1. GENERAL INFOMATION
1-1. Common Items
････････ 1-1-1
1-2. Specifications
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1
1-1. COMMON ITEMS Scope of Description and Usage of This Manual ･････ 1-1-1 Precautions in Inspection and Service
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General Precautions for Inspection and Service ･････ 1-1-6 General Precautions for Safety Operation
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Disassembly and Assembly
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1. General Instructions
1-1. Common Items
Scope of Description and Usage of This Manual To Readers of This Manual This manual provides service staff who have completed basic training with technical information necessary for service activity. For obtaining satisfaction and trust from customers, you are expected to read through this manual and acquire correct product knowledge and service technique. Reference Material This manual does not, in principle, describe basic items and overlapped areas with other materials (below) to eliminate redundancy. • For basic items, refer to training materials such as "Sales and Technical Material." • For handling and inspection procedures, refer to "Instruction Manual." • For structure and component parts, refer to "Parts Catalog." • For handling, maintenance procedure and parts of the engine, refer to materials issued by the engine manufacturer. Organization This manual is organized into four parts: 1. General Instructions 2. Construction and Function 3. Oveahaul 4. Troubleshooting 1. General Instructions Safety during maintenance work and general cautionary instructions are compiled. 2. Construction and Function An explanation of the construction and function and an explanation of operation (function) by illustrations, circuit diagrams and system diagrams are compiled. 3. Oveahaul Methods of removing hydraulic equipment from a vehicle, its disassembly and reassembly, its adjusting method, standard values used for service work and service limits are compiled. 4. Troubleshooting Probable causes and corrections for troubles are compiled.
1-1-1
1. General Instructions
1-1. Common Items
Scope of Description and Usage of This Manual Items Listed in This Manual Page number (3 digit indication)
Equipment
2-0-1
Equipment name
0
Engine
1 Page in each chapter
2
Equipment code
3
Electric system Power train I (HST, reduction gear) Power train II (Axle)
4
Brake
5
Steering
6
Frame
7
Hydraulic system
8
Working equipment
Number of chapter
Note)
If a page number has a 2 digit indication, the second digit shows the page in each chapter. Equipment code: Refer to the right table. Position and direction of vehicle Respective positions and directions of a vehicle are indicated in the traveling direction of the vehicle (illustration on the right).
Right
Front
Rear
Left Symbols and notation : Items that require special cautions are indicated in a box to prevent personal injuries or damages to the equipment. DANGER : indicates immediate hazards that WILL result in death or severe injury in a box. WARNING: indicates potential hazards or unsafe practices that COULD result in death or severe injury in a box. CAUTION: indicates potential hazards or unsafe practices that MAY result in minor or medium injury in a box. IMPORTANT: indicates important items for operation and maintenance in a box. NOTE: indicates informative items such as technical information and know-how in a box. : indicates a mass of parts that require caution when held or moved. : indicates a specifically set value (torque) when bolts are tightened. : indicates a volume of discharged water or oil. : indicates a volume of filled water or oil.
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1. General Instructions
1-1. Common Items
Scope of Description and Usage of This Manual Indication of Unit In this manual, unit indication of quantity and unit is mainly based on SI (International System) unit system (right table).
Example of main unit conversion SI unit (Conventional unit) Pressure 1 MPa (10.197 kgf/cm2) Force 1N (0.10197 kgf) Torque 1 Nm (0.10197 kgf¡m) 1 kW (1.360 PS) Power
1-1-3
1. General Instructions
1-1. Common Items
Precautions in Inspection and Service This section provides the information which is helpful for disassembling and assembling the machine properly and covers the safety precautions and general instructions.
Dust Prevention
Precaution for Hydraulic and Pneumatic Systems
The most important precaution for maintaininig the longer service life of a machine is to prevent dirt and dust from adhering to the important moving parts. On our produsts, special attention is paid to prevent dirt and dust from getting into each moving part. In a word, an important parts is enclosed and, further, provided with a seal or filter and, thereby, clean air, fule and lubricant are always sent to each part. When disconnecting hydraulic, fuel, lubricating or air pipes and hoses for disassembly, clean each connection and around the connection thoroughly. After disconnectiong the pipes and hoses, immediately cover each opening with a cap, plug or tape to prevent entry of foreign material. When removing an inspection cover or plate also do the same way. Wash and check all parts removed. Check to see that all oil passages and oil holes are not clogged. Cover all parts to prevent dirt and dust from adhering to each part and, when reinstalling each part, check to see that it is clean. On a new part, do not unpack the part until it is installed.
Engine Overhaul Timing For details, refer to the documents supplied by the engine manufacturer.
When impurities such as dirt and dust enter the hydraulic and pneumatic systems, the operation is affected adversely and, further, the parts in the system are damaged excessively to result in the failures of the machine. Accordingly, when the parts in the hydraulic and pneumatic systems have been removed, cover the openings. Further, when pieces of broken metal and rubber have been found in the hydraulic system, flush the whole of the system. Remove and install the parts related to the hydraulic and pneumatic systems in a clean place. Wash all metallic parts in uninflammable safety solvent and coat them with lubricating oil for easier instllation.
Danger Prevention Before servicing the hydraulic system for the working equipments, perform the following steps: (1) Lower all working equipments (bucket, etc.) on the ground. If a working equipment must be removed while holding it in a certain position, refer to “Disassembly and Assembly�. (2) Stop the engine and move each working equipment control lever to all positions to make sure that no pressure is applied to the hydraulic system. (3) Set all control levers to neutral and lock them.
Hydraulic and Pneumatic Valves Check all valves, valve holes and valve seats for scratches and folds. Remove them with a fine oil stone or sand paper. All the valves should move smoothly in their respective holes. Make sure that all passages are free from foregin materials and clean.
1-1-4
1. General Instructions
1-1. Common Items
Precautions in Inspection and Service Hydraulic Hoses
and
Pneumatic
Pipes
and
When connectiong a metallic pipe, first finger-tighten all bolts and then tighten each end and attaching bracket bolts. After connecting the pipe, connect the hose. At this time, finger-tighten the bolts at both of the hose as a temporary measure. Take care not to allow the hose to come in contact with the parts and other hoses, reduce the bend and twist and then tighten the coupling bolts. A hydraulic hoses has its own bending pattern depending on the manufacturing method. Accordingly, when bending a hydraulic hose for connecting, bend according to the bending pattern. Furhter, when replacing a hose provided with angled stem, assemble and connect with the hose bending pattern fully taken into consideration. After connecting the hoses, proceed as follows: Run the engine and move each control lever to move the working equipments to position. (Refer to “Bleeding Air from Hydraulic System� to be mentioned later.) During that time, observe each hose carefully. Lower the working equipments on the ground, stop the engine and then recondition the twist, interference or excessively hanging, etc. of the hose by turning the stem.
Hydraulic Cylinder The terms for the cylinder have been decided as follows: Rod End (Part)
Cylinder Bottom (Chamber)
Tube End (Part)
NEUTRAL position, hydraulic oil will flow out of the tank. Bleeding Air from Hydraulic System When a hose has been replaced, the hydraulic oil has been changed, a cylinder has been removed and other similar work has been performed, start the engine, move the control levers to move the working equipments to all positions and bleed air in the hydraulic system. After making sure that the hydraulic system operates properly, check the oil level in the tank. NOTE: Run the engine at low idle speed and, in that condition, extend and retract each cylinder about ten times. At this time, do not move the cylinder to the stroke end. When the engine is run at high idle speed and each cylinder is moved to the stroke end from the first, air in the cylinder may damage the seals.
Cleaning the Hydraulic Brake System Use the specified brake fluid. If other brake fluid is used, a rubber part may be deteriorated and swollen. When adjusting the hydraulic brake system, take care not to allow foreign material to get into the brake fluid. To wash the master cylinder, wash in general part washing agent and then wipe the trace of solvent with denatured alcohol or brake fluid. After that, dry the cylinder and take care not to allow dirt and dust to adhere to the cylinder until it is assembled. Wash rubber parts in denatured alcohol or brake fluid. Do not use solvent of petroleum series, such as gasoline, kerosene, acetone, paint thinner, which will soften and swell a rubber part.
Cylinder Head (Part) Rod (Chamber)
Removal of Cylinder When removing each cylinder, it is not required to drain the hydraulic system. Only a small amount of hydraulic oil in the oil passage between the cylinder and control valve flows out. However, when the control lever is not placed in the 1-1-5
1. General Instructions
1-1. Common Items
General Precautions for Inspection and Service General Precautions for Checking and Servicing the machine 1. When checking and servicing the machine, decide the leader and working procedures. 2. When checking and servicing the machine, hang a “CAUTION TAG� on the starter switch, control levers and steering wheel to prevent the engine from being started and the control levers from being moved carelessly. Disconnect the cable from the negative terminal of each battery for safety. 3. When checking and servicing the machine, pay attention to the following points. (1) Place the machine on the level ground, lower all working equipments on the ground, apply parking brake and place the shift lever in the neutral position. Stop the engine and remove the starter switch key. (2) Move the working equipments control lever to relieve the pressure in the hydraulic system. (3) Engage the steering frame lock and block the tires. 4. When disassembling and assembling the machine, do it in order and securely. After assembling, adjust and lublicate properly. After that, be sure to check for proper adjustment. Before using the machine, operate it to check for proper adjustment again. When the machine is checked, adjusted and measured, the performances should be as specified. Check, adjust and measure in the following conditions: (1) Warm up the engine sufficiently and the needle of the water temperature gauge should stay in the green zone. (2) The hydraulic oil temperature should be the temperature at operation (40 - 60 °C). (3) HST oil temperature gauge should stay in the green zone. If the gauge is not equipped, raise the oil temperature to the normal operating temperature.
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1. General Instructions
1-1. Common Items
General Precautions for Safety Operation General Precautions for Safety Work 1. Wear a helmet and safety shoes. Wear safety glasses and a dust-proofing mask if necessary by the job conditions. Wear neat so that your clothing is not caught by the projections of the machine and the control levers. Empty your pockets to avoid dropping anything in the equipment when working with your body facing downward. Take off rings, watches and jewelry.
2. When using a grinder, crane or welding machine, etc., follow the instructions for handling and use it carefully. Prepare safety equipment such as fire extinguishers. Remember where it is stored and know how to use it.
3. Do not leave tools and parts scattered on the floor plates and steps which are the footholds for working because serious accidents may be caused. Also, if mud and oil adheres to floor plates and steps, it is slippery and might cause sudden accident. Therefore, wipe it off completely. When getting on and getting off the machine, use the steps. Grasp both handrails and get on or off the machine with your body facing toward the machine straightly.
4. Clean any mud, grease and oil off the machine. When using compressed air for cleaning the machine, always wear safety glasses and protective clothing against the air pressure.
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1. General Instructions
1-1. Common Items
General Precautions for Safety Operation 5. During operation or immediately after the machine stops, the temperature of each section on the machine is hot with heated oil and water. DO NOT touch such sections until the temperature goes down because it might cause burn or an unexpected accident. In particular, take care of the engine, turbo-charger, muffler and exhaust pipes.
6. Immediately after the machine stops, DO NOT drain the oil and water because scald or unexpected accidents may be caused by hot oil and water. Drain the oil and water after making sure that the temperature has gone down. When removing the radiator cap and hydraulic oil tank cap, be sure to relieve the internal pressure beforehand.
7. Moving parts (especially rotating parts) are very dangerous. Before servicing the machine, be sure to stop the engine and remove starter switch key. Before cranking or starting the engine for check and adjusting, always signal to the other persons and make sure of safety. DO NOT leave any tools and parts, around a turnig/moving part such as the cooling fan.
8. When jacking up only front or rear of the machine, do it on the level, hard ground. Be sure to block the wheels and support the machine with a stand.
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1. General Instructions
1-1. Common Items
General Precautions for Safety Operation 9. When the work is done with two or more persons, do it while marking sure of the safety of each person. Catch hand signals from one designated person, NOT from plural persons.
10. When checking and servicing the hydraulic system, put all the working equipments to the ground. However, when the hydraulic system must be checked and serviced with the working equipments raised, install the falling prevention devices to the lift cylinders. Or securely hold the working equipments with wood blocks to prevent falling. DO NOT use a crane for holding because serial accidents may be caused.
11. Before servicing the engine, the electric system or welding, always disconnect the cable from the negative terminal of each battery.
12. Fuel and all oils are flammable. DO NOT smoke in the place where the battery is charging and flammables are stored. DO NOT allow any flame near it. A battery generates flammable gas. DO NOT allow any flame near it when the battery is handled. Oiled cloths or other flammable things which are easy to burn should be gotten into a container and then placed in safety place. DO NOT put any container including flammable liquid such as fuel or oil, on the vehicle. When any liquid of high volatility is handled, pay special attention to ignition.
1-1-9
1. General Instructions
1-1. Common Items
General Precautions for Safety Operation 13. For washing a part, use non-flammable safety solvent. DO NOT use gasoline or light oil for washing. When a part cannot be cleaned only by washing, first smooth it with fine sand-paper before washing it. Check each luburicating oil passage for clogging and wash with non-flammable safety solvent or compressed air. After washing, dry it with compressed air. When drying a bearing with compressed air, take care not to rotate the bearing. Wash a rubber part with denatured alcohol or only wipe a matter adhering to the part off.
14. When servicing the fuel system, be sure to check to see that no fuel leaks. When fuel and oil pipes and hoses are loosened or damaged, fuel and oil leak to result in a fire.
15. DO NOT run the engine for a long time or allow painting in an indoor workshop with bad ventilation.
16. When connecting a pipe or hose, use two spanners (tools) to prevent twist and damage. Connect a hose so that it does not twist. Because a twisting high-pressure hose may burst. Be sure to tighten a pipe or hose to the specified torque.
1-1-10
1. General Instructions
1-1. Common Items
General Precautions for Safety Operation 17. DO NOT check an oil leakage with your hand. If oil gets into your body, it is very dangerous. Especially, DO NOT approach oil leakage from pin-hole.
18. Before disconnecting a pipe or a hose for hydraulic and pneumatic systems is to be removed, relieve the internal pressure. Before disconnecting an air piping, discharge the air in the tank. Before disconnecting a hydraulic piping, move the working equipment control levers to relieve the internal pressure, and then remove the tank cap. If high pressure oil blows out it is very dangerous.
19. Always check the tools to be used. DO NOT use any spanner whose corners are chipped, a hammer whose edges are folded, a broken screwdriver, etc. If an improper tool is used, the part is damaged and, further, you may be injured. use proper tools and work carefully.
20. For work where a special tool is recommended, always use the specified special tool. If any unspecified tool is used, it might cause damage or injury.
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1. General Instructions
1-1. Common Items
General Precautions for Safety Operation 21. When a pin is removed or installed by tapping, broken pieces may fly about. Be sure to wear safety glasses. When removing the pin, DO NOT allow a person to approach in the direction of removal.
22. DO NOT check the alignment of the pin holes by inserting a finger. When inserting a pin, apply a small amount of grease to the pin and mating part. Further, after assembly, lubricate each pin with grease. When a dust seal is provided, apply a coat of grease to the seal lip and take care not to damage the seal lip.
23. DO NOT use kinked or worn wire rope. When handling a wire rope, wear leather gloves. Select a wire rope refering to “Disassembly and Assembly� in which the weight of each part is shown. If the weight of a part is not judged correctly, the part may be dropped and scratched and, further, a person may be injured seriously. If necessary, use lifting tools by which a part can be lifted properly and lift safely.
24. DO NOT leave a heavy part in an unstable place or do not keep it hung down from a crane. Place a heavy part on blocks or on a stand properly.
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1. General Instructions
1-1. Common Items
General Precautions for Safety Operation 25. When removing a cover which is pushed with the springs, remove the bolts or nuts with the cover pressed down with hand. However, if the spring force is strong, follow the instructions in “Disassembly and Assembly�. When removing a side cover of the machine, leave the two upper bolts or nuts installed. Then, while holding the cover with hand, remove the two bolts or nuts and remove the cover taking care not to drop.
26. Close the engine side covers except when checking and servicing the engine room.
27. Handle a battery carefully. Battery liquid is diluted sulfuric acid. DO NOT allow it adhere to your eyes, skin, cloth or other metal surface. If electrolyte has adhered, immediately wash away thoroughly. When handling a battery, wear safety glasses and take care of a fire.
28. When inflating a tire, stand on the tread side of the tire and use a selfattaching chuck.
29. When welding a part near a tire, be careful especially because the tire may burst.
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1. General Instructions
1-1. Common Items
Disassembly and Assembly Disassembly and Assembly of General Parts
Heel Toe
Oil Seal
Gear Spring
Most seals are used as an oil seal with the toe or the lip, in which the garter spring is installed, facing toward a lubricating oil or pressurerized oil to be sealed. However, when sealing a lubricant such as grease, a seal is generally installed with the toe or lip facing toward the oppsite side. A lip type seal consists of the case, sealing part and garter spring. The right upper figure shows the rough construction of a lip type seal and, in the right sectional view, the seal is divided into the heel and toe.
Sag Section Lip Section contacting to the shaft Trim Section
Garter Spring Groove
Case
Bond Area
Heel
Toe
Heel
Toe
Heel
Toe
Heel
Toe
Heel
Toe
When installing an oil seal, pay special attention to the following points: When Installing to Housing: (a) Check the seal lip for scratches and allow the lip to face in the correct direction. (b) Apply a small amount of liquid packing to the external surface of the seal (coming into contact with the housing) and then install the seal. (c) Apply a coat of lubricating oil to the lip. Use the same lubricating oil as the oil to be sealed. DO NOT apply a coat of grease to any other seals than a grease seal. (d) To install the seal, guide the seal lip, use a seal driving tool which comes in contact with the external surface of the seal and drive in the seal in beeline as shown at right. DO NOT tap the seal directly with a hammer because it may be damaged to result in oil leak. When installing to Shaft: (a) Apply a coat of lubricating oil to the seal lip. (b) When installing the oil seal through the stepped part, threaded part or key groove, the lip may easily be damaged. Use a guide shown at right or wind a tape on such a part to allow the seal to slide easily.
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Heel
Toe
1. General Instructions
1-1. Common Items
Disassembly and Assembly O-ring When installing an O-ring through the stepped part, splined part, threaded part or key groove, it may be damaged. Use a guide shown at right or wind a tape on such a part to allow the O-ring to slide easily. DO NOT install an O-ring by rolling it. When the O-ring is twisted, oil may leak.
Packing When installing a packing, check if the holes in the packing align with the oil passages in the mating part. When a packing must be made, select a proper material and check if holes are made in place. DO NOT forget to install a packing because a serious damage may be caused.
Lock A lock washer, a flat metal lock or a cotter pin is used for locking a nut or a bolt. Bend a lock plate securely. The right figure shows the proper and improper bending manners of the typical lock plate. Proper
On a flat metal lock, vertically bend one end of the lock against the perphery of the edge of a part and vertically bend the other end along one side of a bolt or nut. In a compartment in which the moving parts are installed, install new locks. When installing a lock washer to an aluminum housing, insert a flat washer between the lock washer and housing.
Proper
Proper
Improper
Improper
Split Pin and Spring Pin As a rule, replace a split pin with a new one. Bend the split pin securely. Drive in a spring pin securely.
Proper
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Improper
1. General Instructions
1-1. Common Items
Disassembly and Assembly Bearing Wash a usable bearings with nonflammable safety solvent and dry it naturally. The bearing may be dried with compressed air but DO NOT turn the bearing at that time. If dirt and dust get into the bearing, the bearing is locked, thereby, the shaft is turned in the inner race or the outer race is turned in the cage. DO NOT unpack a new bearing until it is installed.
Dirt and dust locks the bearing
The shaft is turned in the inner race. Actions of dirt and dust in bearing
(1) Installation of Bearing When installing a new bearing or used bearing, apply sufficient coat of oil to the bearing. If pre-loading a bearing, a sufficient oil film should be made on the bearing. When press fitting a bearing into a retainer or a bore, apply a pressure onto the outer race (outer wheel). When press fitting the bearing into a shaft, apply a pressure onto the inner race (inner wheel). When installing a bearing, use a driving tool coming into contact with each race shown at right. Use a press for installing a bearing, if possible, and apply a pressure to each race for the secure work. (2) Double-row Taper Roller Bearing The combination of cup, corn, spacer and rollers of each double-row taper roller bearing is already decided and, accordingly, one duble-row taper roller bearing is not interchangeable with other one. Those components are generally stamped with the same part and manifacturing number but, when the components are no numbers, put them together with a wire. When installing a reusable part, be sure to install it in the previous positions. (3) Plain Bearing (Sliding Bearing) When installing a plain bearing, DO NOT use a hammer. Use a press, if possible, and apply a uniform pressure to the bore. When a bearing must be driven in, use a bearing driver or a bar with smooth, flat end. When a plain bearing is provided with an oil hole, align it with the oil hole in the mating part.
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1. General Instructions
1-1. Common Items
Disassembly and Assembly (4) When installing a bearing, spacer or washer to the shoulder of a shaft, install it with the chamfered side facing toward the shoulder of the shaft. (5) Preload The preload is a thrust load to be applied to a bearing beforehand in order to increase the rigidity of the bearing or remove a clearance. The preload to be applied to a taper roller bearing is decided according to the rigidity of the housing and shaft, and the swelling and turning speed of the bearing, etc. To know that a preload must be applied to the bearing or that an end clearance must be given to the bearing, refer to “Disassembly and Assembly�. When a bearing, to which an end clearance must be given, is preloaded carelessly, the bearing may be damaged. When preloasing a bearing, be careful thoroughly.
Correct
Incorrect
(6) Shrink Fit When a bearing must be shrunk on, it must be heated in oil whose temperature is 120℃ or below. When the diameter of the hole (the bearing bore) is smaller than the shaft diameter, the bearing is heated for expanding and then the shaft is fitted into the bearing. After that, the inner race of the bearing holds the shaft firmly at normal temperature.
Press Fit When press fitting a part into other part, apply a coat of proper lubricant to the contact surface. However, when that part is tapered, press fit it without coating with lubricant. When press fitting a taper splined part, check to see that no dirt and dust adhere to the splines and the splines are dry and not folded. After that, first push in the part by hand to align the splines and the mating part and then press fit. In press fitting with taper splines, the connection must always be firm. If not, check the taper splines and, if it is worn, replace.
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Stopper Metal
1. General Instructions
1-1. Common Items
Disassembly and Assembly Lines and Wires When any lines (tubes, hoses, etc.) or wires are removed, put a tag on it for correct connection.
Shim (Spacer) After removing shims, bundle them and mark so that the installation position can easily be caught. Keep shims in such a manner that they are clean and not bent until they are reinstalled.
Sealing Parts When disassembling the hydraulic and pneumatic systems and then assembling them, be sure to replace the sealing parts, such as O-rings, gaskets and oil seals with new one as a rule. Always use genuine parts. Similar seals cannot always be used.
Spring Check if the tensions of all springs are as specified. Check with the free lengths in “Maintenance Standard�.
Rust Preventive When installing a new part, thoroughly remove the rustproof solvent from the machined surface of the part.
Battery Wipe a battery with diluted sodium bicarbonate solvent and dry it well. Then, apply a coat of rust proof solvent or grease to the terminals and connections. When a machine is stored or it is not used for a long peirod of time, remove the batteries. Place the removed batteries on a wooden shelf in a warm and dry place. DO NOT place the batteries on the concrete floor. Charge the batteries periodically so that the specific gravity of the electrolyte is always proper.
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1. General Instructions
1-1. Common Items
Disassembly and Assembly Bolt and Nut Tightening Torque The bolt length must be proper. If the bolt is too long, it comes in contact with the bottom of a part to be secured before the head comes in contact with the upper surface of the part. Further, when a long bolt is removed, take care not to damage the thread. On the contrary, If the bolt is too short, the threads for securing a part are insufficient. When securing two or more parts, tighten the bolts or nuts to the specified torque. For each tightening torque, refer to “Maintenance Standard” or “Disassembly and Assembly”.
Table of Retightening Turn of the bolt or nut Turning Angle
1/2 Turn 1/3 Turn 1/4 Turn 1/6 Turn 1/12 Turn
Tightening In most cases, tightening in “Maintenance Standard” is done in the following procedures: (1) Clean the threads of bolt and nut. (2) Apply a coat of oil to the threads and seat of bolt or nut. (3) Tighten a bolt or nut to the specified torque.
Retightening (1) Put an alignment mark on the bolt or nut and the part to be secured in that position. (2) Further tighten the bolt or nut by the specified angle from the above-mentioned mark. When no alignment marks can be put, the head of the bolt or nut can be positioned as specified at right.
Locking of Double Nut A double nut is a means of preventing the threaded part from loosening and it must be tightened properly. If tightening a double nut is insufficient, the effect of preventing looseness is lost. Tighten a double nut in the following procedures: As shown in (a) of the right figure, first tighten the lower nut ① to 80% of the specified torque. Then, as shown in (b), tighten the upper nut ②. Finally, as shown in (c), use a spanner to prevent the lower nut from turning and tighten the upper nut to the specified torque for locking.
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(a)
(a)
(b)
(b)
(c)
(c)
1. General Instructions
1-1. Common Items
Disassembly and Assembly Torque Wrench Extension When an extension is used for a torque wrench, the graduation of the torque wrench indicates smaller value than an actual torque value. (1) Put a mark on the handle. Measure the dimension (W) between the mark on the handle and the center of the torque wrench drive. (2) Measure the dimension (E) between the torque wrench drive and the center of the torque wrench extension drive. (3) When the correct torque (RT) is known, find the graduation corresponding to the correct torque by the following equation: RT x W W+E Example: W = 304.8mm (12 in) E = 65.0mm (2.55in) RT= 17.3kgf-m (125lb-ft) (Maintenance Standards) 17.3 x 304.8 TI = 304.8 + 65.0 =14.2kgf-m TI =
(4) Grip the torque wrench handle so that the middle finger is placed on the mark and obtain the correct torque (RT) from the graduation (TI) of the torque wrench.
Applying Adhesives (Thread Lock) An adhesive may be used to prevent the threaded part from loosing. When coating a part with adhesive is specified, pay attention to the following points: (1) Clean the component (De-oiling) (2) Dry the surface where adhesive is to be applied. Blow clean air or dry the component naturally. (3) Apply a small amount of adhesive to the internally threaded part one or two threads away from the end. After applying, finish assembling before the adhesive is dried. When a part coated with adhesive has been left, remove the adhesive and perform the above steps again.
1-1-20
W E Mark Torque TI Torque RT
E: Dimension between center of the torque wrench drive and center of the extension drive. W: Dimension between mark on the handle and center of the torque wrench drive
1. General Instructions
1-1. Common Items
Disassembly and Assembly Tightening Torque for Metric Bolts and Nuts The following are the metric bolt and nut tightening torques in servicing a construction machine, except the torques stated specially in the shop manual. The following table covers the hexagonal coarse and fine threads (Strength 8.8, 10.9). For the tightening torque of hexagonal socket head bolts, follow the grade 10.9 of this table. (Nm) 8.8
Grade Nominal Diameter Ă— Pitch M4x0.7 M5x0.8 M6x1.0 M8x1.25 M8x1.0 M10x1.5 M10x1.25 M12x1.75 M12x1.25 M14x2.0 M14x1.5 M16x2.0 M16x1.5 M18x2.5 M18x1.5 M20x2.5 M20x1.5 M22x2.5 M22x1.5 M24x3.0 M24x2.0 M27x3.0 M27x2.0 M30x3.5 M30x2.0
10.9
Standard
Range
Standard
Range
3.24 6.27 10.9
2.94 ~ 3.53 5.68 ~ 6.86 9.80 ~ 12.0
4.22 8.24 14.3
3.82 ~ 4.61 7.45 ~ 9.02 12.8 ~ 15.7
25.4
22.8 ~ 27.9
33.2
29.8 ~ 36.5
49.1
44.2 ~ 54.0
64.3
57.8 ~ 70.7
85.8
77.2 ~ 94.4
112
101 ~ 123
136
122 ~ 149
177
159 ~ 194
209
188 ~ 229
273
245 ~ 300
288
259 ~ 316
376
338 ~ 413
418
375 ~ 460
545
490 ~ 600
549
494 ~ 604
718
646 ~ 789
699
629 ~ 768
910
820 ~1000
861
774 ~ 948
1132
1019 ~ 1245
1186
1068 ~ 1303
1539
1382 ~ 1695
1-1-21
1. General Instructions
1-1. Common Items
Disassembly and Assembly Tightening Torque for Unified (UN) Bolts and Nuts The following are the unified (UN) type bolt and nut tightening torques in servicing a construction machine, except the torques stated specially in the shop manual. (Nm) Grade Nominal Diameter × Pitch 20 UNC 1/4 28 UNF 18 UNC 5/16 28 UNF 16 UNC 3/8 24 UNF 14 UNC 7/16 20 UNF 13 UNC 1/2 20 UNF 12 UNC 9/16 18 UNF 11 UNC 5/8 18 UNF 10 UNC 3/4 16 UNF
Standard
Range
Standard
Range
11.9
10.7 ~ 13.0
13.7
12.3 ~ 15.0
23.9
21.5 ~ 26.2
27.3
24.5 ~ 30.0
41.7
37.5 ~ 45.9
47.7
42.9 ~ 52.5
66.6
60.0 ~ 73.1
76.1
68.4 ~ 83.7
100
90.0 ~110
115
103 ~ 126
144
129 ~159
165
148 ~ 181
198
178 ~ 218
227
204 ~ 249
339
305 ~ 372
388
349 ~ 426
1-1-22
1-2. SPECIFICATIONS Outline Drawings/Specifications
･････････ 1-2-1
Fuel, Water and Oil Selection and Capacities ････････ 1-2-5 Weight of Main Components
･････････ 1-2-9
Check and Service List
････････ 1-2-10
1–2
1. Specifications
1-2. Specifications
Outline Drawings/Specifications ■ Outline Drawings/Specifications LX15-7
Engine
Bucket Capacity (with BOC) Operating Weight Maker / Model Rated Output Rated Speed Total Piston Displacement
Performance
Fuel Tank Capacity Operating Load Max. Drawbar Pull Travel Speed 1st Gear (2 forward & 2 2nd Gear reverse) Max. Grade of Hill Climb Turning Radius (Center of Outside Wheel) Articulation Angle
3
Overall Length (with BOC, Bucket on ground) Total Width (with Bucket)
0.3m 1915kg KUBOTA / D1105-K2A 16.2kW (22PS) 2500rpm 1.123 L
Dimensions
•
33 L (Light Oil) 500kg 17200N (1750kg)
2350mm
Wheel Base Ground Clearance
1500mm 215mm
Dumping Clearance (with BOC) Dumping Reach (with BOC)
1850mm 570mm
Transmission Control Tire Size Air Pressure (Standard)
15km/h 30° 2545mm 42°
1-2-1
1350mm
Total Height (with Canopy)
Hinge Pin Height (Max.) Battery
6.2km/h
3440mm
12V-75D26
2335mm ×1pce
HST (Electrical) 10-16.5-4PR 200kPa
1. Specifications
1-2. Specifications
Outline Drawings/Specifications LX20-7
Bucket Capacity (with BOC)
Engine
Operating Weight Maker Model Rated Output Rated Speed Total Piston Displacement
Performance
Fuel Tank Capacity Operating Load Max. Drawbar Pull Travel Speed 1st Gear (2 forward & 2 2nd Gear reverse) Max. Grade of Hill Climb Turning Radius (Center of Outside Wheel) Articulation Angle
0.4m
3
Overall Length (with BOC, Bucket on the ground) Total Width (with Bucket)
2645kg KUBOTA D1503-DI-K2A 21.3kW (26PS) 2400rpm 1.499 L
Dimensions
•
50 L (Light Oil) 650kg 27000N (2750kg) 15km/h 30° 3040mm 41°
1-2-2
1570mm
Total Height (with Canopy)
2415mm
Wheel Base
1780mm
Ground Clearance Dumping Clearance (with BOC)
255mm 2155mm
Dumping Reach (with BOC) Hinge Pin Height (Max.)
815mm 2685mm
Battery Transmission Control Tire Size Air Pressure (Standard)
7.5km/h
4140mm
12V-75D26 ×1 HST (Electrical) 12.5/70-16-6PR 200kPa
1. Specifications
1-2. Specifications
Outline Drawings/Specifications LX30-7
Bucket Capacity (with BOC)
Engine
Operating Weight Maker Model Rated Output Rated Speed Total Piston Displacement
Performance
Fuel Tank Capacity Operating Load Max. Drawbar Pull Travel Speed 1st Gear (2 forward & 2 2nd Gear reverse) Max. Grade of Hill Climb Turning Radius (Center of Outside Wheel) Articulation Angle
0.5m
3
Overall Length (with BOC, Bucket on the ground) Total Width (with Bucket)
3265kg KUBOTA D1503-DI-T-K2A 27.2kW (37PS) 2500rpm 1.499 L
Dimensions
•
50 L (Light Oil) 850kg 33350N (3400kg) 15km/h 30° 3220mm 41°
1-2-3
1690mm
Total Height (with Canopy)
2495mm
Wheel Base
1900mm
Ground Clearance Dumping Clearance (with BOC)
295mm 2445mm
Dumping Reach (with BOC) Hinge Pin Height (Max.)
845mm 3030mm
Battery Transmission Control Tire Size Air Pressure (Standard)
8km/h
4425mm
12V-75D26 ×1 HST (Electrical) 15.5/60-18-8PR 220kPa
1. Specifications
1-2. Specifications
Outline Drawings/Specifications LX40-7
Bucket Capacity (with BOC)
Engine
Operating Weight Maker Model Rated Output Rated Speed Total Piston Displacement
Performance
Fuel Tank Capacity Operating Load Max. Drawbar Pull Travel Speed 1st Gear (2 forward & 2 2nd Gear reverse) Max. Grade of Hill Climb Turning Radius (Center of Outside Wheel) Articulation Angle
0.6m
3
Overall Length (with BOC, Bucket on the ground) Total Width (with Bucket)
3565kg KUBOTA D1503-DI-T-K2A 27.2kW (37PS) 2500rpm 1.499 L
Dimensions
•
50 L (Light Oil) 960kg 3400kg 15km/h 30° 3220mm 41°
1-2-4
1690mm
Total Height (with Canopy)
2495mm
Wheel Base
1900mm
Ground Clearance Dumping Clearance (with BOC)
295mm 2500mm
Dumping Reach (with BOC) Hinge Pin Height (Max.)
915mm 3140mm
Battery Transmission Control Tire Size Air Pressure (Standard)
8km/h
4695mm
12V-75D26 ×1 HST (Electrical) 15.5/60-18-8PR 200kPa
1. Specifications
1-2. Specifications
Fuel, Water and Oil Selection and Capacities ■ Fuel Use only clean, high-quality fuel. Use Grade No.2-D fuel above 4°C Use Grade No.1-D fuel below 4°C Do not use fuel that contains gasoline or alcohol or any substitute such as kerosene. Use of these fuels causes performance deterioration or other defects.
● Handling of Fuel Both the injection pump and the injection nozzle, which are very precise components, are lubricated by the fuel, that is, the fuel oil itself. Use of a fuel that contains water or dirt causes machine trouble. A clean fuel must therefore be used. Storage of the fuel requires strict observation of the following precautions. 1. Fill the fuel tank at the end of each day's operation. This prevents condensation of any air within the tank and, hence, entry of the resulting moisture into the fuel, and gives time for any internal dirt and moisture to separate from the fuel and settle inside the tank. 2. Fill a fuel storage tank and leave it for at least 24 hours, and use only the supernatant after allowing any dirt and moisture to settle. 3. While filling the fuel tank, be careful not to allow any sediment in the fuel storage tank to be pumped up together with the supernatant. 4. Open the drain plugs on the bottoms of both storage tank and fuel tank periodically to drain any entrapped water and sediment. 5. Replace the fuel filter and element periodically.
■ Grease Use grease of NLGI No. 2 for air temperatures of 0°C or more, or use grease of NLGI No. 1 for air temperatures below 0°C.
1-2-5
1. Specifications
1-2. Specifications
Fuel, Water and Oil Selection and Capacities ■ Lubrication Oil •
•
•
•
Always use engine oil of Grade CD based on API Service Classifications. Use highly wear-resistant hydraulic oil (ISO No. 46). The viscosity of oils changes as the temperature changes: when air temperature is high, the oil is thinned, and when air temperature is low, the oil is thickened. Use oils of the viscosity appropriate for the particular air temperature. The characteristics of oils vary from manufacturer to manufacturer, and use of oils of different brands in mixed form may impair performance. Always use oil of the same brand to refill. To replace the engine oil, first completely drain the old oil and fill the engine with new engine oil after having cleaned with flushing oil.
■ Coolant The coolant should be soft water, such as city water, that contains the minimum of impurities. Well water or river water must not be used. When antifreeze is not used, add a rust-preventive agent to the coolant to prevent rust in the cooling system. (Follow the instructions of rust preventive manufacturers for mixing ratio). When antifreeze is used, a rust-preventive agent is not needed. When refilling of coolant is required, use a coolant with an antifreeze or a rust-preventive agent and soft water at the same mixing ratio as that of the initial water mixture.
■ Antifreeze • • • • • •
Antifreeze prevents freezing and rusting in the cooling system. Use antifreeze when the air temperature is lower than 0°C. Use antifreeze which can be used throughout a year. Change antifreeze every 2 years (autumn). If other types of the antifreeze than long-life coolant (LLC) is used, change it twice a year in Spring and Autumn. When coolant (antifreeze) is changed, be sure to clean inside the cooling system. The freezing temperature of the coolant changes according to the particular mixing ratio relative to the antifreeze. To set a mixing ratio, assume that the coolant freezes at temperatures from about 5 - 10°C lower than the minimum level estimated. (Follow the instructions of the antifreeze manufacturers).
1-2-6
1. Specifications
1-2. Specifications
Fuel, Water and Oil Selection and Capacities ■ Antifreeze Mixing Ratio Table Minimum Air Temperature (°C) -15 -20 -25 -30 -35 -45 -55 Ratio Relative to Water (%) 30 35 40 45 50 55 60 LX15-7 Amount of Antifreeze (L) 1.7 2.0 2.2 2.5 2.7 3.0 3.3 5.5(L) Amount of Water (L) 3.8 3.5 3.3 3.0 2.8 2.5 2.2 LX20-7 Amount of Antifreeze (L) 1.8 2.0 2.3 2.6 2.9 3.2 3.5 5.7 (L) Amount of Water (L) 3.9 3.7 3.4 3.1 2.8 2.5 2.2 LX30-7/ Amount of Antifreeze (L) 1.9 2.2 2.5 2.8 3.1 3.4 3.7 LX40-7 Amount of Water (L) 4.2 3.9 3.6 3.3 3.0 2.7 2.4 6.1 (L) • Antifreeze must always be used at a mixing ratio of from 30% to 60%, one that is appropriate for the particular air temperature. Mixing ratios less than 30% not only freeze the coolant and cause damage to the radiator, but also give insignificant corrosion prevention results. Mixing ratios exceeding 60% not only give insignificant antifreeze results, but also increase the risk of overheating. • If the antifreeze comes into contact with your skin, immediately wash away the agent using running water. Note)
In a new machine the coolant with long-life coolant (LLC) will have been used, so no coolant change is required until the temperature goes down to -20°C or below. When the temperature goes down to -20°C or below, adjust the concentration of the coolant according to the above Antifreeze Mixing Ratio Table.
■ Applicable Oil List Important 1. The characteristics of oils differ according to the manufacturers, so be sure to use the same oil. 2. When the type of oil is to be changed to another after overhaul, completely remove the old oil. Completely bleed air as well. When supplying oil for replenishment, be sure to supply the same oil as before. 3. When supplying oil of another brand name, carefully check its specifications. 4. The oils with a * mark have been used in the machine when it is delivered from the factory.
Engine Oil Radiator (Engine Cooling Water) Hydraulic Oil Brake Oil Decelerator Differential (Axle) Grease
Apoloil Motive CD-M 10W-30* Sanshin Chemical Coaran Long Life Coolant* Nisseki Mitsubishi HP46* Idemitsu Daphne Torque Oil B* Nisseki Mitsubishi Firm Gear B (Old Name is Nisseki Mitsubishi Antoil Super B)* Cosmo Gear SAE90* Cosmo Dynamac Super No. 2
1-2-7
1. Specifications
1-2. Specifications
Fuel, Water and Oil Selection and Capacities ■ Applicable Fuel, Water, Oil Table A B C D
FL301-3, LX15-7, L3-2 FL302-3, LX20-7, L4-2 FL303-3, LX30-7, L5-2 FL304-3, LX40-7, L6-2
Specified Capacity (L) ① LX15-7 3.6 LX20-7 5.6 LX30-7/ 5.6 LX40-7 Section to be Refilled
② 33 50
③ 5.5 5.7
④ 18 (Total 25) 28 (Total 42)
⑤ 0.1 (Total 0.3) 0.1 (Total 0.3)
⑥ 1.8 1.8
⑦ 3.5 /Each 4.5 /Each
50
6.1
28 (Total 42)
0.1 (Total 0.3)
1.8
4.5 /Each
Type Applicable Standard Value
Engine Oil Pan
Engine Oil CD Grade Diesel Engine Oil
②
Fuel Tank
Diesel Oil (Light Oil)
③
Radiator
Soft Water (City Water)
④
Hydraulic Tank
Wear-Resistant Hydraulic Oil
Brake Oil Tank
Torque Converter Oil (SAE5W Mineral Oil)
⑥ Decelerator
Nisseki Mitsubishi Firm Gear B or SAE
①
⑤
⑦
Axle
Pin Bearing
For Temperature Range
250 hours (3 months) No.2 この部分は FL310-1 JIS の英文取説を 参照し記入する。 JIS No.JIS 3 規格は通用 しないため。 JIS Special No.3
Adding Long Life Coolant (LLC)
Every day
Every 2 Years (in Autumn) (Note) 1000 hours (12 months)
ISO VG46
Torque Converter Oil SAE5W
1000 hours (12 months)
Special Oil or SAE10W
1000 hours (12 months)
Special Oil
1000 hours (12 months)
Nisseki Mitsubishi Firm Gear B Lithium Type Multi-Purpose Grease
Replacement Period
NLG No.12 NLG No.11
1-2-8
As Required.
1. Specifications
1-2. Specifications
Weight of Main Components ■ Weight of Main Components
Engine Related Equipment
Power Train
Steering
Exterior
Hydraulic System
Operating Device
Item Engine Air Cleaner Muffler Radiator Fuel Tank Battery Coupling Assembly HST Pump (Main Pump with a Charging Pump) HST Motor Decelerator HST Oil Filter Propeller Shaft (Front) Propeller Shaft (Rear) Front Axle Rear Axle Suspension Bracket Wheel Assembly Rim Steering Wheel Power Steering Steering Cylinder Center Pin Front Frame Cover Operator Frame (F) Floor Plate Hood Support Hood Front Cover Operator Seat Weight Control Valve Oil Tank Return Filter Lift Arm Assembly Lift Cylinder Bell Crank Assembly Tilt Cylinder Link Assembly Bucket (Standard) Edge
Unit: kg LX40-7 ← ← ← ← ← ← ←
LX15-7 115 1.1 6.5 22.5 25 17.3 2.1
LX20-7 170 ← 7.0 22 32.1 ← ←
LX30-7 173 ← ← 26 ← ← ←
37
38.9
39.3
←
21 57 1.1 9.7 3.1 108 108 10.1 40.6 19.6 2 7 8.3 6.1 1.9 27.8 4.9 8.8 8.3 4.5 10.0 151.2 7.9 24.2 1.0 86.8 13.8 33.1 12.5 5.6 99.3 24.6
37 ← ← 10.5 ← 131 126 ← 47.8 19 ← 7.1 ← ← ← 32.3 4.7 4.1 7 ← ← 351 ← 31.6 ← 156.8 23.5 53.5 17.5 10 149 29.6
← ← ← 11 ← ← ← ← 73.5 29.6 ← ← 10 6.9 ← ← ← ← ← ← ← 635 ← ← ← 215.8 26.0 62.3 24.0 12.6 169.8 31.6
← ← ← ← ← ← ← ← ← ← ← ← ← 6.9 ← ← ← ← ← ← ← 940 ← ← ← 226 31.5 63.5 25.3 ← 185.2 ←
1-2-9
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