PARK ING BRAKE ND FRICTION PLATE THICKNESS

3.3

SPACER THICKNESS

9.0

DISC SPRING HEIGHT

6.5

45. 5 *

PISTO'.'J HEIGHT PLATE THICKNESS *

1.8

CASING

ND:

Nominal Dimension

LU:

Limit of Use

RL:

Recommended Service Limit

3.3 SPECIFICATIO'.'JS--------------------------- ---

3.3.l TRAVEL DEVICE Model

Weight

HMGC42AA

427 kg

(Motor)

70. 9 kg

Lubrication oil capacity

7.5 £

(Sprocket)

Reduction ratio 3.3.2 TRAVEL MOTOR Model

59. 8 kg 61.207

HMT134CF-26A

Parking brake releasing pressure

8.5 � 9.8 kgf/cm 2 (830 � 960 kpa)

Weight

70.9 kg . 2045 min -1

Displacement

Max. rotation speed Theoretical torque

3.3.3 BRAKE VALVE

Relief set pressure Weight

134 cm 3 /rev.

74.6 kgf.m (at 325 kgf/cm 2) (at 31873 kpa)

330 kgf/cm 2 (32363 kpa)

27. 9 kg

UNDERCARRIAGE

UC-25-18

------------- UNDERCARRIAGE--------------

3.3.4 MAIN COMPONENTS WEIGHT TRAVEL DEVICE UNIT TRAVEL MOTOR

HOUSING

SPROCKET CARRIER PLANETARY GEAR RING GEAR SUN GEAR CARRIER

PLANETARY GEAR SUN GEAR CARRIER

PLANETARY GEAR PROPEL SHAFT

COVER BRAKE VALVE DRUM

TRAVEL PIPING

Weight (kg) 427 70.9 67.1 59.8 28.8 2.6 51.0

4.8 9.7 1.3

2.3 5.2 0,7

5.3 10.0 27.9 58.9 45.7

UNDERCARRIAGE

UC-25-19

-------------UNDERCARRIAGE-------------4. FRONT IDLER 4.1 CONSTRUCTION

The front idler is equipped with both ends of the side frame and can be moved back and forth.

The bearing in it is fitted with the yoke of track spring.

IDLER

BEARING SEAL

BUSHING

AXLE

UNDERCARRIAGE

UC-25-20

------------- UNDERCARRIAGE-------------4.2 MAINTENANCE

4.2.1 ASSEMBLY DRAWING

,,i-..-++- ! l

, \\I I I

�µ LJ

NOTE

1) Apply engine oil to the sliding face of seal group. 2) Recommended oil:

Volume:

Class 3 300 cm

SAE 30

3) After assembling, rotate front idler 10 times.

4) Apply plastic gasket to plug (27).

Check oil leakage.

UNDERCARRIAGE

UC-25-21

-------------UNDERCARRIAGE--------------

4.2.2

12)

REMOVAL

Disconnect track link

Move front idler and york assembly to the

end of track frame with bar.

(I)

Fasten wire around idler wheel and york.

Remove idler and york assembly from track

frame.

II}

If keep it for a time, place it as shown.

II)

Installation is the reverse order.

Q Note :

Make sure that upward or downward of the yoke.

4.2.3 DISASSEMBLY

ASSEMBLY

DISASSEMBLY Remove plug (02) and drain the oil.

12)

UC-25-22

UNDERCARRIAGE

------------- UNDERCARRIAGE--------------

Remove pin (03).

@)I .'

'' ' ' ''' ..'

....

'2]

Press axle (05) and remove bearing (01)

from the axle.

�

LJ,

'=' r11117777J/77 �

lllil/11/1/J� I

[!]

I!]

Remove 0-ring (04) from the axle and push

out the axle with the bearing.

0-® --

fe 1:..__________,J: I E:3

Remove seal groups (06) from idler (07)

and bearings (01).

Note: The seal groups can be reused if they are not worn. Seal groups are to be kept in matched sets and to

put cardbord between seals to protect the sealing face.

Press axle (05) and remove axle (05) , 0-

@ @

ring (04) and bearing (01).

UNDERCARRIAGE

UC-25-23

------------- UNDERCARRIAGE--------------

II)

Press out bushing (09) using press and

special tool (ST-1968)

SPECIAL TOOL

ASSEMBLY

II)

Before assembling, clean all parts.

Press bushing (09) to idler (07).

Apply a grease to 0-ring (04) and install

it to axle (OS).

Install axle (OS) to bearing (01) and fix it by pin (03).

ll]

Install seal groups (06) to idler (07) and

[!]

Intall the axle to the idler.

bearing (01).

Install bearing (01) and pin (03) to the axle.

Supply oil through plug hole. Recommended oil Class:

Volume:

API CD

3 300 cm

SAE30

UNDERCARRIAGE

UC-25-24

-------------UNDERCARRIAGE--------------

4.2.5

MAINTENANCE STANDARD

cc <

ND:

Nominal Dimension

RL:

102

204

530

524

22.5

575

Limit of Use

LU:

i---------- D F --

Mark

Recomended Service Limit

Unit:

Remedy Buildup & Finish

520

Unit: ND

Description Axle Bushing

Outside Dia.

84.5

84.2

Inside Dia.

85 .5

86.0

Flange Thickness

4.5

4.0

3. 8

Outside Dia.

Remedy Replace

Unit:

Clearance between Axle Gap between Axle

Bushing

Side Coller

ND 0.147 0.402 0.25

1.0

1.8

1.0

1.5

Note Total dimension of both side

UNDERCARRIAGE

UC-25-25

------------- UNDERCARRIAGE-------------4. 3 SPECIFICATIONS---------------------------

Weight Idler Axle

Bearing

Trade diameter

Recommended oil

Volume

;;61

150 kg 107 kg 16 kg 11. 9 kg 530 mm Class 3 300 cm

SAE30

UC-25-26

-------------UNDERCARRIAGE-------------5. ADJUSTER 5.1 CONSTRUCTION Track adjuster consists of track spring, cylinder, piston rod,cylinder rod and other small parts. The back-end of spring is seated on washer and supported track frame structure. The front-end of piston rod contacts with yoke.

YOKE FLANGE

CYLINDER ROD PISTON ROD CYLINDER

SPACER

SPRING

r, ,

.,.. (L,jI/. l /T) !/ l.:)-!

WASHER/

NUT

o lf l ��

~YJ/:

VALVE

v------��

FITTING UC-26 Cl

UNDERCARRIAGE

UC-25-27

UNDERCARRIAGE 5.2 MAINTENANCE ------------------------- -----

5 .2. l ASSEMBLY DRAWING

------In

---------.. - --

--·-

-··--;;:=

-�

-----== � -··-

------l

Tightening torque 4 kgf-m

·�

··-

�i.,

UC-26 C2

ITEM

PART NAME

ITEM

PART NAME

Cylinder

Flange

01 02

0-ring

Wear ring

Washer

Cylinder rod

Spacer

Nut

Piston rod

U-ring

Valve

Fitting

DIMENSIONS A

(Set length)

575

(Back stroke)

(Adjustable length)

105

(Ass'y length)

828

(P.C.D.)

183

(Dia.)

Unit: mm H

(Dia.)

233

UNDERCARRIAGE

UC-25-28

-------------UNDERCARRIAGE------------5.2.2 REMOVAL & INSTALLATION PREPARATION

[!]

Clean track adjuster, then carefully

check it for damage or breakage.

DAMAGE CHECK

It must be noticed to be irregular if tracks are tight after releasing grease from adjuster or loose after feeding grease.

[!]

Check if adjuster is damaged or not. •If spring is broken,track becomes loose.

•If rod is broken or cracked, track

remains tightened even after releasing

grease

-reE • r•• 1 ••... I ...f .... I

I·�., ~-1 ...

UC-26 DCl/UC-26 DC2

Add grease to adjuster and check for leakage.

•If there is any leakage, track becomes loose.

Wipe grease off and find out leaking points and causes.

When releasing grease, gradually turn

the valve one turn.

Never loosen the fitting.

WARNING: Spring i n t r ack adjuster is preloaded heavily, and grease in cylinder is under high pressure.Improper handling of spring system and grease cylinder may cause a dangerous situation, leading to serious personal injury. Pay utmost care for handling of spring system and grease cylinder.

ONETURN

UNDERCARRIAGE

UC-25-29

-------------UNDERCARRIAGE------------REMOVAL

Remove track adjuster after removing

yoke with front idler.

Adjuster weight: 147 kg

UC-26 Rl

Lay down adjuster carefully. Protect adjuster with transportation

jig if needed for transportation.

INSTALLATION

[!]

Instal adjuster onto track frame.

Adjuster weight: 147 kg

NOTE: Key ®in track frame must align with notch@on washer.

Check that length@ is 14 mm. UC-2611

TRACK FRAME

UC-26 llA

,,,,-.,,1, i.,

UC-25-30

UNDERCARRIAGE

-------------UNDERCARRIAGE-------------

5.2.3 DISASSEMBLY & ASSEMBLY DISASSEMBLY

III

Place oil jack on bottom of the special

tool (ST-4920)

Remove nuts and plate. �

PLATE

III

Lift adjuster.

Place adjuster 1n the special tool.

UC-26 D3

UC-25-31

UNDERCARRIAGE

-------------UNDERCARRIAGE-------------

[!]

Install plate. Remove valve with fitting. Tighten nuts to secure adjuster.

"'l�----,L,

UC-26 D4

[!)

Operate jack and compress spring until nut fully extends through hole in plate.

�

Remove lock bolt and nut.

-"'1,._..,L,

LOCK BOLT

17 and 80

UC-26 D6

12]

Lower jack slowly.

UC-26 D7

UN DE RCARRIAG E

UC-25-32

------------UNDERCARRIAGE------------

[!]

[!)

Remove nuts and plate.

Remove washer.

Install lifting tool, and remove

adjuster from the special tool.

�

Remove spring from rod. ROD

SPRING

(!I)

UC-26 D 10A

Remove spacer.

UNDERCARRIAGE

UC-25-33

------------UNDERCARRIAGE------------

�

Remove socket bolts and flange.

UC-26 D12

II!)

Pull out piston rod from cylinder.

13!)

Push out rod. Remove 0-ring.

UC-26 D14

13]

Remove wear ring, retaining ring and U-ring from piston rod.

RETAINING RING

UC-26 D15

UNDERCARRIAGE

UC-25-34

-------------UNDERCARRIAGE------------ASSEMBLY

�

Clean all parts.

Install U-ring,retaining ring and wear

ring.

Apply grease to 0-ring and install it on rod.

ROD

Install rod into cylinder.

NOTE: Handle carefully not to damage 0-ring.

[!]

CYLINDER

Apply grease to U-ring and wear ring.

Apply hydraulic oil to cylinder and

piston rod.

Install piston rod into cylinder.

NOTE: When installing piston rod, apply grease (about 100 cm3) onto its head. GREASE �ISTON ROD

[!]

Fill flange inside grooves with grease. Install flange into cylinder and

tighten socket bolts.

FLANGE

---1-111-1--11+- -¼�-

�

GROOVES

FLANGE UC-26 012

Install spacer on rod. SPACER

UNDERCARRIAGE

UC-25-35

-------------UNDERCARRIAGE-------------

(!]

Install spring on rod.

SPRING UC-26 D10A

Lift adjuster.

Place adjuster in the special tool.

UC-26 D9

(!]

Remove lifting tool.

Install washer on rod. Install plate.

�

Align jack and adjuster with hole in

plate.

Install and tighten nuts to secure

adjuster. '11!�--•(.L

46 UC-l6 l\9

UC-25-36

UNDERCARRIAGE

------------UNDERCARRIAGE------------

13!)

Operate jack and compress spring to the

set length.

(!I)

Install nut and lock bolt.

13:!)

Install valve with fitting.

13:!)

-,�--•(,w

80 and 17

Valve tightening torque:

Lower jack.

15 kgf•m

(110 lbf•ft)

UNDERCARRIAGE

UC-25-37

-------------UNDERCARRIAGE-------------

ll!)

Remove nuts and plate.

13!)

Lift adjuster and remove it from the

13!]

�

special tool.

UC-26 D3

Lay down adjuster carefully.

Protect adjuster with transportation

jig if needed for transportation or storage.

5-3 SPECIFICATIONS (EX300/EX300LC)

5.3.1 SPECIFICATIONS Spring free length

700 mm

Spring set length

575 mm

Cyl. bore x rod dia.

85 mm x 80 mm

Adjuster assembly

147 kg

Spring set load

5.3.2 WEIGHTS OF MAIN COMPONENTS

15400 kgf

Cylinder

30.6 kg

Rod

9.3 kg

Spring

87.3 kg

L;�.uc:RCARRIAGE

UC-25-38

-------------UNDERCARRIAGE------------6. UPPER ROLLER & LOWER ROLLER 6.1 CONSTRUCTION

6.1.1 UPPER ROLLER

Two upper rollers are equipped on each side track frame to support track link.

This roller is an overhang support type.

BRACKET

6.1.2 LOWER ROLLER

Eight lower rollers are equipped under each side of track frame to stable rotating of track link. ROLLER -------

--COLLER

AXLE

UNDERCARRIAGE

UC-25-39

-------------UNDERCARRIAGE-------------6.2 MAINTENANCE

6.2.1 ASSEMBLY DRAWING (1) Upper roller

r120 I

---------165-----t

NOTE

1) Apply a grease to the sliding face of seal group.

2) Lubrication oil

Class:

Volume:

S-3

SAE30

75 cm 3

3) Place upper roller in above condition, supply oil through plug hole. 4) After assembling, rotate upper roller 10 times and check oil leakage. 5) Apply plastic gasket to plug (10).

UNDERCARRIAGE

UC-25-40

-------------UNDERCARRIAGE--------------

(2) Lower roller

-+--+�-+--+-++---!-1--4-----�---- ----,-+---+--1--� .-l

114.3

NOTE

1) Apply a grease to the sliding face of seal group.

2) Lubrication oil

Class:

Volume:

S-3

SAE30

450 cm 3

3) Place upper roller in above condition, supply oil through plug hole.

4) After assembling, rotate upper roller 10 times and check oil leakage. 5) Apply plastic gasket to plug (10).

UNDERCARRIAGE

UC-25-41

-------------UNDERCARRIAGE--------------

6.2.2. REMOVAL

(1) UPPER ROLLER

12)

Removal

Open valve to drain grease

�

12)

INSTALLATION

Jack up track link high enough to permit

upper roller removal

12]

Put wooden blocks between track link and

[!}

Remove bolts.

side frame.

I!}

Remove upper roller.

Weight:

20.9 kg

UNDERCARRIAGE

UC-25-42

-------------UNDERCARRIAGE--------------

[I)

INSTALLATION

Install upper roller and bolts. Tightening torque:

�

12]

27 kgf.m

(200 ft.lbs)

Remove wooden blocks and jack.

Supply grease to cylinder through valve to

adjust track link tension. Track tension sag; 330 to 350 mm (For normal ground) 400 mm (For sandy soil) 350 to 400 mm (For muddy ground)

(2) LOWER ROLLER

Removal

-�

[I) Remove roller guard. Loosen bolts.

Lift the one side of unit high enough to remove lower roller.

Put wooden blocks under unit.

UNDERCARRIAGE

UC-25-43

-------------UNDERCARRIAGE--------------

(!)

Open valve to bleed out grease. �

[!]

IJ:}

(, 24

Remove lower roller.

Weight:

54.1 kg

INSTALLATION

Put rollers on track link with flat portion

of collar pointing up.

Align with tapped holes in track frame.

II)

(!)

Lower unit enough to allow bolts to be

installed into track frame.

Instal 1 bolts.

Tightening torque: 30

55 kgf-m

(398 ft.lbs)

UNDERCARRIAGE

UC-25-44

-------------UNDERCARRIAGE-------------

[!]

Supply grease to cylinder through fitting. Track tension sag;

6.2.3 DISASSEMBLY (1) UPPER ROLLER

330 to 350 mm (For normal ground) 400 mm (For sandy soil) 350 to 400 mm (For muddy ground)

ASSEMBLY

DISASSEMBLY

[I)

Remove plug (01) and drain the oil.

Remove bolts (02) and cover (03).

Remove bolts (04) and plate (OS).

@) \

'17

�-®

ll}

Pull out roller (06) from axle (07).

[!]

Remove seal group (08) from bracket (09)

and roller (06).

Note: The seal group can be reused if it is not worn.

Seal group is to be kept

in matched set and to put cardbord

between seal to protect the sealing face.

UC-25-45

UNDERCARRIAGE

--------------UNDERCARRIAGE--------------

I!]

In case of changing bushing (10), remove

the bushing from the roller by using press and special tool (ST-1966).

PRESS

SPECIAL��- -� TOOL

@ ASSEMBLY

Before assembling, ·Clean all parts.

·Polish up scratches and roughness of the parts by using oil stone.

•Replace 0-ring and seal group with new as a rule.

Press bushing (10) into roller (06).

@) Install seal group (08) to roller (06) and

bracket (09).

Note: •Apply grease to 0-ring part of seal group.

·Apply engine oil to matching surface of seal group.

12]

Install roller (06) to axle (07).

Install plate (05) and bolts (04)

® ld i� nH ; � � ! CJ @ @)@@)

J-!j

UC-25-46

UNDERCARRIAGE

------------- UNDERCARRIAGE--------------

I!]

Apply grease to 0-ring and instal 1 it to cover (03).

Install cover (03) and bolts (02) to roller (06).

�

I!)

Supply engine oil to the roller through

the plug hole and tighten plugs (01). Note: Recommended oil Class: API-CD SEA30

Volume: 75 cm 3

(2) LOWER ROLLER

DISASSEMBLY

II) Remove plug from collar and drain the oil.

L ,,,,,..,

)._ ,,,,

Remove pin (01).

Press axle (04) to end of collar (03).

Remove collar and 0-ring.

seal groups [I Remove and collar (03).

(06) from the roller

The seal groups can be reused if they are not worn. Seal groups are to be kept in

matched sets and to put cardbord to protect

the sealing face.

� -�

UC-25-47

UNDERCARRIAGE

-------------UNDERCARRIAGE--------------

[!]

Press axle (04) and remove collar (03) and

I!}

In case of changing bushings (07), remove

0-ring (02) from the axle.

the bushings using press and special tools (08) (ST-1967).

ASSEMBLY

Before assembling, ·Clean all parts.

•Polish up scratches and roughness of the parts by using oil stone.

•Replace 0-ring and seal group with new as a rule.

Q:} Press bushing

(07) into roller (05) by

using press and special tools (ST-1967).

Apply grease to 0-ring (02) and install it

to axle (04).

Install collar (03) to axle (04) and fix it

by pin (01).

@) @)

UNDERCARRIAGE

UC-25-48

-------------UNDERCARRIAGE--------------

Install seal groups (06) into roller (05)

and collar (03).

Note: Apply grease to 0-ring part of seal groups.

Apply engine oil to matching surface

of seal groups.

� Install axle (04) into roller (05).

Fix another collar (03) to the axle by pin (01).

Supply engine oil to the roller through

the plug hole.

Install plug (01) to collor (03).

Note: Recommended oil Class:

API-CD

Volume:

450 cm 3

SEA30

PLUG®

UNDERCARRIAGE

UC-25-49

-------------UNDERCARRIAGE-------------

6.2.4 MAINTEN��CE STN�DARD (1) UPPER ROLLER

,----A---

ND:

Nominal Dimension

LU:

Limit of Use

RL:

i--------B-------.

Recommended Service Limit

Weight:

14.5 kg

Mark

Remedy

Replace

165

150

144

140

Unit:

Unit: ND

Description Axle

Outside Dia.

44.5 44.2

Inside Dia.

45.5 46.0

Outsdie Dia.

Bushing

Remedy Replace

Unit:

ND Clearance between Axle Gap between Axle

Bushing

Side Coller

O.l<v0.205 1.0

1.2

0.03 '\., 0.1

Note Replace

Total dimension of both side

UNDERCARRIAGE

UC-25-50

-------------UNDERCARRIAGE--------------

(2) LOWER ROLLER

'---.., I

ND:

Nominal Dimension

LU:

Limit of Use

Recommended Service Limit

RL:

�

A B

Weight:

32. 0 kg

Mark

Unit:

203

209

213

256

180

174

Remedy Replace

Buildup or Replace

4.5

170

Unit: Description Axle Bushing

Outside Dia.

74.5 74.2

Inside Dia.

75.5 76. 0

4. 5

Flange Thickness

Outside Dia.

Remedy Replace II

4.0

3.7

,, Unit:

Clearance between Axle Gap between Axle

Bushing

Side Coller

1.0

1.8

Note Total dimension of both side

UNDERCARRIAGE

UC-25-51

-------------UNDERCARRIAGE-------------6.3 SPECIFICATIONS------------------------------

6.3. l UPPER ROLLER Weight

20.9 kg

(Roller)

14.5 kg

Lubrication oil

Class Engine oil 3

Tread diameter Volume 6.3.2

LOWER ROLLER

150 mm

75 cm

Weight

54.1 kg

Tread diameter

180 mm

(Roller)

Lubrication oil

Volume

SEA30

32.0 kg

Class En gine oil 3 SAE30 450 cm 3

UNDE RCAR R IAG E

UC-25-52

-------------UNDERCARRIAGE------------7. TRA CK LINK 7.1 CONSTRUCTION

------------------------------

The track link is provided with a center strut for reinforcement to withstand heavy loads encountered in digging operations.

MASTER LINK

RING

TRACK LINK B

BUSHING

UNDERCARRIAGE

UC-25-53

------------- UNDERCARRIAGE-------------7.2

MAINTENANCE

-------------------------------

7. 2 .1 ASSEMBLY DRAWING

= I

Retaining ring installing part

� LL 1-

203.2

UNDERCARRIAGE

UC-25-54

UNDERCARRIAGE-------------7.2.2 ADJUST TRACK LINK TENSION

The track link tension is adjusted by

either adding grease to the adjustment cy

linder inside the side frame through the

fitting

the valve

or draining the grease from

1 .

For checking the te�sion, jack up the

machine as shown on the right, and measure the distance between the upper surface of

the shoe and the lower surface of the side

frame at the center of the side frame.

The

distance should be 330 � 350 mm for general

ground, about 400 mm for gravel, and 350 �

400 mm for damp ground.

Loosening Track Link:

Apply a socket (tool: long socket 24) at

the hexagonal part of the valve body

and drain grease by loosening the valve little by little.

The valve

should be

loosened at most 1 � 1. 5 turns. If the

gr�ase does not drain well, jack up the �

track belt to be loosened. CAUTIONS:

(1) Do not loosen the valve

Fitting

too much or

suddenly, as it causes the high pressure grease to pour out from the adjustment cylinder.

little.

It should be loosened little by

(2) Check and remove any foreign matters such as gravel caught at the sprocket. Tightening Track Link:

Retighten the valve, and add grease from the fitting

2 .

UNDERCARRIAGE

7. 2. 3

UC-25-55 UNDERCARRIAGE--------------

DETERMINATION

(1) LINK PITCH

While lifting track link assembly, measure

II ,,

.!..

I II I

I II II I

II ol II II I II II I II II I II II I II

Measure gap between link sides.

(2) PIN BUSHING

Check score and crack.

Measure pin and bushing diameter at three places.

q II II

UNDERCARRIAGE

UC-25-56 UNDERCARRIAGE--------------

7.2.4 REMOVAL t� INSTALLATION REMOVAL

[!]

Move track link until master pin is over front idler in the position as shown.

Put wooden block.

Open valve to bleed out grease.

CI)

Remove retaining ring.

13]

Pull out master pin by using a special tool (ST-1970).

I!]

Master Pin Operate the machine to backward.

UNDERCARRIAGE

UC-25-57 UNDERCARRIAGE -------------

I!)

Juck up the machine as shown.

Put wooden blocks under the machine. P.ull out the track link.

INSTALLATION

Juck up the machine and put the track link

I]]

Lift the track link and place it on the

[I}

under the lower roller.

sprocket.

Slowly operate the sprocket in forward

direction.

� Keep on ope,ating the sprocket until end of track link is over front idler. Lower the machine.

Put wooden block as shown.

UNDERCARRIAGE

UC-25-58 UNDERCARRIAGE--------------

� Install master pin using a special tool (ST-1970).

Master Pin

[!]

[Z)

Install retaining ring.

Supply grease to the cylinder through the

fitting to adjust track link tension. ,

t, 24

7.2.5 SPECIFICATIONS (1) TRACK LINK

Parts Number Weight

1010688

5.5 kg

4186652

5.1 kg

1010689

5.5 kg

Mark

203.2

206.5

208.S

116.4

113

111

Remedy

Rebuild fi Fini�h

1-------A---�

* The pitch should be determined by taking the average of 5 links. ND:

Nominal Dimension

LU:

Limit of Use

RL:

Recommended Service Limit

UNDERCARRIAGE

UC-25-59

------------- UNDERCARRIAGE --------------

(2) MASTER PIN

Weight:

..d

CJ-

,.. (3) PIN

,___j

( 4) BUSHING

44.13

44.45

42.5

41.5

44.69

231. 0

ti.--__

L--------:l l l fr-

__..----,.

Replace

Unit: mm

245

44.45

42.5

Remedy Replace

41.5

2.4 kg

Unit: mm

Mark

44.8

47.0

48.0

66.27

63.5

61.5

158.4

Weight:

Remedy

3.0 kg

Mark

Weight:

(5) MASTER BUSHING

Unit: mm

Mark

Weight:

-A ---,1

2.9 kg

Remedy Replace

2.3 kg

Unit: mm

Mark

44.8

47.0

48.0

66.27

63.0

61.0

148.8

Remedy Replace

ND:

Nominal Dimension

LU:

Limit of Use

RL:

Recommended Service Limit

UNDERCARRIAGE

UC-25-60

-------------

(6) SHOE PLATE 600 mm

(7) SHOE PLATE 800 mm

(8) SHOE PLATE

910 mm

UNDERCARRIAGE -------------

Weight:

20.3 kg

Unit: mm

Mark

Weight:

Remedy Rebuild

28.4 kg

Unit: mm RL

Mark

Remedy

Rebuild

Weight: 33.9 kg

Unit: mm

Mark

108

104

102

ND: RL:

LU:

Remedy Replace

Nominal Dimension

Recommended Servjce Limit

Limit of Use

UNDERCARRIAGE

UC-25-61

UNDERCARRIAGE ------------7.3 SPECIFICATIONS

EX270

600G

800G

910A

TRACK LINK

1796 kg

TRACK LINK

770 kg

�

MASTER LINK

5.1 kg

�

TRACK LINK B

5.5 kg

�

TRACK LINK B

s.s

�

MASTER PIN

2.9 kg

�

SHOE

20.3 kg

NUMBER OF LINK TIGHTENING TORQUE

2176 kg 2439 kg

28.4 kg 33.9 kg

�

-4-

86kgfm

�

*1 Both sides with shoe *2 One side with shoe *3 One side without shoe

UNDERCARRIAGE

UC-25-62

UNDERCARRIAGE-------------8.

CENTER JOINT

8.1 CONSTRUCTION

The center joint is a kind of rotary joint . . It is located at the center of the machine to connect the hydraulic lines from the superstructure to the travel

device.

It comprises a spindle and a body on which seals are installed.

The spindle is

stationed and installed at the center of the main frame, and the body is in

stalled in the track frame of the superstructure to rotate around the spindle.

---COVER DUST SEAL

UNDERCARRIAGE

UC-25-63

------------- UNDERCARRIAGE --------------

8.2 MAINTENANCE ------------------------------

8. 2 .1 ASSEMBLY DRAWING

r--------154 ---� �--108--�

01 -----

O') Ill (")

r«------170 -----,

UNDERCARRIAGE

UC-25-64

UNDERCARRIAGE -------------

8.2.2 REMOVAL (1) REMOVAL

[!]

INSTALLATION

Release air pressure from the hydraulic

tank.

ll]

Remove hose for releasing air from control

valve.

Set the vaccume pump and operate it. �

[!}

CAP

� 17, 19

Remove hoses from center joint. �

C, 41, 22

13]

Remove adapters from center joint.

II)

Remove bolts (09) and stopper (11). �

� 22

ARROW

UNDERCARRIAGE

UC-25-65

UNDERCARRIAGE

I!]

Remove covers (12) and (13). �

'7 19

fl)

Remove pipes (15) and (16).

[!)

Remove bolts and cramps.

[' Remove pipes (17) and (22). �

'7 22 10

� Install a lifting tools to center joint and hold it.

Lift center joint.

Weight:

34 kg

-------------

UNDERCARRIAGE

'2lJ

UNDERCARRIAGE-------------Remove bolts (19)

jill

UC-25-66

t, 19

Remove center joint.

(2) INSTALLATION

[!]

Install lifting tools and lift center joint. Weight: 34 kg

Install bolts (19). �

(, 19

Tightening torque: 9 kgf-m, 65 ft.lbs

II)

Remove lifting tolls and install rubber cover.

UNDERCARRIAGE

UC-25-67

UNDERCARRIAGE --------------

[!]

Install pipes (17) and (18). .I)

'°

22 10

Tightening torque: 4 kgf-m, 29 ft.lbs

9 kgf-m, 65 ft.lbs

I!}

Install pipes (15) and (16). �

C, 22, 41

Tightening torque: 4 kgf-m, 29 ft.lbs

21 kgf-m, 152 ft.lbs

II)

Install bolts, cramps and covers. .I)

'°

Tightening torque: 9 kgf-m, 65 ft.lbs

II)

Install stopper (11) and bolts (09). ,

C, 22

Tightening torque: 14 kgf-m, 101 ft.lbs

� Install adapters to center joint and in stall hoses.

� '°

22, 41

Tightening torque: 4 kgf-m, 29 ft.lbs

21 kgf-m, 152 ft.lbs

UNDERCARRIAGE

UC-25-68

--------------UNDERCARRIAGE-------------8.3 SPECIFICATIONS ----------------------------

Weight Body

Spindle

33.9 kg

15.7 kg 15.1 kg

OPERATIONAL PRINCIPLE

HYM-48A-1 (0/P)

--------------TRAVEL MOTOR-------------1. OUTLINE (HMT134CF) -----------------------

Two travel motors each mounted on the rear end of each track frame drive the

machine to move forward and backward, and to perform pivot turn and spin turn freely.

The travel motor includes the brake valve assembly and the disk brake system. (l{MT134CF: 134 cm 3 /rev)

2. TRAVEL MOTOR--------------------------

The travel motor, HMT-Cf-, is a bent-axis piston type motor which includes

the brake valve assembly and the disk brake system.

The main components of HMT-Cf- motor are valve plate, rotor, piston, center

shaft, driving disk, roller bearing, casing, brake piston and friction

plate.

Model: HMT134C:F-26J\

Applicable Serial �o. EX270: 05001

EX300: ll2ll,'l

ri.,

05 377

BRAKE VALVE FRICTION PLATE & PLATE

ROTOR SPRING

ROLLER BEARING

OPERATIONAL PRINCIPLE

HYM-48A-2 (0/P)

--------------TRAVEL MOTOR--------------

Mo<lel: HMT134C:F-26B

Applicable Serial No. EX270: OS 378

°u

BRAKE VALVE

FRICTION PLATE & PLATE DRIVING DISK CASING

ROTOR

SPRING

ROLLER BEARING CENTER SHAFT

ROLLER BEARING

OPERATIONAL PRINCIPLE

HYM-48A-3 (0/P)

--------------TRAVEL MOTOR--------------

Pressure oil fed to the valve plate port-Am through the brake valve enters

the cylinder ports in one half of the rotor and acts on the pistons.

At the sametime brake release oil fed to the casing port pushes the brake piston against the disk spring to release the drive disk.

These pistons connected to the port-Am exert a force on the drive disk to turn it.

As the rotor and drive disk rotate, these pistons move out of their bores

to the stroke end respectively.

These port connection is changed to the valve plate port-Em and oil returns to the tank.

At this time th� pistons 111 the other half of the rotor are connected to the valve plate port-Am to turn the drive disk and motor rotating is

continuing.

To rotate the motor 111 opposite direction, pressure oil 1s fed to the port Bm and return oil flows through the port Am.

CASING BRAKE RELEASE -----.i PRESSURE

DISK SPRING

BRAKE PISTON ROTOR

t I

DRIVE GiSK

VALVE PLATE

OPERATIONAL PRINCIPLE

HYM-48A-4 (0/P)

--------------TRAVEL MOTOR-------------3.

BRAKE VALVEAS SEMBLY-----------------------

The brake valve assembly is located on the motor head of each travel motor. The brake valve assembly consists of the following valves. (1) SHUTTLE VALVE: controls the counterbalance valve and parking brake operation. (2) COUNTERBALANCE VALVES: provide smooth travelling on the down slope and block the circuits when stopping. (3) CHECK VALVES: assist the counterbalance valve operation and prevent cavitation in the motor. (4) OVERLOAD RELIEF VALVES: prevent overload of the motor. (5) REDUCING VALVE: controls the parking brake release pressure.

COUNTERBALANCE VALVES SHUTTLE VALVE REDUCING VALVE

OVERLOAD RELIEF VALVE

OPERATIONAL PRINCIPLE

HYM-48A-5 (0/P)

--------------TRAVEL MOTOR--------------

Driving the motor in normal condition and in the case oil enters port (BV), oil flows around spool (Bs), opens check (Be) and flows into motor port (Bm).

Return oil from motor port (Am) is blocked by check (Ac) and spool (As),

h01,ever, oi 1 pressure increases 1n port (BV) and enters chamber (D) through the shuttle valve.

High pressure oil in chamber (ll) moves spool (As) to the right side, and oil returns from motor port (Am) to port (AV).

When travelling down a hill, the excavator may be begin to overrun the travel motors.

This would cause faster travel than desired and would

cavitate the inlet side of the motor.

But as pressure decreases in the inlet passage of the motor, the pressure holding spool (As) also decreases.

Back pressure created 111 chamber (Am) slows motor rotation. dynamic braking.

This is

Am r ��::c..� --=---._ -1,;

OVERLOAD RELIEF VALVE

OPERATIONAL PRINCIPLE

HYM-48A-6 (0/P)

--------------TRAVEL MOTOR--------------

When oil pressure exceeds the setting pressure of the overload relief valve,

high pressure oil is relieved to the lower pressure side to prevent over loading of the motor.

High pressure caused by inertia force when the machine stops is also

relieved by the relief valve.

The reducing valve supplies oil pressure to release the parking brake. Primary pressure is supplied from port (BV) or port (AV) depending on

travelling direction.

Brake release pressure is controlled by the spring

force of the reducing valve.

When the control lever is moved to the neutral position, release pressure

is drained to the motor housing.

To apply the parking brake after the

motor stops, release pressure drains slowly through small orifice in the

valve spool.

REDUCING VALVE

VALVE SPOOL

TO PAKING BRAKE

DISASSEMBLY and ASSEMBLY

HMT 134 CF MOTOR

HYM-48A-1 (D/A)

1. DISASSEMBLE TRAVEL MOTOR----- Note: Before disassembling, thoroughly

-�

clean outside of motor.

Remove bolts and socket bolts (31). 24 mm

14 mm r Install eye bolts (ST-9063) and lift up motor assembly above travel device.

ll}

Removing 0-ring from casing.

[!]

Install travel motor on work bench (ST-5052) and remove socket bolts.

I!]

14 mm

Remove brake valve from travel motor.

Note: Be careful not to let valve

plate (29) fall away from brake

valve when removing.

HYM-48A-2 (D/A)

DISASSEMBLY and ASSEMBLY

HMT 134 CF MOTOR

I!]

Removing 0-rings (26 and 27) from casing.

11]

Remove valve plate (29).

I!)

Remove retaining ring (18) from center

shaft.

[!) Remove rotor

(17).

Note: !\lark pistons and rotor holes to

@"--:.��' - ti' �

match during assembly.

[ill Remove center spring

(16).

DISASSEMBLY and ASSEMBLY

a !ill

!ill

HMT 134 CF MOTOR Remove retaining ring (14) from drive disk (01).

Pull out center shaft (12) from drive disk.

Remove pistons (11) from drive disk (01).

PISTON

DRI\'E DISK (01)

Remove spring disk (25).

[ill

Remove brake piston (22) from motor casing using compressed air.

Note: Air pressure is 1 " 2 kgf/ cm 2 0

( 100

200 kpa) .

HYM-48A-3 (D/A)

HYM-48A-4

DISASSEMBLY and ASSEMBLY ------------

!ill

(D/A)

HMT 134 CF MOTOR

Remove D-rings (23 and 24) from piston (22).

@- @--

!ill

Remove plates (20) from casing.

\ill

Remove friction plates (21).

!ill

Remove spacer (19).

j2ol Rotate motor casing 180 ° .

Remove retaining ring (10) from casing.

Applicable Serial No. EX270: 05001 � 05377

EX300: 02001 "-'

HYM-48A-5 (D/A)

DISASSEMBLY and ASSEMBLY ------------

HMT 134 CF MOTOR

Rotate motor casing 180 ° . Note: Instead of steps

G:IJ - [2!1, 0

plates

(20), friction plates (21}, and spacer

(19) can be removed altogether by ap

plying impact on motor casing with

plastic hammer as shown.

Applicable Serial No.

jill

EX270: 05378

Remove seal cover (07) using a driver.

Applicable Serial �o. EX270: 05001

EX300: 02001 "v

05377

1221 Remove oil seal (08) from cover (07). � Note: Replace seal if removed.

Applicable Serial No.

EX270: 05001

EX300: 02001 "-'

05377

Remove oil seal (08) from casing (06).

Applicable Serial No. EX270: 05378 ru

j23I Rotate motor casing 180 ° .

Remove drive disk (01) from motor casing

using special tool (ST-2283) and a press.

J..,ST2283 •

Applicable Serial No. EX270: 05001

EX300: 02001

05377

'0 ..

••

•,,..

DISASSEMBLY and ASSEMBLY

HYM-48A-6 (D/A)

HMT 134 CF MOTOR 1231 Remove drive disk (01) from casing using

a puller.

Applicable Serial No. EX270: 05378

I\,

Note: Push down the spline side of drive

disk (01) as shown.

1241 Remove 0-ring (09) from casing.

Applicable Serial No.

EX270: 05001 EX300: 02001

I\,

05377

/ ---

I\,

1251 Remove retaining ring (10) from casing.

Applicable Serial No. EX270: 05378

I\,

!2sl Remove bearing nut (OS) using special tool (ST-5904).

-./

ST-5904

DISASSEMBLY and ASSEMBLY ------------

HMT 134 CF MOTOR

� Install bearing pulling attachment on bearing outer race (02).

Remove bearing outer race (02), spacer (03), and bearing (04) using a press.

l2al Remove bearing outer race (04) from spacer using a punch.

Remove bearing inner race (02) from drive j29I disk using a bearing pulling attachment. Note:

Replace bearing (02) if removed.

HYM-48A-7 (D/A)

DISASSEMBLY and ASSEMBLY

------------ HMT 134 CF MOTOR 2. INSPECT TRAVEL MOTOR--------

11)

Measure thickness of splines on drive disk.

Maximum allowable wear (A) is

0.5 mm (0.019 in).

replace drive disk.

ll]

t,leasure sleeve diameter.

Standard

60.0 mm

II)

If worn more,

Limit of use 59.8 mm

Move piston up and down to measure

clearance between piston and drive

disk.

Standard clearance Max. 0. 055 mm

[!]

Limit of use 0. 4 mm

Move piston up and down to measure

clearance between connecting rod and

piston.

Standard clearance Max. 0.1 mm

I!) Move

Limit of use 0.4 mm

center shaft up and down to meas

ure clearance between connecting rod and holder.

Standard clearance Max. 0.4 mm

Limit of use 1.0 mm

HYM-48A-8 (D/Al

DISASSEMBLY and ASSEMBLY ------------

I!]

HMT 134 CF MOTOR

Measure cylinder bore inside diam

eter and piston outside diameter. Calculate clearance between them. Standard clearance Max. 0.044 mm

(I)

Limit of use 0.08 mm

Measure outside diameter of shaft

sleeve and internal diameter of valve plate bushing. between them.

Calculate clearance

Standard clearance Max. 0.084 mm

Limit of use 0.3 mm

HYM-48A-9 (D/A)

HYM-48A-10

DISASSEMBLY and ASSEMBLY ------------- HMT 134 CF MOTOR 3.

ASSEMBLE TRAVEL MOTOR----------------------

Note: Before assembling, clean all parts and dry with compressed air.

Apply

clean hydraulic oil to all internal

parts.

II) Install bearing inner race

(02) using

special tool (ST-2265) and a press.

Note: Preheat bearing to approximately 70

90 ° C.

ll] Put bearing outer race on inner race.

(D/A)

Install bearing outer race (04) into spacer (03) using special tool (ST-2266) and a press.

� Install spacer and bearing outer race (04) on bearing (02).

HYM-48A-11 (D/A)

DISASSEMBLY and ASSEMBLY

HMT 134 CF MOTOR

I!]

Install bearing inner race (04) on drive

press.

Note: Preheat bearing to approximately

�

90 ° C.

•

Place drive disk on special tool

(ST-5904).

�--

ST-5904

Tighten bearing nut (05) temporarily to 20 kgf.m (145 ft.lbs).

Apply clean hydraulic oil.

I!)

Adjust drive disk rolling torque to specification. ""

--e: 0.25

(1.81

0.35 kgf.m

2.53 ft.lbs)

If rolling torque is not to specification,

adjust it by tightening or loosening

bearing nut (05).

I!}

Preheat casing to approximately 70 r" 90 ° C.

-)_,_§, -

� J

disk using special tool (ST-2265) and a

HYM-48A-12 (D/A)

DISASSEMBLY and ASSEMBLY

HMT 134 CF MOTOR

(ill

Steps

(ill '\, jill are applicable to Serial

No. EX270: 05001

'\J

05377; EX300: 02001

'\J

Install drive disk using a plastic

hammer into casing.

!ill

Install 0-ring (09).

Apply liquid packing to outer surface of

seal (08) and install it using special

tool (ST-2284).

!ill

Apply grease to seal cover (07), oil

seal lip and 0-ring (09).

Install special tool (ST-2287) on drive

disk.

HYM-48A-13 (D/Al

DISASSEMBLY and ASSEMBLY

!ill

HMT 134 CF MOTOR Install seal cover (07) with oi 1 seal (08)

jill

!ill

[ill

Install retaining ring (10).

Rotate motor casing 180 ° .

Install spacer (19) into casing with notches toward casing. Note: Align notches in spacer with oil passage holes in casing.

DISASSEMBLY and ASSEMBLY

!ill

HMT 134 CF MOTOR

Apply liquid packing to outer surface

of oil seal (08) and install it using

special tool (ST-2409) and a plastic hammer.

Applicable Serial �o. EX270: 05378

I 201 Apply grease to oil seal lip.

Install retaining ring (10) into casing.

Applicable Serial �o. EX270: 05378

@II

Install drive disk into casing using

a plastic hammer.

Applicable Serial No. EX270: 05378

Note: Be careful not to damage oi1 seal during installation.

HYM-48A-14 (D/A)

HYM-48A-15

DISASSEMBLY and ASSEMBLY ------------

(D/A)

HMT 134 CF MOTOR

1221 Install plates (20) and friction plates

(21) alternately into casing.

Note: Align notches in plates with oil

passage holes in casing.

j23I Install 0-rings (23 and 24) on brake piston (22) and apply grease.

Install brake piston (22) into casing

using special tool (ST-2902).

ST-2902

,��

�·· \-· 1241 Install disk spring (25) on brake piston

(22) so that periphery faces upward.

DISASSEMBLY and ASSEMBLY ------------ HMT 134 CF MOTOR

HYM-48A-16 (D/A)

Install pistons (11) in spherical joint

holes in drive disk (01).

Note: Make sure each piston moves smoothly.

1261 Secure pin (15) and ball (13) to center shaft (12) with grease.

Install center shaft on drive disk. Be careful not to lose ball (13)

during installation since it tends

to drop.

� Install retaining ring (14) into groove of drive disk.

l2sl Install center spring (16) on center shaft.

� Install rotor (17) on pistons according to matching marks.

Note: Align center shaft pin (15) with notch in rotor.

DISASSEMBLY and ASSEMBLY

HMT 134 CF MOTOR

HYM-48A-17 (D/A)

l3ol Install retaining ring (18) into groove of center shaft (12).

Apply clean hydraulic oil 1. 3 liter to

pistons in rotor (17) its spherical

surface and casing.

J32I Install 0-rings (26 and 27) on casing.

J33I If replacing valve plate bushing (30) is

required, install bushing (30) into valve plate (29) using special tool (ST-2285)

and a hammer.

I Note: Position of oil grooves in bushing (30) must be as shmm.

HYM-48A-18 (D/A)

DISASSEMBLY and ASSEMBLY

HMT 134 CF MOTOR

1341

Install guide pin (ST-7085) on center

shaft (12) .

ST-7085

---

\ 1351

1361

137

Remove plug from brake valve.

6mm

Apply grease to valve plate (29) after washing, and install on brake valve.

Install brake valve on motor casing.

l3al Remove guide pin and instal 1 plug with O-ring.

- :

6mm

3 kgf .m (22 ft. lbs)

• -

DISASSEMBLY and ASSEMBLY

HMT 134 CF MOTOR 1391

Temporarily tighten socket bolts (31).

14 mm

l4ol Lift brake valve and motor casing as an assembly using two eye bolts (ST-9063)

and slings.

Apply grease to 0-ring and install it

onto motor casing.

Apply grease to travel gear housing and

fill with gear oil.

Applicable Serial No. EX270: 05001

EX270: 05378

EX300: 02001 "-'

05377

Capacity

7.5 liters 7.8 liters 8.5 liters

1421 Install travel motor on travel device. Note: Be careful not to damage mating

splines on driving disk of motor

and driving shaft of travel device.

14 1 Install bolts and tighten socket bolts 3

( 31) .

14 mm

,... : 27 kgf.m (195 ft. lbs)

HYM-48A-19 (D/A)

HYM-48A-20 (D/A)

DISASSEMBLY and ASSEMBLY ------------ HMT 134 CF MOTOR

1441

Tighten bolts.

mtJ

----�M

24 mm 27 kgf.m (195 ft.lbs)

Finish 4. SPECIAL TOOLS-------------------------ST-No.

ST-9063

Title

Eye bolt

Q'ty 2

Use Remove and install motor.

ST-5052

Work bench

Disassemble and assemble motor.

ST-5904

Drive disk fixing tool

Measure bearing preload.

ST-2266

Puller

Install bearing outer race.

ST-2283

ST-2265 ST-2284

ST-2287

Puller

Install bearing inner race.

Puller

Install oil seal.

Install brake piston.

Puller

ST-2902

Puller

ST-7085

Guide pin

ST-2285

Remove and install bearing.

Puller

Install oil seal.

Install bushing.

Install brake valve on motor

casing.

•I

ST-5904

ST-2902

=-----

DISASSEMBLY and ASSEMBLY

HYM-48A-21 (D/A)

HMT 134 CF MOTOR

Applicable Serial No. EX270: o5001

EX300: 02001

Item 01 02

05377

Part Name .

. k Driving dis

Roller bearing

Q'ty 1

Item

Roller bearing

Motor casing

Oil seal

03 04

Spacer

Bearing nut

Seal cover

1 1

0-Ring

Piston Center shaft

Retaining ring

13 15

;;,'i't

18 19

Retaining ring

D-Ring

Disk spring 0-Ring

0-Ring

Brake valve

1 1

Socket bolt

Spacer

· ton Brake pis

Valve plate

Retaining ring

Rotor

. ti· on plate Frie

Q'ty 4

Ball

Compression spring

Plate

Part l\'ame

Bushing

DISASSEMBLY and ASSEMBLY

HYM-48A-22 (D/A)

-------------HMT 134 CF MOTOR------------Applicable Serial No.

EX2 70. 05 378 °

Item 01

03 04

Part Name

Driving disk

Roller bearing

Spacer

Roller bearing

Bearing nut

Motor casing

Oil seal

Piston

12 13

14 15

17 18 19

Retaining ring Center shaft Ball

Retaining ring Pin

Compression spring

Rotor

Retaining ring

Spacer

Part Name

Q'ty 1

I tern

Friction plate

D-Ring

1 1 1 1 1 1

24 25

Plate

Piston

D-Ring

Disk spring

0-Ring

Brake valve

Valve plate Bushing

Socket bolt

Q'ty 4 3 1 1 1 1 1

1 1 1 1 4

HYM-48A-23 (D/A)

DISASSEMBLY and ASSEMBLY

------------ HMT 134 CF MOTOR 1. DISASSEMBLE BRAKE VALVE------Note:

Before disassembling, thoroughly

clean outside of brake valve.

Remove bolts and socket bolts from travel motor. �

II)

24 mm

14 mm

Remove drain plugs and instal 1 eyebolts (ST-9062).

8 mm

,,,, llJ

Install brake valve on work bench (ST-5055) using bolts.

. ..

DISASSEMBLY and ASSEMBLY ------------- HMT 134 CF MOTOR

[!}

Remove plug (06) of the counterbalance valve.

Remove springs (03 and 04).

I!]

Remove spool (02).

III

Remove cartridge (33) of overload relief valve.

�

C..: 32 mm

I!) Remove O-rings

(24 and 30) and back-up

rings (25) from overload relief valve.

HYM-48A-24 (D/A)

DISASSEMBLY and ASSEMBLY ------------

[!)

Place relief valve in a vise as shown and

measure dimension between adjusting screw (31) and cartridge (33).

of measurement.

II2)

Make a record

Remove lock-nut (32).

I )

!ill

HMT 134 CF MOTOR

10 mm

�: 32 mm

Remove adjusting screw (31).

10 mm

[ill Remove plug

(27) from cartridge (33).

[ill Remove spring

(26) and piston (34).

HYM-48A-25 (D/A)

DISASSEMBLY and ASSEMBLY

HYM-48A-26 (D/A)

-------------HMT 134 CF MOTOR-------------

!ill

Remove 0-ring (29) and back-up ring (28) from plug (27).

Remove plug (09) of shuttle val ve.

[ill Remove I:

!ill

6 mm

seat (08) and ball (07). 5mm

Remove plug (13) of reducing valve.

8 mm

HYM-48A-27 (D/A)

DISASSEMBLY and ASSEMBLY

------------ HMT 134 CF MOTOR-------------

!ill

Remove spool (11) and spring (10).

!ill

Remove plug (17) of check valve.

I :

14 mm

1201 Remove spring (15) and poppet (14).

./ I ,,i <,

HYM-48A-28 (D/A)

DISASSEMBLY andASSEMBLY

------------- HMT 134 CF MOTOR -------------

@:!)

Remove plugs (19).

4 mm

j22I Remove plug (45) and orifice (18).

2.5

mm,

2. ASSEBLE BRAKE VALVE-------Note: Before assembling, clean all parts

and dry with compressed air.

Apply clean hydraulic oil to all internal parts.

II) Install counterbalance spool

l.lJ

(02).

Install springs (03 and 04).

[!) Install O-ring

(05) onto plug (06). #

,e,

,.,.,,,./� �'

I@'

DISASSEMBLY and ASSEMBLY

HYM-48A-29 (D/A)

------------- HMT 134 CF MOTOR-------------

(!]

Install and tighten plug (06).

....

58 mm

45 kgf.m (325 ft.lbs)

I!}

Install piston (34) and spring (26) into

I!]

Install O-ring (29) and back-up ring (28)

cartridge (33).

onto plug (27).

Install plug into cartridge.

11)

Place relief valve in a vise.

Install adjusting screw (31) into

cartridge (33).

I!)

Install lock-nut (32) on adjusting scre1� (31) .

DISASSEMBLY and ASSEMBLY

-� ·

-------------HMT 134 CF MOTOR

I!)

Screw in adjusting screw (31) to original dimension measurement.

(See disassembling

step 9.)

Tighten lock-nut (32)

�

10 mm

--41: 5 kgf.m (36 ft. lbs)

Install 0-rings (24 and 30) and back-up

rings (25) onto cartridge (33).

!ill

Install and tighten overload relief valve.

...

32 mm

22 kgf.m (159 ft.lbs)

�,-,.

,�

HYM-48A-30 (D/A)

HYM-48A-31 (D/A)

DISASSEMBLY and ASSEMBLY

-------------HMT 134 CF MOTOR

� Install poppet (14) and spring (15).

�f:' .,-�'i�?::� ;\.

,,,

!ill

Install 0-ring (16) onto plug (17).

Install and tighten plug.

r--

22 kgf.m (159 ft. lbs)

Apply thread lock liquid to orifice (18).

Install orifice and plug (45).

! r

!ill

14 mm

2.5 mm, 5 mm

_,,.: 0.1 kgf.m (0.72 ft.lbs) 2 kgf.m (15 ft.lbs)

Install ball (07) into AV port.

�

HYM-48A-32

DISASSEMBLY and ASSEMBLY

(D/A)

------------- HMT 134 CF MOTOR

!ill

Apply thread lock liquid to seat (08) and

r :

install.

5 mm

..,,. :1.5 kgf.m (11 ft.lbs)

II2J

Check ball (07) movement using wire.

1201

Install plug (09) with seal tape_

(Ball movement must be 0.5 � 1.0 mm.)

body.

..,,.:

6 mm 2 kgf.m (15 ft.lbs)

� Install spring (10) and spool (11).

',/...,,_,./ , \

.�:'

HYM-48A-33 (D/A)

DISASSEMBLY and ASSEMBLY ------------

jill

HMT 134 CF MOTOR

Install 0-ring (12) onto plug (13).

1231 Install and tighten plug (13).

,... ·

8 mm 4 kgf.m (29 ft. lbs)

1241 Install plug (19) with seal tape.

4mm ,... : 1 kgf.m (7 ft.lbs)

1251 Remove plug.

I :

6 mm

1261 Install guide pin (ST-7085) on center

shaft of travel motor. Note:

Check if enough quantity of hydraulic

oil remains in motor casing.

HYM-48A-34 (D/A)

DISASSEMBLY and ASSEMBLY ------------ HMT 134 CF MOTOR

@zJ

Apply grease to valve plate and install on brake valve.

Apply clean hydraulic oil to mating

surface of valve plate.

l2al Install brake valve on motor as shown. ►

I I

� Tighten bo 1ts and remove guide pin.

-1..:

24 mm

HYM-48A-35 (D/A)

DISASSEMBLY and ASSEMBLY ------------

HMT 134 CF MOTOR

1301 Install and tighten socket bolts.

14 mm .-.. : 27 kgf.m (195 ft. lbs)

Tighten bolts. 24 mm 27 kgf.m (195 ft.lbs)

1 321 Install plug with seal tape.

--«

6 mm 3 kgf.m (22 ft.lbs)

1331 Fill reservoir with hydraulic oil to 1.3

liter.

1341 Install and tighten plug with 0-ring.

8 mm --« : 4 kgf.m (29 ft. lbs)

HYM-48A-36 (D/A)

DISASSEMBLY and ASSEMBLY

------------- HMT 134 CF MOTOR Finish

•

3. SPECIAL TOOLS-------------------------ST-No

ST-9062

ST-5055

ST- 7085

Title

Eye bolt

Work bench Guide pin

Q'ty 2 1 1

Use Remove brake valve.

Disassemble and assemble brake valve.

Install brake valve.

ST-7085

HYM-48A-37 (D/A)

DISASSEMBLY and ASSEMBLY ------------ HMT 134 CF MOTOR

I I I

:::

:.--;:;..--:::....-,_ _

11 + , 11

;

I 1

ii I I

r-----

�J�-----�-- - -t

® '

t-- --

Item 01 02

Part ;--;ame

Casing

Spool

Part Name

Q'ty

Itern

0-ring

Relief assembly

Plug

QI ty 2 2 2

Spring

0-ring

Ball

Spring

Plug

04 06

Spring Plug

Seat

Spring

Spool

1 1

0-ring

Poppet

0-ring

Orifice

12 13 14

15' 17

Plug

Spring Plug

Plug

Back-up ring

0-ring

Back-up ring

0-ring

Adjusting screw

Nut

Piston

Plug

1 1 1 1

Cartridge

0-ring

Plug

0-ring

1 1

I ..•

,----

TD-1BA-1 (D/A)

DISASSEMBLY and ASSEMBLY

------------- TRAVEL DEVICE -------------1. DISASSEMBLE------------ Note : Before disassembling, thoroughly

clean outside of travel device.

[I}

Lift travel device in an assembly and

remove plugs (41) to drain gear oil.

! :

10 mm

ml..:

24 mm

Remove bolts ( 43).

Remove socket bolts.

[!]

[!}

14 mm

Install eye bolts (ST-9063) and remove

travel motor from travel device.

Rotate travel device 180 ° .

., a

DISASSEMBLY and ASSEMBLY

TD-18A-2 (D/A)

------------- TRAVEL DEVICE -------------

I!]

Remove bolts ( �O) _

19 mm

11]

Remove cover (38) using a plastic hammer.

I!}

[!}

II Remove carrier (30) and propel shaft (37)

from travel device.

Remove sun gear (29) from carrier (22).

� Remove carrier (22) from ring gear.

TD-18A-3 (D/A)

DISASSEMBLY and ASSEMBLY

-------------- TRAVEL DEVICE --------------

III)

Remove sun gear (18) from carrier (12).

[ill

Remove bolts (21) .

,,_

,Al!!

�

aa-: 24 mm

!ill

Lift and remove ring gear (19) using two

eye bolts and a plastic hammer as shown.

Remove carrier (12) from housing (02).

•

!ill

- ... ______, _ .......

Remove bolts ( 11) and lock pl ate (10). �:

19 mm

JIIIIIA,.._',_

DISASSEMBLY and ASSEMBLY

TD-18A-4 (D/A)

-------------- TRAVEL DEVICE --------------

� Remove bearing nut (09) using special tool (ST-3926).

� Remove drum (OS) from housing (02) using special tool (ST-9063).

G!J

Remove bearing inner race (04) from drum.

� Remove part of floating seal (03) from drum (OS).

1201 Remove part of floating seal from housing (02).

Note: Unnecessary to remove bearing inner race (04) from housing unless

damaged.

·---

DISASSEMBLY and ASSEMBLY

TD-lBA-5 (D/A)

------------- TRAVEL DEVICE--------------

@:I)

Remove bearing outer race (04) from drum (OS) using a bar and a hammer.

1221 Remove spring pin (36) from carrier (30)

using a punch.

1231 Remove pm (35), planetary gear (32}

thrust plates (34) and needle bearing (33}

j24I

?°J

Remove spacer (23) from carrier.

TD-18A-6

DISASSEMBLY and ASSEMBLY

!D_I_A_l -------------- TRAVEL DEVICE _____________

[fil

Disassemble carrier assembly (22) with

the same manner shown in steps

and IE)).

c0 , fill

.:·• 6 ..

j26I Disassemble carrier assembly (12) with the same manner shown in step s

and IE)) .

(0,

fill

DISASSEMBLY and ASSEMBLY

TD-18A-7 (D/A)

-------------- TRAVEL DEVICE--------------

[ill

Remove bolts (08) . � aa-

30 mm

l2al Remove sprocket (06) from drum (05).

DISASSEMBLY and ASSEMBLY

TD-18A-8 (D/A)

------------- TRAVEL DEVICE -------------2. ASSEMBLE--------------

Note: Before assembling, clean all parts and dry with compressed air.

Apply

clean hydraulic oil to all internal

[J:}

parts. If bearing inner race (04) removed, heat

new bearing in oil approximately to 50 '\., 70 ° C.

Install bearing inner race (04) on housing (02) using special tool (ST-2276).

fl}

Apply grease to O-ring of floating seal (03) and mating surface of housing.

Install floating seal on housing using

a bamboo stick.

12]

Install bearing outer race (04) into drum (05) using special tool (ST-2278) and a

ST-2278

plastic hammer.

[!]

llJ·

Install floating seal (03) on drum (05)

with the same procedure as step

� Apply clean hydraulic oil to mating surface of floating seal.

. �..

DISASSEMBLY and ASSEMBLY

TD-18A-9 (D/A)

------------- TRAVEL DEVICE --------------

I!]

Install drum (OS) on housing (02).

llJ

Heat bearing inner race (04) in oil approximately to 50�70 ° C.

Install bearing inner race on housing

using special tool (ST-2276) and a

plastic hammer.

Make sure that drum can rotate smoothly.

I!)

Install bearing nut (09) on housing (02).

DISASSEMBLY and ASSEMBLY

TD-18A-10 (D/A)

TRAVEL DEVICE--------------

I!} Tighten bearing nut

(02) to specification

using special tool (ST-3926).

G1J

30 mm -.. : 50 kgf.m (362 ft. lbs)

Fill up a gap using a plastic hammer

as shown.

!ill

Turn drum (05) clockwise and counter

!ill

Tighten bearing nut (09) again to

clockwise each three times.

specification.

Align hole on lock plate (10) with hole

on housing (02). ,.

jill

30 mm .-.i: 50 kgf.m (362 ft.lbs)

Install lock plate (10).

J__..--v

DISASSEMBLY and ASSEMBLY

TD-18A-11 (D/A)

-------------- TRAVEL DEVICE --------------

II!) Apply thread lock liquid to bolts and tighten to specification. � �: F

(11)

19 mm

--«: 9 kgf.m (65 ft.lbs)

!ill

Install sprocket (06) on drum (OS).

[ill

Install spring washer (07).

Apply thread lock liquid to bolts (08) and tighten to specification.

�

�: .)~o mm F --«: SO kgf.m (362 ft. lbs)

[ill

Install needle bearing (14) into planetary

gear (13).

� Install thrust plate (15) on each side of planetary gear. Install planetary gear (13) into carrier (12) with circular groove side up.

DISASSEMBLY and ASSEMBLY -------------

!ill

TRAVEL DEVICE

Install pin (16) aligning spring pin

hole on pin (16) with hole on carrier (12).

1201

Install spring pin (17) into aligned

hole on carrier and pin, with slit facing

carrier (12) plate surface.

[ill

TD-18A-12 (D/A)

Install carrier (12) on housing.

Note: Select carrier (12) position so

it does not overlap with lock plate bolts on housing.

1221

Apply liquid packing to mating surfaces

1231

Install ring gear (19) on drum (OS).

of drum and ring gear.

DISASSEMBLY and ASSEMBLY

1241

TD-18A-13 (D/A) TRAVEL DEVICE------------

Install bolts (21) and spring washer (20) and tighten to specification.

�: 24 mm F

_..;

27 kgf.m (195 ft.lbs)

1251

Install sun gear (18) into carrier (12).

1261

Install spacer (23) into carrier (22).

1211

Install needle bearing (25) into

planetary gear (24).

l2al Install thrust plate (26) on each side of planetary gear.

Install planetary gear (24) into carrier (22)

TD-18A-14 (D/A)

DISASSEMBLY and ASSEMBLY

-------------- TRAVEL DEVICE --------------

[fil

Install pin (27) aligning spring pin hole on pin with hole on carrier (22) Install spring pin (2 8) into aligned

hole on carrier and pin with slit facing

carrier (22) plate surface.

I !Joi

@l)

Install carrier (22) into ring gear.

Install sun gear (29) into carrier (22).

1321 Install spacer (23) into carrier (30).

j331 Install needle bearing (33) into

planetary gear (32).

TD-18A-15 (D/A)

DISASSEMBLY and ASSEMBLY

------------- TRAVEL DEVICE -------------1341 Install thrust plate (34) on each side

of planetary gear (32).

Install planetary gear into carrier (30).

I,.

1351 Install pin (35) aligning hole on pin

with hole on carrier.

Install spring pin (36) into aligned

hole on carrier and pin with slit facing

carrier (30) plate surface.

N 1361 Install carrier (30) into ring gear.

@zJ

3/Z.

·.._- .. -� • ,.. erer Install propel shaft (37) into carrier.

DISASSEMBLY and ASSEMBLY

TD-18A-16

(D/A)

------------- TRAVEL DEVICE -------------\381 Apply liquid packing to mating surfaces

of ring gear and cover (38).

Install cover on ring gear (19).

1391

Install bolts (40) and spring washer (39) and tighten to specification.

�: 19 mm t ...a: 11 kgf.m (80 ft. lbs)

l4ol Apply teflon tape to plug (41) thread. Install and tighten plug (41) to

.._

specification.

�

10 mm

5 kgf.m (36 ft.lbs)

Rotate travel device 180 ° .

Fill travel device with gear oil.

Applicable Serial No. EX270: 05001

EX270: 05378

EX300: 02001

05377

Oil capacity 7.5 liters

7.8 liters

8.5 liters

�-

DISASSEMBLY and ASSEMBLY

TD-18A-17 (D/A)

------------- TRAVEL DEVICE --------------

1431

Install O-ring (42) on motor casing.

Apply grease to mating surface on housing ( 02)

1441

1451

Install motor into travel device using

eye bolts (ST-9063).

Install spring washers (20) and bolts (43).

�

1 461

Temporarily tighten bolts (43). 24 mm

Tighten socket bolts and bolts (43) to specification.

m�

24 mm

27 kgf.m (195 ft.lbs)

r--

Finish

14 mm

DISASSEMBLY and ASSEMBLY

TD-18A-18 (D/A)

-------------- TRAVEL DEVICE --------------

3. SPECIAL TOOLS --------------------------

ST-\o.

Title

ST-9063 Eye bolt

ST-2276 Puller

ST-3926 Bearing nut Krench

Q'ty 2

1 1

Lift travel motor.

Install bearing.

Use

Remove and install bearing nut.

TD-lBA-20 (D/A) ---------- TRAVEL DEVICE----------

DISASSEMBLY and ASSEMBLY

Applicable Serial No. EX270: 05001 � 05377 EX300: 02001 �

@ �'

TD-18A-21 (D/A)

DISASSEMBLY and ASSEMBLY

------------- TRAVEL DEVICE --------------

Item 01 02

Part name

Oil motor Housing

Seal group

Roller bearing

QI t_\' 1

Item

- .)

Part \ame

Spacer

Planetary gear

\eedle bearing

Q'ty 2

Thrust plate

Spring pin

Carrier

Lock plate

Carrier

Needle bearing

Drum

Sprocket

Bolt

09 10

11 13 15

Spring washer

Nut

Bolt

Planetary gear

1 2

Thrust plate

Spring pin

Ring gear

Sun gear

Cap

t\eedle bearing

-7 .),

Spring washer

Carrier

Bolt

Spring pin

Propel shaft

Cover

Plug

Thrust plate

Spring washer

Planetary gear

Sun gear

Bolt

0-ring Bolt

3 1

DISASSEMBLY and ASSEMBLY

TD-18A-22 (D/A)

------------ TRAVEL DEVICE-------------

Applicable Serial No.

EX270: 05378 '\,

DISASSEMBLY and ASSEMBLY

TD-18A-23 (D/A)

--------------TRAVEL DEVICE--------------Item Lll Ll 2 03

04 05

09 10 11 L?

13 14

17 18

20 21

rart name

Oil motor !lousing

Seal group

Roller hearing Drum

Sprocket

Spring \\'asher Bolt

\ut

Lock plate Bolt

Carrier

Planetary gear

\eedle bearing Thrust plate Pin

QI t y 1

l -,

I tern -,

...: ,)

24 -,-:,

-,-,

3()

Part \ame

Spacer

Planetary "'oear

\eedle bearing

Thrust plate rin

Spring pin

b ,)

Cap

\eedle hearing

- -, ,)_

Planetary gear

Thrust plate

3 3

Spring pin

Cover

Propel shaft

Spring washer

Plug

Carrier

Bolt

Carrier

Ring gear

Spring washer

Sun gear

Spring pin

QI ty

Bolt

0-ring Bolt

CJ-10-1 (0/P)

OPERATION PRINCIPLE

CENTER JOINT

1. OUTLINE----------------------------The center joint is a kind of rotary joint.

It is located at the center of

machine to connect the hydraulic lines from the superstructure to the travel

device.

It comprises a spindle and a body on which seals are installed.

The spindle

is stationed and installed at the center of main frame, and the body is installed in the center of track frame to rotate around the spindle.

TLF-----, TLR-----,

,--- ---TRF r------TRR

TLF----,� -TRR -TLR �--TRF

TRF

TLF TLR

TRR

DISASSEMBLY and ASSEMBLY

CJ-10-1 (D/A)

--------------CENTER JOINT-------------1. DISASSEMBLY--------------------------Note: Before disassembling, clean the all

parts. Put a fitting mark on body and spindle.

II)

Install center joint on workbench (ST-5049) using two eye bolts as shown. �

Remove the another two tighten bolts to remove cover (10). �

I!)

(,: 17mm

(, : 17mm

Remove O-ring (11).

Remove retaining ring (08).

DISASSEMBLY and ASSEMBLY

CJ-10-2

(D/A)

--------------CENTER JOINT---------------

I!}

Remove ring ( 07).

I!]

Install special puller (ST-19'.)0) on bod\

(00) using two tighten bolts (12). �

[:I

------� 11- I

(,:17mm

Slowly raise body (00) to remove balls (06} .

(!) Remove twenty balls

I!]

(06).

Remove body (00) from spindle (01}.

' l

-----@

DISASSEMBLY and ASSEMBLY

--------------

[ill

a !ill

CJ-10-3 (D/A)

CENTER JOINT --------------

Remove cover (02) using a press.

Remove 0-ring (03)

Remove five oil seals (05).

[ill

Remove 0-ring (04).

[ill

Remove dust seal (09) .

\)' '

DISASSEMBLY and ASSEMBLY

CJ-10-4 (D/A)

-------------- CENTER JOINT -------------2. ASSEMBLY---------------------------Note: Before assembling,

o Clean all Parts

o Polish up scratches and roughness

o Replace 0-ring and seal group with new one.

II)

Install dust seal (09).

ll}

Install 0-ring (04)

Install five oil seals (OS) Apply grease to lip face of oil seals (OS)

dust seal (09) and 0-ring (04).

(!]

Install 0-ring (03)

DISASSEMBLY and ASSEMBLY

CJ-10-5 (D/A)

CENTER JOINT

I!]

Put in cover (02) on spindle (01).

Note: Cover (02) will be pressed with body (00) later on.

[!]

Carefully install body (00) so seals are against spindle (01).

Note: Apply hydraulic oil to spindle (01)

)

before installing body (00).

11)

Keep body (00) to install balls (06).

I!)

Install twenty balls (06) on the cover ( 02) •

II)

Install body (00) and cover (02) using a press and plate (ST-2291). Body against spindle: 0.2�0.25 ton Cover against spindle: 2.5�3.0 ton

.-_

_, I

t I

�

.•.,

�00 .

�

DISASSEMBLY and ASSEMBLY

CJ-10-6

(D/A)

-------------- CENTER JOINT ---------------

jill

Install ring (07).

Note: Chamfer face is bottom side.

[ill

Install retaining ring (08).

!ill

Make sure retaining ring (08) is installed

!ill

against spindle (01).

Install O-ring (11).

Install cover (10). ,

�

: 17 mm

Tighten torque: 5 kg·m (36.17 ft.lbs) Note: Drain port is marking side of L

CJ-10-7 (D/A)

DISASSEMBLY and ASSEMBLY

--------------CENTER JONT-------------I 3. SPECIAL TOOLS ST-�umber

Tool Name

Q'ty

ST-5049

Workbench

ST-1930

ST-2291

ST-1930

ST-5049

ST-2291

Puller Plate

Use

To remove body from spindle

To press spindle

To set center joint

DISASSEMBLY and ASSEMBLY

CJ-10-8

-------------- CENTER JOINT _____________to_f_A_l

01J----.-J 03

Item

Parts Name

Q' ty

Body

Cover

0-ring

03 04

Spindle

0-ring Oil Seal Ball

Item ()-;-

11 12

Ring

Parts \ame

Q'ty 1

Retaining Ring

Cover

Bolt

Dust Seal

0-ring Spring Washer

1 4

INDEX EX270-6-1

�

FRONT-END ATTACHMENTS

CONTENTS Group 1-FRONT-END ATTACHMENT 1. 2. 3. 4.

FA15-1-1-30 Boom Assembly .................................. FA15-1-1 Arm Assembly .................................... FA15-1-3 Bucket Assembly .................................. FA15-1-6 Front Pipings ...... ............................. FA15-1-17

Group 2-HVDRAULIC CYLINDER

■ ■

Operational Principle .............................. CV12-1-2 Disassembly&Assembly ......................... CV19-1-10

Group 3-PIN & BUSHING . . . . . . . . . . . . . . . . . . . . 1.

FA15-3-1-2 Specifications ..................................... FA15-3-1

Group 4-POINT & SIDE CUTTER . . . . . . . . . . . . 1.

FA15-4-1-2 Maintenance ......... ............................. FA15-4-1

FRONT-END ATTACHMENTS

FA-15-1-1

------------FRONT-END ATTACHMENTS-----------1. BOOM ASSEMBLY-------------------------1.1 CONSTRUCTION --------------------------------

Boom assembly consists of Boom with bushings and pins for Boom cylinders

and arm cylinder.

cylinder rod side.

The stoppers are weded on the boom except the boom

SHIM

STOPPER

�· ��SPACER

� DUST SEAL

�

BUSHING

1.2 SPECIFICATIONS -------------------------------

Boom assembly

1740 kg

Boom

1640 kg

Boom with bushing

1650 kg

FA-15-1-2

FRONT-END ATTACHMENTS

------------FRONT-END ATTACHMENTS-----------DIMENSIONS

EX270 Q, l

6200 mm

Q,2

2360 mm

Q, 3

895 mm

Q, 4

ll80 mm

Q, 5

270 mm

Q,6

726 mm

£7 Q,8

£9 Q, 1 0

576 mm 139 mm 409 mm 566 mm

FA-15-1-3

FRONT-END ATTACHMENTS

------------FRONT-END ATTACHMENTS-----------2. ARM ASSEMBLY 2.1 CONSTRUCTION-----------------------------

Arm assembly consists of arm i-·ith bushings, link and pins. \ ariety: 3.1

m Standard

3. 75 m Long 2.4

m Short

BUSHING

FRONT-END ATTACHMENTS

FA-15-1-4

------------FRONT-END ATTACHMENTS-----------2.2 SPECIFICATIONS

EX270 3.lm Standard

3.75m

2.4m

1120 kg

1220 kg

1010 kg

Arm with bushing

825 kg

932 kg

721 kg

Arm

811 kg

916 kg

705 kg

Link (R) rear

24.0 kg

Link (L) rear

27.3 kg

Link (R) front

51. 1 kg

Link (L) front

51. 1 kg

Weight Arm assembly

FRONT-END ATTACHMENTS

FA-15-1-5

------------FRONT-END ATTACHMENTS-----------DIMENSIONS

�1

STANDARD, SHORT

LONG

Dimension X, 1 X-2 X, 3 X, '+

£5

£6 £7 £9 2, 9 £, 1 0

Standard 3100 980

475

EX270

Long

Short

970

1040

3750 +

2638,9

2632,3

310

325

2400 +

2647,8

440

400

408

139

408

325

340

FRONT-END ATTACHMENTS

FA-15-1-6

------------ FRONT-END ATTACHMENTS-----------3. BUCKET ASSEMBLY 3.1 CONSTRUCTION ---

-----

- ------

----

( l) HOE BUCKET

------- -

The hoe bucket is of all-welded, high-strength steel structure and

provided teeth and side cutter.

Variety: 1.0 m 3 Standard, 0.9 m 3, 1.2 m 3, 1.4 m 3 1.4 m 3 (with out side cutter)

SIDE CUTTER

I/�

LOCK PIN

FRONT-END ATTACHMENTS

FRONT-END ATTACHMENTS (2) ROCK BUCKET

)'�

LOCK PIN

];.7

---= F�l�l�

� TEETH

LOCK RUBBER

FA-15-1-8

FRONT-END ATTACHMENTS

----------FRONT-END ATTACHMENTS----------

(3) RIPPER BUCKET

TEETH

FRONT-END ATTACHMENTS

FA-15-1-9

-----------FRONT-END ATTACHMENTS------------

(4) ONE-POINT RIPPER BUCKET

BOSS

TEETH

<?�� t PIN

BUSHING RUBBER

FRONT-END ATTACHMENTS

FA-15-1-10

------------FRONT-END ATTACHMENTS-----------J_2 MAINTENANCE STANDA RD ADJUSTED THE BUCKET CLEARAi'-iCE

(1) Check the bucket clearance "a". If

necessary adjust the shim as follows.

(2) Adjustment of bucket linkage (standard bucket)

This machine has a bucket adjustment

system to take up play in the linkage.

When play in the linkage increases,

remove shims as explained below. This wi11 allow the bush @ to move to

the right and take up the clearance "a"

between the bush and the arm boss. Remove bolt @ and plate (D (i) (ii)

Remove shims Q) according to the

clearance "a". (iii) Fit plat (D to pin @ and tighten bolt @. NOTES:

Bucket clearance "a" should not be

adjusted below 0.5 mm.

BOLT PIN

ARM END BOSS

BUCKET

CLEARANCE "a" CLEARANCE "b"

CLEARANCE ADJUSTMENT

FRONT-END ATTACHMENTS

FA-15-1-11

-----------FRONT-END ATTACHMENTS-----------3.3 SPECIFICATIONS

BUCKET-1

EX270 Weight

0.9 m 3 Hoe bucket

1 .0 m 3 Hoe bucket

Assembly

852 kg

879 kg

1035 kg

Bucket

765 kg

791 kg

946 kg

Side cutter

16. 3 kg

Teeth

7.5 kg x 5

BUCKET-2

EX270 Weight Assembly Bucket

'"" ) -,

1.2 m 3 Hoe bucket

1.4 m 3 Hoe bucket

0.8 m 3 Rock bucket

1021 kg

985 kg

970 kg

935 kg

Side cutter

Teeth

7.5 kg x 5

10. 0 kg x 5

FRONT-END ATTACHMENTS

FA-15-1-12

------------FRONT-END ATTACHMENTS------------

BUCKET-3 EX270 Weight

0.7 m 3 Ripper bucket

One-point Ripper

Assembly

1210 kg

681 kg

Bucket

1170 kg

655 kg

Side cutter Teeth

13.2 kg 7.5 kg

13.2 kg X

FRONT-END ATTACHMENTS

FA-15-1-13

-----------FRONT-END ATTACHMENTS------------

BUCKET DIMENSION-I '-

@)@ 03

EX270 Dimension "

22'

0.9 m 3 Hoe bucket

1.0 m Hoe bucket

470 mm

69 mm

1158 mm

Teeth

ESC040SI

Material

CD 0

(_D

,})

HT80 (25 mm) SM50 ( 8 mm) HT80 (40 mm) SM50 ( 8 mm) \\'EL-TEN 70RE (10 mm)

(10 mm)

HT60 (28 mm) WEL-TEN (8 mm) AR360E +-

HT50 ( 8 mm) WEL-TEN AR360E (8 mm) (8 mm)

Standard HT: High-tensile steel

FRONT-END ATTACHMENTS

FA-15-1-14

-----------FRONT-END ATTACHMENTS------------

BUCKET DIMENSION-2

r---f,-----i

EX270 Dimension

1. 2 m 3 Hoe bucket

1.4 m 3 Hoe bucket

Q, l

470 mm

Q,z

69 mm

Teeth

1553 mm

1558 mm

ESCO 40S1

Material

13)

0 ®

HT80 (28 mm)

HT80 (25 mm)

SM50 ( 8 mm)

HT80 (40 mm)

SM50 ( 8 mm)

WEL-TEN 70RE (10 mm)

t (10 mm)

HT: High-tensile steel

FRONT-END ATTACHMENTS

FA-15-1-15

------------FRONT-END ATTACHMENTS------------

BUCKET DIMENSION-3

'-- - [.

Dimension ,Q, l

£2

Teeth

I i

EX270

0.8 m Rock bucket 470 mm 3

69 mm

1549 mm

ESCO 12MS2-46

;

Material

CD 0 G)

I i I

I I i

HT80 (28 mm) SMS0 ( 9 mm)

SMS8 (SO mm) ! WEL-TEN c12 mm) iI 70RE

i HT: High-tensile steel SM: Rolled steel

c12 mm)I

(10 mm) 1

FA-15-1-16

FRONT-END ATTACHMENTS

------------FRONT-END ATTACHMENTS-----------

BUCKET DIMENSION-4

·-

Dimension £1

0.7 m 3 Ripper bucket 522 mm 5 mm

£2

Material

® ®

(j)

SM: Rolled steel

1552 mm

SM58 (19 mm)

t (10 mm) t (40 mm)

EX270

One point ripper 550 mm 0 mm

1520 mm

t (12 mm)

SM58 (32 mm)

SS41 (100 mm)

HT: High-tensile steel

�

HT80 (36 mm)

FA-15·1·17

FRONT-END ATTACHMENTS

------------FRONT-END ATTACHMENTS-----------4. FRONT PIPINGS 4.1 CONSTRUCTION -------------------------------

( l) GENERAL

Front pipings consist of boom cylinder pipings, arm cylinder pipings,

bucket cylinder pipings and hoses.

BUCKET CYLINDER

ARM CYLINDER

BOOM CYLINDER (R)

DUST SEAL

FA-15-1-18

FRONT-END ATTACHMENTS

(2) LUBRICATE PI PINGS

BOOM FOOT (L)

BOOM FOOT (R) BOOM CYL (L)

FRONT-END ATTACHMENTS

FA-15-1-19

------------FRONT-END ATTACHMENTS-----------4.2 MAINTENANCE STANDARD 4.2.1 REMOVAL & INSTALLATION (1) REMOVE BUCKET CYLINDER

[!]

Place the unit on level ground.

Put wooden block under the bucket

12]

cylinder.

Stop the engine, then, loosen the

air breather cap to release

pressure in hydraulic tank.

{!]

Remo\'e stopper bo 1 t. .,

(l}

4mm

, : 30 mm

Push out pin with bar and hammey.

FRONT-END ATTACHMENTS

FA-15-1-20

-----------FRONT-END ATTACHMENTS------------

11)

(!)

Fasten wire to bucket cylinder to

hold cylinder rod.

Remove bucket cylinder hoses.

Install plugs to the bucket cylinder.

mm 41 mm 36

I!)

Hoist bucket cylinder. Note: The approximate weight of the bucket cylinder is 240 kg.

[!}

Remove stopper bolt, then, remove bucket

cylinder. �

(; : 30

FRONT-END ATTACHMENTS

FA-15-1-21

------------FRONT-END ATTACHMENTS------------

(2) INSTALL BUCKET CYLINDER

Install bucket cylinder to the arm.

Note: The approximate of the bucket cylinder is 240 kg.

Align bucket cylinder with arm.

Install pin, and stopper bolt.

Tightening torque: 55 kgf.m, 398 ft.lbs ,

ll}

� : 30 mm

Install bucket cylinder hoses to the cylinder.

Tightening torque: 18 kgf.m, 130 ft.lbs ,

36 mm

21 kgf.m, 152 ft.lbs

41 mm

[!]

Hoist bucket cylinder, then, align

I!]

Install pin, and stopper bolt.

bucket cylinder rod with link.

Tightening torque: 55 kgf.m, 398 ft.lbs

FRONT-END ATTACHMENTS

FA-15-1-22

----------- FRONT-END ATTACHMENTS------------

[II

(3) REMOVE ARM CYLINDER

11]

Place the unit on le\·el ground.

Put wooden block under the arm cylinder.

Stop the engine, then, loosen the

air breather cap to release pressure 1n

hydraulic tank.

�

Remove stopper bolt. : 30 mm

I!}

Push out pin with bar and hammer.

FRONT-END ATTACHMENTS

FA-15-1-23

------------FRONT-END ATTACHMENTS------------

[!}

Fasten wire to arm cylinder to hold cylinder rod.

[!}

Remove arm cylinder hoses. Install plugs to the arm cylinder. ,

I!}

C, : 41 mm

Remove lubricate piping from the arm cylinder.

Hoist arm cylinder. \ote: The approximate 1>·eight of the arm cylinder is 377 kg.

Remove stopper bolt and pin, then, remove arm cylinder.

FRONT-END ATTACHMENTS

FA-15-1-24

----------- FRONT-END ATTACHMENTS------------

(4) INSTALL ARM CYLINDER

[I)

Install arm cylinder to the boom.

Note: The approximate of the arm cylinder is 377 kg.

11]

Install pin, and stopper bolt.

(I)

Install lubricate piping to the arm

55 kg£.m, 398 ft.lbs

cylinder.

Tightening torque: 3 kgf.m, 22 ft.lbs

[!}

Install arm cylinder hoses to the cylinder.

Tightening torque: 21 kgf.m, 152 ft.lbs 41 mm

� Hoist arm cylinder, then, align arm cylinder rod with arm.

FRONT-END ATTACHMENTS

FA-15-1-25

-----------FRONT-END ATTACHMENTS-----------Install pin, and stopper holt.

Tightening torque: 55 kgf.m, 398 ft.lbs ,

(. : 30 mm

FRONT-END ATTACHMENTS

FA-15-1-26

------------ FRONT-END ATTACHMENTS-----------(5) REMOVE BOOM CYLL\DER

[!]

Place the unit on leve 1 ground.

Remove lubricate piping from the boom

cylinders. �

[!]

(, : 19 mm

Hoist boom cylinder.

Note: The approximate weight of

the boom cylinder is 269 kg.

Remove stopper bolt, then, push out pin

1.;ith bar and hammer. 30 mm

Lower boom cylinder to put it on stand.

Push pin in other direction and lower

cylinder.

FRONT-END ATTACHMENTS

FA-15-1-27

------------FRONT-END ATTACHMENTS------------

Fasten wire to boom cylinder to hold

cylinder rod.

Stop t he engine, then, loosen the air breather cap to release pressure in

hydraulic tank.

r: 4 mm

I!)

Remove boom cylinder hoses.

Install plugs to the boom cylinder. ,

I!)

(, : 41 mm

Remove stopper bolt and pin. ,

(, : 30 mm

Remove boom cylinder.

Remove boom cylinder other direction

as above.

FRONT-END ATTACHMENTS

FA-15-1-28

------------FRONT-END ATTACHMENTS------------

(6) INSTALL BOOM CYLI�DER

[!]

Hoist boom cylinder, then, align boom

cylinder bottom side with main frame.

Note: The approximate of the boom cylinder is 269 kg.

(I}

Install pin, stopper bolts.

Tightening torque : 55 kgf.m, 398 ft.lbs �

11]

(!)

C. : 30 mm

Install boom cylinder other direction

as above.

Install hoses to the boom cylinder.

Tightening torque: 21 kgf.m, 152 ft.lbs �

I!)

C, : 41 mm

Hoist boom cylinder, then, align boom cylinder rod with boom.

FRONT-END ATTACHMENTS

FA-15-1-29

------------FRONT-END ATTACHMENTS------------

f!]

Install boom cylinder.

12]

Install stopper bolt.

Tightening torque: 55 kgf.m, 398 ft.lbs ,

[!)

[I)

(, : 30 mm

Install lubricate piping to the boom cylinder.

torque: 3 kgf.m, 22 ft.lbs

Install boom cylinder other direction as

above.

FRONT-END ATTACHMENTS

FA-15-1-30

------------FRONT-END ATTACHMENTS-----------4.3 SPECIFICATIONS---- ---------------- ----------

4.3.1 Front piping Weight

4.3.2 Lubricate piping

Weight

4.3.3 Boom cylinder

Bore x Rod dia. x stroke

Minimum retracted length

Weight

4.3 .4 Arm cylinder

Bore x Rod dia. x stroke

Minimum retracted length Weight

4.3.5 Bucket cylinder

Bore

x Rod dia. x stroke

Minimum retracted length Weight

1240 kg 2.0 kg 145 mm x 95 mm x 1360 mm 1950 mm 269 kg

150 mm x 105 mm x 1785 mm 2450 mm 377 kg

145 mm x 95 mm x 1080 mm 1630 mm 240 kg

OPERATIONAL PRINCIPLE

CY-12-1 (0/P)

--------------- CYLINDER

1. CONSTRUCTION AND FUNCTION--------------------

Four double acting cylinders-bucket, arm and two boom cylinders - are used on

the hoe attachment.

general.

All cylinders are similar operation and construction in

Two boom cylinders are interchangeable each other except pipes.

Bucket

cylinder has interchangeable parts \ii th boom cylinder around piston and head.

Arm cylinder of larger diameter has no interchangeability with other

cylinders.

CUSH IO� CY LI:\ DE R

For shock absobing of rod movement at the stroke end, cushion mechanism is

provided in the top chamber of all cylinders, and the bottom chamber of arm cylinder as shown in the following figures.

When piston aproches to the stroke end, return oil flow through throttled

passage between cushion ring and bore.

BOOM CYLINDER, BU KET CYLINDER

ARM CYLINDER

DISASSEMBLY and ASSEMBLY

--------------- CYLINDER

CY-19-1 (D/A)

1. DISASSEMBLY ----------------------------

Instructions for the disassembly of boom, arm and bucket cylinder are similer,

the bucket cylinder is shown and apply to all cylinders.

Note: Before disassembly, throughly clean the outside of the cylinder.

II)

I]]

Fasten the cylinder assembly on the

workbench.

Remove the pipes from the cylinder.

Fully extend rod (02) and support the

weight of the rod with a hoist.

Remove

eight socket bolts (0.1-) from head (()3).

19 mm for all cylinder

Tap the head out of the cylinder using

a soft hammer.

CY-19-2

DISASSEMBLY and ASSEMBLY

--------------- CYLINDER

11]

Pull the rod assembly out of cylinder lUl).

11]

Fasten the rod assembly on the v,orkbench.

II)

To aid assembly, put marks on the rod end and nut (16).

Remo\·e set sere\\ c1-:--1 from

nut.

r [!)

Remove the nut Kith tool as bel01,·. Tool :

11}

6 mm for all cylinder

--------

EX270

EX300

Bucket, Boom

ST-3266

Arm

ST-3267

ST-3268

Remo\·e piston ci:::) and cushion ring Lll) from the rod.

(D/A)

DISASSEMBLY and ASSEMBLY

--------------- CYLINDER

� Remove seal ring (13), two \\·ear rings (1--l) and tho teflon rings (15) from the piston.

II!)

Pull head (03) out of the rod_

!ill

Remove O-ring (09) and buck-up ring (10)

from the head.

!131 Remove seal (06), ring (07) and dust seal

Cos)

Remove bushing (08) from the head.

- End disassembly -

CY-19-3 (D/A)

DISASSEMBLY and ASSEMBLY

CY-19-4

---------------- CYLINDER _______________l_D_IA_l_ 2. INSPECTION-------------

Check the surfaces of piston and head for

damage or score.

If repared leaks occure,

care particularly attention to score or

wear on the seal lips.

When assembling cylinder, renewed consum

able parts such as dust seal, oil seals, wear rings, 0-rings and buck-up rings

ll}

Check the grooves and lands on piston and

head are clear and free from nicks or burrs.

Exsamine the sliding surface of bushing. If copper found, the part should be

renewed.

I]]

Check the threads of rod and nut for

damage or fault.

Light damage may be

repaired using a file or a lathe.

If damaged excessively the part should

be renewed.

13]

Examine bent of the rod.

Place the rod on the \'-blocks and set a

guage, rotate rod to measure bent of rod. If bent is excessive the rod should be

renewed.

Bent limit; 0.5 mm par 1.0 m length � Check the surfaces of rod and cylinder bore for scores, scratches and wear.

If score or wear is excessive, the part

should be renewed.

Score depth limit; 0.1 mm

Wear limit; 0.2 mm

CY-19-5

DISASSEMBLY and ASSEMBLY

--------------- CYLINDER ______________!_D_IA_l 3. ASSEMBLY----------------------------

Instructions for the disassembly of boom, arm and bucket cylinder are similer,

the bucket cylinder is shown and apply to all cylinder.

�ote: Before assembly, clearn all internal parts using clearn hydraulic oil and dried by air.

No foreign material should be remain inside the cylinder.

[!]

Install seal ring (13) on piston (12) \,ith

tools as shm,·n.

EX270

EX300

Bucket, Boom

ST-2367 ST-2366 ST-2300

Arm

ST-2221 ST-2197 ST-2185

ST-2399 ST-2388 ST-2387

00 8;

I Install two wear rings (l�J and two teflon

rings llS).

Stagger ring gaps on the

piston as shown in the figure.

12]

Put hydrauli\.· oil on outside of piston.

l'ress the piston i;1to tool to shrink the

seals their original si=e. Tool

--------Bucket,

Boom Arm

[!]

EX270

EX300

ST-2310

ST-2209

ST-2389

: .i

Press husing l08J 1n bor� of head co::;)

with tool. Tool

---------

EX270

EX300

Bucket

ST-2360

Arm

ST-2393

ST-2394

ST-2360

ST-2294

Boom

DISASSEMBLY and ASSEMBLY

CY-19-6 (D/A)

CYLINDER

I!]

install ring lU71 in groon' on the head Kith seal lip toKard the inside of cylinder.

I!]

Instal 1 seal (06) 1,·ith seal lip toward the inside of cylinder.

Install dust seal (05) 1,ith seal lip toward the outside of cylinder. Use tool as below.

Tool

------------

EX270

EX300

Bucket

ST-2357

Arm

ST-2391

ST-2392

Boom

ST-2357

ST-2309

[!)

Instal 1 buck up ring ( 1 O! and 0-ring ( 09 ! .

I!)

Put hydraulic oil on the 0-ring and the seals in head.

�"�

DISASSEMBLY and ASSEMBLY

CYLINDER � Install tool on rod (02) hi th taper end toward the thread.

Install head (031

onto the rod.

------------

Tool

QJ]

EX270

EX300

Bucket

ST-2363

Arm

ST-2349

ST-2350

Boom

ST-2363

ST-2311

Install cushion rjng i 111 on ti1e rod hith square end toward the piston.

Install

piston ll..:) on the rod.

Gl)

1nstall nut llCJl on the rod.

[ill

Tighten the nut 1,·i th tool.

--------

Tool

Bucket

Torque Too!

Arm

Torque Tool

Boom

Torque

EX270 ST-3266 980 , 98kgf. m (7088 : 709 ft.lbs) ST-3267

I I I

EX300 ST-3266 10'.lO: 100 kgf.m !7233 !: 723 lbs) ST-3268

1530,153kgf.m \ 1950:195kgf.m I 111066, 1106ft.lbs) !(14104: 1410ft. l bsl i ST-3266 810, 81 kgf.m 15858: 586 't. l bsl

ST-3266 850 : 85 kgf.m 16148 - 615ft.lbs)

Lock the nut hith set sere\\ �17). If the hole on rod is not align hith set scre1,, drill a hole on the rod, then -:lean the hole completely.

aat :

6 mm for all cylinder b . 5 :!: l) . 6 kg f · m ( 4 7 ± 4 ft . 1 b s :

CY-19-7 (D/A)

CY-19-8 (D/A)

DISASSEMBLY and ASSEMBLY

---------------CYLINDER----------------

12!)

Lock the set screw with a hammer and a punch.

Gil

Hoist rod assembly (02) and keep it horizontally.

Put hydraulic oil on

piston (12) and bore of cylinder.

[ill

Enter the piston (12) into cylinder (01) aligning rod center with bore cneter. Be carefull not to damage the piston seals.

[ill

Install head (03) hith eight socket bolts (04).

"" _,,. :

[ill

19 mm for all cylinder

---------

EX270

EX300

Bucket, Boom

85 ± 9 kgf.m (615 ± 65 ft.lbs)

Arm

85 ± 9 kgf.m (615 ± 65ft.lbs)

125 ± 13 kgf.m (904 ± 94 ft.lbs)

Fully retract the rod into the cylinder. Install the pipes on the cylinder.

10 mm 1 7 mm

,-- : 9±0.9 kgf·m (65±6 ft.lbs) - End assembly -

DISASSEMBLY and ASSEMBLY

CY-19-9

---------------

-----

CYLINDER ______________(_D_IA_l

4. SPECIAL TOOLS -----------EX270

EX300

For the nut loosen/tighten

Bucket, Boom

ST-3266

Arm

ST-3267

ST-3268

Bucket, Boom

ST-2367

Arm

ST-2221

ST-2399

Bucket, Boom

ST-2366

Arm

ST-2197

ST-2388

Bucket, Boom

ST-2300

Arm

ST-2185

ST-2387

Bucket, Boom

ST-2310

Arm

ST-2209

ST-2389

Bucket

ST-2357

Boom

ST-2357

ST-2309

Bucket

ST-2360

Boom

ST-2360

For the seal ring installation

For the seal ring shrink

For the wiper ring installation

Arm

ST-2391

ST-2392

For the bushing installation

Arm

ST-2393

ST-2394 ST-2294

For the head installation

Bucket

Arm

Boom

ST-2363

ST-23ll

ST-2349

ST-2350

DISASSEMBLY and ASSEMBLY

CY-19-10 (0/A)

---------------- CYLINDER -----------------

DETAIL A

DETAIL B

·�\

rart name

Item ()1

0�

() �

Cylinder Rod Head Socket bolt

Q 1 ty

r art name

Q 1 t_,-

L:ush ion rj no0

1-.::

!'i.-:;ton

Seal ring

I l

\\car r In,,0

1 :;

Tc fl 011 r1nu

l I-

\ut

Set s crch

O.:i

!lust seal

()(,

Seal

l) :-

Rino

l1S

Bushjng

l l �)

0-ring

l ()

Back up r1nu

!c>

T ten·

FA-15-3-1

FRONT-END ATTACHMENTS

-------------- PIN & BUSHING -------------1. SPECIFICATIONS ------ --- -- --------- -----1.1 PIN & BUSHING F

Unit: mm Mark

Measuring part

Boom foot

Boom cylinder bottom side Boom cylinder rod side

Boom top

Arm cylinder rod side

Arm cylinder bottom side

H I

90 90

91.5

Replace

91.5

Replace

91.5

Replace

81.5

Replace

81.5

Replace

81.5

Replace

91.5

Replace

I 80

81.5

Replace

i 89

91.5

Replace

91.5

Replace

89 I

! I

! I I

89 89

80 :

i' 79 !

Bucket cylinder, rod side I

;

' !

I I

90 !

Bucket arm side

! I

Link "A" bucket side

100

I Ii 90

Remedy

Replace

i I

Bushing

101.5

I 100 '

Nominal Dimension

Bucket cylinder bottom side

Link "B" arm side

Recommended Service Limit

Limit of Use

FA-15-3-2

FRONT-END ATTACHMENTS

-------------- PIN & BUSHING-------------1.2 CLEARANCE BElWEEN PIN & BUSHING

Mark A B C D E

Clearance between Pin and Bushing

Measuring part Boom foot

Boom cylinder bottom side

Boom cylinder rod side Boom top

Arm cylinder rod side Arm cylinder bottom side

Bucket cylinder bottom side

I J

Bucket cylinder rod side

Ling "B" bucket side

Ling "A" bucket side

Bucket arm side

Nominal Dimension

Remedy

Replace

0.215 'v 0.487 0.15 rv 0.42

2.5

Replace

0.10

.:: .5

Replace

0.27

0.199 •'\, 0,453 0.15 '\,

-. )

o ...i::2

;:,

+�·-------+--��--�

- ---+-

0.15 'v 0.42

2.5

0,205

', r .:. • J

0,456

0.2 88 "-, 0.5 0 4 0.27

.::.s

0.15 rv 0.-+2

. .._,

i O • 1 S '\, 0. 42

1-----+----- - - --------t--------

Unit: mm

0.10

Recommended Service Limit

Replace Replace Replace Replace

Replace � Replace

Replace

'') .::. . :-i

--------,,

i j

Replace

I I

Limit of Use

II I

FRONT-END ATTACHMENTS

FA-15-4-1

-------------POINT & SIDE CUTTER------------1. MAIN TENANCE--------------------------1.1 POINT ---1.1.1

-----

------ -------------'-----

HOE BUCKET

1 ( L r---\--.:\_ "'

=-=-=-=Li

-----A---

A B C

Weight

Standard 230

130

105

Unit: mm

Limit of use 110 -

7.5 kg

1.1.2 ROCK BUCKET

Standard

J I I \

'-----

C D

Weight

220

Unit: mm

Limit of use 105

121

117

141

10.0 kg

1.1.3 ONE-POINT RIPPER BUCKET/RIPPER BUCKET

A B

A---.

Weight

Standard 354

76.2

118 145

13.2 kg

Unit: mm

Limit of use 155

FA-15-4-2

FRONT-END ATTACHMENTS

------------- POINT & SIDE CUTTER -----------1.2 SIDE CUTTER

A B C D

Weight

Standard 258

300

400

300

Unit: mm

Limit of use 170

16.3 kg (One-side)

INDEX EX270-7A-1 A

�

HYDRAULIC SYSTEM

CONTENTS Group 1-0UTLINE ................................

HS-12A-1

Group 2-MAIN HYDRAULIC CIRCUIT ..... 1. 2. 3.

HS-12A-2-12 Suction Circuit & Delivery Circuit .................. HS-12A-2 Return Circuit .................................... HS-12A-6 Drain Circuit ..................................... HS-12A-8

Group 3-PILOT CIRCUIT . . . . . . . . . . . . . . . . . . . . 1. 2. 3. 4. 5. 6. 7. 8.

HS-12A-13-28 Suction, Delivery & Return Circuit ................ HS-12A-14 Accumulator .................................... HS-12A-16 Control Neutralizer Valve ........................ HS-12A-16 Pump Displacement Control Circuit ............... HS-12A-18 Relief Pressure Change Circuit .................... HS-12A-23 Switch Valve Circuit ............................. HS-12A-23 Heat-Run Circuit ............. ................... HS-12A-24 Swing Parking Brake .. .......................... HS-12A-26

Group 4-SINGLE OPERATION ............. 1. 2. 3. 4. 5. 6. 7. 8. 9.

HS-12A-29-46 Boom Raise Circuit Operation .................... HS-12A-29 Boom Lower Circuit Operation ................... HS-12A-31 Arm Roll-in Circuit Operation ..................... HS-12A-33 Arm Roll-Out Circuit Operation ................... HS-12A-35 Bucket Circuit Operation ......................... HS-12A-37 Swing Circuit Operation ......................... HS-12A-39 Swing Operation ................................ HS-12A-41 Travel Circuit Operation ......................... HS-12A-43 Travel Forward & Reverse Operation .............. HS-12A-45

Continued on next page

INDEX EX270-7A-2 A

CONTENTS {continued)

Group 5-COMBINED OPERATION ........

HS-12A-47-55 Outline ......................................... HS-12A-47 Combined Swing & Boom Operation ............. HS-12A-48 Combined Swing & Arm Operation ............... HS-12A-49 Combined Swing & Bucket Operation ............. HS-12A-50 Combined Swing, Boom, Arm & Bucket Operation . . ............................. HS-12A-51 6. Combined Swing & Travel Operation ............. HS-12A-52 .7. Combined Boom & Travel Operation .............. HS-12A-53 8. Combined Arm & Travel Operation ............... HS-12A-54 9. Combined Bucket& Travel Operation ............. HS-12A-55 1. 2.3. 4. 5.

Group 6-EXTRA CONTROL CIRCUIT .....

HS-12A-56-60 1. Outline ........................................• r HS-12A-56 2. Single Operation ................................ HS-12A-58 3. Combined Extra & Arm Roll-In Operation .......... HS-12A-59 4. Combined Extra & Arm Roll-Out Operation ........ HS-12A-60

HS-12A-1

------------- HYDRAULIC SYSTEM------------1. OUTLINE----------------------------

Hydraulic circuit mainly consists of i'-IAII\ HYDRAULIC CIRCUIT AND PILOT HYDRAULIC

CIRCUIT.

The main hydraulic circuit is mainly used for supplying the oil to the actua

tors from the pumps.

The pilot hydraulic circuit is mainly used for operating the control valve.

The hydraulic system consists of one engine, two main pumps, one pilot pump,

one control valve, four hydraulic cylinders, one swing motor and two travel motors.

The pumps are connected to the engine through a pump transmission.

The oil discharged from the main pumps flows to each function through the con

trol valve.

valves.

The oil discharged from the pilot pump flows to three pilot

SWING MOTOR CONTROL VALVE

HYO. OIL TANK

TRAVEL MOTOR

HS-12A-2

------------- HYDRAULIC SYSTEM------------2. MAIN HYDRAULIC CIRCUIT----------------------

This circuit is provided with a suction circuit, delivery circuit, return

circuit and drain circuit.

And the circuit is mainly consisted of two main

pumps, one control valve, one swing motor, four cylinders and two travel motors.

Two bent axis, variable displacement, axial piston pumps are used as the main

pumps and are driven by the engine at ratio of 0.9722 of engine speed through

the pump transmission.

The oil discharged from the main pumps flows to the

control valve, and the control valve controls the hydraulic functions.

the oil flows to the actuators through the control valve.

And

The return oil pushed out the actuators flows to the hydraulic tank through

the control valve and the oil cooler. 2.1 SUCTION CIRCUIT AND DELIVERY CIRCUIT

The front and rear pumps receive oil from the hydraulic tank through a suction

filter.

The discharged oil from the front pump flows into the right block of

control valve and goes out the tank ports.

The discharged oil from the rear

pump flows into the left block of control valve and goes out the tank ports•

TO 01 L COOLER

RIGHT BLOCK

TO HYO. TANK

LEFT BLOCK P2

FRONT

PUMP SUCTION FILTER

REAR

PUMP

HS-12A-3

------------ HYDRAULIC SYSTEM

CONTROL VALVE LEFT BLOCK

SUCTION FILTER

RIGHT BLOCK

,....

', ....

.... OIL COOLER

HS-12A-4 HYDRAULIC SYSTEM------------a.

DELIVERY PRESSURE CO\TROL

Two main relief valves in the control valve limit the output pressure of the pumps.

The setting pressures of tho main relief val\·es are different.

high setting pressure valve is used in the travel ooeration. pressure valve is used in the other operations.

The

The low setting

The main relief valve works to release the high pressure oil to the hydraulic

tank for preventing overload to the hydraulic unit and the engine. b.

Main relief valve set pressure

Applicable Serial No.

PU�IP DISPLACEME:\T CONTROL (See PILOT CIRCUIT) EX270

05001 05378

'\,

EX300

02001

'\,

RELIEF VALVE L

285 kgf/cm 2 285 kgf/cm

05377

'\,

RELIEF VALVE

HIGH

LOW

285 kgf/cm 2

325 kgf/cm 2 2 350 kgf/cm 2 350 kgf/cm

r--------------7 ____ , ____ 1

TO �-:- ------- -- +--� TANK ---+--__:.1 -�-----------'-

SWITCH VALVE

SOLENOID , VALVE

I I I

r ____ .J

! I I PILOT PUMP

I I I I

L _______ _j

FROM REAR PUMP

FROM FRONT PUMP

HS-12A-5 HYDRAULIC SYSTEM-------------

� - --.

MAIN RELIEF VALVE

(

t-- ------- �- -- --7 I I

(

I I I I I

t- -

TRAVEL MOTOR

-- ; I 'I ti

0 0

ARM CYLINDER

I I I I

(

I I I I I

SWING MOTOR

--- - _J

REAR PUMP

FRONT PUMP

HS-12A-6

------------- HYDRAULIC SYSTEM------------2.2 RETURN CIRCUIT

All oil of each actuator returns to the hydraulic tank from the control

valve.

Two different setting pressure valves are provided in the return circuit.

The setting pressure of restriction valve is 1.5 kgf/cm 2 (147kpa). valve is 3.0 kgf/cm 2 (294 kpa).

Bypass check

In usually, the oil returns to the hydraulic tank from the right of control

valve through restriction valve and oil cooler.

temperature bu the oil cooler.

The oil is cooled to a proper

When the oil temperature is low, the \'iscosi ty becomes high and flow resis tance increased when passing the oil through the oil cooler. pressure exceeds 3 kgf/cm 2

When the oil

(294 kpa), the oil returns directly to the hydraulic

tank, resuluting in the oil temperature being raised quickly at an appropriate level.

When the oil cooler is clogged, the oil returns directly to the hydraulic tank.

A full-flow filter is provided in the hydraulic tank. ,.

The oil from right and

left blocks of control valve is combined and filtered by the full-flow filter. A bypa.?_s relief valve is provided in the full-flow filter.

When the filter

element is clogged, the bypass relief valve opens at 1. 5 kgf/cm 2 differential pressure.

FULL-FLOW FILTER

RESTRICTION VALVE

( 14 7

kpa)

OIL COOLER

T2 RIGHT BLOCK ACTUATOR

BYPASS RELIEF VALVE

I I

L __ J

BYPASS CHECK VALVE

LEFT BLOCK

CONTROL VALVE

HS-12A-7

HYDRAULIC SYSTEM

BYPASS CHECK VALVE FULL-FLOW FILTER

(R)

OIL COOLER

RELIEF VALVE "OFF"

RELIEF VALVE "ON"

HS-12A-8 ------------ HYDRAULIC SYSTEM------------2.3 DRAIN CIRCUIT

Internal leak from the motors and brake valves and also, oil for lubrication are generated.

These oils have to be fed back to the tank.

A circuit avail

able then is the drain circuit discussed here. Travel motor drain circuit. Oils leaking from the right and left travel motors come out of the drain ports provided in the respective motor casing and join with each other.

These oils

pass through the center joint to join with drain oil from the swing motor and return to the hydraulic tank after filtrating by a full-flm, filter . Swing motor drain circuit. Oil leaking from swing motor comes out and join \�·ith each other and further with drain oil from the travel circuit and return to the hydraulic tank passing through a full-flow filter.

00 0 SWING MOTOR

TRAVEL MOTOR

'-T .../

(

CENTER JOINT

I I I

-------�---------� FULL-FLOW FILTER

HS-12A-9 HYDRAULIC SYSTEM-------------

CENTER JOINT

SWING MOTOR

FULL-FLOW FILTER

TRAVEL MOTOR

HS·12A l l

HYDRAULIC SYSTEM BUCKET CYLINDER

CONTR NEUT R�t l SER VALVE

OIL COOLER

HS-12A-13

HYDRAULIC SYSTEM------------3. PILOT CIRCUIT

The pilot circuit consists of the pilot pump, shockless valve, control neutralizer valve, solenoid valve and three pilot valves.

The pilot pump

receives the oil from the hydraulic tank through the suction filter.

The

discharged oil from the pilot pump flows to the pilot valves through the solenoid valve and the control neutralizer valve. Pilot oil is utilized as follows. 1. 7

3. -l . J .

6. 7.

Applied to pilot valves to operate the control valve.

Applied to pump regulator for controlling the pump displacement.

Applied to low-pressure set main relief valve to change the relief

pressure in main circuit.

Applied to si-·itch valve to combine the main pump outputs.

Applied to parking brake valve to alloK Shing motor operation.

Applied to pump regulator to change the travel speed.

Applies to two cylinders to limit the maximum engine speed.

Applied to pump regulator for controlling the pump input torque. SOLENOID VALVE

SUCTION FILTER

PILOT PUMP

Pl LOT FILTEA 1--�-1----�------'

L-

CYLINDER II

RELIEF VALVE CYLINDER I -----+---

REGULATOR

SHOCKLESS VALVE

SOLENOID VALVE FRONT PUMP CONTROL VALVE REAR PUMP

CHECK BLOCK

ACCUMULATOR

CONTROL NEUTRALIZER VALVE

PILOT VALVE

SWING f1ARKING I-----' BRAKE PILOT VALVE

PILOT VALVE

HS-12A-14

------------- HYDRAULIC SYSTEM------------3.1 SUCTION, DELIVERY AND RETURN CIRCUIT

The pilot pump receive oil from the hydraulic tank through a suction filter.

The discharged oil from the pilot pump flows to the solenoid valves through

the pilot filter_

The oil is filtered by the pilot filter.

The pilot relief

valve is provided in the solenoid valve for limiting the pilot circuit pres

sure.

The oil is divided into two lines.

neutralizer valve.

One line oil flows to the control

The other line oil flo�s to two cylinder mounted on the

engine and the regulator through the solenoid valve.

The oil from the control neutralizer valve flows to three pilot valves through

the filters.

The return oil from the pilot valve for traveling is returned

directly to the hydraulic tank.

The return oil from the pilot valves for

swing, boom, arm and bucket is returned to the hydraulic tank through the control neutralizer valve.

REGULATOR

CYLINDER I

SOLENOID VALVE

CYLINDER II

FULL-FLOW FILTER CHECK BLOCK

SOLENOID VALVE

CONTROL NEUTRALIZER VALVE TO SHOCKLESS VALVE

PILOT VALVE

HS-12A-15

HYDRAULIC SYSTEM

HYO. TANK

HS-12A-16 HYDRAULIC SYSTEM ------------3.2 ACCUMULATOR

The actuator piping can be remo\·ed any time as required.

Be.fore removing the

piping from the actuator, place the machine on a firm, le\·el ground, put its

attachments on the ground and stop the engine.

Under this condition, pressure exists in the actuator circuit.

This pressure should be released to the tank; otherwise, oil may spout out

upon removing the piping, resulting in being injuried.

Since the control valves used for this machine are of pilot operated type,

their control spools cannot be shifted to release the above pressure h·hile

the engine is out of operation - that is, there is no pilot pressure in the

circuit.

For this reason, an accumulator is provided in the pilot control

circuit to secure pilot pressure as sho�n.

Upon shifting the pilot control lever, pilot pressure is produced in the case

of accumulator because compressed nitrogen gas is charged into the bladder.

Then, the pilot pressure is delivered to the control valve thereby to move

the spool, thus releasing the above pressure.

ACCUMULATOR

SOLENOID VALVE

PILOT FILTER

SUCTION FILTER

r-----CHECK BLOCK

3.3 CONTROL NEUTRALIZER VALVE

When the control neutralizer lever is moved upward, the pilot oil of control neutralizer valve port Pis closed by the spool.

Then, the ports Al, A2 and

The pilot oil does not flow to the pilot valves.

When the control lever is

A3 are connected to the port T by the spool.

operated, the pilot valve does not supply the pilot oil to the control valve.

When the control neutrali::er lever is moved dowrn,·ard, the pilot oil from the

pilot pump is supplied to the pilot valves through the control neutralizer valve.

So, when the control lever is operated, the pilot oil is supplied to

the control valve.

HS-12A-17

HYDRAULIC SYSTEM

CONTROL NEUTRALIZER VALVE

'",

-f ?

HS-12A-18 ------------- HYDRAULIC SYSTEM------------3.4 PUMP DISPLACEMENT CONTROL CIRCUIT

a. l\Li\XIMUM PUMP DISPLACEMENT CONTROL

The maximum pump displacment is changed by the mode select and the travel

speed select switch on the instrument panel.

The lines A and Bin the following graph are selected by the travel speed

When the switch was placed in the high-speed position, the maximum

switch.

pump displacement follows the line A and the line Bis used for the low speed

position.

The engine speed lines C, D and E are selected by the mode switch even if the

When the switches are operated,

,engine fuel lever is in maximum speed position.

electric signals are sent to the solenoid valves to control the cylinders or pump regulator for changing the engine speed and pump displacment from the

controller according to the position of the auto-idle switch, mode select The following chart shows the

switch and the travel speed celect switch.

maximum pump displacement and engine speed according to the switch operation. Switch

.µ C (I) E (I)

speed

0.. I.fl

Cl 0.. E :::J 0.. E :::J E

Po(0

X (0

Engine Speed

/�

�

�:�-- ©) * � ___,

Governor l , L

- -;,

I I

,,,,

:,;:

�,

l . (1) Cy r - b

I IT ,_ I I 1 '. l ' I/

]

EX300

�'\ -

Flil)J

SB :

\ !Reg. \

L-

SC:

Fue 1 Lever

lI i I

1400

1910

1400

2250

1870 2150

0 0 0 0

0 0 0

0 0

�

Mode SW

Jp' Reg. /

g;] Auto idle SW

@+@

.---- � Travel speed SW

OFF

Solenoid Valve

: 1

1 Engine speed (min- ) EX270

' 1 Cyl. (·;) - -;A-:

L2:J

IDI E C

rn ru

Increase Flow

0 0 0 0 0 0

�

P6L

Traver only

ru rn

®QL

Attachment/ swwg

selectton

�

Travel

Mode

selection

Operation

Pi 1 ot Pump I I DC

Micro Processor

HS-12A-19

HYDRAULIC SYSTEM b. PUMP OUTPUT CO:HROL

The pump output is changed according to the control lever stroke.

Two pump

control vlave are provided in the control valve for finding the control

lever stroke and send a signal pressure to the pump regulator to control the

pump output.

Discharged oil from the pump passes the neutral oil passage in the control valve

and flm,·s to the pump control relief valve then returns to the hydraulic tank through the orifice in the pump control valve.

When all spools in the control valve are in neutral position, the signal pre

ssure increases due to orifice operation, and this high-pressure decreases the

pump displacement.

When a spool was moved to operate an actuator, the oil to

the actuator thus the signal pressure decreases and this low-pressure increases the pump displacement.

A relief valve is provided 1n the pump control valve to releases excessive

pressure in the circuit when the spool was moved from full stroke to neutral position.

jcharacte:cics Purno Control valve

r--�------ --7

I I

Pump Control Valvef �------1 Relief )( Valve 1 l__!___J ! / I I�

I :

C/V Neutral oil Right Block Spool

1 Reaulator

Pump Reaurator Q

Pump displacement

Control Q

Fror.t Pump

Left Block

I I

"' I

L _______ _

LLJ

_�l�v�e�

Pump Control Valve

HS-12A-20

HYDRAULIC SYSTEM

PILOT FILTER

SOLENOID VALVE

Jj__ -!

HS-12A-21

HYDRAULIC SYSTEM C. PUMP INPUT TORQUE CONTROL

This is to prevent the engine stole owing to pump input torque exceeds engine

torque when the engine speed decreases.

When the control lever comes in position "B" the switch of solenoid valve is

pushed and port "PP" to pump regulator "PS" is opened.

So that oil from pilot

pump goes to the pump regulator. This causes the compensation mechanism is operated earier and maintains the

P-Q curve of the pump below the engine output curve to prevent the pump from overloading the engine.

POSITION "B":

. -1 EX270•.• 1500±100 min . -1 EX300•••1300±100 min

OUTPUT TORQUE FROM ENGINE

w ::::> 0 cc 0 1w z

---

_:...--

----- ... _J

-- - ---- -'

(.!)

z w

INPUT TORQUE TO PUMP TRANSMISSION SHAFT

LOW IDLE

INPUT TORQUE TO PUMP SHAFT

ENGINE SPEED (min·1)

LOW IDLE

HS-12A-22

------------- HYDRAULIC SYSTEM-------------

SOLENOID VALVE

PILOT FILTER

SOLENOID VALVE ( MODE SELECT)

H S-12A-23 HYDRAULIC SYSTEM ------------3.5 RELIEF PRESSURE CHANGE CIRCUIT ------------- --------- --

This circuit is provided in the control valve for changing the circuit pres The circuit pressure is 285 kgf/cm 2 (27930 kpa)

sure in the main circuit.

in the all operation except travel operation and is 325 kgf/cm 2 (31850 kpa) [OR 350 kgf/cm 2 (34300 kpa)] in the travel operation.

When the swing, boom, arm or bucket is operated, the pilot oil from the pilot pump is returned to the tank through the le ft travel spool and right travel

When any travel lever is operated, the pilot oil

spool in the control valve. is closed by the spool.

Consequently, the pressure of port "PP" of low

pressure set main relief valve is raised and the poppet is moved.

The relief

valve "L" is disconnected to the main circuit and the main circuit pressure is limitted by the relief valve H.

3.6 SWITCH VALVE CIRCUIT

This circuit is provided in the control valve.

When the spool except travel spool is moved, the pilot oil from the pilot pump is closed by its spool.

Consequently, the pilot pressure of pilot port of the

switch valve is raised and its spool is moved.

Then the oil flow from the

front pump is changed from the right block to the left block. RELIEF

�---1----

TO TANK

FROM FRONT PUMP

SWITCH VALVE

LLr�_.L..SOLENOID , VALVE

RELIEF VALVE H

' 325 kgf/cm2

Applicable Serial No.

EX270: 05001 � 05377

PILOT FILTEA I I

350 kgf/cm2

Applicable Serial No.

EX270: 05378 � L _______ _J

FROM REAR PUMP

EX300: 02001 �

HS-12A-24 HYDRAULIC SYSTEM ------------3.7 HEAT-RUN CIRCUIT

The hydraulic oil viscosity becomes high in the low temperature and the time

lag is produced.

perature.

This circuit is provided for raising quickly the oil tem

Tank port of pilot relief connects with port X of shockless valve.

pilot valve is not operated, the pilot relief valve always works.

When the

The pilot

oil temperature is raised by the pilot relief valve, and then the oil flohs to the pilot valves.

Consequently, the pilot line is warmed up

CONTROL -+-.---.---+ NEUTRALIZER VALVE

quickly.

PILOT VALVE

CHECK BLOCK

SOLENOID VALVE

·----1

'- -

____ _J

__J SHOCK LESS VALVE

CONTROL VALVE

PILOT FILTER

PILOT PUMP

SUCTION FILTEA

FULL-FLOW FILTER

HS-12A-25

HYDRAULIC SYSTEM

PILOT VALVE

CONTROL VALVE

PILOT FILTER

HS-12A-26

------------- HYDRAULIC SYSTEM------------3.8 SWING PARKING BRAKE CIRCUIT

Swing parking brake is released by pilot pressure when operating actuators

except travel only operation.

Timer is provided to give � second time lag

when stopping swing motion to prevent the parking brake from being managed to slip by inertia of superstructure.

SWING PARKING BRAKE

CHECK BLOCK

SOLENOID VALVE

PILOT FILTER

HS12A2l

HYDRAULIC SYSTEM

�LFLOW FILTEA

SUCTION FILTER

TRAVEL MOTOR

HS 12A·19

HYDRAULIC SYSTEM---------------------------------4. SINGLE OPERATION 4.1 BOOM RAISE CIRCUIT OPERATION

When the right control lever is pulled to boorn raise position. Then the oi1 frorn pilot pump through the pilot valve to Boom (1) and Boom (II) sections of the control valve.

Herc, the spool positions are moved to the boom raise position, and the boorn circuits are opened.

The oil flows from both main pumps through Boom ( 1) ;rnd Boom (I I J sections of

the control valves to the bottom end of the boom cylinders, and to raise the

boom.

The return oil flow from the rod end of the cylinders are directed to the tank

through the only Boom (I) sect.ion of the control valve.

Cavitation and excessive pressure in the boom cylinder bottom end circuit is prevented by a overload relief and make-up valve for the Boorn (1) section of

the control valve.

�

o.c:=::::::rn i=::::::11..J

:- - . I

BOOM CYLINDER

300 kgf/cm 2 (29400 kpa)]

(Overload relief set pressure: BOOM CYLINDER

r--r- -_-_-_-_-:_-_-_-_-_-_-_-�----, RELIEF VALVE .-- (300 kgf/cm z )

OVERLOAD

r--r, __,.__r-:_-:_-:_-:_-:_-:_-:_-:_-:_-:_-:_-:_-:_-:_-:_-:..11':_--:_ _ -:_-:_-:_-:_-:_11-<.f!-_--;( t!Q � )( r----1-· ,.......l :

1<)

I"'

OVERLOAD -RELIEF VALVt: 300 kgf/cm'

�: ·-, � I

�

� -

�·-

�r-< �

�-,◊

�-

;;:::_

�

.......

�

,,,

-:' '

:;::;: �

�,'--;==�iJ

..,,Pl LOT VALVE

__::

:;t'. __

k>-

LO-

+'-...----,4,

OIL COOL FR

FRONT

PUMP

PILOT

PUMP

REAR PUMP HYO TANK

BOOM 11

-._ PILOT PUMP

HS-12A-31

---------------------------------- HYDRAULIC SYSTEM---------------------------------4.2 BOOM LOWER CIRCUIT OPERATION

When the right control lever is pushed fornard to boom l01,cr position.

!'hen

the oil from pilot pump through the pi lot valve to boom sections of the cont rol valve.

llere, the spool positions arc moved to the hoom lower position,

and the boom lower circuit is opened. Oil flows from front pump through Boom (I) section of the control valve to the rod end of the hoom cylinders, and to lower the boom. The return oil flows from the bottom end of the cylinders to the tank through the only Boom (I) section of the control valve. Cavitation and excessive pressure in the boom cylinder rod end circuit is prevented by a overload relief and make-up valve for the Boom (I) section of the control valve.

OVERLOAD - -RELIEF VALVE JOO kqf.lcm' 011 COOl [H

FRONT PUMP PILOT PUMP

RE.AR PUMP

HYO TANK

Pl( OT PlJMP

,.,____.....

HS·12A33

HYDRAULIC SYSTEM 4.3 ARM ROLL-IN CIRCUIT OPERATION When the left control lever 111an11ally is placed in the arm roll-,11 p,i,;itio11. Then the oil flows from pilot pump through thf.' pi lot val V<' to ar111 ,,cctions of the control valve.

llere, the spool positions arc 111oved to arm roll-in posi

tion. The oil flows from the front pu111p to the arm (I) section through the con fluence passage, because the arm section (I I) is blocked. The oil flows from the rear pump to the arm (1) section, then confluence with the oil from the front pump.

This oil from the arm (!) section to the bottom end of the arm

cylinder to roll-in arm. The return oil flows from the rod end of the cylinder through the arm (1) section only returned to the tank. The cavitation which will happen to the bottom of the arm cylinder is pre vented by a make-up valve, on other hand.

The excess pressure is also pre

vented by an overload relief valve in the control valve.

copIJ_ (0

co�

I f-----� I

I I

.....l

- --¢-

l"Y

�

'--

}

----�

�

/_r

{y'(; -rARM I

--·••· +�---�K-------- -- _ _ _ 0 V E R L OAD RELIEF VALVE (300 kgf/r.m' I ' 1 ��INDER_c='.

ARM II

' <r

FRONT PUMP

� -

PILOT

PUMP

◊

.....,.

--+<�

REAR PUMP

HYO, TANK

----------------------------------

HS-1:?A 35

---------------------------------- HYDRAULIC SYSTEM--------------------------------- 4.4 ARM ROLL-OUT CIRCUIT OPERATION

When the lL·ft cuntt·ol lever m;rnu�llly is pla<:L'J in thl' arm roll-out po�;ition. Then the 011 flo\�s from pi lot pump through the pi lot \'al\·c tl> arm sect ions of the control valve.

Here, the spool po:--itions are moved to arm roll-out

position. The oil flows from th,, front pump Lo the arm (1) section through the con fluence passage, because the arm section ([I) is blocked. The oil flm,s from the rear pump to the arm (I) section, then confluence with the oil from the front pump.

This oi 1 from the arm (I) section to the bottom end of the arm

cylinder to roll-out arm. lbe return oil flows from the bottom end of the cylinder through the arm ([) and arm (II) sections returned to the tank. The cavitation which will happen to the rod of th,, arm cylinder is prevented hy a make-up valve, on other hand.

The excess pressure is also prevented by

on overload relief valve in the control valve.

OVERLOAD RELIEF VALVE

ARM ti "' > -' r· <( I >, !!; I :::; I "'I a: '

z L _J

;; ::;

FRONT

PUMP

PILOT PUMP REAR PUMP

HYO. TANK

Pl l OT 1-'lJMP HYLJ T /\NI<

HS-12A-37

---------------------------------- HYDRAULIC SYSTEM---------------------------------4.5 BUCKET CIRCUIT OPERATION

l�lwn till' left t j 011.

UUCKET CYLINDEH

control lever 11i;ll1t1a!l,· placed in the bucket roll-in (out) posi-

!"hen the oil from pilot pump through the pi lot valve to bucket section

of the control valve.

llerc, the spool position is moved to bucket roll-in

(roll-out) position. The oil flows from front pump throllgh bucket section of the control valve to the bottom end (rod-end) of the bucket cylinder and roll-in (roll-out) the hucket.

The return oil flows from bucket cylinder through the bucket section

of the control valve returned to the tank.

Cavitation and excessive pressure

in the bucket cylinder circuit is prevented by a overload relief and make-up valve for the bucket section of the control valve.

BUCKET CYLINDER

__./

PILOT VALVE

OVERLOAD

FRONT

PUMP

PILOT PUMP

REAR

PUMP

HYO TANK

HYD

HS-12A-39

------------- HYDRAULIC SYSTEM------------4.6 SWING CIRCUIT OPERATION OUTLINE

When the left control lever manually is placed in the swing position.

Then

the oi1 flows from pi lot pump through the pi1 ot valve to the swing section of the control valve.

position.

Here, the spool position is moved to right or left swing

The oi1 flows from rear pump through swing section of the control valve to the

swing motor and swings the superstructure.

The cross-over relief valve, make-up valve and swing parking brake are pro

(1)

vided in the swing mtor.

CROSS-OVER RELIEF \'A.L\T

Cross-over relief valve for the swing motor limits to cushion the starting

RELIEF VALVE SET PRESSURE 2 EX270: 235 kgf/cm (23030 kpa) 2 EX300: 250 kgf/cm (24500 kpa)

and stopping pressure of swing operation. (2) MA.KE-UP VALVE

The make-up val\'es prevnet cavitation by supplying return oil to the vacuum

side of the motor.

thJ .. � �T �

SWING MOTOR

._::-

�a

,- "I

�-� J

CROSS-OVER RELIEF VALVE

MAKE-UP VALVE

I I I I I I I I I I I I ♦ -------♦ I REAR I PUMP: I

.! OVERLOAD

: RELIEF VALVE 300 kgf1cm' I I I

CONTROL VALVE

◊

-----

PILOT PUMP

HYO. TANK

__ J

MAIN RELIEF VALVE 285 kgf/cm'

HS-12A-40

------------- HYDRAULIC SYSTEM-------------

(3) PARKING BRAKE In case that the parking, of the machine at slope is required during opera

tion, there is the danger of involuntary swing caused by the self 1,·eight of

the machine.

The brake is connected to prevent this invaluntary swing.

PARKING BRAKE "OFF" OPERATION

The parking brake is released by the pilot pressure oil from the pilot pump.

When the left control lever placed in the swing position, the signal circuit

of the control valve blocked, then the pilot oil pressure at the pilot passage

rise [40 kgf/cm 2 (3920 kpa)] and the brake release valve is change over.

Then

the pilot pressure lift the brake piston and release the parking brake. PARKING BRAKE "ON" OPERATION

When the control lever placed in the neutral position, the pressure of the

pilot oil passage down.

Then the brake release valve returned to the neutral

position and the oil is returned from the brake piston to the tank. brake is set to "ON".

PARKING - - -, BRAKE PISTON r--------r--------r� I • 1=!71 �

SWING MOTOR L.'...:_J

.:: '

� 1-1

----

i-� I

PILOT RELIEF VALVE

,,,,

---- ---♦

BRAKE RELEASE VALVE

Pl LOT 01 L PASSAGE

--- -- _________ __

r-----------�-_, L ___________J

: I

And the

SWING SECTION

REARll PUMP:

_ _ c o N TR o::ALVE

RETURN OIL PASSAGE SIGNAL CIRCUIT

I I

,-i,.,.____;_;_______.__----\�

RESTRICTION VALVE 1.5 kgf/cm'

___ _J

HS-12A41

HYDRAULIC SYSTEM

--------------------------------- -

4.7 SWING OPERATION

When the left control lover is manually placed in the left [right) s1,1ng poSJ tion.

Then the oil flows from rear p11111p thrn11gh the> swing sc•ction of the

r- --....,

control valve to swing mot.or to lc'ft (right) s1✓ ing the superstructure.

''-

The return oil flow from swing motor th rough thl' swing section of tlw control

I I I

valve returned to the tank.

relief oil when stopping a high speed swing. swing, the class-over relief opens first.

♦

When stopping a high spc•ed

I�..., I I5 I I:: I� "I I:; I� I� Ii I;;'. I'-' 1° I� I is I I� 15 I� I� 1::1

w ...J

OVERLOAD RELIEF VALVE

·rhc pressure can increase to the

overload relief valve setting causing it to open.

1 � I :5 I w..., I I� I.: I g; I'-'

�

Then tho restriction resulting from

a high amount oil flows through the this rl'licf valve causes pressure to increase to more than the valve setting.

ts t

'1 w I

The overload relief valves in the swing section of tho control valve also

Relieved oil goes to return

'�a:

through the overload relief valve. ,, __________ ..,.,....-

)

♦

I I I I I I I :,,,-1 I I )

FRONT

PUMP

PILOT" PUMP

REAR

PUMP

t\=-\--- __-__

I�

HYO. TANK

OVEflLOAD

UELIEF VALVE

(300 kgf/r:m 1 ) SWING MOTOR

♦

HYD TANK

Pl LOT PUMP Pl

♦

HS 1? A-43

---------------------------------- HYDRAULIC SYSTEM---------------------------------4.8 TRAVEL CIRCUIT OPERATION OUTLINE-

----- - - - - ----

- ------

-----

---

·---�----

When the travel levers are manually placed to the forward or reverse position. Then the oi I flows from pi lot pump through the pilot valve to travel sections of the control valve. posit.ion.

Here, spools position is moved to forward and revers<'

The oil flows from both main pumps through the travel sections of

the control valves to the travel motors, and move the machine forward and rcvc rse. A brake valves arc provided on travel motors to offer the following functions:

r------ ___J

REDUCING I I VALVE r·•

@) L[l} I

15T020 kgf/cmi

L __ .J '-------7

I I

( 1) SHUTTLE VALVE

I I

------<o>---- --

---- - -<o>-------

reverse side, and send the pressure oil to the reducing valve. (2) REDUCING VALVE

--- --t----

.. -t-----

Select the high pressure side of the travel pressure from the forward and

COUNTERBALANCE VALVE

L__..J'\.... _______ 7

CHE:CK VAL VF

@ SHUTTLE VALVE

Reduce the travel pressure 15 to 20 kgf/cm 2 (1470 to 1%0 kpa) in order to

CENTER JOINT

use for the parking brake release pressure and supply it to the brake chamber. Also throttle is installed to delay (4 seconds) the brake "OFF" to the "ON". (3) CIIECK VALVE Stopping the motor, this valve sucks the oil from lower pressure passage for preventing the negative pressure and the cavitation of the motor.

L _ _.,

( 4 J COUNTERBALANCE VALVE

MAlN RELIEF VALVE {LOW PRESSURE)

When stopping the motor or slope descending, this valve is used to prevent the motor from overrun. (5)

OVERLOAD RELIEF VALVE

------

Relief valve limit the circuit pressure is below 330 kgf/cm

I I I

[OR 355 kgf/cm 2 (34790 kpa)] to prevent high pressure generated at a time

when stopping the machine. Applicable Serial No. EX270 EX300

05001

'\,

05378

'\,

02001

'\,

05377

Set pressure 3.,0 kgf/cm 2 2 355 kgf/cm

355 kg f/ cm

-- -- 7

.. .J

I --- --ITRAVtL I LI SECTION:

(32340 kpa)

MAIN RELIEF VALVE (HIGH PRESSURE I :

r- .. --

r I

: TRAVEL l♦- - -< - IRI SECTION 1 I I I I l

RESTRICTIO

VALVF

01 L COOLER

L_ - - - '. - · -t-- - - - - - - - - - - - -

[

>l<

---j\· --t-;Cs-� I T l

L ___________________________J

I I I I I

HS-12A-45

---------------------------------- HYDRAULIC SYSTEM---------------------------------4.9 TRAVEL FORWARD and REVERSE OPERATION When the right and left travel lcvl'rs arc m anually placed to the fonard <ll" reverse position.

Then the oil flows from front pump through till' travel (10

section of the control valve and center joint to the right travel motor and oil flows from rear pump though the travel (L) section of the control valve and center joint to the left travel motor and move the machine fornard and reverse. The return oil flows from hoth tr,1vcl motor through the center joint and travel (R) (L) sections returned to the tank.

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CENTER ) JOINT

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HYO. TANK FRONT PUMP PILOT PUMP REAR PUMP

HYO TANK

TRr: TRR: TLF: Tl.I!:

RI Ci IT MOTOR l'ORIVARll R [(;IIT MOTOR Rl:VLRS[ LHT MOTOR l'ORIVARll LITT" �IOTOR REVI:RSI:

LEFT TRAVEL MOTOR

HS-12A-47 HYDRAULIC SYSTEM ------------5. COMBINED OPERATION 5.1 OUTLINE

In case operation, the oi 1 flo1s·s from both main pumps through the neutral oi 1

passage, parallel oil passage, bypass oi 1 passage and confluence oil passage. Then the oil is supplied to each actuator and function them.

orifices (A, B, C, D) are provided with on these flow passage.

Check valves and These control

the oil flows from the pump corresponding to the each actuator's state of functioning and smooth the combined operation_

SWITCH VALVE

This switch valve is provided in the control valve.

When the spool except travel is moved, the pilot oil from the pilot pump is

closed by its spool_

Consequently, the pilot pressure port of the switch

valve rised and its spool is moved.

And the oil flows from the front pump

is changed from the right block to the left block of the travel section (L), and the machine straight travelling.

BOOM CYLINDER I - -- - - - - I

,-- __,,.

- - - --

--------- -----,---�-----, T2

-- !f- - - -�•(;::

--t- - ---- - --

RIGHT CONTROL VALVE

J __ - ·---~

::; r JI �-.--.-l.l>---,.....,.,.____________...,...________...,..__

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tii:::;

OIL COOLER RESTRICTION VALVE FRONT PUMP PILOT PUMP

I ..__,......,__--' I UJ I .L.r...-..,_.�__J CJ: I � L _J

REAR PUMP

HYD. TANK

LEFT TRAVEL MOTOR

ARM CYLINDER

HS-12A-48

------------- HYDRAULIC SYSTEM------------5.2 COMBINED SWING AND BOOM OPERATION

When the swing and boom functions are operated, simultaneously the swing spool and boom (I) (II) spools changed.

The oil £101,'s from the front pump through

parallel oil passage and boom (I) section of the control valve to boom cylinders and the boom functions. The oil flows from rear pump through paralle 1 oil passage and swing section to swing motor.

At the same time the pressure 1n the boom circuits can be

high while the swing pressure is low therefore the oil flows from rear pump to boom cylinders through the parallel oil passage and boom confluence passage.

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-I

BOOM

CYLINDER

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FRONT PUMP

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REAR PUMP

HYO.TANK

HS-12A-49

------------- HYDRAULIC SYSTEM------------5.3 COMBINED SWING AND ARM OPERATION

When the swing and arm functions are operated, simultaneously the swing and arm (I) and arm (II) spools changed.

The oil flows from front pump through

the neutral oil passage to arm (II) section of the right control valve.

However, the oil through the confluence oil passage, because the valve at arm (II) section is blocked.

Then through arm (I) section of the left control

valve to the arm cylinder and the arm function.

The oil flm,,s from rear pump through the parallel oi 1 passage and swing sec tion of the left control valve to the swing motor and swing the superstruc ture.

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PILOT PUMP

REAR PUMP HYD. TANK

,----.L---t i •

-OJ-OJ YJ3

FRONT PUMP

I ARM CYLIN DER I ,

SWING MOTOR

HS-12A-50

------------- HYDRAULIC SYSTEM------------5.4 COMBINED SWING AND BUCKET OPERATION--------------------

When the swing and Bucket functions are operated, the sh·ing and bucket spools changed.

The oil flows from front pump through the bucket section of the

right control valve to the bucket cylinder and the bucket function.

The oil

flows from rear pump through the parallel oil passage and swing section of the left control valve to the swing motor and swing the superstructure.

BUCKET CYLINDER

L__

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sw1NG MOTOR

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FRONT PUMP PILOT PUMP REAR PUMP

HYD. TANK

HS-12A-51

------------- HYDRAULIC SYSTEM------------5.5 COMBINED SWING, BOOM, ARM AND BUCKET OPERATION

When the swing, boom, arm and bucket functions are operated, the each spools of the control valve changed. The oil flows from front pump through parallel oil passage and boom and bucket section to boom and bucket cylinders.

The oil flows from rear pump through

the parallel oil passage and the swing and arm (I) section to swing motor and arm cylinder.

Then the functions to each actuators.

According to the state of each actuators functioning, the oil flows from front pump through the bypass oi: passage and orifice "C" to the arm (I) section and the oil flows from rear pump through the confluence oil passage to the boom (I) section.

However the speed of each actuator becomes slower in this

case.

BUCKET CYLINDER

c§

I-

BOOM CYLINDER

I I

,--

;

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L-

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ARM CYLl DER �

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SWING MOTOR

FRONT PUMP PILOT PUMP REAR PUMP HYO. TANK

HS-12A-52

HYO RAU LIC SYSTEM 5.6 COMBINED SWING AND TRAVEL OPERATION When the swing and right and left trave 1 functions are operated, the S\,ing and travel (R) (L) spools and the switch valve changed. front pump through the travel (R)

The oil flm,·s from

(L) section of the control valve to the

right and left travel motor. And the oil flows from rear pump through parallel oil passage and swing sec tion of the left control valve to the swing motor. Because of check valve "A" with orifice, the pressure in the travel circuit can be high while the swing pressure is low.

When the travel circuit pressure

drops lower than swing pressure, as when traveling downhi11, swing priority and smoothness are maintained because of the orifice in the check valve.

either case, the machine will continue to travel straight.

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t!i::i II

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SWING MOTOR

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FRONT PUMP PILOT PUMP REAR PUMP HYO. TANK

HS-12A-53

HYDRAULIC SYSTEM 5.7 COMBINED BOOM AND TRAVEL OPERATION

When the boom and travel (R) (L) functions are operated, the boom (II)

and travel (R) (L) spools and the switch valve changed.

The oil flows from

front pump through the travel (R) (L) section of the control valve to the right and left travel motor.

And the oil flows from rear pump.through parallel oil passage and boom (II)

section of the left control valve to the boom cylinder.

Because of check valve "A" with orifice, the pressure 1n the travel circuit

can be high while the boom pressure is low.

When the travel circuit pressure

drops lower than boom pressure, as \\·hen tra\·eling dm,nhi11, boom priority and

smoothness are maintained because of the orifice in the check valve.

either case, the machine will continue to travel straight.

,--

L__

BOOM

CYLINDER

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FRONT PUMP PILOT PUMP REAR PUMP HYO. TANK

HS-12A-54

HYDRAULIC SYSTEM 5.8 COMBINED ARM AND TRAVEL OPERATION

When the arm and travel (R) (L) functions are operated, the arm and travel (R) (L) spools and the S\,'itch vahe changed.

The oil flows from front pump

through the travel (R) (L) section of the control valve to the right and left travel motor. And the oil flows from rear pump through parallel oil passage and arm (I) section of the left control valve to the arm cylinder. Because of check valve ''N' with orifice, the pressure in the travel circuit can be high while the arm pressure is low.

When the travel circuit pressure

drops lower than arm pressure, as when traveling downhill, arm priority and smoothness are maintained because of the orifice in the check valve.

either case, the machine will continue to travel straight.

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: I'•

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I , I :TRAVEL 1(LEFT)

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CENTER D JOINT

TRAVEL MOTOR

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'ARM 11

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ARM I

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CYLINDER

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FRONT PUMP PILOT PUMP

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REAR PUMP HYD. TANK

HS-12A-55

HYDRAULIC SYSTEM 5.9 COMBINED BUCKET AND TRAVEL OPERATION

When the bucket and travel (R)

(L) functions are operated, the bucket and

trave 1 (R) ( L) spools and the switch val\·e changed. pump through the travel (R)

The oi 1 flows from front

(L) section of the control valve to right and

left travel motor and the machine traveling. The oil flows from rear pump through neutral oil passage, check valve with orifice

B" and bucket section of the control valve to the bucket cylinder

and the bucket functions.

BUCKET CYLINDER

,-1

1, L -• SWITCH1 VALVE ; ___ w I �rJ L----,--,r-O----E-:-,--'<-:£::,----r-{;----J"�--�-<;---,---�7

I FRONT I PUMP

<( I

tti:i

PILOT PUMP

I._,-�_,

I w I LI"�--'

REAR PUMP

� L _J <(

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o, �

TRAVEL MOTOR

�

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HYO. TANK

HS-12A-56 ------------ HYDRAULIC SYSTEM 6. EXTRA CONTROL CIRCUIT 6-1 OUTLINE------------------------------

Extra control circuit is used for the extra section of the control valve,

when using an extra attachment. Extra control circuit is composed by

adding the optional parts witch are pilot pump, extra pilot valve, a

shuttle valve, a stop valve and a preference valve. These are connected

with pipings between the extra section an the Arm II section of the control valve. Thus the oil from front pump flo\\·s not only to arm section but also

to the extra section by control Arm II spool. As a result, the extra single

operation and the conbined extra and arm operation become more smooth. ARM CYLINDER

PILOT VALVE (EXTRA)

r---------,

r------._----

\...

I I

_________ FRONT PUMP

: l_1_J

Pl------�

CHECK

OPEN : At crusher oneration

VALVE

I I

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1 I I I I I I I I I

"4B"

♦: I I I

.-+-+-��

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I I I I

SHUTTLE 0---�---- -----�-- _11\._ _ _J VALVE (B) '( 1 :ROLL-IN

L-------------------r----

ROLL-OUT

STOP VALVE (Bl

LA_-f><1-�--W

I I I I

I CLOSE I : At breaker operation I

:♦ ,--------PJ

STOP VALVE (Bl

I I I

IPILOT I PUMP

-----7 LU

L ____________________ .____________

I :

_,/

HS-12A-57

------------- HYDRAULIC SYSTEM ------------EXTRA CIRCUIT PILOT VALVE (ARM)

... ... , ...

ROLL-OUT

,,•, 'r I I

PREFERENCE VALVE

I I I I I

♦

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♦ I I

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',,

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...

SHUTTLE VALVE (Bl

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+ +

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c.. o....J,I >1

f- <(

Ul>

CHECK VALVE

;77

HS-12A-58

------------ HYDRAULIC SYSTEM ------------------ ------ - --

6-2 SINGLE OPERATION -

When the EXTRA control lever manually is placed in the EXTRA control position. Thea the oil flows from pilot pump through the pilot vahe to the EXTRA and ARM II sections of the control valve. Here, the spool positions are move<l to actuator control position. The oil flows from the front pump "Pl" to the EXTRA section through the PORT "..J.B", STOP VALVE and CHECK VALVE, and joins the oil flows from the rear pump "P2", and flows to the ACTUATOR. ARM CYLINDER

PILOT VALVE (EXTRA)

,-----� :♦ r---------

---

I I I I

FRONT PUMP

L'.J

Pl--------,

CHECK VALVE

I I I I I

' - - -1

L_}.,__

l � I) \ �-+-�--�

_,.

---{Xf--

J_,

L..'_J

PREFERENCE VALVE_

STOP VALVE (B)

,-----�.��-;,-L��

_ -- ___ _ j 1 ' ARM) SHUTTLE 0----�--------�--__/1'1.._ _ _J 1 :ROLL-IN ROLL-OUT VALVE (B) 'y ,

L-------------------�----

IPILOT : PUMP

L'.J

-----�

L _____________________________ _______

HS-12A-59 HYDRAULIC SYSTEM------------6-3 COMBINED EXTRA AND ARM ROLL-IN OPERATION h'hen the EXTRA and ARM control lever are operated simultaneously, the spools are changed to EXTRA and ARM ROLL-n position. The oil flows from the front pump "Pl" to the ARM (I) section through the ARM (I I) section and confluence oil passage, and joins the oil from the rear pump "P2", and flows to the arm cylinder. And the oil flo\\S from front pump "Pl" to the EXTRA section througe the PORT "4B", STOP VALVE and CHECK VALVE, and _ioins the oil from the pump "P2", and f101,;s to the actuator. The ARM (II) spool changed to either side as selected by the shuttle valve (B) that functions by the higher pilot pressure, either the nressure from the EXTRA nilot valve or ARM pilot valve. ARM CYLINDE R

�.

,-: �--------------I I

: LcJ I I I

-----�

FRONT PUMP

Pl------�

-:+--

I I I

I I

"4B"

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L-+-- -W-- ------, I

I I

! :

i I I

P RE F E RENCE V AL VE

I -----

t.11:�11 I

I I

1':

STOP VALVE (B)

�

(--1 f-Pl�O;��,;��)-i·· _____ =1----- --.JTL.J I

SHUTTLE 0--�------V L A V E (B))_____

�

�------1----:=�� IPILO T 1PUMP

......

L.!.J

��

OUT

: 1

:_ - - - - - - - - - - - - - - - - -- - - - ... - - - - - - - - - - - _J

HS-12A-60

------------ HYDRAULIC SYSTEM------------6-4 COMBINED EXTRA AND ARM ROLL-OUT OPERATION

When moving the lever of the EXTRA pilot valve and the lever of the ARM pilot valve to the ARM ROLL-OUT position simultaneously, the pressure on the pilot line of the ARM ROLL-OUT is generated. This makes the preference valve spool to move to the left side shown figer, then cuts off the pilot pressure provided from the EXTRA pilot valve. As a result, only the pilot pressure of the ARM ROLL-OUT works on the ARM (II) spool, and the spool is changed to the right side. The oil flows from the front pump "Pl" to the ARM (I) section through the ARM (II) section and confluence oil passage, and joins the oil from the rear pump "P2", and flows to the arm cylinder. ARM CYLIN DER

PILOT VALVE (EXTRA)

r------------

: f-----�--:

L---..._--

FRONT PUMP

: L!.J

P2 t--------,

CHECK VALVE

ARM (II)

--=.- - -

I I I I

i-...-

i♦

:♦

I I

PREFERENCE L�---i><!-------, VAL VE

I I

... --+ �... i I L� 11 :A � ____

�--� 1

�

:♦

I I I I I I I I I

I I

I I I I

I I

----, I

I I

♦

�

"48"

STOP VALVE (Bl

: I

�r,C�T-��'7�;-;;�,--

_J l_ I : - - IN SHUTTLE �- ----- -- - -----r----;>-R-0LL ROLL-OUT VALVE (B) I I : �..,._ -� --�----------------- -- -�---I

♦

1 I I I I PILOT L.!...J I U _._ L _______� __________ __ P MP ___.,_ __ _J

I I

HS-12A-61

HYDRAULIC SYSTEM

BOOM CYLINDER

�� L MOTOR

INDEX EX270-9-1

�

ELECTRICAL SYSTEM

CONTENTS Group 1-SAFETY PRECAUTIONS ............. 1.

ESs-1-1-2 Safety Precautions ................................. ES5-1-1

Group 2-SPECIFICATIONS ............... . ...

Battery, Starter, Safety Relay, Alternator, Regulator, Headlight, Wiper Motor, Speaker, Fuse,

Es12-2-1-2

Group 3-CONSTRUCTION AND FUNCTION 1. 2. 3. 4.

.................. ES12-3-1-26 Construction of Electrical System .................. ES12-3-1 Monitor .......................................... ES12-3-3 Control (E-P Control) System ..................... ES12-3-12 Function of Sensors and Relays .................. ES12-3-21

Group 4-CIRCUIT OPERATIONS ...... . . ...

1. 2. 3. 4. 5. 6. 7. 8. 8. 10.

ES12-4-1-20 Characteristics of Electrical Circuit .................. ES12-4-1 Electrical Circuit ................................... ES12-4-3 Battery Circuit .................................... ES12-4-5 Preheat Circuit .................................... ES12-4- 6 Starting Circuit ................................... ES12-4-7 Charging Circuit ................................. ES12-4-11 Engine Stop Circuit .............................. ES12-4-14 Accessory Circuit ................................ ES12-4-·18 Gauge Panel Circuit ..... . ....................... ES12-4--19 Control Circuit .................................. ES12-4-20

Group 5-MAINTENANCE ... . ......... . .... . . 1. 2.

ES5-5A-1-10 Replacing Panel Gauge Parts ...................... ES5-5A-1 Assembly and Adjustment of Engine Control Device ............................ ES5-5A-9

ES5-1-1

ELECTRICAL SYSTEM

------------SAFETY PRECAUTIONS------------SAFETY PRECAUTIONS

A CAUTION: Wear eye protection and remove rings, metal watch bands and

other metal jewelry when working on the electrical system.

A CAUTION: When checking or repairing the Electric Parts, DISCO NNECT TI-IE

EARTH LINE "A" from Minus Termi

DISCONNECT

A-.

nal "B" on the battery.

A CAUTION:

EARTH LINE NEVER LAY A METAL OBJECT on top of a battery as short circuit can result.

A CAUTION:

GA S FROM BATTERY ELECTROLYTE IS FLAMMABLE. fires away from the battery.

Keep all sparks and

When charging the battery, gas is

created more rapidly.

A CAUTION: BATTERY ACID IS HARMFUL O� COKTACT with the skin or materials.

ES12-2-1

ELECTRICAL SYSTEM

SPECIFICATIONS

-------------

SPECIFICATIONS This machine uses a 24 volt, negative earth type system. (1) BATfERY o Model

l 70G51-MF

o Rated voltage and capacity

12 V, 150 AH

o Weight

44 kg/unit

(2) STARTER o Mode1

28100-1940

o Rated output

6 kW

o \'o 1tagc

24 V

(3) SAFETY RELAY o Mode 1

28410-1081

o Operating voltage

less than 16 \'

(4) ALTER.'JATOR (AC GE>JERATOR) o Mode1

27020-1080

o Rated voltage

24 V

o Rated current

25 A

(5) REGULATOR o Mode1

27700-1530A

o Voltage regulation

29.0 ± 0.5V

o Rated current

(6) HEADLIGHT o Model

10(010-0000

o Voltage and watt

Halogen 24 V, 70 W

( 7) WI PER �TOR o Rated voltage

24 V

o Weight

1. 0 kg

o Operating angle

110 ± 5 °

(8) SPEAKER o Rated impedance

8 ohm

o Allowable input

5 W (Rated) 8 W (Max.)

ES12-2-2

ELECTRICAL SYSTEM

SPECIFICATIONS ( 7) FUSE

o Head lamp

o Room lamp

o Heater. Cooler

o Wiper

o Horn

o Lighter

o Monitor

o Controller

o Radio

o Clock

15 A

10 A

15 A

10 A

1 A 1 A

...,._,

<y, "A: ,-,, I-'

m r m (") --i :::0 (") )> r (J)

,__, C"') :i:,-0

..., z

ANTENNA

HEAD LAMP

..., V, p) -I ::l :0 � C ::l C"') -I (1) ::l rt 0 O Z

FUEL METER SENSOR

m 'Tl

COOLING WATER LEVEL SENSOR

HORN SWITCH

�

�o

FUEL LEVEL WARNING SENSOR WIPER MOTOR

(J) --i m

..a m C r

�- m ::l C"') -I (1) ::l :0 rt C"') )> r V,

V, ENGINE COOLANT-I m TEMPERATURE _ l: /!SENSOR BATTERY RELAY

C"') 0

Cl) -I :0 C C"') -I

ALTERNATOR

'Tl C

C"') --! ENGINE OIL PRESSURE SENSOR & HOUR METER SWITCH � HYDRAULIC OIL TANK LEVEL SENSOR

REGULATOR BATTERY

AIR CLEANER FILTER CLOG SENSOR

HEATER RELAY

FUSIBLE LINK m (J)

.... � ....

l',J

ELECTRICAL SYSTEM

ES12-3-2

---------- CONSTRUCTION AND FUNCTION -----------

(2) Control Box (Right Side)

PRE-HEAT TIMER

FUSE

ENGINE STOP RELAY

DIODE

UNIT CONTROL HORN RELAY HOURMETER RELAY

In addition to the above devices, the control box is equipped with a gauge

panel, a mode selection switch, an auto-idle switch and other switches and

a radio.

ELECTRICAL SYSTEM

ES12-3-3

---------- CONSTRUCTION AND FUNCTION----------2. MONITOR 2.1

OUTLINE

To operate the machine safely, the operator should have a thorough understanding of the machine condition.

However, the operator may overlook soDe abnormality

of the machine while concentrating on the job.

To allow the operator to become aware of abnormality of the machine as early as possible, various gauges and alarm devices are providec.

"�10:--.:ITOR" (monitoring

system of operating conditions) is a general term for these things.

(1) Gauge Pane 1

UPPER HOUSINIG

CLOCK

COVER

�

MONITOR LAMP SWITCH

TEMPERATURE METER LAMP HOUSING

METER BOARD

CONTROL BOARD

LOWER HOUSiNG

COVER

BUZZER

ELECTRICAL SYSTEM

ES12-3-4

---------- CONSTRUCTION AND FUNCTION -----------

(2) The rnonitor (in case of super deluxe type) provides the fol lowing features: 1)

The feeling of automobile instrument panel (instrumentation board) has

been added not only by integrating various types of meters and such display lamps as the OK lamps and warning lamps into a single box but also by

making the meters easier to be seen during night through the provision of transparent dial interior illurninators.

2) The layout has been renovated and a clock is added.

3) 18 iterns in total with provision of 1 clock, 3 types of OK lamp, 3 types of meters, various warning lamps and pilot lamps are to be monitored.

Classification of Display Methods.

The monitor is to be classified by the following terms depending on the dis

play methods. 1)

Meter in analogue

2) Warning lamp

It means the needle type meter for displaying the state of machine 1n analogue.

It means the red lamp which comes on hhen the machine is in abnormal state.

Out of them, the over heat

warning lamp and the engine oil pressure warning

lamp are designed to give the alarm through red lamp

and buzzer as they are the emergency monitoring

3) OK lamp

items.

It means the green lamp which comes on when the machine is in normal state.

The OK lamp and the warning lamp are named the moni 4) Pilot lamp

toring lamps in general term.

This 1 amp comes -n \,hen the equipment is in the service condition.

The preheat timer pilot lamp

(orange) comes on during the preheat.

Resides the

head light pilot lamp, there also are the pilot lamps (all of them are in green) for auto idling, low speed

travel and high speed travel that are related to the

5) Dash board lamp

control.

4 pcs of dash board lamp are built in the gauge panel

and lighted up in interlock with the lighting switch.

CAUTIO� --------------------------------�

MONITOR is not such a system which guarantees the machine working conditions.

It is necessary to guide the operator to perform the daily check following the OPE�ATION MANUAL without being dependent only on MO�ITOR.

ELECTRICAL SYSTEM

ES12-3-5

---------- CONSTRUCTION AND FUNCTION ----------2.2 GAUGES AND INDICATORS IN THE MONITOR PANEL

CD CV @ © ® ® (J) @

(jJ) @ @

B �--II FUEL

SERVICE METER

(±)

jo I 0101 ol ol ¼H QUARTZ

(jJ) @ @ @ @ <Si) @

Clock Engine Coolant Temperature Gauge Fuel Gauge Service Meter Charge Lamp Engine Oil Pressure Warning Lamp Engine Oil Filter Clog Warning Lamp Air Cleaner Filter Clog Warning Lamp Overheat Warning Lamp Fuel Level Warning Lamp Preheat Timer Pilot Lamp Head Light Pilot Lamp Engine Oil Level OK Lamp Cooling Water Level OK Lamp Hydraulic Oil Tank Level OK Lamp Auto-Idling Pilot Lamp Low-Speed Travel Pilot Lamp High-Speed Travel Pilot Lamp Preoperation Check Switch Buzzer Stop Switch

(±)

ALARM BUZZER SOUi\D O'.\LY WHE;; LAl'lPS 6 or 9 LIGHTS

ES12-3-6

ELECTRICAL SYSTEM

---------- CONSTRUCTION AND FUNCTION ----------2.3 CONSTRUCTION METER AND GAUGE

(1) Clock

The clock is a digital indicator and

always functions even with the starter

switch turned OFF.

However, the clock will stop if the ter minal of the battery is removed to turn

off power during, for instance, mainte nance.

The clock has time-set and minute-set

switches for adjustment.

(2) Engine coolant temperature gauge

It is normal so long as the pointer is in

the GREEN zone during operation of the

�R

machine.

General standard for \,ater temperature: ° 0 When pointer is at II l" position: 50 C

0 0

When pointer is at

2 II position: 6 7 ° C

"311

position: 103 C

W: White, G: Green, R; R�d

(3) Fuel gauge

When the pointer reaches point "E", it

denotes that fuel remains in the tank for

permiting the machine to be operated about

FUEL

I ' �

an hour.

(About 16.5 liters in the condition of the

machine on a leve1 ground.)

W: White, G: Green

(4) Service meter

When the engine starts and the hourmeter

switch is excited to allow the hourmeter

starting to work.

SERVICE METER B

ES12-3-7

ELECTRICAL SYSTEM

---------- CONSTRUCTION AND FUNCTION ----------WARNING LAMPS (RED) (1) Battery charge warning lamp

When N terminal voltage of alternator is low, the lamp goes on.

Alternator 1" terminal voltage

ll.5vl4.5V LAMP GOES OUT

t---------L---J

8. Srvl 1.5\'

LAMP GOES O'.\

(2) Engine oil pressure warning lamp

lvhen the engine oi 1 pressure is low, the lamp

goes on and the buzzer also sounds.

0.4v0.6 bar LAMP GOES ON

PRESSURE

LAMP GOES OUT 0.43v0.63 bar

(3) Engine oil filter clog warning lamp

When the engine oil filter element is clogged,

the lamp goes on. Difference pressure (4)

LAMP GOES OUT

1.5 bar

LAMP GOES ON

1.0 bar

Air cleaner clog warning lamp

«v

tfiJ

When the air cleaner element is clogged, the

lamp goes on. Suck pressure

630mmAq LAMP GOES ON

L..'..�!P GOES OUT 520mmAq

(5) Engine overheat warning lamp

1111en the engine is over-heated, the lamp goes on

I (6)

and buzzer also sounds.

lfater temperature

102 °C

LAMP GOES OUT

9s 0 c

LA!,IP GOES ON

Fuel level warning lamp

When the fuel that remains 1n the tank 1s about A 1i ters, the lamp comes on.

fuel

H rA6 ;� LAMP GOES ON L\\lP GOES OUT

Hysteresis � 7 C

ELECTRICAL SYSTEM

ES12-3-8

---------- CONSTRUCTION AND FUNCTION----------OK LAMPS (GAREN} (1}

Headlight pilot lamp

Upon lighting the headlight, the lamp goes on.

(For preventing fault to turn off the headlight

in the daytime.)

(2) Engine oil level OK lamp

\\Then the oil level is below "L" of dipstick, i.e.,

6Y=O to 3.5mm, this lamp goes on.

(3) Cooling water level OK lamp

When the water level is over (LOW ±Smm) of reserve tank, this lamp goes on.

mm mm

Radiator

(4) Hydraulic oil tank level OK lamp

When tie oil level is below LOW of the tank level gauge, i.e ., 6Y=79mm, this lamp goes on.

NOTE: Keep the front-end attachment in a range as shown.

ES12-3-9

ELECTRICAL SYSTEM

---------- CONSTRUCTION AND FUNCTION---------2.4 MONITOR CHECK PROCEDURE

(1) CHECK FOR BURN-OUT OF LAMP FILAMEt\T (Before Engine Start)

Upon turning the key S\,itch (clockwise) to "0:--.J", all warning lamps light

while 2 second. If there is any lamp 1�hich does not light, it denotes that the lamp filament is burnt out. (2) CHECK OF AMOUNTS OF 01 L & WATER (Before Engine Start)

Upon pushing the monitor lamp Sh'itch (green button) with the starter switch

set to ON position before starting the engine, OK lamps (green) of engine oil

level, engine coolant level and hydraulic oil level go on.

If the lamps do not go on, it denotes that the amounts are short.

(It is

also necessary to make certain directly with the conventional level gauge.) o In this case, the engine oil pressure warning lamp and battery charge warning lamp go on, but it is not abnonnal.

ounless the basic machine is placed level or the bucket is put on the

same level as with the basic machine, incorrect indication may be given.

(3) START OF ENGINE

a. When the engine is started initially, the engine oil pressure warning lamp and battery charge warning lamp light respectively.

b. Once the engine starts, the engine oil pressure warning lamp and battery charge warning lamp go out in slow.

o When the engine is kept lower than idling speed, the battery charge warning lamp may not go out sometime.

In such a case, the speed should be increased

to the specified low idling speed.

o If the engine oil pressure warning lamp is still going an despite 6 � 8

seconds having elapsed after the battery charge h'arning lamp has gone out,

a buzzer will sound.

In that case, it is necessary to check the lubricating

oil system of the engine.

ELECTRICAL SYSTEM

ES12-3-10

---------- CONSTRUCTION AND FUNCTION----------

(4) IN ENGINE RUNNING

Should any abnormality occur during operation of the machine, the warning lamps (red lamp) go on.

If so, take the following remedies: a. Battery charge warning 1 amp

Check the electric system and repair if any.

If use as it is, the battery may be discharged.

b. Engine oil pressure warning lamp (Buzzer sounds 2 to 5 seconds later)

Luwer the bucket onto the ground, put the machine 1n safe status and stop the engine. If the -achine operation is continued as it is, it may lead

to the damage of the engine.

c. Engine oil filter clog warning lamp

Replace the engine oil filter element.

If use it is, the engine may be damaged.

d. Air cleaner filter clog warning lamp

Clean or replace the air cleaner element.

If use as it is, the engine may be damaged. e. Overheat warning lamp (Buzzer sounds at the same time)

Remove the load from the engine and keep idling unit the water tempreature

comes donw.

If the engine is stopped at once, water temperature may go up rather high. Don't stop the engine before the lamp goes out.

o In order to stop the buzzer sound, push the buzzer stop switch. f. Fuel level warning lamp

Refuel until the pointer of fuel gauge swings to "F".

ELECTRICAL SYSTEM

ES12-3-11

----------- CONSTRUCTION AND FUNCTION -----------

When the engine is stopped, it is nor�al that all warning lamps go

out except the engine oil pressure 1varning lamp and battery charge warning lamp.

While the engine 1s running, it is normal that all red lamps go

out.

When preheating and starting the engine, it is normal that all

l amps light.

o When the buzzer stop switch is pushed about one second, the buzzer does not sound even though the switch is released.

Since the buzzer function is automatically resetted the switch is released

the buzzer sounds, if a abnormality occurs again.

ES12-3-12

ELECTRICAL SYSTEM

---------- CONSTRUCTION AND FUNCTION-------- 3. CONTROL (E-P Control System: Option) 3.1 CHARACTERISTICS OF E-P CONTROL

The E-P control is a system that controls the engine and the pump simul

taneously.

It selects and controls the engine speed and the pump delivery to fit the

current working conditions and atmosphere through mode selection and change

over between 2-speed travel and auto-idling.

The engine speed is variable in 3 steps: 100%, 85% and auto idling set speed,

while the pump calacity can be changed between 100% and INCREASE.

Their

control is effected by the operation of the switches and levers, through

signal input to the built-in microcomputer of the controller. 3;2 CONSTRUCTION OF CONTROL UNIT AND ARRANGEMENT OF EQUIPMENT

AUTO IDLING SWITCH

TRAVEL SPEED SELECTION SWITCH

CONTROL UNIT SOLENLED VALVE 8

SOLENLED VALVE A

ES12-3-13

ELECTRICAL SYSTEM

---------- CONSTRUCTION AND FUNCTION----------

(1) Mode selection

3 operation modes can be selected by

operating the mode selection switch located on the right console.

In each of

these operation modes, a microcomputer

selects automatically the best combination of the engine speed and the flow rate of the pump which fits the current working

conditions and purpose.

Use the following table for making the

best choice to improve the working efficiency.

P (Power) Mode

For high speeds and large work volumes

E (Economy) Mode: The work volume will be slightly lowered from P Mode, but it improves fuel efficiency greatly and reduces noise

L ( Light) Mode

level.

For low speeds to obtain high precision.

The engine speed is further lowered, allowing more improved

fuel consumption and noise level. same as in P and E Modes.

The digging power is the

ELECTRICAL SYSTEM

ES12-3-14

---------- CONSTRUCTION AND FUNCTION----------

Mode Selection Criteria

Mode Q)

Selection Points

For handling many works in

a short time.

�

4-<

..,

2 3

Digging and loading earth and sand.

Preparing agricultural land. Levelling ground.

High precision works such as normal

To further reduce noise.

cutting and levelling.

speed.

more weighted than working

\forks in limited spaces

Lifting works using soil supports.

Night works in urban areas.

:--loving in small sites.

Carrying unhardened concrete.

Getting out of fragile lands.

Characteristics of P, E and L Modes

Front speed

\fork loaJ

Digging power

E L

□: (2)

High speed travelling.

When working at lm,· speed

Heavy duty digging.

1'-loving in site

When fuel consumption is

Digging and loading earth and sand.

to improve precision.

Digging and dumping 1,orks.

consumption rate.

For reducing noise.

efficiency and fuel

.::

General works. For improving working

•ri

•H

waiting for loading.

•ri

When many dump trucks are

::= u

Examples of \fork

Normal

Good

O,:

Fuel consumption

Very good

SELECTION OF HIGH-SPEED AND LOW-SPEED

TRAVEL

Either high-speed or low-speed trave 1 can

be selected in each working mode by chang

ing over the high/low speed selection

switch provided on the right console.

When you wish to lower the travel speed,

such as in travelling on a tilted ground or moving in a limited space, the travel

ground or moving in a limited space, the travel speed can be adjusted simply by

changing over this switch.

Fuel efficiency

\oise

ES12-3-15

ELECTRICAL SYSTEM

---------- CONSTRUCTION AND FUNCTION

C."'..UTION:

In this system, a microcomputer automati

cally selects the best combination of the

engine speed and the flow rate of the pump

according to the position of the selection There

switch and the current operation.

fore, the engine speed is changed by a

lever control or switch selection, which

should not be regarded as abnormal. (3)

AUTO IDLI�G DEVICE

This machine is equipped with Auto Idling Device which automatically reduces the

engine speed when control levers are put in the neutral position.

Turning

O�/OFF of this auto idling device can be

done by the auto idling s1,itch @ easily. (1) When auto idling is activated:

Engine speed increases when each

control levers are operated up to the

level controlled by the fuel lever

®·

Four seconds after the control levers

are returned to the neutral, the

engine speed 1s reduced automatically

to the level set by the auto idling

device.

(2) When auto idling is turned "OFF".

The engine speed can be controlled by

the fuel lever at your will. CAUTim:

Auto idling device does not work if

the engine speed set by the fuel lever is lower than the engine speed set by

the auto idling device.

ES12-3-16

ELECTRICAL SYSTEM

---------- CONSTRUCTION AND FUNCTION PRECUTIONS BEFORE OPERATION

(1) Always check ON/OFF of auto idling device before operating any control levers.

(2) When the machine is used with the auto

idling switch turned ON, the engine speed lowers to an auto-idling set speed

(1,300 � 1,500 rpm) despite a higher speed

set by the fue1 lever if the control levers are in the neutral position.

operating a control lever, the engine

speed increases sharply.

(3) When loading/unloading the machine, al1\lays

turn "OFF" the auto idling switch for your

safety.

-·m m

(.,)

□ ,&

ACTUATOR

-3 ::r"' (1)

I-ti

HYDRAULIC PILOT

CONTROL L----------

DIGGING BUCKET CYLINDER

PRESSURE SENSOR

:;: I-'· ::l

OUTSIDE OF,_________ � TRAVEL

(1q

I-ti I-'· (1q

C >i

TRAVEL��----,

(1)

SWING MOTOR

::r"' 0 ::;:

RIGHT TRAVEL MOTOR LEFT TRAVEL MOTOR

LARGE

::,-E MODE DIGGING

SMALL

(1)

SMALL

Vl rt

GOVERNOR

>i C

MONITOR

{") )>

I-ti I

s::

-I

:0 C

-I C

"Tl

-i:,

n 0

("')

z Cl)

-i ::1J

("')

-I :x,

C -i

z "TI

z ("')

-i

0 z

AUTO IDLING SWITCH CONTROL•

PUSH-PULL CABLE

-I m

Cl)

()

ENGINE CONTROL LINK

Cl)

(1)

tTl

SOLENOID VALVE

ENGINE LEVER

0 ,.... ,.... z )>

CONTROL VALVE

ARM CYLINDER

ENGINE

-I :0

BOOM CYLINDER

TRAVEL

{")

"Tl

UNIT

TRAVEL SPEED SELECTION SWITCH p

MODE SELECTION SIWTCH

m V,

ELECTRICAL SYSTEM

ES12-3-18

---------- CONSTRUCTION AND FUNCTION

2 pressure sensors are provided at the control valve.

They detect the pres

surized oil and send electric signals to the control unit.

Of the 2 pressure

sensors, one detects the travel control pressure, and the other handles all

the other control pressures.

In the operator's cab are the auto-idle switch, travel speed selection switch

and mode selection switch, the status of which is kept informed to the control unit in the form of electric signals.

The control unit has a built-in microcomputer, which computes the electric

signals sent from the pressure sensors and the selection switches to control the 3 solenoid valves.

When the No. 1 solenoid valve is activated, the E mode cylinder starts 1,·orking to lower the engine speed to 85% from the maximum level.

If the \o. 2

solenoid valve is activated, the auto-idle cylinder functions to further reduce the engine speed to auto idling set speed.

When the No. 3 solenoid

is activated, the tilt angle of the pump swash-plate to increase its delivery.

Output:

Input : Signal

Controlled Action

Pressure Sensor (2 units)+ Select Switch (3 units) o Auto Idling

o Travel Speed (High, Low) o Mode (P, E and L)

Control + Unit

Solenoid Valve (3 units)

+ +

Engine Speed Conrol, Pump Delivery Control

ELECTRICAL SYSTEM

ES12-3-19

---------- CONSTRUCTION AND FUNCTION The microcomputer instructs the following 9 points to select the engine speed and the pump delivery:

Pump is at 2nd step swash-plate angle

!�

,.___�i__

.2: oi "O

Difference of delivery: Approx. 10%

Approx. 5%

C. E :, C. E

2nd step

-� Q

p Pump performance

auto idling set speed

100%

85%

Engine speed (rpm)

Operator's Selection p

H L

Travel

Ci)

Digging

Travel+Digging

Auto-idle Off

Auto-idle On

Controller's Selection

1 �

Application

® ®

Reference (D H: Pump at 2nd step swash-plate angle, engine speed unchanged. L: Pump swash-plate angle unchanged, engine speed lowered by 1 step. @ Hand L: Same in P, E and Lmodes G) H: Both pump swash-plate angle and engine speed unchanged.

L: Pump swash-plate angle unchanged, engine speed lowered by 1 step. Pump at m1n1mum swash-plate angle, engine speed unchanged. Pump at minimum S\,ash-plate angle, engine speed lo\,·ered by 2 steps (to auto idling set speed).

ELECTRICAL SYSTEM

ES12-3-20

---------- CONSTRUCTION AND FUNCTION * Requirements for activation of E mode cylinder

o Mode selection switch: P, Travel selection switch: Lin travel operation.

o Mode selection switch: P in travel and non-travel operations.

o Mode selection switch: E, Travel seletion switch: Hin all operations. o Mode selection switch: E, Travel selection switch: L in non-travel operations.

* Requirements for activation of auto-idle cylinder o Auto-idle switch: ON, Levers: Neutral 0 0 0

Mode selection switch: L in all operations

Mode selection switch: E' Travel selection switch: L in travel operation. Mode selection switch: E' Travel selection switch: L in trave 1 and nontravel operations.

* Requirements for non-activation of mini-cylinder 0 Mode selection switch: p' Auto-idle switch: OFF 0 0

Mode selection switch: p' Travel selection switch: Hin all operations. Mode selection s1,itch: P, Travel selection switch: Lin r.on-trave 1 operations.

ELECTRICAL SYSTEM

ES12-3-21

-----------CONSTRUCTION AND FUNCTION----------5. FUNCTION OF SENSORS AND RELAYS-----------------(1) Engine oil pressure sensor (pressure switch) As soon as engine oil pressure goes up, the oil pressure sensor turns OFF, shut

ting off the engine oil warning lamp.

As soon as engine oil pressure goes down,

the sensor turns ON, lighting the warning lamp. (2) Engine oil filter clog sensor When the filter becomes clogged and the relief valve is actuated, this sensor (attached to the relief valve of engine oil filter) turns ON, lighting the engine oil filter clog warning lamp.

(3) Overheat sensor When engine cooling water is overheated, the overheat sensor turns ON to light the engine overheat warning lamp.

(4) Engine coolant temperature sensor (unit) This theIT11istor-type sensor detects engine cooling water temperature and actuates the water thermometer.

Water temperature vs. resistor Water temp. ( o C) Resistance

(i.2)

50±0.2

60±0.2

80±0.2

100±0.3

105±0.3

120±0.3

112.4±10 79. 3±5 41. 8±2.5 23.6±0.9 20. 7±0.6 14.2±0.3

ES12-3-22

ELECTRICAL SYSTEM

-----------CONSTRUCTION AND FUNCTION----------(5) Engine oil level sensor The engine oil level sensor is ON when the engine oil is at the specified

level. It is OFF when the engine oil is not at the specified level. Thus, when the engine oil is above the specified level, the engine oil level OK lamp lights with a push of the preoperation check switch.

(6) Air cleaner filter clog sensor When the air cleaner filter is clogged,

AIR CLEANER FILTER CLOG SENSOR

the vacuum force turns ON the air cleaner filter clog sensor attached to the

air cleaner element outlet, lighting the air cleaner filter clog warning lamp.

(7) Fuel level sensor As the amount of residual fuel decreases and the float goes down, the sensor attached to the fuel tank bottom turns ON the fuel level warning lamp.

OFF

FLOAT_

FUEL LEVEL ,n +I ,n

MAGNET

M22P1.5

ES12-3-23

ELECTRICAL SYSTEM

-----------CONSTRUCTION AND FUNCTION----------(8) Fuel gauge sensor As the fuel level goes up and down, the float goes up and down accordingly so its lever angle changes.

The change in lever

angle is taken as electric resistance and detected by the fuel gauge.

Float level FULL

,.... Lt> N

3/4

co M M

......__---l::=--___.,'t

(9) Cooling water level sensor As the water level in the reserve tank decreases, the float is lowered to turn OFF the cooling water level sensor attached to the reserve tank bottom. Thus, when water volume is above the specified level, the engine cooling water

level OK lamp lights with a push of the preoperation check switch.

(19.5)

1/2

32±3

EMPTY

80+2 - 12

1/4 �

Resistance (rl) 10-0. 5 _+ 1. 0

(49.5)

ELECTRICAL SYSTEM

ES12-3-24

----------- CONSTRUCTION AND FUNCTION-----------

(10) Hydraulic oil level switch As the amount of hydraulic oil falls

below the specified level, the float is lowered, turning OFF the hydraulic oil level switch attached to the side of the hydraulic oil tank.

Thus, when the oil

level is above the specified level, the hydraulic oil tank level OK lamp lights

with a push of the preoperation check switch.

� _ _j

�·

OFF

(11) Pressure switch When the control valve spool is opera ted, the pressure switch is turned ON

by the circuit oil pressure so an elect ric signal is sent to the controller.

This pressure switch, interlocked with the mode selector switch, high/low speed

travel switch and auto idling switch, maintains the engine speed and pump

delivery at their optimum conditions. (12) Battery relay Mounted near the battery, this relay turns ON/OFF the battery current accord ing to the small current from the starter switch. This permits use of a small-capacity wire between the battery and starter switch. (13) Fusible link

This protects the main wiring from

overcurrent resulting from shorting, etc.

PROTECT TUBE AGAINST MELTING

CONNF''.1O11

WIRE

l CONTROL OIL

PRESSURE SENSOR;: .

,...

..,.

. _-r..., ." ' _,"4¥_,.._ ".:

ELECTRICAL SYSTEM

ES12-3-25

----------CONSTRUCTION AND FUNCTION----------(14) Safety relay

Combined with the starter and generator,

the safety relay prevents the starter from being disengaged at engine startup,

from being engaged during engine running,

and from being re-engaged during starter idling.

(15) Regulator This regulates the voltage developed by the alternator. (16) Current sensor This senses the glow plug temperature (the temperature in the engine combustion

chamber) in terms of electric current,

and, in combination with the glow plug timer, controls the current flowing to the glow plug. (17) Intake heater relay This relay interrupts the current flowing

to the glow plug.

The exciting current

to the relay is interrupted by instruction from the timer.

(18) Controller

The controller is based on a microcom puter that controls the solenoid valves for Auto-id�ing and Engine-Pump control. (19) Horn relay The electric current to the horn is turned

ON/OFF by the horn relay which is switche ON/OFF with the horn switch.

This arrange-

ment protects the contacter of the horn switch from damage. (20) Charge lamp relay

As the current from the generator deactuates the charge lamp relay, the charge lamp goes out.

(21) Glow plug timer

When the starter switch is set to the glow plug position, the timer automatically cuts off the current flowing to the plug after a certain period.

--41,, ? I_,

ES12-3-26

ELECTRICAL SYSTEM

----------CONSTRUCTION AND FUNCTION----------(22) Diode This prevents the buzzer on the panel from beeping each time the switch is turned ON/OFF from preheat to start

position.

DIODE V06G

14.7

(23) Resistor

In the regulator circuit of the Hino engine, current flows through the L

terminal as follows:

Current flow without power generation Resistor

-+ L terminal

Generator field } coil lg terminal-------�

Battery(+){

Earth

Current flow during power gen2ration

On the other hand, current flows through the charge lamp on the panel as follows: Battery(+)-+ Charge lamp relay-+

Charge lamp-+ Earth

The regulator's L terminal is required to run the generator's initial exciting current.

If the current does not flow through a resistor

equivalent to the charge lamp resistance value, the transistor in the regulator is broken down. (24) Solenoid valve In accordance with the direction from the controller, this valve actuates the mini-cylinders for auto idling and E-P control. delivery.

It also controls the pump

ES12-4-1

ELECTRICAL SYSTEM

------------ CIRCUIT OPERATIONS ------------

CIRCUIT OPERATIONS 1. CHARACTERISTICS OF ELECTRICAL CIRCUIT

The electrical system is composed of the main circuit for the engine start,

charging and lighting, a monitor incorporating a monitor display, and the en

gine-pump control unit that controls the engine speed and the pump delivery

through the selection of auto-idle, 2-speed travel and operation mode. Its major characteristics include:

(1) The battery relay switches off on the plus (+) side. circuit diagram).

(See the electrical

Unlike the conventional systems, EX Series has adopted a battery relay that

switches off on the plus (+) side to allow operation of the clock and the

engine stop motor.

Because of the plus-switching arrangement, the battery must be taken off from

the minus side. (2) Fusible links

On the conventional electrical circutis, a fuse is used only in the fuse box. In EX Series, it is used between the battery and the starter switch as well

as between the generator and the battery relay to protect the main circuit against overcurrent taused by short-circuit.

(3) Microcomputer-controlled monitor

Though basically the same as the existing versions, the EX Series monitor

features a microcomputer for processing monitor signals to further ensure the

operations and alarm function.

ELECTRICAL SYSTEM

ES12-4-3

--------------------------------- CIRCUIT OPERATIONS

NOTES, Colour distinction of electrical wires.

2. ELECTRICAL CIRCUIT

Black B Br Brown Green G Gr : Gray Blue L 0 Orange R Red

This machine uses a 24 volt, negative·earth type system. For additional details, refer to the HINO H06C-TI engine operation manual. Sw,1ch, S1■r1

w y

: White Yellow

Slack/Red

Black/Wh1te Black/Yellow

GW : Green/White

GY LB LR LW LY RB

Green/Yellow Blue/Black Blue/Red Bluetv,/h1te Blue/Yellow

Red/Black

RW : Aed/\Nhite

RY Red/Yellow WG : White/Green WL : White/Blue WR : White/Red

YB YR

Yellow/Black Yellow/Red

(Notes) Re the wires consisting of 2 colors. lhc first color md1cates the base color of wire. and the second color 1s the color of marking h ) BW: Black base and whrte marking

1a11:�11t=;� \

.. Panelgaugl'

Pump

Controller

70W1.2 -� 1 M,. m ne dyl R �

PrenureSW Travl'I Soleno,d vah,e

Sw••��l

--- ---

-1

Eng,ne 11oprelay•]

Engmei1npmow,

Non-travel

Notes 1 Unless specified, atl wires shall be 0.85 mm 2 1n sectmn.

2. SYMBOLS

ES12-4-5

ELECTRICAL SYSTEM

CIRCUIT OPERATIONS-----------3. BATTERY CIRCUIT The negative terminal of the battery is grounded to the main frame.

The

current from the positive terminal once flows to the terminal B of the battery relay before flowing to the terminal B of the starter switch, then it is

There

carried to the digital clock on the gauge panel through the fuse box.

fore, the digital clock will always operate even with the starter switch set

to OFF.

Solenoid valve

G'Y

Regis10r

STARTER

Charge Lamp Relay GB

WG SAFETY RELAY

ALTERNATOR

CPU

REGULATOR

Clock LW

-i-.

_...__24

� !!UUl � Gauge Panel

>-3:

0 @

EnginP stop relay-1

Glow plug

Engine stop ret�,·-2

: 23

�

ES12-4-6

ELECTRICAL SYSTEM

------------ CIRCUIT OPERATIONS 4. PREHEAT CIRCUIT

When the star ter switch is turned to nects with B r, Rl

and

the

PREHEAT position, its B te rminal con-

ACC inside the switch .

The current from Rl terminal of star ter switch flows to

the timer, and switches on th e

current

that has

plug via

th e

a quick pre heat system,

and

start of preheating, wh ich

notifies t he end of preheating. of current sensor

constant temp eratu r e.

and

the

turns

timer

th e batte ry

the p reheat

actu ated a fte r

off the p reheat lamp

If the starter switch is set to the

starting position under th is situation, t he

reason,

p assed through the fusible link ( a) flows

employs

S seconds since

actions

Fo r this

the hea ter rel ay.

This circuit and

heater relay.

heater relay via

the

h e ater

relay is continu ed by

timer, and the preh eat plug is controlled s,..,.,,.,.,d ""'""

RaH.-ry l"]V • ']

l'u1,hll!' ltnl,

Charge Lamp Relay GB WG

--�

CPU

_,,______,·ci

1 iill[)�-� 'i Clock

�

Gauge Pone I

G1owplug

Eng,nr lloP roo10,

ES12-4-7

ELECTRICAL SYSTEM

CIRCUIT OPERATIONS 5. STARTING CIRCUIT When the starter switch is set to the starting position, the terminal B, in-

Since the current

side the starter switch, connects with Br, R2, C and ACC.

from the terminal Br excites the battery relay via the regulator, the battery power is led to the terminal B of the starting motor and that of the safety

relay via the battery relay.

The terminal C of the starter switch is con-

nected to the terminal SW of the safety relay to flow current through the

relay coil of the safety relay which causes the relay to be connected. Current also flow� through the starting motor to be rotated.

To protect the main circuit, a fusible link is used.

Sw,1ch; Suri

Charge Lomp Relay GO WG

�

Gouge Pone I

Eng,nf' ,,oo •f'lay•1

Glowolug

{fil[J�-�i Clock

..,

ES12-4-8

ELECTRICAL SYSTEM

CIRCUIT OPERATIONS-----------Explanation on the Function of Safety Re lay The safety relay, in connection with the starter and the generator, serves to

prevent the starter from being disengaged when the engine is started, the starter from diving during the engine rotation and further from re-diving during the inertia rotation of starter.

What's more, this safety relay is of

semi-conductor type which has a superior temperature characteristics in the

release rotation and a more compact and ligher weight design as compared with the conventional relay system.

SWICOUPLERI

RATED VOLTAGE

ICOUPLER)N WAVEFORM FAIRING

B(M5)

INTEG RATION

VOLTAGE C OMPARISO N -VOLTAGE CONTROL

L= SAFETY RELAY

OUTPUT

RELAY

C(M6)

I lees,

Fll �

STARTER SW

BATTERY

24 V

�--o-;1

,,_,,.,..__.,.,._

STARTER

ES12-4-9

ELECTRICAL SYSTEM

------------ CIRCUIT OPERATIONS------------The Diving Preventive Circuit during the Starter Inertia Rotation (1) When the reference vo1tage "Vref" is larger than the input voltage

AA TED VOLTAGE VB

"Vin", namely Vref > V in, the

voltage comparator section supp lies the current "il" to the base OUTPUT TRANSISTOR

of output "Tr", while the "il" REFERENCE VOLTAGE CONTROL

won't flow in case of "Vref" < "Vin".

The Driving Preventive Circuit during the Starter Intertia Rotation

(2) The reference voltage when the engine is in stop and the starter SW is in OFF remains stable to a constant value (around 0.1 V) by means of the constant voltage power source.

On the other hand, the input voltage "Vin" is at the

:ero potential because it drops to the earth via the C terminal of starter. Therefore, the relation of "\'ref" > "Vin" is established when the starter is stationary, 1,hile the output "Tr" is continued and the relay is actuated i-;hen the starter SW 1s set to 0�. l_)) When the relay 1s actuated, "i2" flows, and the starter engagement is sacked and the starter is put in service. The poher source \'Ol tage \'B is impressed to the C terminal by the actuation of starter, but the relation of "\'ref" > "\'in" is maintained at this instance because the input voltage "Vin" turns to be a diode fon,ard direction voltage (0.5\') and the reference voltage to be a :enner specified voltage (about 1.2V). Therefore, i-·hile the starter SW is "0:J", the starter continues to operate until the engine is started. (4) \ext, if the starter SW is set to OFF before the engine is started, the relay is s1,itched off and the voltage being generated by the inertia rotation of starter is impressed to the C terminal of starter.

This impressed voltage is

extremely smaller as compared with the po1,·er source voltage VB, and the reference \'Oltage "\'ref" returns to the stationary \'Ol tage (about O. 1V). On the other hand, since the input voltage "Vin" is higher than the reference \'Oltage "\'ref" due to the inertia rotation relation of "\"ref"

(about 0.5\'), it becomes the

< "Vin", the current ''il" i-·on't flow and the relay can

not be actuated e\·en if the starter SW is turned on. If the inertia rotation of starter drops, the input voltage "Vin" becomes smaller than the reference voltage, which therefore results in the state of (2), and the starter can not be actuated even if the relay SW is turned on.

ES12-4-10

ELECTRICAL SYSTEM

------------ CIRCUIT OPERATIONS------------Starter Disengagement Circuit

RATED VOLTAGE V B

�-+----OSW 1-+---0 B

t---+---o C

N WAVEFORM FAIRING

INTEG RATION

CONSTANT VOLTAGE POWER SOURCE

Starter Disengagement Circuit (1) Since the generator N voltage is the direct current voltage containing an alternating current portion, it takes out the alternating current portion from "f" detector section and performs the positive pulse exchange propor tionate to the speed of generator. The waveform fairing section fairs the waveform which is detected by the "f" detector. The circuit pulse which has been faired is differentiated and inte grated, thus the direct current voltage proportionate to the rotation speed of generator is 0utput from "a" point of integrated circuit output (input voltage at voltage comparator section). (2) In the cranking state before the engine is started, the input side of voltage comparator section in the state of (3) of the diving prevnetive circuit during the inertia rotation of starter, but the integrated voltage at "a" point goes up if the engine speed is increased. When the integrated voltage "Vin" goes up to the state of "\'ref" (about 1. 2\') < "Vin" (the integrated voltage at "a" point), the "il" won't floi-·, the output "Tr" becomes OFF and the relay is also switched off.

In other words, the

starter is automatically disengaged by the ring gear in the set circuit (650 rpm in terms of generator) even if the starter SW is O:J. The Starter Diving Prevention during Engine Rotation The relay is switched off when the engine is started, and the reference voltage "Vref" will be around 0.1\'.

Moreover, since the voltage 1.2V is

reduced to O. 1V when operating the starter, the starter can not be dived unti1 the engine speed goes down sufficiently for the integrated voltage "Vin" to be smaller than O. lV while the integrated voltage "Vin" at "a" point remains at "Vin" = "Vref" (about O. lV) even if the starter SW is set to ON after the disengagement.

ES12-4-11

ELECTRICAL SYSTEM

------------ CIRCUIT OPERATIONS 6. CHARGING CIRCUIT

When the starting motor is activated to start rotating the engine, the starter

switch is set to the position of operation, where the terminal B connects with Br and ACC inside the switch.

Engine rotation causes the alternator to rotate, starting to generate power,

with the result that charging current flnws from the terminal B of the alter nator to the battery.

From the terminal � (14 \" line) of the alternator, the

generated current flm,s to turn off the battery charge warning lamp via charge re 1 ay.

8.111e1v 12V-. 2

1 GY

Charge Lamp Relay

Glo...., plug

L/D'

ELECTRICAL SYSTEM

ES12-4-12

------------ CIRCUIT OPERATIONS Explanation of the Function of Regulator (1) Initial excitation

When the starter SW is turned on in the connection diagram (Engine stop state). REGULATOR

r-----·-��ALTERNATOR

r- ----- -----,1 ----

-�L-�

FUSE

R • Rs

1) Because the generator is in the state generating no power and the voltage at the voltage at\ terminal is at 0V, the transistor T2 is in the OFF state.

When the T3 is in the OFF state, the base circuit for transistor

Tl is also in the OFF state.

2) On the other hand, the base current flows to the transistor T4 from the battery via the resistor R3, and the T4 becomes the ON state, and the

initial exciting current flows via the charge lamp and resistor R4.

3) If the engine is started and the generator is rotated under this situation, the power generation is started.

(2) Voltage regulation

1) When the power generation is started, the voltage is impressed to the \ terminal, and the base current flows to the transisotrs TS and

,� l.)

the resistors Rl and RS, resulting in the 0\ state of T5 and T3.

through

2) Since the transistor T4 for initial excitation circuit turns to be OFF

state with the TS in ON state, the initial exciting current ceases flowing,

and the charge lamp goes out.

Since the T3 becomes 0\1 state at the same

time, the base current flows to the transistor Tl, and hith Tl in the 0\

state the exciting current flows.

ES12-4-13

ELECTRICAL SYSTEM

------------ CIRCUIT OPERATIONS-------------

REGULATOR

r -·--·--;:_-:_-:_-:___-<>-"L

_....,

ALTERNATOR

FUSE

T BATTERY N

_ _J 3) When the generator starts generating the power, increases the voltage and

has reached the regulated voltage value, the zener diode (ZD) is switched

on and the base current flows to the transistor T2, which turns on the T2.

With the T2 in ON state, the base current ceases flowing to the Tl, which results in the OFF state of Tl, so no exciting current flows and the terminal voltage of generator drops.

4) If the generator terminal voltage falls belm,· the regulated voltage under

this situation, ZD is switched off and the T2 becomes OFF state, so the Tl

turns to be the 0:\ state again for flowing the exciting current, and the

generator terminal voltage goes up.

5) The generator terminal voltage is regulated through the repetition of the switching actions as mentioned above.

(3) Operation of "S" terminal function

FUSE

KEY SW

BATTERY

When the engine is started and the generator starts generating the power, the voltage is applied to the \ terminal, 1-,hich turns on the TS, and the base

current flows to the transistor TS, thus switching on the TS.

Since the current is supplied to the battery relay via TS even if the starter

SW is set to OFF in this situation, the battery relay can maintain the 0\ state.

ELECTRICAL SYSTEM

ES12-4-14

CIRCUIT OPERATIONS 7. ENGINE STOP CIRCUIT---------------------- This system has following two functions. (1) Can stop the engine by Starter Switch turned to OFF.

(2) When engine oil pressure comes down in running, the oil pressure switch works to stop the engine.

Solenoid valve Battery 12V x 2

Fusible link

G'(

Registor

STARTER

Charge Lamp Relay GB

SAFETY RELAY

ALTERNATOR CPU

REGULATOR

Clock .___�LW __ _ � � 2 4

-- �

Gouge Panel

Engine stop relav-1

Glow plug

Engme stop relay-2

Engine stop motor

r---1 � �

ELECTRICAL SYSTEM

ES12-4-15

------------ CIRCUIT OPERATIONS-----------7.1 GENERAL---------------------------------

This engine stop system is consist of the sensor section, judging section and

output section.

The control relay works for judging and output control.

ENGINE OIL PRESSURE SENSOR

w�

No---

ENGINE STOP DELEY

Tr¥.�::i=Jin

ENGINE START DELAY

JUDGING CIRCUIT

STOP DELAY CIRCUIT

JUDGING CIRCUIT

n-t--<1..,_oC

ABNORMAL DETECTING

RELAY

OUTPUT CIRCUIT

��==-=-=��======-=- 1J Control relay block diagram

7.2 PRINCIPLES OF OPERATION ---------------------------

This engine stop system is made up a starter switch, control relay, two relays

and an engine stop motor.

The electric current from· Ace terminal on starter

switch or the engine oil pressure sensor controls engine start/stop.

STARTER SWITCH

ACC

BATTERY RELAY

FUSE

RELAY 1 C

B N E

ALTERNATORL-_.__..._____, CONfROI, REL AY ENGINE OIL PRESSURE SENSOR BATTERY

System schematic

RELAY 2 Pl

ES12-4-16

ELECTRICAL SYSTEM

------------CIRCUIT OPERATIONS-----------(1) Engine start/stop with Starter Switch a. Engine start

Turn the Starter Switch ON to send an electric current to Ace terminal.

Battery0-Acc-Relay 1 (Q}'v(D)-Relay 2 (@'v®)-Earth. Then circuit makes contact as follows.

Battery0-Fuse--Stop motor B -P -Relay 2 CG) 'vQ)) -Stop motor Ar 2 - Earth.

Therefore the Stop motor returns the injection pump lever to driving position.

ST/\RTER SWITCII fUSE

01\TTERY RELAY

REl,IIY l

8 N

RELAY 2

E w ALHI\NIITOR .__..______.____,

CONTROL RELAY

ENGINF. QI L rRESSURE SENSOR

MITERY

Furthermore turn the Starter Switch to Engine start position to drive the

Starter Motor. b. Engine stop

Turn the Starter Switch OFF to cut the electric current on Ace terminal.

Ace electric current OFF-Relay 2 CG) 'v (V) ON. as follows.

Then circuit makes contact

Battery0-Fuse--Stop motor B--P --Relay 2 ((V'vQ))--Stop motor A J.. 1 -- Earth. Therefore the Stop motor drives the injection pump lever to fuel cut position to stop the engine.

ST/\RTER SWITCII fUSE

RAHERY REL/\Y

REI.IIY I

B N E

RELAY 2

w COHROL REL�Y ENGINE 01 L PRESSURE SENSOR

RlllTERY

OFF

ES12-4-17

ELECTRICAL SYSTEM

------------CIRCUIT OPERATIONS------------(2) Engine stop When the engine oil pressure comes down by trouble in engine running, the pressure sensor comes ON. turns on B "'C terminal.

Then the control relay detects the trouble and

And the circuit makes contact as follows.

Battery 0 - Starter Switch Ace --Control Relay ( B "'C ) Relay 1 (@)"' (I))- Earth.

STARTER Sll'ITCII BATTERY RELAY

FUSE

RELAY l C N

E w II LTERNATOR ._____,______,

RELAY 2

COliTROL RELAY

ENGINE 01 L PRESSURE SENSOR

rt r2

Fuel

OFF

MTTERY

Notes:

1. At the engine start, the engine oil pressure does not come up immediately. Therefore the control relay is adjusted to do not stop the engine while 20 seconds after engine started.

2. Once the engine oil pressure is dropped by trouble, the control relay keeps B � C : ON while 10 seconds to stop the engine completely.

3. When the engine oil pressure comes down by the engine over load, the control relay keeps the pressure ON around 6 seconds by signal of N terminal

voltage on alternator. If over load is put off before the engine stop, the

engine is avoidable from sudden stop and available to recover the normal

running.

ES12-4-18

ELECTRICAL SYSTEM

------------ CIRCUIT OPERATIONS 8. ACCESSORY CIRCUIT

With the starter switch set to other positions than OFF, the battery power is led to all the switches of accessory equipment through the fuse box. The window washer and air cooler is optional.

<( <(

O 0

-I -I -

/ >-

.J N

to Gauge Panel

� � �

<( �� <(�<(

- I -!� 0

I() 0 tO O -

-1

/ "' >- � m"' � a: �-

�

a: -

ANTENNA RADIO

�

"�u :B :tJ») SPEAKER

CIGARETTE LIGHTER

l7L

M4x3

-b

��

- .fl::-1 .., G

�

((

SWITCH

�

0--0

INSIDE O F CAB WALL

M E �-t..§__

�

-��

BLOWER SW OFF 0 I 0- "'M J"" -0H

"' C)

� L

_L J

- - L

' R

M OTOR

�

�1

I.::::,. - I o,-v - I 'l OOM LAMP 70Wx2

0-K) E

OFF

f"""Il

•• • r ••

1.25LB l.25LR l.25R

I- .. -

LIGHTING SW

HEATER ---

-�

AIR COOLER IOPTI ONALI

WINDOW WASHER

-<)

L L

- j

,----, I

WIPER SW O FF

to Gauge Panel

ORN

H ORN RELAY

- -

�

l=-.J

J---;},.

� B

R HEAD LIGHT

�iBOOMI

rlr

� IBASE MACHINE I

4-s to Gauge Panel

ES12-4-19

ELECTRICAL SYSTEM

CIRCUIT OPERATIONS------------9. GAUGE PANEL CIRCUIT

Like in the accessory circuit, if the starter switch is not turned off, the

battery power is always led to each indicator through the fuse box. meter is designed as to be actuated when the engine rotates.

The hour

Each sensor used for engine oil level, radiator water level, hydraulic oil

level and engine oil pressure detection is of normal close type, while for

others normal open type.

The CPU detects the signal sent from each sensor to control the transistor of

each indicator.

RB to Alternator N Terminal

12v

Hour Meter Switch

10 II

,31

.'5

: p u

16 I i7

BR B'JZER CANCE-SWITCH

-�

21 22

CLOCK

[rn ��

24 '....'-l'i

for

L __

HOUR SET SW

GAUGE PANEL

__ _J

ELECTRICAL SYSTEM

ES12-4-20

------------CIRCUIT OPERATIONS------------10. CONTROL CIRCUIT

The current from ACC of the starter switch is input to the terminal 1 of the gauge panel through the fuse, being led to each indicator.

is input to the CPU.

A current of 5 Volt

The controller, based on the electrical signals from the auto idle, mode and travel switches, controls engine rotation, pump flow and travel speed, etc.

10 R2

,o ,2

,".L TC ,DLING SW

' TRAVE:Ll"iG SPEED SW

,0 ,,,, 30•

•

1� Fw�e

80,

� �

�

_:_11

----------------, p ._,yp

'6: 7 5

CC",TRCL.._ER

F�ESSURE SW

iR.tl.VE-1-.G

EXCEP� roH TA,'1\l['_l"IG

ES5-5A-1

ELECTRICAL SYSTEM

MAINTENANCE 1. GAUGE PANEL 1.1 REPLACING PANEL GAUGE PARTS

* Precautions

(1) The front cover of the gauge panel is made of a resin forming. to wipe off dusts or dirts. be flawed.

thinner.

Use a wet cloth

If wiped strongly with a dry cloth, the cover may

For cleaning, never use organic solvents such as toluene and

(2) When products are carried, do not hold the harness to perform part replacement. (3) Do not touch the mechanical part since the electric parts used for the gauge panel may fail to function due to static electricity.

(4) Do not secure the screws too tight since the gauge panel is made of resin.

During maintenance, it is desirable to lay a cloth or the like under the panel.

* Tools used

(1) Screwdriver (magnetized)

(2) Box screwdriver (for M3 nut) (3) Cutting pliers

(4) Socket wrench 17 mm

(1) Replacing indicator and service meter

Draw out the connector for the main harness

and meter harness.

(2) Remove four bolts from the panel gauge

(gauge cluster) and the panel gauge assembly

from the console.

ELECTRICAL SYSTEM

ES5-5A-2

MAINTENANCE

(3) Remove the housing screws (4) to sepa rate the housing.

(4) When separating the housing, remove the

plug terminals (4) and the connector (1) from the LED board.

(5) Remove the meter board fixing screws (6)

to take off the meter board.

When removing the meter board, disconnect the connector from the crystal clock.

(6) Remove each gauge and service meter from the meter board:

in an order of

service meter, fuel gauge and engine coolant temperature gauge. meter, remove the tapping scre¼s (3) and flat terminals (2).

remove each nuts (4).

For the sen·ice

For the gauge,

(7) For mounting, reverse the above procedure.

Note: To mount, temporarily secure the parts so as not to bend the gauges be fore final tightening.

Gauge tightening torque:

7 kgf-cm

Meter board tightening torque:

17 kgf-cm

Fix the·housing so as not to make the harness caught in.

the cords of the same color.

will do.

For wiring, use

Either of two cords having the same color

ELECTRICAL SYSTEM

ES5-5A-3

MAINTENANCE 1.2 REPLACING WARNING LENS

(1) The gauge assembly will be removed in the same manner as in steps (1) to (4) for replacing the gauge and service meter.

(2) Lift one side of the waring lens to slide and remove.

(3) For setting, reverse the order of removal (pass through the center groove to set).

1.3 REPLACING BULB

(1) The gauge assembly will be removed in the same manner as in steps

and

for

replacing the gauge and service meter.

(2) Turn the blown bulb to remove.

ELECTRICAL SYSTEM

ES5-5A-4

MAINTENANCE

(3) For setting, reverse the removal procedure.

Note: After the bulb is set, check if the socket is directed in the same direc tion as of other sockets.

1.4 REPLACING CRYSTAL CLOCK

(1) The gauge assembly will be removed in the same manner as in steps (1) to (4) for replacing the gauge and service meter.

(2) After removing the meter board, take off the tapping screws (2) to remove bracket A.

(3) Remove the tapping seres (2) to discon nect the clock.

(4) For setting, reverse the removal pro cedure.

1.5 REPLACING LED BOARD

(1) The gauge assembly will be removed in the same manner as in steps (1) to (4) for replacing gauge and service meter.

ELECTRICAL SYSTEM

ES5-5A-5

MAINTENANCE (2) After removing the meter board, take off tapping seres (2) to remove bracket B.

(3) Remove tapping screws (2) to take off the LED board.

(4) To set the board, reverse the above pro cedure.

1.6 REPLACING BUZZER STOP AND PREOPERATION CHECK SWITCHES

(1) The gauge assembly will be removed in the same manner as in steps (1) and (2) for replacing the gauge and service meter.

(2) Remove the switch nut.

(3) Remove the switch

ELECTRICAL SYSTEM

ES5-5A-6

MAINTENANCE

(4) For mounting, reverse the procedure above.

1.7 REPLACING CONTROL BOARD

(1) The gauge assembly will be removed in the same manner as in steps (1) and (2) for

replacing the gauge and service meter.

(2) Remove the screws (1) at the main harness clamp.

(3) Remove buzzer fixing screws (2).

(4) Remove tapping screws (5) fixing the control board.

ELECTRICAL SYSTEM

ES5-5A-7

MAINTENANCE

(5) Draw out the control board in the arrow direction.

(6) For mounting, reverse the removal procedure.

Note: Two of the control board fixing tapping screws (5) on the clock regular switch side has a length of 8 mm while other three screws 12 mm.

1.8 REPLACING FRONT COVER

(1) Remove front cover fixing tapping screws (4)

to take off the front cover.

(2) To set the front cover, tighten the tapping screws (4).

1.9 REPLACING BUZZER

(1) Remove buzzer fixing screws (2).

ES5-5A-8

ELECTRICAL SYSTEM

MAINTENANCE (2) Remove flat terminals (2) connected to the buzzer.

(3) For mounting, reverse the above procedure.

oler'.

ELECTRICAL SYSTEM

ES5-5A-9 MAINTENANCE-------------

2. ASSEMBLY AND ADJUSTMENT OF ENGINE CONTROL (MODE SELECTION) DEVICE THROTTLE LEVER: A IDLE POSITION

AUTO-IDLE LEVER: I Make clearance to avoid contact when engine is cut.

IDLE POSITION ENGINE CUT Hm.. �..11111-+-�--.u STOPPER: M

FULL STOPPER: C

ENGINE CUT STOPPER: B

STOPPER POSITION (BEFORE OPEN)

PUSH-PULL CABLE: E

Model

EXl00,120 350

L mm

EX150

350,5

ROD: J

BALL JOINT: H

(1) Adjust the length of the rod J at L - 0.5 mm

EX200 380

ENGINE GOVERNOR LEVER: K

EX220,270 470

L±0.5

EX300 495

(2) Install the rod J bet\\·een the go,:crnor lc\·er and the auto-idle lever. (3) Install the cable E between the slottle lever A and the auto-idle lever I. Install the cable 1n the following procedures: 1

Turn the governor lever to the idle position.

Install the cable in the order of: Ball joint D

➔

Bracket F

➔

Bracket G

➔

Ball joint H. Cautions o The ball joint H should be fixed with the auto-idle lever so that the cable is pulled slightly (to keep the idle speed from lowering). o To turn the throttle lever to the idle position, at first turn it to cut the engine, and put it back until it stops. (4) Loosen the stopper bolt C, turn the throttle lever to "FULL" little by little, and turn the governor lever to make it contact with the ful1 stopper. (5) Adjust the full stopper C \,hile keeping the governor lever K contact with the stopper L.

The adjustment should be made so that the clearance between the

throttle lever and the stopper bolt becomes 0.5 mm when the throttle lever is in the fULL position. (6} Turn the throttle lever to the STOP position, and make adjustments so that the engine cut stopper bolt comes in contact with the throttle lever.

ELECTRICAL SYSTEM

ES5-5A-10

MAINTENANCE

(7) Adjust the auto-idle lever adjuster bolt in the following procedures:

MINI CYLINDER--......._

CLEARANCE: C AUTO-IDLE LEVER

ADJUSTER BOLT

Model

CA mm

CE mm

Notes

EXl00 0.8

1.0

EXlSO 0.8

4.0

3.5 CE

EX120

2.4

EX200

EX220

2.0

1.9

3.4

EX270

EX300

2.9

3.0

1.9

2.0

Auto-idle cylinder clearance

E mode cylider clearance-

Loosen the auto-idle lever adjuster bolt in advance.

Turn the throttle lever to FULL (Confirm that the governor lever is contact

Adjust the clearance between the top of the mini cylinder and the adjuster

with the stopper L ).

bolt by using a thickness gauge (The auto-idle cylinder is the one closer to the auto-idle lever pin, and the E mode cylinder is the remote one).

Model

Low Idle

Auto Idle E p

Mode

EXl00

EX120

1400±100

850±50

2150±50

2450±50

850±50

2050±50

2.350±50

EX150

EX200

EX220

EX270

EX300

1400±100

1400± 100

1400±100

2450±50

2180±50

1000±50

2080±100

780±50

1850±100

800±50

1910±100 2250±50

Engine Setting Speed (rpm)

800±50

1910±100 2250±50

800±50

1870±100 2150±50

INDEX EX270-10A-1

�

TROUBLESHOOTING

CONTENTS Group 1-INTRODUCTION .. ... . .. ... . .. ... . .. 1. 2.

TS11-1-1-6 General Information ............................... TS11-1-1 Notes on Performance Measurement ............... TS11-1-3

Group 2-DIAGNOSE MALFUNCTIONS 1. 2.

TS11-2A-1-46 Malfunctions Phenomena ........................ TS11-2A-1 Hydraulic System . .............................. TS11-2A-3 Electric System .. . ............................. TS11-2A-18

Group 3-EXCAVATOR PERFORMANCE TEST 1. 2. 3. 4. 5. 6.

...................... TS18-3A-1-22 Introduction .................................... TS18-3A-1 Engine Performance Measurement ............... TS18-3A-1 Travel Performance Measurement ................ TS18-3A-4 Swing Performance Measurement ............... TS18-3A-10 Front-end Attachment .......................... TS18-3A-14 Control Lever Performance Measurement ........ TS18-3A-18

Group 4-COMPONENTS PERFORMANCE STANDARD ........................ TS18-4B-1-20 1. 2. 3. 4. 5. 6. 7. 8. 9.

Introduction ..................................... TS18-4B-1 Pilot Relief Valve ................................. TS18-4B-1 Main Relief Valve ................................. TS18-4B-3 Overload Relief Valve ............................. TS18-4B-6 Swing Crossover Relief Valve ..................... TS18-4B-8 Travel Crossover Relief Valve ..................... TS18-48-9 Main Hydraulic Pump ............................ TS18-4B-11 Travel Motor .................................... TS18-4B-18 Swing Motor ................................... TS18-4B-18 Continued on next page

INDEX EX270-10A-2

CONTENTS (continued)

Group 5-ELECTRICAL SYSTEM TEST 1. 2. 3. 4.

............ . ........... TS18-5-1-14 Common Circuit Test .............................. TS18-5-1 Articles Necessary for Electric Circuit Test ........... TS18-5-3 Measurement Procedure ........................... TS18-5-4 Measurement Standard ........................... TS18-5-5

TROUBLESHOOTING ------------- INTRODUCTION

TS11-1-1

1. GENERAL INFORMATION --------------------- USE THESE SEVEN BASIC STEPS TO DIAGNOSE AND TEST THE MACHINE 1. Know the System

In other words, "Do your Homework." Study this manual to know how the individual components work and what their function is in the over-all system.

Keep up with the latest service information. Read and then file in a handy place. Information received today may have the cause and remedy of a problem being encountered.

2. Ask the Operator

Question the operator as to how the machine acted when it started to fail. Find out what was unusual about it. Also find out if any do-it-yourself service was per formed. (You may find out later that the trouble is somewhere else, but you should know if any com ponents were tampered with.)

Ask how the machine is used and when it is serviced. l\1any problems can be traced to poor maintenance or abuse.

3. Operate the Machine

Get on the machine and operate it. Warm it up and put it through its paces. Don't completely rely on the operator's story-check it yourself. Are the gauges reading normal? (If not, it may be that the component being monitored is not function ing correctly or it may mean that the gauge is faulty). How's the performance? Is the action slow, erratic, or nil? Do the controls feel solid or "spongy"? Do they seem to be "sticking".

Smell anything? Any signs of smoke? Hear any unusual sounds? Where? At what speeds or during what cycles?

4. Inspect the Machine

Get off the machine and make a visual check. Use your eyes, ears, and nose to spot any signs of trouble. Look closely at the components, Inspect for cracked welds, loose tie bolts, damaged linkages, worn or broken lines, etc.

During the inspection, make a note of all the trouble signs.

TROUBLESHOOTING

TSl 1-1-2

-------------- INTRODUCTION -------------5. List the Possible Causes. With the information obtained during steps 1 through 4, make a list of the possible causes.

What were the signs you found while inspecting the machine? What is the most liekly cause?

6. Reach a Conclusion Look over the list of possible causes and decide which are the most likely and which are easiest to verify.

Diagnosing Malfunctions" given in the following groups will be a helpful guide. Reach your decision on the leading causes and plan to check the first.

7. Test Your Conclusion Before repairing components in the system, test your conclusions to make sure they are correct.

Some of the possible causes can be verified without further testing. Check these possibilities first. Tests will soon narrow the remaining list of possible causes and soon the actual source of trouble will be pinpointed. With the trouble accurately located, it is now a simple matter to remove and repair the component at fault.

TSl 1-1-3

TROUBLESHOOTING

INTRODUCTION 2. NOTES ON PERFORMANCE MEASUREMENT 2.1 CONCEPT OF PERFORMANCE MEASUREMENT

"Performance measurement" menas to understand how the functions of the hydraulic excavator parts change depending upon their past working loads and maintenance conditions and their quanti tative levels. The performance measurement is largely classified into the "machine performance measurement" for each functional factor such as travelling, swinging and hydraulic cylinder performance and the "hydraulic unit performance measurement" of each hydraulic unit such as the hydraulic pump, motor and the performance of the various valve and the "engine performance measurement". The main purpose of the p·erformance measurement is to perform these three performance measu rements, collate obtained data with the standard values and globally judge the level of each hyd raulic excavator function. Then, based on the evaluation, repair, adjustment, replacement and other treatments performed on the necessary parts, to realize economical operation of the hydraulic excavator by restoring the machine performance to a required level. At this time, the "maintenance standard" comprise the basis for evaluating the data obtained as the result of the performance measurement. This maintenance standard is represented by the "STANDARD", "RECOMMENDED TO SERVICE" and "LIMIT OF USE". Therefore, obtained data should be evaluated not by judging the "goodness" of the machine performance with regard to the "STANDARD" but by judging the "degree or level of the obtained data". It can be said that mahcine parts wear and that their performance drops according to the progres sion of operating time. When evaluating sufficient attention should be paid to machine operating time, the kinds and conditions of the working loads, and the maintenance conditions.

O erating ® p time ®Working conditions 0 Maintenance conditions

In addition, machine performance is not always pro portional to the operating time, but naturally drops with an extended lapse of time. When repairing, adjusting and replaceing a machine to restore its performance,

countermeasures should be limited

to the necessary degree. Performance recovery is not intended to produce a brand-new status but to recover a "STANDARD".

TROUBLESHOOTING

TS11-1-4

-------------- INTRODUCTION-------------2.2 DIFINITION OF TERMS

[I STANDARD

The speed, dimensions and unit performances at a brand-new state with regular adjustment is referred to as the "STANDARD". They are sometimes appended with an allowance, depending on the case.

RECOMMENDED TO SERVICE When covering the recommended to service from standard, the level of performance required for some services such as repair, adjustment and replacement is referred to as the "recommended to service". Depending on the case, it serves as the limit of use. In addition, no special service performance is required for the limits between the standard and recommended to service. However, it is quit natural for the level of performance to drop.

[) LIMIT OF USE Generally, performance at a state in which ordinary work is difficult or repair and adjustment are hard or made impossible by exceeding the performance level is referred to as the "limit of use". Therefore, in view of the availability or service fee of the machine, it is desirable to do some suitable service before attainment of the limit of use.

RECOMMENDED TO SERVICE

2.3 PERFORMANCE MEASUREMENT CONDITIONS AND OTHERS

To do performance measurement work, observe the following precautions to maintaip measurement accuracy or operator's safety during work. 2.3.1 Machine to be measured

[)

I]]

For a machine to be measured, each part should be previously inspected to make sure that each function is not damaged. The performance measurement is not intended for such a faulty machine. Before work, conduct a specified repair. Before starting work, check the conductance states of the daily and monthly inspections.

TROUBLESHOOTING

TSl 1-1-5

--------------INTRODUCTION-------------2.3.2 Measuring place and tools

The measurement location must be flat and the ground must be solid. A space large enough to allow for a straight forward 20m travelling measurement should be secure. A swinging space suitable for the kinds and sizes of front attachments shou Id be secured. Various kinds of measuring instruments should be prepared. A specified weight or its equivalent should be pre

I!]

pared. Depending on the case, a measurement location should be sectioned using a rope, and Keep Off and

II)

other warning signs should be provided. A premilinary arrangment for a signalling method should be made with a co-worker.

2.3.3 Notes on measurement

Q] I]] [lJ I!)

During measurement, attention should be paid to the ground, swinging space high-pressure trans mission line and the other ambient environmental conditions at all times in order to maintain safety. During should be done carefully and a safety first approach should be kept in mind while fully understanding the signalling method. When removing hydraulic piping, attention should be paid to keep the ground and machine free of contamination by oil. Bring back waste oil or cloth brough from work and completely perform treatment after work to prevent environmental pollution.

2.3.4 Securing measurement accuracy

Q] I]]

To secure the accuracy of measurement data, instruments should be properly calibrated. The measuring conditions stipulated for each measurement item shojld be strictly observed. Measurement should be performed more than once. Several similar measurements should be per formed to check data for repeatability. Also, depending on the case, obtain the average value and

I!)

u.!f

take it as the measurement. Care should always be taken to improve measurement techniques.

TROUBLESHOOTING

TS11-2A-1

DIAGNOSE MALFUNCTIONS ----------MALFUNCTIONS PHENOMENA 1. HYDRAULIC SYSTEM 1.1 General

All actators do not work when control lever is operated ...... TS11-2A- 3

Actuator moves when lever is returned to neutral ............. TS11-2A- 4

Oil temperature rises ........................................ TS11-2A- 5

1.2 Front attachment

Some of the cylinders do not move when control lever is operated ..................................................... TS11-2A- 6

Front speed is slow .......................................... TS11-2A- 7

No digging power ............................................. TS11-2A- 8

Failure to hold rn lever neutral (leak) ..... _................ TS11-2A- 9

Failure to hold in operation ................................. TS11-2A- 9

1.3 Swing

'.'Jo swing motion

No swinging pow er ............ . ........ ..... .................. TS11-2A-ll

Swing is not smooth . . . ............... .................. . ..... TS11-2A-12

1.4 Traveling

--------------

TS11-2A-1O

-------------�------

No travel motion

Traveling speed is slow ...................................... TS11-2A-14

No traveling power

TS11-2A-15

Traveling snakes ........................................... , . TS11-2A-16

1.5 Others

TS11-2A-13

--------- -------------- -------------

Enigne stopped in idling position ............................

2. ELECTRIC SYSTEM

TS11-2A-17

2.1 Power Line

TS11-2A-18

2.2 Accessory

TS11-2A-19

2.3 Monitor (with VOLT-OHM METER)

Meter (s) does not work

Service meter not integrate during engine rotation ........... TS11-2A-2O

Maloperation of warter temperature gauge ..................... TS11-2A-21

Maloperation of fuel gauge ................................... TS11-2A-23

Accuracy check of fuel gauge .................................

OK lamp check .. . . .. .......................................... TS11-2A-26

1.1 1 6

TS11-2A-2O

Accuracy check of water temperature gauge .................... TS11-2A-22 TS11-2A-24

Monitor lamp bulb checking for burn out ..... ................. TSll-2A-25

Maloperation of battery charge warning lamp

TS11-2A-27

10.

Maloperation of engine oil pressure warning lamp ............. TS11-2A-28

11.

Maloperation of engine oil filter clog warning lamp ...._......

12.

Maloperation of air cleaner clog warning lamp ................ TS11-2A-3O

13.

Maloperation of engine overheat warning lamp .................

TS11-2A-29 TS11-2A-31

TS11-2A-2

TROUBLESHOOTING

DIAGNOSE MALFUNCTIONS 14.

15. 16.

Maloperation of Maloperation of

17. Maloperation of 18.

19.

..................................... headlight pilot lamp . . . . . . . . . . . . . . .. . . . . . . . . . . . engine oil level OK lamp . . . . . . . . . . . . . . . . . . . . . . warter level OK lamp . . . . . . . . . . . . . . . . . . . . . . . . . .

Maloperation of fuel lamp

TS11-2A-32

TS11-2A-33

TS11-2A-34

TS11-2A-35 Maloperation of hydraulic oil level OK lamp ................... TS11-2A-36

Buzzer ........................................................ TS11-2A-37

2.4 Control Syatem (!:with VOLT-OHM METER)

Checking (when MECHATRO CHECKER is not available) ............. TS11-2A-39

Checking auto idle system ..................................... TS11-2A-40

Checking travel speed change system ........................... TS11-2A-43

3. 5.

Checking mode switching system ................................ TS11-2A-42

Wire harness or controller defective

TS11-2A-43

2.5 Control System (1I:with MECHATRO CHECKER)

Checking control system ....................................... TS11-2A-44

Checking imput SW and sensor .................................. TS11-2A-45 Checking output line .......................................... TS11-2A-46

•This diagnosing malfunction charts show a sample of the process to make sure the cause of machine trouble.

•This charts are common to EX series. difference among these models.

However there are some portional

In-that case, refer to the description of

corresponding model shown in the charts.

•Actual examination should be done by certain method which shown in the

"Performance Standards" or "Test" (refer to Group 3, Group 4, and Group 5).

eHow to refer to this DIAGNOSING MALFUNCTIONS.

<> (_)

Troubles Details of examination work Items to be ascertained Factors of troubles or remedies

TROU8LESHOOTING

TS11-2A-3

--------------------------------- DIAGNOSE MALFUNCTIONS--------------------------------1. HYDRAULIC SYSTEM 1.1

GENERAL

All actuators dc1 11ot work when c·ontrol lever is operated.

Release lock lever. NO

when control locked.

Adjust suction assy. Replace pilot pump.

Disassemble and adjust or replace pilot line check valve. Add hydraulic oil.

Disassemble and adjust or replace solenoid valve

Jisassemble and adjust or replace if lock valve is faulty.

YES

is abnorma J •

Disassemble and

adjust or repl�ce main pump.

Disassemhly and Adjustment of Suction Part. Check pump driving device, spline and coupling.

Clean suction strainer.

TS11·2A·4

TROUBLl=SHOOTING

---------------------------------DIAGNOSE MALFUNCTIONS--------------------------------1.1 GENERAL

0 L..::::::=======::::::;:::======:::::::!.I Actuator moves when lever is returned to neutral,

YES Replace or disassembly/ adjust pilot valve.

YES

c oo

EX120 EXlSO EX200, EX270,

15,0'\,17.0 16.4"'18.4 23±0, 5 220 20'\,22 300 25±2

kg/cm') kg/cm 2 kg/cm 2 kg/cm 2 kg/ cm 2

Control valve spool is abnormal. o Broken spring o Loose spring bolt o Spool stick

Actuator is internally leaking.

fHOUIJUSHUU l ING

1S11 2k5

---------------------------------DIAGNOSE MALFUNCTIONS--------------------------------1.1 GENERAL

[I} L:l==O;;i;;l=t;;c;;m;;p;;<';;r;;a,;;t;;u;;r;;e=r=i s;;'e;;s=, =:.I Give operating instructions.

Examine metal color, etc. Replace hydraulic component.

Clean

Remove YES Adjust

Replace Is low-pressu re line clogged? YES

Disassemble and

examine.

YES Replace

TROUBLESHOOTING

1 S11 2A 6

-------------------------------DIAGNOSE MALFUNCTIONS------------------------------1.2 FRONT ATTACHMENT

Som<' of the cylinders do not move when control lever is operated.

l..::::::=====;;;;;;;;;;;========..I YES

YES

Replace overload relief valve. Disassemble and repair clean, or replace cylinder rod seal:

YES Disassemble and clean or repla'ce control valve spool stick.

YES Disassemble and clean or replace flow regulator spool stick or pilot piping.

YES

Disassemble and clean pilot line filter.

Disassemble and clean or replace pilot valve.

TS11 2A7

TROUBLESHOOTING

--------------------------------- DIAGNOSE MALFUNCTIONS-------------------------------1.2 FRONT ATTACHMENT

ro t sp ed i s s ow . 1.!'==F= = =1=1== = = c = = = l = = = = ==J ::;;::

YES

YES Adjust, disassemble and repair, rear pump or regulator.

EXl00 EX120 EX150 ( EX200 EX220 EX270 EX300

)

5.6±0.5 kg/cm 2 6 .1±0. 5 kg/cm 2 6.5±0.5 k /cm 2 6. 7 kg/cm�

Disassemble and

Some cylinder is slow.

YES

pump control valve. Adjust, disassembly and repair front pump or regulator.

YES

Re place combination

valve.

YES

adjust S�series

6.5±2 kg/cm 2 7±2 kg/cm 2 5.9±2 kg/cm 2

Disassemble and replace cylinder rod seal.

Refer to remedies for mode change and auto idling system.

adjust 4-series pump control valves.

(Control valve spool does not fully

stroke or return

spring bolt is loose.) Disassemble, clean or replace. Disassemhlc, clean

and adjust pilot valve.

Disassemble and clean or replace pilot piping, flow regulator or spo ol stick.

Adjust engine accordinr to

engine operatior1

manual.

Adjust fuel cable or auto-idle device.

THOUB LlSHOOT ING

TSl 1·2A-8

-------------------------------DIAGNOSE MALFUNCTIONS------------------ ------------1.2 FRONT ATTACHMENT

01t-=====;:::===;;;;;;;;:J No digging power.

YES

One actuator fails to provide d igging power?

YES

5.6±0.S kg/cm 2 6.1± 0 .5 kg/cm 2 6.5±0 .S k�/cm 2 6. 7 kg/cm 6. 0 ±2 kg/cm 2 7±2 kg/cm 2 5.9±2 kg/cm'

)

due to hydraulic oil shortage. Add hydraulic oil.

Pump is abnormal (reduced delivery).

YES

EXl00 EX120 EXlS0 ( EX200 EX220 EX270 EX300

Cause is aeration.

Adjust or replace main relief valve

YES

(for excavation or

traveling).

Replace seal.

YES

Pilot systern is abnormal. See 1.2 No.S *S.

Contro 1 valve spool stick does not fully stroke. Remove dust or replace.

Pump is abnormal or suction filter is clogged.

Retighten or replace O-ring.

I HUUllLlSHUUl ING

TSl 1-2A-9

------------------------------- DIAGNOSE MALFUNCTIONS------------------------------1.2 FRONT ATTACHMENT

Failure to hold in lever meutral (leak).

Pilot valve output

L..:I

n a l ure t hold e 1::· n::::c::1 p:: r :::::::::::::::::::::F:: ::i:: :: :: :: ::::: ::<::> :: :: :: :: a :: ::t ·:: ::io :: :: ::.:::::::::::::::::::J :: �

In slight operation, atLempt to lift front results in front falling in direction of gravity. *This is easily checked when engine is stopped.

pressure is

improperly adjusted. Replace or disassemble and adjust.

YES Replace combination valve. Load check function is faulty. o Broken spring o Damaged poppet o Clogging

Cylinder rod seal is leaking. Replace cylinder assy or seal.

Damaged spool-+ Replace control valve. Broken spring-+ Replace spring. Loose bolt -+ Tighten.

TROUBLESHOOT I Nci

TS11-2A-10

DIAGNOSE MALFUNCTIONS -------------------------------1.3 SWING

�

L!:I

No s win g o t '·= = ·= <=ll= = == = = = = = = m= = 1 .= =-I

YES Release lever lock.

All functions do not work.

Is it only swin g s ystem and arm

that do not move?

Refe r to 1. l No. 1. EXIOO, 120 less than 0. 3 EXISO less than 0.5 ( EX200, 220 less than 1. 0 EX270, 300

Control valve is abnormal.

less than 2.0

Swing motor is abnormal. Lock valve is abnormal.

Clean fi 1 ter.

NO Recheck swing system and arm separately. Left pilot valve is abnormal.

Swing motor is abnormal.

1S11 2A-1 I

I tH.JUULt.,)11lJUI !l\lli

---------------------------------DIAGNOSE MALFUNCTIONS--------------------------------1.3 SWING

pow o w g = ='= = = e [} �'=========N =s= =i n= i= n= g = r = . = ======� ;:

Swing is slow in combined swing an d boom lift operation.

If all other functions are normal, possibly there is abnormal pressure loss in swing circuit.

Measure pressure.

Swing power is decreased when arm

moves in swing pressed excavation.

N o swing power.

Tilted climbing swing cannot be done.

If all other functions are norn,al, parts (orifice of check valve) in control valve are possibly abnormal.

Accelcraliot1 of single swing opcr;1tion is slow.

At Main pump

Check control valve.

Check control valve and swing motor.

pressure setting.

Replace cross relief valves.

Check pilot hydraulic supply and pilot valve. Examine swing

swing motor and device. Check swing motor.

Replace pilot

valve.

Be sure to cht>ck other full flow filters,

T HOUBLLSHOOTING

TS11-2A-12

---------------------------------DIAGNOSE MALFUNCTIONS--------------------------------1_3 SWING

01 NO

Swing is not smooth. I

YES

YES Examine pump control valve. Examine pilot hydraulic system.

Examine motor.

YES Examine motor and swing device.

Examine motor.

Examine control valve

spool.

Examine pilot valve.

TS112A-13

I I\UUtJLL�liUUI !NL,

-------------------------------DIAGNOSE MALFUNCTIONS----------------- -------------1.4 TRAVELING

Q] L:l::::::==N c1= =t=r=:=1 v;::c;:=l="='="=L=i= o=n=.=.i EXlOO EX120 EXlSO ( EX200 EX220 EX270 EX300

S.6±0.S kg/cm 2 6.1±0.S kg/cm 2 6.5±0. 5 kfcm 2 6. 7 kg/cm 6.0±2 kg/cm 2 7±2 kg/cm 2 S.9±2 kg/cm 2

Right and left traveling motors fail to move only forward or backward.

Right or left traveling motor fails to move forward and backward.

Neither r1gt1t r1or left motor rt111s.

YES NO

YES

lock

EXl00 EXJ20 EX!S0 (EX200 EX220 EX270 EX300

NO replace traveling valve.

faulty: No.l *3 or main relief is faulty

YES Traveling motor is faulty: disassemble or rep lace traveling

motor.

n traveling motor parking brake funcLion is faulty or traveling motor is faulty. Disassemble or djus t.

Center joint is

internally leaking. Replace' seal.

Disassemble and adjust or replace rC'lief

YES

valve.

Disassemble or

Center joint is internally leaking. Replace seal.

rPplace control vi1lvc spool stick.

Pi lot line is faulty: refer Lo 1. 2 No. 5 *5.

Pilot line is faulLy: refer Lo 1. l No. I * 1.

TS11-2A 14

TROUBLLSHOOTING

---------------------------------DIAGNOSE MALFUNCTIONS--------------------------------1.4 TRAVELING

fI) L.!'==1r·= a= v= e= l=' =in=g==sp= e e= d= =i=s= s=l=ow= =. ==:.J ;:

Steering on one side is slow although straight-line travel and spin turn are normal.

YES 2450±50 rpm 2350±50 rpm 2450±50 rpm 2180!.50 rpm 270 2250±50 2150±50 rpm

Piping is reversed b etween pump control valve and pump.

EX!00 EX120 EX150 ( EX200 EX220 EX270 EX300

5.6±0.5 kg/cm 2 6.1±0.5 kg/cm 2 6.5±0.5 k /cm 2 6.7 kg/cm� 6.0±2 kg/cm 2 7!.2 kg/cm 2 5.9±2 kg/cm 2

YES

YES In pump, maximum change valve is faulty or stopper is faulty. Disassembly and adjust or replace

YES

Control system is faulty. Refer to mode change and auto idling sys tc,m.

Pump swash plate does not tilt to maximum angle unless SC pressure is Jess than 10 kgf/cm 2 •

NO Pilot line is faulty: refer to 1. 2 No. 4 *4.

Adjust or replnce pump control valve.

NO Adjust enginP

according to engine operation

manual.

Adjust fuel cable or auto-idle device.

TS11-2A-15

1 HOU�l t:::)HlJll !Nl.1 J

--------------------------------- DIAGNOSE MALFUNCTIONS--------------------------------1.4 TRAVELING

Only forward or backward

traveling

provided.

power is not

No traveling power.

Motor c>n one sidr fails to deliver

forward/backward traveling power.

Traveling motor fail to deliver forward and backward traveling power.

YES

NO Disassembl e and adjust or replace pump.

Control valve spool does not fully stroke. Disassemble and correct or replace.

internally lcakinp,. Replae,, seal.

EX120 EXlSO EX200 EX220 l:X270 CX300

or replace.

Disassemble and adjust or replace traveling motor.

r replace.

Disassemble and adjust or replace pilot valve.

Less than 285 kg/cm 2

Relief valve for traveling is faulty. Adjust

Center joint is

(EXlOO

isassemble and adjust solen aid relief valve.

Main rerief pressure at traveling:

Center joint is internally leaking. Replace seal. Improper link tension or abnormal of track parts.

285 kg/cm 2

325 350 kg/cm 2

Travel reduction device improper brake.

Rerief pressure select valve is faulty during operation. Disassemble and adjust or repair.

THOUBLlSHOOTINl,

TS11-2A-16

-------------------------------DIAGNOSE MALFUNCTIONS------------------------------1.4 TRAVELING

[I l![==Tr;;; a;;; ;;;v;;;e;;;l;;;1;;;· 1;;;1,;;p=sn;;; ;;;a;;;ke;;; ;;;s=. =di In single travelinp operation, both forward and backward

�,en combined fronl operation, traveling motion is curved.

motion deviates in one

150 less than l t/min less than 1.7 t/min) less than 1.9 t/min

YES

direction.

In single traveling operation, either forward or backward traveling, motion diviates

Traveling motor operation is faulty. Disassemble and repair or replace.

in one direction.

Swith valve in control valve is faulty in operation. Disassemble r replace.

Disassemble and adjust or replace

pump control valve.

>�Y�E�S::.....___________

damper lever and damper interfere with mounting Adjust.

YES YES

Maximum tilt stopper for swash plate oump repulator is faulty during operation. Disassemble and adjust or replace pilot valve.

Pilot line is faulty: refer to 1.1 No.l *l.

Pump is fualty (improperly adjusted regulator or reduced de] ivery). Ad_iust or replace.

YES 5.6.!0.S kg/cm 2 6.1±0.5 kgic)'

YES

::��c�f cm

.-----....1..----Center joint is internally leaking. Replace seal.

6 .0±7 kg/c-m 2 7�2 k.g/cm 2 5.9�2 kg/cm 1

Control valve spool fails to fully stroke. Disassemble and clean or replace.

Cc,ntrc,l valve spc1c1 does not fully Spool stick or pilot is faulty.

Traveling motor operation is faulty. Disassemble and repair or replace.

I HlJUlll c�HOU I ING

TS11-2A 17

1.5 OTHERS

Engine stopped in idling position

(EX270, EX300)

Pump torque cont rol switch or electric cable are faulty refer to electric system

Adjust fuel lever set position EX270 22.1±1 mm EX300 17.7±1 mm from low idle position NO

YES

Pump regulator is abnormal. spool stick . piston stick Adjust suction assy. Replace pilot pump.

Solenoid valve is abnormal

spool stick

TROUBLESHOOTING

TS11-2A-18

--------------------------------- DIAGN OSE MALFUNCTIO NS --------------------------------2. ELECTRICSYSTEM 2.1 POWER LINE

Q) L.:\

o er l i n e h k . =P;;;: w= ;;;: = ;;;: ;;;: ;;;: =c;;;: ;;;:ec :;; :;; :: =�

:::::

NO Recharge or replace battery.

Battery cable is defective.

Wire harness is defective, or either alternator or regulator is faulty. Battery, alternator and regulators are OK.

Stop engine and set starter sw itch to OFI-'.

NO If current is highPr, there is

If no current, power for age. is not suppling. Wire harness is

defe tiv,•. c

YES

There is no leak or shorting.

TS11-2A-19

r HUUlJLLSHUUf I Nu

--------------------------------- DIAGNOSE MALFUNCTIONS--------------------------------2.2

ACCESSORY

Accessory system check.

NO Mount fuse.

YES

NO Wire harness of fusible link is defective.

YES Try to operate each accessory.

accessory fails to operate, measure

voltage at power supply of each

NO Wire harness is defective.

Accessory or accessory connector is

defective.

TROUBLESHOOTING

TS1 l-2A-20

DIAGNOSE MALFUNCTIONS 2.3 MONITOR (with VOLT-OHM METER)

The monitor may fail due to unlooked-for cause.

Though there might be some thing against reason in ascertaining a ll causes, you should refer to this troubleshooting as a step helpful to examination of the causes.

[I) I Meter(s) docs not work

Service meter not inte�rate during engine rotation.

(OFF)

One Refer to Item of faulty meter Turn key switch to ON position (Check of power supply)

Measure regulator terminal •1 R(or F) after ENG started.

Yes Yes Refer to Item of faulty meter Wiring fault Ex: (1) Fuse blowout (2) Harness disconnection (3) Battery relay defective

Alternator or regulator

Uc fC'cti ve.

Remove the connector of gauge panel a11d i11crcase engine rotation to 1000 rpm to check continuity be t\"ccn harness-side connec tor tcrn1i11;1l N7 and body (I.).

Yes

etc.

• 2Rep lace relay or hourmeter s,vi tch

*l *2

EXlOO,12O,15O,2OO

Terminal: R

llourmetcr relay

!k11 l ;1L"l.' met c r .

:-.l'

rv 11..:c

EX2.?_O '. 27O,3OO Terminal: I'

Hourmetcr switch

TS11 2A21

THOUBU:SHUU ! ING

DIAGNOSE MALFUNCTIONS 2.3 Monitor

�1alopcrat1on of water tcmpP1-atur<' �!•1t1�e

PointC'r doc� not S\ving. ( [t Jocs not rise from zero point)

Pointer swings <;caleovcr

l'ointcr ,._,.,:1ngs unstably

l'uint<.'r rC'main� indicating ;1 certain valuc-

Q-ieck connection of terminal of

Extracting terminal of sensor ur1it, tur11 �ry switch ON.

Chee!.. ..:onncct ion of tc rmi na l of sensor unl t.

point)

sensor unit of water temperature

gauge.

( Loose)

(Loose) \'cs

Yes

of terminal

Remove BP connector at gauge panel, check continuity between No.B terminal at harness side and body (EJ (With terminal of sensor unit left extracted)

round terminal at harness side through resistance of 10 to 20n.

Extracting terminal of sensor unit, ground terminal at harness side through resistance of 10 to 20Q.

Yes

Harness defective

sensor unit

sensor unit teminal at harness side.

(With terminal of sensor unit left extracted)

(R=O) Yes Exchange water temperature gauge

Harness defective (disconnection)

Exchange sensor unit

Yes

Exchange

(short)

Exchange water

temperature gauge

Normal

Exchange water temperature gauge

Yes

Remove BP connector at back of gauge panel, check continuity between No.B terminal at harness side and

Ye-.

sensor unit

Poor connection sensor unit, ground

Turn key s1<i tch OFF

Poor connect ion of tcnninal

Exchange

Extracting terminal of

(lt Jocsn't swi11g l1acl.. to zvr,1

Exchange water

temperature gauge

TS11-2A-22

TROUBLESHOOTING

DIAGNOSE MALFUNCTIONS 2.3 Monitor

{!]

INDICATION CIIARACTl'R I ST IC c1mvi:

Accuracy check of water temperature gauge

IIOW TO CHECK ACCURACY OF GAUGE

Removing the terminal of harness side from the sensor unit of water temperature

,-' ------

gauge, ground the terminal through a reference resistance, and judge it by the pointer movement. (Tap the gauge panel with finger, and read the pointer swing) TERMINAL AT IIARNESS SIDE

"""J.I

REMOV E

(2)

E=27V

SENSOR TEI�I NAL VOLTAGE (V) P W O ER V OLTAGE (VJ

�

�R

PANEL

I JUDGMENT! (I)

tlit._MP �

F O IVATrn TLMPLllATlll(E CAIIGE

point t3 mm in case of R If the pointer swings to If the pointer swings to 3 point t3 mm in case of R

son,

it is normal.

160, it is normal.

HOW TO CHECK ACCURACY OF SENSOR UNIT

Measuring the power voltage (E) of fuse box and the terminal voltag_e (V) of

sensor unit, judge it by referring to the indication characteristic curve of water temperature gauge (right chart .)

9n CJ

SENSOR UNIT !JUDGMENT!

!---

(;AIJCI' PANEI.

FUSE BOX

With accuracy checked gauge, if Vis 2 V when pointer is at position (S) and E is 24 Vin the right chart, it is normal. If Vis I V to 3 V, the sensor unit can generally be guessed to be faulty.

NOTE It is difficult to ascertain the accuracy of the sensor unit correctly by referring the

above

chart.

This characteristic curve should he referred to as a guide for checking if the meter is out of order completely.

TS112A23

-- f Ull [1 ~

I HUUIJL�SHUU IINli

DIAGNOSE MALFUNCTIONS 2.3 Monitor

t'oi11tcr docs not swing ft ,oc<;, not rise from zero point) Cl1cck connection of float tcrn1ir1al

of foe I gauge.

'IAL!ll't:llATION 01' 1111 I. ChlJCI.

1'01ntl'r ,;;,wing,; over

Po111tcr swings unst;_i,lily

(Scalcovcr)

L:xtracting (•) tcrmirt�ll of float, t11rn key switcli ON.

Pointc-r remains i11Jicat1ng ;1 certain value.

{Pointer docs not swing hack to zero point.)

Chcrk if oi I level of fuel tank fluctU:JlC'S.

( Loose) Yes

Try to turn �<'�' switch OIT

Poor conncc ti on of terminal Extracting(•) terminal of float, ground terminal at harness side

through resistance of 10 to 20n (Key switch� ON)

Removing BP connector at back of gauge panel, check continuity between No.9 terminal at harness side and body (E). (With(•) terminal of float left' extracted)

Check connection of float terminal. Exchange fuel gauge Yes

Yes Yes

Exchange float

Poor connection of terminal

Harness defective

Removing BP connector at gauge panel, check continuity between No. 9 terminal at harness side and float tenninal at harness side. (With(•) terminal of float left extracted)

(short)

Exchange fuel gauge

Extracting (•) terminal of float

ground terminal at harness side

through resistance nf 10 to 20n

Yes Exchange float

(R=O) Yes Exchange fuc I gauge Harness defective (disconnection)

'P-1

Exchange fuel gauge

TSl 1 2A-24

TROUBLESHOOTING

DIAGNOSE MALFUNCTIONS

2.3 Monitor

I!] II ACCURACY Clll'CK

OF FUEi. GAUGE

INDICATION CHARACTERISTIC CURVE OF Fl/LI. C/\IICI'

IIOW TO CIIECK ACCURACY OF FUEL GAUGE Removing the terminal of harness from the fuel float unit, ground the terminal

through a reference resistance, and judge it hy the pointer movement. (Tap the gauge panel with finger, and read the pointer swing.)

,-·-------

V: E:

E=271'

!"I.OAT LJN IT TERMINAL VOLTAGE (VJ

POWER VOLTAGE (VJ

I I

•UEL E)

) I

GAUGE/l./1· PANEL

I JUDGMENT I (1) (2) 2.

If the pointer is under E point in case of R = SOil, it is normal. If the pointer is over F point in case of R = !Oil, it is normal.

OL-----4-----+--+---+-----+-----+-------

HOW TO CHECK ACCURACY OF FLOAT UNIT

Measuring the power voltage (E) of fuse box and the terminal voltage

(V)

float unit, judge it by referring to the indication characteristic curve of fuel gauge (right chart)

�Q -�---..�□ V

!JUDGMENT!

1---

t;AUCI' !'/\NE L

Bf \. . ·----l /

FUEL

HISE BOX

With accuracy checked meter, if Vis 2.8 V when the pointer is at (A) position and E is 24 V, it is normal.

·%

If V is 2 V or 4 V, the float unit can generally be guessed to be faulty.

NOTE

Since the accuracy of float unit has been adjusted at point E and F only, this

characteristic curve should be referred to as a guide for checking whether the gauge is out of order completely or not.

TSl 1 2A-25

TROUBLESHOOTING

12.]

2.3 Monitor

DIAGNOSE MALFUNCTIONS '10\ !TOR L\.'IP Bl/LB CHE:CK I �r; FOR BIIR.\ Dir!

Monitor lamp is not turned on when starter s�.,.itch is

turned on. (Normally OK lamps and warning lamps turn on for about 2 seconds.)

Not turned on

Partly not

turn on

( Exchange bulb )

Check power line Ex: • Exchanj:!C fuse · Check continuity between No. 12 terminal of black

connector of gauge

pane I and fu sc

Take measures for each monitor item that docs not light. referencing the troubleshooting <lcscril>cd.

REMARK These lamps also turn on for about 2 seconds hy turning the stater switch to PREHEAT or START, 1,hich not abnormal.

TS11-2A-26

TROUBLESHOOTING

DIAGNOSE MALFUNCTIONS

[!] OK LAMP CHECK

2.3 Monitor

Lamp is turned on even if preoperation check-s�itch is not pushed.

Lamp is not turned on even if preoperation

check-s�itch is pushed.

•1

Refer to Item of faulty lamp

Refer to ltcrn of faulty lamp

CHECK AMOUNT OF OIL AND WATER ·Engine oi I: •llyd. oil: ·Engine coolant:

Replace before-start check-switch (Contacts shorts)

Oil level in oil pan with dipstick. Oil level in hyd. tank with pipe gauge. Water level in reserve

tank

•2

Yes

If found to be short, refi 11

NOTE 0

•2: Poor contact of before-start check-switch or harness defective (disconnection)

When checking the oil levels and water amount before starting to work, place the machine on a level ground and lower the bucket onto ground. (I)

Engine oi I

(2)

Hydraulic oil Oil level in the hydraulic tank must he able to be seen through the pipe gauge. Engine coolant

(3)

Oi 1 level in the oi: pan must be over "LOW11 mark of dipstick.

Water amount in the radiator must be over

LOW" mark of rcs�rve tank.

TROUtlLESHOOTING

TS11 ·2A 27

DIAGNOSE MALFUNCTIONS 2.3 Monitor

Malopcration of hattcry charge warni111: lamp

Lamp is not turned on despite

Lamp is not turned off dcspitt' cngi11c is running.

l.ey switch is ON.

No Exchange bulb

• l(F) . Measure R terminal voltage of regulator. (With engin� kept in operation)

•1 (Fl Measure R terminal voltage of regu I ator.

(Usually, V • 28V)

(Key switch is "ON" but do not start

Measure No.4 terminal voltage at harness side of gauge panel. (With engine kept in operation)

No (V > lOV) Yes (V � IOV)

Regulator or alternator

de feet i vc.

Yes

the engine.)

\I < lSV)

Replace regulator No (V � 15\1) Gauge pane I defective

(Usually, V

28V) Yes

Gauge pane 1 defective

EXl00,120,150,200

Terminal: R

EX220,270,300

Terminal: r-

Disconnection of harness between No.4 terminal of gauge panel and R terminal 'l{FJ of regulator.

TS11-2A-28

TROUBLESHOOT ING

DIAGNOSE MALFUNCTIONS 2.3 Monitor

Malnperation of cnginc- oil prl's'>ure warn111_1' lam1i

I.amµ is not tutncd on despite' key switch is ON.

Lamp is not turned off despite

Yes

Exchange bulh Remove harness from tcrmi nal of oi 1 pressure switch, ground harness terminal. (Key switch is turned to "ON" but do not

start the engine)

1:xd1angc filter elcmc·nt

Cl,eck continuity between

switch terminal and body (E)

Yes Replace oil pressure switch

Check continuity between lso. 13 terminal (12P connector) of gauge panel and terminal at harness side of oil pres

sure switch.

Exchange gauge panel

(disconnection)

Perform warming-up Remove l1arncss from terminal of oil pressure switch.

(Key s,;itch is turned to "ON" but

do not start the engi11c)

Yes Replace oil pressure switcl1

Yes

Harness defective

to ma�c sure of it. If no contint1ity is obtained, it proves switch is faulty.

Harness defective (short) across (No.13 terminal of gauge panel and terminal of oil pressure switch.)

,---�--7

l ROUBl[SHOOTIN(;

2.3 Monitor

�

TS11 2A 29

DIAGNOSE MALFUNCTIONS �Lt lope-rat ion of cn).!iru• 01 l

I.amp is not turned on

ft lter clog warning I.imp

Lamp i-.; left ON

Yes

l:xchang,c clement

l'xchangc hulh !lemovc harness from pressure :-,-1iitch of engine oil filter,

(clogged)

Remove 12P connector of switch of engine oil filter (Key switch ➔ ON)

'..!roun<l harness terl!linal. (Key switch ➔ ON)

Yes

Harness defective (disconnection) (Disconnection between No.17 terminal of 12P connector of gauge panel and switch)

Pressure switch dcfccti vc (Check continuity between tcrmi11a l

of pressure switch and body (E). Continuity should be obtained.

No Remove 12P connector of

It is normal if lamp is not turned on.

gauge panel (Key switch

➔

ON)

Replace pressure switch

No Gauge panel defective

llarness defective (short ) (Across No.17 term inal of 12P

connector of gauge panel and pressure switch)

TROUBLESHOOrlNG

TSl 1 2A-30

DIAGNOSE MALFUNCTIONS 2.3 Monitor Maloperation of nir clt•aner l·lng Wi.irning lamp

I.amp is not tu rncd

l.a111p i <:.. 1 c ft ON

Yes (cloggcJ)

Exchange hulh

Clean clcml'llt or c>.cliange

Remove harness from pressure switch of air cleaner, ground harness termin�l

(Key switch• ON)

llry clement or cxcl1angc Remove harness from pressure

switch, (Key switch • ON)

No Harness defective (disconnection) (Disconnection between No.18 terminal of 12P connector of gauge panel and pressure switch)

Yes

Remove 12P terminal of gauge panel, terminal at harness side and body

It is normal if lamp

Replace pressure switch

Replace pressure s�itcl,

chetk continuity between No. 18

t,;o

Yes

(E).

is not turned on.

No Gauge pane I def cc ti vc

Harness defective (short) (Short across No.18 terminal of 12P connector of gauge panel and pressure switch.)

TS11-2A-31

TROUBU:SHOOTIN(;

DIAGNOSE MALFUNCTIONS 2.3 Monitor

I.amp

Lamp is not turned on whc11 eng 1111.' is ovC'rheatcJ.

i � turn<'d ():-.J C\.'<.'11 if \o.':ttcr

t cmp. 1 ..; I mv.

Remove' lian1c�s from overhc;it alarm sv. itch 1

Chee� cont I !HJ it y bct�,·ccn switch terminal ;rnd ho<ly (L) to mai..e sure of it. (Continuitv :--hould be oht.1 i ncd.)

(�cy switch • ON)

l: x.changc hul h Yes

Remove harness from terminal of overheat alarm switch, ground harness terminal.

(Key switch� ON)

Remove 12P connector from gauge panel. (Key switch� ON)

Yes

Harness defective (disconnection) (Disconnection between No.14 terminal of l2P connector of gauge panel and switch)

Was pointer of water temp. gauge in red range when engine was overheated?

No Normal Overheat alarm switch defective

43 I

Replace overheat al�rr1 switch.

No Replace gauge panel

Harness defective (short) (Short across No.14 terminal of 12P connector of gauge panel and overheat alarm switch)

TROUBLESHOOTING

TS117A37

DIAGNOSE MALFUNCTIONS 2.3 Monitor

'.'-1alnper;1tio11 of fuel lamp

Lamp is not turncJ on <lesp i tc pointer c,f fticl ga,1gc ir1Jicating "E" point.

Lamp is turned ON dc-<:..111te ful'I Lrn hcing filled fullv ,�ith fu<'I Remove- h;.irncss fr<.ln1 con11cctor (malc-/fcm:1lc tcrml11:ll) of float Sh' itch at lm"cr pnrt i011 of fuc I tank..

Yes Remove harness from connector (maic/ female terminal) of float switch at lower portion of fuel tan!., ground tenninal at harness si<lc.

Replace float switch Remove 12-pole connector of gauge panel

Yes

Replace float switch

Yes

Check continuity between tcminal of lead wire of float switch and body (E).

Gauge pane I

defective

No Replace float switch Reconnect float switch lead wire to place, remove 12-pole'connector and check continuity between No. 19 tenninal at harness side and body (E).

Yes

Gauge panel de feet i ve

Harness defective (disconnection) (Between No.19 terminal of gauge panel and float switch)

Harness defective (short) (Across No. lY terminal of gauge panel and float switch)

TS11-2A-33

TROUBLESHOOTING

2.3 Monitor

,------- -------------------------'------------ - ----� Lamp 1s not t11n1cd off despite li r,hting switch is turnC'J OFF

Lamp is not turned on d(•spi n� llh\OLIGIIT switch is ON.

No lxchangc uulb Yes

Remove 6-pole connector of gauge panel, turn OFF lighting switch and measure voltage of No.S terminal at harness side. (Key switch� ON)

) Remove 6-pole connector of gauge panel, turn on headlight and measure voltage of No.S terminal at harness side.

241'

OV V > 20V

Gauge pane 1 de feet i vc

Lighting switch defective or

poor connection of lcad(s)

Harness d efective (disconnection) (Disconnection between lighting switch and No. S terminal of gauge panel.)

(:augc panel defective

TROUBLESHOOTING

[ill

2.3 Monitor

f �- l W

Lamp is not turned on even if hcforC' start ct1cck-switch is pushed.

Removing connector of level switch of oil pa11, ct1eck continuity bctwcer1

switch lead and body (I').

DIAGNOSE MALFUNCTIONS r;::=f=,,=,1= ,=, ="=,=,.=.,,=t=i =o=11=o=f=c=n= =i = =c=o=,= l = l =c=v=c= l =O=,= = = = ==:::i la m p l g n

•Fi lament 1'> not burnt out.

·Machine is kept placed level.

·Oi I !eve l is over "LOW" marl-.. in g.

CCNll lT I ON

I.amp is turnc-<l on r-vcn if in oi 1 short.

[Basic machine i" kep t placC'J l<'vcl

Check oil level with dipstick of oi I pa n, Less than 8mm "'>--�

Normal

Replace level switch Remove connector of level switch

!Reconnect the level switch connector in 1place (connection of harness), remove 18-pole connector of gauge panel, and .check continuity between No.10 terminal .at harness side and body (E).

of oil pan, push before-start check-switch.

No Replace level switch

No Harness de feetivc

(disconnection)

Remove 8-pole connector of gauge panel, check continuity between No.I terminal at harness side and body [E). (With connector of level switch left removed)

Gauge panel defective

No l;augc panel defective

llarness defective (short)

TS11 ·2A·34

TROUBUC:SHOO TING

TS11 ·2A·35

DIAGNOSE MALFUNCTIONS �

2.3 Monitor

@) � L==lla= l= o= p= =er= a= =ti= o= =n=o=t=· ="='='t=''= r=:;:eI = ve= = l=Os= ·= =I ''="'= l'= =='..l

I.amp is not turnC'd on C'Vl'n if before start chC'cl..-switch is puc;hcd.

Rc�ovc connector of level switct1 of reserve tank, check continuity hct\H'er 2-pble terminals of leve l switch.

•l'i l:11ne11t 1-.; not h11r11t out .

•�lacli inc t � 1-.l'pl placed level.

•l'Jater l<'v C'l {r('scrvc tan!..) 1s over "LOW" marl..ing

CONII I 'I Ill� (Machine 1-; \-_cp: ltl;1ccd level.

l.:·r.ip is turned nn even if In n i I c;hort. Check w ater level in reserve tank

No No Replace level switch Re-put level switch connector in place (connection of harness), remove 8-pole connector of gauge panel and check continuity between No.II terminal at harness side and body (F),

Normal Remove connector of level switch of reserve tank, plJSh before-start chcck-swi tch.

Replace level switch

Yes

l1arness defective (disconnection)

Remove 8-pole connector (smaller) of gauge panel, check continuity between No, 11 terminal at harness side and body (E),

Gauge panel defective

(;auge pane I de feet ivc llarncss defective (short)

TS112A36

TROUBLESHOOTING

DIAGNOSE MALFUNCTIONS

2.3 Monitor

Maloµeration of hydraulic oil level OK Lamp ------··-·-- - -------' ---------- -

Lc:1mp is not turned on even if lwfor·c start check-switch is pushed.

•Fi lament i.;;; not burn out. • �la chi 11c is 1-.cpt placed level.

Remove connector of level s�itcl1 of

hydraulic tank, check continuity between switch lead and hody (E).

·Buchct is left on ground.

r.=======�========:i corm a I UN :.;1mn is tl1rned 011 even if in i;�chinc is hcpt ci: ,;iwrt. ( I. �=======:::::========!.I p 1 aced 1 eve Check oi 1 level through pipe gauge of hydraulic tank.

•Oi 1 level can h� con fi rmcd right through pipe r,augc.

Yes

Normal

Replace level switch Remove connector of level switch

Re-put level switch connector in place (connection of harness), remove 8-pole connector of gauge panel and check continuity between No.12 terminal at harness side and body (E).

of tank, push before-start check switch.

No Reprace level switch

Yes

Harness defective

(disconnection)

Remove 8-pole connector of gauge panel, check continuity between No.12 terminal at harness side and body (E), (With level switch connector left removed)

(;auge pane I de feet i vc

Gaguc pane 1 de feet i vc

Harness defective (short)

IS11-2A37

HWUBL.[SHOUI INl;

DIAGNOSE MALFUNCTIONS

@) IT

2.3 Monitor I I)

Btmer I

(2)

Huu.t'r '-ound" -.twrt at timC' of t·11gine :--tart.

Buzz.er r0ni:iin<; sounJin'g wh<•n 1-..t�y switch is merelr turnc>d ON hefor<.' :--t:..irt ing tl1e c1;gi11t•. • I (N)

Yc>s

�k�Hsurc I� tc-rminal voltage of regulator.

(�cy �witch is t11rncd ON, l1ut do 11ot start t!1C' engine)

Norma I

> 101' Regulator defective Gauge panel defective

REMARK HO\'/ TO Clll'CK IF BUZZER IS NORl-1AL

OVERHEAT SWITCH

FITTED WITH CLIP

When the terminal of engine overheat

switch or the terminal of oil pressure switch is grounded with a lead wire fitted with insulated clip and the engine speed is increased over 1,000 min- 1 (rpm), the buzzer should sound. If it fails to sound, take a proper action referring to the troubleshooting procedures of BUZZER in Item (4) on the succeeding page.

* "NORMAl.1' discussed here means that the buzzer circuit is

normal. When the fact that engine oil pressure or engine overl,cat warnir1g lamp to be turned ON is abnormal itself,

take a proper action by referring to the troubleshooting procedures of the lamp.

OIL PRESSURE SWITCH LEAD WIRE FITTED ,,....._______ WITIJ INSllLATEll CLIP

EXl00,120,150,200 *l

Terminal: R

EX220,270,300

Terminal: N

TROUBLESHOOTINli

TS112A38

DIAGNOSE MALFUNCTIONS

2.3 Monitor (3) Buzzer remain..:. sounJ1n)! onL'C cng1n is St.!rtcJ.

Humr 11

( 4) Bu2zc-r Joe'> not ..;ound alt hou�:11 C'nginc oi I prcs..;urc or ovl'rhc,1t w�1·ning lamp is tt1rr1eJ lJll.

Normal

Norm,1 l

Normal No Gauge pane 1 de feet i vc

Yes Normal

Gauge panel defective

*I (NJ

Measure R terminal voltage of

regulator (With engine speed kept more than 1,000 rpm))

No Replace regulator Measure voltage of No.4 terminal at harness side of gauge pane 1. (With engine speed kept more than I ,ODO rpm))

EXl00,120,150,200 Terminal: R

EX220,270,300 Terminal: N

G;wgc panel defective

Harness defective (disconnection) (Between R terminal of regulator and No.4 tenninal of gauge panel.)

THUUBLl::SHUU I INl,

TS112A39

DIAGNOSE MALFUNCTIONS 2.4 CONTROL SYSTEM (I : with VOLT-OHM METER)

r,l i..:.J

Checking (when �t[CHATRO CHECKER is not ay_v;!_a.!_i_!:I a�b�l!_!eel.cc:::!J lk=========:;::::====::J!.

Check controller connector for mad or dust. If abnormal, replace or repair.

Measure voltage across tcnninals Nll anJ #21 (Key SW ON, engine stopped)

,\o

Voltage:

terminal #JJ-# 21

Wire harness defective which connects to terminals #ll and #21.

24V

Yes Start the engine.

Enter P mode to fully run the engine.

Engine rotation decreased 3.5 sec after turning on auto idle SI"? Check auto idle system. Yes \o

IHth travel or digging operation, engine rotation returns to become full?

Turn off auto idle SW. \o Check mode switching system.

Mode SW work? (engine rpm:

.---------L...-Ye_s___________� Traveling or shortening the terminal of traveling pressure switch, set 2 speed travel SW in P mode (with auto idle SW OFF).

Engine rpm:

Check. travel speed switching system.

P=full, E�J800 rpm, L�!400 rpm)

(Set of 2 speed travel SW) H•ful I L=.1800 rpm Yes Normal

l HUUHU.:SHUOl lNl,

TS11-2A-40

DIAGNOSE MALFUNCTIONS 2.4 Control System I

0 I!::::====:;======= Checking auto idle system.

Check the engine oil S� according to engine pressure sarning lamp defective. No

Engine oil pressure SI" normal-:'

Replace engine 011 pressure No

Voltage:

Wire harness ("l,�u,<lJ u1 controller defect1 vc.

Yes

controller terminal ti about 4V engine operated engine stopped = ov Yes

Continuity of auto idle terminals #3 and P4 normal? (!"emovc connector to measure}

Replace auto idle SI</.

Yes No

Voltage:

Wire harness (#6, #13) or controller defective.

controller terminal #6-#13 auto idle SW OFF about 4V SW ON = OV Yes

Voltage:

emove t e p ug o travel pressure SN to check the continuity of the SW. N_o_ ON during travel (slight travel r-____ < enought) and OFF with lever in neutral ep ace the Yes pressure SW'. Wire harness (#3, #4) or controller de fee tive.

controller terminal #3-#4 engine started, shift the lever to travel (slight travel enough) OV lever in neutral = about 4V .Yes

Voltage:

controller terminal #2-#5 engine started, shift the lever to dig (slight digging enough) = OV lever in neutral = about 4V Yes

Checking auto idle sys tern (cont.)

No Remove the plug of digging pressure SW to check the continuit of the Sh'. o:,.,- during digging (slight travel enough; and OFF �ith lever in neutral?

Yes

\\'ire harness ("2, ".:.i) or controller defective.

No Replace the pressure SI'/.

TSl1-2A41

I HUUtlLl:�liUU I ING

DIAGNOSE MALFUNCTIONS 2.4 Control System I

l==C=h=e=c=k =in=g=•=u=t=o=; l;:: d=l c=s=)=·s=t= e=m=( =c,=,n=t=·=)

==!I

Start f.'ngine and set the le\er in neutral.

Voltage:

controller terminal #9-#19 auto idle SW ON 28V (after 3.5 s�c) auto idle SW OFF = av Yes

Controller defective.

• Travel or digging operation made afte:- the voltage across terminals #9 and #19 becomes about 28 \' 3.5 sec after turning on auto idle SW causes that voltagc to become O \'?

) Controller defective.

Yes With the above operation (•), the voltage across the plug of solenoid valve become about 28 V or O V with terminals lf9 and # 19 corresponding to wire harnesses L and LY?

Wire harness defective.

Yes No

Solenoid valve or pilot pressure line defective.

Pressure on the rni11L...-yl1ndcr:

Ye'.'> Minicylinder S\Stcm defectl\'C.

P (with the .iliovc upcr.1tlo11 (*)) 11 40 1--g/cm; at volt.1gc on solenoid valve L-LY P = () 1,.g/c;n;..i at voltage on solenoid valve L-1.Y

28V ov

TS11-2k42

l HUUtlLtSHUU IINlj

DIAGNOSE MALFUNCTIONS 2.4 Control System I

0 No

Checking mode switching system

Continuity of mode S\'i1 and :erminals E, L and M normal? (check 1,d th connectors removed)

Yes

Replace mode SI�. Volt.age:

No Wire harness (#7,#12,#16,•ll,#21)

controller tC'rminals Ul2 anJ llll1 (1vitli #7 on ncga t i vc side J 1 1 mode l: mode I. mode

n12 "12 #12

4V, #16 IIV, #16 ov, #16

4V 4V ov

or controller defective.

Yes Measure the voltage across controller terminals #9 and #19 and across #10

and #20.

Vo I tagc:

Controller defective.

(with engine stopped) I' mode #9-19 0'1, #10-20 = OV E mode #9-19 OV, #10-20 = 24V #9-19 24V, #10-211 = 24V L mode

Yes •Voltage:

No Wire harness defective.

(at the plug of solenoid valve) p mode L-LY Ov, W-WY = av E mode --- L-LY = OV, W-WY = 24V (28V) L mode --- L-LY = 24V (28V), W-WY = 24V ( ) shows at engine operated

Yes

Solenoid valve or pilot pressure line defective.

Pressure on the minicylinder:

Yes Minicylinder system defective.

(28V)

P (with the above conditions (*) and engine operated) P 40 kg/cm' at voltage on solenoid valve 28V P = 0 kg/cm 2 at voltage on solenoid valve = OV

TROUBLESHOO I IN(i

TS1 l-2A-43

DIAGNOSE MALFUNCTIONS 2.4 Control System I

Checking travel speed change sysytem. Continuity of 2 speed travel SW terminals ;r4 and NS normal? (remove connectors to measure)

Yes

Replace 2 speed travel SW.

Wire harness (#14, #17) or controller detective.

ts)

Wire harness or controller ct i

i..;;..a l====d=e=f=e===v=e=.=:::::;=========�

Wire disconnected? (check ...,ire harness for continuity)

Yes

>-----------------� Repair win::.

No Wire has continuity with other wires or shovel frame?

___.,_____

.,,-

Controller defective

Yes

>---------, Remove the cause of short .

TROUBLESHOOTING

TSTT-2A-44

DIAGNOSE MALFUNCTIONS 2.5 Control System (It: with MECHATRO CHECKER)

r,) Checking control system (for failure l..:..J l.!:::de: ::::t:::c:::c:::t::ioaa aan;;;;a;;wa:ai::tha=:::�![=:- :;:Cl::l.::�-:::, RO:: :::::C::H::E::C::K:::E::::R::::::==:::!J

Notes I: See "HEU\ATHO CHECKER." 2: Circled numbers (I) to (7) correspond to those

ir1 tl1c panel top view.

Connect t e c ec er an set Ace to ON with key SW (engine stopped).

No contra lcr terminal #ll

Yes Put up switches (6) and (7) to check the controller according to the controller

check list. (First put up all the switches of (4) and put down them one by one from the left to check if the output becomes as on the list.

For TRAV SW, output will

be effected 3.5 sec after being put down).

Harness connection (to I'll) defective.

Yes Check continuity between controller terminal •21 (harness side) and body earth.

No Yes Check controller connector for mud or dust and abnorma 1 ty.

Control }er normal. Check SW and sensor.

Controller connector contact defective (lfll or ,21).

\o Harness connection (to #21) defective.

Checking input SW and sensor.

Yes Controller defective

No Repair abnormal

part.

I H()UtH_I :,11<JU I INl,

DIAGNOSE MALFUNCTIONS 2.5 Control System 11

[I)

c c k n g i np t SW an s n s = = = = = =d c = = = o=r = · =:!I l!'==Cl=, = =· =i= = = = = u = .= Put down si,.1tchcs of (b).

ENG OIL lamp turns on with engine stopped and turns off when operated?

Yes

Engine oil pressure I ine defect1,e Check if the oil pressure s..,,ttch 1s defective, according to th1.• item of dc fcct1,·e engine oil press ure "'arr11ng lamp. If normal, harness defrt.:t1,·1.•.

S etting mode SW to P, MODE L and flJlll·. l go off, setting to [ cause s E to light, and to L, E and L light?

Yes No

Harness defective ("15)

Continuity between mode SW terminal E and terminals Land M normal?

''"''' is turned off?

Yes

When 2 speed t rave 1 SW is set to H, LOW SPEED lamp goes off, and to L, it goes on?

Rep lace pressure SW.

Harness defecti\·e. No

Continuity of 2 speed travel S'n terminals 1'4 and •S normal?

DIG lamp lights 1,,ith engine started to dig (slightly enough) and it goes off ,,,;i th lever returned to neutral"

Harness defective.

Yes

ON 1-,ith engi.ne started to dig and OFF 1n neutral"

TRAV lamp lights with engine started to tra\el (slightly enough) and goes off with lever retun1ed to neutral?

Yes

Yes No

Replace auto idle s�·.

Continuity of auto idle SN terminals #3 and #4 normal?

Yes

Harness defective.

No Rep lace 2 speed travel SW.

Yes

Harness defective.

Replace mode s�.

Yes

Yes No

AUTO IDLE lamp goes on with auto idle SW tuntf'd on and goes off with the SW turned off? Yes Input SW/sensor normal. Next check output 1 inc

Checking output line.

Remove t e p ug o check continuitv.

pressure s

OS \<i'ith engine started tu travel and OFF in neutra 1 '?

Yes Harness dc fcc ti.ve.

;,o Replace pressure SW.

TSl 1-2A-46

l HOUHLcSHUO! ING

DIAGNOSE MALFUNCTIONS

2.5 Control System II

h c ing out p t line l!l==: =C= =•= =k= = = = = = u= = = = = =::::::!J ;:: Put own switches (S)and(7).

St.art th•." CUJ.:illl' :111d i...:c11 hi 1:ll idling (full "JlCCd).

No No Ha mess defective. No

Solenoid valve or pilot hydraulic system defective.

A voltage of 24 to 30 V developed across terminals W and WY connected to solenoid valve?

Yes With ENG HLV. II set to ON, engine

Yes

speed becomes auto idle rotation (approx. 1400 rpm)?

Solenoid valve is switched to allow pressure to be applied to minicylinder?

Yes

Fully rotate the en gine and jack up one side of crawler to idle.

Minicylindcr or link mechanism defective.

No No Harness defective. No

Solenoid valve or pilot hydraulic system defective. No

Solenoid valve or pilot 'hydraulic system defective.

A voltage of 2� to 30 V developed across terminals R and RY connected to solenoid valve? Yes

Solenoid valve is 51,:itched to have a tank pressure? Yes With PUMP set to OFF and zero voltage across terminals R and RY, pressure applied from solenoid valve to pump becomes 40 kg/cm 2 ? Yes The maximum list switching portion of pump defective or pump discharge pressure is abnormally high due to a failure of other hydraulic system.

With ENG REV. I set to ON, engine speed becomes medium (approx. 1800 rpm) 1

>-------------------

A voltage of 24 to 30 V developed across terminals [, and LY con ne ctc d to solenoid valve?

Yes

Solenoid valve is switched to al lo-..· pressure to be applied to minicyl inder? Yes

With PUMI' set to ON, crawler speed increased'? Yes

Output line 1s nonndl.

Minicylinder or link merhansim defective.

No Harness defective. No

Solenoid valve or pilot hydraulic system defective.

TS18-3A-1

TROUBLESHOOTING

EX 270, EX 300 EXCAVATOR PERFORMANCE TEST 1. INTRODUCTION The standard listed below is applied to a new machine.

For already working

machines, a certain allowance is permitted according to field condition.

Unless otherwise specified, measurements should be performed under following

conditions.

Engine speed

Hydraulic oil temperature

Fast idle

50±5 ° (

2. ENGINE PERFORMANCE MEASUREMENTS

IJ:} The engine is the driving source of a hydraulic pump.

Therefore, the engine

performance has a great effect on the performance of the various hydraulic units, and the engine performance must be measured before the measurement

of the other performance.

ll] Before starting the measurement of the engine performance, injection timing and valve clearance.

inspect the fuel

2.1 ENGINE SPEED ------------------------------- Note: ■ Measure the engine speed in an unloaded state, at an auto-idling time and at system pressure relief time. ■ The engine speed, which is the driving source of the hydraulic pump, has a great effect on the measurement of various performances. During measurement. therefore the engine speed is an essential factor.

(1) .\leasurement preparation

0 .\lake

sure that the governor le\·er makes

contact �ith the fast idle stopper in

accordance \\·ith the movement of the

engine control lever provided on the

right console.

@: Engine control lever

@ : Engine control lever stopper @: Cable

@ : Governor lever

@: Fast idle stopper

TROUBLESHOOTING

-------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST

Install a sensor @ of tachometer onto

the injection pump piping �' .

@) Start and run the engine at fast idle. Warm up the water temperature to 50 ° C

or above and the hydraulic temperature

to 50±5 ° C.

(2) Measurement

[I} Unloaded low idle 8 Switch

selection

@: Mode selector switch ...... P

®:

Auto-idle switch .......... OFF

f) Start and run the engine at loh" idle and read the engine speed.

Unloaded fast idle (P mode)

Switch selection

@ �lode selector switch ........... P

@ Auto-idle witch ............... OFF

f) Start and run the engine at fast idle and read the engine speed.

Unloaded fast idle (E mode)

Switch selection

@Mode selector switch ........... E

@ Auto-idle switch ............... OFF

f) Start and run the engine at fast idle and read the engine speed.

[!] Auto-idle condition engine speed 8

Switch selection

@ Mode selector switch ........... P

@ Auto-idle switch ............... O�

f) Start and run the engine at fast idle. @) Hold the bucket lever to the position roll-in and reset it to the neutral

position.

After about four seconds, read the

engine speed when it is automatically decreased.

TS18-3A-2

TROUBLESHOOTING

TS18-3A-3

-------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST � System pressure relief condition engine speed.

0 Switch

selection

Mode selector switch ............ P

Auto-idle switch ................ OFF

fj Start and run the engine at fast idle. @Hold the bucket lever and arm lever to

the roll-in, and read the engine speed

when the system pressure is relieved.

(3) Judgement

Engine speed EX270

Unloaded low idle Unloaded fast idle Auto-idle condition

Standard Recommended to service Limit of use p mode

E mode

800:i:so

2250±50

1910±100

1400±100

System pressure relief conditio1 2170±50

EX300

Unloaded low idle Unloaded fast idle Auto-idle condition

ll]

Standard Recommended to service Limit of use p mode

mode

800±50

2150±50

1870±100

1400±100

System pressure relief condition 2170±50

0 There

mustn't be a hunting of more than SO rpm at the 10\v idle.

fj Be sure that auto-idling operation performs well.

2.2 COMPRESSION PRESSURE Note:

■ Judge the degree of engine output drop by measuring the cylinder compression pressure. ■ Before begining check, insure that battery is fully charged, valve clearance is correct and glow plugs are is

thoroughly cleaned.

(1) Measurement preparation

0 Make

sure that the engine is not warmed up.

fj Remove all of the glow plugs, return pipe and fuel injection piping.

@Attach a gauge and adapter to the glow plug mounting hole.

TS18-3A-4

TROUBLESHOOTING -------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST

(2) Measurement

0Run the engine and measure the compre ssion pressure for each cylinder.

@ Measure compression pressure three

times for each cylinder, and read the values higher in stability.

(3) Judgement

EX300 Compression pressure

EX270 Compression pressure Important:

Unit: Kgf/cm 2 (MP a)/ rpm

Standar d

33~36(3.2~3.5)/280

Recommended to service

Limit of use

30�33(2.9~3.2)/200

The maximum difference between the highest reading and lowest reading must not be more than 2 2 kgf/cm (196 Kpa).

3. TRAVEL PERFORMANCE MEASUREMENT---------------3.1 TRAVEL SPEED Note: ■ Judge the global performance of the hydraulic pump to the travel motor comprising the travelling system by measuring the time required for 20m running. ■ The measurement should be made for each high and low speed of the system. ■ Adjust the tension of the each side track links so that they are equal each other.

(1) Measurement preparation

0 Set

a straight forward 20m running course on flat, solid ground, and draw

a base line for each starting point and end point.

in the front and in the rear.

@ The front posture for the arm and bucket should be set to the roll-in.

The

bucket should be held at 0.3 or O.Sm

above the ground.

20m

Allow 3 to Sm approach

TROUBLESHOOTING

TS18-3A-5

-------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST

(2) Measurement

0 The

measurement should be made for each high and low speed of the system.

The switch selection is as follm,s:

Low

speed

Mode selector switch Auto-idle S\,itch Travel Z-speed switch OFF

High speed

LOW

OFF

HIGH

f) Place the system 1n the approach position, set the engine control lever to the fast-idle position and operate the each travel levers at full

stroke. C) Measure the required time for the machine while it passes from the starting point to the end point.

0 After

measuring the going run. turn the superstructure by 180 ° , and make

the same measurement for a return run.

0 Perform

the measurement three times, obtain

the average value, and take it as the measurement.

(3) Judgement

Judgement (A): Applicable Serial No.

EX270: 05001 � 05377; EX300: 02001 � Model name EX270 EX300

Travel-speed

Standard

Recommended to service

High

17.5±1.0

20.4

High

17.2±1.0

Low Low

21.0±1.0 21.0±1.0

Judgement (B): Applicable Serial No. EX270: 05378 � Model name EX270

Travel-speed Low

High

24.2 24.2

20.0

Standard

Recommended to service

16.3±1.0

19.0

19.9±1.0

23.0

Unit: sec/20 m Limit of use 25.4

21. 4 25.4 21.0

Unit: sec/20 m

Limit of use �4.1

20.0

TROUBLESHOOTING

TS18-3A-6

-------EX270, EX300 EXCAVATOR PERFORMANCE TEST 3.2 TRACK-LINK REVOLUTION SPEED Note: ■ Jack up the one-side track link (either right or left is O.K), measure the time required to turn the track-link three times to judge the global performances of the hydraulic pump to the travel motor. ■ The measurement should be made for each high and low speed of the sytem. ■ Adjust the tension of the right and left track links so that they should be equal each other.

(1) Measurement preparation

0 Mark

one shoe in a track link to be

measured using cloth or chalk or the like.

f) Jack up a track to be measured.

The jacking up posture is as follows.

(2) Measurement

0 The

measurement should be made for each high and low speed of the system.

The switch selection is as follows:

Low speed

Mode selector switch Auto-idle switch Travel 2-speed switch

High speed

OFF

LOW

OFF

HIGH

@ Set the t�:1gine control lever to the fast-idle posit�on, and operate the travel lever to be measured at full stroke.

@After the track-link speed has made uniform rotation, measure the time required to turn the shoe mark three times.

0 Measure

the right and left track revolution each in fon�·ard and reverse

operations.

0 Make

measurement three times, obtain the average value and take it as the

measurement. (3) Judgement

Judgement (A): Applicable Serial No.

EX270: 05001 � 05377; EX300: 02001 � Model name

Travel-speed

Standard

Recommended to service

Limit of use

High

24.0±1.0

27.5

28.9

Low

EX270

Low

EX300

High

30. 0±1.0

29.0±1.0 24.0±1.0

Judgement (B): Applicable Serial No.

EX270: 05378 � Model name EX270

Unit: Sec/3-turn

34.1

33.0

35.8 34.7

28.9

27.5

Unit: Sec/3-turn

Travel-speed

Standard

Recommended to service

Limit of use

High

22.6±1.0

26.0

27 .3

Low

27.9±1.0

31. 8

33.4

TS18-3A-7

TROUBLESHOOTING

-------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST 3.3 STRAIGHT TRAVELLING TEST ------------------------- Note: ■ Judge the right and left balance of the travel driving system by the track trace running 20m on flat, solid ground. ■ The measurement should be made for low and high speeds of the system. ■ Adjust the tension of the right and left tracks so that they are equal to each other. ■ On concrete ground, bending tends to be decreased.

(1) Measurement preparation 0Take a running course of about 30m on flat, solid ground and Sm in front and in the rear should be taken as an approach.

f)For the front posture, the arm and bucket should be set to the roll-in, and hold the bucket 0.3 to O.Sm above the ground.

30m

APPROACH (ABOUT 5 m)

(2) �leasurement

0 The

measurement should be made for the high and low speeds of the system.

The switch selection is as follows:

Low speed

High speed

Mode selector s1,itch

Auto-idle s1,itch

Travel 2-speed switch

OFF

HIGH

p p

OFF

LOW

f)Set the machine to the approach position, set the engine control lever to

the fast-idle position and operate the right and left travel levers at full stroke.

8 After

running is completed, measure a 20m straight line with regard to the

trace, and measure the maximum distance between the chord (20m straight

line) and the arc (running trace).

0After measuring the going run, turn the superstructure by 180 ° , and make the same measurement for the return run.

0 Make

the measurement three times, obtain the average value, and take it

as the measurement.

TROUBLESHOOTING

TS18-3A-8

-------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST

Unit:mm/20m

(3) Judgement

Model name Trave 1- speed EX270 EX300

Low

High

Standard

Less than 200

Recommended to service Limit of use

Less than 200

220

230 230

3.4 PARKING BRAKE TEST Note: ■ Determine the function of the parking brake at a specified slope by measuring time lag after operating the travel ling stop of the levers until the activation of the brake.

(1) Measurement preparation

0 The

slope to be measured should have a

gradient of 1/5. and the road surface

must be flat.

8 �lark

a white line to the outer coyer of

the travel reduction device.

8 For

the front posture, set the arm and

bucket to the roll-in, and hold the

bucket 0.3 to 0.Sm above the ground

surface_

TROUBLESHOOTING

TS18-3A-9

-.------EX 270, EX300 EXCAVATOR PERFORMANCE TEST

(2) Measurement Note:

The measurement is made at a high-speed travelling condition. The switch selection is as follows.

�lode selector si-·i tch

Auto-idling S\vi tch

Travel 2-speed switch

HIGH

OFF

[2] Time lag measurement until the activation of the parking brake_ 0 Climb

the slope and set the trave 1 control lever to the neutral position.

f) �leasure the movement (rotation) of the mark on the cover of the travel

motor reduction device when the lever is set to the neutral position and the machine body has stopped.

When the machine body has stopped

Measure the movement

When the mark goes to the top, set the travel lever to the neutral position

(3) .Judgement

�lode 1 name

Note:

Unit: turn

Limit of use

Less than 1/6

The "1/6 rotation" of the mark of the travel reduction device cover is replaced by the following dimentions: When taking the radius of the drive sprocket including the track link as R, 1/6 of the outer circumference length of the drive sprocket is L = 1/6 x 21rR�Rand approximately equal to the radius of the drive sprocket. Therefore, it suffices to mark the shoe, measure the amount of movement of the rr.ark and to compare that amount with the radius of the drive sprocket.

TROUBLESHOOTING

TS18-3A-10

-------EX270, EX300 EXCAVATOR PERFORMANCE TEST 4. SWING PERFORMANCE MEASUREMENT 4.1 SWING SPEED Note: ■ Judge the global performance of the hydraulic pump and swing motor comprising the swing driving system by measuring the time required to turn the superstructure three times. ■ Check the swing pinion gear and swing bearing for greasing. ■ Do not measure the swing speed on a slope.

(1) Measurement preparation

For the front posture, set the arm to the

roll-out and bucket to the roll-in and

hold the bucket about lm above the ground

surface.

The bucket should be unloaded.

(2) Measurement

0 Switch

selection

Mode selector switch Auto-idle switch

p OFF

f)Set the engine control lever to the fast-idle position and operate the swing lever at full stroke.

8 After

attain of uniform swinging, measure the time required to turn the

superstructure three times.

0 Measure

each swinging at the right and left sides.

C)Make measurement three times, obtain the average value, and take it as the measurement.

(3) Judgement

Model name EX270

EX300

llnit:sec/3 turns

Standard

Recommended to service

Limit of use

15.0±1.0

17 ._6

18.5

15.0±1.0

17.6

18.5

TS18-3A-11

TROUBLESHOOTING

CE TEST -------EX 270, EX 300 EXCAVATOR PERFORMAN 4_2 COASTING AT A TIME OF SWING STOP NoM: ° rate until the full stop of the superstructure using ■ At time of 180 full-speed swinging stop, measure the coasting the swing brake valve performance. the outer circumferential dimension of the swing bearing to judge . greasing for bearing ■ Check the swing pinion gear and swing ■ Do not measure the coasting rate at a slope.

(I) Measurement preparation

0 For

the front posture, set the arm to

the roll-out and the bucket to the roll-in.

Hold the bucket Im above the

ground surface. unloaded.

8 Attach

The bucket should be

0 .

the identification mark to the

outer circumference of the swing bear

ing (superstructure side) and the track frame using tape.

8 Attach

the swing bearing mark and the

track frame mark at a position separated

180

( 2) Measurement

0 Switch

IDENTIFICATION MARK

selection

Mode selector switch .Auto-idle switch

OFF

@Set the engine control lever to the fast-idle position and operate the swing control lever at full stroke.

8 When

turning the superstructure by

180

and matching the mark of the swing

bearing with that of the track frame, return the swing control lever to the neutral position.

0After stopping the superstructure measure the slipage between the marks of the

swing bearing and track frame by the

length of the arc of the outer circum ference of the swing bearing.

@1=�

MEASURE THE LENGTH

TRACK FRAME'S MARK

SWING BEARIN'S MARK

TROUBLESHOOTING

TS18-3A-12

-------EX 270, EX 300

0 Make

EXCAVATOR PERFORMANCE TEST-------

measurement for each swinging at the right and left sides.

@�take measurement three times, ohtain the average value, and take it as the measurement.

(3) Judgement Model name EX270

EX300

Standard Less than 1200

Recommended to service

Less than 1600

1320

1760

Unit: mm

Limit of use 1390 1850

4.3 ABRASION (PLAY) AMOUNT OF THE SWING BEARING Note: ■ Measure the degree of abrasion for the swing bearing race surface and ball by the opening amount of the innerrace and outer-race. ■ Make sure that the mounting bolt for the swing bearing has been tightened with a specified torque. ■ Check the swing bearing for greasing and abnormal noises during swinging and smoothness of swinting. ■ Care must taken to maintain safety during measurement.

(1) Measurement preparation

0Attach a dial gauge to the support such as a magnetic hase and fix it to the center of the track frame upper surface at the front idler side.

@The direction of the superstructure is the same as that of the travelling direction of the track frame.

@Make the measuring element of the dial gauge 1n contact 1,ith the lower surface of the swing hearing outer surface.

TS18-3A-13

TROUBLESHOOTING

------- EX 270, EX 300 EXCAVATOR PERFORMANCE TEST--------

( 2) �leasurement

0 Set

the arm to the roll-out and the

bucket to the roll-in, hold the bottom

face of the bucket to the same height of boom foot pin, and read the

indicated value of the dial gauge (hl).

@Jack up the front idler by about 50cm and read the indicated value (h�) of

the dial gauge.

@ Determine the opening amount (H) for the swing bearing from the two

indicated values.

H = h2 - h1 (3) Judgement

Model name EX270

EX300

Standard

Less than 1.3 Less than 1. 4

Limit of use 4.3

4.7

SAME HEIGHT

(h 1) MEASUREMENT

(h 2) MEASUREMENT

Unit: mm

TS18-3A-14

TROUBLESHOOTING

-------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST------5.

FRONT-END ATTACHMENT-- ------- -------------

5.1 WORKING TIME OF HYDRAULIC CYLINDER Note: ■ Measure the operating time for each boom, arm and bucket cylinder in the standard front state (standard arm, standard hoe-bucket). ■ Each circuit for lowering the boom cylinder (at the rod side). extending the arm cylinder (at the rod side) and extending the bucket cylinder (at the rod side) throttles the return oil using the spool of the control valve, contributing toward a slow-return function.

(1) Measurement

0 Si,·itch

selection

Mode selector Sh'itch

Auto-idle si,i tch

OFF

f) Set the engine control lever to the fast idle.

@ Each measuring posture and operation is as fol101,s:

Q] Boom cylinder measurement 0 Set

the arm rol1-out and the bucket to

the roll-in, and ground the bucket.

However, it must be unloaded.

f) Operate the boom control lever at full stroke and measure the required time for each raise of lower movement of

the boom.

ll} Arm cy 1inder measurement 0 When

setting the bucket rol 1-out and

the center of the arm vertically with

the ground, adjust the boom height so that the interval between the bucket

bottom and the ground surface can be set to about O.Sm.

0.5m

TROUBLESHOOTING

TS18-3A-15 EX 270, EX 300 EXCAVATOR PERFORMANCE TEST--------

f) Operate the arm control lever at ful 1 stroke and measure the time required

for each roll-in and roll-out setting of the arm_

Bucket cylinder measurement

0Adjust each b oom and arm cylinder so that the center of the full stroke

operation of the bucket is vertical

set.

f) Operate the bucket control lever at full stroke and measure the time

required for each roll-in and roll-out

setting of the bucket_

Note: Make the measurement three times, obtain the average value, and take it as the measurement.

(2) Judgement Model

llnit: sec. I tern

name

EX270 Standard Limit of use

EX300 Standard

Limit of use

Boom cylinder

Arm cylinder

Bucket cylinder

Roll-in Roll-out Roll-in Roll-out 3.4±0.3 2.9±0.3 4.3±0.3 3.3±0.3 4.3±0.3 2.8±0.3 3.6 3.7 4.3 5.3 5.3 4.2 Raise

Laher

3.3±0.3 2.6±0.3 4.8±0.4 3.5±0.4 4.2

3.3

6.0

4.5

4.7±0.4 2.9±0.3 5.9

3.7

TROUBLESHOOTING

TS18-3A-16

------- EX 270, EX 300 EXCAVATOR PERFORMANCE TEST-------5.2 CREEPING OF HYDRAULIC CYLINDER Note: ■ In the standard front state (standard arm, standard hoe bucket), apply a reference load into the bucket, judge the internal leakage from boom, arm, bucket cylinder and control valve by the creeping amount of the cylinder rod. ■ When measuring the amount following cylinder replacement, air may be settled inside the cylinder. Before measurement, operate the cylinder at full stroke.

(1) Measurement preparation

0 Fi11

the bucket with sand or a \\'eight.

be obtained by the following formula;

The \,·eight of the \,'eight (W) can

W = standard bucket capacity x sand specific gravity (1.5) In the case of EX270 ....... - ... -lSOOkg

In the case of EX300 ............. 1800kg @For the front posture, set the arm to the roll-out and the bucket to the roll-in.

foot pin.

Hold the arm tip pin at the same height as that of the boom

However, extend the arm cylinder 20 to 50mm from the stroke end,

and retract the bucket cylinder by 20 to 50mm from the stroke end. EXTENDED AMOUNT RETRACTED AMOUNT

( 2)

\leas urcme nt

0 Stop

the engine.

RETRACTED AMOUNT

SAME HEIGHT

@ After 5 minutes, measure the retraction rate of hoom cylinder, extension rate of arm cylinder and retraction rate of bucket cylinder.

( 3) Judgement

Model name EX270

EX300

Boom cylinder

Arm cylinder

Bucket cylinder Boom cylinder

Arm cy1inder

Bucket cylinder

llnit:mm/5 minutes

Recommended to service

Limit of use

Less than 40

Less than 30

Less than 20

Less than 20 Less than 30 Less than 15

23 35 17

TS18-3A-17

TROUBLESHOOTING

------- EX 270, EX 300 EXCAVATOR PERFORMANCE TEST------5.3 CREEPING OF FRONT-END ATTACHMENT Note: ■ When applying the standard load to the bucket in the standard front state (standard arm, standard hoe bucket), measure the amount of creeping for the entire front-end attachment produced by the internal leakage of each boom, arm, bucket cylinder and the control valve using the bucket section. ■ When measuring the amount following cylinder replacement, air may be settled inside the cylinder. Before measurement, operate the cylinder at full stroke.

( 1) l\leasurement preparation

0 Fi 11

the bucket \,ith sand or a weight.

The weight of the weight (W) can

be obtained by the following formula. W = standard bucket capacity x sand specific gravity (1.5) In the case of EX270 .................. 1500kg In the case of EX300 ................. -1800kg

8 For

the front posture, set the arm to the roll-out and the bucket to the

roll-in. pin.

Hold the arm tip pin at the same height as that of the boom foot

However, extend the arm cylinder 20 to 50mm from the stroke end, and

retract the bucket cylinder by 20 to Stlmm from the stroke end.

SAME HEIGHT

MEASURE THE CREAPING AMOUNT�

(2) Measurement

0 Stop

the engine

@After 5 minutes, measure the amount of creeping at the bucket bottom. llnit:mm/5 minutes Model name

Standard

Limit of use

EX270

Less than 200

230

EX300

Less than 300

350

TS18-3A-18

TROUBLESHOOTING

------- EX 270, EX 300 EXCAVATOR PERFORMANCE TEST ------6. CONTROL LEVER PERFORMANCE MEASUREMENT 6.1 LEVER OPERATING FORCE Note: ■ Check each control lever for play and function and measure the operating force. ■ For the control lever of the front-end attachment, measure the maximum operating force in the system pressure released condition. ■ Measure the operating forces of each control lever under the grip.

(1) Measurement

[!] Switch selection

Mode selector s1,itch p

Boom, arm and bucket control levers

0 Set

the engine control lever to the

fast idle position.

@When raise and 101,er the boom and sett ing the �rm and bucket respectively to

the roll-out and roll-in, measure the maximum operating force in the system pressure released condition.

Swing control lever

0 Set

the engine control lever to the

fast idle position.

f) Measure the maximum operating force during right and left swinging.

I!] Travel control lever 0 Set

the engine control lever to the

fast idle position.

@Jack up the track at the measured side,

and measure the maximum operating force

during forward and reverse operations. (For the jack-up posture, see 2.2,

track-link revolution speed.)

A.uto-jdle swjtch OFF

TROUBLESHOOTING

TS18-3A-19

------- EX 270, EX 300 EXCAVATOR PERFORMANCE TEST -------

I!}

Engine control lever

0 Measure

the maximum operating force

while the engine control lever is set

from the slow-idle position to the fast-idle position.

f) Measure the maximum operating force

while the engine control lever is set

from the fast-idle position to the

slow-idle position.

(2) Judgement Judgement (A) Applicable Serial No.

EX270: 05001 � 05375; EX300: 02001 � 02360 Boom control lever

Standard

Less than 2 . ()

Arm control lever

Less than 1. 5

Sh·ing control lever

Less than 2.n

Bucket control lever Travel control lever

Engine control lever

to fast-idle

to s lm,- idle

Unit: kgf Limit of use

Less than 1. 5

Less than �, . :,

Less than L1 . 0

Judgement (B) Applicable Serial No.

EX270: 05376 �; EX300: 02361 �

Standard

Boom control lever

Less than 2.0

Bucket control lever

Less than 1.5

Arm control lever

Less than 1.5

Swing control lever

Less than 2.0

Travel control lever Engine control lever

to fast-idle

to slow-idle

Less than 2.5

Less than 5.0

Unit: kgf

Limit of use

TS18-3A-20

TROUBLESHOOTING

EX 270, EX 300 EXCAVATOR PERFORMANCE TEST 6.2

LEVER STROKE

Note:

■ Check each control lever for play and operating state and measure the stroke. ■ Measure the stroke of each control lever at the tip center of the grip. ■ When the lever is loosened while it is set to the neutral position, measure the stroke while distributing the

positions.

( 1) t-leasurement

Stop the engine.

[!J Boom,

levers

arm, bucket, and swing and travel

0 During

the operation of each control

lever, measure the stroke while the

lever is set to the neutral position

at the stroke end and at the tip center

of the grip.

f) Measure the straight dimension of the lever stroke.

ll} Engine control lever 0 Measure

the lever stroke 1-,hile the

engine control lever is switched from

the slow-idle position to the fast-idle

position.

f) Measure the straight dimension of the lever stroke.

(2) Judgement Judgement (A) Applicable Serial �o.

llni t: mm

EX270: 05001 �; EX300: 02001 � 02360 Boom control lever

Arm control lever

Bucket control lever

S1,i ng control lever

Trave 1 control lever

EX270 Engine control lever EX300 Engine control lever

Standard 100± l0

90± 10 90± 10

1()0± 10

95± 10

n_,

120

130

Limit of use

TROUBLESHOOTING

TS18-3A-21

-------EX 270, EX 300 EXCAVATOR PERFORMANCE TEST--------

Judgement (B) Applicable Serial No. EX300: 02361

llnit: mm

Boom control lever

Arm control lever

Bucket control lever Shing control lever

Travc l control lever

Engine control lever

Standard 100± 10 90± 10 90± 10 1()0±10 95± 10

120

Limit of use

TROUBLESHOOTING

TS18-4B-1

------- EX 270, EX 300

COMPONENTS PERFORMANCE TEST-------

1. INTRODUCTION-------------------------

The tolelance listed below is applied to a NE\\' machine.

For already working

machines, a certain allowance is permitted according to field condition.

Unless otherwise specified, measurements should be performed under following conditions. Engine speed

Hydraulic oil temperature

Fast idle

50±5 ° C

2. PILOT RELIEF VALVE ----------------------2.1

SPECIFICATIONS & JUDGEMENT

Engine speed Slow idle Fast idle

Standard

Unit: kgf/cm 2 (MPa)

Recommended to service

Limit of use

45±5(4.4±0.5) Max.:50(4.9) ,Min.:36(3.5) Max.:50(4.9),Min.:34(3.3) 50± 5(4. 9± 0. 5) Max. :55(5.4) ,Min. :41(4) Max. :55(5.4) ,Min. :38(3. 7)

2.2 MEASUREMENT

[2] Stop the engine.

Release the air pressure from the hydraulic tank. Connect the Oto 100 kgf/cm 2 (0 to 9.8 �lPa) pressure gauge assembly (ST-6932) to the

test port of adapter (ST-6450).

Use adapters to make the connections.

® © @

Pressure gauge: ST-6315, @ Coupling: ST-6332 Nipple: ST-6069, @ Adapter; ST-6450 Pilot filter, ® Pilot piping ST-6450

ST-6932 Pressure Gauge Ass'y Coup I ing (ST-6332)

Coupling (ST -6332)

--538---

Jto

Oil Pressure Gauge (ST-6315)

TS18-4B-2

TROUBLESHOOTING

------- EX 270, EX 300 COMPONENTS PERFORMANCE TEST -------

Turn mode switch to P mode and auto-idling switch "OFF".

Warm up the hydraulic oil temperature to

50�5 ° C by operating the machine.

Check oil leakage from the connections.

@: @:

[!]

Auto-idling switch Mode switch

Run the engine at sloh idle. Read the pressure gauge.

The pressure

indication must be 45±5 kgf/cm 2 ( 4. 4± 0. 5 �!Pa) .

I!}

Run the engine at fast idle.

Read the pressure gauge.

The pressure

indication must be 50±5 kgf/cm 2 ( 4 . 9± 0 . 5 MP a) .

I!]

If necessary, adjust the pilot relief

valve.

Add adjustment shim to increase the pre

ssure setting or remove shim to decrease

the pressure setting.

Note: Refer to Section 4-SOV9 for shim of pilot valve servicing procedure.

TS18-4B-3

TROUBLESHOOTING

-------EX 270, EX 300 COMPONENTS PERFORMANCE TEST-------3.

MAIN RELIEF VALVE ------------------------

3.1 SPECIFICATION & JUDGEMENT Unit : kgf/cm2 (MPa)

EX270

Standard

Recommended to service

Limit of use

For Front Use

290±10 (28.4±1)

Max. 300 (29.4) Min. 252 (24.7)

Max. 300 (29.4) Min. 240 (23.5)

For Travel Use (S/No. 05001 ~05377)

340±10 (33.3±1)

Max. 350 (34.3) Min. 297 (26.7)

Max. 350 (34.3) Min. 282 (27.7)

For Travel Use (S/No. 05378~)

350±10 (34.3±1)

Max. 360 (35.3) Min. 306 (30.0)

Max. 360 (35.3) Min. 291 (28.5)

Unit : kgf/cm2 (MPa)

Standard

Recommended to service

Limit of use

For Front Use

290±10 (28.4±1)

Max. 300 (29.4) Min. 252 (24.7)

Max. 300 (29.4) Min. 240 (23.5)

For Travel Use

355±10 (34.8±1)

Max. 365 (35.8) Min. 311 (30.5)

Max. 365 (35.8) Min. 295 (28.9)

EX300

3.2 MEASUREMENT

[I} Stop the engine. Release the air pressure from the hydrau

lic tank.

Connect the 0 to 400 kgf/cm 2 (0 to -l0 MPa)

pressure gauge assembly (ST-69j-l) to the front pump test port. Note:

Use nipples to make the connections. @ Pressure gauge: ST-6308 @ Coupling: ST-6332 Nipple: ST-6069

ST-6934 Pressure Gauge Ass'y

-� ·

Hose (ST -6324)

Coupling (ST-6332)

f.1.rl

Oil Pressure Gauge IST-6308)

TS18-4B-4

TAOUBLESHOOTING

------- EX 270, EX 300 COMPONENTSPERFORMANCE TEST--------

[I}

Turn mode switch to "P" mode and auto

idling sh·itch "OFF".

Start and run the engine at fast idle.

Check oil leakage from the connections.

@: @:

[!]

Auto-idling switch Mode switch

� For Front use�

Operate and hold each dig function in the

actuated position, one at a time. Read the pressure gauge.

The pressure

indication must be 290±10 kgf/cm 2 (28.4 ±1 MPa) for al 1 six dig functions.

Note: If some (not all) pressure indications are low, TEST THE OVERLOAD RELIEF VALVES.

� For Travel use�

� Set the front attachment as shm,·n in the photo, and grasp earth by the bucket securely.

Start and run the engine at fast idle.

� Operate and hold either left or right

travel control lever full stroke sloKly. Read the pressure gauge.

The pressure

indication must be specified value for

travel functions.

Note: If necessary, adjust the main relief valve. Keep the test equipment installed if you are going to test another relief valves.

TROUBLESHOOTING

TS18-4B-5

--------EX 270, EX 300 COMPONENTS PERFORMANCE TEST-------3.3 ADJUSTMENT

fJ:)

>lain relief valves are located 1n control valve as sho\\·n.

®:

Front use Travel use

00 Loosen nut @(Front use only). Loosen lock nut @. @ Turn adjusting screw @(Travel use) or adjuster@ (Front use).

For front use After adjusting, tighten nut@to 8-,o9kgf.m (58 to 65 ft.lbs), and tighten nut@ to 5�6 kgf.m (36 to 43.5 ft.lbs). For Travel use After adjusting, tig hten the lock nut@ to 2.8

3.2 kgf.m (20.2 to23.l

ft.lbs) Turn

Note:

2 Pressure variation;kgf/cm (�Pa)

181(17.8)

3/4

136 (13. 3)

1/2

90( 8. 8)

1/ 4

45 ( .-1-. 4)

Make sure its relief set pressure again after adjusting.

TROUBLESHOOTING

TSlB-48-6

------- EX 270, EX 300 COMPONENTS PERFORMANCE TEST ------4. OVERLOAD RELIEF VALVE 4.1 SPECIFICATIONS & JUDGEMENT

Component standard 30o + l0 (29.4 + 8·98) 0

Unit: kgf/cm 2 (MPa)

Recomended to service Max.: 310 (30.4) Min.: *

*· Not less than main relief pressure 4.2 MEASUREMENT

[!] 0 8

Stop the engine. Release the air pres-

sure from the hydraulic tank.

Connect the Oto 400 kgf/cm 2 (0 to 40

MPa) pressure gauge to each pump test

ports.

@ Turn mode switch to "P" mode and auto idling switch "OFF".

engine at fast idle.

Start and run the

Check oil leakage from the connections.

Turn adjusting screw of the front use main

relief valve, approximately 1/4 turn clock wise to increase the pressure setting of the front use main relief valve.

Note: This is to set the front-line and swing-line pressure above overload relief valve setting pressure.

ll] � For Front use►

Operate and hold each dig function in the actuated position, one at a time.

Read the pressure gauge, the pressure indication must be 300 + 50 kgf/cm� (29.4 + g.98

MPa) for all six dig functions. Note:

If necessary, adjust the overload relief valves.

� For Swing use►

Turn adjustment screw of the swing cross-

over relief valve approximately 1/2 turn

clockwise to increase swing crossover relief valve pressure setting as 326kgf/cm 2 (32MPa).

®:

Swing crossover relief valve

TS18-4B-7

TROUBLESHOOTING

EX 270, EX 300 COMPONENTS PERFORMANCE TEST -------

f!]

Set the front attachment as shoh"n in the photo. Start and run the engine at fast idle.

� Operate and hold

Shi ng

contro 1 le\·er ful1

stroke slmdy.

Read the pressure gauge, the pressure 2 indication must be 3oo + b0 kgf/cm

29.4 + 8·98 >!Pa) for sh·ing function.

If necessary, adjust the swing overload relief valve.

Note:

4.3 ADJUSTMENT

12}

Loosen lock nut.

f) Turn a·djusting sere\\.

After adj us ting, tighten the lock nut to 2_8 "v 3.2 kgfm (20.2 u �3.1 ft. lhs1.

Turn

Pressure variation kgf/cm 2 (MPa)

160 (15. 7)

1/2

80 ( 7.9)

1/4

40 ( 3.9)

1/8

20 ( 2

ADJUSTING SCREW

) INCREASE

Note:

DECREASE

Make sure its relief set pressure again after adjusting.

Important:

After test'and adjustment of the overload relief valves, the swing crossover relief valve and main relief valve must be adjusted to its normal setting. If not, hydraulic components can be damaged.

TROUBLE SHOOT I NG

TS18-4B-8

------- EX 270, EX 300 COMPONENTS PEROFRMANCE TEST -------5. SWING CROSSOVER RELIEF VALVE ------------------5.1 SPECIFICATIONS & JUDGEMENT Unit: kgf/cm 2 (MPa) Applicable Serial No.

Model

Standard

Recommended to service

Limit of use

270 ± 10 (26.5 ± 1)

Max. 280 (27.5) Min. 234 (21.1)

Max. 280 (27.5) Min. 222 (21.8)

02001 ~02488 02492~02579

270 ± 10 (26.5 ± 1)

Max. 280 (27.5) Min. 234 (21.1)

Max. 280 (27.5) Min. 222 (21.8)

02489~02491 02580~

285 ± 10 (27.9 ± 1)

Max. 295 (28.9) Min. 248 (24.3)

Max. 295 (28.9) Min. 236 (23.1)

EX270

EX300

5.2 MEASUREMENT

Q] 0

Stop the engine.

Release the air pressure

from the hydraulic tank.

@ Connect the O to 400 kgf/cm 2 (0

pressure gauge assembly (ST-69341 to the

rear pump test port.

Turn mode swith to "P" mode and auto

idling switch "OFF".

engine at fast idle.

fl] ll] [!]

Start and run the

Check oil leakage from the connections.

I'"

Set the front attachment as shown in the

photo of TS18-4-7.

Start and run the engine at fast idle.

Operate and hold swing control le\·er ful 1

stroke slowly.

Read the pressure gauge, the pressure indi-

cation must be specified value for swing functions.

Note: If necessary, adjust the swing crossover relief valve.

5.3 ADJUSTMENT

Q] 0

Loosen lock nut

@ Turn adjusting screi..;.

After adjusting, tighten the lock nut

to 1.5±0.15 kgf.m

Turn 1/4

(10.9=1.l ft.lbs).

Pressure variation kgf/ cm 2 (�!Pa) 28 (2.8)

Note: Make sure its relief set pressure again after adjusting.

/ ,. \

·.'-··/

TROUBLESHOOTING

TS18-4B-9

-------EX 270, EX 300 COMPONENTS PERFORMANCE TEST-------6.

TRAVEL CROSSOVER RELIEF VALVE

6.1 SPECIFICATIONS & JUDGEMENT Unit : kgf/c m2 (MPa) Model

Standard

Recom mended to service

Limit of use

EX270, EX300

355 + 100 (34.8 + 10)

Max. 365 (35.8) Min. 320 (31.4)

Max. 365 (35.8) Min. 304 (29.8)

o.2 MEASUREMENT

Q] 0

Stop the engine and release the air pressure from the hydraulic tank.

@ Connect 2 (two) 0 to 400 kgf/cm = (0 to

40 MPa) pressure gauges to each pump

test ports.

Note: Use nipples to make the connections. Pressure gauge: ST-6308 @ Coupling: ST-6332 Nipple: ST 6069

® ©

Turn adjusting sere\\ of the tra\·el use main relief ,:ahc

2) approximately l/3 turn

clockh·ise to increase the pressure setting of the tra\·cl use main relief \·al\·e.

[l]

Set the front attachment and grasp earth by the bucket securely as shown in the photo of TSlS-4-4 \o.5.

Start and nm the en�inc at fast iJlc.

and hold either left or right Onerate ' travel control lever ful 1 stroke sl01dy. '

Read the pressure gauge.

The pressure

indication must be specified value for travel function. Note: If necessary, adjust the travel crossover relief valve.

T.ROUBLESHOOTING

TS18-4B-10

------- EX 270, EX 300 COMPONENTSPERFORMANCE TEST-------6.3 ADJUSTMENT

ll}

Loosen lock nut.

RELIEF VALVE

f) Turn adjus ting screK. @ ..'\fter adjusting, tighten the lock nut

RELIEF VALVE

to 5 kgf .m (36 ft. lbs).

Turn

Pressure variation kgf/cm 2 (�1Pa I

160 (15. 7)

1/2

80 ( 7.9)

1/4

40 ( 3.9)

1/8

)

20 ( 2

Note: The top relief valve is for forward operation. The bottom relief valve is for reverse operation. Make sure its relief set pressure again after adjusting. Important:

After repair or adjustment of the travel crossover relief valve, the travel use main relief valve must be adjusted to its normal setting. If not, hy draulic components can be damaged.

ADJUSTING SCREW

INCREASE

QECREASE

TROUBLESHOOTING

TS18-4B-11

------- EX 270, EX 300 COMPONENTS PERFORMANCE TEST------7. MAIN HYDRAULIC PUMP 7.1 SPECIFICATIONS

EX270 P-Q LINE STANDARD

Note: Unit test standard data by hydraulic test stand.

[I] ----------------250---77

£ C:

Test Condit ion: I}) Oi1 Temperature: 50±5 °C 1992 rpm � Pump Speed Standard: ®: Qmax.1=262±3 L/min. at SO kgf/cm 2 ®: Qmax.2=252±3 L/min. at SO kgf/cm 2 '.g: 240±6 L/min. at 120 kgf/cm 2 (ID: 179±6 L/min. at 160 kgf/cm 2 @: 90±6 L/min. at 260 kgf/cm 2 ®: 60±6 L/min. at 325 kgf/cm 2

200

1z w � w

� 15

...J Cl. C/l C Cl. � ::::> Cl.

100

0 250

200

EX300 P-Q LINE STANDARD

150

100

. �\

200

DELIVERY PRESSURE (kgf/cm 2 )

1z w � w

� 150

...J Cl. C/l C Cl. � ::::> Cl.

250

300

: I

Test Cortdition: (!)Oil Temperature: SO±S ° C 1897 rpm G) Pump Speed Standard: ®: Qmax.1=273±3 L/min. at SO kgf/cm 2 Qmax.2=260±3 L/min. at SO kgf/cm 2 : 250±6 L/min. at 150 kgf/cm 2 : 187±6 L/min. at 200 kgf/cm 2 : 105±6 L/min. at 300 kgf/cm 2 ®: 75±6 L/min. at 350 kgf/cm 2

100 70

100

150

200

DELIVERY PRESSURE (kgf/cm 2 )

250

300

350

TROUBLESHOOTING

TS18-4B-12

------- EX 270, EX 300 COMPONENTS PERFORMANCE TEST------7.2 MEASUREMENT 7.2.1 FRONT PUMP

[I}

Stop the engine. Release the air pressure from the hydrau lic tank. Note: Close the cap after the air pressure has been released.

[I}

Install a vaccum pump on the hydraulic tank and operate it while the test piping is setting. Note: Dismount the vacuum pump after the test piping has been set.

(&• : ST-6444

12]

Disconnect front main pump outlet hose at pump discharge port and the plug from front main pump pressure measuring port. Install FLO� METER and pressure gauge assembly. Note: Use fittings from the test kits to make the connections.

® Flow meter @ Flow meter inlet hose © Flow meter outlet hose © Pump outlet hose © Split flange (make use of the machine) ®Bolt (4 pcs.,make use of the machine) @ Pipe (ST-6128) (8) Adapter (ST-6118) CD Bolt (4 pcs.,M341240) (ST-6409) Q) 0-ring (ST-6385) ,19 Split flange (2 pcs.) (ST-6130) CU Pressure gauge (ST-6308) ·� Coupling (ST-6332) ® Nipple (ST-6069)

d," \H"· \

'C /

TROUBLESHOOTING

TS18-4B-13

-------EX 270, EX 300 COMPONENTS PERFORMANCE TEST-------

� 0 Disconnect

FRONT MAIN PUMP CONTROL PIPING

@at regulator and install plug (ST-6211) to the piping.

fl Install

test piping@ (ST-6327) to the

regulator for receiving drain oil in the vessel. Note: This causes the pump displacement to keep upto the maximum value even If each control lever is not operated. :'/lb U\F

�.S ( 8)

ST-6211

7�

-·-

-· .,

I!] 0 Disconnect each main pump control piping (g,@ from regulator and install plugs (ST-6231) to rear pump's regulator.

fl Install

test piping@ (ST-6339) to front

pump's regulator between piping

'g port

and piping� port.

@] 0

Open the hydraulic tank cap.

f) Disconnect the vacuum pump.

@ Loosen plug@and fill up oil until oil

comes out of the port. Close the cap.

Note: This will remove all air from the pump casing. If not, hydraulic pumps can be damaged.

[lJ

Install a sensor @ of tachometer onto the injection pump piping

TROUBLESHOOTING

TS18-4B-14

------- EX 270, EX 300 COMPONENTSPERFORMANCE TEST-------

I!} 0

Turn mode switch @ to P mode and auto

idling switch "OFF".

f) Start and run the engine at fast idle.

Check oil leakage from the connections.

Important:

•a

Before starting the engine be sure the flow meter loading valve is open until it stops.

II) = Load pressure setting =

EX270: 120,180 kgf/cm 2

EX300: 160,220 kgf/cm 2

� 0Slmdy close portable tester loading

valve @ just enough to get tl1c al,o\·c

load pressure on pressure gauge.

If necessary, adjust engine rpm.

f) Read the pump flow indications on flow meter and engine rpm.

7 .2.2 REAR SIDE PUMP

Prepare with the same manner in the FRONT

side PUMP TEST steps IT)

, [3_], �, [z} and @J

Ci] Disconnect rear side main pump outlet hose @ at pump discharge ports and the plug

from main pump pressure measuring port. Ins tall FLOW METER @ and gauge assembly.

pressure

Use fittings from the test kits to make the connections.

Flow meter Flow meter inlet hose Flow meter outlet hose Pump outlet hose Split flange (make use of the machine) Bolt (4 pcs.,make use of the machine) Pipe (ST-6128) Adapter (ST-6118) Bolt (4 pcs.,M341240)(ST-6409) 0-ring (ST-6385) Split flange (2 pcs.)(ST-6130) Pressure gauge (ST-6308) Coupling (ST-6332) Nipple (ST-6069)

.J .,

fH\ "-.!__y'

TROUBLESHOOTING

TS18-4B-15

------- EX 270, EX 300 COMPONENTSPERFORMANCE TEST------- ..

[!)Ooisconnect REAR MAIN PUMP CONTROL PIPING

(JS1 at 1:E) to

regulator and install plug (ST-6212) the piping.

@ Install test piping

(a (ST-6327)

to the

regulator for receiving drain oil in the vessel.

Note: This causes the pump displacement to keep upto the maximum value even If each control lever is not operated.

Disconnect each main pump control piping

:C:

(Q) from regulator and instal 1 plugs :'.g,' (ST-6231) to front pump's regulator. 1

Install test piping'�' (ST-6339) to rear

pump's regulator between piping@port

and piping@port.

[!] = Load pressure setting = EX270: 120,180 kgf/cm 2

EX300: 160,220 kgf/cm 2

�QSlowly close portable tester loading valve @just enough to get the above load press ure on pressure gauge.

If necessary, adjust engine rpm.

f} Read the pump flow indication on flow meter and engine rpm.

TROUBLESHOOTING

TS18-4B-16

------- EX 270, EX 300 COMPONENTS PERFORMANCE TEST------7.3 JUDGEMENT

Convert the measured flow rate to the specified pump revolution. Np Oc=--xQ iv x Ne

Qc:Convertion flow rate (�/min)

\e:Measured engine speed (rpm)

iV:Trans�ission gear ratio (0.9487) EX270

Q: �easured flow rate (,/min)

\p:Pump speed (EX270:1992rpm,EX300:1897rpm)

Convertion flow rate

2100 1992 X Q Qc = 0.9487 x Ne =-l\e Q

Qc =

EX270 PUMP PERFORMANCE TEST Setting Test Pressure

Ne Measured Engine Speed Q

(*)

kg/cm 2 rpm

EX300

2000 1897 X Q =-- X Q e '.'Je 0.9487X :-J

Front side Pump Test 120

180

Rear side pump Test 120

180

Oil Temperature

1/min.

Measured Flow Rate

1/min.

Qc Convertion Flow Rate

1/min.

Permissible Flow Rate

271- 210 183~138 271~210 183 ~138

(*):Pressure Gauge Indications

EX300 PUMP PERFORMANCE TEST Setting Test Pressure

Ne Measured Engine Speed

(*)

rpm

160

220

Rear side Pump Test 160

220

Oil Temperature

kgf/cm 2

Front side Pump Test

1/min.

Measured Flow Rate

1/min.

Qc Convertion Flow Rate

1/min.

Permissible Flow Rate

265-206 195~148 265-206 195~148

(*):Pressure Gauge Indications IMPORTANT!!

WHEN THE CONVERTION FLOW RATE IS NOT NORMAL VALUE, THE PUMP MUST BE TESTED AGAIN BY USING HYDRAULIC TEST STAND.

TROUBLESHOOTING

TS18-4B-17

------- EX 270, EX 300 COMPONENTSPERFORMANCE TEST-------7.4 ADJUSTMENT

ADJUSTING SUBJECT

®,

1. Minimum Flow Q

Loosen lock nut and turn adjusting screw ®. Screw in 1/4 rotation, and minimum flow increases bv about 9.lcm 3/rev.

1---..... \

\ \ \ \ \

..._ ---

t::==:3•-;::._-_--_ -,-!

,(D ·:D

3. Torque Adjustment ''

(1) Do not screw in more than 2 rotation. (2) Firmly fasten the lock nut after adjustment.

Loosen lock nut @, and turn adjusting scre1, @. Screw in 1/4 rotation, and maximum flow decreases bv about 12.lcm 3/rev. ('J) Loosen. lock nut and turn adjusting screw @ . Screw in 1/4 rotation, and 110% maximum flow decrease by about 12.lcm 3/rev.

(1) Do not screw in more than 1 rotation. (2) Do not adjust for flow increasing (loose adjusting screw) (3) Firmly fasten lock nut after adjustment.

Loosen lock nut (D , and turn adjusting screw Q). Screw in 1/4 rotation, and P-Q line raise up about 15.lcm 3/rev. ·-1) Loosen lock nut ©, and turn adjusting screw ®. Screw in 1/4 rotation, P-Q line raise up about 7.6cm 3 / rev.

(1) Proceed adjustment checking load condi tion of Engine. (2) Firmly fasten lock nut after adjustment. (3) Do not screw in more than 1 rotation.

©,

REMARK

2. Maximum Flow Q

ADJUSTI\G t'-,IETHOD

TROUBLESHOOTING

TS18-4B-18

------- EX 270, EX 300 COMPONENTS PERFORMANCE TEST-------8. TRAVEL MOTOR -------------------------• Judge the travel motor condition by measuring the amount of drain oil. • Judge the travel motor performance as a whole, by referring to the results of the inspection of the travel mechanism performance (travel speed, going straight ahead, etc.), too.

8.1 SPECIFICATIONS & JUDGEMENT

Test condition

Jack up the track of the measuring side

Unit: £,/min Standard (New) 1. 3

'\,

1. 9

Limit of use 3.8

8.2 MEASUREMENT

[I}

Jack up the track of the measuring side as

sho1m.

Turn mode s\\·i tch the P mode and

auto-idling Shi tch "OFF''.

ll]

Release the air pressure from the hydrau

lic tank.

Disconnect the drain hose @ from the

return piping.

Install the plug (ST-6214)

to the piping while testing.

ST-6214

IJ]

HE\.22

Start and run the engine at fast idle.

Operate the travel lever of the measuring

side and receive the drain oil from the

drain hose into the vessel, at the same

time measure the time required for receiv ing oil.

Note: The measurement should be performed 3 times for for ward and reverse direction. Important: Duration of measurement should be over 20 seconds at least.

TS18-4B-19

TROUBLESHOOTING

-------EX 270, EX 300 COMPONENTS PERFORMANCE TEST --------

(!]

Measure the amount of hydraulic oil caught

in the vessel by means of measuring equip ment and calculate it by the following

equation.

L'IO: t: q:

L'IO = � q (£/min) t Note:

Amount of drain oil(£/min) Time required for measurement(sec.) Amount of measured drain oil(£)

If necessary, do this test again for the other travel motor. After measurement, the drain hose must be connected to the return-piping.

9. SWING MOTOR • To judge the swing motor unit performance, swing the machine with boom, arm and bucket cylinders extended fully and measure the amount of drain oil. • Before test the motor, make sure that the surroundings are free from danger.

9.1 SPECIFICATIONS & JUDGEMENTS

Test condition

While the superstructure is turning

While the superstructure is blocked

Standard ('.\e\,·)

Less than 2.0

Less than 10 Q,/min

9.2 MEASUREMENT

[I)

Set the front attachment as shm,n in the photo.

Note: Turn mode switch to P mode and auto-idling switch

"OFF".

Release the air pressure from the hydrau

lic tank.

Disconnect the drain hose @ from the

return piping.

Install the plug (ST-6214) to the piping

while testing.

11]

Start and run the engine at fast id le.

Operate and hold the swing function in the

actuated position, and receive the drain oil from the drain hose into the vessel,

at the same time measure the time required for receiving oil.

Note: The measurement should be performed 3 times for left and right swing. Important: Duration of measurement should be over 20 seconds at least.

Unit: l/min

Limit of use 4.0

x,/min

Q,/min

TS18-4B-20

TROUBLESHOOTING

-------EX 270, EX300 COMPONENTS PERFORMANCE TEST

[!}

Measure the amount of hydraulic oi 1 caught

in the vessel by means of measuring equip ment and calculate it by the following

equation.

60 = � q (Q/min) t

60: t: q:

Amount of drain oil (Q/min) Time required for measurement (sec.) Amount of measured drain oil (£)

Note: After measurement, the drain hose must be connected to the return piping.

I]]

Set the front attachment as shmm in the

photo, and grasp earth by the bucket securely.

[!]

Prepare i-·ith the same manner in this test

ll}

Operate the si-ing le\·er of the measuring

steps

[I].

side and keep to stall the swing motor.

Receive the drain oil from the drain hose

into the vessel, at the same time measure

the time required for receiving oil.

Note: The measurement should be performed 3 times for left and right swing. Important: Duration of measurement should be over 20 seconds at least.

[!) Measure the amount of hydrauiic oil caught in the vessel by means of measuring equip ment and calculate it by the folloi-ing

equation.

60 =

60 q (£/min) t

60: t: q:

Amount of drain oil (£/min) Time required for measurement (sec.) Amount of measured drain oil (Q)

Note: After measurement, the drain hose must be connected to the return piping.

TS18-5-1

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST

1. ELECTRIC CIRCUIT TEST 1.1 COMMON CIRCUIT TEST

A cut-off wire, a faulty circuit and a short-circuit are the majority of causes

of troubles on an electrical system.

They are checked mainly by measuring voltage or testing electrical continuit� Measurement of resistance or current is also effetive in special cases.

( 1) Measurement of voltage (Use your tester in the range of voltage measurement.) The power source voltage differs between a battery-fed power and an

alternator-generated power.

a. Battery-fed power source This machine uses a 24V power source consisting of two serially connected 12V batteries.

Therefore, when power is not supplied by the alternator

with the engine stopped, the tester should indicate 24V (Allowable voltage:

20 � 25V) for the power source circuit.

b. Alternator-generated power source

The tester indicates 24V immediatelv after the engine 1s st�rted because

the alternator's field coil is externally excited by poher supplied from

the batteries.

After a few seconds, the alternator will switch to self

excitation, and the tester 1,ill read 28\" (Allo1,able voltage: 26 " 30\').

(2) Continuity test (Use your tester 1n the range of rated voltage measurement.) Failure of electrical continuity is caused by a cut-off wire, a faulty

contact or a short-circuit.

a. Cut-off wire (The indicator shows co resistance.) • Parts liable to wire cut-off by melting:

Fuses, fusible linkes, bulbs,

heat plug, diodes and transistors (safety relay, regulator, motor, controller, etc.)

• Parts liable to wire cut-off:

Cables and coils (Starting motor, alternator,

relays, buzzer, solenoid valves, etc.)

b. Faulty contact (The indicator is unstable or reads co.) • Due to corrosion:

Battery terminals, connectors exposed to rain.

• Due to defective connection: receptacles

• Defect of contact surface: for sensor.

c. Short-circuit

Screw terminals, connectors, plugs and plug

Contactor for switches and relays, variable resistor

(Continuity is lost between certian parts, which are contacting

to somewhere elese.)

• Between wires:

Wire harness, congested wires

• Short-circuit inside parts:

Coils, switches, relays, etc.

TS18-5-2

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST

• Contact h'ith active hire:

Battery circuit, charge circuit, preheat cir

cuit; especially, clock circuit and emergency stop circuit ('Model EX 120)

may have an electrically active line even hhen the starter Shitch is turned

OFF.

(3) Measurement of resistance (Use your tester in the range of resistance measurement)

This machine requires the measurement of resistance to check the normal

resistance (or accurary) of the sensors for the engine coolant temperature gauge and the fuel gauge.

For the measurement procedures in each case, refer

to CHAPTER 10 "TROUBLESHOOTING". (4) Measurement of current

E lectric current is measured to find a faulty part when the batteries consume too much or there is a possibility of short-circuit.

(5) Control System Check

This machine uses an E -P control system that controls the engine and the pump at the same time. computer. 4 bolts.

The control is effected by a controler having a built-in micro

The controller is located in the control box (right) and fixed hith

The controller can be checked by using an ordinary volt-ohm meter, �hich

however, requires complicated testing procedures.

As to the checking procedures, refer to "TROUBLESHOOTING OF CO\TROL SYSTDl'' (I: with VOLT-OHM '.'-JETER).

Hitach makes available an *�lECHATRO CHECKER. (option) specially designed for the control system check.

For the checking procedures and usage of the test

kit, refer to "TROUBLESHOOTI\.JG OF CO\TROL SYSTD1" (II : h·ith MECH.-HRO CHECK ER) and the separate operation manual for the CHECKER. *NOTE

MECHATRO CHECKER:

MECHAnics-elecTROnics CHECKER

TS18-5-3

TROUBLE SHOOTING ELECTRICAL SYSTEM TEST 1.2 ARTICLES NECESSARY FOR ELECTRIC CIRCUIT TEST

Articles of circuit test are needed as follows.

Applications Volt-Ohm meter x 1 pc.

Measurement of voltage of continuity

10 '\, 20 D: One

Resistors (2 to 3\\')

One each

80 D

current check

Check of water temperature sensor or

fue 1 gauge float.

16 & SO 10

Accuracy check of water temperature

gauge

Accuracy check of fuel meter

Further, check of MAX. and MIN. points

of water temperature and fuel meter. Lead wire with insulated clip

Usqd as lead wire in case of measurement of voltage

and continuity check

resistance

Red & black wires each : One each being 1 m long Used at "TROUBLE SHOOTING OF CONTROL SYSTEM (II)".

Mecahtro Checker (Option) 0 0 0 0 0 0 0 0 0

� 0 0 0

cr: 0 00 0

----, I

JI""'' lor •,ro �arfttl I

TS18-5-4

TROUBLE SHOOTING

ELECTRICAL SYSTEl\t1 TEST

1� MEASUREMENT PROCEDURES

Prior to measurement and testing, confirm

the locations of parts to be checked, and

uncover enclosed parts, if necessary.

assure correct measurement, reconfirm the

locations by checking the serial number and

color of terminals and connectors. (1)

\J_

Take off the covers from the right control box.

Cover A: Cover B:

Cover C:

Remove 4 bolts A.

Remove 7 volts B.

COVER A 'll I\

Remove 6 bolts C.

BOLT A

COVER B

'll�

CO:-iTROL BOX (RIGHT)

,.,

�

BOLT B

(2) Monitor

After taking off the cover A from the

control box (right), remove the connector,

pull out the harness, and apply the test bar.

(3) Controller

Take off the cover B from the control box (right) .

Remove the 4 fixing scre\,S, and

turn the controller upside down to make the connector face upward. test bar for measurement.

Insert the

When using the

CHECKER, follow the usage specified in

the operation manual.

(4) Starter SW, control SW, etc.

Take off the cover from the control box

(right), lift the box, and apply the test

bar.

·i . - -.,_y: t �- -- '

'-==-'

.,·

�,/ ._ t,

.-..

.,_ �/:::. ..tlllJiitit,' r.J,,;,,.,,.

I�

•.j VC '

d•

...... -�

·• '

·IJ

TROUBLE SHOOTING

TS18-5-5

ELECTRICAL SYSTEM TEST------------

1.4 MEASUREMENT STANDARD

Measure the voltage in order to see if the power has been supplied to each of

component parts.

The interruption of voltage in the midway of circuit attri

butes to the discontinuation beth·een them, h·hich must therefore be checked b:-· a continuity test.

(1) Battery Circuit

a. :Sleasuring the voltage (Use a \'OLT METER)

Machine Condition For Test Section

Test Points (Power Supply Test)

Condition

Engine

Stop

Starter SW

Off

Maximum \'oltage Differential (\')

1-2 Battery (Single)

2-3 Battery (Single)

1-3 Battery (Dual) 4-E P01,er Supply

r,v

'\,

1-5 Fusible Link

CD®

"v r

12.5

12.5 25 25

_::,

to STERTER S1\'ITCH FUS 1B LE LI\K

STARTER Sl�· DJ (C'.\: Connector)

- E EARTH LINE

b. �leasuring the current (Use an A�lPERE �1ETE R) 0

BATTERY RELAY

�leasure the current under the

Condition of engine stop and starter

S\\ OFF.

(Usually under this condition,

a supply current of around 6mA

flows to the CLOCK).

BATTERY 12\' x 2

A > 10 �A --- Possibility for short circuit.

A = O A ---- - Wire break or defe ctive contact in the CLOC[ cirucit.

EARTH LINE

BATTERY REL."\Y

o If the lamp brighten 1,hcn a bulb for pane1 gauge is connected in-

stead of an ammeter, it can be judged that there is a short circuit.

TS18-5-6

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST------------

(2) Preheat Circuit Machine Condition For Test Section Engine

Starter SW

Condition Stop

�laximum \'oltage Differential (\')

Test Points (Power Supply Test) 1-E Fusible Link

2-E Starter S\\' (B) 3-E Starter SI\' (Rl)

Pre-heat

4-E Starter SW (ACC)

5-E Power Supply (Heat Plug)

7-E Power Supply (Timer)

~::J ,-,

--,-

L:J

-J

.,;:i

-v

--,�::i

6-E Power Supply (Timer)

·r

·'\.,

--, -

lR LB

HfATfR REGISTER Cr.., I HARNESS 510[ I

G'(

Charge Lamp Relay GR

;

ll��.�

ALTERNATOR

_,______·..... u

REGULATOR

Clock lW 24

:t---i1�7

-Orill�-� Gouge Pone I

'i -:-

F]sw [!JL

TIMER CN (HERNESS SIDE I

HEATER RELAY CN (HARNESS SIDE!

E "9'"' �10P l'T>OIOI

CURRENT SENSOR CN (HARNESS SIDEI

(RELAY SIDE)

TS18-5-7

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST------------

(3) Starting Circuit Machine Condition For Test Section Engine

Starter SW

Test Points (Power Supply Test)

Condition

Kranking by Battery Start

illaxi mum \' o 1 t age Differential ( \'}

1-E Starter S\v (B)

2-E Starter SW (Br)

3-E Starter SW (C)

4-E Battery Reray (Coil)

5-E Battery Reray (Contactor)

6-E Starting �-lotor (B)

7-E Starting Motor (C)

8-E Regulator

(C)

�o

'\,

20 20

'\, nv

'\, CV

'\,

2.:i

25 25

Note: After the engine started, the Voltage comes up 26 '\, 30V by charging of alternator.

@) Chorqe Lnmp Reloy

SAFETY

RELAY CM

!HARNESS SrO[I

Glowr,loq

TS18-5-8

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST---------�--

(4) Charging Circuit Machine Condition For Test Section

Condition

Engine

Idling

Starter SW

Test Points (Power Supply Test) 1-E Alternator (B)

Maximum \'oltage Differential ( \ ) 26

2-E Fusible Link

3-E Battery Charge

4-E Power Supply

5-E Alternator (N) 6-E Gauge Panel

'\, rv ' 'v r,

30 30

15 30

@) @) @)

Cho,ge Lomp Reloy

t l.,AB

@ @

REGULATOR {HARNESS

SJOE)

E nt1•-11op,irlay2

TS18-5-9

TROUBLE SHOOTING

----------- ELECTRICAL SYSTEM TEST • HOW TO CHECK lliE MALFW,;CTION IN CHARGE CIRCUIT The charge lamp is kept goes out in general when the alternator is generating. If the charge lamp goes on although the engine is operating, the alternator might be defective. 1.

How to Check the circuit. (1) Make sure that the charge lamp goes on when the starter switch is turned on.

(Engine is stopped)

(2) Measure the voltage between

B 11 and "E" terminal of alternator.

If the measured voltage is around 24V, the alternator circuit can be considered in normal.

If the measured voltage is 10\,' the shortage in

battery capacity or the looseness of h'iring connectors of the alternator circuit might be in malfunction.

When the voltage is OV, the 1,iring

between fuse and generator might be in discontinuity.

(3) Then, start the engine and measure the generated voltage in operation of the alterna tor.

In the same manner, measure the \·oltage bet1seen "B" and

"E" terminal on the side of alternator. it is normal.

If the \·oltage is around ::8\,

If the rated voltage is not generated, it is in a trouble

1,·ith the alternator or the regulator. earth line is needed.)

(�laking sure the continui t>· of the

TS18-5-10

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST

How to check the malfunction between alternator and regulator. The judgement must be made by checking of alternator.

(1) Turn the starter switch on, measure the voltage of generator, between terminals F and E, at engine stop condition.

(2) When the measured voltage is around lSV, the regulator may be normal.

And when the voltage is very low or zero, the trouble may be in regulator.

(When the battery is normal condition.)

TS18-5-11

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST -----------

(5) Engine Stop Circuit Machine Condition For Test Section

Condition Stop

Engine

Maximum Voltage Differential (V)

1-E Emergency Relay

Starter SW

Test Points (Power Supply Test)

2-E Motor Stopper

'\,

Sotenotd valve

STARTER

Charge Lamp Relay GB

EMERGENCY

RELY

(ll/1.RNESS

SIDE)

G•o- plug

En91n� 1101" "'01()1

� � ENGINE

ENGINE

STOP

(1-i/\RNESS

RELAY SIDE)

s,·op

IHJ\RNESS

MOTOR SIDE)

TS18-5-12

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST (6) Accessory Circuit Machine Condition For Test Section Engine Starter SW Horn SW

Wiper SW Wind Washer SW Blower SW Blower SW

Lighting SW

Condition

Test Points (Power Supply Test)

Maximum Voltage Differential (V)

1-E Cigarette Lighter

Stop

2-E Radio

3-E Horn Relay

Off

4-E Wiper

Off

5-E Wind Washer (Option)

Off

6-E Heater

7-E Cooler (Option)

Off M

8-E Head Light (Boom)

9-E Head Light (Base Machine)

'\.,

'\, '\., '\., '\., '\.,

'\, '\.,

20 ��

25 (

Via radio ) Fuse

25 25

�:i

( Inside cab) to Gauge Panel

Joint CN @ (To look inside cab)

ANTENNA

(Inside cab)

))) SPEAKER

to Gauge Pane 1

Joint CN @ (To look inside cab)

Wiper SW CN (herness side)

Blower SW CN (Herness side)

Window washer CN (Herness side)

AIR COOLER lOPTIONALI

�!BOOM!

[;J

M'@'BLANK � 4BASE MACHINE I

E�L

Lighting SW CN (Herness side)

to Gauite- Pane I

LR LB

Heater resister CN (Resister side)

TS18-5-13

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST------------

(7) Guage panel Circuit Machine Condition For Test Section

Condition

Engine

Starter SW

Stop On

Test Points (Power Supply Test)

Maximum \"oltage Differential (\')

1-3 Gauge Panel

2-3 Clock

'\.,

25 25

Note: For a functional trouble, see the diagnose malfunction.

FUSE BOX

Oiorge Relay

6 5

to Alfef"notor N Terminal

Earth� side� Hour Meter Swllch

Hourrneter SW CN (Harness side)

(Harness side)

(Herness side)

17 18

19 20

25 26

(Herness side)

HOUR

SET sw

M,NUTE,

SET SW,.,I,,.

Panel gauqe CN No.

1!/® I

______ _J --- - - ----= G:i.UGE PA�EL

�

TS18-5-14

TROUBLE SHOOTING

ELECTRICAL SYSTEM TEST----------(8) Control Circuit l\lachine Condition For Test Section

Test Points (P01,er Supply Test)

Condition

Engine

Stop

Starter SW

Maximum \'oltage Differential (\")

1-2 Contra l ler

_::,

Note: For a functional trouble, see the diagnose malfunction.

'" Ml

Idle SW CN No. (Herness side) we I'

)

Travelling SW CN No_

- -�

I ,-----,

�Emp t y

Mode SW CN

,. :

lo ...

E�L

I I 10

I!\

Controller CN Nn. ( ll0rnc•ss side)

' HUl,Jf.l\NG Sr>e.EJ Sw

I ru• I= ==j_..c '"ti sw

•

L___--�----� - __ J1 '

2 I 20 19 18 17

""'00[ sw

INDEX

EmlmlJ

EX270-11-1

Hino H06 CTI ENGINE

CONTENTS

Group 1-GENERAL INTRODUCTION .......

EG12-1-1-4 1. General Precaution ................ . . ........... EG12-1-2 2. Identification Information ...................... EG12-1-3

Group 2-ENGINE ... . .... . ........ . .......

EG12-2-1-138 1. Troubleshooting ...................... . .... . ... EG12-2-2 2. Special Tool ............................... . .. EG12-2-16 3. General .. . . ...... . . . .. . ...................... EG12-2-22 4. Dismounting The Engine Assembly ....... . ..... EG12-2-24 5. Removal Of The Engine Component Parts ...... . EG12-2-25 6. Cylinder Head . ...... . ... . . ............ . ...... EG12-2-31 7. Timing Gear And Camshaft .. . ..... . ........... EG12-2-55 8. Cylinder Block, Flywheel Housing, Piston And Crankshaft ....... . ................ EG12-2-69 9. Lubricating System ......... . .............. . .. EG12-2-95 10. Cooling System .............................. EG12-2-105 11. Fuel System . . . ......................... . .. . . EG12-2-117 12. Engine Stop System ......................... EG12-2-125 13. Installation Of The Engine Components Parts ..................... . ..... EG12-2-127 14. Engine Tune-Up ............................. EG12-2-135

Group 3-GENERATOR .....................

EG12-3-1-12 1. Troubleshooting ........ . . . ... . ........ . ....... EG12-3-2 2. Generator ... . . . . . ....... . .......... . . . ...... . . EG12-3-3

Group 4-STARTER ..... . ......... . . ...... . .

EG12-4-1-16 1. Troubleshooting ...... . . . . ..................... EG12-4-2 2. Starter ...................... . ................. EG12-4-4

Continued on next page.

INDEX

EX270-11-2

CONTENTS (continued) Group 5-CALIBRATION . ............ . .... . ..

EG12-5-1-4

Group 6-TURBOCHARGER ................

EG12-6-1-18 1. Troubleshooting .............................. ; EG12-6-2 2. Special Tools ........... ....................... EG12-6-4 3. Overhaul .... ........ ... ................. ...... EG12-6-5 4. Overhaul Factor ............................. ... EG12-6-6 5. Removal ............... ........ ............... EG12-6-7 6. Disassembly ............ ............... ........ EG12-6-7 7. Inspection ............ . .................. ..... EG12-6-11 8. Assembly ............................ ........ EG12-6-13

Group7-SERVICE SPECIFICATIONS ......

EG12-7-1-20 1. Engine Specifications . .. .. .. ... .. .. .. .... . . . . .. . EG12-7-2 2. Repair Specifications .... .. ...... . .. ... ......... EG12-7-5 3. Metric Information ... ......... .. . .. . . . . . .. .... EG12-7-15 4. Decimal And Metric Equivalents ... .. .. ..... .. .. EG12-7-16 5. Standard Tightening Torque . ....... .. ..... .. .. EG12-7-17 6. Recommended Lubricants . .. . ... . . . ....... .. . EG12-7-19

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

ENGINE

EG12-1-1

----------- GENERAL INTRODUCTION

GROUP 1 GENERAL INTRODUCTION GENERAL PRECAUTIONS . . .. . . . . . .. . .. . .. . . . ... . ..... EG12-1-2 IDENTIFICATION INFORMATION ...•..•.............•• EG12-1-3

ENGINE

EG12-1-2

GENERAL INTRODUCTION -----------

GENERAL PRECAUTIONS Some recommended and standard maintenance services for your engine are mentioned in this section. When performing maintenance on your engine be careful not to get injured by improper work. Improper or incomplete work can cause a malfunction of the engine which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your dealer.

WARNING When working on your engine, observe the following general precautions to prevent personal injury and/or property damage in addition to the particular NOTES or WARNINGS. Most threaded fasteners are metric. Be careful not to mix with threaded fasteners using the inch system. 0

Always wear safety glasses or goggles to protect your eyes.

Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the engine.

Bind long hair securely behind the head.

To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator, muffler, exhaust pipe and tail pipe.

Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when the engine is running.

Always stop the engine by pulling out the engine stop knob. Leave the knob pulled out as long as the engine is stopped. And turn off the starter switch, unless the operation requires the engine running. Removing the key from the switch is recommended.

Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.

Do not smoke while working on the truck since fuel and gages from the battery are flammable.

Take utmost care when working on the battery. It contains corrosive sulfuric acid.

Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which can result in personal injury and/or property damage.

Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts and can cause personal injury.

Read carefully and observe the instructions placed on the jack when using it.

Be careful not to damage lines and hoses by stepping or holding your feet on them.

ENGINE

EG12-1-3

------------ GENERAL INTRODUCTION -----------

I DENTI Fl CATION IN FORMATION

ENGINE NUMBER The Engine Number, as shown in Fig. 1-1 on the left rear side of the engine block.

Fig. 1-1

SMl-078

EG12-2-1

ENGINE

--------------- ENGINE--------------

GROUP 2 ENGINE

(MODEL H06C-TI) TROUBLESHOOTING ............................... EG12-2-2 SPECIAL TOOL .................................... EG12-2-16 GENERAL ......................................... EG12-2-22 DISMOUNTING THE ENGINE ASSEMBLY ............. EG12-2-24 REMOVAL OF THE ENGINE COMPONENT PARTS ..... EG12-2-25 CYLINDER HEAD .................................. EG12-2-31 TIMING GEAR AND CAMSHAFT ..................... EG12-2-55 CYLINDER BLOCK, FLYWHEEL HOUSING, PISTON AND CRANKSHAFT ......................... EG12-2-69 LUBRICATING SYSTEM ............................. EG12-2-95 COOLING SYSTEM ................................. EG12-2-105 FUEL SYSTEM ....................... ; ............. EG12-2-117 ENGINE STOP SYSTEM ............................. EG12-2-125 INSTALLATION OF THE ENGINE COMPONENTS PARTS .............................. EG12-2-127 ENGINE TUNE-UP .................................. EG12-2-135

EG12-2-2

ENGINE

---------------- ENGINE----------------

TROUBLESHOOTING Symptom

Possible cause

Remedy/Prevention

Engine overheating -------�-l Coolant • Insufficient coolant .................... Add coolant. • Defective thermostat .. .. . .. . . . ......... Replace the thermostat. • Overflow of coolant due to leakage of exhaust into cooling system

Repair.

• Damaged rubber hose ....

Replace rubber hose.

• Coolant leakage due to deteriorated ......... Replace rubber hose. rubber hose • Coolant leakage from coolant pump ........ . Replace the coolant pump. • Coolant leakage from rubber hose ........ .... Retighten or replace clamp. connection • Coolant leakage from cylinder head ......... Replace gasket. gasket

Coolant pump • Bearing seizure . ... ... ......... ....... Replace bearing. • Damaged (corroded) vane . .... ......... .. Replace vane.

Radiator • Clogged with rust and scale ............... Clean radiator. • Clogged with iron oxide due to leakage ... .... Clean coolant passage and correct exhaust leakage. of exhaust into cooling system • Coolant leakage ........

Repair or replace radiator.

• Damaged cooling fan .....

Replace cooling fan.

• Clogged radiator core due to mud ...... or other debris

Clean radiator.

• Defective radiator cap pressure valve ........ Replace radiator cap.

Abnormal combustion • Incorrect injection timing .

Adjust injection timing.

• Reduced injection pressure . .. .... ........ Adjust injection pressure. • Poor fuel ............. .............. Used good quality fuel. • Poor nozzle spray ..................... Adjust or replace nozzle. • Unsatisfactory automatic timer advance angle .. Repair or replace timer.

EG12-2-3

ENGINE

-----------------ENGINE----------------

Symptom

Possible cause

Remedy/Prevention

Engine overheating -------�---lOther problems • Defective or deteriorated engine oil

Change engine oil.

• Unsatisfactory operation of oil pump .. . ..... Replaced or repair. • Insufficient oil .... ........ .... ....... Add oil. • Brake drag ...... . . .... . . ... . .. . .. ... Adjust.

Severe operating conditions • Lugging the engine .................... Operate engine properly

Excessive oil consumption -----,�-1 Pistons, cylinder liners, and piston rings • Wear of piston ring and cylinder liner

Replace piston rings and cylinder liner.

• Worn, sticking or broken piston rings .........Replace piston rings and cylinder liner. • Insufficient tension on piston rings

Replace piston rings and cylinder liner.

• Unsatisfactory break-in of piston rings ... .... Replace piston rings and cylinder liner. • Unsuitable oil (viscosity too low) ....... .... Change oil as required and replace piston rings and cylinder liners. • Incorrectly fitted piston rings ............. Replace piston rings. (upside down) • Gaps of piston rings in line with each other .... Reassemble piston rings.

Valves and valve guides • Worn valve stem ......

Replace valve and valve guide.

• Worn valve guide ....... . ... .......... Replace valve guide. • Incorrectly fitted valve stem seal ........... Replace the stem seal. • Excessive lubricant on rocker arm .......... Check clearance of rocker arm and shaft.

Excess oil feed • Defective oil level gauge .

Replace oil level gauge.

• Oil level too high .....

Drain excess oil.

ENGINE

EG12-2-4

---------------- ENGINE

Symptom Excessive

Possible cause

Remedy/Prevention

oil consumption ----,---1 Oil leakage from miscellaneous parts • Oil leakage from oil seal ... . ......... . ... Replace oil seal. • Cracks or blowhole in cylinder block ... . .... ReplaCt? cylinder block. • Oil leakage from connections of oil lines ...... Tighten connections of oil lines. • Oil leakage from oil cooler ............... Replace oil cooler. • Oil leakage from oil pan gasket .... . ....... Replace oil pan gasket. • Oil leakage from O-ring ......... . .. . .... Replace O-ring.

Other problems • Overcooled engine (low temperature wear)

NOTE:

Warm up engine before mov ing vehicle. Check cooling system.

If oil consumption is excessive, the above problems will occur. Often, complaints from the customer are related to such problems. 1. 2. 3. 4. 5. 6.

White smoke is emitted continuously when the engine is run at high speed. White smoke is emitted only immediately after the engine speed is abruptly raised when idling. The tail pipe is blackened with oil. Oil leaks from the flanges of the exhaust manifold. Lack of power. Excessive blow-by gas.

Piston seizure----------.,--, Pistons, cylinder liners, and piston rings • Incorrect clearance between piston ......... Replace piston, piston rings and cylinder liner. and cylinder liner • Unsatisfactory installation of piston pin

Replace piston, piston rings, cylinder liner and piston pin as required.

• Broken piston ring . . ... ............. .. Replace piston, piston rings and cylinder liner. • Difference in expansion due to use of .. .. .... Replace piston, piston rings wrong piston and cylinder liner.

EG12-2-5

ENGINE

----------------ENGINE

Symptom

Possible cause

Remedy/Prevention

Piston seizure --------�---1 Coolant • Reduction in capacity of coolant pump (due to vane corrosion)

Replace the coolant pump.

• Leakage of coolant .......... .......... Repair. • Insufficient coolant ..... ..... . ........ Add coolant. • Dirty coolant ............ .. .......... Clean and replace coolant. • Defective radiator ......... . . ... ....... Repair or replace the radiator. (coolant leakage, clogging) • Defective rubber hose (leakage) ....... ..... Replace rubber hose. • Defective thermostat . .................. Replace the thermostat. • Leakage of exhaust into cooling system ...... Repair.

Operation • Abrupt stoppage of engine after running ...... Operate engine properly. at highspeed. • Hill climbing using unsuitable gear .......... Select suitable gear.

• Insufficient oil

Add oil.

• Dirty oil ... ........................ Change oil. • Poor quality oil ........ .. .......... .. Replace with proper engine oils. • High oil temperature .-.................. Repair. • Low oil pressure .............. ........ Repair. • Defective oil pump ... . ................ Repair oil pump. • Reduced performance due to worn ......... Replace oil pump. oil pump • Suction strainer sucking air ............... Add oil and/or repair strainer.

Abnormal combustion • Use of defective fuel ................. .. Change fuel. • Incorrect injection timing ... ........... .. Adjust injection timing. • Engine overheating .................... See Symptom: "Engine over heating."

ENGINE

EG12-2-6

----------------- ENGINE

NOTE:

If piston seizure occun, the above problems will occur. Often, complaints from the customer are related to these problems. 1. White smoke is emitted.

Lack of power

3. Excessive blow-by gas

Symptom

Possible cause

Lack of power ----------.--1 Injection pump

Remedy/Prevention

Refer to "INJECTION PUMP"

Intake • Clogged air cleaner

Clean element or replace element .

• Clogged inter cooler core . ..... _ ......_ ... Clean inter cooler core or replace due to mud or other debris inter cooler • Clogged coolant of inter coolder

Overheating

Clean inter cooler tube or replace inter cooler

See -Symptom: "Engine overheating".

Fuel and nozzle • Poor nozzle spray

Adjust or replace injection nozzle .

• Clogged nozzle with carbon .. . ... ........ Clean nozzle. • Wear or seizure of nozzle . ... . .... .... . .. Replace nozzle. • Air in fuel system .........

Repair and bleed air from fuel system.

• Clogged fuel filter ........ .

Replace element.

• Use of poor fuel ..........

Use good quality fuel.

Pistons, cylinder liners, and piston rings • Seized or wear of piston ...... • Worn or broken piston rings, .. piston and cylinder liner

. ... Replace the piston, piston rings and liner. ...Replace piston rings, piston and liner.

EG12-2-7

ENGINE

---------------- ENGINE

Symptom

Possible cause

Remedy/Prevention

Lack of power --------�--1 Other problems • Connecting rod bent

Replace or repair connecting rod.

• Exhaust pipe or muffler crushed ........... Replace exhaust pipe or muffler. (increased back-pressure) • Breakage of turbine or blower . .. .. . .. .. ... Replace the turbine or blower or turbocharger

Leakage of exhaust ------�--1 Head gasket • Fatigued gasket (aging)

Replace gasket.

• Damage . . . . . . . . ... . .... . . .. . . .. ... Replace gasket. • Improper installation ................... Replace gasket.

Head bolts • Loose bolts

Tighten bolt.

• Elongated bolts . . . . . . . . .. . . . .. . . . . . .. Replace bolt. • Improper tightening torque or ............. Tighten properly. tightening sequence

Cylinder block • Cracking ........................... Replace cylinder block. • Surface distortion . . . . . . . .. . .. . . . . . . . . . Repair or replace. • Fretting of cylinder liner insertion portion (insufficient projection of cylinder liner)

Replace cylinder block.

Cylinder head • Cracking ............................... Replace cylinder head. • Surface distortion ........................ Repair or replace.

Cylinder liners • Cracking ............................... Replace cylinder liner. • Corrosion ............................... Replace cylinder liner. • Insufficient projection of cylinder liner ....... Replace cylinder liner.

ENGINE

EG12-2-8

----------------- ENGINE

Symptom

Possible cause

Remedy/Prevention

Leakage of exhaust ------�--1 Other problems • Incorrect injection timing .... ...... .. . .. . Adjust injection timing.

NOTE:

If leakage of the exhaust occurs, the above prcblems will occur. Often, complaints from the customer are related to these problems. 1. Lack of power. 2. The engine overheats. 3. The coolant is discolored.

Difficulty starting engine----�- Electrical system • Discharged battery

Charge battery.

• Defective wiring in starter circuit . .. ... . .... Repair wiring of starter. • Loose or open-circuit battery cable

Tighten battery terminal connec tions or replace battery cable.

• Breakdown of starter ................... Replace starter. • Break of glow plug . ... . . .... .......... Replace

Injection pump

Refer to "INJECTION PUMP."

Air cleaner • Clogged element ......... .

Clean the element or replace the element.

Fuel system • No fuel in tank .

Supply fuel.

• Clogged fuel line . . .... ... .... .. ... .... Clean fuel line. • Air sucked into fuel system through ......... Tighten fuel line connections. fuel line connections • Clogged fuel filter . ....... . ... . .. ... . .. Replace element. • Loose connection in high-pressure line

Tighten sleeve nut of high pres sure line.

• Water in fuel . . .. .... .. ......... ... .. Drain and clean fuel system.

EG12-2-9

ENGINE

--------------- ENGINE

Symptom

Possible cause

Remedy /Prevention

Difficulty starting engine ----�--l Nozzles • Seized nozzle . .. .. . ... . ... ..... . .. . .. Replace nozzle. • Broken or fatigued nozzle spring .. . .... ... . Replace spring.

Oil system • Oil viscosity too high ..

Use proper viscosity oil, or install an oil immersion heater and warm up oil.

Other problems • Seized piston ....

Replace piston, piston rings, and liner.

• Seized bearing . . ... ... ... . .. . . .... ... Replace bearing and crankshaft. • Reduced compression pressure ............ Overhaul engine. • Ring gear damaged or worn ... ... .... .... Replace the ring gear and/or starter pinion. • Improperly adjusted or broken accelerator cable

Rough idling

---------�--1 Injection pump

Adjust or replace the accelerator cable.

Refer to "INJECTION PUMP."

Nozzles • Uneven injection pressure . . . . .. ...... .... Adjust. • Poor nozzle spray . .. ... . ... ... .... .. .. Adjust or replace nozzle. • Carbon deposit on nozzle tip ... .. ........ Remove carbon. • Seized needle valve . . . . .. ...... .. .. .... Replace nozzle.

Engine proper • Improper valve clearance

Adjust valve clearance.

• Improper contact of valve seat

Replace or repair valve and valve seat.

• Idling speed too low ..... . ............. Adjust idling speed. • Coolant temperature too low ... .. ... . .. . . Warm up engine. • Compression pressure of cylinders .. ... ... .. Overhaul engine. markedly different from one another

EG12-2-10

ENGINE

---------------- ENGINE

Symptom

Possible cause

Remedy/Prevention

Rough idling ----------�Other problems • Clogged high pressure injection line

Replace line.

• Leakage due to improper tightening of high pressure injection line

Tighten sleeve nut.

• Improperly adjusted or broken accelerator cable

Adjust or replace accelerator

• Engine seizure .............

Replace pistons, piston rings and liners.

• Incorrect valve timing .. ... ... .......... Replace camshaft.

Diesel knock ---------�--1 Injection pump

Refer to "INJECTION PUMP."

Nozzles • Incorrect injection prj!ssure

Adjust.

• Poor nozzle spray ....... . ............ . Adjust or replace nozzle. • Sticking of nozzle .................... . Check and/or replace. • Fatigued or broken nozzle spring ........... Replace spring.

Fuel system • Use of poor fuel

Use good quality fuel.

• Fuel leakage into combustion chamber (e.g.during starting)

Adjust nozzles.

Other problems • Excessively cooled or heated engine

Warm up or cool engine.

• Insufficient air intake .................. Correct. • Insufficient compression pressure ... . ..... . Repair. • Compression pressure leaks at cylinder head gasket

Replace head gasket.

• Improper valve clearance or valve ........... Adjust or repair. sticking • Tappet sticking . ..... . ............... Replace tappet and camshaft.

EG12-2-11

ENGINE

---------------ENGINE

Symptom

Possible cause

Remedy/Prevention

Unusual engine noise-------,----, Piston • Wear of piston pin boss or piston pin

Replace piston and/or piston pin.

• Seized, damaged, or worn piston p;r, bushing

Replace piston pin bushing.

• Worn pistons or cylinder liners

Replace piston or cylinder liner.

• Damaged or seized piston ....

Replace piston and cylinder liner.

• Foreign matter on top surface of the piston

Remove foreign matter and repair or replace piston, cylinder liner, and/or cylinder head.

Valve mechanism • Incorrect valve clearance

Adjust valve clearance.

• Valve cotter out of place

Replace valve cotter.

• Seized valve stem .....

Replace valve and valve guide.

• Broken valve .... .... . . ... . . ... ...... Replace valve. • Damaged rocker arm support .

Replace rocker arm support.

• Broken or bent push rod

Replace push rod.

• Damaged or worn tappet

Replace tappet and camshaft.

• Broken valve spring ....

Replace valve spring.

Bearings seizure • Insufficient lubricating oil

Add oil.

• Excessive or insufficient tightening of. bearing housings

Retighten to specified torque.

• Pits and scratches on bearing surface

Replace bearing and crankshaft_

• Oil film formed on back of bearing .....

Replace bearing.

• Improper installation of bearing ... ....... . Replace bearing. • Reduction of spread dimension of bearing ..... Replace bearing. • Distorted bearing housing ......

Replace or correct bearing hous ing.

• Excessive oil clearance . .... ......... .... Replace bearing.

EG12-2-12

EI\IGINE

---------------ENGINE

Symptom

Possible cause

Remedy/Prevention

Unusual engine noise------�--< Other various parts • Exhaust gas leakage from exhaust . . . . . . . . . . Retighten joints. pipe joints • Loosen or missing intake manifold . . . . . . . . . . Retighten or replace flange gasket • Intake valve seating is not concentric

Replace or correct the valve and valve seat

• Intake gas leakage . . . . . . . . . . . . . . . . . . . . . Retighten

Other problems • Loose cooling fan mounting bolts or fan pulley nut

Tighten the fan and crankshaft pulley

• Lack of lubricating oil (coolant pump, valves, etc.)

Lubricate

• Worn timing gear . . . . . . . . . . . . . . . . . . . . . Replace the timing gear • Breakage of turbine or blower . . . . . . . . . . . . . Replace the turbine or blower and/or turbocharger

NOTE:

The items on this page concern unusual engine noise which is due to causes other than, these given for diesel knock.

ENGINE

EG12-2-13

--------------- ENGINE

TROUBLE SHOOTING (INJECTION PUMP)

Symptom

Possible cause

Remedy /Prevention

Engine does not start --------'Fuel not reaching injection pump • Fuel lines clogged or damaged ............. Clean or replace fuel lines. • Fuel filter clogged . ... ..... .. .......... Clean or replace the filter element. • Air in fuel caused by improper . .. ......... Repair connections. connections of fuel line between fuel tank and feed pump • Filter incorporated in inlet side ............ Remove foreign material. of feed pump clogged • Faulty feed pump check valve ..

Repair or replace it.

• Feed pump piston spring broken .... . . ..... Replace it. • Feed pump push rod or tappet sticking ... .... Repair or replace it. Fuel reaching injection pump • Faulty connection of accelerator . . ......... Repair connection. wire to pump adjusting lever. • Control rack faulty or sticking

Repair it.

• Damaged camshaft bearing . . . ............ Repair it. • Plunger worn or sticking ................ Correct or replace it. • Faulty connection of engine . stop wire to pump stop lever.

Repair it.

Nozzle faulty • Fuel leakage caused by loosened ........... Inspect and tighten it. nozzle holder. • Low opening pressure of nozzle ............ Adjust it. • Nozzle pressure spring broken ......... .... Replace it. • Nozzle needle sticking to nozzle body

Correct or replace it.

Pump out of timing • Improperly retarded injection timing

Correct injection timing.

• Incorrect timing caused by improper insta I lation of pump

Check engine timing and correct it.

• Woodruff key for pump camshaft cut off.

Replace it.

• Improper pre-stroke adjustment

Correct it to obtain specified injection timing.

ENGINE

EG12-2-14

--------------- ENGINE

Symptom

Possible cause

Remedy /Prevention

Engine has low power--------r-�Pump out of timing • Excessive advanced timing . . . . . . . . . . . . ... Check and correct it. resulting in loud knocking. • Excessively retarded timing . . . . .. . . . . . . . . Check and correct it. resulting in black smoke. • Defective injection pump overflow .. . . . ... . . Repair or replace it. valve. • Feed pressure too low

Repair the feed pump.

• Improper accelerator cable adjustment .

Adjust it.

Nozzle faulty • Fuel leakage from nozzle holder

Check and repair nozzle holder.

• Bad nozzle spray characteristic .

Repair or replace it.

• Loosened adjusting screw in nozzle . holder, resulting in low opening pressure.

Adjust it.

• Nozzle pressure spring broken . . .. .. .. .. .. . Replace it. Pump faulty • Fuel leakage from delivery valve holder.

Retighten the delivery valve holder if it is loosened or replace O-ring if the O-ring is defective.

•

Repair or replace it.

Defective seat of delivery valve assembly.

• Delivery valve spring broken

Replace the spring.

• Plunger worn ......... .

Replace it.

• Large spread in fuel delivery

Adjust it.

• Wear of tappet roller .....

Replace the roller.

• Camshaf t bearing worn or broken

Replace it.

• Improper adjustment of governor fuel load stopper screw.

Adjust it.

Correct it. Bad fuel nozzle spray pattern after-dribble.

Check and correct it.

High nozzle opening pressure

Adjust the opening pressure.

Incorrect fuel deliveries to some nozzles.

Readjust the fuel deliveries.

ENGINE

EG12-2-15

---------------- ENGINE

Symptom

Possible cause

Remedy/Prevention

Excessive smoke ------- ----1 B lack smoke • Excessive fuel delivery caused by . incorrect adjustment of fuel load stopper screw.

Adjust fuel delivery on test stand.

• Excessively advanced injection .. . ........ . Correct it. timing. • Large spread in fuel delivery

Adjust it.

• Bad nozzle fuel spray characteristics .......

Check and correct them.

White smoke • Improperly retarded injection timing.

Advance injection timing.

• Water in fuel ........................ Check and clean fuel lines. Low idle speed ---------- Improper adjustment of idle button irregular Bad fuel spray characteristic of nozzles.

Correct it. Check and repair them.

Incorrect injection timing .

Correct it.

Incorrect initial tension setting of idling spring or the spring broken.

Adjust or replace it.

Control rack not smoothly move .

Disassemble pump and repair it.

Large spread in fuel delivery

Adjust it.

Plunger worn ..........

Replace it.

Governor linkage not smoothly move.

Correct it.

Defective feed pump Engine always runs--------- Accelerator cable sticking .. at high speed Governor linkage sticking ..

... Disassembled and repair it. Check and correct it. Disassemble and repair the governor.

Control rack sticking ................... Check and correct it. Engine starts and stops ------ --Fuel lines clogged ..................... Clean or replace fuel lines. [ ........ Repair fuel lines or replace fuel Air in fuel caused by damaged . lines and gaskets. fuel lines or improper connection of fuel lines.

ENGINE

EG12-2-16

ENGINE

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have the following.

Illustration

Tool No.

Tool name

Usage

09442-1061

PISTON RING EXPANDER

For removing and install the piston rings

09553-1010

WRENCH

For removing and install the fuel filter

09470-1022

VALVE SPRING PRESS

For installing or removing valve springs

09420-1442

SLIDING HAMMER

For removing the nozzle holder (Used with nozzle holder puller 09462-1130)

09482-1320

PUSH ROD GUIDE PIPE CAULKING TOOL

For caulking the push rod guide pipe

09411-1070

WRENCH

To tighten the cylinder head bolt

ENGINE

EG12-2-17

--------------- ENGINE

Illustration

Tool No.

Tool name

09482-1550

PRESS

For the injection pump drive shaft sleeve (Used with 9851-36104)

9851-36104

0-RING

For injection pump drive shaft sleeve press (Used with 09482-1550)

09420-1490

PULLER

For the injection pump drive shaft sleeve

09444-1290

TARGET PLATE

For inspection of the piston cooling jet

9001-24262

BOLT

For inspection of the piston cooling jet

09472-1620

ADJUSTER

To adjust the piston cooling jet nozzle

�

0 £) ,.......

�·

•

"",.

r·

..�..

Usage

�

�/

ENGINE

EG12-2-18

---------------- ENGINE

Illustration

Tool No.

Tool name

Usage

09552-1030

PRESSURE GAUGE ADAPTER

For the compression gauge

09420-1240

CYLINDER LINER PULLER

For removing the cylinder liner and measuring the pro trusion of the cylinder liner

09402-1340

DUST SLINGER PRESS

For pressing the dust slinger to crankshaft pulley

09402-1210

PRESS

To install the crankshaft front oil seal sleeve

09480-1040

CYLINDER LINER GUIDE

To install the cylinder liner

09441-1101

PISTON RING HOLDER

For piston installation

ENGINE

EG12-2-19

ENGINE --------------

Illustration

Tool No.

Tool name

Usage

09482-1090

PRESS

For front oil seal to timing gear cover

09420-1071

PULLER

To remove crankshaft front oil seal sleeve

09482-1400

PRESS

To install crankshaft rear oil seal sleeve

09420-1420

PULLER

To remove crankshaft rear oil seal sleeve

09431-1010

TOOL

For valve lapping

09819-3003

WRENCH

Tightening or retightening injection pump coupling

VALVE LAPPING

ENGINE

EG12-2-20

--------------- ENGINE

Illustration

Tool No.

09433-1061

09472-1210

Tool name

EYE-BOLT

NOZZLE SLEEVE

BAR

Usage

For hanging the cylinder head

For installing the nozzle sleeve (Used with 9800-06100)

9800-06100

STEEL BALL

For expanding the nozzle sleeve (Used with 09472-1210)

09408-1010

COMPRESSION ADAPTER

For measuring engine compression pressure (Bolt size PF 3/8)

09462-1130

ADAPTER

For with drawing the nozzle holder (Used with 09420-1442)

09472-1781

STEM SEAL PRESS

To install the valve stem seal

EG12-2-21

ENGINE

--------------- ENGINE

111ustration

Tool No.

Tool name

09444-1210

V-BELT TENSION GAUGE

09503-1080

WRENCH

.. .

�

Usage

For V-belt tension

For removing and install the oil filter

EG12-2-22

ENGINE

--------------- ENGINE

GENERAL WARNING The following items should be observed to prevent injury to yourself and others when servicing the engine or vehicle; o Stop the engine and keep the engine off during checks and adjustments. o Place the starter key in the "OFF" position. 0 Leave the engine stop knob pulled out fully.

ENGINE OVERHAUL CRITERIA FACTORS WHICH DETERMINE WHEN AN ENGINE OVER HAUL IS NEEDED. 1. Lowered compression pressure a. Before the measurement a) Correct the valve clearance. Intake: 0.30 mm (0.0118 in) Exhaust: 0.45 mm (0.0177 in) when engine is cold. b) c) d)

Warm up engine [Bring the coolant temperature to about 80 ° C ( 176 ° F)). Charge the battery fully. Remove the air cleaner.

b. Measurement a) Remove the six nozzle holders. b) Install the gauge adapter in the nozzle holder hole. Special Tool: Compression Gauge Adapter (09408-1010) Compression Gauge Adapter (09552-1030) Connect a compression gauge to the gauge adapter. Drive the engine with the starter and read the com pression pressure. Measure the compression pressure for each cylinder. e) If the compression pressure is low, be sure to repeat the measuring. NOTE: Be sure not to leak through sealing face. c) d)

Fig. 1

SM3-388

Unit: kg/cm2 (lb/sq.in)

� Model H06C-TI engine

Assembly standard

Service limit

Difference between each cylinder

Engine speed (rpm)

33-36 (469-511)

28 (398)

Less than 3 (43)

270-310

EG12-2-23

ENGINE

---------------- ENGINE 2.

r----7 l�I

I I

a. b.

6I I

OIL

L ____ ...J

Fig. 2

Decreased oil pressure Check the oil pressure warning lamp when the oil and coolant temperature is hot [about 80° C ( 176 ° F)]. If the warning lamp is light, check the oil level. Check oil deterioration. If oil quality is poor, replace with a suitable grade oil.

SM3-349

Remove the oil pressure switch and install the oil pressure gauge. d. Measure the oil pressure at coolant temperature ° 80 C (176 ° F) or more. Service Limit: 0.5 kg/cm2 (7 .11 lb/sq.in) c.

AtmoJpher,c

SAE

Grad•

!-10

�o

90 10

i-+---+---+-------+---+--+---+r-23 - 18

,emperotur�

•F

39 •c

20W/ 20 15W /40

Fig. 3

3. a. b. c. d. e. f.

Other factors The blow-by gas increases. The engine does not start easily. Engine output decreases. Fuel consumption increases. Engine makes greater noise. Excessive oil consumption.

EG12-2-24

ENGINE

________________ ENGINE

DISMOUNTING THE ENGINE ASSEMBLY

BLOCK THE WHEELS. 1.

Park the vehicle on level ground.

DISCONNECT THE BATTERY CABLES. WARNING Always disconnect the battery cables when servicing the engine.

DRAIN THE COOLANT AND ENGINE OIL. WARNING To avoid the danger of burns do not drain the engine oil and coolant while the engine and radiator are still hot. 1.

Fig. 4

NOTE: The coolant can be drained more easily by re moving the filler cap and breather plug of the inter cooler.

E057

Fig. 5

Drain the coolant from the cylinder block.

Drain the engine oil through the drain plug.

Disconnect the cable of oil level sensor.

SM3-l 544

COVER ELEMENT-"F;.u....-+-.....,i..� HANDLE

BREATHER PLUG GASKET CLAMP

BY-PASS 01 L

1. 2.

DRAIN PLUG--NOZZLE Fig. 6

Drain the coolant from the radiator.

ELEMENT OIL INLET OIL OUTLET SM3-1541

FILTER (OPTION).

Unscrew the breather plug, then unscrew the drain plug and drain the oil through the drain hole. Disconnect the oil lines.

EG12-2-25

ENGINE

--------------- ENGINE

REMOVAL OF THE ENGINE COMPONENT PARTS

CLEANING 1.

Cover all openings with waterproof tape before steam cleaning.

Clean all disassembled parts using a steam cleaner. 2. NOTE: Do not spray steam on electrical parts (generator, starter, etc.).

Fig. 1

Fig. 2

REMOVE THE FUEL FILTER WATER SEPARATOR AND FUEL LINES.

REMOVE THE OIL LEVEL GAUGE.

REMOVE THE STARTER.

SM3-1545

Fig. 3

Fig. 4

SM3-2400

EG12-2-26

ENGINE

----------------ENGINE----------------

REMOVE THE I NJECTION PUMP.

Remove the fuel lines, oil lines and fuel leakage lines.

NOTE: Cover the open ends of the pipes to prevent entry of dirt.

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

SM3-2401

Disconnect the engine stop cable.

Loosen the through bolts.

Remove the coupling bolts and nuts.

Remove the four setting bolts and remove the injec tion pump assembly.

SM3-2402

SM3-2403

SM3-2404

SM3-2405

ENGINE

EG12-2-27

---------------- ENGINE

Fig.10

REMOVE THE COOLING FAN AND SPACER.

REMOVE THE BEL TS ANO GENERATOR.

SM3-1517

Fig. 11

Loosen the belt tension adjusting bolt.

2. 3.

Loosen the through bolt. Remove the belts and generator.

03-2406

Fig. 12

REMOVE THE OIL FILTER. 1.

Remove the oil lines.

Remove the oil filter.

SM3-799

REMOVE THE COOLANT PUMP AND THERMOSTAT CASE. 1.

Remove the nut and pulley.

Remove the coolant line, thermostat case and coolant pump.

SM3-692

Fig.14

SM3-2408

EG12-2-28

ENGINE

---------------- ENGINE

10. REMOVE THE TURBOCHARGER

Fig.16

Fig. 17

Fig. 19

Remove the oil pipes.

Remove the intake pipe.

Remove the exhaust pipe.

Loosen the clip band.

Remove the turbocharger.

03-2410

03-2411

EG12-2-29

ENGINE

_______________ ENGINE

11. REMOVE THE OIL COOLER.

Fig. 20

03-2413

12. REMOVE THE ENGINE STOP MOTOR ASSEMBLY.

Fig. 21

03-2414

13. REMOVE THE INTAKE AIR HEATER RELAY AS SEMBLY.

Fig. 22

03-2434

ENGINE

EG12-2-31

ENGINE

CYLINDER HEAD

{2'1 =

�

/'),

16-----\ '\

CYLINDER HEAD AND RE LATED PARTS 1. Cylinder head 2. Cylinder head cover 3. Cylinder head cover gasket 4. Cylinder head gasket 1 er cap 5. Oil fll 6- Vent1·1 ator 7. Cylinder head bolt 8. Cylinder head cover bolt Fig. 1

9. Valve guide 10. Intake va Ive seat xhaust valve seat 11 : 12. ush rod guide pipe 13 . l'J ozzle sleeve ( copper sleeve) 14- O-ring 15- Oil filler 16- Vent hose SM3-15i8

ENGINE

---------------

EG12-2-32

ENGINE

14 -�

�19

VALVE MECHANISM ANO RELATED PARTS 1. Intake valve 2. Exhaust valve 3. Valve stem cap 4. Stem seal (Inlet) 4'. Stem seal (Exhaust) 5. Valve spring seat 6. Compression spring 7. Valve spring, outer 8. Valve spring upper seat 9. Valve stem key 10. Tappet Fig. 2

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Push rod Rocker arm support Intake rocker arm Exhaust rocker arm Adjusting screw Adjusting screw nut Support bolt Rocker arm shaft Plain washer Snap ring

SM3-1519

=----- .

ENGINE

EG12-2-33

ENGINE

HE11-068-00X01 (1320)

INTA KE AND EXHAUST MANIFOLD 1. Intake manifold 2. Gasket 3 · Inter cooler asse mbly 4. Inter cooI ver cover 5. Intake pipe . 6. Exhaust manifold gasket 7_ Seal ring Fig. 3

8. Exhaust manifold g_ Pipe 10. Flange 11 _ Gasket l 2. Bracket 13. Air breather plug 14. 0-ring SM3-1520

EG12-2-34

.ENGINE --------------- ENGINE

REMOVAL OF CYLINDER HEAD

Fig. 4

Fig. 6

SM3-703

REMOVE THE EXHAUST MANIFOLD.

REMOVE THE GLOW PLUGS CONNECTOR, INTAKE PIPE AND MANI FOLD.

03-2415

Remove the intake manifold brackets.

Remove the glow plugs connector.

REMOVE THE GLOW PLUGS

REMOVE THE INJECTION NOZZLES.

SM3-355

NOTE: When removing the nozzle holder, if foreign matter is allowed to enter the combustion cham ber, engine trouble may result. Be sure to clean off the surrounding area thoroughly before re moving the nozzle holder.

Fig. 7

Remove the nozzle holder fitting bolts.

After removal of the nozzle holder, cover the nozzle holder with cloth. Also cover the cylinder head with a cloth to prevent dust from getting in.

03-1507

Special Tool:

Fig. 8

SM3-356

Sliding Hammer (09420-1442) (09462-1130) Adapter

ENGINE

EG12-2-35

--------------- ENGINE

REMOVE THE CYLINDER HEAD COVER. NOTE: Clean all dust from around the cylinder head cover before removing it to prevent dust from getting in. 1. 2.

Fig. 9

Remove the vent hose. Remove the cylinder head cover.

03-2417

0* 0* ®*' ©*

0 0

o 0

-� Fig. 10

0 0

G)*

REMOVE THE CYLINDER HEAD ADDITIONAL BOLT. Loosen the cylinder head additional bolts in the numerical order shown.

o olo o o 0 Q O O 0 0 ri O O 0 0 O!O O O I S�3-415

REMOVE THE ROCKER ARM ASSEMBLY. Loosen the rocker arm support bolts and cylinder head bolts in the numerical order shown.

Fig. 11

SM3-704

•• •• •• •• •• ••

REMOVE THE PUSH RODS AND VALVE STEM CAPS. NOTE:

Fig. 12

Remove the valve stem caps. Pay special at tension not to drop the stem cap into the interior of the engine. Arrange the push rods and valve stem caps in correct order.

03-2032

LOOSEN THE CYLINDER HEAD BOLTS AND RE MOVE THEM. Loosen the cylinder head bolts in the numerical order shown.

Fig. 13

SM3-415

EG12-2-36

ENGINE

_______________ ENGINE

�

�□

111 t l

--- ------'P= Y �UP ANDDOWN L�

0 D D .

10. LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER BLOCK. 1. If the cylinder head is difficult to lift off, pry with a chisel between the cylinder head and block. NOTE: Do not damage the machined surface of the head or block when removing the cylinder head. Special Tool: Eye Bolt (09433-1061)

CY L l�DER B L O��

Fig. 14

2. Place the head on wooden blocks on a bench. NOTE: O When placing the cylinder head with nozzle holders on the work bench, do not inter ference between the nozzle holder tip and wooden blocks. 0 Check the cylinder head gasket thoroughly for sign of leaks of oil, coolant, or gas, as well as for overheating. SM3-425

Fig. 16

REMOVE THE TAPPET CHAMBER COVER.

12.

REMOVE THE TAPPETS FROM THE CYLINDER BLOCK. Hook the oil hole of each tappets with a hooked wire and lift the tappets up.

03-1516

<;::::J

NOTE: Arrange the tappets in correct order. FRONT

INTAKE EXHAUST

1 Fig. 18

11.

6 SM3-705

EG12-2-37

ENGINE

---------------- ENGINE

DISASSEMBLY OF CYLINDER HEAD 1.

REMOVE THE VALVE SPRINGS. Remove the valve stem cotters, upper valve seats, 1. and valve springs with a special tool. Special Tool: Valve spring press (09470-1022) 2.

,x)l;

!, !, !1 !, !1 !, !; !1 !1 !1 2

Fig. 20

Fig. 21

Remove the intake and exhaust valves.

KEEP THE VALVE SPRINGS ARRANGED IN THE SEQUENCE OF THE CYLINDERS. 1. Tag valves to identify their cylinder numbers and to eliminate valve lapping. Do not remove valve guides and valve seats unless 2. they need to be replaced.

DISASSEMBLE THE ROCKER ARM ASSEMBLY. Keep rocker arms in order so they can be re-installed in the same positions.

SM3-598

03-1518

EG12-2-38

ENGINE

________________ ENGINE ________________

INSPECTION AND REPAIR 1. 0.v,

CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUITABLE SOLVENT. NOTE: Be careful not to damage the cylinder head surface.

C)e_5) G(_) SM3-825

Fig. 22

INSPECT THE CYLINDER HEAD FOR CRACKS.

Check the head surface and intake and exhaust valve seat, for cracks, using a dye penetrant. If cracks are found, replace the cylinder head.

CHECK THE CYLINDER HEAD SURFACE FOR FLAT NESS.

Cylinder Head Surface Flatness: Assembly Standard: 0-0.05 mm (0-0.0019 in) Repair Limit: 0.10 mm (0.0039 in)

Fig. 24

Check the cylinder head surface for flatness with a straight edge and a thickness gauge. Follow the checking pattern as show. If the measurements exceed specified limits, correct by surfacing or re place the head.

-....--------+-------+�c---- A' c·

D---+-�"------4-- - _::,.k--+-D' A

B' SM3-554

Fig. 25

Fig. 26

SM3-706

Check the flatness of the intake and exhaust mani folds mounting surface.

EG12-2-39

ENGINE

----------------- ENGINE----------------

Fig. 27

CHECK THE CYLINDER HEAD HEIGHT (REGRIND ING LIMIT). Cylinder Head Height: Nominal Dimension: 95 mm (3.74 in) Service Limit 94.70 mm (3.7283 in) NOTE: O After the heads resurfaced, grind the valve seats so that the valve recession meet specifi cations. o When the height of a resurfaced head is less than the service limit, replace the head.

SM3-783

INSPECT THE VALVE CONTACT SURFACES FOR PROPER CONTACT.

Visually check valves for excessive wear, burn mark, carbon accumulation, warpage, or cracks in valve heads, valve stems, and valve stem grooves. Replace valves which are excessively worn, burnt, warped or cracked.

Check the valve seating condition. Lightly apply red lead marking compound to the valve face. Install the valve with a special tool, tap and rotate the valve against the seat. Check the valve face and valve seat for seating. When the red lead mark is not concentric or even al I around the valve face or seat, correct the valve face or the valve seat.

u Fig. 28

SM3-833

Special Tool: Valve Lapping Tool (09431-1010)

Fig. 29

HAND-LAP THE VALVE AND VALVE SEAT.

Lightly apply lapping compound to the valve face. Install the valve with a special tool, tap and rotate the valve against the seat.

NOTE: O Following completion of hand-lapping, clean off any lapping compound which has adhered to the valves and valve seats. O Following hand-lapping, always recheck the seating condition. Special Tool: Valve Lapping Tool (09431-1010)

Fig. 30

GRIND THE VALVES AND VALVE SEATS. NOTE:

o o

Grinding of valves and valve seats should only be performed when hand-lapping does not result in proper seating. When repairing or replacing valves and valve seats, always recheck their seating condition after assembly. After grinding, always recheck the valve sink.

EG12-2-40

ENGINE

--------------- ENGINE

\Jwu 1

300 ),-

. /'45

�-

✓

INTAKE

Assembly Standard: Valve Seat (Intake) Valve Face (Intake) Valve Seat ( Exhaust) : Valve Face ( Exhaust):

30 -30 15' ° ° 29 45' -30 ° ° 45 -45 15' ° ° 44 45'-45

EXHAUST

Fig. 32

SM3-899

IJ=--HAMMER -BRASS BLOCK

IF NECESSARY, REPLACE THE VALVE SEAT. 1. Cut the drcumference of a valve head at three places with a grinder and, install it into the seat as shown and weld the valve to the seat. Then drive the valve and the seat out with a hammer and a brass bar.

ELECTRIC WELDING APPLIED GRIND THIS POINT WITH A GRINDER SM3-895

Fig. 33

>--- A __.; ,__ A ---,

INTAKE EXHAUST

Valve seat section machining specifications.

·4 5

-. - C-

lo i)=$

30\,' INTAKE

�-

45''../ EXHAUST SM3-896

Fig. 34

Unit: mm (in) Valve seat dimension

Cylinder head dimension

Intake

52.000 -52.019 (2,0472 -2.0479)

(0.374 - 0.381)

(2.0506 - 2.0511)

(0.296 - 0.303)

Exhaust

45.500 -45.516 (1.7914 -1.7919)

9.5 - 9.7 (0.374 - 0.381)

45.63 - 45.645 (1.7965 - 1.7970)

8.0 -8.2 (0.315 - 0.322)

�

9.5 - 9.7

Fig. 35

SM3-826

52.085 - 52.100

D 7.5 - 7.7

Valve seat installation Heat the cylinder head to about 80° - 100° C (176212 0 F) with hot water. On the other hand, cool the valve seat with dry ice or liquid freon for about 30 minutes. Hold the seat with pincers and place it into the heated cylinder head. The valve seat can be easily made to fit by lightly hitting it.

ENGINE

EG12-2-41

---------------- ENGINE

9. "O" IS CYLINDER HEAD SURFACE

MEASURE THE VALVE SINK. Assembly Standard: Intake -0.05 - 0.25 mm (-0.0019 - 0.0098 in) 0.25 - 0.55 mm ( 0.0098 - 0.0216 in) Exhaust Service Limit: 0.5 mm (0.020 in) 0.8 mm (0.031 in)

Intake Exhaust

Fig. 36

SM3-831

SM3·236

NOTE: If the valve heads are protruding from cylinder head surface, the valve heads may hit against the pistons while the engine is running. 10. MEASURE THE CLEARANCE BETWEEN VALVE STEM AND VALVE GUIDE. 1.

Measure the outside diameter of the valve stem with a micrometer.

Normal Dimension: Intake and Exhaust: 9 mm Service Limit: Intake and Exhaust:

Fig. 38

Measure the inside diameter of the valve guide with a cylinder gauge.

Find the difference between the inside diameter of the valve guide and outside diameter of the valve stem. When the clearance exceeds specification, replace the valve guide or the valve.

------

Clearance between valve stem and guide:

INTAKE EXHAUST

7Iiij ��1 ·. :r=� y J g

,Ill__ i:; I 'f' i /;: _, I I ,i: / r � <� 1((i 1 ','., I ' I ' ,

\·I '

) i• 1U'l

�· r\g -

!. /-' j

:?ef ,P:Srsq .1

Fig. 39

8.89 mm (0.3500 in)

SM3-834

(0.35 in)

Intake

Nominal dimension

Repair Limit

UN IT MM

SM3-1269

·�,. i

0.055-0.088 mm 0.070-0.103 mm (0.0022-0.0035 in) (0.0028-0.0041 in)

_______t_ __

Exhaust

0.10 mm (0.0040 in)

0.12 mm (0.0047 in)

0.10 mm (0.0040 in) 0.18 mm (0.0071 in)

0.12 mm (0.0047 in) 0.20 mm (0.0079 in)

11. IF NECESSARY, REPLACE THE VALVE GUIDE.

(_..�.....t

03-674

Remove the valve stem seal.

Remove the valve guide.

ENGINE

EG12-2-42

_______________ ENGINE

CYLINDER HEAD

Install the valve guide. When installing a new valve guide, drive the guide straight into the head allowing it to protrude as shown.

NOTE: Apply engine oil lightly to the valve guide outer circumference before installation.

Fig. 41

SM3-389

Install the valve stem seal. Replace the valve stem seal when the valve guide is replaced or seal clearance is excessive or the stem seal has been damaged. First, install the lower spring seat and valve (For guide of special tool), then apply engine oil to the lip of the stem seal and drive the guide with a special tool. Special Tool: Stem Seal Press (09472-1781) 4.

SM3-984

Fig. 42

INTAKE

EXHAUST

WHITE PAINT

NONE PAINT

NOTE: Dinstinguish stem seal as shown in the left-hand figure since the same seal is not used for both intake and exhaust. Coat interior surface with oil.

sr-."3-709

Fig. 43

NOTE: After installing stem seal, make sure there is a gap A and B in the left-hand figure. Do not use the special tool if its tip (surface contacting lower spring seat) is worn or deformed.

COAT OIL

Fig. 44

SM3-709

12. INSPECT THE VALVE SPRINGS.

Check the valve springs for squareness using a square and a thickness gauge. If a spring is out of square be yond the service limit, replace it.

Service Limit: 2.5 mm (0.098 in)

Fig. 45

ENGINE

EG12-2-43

--------------- ENGINE

Measure the valve spring force at a specified length with the valve spring tester. If the spring force is lower than service limit, replace it.

Fig. 46

Free length mm (in)

Setting height mm (in)

68_6 (2.701)

47.5 (1.870)

LOWER SPRING SEAT

Fig. 47

Setting load kg (lb)

UPPER SPRING SEAT

Nominal dimension

Service limit

31.0 (68.3)

27.5 (60.6)

Check the contact surface of the upper spring seats and the lower spring seats. Replacement is necessary if damages such as wear and scratches is excessive.

SM3-529

13.

SM3-291

INSPECT THE ROCKER ARMS AND ROCKER ARM SHAFT. 1. Measure the inside diameter of the rocker arm bush ing using a cylinder gauge. If wear exceeds the service limit, replace it. Nominal Dimension: 24.2 mm (0.953 in) Service Limit: 24.28 mm (0.9559 in) NOTE: When installing a bushing into the rocker arm, align the oil holes of the bushing and the rocker arm. Measure the outside diameter of the rocker arm shaft with a micrometer. If _wear exceeds the service limit, replace it. Nominal Dimension: 24.2 mm (0.953 in) Service Limit: 24.12 mm (0.9496 in)

Fig. 49

SM3-836

ENGINE

EG12-2-44

--------------- ENGINE

Find the difference between the rocker arm bushing inside diameter and the shaft outside diameter. If the clearance is greather than the specified limit, replace the shaft and/or the bushing. Assembly Standard: 0.030--0.101mm (0.0012--0.0039in) Repair Limit: 0.15 mm (0.0059 in) 3.

◊ y•

CD EF

X� A'B' C'D' E'F' SM3-558

Fig. 50

SM3-930

Fig. 51

,,�

Fig. 52

( · -· ·

Fig. 53

14.

CHECK THE ADJUSTING SCREWS AND PUSH RODS. Check the adjusting screws for wear, or damage to the threads. If damaged or excessively worn, replace them. Check the push rods for wear. If excessive worn, replace them.

15.

INSPECT THE PUSH RODS FOR BENDING.

SM3-528

Place the push rod on a surface plate and insert a thickness gauge to measure the bend of the push rod. If the measurement is beyond limit, replace the push rod. Also replace the adjusting screw and the tappet if the wear of their contact surfaces is excessive.

Repair Limit:

0.5 mm (0.020 in)

SM3-292

16.

Fig. 54

Check the rocker arm and the valve stem cap. Check the contact between the rocker arm and the valve stem cap. Replace the rocker arm and the stem cap if damages such as wear and scratches are ex cessive. If there is only a minimal amount of wear, the surface can be refaced with a valve refacer.

MEASURE THE TAPPETS. 1.

03-686

Check the tappet face for wear. If excessively worn, replace it.

ENGINE

EG12-2-45

----------------

ENGINE

\./,;J"- ,C:.F-- .-" "

�\

(.):

?-· Fig. 55

/0 n

' n

--- '

Assembly Standard:

,,Q

SM3-420

Measure the outside diameter of a tappet with a micrometer and inside diameter of the tappet guide with a cylinder gauge. Find the clearance by calculating the difference of diameters. If the clearance exceeds the specified limit, replace the tappet and/or cylinder block.

SM3-293

Repair Limit

0.025 - 0.075 mm (0.0010 - 0.0029 in) 0.1 mm (0.004 in)

17. INSPECT THE CYLINDER HEAD COOLANT GALLERY FOR LEAKS. Close all coolant holes and apply air pressure of about 2.5 kg/cm2 (35 sq.in) from one of coolant hole. Immerse the cylinder head into the water, then check the air leakage. If any leakage is found, replace the cylin_der head.

18. IF NECESSARY, REPLACE THE NOZZLE SLEEVE. 1. Remove the nozzle sleeve Place a brass rod with a diameter of 12 mm (0.47 in) at the nozzle hole at the bottom of the cylinder head and remove the cylinder head by hitting the nozzle sleeve.

Fig. 56

Install the nozzle sleeve Set the O-ring into the cylinder head Apply adhesive (Super Three Bond No. 1210 or equivalent) to the lower part of the new copper nozzle sleeve and carefully insert the nozzle sleeve into the cylinder head.

NOTE: A damaged O-ring may cause leaks and lead to overheating or cracked heads.

Fig. 57

SM3-429

EG12-2-46

ENGINE

---------------- ENGINE 3.

Stick the nozzle sleeve fast to the cylinder head by pressing with the special tool. Insert the seat press (Special tool) into the nozzle sleeve. Push the ball through the hole with the special tool. So that the end of the nozzle sleeve with stick fast to the cylinder head.

SPECIAL TOOL

Special Tool:

Sleeve Bar (09472-1210) Steel Ball (9800-06100)

Fig. 58

Measure the protrusion of the nozzle from the cylinder head surface with a vernier caliper after the nozzle holder installation.

Assembly Standard: 3.40-3.90 mm (0.1339-0.1535 in) Tightening Torque: 130-190 kg-cm (10-13 lb.ft) CYLINDER HEAD

Fig, 59

SM3-391

19. IF NECESSARY, REPLACE THE PUSH ROD GUIDE

PIPE. 1.

a. b.

-y---flo!lcl.--PUSH ROD GUIDE PIPE

::i! ::i!

8 NI

�---□-

,,�.

Remove the push rod guide pipe. Screw a tap (TG-1/2 or PT 1/2) into the guide pipe. Drive the guide pipe out of the cylinder head using a hammer and a soft iron bar [ Diameter of 15 mm (0.591 in)] as shown. Hold the guide pipe with a pipe wrench and unscrew the tap from the guide pipe.

SM3-192

Fig. 60

2. a. SPECIAL TOOL

Apply adhesive (Three Bond No.1215 or equivalent) to the holes of the cylinder head.

Place the cylinder head on a surface plate with the cylinder head gasket surface down. Insert a new clean guide pipe into the cylinder head until it contacts the surface plate.

Caulk the guide pipe by driving the push rod guide pipe caulking tool (Special tool) into the guide pipe until the groove on the tool has just entered the pipe, but no farther. Then repeat this procedure with the other end of the pipe.

CYLINDER HEAD PUSH ROD GUIDE PIPE

Installation of push rod guide pipes.

Push Rod Guide Pipe Cauling Tool (09482-1320) d . Remove the caulking tool from the pipe, then check the cylinder head for water tightness. Water pressure or air pressure: About 2.5 kg/cm2 (36 psi) Special Tool:

Fig. 61

SM3-418

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

ENGINE

EG12-2-47

---------------- ENGINE

20. INSPECT THE INTAKE AND EXHAUST MANIFOLDS. 1. Clean the manifold with a brush, etc. 2. Using a dye penetrant, check for cracks of the flange surface. If cracks are found, replace the manifold.

SM3-710

Measure the intake manifold flange surface for flat ness with a straight edge and a thickness gauge. If the value exceeds the service limit, correct the flange by cutting it to become within 0.1 mm (0.004 in). Repair Limit: Within 0.5 mm (0.020 in)

Measure the exhaust manifold flange surface for flat ness with a straight edge and a thickness gauge. If the value exceeds the service limit, correct the flange by cutting it to become within 0.3 mm (0.012 in) per 3 flanges or 0.1 mm (0.004 in) per flange. Repair Limit: Within 0.5 mm (0.020 in)

4. Fig. 63

SM3-711

Fig. 64

SM3-456

Inspect the seal ring of the exhaust manifold. If it is significantly flattened, replace it with a new one.

EG12-2-48

ENGINE

---------------- ENGINE

ASSEMBLV OF THE CYLINDER HEAD 1.

INSTALL THE VALVE SPRINGS. 1.

Apply engine oil to the valve stems and insert the intake and exhaust valves in the cylinder head valve guides.

NOTE: Make sure that the valves are installed in the correct cylinders. 2.

SM3-824

Install the inner and outer valve springs and upper springs seats.

NOTE: 3.

Install the valve springs with their painted side down, since they have variable pitches.

Using the special tool, press upper spring seats and install the valve stem keys securely in the upper spring seats.

NOTE: When pressing with the valve spring press, be careful not to damage the stem seals by contact ing the upper seats.

ORANGE PAINT

Special Tool: Valve Spring P ress (09470-1022) Fig. 66

SM3-402

Fig. 67

THE ROCKER ARM.

Assemble the rocker arm.

Make sure that the rocker arm shaft is installed with the "UP" mark of the shaft upward. Incorrect assembly results in seizure of the valve system. The intake rocker arm is different in length from the exhaust rocker arm. Be sure to install the rocker arm in the correct order.

03-1519

XHAUSi"

INTAKE SM3-401

Fig. 68

Fig. 69

ASSEMBLE

SM3-357

EG12-2-49

ENGINE

---------------- ENGINE

,, '

Fig. 70

INSTALLATION OF THE CYLINDER HEAD 1.

INSTALL THE TAPPETS IN THE CYLINDER BLOCK IN CORRECT ORDER. NOTE: Apply engine oil to the tappet faces and tappet guide when installing them in the cylinder block.

\...

'-.•"•""'1-.

""'.• I

03-661

INSTALL THE TAPPET CHAMBER COVER USING A NEW GASKET. Tightening T orque:

Fig. 71

03-1521

((

Fig. 72

Fig. 73

190 - 260 kg.cm (14 - 18 lb.ft)

INSTALL THE CYLINDER HEAD GASKET. With the part numbers side upward, place a new cylinder head gasket over dowels on the block. NOTE: Always use new cylinder head gasket after clean ing the surfaces of the cylinder head, cylinder block and head gasket free of all dirt, water and grease.

SM3-531

INSTALL THE CYLINDER HEAD OVER THE DOWELS ON THE CYLINDER BLOCK.

APPLY ENGINE OIL TO THE THREADS AND HEADS OF THE CYLINDER HEAD BOLTS AND INSTALL THE BOLTS.

SM3-425

Tighten the bolts provisionally and lightly (exclude the extension bolts for rocker arm support). NOTE: Since the cylinder head bolts are unique to this engine, do not substitute ordinary bolts. Fig. 74

03-1524

EG12-2-50

ENGINE

--------------- ENGINE

INSERT THE PUSH RODS IN CORRECT ORDER, AFTER APPL YING ENGINE OIL TO BOTH ENDS. NOTE: Insert the push rod carefully until they make contact with the tappets. Do not drop them in.

INSTALL THE STEM CAPS

Make sure that both the end of the valve stem and the inside of the valve stem cap are free from dust. Apply engine oil to the valve stem ends and put the stem caps on the valve stem ends. Be careful not to drop the caps into the engine.

SM3-1266

fig_ 76

TIGHTEN THE CYLINDER HEAD AND ROCKER ARM ASSEMBLY.

1. 2. 3. SM3-712

Make sure that the cylinder head top surface and the rocker arm support bottom are free of dust, chips, or other foreign matter. Apply engine oil to the rocker arm end and adjust ing screw. Mount the rocker arm assembly on the cylinder head, make sure that the push rods interlock with the adjusting screws. WARNING

Always loosen the lock nut and raise the adjusting screws fully to the top. If the adjusting screws are too low, the piston and valves may strike each other during valve clearance adjustment. 4.

Fig. 78

SM3-704

Tighten the cylinder head bolts and rocker arm support bolts provisionally. Tightening order: 3-4-2-5-1-6 5.

Tighten the cylinder head bolts in three stages follow ing the tightening order. Tighten the bolts to the specified torque at each stage.

First Stage Second Stage Third Stage Special Tool Fig. 79

900 - 950 kg.cm (66 - 68 lb.ft) 1,350-1,400 kg.cm (98-101 lb. ft) 1,800-1,900 kg.cm (131-137 lb.ft) Wrench (09411-1070)

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

EG12·2·51

ENGINE

---------------- ENGINE

Tighten the rocker arm support bolts in three stages following the tightening order. Tighten the bolts to the specified torque at each stage.

First Stage Second Stage Third Stage

NOTE: The cylinder head extension bolts and the rocker arm support bolts have the same head size, so be sure to tighten them with their respectively correct tightening torques.

SM3-704

®*

I I

0* · Q)*

©*

®*

o o olo o o 0 0 0 Q O O 0

350 - 400 kg.cm (26 - 28 lb.ft) 500 - 600 kg.cm (37 - 43 lb.ft) 700 - 800 kg.cm (51 - 57 lb.ft)

Tighten the cylinder head additional bolt in the numerical order as shown. ( * mark)

Tightening torque: 650-750 kg-cm (47-54 lb.ft)

o o oio o o

Fig. 81

SM3-415

INSTALL THE INJECTION NOZZLE 1.

Insert the nozzle and holder assemblies into the nozzle sleeves with their inlet connectors toward the injection pump.

NOTE: Be careful not to let dust fall into the nozzle holder fits carefully over the top end of the sleeve. Be careful not to damage the ring packing when installing the nozzle holder. If damaged, the entry of oil, water and dust makes removing the nozzle difficult.

NOZZLE HOLDER RING PACKING O-RING

NOZZLE SLEEVE

Tighten the nozzle holder mounting bolts gradually and alternately. Then tighten the bolts at their specified torque.

Tightening Torque:

130 - 190 kg.cm (10 - 13 lb.ft)

NOTE: Insufficient tightening torque causes gas leaks and could result in nozzle seizure.

Fig. 82

SM3400

10. INSTALL THE GLOW PLUGS. Install glow plugs and glow plug connectors. Install screw grommets on the threads of the glow plugs.

Fig. 83

SM3-369

EG12-2-52

ENGINE

---------------- ENGINE

11. ADJUSTING THE VALVE CLEARANCE

FLYWHEEL HOUSING FLYWHEEL

·- - .J

Turning the crankshaft, align the mark "1-6" on the flywheel with the pointer on the flywheel housing. In this position either the No.1 or No.6 piston is at the top dead center end of the compression stroke.

Method for determining if the No. 1 or No.6 piston is at the top dead center of the compression stroke.

While looking at the push rod of No. 1 and No. 6 pistons. Turn the flywheel unticlockwise and clock wise about 30 ° to 40 ° (see left figure). If the piston whose exhaust and inlet push rod do not move during the interval, it is at the top dead center of the compression stroke. If the piston whose push rods have moved, it is at the completion of the exhaust and begun of the intake stroke (overlapping stroke).

Piston No. 1 is at the top dead center end of the compression stroke when the head of the through bolt of the injection pump drive shaft coupling be comes visible to you as the pointer of the flywheel housing aligns with the "1-6" markings on the fly wheel circumference.

If the injection timing mark is nearly aligned with the pointer, the No.1 piston is at top dead center end of the compression stroke.

TDC

- - -.... TIMING POINTER Fig. 84

SM3-8858

��

r-,;jjl ��

�� '�--,,i-� � \ PUSH RODS: STANDING {TDC of compression stroke)

Fig. 85

Fig. 86

PUSH RODS: MOVE {Overlapping stroke)

SM3-713

SM3-1521

ENGINE

EG12-2-53

ENGINE

ITi

VALVE CLEARANCE

1',I

With the No. 1 piston positioned at top dead center end of the compression stroke, adjust the No. 1 valve clearance using a thickness gauge. Insert a thickness gauge between the rocker arm and the valve stem cap to measure clearance. Loosen the lock nut and turn the adjusting screw to set the clearance. While holding the adjusting screw, tighten the lock nut as per specified torque. Check again and confirm the clearance. The thickness gauge should move with a very slight pull. Turn the crankshaft clockwise 120 ° viewing from timing gear cover side. Adjust the valve clearance for each cylinder in the firing order (1-4-2-6-3-5).

Valve Clearance: Intake : 0.30 mm (0.0118 in) Exhaust : 0.45 mm (0.0177 in) Tightening Torque: Adjusting Screw Lock Nut: Fig. 88

400-450 kg-cm (29-32 lb.ft)

SM3-715

12. INSTALL THE CYLINDER HEAD COVER. Make sure that the cylinder head surface is free of dust oi I or dust, and be sure that the gasket is fitted correctly into the groove of the cylinder head cover.

HEAD COVER

NOTE: If a cylinder head cover with the gasket fitted incorrectly is installed, the gasket will be damaged and oil leaks will result.

_-GASKET

Tightening Torque: Fig. 89

SM3 398

13.

Fig. 90

130-180 kg-cm (10-13 lb.ft)

INSTALL THE EXHAUST MANIFOLD.

When installing seal rings on the exhaust manifold, fit new seal rings in such a way that the gaps are equally spaced, as shown, to prevent gas and oil leakage.

Install the exhaust manifold.

SM31011

NOTE: Use a new gasket. Tightening Torque: 450-500 kg-cm (33-36 lb.ft)

Fig. 91

SM3-716

EG12-2-54

ENGINE

---------------- ENGINE

14. INSTALL THE INTAKE MANIFOLD. NOTE: Use a new gasket. Tightening Torque: 190-260 kg-cm (14-18 lb.ft)

15. INSTALL THE INTAKE PIPE. NOTE: Use a new gasket. Tightening Torque: 190-260 kg-cm (14-18 lb.ft)

16. INSTALL THE INTAKE MANIFOLD BRACKETS. Tightening Torque: 350-500 kg-cm (26-36 lb.ft)

ENGINE

EG12-2-55

--------------- ENGINE

TIMING GEAR AND CAMSHAFT

' ,,I

'/ ""

TIMING GEAR 1. Crankshaft gear 2. Ider gear 3. Camshaft gear

4. Injection pump drive gear 5. Oil pump drive gear 6. Timing match mark SM3-1523

Fig. 1

TIMING GEAR COVER AND RELATED PARTS 1. Timing gear cover 2. Gasket 3. Oil seal Fig. 2

4. Flange 5. 0-Ring 6. Blind plate SM3-1524

EG12-2-56

ENGINE

________________

ENGINE

TIMING GEAR AND RELATED PARTS 1. 2. 3. 4. 5.

6. 7. 8. 9. 10. 11. Fig. 3

Camshaft Woodruff key Thrust bearing Bolt Camshaft gear Plain washer Nut Thrust plate Idler gear Bushing Straight pin

Idler gear shaft Injection pump drive gear Collar Injection pump drive shaft Oil seal 17. 0-ring 18. Sleeve

12. 13. 14. 15. 16.

SM3-1525

EG12-2-57

ENGINE

--------------- ENGINE

DISASSEMBLY

Fig. 4

REMOVE THE OIL PAN. Remove the old gasket from the cylinder block and/ or oil pan.

REMOVE THE CRANKSHAFT PULLEY.

03-698

Remove the crankshaft pulley.

03-2420

2. Remove the crankshaft nut. NOTE: o Use a puller if necessary. 0 Do not remove the dust slinger. 3.

Fig. 6

Remove the crankshaft damper.

03-2421

REMOVE THE TIMING GEAR COVER. Remove the old gasket from the cylinder block and/ or timing gear cover.

REMOVE THE OIL STRAINER.

.,)

. .

•,

Fig. 7

Fig. 8

·,

,· .··.·· .. ·�·

. ; . •w:�.�

., ,

03-1528

03-1530

EG12-2-58

ENGINE

---------------- ENGINE

••

Fig. 9

Fig.10

REMOVE THE OIL PUMP.

REMOVE THE IDLER GEAR. Remove the idler gear by removing the mounting bolts.

REMOVE THE CAMSHAFT. Remove the camshaft assembly by removing the thrust bearing mounting bolts. NOTE: o Hold the tappets above the camshaft. o Pull out the camshaft, slowly turning it so as not damage the bearings.

REMOVE THE INJECTION PUMP DRIVE SHAFT.

03-1529

03-702

Fig. 11

03-1531

1. 2. 3.

Fig. 12

Remove through bolt. Remove the injection pump coupling. Remove the injection pump drive gear and shaft by removing the thrust bearing mounting bolts.

03-1385

REMOVE THE IDLER GEAR SHAFT.

Remove the mounting bolts. 1. 2. Using a special tool, remove the idler gear shaft. Special Tool: Sliding Hammer (09420-1442)

Fig. 13

03-1532

EG12-2-59

ENGINE

---------------- ENGINE

10. REMOVE THE CAMSHAFT GEAR. When the camshaft gear is worn or damaged, or the thrust bearing needs to be replaced, remove the cam shaft gear from the camshaft. Hold the camshaft assembly with a vice through wooden plates. Remove the nut, then using a gear puller, remove the gear. Fig. 14

03-706

11. REMOVE THE INJECTION PUMP DRIVE GEAR. When the injection pump drive gear is worn or damaged, or the thrust bearing needs to be replaced, remove the gear in the same manner as above.

Fig.15

03-707

EG12-2-60

ENGINE

--------------- ENGINE

INSPECTION AND REPAIR

Fig. 16

INSPECT THE GEAR TEETH FOR PITTING OR WEAR. If a gear is damaged, replace the gear.

MEASURE THE CLEARANCE BETWEEN THE IDLER GEAR BUSHING AND SHAFT.

SM3-845

Using a micrometer, measure the outside diameter of the shaft.

Fig. 17

Nominal Dimension

34.0mm (1.339 in)

Service Limit

33.85 mm (1.333 in)

SM3-914

Using a cylinder gauge, measure the inside diameter of the bushing. Calculate the clearance from the above measurement.

3. Clearance; Assembly Standard: 0.025 - 0.075 mm (0.0010-0.0029 in) 0.20 mm (0.0078 in) Repair Limit Fig.18

Fig. 19

MEASURE THE IDLER GEAR END PLAY. Using a feeler gauge, measure the clearance between the idler gear and the thrust bearing. If the measurement is greater than the limit, replace the thrust bearing. Clearance; Assembly Standard: 0.04 - 0.13 mm (0.0016 - 0.0051 in) Repair Limit 0.30 mm (0.0118 in)

SM3421

INSPECT THE CAMSHAFT. 1. Visually check the camshaft lobes and journals for damage or wear.

ENGINE

EG12-2-61

ENGINE

Measure the cam lift. Using a micrometer, measure the cam lift. Take a reading of A and B at the two axial points. If the cam lift is below the limit, replace the cam shaft. Cam Lift = A - B 2.

Cam Lift; Assembly Standard 7.18 mm (0.2827 in) 8.17 mm (0.3217 in)

Intake Exhaust

SM3-374

Intake Exhaust

�

Assembly Limit 6.38 mm (0.2512 in) 7 .37 mm (0.2902 in)

8----Fig. 22

SM3-404

Measure the camshaft journal and bearing. Measure the outside diameter of the camshaft jour nals with a micrometer and the inside diameter of the camshaft bearings in the cylinder block with a cylinder gauge. Calculate the clearance from the above measurement. If the clearance is greater than the limit, replace the bearings.

SM3-849

fig_ 24

SM3-850 y

A A"

{11' □ Y'

No. 1

61.5 (2.421)

No. 2

61.3 (2.413)

No. 3

61.1 (2.406)

No. 4

60.9 (2.398)

No. 5

60.7 (2.390)

No. 6

60.5 (2.382)

No. 7

58_3 (2.295)

58.3 (2.295)

Clearance

Y'�

Fig_ 25

Assembly Standard

---------

SM3-786

Unit: mm (in) Inside Diameter

Outside Diameter

Number of Journal

-0.10 (-0.0039)

Service Limit

Assembly Standard

Service Limit

61.1 (2.406) 60.9 (2.398) 60.7 (2.390)

+0.10 (+0.0039)

Assembly Standard

Repair Limit

0.03-0.08 (0.0012-0.0031)

0_15 (0.0059)

EG12-2-62

ENGINE

---------------- ENGINE

Measure the camshaft run out. Support the camshaft with V-blocks and measure the run out at the center journal with a dial gauge. If the run out exceeds the limit, correct with a press or replace. Repair Limit: 0.10 mm (0.0039 in) 4.

SM3-858

Measure the camshaft end play. Measure the clearance between the camshaft gear and the thrust bearing with a feeler gauge. If the clearance is greater than the limit, replace the thrust bearing.

Assembly Standard: Repair Limit

Fig. 28

MEASURE THE INJECTION PUMP DRIVE SHAFT AND BUSHING.

Using a micrometer, measure the outside diameter of the injection pump drive shaft.

Using a cylinder gauge, measure the inside diameter of the bushing. Calculate the clearance from the above measure-· ments.

SM3-1005

Assembly Standard: Repair Limit Fig. 29

0.030 - 0.072 mm (0.0012 - 0.0028 in) 0.30 mm (0.012 in)

SM3-1008

Fig. 30

0.100 - 0.178 mm (0.0040 - 0.0070 in) 0.3 mm (0.012 in)

SM3-10046

MEASURE THE INJECTION PUMP DRIVE GEAR END PLAY. Measure the clearance between the injection pump drive gear and the thrust bearing with a feeler gauge. If the clearance is greater than the limit, replace the thrust bearing. Assembly Standard: 0.100-0.200mm (0.0039-0.0078 in) Repair Limit 0.3 mm (0.012 in)

ENGINE

EG12-2-63

_______________ ENGINE

SLEEVE

INSPECT THE INJECTION PUMP DRIVE GEAR SHAFT SLEEVE. NOTE: If there is oil leakage from the O-ring area or if the contact surface with the oil seal is worn, replace the O-ring or the sleeve.

' , __ /

SM3-717

Fig. 31

DRIVE SHAFT

___ ..:--·,

�. Lr"'\

't.�

_-,

_...., ·,-1;,\ � _______,

��

/�0

SLEEVE

®]

Using a special tool, remove the sleeve. Put the puller [ Q), onto the sleeve. Insert the hook portion of the pulier between shaft and sleeve. c. Insert the puller [@]. d. After inserting the puller, screw in the CE:nter bolt [ A ] , then remove the sleeve. Special Tool: Puller (09420-1490) 1. a. b.

\...>---l:....-� .:..-

IF NECESSARY, REPLACE THE INJECTION PUMP DRIVE SHAFT SLEEVE.

·�' ' G) SLEEVE

Fig. 32

03-812

Using a special tool, install the shaft sleeve with a new O-ring.

a. b.

Put the O-ring 1 into the press 2 . Insert the new oil seal sleeve with new O-ring into the press and then insert them into the drive shaft. c. Hitting the "A" lightly by hammer, contact the press end and the shaft end "B", with this determine the oil seal sleeve position. NOTE: o Be sure to fit an O-ring on the sleeve and also apply a liberal coating of oil to the shaft. O When driving on the shaft sleeve, taking care that the O-ring does not get cut or torn. 0 Once a sleeve has been removed, it cannot be reused.

DRIVE SHAF � ·

y-' •

Fig. 33

0-RING

�

-------\

� ·

Special Tool: Press (09482-1550) O-ring (9851-36104)

ORJNG 03-813

EG12-2-64

ENGINE

---------------- ENGINE

Distance from the shaft end to the sleeve end (A): 27.1-27.7 mm (1.067-1.0905 in)

A Fig. 34

SM3-717

LIP

Fig. 35

SM3-406

INSPECT THE OIL SEAL. Inspect the lip of the oil seal and if it is damaged, replace the oil seal. Check the oil seal in respect of the following items; o Wear of the lip. O Cracking. 0 Adhesion of foreign matter. NOTE: 0 In order to prevent oil leakage from the oil seals due to lip wear, apply grease between the main lip and sub lip. o Grease used: Lithium-based grease. 0 Greasing points: Crankshaft oil seals (front and rear) Oil seal of injection pump drive shaft

10. IF NECESSARY, REPLACE THE TIMING GEAR CASE COVER OIL SEAL. 1. Using a screwdriver, remove the oil seal. 2. Using a special tool, install the new oil seal. Special Tool: Press (09482-1090)

SM3-718

EG12-2-65

ENGINE

---------------- ENGINE

ASSEMBLY 1.

INSTALL THE IDLER GEAR SHAFT Tightening Torque:

Fig. 37

500 - 650 kg.cm (37 -47 lb.ft)

03-1543

INSTALL THE INJECTION PUMP DRIVE GEAR TO THE SHAFT. °

Install the gear 1 heated to about 180 C (356 Fl on the shaft. Make sure that the gear 1 is closely fitted against the shoulder of the shaft 4 through the collar 3 and the thrust bearing 2 . Tightening Torque: 1,600-1,800 kg.cm (115-130 lb.ft) Fig. 38

INSTALL THE INJECTION PUMP DRIVE SHAFT. Apply engine oil to the bearing surface of the shaft and the sleeve. Then insert the shaft assembly into the cylinder block. Be careful not to damage the bushing and the oil seal. Tightening Torque: 190 - 260 kg.cm (14 - 18 lb.ft)

Fig. 39

03-1544

-♦-:i

,-.c:::=--:

�,J_b:,;,, Fig. 40

INSTALL THE CAMSHAFT

S'v13-422

Install the camshaft gear with thrust bearing.

NOTE: When installing the gear to the camshaft: o Before installation of the gear to the cam shaft, heat the gear in hot water [Approx. ° ° 100 c (212 F)], then install the gear to the camshaft by using a press. o When tightening the bolts, apply engine oil to the threads and bearing surface of the bolt. Tightening Torque: 2,500-3,000 kg.cm (181-216 lb.ft)

Fig. 41

03-1545

ENGINE

EG12-2-66

----------------- ENGINE

Lubricate all journals of the camshaft and insert the camshaft assembly into the cylinder block. Tighten the bolts at the specified torque to fix the thrust bearing to the cylinder block.

NOTE: Insert the camshaft, slowly turning while insert ing so that the bearing will not be damaged. Tightening Torque: 190-260 kg-cm (14-18 lb.ft) 03-1546

FLYWHEEL HOUSING FLYWHEEL

SET THE No. 1 PISTON TO TOP DEAD CENTER OF THE COMPRESSION STROKE. Refer to page 3-3-22.

INSTALL THE IDLER GEAR

TDC

..... .,, TIMING POINTER Fig.43

SM3-885B

When installing the idler gear, be sure that the matching marks of the crankshaft gear, camshaft gear, injection pump drive gear, and idler gear aligned correctly. Incorrect installation can results in engine damage or lowering of engine performance by causing improper injection timing. Tightening Torque: 1,100 - 1,300 kg.cm (80 -94 lb.ft)

,______::____:-'----'--.!........!...-'--'--'---�--..c./ __J

Fig.44

SM3-806

MEASURE THE GEAR BACKLASH

Measure the backlash of each gear using a dial indicator. Replace the gear if necessary.

SM3-844 Unit: mm (in) Backlash Gears Crankshaft gear and idler gear Injection pump drive gear and idler gear Camshaft drive gear and idler gear Oil pump drive gear and camshaft drive gear

Assembly standard

0.05-0.11 (0.0020-0.0043) 0.07-0.22 (0.0028-0.0086)

Service limit

0.30 (0.0118) 0.35 (0.0138)

ENGINE

EG12-2-67

---------------- ENGINE

Fig.46

Before installation, visually check the oil pump gear teeth for damage or wear.

Make sure that the O-ring is in place in the oil hole in the cylinder block. If the O-ring is not installed, it causes a lowering of oil pressure. Always use new O-rings.

Install the oil pump.

Tightening Torque:

03-1548

Fig.47

INSTALL THE OIL PUMP AND STRAINER

SM3-380

The oil strainer is fixed to the end of the suction pipe. Install the suction pipe according to the following procedure in order to minimize the setting stress of the bracket.

Be sure to install a new O-ring the pipe flange. If the O-rings are not installed it may result in engine seizure by causing a lowering of oil pressure.

First, finger tighten the bolts 1 to mount the pipe flange on the oil pump. Then check that the bracket is positioned properly and the clearance between the bracket and the block is less than 0.5 mm (0.0196 in).

Finger tighten the bolts 2 to mount the bracket on the block.

Tighten the bolts 1 holding the pipe in place, and then the bolts 2 .

Tightening Torque:

i' a .

Fig.48

380-500 kg-cm (28-36 lb.ft)

180-230 kg-cm (14-16 lb.ft)

03-1530

INSTALL THE TIMING GEAR COVER Install the timing gear cover on the block. Cut the protrusion of the gasket from the oil pan mounting surface of the block and make the gasket flush.

TIMING GEAR COVER

Fig. 49

SM3-268

-·

>,'" .... ii""

Fig. 50

03-1528

EG12-2-68

ENGINE

-------------- ENGINE

10. INSTALL THE CRANKSHAFT DAMPER. Install the crankshaft damper on the crankshaft. Tighten the nut with the spacer in place. NOTE: The nut for mounting the crankshaft damper is designed for this propose only. Never use an ordinary nut as a substitute. Tightening Torque: 5,500-7,000 kg-cm (398-506 lb.ft) Fig. 51

03-2421

11. INSTALL THE CRANKSHAFT PULLEY. Tightening Torque: 450-500 kg-cm (32-36 lb.ft)

Fig.52

03-2423

12. INSTALL THE Oil PAN.

/ L,CYLINDER BLOCK \()) !

(

, I

(a j OIL SEAL CASE Fig.53

Fig.54

SM3-245

When the rear oil seal case have been removed, always use a new gasket when reinstalling. When the ends of the gasket protrude from the bottom surface of the block, make the gasket flush to the bottom surface by cutting the protruded ends. Since a two-ply oil pan gasket is used, install the oil pan gasket with its attached sheet side faced to the oil pan. Tightening Torque: 180-230 kg-cm (14-16 lb.ft)

EG12-2-69

ENGINE

---------------- ENGINE

CYLINDER BLOCK, FLYWHEEL HOUSING, PISTON AND CRANKSHAFT

CYLINDER BLOCK AND RELATED PARTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Fig. 1

Cylinder liner Cylinder block Bearing cap Bearing cap bolt Oil jet pipe Oil check valve Oil pump safety valve Injection pump drive shaft bushing Plug Camshaft bearing

11. 12. 13. 14. 15. 16. 17. 18.

Dowel Seal plate O-ring Oil seal case gasket Oil seal case Oil seal Flywheel housing dust cover Flywheel housing

SM3-1526

EG12-2-70

ENGINE

--------------- ENGINE

CRANKSHAFT, PISTON AND RELATED PARTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Crankshaft Crankshaft gear O-ring Crankshaft sleeve Dust cover Crankshaft pulley Spacer Nut P iston Piston ring set Piston pin Retainer ring Connecting rod bolt

14. 15. 16. 17. 18. 19. 20. 21. 22_ 23. 24. 25.

Connecting rod nut Piston pin bushing Connecting rod assembly Connecting rod bearing Thrust bearing set Main bearing set Ring gear Flywheel Collar Key Bolt Crankshaft damper SM3-1527

Fig. 2

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

EG12-2-71

ENGINE

---------------- ENGINE

DISASSEMBLY 1.

REMOVE THE FLYWHEEL ASSEMBLY

Loosen the flywheel mounting bolts. Hold a metal rod through the starter hole against the flywheel and drive the rod lightly with a copper hammer to remove the flywheel from the crankshaft while rotating the crankshaft.

Remove the ring gear. Heat the ring gear with a blow torch in a uniform ° manner [Approx. 100 ° C (212 F)] b. Using a metal rod as a pad and strike all around the ring gear in a uniform manner and remove the ring gear. NOTE: Remove the ring gear only when replacement is necessary.

2. a.

SM3-787

Fig. 5

Fig. 6

REMOVE THE FLYWHEEL HOUSING.

REMOVE THE OIL SEAL CASE.

REMOVE THE PISTONS WITH CONNECTING RODS. Loosen the connecting rod bolts to remove the connecting rod cap. Extract the piston and connecting rod assembly out through the top of the cylinder. The pistons can be removed two at a time; No. 1 and No.6, No.2 and No.5, No.3 and No.4 are removed together.

03-1552

03-1549

ENGINE

EG12-2-72

---------------- ENGINE

When removing the piston and connecting rod as sembly, be careful not to damage the inside of the liner with the large end of the connecting rod.

When rem�ving the pistons, be careful not to drop the large end bearing of the connecting rod or damage it.

During reassembly, the caps must be reassembled with the same connecting rod and in the same position. likewise, the cap bearings and connecting rod bearings must maintain their original positions. Therefore, be careful to note these positions during removal and not to mismatch one part with another.

Before removing the pistons, remove carbon de posits from upper end of the liners with a scraper or emery paper (recommended: No. 150) in a circular direction.

NOTE: Remove the connecting rod in such a way that the connecting rod does not contact the cooling jet.

Adjust the cooling jet if by any chance the rod and the jet make contact.

Fig. 8

REMOVE THE CRANKSHAFT. Loosen the bearing cap bolts to remove the main bearing cap. Remove the crankshaft.

REMOVE THE CONNECTING ROD. Remove the retainer ring installed on both ends of 1. the piston pin, by means of retainer ring pliers. 2. Apply a metal pad to the pin and strike out the pin with a hammer. NOTE: Warm up the piston first in hot water 80 - 90° C ( 176-194° F) for about 5 minutes before remov ing the pin.

REMOVE THE PISTON RINGS Remove the piston rings using a special tool. Special Tool: Piston Ring Expander

03-729

(f1�:� . / 'f'

Fig. 9

SM3-294

(09442-1061)

NOTE: c Handle the piston rings carefully because they are made of a special casting which is easily broken. c Keep the rings for each cylinder separate. Fig. 10

ENGINE

EG12-2-73

---------------- ENGINE

REMOVE THE CYLINDER LINER. It is possible to remove the cylinder liner by hand. If, however, the liner is struck to the block, pull it towards the head, using a special tool. Special Tool: Cylinder Liner Puller (09420-1240) 3. Successively remove the 6 cylinder liners through this procedure. 4. After removing the cylinder liners, put numbers 01� their periphery or arrange them in sequence. Before removing the cylinder liners, be sure to put 5. matching marks on the cylinder block and liner flange in order to ensure that the liners face their original directions when replacing. This is because the liners are thin and there is a rick of them being deformed by external force when reusing them. Do not make matching marks with a punch. Using a pen. 1. 2.

Fig. 11

SM3-851

Fig. 12

SM3-852

CLEAN THE CYLINDER BLOCK THROUGH THE FOLLOWING PROCEDURE. 1. 2. 3. a. b. c. d. e. f. g. 4. 5.

Shake the block in a hot bath containing a com mercially available alkali solution, in order to remove oil and grease. Wash the block in hot water or steam to remove the alkali solution. If the coolant jacket is particularly dirty, clean it through the following procedure. Shake the block in commercially available pickling acid. Stop shaking the block, then let it lie for about 30 minutes in the bath. Raise the block, drain off the liquid, then immerse it for 10 minutes in the same liquid. Repeat step c. until all scale has been removed from the block. Rinse the block in warm water in order to remove all of the acid. Neutralize any remaining acid by immersing the block in an alkali bath. Wash the block with water or steam. Dry the block with air and blow air through all the bolt holes. Confirm that all water passages and oil galleries have been completely cleaned, then completely dry the block, and drive in new plugs, coated with seal ing compounds.

EG12-2-74

ENGINE

---------------- ENGINE

INSPECTION AND REPAIR 1.

Fit- 14

CONNECTING ROD 1.

Inspect with a dye penetrant or magnetic flaw detection test to see if there are any cracks or other defects on the connecting rod.

An oil hole is provided in the connecting rod for lubricating the small end. Check to ensure that this hole is not clogged up, by blowing air through it or inserting a piece of wire into it.

Measure bending and twisting of the connecting rod. Measure the bending and twisting of the connecting rod using a connecting rod aligner. If the specified limits are exceeded, replace the connecting rod.

SM3-424

Service Limit; Connecting Rod Straightness: 0.05 mm (0.0020 in) for each 100 mm (0.94 in) Connecting Rod Twist: 0.05 mm (0.0020 in) for each 100 mm (3.94 in) Fig_ 15

Fig_ 16

SM3-331

MEASURE THE SMALL END BUSHING AND PISTON PIN. 1.

Fig. 17

Inspect the bushing of the connecting rod for scor ing, seizure, or other damage, and replace it, if it is damaged. Inspect the piston pin for signs of fretting and replace it, if it is damaged. The surface of the pin has been ground to a very fine finish. Do not, therefore, regrind it.

ENGINE

EG12-2-75

---------------- ENGINE 3.

Replace the piston pin if its outside diameter exceeds the specified limit.

Replace the piston pin or bushing if the clearance exceeds the specified limit. Piston Pin Outside Diameter; Nominal Dimension: 38.989 - 39.000 mm ( 1.5350 - 1.5354 in) Service Limit 38J?5 mm (1.5334 in) Clearance Between Piston Pin and Bushing; Assembly Standard: 0.015 - 0.036 mm (0.0006 - 0.0014 in) Repair Limit : 0.1 mm (0.004 in) 4.

SM3-297

Fig.18

. l"

Fig. 19

SM3-299

Fig. 20

SM3-1274

Fig. 21

SM3-298

MEASURE THE ROUNDNESS OF THE CONNECT ING ROD. Tightening Torque: 1,650-1,850 kg.cm (120-133 lb.ft) Connecting Rod; Nominal Dimension 68.985-69.000 mm (2.7160-2.7165 in) Roundness; Service Limit 0.06 mm (0.0024 in)

MEASURE THE SPREAD DIMENSION OF THE CON NECTING ROD BEARING AND INSPECT THE CON NECTING ROD BEARING. Inspect the connecting rod bearing. If there is any scoring, pitching, flaking, corrosion, or seizure, replace both the top and bottom beraring as a set. Nominal Dimension 69.75 - 70.25 mm (2.7461 - 2.7657 in) Service Limit 69.2 mm (2.7244 in)

EG12-2-76

ENGINE

--------------- ENGINE

MEASURE THE OIL CLEARANCE BETWEEN THE CONNECTING ROD AND CRANK PIN. 1. Measure the connecting rod inside diameter. Tightening Torque: 1,650-1,850 kg.cm (120-133 lb.ft)

Fig. 22

Measure the crank pin diameter. If the clearance between the bearing and the crank pin exceeds the specified limit, replace the bearing. If the wear of the crank pin is great or uneven (see item on crankshaft), grind the crank pin to match an undersize bearing 4 types: 0.25 mm (0.0098 in), 0.50 mm (0.0197 in), 0.75 mm (0.0295 in), 1.00 mm (0.0394 in) and replace the bearing with an undersized one. 0.031 - 0.082 mm Assembly Standard: (0.0012 - 0.0032 in) Repair Limit 0.15 mm (0.0059 in)

€9 Fig. 23

SM3-300

Fig. 24

SM3-860

N O TE: The connecting rod bearing consists of a top and bottom half. Be sure to replace both halves together.

y I

x--©-x·

y•

Fig. 25

SM3-430

Fig. 26

SM3-862

MEASURE THE CONNECTING ROD END PLAY. Assembly Stand ard: 0.2-0.5 mm (0.008-0.020 in) Repair Limit 0.6 mm (0.024 in) Tightening Torque: 1,650-1,850kg.cm (120-133 lb.ft)

EG12-2-77

ENGINE

---------------- ENGINE

INSPECT THE CYLINDER LINER 1.

Before measuring the inside diameter of each cylinder liner, check to see that carbon has been removed from the inside of the liner and also if there are any scratch marks on the inside of the liner.

2. a.

Measure the inside diameter of the cylinder liner. Using a cylinder gauge, measure the inside diameter of each liner at two points in the axial direction (X) and the perpendicular direction (Y), respectively. If the service limit is exceeded, replace the liner.

Fig. 27

SM3-359

Nominal Dimention: 108 mm (4.25 in) Service Limit: 108.15 mm (4.2579 in) b.

SM3-313

Fig. 28

If the wear of the cylinder liner is small and only the piston rings are to be replaced, correct the ridge at the top of the cylinder liner.

------'-- co

11-----------_---H-----------_ ___

__l SM3-432

Fig. 29

MEASURE OF THE CLEARANCE BETWEEN CY LINDER LINER AND PISTON. Measure the minimum inside diameter of the cylin der liner (bottom end of the liner) and the maxi mum outside diameter of the piston [64.2 mm (2.53 in) away from the bottom end of the piston and perpendicular to the pin] with a cylinder gauge and a micrometer, and calculate the clearance from the difference of the two. Replace both the piston and the liner if the standard value is exceeded. Nominal Dimension of Liner: 108 mm (4.25 in)

Clearance Between Piston and Liner; Assembly Standard: 0.192 - 0.224 mm (0.0076 - 0.0088 in)

/4.-----0 UTSI DE DIAMETER i

Fig. 31

SM3-433

ENGINE

EG12-2-78

---------------- ENGINE

MEASURE THE PISTON PIN HOLE AND PISTON PIN. If the clearance exceeds the specified limit, replace the piston or piston pin. Clearance Between Piston Pin Hole and Piston Pin: 0.013T - 0.014l mm (0.0005T - 0.0006L in)

Repair Limit: 0.1 mm (0.004 in) NOTE: T = Tight, L = Loose

Fig. 33

SM3-297

10. MEASURE THE PISTON RING GROOVES AND RINGS Insert the piston rings into the piston ring grooves, then measure the clearances between the ring grooves and the piston ring, using a thickness gauge. If the clearances exceed the specified limit, measure the thicknesses of the ring and also the width of the ring grooves. If these values also exceed the specified limits, replace the piston or piston rings_

ll 1/.'

Fig. 35

,,,

SM3-379 Unit: mm (in) Clearance

Ring thickness

Dimension

Service limit

2.25 (0_0886)

2.5 (0.098)

2.75 (0_1083)

2.25 (0.0886)

2.5 (0.098)

2.75 (0.1083)

5.0 (0.197)

5.05 I0.19881

Dimension

Service limit

Assembly standard

Repair limit

2nd ring

0.04-0.08 (0_0016-0.0031)

0.4 (0.016)

2_5 (0.098)

3rd ring

0.04-0.08 (0.0016-0.0031)

0.4 (0.016)

2.5 (0.098)

Oil ring

0.02-0.06 I0.0008-0.0023)

0.08 (0.0031)

5.0 (0.197)

4.95 (0.1949)

�

Groove width

Not easily measured.

Top ring

EG12-2-79

ENGINE

11. MEASURE THE PISTON RING GAP Insert the piston rings into the cylinder liner and measure the gap between the ends of each ring, using a thickness gauge. During this above operation, insert the piston rings into the bottom portion where the wear of the liner is small, using the head of the piston and measure the gap after ensuring that each ring is perpendicular in the cylinder. If the gaps exceed the specified limits, replace the rings. NOTE: If the liner is new, the piston rings may be installed in any part of the liner.

Fig. 36

Piston Ring Gap;

---------------

Unit: mm (in) Assembly standard

Service limit

Top ring

0.3 - 0.45 (0.012 - 0.0171

1.5 (0.0591

2nd ring

0.3 - 0.45 (0.012 - 0.017)

1.2 (0.047)

3rd ring

0.3 - 0.45 (0.012 - 0.017)

1.2 (0.047)

Oil ring

0.3 - 0.5 (0.012 - 0.019)

1.2 (0.047)

12. INSPECT THE CRANKSHAFT 1.

Completely clean the crankshaft with suitable clean ing solvent, and then blow air through the oil hole to see whether it is clogged.

It is necessary to carefully inspect the crankshaft, particularly the R portion and the oil holes of the journal and pin, for cracks, using a dye penetrant or magnetic flaw detector. Check the surface of the crankshaft pin and journal for roughness and scratches, and grind or replace the crankshaft as necessary.

SM3-435

Support the ends of the crankshaft on the V-block, then rotate the crankshaft and measure the amount of bending using a dial gauge. If the amount of bending exceeds the specified limit, replace the crankshaft. Repair Limit: 0.18 mm (0.0071 in) (Indicator Reading)

ENGINE

EG12-2-80

________________ ENGINE

13. MEASURE THE SPREAD DIMENSION OF THE MAIN BEARING AND INSPECT THE MAIN BEARING 1.

Fig. 40

If the spread dimension exceeds the standard dimen sion, replace the main bearing. Inspect the main bearing for scoring, pitching, flak ing, corrosion and seizure. In particular, check to see if there is any abnornality in the contact at the rear face of the bearing. If one of the above defects exists, replace the main bearing.

NOTE: If it is necessary to replace even one main bear ing, replace all of the upper and lower bearings. Also, replace all of the bearings when the crank shaft is replaced with a new one. Nominal Dimension: Service Limit

85.75-86.75 mm (3.3760-3.4154 in) 85.20 mm (3.3543 in)

14. MEASURE THE ROUNDNESS OF THE BEARING CAP

After tightening the main bearing cap of the crank shaft to the cylinder block, using the specified torque, slacken in and then tighten it to the speci fied torque again. Then measure the roundness of the bearing cap using a cylinder gauge. If, as a result of measurement, the specified limit is found to be exceeded, perform build-up welding and line boring or replace the cylinder block.

SM3436

Fig. 41

Tightening Torque: 1,600-1,800 kg,cm (115-130 lb.ft) Repair Limit of Roundness: 0.06 mm (0.0024 in) NOTE: The main bearing cap is machined together with the block. Accordingly, during assembly, be sure to install each bearing cap in its original position. 0

�

SM3438

Fig. 42

15. MEASURE THE OIL CLEARANCE BETWEEN THE CRANKSHAFT JOURNAL AND MAIN BEARING

-4-ftul

Fig. 43

SM3-431

SM3-B60

Crankshaft journal Measure the outside diameter of the journal of the crankshaft using a micrometer.

ENGINE

EG12-2-81

---------------- ENGINE

Nominal Dimension Repair Limit Service Limit

80 mm (3.15 in) 79.9 mm (3.146 in) 78.8 mm (3.102 in)

x{t)x

SM3-431

Fig. 44

Bearing Install the crankshaft main bearing on the cylinder block and cap, then tighten the c.ap bolts to the specified torque and measure the inside diameter with a cylinder gauge.

Tightening Torque: 1,600-1,800 kg-cm (115-130 l b.ft) Assembly Standard Clearance: 0.051-0.102 mm (0.0020-0.004 in) Repair Limit : 0.15 mm (0.0059 in) SM3-437

Fig. 45

)

!�

SM3-440

Fig. 46

Crankshaft maching; Under size

Unit: mm (in)

Outside diameter Crank pin Journal

0.25

64.71-64.69 (2.5477-2.5468)

79.71-79.69 (3.1382-3.1374)

0.50

64.46-64.44 (2.5378-2.5370)

79.46-79.44 (3.1284-3.12750

0.75

64.21-.64.19 (2.5280-2.5272)

79.21-79.19 (3.1185-3.1177)

1.00

63.96-63.94 (2.5182-2.5173)

78.96-78.94 (3.1087-3.1078)

NOTE: 0 If the clearance between the bearing and journal exceeds the specified limit, replace the bearing. 0 If the wear of the crankshaft journal matches an undersize bearing 4 types 0.25mm (0.00984 in), 0.50 mm (0.01968 in), 0.75 mm (0.02952 in), 1.00 mm (0.03937 in), replace the bear ing with an undersized one. 0 The main bearing is a set consisting of upper and lower halves. Consequently, be sure to replace the bearing as a set.

ENGINE

EG12-2-82

---------------- ENGINE

Dimensionof FilletR: Crank pin: 3.75-4.25 mm (0.1477-0.1673 in) Journal : 3.00-3.50 mm (0.1182-0.1377 in)

CORRECT !._______ WRONG----�' Fig. 47

SM3-441

16. MEASURE THE CRANKSHAFT END PLAY

Measure the end play of the crankshaft using a dial gauge. If the end play exceeds the specified limit, replace the thrust bearing with an oversize one 0.25 mm (0.0098 in). A s sembly Stand ar d: 0.05 - 0.219 mm (0.0020 - 0.0086 in) Rep air limit 0.5 mm (0.020 in) Fig. 48

SM3-362

17. INSPECT THE CYLINDER BLOCK 1. Visually inspect each part of the cylinder block for cracking, and if necessary perform a dye penetrant. Clean out the various oil holes with compressed air.

Measure distortion at the top of the cylinder block. Check the distortion at the top of the cylinder block, using a straight edge and a thickness gauge, employing the same procedure as that for the cylinder head. If the specified limit is exceeded, replace the cylind er block. Assembly Standard: 0 - 0.05 mm (0 - 0.0019 in) Repair limit 0.1 mm (0.004 in)

Fig. 49

03-754

EG12-2-83

ENGINE

--------------- ENGINE 18. INSPECT THE PISTON COOLING JET POSITIONING.

Inspection of the piston cooling jet positioning procedure are as follows. 1. Remove the piston cooling jet connector bolt and install a special tool. Special Tool: Connector Bolt (9001-24262)

---__,---

Fig. 51

SM3-957

2. 3.

COOLING JET BOLT FOR INSPECTION

Connect the oil lines. Connect the oil pump outlet to a special tool (con nector bolt).

Install a special tool on the cylinder block with locating pins.

OIL HOSE FOR INSPECTION Fig. 52

Use a commercially available oil pump [pressure about 2 kg/cm2 , flow rate about 3Q/min (0.93 US.gal)]. Prepare new engine oil.

SM3-579 TARGET PLATE

LOCATING PIN

CYLINDER BLOCK

Fig. 53

Special Tool: Target Plate (09444-1290)

SM3-580

Operate the oil pump, and with pressure at about 2 kg/cm 2 (28.44 lb/sq-in),pump.new oil from the jet, and perform a spray test. Conditions are normal if the center of stream hits a target plate of ¢ 10 mm (0.39 in).

WARNING Diesel oil is flamable. This spray test should be done in a well ventilated room and away from any open flames or electric sparks.

,.-----________J\__�

o$- $ ® '----y------'

SPRAY

1(TARGET<t>10

.___________,.-

ABNORMAL NORMAL Fig. 54

SM3-581

EG12-2-84

ENGINE

--------------- ENGINE

If the spray of the cooling jet messes the circle on the target plate, realign then nozzle using a special tool. Special Tool: Adjuster bar (09472-1620) 7.

· fj/ 1,

·,

Fig. 55

� SM3-953

lll SPRAY PATTERN

Fig. 56

8. VSPRAY

�OLINGJET

3 4 2 ,---� NORMAL

ABNORMAL ,/

SM3-582

Spray pattern. When inspecting the piston cooling jet positioning, check that the spray is dispersed as shown in (4) and not as in ( 1), (2), or (3) in the illustration at left. Check that the spray is not a thin muddy color.

WARNING If the tip of the jet is damaged so that'the spray pattern is bad, replace the jet with a new one. When replacing the cooling jet, always inspect the new piston cooling jet's positioning. After inspecting the piston cooling jet pos1t1oning. Remove the special tool (connector bolt), then install the cooling jet on the cylinder block using the correct mounting bolt. Tightening Torque: 200-250 kg-cm (15-18 lb.ft) 9.

10. After installing the piston, make sure that there is no interference between the cooling jet and the piston when the piston is at bottom dead center. NOTE: 0 Do not remove the cooling jet except when performing overhauls or when otherwise necessary. O In the event that the cooling jet is removed, be sure to replace it on the cylinder.

19. INSPECT THE FLYWHEEL 1. Measure the runout of the friction face of the fly wheel using a dial gauge. If the limit is exceeded, re grind the friction face. Repair Limit: 0.3 mm (0.012 in)

Fig. 58

03-2425

ENGINE

EG12-2-85

---------------- ENGINE

SPECIAL TOOL

20. REPLACEMENT OF THE CRANKSHAFT SLEEVE (FRONT AND REAR)

Remove the crankshaft sleeve using a special tool.

Special Tool:

Puller (09401-1071) Puller (09420-1420)

NOTE: Do not remove the crankshaft gear unless it is considered absolutely necessary. I FRONT SIDE)

(REAR SIDE)

SMJ-666

SMJ-665

Fig. 59

SLEEVE O-RING SPECIAL TOOL

.. -

SLEEVE / O-RING -· �;SPECIAL ,. , ' -�.. TOOL ----.,·..a-

�-=-3,

!!--

Install a new sleeve Be sure to fit an O-ring on the sleeve and also apply a liberal coating of oil to the pulley center side at the front, and the crankshaft side at the rear . When driving on the crankshaft sleeve, use a crank shaft sleeve press, taking care that the O-ring does not get cut or torn.

Special Tool: (FRONT SIDE) SMJ-667 Fig. 60

(REAR SIDE) SM3-668

21.

Press (09402-1210) Press (09482-1400)

INSPECT THE OIL SEAL

Inspect the lip of the crankshaft oil seal and if it is damaged, replace the oil seal. Check the oil seal in respect of the following items;

0 O Fig. 61

SM3406

Wear of the lip. Cracking. Adhesion of foreign matter.

NOTE: O In order to prevent oil leakage from the oil seals due to lip wear, apply grease between the main lip and sub lip. O Grease used: Lithium-based grease. o Greasing points: Crankshaft oil seals (front and rear) Oil seal of injection pump drive shaft (installed on cylinder block).'

PRESS

s==

22. METHOD OF INSTALLING OIL SEAL =,- T PECIAL TOOL l �

Using a special tool, insert an oil seal to the timing gear cover, taking care that it does not project from the end of the timing gear cover.

Special Tool:

Fig. 62

SM3-205

Press (09482-1090)

EG12-2-86

ENGINE --------------- ENGINE

Fig. 63

Insert the oil seal to the seal case. ensuring that it is flush with the end of the seal case.

SM3-373

23. INSPECT THE TORSIONAL DAMPER.

1. 2.

Fig. 64

Clean the torsional damper with a suitable solvent cleaner. Check if there are any cracks in the damper rubber section. If the cracks are excessive replacement is necessary.

SM3-372

24. INSTALL THE DUST SLINGER.

When driving in the dust slinger, use a special tool, and drive the dust slinger into the pulley center, ensuring that it is perpendicular to the pulley center.

Special Tool :

Dust Slinger Press (09402-1340)

After driving in the front dust slinger, be sure that the straight portion of the pulley center is visible to ensure that the dust slinger does not drop out.

Fig. 65

25. INSTALL THE RING GEAR (WHEN REPLACING RING GEAR ONLY)

Heat the ring gear uniformly using a blow torch ° [approx.100 C (212° F)].

Drive the ring gear with its chamfered gear teeth facing the block onto the flywheel using a metal rod.

NOTE: Be careful not to overheat the ring gear. Fig. 66

SM3-358

EG12-2-87

ENGINE

---------------- ENGINE

26. REMOVE, INSPECT AND INSTALLING THE COOL ANT GALLERY COVER. 1. Remove the coolant gallery cover. 2. Make sure that there are no holes or other defects in the coolant gallery cover. If there are any defects, replace the cover with a new one. 3. Using a new gasket, install the coolant gallery cover. NOTE: O To ensure that the coola11t passes through the inside of the cover, cut seal rubber to the dimension as shown, then insert it into the cover. 0 Do not apply sealing compound to the gasket face.

Fig. 67

SM3-442

27. INSPECT THE CAMSHAFT END PLATE 1. Make sure that there is no oil leakage from the camshaft hole in the rear wall of the cylinder block. If there is oil leakage, replace the 0-rings.

Fig. 68

SM3-360

2. Install the 0-ring to the end plate. NOTE: Carefully observe the following points to ensure that oil does not leak from the end plate fitted over the camshaft hole. o Do not twist the 0-ring when installing it on the end plate. o As a general rule, fit the end plate on the cylinder block by hand, taking care to avoid damaging (cutting, tearing or twisting) it. Also, coat the periophery of the 0-ring with seal compound (Three Bond 1215). O Do not re-use end plate after removing them.

EG12-2-88

ENGINE

---------------- ENGINE

ASSEMBLY 1.

INSERT THE CYLINDER LINER INTO THE CYLIN DER BLOCK. 1.

There are 4 different liner and cylinder block matches. The flange section of each liner has a marking either, W, X, Y, Z, or indicating the size of the outer diameter of the liner on which it is stamp ed. The markings W, X, Y and Z, indicating the inner diameter of the cylinder bore supporting the liner on the sides and top of the cylinder block (the boss section for attaching the coolant gallery cover), are inscribed on each cylinder.

New cylinder liners When a new cylinder liner is used, make sure that the liner has the same mark as the mark on the cylinder block.

When reusing a liner, insert the liner its original position aligning the marking marked before dis assembly.

W, X, Y ANO Z MARK

W, X, Y AND Z MARK

Fig. 69

Fig. 70

SM3-387

SM3-853

Apply a small amount of clean engine oil on the outer periphery of the liner, and apply pressure on the entire flange section of the liner. If insertion by hand is difficult, use a cylinder press, and the cylinder will easily be pushed in. Special Tool: Cylinder Liner Press (09480-1040) 4.

Fig. 71

SM3-851

NOTE: O Do not use a liner that has been dropped. 0 Take extra care when handling the liner since the liner is easily deformed.

EG12-2-89

ENGINE

---------------- ENGINE

MEASURE THE PROJECTION OF THE CYLINDER LINER. Tighten a special tool 100 kg.cm (7.23 lb-ft) projection of the top cylinder block with a and a thickness gauge.

Cyltnder Liner Puller (09420-1240) Special Tool Tightening Torque : 100 !<g.cm (7.23 lb.ft) Assembly Standard: 0.01-0.08 mm (0.0004-0.0031 in)

SM3-854

Fig. 72

with a tightening torque of and measure the amount of end of the liner from the dial gauge or straight edge

PRESSURE: 500 kg (1,100 lb)

PROTRUSION SM3-572

Fig. 73

MOUNTING THE CRANKSHAFT. 1. Install the crankshaft bearings on the cylinder block. NOTE: 0 Apply new engine oil to each bearing surface. 0 The width of each bearing varies with its position. Accordingly, be sure that the bear ings are installed in the correct order. 0 Install each bearing after aligning the projec tion on one end with the depression in the block and cap.

Pf.,

Install the crankshaft on the cylinder block.

Insert the crankshaft thrust bearings along the groove of the cylinder block. Install the thrust bearings on the No.4 bearing cap sides. Install one bearing on each side of the No.4 cap and on each side of main bearing support that is, a total of 4, with the oil groove side on the thrust direction of the crankshaft.

�

-�

Fig. 75

03-729

Fig. 76

SM3-395

EG12-2-90

ENGINE

NOTE: 0 Make sure which side is the front and which side is the back when installing the thrust bearings. Install the bearings by facing the front side (the side with the groove) towards the crank arm and the back side (the side with the parts number in green) toward the main bearing support and cap and then apply grease or engine oil on both sides of the bearings before installing. o Install the thrust bearings after aligning the lug of the thrust bearing with the groove in the bearing cap.

SM3-378

Install the crankshaft bearing caps tighten them to the specified torque, then slacken and tighten it to the specified torque again. Tighten Torque: 1,600-1,800 kg.cm (115-130 lb.ft)

ARROW

TIMING GEAR SIDE Fig. 78

SM3-855

a. a:.------------____, w >

a: ct w

('.)

� I-

Fig. 79

b. ...J w w I

> ...J u.

SM3-972

c. 6.

Numbers 1 through 7 are marked on the rear of the caps. Install the caps in that sequence from the tim ing gear end. An arrow is embossed on the rear of each cap. Install the caps so that the arrow points toward the timing gear. Tighten the caps in the order No. 4, 3, 5, 2, 6, 1 and 7. After tightening each cap, rotate the crankshaft and make sure that it turns smoothly. Because the main bearing cap bolts have been specially designed for this purpose, do not under any circumstances use or dinary bolts.

EGl 2-2-91

ENGINE

PISTON IDENTIFICATION SYMBOL

ASSEMBLE THE PISTON 1. Matching engine model and piston

WARNING When installing a new piston, be sure that it is matched with the engine model.

H06CTB

Correspondence between engine models and the identification symbol impressed on the piston top is as shown below.

TOP VIEW Fig. 80

SM3-719

* The engine models designation is impressed on the righthand side of the cylinder block as viewed from the fan side.

MARK

NOTE: Assemble the various parts after applying engine oil to the sliding portions. MATCH MARK

Fig. 81

2. a. SM3-407

Fig. 82

a) bl

Assemble the piston and connecting rod. When assembling the piston and connecting rod, ensure that the O-mark at the top of the piston and the H-mark at the back of the piston are in the opposite direction of the matching mark on the con necting rod. When inserting the piston pin into the piston, install one new retainer ring at the end of the piston, heat ° ° the piston to about 80-90 C (176-194 F) in hot water about 5 minutes. Apply oil to the piston pin. Fix the piston and connecting rod by insert ing the pin, and fit the new retainer ring at the other end. When fixing the piston, use a piece of cloth to pro tect it from damage. When inserting the piston pin, be careful not to damage the groove of the retainer ring which has been firmly inserted.

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

EG12-2-92

ENGINE

PISTON RING No.1

Top ring

No.2

2nd ring

No.3

3rd ring

No.4

Oil ring

Install the piston rings.

When installing the piston rings on the piston ensure that the piston skirt is at the bottom, and use a special tool. Install the piston rings in the sequence 4, 3, 2, 1 with the identification mark at the top of the ring facing up.

�

:a :.

Special Tool: Piston Ring Expander (09442-1061)

�·

SM3-295

Fig. 83

\ GAP

Install the oil ring after determining the orientation of the coil expander.

Connect the ends of the coil expander and then fit the coil inside the piston ring after ensuring that ° the gap of the piston ring is 180 away from the joint of the coil.

Because the oil ring forms a set with the coil, be careful not to replace it with a ring belonging to another set.

Install the connecting rod bearing.

Install the connecting rod bearing, which has one oil hole on the connecting rod side, and which has two oil holes on the cap side.

During this operation align the projecting portion at one end of the bearing with the recessed portion at the end of the connecting rod.

When reusing the bearings, reinstall them in their original positions.

SM3-443

Fig. 84

0-MARK

INSTALL THE PISTON IN THE CYLINDER LINER. 1.

Rotate the crankshaft to the bottom dead center position.

Arrange the piston rings so that their gaps are equally spaced.

Hold the piston rings using a special tool.

TOP RING Fig. 85

NOTE: Check the piston that the O-mark on the top is on the tappet chamber side. Special Tool:

Piston Ring Holder (09441-1101)

EG12-2-93

ENGINE

---------------- ENGINE

Fig. 87

SM3-444

Push the piston and connecting rod assembly using a wooden rod.

NOTE: When installing the piston and connecting rod assembly, be careful that the cooling jet is not struck by the connecting rod. If the cooling jet

is struck, adjust or replace

Fig.BB

SM3-383

Fig. 89

. . • • _..,..-:____ :.-�

�:�,

·.

03-767

INSTALL THE CONNECTING ROD 1.

Install the connecting rod with bearing and cap with bearing on the pin of the crankshaft, being sure to align the match marks.

When installing the cap liberally coat the bearing surface with engine oil.

After coating the threaded portions and the bearing surface of the cap bolts with engine oil, tighten the bolts to the specified torque, loosen them, and retighten them to the specified torque.

Tightening Torque:

1,650-1,850 kg.cm (120-133 lb.ft)

EG12-2-94

ENGINE

--------------- ENGINE

INSTALL THE OIL PUMP, TIMING GEAR CASE, SUCTION STRAINER, OIL PAN ETC.

INSTALL THE CRANKSHAFT DAMPER ON THE CRANKSHAFT, INSERT THE SPACER AND THEN TIGHTEN UP THE FRONT NUT.

INSTALL THE OIL SEAL CASE. Tightening Torque: 190-260 kg.cm (1 4-18 lb.ft)

\,�\

.·/��\1 \[

, ;

Fig. 91

SM3-377

Fig. 92

03-1598

10. INSTALL THE FLYWHEEL HOUSING. NOTE: 0 When fitting an 0-ring to the alignment face of the flywheel housing, apply adhesive to the housing to prevent to 0-ring from dropping off. O Adhesive: Three Bond No. 1215 Tightening Torque; Bolt Size: 10 mm Diameter (0.4 in) ....... 400 - 500 kg.cm (29 - 36 lb.ft) 12 mm Diameter (0.47 in) . .....650 - 870 kg.cm ( 47 - 62 lb.ft)

11. INSTALL THE FLYWHEEL. NOTE: Align the "O" mark on the flywheel and crank shaft collar knock-in. Tighting Torquq: 1,800-2,000 kg-cm (130-1 4 4 lb.ft)

Fig. 93

032 - 424

ENGINE

EG12-2-95

---------------- ENGINE

LUBRICATING SYSTEM

___.J(__Jl�tL,

--.1______,,�r

16(2.5 kg/cm l )

11 13 5 (1.5 kg/cm 1 )

9 5 (9.5 kg/cm 1 )

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Fig. 1

Piston Fuel injection pump Fuel injection pump drive gear Oil cooler Safety valve Oil pump Suction strainer Oil pan Crankshaft Main hole Connecting rod

Camshaft Idler gear Oil filter (Full-flow) Regulator valve Check valve Piston cooling jet Pressure gauge Turbocharger Oil filter (By-pass) (OPTION) A: To oil pan

12. 13. 14. 15. 16. 17. 18. 19. 20.

SM3-721

ENGINE

EG12-2-96

________________

ENGINE

OIL PUMP 1. Case 2. Oil pump cover sub assembly 3. Driven gear 4. Straight pin Fig. 2

SM3-1312

OIL COOLER 1. Case 2. Plug 3. Gasket 4. Oil cooler element 5. Element gasket 6. Plain washer 7. Lockwasher Fig. 3

8_ nut

9. Oil cooler pipe 10. O-ring 11. Bolt 12. O-ring 13. Cover SM3-1529

ENGINE

EG12-2-97

---------------- ENGINE

OIL FILTER PARTS A. Regulator valve assembly B. Oil cooler safety valve assembly C. Oil filter safety valve 1. Oil filter assembly 2. Element set ( Full-flow) 3. Plug assembly 4. Plug

5. O-ring

6. Gasket

7. S pring 8. Valve 9. Regulator valve 10. Insulator

SM3-1530

Fig. 4

BY-PASS OIL FILTER PARTS (OPTION) 1. Cover 2. Breather plug 3. O-ring 4. Bolt 5. Clamp Fig.

6. Gasket

1. Element 8. Case 9. Drain plug 10. Bracket

SM3-1547

ENGINE

EG12-2-98

---------------- ENGINE

OIL PUMP

DISASSEMBLY Loosen the bolts to remove the oil pump cover assembly. Remove the driven gear. NOTE: It is not possible to disassemble the oil pump drive gear since it is a press-fit type.

Fig. 6

03-1561

INSPECTION AND REPAIR

Fig. 7

Inspect the gear.

Clean the various parts with cleaning solvent, and then inspect them.

Inspect each gear, shaft, bushing, collar and cover for possible damage. If there is any damage, replace them.

Measure the gear backlash.

03-1562

Assembly Standard: Repair Limit

Fig.8

0.15-0.30 mm (0.0059-0.0118 in) 0.40 mm (0.0157 in)

SM3-867

Measuring the end play of gears. Set the straight edge against the mounting face of the case cover, and measure the end play with a thickness gauge. If it exceeds the specified limit, replace the oil pump assembly.

Assembly Standard: Repair Limit

SM3-868

0.030-0.095 mm (0.0012-0.0037 in)

0.15 mm (0.0059 in)

Measure the outside diameter of the driven shaft and inside diameter of the driven gear. Measure the outside diameter of the driven shaft and the inside diameter of the driven gear using a micro meter and cylinder gauge. If the specified limit is exceeded, replace the bushing and/or oil pump assembly.

ENGINE

EG12-2-99

--------------- ENGINE

Assembly Standard: Repair Limit

Fig. 11

0.040 -0.083 mm (0.0016 - 0.0032 in) 0.15 mm (0.0059 in)

SM3-317

Measuring tt,e outside diameter of the drive shaft and the hole diameter of the case. Measure the outside diameter of the drive shaft and the hole diameter of the case using a micrometer and cylinder gauge. If the specified limit is exceed ed, replace the oil pump assembly and/or case assembly. Assembly Standard: 0.040 - 0.085 mm (0.0016 - 0.0033 in) Repair Limit 0.15 mm (0.0059 in) 5.

Fig. 12

SM3-382

Fig. 13

SM3-381

ASSEMBLY

After installing the driven gear on the cover, install the cover assembly on the case using 4 bolts;

Fig. 14

03-1604

ENGINE

EG12-2-100

---------------- ENGINE

OIL PUMP SAFETY VALVE OISASSEMBL Y

1. 2.

Remove the safety valve from the bottom of the block. Remove the retainer ring, and then disassemble the safety valve.

SM3-1290

SM3-1291

INSPECTION AND REPAIR 1.

2. Fig.17

SM3-1292

Remove the retainer ring, and inspect the valve inside. Inspect the sliding faces of the valve for possible damage, and also see if the valve moves smoothly. If there are any abnormalities, replace the valve assembly. Inspect the spring, and replace it if it is damaged of flattened.

ASSEMBLY

Install the valve, spring, shim seat and retainer ring in that sequence. Install the safety valve to the bottom of the block. 2. Tightening Torque: 800 - 900 kg.cm (58 - 65 lb.ft) 1.

fig_ 18

SM3-1293

OIL COOLER

DISASSEMBLY Loosen the nuts, and then remove the oil cooler element and plugs.

Fig. 19

SM3-1528

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

EG12-2-101

ENGINE

---------------- ENGINE

INSPECTION AND REPAIR 1.

Clean the oil passages of the oil cooler element with cleaning solvent.

In order to inspect the oil passages of the element, perform an air pressure test. If there is any damage or leakage, replace the element with a new one.

Pressure Test:

6 kg/cm2 (85.3 lb/sq.in)

ASSEMBLY 1.

When assembling the oil cooler, be sure to replace the O-ring, gasket, with new ones (be careful to use O-rings of the correct diameter).

Fit the various plugs with O-rings onto the oil cooler case.

Tightening Torque: 190 - 260 kg.cm (14 - 18 lb.ft) 3.

Install the element on the cooler case with a gasket, and tighten up the assembly using 4 nuts. Perform an air pressure test and confirm that there is no leakage of oil from the mounting portion of the case and element. Use a test pressure of 6 kg/cm2 (85.3 lb/sq.in).

Tightening Torque: 4.

Fig. 21

SM3-1529

100 - 150 kg.cm (8 - 10 lb.ft)

Install the oil pipe with O-rings and tighten the oil pipe fitting bolt provisionally.

EG12-2-102

ENGINE

---------------- ENGINE

OIL FILTER DISASSEMBLY

Remove the various valves and springs from the oil filter cover.

INSPECTION AND REPAIR

1. 2. A. B. C. 1. 2. 3. 4. 5. 6.

REGULATOR VALVE ASSEMBLY OIL COOLER SAFETY VALVE ASSEMBLY OIL FILTER SAFETYVALVE ASSEMBLY PLUG O-RING VALVE SPRING VALVE VALVE SEAT GASKET

Wash metal portions with a volatile washing oil to remove oil and dirt. Inspect the valves Inspect the sliding portions of the each valve for possible damage and to see if the valves operate smoothly. If there are any abnormalities, replace the valve assembly. Inspect the valve springs Inspect the valve springs of the each valve. Replace the valves if they are damaged or flattened.

SM3-1530

Fig. 22

ASSEMBLY 1. INSTALL THE OIL FILTER COVER ASSEMBLY.

During assembly, be sure to replace the O-ring and gasket with new ones (be careful to fit O-ring of the correct diameter). 1. Attach an O-ring on the regulator valve case, and install the regulator valve case onto the oil filter cover. Then, insert first the regulator valve and then the valve spring. Next, attach the O-ring to the plug and tighten. Tightening Torque: Regulator valve case 250-300 kg.cm (19-21 lb.ft) Plug 200-300 kg.cm (15-21 lb.ft) Install the safety valves. After inserting each safety valve and valve spring on the oil filter cover, tighten the plug with a O-ring. Tightening Torque: 250-300 kg.cm (19-21 lb.ft) 2.

3. 2.

-�_{)._ --.

Install the oil filter cover assembly.

INSTALL THE OIL FILTER ELEMENT SET. 1. Apply a slight amount of engine oil to the gasket of the new oil filter. Tighten the filter by hand until the gasket touches the filter cover.

Tighten the filter another 3/4 to 1 full turn with a filter wrench.

Special Tool: 09503-1080 Fig. 2;3

SM3-396

EG12-2-103

ENGINE

---------------- ENGINE

COVER ELEMENT-"F�-!--y-11,+4 HANDLE

NOZZLE

REPLACING THE BY-PASS OIL FILTER ELEMENT (OPTION). 1.

Unscrew the breather plug, then unscrew the drain plug and drain the oil through the drain hole.

Unscrew the clamp bolts and clamps, then remove the cover and gasket.

Remove the element by turning it counterclockwise.

Removed and clean the nozzle on the oil outlet.

Install a element in reverse sequence of removal. The tightening torque of each part is as shown below.

ELEMENT

DRAIN PLUG- Fig. 24

BREATHER PLUG GASKET CLAMP

OIL OUTLET SM3-1541

Element: Turn fully by hand: 180-230 kg.cm (13-16 lb.ft) Clamp mounting bolt: 150-210 kg.cm (11-15 lb.ft) Drain plug and breather plug: 150-210 kg.cm (11-15 lb.ft) 6.

After replacing the element, add approximately 4 liters of engine oil. Run the engine for several minutes, then stop it and check the oil level. If necessary, add engine oil.

Start the engine and check to see if there is any oil leakage.

NOTE: O Be sure to replace the gasket and O-ring in each plug with the new gasket and O-rings included in the element kit. O When installing the element, take care not to twist or tear the gasket and O-rings.

ENGINE

EG12-2-105

ENGINE

COOLING SYSTEM

}ff\{

I I

/1:!

� L:zIIZGII(-:=_«��)mEE·2 ····2····z····illclJ -

·.· .•.·.······· ································-·.·.···············

·:,_•=='-,. ·!_:l_='=I-, =

• . • . •• .·. F •·•·Tc•. •••<·• ·co•[·• :C. •• • • •• T YWJ&&{f'.o[· .• ·. ·.··.· .·. . . , ••T\f¥ii1&%. . . . .L. ... ...•. ,.....•� . · ·· · COOLING SYSTEM 1. Radiator 2. Drain plug

9. Thermostat case

4. Coolant pump 5. Cylinder block 6. Drain plug

10. Temperature switch 11. Joint 12. Cab heater 13. Thermostat cover 14. Inter cooler

15. Air breather plug

Joint

Oil cooler

8. Cylinder head Fig. 1

SM3-1531

ENGINE

THERMOSTAT AND RELATED PA ATS 1. Coolant pump asse mblY 2· Coolant pump pu lley 3. Coolant �ump gasket . 4. Coolant intake pipe 5. Gasket 6- Joint 7. Therm ostat case 8. Therm ostat case cover :::;.T_____

Fig. 2

_____________ _

G12-2 10 1 - � 66 :E: � � : �

9. 10. 11 · 12· 13. 14. 15· 16.

Gasket Therm ostat B racket Spacer Cooling fan Coolant h ose O ring Pipe SM3-1532

ENGINE

----------------

INTER COOLER AND RELATED PARTS 1. Intake manifold 2. Gasket 3. Inter cooler assembly 4. Inter cooler cover 5. Intake pipe 6. Gasket 7. Flange Fig. 3

EG12-2-107

ENGINE

8. 9. 10. 11. 12. 13.

O-ring Pipe Air breather plug Gasket Hose Bracket SM3-1533

EG12-2-108

ENGINE

----------------

ENGINE

COOLANT PUMP 1. Case 2. Shaft 3. Vane 4. Coolant seal 5. Bearing 6. Bearing collar 7. Bearing 8. Bearing 9. Washer 10. Retainer ring Fig. 4

11. Plain washer 12. Lockwasher 13. Nut 14. Key 15. Lubrication fitting 16. Gasket 17. Cover 18. Screw 19. Pulley

SM3-1534

EG12-2-109

Ef':JGINE

ENGINE

INSPECT THE V-BEL TS AND COOLING FAN 1.

INSPECTING THE V-BELTS. If a V-belt is damaged, replace it with a new one.

NOTE: There are two generator drive V-belts. Be sure to replace them as a set and ensure that the dif ference in length between them is no more than 2 mm (0.078 in). Use belts having a length of 1,420- 1,440 mm (55.9-56.7 in). If the belts are too long, the clearance between the genera tor and the frame will become too small when the engine is mounted on the vehicle, and when the engine is running, the resulting vibration could cause interference. Conversely, if the belts are too short, it will be difficult to fit them over the pulleys.

2. COOLING FAN

PULLEY

Fig. 5

MAINTAINING AND INSPECTING THE FAN 1. Shock to the fan During maintenance and inspection, be careful not to drop or strike the fan itself. The resulting damage may lower the performance of the fan. Also, note that the fan is made of plastic and may become damaged or deformed if force is applied to it.

Replacing the fan Do not replace the fan unless it is faulty. When replacing the fan, replace it with the same type as the one which was removed. If the fan is replaced with one of a larger capacity becaused of overheat ing or, conversely 'is replaced with one of a smaller capacity due to overheating, the cooling performance may in fact reduced and durability may be jeopardiz ed.

Other items Take care not to apply excessive force particular. Do not paint the fan. Do not place any paint or other reagents which are likely to dissolve plastic in contact with the fan.

SM31517

ENGINE

EG12-2-110

_________________ ENGINE

COOLANT PUMP DISASSEMBLY 1.

Remove the cover after slackening the bolts. The vane is a screw-in type, so it is removed by using the two projections at the back.

NOTE: When removing the vane, the use of the special tool shown in the drawing is recommended.

�__

L _______

VANE Fig. 7

SM3-411

Remove the retainer ring using retainer ring pliers.

Push the end of the shaft on the vane side using a press, and extract the bearings, collar and shaft.

NOTE: 0 If the press is applied without removing the retainer ring, the pump case will be damaged. 0 Do not reuse bearings which have been re moved. Replace them with new ones.

Fig. 9

SM3-994

Strike the coolant seal from the coolant case with a hammer, using a copper rod, or the like.

NOTE: It is not possible to reuse the seal after remov ing it from the case. Accordingly, be sure to replace it with a new one.

Fig. 10

SM3-1000

EG12-2-111

ENGINE

---------------- ENGINE

Remove the bearings and collar using a press.

NOTE: It is not possible to reuse the bearing s after removing them from the coolant case. Accordingly, be sure to replace them with new ones.

I INSPECTION AND REPAIR

Inspect the vane. Inspect the vane for rust, corrosion or damage. If defective, replace it. In particular, inspect the blades of the vane carefully.

Inspect the cover for corrosion, rust or damage. If defective, replace it. Inspect the case. Inspect the portion of the case in which the seal is inserted and also the vane side of the portion in which the bearing is fitted. If there is any corrosion, wear or damage, replace the case. Inspect the shaft. Replace the shaft if there is any damage to the threaded portion, or if the portion on which the inner race is inserted is worn or damaged.

3. Fig. 12

03-783

ASSEMBLY

Fig. 13

SM3-998

NOTE: O Install the bearings properly aligning the centers of the 3 bearings and the collar. O Do not install the bearings by striking the shaft with a hammer. O When installing individual bearings, use grease packed bearings. 2.

Fig. 14

Install the bearing on the shaft. Install the ball bearings with collar on the shaft using a press.

Install the coolant seal. Before fitting the coolant seal into the case, apply liquid gasket (equivalent to Three Bond No. 1104) around the periphery of the coolant seal cage, and then fit the seal using a press.

ENGINE

EG12-2-112

---------------- ENGINE

Fig. 15

Fig. 16

Fit the shaft into the case using a press.

Install the retainer ring After fitting the shaft, install the plain washer, then install the retainer ring by means of an expander.

Install the vane

Install the vane onto the shaft.

SM3-995

SM3-996

Tightening Torque: 500 - 600 kg.cm (37 - 43 lb.ft) After installing the vane, apply a few drops of lock ing adhesive to the threaded portion.

Fig. 17

When tightening up the vane, the use of the special tool.

Install the cover with new gasket.

SM3-1001

Tightening Torque:

Fig. 18

J:"'(_.....-. 03-1574

180 - 230 kg.cm (14 -16 lb.ft)

EG12-2-113

ENGINE

---------------- ENGINE

THERMOSTAT OISASSEMBLY

Loosen the 4 bolts attaching the thermostat cover and case, then remove the thermostat from within the case.

Fig.19

INSPECTION

STARING ROD

Check the thermostat Place the thermostat in hot water and check the opening temperature and the lift. b. Using a thermometer, check to see the thermostat opens at the specified temperature: ° ° 80 - 84 C (176 - 183 F). Immerse the thermostat in water of a temperature c. of 95 ° C (203 ° F), and measure the lift of the pellet after a period of 5 minutes using vernier calipers. Measure the position of the bottom of the pellet before and after heating the thermostat. ° Lift: At least 10 mm (0.4 in) [95 C (203° F)] 2. a.

THERMOSTAT

HEATER� Fig. 21

Inspect the thermostat case. Check to see whether there is deterioration or damage to the thermostat attachment section. Replace any worn or damaged parts.

SM3-888

Immerse a heated thermostat in water of normal temperature. If it completely closes within 5 minutes it is satis factory. If it remains even slightly open, it is defective and must be replaced.

ENGINE

EG12-2-114

----------------ENGINE----------------

ASSEMBLY Install the thermostat in the reverse sequence of removal, paying attention to the following points. Remove water and dirt adhering to the thermostat 1. case. 2. Replace the gasket without fail if it is corroded, damaged or flattened.

GASKET �--PLATE._,___�

3. 4. CASE

Fig. 22

Before installing the thermostat, apply sealing compound to the thermostat gasket and the hose installation portion of the thermostat case cover. In order to prevent clogging of the radiator, do not use a large amount of sealing compound. In par ticular, do not apply a large amount of sealing compound to the hose side.

SM3-412

Tighten up the clamp bolts of the case and thermo stat cover. Tightening Torque: 190 - 270 kg.cm (14 - 19 lb.ft) Carefully observe the following points in order to prevent leakage of coolant from the thermostat case. NOTE: 0 When installing the thermostat in the ther mostat case, be sure to first insert the gasket in the thermostat plate portion, then fit the thermostat cover. (Be careful not to forget this gasket.) 0 Install the thermostat cover, be careful of the direction of installation. If care is not taken, it may not be possible to connect the line. 5.

SM3-446

INTERCOOLER DISASSEMBLY 1. Disconnect the cable of current sensor.

SM3-2422

ENGINE

EG12-2-115

---------------- ENGINE -----------------

Remove the intake pipe.

Remove the coolant hoses, flanges and intercooler cover.

Remove the intercooler.

03-2426

03-2408

Fig. 26

SM3-1535

Fig. 27

2. COOLANT OUTLET

Fig. 28

INTERCOOLER

SM3-1536

AIR PRESSURE REGULATO R VALVE AND GAUGE

CHECK THE INTERCOOLER. 1.

Clean the fins and coolant passages of the inter cooler with cleaning solvent.

Check the intercooler for coolant leakage and clogg ing of the fins.

NOTE: When carrying out high pressure washing to remove fin clogging, avoid applying excessive pressure to the fins owing to the risk of defor mation and consequent performance deteriora tion. 3.

In order to inspect the coolant passages of the inter cooler, perform an air pressure test. If there is any damage or leakage, replace the intercooler with a new one.

Pressure test: 2 kg/cm2 (28.4 lb/sq.in)

Fig. 29

SM3-1546

ENGINE

EG12-2-116

---------------- ENGINE

ASSEMBLY 1. Install the intercooler into the intake manifold. NOTE: During installation, be sure to first install the gasket.

INTER COOLER

Fig. 30

S.M3-1535

Install the intercooler cover on the intercooler, then the flanges and hoses on the cover. NOTE: During installation, be sure to first install the gasket.

Fig. 31

03-2408

Connect the current sensor cables.

4. Install the intake pipe with gasket. Tightening torque: 190-260 kg.cm ( 14-18 lb.ft)

ENGINE

EG12-2-117

----------------

ENGINE

FUEL SYSTEM

FUEL SYSTEM 1. Fuel filter 2. Nozzle holder 3. Feed pump

4. Water separator A: Fuel tank

Fig_ 1

SM3-723

RELATED PARTS OF FUEL SYSTEM 1. Fuel injection pump assembly 2. Fuel feed pump 3. Coupling 4. Fuel injection pump drive gear Fig. 2

5. Nozzle holder 6. Fuel filter 7. Injection line 8. Fuel (Return) SM3-1537

ENGINE

EG12-2-118

ENGINE

NOZZLE HOLDER 1. 2. 3. 4. 5. 6.

Nozzle holder assembly Gasket Inlet connector Pressure pin Pressure spring Adjusting screw

7. Gasket 8. Lock nut 9. Gasket 10. Joint bolt 11. Retaining nut 12. Pin SM3-1538

Fig. 3

Hino H06 H06C H06CT H06CTI Engine Parts Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

EG12-2-119

ENGINE

--------------- ENGINE

WATER SEPARATOR AND FUEL FILTER 1. 2. 3. 4.

Primary fuel filter Water separator Float Drain plug

5. Fuel tank 6. Feed pump A: To injection pump SM3-449

Fig. 4

4---c:)

>------6

WATER SEPARATOR 1. 2. 3. 4. 5. Fig.5

Cover Body Float O-ring Nut

6. 7. 8. 9.

Drain plug O-ring Bolt Gasket

SM3-1430

ENGINE

EG12-2-120

---------------- ENGINE

F· -

FUEL FILTER 1. Fuel filter element assembly 2. Fuel filter cover Fig. 6

3. Breather plug 4. Soft washer SM3-1539

EG12-2-121

ENGINE

--------------- ENGINE

DISASSEMBLY 1.

Fig. 7

DISASSEMBLE THE INJECTION NOZZLE NOTE: When disassembling and re-assembling the nozzle, be very careful of dust and dirt. The work place and all tools must be kept clean. Loosen the adjusting screw, and remove the nozzle spring, nozzle holder, and press pin. Insert the nozzle holder, place it in a vice, loosen the retaining nut, and then remove the ·retaining nut while taking care not to drop the needle valve of the nozzle. NOTE: When extracting the nozzle from the retaining

03-1409

nut, be careful not to damage the end of the nozzle.

Fig. 8

03-786

INSPECTION AND REPAIR 1.

Fig. 9

INSPECT THE NOZZLE

Wash the nozzle proper with diesel fuel oil, them immerse it in diesel fuel oil. Next slide the needle inside the nozzle proper and ensure that it move smoothly. The needle valve should fall under its own weight when withdrawn vertically about 1 /3 and released. If its motion is sluggish, replace the nozzle with a new one.

SM3-905

INSPECT THE NOZZLE AND NEEDLE VALVE FOR DAMAGE.

1. 2. 3. Fig. 10

03-786

If the needle valve is deformed or worn, or the press pin is unevenly worn, replace the nozzle. Inspect the contacting portions of the nozzle holder and nozzle proper for damage. If there is any damage replace the nozzle holder and nozzle proper. Check the nozzle spring for damage, cracking, or flattening. If it is defective, replace it. If the contacting faces of the spring of the spring pin and the needle valve are worn, replace these parts.

ENGINE

EG12-2-122

---------------- ENGINE

ASSEMBLY 1.

ASSEMBLE THE NOZZLE Assemble the nozzle assembly in the reverse sequence of disasembly. When installing the nozzle, however, align the nozzle with the dowel pin of the nozzle holder, then gradual ly tighten the retaining nut until the specified torque is reached.

Fig. 11

Tightening Torque: 600-800 kg-cm (44-57 lb.ft)

03-1417

SM3-816

ADJUST THE INJECTION NOZZLE 1.

Wrap a piece of cloth around the nozzle holder, then place the nozzle holder in a vice, and loosen the retaining nut.

Connect the nozzle holder with a nozzle tester and move the lever at the rate of about 50 to 60 times per minute, rotate the adjusting screw until injection pressure is reached.

Injection Pressure: 200 kg/cm 2 (2,844 lb/sq.in) 3.

When adjusting the injection pressure using the nozzle tester, check the nozzle for clogging improper spray ing. If there are such defects replace the nozzle.

After tightening the retaining nut, re-check the injection pressure using the nozzle tester. When tightening the retaining nut, insert a screw driver into the joint hole to prevent the adjusting screw from turning.

GOOD Fig. 13

COARSE

COARSE SM3-450

Checking the spray profile In the case of the new nozzle, operate the lever at the rate of 30 to 60 strokes per minute, and for a used nozzle, operate the lever at the rate of 15 to 60 strokes per minute.

ENGINE

EG12-2-123

---------------- ENGINE 6.

Fig. 14

Check that the spray profile is conical with respect to axis A of the figure. In the spray profile is unsatisfactory, clean or replace the nozzle. When checking for fuel leakage from the nozzle, apply a pressure of about 10 to 20 kg/cm 2 (284 lb/ sq.in) lower than the correct injection pressure to the nozzle by means of the nozzle tester. If there is no fuel leakage, the nozzle is normal.

SM3-451

WARNING

Diesel fuel is flammable. This nozzle adjusting should be done a well ventilat ed room and away from any open flames or electric spark. O The spray must always be covered. Keep your face and body away from the spray. This is because of the rick if fuel oil getting your eyes or passing into tour the body.

INSTALL INSTALLMENT OF INJECTION NOZZLE HOLDER

1. Install the injection nozzle holder. Tightening Torque: 130-190 kg-cm (10-13 lb.ft)

Fig. 15

03-1507

EG12-2-125

ENGINE

________________

ENGINE

ENGINE STOP SYSTEM

FRONT

�

ENGINE CONTROL LINKAGE 1. Connector 2. Cable, engine stop 3. Motor assembly, engine stop Fig. 1

4. Bracket 5. Cover

SM3-1540

ENGINE

EG12-2-126

ENGINE

INSPECTION

A (LI

P,(LWI B (LAI

P 1 (LY)

E (Bl

Fig. 2

CHECK THE OPERATION OF THE ENGINE STOP MOTOR AND MECHANICAL SWITCH. 1. Apply 24V D.C. across terminals A(L) and E(B). 2. Check the function of the engine stop motor. If the engine stop motor does not operate, replace it.

SM3-1424

A(L)

·-�

Using an ohmmeter, check that there is continuity between terminals and B(LR) and P 1 (LR), B(LR) and P 2 (LW). Make sure that the mechanical switch shifts "ON" and "OFF" with 180° rotation of the motor.

(Connection)

SM3-1425

Fig. 3

EXAMPLE:

3WB BLACK

3mm 2 (0.0047 sq.in)

SM20-340

Fig. 4

NOTE: WIRING COLOR CODE Symbols Green G Black B y Yellow w White Brown Br Blue L Light green Lg Red R Symbols consisting of two letters First letter - Ground color Second letter - Color of stripe Example WB .....Indicates a black stripe on a while ground.

ADJUSTMENT

STOPPER LEVER Fig. 5

SM3-1426

Adjust the cable with the adjusting cable so that the cable and the link can slide vertically and slightly under the condition that the stop lever is struck at the stopper. Assembly standard (L): 10-15 mm (0.40-0.59 in) NOTE: After the adjustment, confirm that the stroke of the cable is 35 mm (1.38 in).

ENGINE

EG12-2-127

-----------------ENGINE----------------

INSTALLATION OF THE ENGINE COMPONENT PARTS

INSTALL THE OIL COOLER AND COOLANT LINE BETWEEN THE CYLINDER HEAD.

Properly install new 0-rings at the coolant inlet and oil inlet and outlet, then, using new gaskets, install the oil cooler assembly on the cylinder block.

SM4-700

Tightening Torque:

NOTE: 0 The length of each bolt is different. o Ensure that the diameter of each O-ring matches the groove in which it is to be in stall. 0 When installing the oil cooler case, make sure that it does not interfere with the tappet guide portion of the block. 0 Reamer bolts (marked with arrows) are used to determine the mounting positions of the oil cooler and oil filter. Be sure to position these bolts in their specified positions. Note that if they are not position in their specified posi tions, improper tightening or thread damage may result.

l ,,,.· ...

REAMER BOLT Fig. 2

03-1135

INSTALL THE OIL FILTER COVER.

a. b.

Fig. 3

03-2429

190 - 260 kg.cm (14 - 18 lb.ft)

Install the oil pipe with 0-rings and tighten the oil pipe fitting bolt provisionally. Align the oil pipe with the oil filter so that there are no gaps at the connection surface (A), then tighten all bolts.

ENGINE

EG12-2-128

------------------ ENGINE-----------------

INSTALL THE OIL FILTER.

Apply a slight amount of engine oil to the gasket of the new oil filter. Tighten the filter by hand until the gasket touches the filter cover. 2. Tighten the filter another 3/4 to 1 full turn with a filter wrench. Tightening Torque: 300-350 kg-cm (22-26 lb.ft) 1.

Fig. 4

SM3-396

Fig. 5

INSTALL THE THERMOSTAT CASE ASSEMBLY AND THE COOLANT PUMP ASSEMBLY WITH A NEW GASKETS AND TIGHTEN THE BOLTS. THEN IN STALL THE COOLANT LINE. Tightening Torque: 380-500 kg-cm (28-36 lb.ft)

INSTALL THE COOLANT PUMP PULLEY. Using a copper hammer, or the like, gently drive the coolant pump pulley onto the shaft, then fit the plain washer and lock washer, and fix the pulley with a nut. Tightening Torque: 1,800-2,400 kg-cm (131-173 lb.ft)

INSTALL THE INJECTION PUMP.

SM3-694

Fig. 6

SM3-473

FLYWHEEL HOUSING FLYWHEEL

1. a.

TIMING POINTER Fig. 7

SM3-8858

Adjusting the injection timing. Rotate the crankshaft clockwise viewing from the front end to u nti I 16 ° before top dead center of the compression stroke of the No. 1 cylinder meet of the timing pointer .. Engine model

Injection timing

H06C-TI

NOTE: The engine models designation is impressed on the righthand side of the cylinder block as viewed from the fan side.

EG12-2-129

ENGINE

----------------ENGINE----------------

Check the rocker arms on No.1 cylinder are loose and rockers on No.6 are tight.

NOTE: If not, turn the crankshaft one complete revolu tion and align marks as above.

SM3-338

Fig. 8

Align the injection timing mark on the coupling and the mark on the pump body.

Position the pump assembly on the pump bracket, adjusting the position of the pump so that its mount ing holes align with those of the bracket, and then tighten bolts.

;\_ �f )

Fig. 9

SM3-1542

Tightening Torque: 190-260 kg-cm (14-18 lb.ft)

Fig. 10

Fig. 11

03-2430

First, manually turn the coupling to counterclock wise (Arrow G)) (viewing from the driving side) to retard the timer, and then slowly turn the coupl ing to clockwise (Arrow � ) to align the timing mark.

Tighten the coupling bolt.

SM3-1543

NOlE: There should not be any gap between the lami nated plates or be any deformation of the flange due to pressure the laminated plates. Tightening Torque: 300-350 kg-cm (22-25 lb.ft)

Fig. 12

03-2404

ENGINE

EG12-2-130

----------------- ENGINE-----------------

f. Tighten the through bolt of the flange. NOTE: Do not tighten the through bolt before tighten ing the coupling bolt. Tightening Torque: 300 - 350 kg.cm (22 - 25 lb.ft) g.

Install the fuel lines, oil lines and fuel leakage lines.

03-2403

INSTALL THE OIL LEVEL GAUGE.

INSTALL THE STARTER

Tightening Torque:

Fig. 15

650 - 870 kg.cm (47-63 lb.ft)

03-2431

INSTALL THE FUEL FILTER AND FUEL LINES.

10. INSTALL THE GENERATOR.

Fig. 17

ENGINE

EG12-2-131

----------------- ENGINE-----------------

11. INSTALL THE TURBOCHARGER. 1. Install the turbocharger. Tightening Torque: 450-500 kg-cm (33-36 lb.ft)

SM3-797

Fig. 18

Tighten the clip band.

Install the intake pipes.

I nstal I the seal rings. When installing seal rings on the exhaust pipe con nector, fit new seal rings in such a way that the gaps are equally spaced, as shown, to prevent gas and oil leakage.

Install the exhaust pipe connector.

03-2410

Fig. 20

45•:

Fig. 21

I 45° � I

SM3-1011

Tightening torque: 450-500 kg.cm (32-36 lb.ft)

Fig. 22

ENGINE

EG12-2-132

------------------ EN GINE-----------------

Fig. 23

Install the oil pipes.

03-2409

12. V-BELT ADJUSTMENT.

1. a. b.

Fig. 24

03-2432

Fig. 25

Install the V-belts, and adjust the belt tension. Do not under any circumstances apply the lever directly against the generator body owing to the risk of damaging the generator. When installing a new V-belt or adjusting the ten sion, be sure to repeat the adjustment two or three times, after running the engine for several minutes each time. V-belt deflection Apply a load of about 10 kg (22 lb) by pressing with your finger (or special tool).

Assembly Standard: Two V-belts, Standard Vehicle: 10 - 15 mm (0.39-0.59 in) Special Tool: V-belt Tension Gauge (09444-1210) NOTE: If the belt is excessively tensioned, there is a rick of damaging the bearings of the generator or coolant pump and also shortening the life of the V-belt. Conversely, if there is insufficient tension on the V-belt, the belt will slip, unusual noise will be emitted, the battery may run down and the engine may overheat.

C-048A

13.

INSTALLTHE COOLING FAN.

Install the pulley on the coolant pump shaft, and tighten the nut. Install the fan on the spacer, then install both together on the coolant pulley. Tightening torque: Pulley nut: 1,800-2,400 kg.cm (131-173 lb.ft) Bolt (Fan): 350-500 kg.cm (26-36 lb.ft) Fig. 26

SM3-1517

ENGINE

EG12-2-133

----------------- ENGINE -----------------

14. INSTALL THE INTAKE AIR HEATER RELAY AS SEMBLY.

ENGINE

EG12-2-135

_________________ ENGINE -----------------

ENGINE TUNE-UP

NOTE: L IG

Starting the engine when the generator is not connected to the battery may damage the generator. Always connect to the battery.

GENERATOR BATTERY SM3-907

Fig. 1

SET THE ENGINE ASSEMBLY ON A TEST BENCH.

Add the proper amount of the specified engine oil through the oil filler cap on the cylinder head cover.

Add coolant. Bleed out air from inside the coolant gallery through the cylinder block drain plug and intercooler air breather plug.

E631

BLEEDING THE AIR FROM THE FUEL FILTER

1. 2. 3.

Fig. 3

SM3-472

4. 5.

Loosen the bleetherplug of the fuel filter. Loosen the primping pump handle. Operate the priming pump handle and bleed the air from the filter until no air comes out through the bleeding plug. Since fuel and air comes out together, cover the opening with a cloth, etc., so that fuel does not splash onto the surroundings. Insert the priming pump handle, turn it to the right, and lock it. Tighten the bleether plug.

Tightening Troque:

40-60 kg.cm (3 - 4 lb.ft)

NOTE: O Make sure that the priming pump handle is locked before tightening the bleether plug. O Remove traces of spilled fuel from around the plug.

Fig. 4

SM3-475

ENGINE

EG12-2-136

----------------ENGINE----------------

Fig. 5

START THE ENGINE. NOTE: Before starting the engine, make sure that the fuel cut lever of the fuel injection pump is operating normally. 1.

Check the oil feed to rocker arms.

a. b.

Set the engine speed to 785-825 rpm.

Check the contact of the rocker arm and valve stem caps. After runing the engine, a contact of 7 to 11 mm (0.276 - 0.433 in) should be obtained at the cap contact face of the rocker arm. If the contact face is one sided, the valve will tilt, resulting in valve seizure, breakage, damage, or wear of the rocker arm stem cap.

Operate the engine for 30 to 40 minutes so that the cylinder head gasket is warmed and stabilized in dimension.

SM3-399

Within one minute after starting the engine, oil should flow to the head (Face A) of all push rods and the head (Face 8) of all valves. If the time required for the oil to flow to the rocker arms is long, various troubles such as seizing, abnormal wear and unusual noize may occur.

NOTE:

Coolant temperature should be 80 ° C (176 ° F). O Check the oil pressure, oil feed to the rocker arms, and check for water and gas leaks, and noise.

RETIGHTEN THE CYLINDER HEAD BOLTS Retighten the cylinder head bolts. After the engine has warmed up, loosen the cylinder head bolts 1 /8 to 1/4 of a turn, then tighten them to the specified torque.

Fig. 6

SM3-457

Fig. 7

SM3-415

NOTE: 0 Perform the above step for a bolt at a time. Loosen and retighten each bolt in one opera tion, in the sequence as shown. o Retighten the six bolts Nos. 4 , 5 , 12 , 13 20 , and 21 using a special tool. Special Tool Wrench (09839-1701) (09411-1080) Tightening Torque: 14 mm Diameter: 1,800-1,900 kg.cm (131-137 lb.ft) 10 mm Diameter: 650 - 750 kg.cm (47 - 54 lb.ft)

EG12-2-137

ENGINE

----------------- ENGINE ----------------

CHECK THE INJECTION TIMING

Adjust the injection timing, refer to Pages 3-10-2 and 3-10-3.

ADJUST THE VALVE CLEARANCE

Set each piston in firing order at top dead center of the compression stroke and adjust the valve clear ance. Firing Order : 1-4-2-6-3-5 Valve clearance, when cold; Inlet 0.30 mm (0.0118 in) 0.45 mm (0.0177 in) Exhaust 1.

Fig. 8

SM3-715

Set the No. 1 piston to top dead center of compres sion stroke and adjust the valve clearance of the valves indicated in the table below. Then set the No. 6 piston to top dead center and adjust the remaining valves.

FLYWHEEL HOUSING FLYWHEEL

TDC - - � ..,, TIMING POINTER SM3-885B

Fig. 9

Cylinder Valve arrangement With No. 1 piston at T.D.C. on compression stroke With No. 6 piston at T.D.C. on compression stroke

• •

•

• •

6 E

10 11 12

EG12-3-1

ENGINE

-----GENERATOR-----------

GROUP 3 GENERATOR Models H06C-Tl, EL 100 and EM 100 TROUBLESHOOTING ................................... EG12-3-2 GENERA TOR.......................................... EG12-3-3

EG12-3-2

ENGINE

---------------GENERATOR---------------

TROUBLESHOOTING Symptom

Possible cause

Charge warning lamp does

Fuse blown ................................Determine cause and replace fuse

not light with starter switch ON and engine off

Remedy

Lamp burned out ............................ Replace lamp Wiring connection loose ....._ ...................Tighten loose ,;onnections IC reg ulator faulty............................Replace IC regulator

Charge warning lamp does not go out with engine running (Battery requires frequent recharging)

Drive belt loose or worn ........................Adjust or replace drive belt Battery cables loose, corroded or worn

.Repair or replace cables

Fuse blown ................. .

.Determine cause and replace fuse

Charge lamp relay, IC regulator or generator faulty ......Check charging system Wiring faulty ...............................Repair wiring

ENGINE

EG12-3-3

---------------GENERATOR----------------

GENERATOR

2. 3.

4. 5. 6.

7. 8.

Fig. 21-1

Pullry with fan Through bolt Drive end frame Felt Felt cover Ball bearing Retainer plate Bearing retainer

9. 10. 11. 12. 13. 14. 15. 16.

Stator assembly Rotor assembly Plate Brush holder assembly Plate Brush spring Brush Brush spring housing

17.

18. 19. 20. 21. 22.

Condenser Cover Insulator Rectifier (Positive) Rectifier (Negative) Rear end frame

EG12-3-4 ENGINE ---------------GENERATOR----------------

DISASSEMBLY 1.

Fig. 21-2

REMOVE THE BRUSH HOLDER ASSEMBLY 1.

Remove the holder cover.

Remove the brush holder set screws.

Remove the lead wire.

Pull out the brush holder assembly.

SMGE-189

SEPARATE THE REAR END FRAME FROM THE DRIVE END FRAME. 1.

Remove the through bolts.

Pull out the rear end frame from the drive end frame. 2. NOTE: Tap the rear end frame lightly with a plastic faced hammer if necessary.

Fig. 21-3

SM21-076A

SM21-077

Fig. 21-4

REMOVE THE PULLEY WITH FAN 1.

Clamp the rotor in a soft jawed vise.

Remove the pulley nut, spring washer, and pulley with fan.

SM21 079

REMOVE THE ROTOR SHAFT FROM THE DRIVE END FRAME. Using a press, remove the rotor shaft.

Fig. 21-5

SM21-085B

Fig. 21-6

SMGE 135A

REMOVE THE BEARING RETAINER SCREWS, BALL BEARING, COVER AND FELT FROM THE DRIVE END FRAME.

EG12-3-5

ENGINE

---------------GENERATOR--------------6.

REMOVE THE BEARING FROM THE ROTOR SHAFT.

1. 2.

Fig. 21-7

Fig. 21-8

Fig. 21-9

Fig. 21-10

Clamp the rotor in a soft-jawed vise. Remove the bearing from the rotor shaft with a bearing remover.

SM21-0B2

UNSOLDER THE STATOR COIL FROM THE RECTI FIER HOLDER. While holding the stator coil with long nose pliers, unsolder the leads from the rectifier holder. NOTE: The long nose pliers are used as a heat sink to help protect the rectifier from the heat.

REMOVE THE "B" TERMINAL, CONDENSER AND RECTIFIER ASSEMBLY FROM THE REAR END FRAME.

UNSOLDER AND SEPARATE THE RECTIFIER.

SMGE-186

SMGE-191

SMGE-188

EG12-3-6 FNGINE ---------------GENERATOR---------------

INSPECTION AND REPAIR

Fig. 21-11

INSPECT THE BEARING. Check that the bearing is not rough or worn. Replace if necessary.

INSPECT THE STATOR FOR OPEN CIRCUIT. Using an ohmmeter, check all coil leads for conti nuity. If there is no continuity, replace the stator.

SM21 083

NOTE: At this time, the meeting wires should be con nected with solder.

SM21-063A

INSPECT THAT THE STATOR IS NOT GROUNDl?D. Using an ohmmeter, check that there is no conti nuity between the coil leads and stator core. If there is continuity, replace the stator.

INSPECT THE ROTOR FOR OPEN CIRCUIT. Using an ohmmeter, check for continuity between the slip rings.

Fig. 21-13

If there is no continuity, replace the rotor. Standard Resistance: 17.5Q

Fig. 21-14

SM21 086

\ i

Fig. 21-15

Sf/21 087

INSPECT THAT THE ROTOR IS NOT GROUNDED. Using an ohmmeter, check that there is no continuity between the slip rings and rotor. If there is continuity, replace the rotor.

INSPECT THE SLIP RINGS. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor.

EG12-3-7

ENGINE

_______________ GENERATOR _______________ 7.

MEASURE THE SLIP RING O UTER DIAMETER. Assembly Standard: 37.5 mm (1.476 in) Service Limit: 35.5 mm (1.397 in)

Fig. 21-16

SM21-062

MEASURE THE BRUSH LENGTH. If the brush length is less than 4.5 mm (0.177 in), replace the brush.

Assembly Standard: 12.5 mm (0.492 in) Service Limit: 4.5 mm (0.177 in)

Fig. 21-17

INSPECT THE BRUSH HOLDER. Inspect the brush holder moves smoothly. Replace if necessary.

' Fig. 21-18

GOOD 1�--7i1

10. INSPECT THE RECTIFIER.

I; _J_J I

l �F' r

" ., '

Rectifier holder positive side Connect an ohmmeter(+) lead to rectifier holder, and (-) lead of meter to rectifier terminal. If there is no continuity, rectifier assembly must be replaced.

J;-��;1

SM21-013A SM21-013A

Fig. 21-19

GOOD

BAD

i�' ' j ! r--__-_ �

SM21-0l 3B Fig. 21-20

SM21013A

Reverse polarity of test leads and check again. If there is continuity, rectifier assembly must be re placed.

EG12-3-8

ENGINE

---------------GENERATOR--------------GOOD

BAD

GOOD

BAD

Fig. 21-21

Fig. 21-22

Rectifier holder negative side Connect an ohmmeter (+) lead to rectifier terminal, and (-) lead of meter to rectifier holder. If there is no continuity, rectifier assembly must be replaced.

SM21-013A

Reverse polarity of test leads and check again. If there is continuity, rectifier assembly must be re placed.

SM21-013A

11. MEASURE THE CONDENSER CAPACITY

Using a condenser tester, measure the condenser capacity. If it exceeds the capacity, replace it with new one. Condenser Capacity: 5 µ F

Fig. 21-23

12. INSPECT THE IC REGULATOR.

Using an ohmmeter, measure the resistance between each terminals. Resistance

Tester

Fig. 21-24

Resistance

Tester

(.Q)

+ Lead

- Lead

Range: X1

+ Lead

- Lead

Range: X1

400

150

500

EG12-3-9

ENGINE

---------------GENERATOR---------------

ASSEMBLY 1.

INSTALL THE BEARING IN THE DRIVE END FRAME. 1.

Install the felt, cover ball bearing, plate and bearing retainer into the drive end frame.

Tighten the bearing retainer screws.

Tightening Torque: 60 - 80 kg-cm (4.4 - 5.7 lb.ft)

Fig. 21-25

SMGE-135A

INSTALL THE BEARING ON THE ROTOR SHAFT. Tap the rotor shaft on with a plastic hammer.

Fig. 21-26

SM21 i00

INSTALL THE ROTOR SHAFT. Using a press, install the rotor shaft in the drive end frame.

Fig. 21-27

SM21-095B

INSTALL THE PULLEY WITH FAN. 1.

Hold the rotor shaft in a soft-jawed vise.

Install the fan with pulley and spring washer on the rotor shaft.

Tighten the pulley nut.

Tightening Torque: 980 - 1,300 kg-cm

(71-94Ib.ft)

Fig. 21-28

SM21-096

INSTALL THE RECTIFIER ASSEMBLY. 1.

Fig. 21-29

SMGE-188

Solder and connect the rectifier.

ENGINE

EG12-3-10

----------------GENERATOR--------------2.

Fig. 21-30

Install the rectifier assembly, condenser and "B" terminal into the rear end frame.

21-283

SOLDER THE STATOR COIL TO THE RECTIFIER HOLDER. While holding the stator coil with long nose pliers, solder the lead to the rectifier holder. NOTE: The long nose pliers are used as a heat sink to help protect the rectifier from the heat.

SMGE-186

CONNECT THE DRIVE END FRAME AND THE REAR END FRAME. 1.

Connect the drive end frame to the rear end frame.

Install the through bolts and tighten to the spectified torque.

Tightening Torque: 37 - 50 kg.cm (2.7 - 3.6 lb.ft)

Fig. 21-32

SM21077

SM21-076A

SMGE-189

INSTALL THE BRUSH HOLDER ASSEMBLY. 1.

Install the brush holder assembly into the brush holder housing.

Install the brush holder cover.

EG12-3-11

ENGINE

---------------GENERATOR--------------9.

AFTER ASSEMBLING THE GENERATOR, MEASURE THE RESISTANCE BETWEEN EACH TERMINALS OF THE GENERATOR. - Lead

(n)

+ Lead

- Lead

(n)

About40

About20

About8

SW2

About 100

About 8

About 20

About 40

GENERATOR PERFORMANCE TEST 1. Connect the leads, voltmeter, and ammeter as shown in the left diagram.

Close SW1 on and increase the generator speed until voltmeter reading reaches approx. 28V. 3. Close SW2. Regulating the load resistance, increase the generator speed, keeping the voltage at 28V until the ammeter reading reaches 25A. Generator Speed: Less than 5,000 rpm at 28V, 25A VOLTAGE REGULATION TEST 1. Connect the leads, voltmeter and ammeter as shown in the left diagram. 2. Close SW1 on and increase the generator speed until voltmeter reading reaches approx. 28V. 3. Close SW2. Increase the generator speed to 5,000 rpm, keeping the ammeter reading at 5A. 4. Check the voltmeter reading. Generated Voltage: 28.5 - 29.5V 2.

= 2.

AM:vlETER

I _J CT:

: enc

I <f � I _(J) I a:: :J)

<( w >a:

ALTANATOR

PERFORMANCE TESTS

---A-----. VARIABLE SPEED MOTOR

I _J

a: w 1w 2 1..J 0 >

Resistance

Tester

+ Lead

AMMETER

Resistance

Tester

EG12-4-1 ENGINE -------------STARTER-------------

GROUP 4 STARTER

Model H06C-Tl

TROUBLESHOOTING ................................. EG12-4-2 STARTER ........................................... EG12-4-4

EG12-4-2

ENGINE

----------------STARTER

TROUBLESHOOTING Symptom

Possible cause

Remedy

Engine does not crank, --�-<Key switch or cranks slowly. ·Poor contact................................Polish or replace contacts Battery ·Discharged battery.

.Charge

·Short circuited between electrodes .

.Replace battery

·Poor contact at battery terminal..

.Polish or retighten

Engine oil •Improper viscosity oil.......... ................ Change oil Magnetic switch ·Poor contact caused by burnt contact plate

.Polish or replace contact plate

•Contact plate worn out... .. . .....

.Repair

·Hold-in coil disconnected .. .. .. ... ...........Replace field coil (Overrunning clutch moves back and forth) • Pull-in coil disconnected or short circuited ............Replace Starter relay ·Defective or poor contact .......................Repair or replace Starter •Brush worn out.

.Replace

·Commutator burnt out.

.Correct on lathe

· Commutator worn out ..

.Correct by undercutting

•Field winding shorted or grounded ..

. Rewind or rep I ace

· Armature winding shorted or grounded .

.Replace armature

•Insufficient brush spring tension.....

. Replace brush spring

· Poor contact between magnetic switch and field windings

.Repair

· Armature contacts pole core because of worn ..........Replace bearing or armature bearing or bent armature shaft ·Overrunning clutch mulfunction...................Replace

ENGINE

EG12-4-3

----------------STARTER-----------------

Symptom

Possible cause

Engine does not crank -------< Overrunning clutch while starter is running ·Overrunning clutch mulfunction. in good condition. ·Pinion teeth worn out ... •Poor sliding of spline teeth .

Starter does not stoprunning.

Remedy

..........Replace .........Replace . Remove foreign materials, dirt, or replace

�----< Key switch ·Contacts keep closing ..........................Replace • Key switch sticks................

.Replace

·Overrunning clutch sticks to armature ..

.Repair or replace overrunning clutch or armature

Starter relay ·Contacts keep closing ..........................Repair or replace

EG12-4-4

----------------STARTER----------------

STARTER

4 '-

1 ------

DETAIL A

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12.

13.

Fig. 22-1

Yoke assembly Brush Brush Commutator end frame Brush holder assembly Brush Brush spring Set bolt Armature assembly Ball bearing Ball bearing Set bolt Gear housing

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Shim Drive shaft assembly Shim Bearing housing Clutch and pinion assembly Pinion stopper Hook Clip Set bolt Gasket Drive pinion lever Lever pinion Lever holder

27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

Holder spring Insert Drive housing assembly Bushing Magnetic switch assembly Contactor with terminal cover assembly Terminal assembly Contactor assembly Moving core assembly O-ring Contactor spring Bolt Plug

ENGINE

EG12-4-5

----------------STARTER----------------

DISASSEMBLY When disassembling the starter, prepare a work stand as shown in the figure. D: Diameter = 130mm(5.118in) T: Thickness = 10mm(0.394 in) = 120mm (4.724 in) H: Hight

Fig. 22-2

SMST-130

Fig. 22-3

Fig. 22-4

Fig. 22-5

REMOVAL OF THE MAGNETIC SWITCH 1. Remove the "M" terminal lead.

SMST-131

Remove the magnetic switch set bolts, then remove the magnetic switch assembly.

Remove the moving core in the direction of the marked arrow in the order G) and

SMST-132

SMST-133

REMOVAL OF THE FIELD COIL ASSEMBLY AND GEAR HOUSING FROM THE DRIVE HOUSING. 1.

Fig. 22�

®.

SMST-134

Remove the gear housing set bolt and commutator and frame set bolt.

ENGINE

EG12-4-6

----------------STARTER----------------

Fig. 22-7

Fig. 22-8

Remove the commutator end frame set bolts, then remove the end frame.

Using long-nose pliers, remove the brushes from the brush holder.

Remove the brush holder.

Remove the field coil assembly.

Remove the armature assembly from the drive housing.

Using a press, remove the armature from the gear housing.

SMST-135

SMST-136

Fig. 22-9

SMST-137

Fig. 22-10

SMST-138

Fig. 22-11

SMST-139

EG12-4-7

ENGINE

STARTER---------------3.

g--- COLLAR

REMOVAL OF THE DRIVE HOUSING. 1.

Remove the gasket, collar, and spring.

Remove the clutch and pinion assembly from the drive housing.

Using a press, remove the drive housing plug. D: Diameter = 16 mm (0.620 in)

� SPRING GASKET

Fig. 22-12

SMST-139

Fig. 22-13

SMST-140

Fig. 22-14

SMST-141

Fig. 22-15

Fig. 22-16

SMST-142

DISASSEMBL V OF THE CLUTCH AND PINION AS SEMBLY. 1.

Remove the clip.

Remove the hooks and stopper.

Disconnect the clutch and pinion assembly, the bearing housing, and the drive shaft.

SMST-143

SMST-144

ENGINE

EG12-4-8 STARTER----------------

INSPECTION AND REPAIR Armature

Fig. 22-17

Fig. 22;18

ARMATURE SHORT-CIRCUIT TEST Place the armature on a growler tester and hold a hack saw blade against the armature core while slowly rotating the armature. A short circuited armature causes the blade to vibrate and to be a�-trncted to the core. An armc1tu,� which is short-circuited must be re placed or repaired.

ARMATURE WINDING GROUND TEST Using a circuit tester, touch one probe to a commu tator segment and the other to the armature core. There should be no continuity. If there is continuity, the armature is grounded. Replace the armature if grounded.

ARMATURE WINDING CONTINUITY TEST.

SMST-091

SMST-092

Using a circuit tester, touch probes to two segments. There should be continuity at any point. If there is no continuity, the winding is open-circuited. Replace the armature if open-circuited.

Fig. 22-19

SMST-125

COMMUTATOR RUN-OUT TEST.

Check the commutator run-out as shown. If it exceeds the limit, repair or replace. Standard: 0.05 mm (0.0020 in) Service Limit: 0.1 mm (0.0039 in)

Fig. 22-20

SMST-093

MEASUREMENT METER.

OF COMMUTATOR OUTER DIA

Measure the commutator outer diameter. If it is worn, replace the armature. Standard: 40 mm (1.575 in) Service Limit: 38 mm (1.496 in)

Fig. 22-21

SMST-126

ENGINE

EG12-4-9 STARTER--------------6.

Fig. 22-22

SMST-126

;

Fig. 22-23

MEASUREMENT OF SEGMENT MICA DEPTH. Check the depth of the segment mica. Undercut the segment mica if necessary. Standard: 0.5 - 0.8 mm (0.0197 - 0.0314 in) Repair Limit: 0.2 mm (0.008 in)

Yoke 1.

VISUAL CHECK Check the field windings for wear or damage. Check all connections for clean and tight solder joints.

FIELD WINDINGS GROUND TEST AND FIELD WINDINGS CONTINUITY TEST. Field windings grounding test. 1. Using a circuit tester, touch one probe to the brushes and the other to the yoke body. There should be no continuity. If there is continuity, the field windings are grounded. Repair or replace if necessary.

SMST-145

Fig. 22-24

SMST-146

Drive shaft 1.

Fig. 22-25

SMST-096

Field windings continuity test. Using a circuit tester, touch one probe to the "M" terminal and the other to the brushes. There should be continuity. If there is no continuity, the field windings are open-circuited. Repair or replace if necessary.

DRIVE SHAFT RUN-OUT TEST. Check the drive shaft run-out as shown. If it exceeds the limit, repair or replace. Standard: 0.05 mm (0.0020 in) Service Limit: 0.1 mm (0.0039 in)

ENGINE

EG12-4-10

---------------- STARTER---------------2.

INSPECTION OF DRIVE SHAFT.

Check the drive shaft spline and gear for wear or damage. Replace if necessary.

SMST-097

Fig. 22-26

Bushing 1.

MEASURE THE DRIVE HOUSING BUSHING.

Measure the inside diameter of the bushing. If it exceeds the limit, replace the bushing. Standard: 17.0 mm (0.669 in) Service Limit: 17.2 mm (0.677 in)

Fig. 22-27

SMST-147

MEASURE THE BEARING HOUSING BUSHING.

Measure the inside diameter of the bearing housing bushing. If it exceeds the limit, replace the bearing bushing. Standard: 28.0 mm (1.102 in) Service Limit: 28.2 mm (1.110 in)

Fig. 22-28

SMST-148

(2)

8 :

i :•

Fig. 22-29

SMST-149

REPLACEMENT OF BUSHING G) Remove the bushing as shown. ® Replace the bushing with a new one as shown. NOTE: In the case of the bearing housing bushing, also replace the bearing housing bushing.

ENGINE

EG12-4-11

-----------------STARTER----------------

Brush and brush holder 1.

MEASUREMENT OF BRUSH LENGTH Check the brush length for wear. If it exceeds the limit, replace the yoke assembly or Brush holder assembly. Standard: 20.0 mm (0.787 in) Service Limit: 13.0 mm (0.512 in)

Fig. 22-30

SMST-150

MEASURE THE BRUSH SPRING. Check the tension of the brush spring. If it exceeds the limit, replace it with a new one. Standard: 3.0 kg (6.6 lb) Service Limit: 2.0 kg (4.4 lb)

Fig. 22-31

SMST-117

Fig. 22-32

BRUSH HOLDER INSULATION TEST. Using a circuit tester, touch one probe to the brush and the other to the holder plate. There should be no continuity. If there is continuity, replace.

SMST-151

Magnetic switch

Fig. 22-33

MAGNETIC SWITCH WINDING CONTINUITY TEST BETWEEN "C" TERMINAL AND THE BODY. Using a circuit tester, touch one probe to the "C" terminal and other to the body. There should be continuity, the magnetic switch windings are open circuited. Repair or replace, if necessary.

MAGNETIC SWITCH WINDING CONTINUITY TEST BETWEEN "C" TERMINAL AND THE "COIL" TER MINAL.

SMST-152

Using a circuit tester, touch one probe to the "C" terminal and other to the "COi L" terminal. There should be continuity the magnetic switch windings are open-circuited. Repair or replace, if necessary.

Fig. 22-34

SMST-153

ENGINE

EG12-4-12

-----------------STARTER---------------REPLACEMENT OF THE MAGNETIC SWITCH.

Fig_ 22-35

Fig. 22-37

Remove the clip, and disconnect the return spring from the moving core.

Unsolder the "COi L" terminal and "C" terminal.

Remove the contact housing screw.

SMST-154

SMST-156

Fig. 22-38

SMST-104

Clutch and pinion 1.

INSPECTION OF SPLINE TEETH Inspect the spline teeth on the shaft and be sure that the clutch moves smoothly on it. Replace if neces sary.

LOCK

Fig. 22-39

Check the contact point for w ear or damage. Replace if necessary.

SMST-157

EG12-4-13

ENGINE

----------------STARTER----------------2.

INSPECTION OF CLUTCH. Inspect the pinion to insure that it can be rotated freely in the direction of starter rotation and that it is looked in the opposite direction of rotation. Replace if necessary.

LOCK Fig. 22-40

SMST-158

Others 1.

INSPECTION OF THE D RI VE PINION LEVER.

Check the drive pinion lever for wear and damage. Replace if necessary.

Fig. 22-41

SMST-158

MEASUREMENT OF COMMUTATOR END FRAME INSIDE DIAMETER.

Measure the end frame inside diameter. If it is worn, replace the end frame. Standard: 32.0 mm (1.260 in) Service Limit: 32.1 mm ( 1.263 in)

Fig. 22-42

SMST-159

INSPECTION OF THE INSULATION PAPER.

Inspect the insulation paper applied at two locations inside for peeling or damage. Replace, if necessary.

ENGINE

EG12-4-14

---------------- STARTER-----------------

ASSEMBLY 1.

LUBRICATION AND TIGHTENING TORQUE Before reassembling, apply the recommended grease as follows and when assembling, tighten the nuts and bolts to the specified torque value. LUBRICATION POINTS:

� @ ® @

(J) ® ®

Bushing Clutch and pinion assembly Bushing and shim Drive shaft Gear housing and shim Bearing Drive pinion lever Moving core Lever holder and pin

TIGHTENING TORQUE: @ @ SMST-158

Fig. 22-43

Magnetic switch set bolt 140- 160 kg-cm (10.2- 11.5 lb.ft) Commutator end frame set bolt 140 - 160 kg-cm (10.2- 11.5 lb.ft) Gear housing set bolt 140- 160 kg-cm (10.2- 11.5 lb.ft) Brush holder set bolt 37 - 50 kg-cm (2. 7 - 3.6 lb.ft)

TO REASSEMBLE, FOLLOW THE DISASSEMBLY PROCEDURE IN REVERSE ORDER. NOTE: When assembling the starter, pay attention to the following points. 1. When installing the drive pinion lever on the shaft, pay attention to the direction in which the lever is installed.

SMST-160

Fig. 22-44

BRUSH HOLDER P l NIG NOTCH �� I '-✓�-

pfe

Fig. 22-45

SMST-160

Match the positioning of the brush holder with the "M" lead.

Match the end frame positioning guide with the notch of the brush holder positioning guide.

ENGINE

EG12-4-15

-----------------STARTER---------------3.

MEASURE THE THRUST GAP. After assembling the starter (without the magnetic switch), use a dial gauge to measure the thrust gap as you move the drive shaft in and out by hand. Standard: 0.1 - 0.5 mm (0.004 - 0.0196 in) If the thrust gap exceeds the standard, adjust by decreasing or increasing the shim.

SMST-161

Fig. 22-46

AFTER MEASUREING THE GAP, INSTALL THE DRIVE HOUSING PLUG AND MAGNETIC SWITCH. NOTE: Use a new plug.

SMST-162

Fig. 22-47

sw,

BATTERY

Fig. 22-48

AFTER ASSEMBLING THE STARTER, MEASURE THE TIMING GAP. Arrange the circuit. Close switches SW1 and SW2. Open SW2 alone when the pinion pops out. In the above condition, push the pinion back to measure the gap.

Standard: 0.5 - 3.0 mm (0.020 - 0.118 in) If the gap exceeds the standard, check the follow ing parts and, if necessary, replace them.

r2) @ @ @

i _ I

SMST-090

SM22-113 Fig. 22-49

Lever holder Lever pin Drive pinion lever Gasket Insert

ENGINE

EG12-4-16

STARTER----------------

TEST

MAGNETIC SWITCH TEST.

The following test should be performed with the starter assembled without the "M" terminal lead with specified voltage applied.

NOTE: Each test should be performed a short time (3 to 5 sec.) to prevent the magnetic switch winding from burning.

1. Fig. 22-50

SMST-163

Fig. 22-51

SMST-163

Fig. 22-52

Pull-in test Connect the test leads as shown. When the switch is closed, the pinion should jump out. Hold-in test With the same procedure as the pull-in test, dis connect the "B" terminal. The pinion should remain in the "jumped out" position.

Return-test With the same procedure as in the hold-in test, disconnect the "EARTH" jumper wire. The pinion should return immediately.

SMST-163

PERFORMANCE TEST

The following test should be carried out aher re assembling the starter. If suitable equipment is not available, at least the no-load test should be carried out. No-load test With the starter securely clamped in a vice, and using a battery and suitable ammeter, connect the positive lead of the battery, and the ammeter to the terminal. Connect the negative lead to the starter body. The starter should show smooth and steady rotation immediately aher jumping out of the pinion and should draw less than the specified current. Specified Current:

Fig_ 22-53

SMST-164

Less than 100A at more than 4,000 rom.

(KY)

EG12-5-1

ENGINE

-----CALIBRATION-----

GROUP 5 INJECTION PUMP

CALIBRATION

ENGINE

EG12-5-2

_______________ CALIBRATION-------------- C-56E-01

CALIBRATION 22020-3001

Injection pump type

NP-PE6AD1058320R

Governor type

RSV

Timer type

Not equipped

Feed pump type Test nozzle type

NP-FP/KE 105780-8140

Test nozzle opening pressure

175 kg/cm2 (2,489 psi)

INJECTION PUMP SPECIFI CATION

Outer diameter

TEST CONDITION

Injection pipe

Calibration oil

OVERFLOW VALVE

INJECTION TIMING

6.0 mm (0.236 in)

Inner diameter

2.0 mm (0.079 in)

Length

600 mm (23.6 in)

Type

SAE J967C

Oil temperature

40 - 45 C (104 - 113 F)

Fuel feed pressure

1.6 kg/cm 2 (22.8 psi)

Opening pressure

1.5 - 1.8 kg/cm 2 (21.33 - 25.59 psi)

Rotation

Clockwise viewed from drive side

Injection order

1-4-2-6-3-5

Injection interval

60 ± 30'

Pre-stroke

4.8 mm (0.189 in)

Rack position mm (in) INJECTION VOLUME

H06C-TI

Engine model Injection pump part number

Pump speed (rpm)

Measuring strokes

Injection volume cc (cu.in)

Max. variation limit cc (cu.in) 1.74 (0.212) - Base -

9.1 (0.358)

1,050

500

50.1-50.6 (3.057-3.086)

About 5.2 (0.205)

410

500

4.5-5.5 (0.275-0.335)

100

500

66.5-71.5 (4.057-4.361)

SWIVEL LEVER ADJUST SCREW

- Rack limit-

CONTROL LEVER ANGLE

ADJUSTING POSITION MAXIMUM SPEED STOPPER BOLT

0.5 (0.031)

IDLING SUB SETTING SCREW

FULL SPEED

IDLING

CONTROL LEVER

GOVERNOR ADJUSTMENT

V.P.

NOTE: ° ° • ANGLE: 1 ... 18 ± 5 ° ° 2 ... 3 ±5 STOP LEVER

FULL LOAD STOPPER BOLT

• Lever angle "V .P." means. Vertical position

ENGINE

EG12-5-3

CALIBRATION

Adjusting item

a::

1--

0�

z�

a: 1--

Maximum speed

Full load

wcn

>::::>

0-, o

<!l <t

Idling speed

Idle

Control rack position mm (in)

Pump speed (rpm)

Adjusting lever position

Adjusting position

Na: 490-530

Ra: 9.1 (0.358 in)

Full load stopper bolt

Nb: About 1,050

Rb: Should be start to pulled control rack

Maximum speed stopper bolt

Ne: 1 ,125-1 ,175

Re: 5.3 mm (0.209 in)

*Swivel lever adjusting screw

N :0 Nd: 275

8.2 mm (0.323 in) R Rd: 5.2 mm (0.205 in)

Idling sub-spring set

* NOTE:

Recommend setting of swivel adjusting screw: 10 clinks from buttom end.

GOVERNOR CHARACTERISTIC DIAPHRAGM GOVERNING RANGE: 410-1,050 rpm More than: 14 -

.§

�r /

_,, , .11.1!

RACK LIMIT

✓ //

Ra: 0.1 R:82

Re: 5.3 Rd: 5.2

-\y //

GOVERNOR SPRING SET

\\ I I

-.,

L-._

IDLING SUB-SPRING SET

LO r--

-c

0 M

I 0

- --g -0 LO r--

q I

I LO

z z .c

Pump speed (rpm) -

ENGINE

EG12-6-1

------------- TURBO CHARGER -------------

GROUP 6 TURBOCHARGER TROUBLESHOOTING ................................. EG12-6-2 SPECIAL TOOLS..................................... EG12-6-4 OVERHAUL ........................................ EG12-6-5 OVERHAUL FACTOR ................................ EG12-6-6 REMOVAL .......................................... EG12-6-7 DISASSEMBLY ...................................... EG12-6-7 INSPECTION ........................................ EG12-6-11 ASSEMBLY ......................................... EG12-6-13

ENGINE

EG12-6-2

TURBO CHARGER

TROUBLESHOOTING Symptom

Possible cause

Dense black smoke ---,--- Insufficient air intake

• Air cleaner is choked with dust, .. causing greater intake air resistance.

• Air inlet is choked ............

Remedy /prevention .Disassemble and clean or replace !he air cleaner element. .F.-�pair.

• Air is leaking from intake menifold .......... Repair. Turbocharger does not rotate smoothly.

• Engine oil impurities deposited ... on rotor, resulting in heavy rotation or sticking.

.Overhaul and clean turbocharger and/or change engine oil.

• lnsuffficient lubrication or blockalge. of lubricating oil lines.

.Check lubricating oil system, and/or repair.

Bearing sticking

• Abnormal wear or damage of seal . ring caused by wear of journal bearing, due to insufficient lubrication.

.Repair.

• Temperature of lubricating oil too high .......Check cooling system.

• Unbalanced rotating parts .....

• Incomplete warming-up, failure . to idle before stopping engine, or jack rabbit starts.

.Change rotating parts.

.Operate vehicle properly.

Loose or damaged turbine wheel or compressor wheel.

•

Over-rotation ..................

• Temperature of exhaust gas too high . • Foreign matter present ..........

• Worn thrust bearing .

• Incomplete assembly High volume exhaust

like noise

Exhaust gas leaking before turbocharger, .. therefore msufficient revolution. L

.Check and adjust the engine.

..Remove foreign material. Inspect the air cleaner and air intake manifold. Repair if necessary. . Overhaul and repair. . Reassembly.

.Check and repair connections.

Deformed or blocked exhaust gas I ines .........Repair.

therefore insufficient revolution.

White smoke

Choking defects, or deformation of............Repair and replace the lines.

oil return lines so that oil leaks around

L compressor or turbme sides.

Seal ring may be broken or worn due ..........Replace the thrust washer.

to abnormal wear of thrust washer.

EG12-6-3

ENGINE

TURBO CHARGER Symptom

Possible cause

Loss of power

Gas leakage from exhaust system .............Repair.

Remedy /prevention

Air leakage from air manifold ...............Repair. L Clogged air cleaner element .................Clean or replace.

Turbocharger dirty or damaged ..............Repair or replace.

Poor response of

turbocharger

- -�L---

Carbon accumulation on the turbine ...........Change engine oil, clean turbocharger. side seal ring and heavy rotation.

Poor combustion ........................Check fuel system and improve combustion.

High pitched noise --�--..... Noise

and vibration

• So cal led "surging" Surging sometimes occurs when the gas passage at the nozzle of the turbine

.....Overhaul and clean tubocharger.

housing is choked or when compressed air does not flow in proper responses to acceleration.

• Loose rotating parts ....................Replace. Vibration

• Joints loose between turbocharger .......... Check the mounting and repair. and intake, exhaust manifold or oil lines. • Damaged bearing, loose rotating parts, ........Repair. imbalanced rotating parts, etc.

ENGINE

EG12-6-4

-------------- TURBO CHARGER -------------

SPECIAL TOOLS Before beginning a turbocharger overhaul, it is necessary to have the following special tools.

Illustration

Tool No.

Tool name

Use

09444-1230

ATTACHMENT

For measuring the turbine shaft play with a dial gauge.

09444-1250

PRESSURE GAUGE (Full scale 1 kg/cm 2 )

For measuring boost pressure.

17108-1040

HOSE

Tool name: *Mounting base

�v-�::::r:=..___:__ 5�

5<! u

•"ld,q

-_____:__:_-:·----=--

===--=:::J _____::_:_

�.,

--�5 _46 _

,�-��

;(}/ 0

•

_o_

For assembly, disassembly or inspecting of the turbo charger.

C·

Tool name: * Attachmnet ,9

�� L___� , ,'

01�·

w"ld,ng ___j

For removing the back plate.

*These special tools are not supplied by Hino motors and must be procured or manufactured by the main tenance shop.

ENGINE

EG12-6-5

--------------

TURBO CHARGER -------------

OVERHAUL

1 ___ ,

3. 4.

5. 6.

8. Fig. 51-1

Blower case Plate Back plate Seal ring Oil thrower Retainer ring Lock nut Blower impeller

9. 10. 11. 12. 13. 14. 15. 16.

Thrust bearing Thrust spacer Bearing Bearing case Heat protector Seal ring Turbine rotor Turbine case

ENGINE

EG12-6-6

-------------- TURBO CHARGER --------------

OVERHAUL FACTOR

CONDITIONS WHICH DETERMINE WHEN A TURBO CHARGER OVERHAUL MAY BE NEEDED.

THE ENGINE LACKS POWER OR ENGINE EXHAUST EMITS BLACK SMOKE.

BOOST PRESSURE IS BELOW THE NORMAL VALUE. Inspect the turbocharger boost pressure according to the following procedures. NOTE: Before measurement o Coolant temperature should approximately 80° C. c Air cleaner element should be clean. WAR NING When making a pressure test, be sure that personnel are adequately protected against any stream of pressurized air that might be released by a i�ak or the rupture of a hose.

Remove the blind plug on the intake pipe and install the hose and pressure gauge (special tools). Special Tools: Pressure gauge (09444-1250) Hose (17108-1040)

Fig. 51-2

Run the engine at maximum rpm.

SM51-069

Read the boost pressure. It the boost pressure is below the normal value, turbocharger overhaul is needed. Boost Pressure: 0.6 - 0.8 kg/cm2

Fig. 51-3

SM51-041

ENGINE

EG12-6-7

------------- TURBO CHAR GER--------------3.

OTHER FACTORS 1. Noisy of excessive vibration of the turbocharger. 2. Excessive engine oil consumption. 3. Gas leakage at the turbine end or blower end. 4. Oil leakage from the turbocharger.

REMOVAL WARNING Do not work on the turbocharger while it is still hot. This can result in personal injury. Dismount and mount, refer to the "CHAPTER 3''.

DISASSEMBLY

Fig. 51-4

SM51-002A

INSPECTION BEFORE DISASSEMBLV. 1. Rotate the blower impeller by hand to see if it turns smoothly. If it does not turn smoothly, clean and inspect the bearings and turbine rotor.

Check the turbine rotor for axial play (A). If the axial play is greater than the service limit, replace the thrust bearing and/or thrust spacer. Axial Play: 0.06 - 0.09 mm (0.0023 - 0.0035 in) Service Limit: 0.11 mm (0.0043 in)

Fig. 51-5

SM51-002

Check the turbine rotor for radial play using a special tool. If the radial play is greater than the service limit, replace the bearings and/or turbine rotor. Special Tool: 09444-1230 3.

Radial Play: 0.11 - 0.18 mm (0.004 - 0.007 in) Service Limit: 0.215 mm (0.0085 in) Fig. 51-o

SM51-002A

ENGINE

EG12-6-8

TURBO CHARGER 2.

DISASSEMBLE THE TURBINE CASE. NOTE: Make mate marks on the turbine case, bearing, housing, and blower case to aid alignment during reassembly.

MATCHING MARK

Fig. 51-7

SM51-017

1. ,

Fig, 51-8

Fig, 51-9

Fig. 51-10

Unlock the lock plate and remove the turbine case fitting bolts.

51-005A

51-006A

2. Remove the turbine case. NOTE: Be careful not to damage the turbine blades.

DISASSEMBLE THE BLOWER CASE.

1. 2. 3.

Reposition the mounting base. Mount the blower case on the mounting base. Remove the blower case fitting bolt.

Remove the blower case.

51-007

NOTE:

Fig. 51-11

51-008

Lightly strike the blower case using a plastic hammer. Be careful not to damage the blower impeller.

EG12-6-9

ENGINE

-------------- TURBO CHARGER 4.

REMOVE THE TURBINE ROTOR.

1. Remove the blower impeller fitting nut. NOTE: Turn the lock nut clockwise to loosen the nut (left-hand threads).

Fig. 51-12

Fig. 51-13

Fig. 51-14

SM51-031

Remove the blower impeller by hand.

Remove the turbine rotor with heat protector.

51-010

51-011

Fig. 51-15

REMOVE THE BEARINGS. 1. Remove the holding plate. NOTE: Mark one side of the holding plate so that it can be replaced in the proper direction during assem bly.

51-012

Fig. 51-16

51-013

Remove the back plate. Pull out the back plate using the attachment and a sliding hammer.

ENGINE

EG12-6-10

-------------- TURBO CHARGER

Fig. 51-17

Fig. 51-18

Remove the oil thrower.

Remove the thrust bearing and thrust bushing.

Remove the retainer rings of each bearing.

Remove the bearings.

Remove the seal rings from the oil thrower.

51-014

51-015

51-016

Fig. 51-19

Fig. 51-20

51-017

•

51-018

0 0

Fig. 51-21

51-019

EG12-6-11

ENGINE

-------------- TURBO CHARGER --------------

INSPECTION

INSPECTION Before cleaning, the disassembled parts should be visually inspected to check for burning, abrasion, carbon deposits, gas and oil leakage.

CLEANING Thoroughly clean all the parts with diesel fuel, using a soft brush, and dry with compressed air. NOTE: :J Never use a caustic cleaning solution, as it may attack aluminum. o Never use a wire brush. WARNING This cleaning should be done in a well ventilated room and away from any open flames or electric sparks.

INSPECT ALL THE DISASSEMBLED PARTS FOR ANY ABNORMAL WEAR, CRACKS, DEFORMATION, OR DISCOLORATION. Replace any faulty part.

Fig. 51-22

MEASURE THE OUTSIDE DIAMETER OF THE TURBINE SHAFT. If the turbine shaft is smaller than the service limit, replace the turbine rotor. Service Limit:

Fig. 51-23

51-021

12.28 mm (0.4835 in)

MEASURE THE RING GROOVE WIDTH. If the ring groove width is greater than the service limit, replace the turbine rotor. Service Limit: 1.63 mm (0.0642 in)

Fig. 51-24

51-022

ENGINE

EG12-6-12

-------------TURBO CHARGER--------------

MEASURE THE BEND OF THE TURBINE SHAFT. If shaft runout is greater than the service limit, replace the turbine rotor.

NOTE: Do not repair the turbine rotor. Service Limit: 0.011 mm (0.0004 in)

Fig. 51-25

51-023

MEASURE THE INSIDE AND OUTSIDE DIAMETERS OF THE BEARING. If the inside diameter is greater than the service Iimit, replace the bearing. If the outside diameter is less than the service Iimit, replace the bearing.

Service Limit: Outside Diameter: Inside Diameter: Fig. 51-26

51-024

16.98 mm (0.6685 in) 12.36 mm (0.4866 in)

MEASURE THE INNER DIAMETER OF THE BEARING HOUSING. If the inner diameter is greater than the service limit, replace the bearing case. Service Limit: 18.55 mm (0.7303 in) A: B: 17.11 mm (0.6736 in)

Fig. 51-27

SM51-006

MEASURE THE HEIGHT OF THE THRUST SPACER. If the height is greater than the service I imit, replace the thrust spacer.

Service Limit: 4.6 mm (0.1811 in)

Fig. 51-28

SM51-007 G1il 7rl

10. G2

MEASURE THE SEAL RING GROOVE WIDTH OF THE OIL THROWER. If the groove width is greater than the service limit, replace the oil thrower.

'-----�--K--��_J SM51-006A Fig. 51-29

Service Limit: 1.75 mm (0.0689 in) G1: 1.52 mm (0.0598 in) G2: K: 4.60 mm (0.1811 in)

EG12-6-13

ENGINE

--------------TU RB O CHARGER -------------11. MEASURE THE THICKNESS OF THE THRUST BEAR ING. If the thickness is less than the service limit, replace the thrust bearing. Service Limit: 4.44 mm (0.1748 in)

Fig. 51-30

51-025

12. MEASURE THE SEALING BORE OF THE SEAL PLATE. If the sealing bore is greater than the service limit, replace the seal plate.

Service Limit: 16.05 mm (0.6319 in) H1: 14.05 mm (0.5531 in) H2: H2 Fig. 51-31

_____ i SM51-006B

ASSEMBLY 1.

ASSEMBLE THE JOURNAL BEARINGS. 1.

Install the first retainer ring in the bearing casing. The position of the retainer ring should be seen in Fig. 51-32.

NOTE: M ake sure that the retainer ring is securely fitted in the groove.

Fig. 51-32

51-026 OIL INLET SIDE

NOTE: The beveles edge of the retainer ring should be positioned toward the bearing case.

·� POSITION OF RING

Fig. 51-33

SM51-003A

Install the bearing in the bearing case.

NOTE: Apply clean engine oil.

Fig. 51-34

51-018

ENGINE

EG12-6-14

-------------- TURBO CHARGER ------------

OIL INLET SIDE

Install the other retainer ring.

NOTE: The only nearest turbine side of the retainer ring should be installed according to the figure on the left.

Repeat step 1) through 4) to install the second bearing.

FLUSH WITH THE CASE Fig. 51-35

SM51-003B

Fig. 51-36

51-027

Fig. 51-37

51-012

Fig. 51-38

51-028

Fig. 51-39

51-011

ASSEMBLE THE TURBINE ROTOR.

I nstal I a new seal ring in the seal ring groove of the turbine shaft.

Replace the holding plate.

Position the heat protector on the bearing case.

Coat the journals of the turbine rotor with clean engine oil and install the turbine rotor in the bearing case.

ENGINE

EG12-6-15

--------------TURBO CHARGER 3.

ASSEMBLE THE THRUST BEARING.

Fig. 51-40

.:� ..

-•;.. ·� :..,.·..�

Fig_ 51-41

...

Install the thrust spacer on the turbine shaft.

51-016

Coat the thrust bearing with clean engine oil and install the bearing case. NOTE: Always use new screws and lock washers. Tightening Torque: 12 - 14 kg·cm (0.87-1.01 lb.ft) 2.

51-029

ASSEMBLE THE BACK PLATE.

Insert two new seal rings on the oil thrower .

Install the oil thrower in the back plate.

�

0 Fig. 51-42

51-019

51-030

Fig. 51-43

NOTE: The openings of seal rings should be positioned as seen in Fig. 51-44.

OIL INLET SIDE

Fig. 51-44

SM51-005A

EG12-6-16

ENGINE

---------------TURBO CHARGER-------------3. Install the back plate in the bearing case. NOTE: The oil return hole should face the oil outlet side. Apply silicone R.T.V. sealer to the flanged sur face of the back plate.

Fig. 51-45

51-031

4. Tighten the four screws with lock washers. NOTE: Always use new screws and washers. Tightening Torque: 25 - 35 kg·cm (1.81 - 2.53 lb.ft)

Fig. 51-46

SM51-030

Fig. 51-47

FIT THE BLOWER IMPELLER ON THE TURBINE ROTOR AND TIGHTEN THE LOCK NUT. NOTE: Remember that this nut has left-hand threads. Tightening Torque: 75 - 85 kg·cm (5.42 - 6.14 lb.ft)

INSTALL THE TURBINE CASE TO THE BEARING CASE, BEING SURE TO ALIGN THE MATE MARKS.

SM51-031

...

Tightening Torque:

5l-033A

Fig. 51-48

7. � /

--� --:::-2>._,_

ASSEMBLE THE BLOWER CASE. 1. Install the blower casing to the bearing case, refer ring to the mate marks. NOTE: Coat the flange face of the blower case with silicone R. T. V. sealant. Tightening Torque:

Fig. 51-49

280 - 290 kg-cm (20.25 - 20.96 lb.ft)

SM51-032

195 - 205 kg·cm (14.10 - 14.82 lb.ft)

EG12-6-17

ENGINE

-------------- TURBO CHARGER --------------

, Fig. 51-50

51-035A

Tighten the six fitting bolts.

ENGINE

EG12-7-1

----------- SERVICE SPECIFICATIONS

GROUP 7 SERVICE SPECIFICATIONS ENGINE SPECIFICATIONS .............................. EG12-7-2 REPAIR SPECIFICATIONS ................. _ ............ EG12-7-5 METRIC INFORMATION................................ EG12-7-15 DECIMAL AND METRIC EQUIVALENTS.................. EG12-7-16 STANDARD TIGHTENING TORQUE...................... EG12-7-17 RECOMMENDED LUBRICANTS ..........................EG12-7-19

ENGINE

EG12-7-2

----------- SERVICE SPECIFICATIONS

SPECIFICATIONS DIESEL ENGINE FOR HYDRALIC EXCAVATOR

HIND

H06C-TI

Ambient conditions: Intake air temperature Barometric pressure Water vapour pressure 0 ENGINE DESCRIPTION 1. Type

Combustion system Cylinder

Bore x Stroke Piston displacement

Compression ratio 6. Direction of rotation 7. Dimensions (L x W x H) 8. Dryweight 0

6.485 liters, 4-cyde, 6-cyl., water-cooled

JIS 01005

20° c

760 mmHg 11.4 mmHg

Diesel, 4-cyc., 6-cyl., in-line, overhead valve, water-cooled, inter-cooled, turbo-charged Direct injection type 108 x 118 mm (4.25 x 4.65 in) 6.485 liters (395.7 cu.in) 17.7 Counter-clockwise viewed from flywheel Approx. 1,221 x 775 x 1,065 mm (48.1 X 30.5 X 41.9 in) Approx. 615 kg (1,356 lb)

FEATURES

1. Cylinder block 2. Cylinder head 3. Crankshaft 4. Piston and rings

5. Camshaft 6. Valves

Mono block cast iron with replaceable dry type liners Special cast iron Induction-hardened die forged special steel with counter weights Heat-resistance aluminum alloy Three compression rings, chrome plated One oil ring, chrome plated with coil expander Induction hardened carbon steel Heat resistance steel

EG12-7-3

ENGINE

------------- SERVICE SPECIFICATIONS O EQUIPMENT 1. Flywheel housing 2. Flywheel 3. Fuel injection pump 4. Governor 5. Fuel injection nozzle 6. Fuel filter 7. Cooling system 8. Lubricating system 9. Oil filter 10. Intake manifold 11. Exhaust manifold 12. Generator 13. Starter

HINO own (SAE No. 2 type) HINO own DIESEL KIKI "�D" type Centrifugal, all speed control type BOSCH hole type Paper element type Forced-circulation by volute pump Full-forced pressure feed by gear pump Peper element type (Full flow), by-pass flow (O.P.T) With inter-cooler With water-cooler 24V, 25A 24V, 6KW

ENGINE

EG12-7-4

----------- SERVICE SPECIFICATIONS

ENGINE PERFORMANCE CURVE

(kgml 60 50

(PS)

160

w ::>

a::

0 f-

140

a:: w 3 0 0...

120

(/)

0 I

100

f0...

� ::>

(/) ( g/pshl z

180

0 _J

170

160

1,000

1,200

1,400

1,600

ENGINE SPEED

1,800

2,000

( r. p .m.l P-H06C-T033-1

ENGINE

EG12-7-5

------------ SERVICE SPECIFICATIONS

REPAIR SPECIFICATIONS ENGINE H06C-TI SERVICE STANDARD Item

-0

...

Unit: mm (inch) Nominal dimensions

Assembly standard or clearance

Repair Hat.it

Service limit

0 - 0.05 (0 - 0.0019)

0.10 (0.0039)

95 (3.74)

94.70 (3.7283)

3.40 - 3.90 (0.1339 - 0.1535)

-0.05- 0.25 (-0.0019 - 0.0098)

0.5 (0.020)

0.8 (0.031)

Flatness

Cl> Cl>

-0

-C

Regrinding limit Protrusion of nozzle

i� m C > .,

- .. 41

Valve seat angle Valve face angle

i �> 1o Valve seat angle

Lia G.>

)(

Valve face angle

24.12 (0.9496)

Replace shaft

Bushing inside diameter

24.2 (0.953)

24.28 (0.9559)

Replace bushing

0.030 - 0.101 (0.0012 - 0.0039)

0.15 (0.0059)

Replace shaft and/or bushing

0.5 (0.020)

Repair by pressing or replace

9.0 (0.354)

8.89 (0.3500)

0.055 - 0.088 (0.0022 - 0.0035)

9.0 (0.354)

8.89 (0.3500)

0.070 - 0.103 (0.0028 - 0.0041)

Free length

...

68.6 (2.701)

Setting height

47.5 (1.870)

"' >

Setting load

31.0 kg (68.3 lb)

27.5 kg (60.6 lb)

Squareness

cii

Clearance

(.)

44 45' - 45

24.2 (0.953)

.:,£

Cl>

Rocker arm shaft outside diameter

"'§

"iii

Regrind with 30 ° or 45 cutter and finish by lapping

"' >

45 - 45 15'

Exhaust valve

"' "'

29 45' - 30

0.25 - 0.55 (0.0098- 0.0216)

Cl>

(.)

Replace gasket or nozzle

..r:

Regrind or replace

Intake valve

.:,£ C

E "'

30 - 30 15'

·-·

Cor rective method

Pushrod bend

:E :::, Cl>

�"' >

-0

"' "'> "' C

..,.,,_"' Cl>"'

.:,£ > C >

.., :::, "'-> ..r: "' "'

Cl>

Valve stem outside diameter Clearance Valve stem outside diameter Clearance

..:!

Replace valve and

valve seat

Replace valve Replace valve guide and/or valve Replace valve Replace valve guide and/or valve

2.5 (0.098)

Replace spring seat Replace spring

EG12-7-6

ENGINE

------------ SERVICE SPECIFICATIONS

SERVICE STANDARD (Cont'd) Nominal dimensions

Assembly standard or clearance

Repair limit

0.025 -0.075 (0.0010 - 0.0029)

0.1 (0.004)

0.30 (0.0118)

0.45 (0.0177)

Top ring

0.3 -0.45 (0.012- 0.0177)

1.5 (0.059)

2nd ring 3rd ring

0.3 -0.45 (0.012 -0.0177)

1.2 (0.047)

Oil ring

0.3 -0.5 (0.012 -0.019)

1.2 (0.047)

Ring thickness

2.5 (0.098)

2.'.?5 (0.0886)

Ring groove width

2.5 (0.098)

2.75 (0.1083)

0.04 -0.08 (0.0016 -0.0031)

0.4 (0.016)

Ring thickness

5.0 (0.197)

4.95 (0.1949)

Ring groove width

5.0 (0.197)

5.05 (0.1988)

Clearance

0.02 - 0.06 (0.0008 -0.0023)

Piston pin hole inside diameter

38.987-39.003 (1.5350 -1.5355)

38.989 -39.000 (1.5350 -1 .5354)

Clearance between piston pin hole _and pin Connecting rod bushing inside diameter

Item

-�E

"' .c C

u E a, > a,

"' >

Cl Cl

i:i:

..."'

-0 C

... ..."'

C 0

·a.

-� -�

.,'; Cl

·o..

a, u Intake > '" p; c-; >.!!u Exhaust a, ::

C 0

Clearance between tappet and tappet guide

"E.

C ·;::: C 0

..."'

C C

-0 -0 C .._

·a. -0 "'C

...

C 0

....,,

c· 0

·a.

..."' a: C 0

Unit: mm (inch)

Clearance

Piston pin outside diameter

Clearance between piston pin and bushing Connecting rod end play

Service limit

I 0.08 (0.0031) l

! '

I 38.95 f (1.5334)

0.013T - 0.014L �0.0005T-0.0006L)

0.1 (0.004)

39.015 -39.025 (1.5361 - 1.5364)

0.0,5-0.036 (0.0006 -0.0014)

0.1 (0.004)

0.2 - 0.5 (0.008 -0.020)

0.6 (0.024)

I I I

Corrective method Replace tappet

Adjust at cold engine

Replace piston ring

Replace piston and/or piston ring

Replace piston and piston pin

Replace connecting rod Replace connecting rod

ENGINE

EG12-7-7

------------ SERVICE SPECIFICATIONS

SERVICE STANDARD (Cont'd)

Unit: IJlm (inch)

Nominal dimensions

Item

Assembly standard or clearance

Repair limit

Service limit 0.05 (0.0020)

Straightness

for each

100 (3.94)

Twist -0 � g' u 11) C: C: 0 u

...

Cl C: ·.;, u '1) C: C: 0 u -0 C: "' ..,

-"'

.c V, .:.:. C:

68.985 - 69.000 (2.7160 - 2.7165)

Connecting rod big end inner diameter Crank pin outside diameter

! i

Clearance

69.7 5 - 70.25 (2.7 461 - 2.7657)

Connecting rod bearing spread

"'C:

�::,

65.0 (2.559)

80 (3.15)

Journal outside diameter Clearance

85.75 - 86.75 (3.3760 - 3.4154)

Main bearing spread End play

-0.10 -1.10 (-0.0039) (-0.0433)

0.031 - 0.082 w.0012 - 0.0032)

: 0.15 I 10.0059)

0 - 0.05 (0 - 0.0019)

Distortion at the top of � � the cylinder

t C:

Liner, inside diameter

Piston clearance

C: > U

108 (4.25)

Height projection

61.5 (2.421)

No. 1

.., "' .c

E"'

I � � E

"' -0 '1) -0 ·;;:; C: Cl C:

�

ro 11)

0.3 (0.012)

Replace or regrind

0.1 (0.004)

Regrind

108.15 (4.2579)

Replace cylinder l iner

I !

61.1 (2.406)

No. 3

60.9 (2.398)

No. 4

+0.10 (+0.0039)

60.7 (2.390)

No. 5

I No. 7 I

Replace bearing

61.3 (2.413)

No. 2

No. 6

0.01 - 0.08 (0.0004 - 0.0031)

Regrind under

size or replace

Regrind or replace

o.192 - 0.224 (0.0076 - 0.0088)

Regrind under size or replace

Replace over size bearing

0.18 I (0.0071)

->� ..c Face alignment LL ic: �

85.20 (3.3543)

0.5 (0.020)

Crankshaft runout

�t

78.8 (3.102)

0.15 (0.0059)

0.050 - 0.219 (0.0020 - 0.0086)

Replace

69.2 (2.7244)

79.9 (3.146)

0.051 - 0.102 (0.0020 - 0.0040)

Corrective method

I i

60.5 (2.382)

58.3 (2.295)

Replace camshaft and/or bearing

EG12-7-8

ENGINE

------------- SERVICE SPECIFICATIONS

SERVICE STANDARD (Cont'd) Item

....

No. 2

No. 3

No.4

-"'

a, "O

::::, 0

-"'

No. 1

.c "'

(.)

.c "'

No. 5 No. 6 No. 7

(.)

Clearance Camshaft end play

·-E "' (.)

Exhaust

Crankshaft gear and idler gear

"' "'

"'u

_)I!

...."'

a, C'> C'> C:

Injection pump drive gear and idler gear

Camshaft drive gear and idler gear

Oil pump drive gear and camshaft drive gear

.... "'

a, C'>

.... a, '15

61.5 (2.421)

Idler gear shaft Clearance Gear end play

Assembly standard

Repair limit

Service limit

-0.10 (-0.0039)

0.03 - 0.08 (0.0012 - 0.0031)

0.15 (0.0059)

7.18 (0.2827)

or clearance

Corrective

method

61.3 (2.413)

61.1 (2.406)

60.9 (2.398)

60.7 (2.390)

Replace camshaft and/or bearing

60.5 (2.382)

58.3 (2.295)

Intake

Runout

Nominal

dimensions

Unit: mm (inch)

0.100 - 0.178 (0.0040 - 0.0070) 8.17 (0.3217)

0.3 (0.012)

0.10 (0.0039)

6.38 (0.2512)

7.37 (0.2902)

Replace cam thrust bearing Replace camshaft Repair or replace

34.0 (1.339)

0.05 - 0.11 (0.0020 - 0.0043) 0.07 - 0.22 (0.0028 - 0.0086)

0.30 (0.0118)

0.35 (0.0138)

0.025 - 0.075 (0.0010 - 0.0029)

0.20 (0.0078)

0.04 - 0.13 (0.0016 - 0.0051)

0.30 (0.0118)

33.85 (1.333)

Replace shaft

Replace bushing and/or shaft Replace thrust bearing

EG12-7-9

ENGINE

------------ SERVICE SPECIFICATIONS

SERVICE STANDARD (Cont'd)

..."' (I)

en en

Unit: mm (inch) Nominal dimensions

Assembly standard or clearance

Repair

Service

Clearance

0.030-0.072 (0.0012-0.0028)

0.3 (0.012)

Replace gear and/or shaft

End play

0.100-0.200 (0.0039-0.0078)

0.3 (0.012)

Replace thrust bearing

End play

0.030-0.095 (0.0012 -0.0037)

0.15 (0.0059)

Replace gear

Gear backlash

0.15 -0.30 (0.0059 - 0.0118)

0.40 (0.0157)

Replace gear

Clearance between drive shaft and case

0.040-0.085 (0.0016 - 0.0033)

0.15 (0.0059)

Clearance between driven gear and shaft

0.040-0.083 (0.0016 - 0.0032)

0.15 (0.0059)

Two-belt standard vehicle

10 - 15 (0.39 - 0.59)

28 kg/cm2 (398 lb/ sq.in) at 270 -310 rpm

Item (I)

c .�

0 ... -� "'C � () C. (I)

-� E en

E. C. :::,

:::, C.

> a:;..,

limit

C 0 ·.,, a, :::,

.,,

...

Compression pressure

�C. � a,

33-36 kg/cm (469 - 511 lb/sq.in) at 270 - 310 rpm

E C. .._ 0

Less than 3 kg/cm (43 lb/sq.in)

Differences between cylinders

limit

Corrective method

Replace bushing

and/or drive gear assembly Replace bushing

and/or driven gear assembly Adjust

Engine overhaul

I i

1.8 kg/cm (25.6 lb/sq.in) at 700 - 750 rpm

Oil pressure

4.0 kg/cm (56.9 lb/sq.in) at 2,000 rpm 2

200 kg/cm (2,845 lb/sq.in)

Injection pressure Intake manifold flatness Exhaust manifold flatness

0.5 kg/cm2 Inspect and/or (7.11 lb/ overhaul sq.in)

Adjust

Within 0.5 (0.020)

Replace

Within 0.5 (0.020)

Replace

ENGINE

EG12-7-10

------------ SERVICE SPECIFICATIONS

TIGHTENING TORQUE Nozzle holder

kg·cm

Tightening position

Tappet chamber cover Oil cooler fitting bolt Cylinder head bolt Rocker arm support bolt

1 30 - 190

)

10 - 13

190 - 260

14 - 18

14 mm diameter

190 - 260

1,800 - 1,900

10 mm diameter

650-750

Rocker arm adjust screw nut

Injection pump drive gear fining nut

29 - 32

130 - 180

Idler gear fitting bolt

115 - 130

14-18

181 - 216

190 - 260

14 -18

180 - 230

14 - 16

5,500-7,000

398-506

1.100 - 1,300

Oil strainer fitting bolt

Crankshaft damper fitting nut

80 - 94

180-230

Oil pan fitting bolt Main bearing cap bolt Cooling jet fitting bolt

14 - 16

1 ,600 - 1 ,800

115 - 130

1,650 -1,850

120-133

15-18

200-250

Connecting rod cap bolt

------------------------� 10 mm diameter

Flywheel housing fitting bolt

10 -13

2,500 - 3,000

Camshaft fitting bolt

33-36

400-450

190-260

Camshaft drive gear fitting nut

14-18

1,600 - 1 ,800

Injection pump drive shaft assembly fitting bolt

51-57

450 - 500

Cylinder head cover

47-54

190-260

Exhaust manifold

14 - 18 131 - 137

700-800

Intake manifold

lb.ft

12 mm diameter

29-36

400 -500 650 -870

;

48 -62

Flywheel fining bolt

1,800-2,000

Oil pump safety valve

I !

800-900

190-260

100-150

8 - 10

250 - 300

19 - 21

Oil cooler various plug

Oil cooler element fitting nut Oil filter regulator valve

131 -144

14 - 18

15 -21

200-300

Oil filter plug

56 -65

19-21

250 - 300 Oil filter safety valve 1---------- --~--- ---- - - - - - ----< ---------- -- --- 1

Coolant pump vane

Coolant pump cover

1 80 -230

Th11rmostat case cover

190-270

Injection nozzle retaining nut

600 - 800

1---------------------�-- - Injection pump mounting bolt

190 - 260

Injection pump through bolt

300 -350

Idle gear shaft fitting bolt

37 - 43

500 - 600

500-650

14 - 16

14 - 19 44 - 57 14 - 18

22 -25 __ ---.i__�_ _ _ _ _ _ ____---l 37-47 ;

Engine Parts: Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

ENGINE

EG12-7-11

------------ SERVICE SPECIFICATIONS TIGHTENING TORQUE (Cont'd) kg-cm

lb.ft

Oil pump fitting bolt

380 -500

28-36

Coolant pump fitting bolt

380 -500

28-36

Coolant pump pulley nut

1,800 -2,400

131 -173

Oil filter

300 - 350

22 -26

Starter

650 - 870

47 -63

Turbocharger fitting nut

450 - 500

32 -36

190 -260

14 -18

350 - 500

26-36

100 -150

8-10

380 -500

28 -36

40 -60

3-4

Crankshaft pulley fitting bolt

450 -500

32 -36

Engine mounting bracket bolt

1,000 - 1,200

72 -86

Thermostat case fitting bolt

380 -500

28 -36

Intake manifold bracket fitting bolt

350 - 500

26-36

Oil seal case fitting bolt

190 -260

14 -18

Tightening position

Intake pipe and intercooler cover fitting bolt Cooling fan fitting bolt Glow plug fitting Oil pump fitting bolt

--- �-----· -

Fuel filter bleeder plug

-�

ENGINE

EG12-7-12

------------ SERVICE SPECIFICATIONS

GENERATOR

H06C-TI, EL 100 and EM100

SERVICE STANDARD Item

Assembly standard

Repair limit

I-

Unit: mm (inch) Service limit

Correct measure

4.5 (0.177)

Replace

Brush

Length

12.5 (0.492)

Slip ring

Outer diameter

37.5 (1.476)

35.5 (1.397)

Replace

Rotor coil

Resistance

17.5fl

Replace

TIGHTENING TORQUE Tightening position Pulley nut

kg·cm

lb.ft

980-1,300

71 -94

Through bolt

37 - 50

2.7 - 3.6

Bearing plate

60-80

4.4-5.7

EG12-7-13

ENGINE

SERVICE SPECIFICATIONS

STARTER H06C-TI SERVICE STANDARD

Unit: mm (inch)

Repair

Assembly standard

Item

limit

Service

Correct measures

limit

Brush leng,h

20.0 (0.787)

13.0 (0.512)

Replace

Brush spring tension

3.0 kg (6.6 lb)

2.0 kg (4.4 lb)

Replace

38.0 (1.496)

Replace

Outer diameter Commutator

Mica depth

40.0 (1.575)

0.5- 0.8 (0.0197 - 0.0314)

0.2 (0.008)

0.05 (0.0020)

Run-out Drive shaft run-out

0.05 (0.0020)

Repair 0.1 (0.0039)

Repair or replace

0.1 (0.0039)

Repair or replace

17.0 (0.669)

17.2 (0.667)

Replace

Bearing housing bushing inside diameter

28.0 (1.102)

28.2 ( 1.110)

Replace

Commutator end frame inside diameter

32.0 (1.260)

32.1 (1.263)

Replace

Drive housing bushing inside diameter

TIGHTENING TORQUE kg.cm

lb.ft

Magnetic switch set bolt

140- 160

10.2 - 11.5

Commutator end frame set bolt

140 - 160

10.2 - 11.5

Gear housing set bolt

140 - 160

10.2 - 11.5

Brush holder set bolt

35- 50

2.7 - 3.6

Tightening position

ENGINE

EG12-7-14

SERVICE SPECIFICATIONS

TURBOCHARGER H06C-TI SERVICE STANDARD Item Shaft outside diameter Groove width

Turbine shaft

Groove width of oil thrower Runout of turbine shaft

Unit: mm (inch) Service limit 12-28

Corrective method

(0.4835;

---

Replacement of turbine shaft

1.63 (0_0642)

1.75 (0.0689) 1.52

(0.0598)

0.011 (0.00043)

Replacement of oil thrower Replacement of turbine shaft

Bearing inside diameter

12-36

Bearing outside diameter

16.98 (0.6685)

Bushing inside diameter

17.11

(0.6736)

Replacement of bearing housing

Thrust bearing width

4.44

(0_1748)

Replacement of thrust bearing

Thrust bush

4.60

(0.1811)

Replacement of thrust bush or oil thrower

18.55

(0.7303)

Replacement of bearing casing

16.05

(0.6319)

14_05

(0-5531)

Bearings

Bearing case Seal plate

(0.4866)

Play in axial direction

o_ 11

Play in radial direction

0.215 (0.0085)

Replacement of bearing

Replacement of seal plate

(0.0043)

TIGHTENING TORQUE kg,cm

lb.ft

Thrust bearing

12 - 14

0.87 - 1.01

Bearing back plate

25- 35

1.81 - 2.53

Blower impeller

75 - 85

5.43- 6.14

Tightening position

Bearing case

280 - 290

Blower case

195- 205

Turbocharger mounting nut

450 - 500

I I

20.25- 20.96 14.10 - 14.82 32.54 - 36.15

ENGINE

EG12-7-15

SERVICE SPECIFICATIONS

METRIC INFORMATION

METRIC FASTENERS 1.

3. 4.

Most threaded fasteners on the Hino Model H06C-TI sereis are metric. Be careful not mix them up with threaded fasteners using the inch system. Mismatched or incorrect bolts, nuts and screws can cause damage or malfunction, resulting in persona! injury and/or property damage. When bolts, nuts and screws are removed form the engine, they should be kept for re-use whenever pos sible. If they are not re-useble, parts that are equivalent to the original parts in dimensions, strength, and thread pitch must be selected. Most original bolts are marked with identification numbers indicating the strength of the bolts. The markings are shown on the following page. When replacing bolts, be careful to use bolts with the same markings as the original bolts.

NOMENCLATURE FOR BOLTS BOLT STRENGTH IDENTIFICATION

METRIC SYSTEM BOLT M12-1.75 x 25 -rT T D

t) • 0-Nominal Diameter (millimeters) L- Length (millimeters)

T-11-

I-

L---1�

P- Property Class (bolt strength) T- Thread Pitch (thread width crest to crest mm)

Metric Bolts - Identification class numbers corres pond to bolt strength - Increasing numbers represent increasing strength.

EG12-7-16

ENGINE

SERVICE SPECIFICATIONS------------

DECIMAL AND METRIC EQUIVALENTS Fractions

Decimal In.

Metric mm.

Fractions

Decimal In.

Metric mm.

1/64

0.015625

0.397

33/64

0.515625

13.097

1/32

0.03125

0.794

17/32

0.53125

13.494

3/64

0.046875

1.191

35/64

0.546875

13.891

1/16

0.0625

1.588

9/16

0.5625

14.288

5/64

0.078125

1.984

37/64

0.578125

14.684

3/32

0.09375

2.381

19/32

0.59375

15.081

7/64

0.109375

2.778

39/64

0.609375

15.478

1/8

0.125

3.175

5/8

0.625

15.875

9/64

0.140625

3.572

41/64

0.640625

16272

5/32

0.15625

3.969

21/32

0.65625

16.669

11/64

C 171875

4.366

43/64

0.671875

17.066

3/16

0.1875

4.763

11/16

0.6875

17.463

13/64

0.203125

5.159

45/64

0.703125

17.859

7/32

0.21875

5.556

23/32

0.71875

18.256

15/64

0.234375

5.953

47/64

0.734375

18.653

1/4

0.250

6.35

3/4

0.750

19.05

17/64

0.265625

6.747

49/64

0.765625

19.447

9/32

0.28125

7.144

25/32

0.78125

19.844

19/64

0.296875

7.54

51/64

0.796875

20.241

5/16

0.3125

7.938

13/16

0.8125

20.638

21/64

0.328125

8.334

53/64

0.828125

21.034

11/32

0.34375

8.731

27/32

0.84375

21.431

23/64

0.359375

9.128

55/64

0.859375

21.828

3/8

0.375

9.525

7/8

0.875

22.225

25/64

0.390625

9.922

57/64

0.890625

22.622

13/32

0.40625

10.319

29/32

0.90625

23.019

27/64

0.421875

10.716

59/64

0.921875

23.416

7/16

0.4375

11.113

15/16

0.9375

23.813

29/64

0.453125

11.509

61/64

0.953125

24.209

15/32

0.46875

11.906

31/32

0.96875

24.606

31/64

0.484375

12.303

63/64

0.984375

25.003

1/2

0.500

12.7

1.00

25.4

EG12 7 17

LNGINl

--------------------------------- SERVICE SPECI Fl CATIONS -------------------------------

STANDARD TIGHTENING TORQUE Bolt tightening torque chart-for general purpose

Bolt 1----

Tightening conditions -+------- ---- -· -

Bolt diameter Imm)

5 t----

Cast iron or a luminium t..ghtening surface. Washers. Medium conditions.

10 - 15 (0_8 -1 0)

36 - 53 (77 3 81

88 - - 128 17 - 9)

174- 255 113 - 18 1

304 445 (22 - 321

48 6 -712 136 51)

759 -- 1.110 155-801

l ,040- l .530 (76-110)

l .48 0 - 2. l 70 (108 -1561

- -- ----+--- ------ � --- -48 71 (35 - 5 l I

14 -20 11_1 -1.41 -- -+--

Tightening area having black coarse surface. Rusty. Naked bolt or lubr1ca11t unavailable. Poor tightening cond1t1ons

-- -+----

17-25 11-3-1-8 1

I-------•-··---- - - -

16-24 11.2-17) ---- - --- - + -

58 -83 (4 2 - 6_0)

Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable, Poor t,ghten•ng cond1t1ons.

75 - 110 (55 - 7_9)

22-32 116-2 31

27 - 40 12 0- 2.8) -

10 11

1 46

- 214 (11-15)

40 5-=(30-421

Even tightening area. Bolt nut, coating. naked bolt, lubricant. etc. Optimum conditions.

138 - 20 1 (1 0 - 141

273-400 120-281

94 - 138 (68 - 9 91 -

--- _2_4___ 3_2 ----+11.8-2.3)

., "0 (6_0-7.91

183 - 270 (14 -- 19)

32-42 12-4-3.0) ---

Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions.

40 -53 (2-9-3.8)

110 - 1 46 (8.0-10.5) -- - - 137 - 18 3 (10_0-13.2)

477-700 135 -50)

364-533 (27 -381

t I' i

636 -- 932 (47 -67)

--:: , ;- -�:; - '"' t;,; -'. 117 - 241

(33 - 48 1

I� : ,�, - '"' (15-19)

S ,0 129-411

267 - 356 119 - 25) ---

--+--

334-445 125-32)

(58

84)

'•"-s,; (51-661

---i------

529-706 (39-51 I - -

662 - 882 (48-63)

1 ,260-1,850

(92-133)

-4-

764-1 ,120 156 -811

---

--+-----

'.,,o - ' ,a,o (92 - 135)

0,: (74-

:� "' 107)

925 - 1 ,230 1,48 0-1,970 j (67-88) (108 - 1421

2,700-3,970 (1 96 -- 287)

3,410-5,000 (247 - 361)

--+--------+---

2.460-3,620 (178-261)

3,380 -4,950 (245-358)

4,260-6,250 (30 9 -- 452)

1,640-2,400 1119 - 1731

2,320 - 3,410 (168 -246)

3,180-4,68 0 (231-338)

4,020 -5,360 (291 ---- 387)

1,190 -1 ,750 (87 - 126)

1,590 -

2,330 (116 - 168)

l ,990 - 2,920 1144 -211 I

3,100 - 4,550 1225 -329)

2,180-3,200 (158- 231 1

2,730-4,00 0 (198 - 289)

3,870-5,68 0 1280 - 4101

1 ,7)0 -2,310

!1 7� -167)

- --

2,310 - 3,08 0 (1 i8 -- 222)

2,380 - 3,170 (1 73-229) ---

- - ---- . -

3,170-4,230 (230-305)

4,250 - 6,210 (30 8 - 449)

3,380 -4,510 1244 - 326)

5,360 -7,8 50 (388 - 567)

�5,310-7,8 00 (38 5 -564) ------

----- - -

- -

- -----.

- -· -- -

- ----+---·· ··-·-

1,740-2,540 (126 - 183)

- ---

1,020-1,500 174 -- 1081

2.030 -2,98 0 2,560-3,750 (1 47 -- 2151 (186 -271)

----·------

1,970 - 2,900 (143 - 20 91

1,390-2,040 (101 -147)

--+--------+---

09-1,180 159-851

--1:

_J__

-------+---· - - - - ------ ·- - +---Cast iron or a luminium t1ghten1ng surface. Washers. Medium conditions.

1,0 10-1,480 (74-10 7)

647 - 950 (47-681

506-742 (37-531

290-425 121-30)

+------+---------+------ _

----·-- ---- ------- - --+

- - -- ---

60-88 (4.4-6 3)

232 - 340 (17-241

-------+-------+----

·-----

Cast iron or aluminium tightening surface. Wash ers. Medium conditions.

117-1 72 19 - 12)

--+-----·-··-- - Even tightening area. Bolt nut. coating, naked bolt, lubril:ant, etc. Optimum conditions.

4 -�

---

Even tightening area. Bott nut, coating, naked bolt, lubncant, etc. Optimum conditions.

Unit kg·crn (lb.ft)

4,630-6,170 1335 -- 4461

6,700-9,8 50 (48 5 -7121

·5,850 -7,790 (424-563)

-- - 4,510 -6,010 (327-434)

6,1 70- 8,230 7,790-10,390 (564-751) (447-595)

-+------+-------+- - ----- -- ------+--- -----1,160 - 1,540 (84 - 111)

1,8 50-2.470 (134 -1781

2,8',0 -3,850 (2 IJ - 278 )

3,970 ---- 5,290 (288 -38 2)

5,640-7,510 (408 - 543)

7,720----10,290 9,740-12,990 (705-9391 1559 -744)

NOTE: The torque values given in this table should be applied where bolt torque is not specified.

EG12-7-19

ENGINE

SERVICE SPECIFICATIONS

RECOMMENDED LUBRICANTS No.

No.

LUBRICANTS

ENGINE OIL (A.P.1. CD) Previous Classification (A.P.1. OS) (MIL-L-2104C) (MIL-L-45199B)

POSITIONS

Cylinder Block Injection Pump

LUBRICANTS

S.A.E. No.

SHEL L

15W40

Rotella T 15W/40

MOBIL

EXXON

XD-3 15W/40 Delvac Super XD-3 Extra 1 SW/40 15W/40

TEXACO

GULF

Ursa Super Plus 15W/40 Ursa l1remium Deo 1 SW/40

Gulf Super Motor Oil 15W/40

Rotella T 40 Delvac 1340 Riumla 40

XD-3 40 XD-3 Extra 40

Ursa Super Plus 40

Gulf Super Duty Motor Oil 40

Rotella T 30 Delvac 1330 Rimula 30

XD-3 30 Ursa Super XD-3 Extra 30 Plus 30

Gulf Super Duty Motor Oil 30

Rotella T 20W/20 Rimula 20W/20

XD-3 20W/20 XD-3 Extra 20W/20

Gulf Super Duty Motor Oil 20

Ursa Super Plus 20W/20

POSITIONS

COOLANT PUMP BEARING GREASE (MIL-G-10924B)

Coolant Pump

STARTER GREASE

Pinion Shaft Lever & Reduction Gear

GENERATOR & STARTER BEARING GREASE

Generator Bearing Starter Bearing

ANTIFREEZE (MI-L-H-5559A)

Engine, Radiator

Notes: Engine Parts: Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638